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Morgana BM350 User Manual

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Read this manual carefully before you use this product and keep it handy for future
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For safety, please follow the instructions in this manual.
Operating Instruction
Doc no: T10200G
Date: 27 June 2017
BM350/BM500
Booklet Maker System

Table of Contents

Questions and Answers:

Morgana BM350 Specifications

General IconGeneral
BrandMorgana
ModelBM350
CategoryPrinter
LanguageEnglish

Summary

Introduction to the Booklet Maker System

How to Read the Manual

Explains document conventions and symbols used in the manual.

Safety Information

Operational and General Safety

Covers electrical safety, grounding, handling moving parts, and general precautions.

1. Basics - System Operation

Turning On / Off Main Power

Instructions on locating and operating power switches for the system.

Loading Feeder AF602/VF602

Step-by-step guide for loading paper into the AF602 or VF602 feeders.

Change staple cartridges and Check stapler

Procedures for replacing staple cartridges and checking the stapler.

Belt Stacker

Guides for configuring the belt stacker for different modes.

Job Preparation

Instructions on preparing paper stacks for optimal feeding.

2. Making Booklets

Changing settings

How to save temporary or permanent changes to job settings.

Paper Size

Setting standard and custom paper sizes for booklet production.

Staple

Enabling or disabling the stapling function and its settings.

2. Making Booklets (continued)

Staple position and Fold position

Fine-tuning staple and fold positions for booklet appearance.

Fine tuning booklet appearance

Adjusting joggers and registration for optimal booklet quality.

Face Trimming

Setting face trimming to Auto, Manual, or No Trim.

Square Fold Module

Using the Square Fold module for booklet finishing.

Crease Trim Module (Option)

Using the Crease Trim module for creasing and trimming.

Hand-feeding

Operating the booklet maker using manual paper feeding.

3. Tools

The Tools screen

Accessing system settings like stacker detection and units.

Square Fold stop gate offset

Adjusting the square fold stop gate for finer control.

4. Jobs

Handling jobs

Storing, modifying, and deleting jobs for booklet production.

5. Clearing Misfeed(s)

General Misfeed Clearing

How misfeeds are indicated and general clearing principles.

CST module misfeed clearing

Procedures for clearing jams in the CST module's paper path.

5. Clearing Misfeed(s) (continued)

Booklet Maker misfeed clearing

Steps to clear misfeeds inside the main booklet maker unit.

AF602/VF602 Feeder module misfeeds

Clearing misfeeds in the AF602/VF602 feeder modules.

Square Fold Module misfeeds

Procedures for removing jams within the Square Fold module.

Trimmer module misfeeds

Steps to clear misfeeds in the input and exit areas of the trimmer.

Belt stacker misfeeds

How to clear misfeeds from the belt stacker.

6. Troubleshooting

Fault codes

Table of fault codes, their messages, and explanations.

General fault codes

Common fault codes and their resolution steps.

Booklet maker fault codes

Specific fault codes for the booklet maker, e.g., staple issues.

AF602/VF602 fault codes

Error codes related to feeder operation and paper handling.

7. Remarks

Do’s And Don’ts

Essential guidelines for operating and maintaining the equipment safely.

Where to put Your Machine

Recommendations for the ideal location and environmental conditions.

Maintaining Your Machines

Guidelines on performing regular maintenance tasks.

8. Specification

Machine Specifications

Comprehensive technical specifications for the booklet maker.

Module Specifications

Specifications for Square Fold, Trimmer, CST, Creaser, and Feeder modules.

Guide To Components

Booklet Maker Overview

Identifies key external parts of the Booklet Maker.

User interface

Control panel

Explanation of the touch screen control panel and its functions.

Options

BM350/500 Booklet Maker Features

Details on features like the Live Logo indicator.

SQF500 Square Fold Module

Module Components

Identification of external parts of the Square Fold module.

FTR500 Trimmer Module

Module Components

Identification of external parts of the Trimmer module.

CST500 Crease Trim Module

Module Components

Identification of external parts of the Crease Trim module.

CR500 Creaser Module

Module Components

Identification of external parts of the Creaser module.

BST4000-1 Belt Stacker Module

Module Components

Identification of external parts of the Belt Stacker module.

BST4000-1 Belt Stacker Module Operation

Principle of Operation

Explanation of how the belt stacker operates.

Air Assist Feeder AF602

Feeder Components

Identification of external and internal parts of the AF602 feeder.

Vacuum Feeder VF602

Feeder Components

Identification of external and internal parts of the VF602 feeder.

VF602 Advanced Settings

Bin Settings and Fan Control

Adjusting bin settings and fan airflow for paper feeding.

DSD and Sensor Calibration

Configuring Double Sheet Detection and calibrating sensors.

VF602 Advanced Settings - Airflow Parameters

Airflow Parameter Explanation

Details on Separation Air, Float Air, and Vacuum Air functions.

Process Position Adjustment

Adjusting the process position for optimal paper separation.

VF602 Advanced Settings - Detection and Calibration

DSD Settings Configuration

Managing active Double Sheet Detection sensors.

Calibrating DSD Sensors

Procedures for calibrating DSD sensors after maintenance.

VF602 Advanced Settings - Vacuum and Size Control

Vacuum Size Valve Adjustment

Adjusting the vacuum suction area based on paper width.

VF602 Advanced Settings - Test and Float Settings

Test Settings Functionality

Using the test settings to check manual adjustments.

Operation with VF602 Feeder

Proofing Booklet Output

Checking the first booklet using the Proof function.

Hand-feeding Operation

Manual Hand Feed Mode

Operating the booklet maker in stand-alone hand-feed mode.

Hand-feeding with Tray

Using the Hand Feed Tray

Instructions for using the hand feed tray for manual operation.

3. Tools - System Settings

Stacker Full Detection Configuration

Enabling stacker full detection to stop the system.

Unit Measurement Settings

Selecting between millimeters and inches for measurements.

3. Tools - Software and Offset

Software Version Information

Displaying software versions for different modules.

Square Fold Stop Gate Offset

Adjusting the square fold offset for stronger or softer folds.

4. Jobs - Handling

Job Saving Procedures

Steps to save current settings as a new or existing job.

4. Jobs - Management

Opening and Managing Stored Jobs

Accessing, renaming, loading, or deleting saved jobs.

5. Clearing Misfeeds - General

Misfeed Indication and Location

How misfeeds are indicated and general clearing principles across modules.

CST Module - Paper Path Misfeeds

Clearing Infeed and Exit Area Jams

Procedures for clearing misfeeds in the CST module's infeed/exit.

CST Module - Registration and Creaser Area

Clearing Waste Transport Jams

Instructions for clearing jams in the waste transport system.

Booklet Maker - Inside Unit Misfeeds

Purging or Removing Misfeeds

Methods to purge or remove misfed sets from the booklet maker.

Booklet Maker - Folder Area Misfeeds

Clearing Folder Area Jams

Steps to clear misfed sheets/booklets from the fold rollers.

AF602/VF602 Feeder Module - Misfeeds

Feeder Bin and Transport Area Jams

Clearing misfeeds within the feeder bin and paper transport.

Square Fold Module - Misfeeds

Clearing Inside Square Fold Module Jams

Steps to clear misfed booklets inside the square fold module.

Trimmer Module - Input Area Misfeeds

Clearing Input Area Jams

Procedures for clearing misfeeds in the trimmer's input area.

Trimmer Module - Exit Area Misfeeds

Clearing Exit Area Jams

Steps to clear misfed sheets from the trimmer's exit area.

Belt Stacker - Misfeeds

Clearing Belt Stacker Jams

Procedures for clearing misfeeds on the belt stacker.

6. Troubleshooting - Fault Codes

General Fault Codes and Explanations

Table of fault codes, their messages, and their explanations.

Troubleshooting - General Fault Codes

Clearing Misfeeds (General Codes)

General guidance on clearing misfeeds indicated by fault codes.

Troubleshooting - Cover and Stacker Status

Closing Machine Covers

Ensuring all covers are properly closed to resume operation.

Emptying the Stacker

Procedure to empty the belt stacker when it is full.

Troubleshooting - Specific Module Faults

CST Module Fault Codes

Fault codes related to the CST module's operation.

Booklet Maker Fault Codes

Fault codes for booklet maker issues like stapling or thickness.

Troubleshooting - Feeder Fault Codes

AF602/VF602 Feeder Misfeed and Jam Codes

Explanations for misfeed and jam errors in the AF602/VF602 feeders.

Troubleshooting - Feeder Advanced Faults

Feeder Thickness and Detection Errors

Codes related to sheet thickness and DSD functionality.

Feeder Empty and Exit Errors

Error codes for empty bins, exit misses, and exit errors.

No Feed Sequence Error

Resolution for the "No Feed Sequence" startup error.

VF602 Jam Recovery - Miss Error

Procedure for Miss Error Recovery

Step-by-step guide to resolve "Miss error" using manual settings.

VF602 Jam Recovery - Long/Thick Errors

Procedure for Long/Thick Error Recovery

Manual recovery steps for "Jam, Too long, Too thick" errors.

Trimmer and Square Fold Faults

Trimmer Fault Codes (Trim Bin, Belts)

Faults related to the trim bin and trimmer belts.

Square Fold Feed Errors

Troubleshooting feed errors in the Square Fold module.

Sensor Calibration Procedures

AF602 Sensor Calibration

Steps to calibrate optical and ultrasonic DSD sensors on AF602.

AF602 Sensor Calibration - Ultrasonic Calibration

Calibrating Ultrasonic DSD and USDS Sensors

Detailed procedures for calibrating ultrasonic sensors.

VF602 Sensor Calibration

Calibrating Optical DSD Sensors

Steps for calibrating the optical DSD sensors on VF602.

VF602 Sensor Calibration - Ultrasonic Calibration

Calibrating Ultrasonic DSD Sensors

Procedures for calibrating VF602's ultrasonic DSD sensors.

7. Remarks - Do's and Don'ts

General Operational Guidelines

Key rules and precautions for operating the equipment.

Machine Placement and Power

Machine Environment Recommendations

Guidelines for selecting an appropriate location for the machine.

Power Connection Requirements

Ensuring proper grounding and connection of the power source.

Machine Accessibility

Clearance Requirements

Recommended clearances around the machine for access.

Maintaining Your Machines

General Maintenance Guidelines

Important rules regarding maintenance procedures.

Square Fold Module Maintenance

Cleaning Feed Belts

Instructions for cleaning the feed belts in the Square Fold module.

CST Module Maintenance

Cleaning Paper Path Nip Rollers

How to clean the paper path transportation nip and idler rollers.

CST Module Maintenance - Fixing Rollers

Cleaning Fixing Rollers

Instructions for cleaning the fixing rollers in the CST module.

CST Module Maintenance - Registration and Friction Tires

Cleaning Registration Rollers and Friction Tires

Procedures for cleaning registration cross rollers and friction tires.

CST Module Maintenance - Rotator Rollers and Sensors

Cleaning Rotator Rollers

Instructions for cleaning the rotator rollers.

Cleaning Paper Path Sensors

How to clean the paper path sensors.

CST Module Maintenance - Creaser Tools

Cleaning Creaser Tools

How to clean the creaser tools for optimal performance.

Bleed Trimmer Adjustment

Adjusting Bleed Trimmer Registration Angle

How to adjust the bleed trimmer's registration angle.

Creaser Registration Angle Adjustment

Adjusting Creaser Registration Angle

How to adjust the creaser's registration angle.

AF602 Feeder Maintenance

Cleaning AF602 Feed Rollers and Sensors

Procedures for cleaning feed rollers and sensors on the AF602.

VF602 Feeder Maintenance

Cleaning VF602 Feed Components

Instructions for cleaning VF602's double sheet sensors and suction belts.

VF602 Feeder Maintenance - Feed Rollers

Cleaning VF602 Feed Rollers

How to clean the feed rollers inside the VF602 baffles.

Limitations in the BM350/BM500 System

General System Limitations

Information on production capacity, media handling, and output quality.

Limitations in the BM350/BM500 System (Continued)

Media and Sensor Limitations

Details on media types and sensor usage limitations.

Best Practices for BM350/BM500 System

Optimizing Booklet Production

Tips for improving registration, staple penetration, and finish.

8. Specifications - Machine Details

BM350/BM500 Booklet Maker Specifications

Comprehensive technical specifications for the booklet maker.

Module Specifications

Specifications for Square Fold, Trimmer, CST, Creaser, and Feeder modules.

Module Specifications - Square Fold and Performance

Square Fold Module Specifications

Technical details for the Square Fold module.

Performance Diagrams

Charts showing approximate system performance.

Module Specifications - FTR Trimmer

FTR Trimmer Module Specifications

Technical details for the FTR Trimmer module.

Module Specifications - CST Crease Trim

CST Crease Trim Module Specifications

Technical details for the CST Crease Trim module.

Module Specifications - CR500 Creaser

CR500 Creaser Module Specifications

Technical details for the CR500 Creaser module.

Module Specifications - Feeders and Stackers

Air Feeder AF602 / Vacuum Feeder VF602 Specifications

Technical details for the AF602 and VF602 feeders.

BST4000-1 Belt Stacker Module Specifications

Technical details for the BST4000-1 Belt Stacker module.

System Set Size Guide

Sheet Capacity Guidelines

Tables indicating maximum sheet counts based on paper weight and size.