BM200e Booklet Maker

BM200e Booklet Maker
Booklet Maker BM200e
Addendum to Booklet Maker BM 2000 Operator Manual
Operator Manual
Doc No. T10194
Morgana Systems Limited ▪ United Kingdom ▪ www.morgana.co.uk ▪ Telephone: ( 01908 ) 608888 ▪ Facsimile: ( 01908 ) 692399
BOOKLET MAKER BM200e
Operating Instruction
Stapler Folder Reference
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.
Part no: 76580
Doc no: T10194
22 June 2010
22 June 2010
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
recievers may be expected within a distance of 10 m of the apparatus concerned.
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. It contains information related to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS.
How to read this manual
Notation conventions
Whenever necessary, the following points for attention are indicated in this manual.
WARNING:
Indicates a potentially hazardous situation which, if instructions are not followed, could
result in death or serious injury.
CAUTION:
Indicates a potentiality hazardous situation which, if instructions are not followed, may
result in minor or moderate injury or damage to machine or property.
Note
This sign refers to:
• Remarks for making the operation much easier. You get practical hints or knowledge to
assist you in the machine operation such as:
• Preparations required before operating
• How to prevent papers from being misfed or damaged
• Precautions required or actions to take after misoperation
• Limitations like numerical limits, functions that cannot be used together or conditions,
under which a particular function cannot be used or obtained.
• Information.
[
]
Keys that appear on the machine’s display panel.
Safety Information
When using this machine, following safety precautions should always be followed.
Safety during operation
WARNING:
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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.
Turn off the power and disconnect the power plug (by pulling the plug, not the cable) if
any of the following conditions exists:
• You drop objects or spill something into the equipment.
• You suspect that your equipment needs service or repair.
• Your equipment’s covers has been damaged.
• You notice unusual noises or odours when operating the equipment.
• If the power cable or plug becomes worn out or otherwise damaged.
• Before cleaning and care (unless otherwise specifically instructed).
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.
General safety
WARNING:
•
•
•
•
•
•
•
•
Always connect the equipment to a properly grounded power source (wall outlet). If in
doubt, have the power source checked by a qualified electrician.
Improper grounding of the equipment can result in electrical shock. Never connect the
machine to a power source that lacks a ground connection terminal. This machine is
destined for specific purpose only. Any use going beyond this specific purpose is regarded as beyond the determination. The manufacturer will not be liable for damages
resulting from any use beyond the determination, unallowed operation, respectively.
The user alone bears the risk.
Do not make arbitrary changes or modifications to the machine. The manufacturer will
not be liable for modifications made at the machine on your own and damages resulting thereof. EC declaration of conformity and the mark CE will be invalidated, if you
make changes at the machine or at the individual components.
Do not override or bypass electrical or mechanical interlock devices.
The machine is to be used only by authorized and instructed persons. The responsibilities on operating the machine have to be strictly laid down and observed so that there
are no unclear competences regarding safety aspects.
Vent holes serve for air circulation to protect the machine from overheating. Make sure
that the holes are not covered.
Do not expose fingers or other parts of the body to moving, rotating or cutting devices
such as for instance between upper and lower trimmer knives.
Allways locate the equipment on a solid support surface with adequate strength tor
the weight of the machine.
General safety, continued
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CAUTION:
The machine and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models.
Allways follow all warnings marked on, or supplied with, the equipment.
When you disconnect the power plug from the wall outlet, allways pull the plug (not the cable).
Disconnect the power cord before you move the machine. While moving the machine, allways
exercise care and make sure that the power cord will not be damaged under the machine.
Allways contact service if relocating the equipment.
Do not move the machine while the machine is running.
Do not open covers while the machine is running.
Do not switch of the power while the machine is running. Make sure the machine cycle has
ended.
Lay the power cord in a way that nobody will stumble over it. Do not place things on the cord.
Never attempt any maintenace function that is not specifically described in this documentation.
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 the machine where it
will be:
• Subject to sudden temperature changes.
• Directly exposed to cool air from an air-conditioner.
• Directly exposed to heat from a heater.
If the machine is not used over an extended period of time it should be unplugged to prevent
damage in the case of overload.
Note
The indications like front and rear, left and right refer to the paper transport direction.
The operator manual always has to be available at the place of use of the machine.
In the interest of technical development the company reserves the right to make alterations to
specifications without prior notice!
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Table of Contents
What You Can Do With This Machine............................................................................................. 9
Guide To Components................................................................................................................... 11
Booklet Maker............................................................................................................................................. 11
Trimmer.......................................................................................................................................................14
Square Folder.............................................................................................................................................. 16
Control Panel.................................................................................................................................. 18
1. Basics................................................................................................ 21
Turning On / Off the Main Power................................................................................................... 21
Booklet Maker, Trimmer and Square Folder................................................................................................ 21
Docking / Undocking...................................................................................................................... 21
Docking the Booklet Maker......................................................................................................................... 21
Adjusting docking assembly to factory settings........................................................................................... 22
Undocking the Booklet Maker..................................................................................................................... 22
Check staples, Staple cartridge and stapler head...................................................................... 23
Removing stapler head............................................................................................................................... 23
Removing staple cartridge........................................................................................................................... 23
Installing stapler head, staple cartridge / clearing staple jam...................................................................... 24
Emptying the trim bin..................................................................................................................... 25
2. Making Booklets............................................................................... 27
Changing settings.......................................................................................................................... 27
General procedure...................................................................................................................................... 27
Setting Paper Size....................................................................................................................................... 27
Selecting standard paper sizes........................................................................................... 27
Custom paper size................................................................................................................ 28
Stapling.......................................................................................................................................................28
Selecting stapling On or Off................................................................................................. 28
Trimming......................................................................................................................................................29
Selecting trimming On or Off............................................................................................... 29
Adjusting the cutting margin............................................................................................... 30
Square Folding............................................................................................................................................ 30
General................................................................................................................................... 30
Setting Mode...............................................................................................................................................31
Procedure.............................................................................................................................. 31
On-line/Hand feeding..................................................................................................................... 31
On-line mode...............................................................................................................................................32
Hand feeding............................................................................................................................................... 32
3. Tools.................................................................................................. 35
The Tools Screen............................................................................................................................ 35
Fold delay....................................................................................................................................................35
Units............................................................................................................................................................35
Software version.......................................................................................................................................... 36
Language....................................................................................................................................................36
Service........................................................................................................................................................37
4. Jobs................................................................................................... 39
Storing and deleting jobs.............................................................................................................. 39
Storing a new Job........................................................................................................................................ 39
Recalling a Job............................................................................................................................................ 40
5. Clearing Misfeed(s).......................................................................... 43
Clearing misfeed(s)........................................................................................................................ 43
General........................................................................................................................................................43
Booklet Maker................................................................................................................................. 44
Clearing misfeed(s)..................................................................................................................................... 44
Inside the Booklet Maker...................................................................................................... 44
Trimmer........................................................................................................................................... 45
Clearing misfeed(s)..................................................................................................................................... 45
Clearing misfeed in input area............................................................................................. 45
Clearing misfeed in exit area............................................................................................... 46
Square Folder................................................................................................................................. 47
Clearing misfeed(s)..................................................................................................................................... 47
Inside the Square Folder...................................................................................................... 47
Exit area................................................................................................................................. 47
6. Troubleshooting............................................................................... 49
Fault codes..................................................................................................................................... 49
General........................................................................................................................................................49
General fault codes..................................................................................................................................... 50
Clear Misfeed(s).................................................................................................................... 50
Close cover(s)....................................................................................................................... 50
Booklet maker fault codes........................................................................................................................... 50
Check staples........................................................................................................................ 50
Stacker full............................................................................................................................. 50
Oil clinchers........................................................................................................................... 51
Check set............................................................................................................................... 51
Trimmer fault codes..................................................................................................................................... 51
Close trimmer belts............................................................................................................... 51
Empty trim bin....................................................................................................................... 51
Stacker full............................................................................................................................. 51
Square Folder fault codes........................................................................................................................... 52
Feed errors............................................................................................................................ 52
7. REMARKS......................................................................................... 55
Do’s And Don’ts.............................................................................................................................. 55
Where to put Your Machine........................................................................................................... 56
Machine environment.................................................................................................................................. 56
Power connection........................................................................................................................................ 56
Access to machine...................................................................................................................................... 57
Maintaining Your Machines........................................................................................................... 58
Booklet Maker.............................................................................................................................................58
Oil Clinchers and Stapler heads.......................................................................................... 58
Square Folder.............................................................................................................................................. 60
Cleaning feed belts............................................................................................................... 60
8. Specification .................................................................................... 63
Machine Specifications.................................................................................................................. 63
Booklet Maker BM200e............................................................................................................................... 63
Trimmer BM200e (option)............................................................................................................................ 64
Square Folder BM200e (option).................................................................................................................. 64
System certifications................................................................................................................................... 65
BM200e System Set Size Guide................................................................................................................. 66
What You Can Do With This Machine
BM200e Square Folder (option)
Belt Stacker
BM200e Trimmer (option)
BM200e Booklet Maker
The Booklet Maker BM 200e, Trimmer FTR 200 and SquareFolder SQF 200 forms a booklet
making system that works online with a Collator or offline/online for hand feeding.
The sheats from the Collator or feeder are transported into the BM 200e Booklet Maker to the
staple area. 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. When a larger number of sheets are folded an effect called creeping occurs. In order
to rectify creep, the FTR 200 Trimmer (optional) can be attached after the Booklet Maker.
The booklets are then transported from the Booklet Maker into the Trimmer where the trail
edge will be cut off. If a FTR 200 Trimmer is installed to the BM 200e Booklet Maker, you can
attach the SQF 200 SquareFolder (optional). The printouts, which have been stapled, folded
and trimmed will be fed into the SQF 200. The SQF 200 will flatten the spine of the booklet
square. The booklets will, after passing the SQF 200, have the look of a perfect bound book.
The booklets are then fed out to the Belt Stacker.
To facilitate hand feeding, the BM 200e is equipped with a sliding top cover. The Booklet
Maker can also be used as a stand-alone unit for hand feeding.
The BM200e Booklet making system is controlled from a single control panel on the Booklet
Maker. The control panel has only four buttons which will allow you to easily set up, adjust
and operate the complete system.
The buttons are multi functional, meaning that the
function of each button depends on the information
displayed.
For example: Pressing button 3 from the Ready screen
takes you to the Tools screen.
Example 2: In this screen, button 3 has no function.
Button: 1
2
3
4
Example 3: Pressing button 3 here will load the stored
Job (4).
Button: 1
2
3
4
Example 4: In this screen pressing button 3 will save
the current settings for job No 1. The asterisk on the
first row shows that the settings for Job (1) has been
changed, but not yet saved.
Button: 1
10
2
3
4
Guide To Components
Booklet Maker
4
1
5
2
3
6
7
8
9
11
10
1
2
3
4
5
6
Top cover
Control panel
Main power switch
Upper Top cover
Infeed assembly
Docking assembly
7
8
9
10
11
12
12
Base
Positioning holes for A3/11” and sizes nearby
Belt Stacker Cover
Belt Stacker
Knob, adjustment for custom paper size
Positioning holes for A4/8.5” and sizes nearby
11
Booklet Maker, continues
9
8
8
9
Stacker
Connections
Fold stop gate
Terminator
Terminator/
COM BM200e
POW BM200e
Main Power
Interlock jumper
Interlock jumper/
POW BM200e
12
Booklet Maker, continues
1
2
3
5
1
2
3
Stapler heads
Staple cartridges
Cartridge locking levers
4
5
4
5
6
Stapler release latches
Staple detection leads
Hand feeding paper guides
13
Trimmer
1
2
3
4
1
2
3
4
Top cover
Trim bin
Base
Connections
Stacker
14
COM BM200e
COM B
M200e
Power from
BM200e
Terminator/
Com BM200e
Trimmer, continues
The Trimmer interior has parts that you will come in contact with if a misfeed occurs.
6
1
7
2
3
4
5
Trimmer, top view
1
2
3
4
5
Set counter
Trimmer stop
Outfeed latch
Exit compressing brackets
Transport belt
8
6
7
8
9
9
Infeed roller shaft
Trimmer fan
Upper knife
Infeed latch
15
Square Folder
1
2
3
1
2
3
4
Top cover
Trim bin
Base
Connections
4
Terminator
COM BM200e
16
Stacker
POW BM200e
Square Folder, continues
The Square Folder interior has parts that you will come in contact with if a misfeed occur.
2
1
Square Folder, top view,
Upper feed belts in lifted up
1 Lower feed belts
2 Upper feed belts
17
Control Panel
The Ready screen.
When the system power is switched on the Ready
screen will be shown. Here you will find information
showing the actual set up. From this screen you can
also access other screens, that will help you operate
the complete BM200e Booklet making system.
arrow button
tools button
change button
jobs button
Changing settings.
To change or adjust settings; Select an item in the
Ready screen with the [arrow] button and press the
[Change] button. For example you can fine adjust the
trimming, turn off the cover feeder or set the Square
Folder to the correct mode. Explore all settings more
thoroughly in section 2. Making Booklets.
The Tools screen.
Pressing the [Tools] button in the Ready screen takes
you to the tools screen. Here you will find all the
necessary tools for a troublefree operation. From here
you can change the display language, set units from
millimeters to inches and more. See section 3. Tools.
for how to get around in the Tools screen.
The Jobs screen.
Pressing the [Jobs] button in the Ready screen opens
the Jobs screen. From here you can load, customize
and save job settings. These procedures are described
in section 4. Jobs.
18
The Processing screen.
This screen is shown when the machine is busy working.
If the machine is used in off-line mode you do not have
to wait for the Ready screen before handfeeding the
next set.
The Please wait screen.
While the machine sometimes needs time to perform
changes in settings, the Please wait screen will be
shown. The machine will automatically return to the
Ready screen after changes have been implemented.
19
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20
1. Basics
Turning On / Off the Main Power
Booklet Maker, Trimmer and SquareFolder
1
Plug the Booklet Maker power cord into the wall
outlet.
The trimmer (optional) and the SquareFolder
(optional) are powered from the Booklet Maker.
Open the Top cover (1).
Set main power switch (2) on Booklet Maker to ON
position.
Note
The main power switch also controls Trimmer (optional)
and SquareFolder (optional).
Close the Top cover.
2
Docking / Undocking
Docking the Booklet Maker to a Collator, standard paper sizes
4
When the Booklet Maker is docked to a collator it must
be correctly positioned in order to have the set fed
entering the infeed assembly correctly. The paper size
used determines which positioning holes to use.
1
3
2
Push the docking assembly (1) to the rear until it
locks.
The docking brackets (2) on the collator should enter
positioning holes:
(3) if you are using A4 / 8 1/2” paper widths or sizes
nearby
or
(4) if you are using A3 / 11” paper widths or sizes
nearby
21
Adjusting docking assembly to factory settings
To adjust the docking assembly back to factory
setting:
1
Loosen the knob.
Slide the docking assembly so that it covers half
the hole (6) in the infeed assembly.
6
Tighten the knob.
Undocking the Booklet Maker from a Collator
Push the docking assembly to the rear until it
locks.
Separate the Collator from the Booklet Maker.
22
Check staples, Staple cartridge and stapler head
Removing stapler head
1
Open the top cover.
Remove the set of paper.
Disconnect the staple indication lead (A) from the
socket.
Hold the stapler head in place, press the release
latch (B) to release the rear end of the stapler head
and lift up this end.
Lift out the head, allowing it to rotate around the
front end. The stapler assembly is spring loaded
and will follow the rotation of the stapler.
B
A
Removing staple cartridge
C
The staple cartridges, containing approximately 5000
staples per cartridge. Cartridge may be removed either
for renewal or for jam clearance.
Raise the handle (C) on the staple cartridge locking
lever.
Remove the staple cartridge from the stapler head
by sliding it away from the stapler head.
23
Installing stapler head, staple cartridge / clearing staple jam
Look inside stapler head for jammed staples in the area
of the staple actuator. Remove staples if any.
1
Position the stapler head on the edge of a firm surface
(for example the top of a table).
While securely holding the head, actuate the Stapler
up and down through full travel. Perform this operation
without staple cartridge
Renewing or reinstalling the staple cartridge, pull 25
mm (1 inch) of staples out of the cartridge and tear the
staples downward starting at one side pulling away
from you. The staple tear line is indicated by an arrow
on the side of the cartridge.
Insert the cartridge into the stapler head with the end
of the staples facing toward the head of the stapler
mechanism. Push it firmly ahead.
Hold the staple cartridge firmly in place and push down
the cartridge locking lever.
IMPORTANT
Keep holding (pushing) the staple cartridge into place
while pushing down the cartridge locking lever.
While securely holding the head, actuate the Stapler up
and down through full travel. Perform this operation with
staple cartridge. Repeat this a few times to ensure that
the staples are ejected at each down movement.
Reinstall the stapler head by inserting the pin at the top of
the stapler head into the stapler retraction swing arm (D).
While rotating the stapler head, insert the pin located
at the rear end of the stapler head into the slots in the
frame of the stapler head assembly. Press down the
rear end of the stapler head until the release lever snaps
into place, locking the stapler head in position.
Press down the front end of the stapler head until it
snaps in position under the frame assembly.
Reconnect the staple indication lead (A), see previous
page.
D
24
Close the top cover and press the [Esc] button. The
booklet maker will automatically go to Ready mode. If
not and/or error message persists, hand feed a four
sheet set of paper. The booklet maker will automatically
cycle and advance staples until both stapler heads are
driving staples. The booklet maker will automatically go
to Ready mode.
Emptying the trim bin
Remove the trim bin by lifting it and pulling it out.
1
trim bin, no Square Folder installed
trim bin, with Square Folder installed
25
1
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26
2. Making Booklets
Changing settings
General procedure
Changing of 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 Ready screen, select the option you wish to change and press the [Change] button.
Confirm changes by pressing the [OK] button.
Procedure for permanent changes:
From the Ready screen, press the [Jobs] button to reach the Jobs screen. Select the Job you
want to change by pressing the [Next] button and then press the [Change] button.
Note
Choose either of the above mentioned procedures when changing size, stapling, trimming,
covers or book folding as follows.
Setting Paper Size
Selecting standard paper sizes
From the Ready screen, select Size and press the
[Change] button.
Select Auto or any standard paper size with the [arrow]
button and press the [OK] button. Selecting Auto means
that the booklet maker will automatically adjust to the
same paper size (A4, A3, 8.5”x11”, 8.5”x14”, 11”x17”
or B4) as the copier.
For other paper sizes, follow “Custom paper size” as
described on the next page.
27
Custom paper size
Select Size and press the [Change] button to display
the preprogrammed paper sizes.
Scroll down to Custom sizes, by pressing the [arrow]
button, and press the [OK] button. Select the custom
paper size you want to use and press the [OK]
button.
2
If you want to adjust, select the custom paper size you
want to change and press the [Change] button. Select
Width or Length with the [arrow] button and press the
[Change] button.
The paper size can now be changed in increments of
0.1 mm or approx.. 0.01 inches. Press the [OK] button
to confirm.
Four different custom paper sizes can be stored.
Stapling
Selecting stapling On or Off
From the Ready screen, select Staple and press the
[Change] button.
28
Selecting stapling On or Off, continues
If stapling was On, the first choice will be Off and vice
versa.
Select On or Off with the [arrow] button and press the
[OK] button.
2
Trimming
Selecting trimming On or Off
From the Ready screen, select Trim and press the
[Change] button.
If trimming was On, the first choice will be Off and vice
versa.
Select On or Off with the [arrow] button and press the
[OK] button.
29
Adjusting the cutting margin
Select Trim and press the [Change] button. Select
Trim length and press the [OK] button. Press the [+]
or [-] buttons to fine adjust in increments of 0.5 mm or
0.02 inches. The trimmed booklet size and waste are
displayed. Press the [OK] button to confirm.
2
Square Folding
General
The Square Folder has six different settings. It can be set to [Auto], [Mode 1], [Mode 2],
[Mode 3], [Mode 4] or [Off].
In [Auto] mode, the Booklet Maker detects how many sheets there are in the booklet, and
automatically set the Square Folder to the correct mode.
Note
When the Square Folder is set to [Auto] and the booklet has less than approximately 6
sheets/booklet, the Square Folder will bypass the Square folding action, transporting the
booklet out to the Belt stacker.
Use the manual modes to override the auto function. There are four different manual modes
to select from.
Mode 1:
Mode 2:
Mode 3:
Mode 4:
Approximately 6 to 11 sheets. Decreased amount of square forming.
Approximately 12 to 16 sheets. Medium amount of square forming.
Approximately 17 to 23 sheets. Increased amount of square forming.
Approximately 24 to 30 sheets. Maximum amount of square forming.
Select [Off] to bypass the Square Folder
30
Setting Mode
Procedure
From the Ready screen, scroll down to BM200e and
press the [Change] button.
2
Select [Auto], [Mode 1], [Mode 2], [Mode 3], [Mode
4] or [Off] with the [arrow] button and press the [OK]
button.
On-line/Hand feeding
The Booklet Maker can be operated in two modes. On-line mode, when used together with
the collator, or Off-line mode working as a stand-alone unit for hand feeding.
The Booklet Maker can be hand fed while it is still docked to a Collator.
Note
If the Collator is to be used (for internal stacking) at the same time as the Booklet Maker is
used for hand feeding, the communication cable between the Booklet Maker and the Collator must be disconnected.
Caution
Before disconnecting the communication cable, switch of the power to the Booklet Maker
and the Collator.
31
On-line/Hand feeding
On-line
When used on-line with a collator, the Booklet Maker operating speed can be set to normal
or fast. The normal setting is optimized for highest booklet quality and the fast setting is
optimized for highest speed.
From the Ready screen, scroll down to Mode and
press the [Change] button.
2
Select either [Normal] or [Fast] and press the [OK]
button.
Note
For further instructions on operating the Booklet Maker with the collator refer to the collator
operating manual.
Hand feeding
Slide the Upper Top Cover to the left.
Adjust the hand feeding paper guides to the correct paper size.
Turn on the Booklet Maker.
From the Ready screen, scroll down to Mode and press the [Change] button.
32
Hand feeding, continues
Select [Manual] and press the [OK] button. You
might be able to hear the infeed motor running
2
The Booklet Maker is now set up for hand feeding.
If settings need to be changed, follow “Changing
settings” earlier in this section.
Note
After approx. five minutes of inactivity, the machine
will automatically return to Normal mode and the
infeed motor stops running.
Start hand feeding by inserting the sets between
the side guides as illustrated.
Note
If optimum productivity is required when there is
a SquareFolder in the system, choose a defined
mode (bypass or mode 1 to 4) instead of [AUTO].
See page 26.
33
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34
3. Tools
The Tools Screen
The Tools screen.
From the Ready screen, press the [Tools] button to get to the Tools screen. Here you will find
all the necessary tools for trouble-free operation.
Fold delay
From this screen you can change the fold delay to on
or off.
Units
From this screen you can change units, between
millimeters and inches. Select Units with the [arrow]
button and press the [OK] button.
35
Tools
Select the millimeters or inch units and then press the
[OK] button.
3
Software version
Select Software version with the [arrow] button and
press the [OK] button. This screen, and sub screens
show the software version for the different modules in
the booklet making system.
Language
From this screen you can change the language in the
user interface.
Select Language with the [arrow] button and press the
[OK] button.
Select desired language with the [arrow] button and
press the [OK] button.
36
Service
This screen is for authorized service personnel only
and is password protected.
3
37
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38
4. Jobs
Storing and deleting jobs
The Booklet Maker has a maximum storage capacity of 10 different jobs. It is not possible
to delete jobs, therefore when you need to store a new job, an old job must be overwritten.
To make temporary changes in the actual job settings or temporary changes of a stored job,
see section 2. Making Booklets.
Storing a new Job
To store a new job or add new settings to an existing
job you need to start from the Jobs screen. From the
Ready screen press the [Jobs] button to enter the Jobs
screen.
Select an already stored job by pressing the [Next]
button. Then press the [Change] button.
Select the option you want to change with the [arrow]
button and then press the [Change] button. See section
2. Making Booklets for how to set up each separate
option.
After changing the options press the [OK] button to
accept the changes you just made.
Continued on next page.
39
Storing a new Job, continues
To store the job, press the [Save] button.
4
If you want to run the actual job, press the [Load] button.
The booklet maker will then automatically setup that
specific job and return to the Ready screen.
Recalling a Job
To recall a stored job press the [Jobs] button from the
Ready screen to enter the Jobs screen.
Select the desired job by pressing the [Next] button.
Then press the [Load] button. The booklet maker will
then automatically setup that specific job and return to
the Ready screen.
40
4
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41
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42
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
as area A, B or C and by the error code BKXXX.
Misfeeds in the Square Folder are indicated
as area E and by the error code BF-XXX.
43
Booklet Maker
Clearing misfeed(s)
Inside the Booklet Maker
To clear a misfeed indicated in Area A or B
Open the top cover.
Remove misfed sheets.
Close the top cover.
5
To clear a misfeed indicated in Area C
Open the top cover.
Close top cover.
If misfeed condition remains:
Switch off the main power.
Switch on the main power.
If misfeed condition remains:
Switch off the main power.
If a Trimmer is installed, first remove the trim bin to
get access to the fold stop. By hand, pull down the
fold stop (page 8, item 9).
Remove misfed sheets.
Push the fold stop back into the upper position.
44
Switch on the main power.
Trimmer
Clearing misfeed(s)
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 misfeed in input area
Raise the infeed roller shaft (A) by lifting latch (B).
5
Remove the misfed sheets in the infeed area.
After the misfed sheets are removed, lower the latch (B) and place the infeed roller shaft
into operating position.
A
B
45
Clearing misfeed(s), continues
Clearing misfeed in exit area
Lift the exit compressing brackets (A).
Secure them under the latch (B).
Remove the misfed sheets from the exit area.
After the misfed sheets are removed, lift up the latch (B) and place the compressing
brackets in operating position.
5
A
B
46
Square Folder
Clearing misfeed(s)
Inside the Square Folder
B
A
B
Open the top cover.
Lift up both upper feed belts (A).
Note
Press the green dots (B) on the latches to release.
Remove the misfeeds.
Place the upper feed belts in normal position.
5
Close the top cover.
Exit area
A
Open the top cover.
Remove the misfeeds through the jam clearance
area (A).
Close the top cover.
47
5
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48
6. Troubleshooting
Fault codes
General
When there is a misfeed or fault condition in the Booklet Maker system, a message will
be displayed on the Booklet Maker. In case there is a problem that can be rectified by the
operator, a fault code and an explanation will be displayed.
Fault codes that can be rectified by the operator:
Booklet Maker:
Trimmer:
SquareFolder:
BM-201 to BM-210, BM-401 and BM-502 to BM-504
FTR-201 to FTR-205, FTR-401, FTR-502 and FTR-503
SQF-201 to SQF-206.
BM-201 to BM-210 indicates “Clear Misfeed(s)” in the Booklet Maker
BM-401
indicates “Check staple(s)” in the Booklet Maker
BM-502
indicates “Stacker full” at the Booklet Maker
BM-503
indicates “Oil clinchers” in the Booklet Maker
BM-504
indicates “Check set” in the Booklet Maker
FTR-201 to FTR-204 indicates “Clear Misfeed(s)” in the Trimmer
FTR-205
indicates “Close trimmer belts”.
FTR-401
indicates “Empty Trim bin” in the Trimmer
FTR-503
indicates “Stacker full” at the Trimmer
SQF-201 to SQF-206indicates “Clear Misfeed(s)” in the SquareFolder
SQF-502 indicates “Stacker full” at the Square Folder
Note
If specifically described procedures in this manual do not rectify the problem:
•
Open covers and verify that everything appears to be in a normal state. Close covers.
•
Switch off the power and wait 10 seconds before power is switched on again.
•
Call for an authorized technician.
49
Trouble shooting
General fault codes
Clear Misfeed(s)
In general, fault codes indicate a misfeed condition.
When a misfeed occurs, the message “Clear Misfeed(s)”,
a code and the jam area will be displayed. See section
5. Clearing Misfeeds, for how to clear a misfeed.
Close cover(s)
6
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.
Booklet Maker fault codes
Check staples
This message will be displayed when a staple cartridge is empty or when stapling could not
be performed. Check in the following order:
–If a staple cartridge is empty, replace according to section 1. Basics.
–If staple cartridges are OK; remove the set and check that the number of sheets is within
specifications.
–If staple cartridges are OK and set is within specifications; remove and check stapler head
according to section 1. Basics.
Stacker full
This message will be displayed when the when the belt stacker on the Booklet Maker is full.
Empty the belt stacker, select Manual mode again (see page 27) and continue hand feeding
or press the start button on the Collator to continue the job.
50
Fault codes
Booklet Maker fault codes, continues
Oil clinchers
This message will be displayed every 20 000 stapling cycles. The purpose is to remind the
operator to maintain stapler head and clinchers. If not doing that every 20 000 there is a great
risk of a costly mechanical breakdown. See section Maintaining Your Machines on page 46
for procedure.
Check set
This message will be displayed when a calibration (Proof) set is sent from the Collator. The
calibration set is stopped in the Booklet Maker, providing the possibility to check or remove
the set before it is being stapeled and folded. The operator now have three choices.
Open the Booklet Maker top cover and check that the set looks okay and is positioned
correctly in the compiler. Close the Booklet Maker top cover. The message “Finish set” will
be displayed.
If you press “Yes”, the set will be finished and fed to the belt stacker. Check that the
finished set is okay and press the start button on the Collator to start the job.
If you press “No”, the message “Remove set” will be displayed. Open the top cover and
remove the set. Close the top cover.
CAUTION:
If you try to remove the set from the compiler before the message “Remove set” is
displayed, there is a possibility that the jogger mechanism will be damaged.
6
Press the purge button on the Collator. Check that the finished set fed to the belt is
okay and press the start button on the Collator to start the job.
Press the start button on the Collator to finish the set in the compiler and start the job.
Trimmer fault codes
Close trimmer belts
This message will be displayed when the when either trimmer belt is in the lifted position. Make
sure that both the infeed roller shaft and the exit compressing brackets are in the operating
position, see section 5, Trimmer, Clearing Misfeed(s).
Empty trim bin
This message will be displayed when the trim bin is full or when a trim strip, due to static
electricity, is prevented from falling down into the trim bin. Empty the trim bin and remove loose
trim strips from inside the Trimmer. See section 1. Basics for how to remove the trim bin.
51
Trouble shooting
Trimmer fault codes, continues
Stacker full
This message will be displayed when the when the belt stacker on the Trimmer is full. Empty
the belt stacker. Open the Trimmer top cover and check that no set remains in the Trimmer.
Close the Trimmer top cover and continue hand feeding or press the start button on the
Collator to continue the job.
SquareFolder fault codes
Feed errors
If feed errors occur, the feed belts needs to be cleaned or the pressure on the upper feed
belts needs to be increased. To clean the feed belts, see section 7, REMARKS Maintaining
Your Machine. To increase the pressure on the upper feed belts follow this procedure.
6
Open the top cover.
Place both springs in the upper position.
Close the top cover.
Spring in normal position
52
Spring in upper position
6
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53
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54
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 powercord from the wall outlet and machine before you move or relocate the equipment.
•
Do not remove the covers or guards that are fastened with screws.
•
Do not override or bypass electrical or mechanical interlock devices.
•
Do not operate the equipment if you notice unusual noises or odors. Disconnect the powercord from the power source and call your authorized technician to correct the problem.
•
Warning:
Do not put fingers or other parts of the body between the upper and lower trimmer knives.
•
Do not switch off the main power switch while machine is running. Make sure machine cycle has ended.
•
Do not open covers while machine is running.
•
Do not move machine while machine is running.
55
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 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:
7
•
Subjected to sudden temperature changes.
•
Directly exposed to cool air from air-conditioner.
•
Directly exposed to heat from heater.
Power connection
56
•
Always connect the equipment to a properly grounded power source. If in doubt, have the power source checked by a qualified electrician.
•
WARNING: Improper grounding of the equipment can result in electrical shock.
•
Never connect the machine to a power source that lacks a ground connection terminal.
Access to machine
Place the machine near the power source, providing clearance as shown.
1
3
2
7
1. Left: more than 400 mm / 15 3/4”.
2. Front: more than 555 mm / 21 7/8”
3. Right: more than 400 mm / 15 3/4” (off-line use).
57
Maintaining Your Machines
Never attempt any maintenance function that is not specifically described in this
documentation.
Booklet Maker
Oil Clinchers and Stapler heads
The clinchers must be oiled every 20 000 stapling cycles to avoid mechanical breakdown.
7
B
Stapling area,
view from infeed
close-up of clincher
lever
close-up of
clincher
A
58
B
close-up of clincher
lever
Open the top cover.
Put a couple of drops of oil in each clincher (A).
To get rid of excessive oil:
Push down clincher (B) lever a couple of times.
Push down clincher lever (B) while wiping of excessive oil with a dry cloth.
Run a few blank booklets.
When clinchers have beed lubricated, the error message must be reset:
Switch of the main power switch on the machine.
Press and hold the two innermost buttons on the UI, buttons 2 and 3.
Switch on the main power switch and release the buttons after 2 seconds.
7
The stapler heads must be oiled every 20 000 stapling cycles to avoid mechanical
breakdown.
C
Remove the Stapler heads according to section 1, BASICS Check staples, Staple cartridge
and Stapler head.
Put a couple of drops of oil on each side of the drive post (C).
Cycle the Stapler head a couple of times before installing it again.
59
Square Folder
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. Clean
the feed belts with water and a lint free cloth.
Open the top cover.
Clean the upper feed belts (A). The upper feed belts can easily be rotated in either
direction.
Lift up the upper feed belts to access the lower feed belts.
Clean the lower feed belts (B). Rotate the lower feed belts towards the outfeed side for
complete cleaning.
7
Place the upper feed belts in normal position.
Close the top cover.
A
B
Upper feed belts in normal position.
60
Upper feed belts lifted up.
7
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61
7
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62
8. Specification
Machine Specifications
Booklet Maker BM200e
Major Specifications
Specifications
Remarks
Speed
Up to 3000 sets/hour
Standard Paper Sizes
A4, A3, B4, 8.5x11”, 8.5x14”, 11x17, 12x18 ,
SRA3
Paper Size (Minimum)
Width 206mm / 8.1”
Length 275mm / 10.8”
Paper Size (Maximum)
Width 320mm / 12.6”
Length 457.2mm / 18”
Paper Weight (Minimum)
64gsm/16 lb. Bond
Paper Weight (Maximum)
300gsm / 172 lb. Index / 115 lb. Cover
Engine Duplex: 216 gsm
Input / Output Sheets
1 – 30 Sheets (80 gsm / 20 lb. Bond)
Stapled
Input / Output Sheets
1 – 2 Sheets
Non Stapled Folding
Off-line Use
Possible
Stitch / Fold (2 staples)
Weight
130 kg / 286.6 lb
Dimensions (L x H x D)
1420 x 970 x 700 mm / 55.9 x 38.2 x 27.6”
Incl. Base and Stacker
Power Source
100 / 110 / 115 / 127 / 220 / 230 50-60Hz
+ - 10%
Power consumption
250 W or less
Continuous Operations
Custom sizes are available
63
Trimmer TR200e (option)
Specifications
Remarks
Speed
Up to 2000 sets/hour
Standard Paper Sizes
Same as BM200e
Custom sizes are available
Default trim length
4.5 mm / (11/64”)
Adjustable in 0.5 mm steps
Minimum trimming
1 mm / (0.0394 in)*
Adjustable in 0.5 mm steps
Maximum trimming
16 mm (0.63”)
Adjustable in 0.5 mm steps
Paper Weight (Minimum)
Same as BM200e
Paper Weight (Maximum)
Same as BM200e
Input / Output Sheets
Same as BM200e
Input / Output Sheets
Same as BM200e
Off-line Use
Possible
Weight
65 kg / 143.3 lb or less
Dimensions (L x H x D)
360 x 900 x 620 mm / 14.2 x 35.4 x 24.4”
Power Source
From BM200e
Engine Duplex: 216 gsm
(Together with Booklet maker)
* When trimming SRA3 (450 mm) Booklets minimum trimming is 5 mm, when trimming 18” Booklets minimum trimming is 9 mm.
8
Square Folder SQF200e (option)
Specifications
64
Speed
Up to 1800 sets/hour
Standard Paper Sizes
Same as BM200e
Paper Weight (Minimum)
Same as BM200e
Paper Weight (Maximum)
Same as BM200e
Input / Output Sheets
Same as BM200e
Input / Output Sheets
Same as BM200e
Off-line Use
Possible
Weight
52 kg / 114.6 lb
Dimensions
360 x 900 x 620 mm / 14.2 x 35.4 x 24.4”
Power Source
From BM200e
Remarks
Custom sizes are available
(Together with Booklet maker &
Trimmer)
System Certifications
The system complies with the following directives:
EU Directive 2006/95/EC
EU Directive 2004/108/EC
EU Directive 2002/95/EC
EU Directive 2002/96/EC
Low Voltage Directive
EMC Directive, Class A equipment
RoHS Directive
WEEE Directive
Turkey RoHS Regulation of May 30, 2008
China RoHS, Standards SJ/T 11363-2006 and SJ/T 11364-2006
Certification
Description
Certification Body
EN 60950-1:2001 + A11:2004, 1st Edition
IEC 60950-1:2001, 1st Edition
UL 60950-1:2003, 1st Edition
CSA C22.2 No. 60950-1: 2003, 1st Edition
Information Technology
Equipment Safety – Part 1: General Requirements
UL (Underwriters
Laboratories, Inc.)
EN 55022:2006 + A1:2007, Class A
EN 61000-3-2:2006
EN 61000-3-3:1995 + A1:2001 + A2:2005
FCC Part 15 (2004) Subpart B, Class A
EMC – emission
Intertek ETL
SEMKO
EN 55024:1998 + A1:2001 + A2:2003
EMC – immunity
Intertek ETL
SEMKO
8
65
BM200e System Set Size Guide
Note
1. For cover jobs, deduct 2 sheets.
2. Area coverage:
Low = Text only
High = Pictures
Full = Maximum coverage
Paper weight
8
66
Paper size
<A3
>A3
Grain direction
Short
Grain direction
Long
Short
Long
Area coverage
Area coverage
Area coverage
Area coverage
Low High
Full
Low High
Full
Low High
Full
Low High
Full
Bond Offset
Cover Tag
Index Gsm
20
50
28
46
42
80
30
25
22
27
22
20
27
22
20
24
17
14
24
60
33
56
50
90
27
23
21
24
20
18
24
20
18
21
17
14
28
70
39
64
58
100
24
21
19
21
19
17
21
19
17
19
16
14
29
73
40
62
60
110
22
20
18
19
17
16
19
17
16
17
16
14
31
81
45
73
66
120
20
19
17
17
16
15
17
16
15
15
15
13
35
90
48
80
74
130
18
17
16
16
15
14
16
15
14
14
13
12
36
90
50
82
75
140
17
16
14
15
14
13
15
14
13
13
12
11
39
100
54
90
81
150
15
15
13
14
13
12
14
13
12
12
11
10
43
110
60
100
90
160
14
14
12
13
12
11
13
12
11
11
11
9
44
110
61
102
92
170
13
13
12
12
11
10
12
11
10
10
10
9
47
120
65
108
97
180
12
12
11
11
10
10
11
10
10
10
9
8
50
128
70
115
104
190
12
11
10
10
10
9
10
10
9
9
9
8
53
135
74
122
110
200
11
10
10
10
9
8
10
9
8
9
8
7
54
137
75
125
113
210
10
10
9
9
9
8
9
9
8
8
8
7
58
146
80
134
120
220
10
9
9
9
8
8
9
8
8
8
7
6
62
156
85
142
128
230
9
9
8
8
8
7
8
8
7
7
7
6
65
165
90
150
135
240
9
8
8
8
7
7
8
7
7
7
7
6
67
170
93
156
140
250
8
8
7
7
7
6
7
7
6
7
6
5
70
177
97
161
145
260
8
8
7
7
7
6
7
7
6
6
6
5
72
183
100
166
150
270
8
7
7
7
6
6
7
6
6
6
6
5
76
192
105
175
158
280
7
7
6
6
6
6
6
6
6
6
5
5
80
201
110
184
166
290
7
7
6
6
6
6
6
6
6
5
5
4
82
208
114
189
170
300
7
6
5
6
5
5
6
6
5
5
5
4
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