Morgana BM 2000, Operator'S Manual

Page 1: ...Morgana Systems Limited United Kingdom www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 Booklet Maker BM 2000 Operator Manual Doc No T10178 ...

Page 2: ...BOOKLET MAKER BM 2000 Operating Instruction Booklet Maker Reference Part no 81248 Doc no T10178 Rev date 14 January 2010 ...

Page 3: ...ted within a distance of 10 m of the apparatus concerned WARNING Electromagnetic compliance This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures The product System which is connected to this machine will be class A ...

Page 4: ...ly hazardous situation which if instructions are not followed could result in death or serious injury CAUTION Indicates a potentiality hazardous situation which if instructions are not followed may result in minor or moderate injury or damage to machine or property Note This sign refers to Remarks for making the operation much easier You get practical hints or knowledge to assist you in the machin...

Page 5: ...ctrician Improper grounding of the equipment can result in electrical shock Never connect the machine to a power source that lacks a ground connection terminal This machine is destined for specific purpose only Any use going beyond this specific purpose is re garded as beyond the determination The manufacturer will not be liable for damages resulting from any use beyond the determination unallowed...

Page 6: ...the power cord will not be damaged under the machine Allways contact service if relocating the equipment Do not move the machine while the machine is running Do not open covers while the machine is running Do not switch of the power while the machine is running Make sure the machine cycle has ended Lay the power cord in a way that nobody will stumble over it Do not place things on the cord Never a...

Page 7: ...Page intentionally blank ...

Page 8: ...per Sizes 18 Changing Stapler and Clincher position 18 Setting up narrow width paper sizes 19 Trimmer 20 Emptying the Trim Bin 20 2 Making Booklets Changing Settings 21 General Procedure 21 Setting Paper Size 21 Selecting Standard Paper Sizes 21 Custom Paper Size 22 Stapling and Folding 22 Edge staple 23 Saddle staple 23 Staple and Fold Alignment 23 Corner staple 24 Trimming 24 Selecting Trimming ...

Page 9: ...ooklet Maker Fault Codes 42 Remove stacked sheets 42 Too many sheets 42 Check Staples 42 Trimmer Fault Codes 42 Close trimmer belts 42 Waste Bin Full 42 Booklet quality 43 Fold Quality 43 SquareFolding Quality 44 7 General Remarks Do s And Don ts 45 Placing Your Machine 46 Machine Environment 46 Power Connection 46 Access to Machine 47 Maintaining Your Machines 48 Booklet Maker 48 Lubricating Stap...

Page 10: ...an effect called creeping occurs In order to rectify creep the FTR 2000 Trimmer optional can be connected to the Booklet Maker The booklets are then transported from the Booklet Maker into the Trimmer where the front edge face will be cut off Another option the SQF 2000 SquareFolder can be installed if a FTR 2000 Trimmer is installed on the BM 2000 Booklet Maker The prints which have been stapled ...

Page 11: ... system The buttons are multi functional meaning that the function of each button depends on the information displayed For example In this screen the icon next to button 1 indicates you will go up one level in the menu when the button is pressed Example 2 In this screen button 1 has no function Example 3 Pressing button 1 here will answer No to the question on the screen 1 2 3 4 5 6 Buttons 1 2 3 ...

Page 12: ...uide To Components 1 4 2 1 Control panel 2 Top cover 3 Power switch 4 Infeed assembly 3 Booklet Maker 5 Hand feed tray optional 6 Belt Stacker 7 Belt Stacker Cover 8 Hand feed slot for on line mode 7 6 5 8 ...

Page 13: ...A Not in use 2 Not in use 3 CAN In Termination socket Communication with Feeder Collator 4 CAN Out Termination socket Communication with FTR 2000 5 Power receptacle 6 Power out to SQF 2000 7 Interlock jumper 8 Interlock jumper Power out to FTR 2000 ...

Page 14: ...kets 7 Side guide extension 8 Thumb screw for Side guide ex tension 9 Stapler heads 10 Side guides 11 Guide 12 Screws for Stapler assy 13 Staple detection leads one on each stapler head 14 Locking pin one on each stapler head 15 Clincher left side Right side not shown in picture Booklet Maker continued 9 7 14 8 11 5 2 3 12 10 6 7 8 Booklet maker top view 1 13 15 4 ...

Page 15: ...14 Trimmer 1 2 1 Top cover 2 Trim bin Options ...

Page 16: ...inued 8 1 9 6 7 4 5 3 1 Trimmer fan 2 Outfeed latch 3 Transport belt 4 Exit compression brackets 5 Trimmer stop 6 Docking bracket 7 Infeed roller shaft 8 Knives not visible in picture 9 Infeed latch Trimmer top view 2 ...

Page 17: ...16 1 1 Top cover 2 Upper feed belts lifted position 3 Docking bracket not visible in picture 5 Lower feed belts 4 Latches SquareFolder 5 2 4 3 SquareFolder top view ...

Page 18: ... SquareFolder optional are powered from the Booklet Maker Open the Top cover A Set power switch B on Booklet Maker to ON position Note The Power switch also controls Trimmer optional and SquareFolder optional Close the Top cover Booklet Maker Turning On Off the Power B A 1 Basics ...

Page 19: ...From here you customize and save job settings Press Jobs again and you can load previously saved jobs These procedures are described in section 4 Jobs The Admin screen Pressing the Admin button in the Main screen takes you to the Admin screen From here you can change the display language set paper size standard and more See section 3 Admin for how to navigate in the Admin screen Changing settings ...

Page 20: ...ge still contains staples pull 20 mm of staples out of the cartridge and tear off at the stapler tear line Check that the first staple is flat If not tear off another 20 mm using less force containing 300 staples or less C Insert the cartridge into the stapler head with the staples facing towards the head mechanism The cartridge should be placed flat on the slide on the bottom of the stapler head ...

Page 21: ... the BM 2000 has recovered and production can continue In case problem persists and no staples were fed the display will indicate that again In such a case Repeat this procedure If problem still persists perform the Removing replacing Stapler Head procedure Select A3 11x17 paper size to facilitate removing or replacing the stapler head From the Main Screen press Admin Select Stapler removal positi...

Page 22: ...taple cartridge see previous section removal replacement of staple cartridge Warning When manually ejecting the stapler stay clear from stapler output area Secure the locking pin by rotating it towards the in feed side until it snaps in position G Check that the stapler head is correctly mounted by pushing the stapler head towards the infeed area If it is still loose it is not correctly mounted In...

Page 23: ... the right machine frame to centre each stapler assembly over each anvil A Thighten the screws C Caution It is very important to align the stapler assembly correctly over the anvil B A A C Changing Staple position and Narrow width Paper Sizes Note Some situations require that the stapler assemblies are repositioned and or that the side guide extensions are removed This to avoid that the side guide...

Page 24: ...re install the side guide extensions after the run Otherwise paper jams might occur B A F The anvil positioning scale F indicates the distance in millimetres from centre to centre cc of the staples Type of finishing Paper format Setting cc booklet making 5 5 CD 98 booklet making A5 98 booklet making 8 5 A4 120 default position booklet making 11 A3 120 or 200 edge stapling 11 A4 144 recommended cor...

Page 25: ...1 Basics 24 Emptying the Trim Bin Remove the trim bin by pulling handle 1 1 2 Trimmer Lift out the Trim Bin by grasping the rod 2 and handle 1 ...

Page 26: ...dure as for temporary changes But in addition from the Main screen press the Jobs button to reach the Jobs screen Select Save if you want to incorporate the change in the current job or Save as if you want to store the changed job as a new job Note Choose either of the above mentioned procedures when changing size stapling trimming or Square folding as follows From the Main screen select Size and ...

Page 27: ...al point The machine has however recognised and set up according to the exact size including the decimal point Stapling and Folding From the Main screen select Staple and press the Enter button There are four different stapling modes Off Edge staple Saddle staple and Corner staple With the Staple line highlighted press or to choose stapling option Note Some combinations of paper size and staple mo...

Page 28: ...les centred on the fold or if stapling position is desired on the top or bottom of the spine that can be adjusted from the control panel With Fold correction highlighted press or to move staple positioning on the spine Press the Enter button to confirm Note This adjustment can also be done during booklet making If the booklet fold line is not in the centre of the sheet or if it is desirable to mov...

Page 29: ...g margin i e the length of the booklet needs to be adjusted see Adjusting the Cutting Margin below Otherwise press the Enter button to confirm From the Main screen select Front Trim and press the Enter button Adjusting the Cutting Margin With Book length highlighted press or adjust the cutting margin The measurement displayed is the width of the finished trimmed booklet Press the Enter button Note...

Page 30: ... the SquareFold will bypass the Square folding action transporting the booklet out to the Belt stacker Use the manual modes to override the auto function There are five different manual modes to select from Mode 1 Approximately 6 10 sheets Mode 2 Approximately 11 15 sheets Mode 3 Approximately 16 20 sheets Mode 4 Approximately 21 25 sheets Mode 5 Approximately 26 sheets Select Off to bypass the Sq...

Page 31: ...the Booklet Maker The message Open cover and check set will be shown in the Booklet Maker control panel Open the Booklet Maker top cover and check the set regarding number of sheets and paper size Try to move the sheet set as illustrated to detect play If there is play adjust the paper size setting in the Booklet Maker accordingly Send a calibration set again and check that there is no play Contin...

Page 32: ... remove set will be shown in the Booklet Maker control panel Open the Booklet Maker top cover and remove the set Close the top cover Press the green button B on the Feeder Collator to start making booklets Note In either step 4 or 6 above instead of following the calibration procedure you can Press the Purge button on the Feeder Collator The set will be finished and fed to the belt stacker and or ...

Page 33: ...and by mode and will start automatically when a set is manually fed into the Booklet Maker Sets can be fed either to the optional hand feed tray A or to the hand feed slot B in the top cover Off line Mode A B Note The Booklet Maker can be hand fed while it is still docked to a Collator Feeder The Collator Feeder can be used for internal stacking at the same time as the Booklet Maker is used for ha...

Page 34: ...alibration set has been sent from the Feeder Collator see On line mode under section 2 Select Paper Size Check and press the Enter button The Message Hand feed set or print one set is displayed Hand feed a set to the Booklet Maker The message Open cover and check set will be shown in the Booklet Maker control panel Open the Booklet Maker top cover Try to move the sheet set as illustrated to detect...

Page 35: ...Paper size check continues Close the Booklet Maker top cover The message Finish set will be displayed There are now two choices Press the Yes button on the Booklet Maker The set will be finished and fed to the belt stacker or Press the No button on the Booklet Maker The message Open cover and remove set will be shown in the Booklet Maker control panel Open the Booklet Maker top cover and remove th...

Page 36: ... desired standard and then press the Enter button System Setup Scroll to the right system configuration and press the Enter button System Setup allows you to change how the booklet making system setup will appear in the control panel Select System Setup and press the Enter button Language From this screen you can change the language in the user interface Select Language and press the Enter button ...

Page 37: ...rimknife This is useful when the knife is stuck in the active down position You will get fault codes TR 201 202 or BM 210 211 Select Reset trim knife and press the Enter button Service This screen to access service is for authorized service personnel only and is password protected ...

Page 38: ...for the current job The Booklet Maker has a maximum storage capacity of 10 different jobs Also see section 2 Making Booklets Storing a Job Change all settings according to section 2 for a particular job Now the changes are just temporary You can run the system with these changes but as soon as you change something again the previous settings will be lost To store the settings press Jobs from the M...

Page 39: ...d job press the Jobs button from the Main screen Then press the Jobs button from the Jobs screen Select one of the previously stored jobs from the list Press the Enter button to recall the job This Job is now uploaded and becomes the current job ...

Page 40: ...ntre of the display the diagram shows in which module and where the error has occurred At the bottom of the display an error code is displayed and a text explaining the error See examples below General Jams in the Booklet Maker are indicated by a square shaped flashing symbols in the control panel If one of the top covers is open the symbol on the control panel shows the top cover flashing Flashin...

Page 41: ... Remove jammed sheets Close the top cover To clear a jam indicated in the folding area Open the top cover Close top cover If the jam still remains Switch off the Power Switch on the Power Continue on next page Clearing a Paper Jam Booklet Maker Inside the Booklet Maker Folding area Stapling area ...

Page 42: ... roller C Use the key D from the tool box and crank the upper fold roller to remove jammed sheets If a Trimmer is installed removing the Trim Bin gives you access to the fold stop area from the outfeed side of the Booklet Maker Put the key back in the tool box Replace the Trim Bin if the Trim Bin was removed Switch on the power Inside the Booklet Maker continues C D B A Booklet Maker top view ...

Page 43: ...he infeed roller shaft in the operating position Clearing Jam in Input Area The upper trimmer blade on the trimmer is protected by a knife protection plate that moves away during the cutting stroke Jams can occur in the input area or the exit area WARNING Never put fingers or other parts of the body between the upper and lower trimmer knives B A Infeed roller shaft operating position Infeed roller...

Page 44: ...ove the jammed sheets from the exit area After the jammed sheets are removed lift up the latch B and place the compression brackets in the operating position Clearing a Paper Jam continued B A Clearing Jam in Exit Area B Compression brackets operating position Compression brackets lifted position ...

Page 45: ...ches B to release Remove the jams Place the upper feed belts in normal position Close the top cover Inside the SquareFolder Exit Area Open the top cover A Lift up the Belt Stacker Cover B Remove the jam Place the Belt Stacker Cover in normal position Close the top cover A A Clearing a Paper Jam SquareFolder B B ...

Page 46: ...Too Many Sheets BM 401 indicates Check Staples Trimmer TR 201 to TR 204 indicates Clear area TR 205 indicates Close trimmer belts TR 501 indicates Waste bin full SquareFolder SQF 201 to SQF 206 indicates Clear area How to clear a paper jam when the message Clear area is shown is described in section 5 Actions to solve the remaining fault codes are described on the next page Note If procedures spec...

Page 47: ...specification remove and check stapler head according to section 1 Basics Close trimmer belts This message will be displayed when either of the trimmer belt is in the lifted position Make sure that both the infeed roller shaft and the exit compressing brackets are in the operating position see section 5 Trimmer Clearing a Paper Jam Too many sheets This message will be displayed when the set fed to...

Page 48: ...alls closest to the outfeed and plastic balls closest to the infeed Additional replacement steel glass and plastic balls are located in the tool box above the fold section Example If booklets comes out with the staples on the back of the booklet the configuration is to heavy The set was allowed to buckle travel to far before it was folded If booklets comes out with the staples on the front of the ...

Page 49: ...prings in the upper position SquareFolding Quality Under extreme circumstances when the cover sheet tends to be torn from the rest of the set this can be rectified by adjusting the Fold Adjust Levers located above the pre fold transport There are eight positions for each lever The topmost notch is the default position Move the lever notch by notch until performance is satisfactory Fold Quality con...

Page 50: ... call your authorized technician to correct the problem Warning This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures Note The domestic environment is an environment where the use of broadcast radio and television receivers may be expected within a distance of 10 m of the apparatus concerned Do...

Page 51: ...ect the machine to a power source that lacks a ground connection terminal Always locate the equipment on a solid support surface with adequate strength for the weight of the machine Always keep magnets and all devices with strong magnetic fields away from the machine If the place of installation is air conditioned or heated do not place the machine where it will be Subjected to sudden temperature ...

Page 52: ... Access to Machine Place the machine near the power source providing clearance as shown 1 Left more than 400 mm 15 3 4 2 Front more than 555 mm 21 7 8 3 Right more than 400 mm 15 3 4 for stand alone installation only 2 3 1 ...

Page 53: ... table below Drive post Stapler drive bar Stapler lift bracket Staple driver Clincher PART FREQUENCY PART LOCATION Clinchers Every 20 000 booklets Beneath the stapler head assembly thin oil Drive posts Every 20 000 booklets Staple cartridge grease Stapler drive bar Every 20 000 booklets Above the stapler head grease Stapler lift bracket Every 20 000 booklets Above the stapler head grease Staple dr...

Page 54: ...the need to clean the feed belts Clean the feed belts with water and a lint free cloth Open the top cover Clean the upper feed belts A The upper feed belts can easily be rotated in either direction Lift up the upper feed belts to access the lower feed belts Clean the lower feed belts B Rotate the lower feed belts towards the outfeed side for complete cleaning Place the upper feed belts in normal p...

Page 55: ...ral Remarks 54 Cleaning Square Folding Clamps A Remove any residue from upper and lower clamps A which is the area clamping the booklet Pay special attention to the right angled corners of the clamp profiles ...

Page 56: ...imum 60 gsm 16 lb Bond Paper Weight Maximum 300 gsm 172 lb Index 115 lb Cover Input Output Sheets 1 25 Sheets 80 gsm 20 lb Bond equivalent Stapled Input Output Sheets 1 2 Sheets Folding only Hand feeding Possible Weight 161 kg 354 lb Including Stacker Dimensions L x H x D 1520 x 1135 x 680 mm 60 x 45 x 27 Including Base and Stacker Power Source 100 110 115 127 220 230 VAC 50 60 Hz 10 Power consump...

Page 57: ...ing Possible Together with Booklet Maker Weight 83 kg 183 lb Dimensions L x H x D 350 x 1100 x 595 mm 14 x 43 x 23 Power Source From BM 2000 Maximum width of the finished trimmed booklet is 220 mm 8 5 8 This means when trimming SRA3 450 mm booklets the minimum trim is 5 mm When trimming 18 booklets the minimum trim is 9 mm SquareFolder SQF 2000 option Specifications Remarks Speed 1800 booklets hou...

Page 58: ...Page intentionally blank ...

Page 59: ......