Plockmatic BM 61 - User Manual

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Service Manual38 pages

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Summary

Introduction to the Booklet Maker

Safety Notices

Provides essential safety instructions, emphasizing manual reading and sharing instructions with users.

Operational Safety

Details operational safety, including proper grounding, stable support, care during movement, and avoiding magnetic fields.

Safety Notes

General safety reminders: preserve manual, cord safety, humidity protection, vent hole clearance, and using original spare parts.

Belt Stacker Safety

Specific safety measures for the belt stacker, emphasizing the installation of Tip Protection bars when a base is used.

Problem Solving Guide

6.1 Troubleshooting

A guide listing common problems, their possible causes, and recommended actions for resolving issues with the booklet maker.

Summary

Introduction to the Booklet Maker

Safety Notices

Provides essential safety instructions, emphasizing manual reading and sharing instructions with users.

Operational Safety

Details operational safety, including proper grounding, stable support, care during movement, and avoiding magnetic fields.

Safety Notes

General safety reminders: preserve manual, cord safety, humidity protection, vent hole clearance, and using original spare parts.

Belt Stacker Safety

Specific safety measures for the belt stacker, emphasizing the installation of Tip Protection bars when a base is used.

Problem Solving Guide

6.1 Troubleshooting

A guide listing common problems, their possible causes, and recommended actions for resolving issues with the booklet maker.

The Plockmatic BM 61 2006 Bookletmaker is an automatic booklet-making machine designed for high productivity, safety, and ease of operation, combining features typically found in larger, more advanced systems into a compact unit. It can operate both ON-line (connected to a collator) and OFF-line.

Function Description:

The BM 61 is capable of stapling and folding documents to create booklets. It offers several operational modes:

Stapling and Folding (ON-line): When connected to a collator, the machine automatically receives sets of paper, jogs them for alignment, staples, and folds them into booklets.
Folding Only (ON-line): Similar to stapling and folding, but only performs the folding operation.
Stapling and Folding (OFF-line): For standalone operation, users manually feed sets into the machine for stapling and folding.
Folding Only (OFF-line): Standalone operation for folding manually fed sets.
Block Stapling (OFF-line option 1): This mode allows for stapling without folding, with the option to use an adapter for a Belt Stacker or Delivery Tray to stack stapled sets.
Block Stapling (OFF-line option 2): A manual stapling mode where sets are inserted, stapled, and then removed one by one, without being transported through the machine for folding.

The machine features an infeed section with upper and collator-side components for precise paper handling. The upper infeed section includes side joggers, a rear jogger roller, and an upper pressure roller assembly, all with scales for accurate paper length and width adjustments. The collator-side infeed section has positioning holes for standard paper widths, a positioning mark for alignment with the collator, a paper stop crank, and rear jogger latches for adjustment and OFF-line operation. A knob for adjusting to odd paper sizes and a docking bracket are also present for flexible paper handling.

The control panel provides intuitive operation with a power switch, indicators for low staples and jams, and switches to enable/disable stapling and folding. For OFF-line modes, it includes an automatic start ON/OFF switch, a time delay adjustment, and a manual start button.

Important Technical Specifications:

Capacity (ON-line): 10 sheets of 80 gsm (including cover) or 10 sheets of 20 lb bond (including cover).
Capacity (OFF-line): 22 sheets of 80 gsm or 22 sheets of 20 lb bond.
Speed (ON-line): 1800 A5 sized booklets/hour or 1400 A4 sized booklets/hour.
Speed (OFF-line): Adjustable up to 1800 A5 or 1400 A4 sized booklets/hour.
Paper Size (Min): 200 x 270 mm (7 7/8" x 10 5/8").
Paper Size (Max): 305 x 440 mm (12" x 17 1/4").
Stapler Head: 210 Plockmatic chisel point.
Low Stapler Detection: Yes.
Jam Detection: Yes.
Jogging: Side and back.
Height: 550 mm (880 mm including base) or 21 5/8" (34 5/8" including base).
Width: 780 mm (1420 mm including Belt Stacker) or 30 11/16" (55 7/8" including Belt Stacker).
Depth: 500 mm (19 5/16").
Weight: 58 kg (128 lb).
Voltage: 115 V 60 Hz or 230/240 V 50 Hz.

Usage Features:

ON-line Operation: Seamless integration with a collator, allowing for automatic processing of collated sets. Calibration and verification steps ensure correct setup.
OFF-line Operation: Flexibility for standalone use, with options for manual or automatic start. A time delay can be set in automatic mode for careful alignment of manually inserted sets. The manual start button lights up to indicate when the next set can be inserted.
Paper Settings: Adjustable side joggers and paper stop crank for precise alignment according to paper size. Special positioning holes and a knob for odd paper sizes allow for non-standard paper processing.
Safety Features: Includes safety notices, general safety guidelines, and operational safety instructions. Warnings are provided for potential dangers, and cautions for machine damage. Tip Protection bars are required when using the Belt Stacker with a Base.
Accessories (Optional): Can be equipped with a Belt Stacker or Delivery Tray for stacking finished booklets or stapled sets. An adapter is used to connect these accessories.

Maintenance Features:

Roller Cleaning: Regular cleaning of rollers with a rubber reactivator fluid or similar cleaner is recommended to prevent grease and oil buildup, which can negatively affect operation.
Problem Solving: A dedicated section in the manual provides a table of common problems, possible causes, and corresponding actions to resolve issues such as paper jams, bad sheet alignment, and stapler malfunctions.
Safety for Maintenance: Users are advised not to perform maintenance functions not specifically described in the documentation, to never remove fastened covers or guards, and to contact a service representative for service and repair. The machine should be unplugged if not in use for an extended period or if unusual noises/odors are detected.