User manual BLM 500 / Bookletmaker 50 Operating information
Copyright Copyright 2008 Océ All rights reserved. No part of this work may be reproduced, copied, adapted, or transmitted in any form or by any means without written permission from Océ. Océ makes no representation or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose.
Table of Contents Table of Contents Chapter 1 Introduction to the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description of the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Right-Hand Side of the Booklet maker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 The Rear Panel of the Booklet maker . . . . . . . .
Table of Contents Chapter 5 Error Conditions, Problems, and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear a Printer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear a Booklet maker error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 Introduction to the Booklet maker 5
Introduction Introduction Introduction Thank you for choosing the Booklet maker. Your Manual The User Manual for the Booklet maker describes how to perform these tasks: ■ Operate the Booklet maker ■ Find and correct error conditions ■ Perform normal maintenance tasks Operator training is given when the Booklet maker is installed. To make sure you use your Booklet maker correctly, read your manual. The User Manual for the Booklet maker does not describe the operation of the printer.
Introduction How to Get Help If you have any questions or problems, refer to the problem-solving section in this manual (see the chapter “Error Conditions, Problems, and Solutions”). Contact your Booklet maker supplier for further help.
Description of the Booklet maker Description of the Booklet maker Introduction The Booklet maker operates online with digital printers to process sets of printed pages into stitched books. The main parts are shown below. Illustration [1] A B C D [1] Operator Side of the Booklet maker Component - function table [1] [1] Operator Side of the Booklet maker 8 Component Function A The connecting bridge The connecting bridge moves the printed sheets from the printer to the Booklet maker.
Right-Hand Side of the Booklet maker Right-Hand Side of the Booklet maker Illustration [2] A B [2] Right-hand side of the Booklet maker Component - function table [2] [2] Right-hand side of the Booklet maker Component Function A The stitch-wire cabinet The stitch-wire cabinet holds the spool of stitch-wire.
The Rear Panel of the Booklet maker The Rear Panel of the Booklet maker Illustration [3] A B C D E F [3] The Rear Panel of the Booklet maker Component - function table [3] [3] The Rear Panel of the Booklet maker 10 Component Function A Rating and serial label The rating label displays the type of machine, serial number, power use, and fuse information. B Power ON/OFF switch The power ON/OFF switch turns the Booklet maker ON or OFF.
Chapter 2 How to run the Booklet maker This chapter gives information on how to run a job on the Booklet maker. For information on how to operate the printer, refer to the printer documentation. Information about the user interface is included in the chapter “The User Interface.” Information about standard procedures, for example opening covers to clear a paper jam, is included in the chapter “Standard Tasks.
Before You Begin Before You Begin Paper and Book Quality Instructions ■ ■ ■ ■ ■ The size of paper and the thickness of the set must be measured. These measurements are entered via the touch screen before you begin a print job. Measure the size of the printed paper. The paper dimension changes when the paper is printed. Measure the set thickness as accurately as possible. Use the measuring tool supplied with the machine. Enter accurate dimensions via the touch screen.
Turn ON the Booklet maker Turn ON the Booklet maker Procedure 1. Connect the Booklet maker to the power supply. 2. Use the ON/OFF switch to turn ON the Booklet maker. Result The machine makes this sequence of beeps: 'beep__beep beep beep beep_____ beep beep'. The touch screen illuminates and the machine is ready for use.
Enter the Job Settings Enter the Job Settings Introduction Enter the settings for a new job in the BASIC window on the touch screen. See the chapter “The User Interface” for more information. The PAPER SIZE and PAGE DIRECTION settings are entered on the touch screen. These dimensions refer to the format of the paper when it enters the Booklet maker. Attention: Do not operate the touch screen with a sharp object or with too much force. These actions can damage the touch screen.
Enter the Job Settings Procedure for a New Job [5] Step Action Information 1 Touch BASIC 2 Enter the paper size Touch PAPER SIZE. Enter the dimensions of the paper. The job setting is easier if you first select a preset paper size, then adjust the settings as necessary Touch PAPER SIZE > PRESETS > A3 or A4. (USA: 11x17, 8.5x11 or 8.5x14) 3 Enter the page direction Touch PAGE DIRECTION > LANDSCAPE or PORTRAIT. If the PAGE DIRECTION option is not available, the PAGE DIRECTION cannot be changed.
Enter the Job Settings 2. Touch the job name or use the Up arrow or the Down arrow to select the job. 3. Touch LOAD. 4.
Stacker adjustment Stacker adjustment Adjust the Stacker Adjust the stacker according to the size and thickness of the finished bookAdjust the Stacker on page 45.
Run the Job Run the Job 1. Make sure the adjustments on the Booklet maker are complete before you release the print job from the print queue. 2. Start the print job. The Booklet maker starts automatically. 3. Check the quality of the first book. 4. If the quality is not acceptable, make adjustments (see ‘Book Quality’ on page 63). Result During the job ■ Unload books from the stacker before the stacker is full. The Booklet maker stops and displays a message if the stacker is full.
Chapter 3 The User Interface 19
The Touch Screen The Touch Screen Introduction [4] A B C [4] The User Interface [6] A START Button B STOP Button C Touch Screen The user interface includes a color touch screen and START/STOP buttons. Operate the touch screen with your fingertip. You can touch the screen with a blunt item, for example a palm-top 'wand' or the blunt end of a pen. Do not use too much force. A light touch is all that is needed. Power save The touch screen has a power-save function.
The Touch Screen Illustration [5] 6 5 7 8 3 4 2 1 [5] The Touch Screen Component - function table [7] No. Component Function 1 Window Tabs The touch screen buttons are divided into groups that have related functions. Each group of buttons has a separate window. Touch the correct tab to select the window. LOAD & SAVE BASIC ADVANCED CONFIGURE MENU 2 Window Buttons Each window contains a group of buttons. Touch the button to select the function.
The Touch Screen No. Component Function 5 Status The STATUS line shows the machine status. - GREEN The Booklet maker is READY or RUNNING. - ORANGE PLEASE WAIT - wait until the Booklet maker is ready. ATTENTION - the Booklet maker needs intervention by the operator. - RED The Booklet maker is in an ERROR condition. 6 Help Help text is available on the touch screen. Touch HELP then touch any button or tab on the screen. Information about that button or tab is displayed.
The Job Mimic The Job Mimic Introduction The job mimic shows the current machine status. Illustration [6] [6] The Job Mimic Component - function table [8] No.
The Job Mimic No. 4 5 24 Icon [10] [11] Chapter 3 The User Interface Information The number of forms is shown. If the pressure is adjusted, the setting is shown in brackets. A red X shows that the form function is not active. The trim setting is displayed. A red X shows that the trim function is not active.
The BASIC Window The BASIC Window Introduction The BASIC window gives you access to frequently-changed machine settings. Button overview [9] [9] The BASIC Window Buttons (1 – 2) Button Information PAPER SIZE Measure the accurate size of the paper before you make a book. Touch PAPER SIZE to enter the paper size. When the machine is in operation, you can adjust the PAPER SIZE by a maximum of +/- 1 mm.
The BASIC Window [9] The BASIC Window Buttons (2 – 2) Button Information FORM To make the square spine of the book, pressure is applied to the spine. This process is called forming. Touch FORM to specify the amount of spine form. To make a good spine on different paper types, the amount of spine form can be changed.
The LOAD & SAVE Window The LOAD & SAVE Window Introduction The LOAD & SAVE window lets you save and reload job settings. Each job is given a name. The jobs are displayed in a list on the screen. Touch the job name or use the Up arrow or Down arrow to make the selection. Button overview [10] [10] The LOAD & SAVE Window Buttons (1 – 2) Button Information SAVE Touch SAVE to save the current settings. An on-screen keyboard is displayed. Enter the job name. Touch OK or CLOSE.
The LOAD & SAVE Window [10] The LOAD & SAVE Window Buttons (2 – 2) Button Information PADLOCK SYMBOL The padlock symbol shows when a saved job is locked or unlocked. There is a small padlock symbol next to each locked job. To lock or unlock a job. 1. select the job from the job list 2. touch the large key symbol. A padlock symbol displayed in light grey shows that a job has been locked by a supervisor to prevent changes to the settings DELETE To delete a particular job it must be unlocked.
The ADVANCED Window The ADVANCED Window Introduction The ADVANCED window gives you access to special machine functions. [11] [11] Button overview Button Information RE-REF If the machine calibration appears incorrect or if an 'axis moving' error message remains on the screen, touch RE-REF to re-reference the adjustment axes. The adjustment axes return to the current settings. At intervals, the machine will re-reference the axes during the set-up procedure.
The CONFIGURE Window The CONFIGURE Window Introduction The CONFIGURE machine. window lets you make changes to the configuration of the Some functions and buttons are only available at certain access levels, see 'ACCESS LEVEL' table 13 on page 31. CONFIGURE Window Buttons [12] [12] Button overview Button Information Supervisor Access MACHINE OPTIONS Touch MACHINE OPTIONS to view the general machine setup. Some of the settings can be changed, depending on the current access level.
The MENU Window The MENU Window Introduction MENU shows the settings that are not changed during day-to-day operation. These settings include ■ Change the Access Level ■ Change the display language ■ Advanced machine settings that are accessed by a person who has the correct access-code.
The MENU Window [13] The MENU Window Buttons 32 (2 – 2) Button Information COUNTERS The counters display the ■ number of books that have been made ■ number of sheets that have been processed ■ number of stitches that have been used -RESET Touch RESET to reset the book, sheet counter, and stitch counter. Touch and hold RESET. A red line appears. The red line fills from left to right. Hold RESET until the red line reaches the right-hand side.
Chapter 4 Standard Tasks This chapter describes the standard tasks that are needed in the day-to-day operation of your Booklet maker.
Load and Save the Job Settings Load and Save the Job Settings Introduction The current job settings can be saved to memory and reloaded for use again at a later date. Load the 'Default Job Template' to reset the Booklet maker to normal settings. Save a job 1. Touch LOAD & SAVE > SAVE. 2. If these options appear, select one. ■ ■ ■ REPLACE to over-write the previous job with the current job settings. SAVE NEW to save the current job with a new name. CANCEL to cancel the job save. 3.
Adjust the Stitch Pitch Adjust the Stitch Pitch Introduction The stitch pitch is the space between the stitches. The machine automatically calculates the stitch pitch according to the size of the paper and the number of stitches. The stitches are inserted symmetrically on the spine of the book. If a non-standard stitch pitch is needed, use STITCH PITCH to make the adjustment. [12] A = Stitch Pitch A [12] Stitch Pitch A B Limitations: ■ The minimum stitch pitch 'A' is 25 mm.
Open the Connecting Bridge Cover Open the Connecting Bridge Cover Introduction The Booklet maker will not stop if you open the connecting bridge cover. [13] A [13] Connecting Bridge Cover in the open position. [14] A Connecting Bridge Cover When to do If a machine error occurs, or for maintenance. ■ To clear a paper jam ■ To clean the static elimination bar Caution: Keep your hands, clothing and hair away from the belts. Procedure Lift the connecting bridge cover.
Open and Close the Folder Cover Open and Close the Folder Cover Introduction If a machine error occurs, or for maintenance. ■ To access the stitch area ■ To access the folder area Note: The folder cover has an interlock switch. The Booklet maker stops if you open the folder cover. [14] [14] Unlock and lock the Folder Cover. Open the Folder Cover 1. Lift the black locking handle against the spring pressure. 2. Turn the handle through 90° to unlock. 3.
Lift and Lower the Clincher Frame Lift and Lower the Clincher Frame Introduction [15] A B [15] Folder Cover in the vertical position. [15] A Folder Cover B Clincher Frame [16] A B C [16] Clincher Frame Components [16] A Clincher B Locking Handle C Clincher Frame When to do If a machine error occurs, or for maintenance.
Lift and Lower the Clincher Frame Lift the Clincher Frame 1. Open the folder cover. 2. Turn the locking handle to the left , until the thread is disengaged. 3. Lift the clincher frame to the vertical position. Lower the Clincher Frame Attention: You must hold the weight of the clincher frame. Do not let the clincher frame fall on your hand. 1. Lower the clincher frame. 2. Turn the locking handle to the right , until the handle is tight. 3.
Open the Gathering Area Cover Open the Gathering Area Cover Introduction [17] A B C [17] Gathering Area Cover. [17] A Connecting Bridge Cover open B Gathering Area Cover C Gathering Area Cover Handle When to do If a machine error occurs, or for maintenance. ■ To access the gathering area ■ To access the static elimination bar in the gathering area The Booklet maker will stop if you open the gathering area cover. Procedure 1. Open the connecting bridge cover. 2.
Lift the Booklet maker Main Deck Lift the Booklet maker Main Deck Introduction [18] A B C D E [18] Lift the Booklet maker Main Deck [18] A Folder Cover open B Connecting Bridge Cover open C Clincher Frame lifted D Gathering Area Cover E Main Deck When to do If a machine error occurs, or for maintenance. ■ To access the stitch head ■ To access the former area ■ To access the trim area Procedure Caution: Keep your hands and fingers clear when you lift the main deck.
Lift the Booklet maker Main Deck [19] 42 Step Action Information 1 Open the connecting bridge cover. (see ‘Open the Connecting Bridge Cover’ on page 36) 2 Open the folder cover. (see ‘Open the Connecting Bridge Cover’ on page 36) 3 Lift the clincher frame. (see ‘Lift the Clincher Frame’ on page 39) 4 Open the gathering area cover. (see ‘Lower the Clincher Frame’ on page 39) 5 Lift the Booklet maker main deck. Chapter 4 Standard Tasks The main deck lifts to approximately 60º.
Empty the Trim Bin Empty the Trim Bin Introduction [19] A B [19] Trim Bin Open. [20] A Trim Bin Side Handle B Trim Bin open Note: The Booklet maker operates with the trim bin removed for a short period of time. The printer waits while the trim bin is removed, then continues when the trim bin is replaced. To prevent lost production, you must remove, empty, and return the trim bin to the Booklet maker as quickly as possible.
Open the Stitch Wire Cabinet Open the Stitch Wire Cabinet Introduction [20] A [20] Stitch Wire Cabinet. [21] A Stitch wire cabinet open When to do ■ ■ To see if the stitch wire is jammed or finished. An error message is displayed on the touch screen when the stitch wire is jammed or finished. To install a new stitch wire spool. (see ‘Install New Stitch Wire’ on page 107). Procedure Open the stitch wire cabinet cover. The cover is held closed by a magnetic catch.
Adjust the Stacker Adjust the Stacker Introduction The collection table must be in the correct position for the stacker to operate. The position of the collection table depends on the finished size of the job.
Adjust the Stacker [23] A Book size in window B Collection table C Orange plastic hand screw D Catch tray Procedure [24] Step Action Information 1 Set the catch tray angle according For books that are 1.5 mm thick or to the thickness of the book. less, use position 1. For books that are 1.5 mm thick or less, use position 2. figure 21 on page 45 2 Set the collection table position according to the size of the book. Read the settings through the window.
Operate the Booklet maker offline Operate the Booklet maker offline Introduction You can hand feed sets into the Booklet maker if offline operation is needed. The machine operates when you push the two buttons. When to do ■ ■ To check the settings are correct To make a small number of books offline Attention: Do not put your hands in the gathering area when the machine operates. Use two hands to push the buttons. For safety reasons, this task is for a single operator. Do not let another person help you.
Operate the Booklet maker offline 48 Chapter 4 Standard Tasks
Chapter 5 Error Conditions, Problems, and Solutions This chapter describes how to correct problems that can occur with your Booklet maker. If a problem persists, contact your service engineer.
Clear a Printer Error Clear a Printer Error Introduction If a paper jam or other error occurs in the printer, the printer and the Booklet maker stop. Procedure 1. Clear the printer error. 2. Follow the instructions on the printer. If the printer tells you to remove paper from the Booklet maker, touch START to start the machine. 3. Then touch ADVANCED > PURGE SET > PURGE SET. 4. The partial book is delivered to the stacker. 5. Discard the book.
Clear a Booklet maker error Clear a Booklet maker error Introduction If a paper jam or other error occurs in the Booklet maker, the printer and the Booklet maker stop. The type of error is displayed on the touch screen (see ‘Error Messages’ on page 54). Procedure 1. Clear the error. The error message on the touch screen tells you about the error. 2. Remove all sheets from the Booklet maker. 3. Follow the instructions on the printer.
General Problems General Problems [25] Problem Cause Solution The Booklet maker does not start The Booklet maker is not turned on. Turn ON the Booklet maker (see ‘Turn ON the Booklet maker’ on page 13). The printer has not sent a Correct the problem at the job to the Booklet maker. printer. The Booklet maker is not connected to the power supply. Connect to the power supply of the correct type and voltage (see ‘Turn ON the Booklet maker’ on page 13) A safety cover is open. Close all safety covers.
General Problems Problem Cause Solution The operation of the touch screen is incorrect The touch screen is in power-save mode Touch the touch screen to restore normal function The Touch Screen on page 20. The touch screen calibration is incorrect Calibrate the touch screen (see ‘Calibrate the Touch Screen’ on page 84).
Error Messages Error Messages [26] 54 Problem Cause AXES MOVING Some of the machine axes are moving. This message clears when the adjustment is complete. If the message does not clear, touch ADVANCED > RE REF BOOK CYCLE TIME TOO LONG The printer has delivered the sets faster than the books can be made.
Error Messages Problem Cause Solution BRIDGE MOTOR STALL Check for a paper jam in (see ‘Clear Paper Jams’ on page 68) the connecting bridge. ■ Touch STOP to stop the Booklet maker. ■ Clear the paper jam. ■ Touch STOP to clear the message from the screen. ■ Continue the print job. CHECK THE TRIM BIN The trim bin is either open or full. Check the trim bin. Empty the trim bin if necessary. COVER OPEN A safety cover is open. The machine will not operate until the cover is closed.
Error Messages 56 Problem Cause Solution FLOW ERROR FORMER There is an error at the former. Open the folder cover and remove the book(s). If necessary, open the main deck to remove the book(s). If there is paper in the gathering area, touch START, then touch ADVANCED > PURGE SET > PURGE SET to clear the set from the machine. Jam in the Folder or Former Area on page 72 FLOW ERROR OUTFEED There is an error at the outfeed. Check the outfeed.
Error Messages Problem Cause FORM CLAMP CLOSED The form clamp is in the wrong position. Touch START to reset the position. Follow the instructions on the screen. FORM ROLLER ERROR The form roller is jammed. Clear the jam and continue. Solution (see ‘Jam in the Trim Area’ on page 74) FORM ROLLER NOT PARKED The form roller is in the wrong position. Touch START to reset the position. Follow the instructions on the screen.
Error Messages Problem Cause JAM IN GATHERING AREA There is a paper jam in the (see ‘Jam in the gathering area. Open the Gathering Area’ on connecting bridge cover, page 71) lift the connecting bridge and remove the paper jam. JAM IN STACKER AREA There is a paper jam at the outfeed of the machine. Remove the jammed books and continue. JAM IN STITCHER AREA There is a paper jam in the (see ‘Jam in the Stitch stitch area. Open the Area’ on page 72) folder cover, remove the paper jam and continue.
Error Messages Problem Cause REMOVE SET FROM FOLD AREA Open the folder cover and remove the set. REMOVE SET GATHERING AREA Open the gathering area and remove the sheets. Or touch START, then touch ADVANCED > PURGE SET > PURGE SET to clear the set from the machine. Rotate axis moving The rotate axis is moving. This message clears when the adjustment is complete. If the message does not clear, touch ADVANCED > RE REF. SET IN GATHERING AREA There is a set or partial set in the gathering area.
Error Messages 60 Problem Cause SHUTTLE MOTOR ERROR Use the ON/OFF switch. Turn the machine OFF, then turn the machine ON. If the problem continues, call your service engineer. SHUTTLE NOT PARKED The shuttle is in the wrong position. Touch START to reset the position. Then touch STOP to clear the message from the screen. Sidelay axis moving The sidelay axis (size adjustment) is adjusting. This message clears when the adjustment is complete. If the message does not clear, touchADVANCED > RE REF.
Error Messages Problem Cause Solution STITCH TIMEOUT There is an error at the Stitch Timeout Error on stitcher. page 75 If the problem continues, call your service engineer. TOO MANY PAGES The printer has delivered (see ‘Open the Gathering more than 55 sheets into Area Cover’ on page 40) the gathering area. Remove the incorrect set. Correct the printer setting. Touch STOP to clear the message from the screen. TOUCH PAD ERROR There is a fault with the START and STOP touch pads.
Error Messages 62 Problem Cause TRIM BLADE NOT PARKED The trim blade is in the wrong position. Touch START to reset the position. Follow the instructions on the screen. USER STOP The user has touched the STOP button while the machine is in operation. Touch START to restart the machine.
Book Quality Book Quality Paper Size and Book Quality Instructions ■ ■ ■ ■ ■ ■ Careful measurement of the paper size and set thickness is important. To make an accurate book you must enter accurate paper dimensions into the touch screen. Measure the size of the printed paper. The paper dimension changes when the paper is printed. If the book is made from several different types of paper, make sure the different paper types are all the same size.
Book Quality [27] Book Quality Problem Cause Solution The finished book The wrong paper size was Measure the paper and enter is not neat and tidy entered on the touch screen. the correct dimensions (see ‘Enter the Job Settings’ on The sheets are not page 14). aligned The book is made from Only use paper of the same 64 paper that is different sizes. size (see ‘Paper Size and Book Quality Instructions’ on page 63). The Booklet maker adjustment system is not calibrated correctly.
Book Quality Book Quality Problem Cause The stitch is not on The wrong paper size was the center-line of entered on the touch screen. the spine The Booklet maker adjustment system is not calibrated correctly. Solution Measure the paper and enter the correct dimensions. Touch RE-REF in the ADVANCED window to calibrate the Booklet maker adjustment axes. (see table 11 on page 29) The books do not stack on the stacker The collection table is in the Adjust the position of the wrong position.
Book Quality Book Quality Problem Cause Solution The book cover is dirty or marked The trimmings-removal fingers are dirty. Clean the Trimmings Removal Fingers on page 98 Curved marks on the book There are grease marks around the stitches. Clean excess grease from the Stitch Head on page 101 [25] [26] Grease marks near the stitches Spine Form Problems To make the square spine of the book, pressure is applied to the spine. This process is called forming.
Book Quality Spine Form [28] Condition Incorrect - The spine needs more form. Check these settings: The SET THICKNESS setting is incorrect Measure the set thickness and enter the correct dimension. Enter the Job Settings on page 14 The folder cover is not securely closed? Close the folder cover.Close the Folder Cover on page 37 The FORM function is not turned on? Turn on the FORM function. See "FORM" in table 9 on page 25 The THRESHOLD Decrease the value is less than the SET THRESHOLD value.
Clear Paper Jams Clear Paper Jams Introduction [30] A B C D E [30] Paper Jam Locations [29] A Connecting Bridge B Gathering Area C Stitch Area D Fold and Forming Areas E Trim Area [31] A [31] Paper Jam Location - Bridge Infeed 68 Chapter 5 Error Conditions, Problems, and Solutions
Clear Paper Jams [30] A Bridge Infeed Cover [32] A B [32] Trimmer Infeed Conveyor viewed from above.
Clear Paper Jams [32] A Orange Plastic Hand Screw B Locking Plate C Trim Stop Guard [34] [34] Gathering Area Belt Positions Jam in the Bridge Infeed Open the bridge infeed cover. Remove the jammed paper. Close the bridge infeed cover. Touch STOP to clear the message from the screen. If there is paper in the gathering area, touch START , then touch ADVANCED > PURGE SET > PURGE SET to clear the set from the machine. 6. Continue the print job. 1. 2. 3. 4. 5.
Clear Paper Jams 5. If there is paper in the gathering area, touch START , then touch ADVANCED > PURGE SET > PURGE SET to clear the set from the machine. 6. Continue the print job. Jam in the Gathering Area 1. 2. 3. 4. 5. 6. 7. 8. Open the connecting bridge cover. Lift the gathering area cover. Remove the jammed paper. Check the belts are in the correct position. Adjust the position of the belts if necessary. figure 34 on page 70 Close the gathering area cover. Close the connecting bridge cover.
Clear Paper Jams Jam in the Stitch Area [33] Step Action Information 1 Open the folder cover. (see ‘Open and Close the Folder Cover’ on page 37) 2 Lift the clincher frame. (see ‘Lift and Lower the Clincher Frame’ on page 38). 3 Remove the jammed paper. 4 Check for broken or damaged stitches in the clincher area. A Manually operate the clincher to clear any stitches that are jammed. Press to manually operate the clincher. Lower the clincher frame.
Clear Paper Jams [34] Step Action 1 Open the Booklet maker main deck 2 Remove the trim bin. 3 Loosen the trimmer infeed conveyor. Information The procedure can be seen from the top of the machine. Access to the parts is through the former-clamp mechanism. Hold the shaft and push to the right, against the spring pressure. Hold the shaft and push to the right, against the spring pressure to disengage the shaft from the drive pin. [36] Lift the left-hand end clear.
Clear Paper Jams Jam in the Trim Area [35] 74 Step Action Information 1 Remove the trim bin. 2 Loosen the 2 orange plastic hand screws to release the locking plates. 3 Pull the trim stop guard towards you. 4 Remove the jammed book. 5 Push the trim stop guard into position. 6 Hold the locking plates in position and tighten the orange hand screws. 7 Attach the trim bin. 8 Touch START, then touch This action clears any other paper ADVANCED > PURGE SET from the Booklet maker. > PURGE SET.
Stitch Timeout Error Stitch Timeout Error Introduction [36] Step Action Information 1 Open the folder cover. Open and Close the Folder Cover on page 37 2 Lift the clincher frame. Lift and Lower the Clincher Frame on page 38 3 Remove the paper. 4 Lower the clincher frame. 5 Close the folder cover. 6 If the error message SHUTTLE NOT PARKED is displayed, touch START 7 Touch STOP and then continue the print job.
Stitch Head Problems Stitch Head Problems [37] Problem Cause Solution The stitch head does not operate The STITCH function is not selected. Make sure STITCH is set to 1 or more (see ‘The BASIC Window’ on page 25). The stitch wire is finished. Load a new spool of stitch-wire (see ‘Install New Stitch Wire’ on page 107). The stitch wire is jammed. Clear the jammed stitch wire (see ‘Clear a Stitch Wire Jam’ on page 77).
Clear a Stitch Wire Jam Clear a Stitch Wire Jam Introduction Before you begin: Lift the Booklet maker main deck. See Lift the Booklet maker Main Deck on page 41 [37] A B C D [37] Stitch Head.
Clear a Stitch Wire Jam [38] A Top location of Middle Wire Tube B Middle Wire Tube C Metal Spring Clip D Feed Gears Before You Begin [39] Step Action Information 1 Turn off the Booklet maker Use the ON/OFF switch. 2 Disconnect the Booklet maker from the power supply.
Clear a Stitch Wire Jam Step Action Information Remove the middle wire tube. figure 37 on page 77 Pull the wire from the stitch head. 5 Install the stitch wire into the (see ‘Install the Stitch Wire into the stitch head.
Clear a Stitch Head Jam Clear a Stitch Head Jam Introduction The error message JAM IN STITCH HEAD is displayed. This may be caused by ■ ■ ■ the SET THICKNESS setting is incorrect the stitch head is jammed by broken wire the stitch head needs lubrication Do Procedure 1. If the error message continues, do Procedure 2.
Clear a Stitch Head Jam Procedure 1 [41] Step Action Information 1 Stop the Booklet maker. Touch the STOP button 2 Open the folder cover. Open and Close the Folder Cover on page 37 3 Lift the clincher frame. Lift and Lower the Clincher Frame on page 38. 4 Remove the jammed paper. 5 Check for broken or damaged stitches in the clincher area. A Manually operate the clincher to clear any stitches that are jammed. Press to manually operate the clincher. Lower the clincher frame.
Clear a Stitch Head Jam B Wire holder C Wire holder retaining spring [43] [43] A [43] Inspect for stitch wire A Inspect this area for pieces of stitch wire Tools and Materials: 1. 2. 3. 4. 82 Klüber Isoflex NBU 15 Grease, 50g. Air duster. Supplied with the machine Wire cutters. Supplied with the machine. Flat blade screwdriver.
Clear a Stitch Head Jam [44] Step Action Information 1 Lift the Booklet maker main deck. See Lift the Booklet maker Main Deck on page 41 2 Remove the wire-holder from the stitch head. ■ ■ Move the wire-holder retaining spring to the right. figure 42 on page 81 Remove the wire-holder If the wire-holder is held in position, use a screwdriver to help remove the wire-holder from the stitch head. [44] 3 Inspect the area behind the wire-holder for stitch-wire.
Calibrate the Touch Screen Calibrate the Touch Screen When to do Calibrate the touch screen if the buttons do not operate or the buttons do not operate correctly. Attention: Use a pencil, the blunt end of a pen or a palm top wand for this procedure. Do not use a sharp object. Sharp objects damage the screen. Procedure 1. Touch the STOP button 5 times. 2. Follow the instructions on the touch screen. 3. Touch DONE in the centre of the screen.
Change the Fuses Change the Fuses Introduction The Booklet maker has two fuses at the power input. If either fuse is blown, the Booklet maker will not operate. Required tool Fuse description: 7A, HRC Quick Acting, F Attention: Turn OFF the machine and remove the power supply cable before you change the fuses. This machine uses two fuses in parallel. To avoid the risk of fire, replace fuses only with the same type and rating. Procedure 1. 2. 3. 4. 5. 6. Turn OFF the Booklet maker.
Manually park the Shuttle Manually park the Shuttle When to do The error messages ‘MANUALLY PARK SHUTTLE’ and ‘SHUTTLE NOT PARKED’ are displayed.
Manually park the Shuttle [45] Step 1 Open the folder cover. Open and Close the Folder Cover on page 37 2 Push the shuttle-assembly to the right. figure 45 on page 86 shows the correct position for the shuttle assembly. If the shuttle assembly does not move to the correct position, push the pick-up fingers away from each other by 2-3mm and try again. Repeat if necessary. 3 Wait until the error message ‘SHUTTLE NOT PARKED’ is cleared from the screen.
Manually park the Shuttle 88 Chapter 5 Error Conditions, Problems, and Solutions
Chapter 6 Maintenance 89
About Maintenance About Maintenance Service Interval The Booklet maker needs service every four months. After every one million stitches, the stitch head needs service. This interval is every third spool of stitch-wire. ■ ■ Only a service engineer can service the Booklet maker. Contact your supplier for further information.
Booklet maker cleaning Booklet maker cleaning Introduction Clean the Booklet maker every week to remove surface dust. Attention: Only clean the machine with materials that are recommended in this manual. Do not use other chemicals or abrasive material. Outside of the Booklet maker Use a moist cloth to clean the outside of the Booklet maker. Touch screen Clean the touch screen with a clean, dry cloth. Never use an abrasive material or chemical to clean the touch screen.
Clean the Static Elimination Bars Clean the Static Elimination Bars Introduction Clean the static elimination bars every week. This action extends the performance and service life of the static elimination bars. The Booklet maker is supplied with a small brush. Use the brush to clean the static elimination bars. There are three static elimination bars.
Clean the Static Elimination Bars [48] Step Action Information 1 Clean the static elimination bar in the connecting bridge. ■ ■ 2 3 Clean the static elimination bars in the gathering area. ■ Close the Booklet maker. ■ ■ ■ Open the connecting bridge cover. Clean the pins on the bottom of the static elimination bar with a small brush Open the gathering area cover.
Clean the Former Roller Clean the Former Roller Introduction Clean the former roller if the spines of the books are dirty. Ink and toner can collect on the former roller. [50] [50] Dirty marks on the spine Required tool Clean, plain paper that is not printed. A3 size (USA: 11 x 17”) is recommended. 4mm thickness is needed for each cycle.
Clean the Former Roller Procedure [49] Step Action Information 1 Enter the correct settings on the touch screen. ■ ■ ■ ■ 2 Touch START 3 Open the connecting bridge cover. 4 Lift the gathering area cover. 5 Put 4mm of clean paper in the gathering area. 6 Press the two orange buttons and hold for 9 seconds, or until you hear the folder operate. Set the touch screen to the correct PAPER SIZE Set the SET THICKNESS to 4.0 Set the number of STITCHES to 0. Set the number of FORMS to 4.
Clean the Polyurethane Strips in the Form Clamp Clean the Polyurethane Strips in the Form Clamp Introduction Follow this procedure if there are dirty marks near the spine on the front and back cover of the book. Ink and toner can collect on these parts, especially when you make thin books. [51] [51] Dirty marks beside the spine Required tools Alcohol wipe or A lint free cloth and alcohol (isopropanol) Caution: Only use alcohol to clean this part of the machine. Other chemicals can damage the machine.
Clean the Polyurethane Strips in the Form Clamp [50] Step Action 1 Open the folder cover 2 Use an alcohol wipe, or apply a small amount of alcohol to a lint free cloth. 3 Reach into the form clamp and clean each of the polyurethane strips. 4 Close the folder cover Information There is a polyurethane strip on the face of each side of the clamp. Repeat this step until the polyurethane strips are clean.
Clean the Trimmings Removal Fingers Clean the Trimmings Removal Fingers Introduction Follow this procedure if there are small, dirty marks on the book. Ink and toner can collect on the trimmings removal fingers and cause marks on the book.
Clean the Trimmings Removal Fingers Illustration [54] A B [51] A Trimmer infeed conveyor B Former clamp mechanism Illustration [55] A B C [52] A Trimmer infeed conveyor B Trimmings removal fingers C Former clamp mechanism Illustration [56] A B 99
Clean the Trimmings Removal Fingers [53] A Trimmings removal fingers B Drive end of the conveyor shaft Procedure [54] Step Action 1 Turn off the Booklet maker 2 Lift the Booklet maker main deck. 3 Remove the trim bin. 4 Clean the visible trimmings-removal fingers with an alcohol wipe. 5 Rotate the conveyor shaft by half a turn. Information The procedure can be seen from the top of the machine. Access to the parts is through the former-clamp mechanism. 1.
Clean excess grease from the Stitch Head Clean excess grease from the Stitch Head Introduction Follow this procedure if there are grease marks around the stitches on the book. [58] Required tool Lint free cloth Procedure [55] Step Action Information 1 On the user interface, touch ADVANCED > STITCHER UP > STITCHER UP The folder cover must be closed. This action moves the stitch head to the correct position for lubrication. 2 Open the folder cover.
Lubricate the Stitch Head Lubricate the Stitch Head Introduction [60] [60] Trim the nozzle of the tube of grease [61] A B C [61] Stitch Head Wire Holder 102 Chapter 6 Maintenance
Lubricate the Stitch Head [56] A Stitch Head B Wire Holder C Wire Holder Retaining Spring [62] A B [62] Driver Bar [57] A Driver, in upper position B Driver Bar Required tools Klüber Isoflex NBU15 Grease, 50g Air duster - is supplied with the machine Attention: - Only use the grease shown in this manual. Correct lubrication extends the performance and service life of the stitch head. Other types of grease do not protect the stitch head - Only apply the grease as shown.
Lubricate the Stitch Head Before You Begin [58] Step Action Information 1. Trim the first part from the nozzle. figure 60 on page 102 2. Remove the cap from the tube of grease. 3. Fit the nozzle to the tube of grease. 4. On the user interface, touch ADVANCED > STITCHER UP > STITCHER UP The folder cover must be closed. This action moves the stitch head to the correct position for lubrication. 5.
Lubricate the Stitch Head Step Action Information 3 Apply 30 mm of grease to the figure 62 on page 103 visible surface of the driver bar [63] 1.2" [64] 4 Re-fit the wire-holder. 5 Lower the Booklet maker main deck. 6 Lower the clincher frame. 7 Close all of the covers. (see ‘Lower the Clincher Frame’ on page 39).
Lubricate the Wire-feed Cam Lubricate the Wire-feed Cam Introduction [65] A B C [65] Lubricate the wire-feed cam [60] A Nozzle for the tube of grease B Wire-feed cam C Feed lever Lubricate the wire-feed cam [61] Step Action 1. Lift the PSQ main deck. 2. Apply 10 mm of grease from the tube between the bearing surface of the wire-feed cam and the feed lever. Information figure 65 [66] 0.4" 106 3. Lower the Booklet maker main deck 4. Lower the clincher frame. 5.
Install New Stitch Wire Install New Stitch Wire Introduction Only use stitch-wire that is approved by your supplier. Stitch-wire that is not approved by your supplier can cause poor performance and voids the warranty. Stitch-wire Description: Stitcher wire S33. Before you begin Lift the Booklet maker main deck.
Install New Stitch Wire [62] A Stitch Wire Guide Block B Stitch wire C Felt wire-cleaning pads Remove the Stitch Wire from the Stitch Head [63] Step 1 Action Cut the stitch wire to the right of the stitch wire guide block. Information [68] A Detail A: Cut here 2 Pull the stitch wire from the stitch wire guide block. 3 Fit a new stitch wire spool.
Install New Stitch Wire Step Action Information 6 Use wire cutters to remove the Remove enough stitch wire to leave damaged end of the stitch the end of the stitch wire clean and wire. straight. 7 Feed the stitch wire through the stitch wire guide. 8 Install the stitch wire.
Install New Stitch Wire Install the Stitch Wire into the Stitch Head [65] Step Action 1 Pull the stitch wire from the end of the stitch wire guide. 2 Make sure the stitch wire runs behind the gas-strut. 3 Feed the end of the stitch wire between the felt wire-cleaning pads. Information [71] [72] A Detail A: Felt Wire-Cleaning Pads 4 Push the stitch wire into the stitch wire guide block. 5 Push the stitch wire as far as possible.
Install New Stitch Wire Step Action 4 Close the folder cover. 5 Close the connecting bridge cover. Information Feed the Stitch-wire [67] Step Action Information 1 Touch START. 3 Set the number of stitches to 6 Touch BASIC > STITCHES. 4 Hand-feed or print an A4 or larger size test job. The stitch-wire loads automatically during the stitch head cycle. 5 Check that the stitch-wire is loaded. Check that a stitch is made. If needed, repeat the previous step.
Install New Stitch Wire 112 Chapter 6 Maintenance
Appendix A Specifications 113
Specifications Specifications [68] Operating Conditions 10-35°C at 35-85% relative humidity Production Cycle time: Printer dependent Interset gap: 2 seconds (if printer has DFD2, then 1.5 or 2 seconds, depending on job settings) Minimum set time: 7.5 seconds (if printer has DFD2, then 5.5 or 7.8 seconds, depending on job settings) Maximum set time: 12.5 seconds Stock Sizes Minimum input size: 203 x 203 mm Maximum input size: 320 x 488 mm [75] A 8" x 8" 12.6" x 19.
Specifications Book Thickness Maximum finished book thickness: 10 mm (approximately 200 pages 80gsm) Maximum set thickness: 5 mm (approximately 50 sheets 80gsm) Stitching 1 - 6 stitches, evenly spaced on the spine of the book Stitches/spool: up to 291,500 Books*/spool: approximately 127,000 Trimming Maximum fore-edge trim: 28 mm Minimum trimmed book size: 80 mm [77] min. ± 3.2" max. ±1.1" † Serial no.
Specifications 116 Appendix A Specifications
Appendix B Declaration of Conformity 117
Declaration of Conformity Declaration of Conformity [69] Name of Manufacturer: Watkiss Automation Limited Address of Manufacturer: Watkiss House Blaydon Road Sandy, Bedfordshire SG19 1RZ United Kingdom Declares that the product: Name of Product: BLM 500 / Bookletmaker 50 serial Number: WA/PSQ/---/010 onwards Conforms to the following Directives: Safety: 290/95/EEC Council Directive 'on the approximation of laws of Member States relating to electrical equipment designed for use within certain volt
