9133506 GB Operator Manual BBF 2005 MK1

Glue Tank with two drums
OPERATOR
MANUAL
Initial issue: 09/01
Latest revision : 12/10
9.133.506
Content of this documentation remains the exclusive property of C.P. Bourg SA and it
is only put at the user (including without limitation: Renter or Purchaser or their
employees) disposal within the exclusive scope of using and servicing the product.
Without C.P. Bourg SA prior agreement in writing, reproductions as well
as changes are prohibited.
Operator Manual
Page 9 - 2
Initial issue: 09/01
Latest revision: 10/02
Table of contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1
1.2
1.3
1.4
1.5
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Instructions for safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1
2.2
2.3
2.4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control panel menus and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Machine set up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1
3.2
3.3
3.4
3.5
3.6
Printer set up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Input module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cover station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Binder module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Output unit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Binding in the on-line mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Machine warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Description of the full, automated binding process: . . . . . . . . . . . . . . . . . . 29
Binding in the off-line mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Machine warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Binding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Booklet removal procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
How to switch back from "off-line" to "on-line" mode . . . . . . . . . . 34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Mechanical trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Some common glueing defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Levers to gain access to paper path in by-pass area
(possible jams) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Environmental compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Product Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operator Manual
Page 9 - 3
Initial issue: 09/01
Latest revision: 08/06
Cette page est intentionnellement vide.
This page is intentionally left blank.
Deze blad is opzettelijk in het wit gebleven.
Diese Seite wurde absichtlich leer gelassen.
Operator Manual
Page 9 - 4
Initial issue: 09/01
Latest revision: 10/02
Introduction
1.1 Foreword
Thank you for choosing a BOURG product.
This manual is a guide to operating the BOURG BBF2005.
The BOURG BBF2005 is an automatic perfect binder destined to work on-line with a XEROX
Docutech DT 135; 6100; 6135; 6180 printers; 4xxx printers (such as DP4090, 4890, 4135, 4635, DP180)
for the on-line production of bound booklets.
If you follow the instructions carefully, you should obtain years of excellent service from your
Finishing on Demand system.
If you have any problems using your equipment, please call us and ask for technical assistance
(phone numbers are listed on the last page). We will be delighted to help you.
1.2 Safety information
You are advised to read the "Instructions for a safe use" before you start to actually use the machine.
Technical safety information such as safety data sheets can also be found.
Where applicable, cautions and warnings are used to draw your attention to safety precautions to be
taken.
ll of the information in this publication is based on the latest information available at the time of
A
approval for printing.
We reserve the right to revise this publication and to make changes in the content without obligation
to notify any person of such revisions or changes.
Operator Manual
Page 9 - 5
Initial issue: 09/01
Latest revision: 10/02
1.3 Safety labels
The following labels are located on the binder:
On the top cover.
MODEL : BBF2005
SER. N° :
Refer to specifications
in Installation Manual
3P+PE
60 Hz 208/220/230/240 V
50 Hz 220/230/240 V
3P+PE
50 Hz 380/400/415 V
3P+N+PE
20 A
20 A
20 A
GLUE TEMPERATURE CONTROL
EMERGENCY
STOP
LEIMTEMPERATURREGULIERUNG
NOTSTOP
REGULATION
TEMPERATURE
COLLE
ARRET
D'URGENCE
MADE IN BELGIUM BY
B-1340 Ottignies - rue des Technologies, 22
Tel : +32 / 10 / 62 22 11 Fax : +32 / 10 / 61 36 38
9139395C
NOODSTOP
LIJMTEMPERATUURSTURING
Inside the binder.
B
TRANSPORT
S E C U R E D W I T H S T R A PS
M I T S C H E L L E N B L O C K I E RT
A
I M M O B I L I S E P A R B R I D ES
9.139.162
A
WARNING
KEEP HANDS CLEAR
A
CAN CAUSE
SEVERE INJURY
A
B
Factory wired for / Verdrahtet für
Cablé pour:
380 / 400 / 415 V
220 / 230 / 240 V
208 / 220 / 230 / 240 V
U
D
D
50 Hz
50 Hz
60 Hz
GB
To connect to different networks, rewiring
according to service manual is compulsary.
Caution: wiring errors can result in heavy
damage and void the guarantee.
D
Für Anschluss an andere Netzspannung,
Verdrahtung wie in Installationsanweisung
ändern.
Wichtig: Falscher Anschluss kann schwere
Schäden verursachen und die
Garantie ausschliessen.
F
Pour des réseaux différents, il y a lieu de
modifier le raccordement comme indiqué
dans le manuel d'installation.
Attention: un raccordement erroné peut
entraîner des dommages graves
que la garantie ne couvre pas
9.139.158
A
TAG
A
Operator Manual
Page 9 - 6
Initial issue: 09/01
Latest revision: 12/10
On the input module:
inside: TAG
High leakage current
earth connection essential before
connecting supply
9.139.163
Inside the power rack:
Courant de fuite élevé
Raccordement à la terre indispensable
avant le raccordement au réseau
Main ground
pictogram
PE
N
L
L 3
L1 2
Power supply
connection
On the back (inside):
GB
WARNING
D
SEE INSTALLATION INSTRUCTIONS
BEFORE CONNECTING TO THE SUPPLY
WHEN WIRING THE BINDER TO A
380v or 415v Y NETWORK ALL
OF THE 5 WIRES MUST BE
CONNECTED.
THE OMISSION OF THE NEUTRAL
WILL RESULT IN HEAVY DAMMAGE
AND BREACH OF WARANTY
(BEWARE OF EXTENSION CORDS)
Operator Manual
Page 9 - 7
WARNUNG
SIEHE INSTALLATIONSANLEITUNG
VOR ANSCHLUSS ANS STROMNETZ
BEIM ANSCHLUSS DER MASCHINE ANS
380v oder 415v Y NETZ MÜSSEN
UNBEDINGT ALLE 5 ADERN
ANGESCHLOSSEN WERDEN.
WENN DIE NEUTRALE ADER NICHT
ANGESCHLOSSEN WIRD, ENTSTEHEN
"
SCHWERWIEGENDE SCHADEN
UND
"
DIE GARANTIE FALLT.
"
(ACHTUNG BEI VERLANGERUNGSSCHNUR)
Initial issue: 09/01
Latest revision: 10/02
F
ATTENTION
VOIR INSTRUCTIONS DE MONTAGE
AVANT RACCORDEMENT AU RESEAU
LORS DU RACCORDEMENT A UN
RESEAU 380v ou 415v Y LES 5
CONDUCTEURS DOIVENT ETRE
RACCORDES.
UN RACCORDEMENT ERRONE
ENTRAINERAIT DES DOMMAGES
IMPORTANTS QUE LA GARANTIE
NE COUVRE PAS.
(MEFIEZ- VOUS DES CORDONS PROLONGATEURS)
1.4 Instructions for safe use
ourg products have been tested in accordance with the strictest international safety stanB
dards. To help assure safety, it is important that you observe the following rules.
Connection:
• Do not move the machine yourself, but contact your Customer Service.
• If for some reason you have to move the machine yourself, please make sure that the mains
power point has the correct fuse capacity. See machine specifications for more information
about the maximum current.
• Do not jumpers any mechanical or electrical circuit breakers.
• Do not use an extension cord to connect the machine.
• This equipment cannot be star mains plugged without connecting the neutral wire.
Rem. : It is not important to know if the mains neutral is or is not linked to the earth.
• For equipment connected via a wall socket, locate the machine close to one that is easily
accessible.
• For equipment connected via a fixed connection to the network. The disconnect device in the
field connection should be easily accessible.
• Do not place the machine in rooms which are too small and insufficiently ventilated.
See safety data sheet (in appendix) for information about space and ventilation requirements.
Note : • If an other type of glue is used of the recommended one (National Coolbind
1300), please refer to the safety data sheet of the used glue.
• Vapours which may be formed at elevated temperature may be irritating to
eyes and respiratory tract. A local exhaust over glue tank and a good
ventilation of the room are required.
• Different fume regeneration/extraction are available following the type of
binder (see spare parts catalog).
Surroundings:
• Do not block the ventilation openings of the machine.
• Ensure that the machine is placed on a level, horizontal surface of sufficient strenght.
See machine specifications for information about the weight of the equipment.
Maintenance:
• Do not remove any screws from fixed panels.
• Do not carry out maintenance activities, except for the parts and maintenance mentioned in this
manual.
• Do not place any liquids on the machine.
• To avoid the risk of introducing hazards, all modifications to the binder are strictly reserved to properly qualified and trained service technicians.
Operator Manual
Page 9 - 8
Initial issue: 09/01
Latest revision: 08/06
General:
• Always use materials recommended by Bourg and developed for this Bourg machine.
Materials not approved by Bourg may result in machine failures.
• Do not use the machine when it is emitting unusual sounds. Remove the plug from the power socket or switch off the fixed connection to the network, and contact Customer Service.
Dangerous area
keep hands clear
Hot glue
burn hazard
Note: T
hese safety alert symbols are for your personal safety. Never operate
without all safety covers in place.
WARNING: This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC* Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate frequency
energy and, if not installed and used in accordance with the instruction manual, may
cause harmful interference to radio communications. Operation of this equipment in
a residential area is likely to cause harmful interference in which case the user will
be required to correct the interference at his own expense.
*F.C.C. = Federal Communications Commission.
Canadian Department of Communications Compliance Statement:
This equipment does not exceed Class A limits per radio noise emissions for digital apparatus set out in the Radio Interference Regulation of the Canadian Departement
Communications.
Operator Manual
Page 9 - 9
Initial issue: 09/01
Latest revision: 10/02
1.5 Safety data sheet
Model
BBF2005
Description
Glue binder for on-line connection to DT135, 6100,6135, 6180, 4xxx
Max. process speed
Maximum 250 cycles/hour
Dimensions & Weight Width: 2,60 m (8.5 ft)
Depth: see Instal. Manual
Height: 1,2 / 1,55 m (4.0/5.0 ft)
Weight: 760 kg / 875 kg
(1676/1929 lbs)
Voltage
208V/220V/230V/3
220V/230V/240V3
380V/400V/415V3 N
Frequency 60
H
z
50 Hz 5 0
Hz
Current, rated
20 A
20 A
20 A
Power consumption, stand by
1500 W
Power consumption, operation
3400 W
Power consumption, maximum
5500 W
Mains connection
Cable with fixed connection and separation switch
Safety class
I (IEC 536) Protective earth connection
Protection class
IP 20 (IEC 529)
Sound pressure level
Standby
In operation
* Operator position
55 db(A)
76 db(A)
* Bystander position
79 db(A)
Radio interference
Complies with Directive 89/336/EEC
Radiation
Not applicable
Radiant heat
11600 Btu/hour
Ozone emission
Not applicable
Room volume
Recommendation: 95 m3 (7 x 4,5 x 3 m) 3321.4 ft3
Room ventilation
Recommendation: min. 47,5 m3/h (natural ventilation)
For heat evacuation at continuous binding, extra ventilation may be necessary
Dust concentration0,04 mg/m3 at continous operation
(TLV for nuisance dust = 10 mg/m3)
Additionnal safety informationTo avoid higher sound pressure levels than given above, the machine should be
installed in a room with at least minimum room volume (see above) and favourable acoustical properties.
MODEL : BBF2005
SER. N° :
3P+PE
60 Hz 208/220/230/240 V
50 Hz 220/230/240 V
3P+PE
50 Hz 380/400/415 V
3P+N+PE
MADE IN BELGIUM BY
B-1340 Ottignies - rue des Technologies, 22
Tel : +32 / 10 / 62 22 11 Fax : +32 / 10 / 61 36 38
Operator Manual
Page 9 - 10
Initial issue: 09/01
Latest revision: 12/10
Refer to specifications
in Installation Manual
20 A
20 A
20 A
9139395C
System description
2.1 Specifications
off-line
on-line
Ma
305
(12")
mini. for BBR
Ma
x.
140
(5"1/2)
mini. (padding
only)
x.
m
320
(12.6")
in
.
140 100
(5"1/2) (3.55")
•
75
(2.95")
210
(8"1/4)
210
(8"1/4)
356
(14")
•
40mm MAX.
15 sheets (80gsm) min.
except for DT135 30 pages min. and
15 sheets min.
356
(14")
Book
Dimensions (MAX - min) See illustration above
Cover types
Any paper
Cover weight
80-250 gsm (may require creasing)
Paper weight
60-160 gsm 40mm MAX.
2 sheets min.
30-90 lb cover
15-40 lb bond
Features
Cover pile height
60 mm/2.36 in.
Miss detector
Yes
Speed max.250 cycles/hour (printer dependent)
Glue temperature
From 115° C to 165° C (239° F to 329° F)
Milling + notching
Yes
Paper waste collection
Yes
Book counter
Yes
24 hour start up timer
Optional
Fume extractor
Yes
Outdoor fume exhaust
Optional
Machine
Dimensions: (l
x w x h)
2,6 m x 1,8 m x 1,2 m
(8' 4" x 5' 11" x 45")
with bypass 2,6 m x 2,52 m x 1,2 m
(8' 4" x 8' 3" x 45")
Entry height standard
102 cm or 85,5 cm
(3'4" or 2'9")
WeightWithout bypassWith bypass
Input unit
150 kg
(331 lbs)
180 kg
(400 lbs)
Binder
560 kg
(1235 lbs)
570 kg
(1257 lbs)
Delivery
55kg
(121 lbs)
55 kg
(121 lbs)
Bypass output
— kg
— lbs
75 kg
(165 lbs)
Electrical supply208V/220V/230V/240V (60Hz)
∆ -20A
220V/230V/240V (50Hz)
∆ -20A
380V/400V/415V (50Hz)Y -20A
Radiant heat
11600Btu/hour
Noise level (Lpa)
76 dB (A) (at operator position)
Operator Manual
Page 9 - 11
Initial issue: 09/01
Latest revision: 10/02
2.2 General
A complete book factory consists of : This operator manual is only for the binder.
c.p.
1.
Printer
2.
BPRF (Bourg Perforating Rotating
and Folding)
3. Complete binder
4. BCFx (Bourg Cover Feeder)
5. BDF (Bourg Document Finisher)
3
bourg
S.
N. A .
V
.
OVERRIDE
c.p.
bourg
S.
N. A .
V
.
BINDER
BYPASS
BP
RF
Bourg
Rotating
Perforatin
and
g
Folding
BOUR
G BINDI
NG
X
SYSTE
M
1
2
BC
Bourg
Cover
FX
Feede
r
BOU
RG
FEED
ER
4
5
Binder description:
13
6
14
10
11
7
8
12
15
9
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
By pass input
Input unit
Binder section
Delivery unit
By pass exit to BDF (optional)
Loading area (off-line mode)
Cover tray
Start up timer (optional) (to skip the 30 minutes warm up)
Glue refill funnel
Main switch
Operator Manual
Page 9 - 12
Initial issue: 09/01
Latest revision: 10/02
2.3 Control panels
Binder section
c.p. bourg
S.A.
N. V .
OFF-LINE
5
6
7
4
MENU
8
3
9
2
ON-LINE
1
10
ENTER
15
16
17
18 19 20
21
22
23
15
15. Process start in off-line mode (2 push buttons to press simultaneously)
16. Digital display (7 languages)
17. Menu selection
18. On/off-line selection
19. Drum heating on-off (rotation starts when the glue is warm enough)
20. Clamping duration adjustment
21. Lateral clamping pressure adjustment
22. Suction level adjustment
23 and the 15. Carriage opening (off-line mode)
24. Emergency stop
By-pass input
Disabled when binder"on"
Not used
BOOK FINISH
BY-PASS
BOOKLET
MAKER
STOP
START
HEATING ON/OFF
(LED ON = HEATING OFF)
By pass output
BY-PASS
STOP
Operator Manual
Page 9 - 13
START
Initial issue: 09/01
Latest revision: 10/02
BINDER
24
Page 9 - 14
Operator Manual
Initial issue: 09/01
Latest revision: 10/02
ENTER
+
MENU
S.A.
N. V .
OFF-LINE
:
N– >1
( mm ) :
XXX
:
yes
Is cover leading edge
flush with book ?
OVER L A P
EX T RA CORREC T I ON
COVER POS I T I ON
Confirms the
selected
parameters
Changes the
parameters
Selects the
desired line
Changes the
screen
MENU
BOOK S I Z E :
S I Z E CORRECT I ON
MOD E
MENU
NR . OF B I ND I NGS : XX
N – > 1 W : X XX CORR : XXX
B I NDER READY
ON-LINE
ENTER
MENU
Press on button
START
c.p. bourg
:
N– >1
no
:
N– >1
yes
Book size
is correct
yes
+
BOOK S I Z E :
S I Z E CORRECT I ON
MOD E
Realign
:
no
(each push = 0.2 mm)
BOOK S I Z E :
S I Z E CORRECT I ON
MOD E
yes
Mode is
correct
no
Mode and parameters
are correct
:
no
+
yes
Book length
is correct
+
no
CYCLE RUN
+
ENTER
ENTER
ENTER
Press on both green buttons
ENTER
MENU
MENU
MENU
MENU
Page 9 - 15
Operator Manual
Initial issue: 09/01
Latest revision: 10/02
MENU
±1 6
: X XX
L ANGU :
F ( GB ) D
NL I E P
MENU
CHANGE TOT AL NUMBER
O F B I ND I NGS x x x
N R . OF B I ND I NGS : x x x
COUN T ER RE SE T
± 7
GLUE F I LM L ENGT H .
MENU
±16
: X XX
yes
The language
is correct
no
CHANGE TOT A L NUMBER
O F B I ND I NGS x x x
N R . OF B I ND I NGS :
COUNT ER RE S E T
yes
Number of bindings
is correct
± 7
GLUE F I LM L ENGT H .
yes
The left end of
glue film is correct
yes
no
no
Reset of
the counter
+
±
INHIBITION CYL.1:
yes
The right end of
glue film is correct
GLUE F I LM L ENGT H
no
+
yes
Inhibition cylinder
state is correct
no
+
no
+
ENTER
ENTER
ENTER
ENTER
ENTER
ENTER
MENU
MENU
MENU
MENU
2.4 Control panel menus and messages
c.p. bourg
S.A.
N. V .
OFF- LI NE
MENU
5
6
4
7
2
9
8
3
ON-LINE
1
10
ENTER
At switch on:
MESSAGE OR
I NS T RUC T .
NR . OF B I ND I NGS : XX X
1 – > N L : 2 1 0 CORR :
Display of the values
previously selected in
next two menu steps.
MENU
MOD E : 1 – >N
CO V ER L EN GT H :
BOOK S I Z E :
S I Z E CORRECT I ON
:
MENU
EX T RA CORREC T I ON
COVER POS I T I ON
OV ER LAP
( mm ) :
XXX
MENU
GLUE F I LM
L ENGT H
7
I n i b i t i on c y l : 1
16
MENU
CHANGE TOTA L NUMBER
O F B I ND I NGS
N R . OF B I ND I NGS :
COUN T ER RESE T
MENU
L ANGU :
F ( GB ) D
NL I E P
MENU
• Emergency pressed or hood not closed
• Reset
• Drum is heating but is still too cold
• Shut sliding perspex door
• Binder ready in on-line mode
• Lift perspex guard remove cover if any
• Binder ready in off-line mode(*)
• Sliding perspex door is not locked(*)
• Press key drum to start heating(*)
• Remove paper from binder if any(*)
• Cover feeder did not move
• Binder is in test mode
• Spine is drying
• Problem with book in delivery area(*)
• Depress both green push buttons(*)
• Cover sheet missfeed(*)
• Place on-line guides / close sliding door
• Problem in input unit
• Lift hood and remove book
• Input too fast
• Milling motor is overheated
• Check rotating clamp
• Switch off and open hood(*)
• Reposition carriage(*)
• Binding in progress
• Problems with carriage position
• Remove cover sheet
• Heating is disabled.
Push key to restore
• Empty delivery conveyer
Not ready / connected
• Replace MCU battery
• Check compiler and rotating clamp S12
• Glue temperature too high
• Replace dust bag
• Jogger lifted for padding
• Paper path not clear of knives Option
• Binder in padding mode
(*) Alternative messages
Operator Manual
Page 9 - 16
Initial issue: 09/01
Latest revision: 10/02
messages # on (earlier) eprom
ERROR MESSAGES
01
Carriage open/close
Motor problem M7 F35
02
Shutter motor
Problem M15 F5
03
F6) Rotating clamp
open/close motor M5
04
over nipping motor
C
Problem - M14 (F12)
05
F47) Input mod. pblm
Transfer motor M3
06
Clamp rotation motor
Problem M6 F49
07
Front stop problem
Up/down motor M4 F48
problem M4 F48
08
uction bar problem
S
Up/down motor M13 F4
09
Clutch or brake problem
K12 F2
10
T21 Time out/process longer
than one min
11
Coupling problem M7 or
switch S51
Machine set up
3.1 Printer set up
• See Installation Manual (9133381).
3.2 Input module
1. Lay a sheet of paper to bind in the Input module.
2. With the T-Wrench tool:
a) Adjust the side jogger until it touches the paper, then rotate it back 1mm (.04 in.).
b) Adjust the front paper stop until it touches the paper, then rotate it back 1mm
(.04 in.).
5
In tool kit
TOP VIEW
Position adjustment
(use scale-add 1mm
(.04 in.) play to sheet width)
Side jogger
Front stop
IN
Position adjustment
Fixed side jogger
Operator Manual
Page 9 - 17
Initial issue: 09/01
Latest revision: 10/02
OUT
3.3 Cover station
Loading of the cover station
4
3
1
2
•R
elease the cover separators support bar (1).
• Move the magnetic side guides (2).
• Move the rear guide (3) if the format changes (the rear guides are locked with knurled
knob located under the cover station).
• Load covers against the front guides and the right guide (4).
Note:- Visible part face down.
- Front page towards front guides (in Mode N 1, by default).
• Adjust rear guides (3) and side guides (2) and (4), against the pile of covers.
Mode by default:
N
1
ar
1
Mode for special
applications:
1
Re
N
The cover are always loaded at
the same place, whatever the
thickness book is.
Use this mode for an optimal
production.
N
t
on
N
Mode for symmetrical
cover:
Fr
1
Sym.
Use this mode for booklet with
notes on the edge of the cover.
Three possibilities are selectable in menu #2
1 mode.
Note: • All Xerox printers can print in N
• The cover exactitude position is better in N
or in SYM mode.
Operator Manual
Page 9 - 18
Initial issue: 09/01
Latest revision: 10/02
1 mode than in 1
N mode
Cover dimensions :
Trimming of the book is mandatory for larger dimensions.
The grain of the covers should be parallel with the arrow to obtain sharp folds around the
spine.
Creasing of the cover may be necessary if the covers are cross-grained or if stiff material is
used for the cover.
It is impossible to press heavy covers on very thin books, nor is it wise to use very thin covers
on thick books.
e
L=l
l
m
h
+e+
h
l + 1m
m
+1
m
The paper side of covers with transparent fronts and pape backs, must be wrapped around the
spine at least 4 mm.
4mm
Operator Manual
Page 9 - 19
Initial issue: 09/01
Latest revision: 10/02
Positioning the cover on the book:
The machine has been factory set to place a perfectly squared cover, in line with the right
edge of the booklet.
The guide angular adjustment is “0”. And its RH
LH adjustment is made to get the cover aligned with the
right edge of the booklet. Do not change this except :
• if you use an unsquared cover.
• if you do not want to align the cover with the right
edge of the booklet.
1
2
3
Lateral adjustment
1
2
3
•A
djust the position of the right side guide (1) using the knob (2) to correctly align the cover to
the book.
• Lock the magnetic side guides (3) on the left against the pile of covers.
Operator Manual
Page 9 - 20
Initial issue: 09/01
Latest revision: 10/02
Squaring of the covers:
Compensation for covers not cut exactly square is provided for
1
2
2
by moving right side guide (1) askew by means of knob (2).
Before adjusting (1), verify that the rear and side are guides
unlocked to prevent bows or warps.
0
Cover picking and front cover separators:
3
4
c.p. bourg
S.A.
N. V .
OFF-LINE
5
6
7
4
MENU
8
3
9
2
ON-LINE
1
10
ENTER
1
2
5
• If the suction cups on the left extend beyond the width of the cover, you must place the
plastic studs (1) from the tool kit in the suction cups.
• According to cover material, one more plastic stud (1) may be required in the suction
cup situed in the middle of the front edge as well.
• Vacuum is continuously adjustable by pot (5).
• Adjust the position and number of the front cover separators (4) only if necessary for
optimum cover separation.
• Use knobs (2) to move the separators (4).
• Use the knob (3) to adjust the air flow.
Operator Manual
Page 9 - 21
Initial issue: 09/01
Latest revision: 10/02
• In some case, the leading edge
(1) of the cover store can be lifted by adjusting knob (2).
•M
ake sure to adjust the
suction cup support bar accordingly by loosening the screw
(3).
This keeps the cover parallel
with the tilted suction cups.
2
1
3
Operator Manual
Page 9 - 22
Initial issue: 09/01
Latest revision: 10/02
Cover clamping :
On control panel :
c.p. bourg
S.A.
N. V .
OFF-LINE
5
6
7
4
MENU
•S
elector (1) provides for the choice of its duration
(off-line mode only).
• Potentiometer (2) adjusts lateral clamping pressure.
8
3
9
2
ON-LINE
1
10
ENTER
1
2
Under cover stockplate:
• The notched handle (3), located under the cover station, adjusts pressure on book
spine.
The six positions correspond to the various thicknesses of the covers.
3
3
Operator Manual
Page 9 - 23
Initial issue: 09/01
Latest revision: 10/02
3.4 Glue
Glue drum temperature:
To select between 140° and 165°C (284°F and 329°F) using the knob (1).
For the supplied glue (National Coolbind 1300), select 140°C (284°F).
See safety data sheet (in appendix) for information about space and ventilation requirements.
Note : • If an other type of glue is used of the recommended one (National Coolbind
1300), please refer to the safety data sheet of the used glue.
• Vapours which may be formed at elevated temperature may be irritating to
eyes and respiratory tract. A local exhaust over glue tank and a good
ventilation of the room are required.
• Different fume regeneration/extraction are available following the type of
binder (see spare parts catalog).
Glue level in the tank:
The check of the glue level takes place when the drums are rotating. When the level
gets low, the minimum mark in the bottom of the tank in the glue compartment becomes
visible.*
To avoid an overflow, fill the tank with glue granules until they reach to the bottom of the
funnel (3).
When melted, they should just cover the maximum mark.
CAUTION: T
he glue amount should never be over the maximum level either below
the minimum level.
Prefer a regular filling.
* Neglecting to refill in time may result in damage to the glue tank.
Glue distribution :
Tde colle
(aiguille noir)
T de travail
(aiguille rouge)
150
T minimum
pour la rotation
des cylindres
(aiguille verte)
10
0
50
25
0
1
4
MENU
5
3
OFF-LINE
6
2
7
1
2
200
3
8
9
10
ON-LINE
ENTER
•A
glue spreader removes the excess of glue from the spine of the book, its
height is adjustable by means of a thumbwheel (2) :
• At zero, almost all the glue is removed from the spine.
• At 9, about 1 mm of glue is left on the spine.
Important: N
ever change the adjustment (2) by more than two graduations without
checking the result.
Never change the adjustment when glue is not at fusion temperature
(glue drum rotating).
Operator Manual
Page 9 - 24
Initial issue: 09/01
Latest revision: 08/06
Over temperature safety detection:
• To comply with international safety regulations, the glue tank and the drum are equipped of temperature regulation circuitry. the system stops the machine if the glue temperature exceeds 170°C either on one or on other sensors.
This system requires a working temperature below 165°C and a glue flash point higher
than 200°C.
•A
fter the system activated, the machine shut down and the binder restart could only be
done by a technician.
Note : • Please refer to the safety data sheet (in appendix) for the National Coolbind
1300.
• If an other type of glue is used of the recommended one (National Coolbind
1300), please refer to the safety data sheet of the used glue.
• Vapours which may be formed at elevated temperature may be irritating to
eyes and respiratory tract. A local exhaust over glue tank and a good
ventilation of the room are required.
• Different fume regeneration/extraction are available following the type of
binder (see spare parts catalog).
Operator Manual
Page 9 - 25
Initial issue: 09/01
Latest revision: 08/06
3.5 Binder module
•S
elect the proper pair of carriage jaw extensions and install them in the corresponding
holes in carriage the jaws.
on-line mode: Long Model (spring - loaded for the Mobile jaw).
off-line mode: shorter model (recommended).
• Load the cover station.
• Select the proper size in the second step of the menu.
• Select the side cover clamping force (1).
• Select the suction level (2).
c.p. bourg
S.A.
N. V .
OFF-LINE
5
6
7
4
MENU
8
3
9
2
ON-LINE
1
10
ENTER
1
2
• Select the spine pressure (3).
3
Operator Manual
Page 9 - 26
Initial issue: 09/01
Latest revision: 10/02
3.6 Output unit (optional)
•W
hen the booklets are delivered on the output unit, the glue is still soft and
warm. Do no take them immediately.
• Adjust the receiver spline with the thickness book by using the knob (4)
according to the size of the books, allow sufficient space.
• For your convenience there is an emergency stop (1) which you can press with
your feet.
Further to the unlocking of the switch, a push on button (2) is required to reset the process.
• The fuses (3).are resettable after tripping.
•W
hen the unit is full, the message “empty output unit” appears in the display.
Empty the BBR and press on the button (2).
1
2
3
4
4
1
2
3
Operator Manual
Page 9 - 27
Initial issue: 09/01
Latest revision: 10/02
Emergency stop
Reset switch
Resettable fuses
Spline adjustment
Binding in the on-line mode
4.1 Machine warm-up
The following illustration shows how to reach the operational state in on-line mode.
1.
+
Action
Display
Turn on master switch
The following two messages
are displayed alternately *
REMOVE PAPER FROM
B I NDER I F ANY
NB OF B I ND I NGS : 0
2.
DRUM I S HEA T I NG BU T
I S S T I L L TOO COLD
+
Turn on
the drum
heater
PRESS KEY DRUM
TO S T AR T HEAT I NG
Warm up period ( 35 min ** )
Duration
1/2 minute
RESE T
B I NDER READY I N
ON - L I NE MODE
NB OF B I ND I NGS : 0
*
**
***
no message: the start up timer is not satisfied. (if running).
10 minutes only if the tank is already warmed up by start up timer.
a warning is diplayed if on-line guides are missing.
Operator Manual
Page 9 - 28
Initial issue: 09/01
Latest revision: 10/02
***
4.2 Description of the full, automated binding process:
Display
B I NDER READY
ON - L I NE MODE
IN
Printed sheets *
are fed and
collated in the input module
One cover is fed
Sheets jogging
Notching, milling
B I ND I NG
I N PROGRE S S
Glueing
Cover Clamping
S P I NE
I S DRY I NG
Booklet dropping
* Reminder: a set has to be at least 15 sheets,
Carriage return
Operator Manual
Page 9 - 29
printed simplex and should not
exceed 350 sheets.
Initial issue: 09/01
Latest revision: 10/02
Binding in the off-line mode
5.1 Machine warm-up
The following illustration shows how to reach the operational state in off-line mode.
Display *
Action
1. • Turn on the master switch
REMOV E PAPER F ROM
B I NDER I F ANY
NB OF B I ND I NGS : 0
2. • Select off
line mode
+
3.
PRE S S KE Y DRUM
TO S T AR T HEA T I NG
OFF-LINE
ON-LINE
Warm up period
( 35 minutes **)
DRUM I S HEA T I NG BU T
I S S T I L L TOO COL D
• Turn on the drum
heater
Duration
1/2 minute
RE S E T
NB OF B I ND I NGS :
S L I D I NG P ER S P E X DOOR
I S NOT LOCKED
NB OF B I ND I NGS : 0
0
B I NDER READY I N
OF F L I NE MODE
NB OF B I ND I NGS :
4. • Press start buttons 15
*
**
no message: the start up timer is not satisfied. (if running).
10 minutes only if the tank is already warmed up by start up timer.
Operator Manual
Page 9 - 30
Initial issue: 09/01
Latest revision: 10/02
0
5.2 Set-up
• Slide the perspex loading door (A) open.
•S
elect the proper pair of carriage jaw extensions (B) and install them in the corresponding holes in carriage jaws.
Small sheet sizes do not necessarily require the presence of these guides.
• Select the cover clamping duration (1).
• Select the side clamping force (2).
• Select the suction level (3).
• Select the spine pressure (4).
• Load the cover station with covers.
• Pre-close the carriage jaws (book thickness + 2cm) (5).
2
3
5
1
5
Operator Manual
Page 9 - 31
Initial issue: 09/01
Latest revision: 10/02
4
5.3 Binding process
*A
t sliding door opening, the carriage opening is pre-adjusted to match with the thickness of
the previous book.
Pressing the green or blue buttons brings the mobile jaw closer to the fixed jaw or not.
Action
Display
• Open sliding door.
• Insert the sheets at the right end of
the open carriage (spine downwards).
• Close the sliding door.
The jogging can be interrupted by the
footswitch.
S L I D I NG P ER S P E X DOOR
I S NOT LOCKED
NB OF B I ND I NGS : 0
B I NDER READY I N
OF F L I NE MODE
NB OF B I ND I NGS : 0
• The feed of one cover and the carriage
closure are controlled by a simultaneous
push on the process start buttons.
Automatic process
• Notching, milling, glueing.
B I ND I NG
I N PROGRE S S
• Cover clamping.
S P I NE
• Booklet dropping
• Carriage return to loading
area and stand-by*.
Operator Manual
Page 9 - 32
Initial issue: 09/01
Latest revision: 10/02
I S DRY I NG
Booklet removal procedure
This label sticked on the carriage indicates how to proceed when the machine is stopped
during a cycle above the nipping station.
+
+
1.
2.
+
3.
Switch off the drum heater
OFF-LINE
Select on-line or off-line mode
ON-LINE
Switch on the drum heater
RE S E T
NB OF B I ND I NGS :
0
B I NDER READY I N
ON - L I NE MODE
NB OF B I ND I NGS : 0
Operator Manual
Page 9 - 33
Initial issue: 09/01
Latest revision: 10/02
or OFF- L I NE MODE
How to switch back from "off-line" to "on-line" mode
• Open the sliding door.
.
• Install the proper jaw extensions.
1.
2.
3.
+
+
+
Switch off the drum heater
OFF-LINE
Select on-line or off-line mode
ON-LINE
Switch on the drum heater
RE S E T
NB OF B I ND I NGS :
0
B I NDER READY I N
ON - L I NE MODE
NB OF B I ND I NGS : 0
Operator Manual
Page 9 - 34
Initial issue: 09/01
Latest revision: 10/02
or OFF- L I NE MODE
Maintenance
Filter inside
Paper
dust bag
Replacement of the paper dust collector bag:
• Replacement about every 20 hours of binding is important.
Otherwise, the dust from the paper dust could ruin the glue.
• Remove and throw the bag away.
• See the above illustration to hook a new paper dust collector bag.
• A pressure switch detects the “Replace dust bag” situation.
Note : T
he message “Replace dust bag” is displayed on the control panel.
In off-line mode, the machine will not start when this message appears.
In on-line mode, a last cycle will be allowed if problems happens during
printing.
Message and stop condition can be erased by depressing the 2 green
knobs.
Glue smell suppression is provided.
When smell neutralization decreases, it is time to replace the filters.
Call technician.
Operator Manual
Page 9 - 35
Initial issue: 09/01
Latest revision: 10/02
Preventive maintenance
Due to the advanced nature of the materials used in our binder, the preventive maintenance is reduced to the level of inspection, cleaning and occasional adjustments.
Warning: Disconnect the main power before
you perform the maintenance.
heck the ejection path and cover
C
clamp for glue particles. Clean as
required,
otherwise, the clamps may freeze
up and may blow a fuse.
Use a cloth with spirit (SOLVOID.
RAP N° 9900 107).
12
1
11
2
10
Note: S
ilicone spray can be
used to stop the glue from
sticking to the mechanism, but if
used, be very careful not to spray
into the glue tank or onto the drum.This
would ruin the glue.
Caution : The glue tank is hot. Use protection gloves to
work around it.
Operator Manual
Page 9 - 36
Initial issue: 09/01
Latest revision: 10/02
3
4
9
8
6
5
7
Mechanical trouble shooting
Symptom
Probable cause
Remedy
The cover is not square on
the paper offset(skewed).
The cover is not cut square.
The cover station and paper
pile are not square to
the machine.
Check the covers.
Check the squareness
with respect to the nippers.
The cover is too far on
the right,
The cover is too far on
the left.
There is not enough glue on
the back of the book.
The pages are warped
where the glue is applied
(spread out).
The covers suffer from
nail head.
There is poor ejection
and nipping.
The book buckles
when cover is applied.
The cover does not show
a sharp crease on
the spine.
Operator Manual
Page 9 - 37
The glue spreader is too high.
The paper is too weak for
milling.
The cover nipping is too hard.
The cover is too weak for the
paper in the nippers.
There is glue on the exit slide
and nippers.
The book is too thin for the
cover weight.
The card is heavy and the
covers varnished.
Cover cross grained.
Initial issue: 09/01
Latest revision: 10/02
Adjust the cover station stop
to the left.
Adjust the cover station
stop to the right.
Check the glue spreader.
Check the cutter.
Check the paper quality.
Check the pressure.
Check the cover material.
Remove the glue.
Select a lighter cover.
Crease the covers.
Some common glueing defects
Gaps in glue film
Check:
- Glue and roller temperature.
- Glue level in tank.
- Running temperature.
Honeycomb film
Check:
- Glue and roller temperature.
- Level of glue in tank.
- Moisture in cover or book stock.
Feather on book spine
Glue and/or roller
temperature too low.
Uneven glue line
Insufficient glue applied.
Nail head
Check:
- Cover press too tight.
- Height of back pressure.
Cavity spine
Cover press too tight.
Sharpen knife.
Cover register
Cover feed not square
with cover clamp.
Operator Manual
Page 9 - 38
Initial issue: 09/01
Latest revision: 10/02
Levers to gain access to paper path in by-pass area (possible jams)
Operator Manual
Page 9 - 39
Initial issue: 09/01
Latest revision: 10/02
Environmental compliance
Product Recycling and Disposal
ENGLISH:
Application of this symbol on your equipment is confirmation that you must dispose of this
equipment in compliance with agreed national Procedures.
In accordance with European legislation dealing with "end of life electrical and electronic equipment", equipment subject to disposal must be managed within agreed procedures.
Prior to disposal please contact your local representative for end of life take back information.
FRANÇAIS:
La présence de ce symbole sur cet équipement indique que ce dernier doit être mis au rebut
selon les conventions nationales.
Conformément à la législation européenne, tout équipement électrique et électronique en fin
de vie et destiné au rebut doit être manipulé selon les procédures convenues.
Veuillez contacter votre distributeur pour en savoir plus sur la reprise du matériel avant toute
mise au rebut.
ESPAÑOL:
La aplicación de este símbolo en el equipo es una confirmación de que en el momento de deshacerse de este equipo debe de hacerlo de acuerdo con los procedimientos nacionales acordados.
La legislación europea exige que para deshacerse de equipos eléctricos y electrónicos al final
de su duración útil deben seguirse los procedimientos acordados.
Antes de deshacerse de un equipo póngase en contacto con su distribuidor local o con el representante para obtener información sobre su devolución.
Operator Manual
Page 9 - 40
Initial issue: 09/01
Latest revision: 08/06
DEUTSCH:
Geräte die dieses Symbol tragen, müssen den nationalen Richtlinien gemäß entsorgt werden.
Den europäischen Bestimmungen zum Umgang mit elektrischen und elektronischen Altgeräten
ist Folge zu leisten.
Bei der Entsorgung des Geräts den Partner kontak-tieren.
ITALIANO:
Questo simbolo applicato sulla macchina indica la necessità di smaltire il prodotto in conformità con le normative nazionali vigenti.
La legislazione europea richiede che lo smaltimento dei dispositivi elettrici ed elettronici a fine
vita venga gestito in conformità con le normative vigenti.
Prima di smaltire il dispositivo, rivolgersi al rivenditore autorizzato di zona per informazioni sul
ritiro dei prodotti a fine vita.
NEDERLANDS:
De aanwezigheid van dit symbool op uw apparatuur geeft aan dat u zich van deze apparatuur
moet ontdoen overeenkomstig de daarvoor in het betreffende land geldende procedures.
Krachtens de Europese wetgeving moet de verwerking van afval van gebruikte elektrische en
elektronische apparatuur geschieden overeenkomstig de daarvoor geldende procedures.
Neem voordat u de apparatuur wegdoet contact op met uw plaatselijke dealer of vertegenwoordiger voor informatie over inzameling.
Operator Manual
Page 9 - 41
Initial issue: 09/01
Latest revision: 08/06
Appendix
National Coolbind 1300
Operator Manual
Page 9 - 42
Initial issue: 09/01
Latest revision: 08/06
rue des Technologies, 22
B-1340 Ottignies (Belgium)
Tel.: + 32 (0) 10 / 62 22 11
Fax: + 32 (0) 10 / 61 69 03
e-mail: [email protected]
Inc.
PARC D'AFFAIRES SILIC
32, rue des Gémeaux
BP 60410
F-94573 Rungis Cedex (France)
Tel.: 33 / 1.46873214
Fax: 33 / 1.46875217
e-mail: [email protected]
50 Samuel Barnet Bd.
New Bedford Industrial Park
Massachussets 02745 (USA)
1285 New Bedford
Tel.: 1/508.9982171
Fax: 1/508.9982391
e-mail: [email protected]
G.M.B.H.
Schweizertrasse 70 / 1
D-72336 Balingen (Deutschland)
Tel.: +49 7433 998 1680
Fax: +49 7433 998 1686
e-mail: [email protected]
rue Millewee, B.P. 85
L-7201 Walferdange (Luxembourg)
Tel.: 352 / 33 24 47
Fax: 352 / 33 19 99
e-mail: [email protected]
http: //www.cpbourg.com
Operator Manual
Page 9 - 43
Initial issue: 09/01
Latest revision: 10/02