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2000
User Manual
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GBC 2000 User Manual

BOOKLET MAKER BM 2000

Operating Instruction
Booklet Maker Reference
Part no: 87967 Doc no: T10170 Rev. date: 5 March 2007

TABLE OF CONTENTS

Booklet Maker ............................................................................................................................... 7
Trimmer ....................................................................................................................................... 10
SquareFolder .............................................................................................................................. 12
1. Basics
Turning On / Off the Power ......................................................................................................... 13
Control Panel .............................................................................................................................. 14
Staples, Staple Cartridge, Stapler Head & Clinchers ................................................................. 15
Removing / replacing Staple Cartridge..................................................................................................15
Removing / replacing Staple Cartridge, continued ................................................................................16
Removing / replacing Stapler Head.......................................................................................................16
Removing/replacing Stapler Head, continued .......................................................................................17
Changing Staple position and Narrow width Paper Sizes .......................................................... 18
Changing Stapler and Clincher position ................................................................................................18
Setting up narrow width paper sizes .....................................................................................................19
Emptying the Trim Bin ................................................................................................................. 20
2. Making Booklets
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 On or Off ................................................................................................................24
Adjusting the Cutting Margin ................................................................................................................. 24
SquareFolding ............................................................................................................................ 25
General..................................................................................................................................................25
Procedure .............................................................................................................................................. 25
On-line Mode .............................................................................................................................. 26
Off-line Mode .............................................................................................................................. 28
3. Admin
Paper size check ........................................................................................................................ 29
Mode, Safe / Fast ....................................................................................................................... 30
System Setup ............................................................................................................................. 30
Standard Paper Size ................................................................................................................... 31
Language .................................................................................................................................... 31
Service ........................................................................................................................................ 31
3
4. Jobs
Storing a Job ............................................................................................................................... 33
Recalling a Job ........................................................................................................................... 34
5. Clearing a Paper Jam
General ....................................................................................................................................... 35
Clearing a Paper Jam ................................................................................................................. 36
Inside the Booklet Maker ....................................................................................................................... 36
Clearing a Paper Jam ................................................................................................................. 38
Clearing Jam in Input Area .................................................................................................................... 38
Clearing Jam in Exit Area ...................................................................................................................... 39
Clearing a Paper Jam ................................................................................................................. 40
Inside the SquareFolder ........................................................................................................................40
Exit Area ................................................................................................................................................ 40
6. Troubleshooting
General ....................................................................................................................................... 41
Booklet 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
Fold Quality ................................................................................................................................. 43
SquareFolding Quality ................................................................................................................ 44
7. General Remarks
Machine Environment ................................................................................................................. 46
Power Connection ...................................................................................................................... 46
Access to Machine ...................................................................................................................... 47
Booklet Maker ............................................................................................................................. 48
Lubricating Staplers and Clinchers........................................................................................................48
SquareFolder .............................................................................................................................. 49
Cleaning Feed Belts ..............................................................................................................................49
Cleaning Square Folding Clamps..........................................................................................................50
8. Specications
Booklet Maker BM 2000 ............................................................................................................. 51
Trimmer FTR 2000 (option) ........................................................................................................ 52
SquareFolder SQF 2000 (option) ............................................................................................... 52
4

What You Can Do With This Machine

FTR 2000 Trimmer (option) BM 2000 Booklet MakerSQF 2000 SquareFolder (option)
Belt Stacker
The Booklet Maker BM 2000, Trimmer FTR 2000 and SquareFolder SQF 2000 form a
booklet making system that works on-line with Feeder/Collators.
The sheets from the Feeder/Collator are transported into the BM 2000 Booklet Maker and
collected in the stapler area of the BM 2000 Booklet Maker. The Booklet Maker now jogs and then staples the set. The set is then transported further to the folding area where the set is folded into a booklet and then fed out to the belt stacker. When a larger number of sheets are folded 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, folded and
trimmed will be fed into the SQF 2000. The SQF 2000 will atten the spine of the booklet
into a square shape. The booklets will, after passing through the SQF 2000, have the look of a perfect bound book.
The booklets are then fed out to the Belt Stacker.
5
The entire BM 2000 Booklet making system is controlled from a single control panel on the
Booklet Maker. The control panel has only six buttons which will allow you to easily set up, adjust and operate the complete system.
Buttons
The buttons are multi functional, meaning that the
1
function of each button depends on the information
2
displayed.
3
For example: In this screen, the icon next to button 1
4
indicates you will go up one level in the menu when
5
the button is pressed.
6
Example 2: In this screen, button 1 has no function.
1 2
3
4
5
6
Example 3: Pressing button 1 here will answer “No”
1
to the question on the screen.
2
3
4
5
6
6

Guide To Components

Booklet Maker

2
1
3
4
5
7
6
1 Control panel 2 Top cover 3 Power switch 4 Infeed assembly
8
5 Hand feed tray (optional) 6 Belt Stacker 7 Belt Stacker Cover 8 Hand feed slot (for on-line mode)
7
Booklet Maker, continued
4321
7
1 DFA. 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
6
8
5 Power receptacle 6 Power out to SQF 2000 7 Interlock jumper 8 Interlock jumper / Power out to FTR
2000
8
Booklet Maker, continued
1
11
2
12
3
13
4
7
5
8
6
7
Booklet maker, top view
14
8
9
10
1 Tool box 2 Ball cage 3 Fold adjust lever, right side
Left side not shown in picture 4 Thumb screws for Stapler assy. 5 Cartridge locking levers 6 Stapler lift brackets 7 Side guide extension
8 Thumb screw for Side guide extension 9 Stapler heads 10 Side guides 11 Guide 12 Staple detection leads, one on each
stapler head 13 Locking pin, one on each stapler head 14 Clincher, left side. Right side not shown
in picture
9
Options

Trimmer

1
1 Top cover 2 Trim bin
2
10
Trimmer, continued
1
2
3
4
6
7
5
8
9
Trimmer, top view
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
11

SquareFolder

1
1 Top cover 2 Upper feed belts (lifted position) 3 Docking bracket (not visible in picture 5 Lower feed belts 4 Latches
2
3
12
SquareFolder, top view
4
5
1. Basics

Booklet Maker

Turning On / Off the Power

Plug the Booklet Maker power cord into the wall outlet.
Trimmer (optional) and 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.
B
A
13

Control Panel

State Current Job
1. Basics
The Main screen.
When the system power is switched on the Main
screen will be shown. Here you will nd information
showing the actual set up. From this screen you can also access other screens, that will help you operate the complete BM 2000 Booklet making system.
At the top, throughout the screens you can see the
current state of the machine and the current job.
Changing settings.
To change or adjust settings; Select an item in the
Main screen with the [arrow] button and press the
[Enter] button. For example you can ne adjust
the trimming, change stapling mode or set the SquareFolder to the correct mode. Settings are explored more thoroughly in section 2. Making Booklets.
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.
The Jobs screen.
Pressing the [Jobs] button in the Main screen opens the Jobs screen. 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.
14

Staples, Staple Cartridge, Stapler Head & Clinchers

Removing / replacing Staple Cartridge
B
A
C
You may remove and replace the staple cartridge
while the stapler head assembly is in place.
Open the top cover.
Raise the staple cartridge locking lever (A) as indicated in the drawing.
Gently twist the staple cartridge (B) from side to side, and pull out the staple cartridge (B) from the stapler head.
If the staple cartridge is empty, discard it and replace it with a new one. Before replacing the cartridge, pull at least 20 mm of the staples out and tear off at the staple tear line (C) which is marked on the cartridge. If there has been a misfeed, and the cartridge still contains staples, pull 20 mm of staples out of the cartridge and tear off at the stapler tear line. Check that the
rst staple is at. If not, tear off another 20 mm,
using less force.
1. Basics
Insert the cartridge into the stapler head with the staples facing towards the head mechanism.
The cartridge should be placed at on the slide
on the bottom of the stapler head and pushed
rmly into the stapler head.
While holding the staple cartridge rmly pressed
into the stapler head, push down the cartridge locking lever.
Note
It is important that the cartridge not is allowed to move away from the stapler head before the locking lever is engaged. If that occurs, remove cartridge and again tear off 20 mm of staples along the staple tear line before inserting the cartridge.
15
Removing / replacing Staple Cartridge, continued
After staple jam or empty staple cartridge has been detected, the BM 2000 will automatically advance and feed staples. This feature is called staple recovery. Follow procedure below after a staple jam or empty staple cartridge indication.
1. Basics
Follow step 1-6 on the previous page.
Close the top cover.
Feed in a four page set. The staple recovery will commence now.
Now 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.
Removing / replacing Stapler Head
Select A3 (11x17”) paper size to facilitate removing or replacing the stapler head.
Loosen the thumb screw (A).
Rotate the locking pin (B) towards the thumb screw and remove the locking pin from the stapler head assembly.
Disconnect the staple detection lead (C).
Push the stapler head towards the in-feed side, out of the stapler head assembly.
16
A
BC
Removing/replacing Stapler Head, continued
Note
Whenever you remove a stapler head, be sure to
manually eject some staples before replacing it in the
BM 2000. To do this, rest the stapler head on a rm
surface (for example, the top of a table) and actu­ate the staple driver post up/down through full travel. Do this a number of times to ensure that the staples are ejected on each down movement. If you need to change the staple cartridge, see previous section, removal/replacement of staple cartridge.
Warning
When manually ejecting the stapler, stay clear from
stapler output area.
1. Basics
G
D
E
F
Before inserting the stapler head, centre the stapler lift bracket (D) over the area that will receive the stapler head. Ensure that the staple driver post (E) is in its uppermost position.
Place the stapler head back into the BM 2000.
The driver post arm (E) must be placed into the
stapler lift bracket (D).
Caution
If the driver post arm is not correctly positioned into the stapler lift bracket (D) it will cause permanent damage to the stapler head as well as the bracket. Subsequently, also future correctly mounted stapler heads will be damaged.
Press on the lower front edge of the stapler head to align the hole (F) in the stapler bracket with the hole in the stapler head. Insert the locking pin (B) so that it engages the stapler head and the metal sides of the stapler assembly.
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.
Insert the staple detection lead (C) into its socket.
17
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