MyBinding Plockmatic BM 200 User manual

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Plockmatic BM200
Booklet Maker
Installation Manual

INSTALLATION INSTRUCTION
BM 200
FTR 200
SQF 200
This manual applies to the mentioned machines both in left and right version.
Within this document, all references to right version also apply to the left version
unless specially mentioned.
The difference is basically that the two models are mirrored.All pictures within this Installation
Instruction are of the right version.
Due to the mirroring, typical Front and Rear designations which normally is viewed from the opera-
tor location has been replaced by Left and Right. Left and Right is viewed from the paper direction.
Clarication:
Left = Rear for right version & Front for left version
Right = Front for right & Rear for left
This Installation Instruction is an excerpt from the Service Manual
31 January, Rev 0.02
Subject to change
Doc. No. T09231
Part No. 76487

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III
IMPORTANT SAFETY NOTICES
1. Beforedisassemblingor assemblingpartsoftheBookletmakerandperipherals
make sure that the Booklet maker power cord is unplugged,
2. The wall outlet should be near the Booklet maker and easily accessible.
3. Notethat some components of the Booklet maker and peripherals aresupplied
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.
Alwaysconnecttheequipmenttoaproperly
grounded power source. In doubt, 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 relocat-
ing the equipment.
Always keep magnets and all devices
with strong magnetic eld away from the
machine.
Neveruseagroundadapterplugtoconnect
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 override or “cheat” electrical or 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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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]

1-8
31 January 2007
BOOKLET MAKER INSTALLATION
4. Lower the front end of the Upper Top Cover so that the holes in the guide bra-
clets and the holes in the Top Cover frame are centered towards each other [E].
NOTE: There are two guides [F] and two brackets [G] on the front side of the
Upper Top Cover. Make sure that these guides are positioned on each side of
the the Upper Top Cover frame part [H].
5. Secure the front end of the Upper Top Cover with screws [I] ( x2).
[E]
[I]
[H]
[F] [G]

1-9
Installation
31 January 2007
1.3.3 ADJUSTMENTS
BOOKLET MAKER INSTALLATION
1. Remove screws [A] and remove the Booklet Maker front cover ( x5).
2. Remove screws [B], loosen screw [C] and remove the Bookler maker rear
cover ( x5).
[A]
[B] [C]

1-10
31 January 2007
BOOKLET MAKER INSTALLATION
3. Mount the supplied positioning pins on the collator.
4. Dock the collator to the Booklet Maker. See picture above.

1-11
Installation
31 January 2007 BOOKLET MAKER INSTALLATION
5. Turn the four adjustment nuts [A] until the distance [B], between the lower
edge of door and the top of side guide, is 3 mm.
6. Reinstall the Booklet Maker front and rear covers ( x 10).
[A]
Booklet Maker, front view
[B]

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31 January 2007
1.3.4 CONNECTORS
1. If a collator is present, connect the communication cable [A] from the collator
( x1), to the Booklet Maker.
2. Connect the Belt Stacker cable [B] ( x1).
NOTE: Unless Trimmer FTR 200 and/or SquareFolder SQF 200 will be installed.
If so, Belt Stacker cable will be connected to the last module in the system.
3. Install the Terminator plug [C] and the Interlock jumper [G].
NOTE: The Terminators and Interlock jumpers are stored in the installation kit.
4. Install the Terminator plug [D] and the Interlock jumper [F].
NOTE: Unless Trimmer FTR 200 will be installed. If so, communication cable
and power cord between BM 200 and FTR 200 will be connected.
5. Connect the powercord [E] to the Booklet Maker ( x1).
6. Mount the cable protector [H] positioned as shown with two screws in the
holes [I] and route the cables inside the cable protector ( x 2).
7. Attach the sticker “Do not lift here” [J] on the cable protector.
8. Install the cable holders [K] on the rear side of the Booklet Maker base and
route the cables through them.
BOOKLET MAKER INSTALLATION
[H]
[J]
[B][A] [C] [D] [E][F][G]
Only Booklet Maker installed
[I]
[K]
Cable protector mounted Cable holder mounted on Booklet Maker

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Installation
31 January 2007
1.3.5 CHANGING SPEED ON THE COLLATOR
BOOKLET MAKER INSTALLATION
1. Enter Collator program mode by pressing hidden button [A] and holding it until
all green LED’s goes out.
2. Press button [B] repeatedly until programmable setting No. 10 is displayed.
This is indicated when bin LED 10 [C] on the Collator display is lit. The correct
value for setting No. 10 should read 120. If so, continue to step 5.
3. Press button [D] once to display the last digit. Press button [B] to change the
last digit.
Press button [D] to also display the middle digit. Press button [B] to change
the middle digit.
Press button [D] to also display the rst digit. Press button [B] to change the
rst digit.
4. Conrm changing setting No. 10 by pressing button [D]
[A] [D] [B]
[C]
Continued on next page....

1-14
31 January 2007
5. Press button [B] repeatedly until programmable setting No. 20 is displayed.
This is indicated when bin LED 10 [C] and third party LED [E] on the Colla-
tor display are lit. The correct value for setting No. 20 should read 180. If so,
continue to step 8.
6. Press button [D] once to display the last digit. Press button [B] to change the
last digit.
Press button [D] to display the middle digit. Press button [B] to change the
middle digit.
Press button [D] to display the rst digit. Press button [B] to change the rst
digit.
7. Conrm changing setting No. 20 by pressing button [D].
8. Press hidden button [A] to exit Collator programming mode.
BOOKLET MAKER INSTALLATION
[A] [D] [B]
[C]
[E]

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Installation
31 January 2007
1.3.6 CHECK THE INSTALLATION
1. If installing a Trimmer FTR 200, continue to section ( 1.4 ) otherwise
continue with step 2.
2. Power on the Booklet maker and the Collator.
3. Remove the two Stapler heads, according to section ( 3.4.12 ).
4. Perform a Detailed self-diagnostic, according to section ( 5.3.3 )
5. Reinstall the two Stapler heads, according to section ( 3.4.12 ).
6. Set up the Collator to send A4/8.5 x 11” sheets to the Booklet Maker.
7. Set up the Booklet maker to A4/8.5 x 11”.
8. Set up the Booklet maker to Staple ON.
9. Feed a A4/8.5 x 11” set to the Booklet maker.
10. Check for the correct feeding of the set from the Collator.
NOTE: If paper is not fed correctly, check adjustment of the Booklet maker
according to section ( 1.3.3 ).
11. Set up the Collator to send A3/11 x 17” sheets to the Booklet Maker.
12. Set up the Booklet maker to A3/11 x 17”.
13. Set up the Booklet maker to Staple ON.
14. Feed a A3/11 x 17” set to the Booklet maker.
15. Check for the correct feeding of the set from the Collator.
NOTE: If paper is not fed correctly, check adjustment of the Booklet maker
according to section ( 1.3.3 ).
BOOKLET MAKER INSTALLATION