Morgana BM350 User manual

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

WARNING:
This is a Class A product.
In a domestic environment this product may cause radio interference,
in which case the user may be required to take adequate measures.
The product (System) which is connected to this machine will be class A.
NOTE:
The domestic environment is an environment where the use of broadcast radio and
television receivers may be expected within a distance of 10m of the apparatus concerned.

Introduction
This manual contains instructions on the operation and maintenance of this machine.
To get maximum versatility from this machine all operators should carefully read and follow the
instructions in this manual. Keep this manual in a handy place near the machine.
Please read the Safety Information before using this machine.
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.

WARNING:
• To avoid hazardous situations e.g. electric shock or danger while exposed to moving,
rotating or cutting devices, do not remove any covers, guards or screws other than
those 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.
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
designed 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 responsibilities on operating the machine have to be strictly laid down and ob-
served 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.
• Always locate the equipment on a solid support surface with adequate strength tor the
weight of the machine.

CAUTION:
• The machine and its peripherels must be installed and maintained by a customer service
representative who has completed the training course on those models.
• Always follow all warnings marked on, or supplied with, the equipment.
• When you disconnect the power plug from the wall outlet, always pull the plug (not the cable).
• Disconnect the power cord before you move the machine. While moving the machine, always
exercise care and make sure that the power cord will not be damaged under the machine.
• Always 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 off 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 maintenance function that is not 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 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 specications without prior notice!

PAGE INTENTIONALLY BLANK.

TABLE OF CONTENTS
What You Can Do With This Machine ............................................................................. 11
Guide To Components ..................................................................................................... 13
Booklet Maker............................................................................................................................. 13
User interface ............................................................................................................................. 16
Control panel ..................................................................................................................... 16
Options.............................................................................................................................. 18
BM350/500 Booklet Maker ......................................................................................................... 18
Live logo ............................................................................................................................ 18
SQF500 Square Fold Module ..................................................................................................... 19
FTR500 Trimmer Module............................................................................................................ 21
CST500 Crease Trim Module ..................................................................................................... 23
CR500 Creaser Module .............................................................................................................. 29
BST4000-1 Belt Stacker Module ................................................................................................ 31
BST4000-1 Principle of Operation..................................................................................... 32
Air Assist Feeder AF602 ............................................................................................................. 33
Vacuum Feeder VF602............................................................................................................... 34
1. Basics
Turning On / Off Main Power ........................................................................................... 35
Locating power switches............................................................................................................. 35
Loading Feeder AF602/VF602 ......................................................................................... 37
Change staple cartridges and Check stapler................................................................. 38
Change left/right staple cartridge(s)............................................................................................ 38
Check left/right stapler ................................................................................................................ 39
Emptying the trim bin....................................................................................................... 40
Undocking the Booklet Maker......................................................................................... 40
Belt Stacker....................................................................................................................... 41
Setting up Belt Stacker for right-angled mode ............................................................................ 41
Setting up Belt Stacker for Straight Mode................................................................................... 42
Job Preparation ................................................................................................................ 43
2. Making Booklets
Changing settings ............................................................................................................ 47
General procedure...................................................................................................................... 47
Paper Size .................................................................................................................................. 47
Selecting standard paper sizes ......................................................................................... 47
Custom sheet size ............................................................................................................. 48
Staple.......................................................................................................................................... 48
Selecting stapling On or Off............................................................................................... 48

Staple position ............................................................................................................................ 49
Adjusting staple position.................................................................................................... 49
Fold position ............................................................................................................................... 49
Adjusting fold position........................................................................................................ 49
Fine tuning booklet appearance ................................................................................................. 50
Face Trimming ............................................................................................................................ 51
Select Face Trimming Auto or Manual .............................................................................. 51
Square Fold Module ................................................................................................................... 52
General.............................................................................................................................. 52
Selecting square folding mode .......................................................................................... 53
Square Fold stop gate offset ............................................................................................. 53
Crease Trim Module (Option) ..................................................................................................... 54
Crease - Selecting Crease Mode ...................................................................................... 54
Bleed Trim Settings - General ........................................................................................... 55
Bleed Trimmer - Asymmetric Side Trim ............................................................................. 55
Setting up a feeder job in AF602/VF602..................................................................................... 56
AF602 Advanced Settings .......................................................................................................... 57
Operation with AF602 ................................................................................................................. 59
VF602 Advanced Settings .......................................................................................................... 60
Operation with VF602 ................................................................................................................. 65
Hand-feeding..................................................................................................................... 66
Hand feed mode ......................................................................................................................... 66
Hand feed mode using the tray................................................................................................... 67
3. Tools
The Tools screen......................................................................................................................... 69
Stacker full detection .................................................................................................................. 69
Units............................................................................................................................................ 69
Software version ......................................................................................................................... 70
Square Fold stop gate offset....................................................................................................... 70
4. Jobs
Handling jobs.................................................................................................................... 71
Saving a Job ............................................................................................................................... 71
Opening and handling stored Jobs ............................................................................................. 72
5. Clearing Misfeed(s)
Clearing misfeed(s) .......................................................................................................... 73
General ....................................................................................................................................... 73
CST module....................................................................................................................... 74
Clearing misfeed(s) in the paper path......................................................................................... 74
Infeed “A” area and exit “D” area....................................................................................... 74
CST, registration and creaser area.................................................................................... 75

Booklet Maker................................................................................................................... 76
Clearing misfeed(s)..................................................................................................................... 76
Inside the Booklet Maker ................................................................................................... 76
Clearing misfeed in folder area.......................................................................................... 77
AF602/VF602 Feeder module........................................................................................... 78
Clearing misfeeds ....................................................................................................................... 78
Misfeed/Jam in feeder bin ................................................................................................. 78
Misfeed/Jam in paper transport area................................................................................. 78
Square Fold Module ......................................................................................................... 79
Clearing misfeed(s)..................................................................................................................... 79
Inside the Square Fold Module.......................................................................................... 79
Trimmer module................................................................................................................ 80
Clearing misfeed(s)..................................................................................................................... 80
Clearing misfeed in input area........................................................................................... 80
Clearing misfeed in exit area ............................................................................................. 81
Belt stacker ....................................................................................................................... 82
Clearing misfeed(s)..................................................................................................................... 82
Clearing misfeed on belt stacker ....................................................................................... 82
6. Troubleshooting
Fault codes........................................................................................................................ 83
General ....................................................................................................................................... 83
General fault codes..................................................................................................................... 85
Clear Misfeed(s) ................................................................................................................ 85
Close cover(s) ................................................................................................................... 86
Empty stacker!................................................................................................................... 86
CST fault codes .......................................................................................................................... 87
Waste bin full ..................................................................................................................... 87
Booklet maker fault codes .......................................................................................................... 87
Check stapler or Change staple cartridge ......................................................................... 87
Set too thick, remove set ................................................................................................... 87
Remove purged set ........................................................................................................... 87
AF602/VF602 fault codes ........................................................................................................... 88
Jam recovery manual setting VF602 .......................................................................................... 90
Miss error........................................................................................................................... 90
Jam, Too long, Too thick errors.......................................................................................... 91
Trimmer fault codes .................................................................................................................... 92
Empty trim bin.................................................................................................................... 92
Close trimmer belts............................................................................................................ 92
Square Fold fault codes.............................................................................................................. 92
Feed errors ........................................................................................................................ 92
Sensor Calibration............................................................................................................ 93
AF602 Sensor Calibration........................................................................................................... 93
VF602 Sensor Calibration........................................................................................................... 95

7. REMARKS
Do’s And Don’ts................................................................................................................ 97
Where to put Your Machine ............................................................................................. 98
Machine environment ................................................................................................................. 98
Power connection ....................................................................................................................... 98
Access to machine...................................................................................................................... 99
Maintaining Your Machines ........................................................................................... 100
Square Fold module maintenance............................................................................................ 101
Cleaning feed belts.......................................................................................................... 101
CST Module maintenance ........................................................................................................ 102
Cleaning the paper path transportation nip rollers (12x) ................................................. 102
Cleaning the xing rollers (3x) ......................................................................................... 103
Cleaning the registration cross roller (4x) & friction tires (4x).......................................... 104
Cleaning the rotator rollers (2x) ....................................................................................... 105
Cleaning the paper path sensors (5x) ............................................................................. 105
Cleaning of creaser tools (2x).......................................................................................... 107
Adjustment of Bleed Trimmer registration angle (parallell cut) ........................................ 108
Adjustment of Creaser registration angle ........................................................................ 109
AF602 Feeder Maintenance ..................................................................................................... 110
Cleaning AF602 ............................................................................................................... 110
VF602 Feeder Maintenance ..................................................................................................... 112
Cleaning VF602............................................................................................................... 112
Limitations in the BM350/BM500 system ..................................................................... 114
Best practice for the BM350/BM500 system ................................................................ 116
8. Specication
Machine Specications.................................................................................................. 117
BM350/BM500 Booklet Maker .................................................................................................. 117
Performance diagrams ............................................................................................................. 118
Square Fold Module ................................................................................................................ 118
FTR Trimmer Module ................................................................................................................ 119
CST Crease Trim Module (option) ............................................................................................ 120
Creaser CR500 (option)............................................................................................................ 121
Air Feeder AF602 / Vacuum Feeder VF602 (options)............................................................... 122
BST4000-1 Belt Stacker Module .............................................................................................. 122
System Set Size Guide............................................................................................................. 123