MyBinding Plockmatic BM 200 User manual

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Plockmatic BM 200
Booklet Maker
Instruction Manual

BOOKLET MAKER BM 200
Operating Instruction
Booklet Maker Reference
Part no: 76489
Doc no: T10169
Rev. ver: 0.02
Rev. date: 6 February 2007

Warning
ThisisaClassAproduct.Inadomesticenvironmentthisproductmaycauseradiointerference
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
Thedomesticenvironmentisan environmentwheretheuse of broadcastradioand television
recievers may be expected within a distance of 10 m of the apparatus concerned.

3
TABLE OF CONTENTS
What You Can Do With This Machine............................................................................................5
Guide To Components ....................................................................................................................7
Booklet Maker ..............................................................................................................................................7
Options...........................................................................................................................................10
Trimmer......................................................................................................................................................10
SquareFolder..............................................................................................................................................12
Control Panel.................................................................................................................................14
1. Basics...............................................................................................17
Turning On / Off the Main Power..................................................................................................17
Booklet Maker, Trimmer and SquareFolder................................................................................................17
Docking / Undocking.....................................................................................................................17
Docking the Booklet Maker to a Collator, standard paper sizes.................................................................17
Docking the Booklet Maker to a Collator, custom paper sizes...................................................................18
Adjusting docking assembly to factory settings..........................................................................................18
Undocking the Booklet Maker from a Collator............................................................................................18
Check staples, Staple cartridge and stapler head......................................................................19
Removing stapler head ..............................................................................................................................19
Removing staple cartridge..........................................................................................................................19
Installing stapler head, staple cartridge / clearing staple jam.....................................................................20
Emptying the trim bin....................................................................................................................21
2. Making Booklets..............................................................................23
Changing settings.........................................................................................................................23
General procedure .....................................................................................................................................23
Setting Paper Size......................................................................................................................................23
Selecting standard paper sizes ..........................................................................................23
Custom paper size ...............................................................................................................24
Stapling ......................................................................................................................................................24
Selecting stapling On or Off................................................................................................24
Trimming.....................................................................................................................................................25
Selecting trimming On or Off..............................................................................................25
Adjusting the cutting margin ..............................................................................................25
SquareFolding............................................................................................................................................26
General..................................................................................................................................26
Selecting SquareFolding mode ..........................................................................................26
On-line/Hand feeding ....................................................................................................................27
Hand feeding..............................................................................................................................................27
On-line........................................................................................................................................................28
3. Tools.................................................................................................29
The Tools Screen...........................................................................................................................29
Units...........................................................................................................................................................29
Software version.........................................................................................................................................29
Language ...................................................................................................................................................30
Service .......................................................................................................................................................30
4. Jobs..................................................................................................31
Storing and deleting jobs .............................................................................................................31
Storing a new Job.......................................................................................................................................31
Recalling a Job...........................................................................................................................................32

4
5. Clearing Misfeed(s) .........................................................................33
Clearing misfeed(s).......................................................................................................................33
General.......................................................................................................................................................33
Booklet Maker................................................................................................................................34
Clearing misfeed(s)....................................................................................................................................34
Inside the Booklet Maker.....................................................................................................34
Trimmer ..........................................................................................................................................35
Clearing misfeed(s)....................................................................................................................................35
Clearing misfeed in input area............................................................................................35
Clearing misfeed in exit area ..............................................................................................36
SquareFolder .................................................................................................................................37
Clearing misfeed(s)....................................................................................................................................37
Inside the SquareFolder ......................................................................................................37
Exit area ................................................................................................................................37
6. Troubleshooting ..............................................................................39
Fault codes.....................................................................................................................................39
General.......................................................................................................................................................39
General fault codes....................................................................................................................................40
Clear Misfeed(s) ...................................................................................................................40
Close cover(s) ......................................................................................................................40
Booklet Maker fault codes..........................................................................................................................40
Set too thick..........................................................................................................................40
Check staples.......................................................................................................................40
Stacker full............................................................................................................................41
Oil clinchers..........................................................................................................................41
Check set ..............................................................................................................................41
Trimmer fault codes....................................................................................................................................42
Close trimmer belts..............................................................................................................42
Empty trim bin......................................................................................................................42
Trimmer fan missing............................................................................................................42
Stacker full............................................................................................................................42
SquareFolder fault codes...........................................................................................................................43
Feed errors ...........................................................................................................................43
7. REMARKS ........................................................................................43
Do’s And Don’ts.............................................................................................................................43
Where to put Your Machine ..........................................................................................................44
Machine environment.................................................................................................................................44
Power connection.......................................................................................................................................44
Access to machine.....................................................................................................................................45
Maintaining Your Machines .......................................................................................................... 46
Booklet Maker ............................................................................................................................................46
Oil Clinchers and Stapler heads.........................................................................................46
SquareFolder..............................................................................................................................................48
Cleaning feed belts ..............................................................................................................48
8. Specication ...................................................................................49
Machine Specications.................................................................................................................49
Booklet Maker BM 200...............................................................................................................................49
Trimmer FTR 200 (option)..........................................................................................................................49
SquareFolder SQF 200 (option).................................................................................................................50

5
What You Can Do With This Machine
The Booklet Maker BM 200, Trimmer FTR 200 and SquareFolder SQF 200 forms a booklet
making system that works online with a collator or ofine/online for hand feeding.
The print-outs from the Copier are collected in the nisher and then transported into the BM
200 Booklet Maker to the staple area. The Booklet Maker now jogs and then staples the set.
Thesetisthentransportedfurthertothe foldingareawheretheset isfoldedintoa bookletand
then fed out to the belt stacker. When a larger number of sheets are folded an effect called
creeping occurs. In order to rectify creep, the FTR 200 Trimmer (optional) can be attached
after the Booklet Maker. The booklets are then transported from the Booklet Maker into the
Trimmer where the trail edge will be cut off. If a FTR 200 Trimmer is installed to the BM 200
Booklet Maker, you can attach the SQF 200 SquareFolder (optional). The printouts, which
have been stapled, folded and trimmed will be fed into the SQF 200. The SQF 200 will atten
the spine of the booklet square. The booklets will, after passing the SQF 200, have the look
of a perfect bound book. The booklets are then fed out to the Belt Stacker.
To facilitate hand feeding, theBM 200 is equipped with a sliding top cover.The Booklet Maker
can also be used as a stand-alone unit for hand feeding.
FTR 200 Trimmer (option)
BM 200 Booklet Maker
SQF 200 SquareFolder (option)
Belt Stacker

6
The BM 200 Booklet making system is controlled from a single control panel on the Booklet
Maker. The control panel has only four buttons which will allow you to easily set up, adjust
and operate the complete system.
The buttons are multi functional, meaning that the
function of each button depends on the information
displayed.
Forexample:Pressingbutton3 fromtheReadyscreen
takes you to the Tools screen.
Example 2: In this screen, button 3 has no function.
Button: 1 2 3 4
Example 3: Pressing button 3 here will load the stored
Job (4).
Button: 1 2 3 4
Example 4: In this screen pressing button 3 will save
the current settings for job No 1. The asterisk on the
rst row shows that the settings for Job (1) has been
changed, but not yet saved.
Button: 1 2 3 4

7
Guide To Components
2
3
7
1
1 Top cover
2 Control panel
3 Main power switch
4 Upper Top cover
5 Infeed assembly
6 Docking assembly
5
Booklet Maker
7 Base
8 Positioning holes for A3/11” and sizes nearby
9 Belt Stacker Cover
10 Belt Stacker
11 Knob, adjustment for custom paper size
12 Positioning holes for A4/8.5” and sizes nearby
6
9
10
4
8
1211

8
89
8 Connections
9 Fold stop gate
Booklet Maker, continues
Main Power
Terminator/COM
FTR 200TerminatorStacker
COM Collator POW SQF 200
Interlock jumper
Interlock jumper/
POW FTR 200

9
1
5
6
1 Stapler heads
2 Staple cartridges
3 Cartridge locking levers
4 Stapler release latches
5 Staple detection leads
6Hand feeding paper guides
Booklet Maker, continues
3
45
2

10
COM BM 200
Trimmer
1
2
4
1 Top cover
2 Trim bin
3 Base
4 Connections
Options
3
Stacker COM BM 200 Terminator/Com
SQF 200
Power from
BM 200

11
Trimmer, continues
5
1
2
3
4
6
7
8
9
The Trimmer interior has parts that you will come in contact with if a misfeed occurs.
1 Set counter
2 Trimmer stop
3 Outfeed latch
4Exit compressing brackets
5 Transport belt
6 Infeed roller shaft
7 Trimmer fan
8 Upper knife
9 Infeed latch
Trimmer, top view

12
1
1 Top cover
2 Trim bin
3 Base
4 Connections
3
StackerCOM FTR 200
Terminator
POW SQF 200
2
SquareFolder
4

13
1 Lower feed belts
2 Upper feed belts
1 2
SquareFolder, top view,
Upper feed belts in lifted up
SquareFolder, continues
The SquareFolder interior has parts that you will come in contact with if a misfeed occur.

14
Control Panel
The Ready screen.
When the system power is switched on the Ready
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 200 Booklet making system.
arrow button
change button
tools button
jobs button
The Jobs screen.
Pressing the [Jobs] button in the Ready screen opens
the Jobs screen. From here you can load, customize
andsavejobsettings.Theseproceduresaredescribed
in section 4. Jobs.
The Tools screen.
Pressing the [Tools] button in the Ready screen takes
you to the tools screen. Here you will nd all the
necessary tools for a troublefree operation. From here
you can change the display language, set units from
millimeters to inches and more. See section 3. Tools.
for how to get around in the Tools screen.
Changing settings.
Tochangeoradjustsettings;SelectanitemintheReady
screen with the [arrow] button and press the [Change]
button. For example you can ne adjust the trimming,
turn off the cover feeder or set the SquareFolder to the
correct mode. Explore all settings more thoroughly in
section 2. Making Booklets.

15
The Processing screen.
Thisscreenisshownwhenthemachineisbusyworking.
If the machine is used in off-line mode you do not have
to wait for the Ready screen before handfeeding the
next set.
The Please wait screen.
While the machine sometimes needs time to perform
changes in settings, the Please wait screen will be
shown. The machine will automatically return to the
Ready screen after changes have been implemented.

17
Plug the Booklet Maker power cord into the wall
outlet.
The trimmer (optional) and the SquareFolder
(optional) are powered from the Booklet Maker.
Open the Top cover (1).
Set main power switch (2) on Booklet Maker to ON
position.
Note
ThemainpowerswitchalsocontrolsTrimmer(optional)
and SquareFolder (optional).
Close the Top cover.
Turning On / Off the Main Power
Booklet Maker, Trimmer and SquareFolder
2
1
1. Basics
Docking / Undocking
Docking the Booklet Maker to a Collator, standard paper sizes
When the Booklet Maker is docked to a collator it must
be correctly positioned in order to have the set fed
enteringtheinfeedassemblycorrectly. Thepapersize
used determines which positioning holes to use.
Push the docking assembly (1) to the rear until it
locks.
Thedockingbrackets(2)onthecollatorshouldenter
positioning holes:
(3) if you are using A4 / 8 1/2” paper widths or sizes
nearby
or
(4) if you are using A3 / 11” paper widths or sizes
nearby
1 3 2
4

1
18
Docking the Booklet Maker to a Collator, custom paper sizes
By loosening the knob (4), the docking assembly can
be individually positioned for custom paper sizes.
Loosen the knob (4).
Position the Booklet Maker so that the sets (5) fed
fromthecollator(6)enterstheBookletMakerinfeed
assembly centered (7).
Note
The knob (4) which prevents the infeed assembly
from moving, can not be thightened when the colla-
tor is docked to the Booklet Maker. If you want to be
sure not to loose positioning, carefully undock the
Collator from the Booklet Maker and thighten the
knob.
4
Push the docking assembly to the rear until it
locks.
Separate the Collator from the Booklet Maker.
Adjusting docking assembly to factory settings
To adjust the docking assembly back to factory
setting:
Loosen the knob.
Slide the docking assembly so that it covers half
the hole (6) in the infeed assembly.
Tighten the knob.
6
Undocking the Booklet Maker from a Collator
Basics
7
5
6

1
19
The staple cartridges, containing approximately 5000
staplespercartridge.Cartridgemayberemovedeither
for renewal or for jam clearance.
Raisethehandle(C)on thestaplecartridgelocking
lever.
Remove the staple cartridge from the stapler head
by sliding it away from the stapler head.
Check staples, Staple cartridge and stapler head
Open the top cover.
Remove the set of paper.
Disconnect the staple indication lead (A) from the
socket.
Hold the stapler head in place, press the release
latch (B) to release the rear end of the stapler head
and lift up this end.
Lift out the head, allowing it to rotate around the
front end. The stapler assembly is spring loaded
and will follow the rotation of the stapler.
Removing stapler head
AB
C
Removing staple cartridge
Staple Cartrigde and Stapler Head