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MyBinding Plockmatic BM 200 Service Manual

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  • Page 1 Plockmatic BM 200 Booklet Maker Service Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
  • Page 2 BOOKLET MAKER BM 200 SERVICE MANUAL 12 February 2007 Subject to change...
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  • Page 4 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY Always connect the equipment to a prop- Never use a ground adapter plug to con- erly grounded power source. In doubt, have nect the equipment to a power source that the power source checked by a qualified lacks a ground connection terminal.
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  • Page 6 TABLE OF CONTENTS 1 INSTALLATION PROCEDURE 1.1 INSTALLATION REQUIREMENTS ............1-1 1.1.1 MINIMUM SPACE REQUIREMENTS ..........1-1 1.1.2 POWER REQUIREMENTS ............. 1-2 1.2 INSTALLATION FLOW CHART ............... 1-3 1.3 BOOKLET MAKER INSTALLATION ............1-5 1.3.1 ACCESSORY CHECK ..............1-5 1.3.2 INSTALLATION PROCEDURE ............1-6 1.3.3 ADJUSTMENTS ................
  • Page 7 3.4.5 INFEED MOTOR M1 & SENSOR Q2 ........... 3-21 3.4.6 SIDE GUIDES ................3-22 3.4.7 SIDE JOGGER MOTOR M3 & SENSOR Q12 ......3-23 3.4.8 SIDE GUIDE TRANSMISSION &SENSOR Q13 ......3-24 3.4.9 BACK JOGGER MODULE & SENSOR Q3 ........3-26 3.4.10 BACK JOGGER FINGERS ............
  • Page 8 3.9.2 SIDE GUIDE PARALLELISM ............3-81 3.9.3 STAPLE POSITION TO CLINCHER ..........3-82 3.9.4 STAPLER PRESSURE ..............3-85 3.9.5 CLINCHER POINTS HEIGHT ............3-86 3.9.6 CLINCHER PRESSURE ............... 3-87 3.9.7 STAPLE AND FOLD POSITION ............ 3-89 3.9.8 FOLD SKEW ................. 3-91 3.9.9 STAPLE POSITION ON SQUARE FORMED SPINE ....
  • Page 9 6.2.3 CONTROLLER MD6DC ..............6-15 6.2.4 CONTROLLER MD3DC ..............6-17 6.2.4 CONTROLLER MD3DC, CONTINUES ......... 6-18 6.3 BOOKLET MAKING PROCESS ............6-19 6.3.1 PRINCIPLE OF OPERATION ............6-19 6.3.2 SIZE ADJUSTMENT ..............6-23 SPECIFICATIONS BOOKLET MAKER BM 200 ..............Spec-1 TRIMMER FTR 200 ................Spec-1 SQUAREFOLDER SQF 200 ..............Spec-1 WIRING Booklet Maker ....................Wir-1...
  • Page 10 PERIPHERALS TRIMMER FTR 200 1 INSTALLATION PROCEDURE 1.1 INSTALLATION PROCEDURE ............FTR-1-1 2 PREVENTIVE MAINTENANCE SCHEDULE 2.1 PREVENTIVE MAINTENANCE SCHEDULE ........FTR-2-1 3. REPLACEMENT AND ADJUSTMENT 3.1 COVERS ..................FTR-3-1 3.1.1 FRONT AND REAR COVER ...........FTR-3-1 3.1.2 TOP COVER ................FTR-3-2 3.1.3 BLOWER MOTOR M5 / M6 ............FTR-3-3 3.1.4 INFEED COVER ..............FTR-3-4 3.1.5 LOCKING BRACKET ..............FTR-3-5 3.1.6 UPPER OUTFEED COVER ............FTR-3-6...
  • Page 11 6. DETAILED SECTION DESCRIPTIONS 6.1 ELECTRICAL COMPONENT LIST ..........FTR-6-1 6.1.1 REAR VIEW ................FTR-6-2 6.1.2 INFEED VIEW .................FTR-6-3 6.1.3 OUTFEED VIEW ..............FTR-6-4 6.1.4 STOP CARRIAGE VIEW ............FTR-6-5 6.2 BOARD STRUCTURE ..............FTR-6-7 6.2.1 BLOCK DIAGRAM ..............FTR-6-7 6.2.2 CONTROLLER MD6DC ............FTR-6-8 6.2.2 CONTROLLER MD6DC, CONTINUES ........FTR-6-9 6.3 TRIMMING PROCESS ..............
  • Page 12 PERIPHERALS Squarefolder SQF 200 1 INSTALLATION PROCEDURE 1.1 INSTALLATION PROCEDURE ............SQF-1-1 2 PREVENTIVE MAINTENANCE SCHEDULE 2.1 PREVENTIVE MAINTENANCE SCHEDULE ........SQF-2-1 3 REPLACEMENT AND ADJUSTMENT 3.1 COVERS ..................SQF-3-1 3.1.1 FRONT COVER ..............SQF-3-1 3.1.2 REAR COVER ................SQF-3-2 3.1.3 INFEED COVER ..............SQF-3-3 3.1.4 OUTFEED COVER ..............SQF-3-4 3.1.5 TOP COVER ................SQF-3-6 3.1.6 TILT THE MACHINE ...............SQF-3-7 3.2 MOTORS ..................SQF-3-9...
  • Page 13 5 SERVICE TABLES 5.1 SERVICE TABLES ................SQF-5-1 6. DETAILED SECTION DESCRIPTION 6.1 ELECTRICAL COMPONENT LIST ..........SQF-6-1 6.1.1 COMPONENT LAYOUT ............SQF-6-2 6.2 BOARD STRUCTURE .............SQF-6-5 6.2.1 CONTROLLER MD6DC “D” ............SQF-6-5 6.3 PRINCIPLE OF OPERATION ............SQF-6-7 SPECIFICATIONS SPECIFICATIONS ................SQF-Spc-1 WIRING Squarefolder ..................SQF-Wir-1...

  • Page 14: Installation Requirements

    31 January 2007 INSTALLATION REQUIREMENTS INSTALLATION PROCEDURE INSTALLATION REQUIREMENTS 1.1.1 MINIMUM SPACE REQUIREMENTS 400 mm Stacker 15.75” SQF 200 FTR 200 BM 200 625 mm 350 mm 350 mm 810 mm 24.38 ” 13.75” 13.75” 31.9” 2135 mm 84”...

  • Page 15: Power Requirements

    INSTALLATION REQUIREMENTS 31 January 2007 1.1.2 POWER REQUIREMENTS WARNING 1. Make sure that the wall outlet is near the main machine and easily accessible. Make sure the plug is firmly inserted in the outlet. 2. Avoid multi-wiring. 3. Be sure to ground the machine. 1. Input voltage level: North America 120V AC, 50-60Hz: More than 4 A. Europe/Asia 230V AC, 50-60Hz: More than 2 A.

  • Page 16: Installation Flow Chart

    31 January 2007 INSTALLATION FLOW CHART INSTALLATION FLOW CHART The following flow chart shows how to install the optional units more efficiently. Install the Booklet Maker BM 200 Does the user require a Trimmer? Install the Trimmer FTR 200 Does the user require a SquareFolder? Is a Trimmer installed? Install Trimmer Install the SquareFolder SQF 200...
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  • Page 18: Booklet Maker Installation

    31 January 2007 BOOKLET MAKER INSTALLATION Booklet Maker INSTALLATION 1.3.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description Q’ty A. Communication Cable ............1 B. Powercord ................1 C. Terminator plug, will always be installed onto BM 200 ..1 D Terminator plug FTR 200 .............

  • Page 19: Installation Procedure

    BOOKLET MAKER INSTALLATION 31 January 2007 1.3.2 INSTALLATION PROCEDURE Unpacking Remove all parts from the pallets. Slide the Booklet Maker off the pallet by pulling the two cardboard handles [A] underneath the Booklet Maker straight out. WARNING 2 persons are required to slide the Booklet Maker off the pallet.
  • Page 20 31 January 2007 BOOKLET MAKER INSTALLATION Upper Top Cover Hold the Upper Top Cover in position and lower the rear end so that the grom- mets [A] and the holes in the guide brackets [B] are centered towards each other [C]. Secure the rear end of the Upper Top Cover with screws [D] ( x2).
  • Page 21 BOOKLET MAKER INSTALLATION 31 January 2007 Lower the front end of the Upper Top Cover so that the holes in the guide bra- clets and the holes in the Top Cover frame are centered towards each other [E]. NOTE: There are two guides [F] and two brackets [G] on the front side of the Upper Top Cover.

  • Page 22: Adjustments

    31 January 2007 BOOKLET MAKER INSTALLATION 1.3.3 ADJUSTMENTS Remove screws [A] and remove the Booklet Maker front cover ( x5). Remove screws [B], loosen screw [C] and remove the Bookler maker rear cover ( x5).
  • Page 23 BOOKLET MAKER INSTALLATION 31 January 2007 Mount the supplied positioning pins on the collator. Dock the collator to the Booklet Maker. See picture above. 1-10...
  • Page 24 31 January 2007 BOOKLET MAKER INSTALLATION Booklet Maker, front view Turn the four adjustment nuts [A] until the distance [B], between the lower edge of door and the top of side guide, is 3 mm. Reinstall the Booklet Maker front and rear covers ( x 10).

  • Page 25: Connectors

    BOOKLET MAKER INSTALLATION 31 January 2007 1.3.4 CONNECTORS If a collator is present, connect the communication cable [A] from the collator x1), to the Booklet Maker. Connect the Belt Stacker cable [B] ( x1). NOTE: Unless Trimmer FTR 200 and/or SquareFolder SQF 200 will be installed. If so, Belt Stacker cable will be connected to the last module in the system.
  • Page 26 31 January 2007 BOOKLET MAKER INSTALLATION 1.3.5 CHANGING SPEED ON THE COLLATOR Enter Collator program mode by pressing hidden button [A] and holding it until all green LED’s goes out. Press button [B] repeatedly until programmable setting No. 10 is displayed. This is indicated when bin LED 10 [C] on the Collator display is lit.
  • Page 27 BOOKLET MAKER INSTALLATION 31 January 2007 Press button [B] repeatedly until programmable setting No. 20 is displayed. This is indicated when bin LED 10 [C] and third party LED [E] on the Colla- tor display are lit. The correct value for setting No. 20 should read 180. If so, continue to step 8.
  • Page 28 31 January 2007 BOOKLET MAKER INSTALLATION 1.3.6 CHECK THE INSTALLATION If installing a Trimmer FTR 200, continue to section ( 1.4 ) otherwise continue with step 2. Power on the Booklet maker and the Collator. Remove the two Stapler heads, according to section ( 3.4.12 ).
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  • Page 30: Trimmer Installation

    31 January 2007 TRIMMER INSTALLATION TRIMMER INSTALLATION 1.4.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the follow- ing list: NOTE: - The Installation Box is located in the trim bin on the Trimmer. - The trim bin is tie wrapped on the rear side.

  • Page 31: Installation Procedure

    TRIMMER INSTALLATION 31 January 2007 1.4.2 INSTALLATION PROCEDURE Unpacking Remove all parts from the pallets. Ensure all of the packing material is removed from the outside of the Trimmer. Tilt the Trimmer to upright position. WARNING 2 persons are required to tilt the Trimmer to the upright position. 1-18...
  • Page 32 31 January 2007 TRIMMER INSTALLATION Remove the Belt Stacker Booklet Maker Loosen screws [A] on the Booklet Maker ( x 2 ). Disconnect the Belt Stacker cable ( x 1). Remove Belt Stacker from the Booklet Maker. Secure screws [A] ( x 2 ).

  • Page 33: Adjustments

    TRIMMER INSTALLATION 31 January 2007 1.4.3 ADJUSTMENTS Height adjustment Remove the Trimmer front cover by removing the screws [A] ( x 5). Move the Trimmer up to the Booklet Maker. 1-20...

  • Page 34: Docking

    31 January 2007 TRIMMER INSTALLATION Height adjustment Adjust the height of the Trimmer, so that the docking bracket [B] on the Trim- mer fits in the docking hole [C] on the Booklet Maker (one revolution on the nuts is 1.5mm / 1/16” in height). Adjust by turning the four nuts [D] on the Trim- mer with the Multi tool.
  • Page 35 TRIMMER INSTALLATION 31 January 2007 Looking from behind the system, make sure that the Trimmer is parallel to the Booklet Maker [E] ± 2mm. If necessary, adjust by turning the two nuts [F] on the outfeed side of the Trimmer. 1-22...
  • Page 36 31 January 2007 TRIMMER INSTALLATION 1.4.4 DOCKING Docking procedure Trimmer interior towards Booklet Maker Loosen nuts [A] to the Locking bracket [B] ( x 2). Dock the Trimmer to the Booklet Maker. Secure the Trimmer by lifting the Locking bracket [B] and tightening nuts [A] x 2).
  • Page 37 TRIMMER INSTALLATION 31 January 2007 Install Trimmer fan Trimmer interior towards Booklet Maker Install Trimmer fan [A] by hanging it onto the position pins [B] inside the Trimmer. 1-24...
  • Page 38 31 January 2007 TRIMMER INSTALLATION Install Belt Stacker Trimmer Loosen screws [A] ( x 2) on the Trimmer. NOTE: Unless the SquareFolder SQF 200 will be installed. If so, the Belt Stacker will be installed on to the SquareFolder instead. Install the Belt Stacker on to the Trimmer.

  • Page 39: Connectors

    TRIMMER INSTALLATION 31 January 2007 1.4.5 CONNECTORS Connect the Belt Stacker cable [A] to the Trimmer ( x1). NOTE: Unless a SquareFolder SQF 200 also will be installed. If so, the Belt Stacker cable will connected to the SquareFolder instead. Remove the Trimmer Terminator plug from the Booklet Maker [B] ( x1).
  • Page 40 31 January 2007 TRIMMER INSTALLATION Trimmer with cable protector installed Continued on next page..1-27...
  • Page 41 TRIMMER INSTALLATION 31 January 2007 [ I ] Booklet Maker with Trimmer installed Cable holder mounted on Booklet Maker Cable holder mounted on Trimmer Booklet Maker, rear side 1-28...
  • Page 42 31 January 2007 TRIMMER INSTALLATION 1.4.6 CHECK THE INSTALLATION If installing a SquareFolder SQF 200, continue to section ( 1.5 ) other- wise continue with step 2. Trimmer interior towards Booklet Maker In the Trimmer, check the Index 16 value [A]. Power on the Booklet maker.
  • Page 43 TRIMMER INSTALLATION 31 January 2007 20. Check for the correct feeding of the set from the Collator. NOTE: If paper is not fed correctly, check adjustment of the Booklet maker according to section ( 1.3.3 ). 21. Check that the set has been trimmed correctly. 22.

  • Page 44: Squarefolder Installation

    31 January 2007 SQUAREFOLDER INSTALLATION SQUAREFOLDER INSTALLATION 1.5.1 ACCESSORY CHECK COM. SQF 200 [ I ] Check the quantity and condition of the accessories in the box against the following list: Description Q’ty A. Communication cable ............1 B. Power cord ................1 C.

  • Page 45: Installation Procedure

    SQUAREFOLDER INSTALLATION 31 January 2007 1.5.2 INSTALLATION PROCEDURE Unpacking Remove all parts from the pallets. Ensure all of the packing material is removed from the outside of the Square- Folder. Tilt the SquareFolder to upright position. WARNING 2 persons are required to tilt the SquareFolder to the upright position. 1-32...
  • Page 46 31 January 2007 SQUAREFOLDER INSTALLATION Remove the Belt Stacker Trimmer Trimmer Trimmer, inside view Disconnect the Power cord to the Booklet Maker ( x 1). Loosen screws [A] ( x 2 ) securing the Belt Stacker on the Trimmer. Disconnect the Belt Stacker cable ( x 1) from the Trimmer.
  • Page 47 SQUAREFOLDER INSTALLATION 31 January 2007 Extended trim bin Remove the existing trim bin from the Trimmer. This trim bin can not be used together with the SquareFolder. Assemble the new extended trim bin [A] with the four screws and nuts from the installation kit ( x 4, x 4).

  • Page 48: Adjustments

    31 January 2007 SQUAREFOLDER INSTALLATION 1.5.3 ADJUSTMENTS Height adjustment Remove the front cover of the SquareFolder by removing the screws [A] ( x 5). Move the SquareFolder up to the Trimmer. 1-35...

  • Page 49: Docking

    SQUAREFOLDER INSTALLATION 31 January 2007 SquareFolder Trimmer SquareFolder, front view SquareFolder, rear view Adjust the height of the SquareFolder, so that the positioning pins [B] on the Trimmer fits in the docking holes [C] on the SquareFolder. Adjust by turning the four nuts [D] on the SquareFolder with the Multi tool (one revolution on the nuts is 1.5mm in height).
  • Page 50 31 January 2007 SQUAREFOLDER INSTALLATION Parallellity adjustment Looking from behind the system, make sure that the SquareFolder is parallel to the Trimmer [E] ± 2mm. If necessary, adjust by turning the two nuts [F] on the outfeed side of the SquareFolder . 1-37...
  • Page 51 SQUAREFOLDER INSTALLATION 31 January 2007 1.5.4 DOCKING Docking procedure SquareFolder interior, view towards Belt Stacker Loosen nuts [A] to the Locking bracket [B]. Dock the SquareFolder to the Trimmer. Secure the SquareFolder by lifting the Locking bracket [B] and tightening nuts [A] ( x 2).
  • Page 52 31 January 2007 SQUAREFOLDER INSTALLATION Installing Belt Stacker SquareFolder Loosen screws [A] ( x 2) on the SquareFolder. Install the Belt Stacker on to the SquareFolder. Secure the Belt Stacker by tightening screws [A] ( x 2) on the SquareFolder. 1-39...

  • Page 53: Connectors

    SQUAREFOLDER INSTALLATION 31 January 2007 1.5.5 CONNECTORS Move the Belt Stacker cable [A] to the SquareFolder ( x 1). NOTE: Do not connect the Belt Stacker cable [A] to the Trimmer. Move the Terminator plug [B] from the Trimmer to the SquareFolder ( x 1).
  • Page 54 31 January 2007 SQUAREFOLDER INSTALLATION Cable holder mounted on Booklet Maker Cable holder mounted on Trimmer Cable holder mounted on Square- Folder 1-41...
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  • Page 56: Auto Set Thickness Bracket

    31 January 2007 SQUAREFOLDER INSTALLATION 1.5.6 AUTO SET THICKNESS BRACKET Auto set thickness bracket Booklet Maker, rear side view Remove the rear cover on the Booklet Maker ( 1.3.3) ( x 5 ). Install the Spacer pin [A], with the collar out. NOTE: Install the Spacer pin’s on the rear side of the Booklet Maker.
  • Page 57 SQUAREFOLDER INSTALLATION 31 January 2007 Sensor bracket Booklet Maker, rear side view Booklet Maker, rear side view Booklet Maker, rear side view Place the spring [A] on the screw on the Sensor bracket. Secure the Sensor bracket by tightening it with the screws [B] & [C] ( torx).
  • Page 58 31 January 2007 SQUAREFOLDER INSTALLATION 1.5.7 CHECK THE INSTALLATION Trimmer interior towards Booklet Maker In the Trimmer, check the Index 16 value [A]. Power on the Booklet maker. Press the Tools button on the Booklet Maker. Scroll down to Service and press the OK button. Key in the Password.
  • Page 59 SQUAREFOLDER INSTALLATION 31 January 2007 20. Check for the correct feeding of the set from the Collator. NOTE: If paper is not fed correctly, check adjustment of the Booklet maker according to section ( 1.3.3 ). 21. Check that the booklet has been trimmed correctly. 22.

  • Page 60: Pm Table

    29 November 2006 PM TABLE PREVENTIVE MAINTENANCE SCHEDULE PM TABLE NOTE: Amounts mentioned as the PM interval indicate the number of sets. CAUTION If any of the checkpoints or other parts show indication of wear at any point, replace the part. When lubricating, clean the surface if necessary before applying new lubricant.
  • Page 61 PM TABLE 29 November 2006 FTR 200 125K 250K 375K 500K NOTE REFERENCE Paper paths Blower Brush Sensors Blower Brush Infeed module Infeed belts (4x) Alcohol 3.2.20 Outfeed module Upper outfeed belts C/ I C/ I Alcohol 3.2.15 (2x) Lower outfeed belts C/ I C/ I Alcohol...

  • Page 62: General Cautions

    2 February 2007 GENERAL CAUTIONS REPLACEMENT AND ADJUSTMENT GENERAL CAUTIONS WARNING Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. Using the ESD Ground Strap Purpose The purpose of the ESD (Electrostatic Discharge) ground strap is to preserve the inherent reliability and quality of electronic components handled by the Service Representative.
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  • Page 64: Special Tools And Lubricants

    2 February 2007 SPECIAL TOOLS AND LUBRICANTS SPECIAL TOOLS AND LUBRICANTS 3.2.1 SPECIAL TOOLS In order to facilitate the service of the BM 200 Booklet Making system there are a few special tools needed. Where part number is written it can be purchased from your supplier.
  • Page 65 2 February 2007 For the BM 200 Booklet Making system not to be interlocked (interlocked=36V interrupted), the Interlock switch must be activated and the Interlock magnet must be blocked with a metal. Use the Cheater to override the interlock for running the system with open top covers.

  • Page 66: Required Tools

    2 February 2007 SPECIAL TOOLS AND LUBRICANTS 3.2.2 REQUIRED TOOLS Open wrenches: 5.5, 7, 8, 10, 13, 17, 19 mm Allen keys: 1.5, 2, 2.5, 3, 4, 5 mm Torx T-20 Circlip pliers Metric Feeler gauge set Metric Sliding calliper 3.2.3 SYMBOLS USED IN TEXT Go to section: Screw:...
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  • Page 68: Covers

    2 February 2007 COVERS COVERS 3.3.1 FRONT AND REAR COVER Open top cover. Remove screws [A] to Front cover ( x5 ). Remove screws [B] to Rear cover ( x4 ). Loosen screw [C] ( x1 ). NOTE: Unhook the Rear cover.

  • Page 69: Infeed Cover

    COVERS 2 February 2007 3.3.2 INFEED COVER Remove Front and Rear cover ( 3.3.1 ). Remove screws [A] ( 2 ). Support Infeed Cover. Remove screws [B] to remove Infeed Cover. NOTE: Remove screws in this order to avoid bending front frame part. WARNING Infeed cover is very heavy and could cause injury if it falls down.

  • Page 70: Infeeder

    2 February 2007 COVERS 3.3.3 INFEEDER Open the Top Cover. Remove screws [A] ( x4 ). Disconnect connector [B]. Lift out the Infeeder.

  • Page 71: Outfeed Cover

    COVERS 2 February 2007 3.3.4 OUTFEED COVER Set the machine to A4. Remove Stacker module ( 3.8.1 ). Remove Front and Rear cover ( 3.3.1 ). Remove screws [A] ( x2 ). Remove screws [B] ( x2 ). Remove screws [C] ( x2 ).

  • Page 72: Upper Top Cover

    2 February 2007 COVERS 3.3.5 UPPER TOP COVER Open the Top Cover. Remove screws [A] ( x4 ). Lift off the Upper Top Cover [B]. 3-11...

  • Page 73: Rear Top Cover

    COVERS 2 February 2007 3.3.6 REAR TOP COVER Remove the nut [A] ( x 1). Remove the screw [B] ( x 1). Remove the screws [C] ( x 2). Remove the Rear Top Cover. 3-12...

  • Page 74: Top Cover Assembly

    2 February 2007 COVERS 3.3.7 TOP COVER ASSEMBLY Removal Remove Front and Rear cover ( 3.3.1 ). Remove nuts [A] ( x4 ). Remove screw [B] ( x1 ) and [C] ( x1 ). Move Top cover towards the front side. Remove screws [D]( x2 ) and adjustment plates [E] ( x2 ).
  • Page 75 COVERS 2 February 2007 Adjustment Loosen screw [D] ( x1 ) and screws [F] ( x2 ). Adjust so that the Top cover rests on the rubber supports [H] ( x3 ) when closed. Loosen nuts [C] ( x4 ) and adjust so that the plate [I] holding the upper part of the Top cover lock enters the cut-out in the front frame centered.

  • Page 76: Interlock Switch S16 &S17

    2 February 2007 COVERS 3.3.8 INTERLOCK SWITCH S16 &S17 Removal Remove Front cover ( 3.3.1 ). Remove connector [A] ( x1 ). Remove nuts [B] to Interlock box ( x2 ). Remove screws [C] to Switch PCB ( x2 ). Replacement Reverse the removal procedure.
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  • Page 78: Infeed Module

    2 February 2007 AREA A AREA A 3.4.1 INFEED MODULE Remove Front and Rear cover ( 3.3.1 ). Remove Infeed cover ( 3.3.2 ). Remove connectors [A] ( x2 ). Unhook of the length adjustment strap [B]. Remove screws [C] on the Front side of the Booklet maker ( x2 ).

  • Page 79: Paper Infeed Sensor

    AREA A 2 February 2007 3.4.2 PAPER INFEED SENSOR Remove Infeed Module ( 3.4.1 ). Remove screw [A] ( x1 ). NOTE: You do not have to remove the Infeed module to reach the screw, you are able to reach the screw through the hole in the Infeed module. Remove connector [B] ( x1 ).

  • Page 80: Infeed Transport Module

    2 February 2007 AREA A 3.4.3 INFEED TRANSPORT MODULE Remove connectors [A] ( x2 ). Cut tie wrap [B] . Remove E-clip [C] ( x1 ). Remove pin to the Infeed transport module. 3-19...
  • Page 81 AREA A 2 February 2007 3.4.4 INFEED TRANSPORT WHEEL Remove Infeed transport module ( 3.4.3 ). Remove nuts [A] ( x3 ). Remove E-clip [B] ( x1 ). 3-20...

  • Page 82: Infeed Motor M1 & Sensor Q2

    2 February 2007 AREA A 3.4.5 INFEED MOTOR M1 & SENSOR Q2 Remove Infeed transport wheel ( 3.4.4 ). Remove screws [A] ( x3 ). Pull out the Infeed motor M1 & sensor Q2. NOTE: The sensor Q2 is located on the motor. 3-21...

  • Page 83: Side Guides

    AREA A 2 February 2007 3.4.6 SIDE GUIDES Removal Front Remove Infeed module ( 3.4.1 ). Remove screw [A] and [B] to the Front side guide [C] ( x2 ). Same procedure on the Rear side guide [D]. Replacement Reverse the removal procedure. NOTE: Make sure that you are using the correct screws (M4 x 8mm) when reinstalling the side guides.

  • Page 84: Side Jogger Motor M3 & Sensor Q12

    2 February 2007 AREA A 3.4.7 SIDE JOGGER MOTOR M3 & SENSOR Q12 Removal Remove Infeed module ( 3.4.1 ). Remove connectors [A] ( x2 ). Loosen allen screw [B] to pulley ( x1 ). Remove screws [C] to motor bracket ( x2 ).

  • Page 85: Side Guide Transmission &Sensor Q13

    AREA A 2 February 2007 3.4.8 SIDE GUIDE TRANSMISSION &SENSOR Q13 Continued on next page..3-24...
  • Page 86 2 February 2007 AREA A Removal Sensor Q13 Remove Infeed module ( 3.4.1 ). Disconnect connector [A] to sensor Q13 ( x1 ). NOTE: Make sure that the side guides are in there most inner position and move the Back jogger module by hand, to make it easier to get to the sensor. Replacement Reverse the removal procedure.

  • Page 87: Back Jogger Module & Sensor Q3

    AREA A 2 February 2007 3.4.9 BACK JOGGER MODULE & SENSOR Q3 [ H ] Continued on next page..3-26...
  • Page 88 2 February 2007 AREA A Removal Sensor Q3 Remove Infeed cover ( 3.3.2 ). NOTE: Picture shows Infeed module removed for clarity. It is not necessary to remove Infeed module to replace Sensor Q3. Disconnect connector [A] to Sensor Q3 ( x1 ).

  • Page 89: Back Jogger Fingers

    AREA A 2 February 2007 3.4.10 BACK JOGGER FINGERS [ I ] Continued on next page..3-28...
  • Page 90 2 February 2007 AREA A Removal Remove Back jogger module ( 3.4.9 ) Loosen spring [A] with a screwdriver [B], by pulling the screwdriver straight out according to the arrows [C] ( x1 ). Remove screws [D] ( x2 ). Remove E-clips [E] ( x4 ).

  • Page 91: Back Jogger Motor M2

    AREA A 2 February 2007 3.4.11 BACK JOGGER MOTOR M2 Removal Remove Back jogger module ( 3.4.9 ). Remove screw [A] and nut [B] ( x1 ). Remove the Bracket [C] from the motor axel. Remove connector [D] ( x1). Remove screws [E] to the motor ( x3 ).

  • Page 92: Stapler Head

    2 February 2007 AREA A 3.4.12 STAPLER HEAD Replacement of staple cartridge Open the booklet maker top cover. Raise the handle (A) on the staple cartridge locking lever. Remove the staple cartridge [B] from the stapler head by sliding it away from the stapler head.
  • Page 93 AREA A 2 February 2007 Removal of stapler head Open the booklet maker top cover. Disconnect the staple indication lead [D] from the socket. Hold the stapler head in place, press the release lever [E] 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.
  • Page 94 2 February 2007 AREA A Maintenance of stapler head The stapler head drive post on each stapler head should be lubricated every 20 000 cycles. Put a couple of drops of oil [F] on each side of the drive post [G]. Cycle the stapler head a few times before installing it again.

  • Page 95: Stapler Head Retraction Distance

    AREA A 2 February 2007 3.4.13 STAPLER HEAD RETRACTION DISTANCE 1,0 - 2,0 mm Purpose The purpose is to ensure the staple feed. Removal Remove Infeed cover( 3.3.2 ). Make sure that the Stapler motor linkage is in the top dead center. Adjustment Push down the stapler head [A].

  • Page 96: Stapler Motor M4

    2 February 2007 AREA A 3.4.14 STAPLER MOTOR M4 [ I ] Removal Remove Infeed cover( 3.3.2 ). Disconnect connector [A] ( x1 ). Remove nut [B], brass spacer [C] and screw [D] ( x1 ). Remove Crank journal [E] with an 17 mm open wrench. Remove screw and washer [F] ( x1 ).

  • Page 97: Stapler Assy Drive Bar & Sensor Q14

    AREA A 2 February 2007 3.4.15 STAPLER ASSY DRIVE BAR & SENSOR Q14 0,05 to 0,15 mm Purpose The purpose is to limit the front-to-rear movement of the Stapler assembly drive bars, without causing them to bind. Removal Remove Front and Rear cover ( 3.3.1 ).

  • Page 98: Clincher Bar Assembly

    2 February 2007 AREA A 3.4.16 CLINCHER BAR ASSEMBLY Incorrect, with gap Correct, no gap Removal Set the machine to A3 / 11x17”. Remove Infeed module ( 3.4.1 ). Remove screws and nuts [A] on both sides of the Booklet maker ( x2 ).

  • Page 99: Cleaning Clincher Points

    AREA A 2 February 2007 3.4.17 CLEANING CLINCHER POINTS Removal Remove Clincher bar assembly [A] ( 3.4.16 ). Remove screws [B] to clincher plate [C] ( x3 ). Remove clincher plate [C]. NOTE: The clincher points [D] are not interchangeable. They must be refitted on their original position.

  • Page 100: Set Transport Drive Alignment

    2 February 2007 AREA A 3.4.18 SET TRANSPORT DRIVE ALIGNMENT [ I ] Continued on next page..3-39...
  • Page 101 AREA A 2 February 2007 Purpose The purpose is to horizontally align the Set transport drive rollers with the Idler wheels, to ensure the correct set transportation into the fold area. Set the machine to A4 / 8.5x11”. Ensure that the tires [A] are centered on the hubs [B] of the drive rollers. Manually move the Drive rollers [C] up against the Pressure rollers [D], by pushing the Staple stop gate down.

  • Page 102: Pressure Roller

    2 February 2007 AREA A 3.4.19 PRESSURE ROLLER 7-10 mm 7-10 mm Purpose The purpose is to position the Pressure rollers for the correct engagement with the Drive rollers. This adjustment interacts with 3.5.1. Adjustment Set the machine to A3 / 11x17”. Check that the distance [A] is 24.5 mm.

  • Page 103: Set Transport Motor M5

    AREA A 2 February 2007 3.4.20 SET TRANSPORT MOTOR M5 Remove Infeed cover ( 3.3.2 ). Remove screw [A] to ground strap ( x1 ). Remove O-ring [B]. Loosen the allen screw underneath the O-ring ( x1 ). Loosen screws [C] and remove the motor ( x2 ).

  • Page 104: Thick Set Sensor Q36

    2 February 2007 AREA A 3.4.21 THICK SET SENSOR Q36 View from infeed View from outfeed Removal Remove the outermost stapler head [A] ( 3.4.12 ). Remove nut [B] ( x1 ). NOTE: In order to maintain distance [C], do not loosen screws [D] or [E]. Disconnect connector [F] ( x1 ).
  • Page 105 AREA A 2 February 2007 Replacement Reverse the removal procedure. Check Install interlock cheater in order to operate BM 200 with Top Cover open. Set trimming to off. Check sensor Q36 adjustment by hand feeding sets of 80 gsm sheets. A set of 32 sheets should pass but a set of 35 sheets should be stopped in the stapling area with the display showing the message “Set to thick”.

  • Page 106: Staple Stop Gate Solenoid Sol1

    2 February 2007 AREA B AREA B 3.5.1 STAPLE STOP GATE SOLENOID SOL1 Purpose The purpose is to ensure adequate engagement of the pressure rollers. NOTE: This adjustment interacts with 3.4.19. Perform adjustment 3.4.19 before this adjustment 3.5.1. Removal Check/Adjust the Pressure roller ( 3.4.19 ).

  • Page 107: Staple Stop Gate Release Solenoid Sol2

    AREA B 2 February 2007 3.5.2 STAPLE STOP GATE RELEASE SOLENOID SOL2 Continued on next page..3-46...
  • Page 108 2 February 2007 AREA B Removal Start Staple / Fold positioning motor M9, in Check motors ( 5.1.1 ). Engage the motor until you can see the screws [A]. Remove Infeed cover ( 3.3.2 ). Cut the tie wrap, securing the cable. Disconnect connector to SOL2 ( x1 ).

  • Page 109: Saddle Stapling Start Sensor Q4

    AREA B 2 February 2007 3.5.3 SADDLE STAPLING START SENSOR Q4 Removal Remove nut [A] ( x1 ). Disconnect connector [B] ( x1 ). Replacement Reverse the removal procedure. NOTE: Make sure that the sleeve of the wire, do not interfere with the paper path. 3-48...

  • Page 110: Staple / Fold Position Motor M9 & Sensor Q10

    2 February 2007 AREA C AREA C 3.6.1 STAPLE / FOLD POSITION MOTOR M9 & SENSOR Q10 Set the machine to A4 / 8.5x11”. Remove Outfeed cover ( 3.3.4 ). Disconnect connectors [A] ( x2 ). Remove screws [B] to the motor bracket ( x3 ).

  • Page 111: Length Transmission Shaft & Sensor Q11

    AREA C 2 February 2007 3.6.2 LENGTH TRANSMISSION SHAFT & SENSOR Q11 View inside Booklet maker with Infeed cover removed View on Length adjustment shaft with Rear cover removed Continued on next page..3-50...
  • Page 112 2 February 2007 AREA C Removal Sensor Q11 Remove Rear cover ( 3.3.1 ). Remove Infeed cover ( 3.3.2 ). Disconnect connector [A] ( x1 ). Remove sensor Q11 [B]. Replacement Sensor Q11 Reverse the removal procedure. Lubricate Length transmission shaft Remove Rear cover ( 3.3.1 ).

  • Page 113: Fold Stop Gate Motor M8 & Sensor Q7

    AREA C 2 February 2007 3.6.3 FOLD STOP GATE MOTOR M8 & SENSOR Q7 Removal Set the machine to A3 / 11x17”. Disconnect connector [A] ( x1 ). Loosen allen screw [B] and remove the linkage ( x1 ). Remove screws [C] to the motor ( x3 ).

  • Page 114: Fold Stop Gate

    2 February 2007 AREA C 3.6.4 FOLD STOP GATE Removal Set the machine to A3 / 11x17”. Loosen locknut [A] ( x1 ). Remove screw [B] ( x1 ). Remove the Fold stop gate. Replacement Reinstall the Fold stop gate. NOTE: Make sure that the shaft on the Fold stop gate, is positioned in the linkage.

  • Page 115: Fold Knife Motor M7 & Sensor Q15

    AREA C 2 February 2007 3.6.5 FOLD KNIFE MOTOR M7 & SENSOR Q15 [ I ] Continued on next page..3-54...
  • Page 116 2 February 2007 AREA C Removal Set the machine to A4 / 8.5x11”. Remove Front and Rear cover ( 3.3.1 ). Remove Infeed cover ( 3.3.2 ). Disconnect connector [A] to motor M7 ( x1 ). Disconnect connector [B] to sensor Q15 ( x1 ).

  • Page 117: Fold Transmission Module

    AREA C 2 February 2007 3.6.6 FOLD TRANSMISSION MODULE Remove Front cover ( 3.3.1 ). Disconnect connector [A] to Fold roller motor M6 ( x1 ). Disconnect connector [B] to Fold roller sensor Q9 ( x1 ). x3 ). Remove nuts [C] to the Fold transmission module ( 3-56...

  • Page 118: Fold Transmission Belt & Sensor Q9

    2 February 2007 AREA C 3.6.7 FOLD TRANSMISSION BELT & SENSOR Q9 Continued on next page..3-57...
  • Page 119 AREA C 2 February 2007 Removal Remove Fold transmission module ( 3.6.6 ). Remove screws [A], [B] and [C] to Fold transmission plate ( x3 ). Remove the Fold transmission plate and Fold roller sensor Q9 plate [D]. Loosen screw [E] ( x1 ).

  • Page 120: Fold Roller Motor M6

    2 February 2007 AREA C 3.6.8 FOLD ROLLER MOTOR M6 Continued on next page..3-59...
  • Page 121 AREA C 2 February 2007 Removal Remove Fold transmission belt ( 3.6.7 ). Remove screw and washer [A] ( x1 ). Remove bearing [B]. Remove the Motor transmission pulley [C]. Remove screws [D] ( x3 ). Replacement Reinstall screws [D] ( x3 ).

  • Page 122: Fold Transmission Gear Assemblys

    2 February 2007 AREA C 3.6.9 FOLD TRANSMISSION GEAR ASSEMBLYS Remove Fold transmission belt ( 3.6.7 ). Remove E-clips ( Remove transmission gears. It is the same Fold transmission coupling assembly [E] on all of the Fold trans- mission gear assembly’s. 3-61...

  • Page 123: Fold Distance Bracket

    AREA C 2 February 2007 3.6.10 FOLD DISTANCE BRACKET Removal Remove Fold transmission module ( 3.6.6 ). Remove nut [A] to the middle bearing bracket ( x1 ). Remove the bearing bracket [B]. Remove Fold distance bracket [C]. NOTE: DO NOT LOOSEN OR REMOVE THE NUT [D] TO THE EXCENTER. Replacement Reverse the removal procedure.

  • Page 124: Upper Folder Roller

    2 February 2007 AREA C 3.6.11 UPPER FOLDER ROLLER [ I ] Continued on next page..3-63...
  • Page 125 AREA C 2 February 2007 Removal Remove outfeed cover ( 3.3.4 ). Remove the paper guide [A] by pressing it against the rear side of the Booklet maker. Loosen springs [B] to the Cams to the Upper folder rollers ( x2 ).

  • Page 126: Lower Folder Roller

    2 February 2007 AREA C 3.6.12 LOWER FOLDER ROLLER Continued on next page..3-65...
  • Page 127 AREA C 2 February 2007 Removal Remove outfeed cover ( 3.3.4 ). Remove the paper guide [A] by pressing it against the rear side of the Booklet maker. Remove Fold distance bracket ( 3.6.10 ). Remove nuts [B] and bearing brackets [C] on the front and rear side of the booklet maker ( x2 ).

  • Page 128: Outfeed Sensor

    2 February 2007 AREA C 3.6.13 OUTFEED SENSOR Remove outfeed cover ( 3.3.4 ). Remove nut [A] ( x1 ). Disconnect connector [B] ( x1 ). 3-67...
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  • Page 130: Md3Dc Pcb "H"

    2 February 2007 3.7.1 MD3DC PCB “H” H.P14 H.P2 H.P5 H.P4 H.P11 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 131: Upper Md6Dc Pcb "B"

    2 February 2007 3.7.2 UPPER MD6DC PCB ”B” B.P4 B.P5 B.P12 B.P11 B.P13 B.P3 B.P2 B.P14 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 132: Lower Md6Dc Pcb "C"

    2 February 2007 3.7.3 LOWER MD6DC PCB ”C” C.P4 C.P5 C.P12 C.P11 C.P13 C.P3 C.P2 C.P14 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 133: Interlock Pcb "D"

    2 February 2007 3.7.4 INTERLOCK PCB ”D” D.P5 D.P6 D.P8 D.P9 D.P13 D.P10 D.P11 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 134: Cpu Pcb And Collator Interface Pcb "A"

    2 February 2007 3.7.5 CPU PCB AND COLLATOR INTERFACE PCB ”A” A.P5 A.P4 A.P3 A.P2 A.P9 A.P1 A.P13 A.P10 A.P8 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs).
  • Page 135 2 February 2007 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 136: Addon Pcb "F"

    2 February 2007 3.7.6 ADDON PCB ”F” F.P1 F.P2 F.P3 F.P6 F.P4 F.P5 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 137: Lcd Panel

    2 February 2007 3.7.7 LCD PANEL CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 138: Stacker

    2 February 2007 STACKER STACKER 3.8.1 STACKER MODULE Loosen screws [A] to the Stacker Module ( x2 ). Disconnect the connector to the Stacker Module ( x1). Lift off the Stacker Module. 3-77...

  • Page 139: Stacker Motor M1

    STACKER 2 February 2007 3.8.2 STACKER MOTOR M1 Removal Remove Stacker Module ( 3.8.1 ). Loosen nuts [A] ( x3 ). Slide the motor bracket [B] and remove. Disconnect connector [C] ( x1 ). Remove screws [D] ( x3 ). Replacement Reverse the removal procedure.

  • Page 140: Booklet Quality Adjustment

    2 February 2007 BOOKLET QUALITY ADJUSTMENT BOOKLET QUALITY ADJUSTMENT 3.9.1 STAPLE STOP GATE PARALLELISM Continued on next page..3-79...
  • Page 141 BOOKLET QUALITY ADJUSTMENT 2 February 2007 Purpose The purpose is to ensure that the staples are parallel to the edge of the sets. Removal Set the machine to A3 / 11x17”. Open Top cover. Remove the rear stapler head ( 3.4.12 ).

  • Page 142: Side Guide Parallelism

    2 February 2007 BOOKLET QUALITY ADJUSTMENT 3.9.2 SIDE GUIDE PARALLELISM Stapler area seen from above, with the stapler heads removed. Removal Front Check/adjust Staple stop gate parallelism ( 3.9.1). Remove Infeed cover ( 3.3.2 ). Remove screw [A] and [B] to the Front side guide [C] ( x2 ).

  • Page 143: Staple Position To Clincher

    BOOKLET QUALITY ADJUSTMENT 2 February 2007 3.9.3 STAPLE POSITION TO CLINCHER CAUTION Alignment of the stapler head to clincher is carried out at factory. Screws are sealed with red paint to ensure that alignment is maintained and also to indicate if it has been moved.
  • Page 144 2 February 2007 BOOKLET QUALITY ADJUSTMENT Remove Infeeder ( 3.3.3). Disconnect the Staple detection lead [G]. Push down latch [E] and lift the Stapler head out. Push the plunger [C] slowly so that the legs of the staple comes out about 1-2 mm.
  • Page 145 BOOKLET QUALITY ADJUSTMENT 2 February 2007 12. Push gently on plunger [C] and check if the staple legs are positioned in the center of the clincher points [K]. Check both sidewise and lengthwise. NOTE: Use a flash light to clearer see the alignment. 13.

  • Page 146: Stapler Pressure

    2 February 2007 BOOKLET QUALITY ADJUSTMENT 3.9.4 STAPLER PRESSURE Removal Front Remove Infeed cover ( 3.3.2 ). Remove Stapler heads ( 3.4.12 ). Check/adjust the Clincher Pressure ( 3.9.6 ). Rotate the motor linkage [A] to the down dead center. NOTE: Use a 17 mm open wrench.

  • Page 147: Clincher Points Height

    BOOKLET QUALITY ADJUSTMENT 2 February 2007 3.9.5 CLINCHER POINTS HEIGHT Purpose The purpose is to achieve the correct, flat form of the staples and to maintain life- time of the clincher points and stapler heads. NOTE: Adjustment of clincher points can be performed with clincher beam in- stalled.

  • Page 148: Clincher Pressure

    2 February 2007 BOOKLET QUALITY ADJUSTMENT 3.9.6 CLINCHER PRESSURE Continued on next page..3-87...
  • Page 149 BOOKLET QUALITY ADJUSTMENT 2 February 2007 Purpose The purpose is to achieve the correct, flat form of the staples. Removal Front Check/adjust Clincher points height ( 3.9.5 ). Remove Infeed cover ( 3.3.2 ). Remove Stapler heads ( 3.4.12 ). Rotate the motor linkage (see Removal step 4, ( 3.9.4) to the down dead center.

  • Page 150: Staple And Fold Position

    2 February 2007 BOOKLET QUALITY ADJUSTMENT 3.9.7 STAPLE AND FOLD POSITION Purpose The purpose is to ensure that the set is folded in the center of the set, and that the staple is positioned in the center of the set. Shown in tipped position for clarity Initial Action Check/adjust Side Guide Parallelism (...
  • Page 151 BOOKLET QUALITY ADJUSTMENT 2 February 2007 Staple Adjustment: Check/adjust Paper size reset ( 5.4 ). Set up the Booklet maker for 297x420 mm / 11x17” in Custom size. NOTE: Do NOT use the preset A3 or 11x17” paper sizes. Hand feed a 2-sheet set, using 297x420 mm / 11x17” paper. Run a few sets.

  • Page 152: Fold Skew

    2 February 2007 BOOKLET QUALITY ADJUSTMENT 3.9.8 FOLD SKEW Shown in tipped position for clarity Purpose The purpose is to ensure that the fold is parallel to the edge of the sets. Adjustment Hand feed a 2-sheet set, using A3/ 11x17” paper. Run a few sets.

  • Page 153: Staple Position On Square Formed Spine

    BOOKLET QUALITY ADJUSTMENT 2 February 2007 3.9.9 STAPLE POSITION ON SQUARE FORMED SPINE Purpose The purpose is to position the staples on the square formed spine according to customer preferences. Factory default is within the spine. Shown in tipped position for clarity Adjustment NOTE: This adjustment will affect all types of booklets! If the staple position is adjusted on a 20 sheet booklet with Square formed...

  • Page 154: Power Requirements

    2 February 2007 POWER REQUIREMENTS 3.10 POWER REQUIREMENTS 3.10.1 TAPPING THE TRANSFORMER Transformer in picture tapped for 230V Purpose To be able to change the Transformer setting. Removal Remove screw [A] and renove Transformer cover [B] ( x1 ). Remove Front Cover ( 3.3.1 ).
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  • Page 156: Fault Code Descripitions

    12 February 2007 FAULT CODE DESCRIPTIONS TROUBLESHOOTING FAULT CODE DESCRIPITIONS Fault Item Fault description Page code BM-001 BM-M1 Infeed motor No displacement pulses ..........4 - 3 BM-002 BM-M1 Infeed motor Short circuit ..............4 - 3 BM-003 BM-M1 Infeed motor Open circuit ..............4 - 3 BM-004 BM-M2 Back jogger motor Cycle time out ............
  • Page 157 FAULT CODE DESCRIPTIONS 12 February 2007 Fault Item Fault description Page code BM-040 BM-M19/Q34 Pre-Infeed Motor No displacement pulses ......... 4 - 19 BM-041 BM-M19 Pre-Infeed Motor Short circuit ............. 4 - 20 BM-042 BM-M19 Pre-Infeed Motor Open circuit ............. 4 - 20 BM-044 BM-Q36 Thick Set Sensor Faulty ...............
  • Page 158 12 February 2007 FAULT CODE DESCRIPTIONS BM-001 Fault Code BM-001, indicates that the Infeed motor (BM-M1) does not receive any displacement pulses. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Infeed motor (BM-M1) in check motors. Procedure Disconnect the sensor plug Q2 to motor BM-M1.
  • Page 159 FAULT CODE DESCRIPTIONS 12 February 2007 BM-004 Fault Code BM-004, indicates that the Back jogger motor (BM-M2) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Back jogger motor (BM-M2) in check motors. Make sure that the Back jogger home position sensor (BM-Q3) is installed correctly.
  • Page 160 12 February 2007 FAULT CODE DESCRIPTIONS BM-006 Fault Code BM-006, indicates that the Back jogger motor (BM-M2) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M2. Enter Service mode and start Back jogger motor (BM-M2) in check motors. Measure between the orange wire M2 and the violet wire M2 (PWM 36V and ground).
  • Page 161 FAULT CODE DESCRIPTIONS 12 February 2007 BM-008 Fault Code BM-008, indicates that the Side jogger motor (BM-M3) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Side jogger motor (BM-M3) in check motors. Make sure that the Side jogger home position sensor (BM-Q13) is installed correctly.
  • Page 162 12 February 2007 FAULT CODE DESCRIPTIONS BM-010 Fault Code BM-010, indicates that the Side jogger motor (BM-M3) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M3. Enter Service mode and start Side jogger motor (BM-M3) in check motors. Measure between the orange wire M3 and the violet wire M3 (PWM 36V and ground).
  • Page 163 FAULT CODE DESCRIPTIONS 12 February 2007 BM-011 Fault Code BM-011, indicates that the Stapler motor (BM-M4) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Stapler motor (BM-M4) in check motors. Make sure that the Stapler home position sensor (BM-Q14) is installed correctly.
  • Page 164 12 February 2007 FAULT CODE DESCRIPTIONS BM-012 Fault Code BM-012, indicates that the Stapler motor (BM-M4) has a Short circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M4. Run the Diagnostics again. Fault code BM-013 (Open circuit) is displayed? Disconnect plug C.P3 from PCB “C”.
  • Page 165 FAULT CODE DESCRIPTIONS 12 February 2007 BM-015 Fault Code BM-015, indicates that the Set transport motor (BM-M5) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M5. Enter Service mode and Set transport motor (BM-M5) in check motors. Measure between the orange wire M5 and the violet wire M5 (PWM 36V and ground).
  • Page 166 12 February 2007 FAULT CODE DESCRIPTIONS BM-017 Fault Code BM-017, indicates that the Fold roller motor (BM-M6) has a Short circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M6. Run the Diagnostics again. Fault code BM-018 (Open circuit) is displayed? Disconnect plug C.P3 from PCB “C”.
  • Page 167 FAULT CODE DESCRIPTIONS 12 February 2007 BM-019 Fault Code BM-019, indicates that the Fold knife motor (BM-M7) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Fold knife motor (BM-M7) in check motors. Make sure that the Fold knife home position sensor (BM-Q15) is installed correctly.
  • Page 168 12 February 2007 FAULT CODE DESCRIPTIONS BM-021 Fault Code BM-021, indicates that the Fold knife motor (BM-M7) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M7. Enter Service mode and start Fold knife motor (BM-M7) in check motors. Meas- ure between the orange wire M7 and the violet wire M7 (PWM 36V and ground).
  • Page 169 FAULT CODE DESCRIPTIONS 12 February 2007 BM-024 Fault Code BM-024, indicates that the Staple / Fold positioning motor (BM-M9) does not receive any displacement pulses. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Staple / Fold positioning motor (BM-M9) in check mo- tors.
  • Page 170 12 February 2007 FAULT CODE DESCRIPTIONS BM-025 Fault Code BM-025, indicates that the Staple / Fold positioning motor (BM-M9) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Staple / Fold positioning motor (BM-M9) in check motors. Make sure that the Staple / Fold home position sensor (BM-Q11) is installed correctly.
  • Page 171 FAULT CODE DESCRIPTIONS 12 February 2007 BM-027 Fault Code BM-027, indicates that the Staple / Fold positioning motor (BM-M9) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M9. Enter Service mode and start Staple / Fold positioning motor (BM-M9) in check motors. Measure between the orange wire M9 and the violet wire M9 (PWM 36V and ground).
  • Page 172 12 February 2007 FAULT CODE DESCRIPTIONS BM-033 Fault Code BM-033, indicates that the stopgate release solenoid has an Open circuit Initial Actions Make sure that the connectors are properly connected to the Solenoid. Check fuse F3 Procedure Power off the machine. Remove connectors from solenoid SOL2. Measure on the contacts on the Solenoid. Is there an open circuit? Reinstall connectors.
  • Page 173 FAULT CODE DESCRIPTIONS 12 February 2007 BM-035 Fault Code BM-035, indicates that the Start sensor, Saddle stapling sensor (BM-Q4) is faulty. Initial Actions Make sure that the Start sensor, Saddle stapling sensor (BM-Q4) is installed correctly. Procedure 1. Replace sensor BM-Q4. 2.
  • Page 174 12 February 2007 FAULT CODE DESCRIPTIONS BM-039 Fault Code BM-039, indicates that the Outfeed sensor Booklet maker (BM-Q8) is faulty. Initial Actions Make sure that the Outfeed sensor Booklet maker (BM-Q8) is installed correctly. Procedure 1. Replace sensor BM-Q8. 2. Disconnect plug A.P1 from CPU PCB. Measure between J1-17 and J1-19 (5V and ground). The voltage is approximately 5 VDC? Replace CPU PCB.
  • Page 175 FAULT CODE DESCRIPTIONS 12 February 2007 BM-041 Fault Code BM-041, indicates that the Pre-Infeed Motor (BM-M19) has a Short circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M19. Run the Diagnostics again. Fault code BM-042 (Open circuit) is displayed? Disconnect plug H.P2 from PCB “H”.
  • Page 176 12 February 2007 FAULT CODE DESCRIPTIONS BM-045 Fault Code BM-045, indicates that the Fold Gap Sensor (BM-Q37) is faulty. Initial Actions Make sure that the Fold Gap Sensor (BM-Q37) is installed correctly. Procedure 1. Replace sensor BM-Q37. 2. Disconnect plug F.P3 from Addon PCB. Measure between J3-2 and J3-4 (5V and ground). The voltage is approximately 5 VDC? Replace Addon PCB.
  • Page 177 FAULT CODE DESCRIPTIONS 12 February 2007 BM-151 Fault Code BM-151, indicates that the 36V input is low. Initial Actions Check fuse F3. Check the Voltage protection plug P7 on the interlock PCB. The resistance must be grater than MOhm. Make sure that contact P8 on interlock PCB is correctly installed. Make sure that contact P12 on controller PCB is correctly installed Make sure that the transformer in the machine is wired correctly.
  • Page 178 12 February 2007 FAULT CODE DESCRIPTIONS BM-153 Fault Code BM-153, indicates that the 36V output is low. Initial Actions Make sure that all the connectors are properly installed on the interlock PCB Procedure Power on machine and close covers. Measure between P6-1 and P6-3 on the interlock PCB. The voltage is approximate- ly 36V.
  • Page 179 FAULT CODE DESCRIPTIONS 12 February 2007 BM-155 Fault Code BM-155, indicates that the 24V output is low. Initial Actions Make sure that all the connectors are properly installed on the BM 200 interlock PCB. Enter Service mode, and run Trimmer motors M5/6, make sure that they run correctly. Procedure Power on machine and close covers.
  • Page 180 12 February 2007 FAULT CODE DESCRIPTIONS BM-157 Fault Code BM-157, indicates that the 36V output relay is faulty. Initial Actions Check fuse F2. Procedure Power on machine. Measure between P6-1 and P6-3 on the Interlock PCB. The voltage is approximately 36VDC. The voltage is less than 26VDC.
  • Page 181 FAULT CODE DESCRIPTIONS 12 February 2007 BM-159 Fault Code BM-159, indicates that the PCB MD6DC B is not connected. Initial Actions Make sure that all connectors are properly connected to PCB MD6DC B. Make sure that the dipswitches on the PCB are set correctly ( 5.2.1).
  • Page 182 12 February 2007 FAULT CODE DESCRIPTIONS BM-201 Fault Code BM-201, indicates that during a run, the Paper infeed sensor (BM-Q1), was not blocked within timeout after the start signal from the collator was detected. Initial Actions Check fuse F2 on Transformer. Make sure that the Paper infeed sensor (BM-Q1) is installed correctly.
  • Page 183 FAULT CODE DESCRIPTIONS 12 February 2007 BM-204 Fault Code BM-204, indicates that at “initialization” or during a run, the Start sensor Saddle stapling (BM-Q4), was blocked, exceeding timeout. Initial Actions Check fuse F2 on Transformer. Make sure that the Start sensor Saddle stapling (BM-Q4) is installed correctly. Ensure that the Start sensor Saddle stapling (BM-Q4) is clean.
  • Page 184 12 February 2007 FAULT CODE DESCRIPTIONS BM-209 Fault Code BM-209, indicates that during a run, the Outfeed sensor Booklet maker (BM-Q8), was not blocked within timeout. Initial Actions Check fuse F2 on Transformer. Make sure that the Outfeed sensor Booklet maker (BM-Q8) is installed correctly. Ensure that the Outfeed sensor Booklet maker (BM-Q8) is clean.
  • Page 185 FAULT CODE DESCRIPTIONS 12 February 2007 BM-401 Fault Code BM-401, indicates that the stapler head is faulty or stapler cartridge is empty. Initial Actions Check stapler head ( 3.4.12 ). Procedure Disconnect the connectors to the stapler heads. Disconnect plug A.P1 from CPU PCB. Check wire for Continuity / Short circuit from the rear stapler head lead to the A.P1-24 and the front stapler head lead to the A.P1-15.

  • Page 186: Blown Fuse Conditions

    12 February 2007 BLOWN FUSE CONDITIONS BLOWN FUSE CONDITIONS WARNING ONLY USE SLOW BLOW FUSES. Fuse Sec. Rating Symptom at power on 6.1.3 No response 6.1.1 Fault in area B, BM-151 6.1.1 No response 6.1.1 Not in use 4-31...
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  • Page 188: Leds

    12 February 2007 LEDS LEDS Motor Drive PCB (MD6DC) in Booklet Maker & Trimmer D1: Yellow LED flashes when power is on. The flashing indicates that a program is present and functioning. Should a download fail or the 5V is missing, LED would be OFF. D2: Red LED flashes whenever information is sent or received on the Internal CAN. If power is switched on but no operations are performed, LED is OFF.
  • Page 189 LEDS 12 February 2007 Motor Drive PCB (MD3DC) in Booklet Maker D1 (B) D2 (A) D1: Red LED flashes when power is on. The flashing indicates that a program is present and functioning. Should a download fail or the 5V is missing, LED would be OFF. D2: Yellow LED flashes whenever information is sent or received on the Internal CAN.
  • Page 190 12 February 2007 LEDS CPU PCB in Booklet Maker D5: Yellow LED flashes when power is on. The flashing indicates that a program is present and functioning. Should a download fail or the 5V is missing, Yellow LED would be OFF. 4-35...
  • Page 191 LEDS 12 February 2007 Interlock PCB in Booklet Maker PGND (TP2) +UNREG +24V D6: Red LED is ON when unregulated 36V is present. If machine is interlocked (i.e. the top cover is open and 36V is cut off) or 36V is missing, LED is OFF. The unregulated 36V can be measured between +UNREG Test Point and PGND Test Point.
  • Page 192 12 February 2007 LEDS Coollator Interface PCB in Booket Maker D8 D7 D6 D5 D4 D3 D2 D1 D9 D10 D11 D12 D13 D14 D15 D16 D1 - D8 are signals from BM 200 D9 - D16 are signals from Collator D5-8 and D11-D16: Not used. D1: Connection detect.
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  • Page 194: Test Points

    12 February 2007 TEST POINTS TEST POINTS Motor Drive PCB (MD6DC) in Booklet Maker & Trimmer +UNREG GND/ PGND +UNREG: Outgoing unregulated 36V, after interlock relay. Measure between Test Point +UNREG and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter unless: - Voltage is outside allowed range 29-43V. Voltage will be 0V. - Machine is interlocked (i.e.
  • Page 195 TEST POINTS 12 February 2007 Motor Drive PCB (MD3DC) in Booklet Maker GND/ PGND VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer. Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter. Range 4.9-5.1V. GND / PGND: Ground /Power Ground is the minus when measuring 5V (VCC).
  • Page 196 12 February 2007 TEST POINTS CPU PCB in Booklet Maker GND / PGND VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer. Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter. Range 4.9-5.1V. GND: Ground is the minus when measuring 5V (VCC).
  • Page 197 TEST POINTS 12 February 2007 Interlock PCB in Booklet Maker PGND (TP2) +UNREG +24V TP1: Incoming unregulated 36V, before interlock relay. Measure between Test Point TP1 and Test Point PGND using a voltmeter. The voltage will be shown on the volt- meter regardless of the voltage being outside allowed range 29-43V. +UNREG: Outgoing unregulated 36V, after interlock relay.
  • Page 198 12 February 2007 TEST POINTS Addon PCB in Booklet Maker GND / PGND: Ground /Power Ground is the minus 4-43...
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  • Page 200: Service Program Mode

    2 February 2007 SERVICE PROGRAM MODE SERVICE TABLES CAUTION Never turn off the main power when motors are cycling. To avoid damaging the circuitry, stop the motor/motors running under the Check Motors menu, and then switch the main power off. SERVICE PROGRAM MODE 5.1.1 SERVICE PROGRAM MODE OPERATIONS The Service Program (SP) mode is used to check electrical data, check electrical...
  • Page 201 SERVICE PROGRAM MODE 2 February 2007 Checking Motors and Solenoids 1. Go to Check Motors or Check Solenoids. Press OK. 2. Go to the unit in which the motor/solenoid to be checked is located. Press OK. 3. Go to the motor/solenoid to be checked. Press OK. 4.
  • Page 202 2 February 2007 SERVICE PROGRAM MODE Interface Under Interface you adapt the BM 200 interface to the correct host machine. 1. Go to Interface. Press OK. 2. Press Arrow to select correct host machine. Press OK. Changing NVM Values 1. Go to NVM values. Press OK. 2.

  • Page 203: Service Program Mode Tables

    SERVICE PROGRAM MODE 2 February 2007 5.1.2 SERVICE PROGRAM MODE TABLES Check Motors and function Booklet Maker Motor Normal Reading Function 14V ±2V, ≈0.90m/s BM-M1 Infeed Motor transports the set to the stapling section. 9V ±2V BM-M2 Back Jogger Motor jogs the sheets together lengthwise.
  • Page 204 2 February 2007 SERVICE PROGRAM MODE Trimmer Motor Normal Reading Function 22V ±2V, ≈0.70m/s FTR-M1 Transport/Knife Motor transports the booklet in and out ≈0.70m/s of the Trimmer unit. It also functions as a second Trim Knife Motor when reversed. In Service mode, only transport direc- tion can be run.
  • Page 205 SERVICE PROGRAM MODE 2 February 2007 Check Solenoids and function Booklet Maker Solenoid Normal Reading Function BM-SOL1 Will be actuated Stop Gate Solenoid moves the staple stop down for appr. 30 sec. and the set transport rollers up/down. BM-SOL2 Will be actuated Stop Gate Release Solenoid releases the staple for appr.
  • Page 206 2 February 2007 SERVICE PROGRAM MODE Check Sensors/Switches and function Booklet Maker Sensor Normal State Function BM-Q1 0 = Unblocked Paper Infeed Sensor BM-Q3 0 = Unblocked Back Jogger Home Position Sensor BM-Q4 0 = Unblocked Start Sensor, Saddle Stapling BM-Q7 0 = Unblocked Fold Stop Sensor BM-Q8 0 = Unblocked...
  • Page 207 SERVICE PROGRAM MODE 2 February 2007 Squarefolder Sensor Normal State Function SQF-Q1 0 = Unblocked Stop Gate sensor SQF-Q2 1 = Blocked* Rear sensor SQF-Q3 0 = Unblocked* Front sensor SQF-Q4 0 = Unblocked Home position sensor SQF-Q5 0 = Unblocked Infeed sensor SQF-Q6 0 = Unblocked...
  • Page 208 2 February 2007 SERVICE PROGRAM MODE Voltmeter Voltage at Range MD3DC (H) 29-43V Unregulated 36V (after interlock relay) distributed from Interlock PCB in Booklet maker. Voltage supplies: BM-M19 Pre Infeed motor MD6DC (B) 29-43V Unregulated 36V (after interlock relay) distributed from Interlock PCB in Booklet maker.
  • Page 209 SERVICE PROGRAM MODE 2 February 2007 NVM Values Index Default Function Password 1974 The password to enter service mode from the Tools menu can be changed here. FTR.Trim(STD) 004.50 Standard trim margin that is default presented in the user menu. Value re- flects how many millimetres that will be trimmed off from the longest sheet (cen- tre fold) in the booklet.
  • Page 210 2 February 2007 SERVICE PROGRAM MODE NVM Values Index Default Function ≈01800 The value reflect calibration of Transport FTR.M1(Speed) motor M1. The value reflects the time that you can Service Timeout be logged in to service mode without touching any buttons before the machine closes the service mode.
  • Page 211 SERVICE PROGRAM MODE 2 February 2007 5.1.3 EEPROM NVM RESET If minor logic problems arise the EEPROM NVM reset procedure can be initiated. All data in the EEPROM will be cleared including jobs, jam history etc. The only data not cleared are: Counters: - Staple - Fold...

  • Page 212: Software Download

    2 February 2007 SERVICE PROGRAM MODE SOFTWARE DOWNLOAD 5.2.1 Downloading to upper PCB MD6DC B in Booklet maker. CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 213: Downloading To Lower Pcb Md6Dc C In The Booklet Maker

    SERVICE PROGRAM MODE 2 February 2007 5.2.2 Downloading to lower PCB MD6DC C in the Booklet maker. CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 214: Downloading To Pcb Cpu In Booklet Maker

    2 February 2007 SERVICE PROGRAM MODE 5.2.3 Downloading to PCB CPU in Booklet maker. CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 215: Downloading To Lower Pcb Md3Dc H In The Booklet Maker

    SERVICE PROGRAM MODE 2 February 2007 5.2.4 Downloading to lower PCB MD3DC H in the Booklet maker. CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 216: Downloading To Pcb Md6Dc A In Trimmer

    2 February 2007 SERVICE PROGRAM MODE 5.2.5 Downloading to PCB MD6DC A in Trimmer. CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 217: Downloading To Pcb Md6Dc D In Squarefolder

    SERVICE PROGRAM MODE 2 February 2007 5.2.6 Downloading to PCB MD6DC D in Squarefolder. CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD pro- cedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all machine ground con- nections, ensuring the proper handling of circuit boards and sensors.

  • Page 218: Self-Diagnostic Mode

    2 February 2007 SELF-DIAGNOSTIC MODE SELF-DIAGNOSTIC MODE 5.3.1 RUN TIME DIAGNOSTICS Throughout the operation of the machine all functions and components are moni- tored. Should an error occur, a fault code is displayed. Many faults can simply be corrected by the operator. In that case a picture shows the location of the fault with a text message, such as ”Clear Misfeed(s)”.

  • Page 219: Detailed Self-Diagnostic Mode

    SELF-DIAGNOSTIC MODE 2 February 2007 5.3.3 DETAILED SELF-DIAGNOSTIC MODE The main self-diagnostic mode, Diagnostics, is available from the service program mode. Diagnostics checks the EEPROM, the sensors and the motors. If a fault is found it will be displayed as a fault code. To remedy the fault, go to Fault Code Description 4.1).

  • Page 220: Paper Size Reset

    2 February 2007 PAPER SIZE RESET PAPER SIZE RESET If any mechanical adjustments have been carried out that effects the positio- ning of side guides, staple stop or fold stop, this procedure must be performed. If the EEPROM or the CPU PCB has been replaced, this procedure must be performed.
  • Page 221 PAPER SIZE RESET 2 February 2007 Executing Paper Size Reset The side guides and stop gate must be parallel and square before this procedure is carried out ( 3.8.1, 3.8.2 ). 1. Remove the two stapler heads ( 3.4.12 ). 2. Insert a Interlock cheater. 3.
  • Page 222 2 February 2007 PAPER SIZE RESET If the purpose of performing the paper size reset procedure is strictly a result of an electronical or logical operation, such as replacement of CPU PCB, the procedure can be ended her by pressing ESC. If any changes has been made that effects the geometry regarding the paper size, such as mechanically adjusted stop gate, back jogger or replaced/moved home position sensor, the procedure must be continued to the end.
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  • Page 224: Sqf Service

    2 February 2007 SQF SERVICE SQF SERVICE In the Squarefolder Service menu, you are able to set up the Squarefolder to Ad- justment mode. Use the Adjustment mode when adjusting the Square folding qua- lity. When the Adjustment mode is set to ON, the Home position of the Stop gate is changed.
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  • Page 226: Electrical Component List

    2 February 2007 ELECTRICAL COMPONENT LIST DETAILED SECTION DESCRIPTIONS ELECTRICAL COMPONENT LIST Page Grid code BM-M1 Infeed motor ....................6-8 ..E2 BM-M2 Back Jogger motor ................... 6-10 ..D2 BM-M3 Side jogger motor ..................6-10 ..F2 BM-M4 Stapler motor ....................6-9 ..H20 BM-M5 Set transport motor ..................
  • Page 227 ELECTRICAL COMPONENT LIST 2 February 2007 Page Grid code Communication Collator ....................6-5 ..L10 Stacker Receptacle......................6-5 ..A18 Terminator ........................6-5 ..N5 Interlock jumper......................6-5 ..M15 Terminator / Communication Trimmer ................. 6-5 ..N4 Interlock jumper / Power supply Trimmer ..............6-5 ..M18 Power supply Squarefolder ..................

  • Page 228: Front View

    2 February 2007 ELECTRICAL COMPONENT LIST 6.1.1 FRONT VIEW Main Power SW Panel Switches Addon PCB Interlock switch PCB Set Counter Softstart PCB CPU PCB Rectifier BM-Q9 BM-M6 BM-M4 Transformer Capacitor...

  • Page 229: Rear View

    ELECTRICAL COMPONENT LIST 2 February 2007 6.1.2 REAR VIEW BM-M19 MD3DC PCB “H” MD6DC PCB “B” BM-Q11 MD6DC PCB “C” Interlock PCB BM-Q37 Collator Interface PCB...

  • Page 230: Connector View

    2 February 2007 ELECTRICAL COMPONENT LIST 6.1.3 CONNECTOR VIEW Terminator Terminator/ Stacker COM. FTR 200 Power Receptacle / Receptacle Line Filter Collator Interlock jumper Interlock jumper/ Power Supply Power Supply FTR 200 SQF 200...

  • Page 231: Outfeed Upper View

    ELECTRICAL COMPONENT LIST 2 February 2007 6.1.4 OUTFEED UPPER VIEW Staple Detection Lead Interlock Switch BM-Q19 / BM-Q20 BM-S16 / S17 BM-Q36 Set Counter Outfeed cover removed BM-Q4 BM-Q8...

  • Page 232: Outfeed Lower View

    2 February 2007 ELECTRICAL COMPONENT LIST 6.1.5 OUTFEED LOWER VIEW BM-Q8 Outfeed cover removed BM-M9 / BM-Q7 BM-M8 BM-Q10...

  • Page 233: Infeed Upper View

    ELECTRICAL COMPONENT LIST 2 February 2007 6.1.6 INFEED UPPER VIEW BM-M1/ BM-Q2 BM-Q1 Inffeder removed...

  • Page 234: Infeed Lower View

    2 February 2007 ELECTRICAL COMPONENT LIST 6.1.7 INFEED LOWER VIEW BM-SOL2 BM-M5 BM-SOL1 BM-Q14 BM-Q15 BM-M4 BM-M7...

  • Page 235: Infeed Module View

    ELECTRICAL COMPONENT LIST 2 February 2007 6.1.8 INFEED MODULE VIEW Bottom view BM-M3 / BM-Q13 BM-Q3 BM-M2 BM-Q12 6-10...

  • Page 236: Stacker Module View

    2 February 2007 ELECTRICAL COMPONENT LIST 6.1.9 STACKER MODULE VIEW ST-M1 6-11...
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  • Page 238: Board Structure

    29 November 2006 BOARD STRUCTURE BOARD STRUCTURE 6.2.1 BLOCK DIAGRAM xCAN Bookfold Trimmer Bookletmaker Addon PCB iCan Optocouplers Collator Collator Comm. MD3DC electrical MD6DC signals MD6DC Interlock Interlock Lead The electronics in the BM 200 is distributed and divided in four different PCBs, one CPU board (CPU PCB PL76) and three motor drive boards (two PCB MD6DC and one MD3DC) .

  • Page 239: Controller Cpu

    BOARD STRUCTURE 29 November 2006 6.2.2 CONTROLLER CPU GPIO / AD CAN2 LPC2292 xCAN Interlock Expansion 1 Start/Exit ARM CPU 16 KB / 256 KB GPIO iCAN CAN1 128KB Expansion 2 Atmega48 Flash download Support UART0 GPIO 2 MB Data Debug UART1 Expansion...

  • Page 240: Controller Md6Dc

    29 November 2006 BOARD STRUCTURE 6.2.3 CONTROLLER MD6DC The MD6DC PCB is present in Booklet maker (x2), Trimmer (x1) and Squarefolder (x1). The xCAN portion on MD6DC is not used in the Booklet maker as the external communication is handled by the xCAN portion on the CPU PCB. In the Trimmer and the Squarefolder the xCAN portion on MD6DC is used for ex- ternal communication.
  • Page 241 BOARD STRUCTURE 29 November 2006 6.2.3 CONTROLLER MD6DC, CONTINUES BM-M1 BM-M8 BM-M7 BM-M9 ST-M1 BM-M6 BM-M4 BM-M2 BM-SOL1 BM-M3 BM-SOL2 Booklet maker Set counter BM-M5 6-16...

  • Page 242: Controller Md3Dc

    29 November 2006 6.2.4 CONTROLLER MD3DC The MD3DC PCB is present in Booklet maker (x1). 6-17...

  • Page 243: Controller Md3Dc, Continues

    29 November 2006 6.2.4 CONTROLLER MD3DC, CONTINUES BM-M19 6-18...

  • Page 244: Booklet Making Process

    29 November 2006 BOOKLET MAKING PROCESS BOOKLET MAKING PROCESS 6.3.1 PRINCIPLE OF OPERATION Compiling Collator sends a start signal. The pre infeed motor (BM-M19) and infeed motor (BM-M1) start. The set enters the infeed module. Infeed sensor (BM-Q1) activates. Side guides moves half way in (BM-M3). The infeed wheel transports the set down to the staple stop.
  • Page 245 BOOKLET MAKING PROCESS 29 November 2006 M3 & Q12 Jogging and Stapling When start sensor (BM-Q4) is activated and infeed sensor (BM-Q1) deactivated back jogger motor (BM-M2) moves the back jogger up to knock the trail edge of the set. At the same time the side jogger motor (BM-M3) moves the side guides against the paper plus a few millimeters to over jog the set by about 5mm, depend- ing on the set stiffness.
  • Page 246 29 November 2006 BOOKLET MAKING PROCESS Pre-fold transport When staples are detected (BM-Q19/Q20) the back jogger motor (BM-M2 - see page 6-20) moves the back jogger down to release the trail edge of the set. The side guides (BM-M3) move out slightly. Just enough to release the grip of the set but still to guide the set straight to the fold stop.
  • Page 247 BOOKLET MAKING PROCESS 29 November 2006 Folding Folder roller motor (BM-M6) that drives the first and second pair of fold rollers starts about the time when the start sensor (BM-Q4) is activated. Also the fold stop gate motor (BM-M8) moves the fold stop away a bit at that time. Slightly after the fold stop sensor (BM-Q7) is activated, the fold stop gate motor (BM-M8) jogs the set upwards into position.

  • Page 248: Size Adjustment

    29 November 2006 BOOKLET MAKING PROCESS 6.3.2 SIZE ADJUSTMENT Initialization cycle Main power is switched on Staple/fold positioning motor (BM-M9) and side jogger motor (BM-M3) starts. Staple/fold positioning motor (BM-M9) moves staple stop and fold stop to the shortest sheets size. Side jogger motor (BM-M3) moves side guides to the widest paper size.
  • Page 249 BOOKLET MAKING PROCESS 29 November 2006 Changing paper size New paper size is selected on the UI. Staple/fold positioning motor (BM-M9) and side jogger motor (BM-M3) starts. Side jogger motor (BM-M3) runs in the direction towards the new paper size. Side jogger motor sensor (BM-Q12) counts pulses from the previous paper size to the new paper size and stops the motor (BM-M3) when the correct amount of pulses are received.

  • Page 250: Specifications

    30 January 2007 SPECIFICATIONS SPECIFICATIONS BOOKLET MAKER BM 200 Capacity 25 sheets of 80 gsm (20 lb. Bond) Speed Up to 3000 sets/hour Sheet size, max 320 x 457 mm (12.6 x 18”) Sheet size, min 206 x 275 mm (8.1 x 10.8”) Paper weight, max 300 gsm (115 lb.
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  • Page 252 29 November 2006 WIRING Booklet Maker See pocket at rear of manual for wiring diagrams. Trimmer See pocket at rear of manual for wiring diagrams. Squarefolder See pocket at rear of manual for wiring diagrams. Wir-1...
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