Plockmatic BM 82 Installation manual

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Plockmatic BM 82
Bookletmaker
Operation Manual

Stapler-Folder Model 82
Operator Manual
February 2003
Part No 76174

Stapler Folder Model 82 Operator Manual
T10136
Table of contents
1. Introduction
2. Getting to know the Model 82
2.1 Main components
2.2 The control panel
3. Operating and finishing modes
3.1 The operating modes
3.2 The finishing modes
3.3 Jam indications
4. Operatorinstructions
4.1 Connecting the Model 82 to a collator
4.2 Setting / Changing paper size
4.3 Adjusting the Stacker
4.4 Beginningtheproduction
5. Maintenance
5.1 Replacing the Staple cartridge
5.2 Removing Stapler head / clearing staple jam
5.3 Lubrication of Clinchers and Stapler Head
5.4 Cleaning of Fold rollers
5.5 GFI function test and resetting
6. Troubleshooting
7. Specifications
i

Stapler Folder Model 82 Operator Manual
T10136
Operational safety
This operator manual describes how to operate the Stapler-folder
Model 82 on-line together with collator Models 300/400, Model 100 or
as a stand alone unit.
1. Introduction
Always connect the equipment to a properly
grounded power source receptacle. In doubt,
have the receptacle checked by a qualified
electrician.
WARNING: Improper connection of the equip-
ment grounding conductor can result in electri-
cal shock.
Always follow all warnings marked on, or sup-
plied 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 field 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 specifically 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 odors. 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 safety operation of your equipment.
1-1

Stapler Folder Model 82 Operator Manual
T10136
10
2. Getting to know the Model 82
Takea fewminutes tobecome familiar withthe maincomponents
ofthe Model82.
1. Output wheels 7. Power switch
2. Belt stacker 8. Ground fault interruptor (GFI )
3. Control panel 9. Power cord receptacle incl. fuses
4. Top cover 10. Connection cable outlet
5. Docking assembly 11. Base
6. Back jogger adjustment screw
2.1 Main components
2
3
4
5
7
8
9
1
11
2-1
6

Stapler Folder Model 82 Operator Manual
T10136
1
2.1 Main components cont.
1. Stapler head 6. Rear Side guide
2. Staple cartridge 7. Back jogger
3. Cartridge locking lever 8. Scale, length adjustment
4. Stapler release latch 9. Front Side guide
5. Staple detection lead 10. Release handle, Side guide
2
3
4
5
6
7
8
9
10
Whensetting upthe Model 82 or performingmaintenance itis
sometimesrequiredto moveinternal components ofthe machine.
Take afew minutes tobecome familiarwith these components.
2-2

Stapler Folder Model 82 Operator Manual
T10136
1
2.2 Control panel
1. Auto mode indicator 9. Stacker full indicator
2. Manual mode indicator 10. Staple(s) missing indicator
3. Staple and fold mode indicator 11. Manual / Auto mode button
4. Fold mode indicator 12. Program select button
5. Edge stapling mode indicator 13. Run / Adjustment mode button
6. Run mode indicator 14. Length adjustment button, decrease
7. Adjustment mode indicator 15. Length adjustment button, increase
8. Paper jam indicator
23 645 7 8910
11 12 13 14 15
2-3

Stapler Folder Model 82 Operator Manual
T10136
3. Operating and finishing modes
TheModel 82 canbe operated inseveral combinations ofmodes.
Thesemodes aretwo operatingmodes and threefinishing
modes.In this sectionwe will explainthe different modesand how
theyareselected.
3.1 The operating modes
3.2 The finishing modes
3-1
Thethreefinishing modesare:
1. Edge stapling
Whenselecting thismode by pressingthe Programselect
buttontheset willexitat the loweroutputarea.Adeliverytrayfor
edge stapled sets is available, part no. 750004.
IfaTrimmeris installedto yourModel 82, remove the scrappaper
binto allow theedge stapledsetsto enterthe delivery traywhich
isintegrated inthe baseof theTrimmer.
2. Fold only
Whenselecting this modeby pressingtheProgram selectbutton,
thestapler actionis switched off and thefolded setwill exitat the
upperoutputarea ontothebelt stacker.
3. Saddle stapling and fold
Whenselecting this modeby pressingtheProgram selectbutton,
thestapled andfoldedsets willexit attheupper outputarea onto
thebeltstacker.
Thetwo operatingmodes are:
1. Manual mode
SelectManual mode ifoperating the Model82 as astand alone
unit,forhandfeeding.
TheManual modeis selectedwhen theMAN LEDis lit.
Pressthe Manual /Automodebutton tochangeoperating mode.
2. Automatic mode
SelectAutomaticmode if operating theModel 82together witha
collatorasan on-line system.
TheAutomaticmode isselected whentheAUTOLEDis lit.
Pressthe Manual /Automodebutton tochangeoperating mode.
Note: If in manual mode when the on-line connected collator starts, the
mode will automatically switch from Manual to Automatic mode, to
preventinterruptions.

Stapler Folder Model 82 Operator Manual
T10136
3.3 Jam indications
1. Staple(s) missing indicator
TheStaple(s) missingindicator isilluminated whena setis
missingone or twostaples. TheModel82 willautomatically
stopthe on-linesystem when thisindicator LEDis lit.
Uponindication afterloading anew staplecartridge, open
andclose the Topcover.TheModel82 willnow cycle and
advancestaples onthe sameset fora maximumof 5
staplingcycles or untilstaples are resumed.Replacing the
staple cartridge is described in section 5.
2. Stacker full indicator
TheStackerfullindicator islit when thebelt stackerorthe
deliverytray is full.Remove the finishedsets.Assoonasthe
stackerfull sensoris clear theindication willgo off. The
Model82will automatically stoptheon-line system whenthis
indicatorLED is lit.All setsalready fedfrom the Collatorwill
beprocessed until fullstoppage.
3. Paper jam indicator
ThePaper jamindicator is illuminatedwhen anoperation in
theModel 82is not done within thepreset time.Open the
topcover andremovethe jammedsets reachable,closethe
topcover and theModel 82willautomatically purge
remainingjammed sets. Model82 willautomaticallystop the
on-linesystem whenthisindicator LEDis lit.
3-2

Stapler Folder Model 82 Operator Manual
T10136
4. Operator instructions
1. Makesure themain power isswitched offon bothmachines.
For300/400 seriescollator: Plugthe Connectioncable
betweenthe jackon thestacker sideof the Collator to the 25-
pinjack onthe Model82.
ForModel 100collator: Plug the 9-pin Connectioncable
betweenthe collator andthe upper 9-pinjack ofthe
Communicationbox.Plug theotherconnectioncable between
the15-pin jackof the Communicationbox tothe 25-pinjack
onthe Model 82.Connect atermination plug inthe lower9-pin
jackofthe Communicationbox.Connectanother termination
pluginthe Collator.
2. Connectthe Powercord tothe receptacleon theModel 82
andintothe walloutlet. Switch onthe Model 82and Collator.
3. Movethe Model82 infeedend to theoutfeed endof the
Collator. Thedocking assemblywillautomatically lock onto
the Collatorwhenstudsof theCollator enters theModel 82
A4(8.5”) orA3(11”)-position openings.The greenmark on
therear side guidecorresponding to greenstrip on the
Collatorhelps youdockingin thecorrect position.
4. Thedocking assemblyis releasedby pressingthe greenarea
onthe sideofthe assembly.
5. Ifrunningan oddpapersize, loosentheknob onthelower
sideof the docking assembly. Movethe Model82 sideways
sothe greenmark onthe rearside guidealigns withthe green
striponthe Collator.
Normal position of the docking assembly is indicated by a
centringnotch.
4.1 Connecting the Model 82 to a Collator
A3 / 11”
A4 / 8.5”
Adjustment
knobfor
odd sizes
Studs
4-1
Communication
box
15-pin
jack
9-pin
connection
cable
Termination
plug
25-pin
jack

Stapler Folder Model 82 Operator Manual
T10136
1. Selectprogram on theControl panel:
Edgestapling,onlyFolding orStapling/Folding.
2. Openthetopcover and presstheRun/Adjustmentbutton to
accesstheSheetlength adjustment buttonsontheControl
panel.
3. Adjustthe frontand rear Side guide tothe paperwidth that
willbe used.Adjusttheside guides bysqueezing atthe
greenmarkson thereleasehandles.
4. Releasethe Dockingassembly to shiftthe positioningof the
Model82 inorder toalign thegreen stripeon thecollator
withthe greenmark onthe rearSide guide.
5. Adjustthesheetlength slightlylargerthanthe paper size
beingused.
Closethe topcover.
6. Feed one test set into the Model 82.
7. Openthetop coverandadjustthe sheetlengthso that the
trailedge of theset justabout touches thebackjogger.
8. Checkthat theset is not squeezed soit bucklesbetween the
sideguides. Thesideguides shouldjust abouttouchthe set.
Fineadjust theSide guidesif necessary.
Closethetop cover andpushthe Run /Adjustmentbutton to
exittheAdjustmentmode.Thesetwill beprocessedthough
themachine.
4.2 Setting / Changing paper size
Program
select
button
Run/Adjust-
mentbutton
Run/Adjust-
mentbutton
4-2
Sheetlength
adjustment
buttons

Stapler Folder Model 82 Operator Manual
T10136
4.3 Adjusting the Stacker
Theoutput wheels canbe positioned infour differentpositions.
1. TheA4 / 8.5 x 11” position.
Usethis position whenmaking bookletsfromA4 (8.5 x 11”)
sizepaper.
2. The8.5 x 14”position. ( N/AonA4 /A3 Machines)
Usethis positionwhen makingbooklets from8.5 x14” size
paper.
3. TheA3 / 11 x 17” position.
Use this position when making booklets fromA3 ( 11 x 17”)
sizepaper.
4. Theoutermostposition.
Usethis positionwhen storing theequipment orfor easier
accesstothe deliverytraywhen edgestapling.This allows
youto fold theBelt stackerto an uprightposition.
Tochange thepositionofthe Output wheels:
1. Placethewheels ontheconveyorbelts .
2. GrasptheOutput wheels andturnthem towards decired
position.TheOutputwheelsshould contacting thebeltswhen
shiftingposition.
To changethe positionofthe Endplate:
1. GrasptheEnd plateand pull theknob.
2. Tiltthe endplate todecired angle and release theknob.
Thestackershouldnormally be straightwhenconnecteddirectly
toModel 82.If Stackeris connected to theTrimmerit is
recommendedto angle thestacker.
To changetheangle oftheStacker:
1. LifttheStackertoan angle.
2. Turntheangle blocks andrelease the stacker.
4.4 Beginning the production
1. Setoperating modeto ManualorAutomatic (accordingto
3.1).
2. Setthe finishingmode (accordingto 3.2).
3. Makethe papersize adjustments (according to 4.2and 4.3).
4. Ensurethat the Model82 isin Run modeand:
5a. IfrunninginManualmode:
Starthand feedingtheset.
5b. IfrunninginAutomode:
Setup the Collator, runatest setand startthe production.
4-3
Knob
Endplate
Angle
block
Outputwheel
Coveyorbelt

Stapler Folder Model 82 Operator Manual
T10136
Youmayremove andreplacethe Staplecartridge while the
Staplerhead isin placewithin theModel 82.The Staplecartrid-
ges contain approximately 5000 staples per cartridge and can be
replacedas oftenasnecessary.
1. Ifthe staplesmissingindicator isilluminated,open theTop
coverandremoveeventual jammedsets.
NOTE! One set must be left in stapling position (see item 8 below).
2. Raisethe redhandle onthe Staplecartridge Lockinglever.
3. Removethe Staplecartridge from the Stapler headby sliding
ittothe left.
4. Ifthe cartridge is empty, discard itand replaceit with a new
one.Before replacingthe cartridge,pull 25 mm (1 inch)of
staplesout ofthecartridge andtear thestaples downward
againstthe stapletear line.The stapletear lineis indicatedby
anarrow onthe sideof thecartridge.
5. Ifthere hasbeen a staple misfeed, andif itis necessaryto
removethe cartridgein orderto clearthe misfeed,
pull25 mm(1 inch)of staples outof thecartridge andtear the
staplesdownward againstthe staple tearline before
reinstallingthecartridge.
6. Insertthecartridge intotheStaplerhead with theend of the
staplesfacing toward thehead ofthestapler mechanism.
Pushitin firmly.
7. Holdthe Staple cartridgefirmly inplace and pushdown the
cartridgelocking lever. ClosetheTopcover.
8. TheModel82 willautomaticallycycle andadvancestaples
untilboth staplerheads are drivingstaples fora maximumof 5
staplingmovements.
Ifstaples are notresumed after5stapling cycles,the staple
indicationwill comeon. This indicatesthat thestaple cartridge
wasnotloaded sucessfully.Repeat thisprocedure.
5. Maintenance
5.1 Replacing the Staple cartridge.
5-1

Stapler Folder Model 82 Operator Manual
T10136
1
2
3
1. Switch the power switch to OFF (0) position. Open the Top cover
on the Model 82. Disconnect the Staple indication lead (1) from
the socket.
2. Hold the Stapler head in place, press the Release lever (2) to
release the rear end of the stapler head and lift up this end.
3. Lift out the head, allowing it to rotate around the front end. The
Stapler assembly is spring loaded and will follow the rotation of
theStapler.
4. Remove stapler cartridge. Look inside stapler head to locate
jammed staples by eject point. Remove staples if any.
5. Position the Stapler head over the edge of a firm surface (for
example, the top of a table or the Model 82).
6. While securely holding the head, actuate the Stapler up and down
through full travel. Perform this operation first without staple
cartridge then with staple cartridge. Repeat this a few times to
ensure that the staples are ejected at each down movement.
NOTE: Actuation must be performed without excessive force. If binding
occurs there may be broken staples inside. Dis-assembly may be
required.
7. To reinstall the Stapler head, insert the pin at the top of the stapler
head into the Stapler retraction swing arm (3).
8. While rotating the Stapler head, insert the pin located at the rear
end of the Stapler head into the slots in the frame of the Stapler
head assembly. Press down the rear end of the Stapler head until
the release lever (2) snaps into place, locking the Stapler head in
position.
9. Press down the front end of the Stapler head until it snaps in
position under the frame assembly.
10. Reconnect the Staple indication lead (1).
5.2 Replacing the Stapler head / Clearing staple jam
5-2

Stapler Folder Model 82 Operator Manual
T10136
5.3 Lubrication of Clinchers and Stapler Head
TheClinchers mustbeoiled every20 000cycles.
Whenlubrication is due,out ofstapleindicator flashes.
1. Puta coupleof dropsof oilin eachclincher.
To get rid of excessive oil:
2. Pushdown each clincherlever a coupleof times.
3. Pushdownclincher leverwhilewiping offexcessiveoil
usingadrycloth.
4. Runafew blankbooklets.
Oil
Push
Push
Whenclinchershave beenlubricated,the flashing stapleindicator
mustbe reset:
5. Pressandholdboth sheet lengthadjustmentbuttons
simultaneously.
Thestaple indicator willfirst gofrom flashing toon.
After4 secondsthe indicatorwill gooff.
6. Releasethebuttons.
Thestapler headdrive poston each staplerhead mustbe
lubricatedevery 20 000cycles.
1. Removethe staplerhead accordingto section 5.2.
2. Put a couple of drops of oil on each side of the drive post.
3. Cyclethe staplerhead afew timesbefore installingit again.
Oil
Oil
Sheetlength
adjustment
buttons

Stapler Folder Model 82 Operator Manual
T10136
WARNING: DO NOT use the Model 82 if the following test fails.
No additional testing should be performed. Call for service.
WhentestingtheGroundFault Interruptor (GFI),theModel82
Powercord mustbe connected tothe wallreceptacle andthe
MainPower switchin ON(1) position.
1. Pressthered ”TEST”- button.
2. Pressthe black”RESET”-button. A redflag shouldappear in
the window of theGFI.
3. Pressthe red ”TEST”-button.The redflag should disappear.
4. Pressthe black ”RESET”-buttonagain. The Model82 should
nowbe readytouse.
5.4 Cleaning of Fold rollers.
TheFoldrollers needtobe cleanedregularlywhen inuse.How
oftenthis shouldbe doneis dependingon whatkind ofpaper and
printthatis usedinthe unit.
1. OpentheTopcover.Clean theaccessible areasof theFold
rollerswith a rubberreactivator liquid.
Cleanfromboth the insideofthe unit andthroughthe output
opening.
2. ClosetheTop coverand runoneset oftwosheetsthrough
theunit.
3. Repeatstep 1and 2until rollersare cleaned
(approximately2-3times).
5.5 GFI function test and resetting.
5-3

Stapler Folder Model 82 Operator Manual
T10136
6. Troubleshooting
6.1 Troubleshooting
6-1
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Stapler Folder Model 82 Operator Manual
T10136
7. Specifications
7.1 Specification
7-1
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Notes