MyBinding Plockmatic BM 200 User manual

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Plockmatic BM 200
Booklet Maker
Service Manual

BOOKLET MAKER BM 200
SERVICE MANUAL
12 February 2007
Subject to change

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III
IMPORTANT SAFETY NOTICES
1. BeforedisassemblingorassemblingpartsoftheBookletmakerandperipherals.
make sure that the Booklet maker power cord is unplugged,
2. The wall outlet should be near the Booklet maker and easily accessible.
3. Note that some components of the Booklet maker and peripherals are supplied
with electrical voltage even if the main power switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers off or
open while the main switch is turned on, keep hands away from electrical or
mechanically driven components.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The Booklet maker and its peripherals must be installed and maintained by a
customerservicerepresentativewhohascompletedthetrainingcourseonthose
models.
Alwaysconnecttheequipmenttoa prop-
erlygroundedpowersource.Indoubt,have
the power source checked by a qualied
electrician.
WARNING: Improper connection of the
equipment grounding conductor can result
in electrical shock.
Always follow all warnings marked on, or
supplied with, the equipment.
Always locate the equipment on a solid
support surface with adequate strength for
the weight of the machine.
Always exercise care in moving or re-
locating the equipment.
Always keep magnets and all devices with
strong magnetic eld away from the ma-
chine.
Never useagroundadapterplugto con-
nect the equipment to a power source that
lacks a ground connection terminal.
Never attempt any maintenance function
that is not specifically described in this
documentation.
Never remove the covers or guards that
are fastened with screws, unless you are a
trained Service representative.
Never install the unit near a radiator or any
other heat source.
Never overrideor “cheat” electricalor me-
chanical interlock devices.
Never operate the equipment if you notice
unusual noises or odors. Disconnect the
power cord from the power source and call
your customer service engineer to correct
the problem.
PREVENTION OF PHYSICAL INJURY
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Dispose of replaced parts in accordance with local regulations.

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V
TABLE OF CONTENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS..........................................................1-1
1.1.1 MINIMUM SPACE REQUIREMENTS.............................................1-1
1.1.2 POWER REQUIREMENTS.............................................................1-2
1.2 INSTALLATION FLOW CHART...............................................................1-3
1.3 BOOKLET MAKER INSTALLATION........................................................1-5
1.3.1 ACCESSORY CHECK....................................................................1-5
1.3.2 INSTALLATION PROCEDURE.......................................................1-6
1.3.3 ADJUSTMENTS..............................................................................1-7
1.3.4 CONNECTORS.............................................................................1-10
1.4 TRIMMER INSTALLATION.................................................................... 1-11
1.4.1 ACCESSORY CHECK .................................................................. 1-11
1.4.2 INSTALLATION PROCEDURE.....................................................1-12
1.4.3 ADJUSTMENTS............................................................................1-14
1.4.4 DOCKING.......................................................................................1-17
1.4.5 CONNECTORS.............................................................................1-20
1.5 SQUAREFOLDER INSTALLATION.......................................................1-23
1.5.1 ACCESSORY CHECK..................................................................1-23
1.5.2 INSTALLATION PROCEDURE.....................................................1-24
1.5.3 ADJUSTMENTS............................................................................1-27
1.5.4 DOCKING.......................................................................................1-30
1.5.5 CONNECTORS.............................................................................1-32
1.5.6 AUTO SET THICKNESS BRACKET.............................................1-33
2. PREVENTIVE MAINTENANCE SCHEDULE
2.1 PM TABLE ...............................................................................................2-1
3. REPLACEMENT AND ADJUSTMENT
3.1 GENERAL CAUTIONS............................................................................3-1
3.2 SPECIAL TOOLS AND LUBRICANTS ....................................................3-3
3.2.1 SPECIAL TOOLS............................................................................3-3
3.2.2 REQUIRED TOOLS........................................................................3-5
3.2.3 SYMBOLS USED IN TEXT.............................................................3-5
3.3 COVERS..................................................................................................3-7
3.3.1 FRONTAND REAR COVER...........................................................3-7
3.3.2 INFEED COVER.............................................................................3-8
3.3.3 INFEEDER......................................................................................3-9
3.3.4 OUTFEED COVER.......................................................................3-10
3.3.5 UPPER TOP COVER.................................................................... 3-11
3.3.6 REAR TOP COVER......................................................................3-12
3.3.7 TOP COVER ASSEMBLY .............................................................3-13
3.3.8 INTERLOCK SWITCH S16 &S17.................................................3-15
3.4 AREAA..................................................................................................3-17
3.4.1 INFEED MODULE.........................................................................3-17
3.4.2 PAPER INFEED SENSOR............................................................3-18
3.4.3 INFEED TRANSPORT MODULE..................................................3-19
3.4.4 INFEED TRANSPORT WHEEL....................................................3-20

VI
3.4.5 INFEED MOTOR M1 & SENSOR Q2...........................................3-21
3.4.6 SIDE GUIDES...............................................................................3-22
3.4.7 SIDE JOGGER MOTOR M3 & SENSOR Q12..............................3-23
3.4.8 SIDE GUIDE TRANSMISSION &SENSOR Q13...........................3-24
3.4.9 BACK JOGGER MODULE & SENSOR Q3 ..................................3-26
3.4.10 BACK JOGGER FINGERS...........................................................3-28
3.4.11 BACK JOGGER MOTOR M2........................................................3-30
3.4.12 STAPLER HEAD...........................................................................3-31
3.4.13 STAPLER HEAD RETRACTION DISTANCE................................3-34
3.4.14 STAPLER MOTOR M4..................................................................3-35
3.4.15 STAPLERASSY DRIVE BAR & SENSOR Q14............................3-36
3.4.16 CLINCHER BAR ASSEMBLY........................................................3-37
3.4.17 CLEANING CLINCHER POINTS..................................................3-38
3.4.18 SET TRANSPORT DRIVE ALIGNMENT.......................................3-39
3.4.19 PRESSURE ROLLER...................................................................3-41
3.4.20 SET TRANSPORT MOTOR M5....................................................3-42
3.4.21 THICK SET SENSOR Q36............................................................3-43
3.5 AREA B..................................................................................................3-45
3.5.1 STAPLE STOP GATE SOLENOID SOL1......................................3-45
3.5.2 STAPLE STOP GATE RELEASE SOLENOID SOL2....................3-46
3.5.3 SADDLE STAPLING START SENSOR Q4...................................3-48
3.6 AREA C..................................................................................................3-49
3.6.1 STAPLE / FOLD POSITION MOTOR M9 & SENSOR Q10..........3-49
3.6.2 LENGTH TRANSMISSION SHAFT & SENSOR Q11 ...................3-50
3.6.3 FOLD STOP GATE MOTOR M8 & SENSOR Q7..........................3-52
3.6.4 FOLD STOP GATE .......................................................................3-53
3.6.5 FOLD KNIFE MOTOR M7 & SENSOR Q15.................................3-54
3.6.6 FOLD TRANSMISSION MODULE................................................3-56
3.6.7 FOLD TRANSMISSION BELT & SENSOR Q9.............................3-57
3.6.8 FOLD ROLLER MOTOR M6.........................................................3-59
3.6.9 FOLD TRANSMISSION GEAR ASSEMBLYS...............................3-61
3.6.10 FOLD DISTANCE BRACKET........................................................3-62
3.6.11 UPPER FOLDER ROLLER...........................................................3-63
3.6.12 LOWER FOLDER ROLLER..........................................................3-65
3.6.13 OUTFEED SENSOR.....................................................................3-67
3.7 PCB .......................................................................................................3-69
3.7.1 MD3DC PCB “H”...........................................................................3-69
3.7.2 UPPER MD6DC PCB ”B”..............................................................3-70
3.7.3 LOWER MD6DC PCB ”C”.............................................................3-71
3.7.4 INTERLOCK PCB ”D”...................................................................3-72
3.7.5 CPU PCB AND COLLATOR INTERFACE PCB ”A” ......................3-73
3.7.6 ADDON PCB ”F”...........................................................................3-75
3.7.7 LCD PANEL...................................................................................3-76
3.8 STACKER..............................................................................................3-77
3.8.1 STACKER MODULE.....................................................................3-77
3.8.2 STACKER MOTOR M1.................................................................3-78
3.9 BOOKLET QUALITYADJUSTMENT.....................................................3-79
3.9.1 STAPLE STOP GATE PARALLELISM..........................................3-79

VII
3.9.2 SIDE GUIDE PARALLELISM........................................................3-81
3.9.3 STAPLE POSITION TO CLINCHER.............................................3-82
3.9.4 STAPLER PRESSURE .................................................................3-85
3.9.5 CLINCHER POINTS HEIGHT.......................................................3-86
3.9.6 CLINCHER PRESSURE...............................................................3-87
3.9.7 STAPLE AND FOLD POSITION....................................................3-89
3.9.8 FOLD SKEW.................................................................................3-91
3.9.9 STAPLE POSITION ON SQUARE FORMED SPINE....................3-92
3.10 POWER REQUIREMENTS...................................................................3-93
3.10.1 TAPPING THE TRANSFORMER..................................................3-93
4. TROUBLESHOOTING
4.1 FAULT CODE DESCRIPITIONS..............................................................4-1
4.2 BLOWN FUSE CONDITIONS ...............................................................4-31
4.3 LEDS .....................................................................................................4-33
4.4 TEST POINTS.......................................................................................4-39
5. SERVICE TABLES
5.1 SERVICE PROGRAM MODE..................................................................5-1
5.1.1 SERVICE PROGRAM MODE OPERATIONS.................................5-1
5.1.2 SERVICE PROGRAM MODE TABLES...........................................5-4
Check Motors and function.........................................................................5-4
5.1.3 EEPROM RESET..........................................................................5-12
5.2 SOFTWARE DOWNLOAD ....................................................................5-13
5.2.1 Downloading to upper PCB MD6DC B in Booklet maker..............5-13
5.2.2 Downloading to lower PCB MD6DC C in the Booklet maker. .......5-14
5.2.3 Downloading to PCB CPU in Booklet maker.................................5-15
5.2.4 Downloading to lower PCB MD3DC H in the Booklet maker. .......5-16
5.2.5 Downloading to PCB MD6DC A in Trimmer. .................................5-17
5.2.6 Downloading to PCB MD6DC D in Squarefolder. .........................5-18
5.3 SELF-DIAGNOSTIC MODE ..................................................................5-19
5.3.1 RUN TIME DIAGNOSTICS...........................................................5-19
5.3.2 POWER ON SELF TEST..............................................................5-19
5.3.3 DETAILED SELF-DIAGNOSTIC MODE........................................5-20
5.4 PAPER SIZE RESET ....................................................................5-21
5.5 SQF SERVICE.......................................................................................5-25
6. DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST..........................................................6-1
6.1.1 FRONT VIEW..................................................................................6-3
6.1.2 REAR VIEW....................................................................................6-4
6.1.3 CONNECTOR VIEW.......................................................................6-5
6.1.4 OUTFEED UPPER VIEW ...............................................................6-6
6.1.5 OUTFEED LOWER VIEW...............................................................6-7
6.1.6 INFEED UPPER VIEW ...................................................................6-8
6.1.7 INFEED LOWER VIEW...................................................................6-9
6.1.8 INFEED MODULE VIEW ..............................................................6-10
6.1.9 STACKER MODULE VIEW........................................................... 6-11
6.2 BOARD STRUCTURE...........................................................................6-13
6.2.1 BLOCK DIAGRAM........................................................................6-13
6.2.2 CONTROLLER CPU.....................................................................6-14

VIII
6.2.3 CONTROLLER MD6DC................................................................6-15
6.2.4 CONTROLLER MD3DC................................................................6-17
6.2.4 CONTROLLER MD3DC, CONTINUES.........................................6-18
6.3 BOOKLET MAKING PROCESS............................................................6-19
6.3.1 PRINCIPLE OF OPERATION .......................................................6-19
6.3.2 SIZE ADJUSTMENT .....................................................................6-23
SPECIFICATIONS
BOOKLET MAKER BM 200..................................................................Spec-1
TRIMMER FTR 200..............................................................................Spec-1
SQUAREFOLDER SQF 200.................................................................Spec-1
WIRING
Booklet Maker...............................................................................................Wir-1
Trimmer.........................................................................................................Wir-1
Squarefolder.................................................................................................Wir-1

IX
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE........................................................FTR-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE..................................FTR-2-1
3. REPLACEMENT AND ADJUSTMENT
3.1 COVERS..........................................................................................FTR-3-1
3.1.1 FRONTAND REAR COVER...................................................FTR-3-1
3.1.2 TOP COVER...........................................................................FTR-3-2
3.1.3 BLOWER MOTOR M5 / M6....................................................FTR-3-3
3.1.4 INFEED COVER.....................................................................FTR-3-4
3.1.5 LOCKING BRACKET..............................................................FTR-3-5
3.1.6 UPPER OUTFEED COVER....................................................FTR-3-6
3.1.7 INTERLOCK SWITCH S9 &S10.............................................FTR-3-7
3.1.8 LOWER OUTFEED COVER...................................................FTR-3-8
3.1.9 PROTECTION COVER...........................................................FTR-3-9
3.2 AREA C..........................................................................................FTR-3-11
3.2.1 INFEED SENSOR Q13.........................................................FTR-3-11
3.2.2 CONTROL SWITCH S2........................................................FTR-3-12
3.2.3 CONTROL SWITCH S3........................................................FTR-3-13
3.2.4 TRANSPORT MOTOR M1....................................................FTR-3-14
3.2.5 TRANSPORT BELT SENSOR Q4.........................................FTR-3-15
3.2.6 TRIM KNIFE MOTOR M2......................................................FTR-3-16
3.2.7 TRIM KNIFE HOME POSTITON SENSOR Q5.....................FTR-3-17
3.2.8 TRIM KNIFE..........................................................................FTR-3-18
3.2.9 PAPER PATH & OUTFEED SENSOR Q6.............................FTR-3-22
3.2.10 STOP GATE CARRIAGE ......................................................FTR-3-23
3.2.11 STOP GATE MOTOR M3 & SENSOR Q7.............................FTR-3-24
3.2.12 LENGTH ADJUSTMENT MOTOR M4 & SENSOR Q12.......FTR-3-25
3.2.13 LENGTH ADJUSTMENT HOME POSITION SWITCH S11 ..FTR-3-26
3.2.14 LOWER OUTFEED BELTS...................................................FTR-3-27
3.2.15 UPPER OUTFEED BELTS....................................................FTR-3-28
3.2.16 TRIM BIN FULL SENSOR Q8...............................................FTR-3-29
3.2.17 TRANSMISSION CHAIN.......................................................FTR-3-30
3.2.18 KNIFE SUPPORT CHAIN.....................................................FTR-3-31
3.2.19 KNIFE CHAIN .......................................................................FTR-3-32
3.2.20 INFEED BELTS.....................................................................FTR-3-33
3.3 PCB ...............................................................................................FTR-3-35
3.3.1 MD6DC PCB ”A”...................................................................FTR-3-35
4. TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS.......................................................FTR-4-1
5 SERVICE TABLES
5.1 SERVICE TABLES...........................................................................FTR-5-1
PERIPHERALS
TRIMMER FTR 200

X
6. DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST..................................................FTR-6-1
6.1.1 REAR VIEW............................................................................FTR-6-2
6.1.2 INFEED VIEW.........................................................................FTR-6-3
6.1.3 OUTFEED VIEW.....................................................................FTR-6-4
6.1.4 STOP CARRIAGE VIEW.........................................................FTR-6-5
6.2 BOARD STRUCTURE.....................................................................FTR-6-7
6.2.1 BLOCK DIAGRAM..................................................................FTR-6-7
6.2.2 CONTROLLER MD6DC..........................................................FTR-6-8
6.2.2 CONTROLLER MD6DC, CONTINUES...................................FTR-6-9
6.3 TRIMMING PROCESS..................................................................FTR-6-11
6.3.1 PRINCIPLE OF OPERATION ...............................................FTR-6-11
6.3.2 SIZE ADJUSTMENT .............................................................FTR-6-13
6.3.2 SIZE ADJUSTMENT .............................................................FTR-6-14
SPECIFICATIONS
SPECIFICATIONS...............................................................................FTR-Spc-1
WIRING
Trimmer.................................................................................................FTR-Wir-1

XI
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE........................................................SQF-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE..................................SQF-2-1
3 REPLACEMENT AND ADJUSTMENT
3.1 COVERS..........................................................................................SQF-3-1
3.1.1 FRONT COVER......................................................................SQF-3-1
3.1.2 REAR COVER ........................................................................SQF-3-2
3.1.3 INFEED COVER.....................................................................SQF-3-3
3.1.4 OUTFEED COVER.................................................................SQF-3-4
3.1.5 TOP COVER...........................................................................SQF-3-6
3.1.6 TILT THE MACHINE ...............................................................SQF-3-7
3.2 MOTORS.........................................................................................SQF-3-9
3.2.1 TRANSPORT BELT MOTOR (M1)..........................................SQF-3-9
3.2.2 STOP GATE MOTOR (M2) ...................................................SQF-3-10
3.2.3 CLAMP MOTOR (M3)...........................................................SQF-3-11
3.2.4 ROLLER MOTOR (M4)AND PRESSURE ROLLER.............SQF-3-12
3.3 SENSORS AND SWITCHES.........................................................SQF-3-15
3.3.1 STOP GATE SENSOR (Q1)..................................................SQF-3-15
3.3.2 ROLLER MOTOR FRONT/REAR SENSORS (Q2AND Q3)SQF-3-16
3.3.3 CLAMP MOTOR HOME POSITON SENSOR (Q4) ..............SQF-3-17
3.3.4 INFEED / OUTFEED SENSORS (Q5 AND Q7)....................SQF-3-18
3.3.5 CLAMP SENSOR (Q6)..........................................................SQF-3-20
3.3.6 MOTOR M4 ENCODER SENSOR (Q8)................................SQF-3-21
3.3.7 TOP COVER INTERLOCK SWITCHES (S2 & S4)...............SQF-3-22
3.3.8 UPPER TRANSPORT BELT CLUTCHES (SOL1 & SOL3)...SQF-3-23
3.3.9 LOWER TRANSPORT BELT CLUTCHES (SOL2 & SOL4)..SQF-3-24
3.4 BELTS............................................................................................SQF-3-25
3.4.1 UPPER TRANSPORT BELT.................................................SQF-3-25
3.4.2 LOWER TRANSPORT BELT ................................................SQF-3-26
3.4.3 TEFLON TAPE LOWER TRANSPORT BELT ....................SQF-3-29
3.5 MECHANICS.................................................................................SQF-3-31
3.5.1 SET CLAMPS........................................................................SQF-3-31
3.5.2 STOP GATE..........................................................................SQF-3-34
3.6 PCB ...............................................................................................SQF-3-37
3.6.1 PCB MD6DC “D”...................................................................SQF-3-37
3.7 POWER REQUIREMENTS...........................................................SQF-3-39
3.7.1 TAPPING THE TRANSFORMER..........................................SQF-3-39
4. TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS.......................................................SQF-4-1
4.2 BLOWN FUSE CONDITION..........................................................SQF-4-13
4.3 LED’S.............................................................................................SQF-4-15
4.4 TEST POINTS...............................................................................SQF-4-17
PERIPHERALS
Squarefolder SQF 200

XII
5 SERVICE TABLES
5.1 SERVICE TABLES...........................................................................SQF-5-1
6. DETAILED SECTION DESCRIPTION
6.1 ELECTRICAL COMPONENT LIST..................................................SQF-6-1
6.1.1 COMPONENT LAYOUT..........................................................SQF-6-2
6.2 BOARD STRUCTURE .....................................................SQF-6-5
6.2.1 CONTROLLER MD6DC “D”....................................................SQF-6-5
6.3 PRINCIPLE OF OPERATION..........................................................SQF-6-7
SPECIFICATIONS
SPECIFICATIONS.............................................................................. SQF-Spc-1
WIRING
Squarefolder........................................................................................SQF-Wir-1

1-1
Installation
31 January 2007
1 INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS
1.1.1 MINIMUM SPACE REQUIREMENTS
INSTALLATION REQUIREMENTS
SQF 200 FTR 200 BM 200
Stacker
810 mm
31.9”
350 mm
13.75”
350 mm
13.75”
625 mm
24.38”
400 mm
15.75”
2135 mm
84”
670 mm
26.4”
555 mm
21.9”

1-2
31 January 2007
1.1.2 POWER REQUIREMENTS
1. Input voltage level:
North America 120V AC, 50-60Hz: More than 4 A.
Europe/Asia 230V AC, 50-60Hz: More than 2 A.
2. Permissible voltage uctuation: ± 10%
3. Never place anything on the power cord.
INSTALLATION REQUIREMENTS
WARNING
1. Make sure that the wall outlet is near the main machine and easily
 accessible.Makesuretheplugisrmlyinsertedintheoutlet.
2. Avoid multi-wiring.
3. Be sure to ground the machine.

1-3
Installation
31 January 2007 INSTALLATION FLOW CHART
1.2 INSTALLATION FLOW CHART
The following ow chart shows how to install the optional units more efciently.
FTR 200 Trimmer: Enables On-line trimming. Especially thicker sets ( > 4
sheets) look unprofessional because of ”creep”. FTR 200
will trim those edges (up to 15 mm / 19/32”).
SQF 200 SquareFolder:Enables the possibility to give the booklets the perfect
bound look.
Yes No
Install the Booklet Maker BM 200
Does the user require a Trimmer?
Install the Trimmer FTR 200
Does the user require a SquareFolder?
Is a Trimmer installed?
Yes No
Install the SquareFolder SQF 200
Install the Belt Stacker
Yes
Install Trimmer
No
Check the Installation

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1-5
Installation
31 January 2007
1.3 Booklet Maker INSTALLATION
1.3.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following list:
Description Q’ty
A. Communication Cable.......................................................... 1
B. Powercord............................................................................ 1
C. Terminator plug, will always be installed onto BM 200......... 1
D Terminator plug FTR 200 ..................................................... 1
E. Interlock Jumper, will always be installed onto BM 200 ...... 1
F. Interlock Jumper FTR 200.................................................... 1
G. Cable protector..................................................................... 1
H. Cable protector sticker ........................................................ 1
I. Cable holder......................................................................... 1
[A] [B] [D]
[C]
[E] [F]
BOOKLET MAKER INSTALLATION
[G] [H] [I]

1-6
31 January 2007
BOOKLET MAKER INSTALLATION
1.3.2 INSTALLATION PROCEDURE
Unpacking
1. Remove all parts from the pallets.
2. Slide the Booklet Maker off the pallet by pulling the two cardboard handles [A]
underneath the Booklet Maker straight out.
WARNING
2 persons are required to slide the Booklet Maker off the pallet.
[A]

1-7
Installation
31 January 2007 BOOKLET MAKER INSTALLATION
Upper Top Cover
1. Hold the Upper Top Cover in position and lower the rear end so that the grom-
mets [A] and the holes in the guide brackets [B] are centered towards each
other [C].
2. Secure the rear end of the Upper Top Cover with screws [D] ( x2).
NOTE: After securing the rear end of the Upper Top Cover, be careful not to dam-
age the guide by lifting the front end.
[A] [C]
[D]
[B]