Morgana BM 2000 User manual

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

BOOKLET MAKER BM 2000
Operating Instruction
Booklet Maker Reference
Part no: 81248
Doc no: T10178
Rev. date: 14 January 2010

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.
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.
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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 re-
lated 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.
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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 specied 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 specically 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.
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Safety Information
When using this machine, following safety precautions should always be followed.
Safety during operation
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 qualied 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 specic purpose only. Any use going beyond this specic purpose is re-
garded 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 modications to the machine. The manufacturer will
not be liable for modications made at the machine on your own and damages result-
ing 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 responsibil-
ities 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 ngers 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.
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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
specications without prior notice!
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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.
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 specically described in this documentation.
Always keep magnets and all devices with strong magnetic elds 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.
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General safety, continued

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7
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.........................................................................................................13
Control Panel .............................................................................................................................. 14
Staples, Staple Cartridge, Stapler Head & Clinchers .................................................................15
Removing / replacing Staple Cartridge..................................................................................................15
Removing / replacing Staple Cartridge, continued................................................................................16
Removing / replacing Stapler Head.......................................................................................................16
Removing/replacing Stapler Head, continued.......................................................................................17
Changing Staple position and Narrow width Paper Sizes ..........................................................18
Changing Stapler and Clincher position................................................................................................18
Setting up narrow width paper sizes .....................................................................................................19
Trimmer ..........................................................................................................................................20
Emptying the Trim Bin................................................................................................................. 20
2. Making Booklets
Changing Settings......................................................................................................................... 21
General Procedure ..................................................................................................................... 21
Setting Paper Size......................................................................................................................21
Selecting Standard Paper Sizes............................................................................................................21
Custom Paper Size ...............................................................................................................................22
Stapling and Folding...................................................................................................................22
Edge staple ...........................................................................................................................................23
Saddle staple.........................................................................................................................................23
Staple and Fold Alignment ....................................................................................................................23
Corner staple.........................................................................................................................................24
Trimming ..................................................................................................................................... 24
Selecting Trimming On or Off................................................................................................................24
Adjusting the Cutting Margin.................................................................................................................24
SquareFolding ............................................................................................................................ 25
General..................................................................................................................................................25
Procedure..............................................................................................................................................25
On-line / Off-line.............................................................................................................................26
On-line Mode .............................................................................................................................. 26
Off-line Mode .............................................................................................................................. 28
3. Admin
The Admin Screen.........................................................................................................................29
Paper size check ........................................................................................................................29
Mode, Safe / Fast .......................................................................................................................30
System Setup ............................................................................................................................. 30
Standard Paper Size...................................................................................................................31
Language.................................................................................................................................... 31
Service........................................................................................................................................ 31

8
4. Jobs
Storing and Deleting Jobs............................................................................................................33
Storing a Job...............................................................................................................................33
Recalling a Job ...........................................................................................................................34
5. Clearing a Paper Jam
Clearing a Paper Jam....................................................................................................................35
General.......................................................................................................................................35
Booklet Maker................................................................................................................................36
Clearing a Paper Jam.................................................................................................................36
Inside the Booklet Maker.......................................................................................................................36
Trimmer ..........................................................................................................................................38
Clearing a Paper Jam.................................................................................................................38
Clearing Jam in Input Area....................................................................................................................38
Clearing Jam in Exit Area......................................................................................................................39
SquareFolder .................................................................................................................................40
Clearing a Paper Jam.................................................................................................................40
Inside the SquareFolder........................................................................................................................40
Exit Area................................................................................................................................................40
6. Troubleshooting
Fault codes.....................................................................................................................................41
General.......................................................................................................................................41
Booklet Maker Fault Codes ........................................................................................................42
Remove stacked sheets........................................................................................................................42
Too many sheets ...................................................................................................................................42
Check Staples.......................................................................................................................................42
Trimmer Fault Codes .................................................................................................................. 42
Close trimmer belts ...............................................................................................................................42
Waste Bin Full .......................................................................................................................................42
Booklet quality............................................................................................................................... 43
Fold Quality................................................................................................................................. 43
SquareFolding Quality ................................................................................................................ 44
7. General Remarks
Do’s And Don’ts............................................................................................................................. 45
Placing Your Machine ................................................................................................................... 46
Machine Environment ................................................................................................................. 46
Power Connection ...................................................................................................................... 46
Access to Machine...................................................................................................................... 47
Maintaining Your Machines .......................................................................................................... 48
Booklet Maker............................................................................................................................. 48
Lubricating Staplers and Clinchers........................................................................................................48
SquareFolder .............................................................................................................................. 49
Cleaning Feed Belts..............................................................................................................................49
Cleaning Square Folding Clamps..........................................................................................................50
8. Specications
Machine Specications................................................................................................................. 51
Booklet Maker BM 2000 .............................................................................................................51
Trimmer FTR 2000 (option) ........................................................................................................52
SquareFolder SQF 2000 (option) ...............................................................................................52

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What You Can Do With This Machine
The Booklet Maker BM 2000, Trimmer FTR 2000 and SquareFolder SQF 2000 form a
booklet making system that works on-line with Feeder/Collators.
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.
When a larger number of sheets are folded an effect called creeping occurs. In order to
rectify creep, the FTR 2000 Trimmer (optional) can be connected to the Booklet Maker.
The booklets are then transported from the Booklet Maker into the Trimmer where the front
edge (face) will be cut off.
Another option, the SQF 2000 SquareFolder, can be installed if a FTR 2000 Trimmer is
installed on the BM 2000 Booklet Maker. The prints, which have been stapled, folded and
trimmed will be fed into the SQF 2000. The SQF 2000 will atten the spine of the booklet
into a square shape. The booklets will, after passing through the SQF 2000, have the look
of a perfect bound book.
The booklets are then fed out to the Belt Stacker.
FTR 2000 Trimmer (option) BM 2000 Booklet MakerSQF 2000 SquareFolder (option)
Belt Stacker

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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.
The buttons are multi functional, meaning that the
function of each button depends on the information
displayed.
For example: In this screen, the icon next to button 1
indicates you will go up one level in the menu when
the button is pressed.
Example 2: In this screen, button 1 has no function.
Example 3: Pressing button 1 here will answer “No”
to the question on the screen.
1
2
3
4
5
6
Buttons
1
2
3
4
5
6
1
2
3
4
5
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Guide To Components
1
4
2
1 Control panel
2 Top cover
3 Power switch
4 Infeed assembly
3
Booklet Maker
5 Hand feed tray (optional)
6 Belt Stacker
7 Belt Stacker Cover
8 Hand feed slot (for on-line mode)
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6
5
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Booklet Maker, continued
5
4321
6
78
1 DFA. Not in use.
2 Not in use.
3 CAN In: Termination socket /
Communication with
Feeder/Collator
4 CAN Out: Termination socket /
Communication with FTR 2000
5 Power receptacle
6 Power out to SQF 2000
7 Interlock jumper
8 Interlock jumper / Power out to FTR
2000

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1 Tool box
2 Ball cage
3 Fold adjust lever, right side
Left side not shown in picture
4 Alignment tool, stapler assy.
5 Cartridge locking levers
6 Stapler lift brackets
7 Side guide extension
8 Thumb screw for Side guide ex-
tension
9 Stapler heads
10 Side guides
11 Guide
12 Screws for Stapler assy.
13 Staple detection leads, one on each
stapler head
14 Locking pin, one on each stapler head
15 Clincher, left side. Right side not shown
in picture
Booklet Maker, continued
9
7
14
8
11
5
23
12
10
6
78
Booklet maker,
top view
1
13 15
4

14
Trimmer
1
2
1 Top cover
2 Trim bin
Options

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Trimmer, continued
8
1
9
6
7
4
5
3
1 Trimmer fan
2 Outfeed latch
3 Transport belt
4 Exit compression brackets
5 Trimmer stop
6 Docking bracket
7 Infeed roller shaft
8 Knives (not visible in picture)
9 Infeed latch
Trimmer, top view
2

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1
1 Top cover
2 Upper feed belts (lifted position)
3 Docking bracket (not visible in picture
5 Lower feed belts
4 Latches
SquareFolder
5
2
4
3
SquareFolder,
top view

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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).
Close the Top cover.
Booklet Maker
Turning On / Off the Power
BA
1. Basics

1. Basics
18
Control Panel
The Main screen.
When the system power is switched on the Main
screen will be shown. Here you will nd information
showing the actual set up. 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.
State Current Job
The Jobs screen.
Pressing the [Jobs] button in the Main screen opens
the Jobs screen. From here you customize and
save job settings. Press [Jobs] again and you can
load previously saved jobs. These procedures are
described in section 4. Jobs.
The Admin screen.
Pressing the [Admin] button in the Main screen takes
you to the Admin screen. From here you can change
the display language, set paper size standard and
more. See section 3. Admin, for how to navigate in
the Admin screen.
Changing settings.
To change or adjust settings; Select an item in the
Main screen with the [arrow] button and press the
[Enter] button. For example you can ne adjust
the trimming, change stapling mode or set the
SquareFolder to the correct mode. Settings are
explored more thoroughly in section 2. Making
Booklets.

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1. Basics
Staples, Staple Cartridge, Stapler Head & Clinchers
Removing / replacing Staple Cartridge
A
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.
Gently twist the staple cartridge (B) from side to
side, and pull out the staple cartridge (B) from the
stapler head.
B
If the staple cartridge is empty or allmost empty*,
discard it and replace it with a new one. Before
replacing the cartridge, pull at least 20 mm of the
staples out and tear off at the staple tear line (C)
which is marked on the cartridge. If there has been a
misfeed, and the cartridge still contains staples, pull
20 mm of staples out of the cartridge and tear off at
the stapler tear line. Check that the rst staple is at.
If not, tear off another 20 mm, using less force.
*containing 300 staples or less
C
Insert the cartridge into the stapler head with the
staples facing towards the head mechanism. The
cartridge should be placed at on the slide on the
bottom of the stapler head. Push the cartridge rmly
into the stapler head and keep holding it pressed.
While holding the staple cartridge rmly pressed
into the stapler head, push down the cartridge
locking lever.
Note
It is important that the cartridge not is allowed to move
away from the stapler head before the locking lever
is in engaged. If that occurs, remove cartridge and
again tear off 20 mm of staples along the staple tear
line before inserting the cartridge.
Replacing the staple cartridge