Plockmatic BM 61 User manual

Provided By
http://www.MyBinding.com
http://www.MyBindingBlog.com
Plockmatic BM 61
2006 Bookletmaker
Instruction Manual

BOOKLET MAKER BM 61
Operating Instruction
Booklet Maker Reference
Part no: 61229
Doc no: T10165
Rev. date: 28 September 2006

T10165 OPERATOR MANUAL BM 61
3
TABLE OF CONTENTS
1. Introduction
1.1 Safety notices..................................................................................................................... 5
1.1.1 Notation conventions..................................................................................................................5
1.1.2 General safety............................................................................................................................6
1.1.3 Operational safety......................................................................................................................7
1.1.4 Safety notes ...............................................................................................................................8
1.1.5 Safety measures when using the belt stacker............................................................................9
2. Installation
2.1 Installation......................................................................................................................... 10
3. Getting to know the Booklet Maker
3.1 Main components ..............................................................................................................11
3.2 Infeed section, upper........................................................................................................ 12
3.3 Infeed section, collator side.............................................................................................. 13
3.4 The control panel.............................................................................................................. 14
3.5 Accessories (optional)....................................................................................................... 15
4. Operator instructions
4.1 Settings............................................................................................................................. 16
4.1.1 Stapling and folding..................................................................................................................16
4.1.2 Folding only..............................................................................................................................16
4.1.3 Stapling and folding - OFF-line.................................................................................................17
4.1.4 Folding - OFF-line ....................................................................................................................17
4.1.5 Block stapling - OFF-line option 1............................................................................................18
4.1.6 Block stapling - OFF-line option 2............................................................................................19
4.2 Operation.......................................................................................................................... 20
4.2.1 Operating the Booklet Maker ON-line ......................................................................................20
4.2.2 Operating the Booklet Maker OFF-line.....................................................................................20
4.3 Paper settings................................................................................................................... 21
4.3.1 Set up for non-standard paper sizes........................................................................................21
4.3.2 Reset to standard paper sizes..................................................................................................21
5. Maintenance
5.1 Cleaning of rollers............................................................................................................. 22
6. Problem solving
6.1 Problem solving ................................................................................................................ 23
7. Specications
7.1 Specication table............................................................................................................. 24

4
OPERATOR MANUAL BM 61 T10165

T10165 OPERATOR MANUAL BM 61
5
1. Introduction
The Plockmatic BM 61 automatic Booklet Maker combines features from large and
advanced systems into one compact unit designed to meet the highest demands for
productivity, safety and ease of operation.
1.1 Safety notices
Prior to start up – read the Operator Manual and observe the safety notes!
Please forward all safety instructions to other users of this machine.
1.1.1 Notation conventions
Whenever necessary, the following points for attention are indicated in this manual.
WARNING:
This remark in the text means a potential danger of injuries to the operator.
CAUTION:
This remark in the text means a potential risk of machine damage.
NOTE:
This sign refers to remarks for making the operation much easier. You get practical hints to
assist you in the machine operation.

6
OPERATOR MANUAL BM 61 T10165
1.1.2 General safety
The following points are brought to the attention of the user of this unit:
This machine was manufactured according to the latest technical development and
the recognized safety regulations. Nevertheless, the usage of this system could pose
dangers to the operator‘s life and limb or impair the machine functions.
This machine is destined for specic purpose only. Any use going beyond this specic
purpose is regarded 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.
For your own safety please observe the information labels on your machine and the
hints given in the text.
The manufacturer will not be liable for modications made at the machine on your own
and damages resulting thereof.
EC declaration of conformity and the mark CE will be invalidated, if you make changes
at the machine or at the individual components.
For all questions concerning service and repair contact your sales representative in
charge.
The machine is to be used only by authorized and instructed persons. The responsibili-
ties on operating the machine have to be strictly laid down and observed so that there
are no unclear competences regarding safety aspects.
The operator‘s 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 altera-
tions to specications without prior notice!
WARNING: It is the duty of the service staff to correctly instruct the operator and to point
out specic dangers and possible operating errors.
NOTE: The indications like front and rear, left and right refer to the paper transport
direction.
1.
2.
3.
4.
5.
6.
7.
8.

T10165 OPERATOR MANUAL BM 61
7
Always connect the equipment to a properly grounded power source receptacle. In doubt,
have the receptacle 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 relocating the equipment.
Always keep magnets and all devices with strong magnetic eld away from the machine.
Never use a ground adapter plug to connect the equipment to a power source receptacle
that lacks a ground connection terminal.
Never attempt any maintenance function that is not specically described in this
documentation.
Never remove the covers or guards that are fastened with screws.
Never install the unit near a radiator or any other heat source.
Never override or “cheat” electrical or mechanical interlock devices.
Never operate the equipment if you notice unusual noises or odours. Disconnect the
power cord from the power source receptacle and call your customer service engineer to
correct the problem.
Attention to the following notes ensures the continued safe operation of your equipment.
1.1.3 Operational safety

8
OPERATOR MANUAL BM 61 T10165
1.1.4 Safety notes
Preserve this operator manual carefully for later use.
Lay the power cord in a way that nobody will stumble over it. Do not place things on the
cord.
The machine should be protected against humidity.
The vent holes serve for air circulation to protect the machine from overheating. Make
sure that the holes are not covered.
WARNING: Objects or liquids must never penetrate the machine  Danger of life!
WARNING: Pull mains plug before cleaning and care!
WARNING: Observe the legal regulations of the local institutions concerning protective
clothing and preventive measures.
Keep your hands off moving, rotating or cutting assemblies.
Wear proper protection for the head (e.g. hairnet) to prevent dangers caused
by loosely hanging hair.
Pieces of jewellery, wristwatches or other comparable objects must not be
worn during operation due to possible dangers.
NOTE: If the machine is not used over an extended period it should be unplugged to
prevent damage in the case of overload.
Do not use any uid or aerosol purier.
The best suitable for cleaning is a slightly moistened cloth.
In the case of the following conditions the machine must be unplugged and checked by
a qualied service technician:
a)Power cord or plug damaged.
b)Liquid has penetrated the machine.
c)The machine has been exposed to moisture.
d)The machine is not working according to the operator’s manual and no
improvement has been brought about with the help of the manual.
e)The machine has been dropped and/or the housing damaged.
f)The machine is showing clear signs of defects.
For repair use only the original spare parts or those spare parts that correspond to the
original parts.
For all questions concerning service and repair contact your SALES representative in
charge. In this way the operating safety of the machine is ensured.
•
•
•
•
•
•
•
•

T10165 OPERATOR MANUAL BM 61
9
1.1.5 Safety measures when using the belt stacker
WARNING: If the Belt Stacker is used and the machine is placed on a Base, the Tip
Protection bars must be installed. They are indicated in the picture below.
Belt Stacker
Tip Protection bars
Base

10
OPERATOR MANUAL BM 61 T10165
2. Installation
2.1 Installation
Attach the power cord to the Booklet Maker.
Attach the connection cable between the Booklet Maker and the Collator.
Roll the Booklet Maker up against the Collator make sure that the Collator studs enter
the Docking Bracket on the Booklet Maker for the correct paper size.
1.
2.
3.

T10165 OPERATOR MANUAL BM 61
11
3. Getting to know the Booklet Maker
Take a few minutes to become familiar with the main components of the Booklet Maker.
3.1 Main components
Top cover
Upper pressure roller assembly (Only used for ON-line operation to Collator)
Press area, machine release (Press here and the Booklet Maker will be
released from the Collator and can be rolled
away)
Control panel
Fold stop assembly
Belt Stacker (Optional accessory)
1.
2.
3.
4.
5.
6.
5
3
4
1 2
6

12
OPERATOR MANUAL BM 61 T10165
Upper guide, side jogger
Side jogger, rear
Scale, paper length
Rear jogger roller
Side jogger, front
Upper guide, side jogger
Release handle, side jogger
Scale, paper width
Anvil
Release handle, side jogger
Scale upper pressure roller assembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
1 42 3 5 6
7
8
9
10
11
3.2 Infeed section, upper

T10165 OPERATOR MANUAL BM 61
13
Positioning holes, small paper width (Used for A4/8”1/2paper widths or sizes
nearby)
Positioning holes, large paper width (Used for A3/11” paper widths or sizes nearby)
Positioning mark (green) (Shall correspond to the green mark on the
Collator)
Paper stop crank (Used for adjustment to correct paper length)
Rear jogger latch (Used to lower the rear jogger and enable
OFF-line operation)
Rear jogger adjustment latch (Used to position the rear jogger to the paper
length)
Receptacle, connection cable (The connection cable from the Collator
connects here)
Knob, adjustment for odd paper size (By loosening the knob the Docking Bracket
can be individually positioned for odd paper
sizes)
Docking Bracket
1.
2.
3.
4.
5.
6.
7.
8.
9.
1 2 3
4567
8
9
3.3 Infeed section, collator side

14
OPERATOR MANUAL BM 61 T10165
Power switch
Low staples indicator
Jam indicator *
Stapling ON / OFF
Folding ON / OFF
Automatic start ON / OFF (Can only be used OFF-line)
Time delay (Can only be used OFF-line)
Manual start button (Can only be used OFF-line)
1.
2.
3.
4.
5.
6.
7.
8.
2
1 3 4 5 6 7 8
3.4 The control panel
I
0

T10165 OPERATOR MANUAL BM 61
15
Belt Stacker
Adapter
Delivery Tray
Knob, Delivery Tray (By loosening the knob the Delivery Tray can be
adjusted for correct paper size)
1.
2.
3.
4.
3.5 Accessories (optional)
21
3 4

16
OPERATOR MANUAL BM 61 T10165

T10165 OPERATOR MANUAL BM 61
17
4. Operator instructions
4.1 Settings
4.1.1 Stapling and folding
Open the top cover.
Set the two side joggers to the correct paper size according to the scale.
Insert a set to the stapling area.
Move the rear side jogger up against the paper to verify that the side jogger aligns the
sheets.
NOTE: When checking the alignment, do not squeeze the release handle, only push
on top of the side jogger at the green label, to simulate the jogging action that the
BM 61 does during run.
Turn the paper stop crank until the trail edge of the set is in line with the scale for paper
length.
Move the rear jogger up against the trail edge of the set.
Remove the set.
Position the upper pressure roller according to the scale.
Position the stapler heads over the anvils to be used.
Attach the Booklet Maker to the Collator and make sure that the green mark on the
Docking Bracket aligns with the green mark on the Collator.
Set the stapling switch to ON position.
Set the folding switch to ON position.
Close the top cover.
Set the power switch to ON position.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
4.1.2 Folding only
1. Same procedure as above with the exception that on point 11 the switch is set to OFF
position and point 9 is not performed.

18
OPERATOR MANUAL BM 61 T10165
4.1.3 Stapling and folding - OFF-line
Remove the upper pressure roller assembly.
Flip over the side jogger upper guides (both side joggers).
Lower the rear jogger unit by pressing the rear jogger unit forward and downwards
(green marked).
Open the top cover.
Set the side jogger to the correct paper size according to the scale.
Insert a set into the stapling area.
Move the rear side jogger up against the paper to verify that the side jogger aligns the
sheets.
NOTE: When checking the alignment, do not squeeze the release handle, only push
on top of the side jogger at the green label, to simulate the jogging action that the
BM 61 does during run.
Turn the paper stop crank until the trail edge of the set is in line with the scale for paper
length.
Remove the set.
Position the stapler heads over the correct anvils.
Set the stapling switch to ON position.
Set the folding switch to ON position.
Close the top cover.
Set the power switch to ON position.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
4.1.4 Folding - OFF-line
Same procedure as above with the exception that on point 11 the switch is set to OFF
position and point 10 is not performed.
1.

T10165 OPERATOR MANUAL BM 61
19
4.1.5 Block stapling - OFF-line option 1
Lower the rear jogger by pressing the rear jogger unit forward (green marked).
Remove the upper pressure roller assembly.
Flip over the side jogger upper guides (both side joggers).
Open the top cover.
Set the side jogger to the correct paper size according to the scale.
Insert a set into the stapling area.
Move the rear side jogger up against the paper to verify that the side jogger aligns the
sheets.
NOTE: When checking the alignment, do not squeeze the release handle, only push
on top of the side jogger at the green label, to simulate the jogging action that the
BM 61 does during run.
Turn the paper stop crank to position the set to the stapler.
Remove the set.
Position the stapler heads over the correct anvils.
Close the top cover.
Set the stapling switch to ON position.
Set the folding switch to OFF position.
Select manual or automatic start.
Flip down the fold stop to enable the sets to pass through the machine.
Set the power switch to ON position.
NOTE: By using the adapter (optional) either the Belt Stacker or the Delivery Tray can be
used for stacking of stapled sets.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.