Plockmatic BM500 User manual

T08134A
1 July 2019
Plockmatic BM500
Booklet Maker Service Manual

27 August 2019
BM3050 ii Cover
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 10 m of the
apparatus concerned.

27 August 2019
BM3050 iii Cover
Introduction
This manual contains instructions on the operation and maintenance of this machine. To get the 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 PROB-
LEMS.
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 prop-
erty.
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.

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BM3050 iv Cover
Safety Information
When using this machine, following safety precautions should always be followed.
Safety during operation
WARNING:
• To avoid hazardous situations such as 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 exist:
• Before disassembling or assembling parts of the System and peripherals.
• You drop objects or spill something into the equipment.
• You suspect that your equipment needs service or repair.
• Machine covers have 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).
• If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hand away
from electrical or mechanically driven components.
• Note that components of the System and peripherals can be supplied with electric voltage even if the main power switch is turned off
and the power cord is disconnected.
• 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 re-
quired to take adequate measures.
• The product (System) which is connected to this machine will be class A.

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BM3050 v Cover
WARNING:
• Always connect the equipment to a properly grounded power source (wall outlet). Wall outlet should be located near the system and eas-
ily accessible. 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 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.
• Do not make arbitrary changes or modications to the machine. The manufacturer will not be liable for modications made at the ma-
chine 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.
• 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 observed 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.
General Safety

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BM3050 vi Cover
TABLE OF CONTENTS
1 Installation procedure....................................................1-1
2 Preventive Maintenance (PM) .......................................2-1
3 Repairs and Adjustments (REP and ADJ)....................3-1
4 Troubleshooting (RAP)..................................................4-1
5 Service tables (GP) ........................................................ 5-1
6 Detailed Description ......................................................6-1
7 Specications.................................................................7-1
8 Wiring..............................................................................8-1
9 Booklet Quality (BQ)......................................................9-1

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-1
1 INSTALLATION PROCEDURE
Contents
1.1 Unpacking Instruction
1.1.1 AF602/VF602 Feeder............................................................................. 1-3
1.1.2 CST Module............................................................................................1-7
1.1.3 BM3035 / BM3050 Booklet Maker.........................................................1-14
1.1.4 SquareFold Module............................................................................... 1-17
1.1.5 Trimmer Module..................................................................................... 1-19
1.1.6 BST 4000-1 Belt Stacker Module..........................................................1-21
1.2 Installation Requirements
1.2.1 Minimum Space Requirements............................................................ 1-23
1.2.2 Power Requirements............................................................................. 1-24
1.2.3 Pre Installation Information.................................................................. 1-24
1.2.4 Tools....................................................................................................... 1-24
1.3 Installation Precautions
1.4 AF602/VF602 Installation
1.4.1 Accessory check................................................................................... 1-26
1.4.2 Removal of covers ................................................................................ 1-27
1.4.3 Height adjustment................................................................................. 1-28
1.4.4 Wide paper supports (VF602 only)......................................................1-28
1.4.5 Connectors ............................................................................................ 1-29
1.4.6 Re-mounting covers.............................................................................. 1-29
1.4.7 Calibration..............................................................................................1-29
1.4.8 Downstream docking to BM................................................................. 1-29
1.5 CST installation
1.5.1 Accessory check................................................................................... 1-30
1.5.2 Installation procedure........................................................................... 1-31
1.5.3 Docking CST with AF602...................................................................... 1-33
1.6 BM3050 Upgrade kit
1.6.1 Installation procedure........................................................................... 1-34
1.7 BM3050 Installation
1.7.1 Accessory Check .................................................................................. 1-35
1.7.2 Manual Feed...........................................................................................1-36
1.7.3 Installation to upstream unit AF602, VF602, cst or cr3050................ 1-36
1.8 Square Fold Module installation
1.8.1 Accessory Check .................................................................................. 1-38
1.8.2 Installation procedure........................................................................... 1-38
1.9 Trimmer Module installation
1.9.1 Accessory Check .................................................................................. 1-41
1.9.2 Installation procedure, Trimmer to Square Fold ................................ 1-41
1.9.3 Installation procedure, Trimmer to Booklet Maker............................. 1-43
1.10 Belt Stacker installation
1.11 BST4000-1 Belt Stacker installation
1.11.1 Installation procedure........................................................................... 1-46
1.12 Cables, plugs and jumpers
1.12.1 Basic rules............................................................................................. 1-52
1.12.2 Example of a stand-alone Booklet Maker .......................................... 1-52
1.12.3 Example of a complete system............................................................ 1-53
1.12.4 Connecting BST4000-1 Belt Stacker ...................................................1-54
1.12.5 main power cord, BM3050 Booklet Maker .......................................... 1-56
1.12.6 main power cord, Rotate Crease Trim Module................................... 1-56
1.12.7 main power cord, BST4000-1 Belt Stacker Module............................ 1-56
1.13 After switching on the power

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-2
1.14 Checking the installation
1.14.1 System alignment.................................................................................. 1-59
1.14.2 Adjusting/checking the CST bleed trim .............................................. 1-62
1.14.3 Checking the CST crease..................................................................... 1-63
1.14.4 Checking the Booklet Maker................................................................ 1-64
1.14.5 Checking the Square Fold.................................................................... 1-65
1.14.6 Checking the Trimmer........................................................................... 1-65

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-3
[1]
[2]
Remove packaging foam
Remove packaging foam and plastic wrap
1.1 UNPACKING INSTRUCTION
1.1.1 AF602/VF602 FEEDER

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-4
[3] [4]
Remove electronics
1. Loosen screw [A]
2. Lift up cover [B]
3. Tilt out top [C]
4. Remove cover
[A]
[B]
[C]
Remove rear cover
Rear Cover Front Cover

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-5
1. Unlock the latches to open the bins by following steps 2-4
2. Cut red tie wrap [D] (transport protection)
3. Lift the latch [E] and push in the bin
4. Repeat on second bin
5. Open the door [F]
6. Lift and remove front cover
[D]
[E]
[F]
[5] [6a]
[6b]
Remove front cover Place packaging foam as shown
Place unpacking ramp as shown

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-6
[7a]
[7b]
[8]Lower wheels (x4)
Remove packaging supports
Stand on edge of ramp to stabilize; carefully roll
unit down ramp

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-7
1.1.2 CST MODULE
[A]
[B]
1. Remove the straps [A]
2. Remove the lid [B]. 3. Remove the Waste Box and ensure it is saved [C].
4. Remove the Ramp Support [D] .
[C]
CAUTION:
Ensure that the waste box is saved.
[D]

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-8
5. Remove the Protection Foam Blocks (x2) [E].
6. Remove Ramp Support Foam (x2) [F].
[F]
[E]
7. Remove from the Corners the Protection Foam Blocks (x4) [G].
[G]

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-9
[J]
[H]
[I]
8. Remove the Paper Box [H].
9. Remove the Plastic Cover [I].
10. Remove Accessories Box [J]
[K]
[L]
11. Open the bottom corners of the box [K].
12. Remove the Protection Foam [L].

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-10
13. Open Top Cover and remove two screws securing Front Cover [M].
14. Lift Front Cover and remove.
15. Remove two screws securing the Rear Cover [N].
16. Lift Rear Cover and remove.
[M] [N]

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-11
17. Retrieve the 24mm open wrench [O] from behind the Booklet Maker
Rear Cover.
[O]
18. Adjust the height of the casters on the CST to 44mm (1.75”).
44mm/
1.75”
19. Pull out the foam blocks (x2) underneath the CST.
WARNING:
Two persons are required to remove the foam blocks.

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-12
20. Mount Ramp Support Foam according to picture [P].
[P]
21. Place Ramp [D] as illustrated.
[D]

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-13
22. Carefully roll CST off the pallet.
WARNING:
Two persons are required to carefully roll the CST off the pallet.
[Q]
23. Remove material packed inside the CST [Q].

Plockmatic BM3050 system 27 August 2019 1. Installation Procedure
1-14
1.1.3 BM3035 / BM3050 BOOKLET MAKER
1. Remove lid.
2. Remove box containing accessories.
3. Remove Ramp.
4. Remove remove Ramp support (x2).