Plockmatic BM3000 User manual

T09343A
1 July 2019
Plockmatic BM3000
Installation Instruction
This Installation Instruction is an excerpt from the Service Manual

Page Intentionally Blank
ii

Plockmatic BM3050 system 1 July 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 CR3050 creaser ..................................................................................... 1-14
1.1.4 BM3035 / BM3050 Booklet Maker......................................................... 1-19
1.1.5 SquareFold Module............................................................................... 1-22
1.1.6 Trimmer Module..................................................................................... 1-24
1.1.7 BST 4000-1 Belt Stacker Module.......................................................... 1-26
1.2 Installation Requirements
1.2.1 Minimum Space Requirements............................................................ 1-28
1.2.2 Power Requirements............................................................................. 1-29
1.2.3 Pre Installation Information.................................................................. 1-29
1.2.4 Tools ....................................................................................................... 1-29
1.3 Installation Precautions
1.4 AF602/VF602 Installation
1.4.1 Accessory check................................................................................... 1-31
1.4.2 Removal of covers ................................................................................ 1-32
1.4.3 Height adjustment................................................................................. 1-33
1.4.4 Wide paper supports (VF602 only) ...................................................... 1-33
1.4.5 Connectors ............................................................................................ 1-34
1.4.6 Re-mounting covers.............................................................................. 1-34
1.4.7 Calibration.............................................................................................. 1-34
1.4.8 Downstream docking to BM................................................................. 1-34
1.5 CST installation
1.6.1 Accessory check................................................................................... 1-35
1.6.2 Installation procedure........................................................................... 1-36
1.6.3 Docking CST with AF602 ...................................................................... 1-38
1.6 CR3050 installation
1.7.1 Accessory check................................................................................... 1-39
1.7.2 Height adjustment................................................................................. 1-39
1.7.3 CR3050 to AF602/VF602 ....................................................................... 1-39
1.7.6 Removal of Front Cover........................................................................ 1-40
1.7.4 Adjustment............................................................................................. 1-40
1.7.5 When docking CR3050 To AF602/VF602 ............................................. 1-40
1.7.7 Cables and cable protector .................................................................. 1-42
1.7.8 Downsteam docking ............................................................................. 1-42
1.7 BM3050 Upgrade kit
1.8.1 Installation procedure........................................................................... 1-43
1.8 BM3050 Installation
1.9.1 Accessory Check .................................................................................. 1-44
1.9.2 BM3050 Installation procedure ............................................................ 1-45
1.9 Square Fold Module installation
1.10.1 Accessory Check .................................................................................. 1-47
1.10.2 Installation procedure........................................................................... 1-47
1.10 Trimmer Module installation
1.11.1 Accessory Check .................................................................................. 1-50
1.11.2 Installation procedure, Trimmer to Square Fold ................................ 1-50
1.11.3 Installation procedure, Trimmer to Booklet Maker............................. 1-52
1.11 Belt Stacker installation
1.12 BST4000-1 Belt Stacker installation
1.13 Cables, plugs and jumpers
1.14.1 Basic rules ............................................................................................. 1-61
1.14.2 Example of a stand-alone Booklet Maker .......................................... 1-61
1.14.3 Example of a complete system............................................................ 1-62
1.14.4 Connecting BST4000-1 Belt Stacker ................................................... 1-63

Plockmatic BM3050 system 1 July 2019 1. Installation Procedure
1-2
1.14.5 main power cord, BM3050 Booklet Maker .......................................... 1-65
1.14.6 main power cord, Rotate Crease Trim Module ................................... 1-65
1.14.7 main power cord, BST4000-1 Belt Stacker Module............................ 1-65
1.14 After switching on the power
1.15.1 Setting NVM value for the Trimmer...................................................... 1-66
1.15.2 Checking software versions................................................................. 1-66
1.15.3 Performing a self diagnostic................................................................ 1-67
1.15 Checking the installation
1.16.1 System alignment.................................................................................. 1-68
1.16.2 Adjusting/checking the CST bleed trim .............................................. 1-71
1.16.3 Checking the CST crease ..................................................................... 1-72
1.16.4 Checking the CR.................................................................................... 1-73
1.17.1 Checking the Booklet Maker ................................................................ 1-73
1.16.5 Checking the Square Fold.................................................................... 1-74
1.16.6 Checking the Trimmer........................................................................... 1-74

Plockmatic BM3050 system 1 July 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 1 July 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 1 July 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 1 July 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 1 July 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 1 July 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 1 July 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 1 July 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 1 July 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 1 July 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 1 July 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 1 July 2019 1. Installation Procedure
1-14
1. Remove straps [A]
2. Remove lid [B].
3. Remove instructions [C] and ramp board [D].
4. Remove protective foam block (x1) [E].
[A]
[B] [C]
[D]
[E]
1.1.3 CR3050 CREASER

Plockmatic BM3050 system 1 July 2019 1. Installation Procedure
1-15
[F]
[G]
[K]
[J]
[I]
[H]
1. Remove protective foam block (x4) [F].
2. Remove ramp support foam (x2) [G].
3. Remove card board sleeve [H].
4. Remove accessories box [I] and protective card board boxes (x2) [J].
5. Remove protective foam blocks (x2) [K] .

Plockmatic BM3050 system 1 July 2019 1. Installation Procedure
1-16
1. Plastic bag [L] is secured with tape at top of machine.
2. Pull down plastic bag and remove silica gel (desiccant) bags [M].
3. Open bottom corners [N].
4. Note position (inside front and rear cover) of board reinforced foam
blocks under machine (x2) [O].
[L]
[O]
[N]
[M]

Plockmatic BM3050 system 1 July 2019 1. Installation Procedure
1-17
1. Tilt machine and remove rst board reinforced foam block (x1) [O].
2. Tilt machine other way and remove second board reinforced foam
block (x1) [O].
3. Tilt machine and move plastic bag [L] in under machine.
4. Tilt machine other way and remove and remove plastic bag [L].
[O]
[L]
1
1
1
1
2
2
2
2

Plockmatic BM3050 system 1 July 2019 1. Installation Procedure
1-18
1. Install ramp support foam (x2) [G]
2. Install ramp board [D].
[G]
[G]
3. Roll machine off of pallet.