Plockmatic Bm 2000 Manual de usuario

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Plockmatic BM 2000

Booklet Maker

Instruction Manual

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 1(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

Contents

1General................................................................................................................................2

2Installation............................................................................................................................2

2.1 Power connection ................................................................................................................2

3Machine Issues....................................................................................................................3

3.1 BM 2000...............................................................................................................................3

3.2 TR 2000...............................................................................................................................6

3.3 SQF 2000.............................................................................................................................9

3.4 Belt Stacker........................................................................................................................10

4Software.............................................................................................................................11

4.1 Loading Software...............................................................................................................11

4.2 Known Bugs.......................................................................................................................11

5Booklet Quality...................................................................................................................12

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 2(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

1 General

This document will describe known issues with the BM 2000 System and their solutions. It will be

distributed to all tech support people that have BM 2000 systems. The information in this

document will eventually migrate into the Service Manuals.

Please handle this as a confidential document. It is not to be distributed to third parties.

Please also contribute with corrections and new tips that you find in the field.

2 Installation

2.1 Power connection

It is important that the line power is stable and the system should not be exposed to

undervoltage.

Do not connect all machines to one power strip. Avoid long extension cables. Connect the units

separately. Avoid connecting all units to the same wall outlet. If possible, connect Feeder VF1008

to a separate circuit.

If available, connect the system to a three

phase outlet with an adaptor cable as shown

right.

Make sure you have the specified voltage in the power outlet. Measure the voltage when all units

are running. If necessary, tap the machines for a lower voltage.

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 3(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

3 Machine Issues

3.1 BM 2000

BM-026 (Fold roller motor M9 pulse timeout)

Cause a): Optic sensor not sitting correctly in

place.

Remedy: Make sure sensor is sitting correctly

in place. Make sure the encoder disc is

entering deep enough between the two sensor

legs.

Long term solution: Sensor bracket has been

redesigned.

Cause b): Weak signal from sensor.

Remedy: Replace sensor.

Possible cause c): Holes in encoder disc

covered with thin film distort the signals.

Remedy: Replace or clean disc with knife/file.

BM-029 (Fold knife motor M10 cycle timeout

Symptom: BM-029 occurs at power-on.

Cause: Microswitch SW5 broken (M10 home position switch).

Side jogger collision

Make sure the Side Guides and the Back Joggers move easily. The 8 mm shaft on which the

Back Joggers sit should be lubricated by a thin oil.

Make sure the screw holding the belt in the Side Guide is not too long or tightly pulled, it could

then touch the shaft.

Make sure the Side Guide Extensions do not hit the Clinch Housing. If so the Side Guides have

to be elevated by turning the allen screws underneath the Side Guides.

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 4(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

Message “Cover Open” won’t go away

First generation machines have Interlock Switch PCBs

where the magnet sometimes is badly attached. New

PCBs have a new magnet holder that won’t fall off and

also positions the magnet at the right spot.

A second cause could be that the dome cap on the

switch has fallen off, due to excessive force from the

interlock cheater.

Remedy: In both cases, replace PCB, P/N 771134

New magnet holder

Q2 Manual Feed Sensor Problems

We have one reported case where sensor Q2 was

activated by the sheet metal, i.e. the cut-out wasn’t big

enough for that particular sensor. The root cause was

a bad sensor. It was, though, possible to use the faulty

sensor by adjusting it slightly sideways. A normal

sensor has a very large margin.

Symptom: This can lead to a number of different

errors. Normally if there is a signal from the sensor the

machine switches to manual feed mode. When a

sheet enters from the Collator it will lead to a jam

situation.

Verification of problem:

1. Remove the front cover so that you can see

the control PCB.

2. Watch the blinking yellow LED on the PCB

shown in picture 1 and 2. The LED makes an

extra blink whenever a sensor is activated or

deactivated. Normally the LED should blink

regularly once per second. If the LED flickers it

indicates a sensor is generating too many

impulses or there is a bad connection between

sensor and PCB.

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 5(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

Stapler interruption

Symptom: Stapling interruptions.

Possible cause: Insufficient retraction of

stapler plunger.

Remedy: Make sure blade spring mechanism

is activated when stapler retracts. If

necessary, place washers in between blade

spring and housing on the screw shown

right..

Blade spring Housing

Screw

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 6(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

3.2 TR 2000

TR-002 (Knife motor M1 cycle timeout)

Symptom: TR-002 (Knife motor M1 cycle timeout) occurs immediately after the booklet is

trimmed. The Air Blast is out of synch. The Trimmer cannot trim even a thin booklet.

Cause: Knife Sensor Bracket was deformed by cable at installation so that the sensor missed the

flags.

Remedy: Bend Bracket back in shape.

Long term solution: New Cable Duct will protect underlying parts.

Knife Sensor Bracket

New Cable Duct

Squeaking Knife

Symptom: Squeaking sound at every trim cycle:

Cause: Steel against steel surfaces are always prone to induce vibration. Of obvious causes it is

not possible to lubricate the surfaces.

Short term remedy: Lubricate upper knife with candle stick.

Long term solution: Tests are presently running with low-friction knives. These knives are PVD-

treated (Physical Vapor Deposition), which makes the surface harder with a lower friction.

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 7(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

Trim Waste Problems

Symptom: Trim strips exit together with the finished booklets.

Cause: Insufficient effect from built-in blower fans.

Remedy: There are two different solutions;

a) Install Compressor Air Blast Kit, part no. 890031, which

needs compressed air

Air Blast Kit

b) Turn over the blower fans as described below. This will soon come in production.

Turning over trim blower fans

Trim waste problems can be reduced significantly if the blower fans are installed as shown right

below. The new method will go in production soon.

Standard mount

New mount

Existing machines can be rebuilt with reasonable efforts:

•Remove the Blower Bracket

•Remove the blower fans from the bracket

•Newer brackets already have threaded holes for turned-over fans, if not, drill and tap

these

•The connecting cable for one of the blower fans has to be extended, this can be done by

crimping or soldering

•Install everything again

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 8(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

Message “Unreg Voltage Low”

This error message is most likely caused by the interlock

switch in FTR 2000. There is a microswitch installed

underneath the ordinary Interlock PCB. The root cause can

be one of the following:

Cause a): Microswitch mounted too low or its bracket has

been bent by excessive force from interlock cheater

Remedy: Readjust (raise) microswitch.

Cause b): First generation top cover without magnetic locks

could vibrate and cause switch to operate

Remedy: Install magnetic lock on top cover (needs drilling).

Title Doc no.

RD07-001

Date (ISO 8601)

Best Practice

BM 2000 Systems 2007-07-05

Process owner Author Sign. Quality Section Revision Page

R&D Dept + Tech Support BOL 1 9(13)

K:\Produkte\PL88 RoHS\BM 2000 Best Practice doc

3.3 SQF 2000

Thin booklets won’t transport well through the SQF

Cause: Static sheets gets stuck inside machine.

Remedy: Antistatic brushes, P/N 56677 mounted in inlet.

Long term solution: Antistatic brushes are already standard.

SQF-013 (Roller Motor Pulse Timeout)

Symptom: Roller motor stops intermittently for no apparent reason.

Possible cause a): Holes in encoder disc

covered with thin film distort the signals.

Remedy: Replace or clean disc with

knife/file.

Possible cause b): Weak signal from

sensor.

Remedy: Replace sensor.

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