Service Manual BB 3002 11 05 [PDF]

Zitiervorschau

SERVICE MANUAL

Initial issue: 02/04 Latest revision: 11a/05 9.133.925

Content of this documentation has a confidential nature and remains the exclusive property of C.P. Bourg SA. 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, disclosure to third party and/or reproductions as well as changes are prohibited.

Changes Page 0 - ii

Initial issue: 02/04 Latest revision: 12/04

TABLE OF CONTENTS Section 1: Introduction Section 2: Not available Section 3: Not available Section 4: Adjustment/Replacement procedures Section 5: Spare parts Section 6: General procedures Section 7: Wiring diagrams Section 8: Installation manual

Changes Page 0 - 1

Initial issue: 02/04 Latest revision: 12/04

This page is intentionally left blank.

Changes Page 0 - 2

Initial issue: 02/04 Latest revision: 12/04

LISTE DE CONTRÔLE DES RÉVISIONS

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

0-i 0-ii 0-1 0-2 0-3 0-4 0-5

11a/05 09/03 09/03 09/03 11/05 11/05 11a/05

1-i 1-ii 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8

06/05 10/03 10/03 10/03 10/03 06/05 06/05 10/03 04/05 10/03

2-i 2-ii

10/03 10/03

3-i 3-ii

10/03 10/03

4-i 4-ii 4-1

11/05 11/04 06/05

4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-27 4-28 4-29

06/05 06/05 06/05 06/05 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 04/05 04/05 11/04 11/04 11/04 11/04 11/04 08/05 08/05

4-30 4-31 4-32 4-33 4-34 4-35 4-36 4-37 4-38 4-39 4-40 4-41 4-42 4-43 4-44 4-45 4-46 4-47 4-48 4-49 4-50 4-51 4-52 4-53 4-54 4-55 4-56 4-57

11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 06/05 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04

4-58 4-59 4-60 4-61 4-62 4-63 4-64 4-65 4-66 4-67 4-68 4-69 4-70 4-71 4-72 4-73 4-74 4-75 4-76 4-77 4-78 4-79 4-80 4-81 4-82 4-83 4-84 4-85

11/04 11/04 12/04 12/04 12/04 06/05 11/04 06/05 12/04 12/04 11/04 12/04 12/04 06/05 11/04 09/05 09/05 11/04 11/04 11/04 11/04 11/04 09/05 11/04 11/04 11/04 11/04 11/04

4-86 4-87 4-88 4-89 4-90 4-91 4-92 4-93 4-94 4-95 4-96 4-97 4-98 4-99 4-100 4-101 4-102 4-103 4-104 4-105 4-106 4-107 4-108 4-109 4-110 4-111 4-112 4-113

11/04 11/04 11/04 11/04 01/05 11/04 11/04 11/04 12/04 11/04 12/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 09/05 11/04 09/05 09/05 11/04 09/05 09/05

4-114 4-115 4-116 4-117 4-118 4-119 4-120 4-121 4-122 4-123 4-124 4-125 4-126 4-127 4-128 4-129 4-130 4-131 4-132 4-133 4-134 4-135 4-136 4-137 4-138 4-139 4-140 4-141

11/04 11/04 11/04 11/04 11/04 11/04 12/04 12/04 11/04 11/04 11/04 11/04 11/04 11/04 12/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04

4-142 4-143 4-144 4-145 4-146 4-147 4-148 4-149 4-150 4-151 4-152 4-153 4-154 4-155 4-156 4-157 4-158 4-159 4-160 4-161 4-162 4-163 4-164 4-165 4-166 4-167 4-168 4-169

11/04 11/04 11/04 11/04 08/05 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/05 11/04 11/04 11/04 06/05 11/04 11/04 11/04 11/04 11/04 11/04

Modifications Page 0 - 3

Initial issue: 02/04 Latest revision: 11/05

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

4-170 4-171 4-172 4-173 4-174 4-175 4-176 4-177 4-178 4-179 4-180 4-181 4-182 4-183 4-184 4-185 4-186 4-187 4-188 4-189 4-190 4-191

11/04 11/04 11/04 12/04 12/04 12/04 12/04 11/04 12/04 12/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04

5-32 5-33 5-34 5-35 5-36 5-37 5-38 5-39 5-40 5-41 5-42 5-43 5-44 5-45 5-46 5-47 5-48 5-49 5-50 5-51 5-52 5-53 5-54 5-55 5-56 5-57 5-58 5-59

09/04 03/05 08/05 08/05 09/04 09/04 03/05 09/05 11/05 11/05 01/05 09/05 11/05 11/05 11/04 03/05 03/05 11/05 03/05 09/04 09/04 09/04 09/04 09/04 09/04 09/04 08/05 09/04

5-60 5-61 5-62 5-63 5-64 5-65 5-66 5-67 5-68 5-69 5-70 5-71 5-72 5-73 5-74 5-75 5-76 5-77 5-78 5-79 5-80 5-81 5-82 5-83 5-84 5-85 5-86 5-87

08/05 09/04 09/04 09/04 11/04 10/05 09/04 09/04 06/05 09/04 09/04 09/04 09/04 09/04 06/05 09/05 05/05 05/05 09/04 09/05 09/05 09/04 08/05 08/05 08/05 08/05 09/05 09/04

5-88 5-89 5-90 5-91 5-92 5-93 5-94 5-95 5-96 5-97 5-98 5-99 5-100 5-101 5-102 5-103 5-104 5-105 5-106 5-107 5-108 5-109 5-110 5-111 5-112 5-113 5-114 5-115

09/04 01/05 09/04 09/04 09/04 09/04 09/04 09/04 09/04 09/04 06/05 11/05 08/05 11/04 09/04 09/04 09/04 11/05 10/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05

11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 11/05 09/04 06/05 09/04 09/04 09/04

11/05 09/04 11/05 11/05 11/05

11/05 06/05 09/04 09/04 03/05 09/04 09/04 01/05 09/04 12/04 09/04 01/05 01/05 09/04 09/04 09/04 10/05 09/04 09/04 03/05 09/04 09/04 09/04 09/04 09/04 09/04 09/04 09/04

5-116 5-117 5-118 5-119 5-120 5-121 5-122 5-123 5-124 5-125 5-126 5-127 5-128 5-129 5-130 5-131 5-132 5-133 5-134 5-135 5-136 5-137

5-i 5-ii 5-1 5-2 5-3

5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 5-28 5-29 5-30 5-31

6-i 6-ii 6-1 6-2 6-3

11/05 01/04 08/05 01/04 08/05

6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 6-20 6-21 6-22 6-23 6-24 6-25 6-26 6-27 6-28 6-29 6-30 6-31

01/04 06/05 08/05 11/05 05/05 01/05 02/05 02/05 01/05 01/05 01/04 01/04 01/04 01/05 01/05 01/05 01/05 01/05 01/05 01/05 01/05 01/05 01/05 01/05 01/05 06/05 01/05 03/04

Modifications Page 0 - 4

Initial issue: 02/04 Latest revision: 11/05

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

Page

Rev.

6-32 6-33

01/04 01/04

7-i 7-ii 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23

11a/05 08/04 11/04 06/05 11/05 11/05 06/05 06/05 11/04 11/04 11/04 11/04 06/05 06/05 11/04 11/04 11/04 11/04 09/05 06/05 11/04 11/04 11/04 06/05 06/05

7-24 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-34 7-35 7-36 7-37 7-38 7-39 7-40 7-41 7-42 7-43 7-44 7-45 7-46 7-47 7-48 7-49 7-50 7-51

11/04 06/05 11/04 11/04 11/04 11/04 06/05 06/05 06/05 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 06/05 06/05 11/04 11/04 11/04 11/04 06/05 06/05 06/05 06/05

7-52 7-53 7-54 7-55 7-56 7-57 7-58 7-597-60 7-61 7-62 7-63 7-64 7-65 7-66 7-67 7-68 7-69 7-70 7-71 7-72 7-73 7-74 7-75 7-76 7-77 7-78 7-79

06/05 06/05 06/05 06/05 06/05 11/04 11/04 11/04 11/04 11/04 06/05 11/04 11/04 11/04 11/04 11/04 11/04 11/04 11/04 06/05 06/05 06/05 06/05 09/05 09/05 06/05 06/05 06/05

7-80 7-81 7-82 7-83 7-84 7-85 7-86 7-87 7-88 7-89 7-90 7-91 7-92 7-93 7-94 7-95 7-96 7-97 7-98 7-99 7-100 7-101 7-102 7-103 7-104 7-105 7-106 7-107

06/05 06/05 06/05 06/05 06/05 06/05 06/05 06/05 06/05 06/05 06/05 08/04 08/04 08/04 08/04 08/04 08/04 06/05 08/04 08/04 08/04 08/04 08/04 08/04 08/04 06/05 08/04 08/04

7-108 7-109 7-110 7-111 7-112 7-113 7-114 7-115 7-116 7-117 7-118 7-119 7-120 7-121 7-122 7-123 7-124 7-125 7-126 7-127 7-128 7-129 7-130 7-131 7-132 7-133

06/05 06/05 06/05 08/04 06/05 08/04 08/04 08/04 08/04 08/04 08/04 08/04 08/04 11a/05 08/04 06/05 06/05 06/05 06/05 06/05 06/05 06/05 06/05 03/05 08/04 08/04

09/04 12/04 03/04 03/04 03/04 03/04 06/05

06/05

01/04 06/05 01/04 03/04 01/04 03/04 06/05 06/05 03/04 03/04 10/04 03/04 09/04 03/04 03/04 10/04 10/04 03/04 10/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04

8-28 8-29 8-30 8-31 8-32 8-33 8-34

8-i

8-ii 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-9 8-10 8-11 8-12 8-13 8-14 8-15 8-16 8-17 8-18 8-19 8-20 8-21 8-22 8-23 8-24 8-25 8-26 8-27

Changes Page 0 - 5

Initial issue: 02/04 Latest revision: 11a/05

Section 2 :

STATUS INDICATOR RAPS LE B A L I VA A T O N

RAPs indication état Page 2 - 0

Initial issue: 02/04 Latest revision: 12/04

This page is intentionally left blank.

Status indicator RAPs Page 2 - ii

Initial issue: 02/04 Latest revision: 12/04

Section 3 :

QUALITY RAPS E L B A L AI V A T NO

Quality RAPs Page 3 - 0

Version initiale: 09/03 Dernière révision: 10/03

This page is intentionally left blank.

Quality RAPs Page 3 - 0

Initial issue: 02/04 Latest revision: 12/04

Section 4:

ADJUSTMENT/REPLACEMENT PROCEDURES

Adjustment/Replacement procedures Page 4 - 0

Initial issue: 06/03 Latest revision: 11/05

This page is intentionally left blank.

Adjustment/Replacement procedures Page 4 - ii

Initial issue: 06/03 Latest revision: 11/04

TABLE OF CONTENTS

Mechanical and electromechanical adjustments ........................................7 1. Carriage movement ................................................................................................................................9 1.1 Adjustment of the position of the carriage end-of-travel guides .................................................................................9 1.2 Adjusting the theoretical position of the Jogger-side switch (36S01p) ......................................................................11 1.3 Adjustment of the drive-belt tension ...........................................................................................................................12 1.4 Technical features ......................................................................................................................................................13 1.5 Alignment of the fitment of the rotary encoder ...........................................................................................................14

2. Jogger module ........................................................................................................................................15 2.1 Adjustment of the jogger plate position ......................................................................................................................15 2.2 Positioning of “jogger plate height” flag .....................................................................................................................16 2.3 Adjustment of the drive-belt tension ...........................................................................................................................17 2.4 Adjustment of the Jogger plate position .....................................................................................................................18

3. Carriage ...................................................................................................................................................21 3.1 Adjustment of mobile carriage jaw .............................................................................................................................21 3.2 Adjustment of the position of the “bundle thickness measurement” magnetic sensor (33B04p) ...............................23 3.3 Mounting the carriage on the beam ...........................................................................................................................24

4. Milling .......................................................................................................................................................25 4.1 Adjusting the height of the milling blade ....................................................................................................................25 4.2 Adjustment of the counter-cut ....................................................................................................................................28 4.3 Adjustment of the height of the notching tools ...........................................................................................................31 4.4 Adjustment of the milling panel ..................................................................................................................................33 4.5 Adjustment of air-gap in the milling motor brake ......................................................................................................35 4.6 Adjustment of the notching tool indexation ................................................................................................................38 4.7 Replacement of the milling blade ...............................................................................................................................40 4.9 Pressure sensor adjustment ......................................................................................................................................42

5. Glue tank .................................................................................................................................................45 Adjustment/Replacement procedures Page 4 - 1

Initial issue: 06/03 Latest revision: 06/05

5.1 Gluing cylinder height .................................................................................................................................................45 5.2 Calibration of the SPINNER height ............................................................................................................................48 5.3 Adjustment of the spinner scraper .............................................................................................................................50 5.4 Fitment of cylinder temperature sensors ....................................................................................................................51 5.5 Draining the glue tank ................................................................................................................................................52 5.6 Adjustment of pre-scrapers ........................................................................................................................................54 5.7 Adjustment of gluing cylinder glue cut-off scrapers ...................................................................................................55 5.8 Lateral glue wire .........................................................................................................................................................59 5.9 Mounting of glue level sensors ..................................................................................................................................60 5.10 Adjustment of the position of the sensor for measuring the length of the book being glued ...................................64

6. Lateral gluing ..........................................................................................................................................65 6.1 Adjusting the fixed cylinder position of the lateral gluing ...........................................................................................65 6.2 Synchronization of the lateral glue cut-off on the gluing cylinders ...........................................................................66 6.3 Adjustment of glue supply for lateral gluing ...............................................................................................................69 6.4 Separation of lateral gluing cylinders .........................................................................................................................70 6.5 Adjusting the home sensor 48B09i position of the lateral gluing. ..............................................................................71

7. Cover clamp ............................................................................................................................................72 7.1 Adjustment of cover clamp position relative to the position of the carriage and to the milling blade ........................72

8. Cover clamps ..........................................................................................................................................81 8.1 Adjustment 8.2 Adjustment 8.3 Adjustment 8.4 Adjustment 8.5 Adjustment

of the end of travel flag for closure of the cover clamp ...........................................................................81 pre-positioning flag for the cover clamp ..................................................................................................82 of the cover clamp gripping “home” flag .................................................................................................83 of cover clamp parallel alignment ...........................................................................................................84 of height of cover clamp relative to the non-stick plate ...........................................................................86

9. Cover clamp and output guide lift ........................................................................................................87 9.1 Adjustment of the cover clamp lift “HOME” position ..................................................................................................87 9.2 Adjustment of the various heights of the cover clamp lift ..........................................................................................89 9.3 Checking the “Home” and “Cover clamp height” flags ...............................................................................................90 9.4 Adjustment cover clamp lift guide ..............................................................................................................................92 9.5 Adjustment of the “Home” position of the outlet guide ...............................................................................................93

Adjustment/Replacement procedures Page 4 - 2

Initial issue: 06/03 Latest revision: 06/05

10. Cover transport clamps .......................................................................................................................94 10.1 Adjustment of opening of clamps .............................................................................................................................94 10.2 Mounting the cover transport clamp guide shafts ....................................................................................................95 10.3 Adjustment of the position of the “paper present in the cover transport clamp” sensor ..........................................96 10.4 Mounting the chain guide rail ..................................................................................................................................98

11. Cover Creasing .....................................................................................................................................99 11.1 Adjustment of the punch matrix assembly ................................................................................................................99 11.2 Adjustment of the position of the creasing module relative to the cover clamp module ..........................................106 11.3 Procedure for removal of the creasing module ........................................................................................................110 11.4 Adjustment of the cover support roller lift .................................................................................................................111

12. Cover station .........................................................................................................................................112 12.1 Adjusting the position of the cover station ...............................................................................................................112 12.2 Adjustment of the cover station register guide .........................................................................................................118 12.3 Adjustment the prefeed trajectory ............................................................................................................................120 12.4 Cover picking and separators ..................................................................................................................................122 12.5 Cover station removal ..............................................................................................................................................124 12.6 Cover station safety plate ........................................................................................................................................126

13. Pre-feed ..................................................................................................................................................127 13.1 Adjustment of the chain guide .................................................................................................................................127 13.2 Adjustment of the turbine suction level ....................................................................................................................128 13.3 Adjustment of the suction bar safety switch .............................................................................................................129

14. Adjustment procedures : BBR ............................................................................................................130 14.1 Adjustment of the BBR stacking head positioning flags ..........................................................................................130 14.2 Adjustment of the BBR head vertical position switch 72S03s .................................................................................133 14.3 Adjusting the BBR book separator harrow end of travels : bottom dead centre position 72S02s ...........................134 14.4 Adjusting the BBR book separator harrow end of travel : top dead centre position 72B06i ....................................135

15. Summary : Alignment of the various modules on the BB3002 chassis ........................................136

Adjustment/Replacement procedures Page 4 - 3

Initial issue: 06/03 Latest revision: 06/05

Preventative and Corrective Maintenance via the U.I. ................................137 1. Introduction .............................................................................................................................................139 2. Technician menu : Header window .......................................................................................................140 2.1 Setting the time and date ...........................................................................................................................................140 2.2 Opening - closing of the cover clamp ........................................................................................................................141 2.3 Re-initialisation of the graphical interface, the PLC and communication between them ...........................................141 2.4 Thickness value of the last booklet bound .................................................................................................................142 2.5 Accessing the advanced menu ..................................................................................................................................143 2.6 The Structure of the Technician Menu .......................................................................................................................144 2.6.1 Accessing the header page of the technician menu : ................................................................................144 2.6.2 Accessing the technician menu’s advanced menu : ..................................................................................144 2.6.3 Password entry : .........................................................................................................................................144 2.6.4 Entering the advanced technician menu : ..................................................................................................144

3. Advanced Menu of the Technician Menu .............................................................................................145 3.1 Advanced Menu : “STATUS” ......................................................................................................................................146 3.1.1 Covers : ......................................................................................................................................................147 3.1.2 Carriage : ....................................................................................................................................................148 3.1.3 Jogger module : ..........................................................................................................................................149 3.1.4 Milling module : ..........................................................................................................................................150 3.1.5 Glue Tank : .................................................................................................................................................151 3.1.6 Carriage Movement : ..................................................................................................................................153 3.1.7 Cover clamp : .............................................................................................................................................154 3.1.8 Cover picking : ............................................................................................................................................155 3.1.9 Scoring : .....................................................................................................................................................156 3.1.10 Cover Transport : ......................................................................................................................................157 3.1.11 Outlet and conveyor : ...............................................................................................................................158 3.1.12 BBR : ........................................................................................................................................................159 3.2 Advanced Menu : “CALIBRATIONS” ..........................................................................................................................160 3.2.1 Setting the gluing temperature : .................................................................................................................161 3.2.2 Calibration of the SPINNER height : ..........................................................................................................162

Adjustment/Replacement procedures Page 4 - 4

Initial issue: 06/03 Latest revision: 06/05

3.2.3 Calibration of glue cut-offs : .......................................................................................................................165 3.2.4 Calibration of the creasing position : ..........................................................................................................175 3.2.5 Calibration of the Jogging vibration frequency : .........................................................................................177 3.2.6 Calibration of carriage braking : .................................................................................................................178 3.2.7 Parameterisation of the touch-screen : ......................................................................................................179 3.3 Advanced Menu : “VARIOUS” ....................................................................................................................................180 3.3.1 Endurance test : .........................................................................................................................................181 3.3.2 Define parameters of the AUTOMATIC menu: ...........................................................................................182 3.3.3 Selection of optional items : .......................................................................................................................186 3.3.4 Binder counter : ..........................................................................................................................................187 3.3.5 Connections : .............................................................................................................................................188

Adjustment/Replacement procedures Page 4 - 5

Initial issue: 06/03 Latest revision: 06/05

This page is intentionally left blank.

Adjustment/Replacement procedures Page 4 - 6

Initial issue: 06/03 Latest revision: 11/04

Mechanical and electromechanical adjustments

Adjustment/Replacement procedures Page 4 - 7

Initial issue: 06/03 Latest revision: 11/04

This page is intentionally left blank.

Adjustment/Replacement procedures Page 4 - 8

Initial issue: 06/03 Latest revision: 11/04

1. CARRIAGE MOVEMENT 1.1 Adjustment of the position of the carriage end-oftravel guides

2

Purpose : The purpose of this procedure is to adjust the position of the carriage end-of-travel guides in order to determine : - The position of the carriage when it is located at the loading area. - The position of the carriage when this is located over the cover clamp module. Prerequisites : Open the top panel. Remove the rear panels from the machine. Connect the technician control box to release the brake on the movement motor.

Fig.1

2 REAR VIEW Detail A

Procedure : 1. Position of the “carriage movement” Jogger-side guide : see Fig.1. • Place a bundle of paper (1) in the carriage clamp against the “jogger guide” (4).

1

4 1

• Adjust the position of the carriage movement guide (2) so that the paper is entirely on the jogger plate (3) + (3 mm) when the carriage is against the “carriage movement” guide (2) (see detail A).

3

3 mm

3 mm

REAR VIEW Adjustment/Replacement procedures Page 4 - 9

Initial issue: 06/03 Latest revision: 11/04

3

2. Position of the “Cover clamp side” guide : see Fig. 2. Adjust the position of the guide as shown in Fig. 2. 3. Return the binder to normal operating conditions. Notes : If the carriage is brought to a stop too violently against the end-of-travel guide, than the motor braking settings must be altered - see Technician Menu “calibration”.

1

1

144mm+/-1

Fig.2

Adjustment/Replacement procedures Page 4 - 10

Initial issue: 06/03 Latest revision: 11/04

1.2 Adjusting the theoretical position of the Joggerside switch (36S01p) Purpose : This switch sends a signal to the automatic control system to indicate that the carriage is in the loading position.

3. Then adjust the support position (2). The switch should operate 10 mm before the carriage reaches the guide. 4. Return the binder to normal operating conditions.

Prerequisite : • Adjust the position of the carriage movement end-of-travel guide. • Open the top panel. • Remove the rear panels from the machine. • Connect the technician control box in order to release the brake on the movement motor. Procedure : 1. Move the carriage so that it is above the loading area. 2. Move the square (1) towards the switch (2) until the switch is heard to operate, move the forward a further 1 mm and fix it in position (Fig.2 & 3). Fig.2

Warning : The switch must not be depressed fully. 1 10 mm

2 Clic

2

93mm+/-1

Adjustment/Replacement procedures Page 4 - 11

Fig.1 Initial issue: 06/03 Latest revision: 11/04

1

+ 1mm

Fig.3

1.3 Adjustment of the drive-belt tension Purpose : The carriage drive belt must be under sufficient tension to ensure that correct positioning of the carriage is obtained. Prerequisites : Initialise the binder; the carriage must be above the jogger module. Open the top panel. Remove the rear panels from the machine.

Procedure : • Tighten the drive belt tensioner bolts (1). • Loosen the three pulley support bolts (2). • Loosen the three lock-nuts (4) and adjust the drive belt using the bolts (3). The drive belt should be tensioned to a value of 475N. To check that the tension is correct, the external gap between the two sides of the drive belt should be 24 mm ± 3 mm when a mass of 5 kg is placed in the middle of the drive belt. • Then tighten the lock-nuts (4) so that the adjustment is set.

24mm

• Return the binder to normal operating conditions.

5 kg

24mm+/-3mm

Fig.1

4

3

1 2

Fig.2

Adjustment/Replacement procedures Page 4 - 12

Initial issue: 06/03 Latest revision: 11/04

1.4 Technical features Purpose : The movement motor brake is used to stop the carriage rapidly when the interlock circuit is opened. Prerequisites : • Initialise the binder - the carriage must be above the jogger module.

Braking torque adjustment. Braking torque is proportional to compression of springs 22; such compression can be varied by acting on nuts 23 (loosen to decrease, tighten to increase). Compression of the three springs must be uniform. Bracking torque : 4Nm. 25

22

23

19 +/- 10.5mm

• Open the top panel. • Remove the rear panels from the machine. • Remove the movement motor panel (1). Procedure : Magnetic gap adjustment. Magnetic gap 40 (i.e. the distance between the two magnetic cores of the electromagnet and of the mobile anchor) must be 3/10th of a millimeter. Magnetic gap should be periodically checked (every 100000 books) since, as the brake disk gaskets wear out, it tends to increase. It order to re-adjust magnetic gap to the required value turn the couples of nuts (19-23) fixing the electromagnet, to advance the latter toward the mobile anchor. Once magnetic gap has been adjusted check that nuts have been correctly tightened.

Adjustment/Replacement procedures Page 4 - 13

Initial issue: 06/03 Latest revision: 11/04

0.3mm

40

2

1

1.5 Alignment of the fitment of the rotary encoder Purpose : The rotary encoder must be aligned with the pulley shaft to avoid damaging the encoder and/or the coupling. Preliminaries : Remove the rear panels from the machine. Procedure : • Fix the coupling sleeve (1) to the pulley shaft (5). • Fix the encoder (2) to its support (3). • Fix the coupling sleeve (1) to the encoder shaft (2). • Fix the support (3) using bolts (4) so that the encoder shaft is aligned with the pulley shaft. • Move the carriage manually and check that the alignment between the encoder and pulley is correct. • Return the binder to normal operating conditions. 5 1 3 2 Fig.1

4

Adjustment/Replacement procedures Page 4 - 14

Initial issue: 06/03 Latest revision: 11/04

2. JOGGER MODULE 2.1 Adjustment of the jogger plate position

Procedure : • Using the locking bolts (3), lock the electromagnetic core (1) of the jogger as high up as possible, at the end of the slots.

Purpose : The air-gap between the core and the vibrating plate of the electromagnet should be 0.4 mm in order to ensure correct operation of the jogger electromagnet.

• Using the locking bolts (4), adjust the height of the plate (2) relative to the core. The air-gap between the core and the electromagnet vibrating plate should be 0.4 mm.

Preliminaries : • The interlock must be open or there must be no power supply to the machine.

• Re-connect the MNL connector.

• Disconnect the MNL connector from the jogger.

• Return the binder to normal operating conditions.

2 0.4mm

2

+0.1 +0

0.4mm

1 1

Adjustment/Replacement procedures Page 4 - 15

4

3

Initial issue: 06/03 Latest revision: 11/04

3

+0.1 +0

4

2.2 Positioning of “jogger plate height” flag • Loosen the pressure bolts on the notched pulley (2). Purpose : The “Jogger Home” flag determines the lowest point of the jogger plate.

• Turn the notched pulley (2) to align the right edge of the flag with the edge of the sensor (when the roller is against the cam guide).

Prerequisites : • Remove the rear panels from the machine, plus the right lateral panel.

• Then tighten the pressure bolts on the notched pulley (2). • Return the binder to normal operating conditions.

• Press the emergency stop button to prevent power reaching the jogger lift motor.

LEFT SIDE VIEW

Procedure : • Manually turn the jogger plate lift shaft until the roller is against the cam guide (1).

4

When the roller (4) is on the guide, align the right edge of the flag (5) with the sensor (3).

1

4 1

5 4

2

5 3

2

Fig.2

1 3

Adjustment/Replacement procedures Page 4 - 16

3

Fig.1 Initial issue: 06/03 Latest revision: 11/04

2.3 Adjustment of the drive-belt tension Purpose : This procedure determines the drive belt tension to be applied to lift the jogger plate.

• Check the drive belt tension by holding it between the thumb and index finger and exerting torsion on it. The drive belt should pivot through 90° over a distance of 100 mm (Fig.2). • Return the binder to normal operating conditions.

Prerequisites : Remove the rear panels from the machine. Procedure : • Loosen the bolts (1) on the motor support (2) (Fig.1).

+/-100mm(4 in.)

• Move the motor support so as to adjust the pulley tension.

1

2

100mm(4 in.)

Fig.2 Fig.1

Adjustment/Replacement procedures Page 4 - 17

Initial issue: 06/03 Latest revision: 11/04

2.4 Adjustment of the Jogger plate position Purpose : When at its highest possible position, the jogger plate should be at the same height as the top tooth on the milling blade. The jogger plate must also be square to the carriage jaw.

• Raise the jogger plate by reducing the milling depth to zero. Warning : The teeth on the milling blade are very sharp.

Prerequisites : • Open the front panel. • Remove the rear panels and the left lateral cover. • Connect the technician control box in order to : - Release the milling blade and movement motor brakes. - By-pass the interlock. Procedure : • In the technician menu’s “STATUS” menu, select the “JOGGER” module.

set to 0

Adjustment/Replacement procedures Page 4 - 18

Initial issue: 06/03 Latest revision: 11/04

The jogger module is fitted to the binder chassis using 3 threaded rods (1). Use these three threaded rods to adjust : • The horizontal position of the jogger plate relative to the carriage. • The height of the jogger plate relative to the top tooth of the milling blade. • The straightness of the jogger plate relative to the carriage jaw.

Pre-adjustment of the jogger plate lateral position : • Place the aquare (ref CPB 9941021000) underneath the jaw on the carriage clamps (as shown in Fig.2). • Adjust the position of the jogger plate using the three threaded rods (1) (Fig.1) so that the shoulder of the jogger plate is set back 1.5 mm in relation to the jaw on the carriage clamps. Pre-adjustment of the jogger plate height : • Place the square (ref CPB 9941021000) underneath the jaw on the carriage clamp (Fig. 2). • Adjust the position of the jogger plate using the three threaded rods (1) (Fig.1) so that the height of the jogger plate is 10 mm below that of the jaw on the carriage clamp.

1

Fig.1

10+/-1mm 10+/-1mm

1 Pre-adjustment of the jogger plate position : This procedure is used to obtain an approximate setting of the jogger plate quickly.

1.5 mm

1.5 mm Fig.2

Adjustment/Replacement procedures Page 4 - 19

Initial issue: 06/03 Latest revision: 11/04

Pre-adjustment of the straightness of the jogger plate : • Place the square (ref CPB 99941021000) as shown in Fig. 3. • Adjust the position of the jogger plate using the three threaded rods (1) (Fig.1) in order to adjust the straightness of the jogger plate relative to the jaw on the carriage clamps. Precise adjustment of the jogger plate position : This procedure is used to achieve a precise setting of the position of the jogger plate. • Mount two comparators in the carriage clamps as shown in (Fig.1).

• Move the carriage towards the loading zone and measure the height of the jogger plate. • The jogger module is fitted to the chassis using 3 threaded rods (Fig.1). Use these three threaded rods to adjust: - The height of the jogger plate. This must be at the same height as the top tooth on the milling blade (0 mm tolerance: +0 / +0.05 mm). - Straightness of the jogger plate relative to the carriage jaw. Use the square (ref CPB 99941021000) to ensure a square alignment. - The horizontal position of the jogger plate. There must be a distance of 1.5 mm between the rear shoulder of the jogger plate and the fixed jaw in the carriage clamps. • Return the binder to normal operating conditions.

1

Fig.1 1

10+/-1mm

• Manually turn the milling blade so that the top tooth (marked during manufacture) is to the left, on the jogger side. • Zero the two comparators on the top tooth of the milling blade.

Adjustment/Replacement procedures Page 4 - 20

10+/-1mm

1.5 mm

1.5 mm

Initial issue: 06/03 Latest revision: 11/04

Fig.2

Fig.3

3. CARRIAGE 3.1 Adjustment of mobile carriage jaw Fig.1

16 Belleville washers are placed on each of the 4 fixing bolts between the grip and the jaw. As a result of the elasticity they posses, a uniform pressure is applied along the entire length of the book. It is essential that each washer be fitted in the correct orientation (Fig.1). The fact that the jaws are not parallel improves the grip on large formats, especially during milling operations.

Procedure #1: • Using the four bolts (4), adjust the deformation of the Belleville washers so that a gap of 2.7+/-0.2 mm is obtained between the grips (2) and the mobile jaw (3) of the clamp. • Close the clamps manually.

Adjustment/Replacement procedures Page 4 - 21

1

Fig.2 2.7mm+/-0.2mm

Prerequisites : • Open the top panel. • Connect the technician control box in order to release the brake on the movement motor. • Manually move the carriage over the glue tank to improve accessibility. • Disconnect the connector (1) from the jaw closure motor.

TOP VIEW

Initial issue: 06/03 Latest revision: 04/05

2.7mm+/-0.2mm

Purpose : • This adjustment will ensure that the paper bundle is gripped correctly when it is being bound.

2

4

3 4

4

• The two jaws of the clamp should not appear to be parallel. On the right hand side of the clamp there should be a distance of 2 mm ± 0.3 mm between the grips of the fixed jaw and the grips of the mobile jaw (Fig.3). If not proceed to procedure #2. Note : It is important that they are not parallel, so that a good grip of the paper can be achieved. If they are not within tolerance, the position of the grips must be corrected (2).

• Move manually the carriage over the cover clamp module. • Loosen the screws (5). • Place a gange of 2 mm between the two jaws of the clamp on the right side and close the clamps. • The jaws have to be in contact on the left side and in contact with the gange on the right side. • Keep the clamp closed and tighten the screws (5). • Reconnect the motor, close the panel and re-initialise the binder.

• Reconnect the motor, close the panel and re-initialise the binder.

2mm+/-0.3mm

0mm

1

5 5

Fig.3 Procedure #2: To obtain the 2 mm ± 0.3 mm: • The main switch should be ON. The technician box: by pass on 1 break on 1.

Adjustment/Replacement procedures Page 4 - 22

5 5

Initial issue: 06/03 Latest revision: 04/05

Fig.4

Paper path direction

3.2 Adjustment of the position of the “bundle thickness measurement” magnetic sensor (33B04p) Purpose : A linear encoder is fitted to the carriage. This is used to measure the thickness of the bundle of paper in the carriage jaw. Prerequisites : • Open the top panel. • Connect the technician control box in order to release the brake on the movement motor. • Manually move the carriage over the glue tank to improve accessibility. • If necessary, remove the rear panels from the machine.

Insert 5 sheets of 80 gsm +0.5 +/- 2mm

Fig.1 Magnetic tape Insert 5 sheets of 80 gsm

There is a high pressure in the sensor. -> It means that electrical contact is closed. Prerequisite : • Check that the flexible tube is properly connected on the ‘HIGH’ entry of the pressure sensor.

Adjustment/Replacement procedures Page 4 - 42

• Remove the waste bin with the bag (1) (Fig.1). • Ensure that the extraction waste tube is clear from paper dust. • Install the perforated jig (2) on the extraction tube not of the waste bin. • Run the motors 42M01p and 45M01p by pressing the key • Unplug the “faston” terminals (3) (Fig.2) from the pressure sensor and plug a multimeter instead. Set the multimeter on ohmmeter and sound signal.

Initial issue: 06/03 Latest revision: 11/04

Then proceed to the pressure sensor adjustment: - Obstruct 1 or 2 holes of the jig (2) by hand. Turn the adjustment screw in order to close the contact (sound signal from the ohmmeter). On the milling status screen, the signal 45S01p should be illuminated . - Remove your(s) finger(s) from the jig. The contact should be open (no sound signal). On the milling status screen, the signal 45S01p should be OFF Turn the adjustment screw if necessary to obtain these results.

Note: Turn the sensor adjustment screw CW in order to close the contact earlier. • Remove the jig, install the waste bin, connect the pressure sensor and restore the binder to operating conditions.

.

3

2

1

Fig.1

Adjustment/Replacement procedures Page 4 - 43

Initial issue: 06/03 Latest revision: 11/04

Fig.2

4.9.2 Milling exhaust vent obstructed Purpose: The pressure sensor (42S01p) detects if the milling exhaust vent is obstructed by paper dust. In this case a message is sent to the touch screen to warn the operator. Caution: DO NOT BLOW OR SUCK INTO THE SENSOR. RISK TO DAMAGE THE SENSOR. 1. Unplug the flexible tube from the sensor. 2. Put 14 mm of water in the tube. For that purpose, immerse the tube in the water, then adjust the amount of water by releasing the surplus. 3. Position the water in the middle of the tube. 4. Plug the tube on the sensor (on adjustment screw side). Attention: Only one part of water should be inside the tube (see illustration). Unplug the “faston” terminal from the pressure sensor and connect the multimeter.

7. Go to the technician menu/milling module status (if you do not used a multimeter). 8. Turn the adjustment screw in order to close the contact (sound signal from the ohmmeter). On the milling status screen the signal 42S01p should be illuminated . Turn the adjustment screw in order to open the contact (sound signal). On the milling statusscreen, the signal 42S01p should be OFF . 9. Remove the flexible tube from the sensor and remove the water. 10. Reinstall the tube on the sensor and milling blade housing. 11. check the adjustment: Run the milling motor, the signal 42s01p should be illuminated (green)

Stop the milling motor, the signal 42s01p should be OFF (gray)

Screw adjustment

14 mm

5. Set the multimeter on ohmmeter and sound-signal. 6. The tube should be suspended from the sensor with the water in the vertical part.

Adjustment/Replacement procedures Page 4 - 44

.

Initial issue: 06/03 Latest revision: 06/05

.

5. GLUE TANK 5.1 Gluing cylinder height Purpose : The height of the gluing cylinders must be adjusted precisely so that they correctly deposit the film of glue on the spine of the book. The first cylinder is very close to the spine of the book. The glue must penetrate inside the notching notches. The second cylinder applies a larger quantity of glue onto the spine of the book.

Procedure : 1. Remove the jogger plate : In the technician menu’s “STATUS” menu, select the “JOGGER” module and reduce the height of the milling to 0 mm.

Notes : These settings specify the use of NATIONAL COOLBIND 1300 glue (ref. CPB : 9195035). Prerequisites : • The jogger plate should be adjusted relative to the milling blade. • The binder must be ready: Green indicator lit (glue up to temperature, cylinders rotating). • Open the top panel. • Connect the technician control box in order to bypass the interlock.

Adjustment/Replacement procedures Page 4 - 45

Initial issue: 06/03 Latest revision: 11/04

set to 0

2. Place 2 comparators in the carriage clamps. 3. Zero the two comparators on the top tooth of the milling blade (marked during manufacture).

4. Move the carriage over the glue tank and measure the distance between the gluing cylinders and the top tooth of the milling blade. - The distance between cylinder 1 and the top tooth of the milling blade should be 0.15 mm ± 0.05 mm (when the tank is hot). - The distance between cylinder 2 and the top tooth of the milling blade should be 1.8 mm ± 0.1 mm (when the tank is hot). Height of the gluing cylinders relative to the spine of the book

1

-0.15 mm

-1.8mm

cylinder 1

cylinder 2

Fig.1

1

Fig.2

Adjustment/Replacement procedures Page 4 - 46

Initial issue: 06/03 Latest revision: 11/04

5. To adjust the height of the cylinders : - Slacken off bolts (2) (Fig.3). - Loosen the nuts (3). - Using a size 19 open ended spanner adjust the height of the tank using the nut (4). • Unscrew nut (4) to raise the tank (Fig.4). • Tighten nut (4) to lower the tank (Fig.5).

6. Also adjust the straightness of the cylinders relative to the fixed grips of the carriage using bolt 2. Re-start at (4) if necessary. ATTENTION: Each component has been fitted and adjusted on the chassis during manufacture. There is no need to alter the adjustment of the threaded rods locked using a spot of colour. If the quality of books produced should start to fall, attempts should be made to resolve the problem without altering the adjustment of the various assemblies on the chassis. The fitment and alignment of the assemblies on the chassis must be adjusted by qualified personnel using suitable tools (micrometers, comparators, stands etc.).

3 4 1

3 4

1

Fig.3 2

7. When the height and square alignment of the cylinders is correct, return the binder to normal operating conditions.

4 Fig.4

Adjustment/Replacement procedures Page 4 - 47

4 Fig.5

Initial issue: 06/03 Latest revision: 11/04

5.2 Calibration of the SPINNER height Purpose : The spinner is the component that determines the thickness of the film of glue left on the spine of the book. It is simply a small cylinder which rotates in the opposite direction to the movement of the paper process. The spinner is fully scraped.

Procedure : • Enter the “GLUE TANK SPINNER” menu of the technician menu.

The spinner is mounted on the chassis. Changing the height of the cylinders and therefore of the tank has no effect on the height adjustment of the spinner. Prerequisites : • The jogger plate should be adjusted relative to the milling blade - see “Adjustment of the position of the Jogger plate “. • The binder must be ready: Green indicator lit (glue up to temperature, cylinders rotating).

The following window will then appear on the screen.

• Connect the technician control box to bypass the interlock and to release the milling blade and movement motor brakes. • Open the top panel.

Adjustment/Replacement procedures Page 4 - 48

Initial issue: 06/03 Latest revision: 11/04

Pre-adjustment of the spinner height. • Place a comparator in the carriage clamp. • Move the carriage over the milling blade and zero the comparator on the top tooth of the milling blade (on the jogger side). • Then move the carriage over the glue tank and using the comparator measure the height distance between the spinner cylinder and the top tooth of the milling blade. • Carry out a mechanical pre-adjustment of the height of the spinner using cams (1) and (2). Adjust the spinner height to 0 mm +/- 1 mm relative to the top tooth of the milling blade. Adjusting the square alignment of the spinner. • Leave the comparator in the carriage clamp and move the carriage slightly towards the cover clamp module. Cam 1

• Then adjust the straightness of the spinner relative to the grips of the fixed clamp on the carriage. - Place the square (Ref. CPB 9941021000) on the cylinder of the spinner. - Turn the cam (2) to adjust the straightness of the cylinder relative to the fixed grips of the clamp on the carriage. Adjusting the height of the spinner. The height of the spinner can be adjusted very precisely using the spinner calibration menu. • Using the comparator (zeroed on the top tooth of the milling blade) measure the spinner height. • Using the or arrows, adjust the height of the spinner so that its cylinder is 0 mm (+0 / +0.05) lower than the top tooth of the milling blade. • Return the binder to normal operating conditions.

Cam 2

Adjustment/Replacement procedures Page 4 - 49

Initial issue: 06/03 Latest revision: 11/04

5.3 Adjustment of the spinner scraper Purpose : The scraper removes glue from the spinner cylinder. Preliminaries : • The glue must be hot and the emergency stop button engaged.

3 1

Procedure : • By slackening bolts (1), move scraper (2) so that it is 0.1 mm ± 0.05 mm from the cylinder (3). • Re-tighten the bolts (1). • Return the binder to normal operating conditions.

Fig.1

Adjustment/Replacement procedures Page 4 - 50

Initial issue: 06/03 Latest revision: 11/04

2

5.4 Fitment of cylinder temperature sensors Purpose : The temperature sensors at cylinders 1 and 2 must be fitted correctly in order that they can measure the glue temperature. Prerequisites : • Open the top panel.

3

2

1

2

3

4

• Connect the technician control box in order to bypass the interlock.

1

• The binder must be ready : Green indicator lit (glue up to temperature, cylinders rotating).

4

Procedure : • Slacken off bolts (2) (Fig.2) and move probe (1); this must emerge 30 mm from its support (see Fig.2). • Re-tighten the bolt (2). • Slacken off the bolt (4) (Fig.3) and move the sensor support (3). The distance between the sensor and the cylinder must be 0.1 mm (when the glue is hot).

Fig.1 30mm

3

• Re-tighten the bolt (4).

0.1mm

WARNING: The sensor must never touch the cylinder (this could activate the safety system of the “GLUETANK” card).

1

4

2

• Once the correct adjustment has been set, return the binder to normal operating conditions. Fig.2

Adjustment/Replacement procedures Page 4 - 51

Initial issue: 06/03 Latest revision: 11/04

Fig.3

5.5 Draining the glue tank Purpose : When the glue starts to oxidise the contents of the tank must be replaced. There is a drainage valve under the tank for this purpose. Prerequisites : • The glue must be up to temperature (+/- 145°C) and the cylinders must be rotating. • First empty the tank, and then refill it. 1

Procedure - DRAINING : • Raise the top panel and open the door on the front. At this point, the cylinders will stop rotating !!! • Place an aluminium container beneath the tank valve (CPB ref.: 9 199 883). • Open the valve fully using the spanner provided for this purpose (CPB ref.: 9 403 843). The glue will then flow into the container. • If the glue does not flow freely, use a fine rod to unblock the valve. • When the tank is almost empty, add a few glue granules to the tank to drain the rest of the used glue. • When the tank is empty, close the drain valve and refill the tank with fresh glue.

Adjustment/Replacement procedures Page 4 - 52

Initial issue: 06/03 Latest revision: 11/04

WARNING : To avoid any possibility of receiving burns, wait until the aluminium container has cooled down completely before handling it.

Procedure - FILLING : • Close the valve using the spanner provided for this purpose (CPB ref.: 9 403 843). • Fill the tank with National Coolbind 1300 glue (CPB ref 9 195 035). Warning : Once the glue has completely melted, the level must still be between the maximum and minimum levels. • When the glue level is correct and the glue has totally melted, close the top panel and restart the binder by pressing the green button on the loading console.

Max level Min level

• The green indicator will light up as soon as the glue has reached the gluing temperature. The binder is then ready for use.

Notes: The minimum and maximum levels are indicated by notches on the pre-scrapers inside the tank.

Adjustment/Replacement procedures Page 4 - 53

Initial issue: 06/03 Latest revision: 11/04

5.6 Adjustment of pre-scrapers Purpose : Each cylinder is fitted with a scraper used to control the thickness of glue left on the cylinder. Scrapers are preceded by pre-scrapers which limit the amount of glue pumped by the cylinder.

scraper scraper pin

Prerequisites : • The glue tank must be hot. • Scrapers (5) and (6) must be removed to allow better access (Fig.2). pre-scraper

Procedure : • Open the top panel.

Fig.1

• On cylinder N°1 : - Slacken off the bolts (1) and adjust the position of the pre-scraper so that a distance of 1.5 mm is left between the cylinder and the pre-scraper. It must be parallel to the cylinder.

pre-scraper 2

pre-scraper 1 1.5mm

• On cylinder N°2 : - Slacken off the bolts (3) and adjust the position of the pre-scraper so that a distance of 7.5 mm is left between the cylinder and the pre-scraper. It must be parallel to the cylinder.

6

5

7.5mm 1

3

cylinder 1

2

cylinder 2

4

• Return the binder to normal operating conditions.

Fig.2

Adjustment/Replacement procedures Page 4 - 54

Initial issue: 06/03 Latest revision: 11/04

5.7 Adjustment of gluing cylinder glue cut-off scrapers Purpose : Glue cut-off is used to stop application of the film of glue onto the spine of the booklet. Glue cut-off may be carried out at both the front and rear of the booklet. A scraper fitted to the gluing cylinder is used to shut off application of glue onto the spine of the booklet.

Booklet

Rear cutoff

Fig.1

Front cut off

The scraper and electromagnet which actuates it require precise adjustment in order to ensure that glue is cut-off at the right point. Prerequisites : • Open the upper panel and the door in the front face. • Connect the technician control box in order to bypass the interlock. • The glue must be hot and the cylinders must be rotating.

Adjustment/Replacement procedures Page 4 - 55

Initial issue: 06/03 Latest revision: 11/04

For the first gluing cylinder : Procedure : - Adjustment of scraper. • When the scraper is raised (electromagnet deactivated), measure the distance between the scraper and the gluing cylinder. For cylinder 1 : Distance = 0.5 mm (when glue is hot) (Fig.3). In order to adjust this distance, slacken off nut (1) and adjust the depth of the threaded rod (2) (Fig.2).

• Push on the core by hand to simulate activation of the electromagnet. Measure the distance between the scraper and the gluing cylinder. For cylinder 1 : Distance = 0 mm (when glue is hot) - the scraper must be against the cylinder (Fig.3). To adjust this distance, slacken off nut (3) and adjust the depth of the threaded rod (4) (Fig.2). When adjustment is correct, re-tighten the nut (3).

Electromagnet activated. Distance between scraper and cylinder = 0 mm.

Electromagnet deactivated. Distance between scraper and cylinder = 0.5 mm.

3 4

0m

0. 5

1

m

m

m

2

5

Fig.2 Fig.3

Adjustment/Replacement procedures Page 4 - 56

Initial issue: 06/03 Latest revision: 11/04

- Adjustment of the electromagnet : The scraper must be adjusted beforehand.

• Check that there is free movement of the scraper.

3 4

Note : This procedure also applies to the glue cut-off electromagnets: - for the second gluing cylinder. - lateral gluing.

1 2

5

• Loosen the fixing bolts on the body of the electromagnet (5). • Push on the core of the electromagnet (downwards, the scraper is against the cylinder). • Raise the electromagnet body until the core touches the bottom of the electromagnet and then lower the body of the electromagnet once more by 2 mm. In this way, when the electromagnet is activated, there will be a distance of 2 mm between the core and the bottom of the electromagnet body. • Re-tighten the fixing bolts on the body of the electromagnet (5).

Adjustment/Replacement procedures Page 4 - 57

Initial issue: 06/03 Latest revision: 11/04

For the second gluing cylinder : Procedure : - Adjustment of scraper : • When the scraper is raised (electromagnet deactivated) measure the distance between the scraper and the gluing cylinder. For cylinder 2 : Distance = 5 mm (when glue is hot). In order to adjust this distance, slacken off nut (1) and adjust the depth of the threaded rod (2).

• Push on the core of the electromagnet by hand to simulate the activation of the electromagnet. Measure the distance between the scraper and the gluing cylinder. For cylinder 2 : Distance = 1 mm (when glue is hot). In order to adjust this distance, slacken off nut (3) and adjust the depth of the threaded rod (4). When the adjustment is correct, re-tighten the nut (3).

Electromagnet activated. Distance between scraper and cylinder = 1 mm.

Electromagnet deactivated. Distance between scraper and cylinder = 5 mm.

3

2

5

Adjustment/Replacement procedures Page 4 - 58

Initial issue: 06/03 Latest revision: 11/04

m

m

1

5m

1m

4

in )

5.8 Lateral glue wire

0 .5

mm

(.02

Purpose : When lateral gluing is not fitted, a wire is placed just behind the second gluing cylinder. The effect of this wire is to increase the amount of glue on the two lateral edges of the spine of the booklet.

1 1

The wire must be 0.5 mm from the cylinder in order to create a wave of glue. Two wires with different diameters exist: - D 1.5 mm standard (National Coolbind 1300). - D 2 mm for low-viscosity glue.

Procedure : 1. Open the top panel. 2. Slacken off the bolts (1) and adjust the position of the wire. The distance between the cylinder and the wire should be 0.5 mm. Warning : The wire must not touch the cylinder. 3. Re-tighten the bolts (1).

With wire set to the left

4. Return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 59

Initial issue: 06/03 Latest revision: 11/04

With wire set to the right

5.9 Mounting of glue level sensors

48B02s

Prerequisites : The glue must be fully melted (±145°C) and the cylinders must be rotating.

48B01s

Purpose : Two sensors, placed at the rear of the tank, check the level of glue in the tank.

2

Procedure : • Slacken off the bolts (2) and remove the sensor support from the glue tank. 40.5mm

• Loosen the nut (1) (Fig.1).

1 65.5mm

• Adjust the height of the glue level probes (Fig.2) : - The bottom of the glue maximum level probe must be 40.5 mm from the the bottom of the probe bracket. - The bottom of the glue minimum level probe must be 65.5 mm from the bottom of the probe bracket.

Fig.1 Fig.2

• Re-tighten the nut (1). • Refit the sensor support to the glue tank using the bolts (2). • Return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 60

Initial issue: 06/03 Latest revision: 09/05

Procedure : Electrical Adjustment : A potentiometer located on the "GLUE TANK" card is used to set the temperature threshold for detecting whether or not the sensors are immersed in glue.

48-B01S 48-B02S 48-B03P 48-B04P

Min glue level Max glue level Cylinder 1 Temperature Cylinder 2 Temperature

Preliminaries : • The glue level probes must be fitted correctly (see previous page). • The glue must have reached gluing temperature. • The glue level probe connectors must be connected correctly (see Fig.1). Caution : If sensor connectors “High level” and “Low level” are inverted, both LED’s will be lit continuously. It will not be possible to adjust the pot R102

Max Min 1-3

1-2

48-B04S 48-B03S

48-B02S

48-B01S

48-B04

S

Adjustment/Replacement procedures Page 4 - 61

Initial issue: 06/03 Latest revision: 12/04

48-B03

S

48-B02

S

48-B01

S

Fig.1

Procedure to be followed : • At the front of the electronic rack connect extension 9 423 010 into the rack at the "GLUE TANK" card location and connect the "GLUE TANK" card to the extension.

Potentiometer R 102 is used to set the temperature threshold for both glue level probes (minimum level and maximum levels).

Carte “GLUE TANK”

• Two LED's located on the "GLUE TANK" card indicate whether or not the glue level probes are immersed in the glue. The LED's are on if the probes are immersed in glue, and are off if the probes are in air. Green led: Yellow led: Yellow led:

Interlock OK. Glue High Level. Glue Low Level.

Red Led: Red Led:

Error Drum 1 Error Drum 2.

R102 Test point

Adjustment/Replacement procedures Page 4 - 62

Initial issue: 06/03 Latest revision: 12/04

• Adjust glue level to have lower sensor in the glue and higher in the air • Motor running and glue at temperature

•Turn R102 clockwise to have level high and Low ON->. ON ON

• Measure tension on test points.X. • Turn R102 counterclockwise to have level high OFF and Low OFF OFF

• Measure tension Y. • Make average between tension • Adjust tension to Z. OFF • You should have ON

Adjustment/Replacement procedures Page 4 - 63

Initial issue: 06/03 Latest revision: 06/05

TOP VIEW

5.10 Adjustment of the position of the sensor for measuring the length of the book being glued Purpose : This procedure defines the position of sensor 36B04p so as to obtain a correct measurement value of the length of the book. Procedure : For improved ease of operation unlace the carriage above the glue tank so that the rear of the carriage clamp is above sensor 36B04p - See Fig.2.

8mm+/-1

Fig.1 Screw 1

Lateral adjustment : The distance between the sensor and the carriage fixed clamp must be 8 mm ± 1 mm See Fig.1. Carry out this adjustment by loosening the bolts (1) and by moving the support (2) - See Fig.2.

Height adjustment : The sensor signal must be on the paper. Perform this adjustment using the set of bolts (1) present in the support (2) - See Fig.1/2 and move to the rear to view the signal on the paper.

Adjustment/Replacement procedures Page 4 - 64

Bracket (2)

Initial issue: 06/03 Latest revision: 11/04

Fig.2

6. LATERAL GLUING 6.1 Adjusting the fixed cylinder position of the lateral gluing

Glue

0.5 +/-0.1

• Bind a book without cover and lateral gluing activated. • Use the screw (1) and nut (2) to adjust the fixed cylinder. For the mobile cylinder see Adjustment of glue supply for lateral gluing. Cylinder too close to the book. the glue is pushed to the high.

1

Correct adjustment

2 2

Cylinder too far or not enough glue. Lack of glue. Bad moving speed -> Lack of glue on the first book (See chapter “Calibration of lateral gluing” (calibration)).

0.5 +/-0.1 1 2

1

- Loosen both nuts (2). - Turn the threated rod (1) to adjust the fixed cylinder position in order that it is 0.5mm behind the fixed jaw of the carriage. Turn the nuts CW to increase the gap. Turn the nuts CCW to decrease the gap.

Adjustment/Replacement procedures Page 4 - 65

Proceed to adjutment Adjusting the home sensor 48B09i position of the lateral gluing.

Initial issue: 06/03 Latest revision: 06/05

6.2 Synchronization of the lateral glue cut-off on the gluing cylinders

Procedure #1 : Cut-off Synchronization. 1

Purpose : The aim of this procedure is to synchronize the glue cut-off on the lateral gluing cylinders. There is only one command for the opening and closing of the lateral gluing scrapers.

2

7

On the lateral gluing cylinders : - You should obtain a gap of 0.5 mm between the scraper and the cylinder when the scrapers are open. - And the scrapers should be in contact with the cylinders when they are closed. Prerequisites: • The fixed cylinder of the lateral gluing should be 0.5mm behing the fixed jaw of the carriage (see chapter Adjusting the fixed cylinder position of the lateral gluing). • Open the top panel and the front door. • Connect the technical control box in order to bypass the interlock. • The binder must be ready (glue tank should be up to temperature). • Remove the small plates (1) above the lateral gluing cylinders (see Fig.1). 1

Fig.1

Adjustment/Replacement procedures Page 4 - 66

3 6

8

5

Fig.2 4

• On the lateral gluing fixed head, loosen the middle screw (1) remove the roller (8), extract the stainless steel cap (2) and reinstall the roller(8) (see Fig.2). • From the U.I., rotate the cylinders to have access to the three screws (3). • Unlock the three screws (3) without removing them. • Remove the lower part of the spring (4) from its fixation point. • Push manually on the solenoid core to simulate a glue cut-off.

Initial issue: 06/03 Latest revision: 12/04

Both scrapers should be in contact with each cylinder. • If not, displace the plate (5) on which the scraper pivot is fixed (see Fig.3). Insert a screwdriver between the scraper (7) and the plate (6) in order that the scraper (7) is in contact with the cylinder. • When both scrapers are in contact with the cylinders and the core inside the solenoid, tighten the screws (3) and install the stainless steel cap (2) and the middle screw (1) (Fig.2).

Screwdriver

• The adjustment is correct if : - When the solenoid is inactive and the cylinders are rotating, the amount of glue on cylinders is equal. - When the solenoid is activated, the glue on cylinders is interrupted.

5 3 7 6

Fig.3

Adjustment/Replacement procedures Page 4 - 67

Initial issue: 06/03 Latest revision: 12/04

Procedure #2 : Scraper opening adjustment. • When the solenoid is inactive, measure the distance between the scraper and the lateral gluing cylinder. For lateral gluing : Distance = 0.5 mm (when glue is hot) (Fig.5). • In order to adjust this distance, loosen the nut (1) and adjust the depth of the threated rod (2) (Fig.4).

5

Fig.4

2

4

5

3

• Push on the core by hand to simulate activation of the solenoid (Fig.4). The scraper should be in contact with the cylinder.

1

If necessary, loosen the nut (3) and raise the threaded rod (4) in order that the scraper is against the cylinder. When the adjustment is correct, tighten the nut (3). Procedure #3 : Solenoid adjustment (see Adjustment of gluing cylinder glue cut-off scrapers).

6

End of procedure. • Install both small plates (5) above the lateral gluing cylinder (see Fig.4).

0.5

mm

• Attach the spring (6). • Restore the binder in normal operating conditions. Fig.5

Adjustment/Replacement procedures Page 4 - 68

Initial issue: 06/03 Latest revision: 11/04

6.3 Adjustment of glue supply for lateral gluing Purpose : Using two openings located on each side of the first gluing cylinder, technicians may adjust the quantity of glue supplied for lateral gluing.

3 3

Prerequisites : • Open the top panel.

1

Fig.1

• Connect the technician control box in order to bypass the interlock. • The binder must be ready : Green indicator lit (glue up to temperature, cylinders rotating). Procedure : • Remove the top covers (3) to visualise the glue flow. • By slackening off the bolts (1) (fig.1), it is possible to move the panel (2) laterally in order to adjust the glue inlet opening for lateral gluing. • In order to obtain a maximum glue supply (fig.3) for lateral gluing, adjust the position of the flap to about the centre of the slots to have a maximum flow.

1

2 2

Fig.2

• When the adjustment is correct, re-tighten the bolts (1). • Return the binder to normal operating conditions. Notes : This procedure should be carried out when the cylinders are rotating and temperature correct, in order that the supply of glue to lateral gluing may be visually observed.

Adjustment/Replacement procedures Page 4 - 69

Initial issue: 06/03 Latest revision: 12/04

Glue surface should be convex

Fig.3

Procedure : See Preventative and Corrective Maintenance via the U.I.->

6.4 Separation of lateral gluing cylinders Purpose : Technicians can correct the separation distance between the lateral gluing cylinders. When booklets are being glued the cylinders are separated by : the thickness of the book + the correction made by a technician. For correct lateral gluing, adjust the distance between the cylinders so that the films of glue on each cylinder just touch one another. Proceed to following adjustment (Adjusting the fixed cylinder position of the lateral gluing).

Films of glue

Adjustment/Replacement procedures Page 4 - 70

Initial issue: 06/03 Latest revision: 12/04

Advanced Menu : “CALIBRATIONS”->

Calibration of lateral gluing

6.5 Adjusting the home sensor 48B09i position of the lateral gluing Purpose : The home sensor 48B09i limits the displacement of fixed cylinder in order to not have the cylinder in contact with the glue tank. Prerequisites : • The binder must be ready: Green indicator lit (glue temperature reached, cylinders rotating). • The following adjustments should be done:

2. Press the button to do a homing then press the button to separate the cylinders to the maximum. 3. Use a screwdriver to check that the cylinder support block (1) is not against the glue tank (detail 1). • If there is a gap between the block and the glue tank, go to step 5. • If not move the sensor bracket (2) to the rear of the machine. 4. Do the procedure from the step 2 again. 5. Restore the binder to operating conditions.

Adjusting the fixed cylinder position of the lateral gluing Advanced menu :”Calibrations” 3. Calibration of lateral gluing.

1

Detail 1

Procedure: 1. Enter the technician menu -> Advanced menu -> Glue tank.

2

Detail 2

Adjustment/Replacement procedures Page 4 - 71

Initial issue: 06/03 Latest revision: 06/05

7. COVER CLAMP 7.1 Adjustment of cover clamp position relative to the position of the carriage and to the milling blade Purpose : The zero level of the machine is the level of the top tooth on the milling blade. There are three adjustments to be carried out in order to correctly position the cover clamp module relative to the milling blade :

Prerequisites : • Open the top panel, open the door at the front, remove the lateral and rear panels. • Connect the technician control box in order to bypass the interlock. • Remove the protective panel fitted to the carriage.

• The height of the cover clamp tray must be adjusted so that there is an adjustable range of pressure between the spine of the book onto the cover. • The cover jaw must be properly aligned relative to the carriage clamps. A gauge provided for this purpose is used to carry out this adjustment. • The non-stick cover clamp tray must be square in relation to the fixed carriage jaw. Tools : • A square (CPB ref: 99 410 21 000). • 2 comparators. • The cover clamp adjustment gauge 9 414 098 with 2 pins 9 231 152. • The technician control box 9 432 545.

Adjustment/Replacement procedures Page 4 - 72

Initial issue: 06/03 Latest revision: 11/04

Procedure N°1 : Pre-positioning of the cover clamp module in the machine 1. Re-initialize the binder by pressing the green button on the loading console.

4. Raise the cover clamp unit and open the cover clamp. In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module.

2. Open the carriage clamps fully by pressing the black button on the loading console.

• Raise the cover clamp module to height “3” by pressing on the icon .

3. Move the cover transport clamps towards the rear of the machine.

• Open the cover clamp jaw by pressing a maximum of 3 times on the icon.

In the technician menu’s “STATUS” menu, select the “COVER TRANSPORT” module. Then press on the arrow to move the cover transport clamp towards the rear of the machine.

5. Depress the emergency stop button. 6. Remove the upper stiffener from the creasing punch (for machines with Tag 18). Position the gauge in the cover clamp by placing both pins 9 231 152 in the holes in the gauge and in holes in the cover clamp module (Fig.1).

Adjustment/Replacement procedures Page 4 - 73

Initial issue: 06/03 Latest revision: 09/05

7. Fix the gauge in the internal threads (5) on the side of the sides of the cover clamp module.

10. Then carry out pre-adjustment of the cover clamp module : 10.1. Adjust the alignment of the cover clamp module relative to the fixed jaw of the carriage. The gauge guides (4) are used as markers. These must both be against the carriage fixed clamp jaw (see Fig.1).

4

3 3

4

5

5

1

2

To align the cover clamp module clamps with the carriage clamps : - Loosen the nuts (1) (the upper ones). - Adjust the alignment using the bolts (2). - Re-tighten the nuts (1).

Fig.1

8. Once the gauge is fixed to the cover clamp module, remove the pins. 9. Using the technician control box, release the movement motor brake and move the carriage over the cover clamp module.

1 3 2

1

3

Warning : Do not apply excessive force if the jaw of the fixed clamp on the carriage rub against the gauge guides.

Adjustment/Replacement procedures Page 4 - 74

Initial issue: 06/03 Latest revision: 09/05

1

3

Fig.2

Note : The cover clamp module must be in position

10.2. Carry out pre-adjustment of the cover clamp module height using the square 99 410 21 000 - see Fig.3.

10.3. At the same time, place the square against the fixed jaw of the carriage clamp (see Fig.3 detail B).

Square 99 410 21 000 has a shoulder of 10 mm. It must be possible to insert the shoulder on the square between the fixed jaw of the carriage and the non-stick tray of the cover clamp assembly (see detail A). In order to adjust the cover clamp height : - Loosen the nuts (1). - Adjust the height of the nuts (3). - Re-tighten the nuts (1) (See Fig.2).

10mm

Detail A

Detail B

Fig.3

Adjustment/Replacement procedures Page 4 - 75

Initial issue: 06/03 Latest revision: 11/04

Straighten the non-stick tray of the cover clamp module relative to the fixed jaw of the carriage using nuts (1) and (3) - See Fig.2.

Procedure N°2 : Precise positioning of the cover clamp module relative to the milling blade Carry out a precise adjustment of the cover clamp module height. This operation is carried out using 2 comparators fitted in the carriage clamp. - Release the emergency stop button. - Move the carriage so that it is above the loading area. - Lower the cover clamp module to its lowest position. - Remove the gauge. - Raise the cover clamp module into position . - Depress the emergency stop button. - Place the two comparators in the carriage clamp and zero both comparators on the top tooth of the milling blade (with the emergency stop button depressed and when the top tooth in the milling blade is to the left jogger side).

Fig.4

Adjustment/Replacement procedures Page 4 - 76

Initial issue: 06/03 Latest revision: 11/04

- Move the carriage so that it is above the loading area. - Using nuts (1) and (2) (See Fig.2) : - Adjust the height of the cover clamp module so that the non-stick plate is 0.8 mm lower than the jogger plate level (height of cover clamp module: ). - Also adjust the square alignment of the cover clamp module relative to the jaw of the fixed clamp of the carriage.

- Release the emergency stop button. - Adjust the cover clamp module heights and check all heights on the UI : - Cover clamp module in position

: 0.2 mm.

- Cover clamp module in position

: 0.5 mm.

- Cover clamp module in position

: 0.8 mm.

- Cover clamp module in position

: 1.1 mm.

- Cover clamp module in position

: 1.4 mm.

- Cover clamp module in position

: 1.7 mm.

- Once this procedure is complete, lower the cover clamp module once more to its lowest position and bring the carriage over the loading area.

(when the glue drum is warm) -0.1mm -0.2mm +0mm +0.05mm

+10mm

Adjustment/Replacement procedures Page 4 - 77

(when the glue drum is warm) -1.7mm -1.8mm

Zero level (coloured tooth) +0.75 +- 0.05 -1.1mm -1.15mm

Initial issue: 06/03 Latest revision: 11/04

up 0 (from the technician menu)

: -0.2mm

down : -1.7mm

Procedure N°3 : Checks on the alignment of cover clamp and creasing modules relative to the carriage 1. Raise the cover clamp unit and open the jaw. In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module.

3. Position the gauge in the cover clamp by placing both pins 9 231 152 in the holes in the gauge and in the cover clamp module holes. 4 3

• Raise the cover clamp module to height “3” by pressing on the icon.

3

• Open the cover clamp jaw by pressing a maximum of 3 times on the icon.

4

5

1

2

5

2. Depress the emergency stop button.

Fig.1 4. Using the technician control box, release the movement motor brake and move the carriage over the cover clamp module. Warning : Do not apply excessive force if the jaw of the fixed clamp on the carriage rub against the gauge guides. 5. Check the alignment of the cover clamp module relative to the jaw of the fixed clamp of the carriage. The gauge guides (4) are used as markers. These must both be against the jaws of the fixed jaw of the carriage (see Fig.1). If the alignment is incorrect, return to procedure N°1. If the alignment is correct, bring the carriage to the loading area.

Adjustment/Replacement procedures Page 4 - 78

Initial issue: 06/03 Latest revision: 11/04

6. Also check the alignment of the creasing module relative to the carriage. - Depress the emergency stop button. - Draw back the cover clamp + gauge to the rear. - Release the emergency stop button. - In the technician menu’s “STATUS” menu, select the “CREASING” module and lower the creasing punch.

Warning : Do not apply excessive force if the jaw of the fixed carriage rub against the gauge guides. When both gauge guides are against the fixed carriage jaw, both front edges of the gauge must be against the punch of the creasing module (see Fig.2 and 3).

Warning : Do not crush the gauge with the creasing punch. Fixed jaws of carriage

- Depress the emergency stop button. - Bring the cover clamp + gauge against the creasing punch. - Using the technician control box, release the movement motor brake and move the carriage over the cover clamp module.

Fig.2

The gauge is against the creasing punch.

Fig.3

Adjustment/Replacement procedures Page 4 - 79

Initial issue: 06/03 Latest revision: 09/05

• Adjust the alignment of the creasing module relative to the gauge using the cam (1) - See Fig.4. • Adjust the distance between the gauge and the punch using the cam (2) - See Fig.4 and 5. 7. Move the carriage towards the loading area, lower the cover clamp module, remove the gauge, install the upper stiffener (for machines with Tag 18) and return the binder to normal operating conditions.

2

3

Fig.4

1 18

Fig.5 2

Adjustment/Replacement procedures Page 4 - 80

Initial issue: 06/03 Latest revision: 09/05

8. COVER CLAMPS 8.1 Adjustment of the end of travel flag for closure of the cover clamp Purpose : Fitted to the rear cover clamp is a flag which, by means of a sensor, indicates the end of travel for closure of the cover clamps. Adjustment of this flag is achieved by means of 2 slots in the rear clamp, to which access may be gained from above. Prerequisites : • Open the top panel. • Connect the technician control box in order to bypass the interlock. • Reinitialising the binder.

1. Open the cover clamp : In the technician menu’s “STATUS” menu, select the “COVERCLAMP” menu and open the cover clamps by pressing once. 2. Place a 3 mm wedge between the cover clamp. 3. Close the cover clamp manually. 4. Adjust the position of the “close clamp” flag so that the status of sensor 54B03p changes when there is a 3 mm gap between the jaw. Move the flag (3) laterally in the slots (5) for this adjustment.

Procedure :

3m

m

5 3

4

5. Return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 81

Initial issue: 06/03 Latest revision: 11/04

8.2 Adjustment pre-positioning flag for the cover clamp Purpose : There is a flag which is used for pre-opening the cover clamp jaw in accordance with the thickness of the book. Adjustment of this flag is achieved by means of 2 slots in the rear clamp.

2. The cover clamp should then have an opening of 40 mm. If this is not the case, correct the position of the flag (3) by slackening the bolts (4).

40

Prerequisites : • Open the top panel. • Connect the technician control box in order to bypass the interlock. • Reinitialising the binder.

1. Pre-opening the cover clamp : In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module and pre-open the cover clamp by pressing the button.

m m

Procedure :

4 3

3. Re-initialise the binder and once more press button check the pre-opening distance of the cover clamp . 4. Return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 82

Initial issue: 06/03 Latest revision: 11/04

to

8.3 Adjustment of the cover clamp gripping “home” flag Purpose : Cell 54B01p indicates to the automatic control system whether or not the cover clamp module is in the “home” position. The cover clamp is in the “Home” position when: - The clamp is closed, - The “clamps + panel” assembly is set back towards the rear of the machine. Prerequisites : • Open the top panel. • Connect the technician control box in order to bypass the interlock. • Reinitialising the binder.

1. Open the cover clamp : In the technician menu’s “STATUS” menu, select the “COVERCLAMP” menu and open the cover clamp by pressing button once. 2. Depress the emergency stop button. 3. Close the clamps manually so that there is a distance of 2 mm between the jaws of the cover clamp. 4. Move the “clamps + panel” assembly until the sensor 54B01p (1) changes state. When this occurs, the distance between the clamp and the aluminium blocks (2) should be 3 mm. 5. If this distance is not correct, correct the position of the flag (3) by slackening the bolts (4). 2

Procedure :

4

3

1

3m

m

2m

m+

/-1

2

6. Re-initialise the binder and check the 3 mm distance between the jaws cover clamp. 7. Return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 83

Initial issue: 06/03 Latest revision: 11/04

8.4 Adjustment of cover clamp parallel alignment Purpose : The cover clamp must be mounted in parallel in order to ensure that cover clamp the cover is performed the same pressure along the entire length of the book.

3. Place both Ø5 cylindrical pins (6) in the holes in the gripping panel provided for this purpose. 4. Loosen bolts (1) and (2). This releases racks (4) and (5).

Tools : • Technician’s control box. • 2 Ø5 cylindrical pins (9231152). Procedure : 1. Open the top panel, remove the right lateral and rear panels.

6

2. Open the cover clamp : In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module and open the cover clamp by pressing once on .

1 3 4 5

6

2

Fig.1

Adjustment/Replacement procedures Page 4 - 84

Initial issue: 06/03 Latest revision: 11/04

5. Close the cover clamp : In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module and close the cover clamp by pressing once.

6. The clamp then closed gently and first come into contact with the left pin.

Select

6

1. Drying Time maximum

7

2. Pressure force minimum In this case, the cover clamp remains closed for 25 sec (time necessary to apply steps 6,7,8 and 9).

1 3 4 5

6

2

Fig.1

7. Continue to close the clamp using the motor until they come into contact with the right pin. 8. With the drive still running, tighten racks (4) and (5) using bolts (1) and (2). 9. Adjust the right rack of the clamp using the knurled knob (3) so that both jaws touch both pins at the same time. 10. Then stop the clamp closure drive. 11. Withdraw both pins and return the binder to normal operating conditions. 2.

Adjustment/Replacement procedures Page 4 - 85

1.

Initial issue: 06/03 Latest revision: 11/04

8.5 Adjustment of height of cover clamp relative to the non-stick plate Purpose : To prevent premature wear of the cover clamp panel and in order to ensure that there is correct gripping of the paper, the maximum play between the panel and the clamps must be 0.1 mm. Prerequisites : • The cover clamp must be parallel. • Tools : 0.1 mm thickness gauge. Procedure : 1. Open the cover clamp to about 50 mm : In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module and open the cover clamp by pressing once on the button.

2. Remove the upper panel and connect the technician control box in order to bypass the interlock. 3. On the front clamp (6) : - Loosen the 4 M4 fixing bolts (1). - Adjust the height of the clamp using the two M8 grub screws (2). There must be a maximum of 0.1 mm play between the panel and the jaw over the entire length of the jaw. - Tighten the four M4 fixing bolts (1) to set the adjustment. 4 7

3

5

1

2 4

1

6

Fig.1 3 2

4. Repeat the operation on the rear jaw by unscrewing the M4 fixing bolts and adjusting the height of the jaw using the M8 (4) bolts. 5. Close the upper panel and return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 86

Initial issue: 06/03 Latest revision: 11/04

9. COVER CLAMP AND OUTPUT GUIDE LIFT 9.1 Adjustment of the cover clamp lift “HOME” position Purpose : The “home” position of the cover clamp lift corresponds to the position : - Cover clamp module lowered. - Outlet guide lowered. On the control rod for the cover clamp lift, there is a rotation zone of 16°. In this neutral zone, rotation of the shaft does not result in any movement of either the cover clamp lift or of the outlet guide lift. The aim of this adjustment procedure is to set the “home” position of the cover clamp lift using the flag (1).

• Re-initialize the binder by pressing the green button on the loading console. • Remove the right lateral panel and the rear panel. • Disconnect the cover clamp lift motor connector. • This adjustment is carried out from the rear of the machine on the cover clamp side.

Prerequisites :

1 1 Adjustment/Replacement procedures Page 4 - 87

Initial issue: 06/03 Latest revision: 11/04

Procedure : • Manually turn the cover clamp lift shaft (3) (Fig.2) to align the markings on the cam (indicating the centre of the neutral zone) with the rollers (2).

2

• At this point, the side of the “home” flag (4) should be centred in the sensor (5). The distance between the edge of the sensor and the side of the flag must be 3.5 mm ± 0.5 mm.

1 4

• The adjustment is carried out by moving the sensor support (6) fitted on the slots on the cover clamp plate. 5

• Reconnect the motor connector and return the binder to normal operating conditions. 6

3.5 +/- 0.5 mm

3

4

6 5

Adjustment/Replacement procedures Page 4 - 88

Initial issue: 06/03 Latest revision: 11/04

9.2 Adjustment of the various heights of the cover clamp lift Purpose : The cover clamp module can be raised to various heights in order for it to be pressed with more or less force against the spine of the book being bound. Cell 54B05p (5) and a 6-position flag (4) are used to indicate the cover clamp height. The aim of this procedure is to get the height of the cover clamp module to correspond to the position of the flag in sensor 54B05p. Procedure : 1. Raise the cover clamp module to height N°1 : In the technician menu's "STATUS" menu, select the "COVERCLAMP" menu and raise the cover clamp module to the first height setting by pressing

2. Remove the main panel, remove the right lateral and rear panels. 3. Connect the technician control box in order to bypass the interlock. 4. Disconnect the cover clamp lift motor connector. Manually turn the cover clamp lift shaft (1) and align the first cover clamp height marker with the roller (3). 5. Re-connect the motor connector to stop the shaft rotating. 6. Adjust the position of the "cover clamp height flag" (54B05p) so that the first height marker on the cams corresponds to the first side of the flag. 7. Return the binder to normal operating conditions.

Centre sensor 54B05p on the first side of the flag.

4

3

2 3

4

4

5

6

1

2

5 3.5 +/- 0.5 mm

Adjustment/Replacement procedures Page 4 - 89

Initial issue: 06/03 Latest revision: 11/04

6

9.3 Checking the “Home” and “Cover clamp height” flags The aim of this procedure is to check adjustments : - “Home” position of the cover clamp lift. - Height of the cover clamp lift. Procedure N°1 : 1. Remove the main panel, remove the right lateral and rear panels. Connect the technician control box in order to bypass the interlock.

3. Check the position of the flags in cells 54B04p (cover clamp lift Home) and 54B05p (cover clamp height). When the outlet guide (1) is lifted and the roller (2) of the cover clamp module is against the cam (3) : - The “home” flag (4) is still in sensor 54B04p (cover clamp module lowered). - One side of the flag (5) is in sensor 54B05p to show that the outlet guide (1) is raised. - Both leds are OFF

2. Raise the outlet guide : In the technician menu’s “STATUS” menu, select the “COVERCLAMP” menu and raise the cover clamp outlet guide by pressing once on the key.

1

2

3 4

2 5

5 4

54B04p

54B05p

4. Return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 90

Initial issue: 06/03 Latest revision: 01/05

Procedure N°2 : The aim of this procedure is to check both following cases : • When cover clamp module is lowered, the cover clamp lift shaft should stop at neutral zone of the cam without raising the cover clamp output guide. In the “COVERCLAMP” menu, raise the cover clamp module by pressing the

key. Then, lower the cover clamp

module by pressing the key. Check that the ouput guide is not slightly raised.

• When the cover clamp output guide is lowered, the cover clamp lift shaft should stop at neutral zone of the cam without raising the cover clamp module. In the “COVERCLAMP” menu, raise the ouput guide by pressing the

key Then lower the output guide by

pressing the key . Check that cover clamp module is not slightly raised.

Adjustment/Replacement procedures Page 4 - 91

Initial issue: 06/03 Latest revision: 11/04

9.4 Adjustment cover clamp lift guide Purpose : On the cover clamp plate, the guide (4) prevents the cover clamp module from moving beyond the maximum height and so falling to the low position. Prerequisites : The flags that determine the height of the various cover clamp lift positions must be adjusted beforehand. - ”Adjustment of the cover clamp lift “HOME” position”. - “Adjustment of the various heights of the cover clamp lift”.

In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module and raise the cover clamp module to the maximum height by pressing the icon . • Adjust the position of the guide (4) by unscrewing bolts (6) and leaving a 5 mm gap between the guide (4) and the cam (5). • Return the binder to normal operating conditions.

Procedure : • Open the top panel, remove the right lateral and rear panels. • Connect the technician control box in order to bypass the interlock. • Raise the cover clamp module (maximum height).

5

6 4

5 4 6

5mm

Adjustment/Replacement procedures Page 4 - 92

Initial issue: 06/03 Latest revision: 11/04

9.5 Adjustment of the “Home” position of the outlet guide Purpose : The outlet guide is in the “Home” position when it has fallen to 4 mm beneath the outlet deflector. Procedure : • Re-initialize the binder by pressing the green button on the loading console. The cover clamp module and the outlet guide initialise in the “Home” position.

3

1

4mm

m

1m

2

• Open the top panel, remove the right lateral and rear panels. • Adjust the “Home” position of the outlet guide using the rubber stops (1). The outlet guide must be 4 mm below the level of the outlet deflector.

3

• Also check that the roller (2) is not against the lift cam of the outlet guide (3). • Return the binder to normal operating conditions. m 1m

4mm

Adjustment/Replacement procedures Page 4 - 93

Initial issue: 06/03 Latest revision: 11/04

2

10. COVER TRANSPORT CLAMPS 10.1 Adjustment of opening of clamps 1

The opening of the cover transport clamps is controlled by an electromagnet via a lever. A tensile spring exerts a force to close the clamp. In order to be 100% certain that the clamp will open, the position of the core in the electromagnet must be adjusted. Procedure : • Remove the right lateral panel and the top panel. • Slacken bolt (2) of jaw (3) to allow the clamp to rotate freely. • Place a 6 mm thick wedge (1) (Fig.1) in the clamp. Fig.1

• Push the core (7) (Fig.2) down to the bottom of the electromagnet and if necessary depress the rubber guide beforehand (4).

5

• Adjust the guide (4) so that the lever (6) makes correct contact with the rubber without the electromagnet core butting against the end of the electromagnet. The core must be +/- 1 mm from the end of the electromagnet. • Place the lever (6) against the guide (4) and tighten bolt (2) when the clamp is opened to 6 mm (using the wedge).

1

3

2

• Return the binder to normal operating conditions.

6

7

4

Adjustment/Replacement procedures Page 4 - 94

Initial issue: 06/03 Latest revision: 12/04

Fig.2

10.2 Mounting the cover transport clamp guide shafts Purpose : Both guide shafts of the cover transport clamp must be completely parallel in order to obtain interference-free movement of the clamp.

1

Prerequisites : Remove the right lateral panel and the top panel (Interlock open).

3

Procedure : • Pre-fit the clamp onto the guide shafts (1) without tightening the shaft bolts into the sides of the cover clamp module. • Move the clamp (3) to the front of the machine next to the pre-feed. The guide shafts (1) are now positioned correctly in the slots to the front of the sides of the cover clamp module. • Tighten the shafts (1) onto the sides of the cover clamp module using bolts (2). • Return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 95

Initial issue: 06/03 Latest revision: 11/04

2 1 2

10.3 Adjustment of the position of the “paper present in the cover transport clamp” sensor

3. Carry out a lateral adjustment of the sensor.

Purpose : Cell 60B01p detects the presence of a cover in the cover transport clamp. The position of this sensor determines the position of the cover on the book. 1

6mm

Procedure : Cover 1

8 mm

8mm

• Check that the cover is correctly gripped in the cover transport clamp: -> The cover must be gripped by the foam on the clamp (1) over a width of 8mm. • Also ensure that the suction caps are not gripped by the cover transport clamp during the transfer of the cover. 1. In the technician menu’s “CALIBRATION” menu, select the “CREASING” module. 2. Press the key. The binder then automatically picks up and creases the cover. The creasing on the cover is therefore centred relative to the cover clamp module.

Adjustment/Replacement procedures Page 4 - 96

Initial issue: 06/03 Latest revision: 12/04

• In order to adjust this setting, slacken off the bolts (1) and move the sensor support laterally. Once the sensor is correctly located, re-tighten bolts (1) to set the adjustment.

4. Carry out an adjustment of the height of the sensor. Cell 60B01p must detect the presence of light and dark coloured covers. It must not, however, detect the black foam (3) placed under the cover transport clamp.

Warning : Any changes to the lateral position of the sensor means that the cover clamp module and creasing must be calibrated from the technician menu’s “CREASING” menu (see Calibration of creasing positions) to adjust the value of creasing position (theoretical value of 86).

The height at which sensor 60B10p is positioned must therefore be : - Low enough to detect dark coloured covers. - Take care, however, as if the sensor is too low it will detect the foam (3) placed opposite the sensor. • Take a sheet of matt black paper. • Place the sheet in the clamp. • Slacken bolts (2) and adjust the position of the sensor. When the sensor detects the cover, an LED on the sensor will illuminate. The LED must therefore be lit when the black paper is in the clamp and should go out when the sheet of paper is removed. Caution : Led can not be blinking.

1

• Carry out a cover detection test with a transparent cover and a white cover to check the sensor height. • Re-tighten the bolts (2) to lock the adjustment. • Return the binder to normal operating conditions. 2 3

m 8m

Adjustment/Replacement procedures Page 4 - 97

Initial issue: 06/03 Latest revision: 11/04

10.4 Mounting the chain guide rail Purpose : The chain guide rails (1) are for linear guidance of the cover transport clamp chain. The chain guide must be located so that it supports the chain properly without offering any resistance during motion of the clamp. Prerequisites : Open the top panel, remove the right lateral and rear panel (interlock open).

2

Procedure : • Using the slots on the sides of the cover clamp module, adjust the height of the rail (1). The clamp (2) must be properly supported by the rail and the movement of the clamp must occur without offering any resistance.

1

• Refit the panels and return the binder to normal operating conditions. 1 3

Adjustment/Replacement procedures Page 4 - 98

Initial issue: 06/03 Latest revision: 11/04

11. COVER CREASING 11.1 Adjustment of the punch matrix assembly The creasing module is used to create folds in the cover to make it easier to open the book. The punch must fall correctly in the matrix in order to produce a sufficiently deep notch in the cover. The creasing must be identical in both directions and over the entire length of the cover. Prerequisites : • Remove the right lateral panel, remove the top panel and the panel above the pre-feed. • Disconnect the creasing motor connector. Procedure : 1. Using the lever (6), adjust the height of the punch to its lowest point (Fig.1). Turn the lever (6) in the anti-clockwise direction to adjust the height of the punch at the lowest point.

6

5

3

4 2

1 4

2. On the left-hand side of the creasing module, undo the fixing bolts (4) for the moving slides. 3. In order to adjust the punch guide slides : • Manually turn the motor shaft (5), bring the punch (1) to the middle of its travel. • Grip the punch between the support panel of the moving slide (2) and the fixed slide (3). • Tighten the bolts (4). • Carry out the same operation on the right hand side of the creasing module.

Adjustment/Replacement procedures Page 4 - 99

Initial issue: 06/03 Latest revision: 11/04

Fig.1

4. Stay on the right-hand side (Fig.2) : • Slacken off the bolts (1) on the punch guide panel. • Centre the punch in the side of the chassis, pass two pins (2) through the punch guide panel and the side of the creasing module chassis (Fig.2). • Re-tighten the fixing bolts (1) then remove the pins (2).

1

3

2

1

1

2 1

Fig.2

Adjustment/Replacement procedures Page 4 - 100

Initial issue: 06/03 Latest revision: 11/04

Fig.3

5. Move over to the left-hand side (Fig.3) : • Loosen the bolts (9). 6. Adjust the punch (1) when the matrix is in the “electromagnet deactivated” position (Fig.4). • Manually turn the motor shaft (4) in order to bring the punch (1) into the matrix (2), in the “electromagnet (8) deactivated” position.

4

• Using the cam (3), align the punch in the matrix (section AA).

7 A Creasing nip point 1

• Re-tighten the bolts (9) to lock the adjustment. • In order to adjust creasing depth : - Raise the punch (1) by turning the motor shaft (4) manually. - On each side of the creasing module, loosen both bolts (7) and raise the punch (1) by means of the cams (5).

9

5

AA

1

3 A

7

1 Creasing nip point

2 5

- Place a large format sheet of 80 gsm paper between the punch (1) and the matrix (2). - Raise the punch (1) by turning the motor shaft (4) manually to bottom dead centre.

2 9 8

2

- Lower the punch by simultaneously turning both cams (5) until resistance is felt. - Re-tighten the bolts (7) to lock the adjustment. Fig.4

Adjustment/Replacement procedures Page 4 - 101

Initial issue: 06/03 Latest revision: 11/04

- Leave the punch in the matrix (at bottom dead centre), bring the rear guide shaft (1) against the matrix (Fig.5).

- Raise the punch by turning the motor shaft (3) manually (Fig.6).

- Tighten the fixing bolts (2). 2

- Lower the punch (1) by manually turning the motor shaft (3) so that only a strip of light remains between the punch (1) and the matrix (2) and visually check that the two are parallel. - Crease a sheet of 80 gsm paper by manually turning the motor shaft (3) and checking that the creasing depth is the same over the entire length of the sheet.

1

3

1 2

Fig.5

X

X

2

Fig.6

Adjustment/Replacement procedures Page 4 - 102

Initial issue: 06/03 Latest revision: 11/04

7. Adjust the punch when the matrix is in the “electro-magnet activated” position (Fig.7). • Switch the matrix over to the electromagnet activated position. Turn the motor shaft manually to bring the punch into the matrix (section AA). When the matrix is in the matrix in “electro-magnet activated” position (Fig.10) : - Bring the front guide shaft (1) against the matrix and lock the fixing bolts (2). - Raise the punch.

A

- If top and bottom creasing is identical, point # 8 is not necessary.

Sheet of 80gsm

Fig.8

AA

Fig. 9

A

2

Fig.7 1

• In the electromagnet activated position, determine whether the punch is too high or too low relative to the matrix by creasing an 80 gsm sheet. The depth of the mark must be the same in both directions of creasing (Fig.8 & 9).

Adjustment/Replacement procedures Page 4 - 103

Initial issue: 06/03 Latest revision: 11/04

Fig.10 2

8. Adjusting the inclination of the punch relative to the matrix :

Fig.11

• Switch the matrix back to the “electromagnet deactivated” position and bring the punch into the matrix.

2 Sheet of 80gsm 1

3

• Loosen the four fixing bolts (1) (Fig.12) from the two guide panels (2). • Adjust the inclination of the punch by turning the two cams (3) by the same amount on each side. The matrix punch restraint acts as a pivot : - If the “electromagnet activated” creasing was shallower than that obtained using “electromagnet deactivated” (Fig.11 & 12), incline the punch forwards towards the front of the machine.

1

Creasing at top electromagnet deactivated

Fig.13

Creasing at bottom electromagnet activated

Fig.12

Sheet of 80gsm 3

2

1

- If the “electromagnet activated” creasing was deeper than that obtained using “electromagnet deactivated” (Fig.13 & 14), incline the punch backwards towards the rear of the machine. 1

Creasing at top electromagnet deactivated

Adjustment/Replacement procedures Page 4 - 104

Initial issue: 06/03 Latest revision: 11/04

Creasing at bottom electromagnet activated

Fig.14

• Lower the punch (1) by manually turning the motor shaft so that only a strip of light remains between the punch (1) and the matrix (2) and visually check that the two are parallel (Fig.15). • Tighten the four fixing bolts (1) for the two guide panels (2) (Fig.12 & 14).

9. Check the punch matrix height from # 7. 10. Carry out a paper test and check that the creasing depth is the same in both positions of the matrix. Creasing should be quite deep with 80 gsm paper. If the punch height is raised to a maximum using the lever (Fig.1), the creasing should be much lighter. 11. Return the binder to normal operating conditions.

3

1 X

X

2

Fig.15

Adjustment/Replacement procedures Page 4 - 105

Initial issue: 06/03 Latest revision: 11/04

11.2 Adjustment of the position of the creasing module relative to the cover clamp module Purpose : The creasing module must be correctly aligned with the carriage so that the cover creasing obtained is parallel with the length of the book.

• Raise the cover clamp module fully by pressing on the icon . • Open the cover clamp jaw by pressing a maximum on the icon.

Tools : • A square. • 2 comparators. • The cover clamp adjustment gauge 9 414 098 with 2 pins 9 231 152. • Technician’s control box 9432545. Prerequisites : • “Adjustment of cover clamp position relative to the position of the carriage and to the milling blade” must have been carried out beforehand. • Open the top panel, open the door at the front, remove the right lateral panel and the panel above the creasing module. • Connect the technician control box in order to bypass the interlock. • Remove the protective panel fitted to the carriage. Procedure : 1. Re-initialize the binder by pressing the green button on the loading console. 2. Open the carriage clamps fully by pressing the black button on the loading console. 3. Raise the cover clamp unit and open the jaw. In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module.

Adjustment/Replacement procedures Page 4 - 106

Initial issue: 06/03 Latest revision: 11/04

4 3 3

4

5

1

2

5

Fig.1

4. In the STATUS menu of the technical menu, select the CREASING module and raise fully the creasing punch. 5. Using the technician control box, release the milling blade brake and the translation carriage brake.

9. Adjust the alignment of the creasing module relative to the cover clamp module. When both gauge guides are against the fixed carriage jaw, both front edges of the gauge must be against the punch of the creasing module (see Fig.2 and 3).

6. Remove the upper stiffener from the creasing punch (for machines with Tag 18). Position the jig using both pins (Ø 5 mm) (3) in the holes of the jig and the cover clamp (Fig.1). 7. Move manually the carriage over the cover clamp module (Fig.1).

The jig is against the fixed jaw of the carriage.

8. Lower the creasing punch. - In the technician menu’s “STATUS” menu, select the “CREASING” module and lower the creasing punch.

Warning : Do not crush the gauge with the creasing punch. If not lower the creasing punch.

Fig.2

The gauge is against the creasing punch.

Fig.3

Adjustment/Replacement procedures Page 4 - 107

Initial issue: 06/03 Latest revision: 09/05

• Slacken off the four bolts (3) and adjust the distance between the creasing module and the punch using the cam (1) - See Fig.4 and 5. • Adjust the alignment of the creasing module relative to the gauge using the cam (1) - See Fig.4 and 5.

10. Adjust the height of the creasing module relative to the cover transport clamp. The creasing matrix (1) must be parallel with and 2 mm below the cover transport clamp (Fig.8). - In the technician menu’s “STATUS” menu, select the “COVERCLAMP” module and lower the cover clamp module by pressing on the icon . - Depress the emergency stop button. - Move the cover transport clamp towards the creasing module.

2

3 1

Fig.4

Fig.5 2

Adjustment/Replacement procedures Page 4 - 108

Initial issue: 06/03 Latest revision: 11/04

- Adjust the height of the creasing module.

11. Install the stiffener (for machines with Tag 18) and return the binder to normal operating conditions.

Slacken off bolts (1&2) (Fig.6 & 7) and adjust the height of the creasing module using the cams (3). The creasing matrix (1) must be parallel with and 2 mm below the cover transport clamp.

2 1 3

Fig.6

3

Fig.7

3 3

2mm

Stiffener

2

Fig.8 1

Adjustment/Replacement procedures Page 4 - 109

Initial issue: 06/03 Latest revision: 09/05

11.3 Procedure for removal of the creasing module Purpose : The creasing module can be easily removed from the binder chassis. This enables technicians :

Procedure : • Open the top panel, open the door at the front, remove the right lateral panel and the panel above the creasing module. • Remove all electrical connectors from the creasing module (motor, electro-magnets, cells).

- to replace the module easily or - to carry out adjustments of the module on a bench rather than on the machine etc.

• Remove the bolts (1), (2), and (3) and take out the creasing module from above (Fig.1 & 2). • In order to refit the creasing module, tighten the bolts (1), (2) and (3) and return the binder to normal operating conditions.

Note : To remove the creasing module, it is not necessary to de mount the cover station.

1

2

2 1

4

3 3

Fig.1

Fig.2 Fig.3

Adjustment/Replacement procedures Page 4 - 110

Initial issue: 06/03 Latest revision: 11/04

11.4 Adjustment of the cover support roller lift Purpose : During transfer of the cover to cover clamp, the pre-feed suction bar passes between the matrix punch and the creasing module. The cover support rollers (1) must therefore be lifted sufficiently to allow the suction bar to pass through. 2

1mm

Procedure : • Open the top panel, open the door at the front, remove the right lateral panel and the panel above the creasing module.

• Adjust the lateral position and height of the slide (2): 2

1mm

• Manually turn the creasing module drive shaft and lift the punch to top dead center.

- Height : - Loosen the bolts (3). - Leave 1 mm play between the slide (2) and the lever (6). - Re-tighten the bolts (3).

5

4

This allows the suction bar to pass freely beneath the rollers (1).

• Return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 111

Initial issue: 06/03 Latest revision: 11/04

2

1

1mm

- Laterally : - Loosen the bolts (5). - Move the support (4) so that the panel (7) is guided correctly in a lateral direction by the slides (2). - Re-tighten the bolts (5).

3

7

6

11.5 Brake adjustment of the roller on the support covers Purpose : To highters the roller axis on the covers uniformaly during its passage through creasing. Procedure : Position the ring (1) against the roller (2) and tighten the screw (3).

3

1

Adjustment/Replacement procedures Page 4 - 112

Initial issue: 06/03 Latest revision: 09/05

2

11.6 Spring position used in the matrix lateral movement Purpose : Increase the speed of the matrix lateral movement. Procedure : Hook the spring at the highest position (#3) (see drawing).

3 2 1

Adjustment/Replacement procedures Page 4 - 113

Initial issue: 06/03 Latest revision: 09/05

12. COVER STATION 12.1 Adjusting the position of the cover station Correct fitting of the cover station is important as it produces correct cover clamp of the cover on a book. Three adjustment procedures must be carried out in order ensure that there is correct fitment :

Prerequisites : • The cover clamp module must be correctly fitted relative to the milling blade and the carriage. • Loosen the bolts (5) to release the (2) puller from the prefeed. • Place 3 levels on the station tray (Fig.1).

- Height : The height of the cover station must be adjusted so that the pre-feed suction bar passes between the punch and the creasing module (with the punch raised to top dead centre). The pre-feed suction bar must also be 4 mm above the cover transport clamp.

2 5

- Straightness : The cover station must be mounted square relative to the cover clamp module. The fitment must also allow the suction bar to carry out the transfer of the cover to the cover transport clamp in a correct manner.

6

- Inclination : The cover station tray must be fixed horizontally.

Fig.1

Adjustment/Replacement procedures Page 4 - 114

Initial issue: 06/03 Latest revision: 11/04

Procedure : • Open the top panel, the right lateral panel and the panel above the pre-feed and the creasing module. • Connect the technician control box in order to bypass the interlock.

Perpendicularity of the registration guide relative to the station tray. • Move the magnetic guides against the cover station registration guide. • Adjust the straightness of the registration guide relative to the station tray.

• Initialise the binder by pressing the emergency stop button, by releasing it just afterwards and by pressing the green button on the loading panel.

- Loosen the bolts (1). - Place the station guide against the magnetic guides. - Tighten the bolts (1).

-> The cover transport clamp moves to the “home” position, that is, just past the creasing module. -> The punch of the creasing module rises to top dead centre.

1 Registration guide

1

Adjustment/Replacement procedures Page 4 - 115

Initial issue: 06/03 Latest revision: 11/04

Height adjustment : 1. Slacken off bolts (7) (see Fig.2) and bolts (10). 2. Loosen the cams (8) and adjust the height of the station by rotating the cam (8).

5

4 7

3. Re-tighten the cam and bolts (7) and (10).

4mm

The correct height of the cover station is : - The pre-feed suction ramp must be able to pass between the punch and the matrix of the creasing module (punch raised to top dead centre).

6 8

- The pre-feed suction bar suction cups must be 4 mm above the cover transport clamp (Fig.1). A more precise adjustment can also be performed by altering the position of the pre-feed chain guide.

Fig.1 9 6

- The station must be level. Use level (9) to carry out this adjustment.

7 8

7 8 10 10

Adjustment/Replacement procedures Page 4 - 116

Initial issue: 06/03 Latest revision: 11/04

Fig.2

Adjusting the straightness of the station relative to the cover clamp module : 1. Turn the straightness adjustment button (1) for the cover on the book so that the upper tray of the station is parallel to the lower plate. Check that the two trays are parallel by ensuring that the lengths (A) and (B) are identical (+/- 12.5 mm). 2. Disconnect the pre-feed motor connector and manually move the suction bar towards the cover transport clamp.

2

3

4

5

+/-12.5 6

7

B 2

1 A

Adjustment/Replacement procedures Page 4 - 117

Initial issue: 06/03 Latest revision: 11/04

3

4

5

+/-12.5 6

7

Fig.4

3. Slacken off bolts (1), (3) and (4) and the cams (5) (Fig. 5 & 6). 4. Using the cams (2), adjust the squareness of the station relative to the cover clamp module so that : • The suction pads on the suction bar can travel further than the upper jaw of the cover transport clamp. • Distances (C) and (D) between the front strut of the cover clamp module and the upper tray of the station are equal (+/- 677 mm) (Fig.6).

Adjustment of the inclination of the station : Using the cams (5), adjust the inclination of the cover station tray so that it is fixed horizontally. 1. Loosen bolts (3) and (4). 2. Adjust the inclination of the cover station tray using the cams (5). Use levels (6) and (7) to carry out this adjustment. 3. Re-tighten bolts (3) and (4).

5. Re-tighten bolts (1), (3) and (4) and the cams (5).

Note : Height, squareness and inclination adjustments may be carried out simultaneously on the cover station.

6 7

1

D C

1 2 2

3 4 5

Fig.5

4

Adjustment/Replacement procedures Page 4 - 118

Initial issue: 06/03 Latest revision: 11/04

5 3 Fig.6

End of the procedure for adjustment of the cover station. Once the height, squareness and inclination adjustments of the cover station have been carried out :

• Re-fit the tie-rod (2) to the pre-feed using the bolts (5), (Fig.7). • If the tappings on the pre-feed are not opposite the tie-rod slots (2) : - Loosen the bolts (6). - Move the pre-feed laterally. 2

- Re-tighten the bolts (6). - Re-tighten the bolts (5).

5

6

Fig.7

Adjustment/Replacement procedures Page 4 - 119

Initial issue: 06/03 Latest revision: 11/04

12.2 Adjustment of the cover station register guide Purpose : Using the register guide mounted on the cover station tray, the position of the cover on the book can be adjusted. 2 knobs on the cover station allow the following adjustments to be carried out (Fig.1) : - Squareness of the cover on the book. - The lateral position of the cover relative to the book.

• Button (1) is used to adjust the lateral position of the cover relative to the book. Adjust the position of the register guide using the knurled knob (1) to align the cover correctly on the document. View of book on the conveyor Fig.2 Conveyor drive belt 1 turn of the knob moves the guide 1 mm. • Button (2) is used to adjust the squareness of the cover on the book.

3

View of book on the conveyor Fig.1 Conveyor drive belt

Fig.3 Adjust the inclination of the register guide using the knurled knob (2) to square the cover correctly relative to the book.

1

2

In N/First and Centred modes, straighten the cover as shown in the diagram (3). In First/N mode, the correction is reversed.

Adjustment/Replacement procedures Page 4 - 120

Initial issue: 06/03 Latest revision: 12/04

Prerequisites : • The cover station must be fitted correctly see “Adjustment of the position of the cover station”. • Place covers in the cover station.

Offset of covers button (1) 1 mm/turn

Procedure : 1. Start a binder cycle by placing a bundle of paper in the carriage clamp. 1

2. Recover the glued book. 3. Examine the positioning of the cover on the book (Fig.4) : - Adjust the offset of the cover relative to the book using knob (1). - Straighten the cover on the book using the knob (2).

Screws

1

1

4. Return the binder to normal operating conditions. Straightening of covers button (2)

Note: During transfer of the cover from the pre-feed to the cover clamp module, check that the cover moves in parallel with the cover station register guide. 2

If it does not, the pre-feed and/or cover station vertical guide shafts must be realigned (See Adjustment of the suction bar safety switch). When the cover correctly fit on the book. Loosen the screws and adjust the arrows in the middle of the sticker (for both indexes). If it is not possible, adjust the carriage mechanical stop.

Adjustment/Replacement procedures Page 4 - 121

Initial issue: 06/03 Latest revision: 12/04

1

2

2

Screws

2

Fig.4

12.3 Adjustment the prefeed trajectory Purpose : This procedure allows adjusting the suction bar trajectory in order that the cover moves parallel to the cover station registration stop. Prerequisite : • The adjustments “Adjustment of the cover station position“ and “Adjustment of the cover station register guide “ should be correctly adjusted. Procedure : 1. Open the top panel and the panel above the prefeed and the creasing module. 2. Connect the technician control box in order to bypass the interlock. 3. In the technical menu “STATUS” menu, select the “CREASING” module.

4. Press the key

.

The binder then automatically picks up and scores the cover. The creasing on the cover is therefore centred relative to the cover clamp module.

Adjustment/Replacement procedures Page 4 - 122

Initial issue: 06/03 Latest revision: 11/04

5. Vertically. During the prefeed lift, the cover path should be observed in order to check that the cover is moved in parallel with the register guide (3). If this is not so, then the prefeed must be re-aligned relative to the cover station guide (3).

6. Check the procedure by carrying out another cover pickup (press button in the CREASING menu). During the pick-up of a cover and its movement using the cover transport clamp, the cover should move in parallel with the cover station register guide. Adjustment of the register setting may perhaps be necessary (see chapter : Adjustment of the cover station register guide). If, despite this adjustment, the cover does not move parallel to the register guide, the straightness of the cover station must be checked relative to the cover clamp module (see chapter : Adjusting the position of the cover station).

- Loosen the bolts (1). - Move the prefeed laterally using the tie-rod (2). - Re-tighten the bolts (1).

2

7. Check the procedure once more by re-starting the binding cycle. Recover the book produced and check that the cover is correctly placed relative to the book. 1

3

Adjustment/Replacement procedures Page 4 - 123

8. Re-fit the panels and return the binder to normal operating conditions.

Initial issue: 06/03 Latest revision: 11/04

12.4 Cover picking and separators 2. Cover suction : Depending on the width of the cover, the cursor (2) is positioned to deactivate the suction cups that are located outside the width of the cover.

1. Separators :

2

1

1

Fig.1

Suction and blowing can be adjusted together in the UI using the icon in the “JOB” menu (see the “JOB menu” in the operator’s manual). Adjust the position and number of the separators (1) to optimise cover separation. Place separators just above the pile of covers (Fig.1). Fig.2

Adjustment/Replacement procedures Page 4 - 124

Initial issue: 06/03 Latest revision: 11/04

Procedure : • Press the button at the bottom of the UI screen to raise the blower bar.

• Unscrew the cursor (2) and adjust its position to the same letter as shown on the cover station just next to the cover.

2

D

• Place the covers in the cover station against the register guide.

• In the example on the previous page (Fig.2), the cover shows the letter “D”. The cursor window must therefore be on the letter “D”. • Re-initialise the binder. Fig.3

Adjustment/Replacement procedures Page 4 - 125

Initial issue: 06/03 Latest revision: 11/04

12.5 Cover station removal Purpose : To displace the binder easily, the cover station and the creasing module can be removed from the binder. The binder width does not exceed 850 mm. Note : To remove the cover station, it is not necessary to de-mount the creasing module. Prerequisites : • The binder must be switch OFF.

A

B

F

J

• Open the top cover, then the front door. Remove the right lateral cover and the cover above the creasing module. • To easily gain access, remove the conveyor and move the BBR. • Remove the tube from the blower bar (A). • Remove the cover suction tube at suction bar (B) and remove the connector from sensor 57B02p located inside the tube. • Remove all electrical connections from the cover feeder (motor, sensors, solenoids, connectors (C) (D) and (E), etc). • To avoid any interference while removing the cover station, remove the bracket (F) from the binder by removing the screws (J).

Adjustment/Replacement procedures Page 4 - 126

Initial issue: 06/03 Latest revision: 11/04

(C), (D), (E)

Procedure : • Remove the four screws (G). The cover station is hung by 2 hooks (H) and rests on the frame.

• Apply the same procedure in reserve order to re-fit the cover station. Check the height, straightness and inclination of the cover station (see chapter “Adjusting the position of the cover station”). • Procedure to put back the cover station : - Re-fit the bracket (F). - Reconnect all electrical devices. - Reinstall the conveyor and the BBR. - Reinstall the covers. - Power ON the binder and reinitialise the machine.

H

H

G

• Two persons are required to lift up the cover station from its 2 points (H) and then pull it out from the binder.

Adjustment/Replacement procedures Page 4 - 127

Initial issue: 06/03 Latest revision: 11/04

12.6 Cover station safety plate For both switches • Loosen the screws (A). • Push as much as possible on the safety plate (1). • Move the switch fully towards the plate and move it back by 1 mm. • Tighten the screws (1). Caution : To avoid damaging the switch, it must not be depressed fully

2

2 2

1 1

A

Adjustment/Replacement procedures Page 4 - 128

1mm

Initial issue: 06/03 Latest revision: 12/04

13. PRE-FEED 13.1 Adjustment of the chain guide Purpose : The guide chain (1) is used to guide the chain (2) and therefore the suction bar. This must be placed so that there is no resistance during the movement of the bar. The slots (3) (Fig.1) are used to adjust the height of the guide chain. The path of the prefeed may therefore be adjusted so that it may pass between the creasing punch (5) and matrix (6) (Fig.2).

Procedure : • Open the top panel and the panel above the prefeed and the creasing module. • The slots (3) (Fig.1), allow the guide chain height to be adjusted so that : - There is no resistance during movement of the suction bar. - The suction bar (4) may pass between the creasing punch (5) and matrix (6) (Fig.2). - The suction cups (7) must be located ± 4 mm above the cover transport clamp, but without touching it. • Re-fit the panels and re-initialise the machine.

3

5

4 1

7

4mm

2

6 8

Fig.2

Fig.1

Adjustment/Replacement procedures Page 4 - 129

Initial issue: 06/03 Latest revision: 11/04

13.2 Adjustment of the turbine suction level Purpose : This operation involves adjusting the prefeed turbine to its maximum level. Prerequisites : Remove the right lateral panel in order to gain access to the turbine. Procedure : • Use the UI to start the turbine and to adjust the speed to its maximum setting. Prefeed menu tech menu STATUS • On the turbine, turn the potentiometer to maximum in a clockwise direction so that the turbine is at its maximum level. • Press icon

and adjust minimum and maximum speed

using • Re-fit the panel. • Return the binder to its normal operating conditions.

Adjustment/Replacement procedures Page 4 - 130

Initial issue: 06/03 Latest revision: 12/04

13.3 Adjustment of the suction bar safety switch During creasing of a cover, the suction bar is located in front of the creasing panel cover opening. Any intrusion through this opening is therefore impossible; there is therefore no possibility of an accident occurring during the creasing of a cover (safety OK). The “home” position of the suction bar is the position of the suction bar when it is located in front of the creasing panel opening. In this position, two cut-off switches activate a safety relay supplying the creasing motor. In any position the creasing motor is disconnected. This means that creasing movements are only allowed when the opening of the panel in front of the creasing module is filled by the suction bar.

Procedure : • Loosen the bolts (1) (Fig.2). • Move support (2) in the slots until the “CLICK” of the switches (3) is heard when the rollers of the latter fall into the notch in the rail (4). • Re-tighten the bolts (1). • Re-fit the panels and return the binder to normal operating conditions.

4 3

Prerequisites : • Remove the right lateral panel and the panel above the prefeed.

2 1

• Re-initialize the binder by pressing the green button on the loading console.

4

3

Fig.1

Adjustment/Replacement procedures Page 4 - 131

1

2

Initial issue: 06/03 Latest revision: 11/04

Fig.2

14. ADJUSTMENT PROCEDURES : BBR 14.1 Adjustment of the BBR stacking head positioning flags Purpose : Cells 72B03p and 72B02i are used to determine the position of the BBR stacking head. Adjustment of the position of the head is achieved using the two flags which block the signals from the two sensors.

72B03p

Sensor signal = 0

Prerequisites : • Remove the upper closure panel from the BBR head by to loosening the screws (1).

72B02i

Sensor signal = 1

• Unplug the motor 72M01p.

1

3 head positions are determined by the signal from the 2 sensors : • If 72B03p = 1 and 72B02i = 0 : The BBR head is in the process of its travel. • If 72B03p = 1 and 72B02i = 1 : The BBR head is at the end of its travel. • If 72B02i = 0 : Pre-positioning of the BBR head in accordance with the thickness of the book by counting of impulses for sensor 72B03p.

Adjustment/Replacement procedures Page 4 - 132

Initial issue: 06/03 Latest revision: 11/04

1 1

Fig.1

• In the technical menu, enter in the BBR status page.

The icon

means that the level is high ->

The icon

means that the level is low ->

Sensor signal = 1

Sensor signal = 0

Adjustment/Replacement procedures Page 4 - 133

Initial issue: 06/03 Latest revision: 11/04

Procedure : Adjusting the head “Home” position : • Move manually the BBR head until the head baffle is at 10 mm from the book separator harrow (the BBR head should not be vertical).

• Loosen the screws of the flag (1) and move it until 72B02i is illuminated . • Tighten the screws of the flag (1).

72B03p

72B02i 10 mm

Flag 1 : Home flag. Flag 2 : Head positioning flag. Head over travel adjustment - see Fig.2 : • Move manually the BBR head until the pushers go over the strippers.

10 mm

• Loosen the screws of the flag (2) and move it until 72B03p is illuminated

(limit of change).

• Tighten the screws of the flag (2). 10 mm

Adjustment/Replacement procedures Page 4 - 134

End of procedure : • Reconnect the motor 72M01p and install the upper closure panel of the BBR head

Initial issue: 06/03 Latest revision: 05/05

14.2 Adjustment of the BBR head vertical position switch 72S03s Purpose : This procedure defines the position of switch 72S03s which detects when the head is vertically aligned.

Procedure : This actually involves adjustment of the depression of the switch pin. To do this : - Manually incline the head of the BBR so that it is vertical. - Move the support by loosening screws (2) laterally until the switch is heard to engage. - Move it further 1 mm and fix it in place.

Prerequisites : • Remove the upper closure panel from the BBR by loosening the screws (1). • Unplug the motor 72M01p.

Attention: The switch pin must not be depressed fully.

1

Finish the procedure by plugging the 72M01p motor and installing the upper closure panel from the BBR.

1

72S03s

1 2

Clic

Adjustment/Replacement procedures Page 4 - 135

Initial issue: 06/03 Latest revision: 11/04

+ 1mm

14.3 Adjusting the BBR book separator harrow end of travels : bottom dead centre position 72S02s Purpose : When the BBR book separator harrow is at bottom dead centre, a switch is activated to send a signal to the BBR automatic control system-it indicates that the book separator harrow is lower than the level of the stacking table.

Adjustment of the switch bracket position : • Move the book separator harrow to the bottom dead centre. The book separator harrow should be 5 mm lower than the level of the stacking table.

This involves a safety switch which, when activated, cuts off the supply to the head movement motor. Procedure :

• Loosen the screws (1) and adjust the switch bracket position so that it is activated when the book separator harrow is at bottom dead centre. In the technician menu, on BBR status page, 72S02s should be illuminated.

Stacking table 5mm

Attention: When the switch is activated, the rod must be depressed by 1 mm after the “CLIC”. The switch rod must not be depressed fully.

72B06i

Clic

+1mm

72S02s

1

Adjustment/Replacement procedures Page 4 - 136

Initial issue: 06/03 Latest revision: 11/04

14.4 Adjusting the BBR book separator harrow end of travel : top dead centre position 72B06i Purpose : This procedure defines the position of sensor 72B06i for detecting top dead centre of the book separator harrow. Procedure : • Move the book separator harrow to the top dead centre. • Loosen the screws (2) of the sensor bracket (1) in order. • That the flag is 8 mm over the middle of the sensor. In the technical menu, on the BBR status screen, the 72B06i should be illuminated. • Re-tighten the screws (2).

2

m 8m

72B06i

1

Adjustment/Replacement procedures Page 4 - 137

Initial issue: 06/03 Latest revision: 11/04

15. SUMMARY : ALIGNMENT OF THE VARIOUS MODULES ON THE BB3002 CHASSIS

(when the glue drum is warm) -0.1mm -0.2mm +0mm +0.05mm

+10mm

Adjustment/Replacement procedures Page 4 - 138

(when the glue drum is warm) -1.7mm -1.8mm

Zero level (coloured tooth) +0.75 +- 0.05 -1.1mm -1.15mm

Initial issue: 06/03 Latest revision: 11/04

up 0 (from the technician menu)

: -0.2mm

down : -1.7mm

Preventative and Corrective Maintenance via the U.I.

Adjustment/Replacement procedures Page 4 - 139

Initial issue: 06/03 Latest revision: 11/04

This page is intentionally left blank.

Adjustment/Replacement procedures Page 4 - 140

Initial issue: 06/03 Latest revision: 11/04

1. INTRODUCTION This manual will enable you to carry out preventative and corrective maintenance on the BB3002 binder. The technician menu used in the graphical user interface (UI) of the binder will allow you, for example to : - Calibrate glue cut-off, calibrate the jogger vibration frequency,… - Adjust gluing temperatures. - Start an endurance test. - Test some electrical elements of the machine (sensors, motors,….). -… The header window of the technician menu is accessible both to you and to the operator. It provides options for reinitialising the binder and for setting the date and time.

• Part Two : CALIBRATIONS : - Calibration of glue cut-off, jogger vibration frequency etc. - Adjustments of specific settings of the binder (gluing temperature, creasing etc.).

• Part Three : VARIOUS : - Configuration of the machine : - Selection of optional installed elements,... - Configuration of gluing AUTO parameters,... - Starting an endurance test,... Detailed explanations of these three parts are given in the following chapters.

A password is required to access the advanced technician menu. Only qualified technicians will know this password. The advanced technician menu is divided into three parts : • Part One : STATUS : - Test some electrical elements of the machine (sensors, switches, motors, solenoids….)

Adjustment/Replacement procedures Page 4 - 141

Initial issue: 06/03 Latest revision: 11/04

2. TECHNICIAN MENU : HEADER WINDOW To access the technician menu, press the button on the right of the screen. The header window is then displayed on the screen. This header window may be accessed by anyone. No password is required in order to access it.

2.1 Setting the time and date • To change the time, press the hours, minutes or seconds. A numeric keypad will then appear on the screen. The correct time may then be entered. 1) To check the time. 2

The header window is used to - Re-initialise the binder, - Alter the time and date, - Open and close the cover clamp, - (To) know the thickness of the last booklet bound.

3

2) To cancel the operation. 3) To delete the last number.

1 • The operation for changing the date is identical.

Adjustment/Replacement procedures Page 4 - 142

Initial issue: 06/03 Latest revision: 11/04

2.2 Opening - closing of the cover clamp

2.3 Re-initialisation of the graphical interface, the PLC and communication between them

These two buttons open and close the cover clamp.

This function is useful for cleaning, and for removing films of glue from the non-stick cover clamp plate.

In the event of problems, it is possible to : 1. Restart the touch screen (UI). This reinitialises completely the UI software. 2. Restart the binder’s computer (PLC). This reinitialises completely the binder software.

Notes : As a safety measure, clean the plate with the interlock open.

Attention: A power OFF/ON does not reinitialize the software. 3. Restart the communication between the screen and the PLC. Note : If the error continues, check the connection from the UI’s serial port to the PLC.

Adjustment/Replacement procedures Page 4 - 143

Initial issue: 06/03 Latest revision: 11/04

2.4 Thickness value of the last booklet bound At any time, the operator can also know the thickness value of the last booklet bound. This can be used in application like “doctor booklet” in which the thickness should be entered for the second wing length.

Adjustment/Replacement procedures Page 4 - 144

Initial issue: 06/03 Latest revision: 11/04

2.5 Accessing the advanced menu To access the technician menu’s advanced menu, press the icon. An alphanumeric keyboard then appears on the screen. You must then enter the password correctly to be allowed to enter the advanced menu. When the correct password has been entered, you then have access to the advanced menu.

The following keys have the following functions : Small letters to capital letters and vice versa (Toggle). Warning : Whether a letter is a small or capital letter will affect password entry.

Adjustment/Replacement procedures Page 4 - 145

Initial issue: 06/03 Latest revision: 11/04

Moves the cursor to the left. Moves the cursor to the right. Deletes the character highlighted by the cursor. Cancels the operation and returns to the header window of the technician menu. Validating the password.

2.6 The Structure of the Technician Menu 2.6.1 Accessing the header page of the technician menu :

Press

to access the header page of the technician menu.

2.6.2 Accessing the technician menu’s advanced menu :

Press

2.6.3 Password entry :

Enter the password and validate it by pressing

.

2.6.4 Entering the advanced technician menu :

to access the advanced technician menu. You can then access all adjustments on the BB3002 binder.

Adjustment/Replacement procedures Page 4 - 146

Initial issue: 06/03 Latest revision: 08/05

3. ADVANCED MENU OF THE TECHNICIAN MENU Once the technician menu password has been correctly validated, the following window is displayed on the screen.

• Part Three : VARIOUS : - Configuration of the machine : - Selection of optional installed elements,... - Configuration of gluing parameters used by default,… - Starting an endurance test.

The advanced technician menu is divided into three parts : • Part One : STATUS : - Verification of the proper operation of inputs (sensors, switches etc.) and outputs (motors, electromagnets etc.). • Part Two : CALIBRATIONS : - Calibration of glue cut-off, jogger vibration frequency etc. - Adjustments to specific settings of the binder (gluing temperature, creasing etc.).

Adjustment/Replacement procedures Page 4 - 147

Initial issue: 06/03 Latest revision: 11/04

3.1 Advanced Menu : “STATUS” The “STATUS” section is used to check that operational status is correct : - for inputs (sensors, switches etc.) and - for outputs (by electrically controlling certain motors and electromagnets).

The different modules of the binder are as follows : - Covers, - Carriage, - Jogger module, - Milling module, - Glue tank, - Carriage movement, - Cover clamp, - Cover loading, - Scoring, - Cover transport clamps, - Output unit + conveyor, - BBR. This menu is very useful for :

Press key

- Checking the operation of a motor, - Checking that sensor connections are OK, - Simulating a cover pick-up in order to carry out an adjustment procedure, - ...

to access the “STATUS” menu.

The binder is made up of various modules. You may then view the inputs and outputs for each binder module.

Adjustment/Replacement procedures Page 4 - 148

Initial issue: 06/03 Latest revision: 11/04

3.1.1 Covers : - 66S06p :

Reporting Interlock - Front door.

- 66S08p :

Reporting Interlock - Top cover.

- Others Reporting Interlock: - CPC connector from the binder to the output conveyor. - CPC connector from the output conveyor to BBR. - CPC connector to ON line module (3502) in the electronics rack. - 66B01p :

Optical barriers reporting.

- 66H01s :

Green signal light.

- 66H02s :

Red signal light.

The status of a sensor or switch can be checked : The

icon means that the signal level is high.

The

icon means that the signal level is low.

Note : To return to the general window from the advanced menu, press icon .

Inventory of inputs : - 66S01p : “Green” push button for closing clamps + Start process. - 66S02p :

“Black” push button for opening clamps.

- 66S03p :

Pedal.

- 66S05p :

Reporting interlock - Emergency stop button.

Adjustment/Replacement procedures Page 4 - 149

Initial issue: 06/03 Latest revision: 11/04

3.1.2 Carriage : Inventory of drives : - 33M01p : Carriage clamp motor. Press

to open the carriage clamp.

Press

to close the carriage clamp.

Press

to keep the clamp closed.

Press

Inventory of inputs : Carriage paper presence detector. - 33B02p : - 33B04p :

Carriage opening encoder + thickness value of the books.

- 33B05s :

Carriage fixed clamp On-line deflector presence detector.

- 33B06s :

Carriage moving clamp On-line baffle presence detector.

Adjustment/Replacement procedures Page 4 - 150

Initial issue: 06/03 Latest revision: 11/04

to initialise the clamp.

3.1.3 Jogger module : - 39M01p :

Jogger plate height motor. -> Increase or reduce milling height to raise or lower the jogger plate.

-> By pressing this key, the height of the jogger plate will move in home position.

Inventory of inputs : - 39B01p : Jogger Home sensor. Inventory of drives : - 39Y02p : Vibrator. -> Press

to make the jogger plate vibrate.

Adjustment/Replacement procedures Page 4 - 151

Initial issue: 06/03 Latest revision: 11/04

3.1.4 Milling module : Inventory of drives : - 42M01p : - 45M01p :

Waste suction turbine motor.

- 42M02i :

Notching tools indexing motor.

Inventory of inputs : - 42S01p : Blocked milling evacuation detection. - 42B04i :

Reporting of order of phases + indexing of notching tools.

- 42B05i :

Reporting of order of phases + indexing of notching tools.

- 45S01p :

Full waste bin detection (if option installed).

- 45S02s :

Presence of waste bin detection (if option installed).

Adjustment/Replacement procedures Page 4 - 152

Milling motor.

Initial issue: 06/03 Latest revision: 11/04

3.1.5 Glue Tank : Note : Press the icon at the bottom of the screen to heat the cylinders. This allows technician to test the cylinder heating resistances and temperature sensors.

- 48B09i :

Lateral gluing Home sensor.

- 48B10i :

Spinner Home sensor.

Inventory of inputs : - 48B01s : Min tank level (should be green if the level of glue in the tank is OK). - 48B02s :

Max tank level (should be green if the level of glue in the tank is OK).

- 48B03p :

Cylinder 1 temperature sensor. Display of the glue temperature (144°C) according to the temperature at which glue is applied (145°C).

- 48B04p :

Cylinder 2 temperature sensor. Display of the glue temperature (141°C) according to the temperature at which glue is applied (145°C).

Adjustment/Replacement procedures Page 4 - 153

Initial issue: 06/03 Latest revision: 11/04

Inventory of outputs : Cylinder rotation motor. - 48M01p : ->

Cylinder rapid rotation command

.

->

Cylinder slow rotation command

.

- 48M02b :

Lateral gluing setup motor.

->

Lateral gluing return home command.

->

Lateral gluing cylinder maximum separation distance command.

->

Bring lateral gluing cylinders together command.

- 48M03i :

Cylinder 1 heating resistance.

- 48E03p :

Cylinder 2 heating resistance.

Spinner height setup motor. Rise or fall of spinner cylinder command.

->

Spinner home command.

Control of activation of cylinder 1 glue cutoff.

- 48Y02p :

Control of activation of lateral gluing glue cut-off.

- 48Y03p :

Control of activation of cylinder 2 glue cutoff.

Adjustment/Replacement procedures Page 4 - 154

- 48E02p :

Note : Press the icon at the bottom of the screen to heat the cylinders.

->

- 48Y01p :

Note : - At rest, the activation command for electromagnets is . - When an electromagnet is activated, the command changes to . - Warning , maximum 3 seconds activation of electromagnet.

- 48E01p + 48E05p : Cylinder 1 resistance command. In normal use conditions, the heating of the glue tank bottom is always activated.

Initial issue: 06/03 Latest revision: 11/04

Notes : Wait until the glue is hot before activating outputs.

3.1.6 Carriage Movement :

Inventory of inputs - 36B03p : - 36B04p : - 36S01p :

: Movement encoder. Book length detection sensor. Movement upstream end of travel.

Inventory of outputs : Carriage movement motor. - 36M01p : -> Command for moving carriage to the left - slow speed. ->

Command for moving carriage to the right slow speed.

->

Carriage home position command.

Adjustment/Replacement procedures Page 4 - 155

Initial issue: 06/03 Latest revision: 11/04

3.1.7 Cover clamp : - 54M02p : ->

Cover clamp opening command.

->

Cover clamp closure command (without squeezing).

->

Squeezing command for clamps with pressure and duration of squeezing determined below.

->

Adjustment of clamp squeezing force.

->

Adjustment of duration of squeezing.

->

Command for Cover clamp opening of 40 mm.

Inventory of inputs : Cover clamp Home sensor. - 54B01p : - 54B06p :

Pre-positioning of cover clamp.

- 54B03p :

Cover clamp closed sensor.

- 54B05p :

Detection of cover clamp + outlet roller raised positions.

- 54B04p :

Cover clamp Home sensor.

- 54M03p :

Inventory of outputs : - 54M01p : Cover clamp module lift and roller lift motor. ->

Cover clamp lift command.

->

Cover clamp descent command.

->

Roller lift command.

->

Roller descent command.

Adjustment/Replacement procedures Page 4 - 156

Clamp motor.

Cover clamp positioning motor.

->

Home positioning command for cover clamp (“ready to discharge a book” position).

->

Cover clamps movement command in centred position.

->

Cover clamps movement command in position.

Cover clamp module testing : Command to start an endurance test. -

Initial issue: 06/03 Latest revision: 11/04

Command to stop an endurance test.

3.1.8 Cover picking : - 57M02p : -> -> - 57Y01p : ->

Suction turbine motor. Turbine start and stop command. Suction increase or decrease command. Blowing bar lifting electromagnet. Electromagnet activation command. (0) : Electromagnet deactivated. (1) : Electromagnet activated

Warning : Maximum 3 second activation of the electromagnet. - 57Y02p : ->

At rest (0) -> suction is produced using the suction bar. When activated (1) -> suction is switched to the surrounding air.

Inventory of inputs : - 57B01p : Cover picking home sensor. Cover pick-up detection. - 57B02p : Inventory of outputs : - 57M01p : Cover pick-up drive motor. -> Cover picking return home command. ->

Cover picking simulation command.

Adjustment/Replacement procedures Page 4 - 157

Turbine solenoid valve. Solenoid activation command.

Initial issue: 06/03 Latest revision: 11/04

Warning : Maximum 3 seconds activation of the electromagnet.

3.1.9 Scoring : - 57Y01p :

Reverse Scoring direction electromagnet. ->

Electromagnet activation command. (0) : Electromagnet deactivated. (1) : Electromagnet activated

Warning : - 3 seconds maximum activation of electromagnet. - Do not reverse the creasing direction when the motor is running.

Inventory of inputs : - 63B01p : Scoring punch position 1 sensor. - 63B03p :

Scoring punch position 3 sensor.

- 63B02p :

Scoring punch position 2 sensor.

Inventory of outputs : Scoring motor. - 63M01p : -> Scoring punch gluing return home command. ->

Motor rotation command : movement of punch to position 2.

->

Command for forward and return motion of punch between position 2 and position 3.

Adjustment/Replacement procedures Page 4 - 158

Initial issue: 06/03 Latest revision: 11/04

3.1.10 Cover Transport : - 60Y01p :

Clamp opening electromagnet. -> Electromagnet activation command. (0) : Electromagnet deactivated. (1) : Electromagnet activated.

Warning : Maximum 3 seconds activation of the electromagnet.

Double detection cover: Not activated (See chapter 3.3: Advanced Menu: Various / 3.3.3 Selection of optional items).

Inventory of inputs : - 60B01p : Cover detection in the transport clamp. - 60B02p :

Cover transport clamp home sensor.

- 60B03p :

Detection of zone where there is no interference of the cover transport with the carriage.

->

Command for forward movement of clamp.

->

Command for backward movement of clamp.

->

Command for Cover transport clamp home position.

Page 4 - 159

1 cover.

2 covers (Double).

Inventory of outputs : Scoring motor. - 60M01p :

Adjustment/Replacement procedures

No cover (Miss).

Initial issue: 06/03 Latest revision: 11/05

3.1.11 Outlet and conveyor :

Inventory of inputs : Book ejection detection. - 69B01p : - 79B01p :

Detection of presence of book on output conveyor.

Inventory of outputs : - 79M01p : Output conveyor drive motor. -> Motor start and stop command.

Adjustment/Replacement procedures Page 4 - 160

Initial issue: 06/03 Latest revision: 11/04

3.1.12 BBR : Inventory of outputs : - 72M01i : BBR head positioning and drive depending on thickness of the book.

Software version implement ed in BBR.

->

Command for backward movement of head (Thick books). Command for forwards movement of head (Thin books).

->

- 72M02p :

Inventory of inputs : - 79B01p : Detection of presence of book on output conveyor. - 72B01p : Book at inlet to BBR detection sensor. - 72B02i : Head Home position sensor. - 72B03p : Head positioning sensor (depending on thickness). Book separator harrow TDC detection. - 72B06i : - 72B08p : Full detection. - 72S01s : - 72S02s : - 72S03s :

Page 4 - 161

->

Book separator harrow lift command.

->

Book separator harrow descent command.

- 79M01p : ->

Output conveyor drive motor. Motor start and stop command.

BBR testing : Command to start an endurance test. -

Command to stop an endurance.

-

Command for BBR home position.

Emergency stop switch. Switch. Book separator harrow BDC detection switch. Book brought to vertical detection.

Adjustment/Replacement procedures

Book separator harrow lift/descent drive (separation of books).

Initial issue: 06/03 Latest revision: 11/04

Notes : This screen is only available if a BBR is connected to the binder.

3.2 Advanced Menu : “CALIBRATIONS” 6. Calibration of carriage braking. 7. Calibration and adjustment of screen brightness.

1

4

2

5

3

6

We shall look again at each of these menus in greater detail later.

7

To access the “CALIBRATIONS” menu, press the button

.

This menu gives you access to the various software adjustments that are available for the binder. The following adjustments are possible : 1. Adjustment of the gluing temperature. 2. Calibration of the spinner height. 3. Calibration of glue cut-offs. 4. Calibration of the creasing positions. 5. Calibration of the jogger frequency.

Adjustment/Replacement procedures Page 4 - 162

Initial issue: 06/03 Latest revision: 11/04

3.2.1 Setting the gluing temperature : • Enter the “GLUE TEMPERATURE” menu of the technician menu.

This allows you to : 1. Adjust the gluing temperature (Cylinder temperature) using the and keys.

Note : - If you press key during “Heating Timeout”, the temperature of cylinders is set to 40°C below the gluing temperature. - However, in the “GLUE” menu in the advanced menu, you will still be able to alter the gluing temperature by ± 15°C.

The following image will then appear on the screen.

2. Add some extra heating time to ensure that the glue temperature is homogeneous throughout the tank. This additional time is set to a default of 0 minutes.

Notes : A switch located on the “Glue tank” card is used to select the temperature at the bottom of the tank : - Switch up : Temperature maximum. - Switch down : Temperature minimum.

Adjustment/Replacement procedures Page 4 - 163

Initial issue: 06/03 Latest revision: 06/05

3.2.2 Calibration of the SPINNER height : The spinner is the component that determines the thickness of the film of glue left on the spine of the book. It is simply a small cylinder whose peripheral motion is in the opposite direction to that of the book. The spinner is fully scraped.

Procedure : • Enter the “GLUE TANK SPINNER” menu on the technician menu.

The spinner is mounted on the chassis. Changing the height of the cylinders and therefore of the tank has no effect on the height adjustment of the spinner. Prerequisites : • The binder must be ready : Green indicator lit (glue up to temperature, cylinders rotating). • Connect the technician control box to bypass the interlock and to release the milling blade and movement motor brakes. • Open the top panel.

Adjustment/Replacement procedures Page 4 - 164

The following screen is displayed.

Initial issue: 06/03 Latest revision: 11/04

Adjusting the height of the spinner :

Mechanical pre-adjustment of the spinner height :

Eccentric 1

• Place a comparator (PN 9 591 153) in the carriage clamp. • Displace the carriage over the milling module and zero the comparator on the highest tooth of the milling blade (on jogging side). • Then displace the carriage over the glue tank and measure (with the comparator) the distance between the spinner cylinder and the highest tooth of the milling blade.

Eccentric 2

• Using the eccentric (1) and (2), adjust the spinner height to obtain a distance of 0 mm ± 0.5 mm in comparaison to the highest tooth.

Adjusting the straightness of the spinner : • Adjust the straightness of the spinner relative to the grips of the fixed clamp on the carriage. - Place the square (PN CPB 9941021000) on the spinner cylinder and against the fixed jaw of the carriage clamps. - Turn the eccentric (2) to adjust the straightness of thecylinder in comparaison to the fixed jaw of the carriage (eccentric (1) is used as pivot).

Adjustment/Replacement procedures Page 4 - 165

The height of the spinner can be adjusted very precisely using the spinner calibration menu.

Initial issue: 06/03 Latest revision: 11/04

• On the UI, adjust the spinner height precisely. - Press to raise the spinner cylinder. - Press

to lower the spinner cylinder.

Once the spinner height is set to 0 mm ± 0.05 mm, return the binder to normal operating conditions.

Adjustment/Replacement procedures Page 4 - 166

Initial issue: 06/03 Latest revision: 11/04

3.2.3 Calibration of glue cut-offs : This calibration is used to cut off the film of glue on the spine of the book in accordance with the glue cut offs required by the operator. To enter the glue cut-off calibration menu, press the key “GLUE TANK SCRAPERS”.

Each of these calibrations can be further divided into three modes : 5. “Notched and variable speed” mode. 6. “Un-notched and high speed” mode. 7. “Notched and low speed” mode. In each case a calibration is performed using booklets of thicknesses 5, 25 and 45 mm. Attention : The calibration is performed using booklets of exact thicknesses 5, 25 and 45 mm only ! 1

2

3

4

5

Calibration of glue cut-off is divided into four parts : 1. Calibration of lateral gluing. 2. Calibration of the first cylinder. 3. Calibration of the second cylinder. 4. Calibration of cylinders 1 + 2.

Adjustment/Replacement procedures Page 4 - 167

6

7

Correction of glue cut-offs. In the above example, calibration of the glue cut-off for the first cylinder is in “notched and high-speed” mode using booklets of thicknesses 5, 25 and 45 mm. Initial issue: 06/03 Latest revision: 11/04

Sign convention for correction of glue cut-off : During calibration, the distance between the glue-cut-off and the edge of the book must be 15 mm , both to the front and rear.

Example: - Front cut off : measured = 20 mm. Desired cut-off: 15 mm.

If this is not the case, a correction must be made in order that cutoff takes place at the correct location. The purpose of this calibration is simply to determine the corrections to be made to ensure that cut-off occurs at the required point.

Reduce the glue cut-off length -> correction = -5. - Rear cut-off : measured = 12 mm. Desired cut-off : 15 mm. Increase the glue cut-off length -> correction = 3. Front glue cut off : 20mm Negative correction : - 5mm

15

15

Correction of glue cut-offs. 12

Positive correction: Increases the glue-cut-off length. Negative correction: Reduces the glue-cut-off length.

Adjustment/Replacement procedures Page 4 - 168

Initial issue: 06/03 Latest revision: 11/04

Rear glue cut off : 12mm Positive correction : + 3mm

20

Elements that influence the glue cut-off : The following elements influence glue cut-off : • Carriage movement speed. • The amount of glue to be applied to the spine of the book (will vary depending on the thickness of the book). The thicker book, the more glue that is to be applied to the spine. The speed of movement of the carriage itself varies depending on the thickness of the book.

Carriage speed

The carriage speed decrease with the increasing of the booklet thickness

0mm

Booklet thickness (mm) 45mm

60mm

Notes : - In “un-notched” mode, irrespective of the thickness of the book, the speed of movement of the carriage is at a maximum. - In some cases, it is not necessary to correct the glue cut-offs. Some keys will then be greyed out. - For calibration of lateral gluing, the amount of glue to be applied does not depend on the thickness of the book.

Adjustment/Replacement procedures Page 4 - 169

Initial issue: 06/03 Latest revision: 11/04

So - In the “un-notched and variable speed” mode, the speed of carriage movement is always at a maximum. A single calibration using a 5 mm booklet is required. - In the “notched at slow speed” mode, the speed of carriage movement is always at a minimum. A single calibration using a 5 mm booklet is required. (See calibration of lateral gluing).

Procedure to follow for calibration of glue cut-offs : Prerequisites : • The binder must be ready : Green indicator lit (glue up to temperature, cylinders rotating). • Connect the technician control box to bypass the interlock and to release the milling blade and movement motor brakes. • Open the top panel. • The height and straightness of the spinner must be correct (see Calibration of the SPINNER height).

- In notched and variable speed mode : • Press key mode.

to enter “Notched and variable speed”

• Take a bundle of paper of 5 mm thickness and place it in the carriage clamp. • Begin a gluing cycle. The gluing mode will then be in “BLOCK mode”, notched and the carriage will move at a variable speed.

1. Calibration of the first gluing cylinder • Press key

to access calibration of the first cylinder.

• To reduce book drying time above cover clamp, press the black button on the loading console to open the carriage jaw to recover the book. Then press the green button to bring the carriage over the loading area. • Examine the front and rear glue cut-offs on the spine of the book. These should be 15 mm from the edge of the book . • If this is not the case, a correction must be made in order that cut-off takes place at 15 mm from the edge of the book. • Repeat the operation using bundles of paper of 25 mm thickness.

Adjustment/Replacement procedures Page 4 - 170

Initial issue: 06/03 Latest revision: 11/04

- In notched and low speed mode :

- In un-notched and variable speed mode :

• Press key speed” mode.

to enter “un-notched and maximum

• Press key mode.

to enter “Notched and minimum speed”

• Take a bundle of paper of 5 mm thickness and place it in the carriage clamp. Withdraw your hands from the loading area and start a gluing cycle. The gluing mode will then be in “BLOCK mode”, un-notched and the carriage will move at maximum speed.

• Take a bundle of paper of 5 mm thickness and place it in the carriage clamp. Withdraw your hands from the loading area and start a gluing cycle. The gluing mode will then be in “BLOCK mode”, notched and the carriage will move at minimum speed.

• Release the book that is produced and correct the glue cutoff length if necessary. Front and rear glue cut-offs must be 15 mm from the edge of the booklet.

• Release the book that is produced and correct the glue cutoff length if necessary. Front and rear glue cut-offs must be 15 mm from the edge of the booklet.

• Repeat the operation using bundles of paper of 25 mm and 45 mm thickness (Correction on the rear glue cut-off only).

• Repeat the operation using bundles of paper of 25 mm and 45 mm thickness (Correction on the rear glue cut-off only).

Adjustment/Replacement procedures Page 4 - 171

Initial issue: 06/03 Latest revision: 11/04

2. Calibration of cylinder 2 and cylinders 1 + 2 To calibrate glue cut-off for cylinder 2 and cylinders 1 + 2, the procedure is exactly the same as for cylinder 1.

For cylinder 1+2.

The cylinder to be calibrated must be selected beforehand : • Press to calibrate cylinder 2. • Press

to calibrate cylinders 1+2.

For cylinder 2.

For each cylinder, calibrate the glue cut-offs in : - “Notched and variable speed” mode : - “Un-notched and maximum speed” mode : - “Notched and minimum speed” mode :

Adjustment/Replacement procedures Page 4 - 172

Initial issue: 06/03 Latest revision: 11/04

3. Calibration of lateral gluing Changing the lateral gluing cylinder separation gap correction value :

A. Separation of lateral gluing cylinders : Press on the icon

to calibrate lateral gluing cylinders. • Press

to start rotation.

• Press

to make a homing

• Press key to reduce the lateral gluing cylinders separation to the minimum gap. Separation gap : book of zero thickness + correction displayed to the screen. • Correct the lateral gluing cylinder separation gap. - Press

to increase gap.

- Press

to reduce the gap.

• Press the You may correct the lateral gluing cylinder separation gap : When booklets are being glued the cylinders are separated by : the thickness of the book + the correction made by a technician.

Adjustment/Replacement procedures Page 4 - 173

Initial issue: 06/03 Latest revision: 12/04

To validate.

Notes : For correct lateral gluing, adjust the gap separating the cylinders so that once the key is pressed, both of the films of glue on each of the cylinders just touch one another.

B. Separation of lateral gluing cylinders according to the booklet thickness :

• When the correction is zero : The distance between the lateral gluing cylinders is equal to the measured paper pile thickness at closing of the carriage.

When the carriage clamp closes, the bottom of the pile (not gripped in the clamp) to be bound is larger than the paper thickness in the clamp. To take this situation into account, a correction on the lateral gluing cylinders separation can be done for each booklet thickness by using icon

• When the correction is different than zero : The distance between the lateral gluing cylinders is equal to : The measured paper pile thickness at closing of the carriage. + A correction depending on the measured thickness.

.

When correction = 1 : if measured thickness is 0 mm -> correction is 0.0 mm. if measured thickness is 30 mm -> correction is 0.5 mm. if measured thickness is 60 mm -> correction is 1.0 mm.

Cylinders gap

When correction = 2 : if measured thickness is 0 mm -> correction is 0.0 mm. if measured thickness is 30 mm -> correction is 1.0 mm. if measured thickness is 60 mm -> correction is 2.0 mm.

61

60 Correction +1

30.5

30

Correction 0

Book thickness 30

Adjustment/Replacement procedures Page 4 - 174

Initial issue: 06/03 Latest revision: 12/04

60

C. Adjustment of displacement speed for the lateral qluing cylinder When books of different thicknesses are bound, the mobile cylinder moves depending on the new book thickness to be bound.

In this case, decrease the speed of the cylinder movement by using the icon (value by default : 10).

Fig.1

If the displacement of the mobile cylinder is too fast, the cylinder may not have sufficient glue applied and you may have a lack of glue on the first book on each series as illustrated on figure 2.

Fig.2

Mobile cylinder side

Adjustment/Replacement procedures Page 4 - 175

Initial issue: 06/03 Latest revision: 12/04

D. Glue cut-offs : - In “un-notched at high speed” mode and in “notched at low speed” mode: • Press key: speed” mode. or key mode.

to enter “un-notched and maximum

to enter “Notched and minimum speed”

• In each mode calibration of lateral gluing follows the normal procedure using only a paper thickness of 5 mm.

- In notched and variable speed mode : • Press key mode.

to enter “Notched and variable speed”

• Calibration of lateral gluing then follows the usual procedure using bundles of paper of 5, 25 mm thickness.

Adjustment/Replacement procedures Page 4 - 176

Initial issue: 06/03 Latest revision: 12/04

3.2.4 Calibration of the creasing position : The following image will then appear on the screen. The creasing module can create folds in the cover to make it easier to open the book. It also makes it possible to obtain bindings with folding wings. This calibration is used to adjust the position of the creasing relative to the cover clamp. Enter the creasing calibration menu by pressing the “CREASING” key.

Adjustment/Replacement procedures Page 4 - 177

Initial issue: 06/03 Latest revision: 11/04

Creasing calibration - Procedure : 4. Then align the cover creasing with the cover clamp. Increase or reduce the value (4) to carry out this alignment. The value in grey (254) is the theoretical value.

6

5

Cover with creasing centred relative to cover clamp

1. Press key

3

4

.

The binder then automatically picks up and scores the cover. The creasing on the cover is then centred relative to the cover clamp.

5. Remove the cover from the clamp and measure the distance between the score and the edge of the cover. Enter this value in the UI (see 5). The value in grey (86.0) is the theoretical value.

5 cm

6. The final operation involves correcting the position of creasing on the spine of the book. - If the correction is zero, the creasing on the spine will be spaced at the thickness of the booklet. - If there is a positive correction, the space between creasing will be greater than the thickness of the booklet. - If there is a negative correction, the space between creasing will be less than the thickness of the booklet. - Usually use a correction of +2,5.

2. Using the technician’s control box, release the movement motor brake and move the carriage over the cover clamp module. Note : This correction only involves the two creases on the spine of the booklet.

3. Align the cover clamp with the fixed carriage clamps. Adjust the alignment using key .

Adjustment/Replacement procedures Page 4 - 178

Initial issue: 06/03 Latest revision: 12/04

3.2.5 Calibration of the Jogging vibration frequency : The following image will then appear on the screen. This calibration is used to adjust the vibration frequency of the jogger plate so that a vibration amplitude of 0.9 mm is obtained.

Sticker

Enter the jogging calibration menu by pressing key : “JOGGER FREQUENCIES”.

A self-adhesive label (ref CPB 99 133 04000) fixed on the jogger plate is used to measure the amplitude of vibration. 1. Press the key to start the jogger plate vibration. 2. When the jogger plate is vibrating : -> Measure the amplitude of movement using the selfadhesive label. A white line is shown between two black arrows. The tip of the white line indicates the amplitude of vibration. 3. Using the and keys, correct the vibration frequency until the movement amplitude obtained is 0.9 mm. Warning : A thermal protection device is activated if power is supplied to the jogger for an excessive period of time. The safety device re-sets itself once it has stopped for a few seconds.

Adjustment/Replacement procedures Page 4 - 179

Initial issue: 06/03 Latest revision: 11/04

3.2.6 Calibration of carriage braking : The following image will then appear on the screen. This calibration is used to adjust carriage braking. Enter the carriage braking menu by pressing key : “TRANSLATION”. Adjustment of braking above the cover clamp module.

Adjustment of braking above the jogger module.

The carriage braking can be either advanced or retarded. Adjust the point at which braking occurs in both directions of movement of the carriage so that it comes gently to a stop at the end of travel. • Increase the time delay value to brake sooner. • Decrease the time delay value to brake later.

Warning : If the time delay value is less than zero, the carriage could hit the end stop with excessive force.

Adjustment/Replacement procedures Page 4 - 180

Initial issue: 06/03 Latest revision: 11/04

3.2.7 Parameterisation of the touch-screen : In order to gain access to the touch screen, press the “TOUCH SCREEN” key.

The following image will then appear on the screen. Two adjustments may be carried out :

1. Screen brightness.

2. Calibration of the screen.

1. Screen brightness. Increase and decrease screen brightness by pressing the and keys.

2. Calibration of the screen. This operation determines the cursor position of the touch screen according to the place the operator touched it. • To calibrate the screen press the “Start screen calibration” button. • Then press on each cross as it appears.

Adjustment/Replacement procedures Page 4 - 181

Initial issue: 06/03 Latest revision: 11/04

3.3 Advanced Menu : “VARIOUS” This menu is used to adjust some of the binder’s parameters. To access the “VARIOUS “ menu, press button

3. Save the current “Calibrations” menu settings in memory in the technician menu.

.

When done after glue cutt-off calibration, this operation define the AUTO parameters to save these adjustments. 1

5

2

6

3

7

4

8

4. Delete the current settings in the “Calibrations” menu in order to restore the settings saved in (3). A confirmation message appears to delete the current settings and restore the saved settings. 5. Determine the cover clamp and gluing parameters in the Automatic menu. 6. Select the optional elements installed on the BB3002 (creasing, lateral gluing etc.). 7. Change the machine counter.

This menu allows you to :

8. Connect to use the binder in a network. 1. Carry out an endurance test - see 3.3.1. 2. By-pass the 55 minutes waiting time for the glue tank. This option is used to avoid the 55 minutes wait when the tank is already hot (after a service intervention, for example). Warning : Do not by-pass the timer if the tank is cold ! (damage could occur).

Adjustment/Replacement procedures Page 4 - 182

Initial issue: 06/03 Latest revision: 11/04

3.3.1 Endurance test : • The following window will then appear on the screen. Endurance testing of the binder can be performed, that is, the machine operates without stopping and without processing the paper. This test is beneficial since it checks that the binder is operating correctly after, for example, service interventions. • Access “LIFE TEST” mode by pressing this

key.

• This allows you to select : 1. The carriage movement speed. 2. Whether or not rotation of the milling blade is activated. 3. The book output mode. 4. Activation or deactivation of each respective creasing. 5. The fold direction of each creasing. 6. Lateral pressure intensity values. 7. Dorsal pressure intensity values. 8. The glue drying time before cover gripping takes place. 9. The glue drying time during which cover gripping takes place. 10. Whether cover picking takes place or not. • Then restart the endurance test by rapidly pressing the green button on the loading console twice. Note : During Life Test mode the green and red signal lamps above the loading zone flash.

Adjustment/Replacement procedures Page 4 - 183

Initial issue: 06/03 Latest revision: 11/04

3.3.2 Define parameters of the AUTOMATIC menu: In the ‘AUTO’ menu or during the creation of a new task (by pressing key ), the parameters for cover clamp and gluing will be reinitialized to their ‘AUTO’ values.

• The following window will then appear on the screen. The technician can now define the ‘AUTO’ parameter values. These parameter values will then be used during creation of a new task or in the AUTOMATIC menu.

This menu defines the value of the ‘AUTO’ parameters. Procedure to change the ‘AUTO’ parameters : • Enter in the JOB DEFAULTS mode for the technician menu.

By pressing key , the technician can define the value of the 6 parameters that change according to the booklet thickness to be bound.

Adjustment/Replacement procedures Page 4 - 184

Initial issue: 06/03 Latest revision: 11/04

The 6 parameters that change with the booklet thickness are the followings: - Thickness of the glue film. - Cover clamp dorsal pressure. - Padding drying time. - Drying time before cover clamp. - Drying time during cover clamp.

These are for each parameter, the recommended ‘AUTO’ value to be entered : Thickness of the glue film.

For each parameter, the technician should defined its value: - For a thickness from 0 to 15 mm. - For a thickness from 15 to 30 mm. - For a thickness from 30 to 45 mm. - For a thickness from 45 to 60 mm. - For the default value, i.e. the parameter value when operator switches from ‘AUTO’ mode to manual mode.

Cover clamp lateral pressure.

Adjustment/Replacement procedures Page 4 - 185

Initial issue: 06/03 Latest revision: 11/04

Cover clamp dorsal pressure.

Drying time before cover clamp.

Padding drying time. Drying time during cover clamp.

Adjustment/Replacement procedures Page 4 - 186

Initial issue: 06/03 Latest revision: 11/04

To return to the first window from the ‘AUTO’ parameters definition, press key .

Adjustment/Replacement procedures Page 4 - 187

Initial issue: 06/03 Latest revision: 11/04

3.3.3 Selection of optional items : At installation of the binder at the client’s premises you should select the optional items fitted to the machine.

You will then be able to select the optional elements that are installed on the binder.

In the technician menu, press “OPTIONAL COMPONENTS” to select the machine options.

The following optional items are available : - Lateral gluing. - Creasing module. - Glue tank heater timer. - Suction of internal paper waste. - Double cover detection. - Multi creasing module. - Activation or deactivation of commercial limits.

Adjustment/Replacement procedures Page 4 - 188

Initial issue: 06/03 Latest revision: 11/04

3.3.4 Binder counter : The binder is provided with a counter that totals the numbers of bindings carried out. This counter may be accessed at any time. In order to access the binder counter, press “MACHINE COUNTER”.

The screen will then display the total number of bindings carried out. Make entries into the counter that is displayed to change the counter value.

You can also change the counter by pressing on the number displayed. An alphanumeric keyboard appears on the screen. Enter the new counter value and confirm it by pressing . There are 2 non-modifiable mechanical counters (1 time counter and 1 set counter). They are on the DISPATCH board at the front of the electronic rack.

Adjustment/Replacement procedures Page 4 - 189

Initial issue: 06/03 Latest revision: 11/04

3.3.5 Connections : You will then have access to : The binder has an Internet address for (for example) : - Remote control of the machine. - Carrying out updates of the programme installed in the PLC. - ... Press the “CONNECTION” button to access the various addresses for the binder.

• Internet address. • Broadcast address. • Subnet Mask. • Default Gateway. That can change by pressing the desired address. To record changes, you must re-start the screen by pressing the “Cold Restart” button .

Adjustment/Replacement procedures Page 4 - 190

Initial issue: 06/03 Latest revision: 11/04

This page is intentionally left blank.

Adjustment/Replacement procedures Page 4 - 191

Initial issue: 06/03 Latest revision: 11/04

Section 5 :

SPARE PARTS

Spare Parts Page 5 - 0

Initial issue: 05/03 Latest revision: 11/05

This page is intentionally left blank.

Spare Parts Page 5 - ii

Initial issue: 05/03 Latest revision: 09/04

TABLE OF CONTENTS Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Symbols and legends

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1. Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 PL1.1 Covers (part 1 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 PL1.2 Covers (part 2 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 PL1.3 Covers (part 3 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 PL1.4 Covers (part 4 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 PL1.5 Covers (part 5 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 PL1.6 Covers (part 6 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 PL1.7 Covers (part 7 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 PL1.8 Covers (part 8 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 PL1.9 Covers (part 9 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 PL1.10 Covers (part 10 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2. Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 PL2.1 Drive system (part 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 PL2.2 Drive system (part 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 PL2.3 Drive system (part 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3. Carriage PL3.1 PL3.2 PL3.3 PL3.4 PL3.5 PL3.6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Carriage Carriage Carriage Carriage Carriage Carriage

(part (part (part (part (part (part

1 2 3 4 5 6

of of of of of of

6) 6) 6) 6) 6) 6)

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

.22 .23 .24 .25 .26 .27

4. Jogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 PL4.1 Jogger (part 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 PL4.2 Jogger (part 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Spare Parts Page 5 - 1

Initial issue: 05/03 Latest revision: 11/05

PL4.3 Jogger (part 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

5. Notching/Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 PL5.1.1 Notching/Milling (without Tag 19) (part 1 of 4) PL5.1.2 Notching/Milling (with Tag 19) (part 2 of 4) . . PL5.2 Notching/Milling (part 3 of 4) . . . . . . . . . . . . . . PL5.3 Notching/Milling (part 4 of 4) . . . . . . . . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

.33 .34 .35 .36

6. Glue tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 PL6.1 Glue tank (part 1 of 14) . . . . . . . . . . . . . . . . . . . PL6.2 Glue tank (part 2 of 14) . . . . . . . . . . . . . . . . . . . PL6.3 Glue tank - lateral gluing (optional) (part 3 of 14) PL6.4 Glue tank - lateral gluing (optional) (part 4 of 14) PL6.5 Glue tank - lateral gluing (optional) (part 5 of 14) PL6.6 Glue tank - lateral gluing (optional) (part 6 of 14) PL6.7 Glue tank (part 7 of 14) . . . . . . . . . . . . . . . . . . . PL6.8 Glue tank (part 8 of 14) . . . . . . . . . . . . . . . . . . . PL6.9 Glue tank (part 9 of 14) . . . . . . . . . . . . . . . . . . . PL6.10 Glue tank (part 10 of 14) . . . . . . . . . . . . . . . . . PL6.11 Glue tank (part 11 of 14) . . . . . . . . . . . . . . . . . PL6.12 Glue tank (part 12 of 14) . . . . . . . . . . . . . . . . . PL6.13 Glue tank (part 13 of 14) . . . . . . . . . . . . . . . . . PL6.14 Glue tank (part 14 of 14) . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

.38 .39 .40 .41 .42 .43 .44 .45 .46 .47 .48 .49 .50 .51

7. Cover nipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 PL7.1 PL7.2 PL7.3 PL7.4 PL7.5 PL7.6 PL7.7 PL7.8 PL7.9

Spare Parts Page 5 - 2

Cover Cover Cover Cover Cover Cover Cover Cover Cover

nipping nipping nipping nipping nipping nipping nipping nipping nipping

(part (part (part (part (part (part (part (part (part

1 2 3 4 5 6 7 8 9

of of of of of of of of of

10) 10) 10) 10) 10) 10) 10) 10) 10)

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

Initial issue: 05/03 Latest revision: 11/05

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

.53 .54 .55 .56 .57 .58 .59 .60 .61

PL7.10 Cover nipping (part 10 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

8. Cover transport

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

PL8.1 Cover transport (part 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 PL8.2 Cover transport (part 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 PL8.3 Cover transport (part 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

9. Suction bar drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 PL9.1 Suction bar drive system (part 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 PL9.2 Suction bar drive system (part 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 PL9.3 Suction bar drive system (part 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

10. Cover station (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 PL10.1 PL10.2 PL10.3 PL10.4

Cover Cover Cover Cover

station station station station

(part (part (part (part

1 2 3 4

of of of of

4) 4) 4) 4)

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

.72 .73 .74 .75

11. cover suction / blower turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 PL11.1 cover suction / blower turbine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

12. Scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 PL12.1 PL12.2 PL12.3 PL12.4 PL12.5 PL12.6 PL12.7 PL12.8

Scoring (part 1 of 8) . Scoring (part 2 of 8) . Scoring (part 3 of 8) . Scoring (part 4 of 8) . Scoring (part 5 of 8) . Scoring (part 6 of 8) . Scoring (part 7 of 8) . Creasing (part 8 of 8)

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

.79 .80 .81 .82 .83 .84 .85 .86

13. Output & conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 PL13.1 Output & conveyor (part 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 PL13.2 Output & conveyor (part 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Spare Parts Page 5 - 3

Initial issue: 05/03 Latest revision: 11/05

14. Output unit (bottom) optional PL14.1 PL14.2 PL14.3 PL14.4 PL14.5 PL14.6 PL14.7 PL14.8 PL14.9

Output Output Output Output Output Output Output Output Output

unit unit unit unit unit unit unit unit unit

(bottom) (bottom) (bottom) (bottom) (bottom) (bottom) (bottom) (bottom) (bottom)

optional optional optional optional optional optional optional optional optional

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 (part (part (part (part (part (part (part (part (part

1 2 3 4 5 6 7 8 9

of of of of of of of of of

9) 9) 9) 9) 9) 9) 9) 9) 9)

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

.91 .92 .93 .94 .95 .96 .97 .98 .99

15. External system for collecting waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 16. Internal system for collecting waste (option)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

17. U.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 17.1 U.I.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

18. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 PL 18.1 Electrical (part 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 PL 18.2 Electrical (part 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

19. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 20. First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 21. Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

Spare Parts Page 5 - 4

Initial issue: 05/03 Latest revision: 11/05

INTRODUCTION 4

Symbols and legends 3 S10 W8

This symbol refers to a spare with exact description and part number listed on the page. - AF

5

10

3

3

3.9

This symbol means item 4 is affected by a configuration change described by tag-3. In the list next to drawings, or on an alternate sheet, the parts references to be used depending on whether or not the machine is tagged, are mentioned.(For tag description see "tag signification" section 6).

For example, to order the front door assy 9403883, you should order the part 9403883-AF.

This symbol means item 5 is to be used when tag-3 is not crossed.(For tag description see "tag signification" section 6). This symbol means that replacement of part 10 requires an adjustment. It is available on section 4 chapter 3.9 in the service manual.

Spare Parts Page 5 - 5

For blue machines

This symbol refers to common hardware. List, descriptiption and part numbers of common hardware is in a separate section at the end of the spare parts manual.

N16

4

This symbol means item 4 is a painted part. All part numbers corresponding to parts which are painted in different colors depending on machine version do require a “color” suffix.

Initial issue: 05/03 Latest revision: 06/05

1. COVERS

See PL1.1 See PL1.3

See PL1.1

See PL1.2

Spare parts Page 5 - 6

Initial issue: 05/03 Latest revision: 09/04

PL1.1 Covers (part 1 of 10) 5 7 1

1 2 3 4 6 7 8

9146339 9422990 9422991 9146354 9413733 9139707 9230354

Emergency button

Quarter turn lock assy

For the blue machines

N006 W185

4

8

N006 W185

8

8

5 9

8

3 8

8

2

9

C431 6

Spare parts Page 5 - 7

Initial issue: 05/03 Latest revision: 09/04

S377

9403885-AF 9403897-AF

PL1.2 Covers (part 2 of 10)

OR

S377 S377 S377 5

S378

1

1

2

S378

1 2 3 5 6

S377

9146373 9432557 NA 9422996 9199448

Actuator black IP40 Safety curtain assembly Dual button board Rubber bumper

S551 For the blue machines S551

4 6

S551 W186 S551

Spare parts Page 5 - 8

S441

S551

W186 S441

Initial issue: 05/03 Latest revision: 03/05

9403925-AF 4

Loading area extension

PL1.3 Covers (part 3 of 10) See PL1.4

2

1

2

W185 S464 See PL1.5 2

1

2

W185 S464 1 2

Spare parts Page 5 - 9

Initial issue: 05/03 Latest revision: 09/04

9201665 9261139

Actuator shaft Actuator shaft spacer

PL1.4 Covers (part 4 of 10) 1 9115031 2 9422990 3 9199985 Gas spring 6 9261850 7 9203754 For the blue machines 4 9231000-AF 5 9403886-AF

S378 S472 1

5 4 S378

S378 S472 1 W187 W185 2

S464

S464

S163

W187

S481

W187 W185 S464

7

S163 3

W187

S481 W185 S464

Spare parts Page 5 - 10

Initial issue: 05/03 Latest revision: 09/04

6

6

PL1.5 Covers (part 5 of 10)

2 S377

R431

S472

S469

W185 N006

See PL1.4

3 S516 1

W003 N005

S472

See PL1.4 S377 W003 1 2 4

9146366 9413733 9104114

Interlock switch Quarter turn lock assy

N005

4 For the blue machines 3 9414070-AF

S374

W187

Spare parts Page 5 - 11

Initial issue: 05/03 Latest revision: 01/05

Plexi cover can not be replaced

PL1.6 Covers (part 6 of 10)

See PL1.7 See PL1.7

See PL1.9

See PL1.9

See PL1.7

See PL1.8 See PL1.10 See PL1.9

Spare parts Page 5 - 12

Initial issue: 05/03 Latest revision: 09/04

PL1.7 Covers (part 7 of 10) S377

S377 S378

7

S377

2

R431

5

R431

5

R431

4 S378 W182 R431

N005

S378

S378 S378

5

8 S462 S461

9

8

6

S377

9

9

6

S377

R431

6

3

1 S377

S377

5 6 7 8 9

C431

6

S377

S377

Spare parts Page 5 - 13

S377

9413733 9199448 9199807 9150065 9260831

Quarter turn lock assy Rubber stop Rubber stop D15 Microswitch microswitch bracket

For the blue machines 1 9414058-AF 2 9414064-AF 3 9414063-AF 4 9414062-AF

Initial issue: 05/03 Latest revision: 12/04

PL1.8 Covers (part 8 of 10) 2

4

S467 W185

S516

S467 W185 S516 1 S377

S377

S515 S515

3 S377 S377

S378 7 S378

1 2 3 4 5 6 9

9115026 9115027 9146379 9146366 9104106 9104105 9261039

Hinge 100D + spring Hinge arm

9 5

Interlock switch Verschlub BDF Snapin handle Rubber distance 5mm

For the blue machines 7 8

9403883-AF 9414066-AF 9

6

8

Spare parts Page 5 - 14

Initial issue: 05/03 Latest revision: 09/04

PL1.9 Covers (part 9 of 10) 5 6

9413733 2985276

Quarter turn lock assy

For the blue machines 1 9230967-AF 2 9414056-AF 3 9231072-AK 4 9403879-AF

1

S304 S304 S304 S304

4

R431

5

R431

6

S377

R431 S459

2

W185

S459

S459

S377

W185

W185 S459 W185

S377

S377

3 S377

S377

Spare parts Page 5 - 15

Initial issue: 05/03 Latest revision: 01/05

PL1.10 Covers (part 10 of 10) S472 W186

2

3

S472 S472

W186

S472

W186 W186 R431 S377 S472

R431

W185

S377

W186

S464

1 W185 S464

1 3 S377

9413733 9403882

For the blue machines 2 9414060-AF

S377

Spare parts Page 5 - 16

Quarter turn lock assy

Initial issue: 05/03 Latest revision: 01/05

2. DRIVE SYSTEM

Spare parts Page 5 - 17

Initial issue: 05/03 Latest revision: 09/04

PL2.1 Drive system (part 1 of 3)

W188

S393

3

3

W188

3 W187

S483 1

4

1 2 3 4

Spare parts Page 5 - 18

Initial issue: 05/03 Latest revision: 09/04

2

9126449 9413909 9190394 9261853

PL2.2 Drive system (part 2 of 3) N008 1

11 11

9

7

S483 W187

11

W187

S473 W186 W187 11 10

W005 11

W188

S374 8

S461

5

S482

S382 6

3 S483

S457 W184

N106 4

11

W187

11

11

S482

2 12

N012 S435

W187

S483

Spare parts Page 5 - 19

Initial issue: 05/03 Latest revision: 09/04

1 2 3 4 5 6 7 8 9 10 11 12

9260831 Microswitch bracket 9261853 9422841 9413908 9222599 9413906 9413907 9203273 9432351 9150065 Microswitch 9190394 9413909

PL2.3 Drive system (part 3 of 3)

1 1 1

1

S607

3 S607

W187 W006

W187

8

W187

2

7

9

S607 S569

5 6 4 4

W187 S569

8

Spare parts Page 5 - 20

Initial issue: 05/03 Latest revision: 10/05

1 2 3 4 5 6 7 8 9

9190394 9432447 9432350 9116005 9203275 068850602000 9215512 9203278 9151922

Shaft key DIN 6885A

3. CARRIAGE

Spare parts Page 5 - 21

Initial issue: 05/03 Latest revision: 09/04

PL3.1 Carriage (part 1 of 6) S378

W188

W188

S374 W187 See PL2.1

S489 W188 S441 1 S377

W186

S441

1

W186

W186

1

W187 S374 W187

S374 W187

S482

Spare parts Page 5 - 22

Initial issue: 05/03 Latest revision: 09/04

9414004

PL3.2 Carriage (part 2 of 6) 6 S474

Spring washer sequence

W041

W034

7

S922

1

S922

W034

S922 W034

S922

2

W034 2 N001 2 W034 N001

W041 N001

S377

3 S474

W186

S471 5

4

R002

Spare parts Page 5 - 23

Initial issue: 05/03 Latest revision: 03/05

1 2 3 4 5 6 7

9230605 9108062 9422774 9175010 9203362 9422773 9230604

Mobile jaw Locking saddle Emitter board Roller 625ZZ Carriage closure guide Receiver board Fixe jaw

PL3.3 Carriage (part 3 of 6)

S548 W188 1 N004

S548 W188

W002 1 W200

1

W188 S548

N004 1

1 W002

W200 W188

W200 S548

W188

S613 W200 W188

S613

Spare parts Page 5 - 24

Initial issue: 05/03 Latest revision: 09/04

9175082

Roller

PL3.4 Carriage (part 4 of 6)

5 5

S471 W186 S460

6 6

S471 W186 4 3

2 1 W186

1 2 3 4 5 6 S472

Spare parts Page 5 - 25

W186

Initial issue: 05/03 Latest revision: 09/04

9432331 9414038 9203365 9422843 9108027 9108070

Pinion

Locking saddle Wire routing clamp

PL3.5 Carriage (part 5 of 6) S378

W188

W188

S374 W187 See PL2.1

S489 W188 S441 1 S377

W186

S441

1

W186

W186

1

W187 S374 W187

S374 W187

S482

Spare parts Page 5 - 26

Initial issue: 05/03 Latest revision: 09/04

9414004

PL3.6 Carriage (part 6 of 6) 7 3

4

S482 W187 5 3

W187 S374

S374 S243

W187

6 2

W187 S374

2 S490 S490 W188 W188

1 2 3 4 5 6 7

W187 S482

W187

1 S546 W187 1

Spare parts Page 5 - 27

Initial issue: 05/03 Latest revision: 09/04

9414076 9414077 9108060 9107061 9230609 9414078 9414079

Flat tie holder blind hole

4. JOGGER 1

1

Spare parts Page 5 - 28

Initial issue: 05/03 Latest revision: 09/04

2081998

Jogging foot lever

PL4.1 Jogger (part 1 of 3) S473 6 W186 1

5

5

S471 W186

S473 W186

W186

W186

S471 5

S471 5 W186

See PL4.3

W186 S472

W186

W186

4

S472 3

R024 7 2

7

W186

W186

W186 S471

R024

S472 3 R024 2 W186

S471

S471 S471

Spare parts Page 5 - 29

Initial issue: 05/03 Latest revision: 09/04

1 2 3 4 5 6 7

9222620 9203318 9175089 9230583-AK 9182065 9432425 9413915

Bearing

PL4.2 Jogger (part 2 of 3) W187

6 1

S233

10 13

S464 W185

6

W187

8

S502 W187

S481

11

W187

N006 S233

S502

7

9

W187

N006 S460

7

S453 N046 W004

S377

3 14

2

W190 N046 W190

S377

N046

W190

S377

W190

1 2 3 4 5 6 7 8 9 10 11 12 13 14

W175 W190

S592

12 N046

S592

W175 N046

N046

W175

W175

W187 S243

4

W175

W187 S243

12

W187 S243

W187 S243

5 W187 S374

Spare parts Page 5 - 30

S453

4 5

W190

W187 S374

S592

Initial issue: 05/03 Latest revision: 09/04

9403737 9107063 9107062 9166277 9211455 9175089 9413916 9126326 9431932 9413917 9413522 9230581 9203317 9203744

Optical switch Photosensor Fly whl washer primary shaft Bearing Belt Stepping motor + hex. shaft Pulley assy

PL4.3 Jogger (part 3 of 3) S377

N152 10 N152 S377 N152 N152 S371

S371 S471 W185 W185 W186

8

S371

S471 W186

W185 3

5 S371

S453 3

N054

7

W185

W186

W186 S471

9

2

W186 3 W186 1 S471 3 1

W186 4

S471

5

4

Page 5 - 31

5

3

3 3

Spare parts

3

6 W186 S471

S471

S471

W185

Initial issue: 05/03 Latest revision: 09/04

1 2 3 4 5 6 7 8 9 10

9413913 9230576 9157011 9230582 9230579 9230578 9166292 9203319 9413914 9199889

o-ring

5. NOTCHING/MILLING

Spare parts Page 5 - 32

Initial issue: 05/03 Latest revision: 09/04

PL5.1.1 Notching/Milling (without Tag 19) (part 1 of 4) A:

N002 S122

S536

S551

S472 S472 W186 16

B:

W186

B A

16

N002 W186

8

12

11 12

A

S453 1

S471

S536

W185

S523 2

W186

S562

S371

S523

N054

W185

14

14

9

3

7 6

7

6

15

13

4 3

S009

13

15 10

W163 N006

5

S009

S378 S378

Spare parts Page 5 - 33

Initial issue: 05/03 Latest revision: 03/05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

9230805 9230802 9203555 9166164 9199999 9199998 2990125 9222738 9199067 9165075 2082806 9403915 9127039 9203552 9203551 9203895

Stationary knife Stationary sliding block Connecting plate Spring Milling blade Notching knife (2 std / 4 opt) Cutter adjusting screw milling shutter Rubber bumper Edge moulding Teflon strip Abrasive tools (option) Nylon sleeve Milling shutter pivot cutter brushing Station knife adj. washer

PL5.1.2 Notching/Milling (with Tag 19) (part 2 of 4) S472 W186 16

S472 W186

B A

A:

16

N002 S122

S536

S551

1

A

B:

S514 W039

S464 W185

N002 W186

8

12

18

11 12

2 17

S462

21

S453

S471 W186 S523

S536

S184 19

S471 W186

W185

S562 20 S371

S523

22

N054 14

W185 6

7

15

W005 N008

7 6

14

9

3

15

23

13

4 3

S009

W163 N006

13 10 5

S009

S378 S378

Spare parts Page 5 - 34

Initial issue: 05/03 Latest revision: 08/05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

9231361 9231360 9203555 9166164 9404141 + 9204100 9199998 2990125 9222738 9199067 9165075 2082806 9403915 9127039 9203552 9203551 9203895 9204120 9240378 9107074 9199678 9199666 9157033 9204100

Stationary knife Stationary sliding block Connecting plate Spring Milling blade assembly Notching knife (2 std / 4 opt) Cutter adjusting screw milling shutter Rubber bumper Edge moulding Teflon strip Abrasive tools (option) Nylon sleeve Milling shutter pivot cutter brushing Station knife adj. washer Roller pivot Bronze roller Pressure Sensor Nozzle Pressure sensor tube Rubber O Ring Centering washer

PL5.2 Notching/Milling (part 3 of 4)

S570

S570

19

S570 W003

19

19

S570 W003

W003

S489

S489

W003

3

3 6

6

W044 W044

6

6

S514

S489

S489

S514

W185

S489

S489

S489

1

S489

W185 S462

W044

W044

W044

W044

W551 1

6

6

S551

6

6

10 10

S462

N008 4 2 7

3

4 N008

1 2 3 4 5 6 7 8 9 10

Spare parts Page 5 - 35

Initial issue: 05/03 Latest revision: 08/05

9198003 9165023 9222351 9261250 NA 9198011 9199678 NA NA 9107074 9591161

Brush Cable grommet Tube fix Pressure sensor tube Brush Nozzle

with tag 6 Pressure sensor without Tag 6 Upgrade Kit Tag 8

PL5.3 Notching/Milling (part 4 of 4) S437

2 W188

S437 W188 S607 S607

S458 N150 N002

1 W190

S378

3

S474

9 N150 W175

S465 W211 W175

3

11

N002 S474 N008

S592 W186 S479 W186 S479

W186 7

W185

W185

8 S514

S479 5

4 7

S042 W200 W188

6 10

Spare parts Page 5 - 36

Initial issue: 05/03 Latest revision: 09/04

1 2 3 4 5 6 7 8 9 10 11

9432373 9151916 9107063 9414035 9222652 9126161 9175012 9175100 9230661 009310806506 9203448

Optical switch

Belt D4x412 Bearing

6. GLUE TANK

Spare parts Page 5 - 37

Initial issue: 05/03 Latest revision: 09/04

PL6.1 Glue tank (part 1 of 14)

N078 W189

1 2

3 N078 W189

1 2 3

S191

Spare parts Page 5 - 38

Initial issue: 05/03 Latest revision: 09/04

9203632 9230889 9203631

PL6.2 Glue tank (part 2 of 14) N009

W188

S472

W192 S377

5

W002 N009

W192

1

S474

S377 2

5

3 N009 W188 W002

N009 N009 W002

10 W467

S465

9 W004

6 S465 S465

1 2 3 4 5 6 7 8 9 10

Spare parts Page 5 - 39

9135095 9172212 9230880 9170402 9183135 9147004 9432392 9196027 9166285 9203681

S465

4

Sealing paste

8

7

7

S465

S465

Initial issue: 05/03 Latest revision: 09/05

PL6.3 Glue tank - lateral gluing (optional) (part 3 of 14)

1

See P.L. 6.4

S138 W007 N002 4

S371

2

W185 3

N012

1 2 3 4 5 6 7 8 9 10

9432339 9414054 9230927 9140079 9432396 9140008 9166286 9203647 9107063 009330500806

Lateral gluing assy Gear Z10 assy Gear Pin Solenoid assy Spring pin Spring Connecting plate Optical switch Screw

8

S484 N012 S484 S377 7 5

6

S377 W186

9

10

S378

Spare parts Page 5 - 40

Initial issue: 05/03 Latest revision: 11/05

PL6.4 Glue tank - lateral gluing (optional) (part 4 of 14) 3

W027

8

C013 4

13

W026 W030 C012 W207

2

8 6

11

13

3

C158 S051 W207

7

S464

W007 W207

W191

13 1 2 3 4 5 6 7 8 9 10 11

9157042 9172207 9261834 9591179 9403992 9204091 9204090 9140079 9204098 9204097 9172213

O ring Spirawave washer Washer Lateral screw kit Recover glue plate Half screw fixed head Half screw mobil head Pin Spring int. support Spring ext support Spiraware washer

9

W026 11

10

13

S377 S464

W002

1

S296 N002 5

Spare parts Page 5 - 41

Initial issue: 05/03 Latest revision: 11/05

1

PL6.5 Glue tank - lateral gluing (optional) (part 5 of 14) S343 S343

S465 7

6 S465 S522

W191

W191

S522 W186 W186

5

9 5

8

2

1

8

3

3 4 S542

8

W191

4

S542 6

W191 7

do not demount

do not demount

W185

W185 S542

S542 W006 W187 S543

Spare parts Page 5 - 42

1 2 3 4 5 6 7 8 9

9215509 9215510 9174011 9204047 9414195 9414198 9414199 9172208 9240361

W185

W185

lateral gluing cylinder

Initial issue: 05/03 Latest revision: 01/05

S542

S542 S542

W006 W187 S543

PL6.6 Glue tank - lateral gluing (optional) (part 6 of 14)

S374

S374

W187

W185 S371

S464

W187

W191 2

3 4

1

3 5 S481 S481

W187 3 W187 3

Spare parts Page 5 - 43

Initial issue: 05/03 Latest revision: 09/05

1 2 3 4 5

9432403 9183135 9147007 9111110 9111026

Master link 8mm

PL6.7 Glue tank (part 7 of 14) Chain path 1 2 3 4 5 6 7

1

W192

7 S474

5 W192 3

9111108 9111026 9230900 9203741 9414045 9210630 9142004

7 3 2

1

W007 W186 S441

S454 W187

4 4

S454

W187 6

S574

W187 W175

6

N150

S503

N150 W187

W211 W187

W211

N150 W175

Spare parts Page 5 - 44

Initial issue: 05/03 Latest revision: 11/05

S503

Master link 8mm

Spacer

PL6.8 Glue tank (part 8 of 14) 1 8 S441 W192 W007

3 R006

S473

14

W186 12 13 S243 W187

1 2 3 4 5 6 7 8 9 10 11 12 13 14

9111109 9230900 9230901 9403928 9166284 9414041 9230903 9111002 9151180 9116012 9116009 9116007 9116040 9142004

R012

10 11

W006 7

W186 N002

S473 W186

S473 R153 W187

Chain link

N001

S607

2

W007 W186

W187

Shaft key DIN6885A 5x5x20 Shaft key DIN6885A 5x5x25 Shaft key DIN6885A 4x4x14

5

S374

Chain path

S465

W187

4 W185

S441 W001

N012 W191 S465 S435

W028 R010

6 W001

9

Spare parts Page 5 - 45

Initial issue: 05/03 Latest revision: 11/05

PL6.9 Glue tank (part 9 of 14) S465

W011 S374

W001

W191 4

S377 W187 S482

S672

S465 W191 9

W001 W011

S502

28

S374

W187

12

W185

S009

8

S482

9

7

W187

W187

W111

3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

S482 W187 13

11 8 10 15 11

W209

2 R012 1

W185 S466 W187 N012

Spare parts Page 5 - 46

Initial issue: 05/03 Latest revision: 11/05

S465

14

2 R016

5

S482

6

9432458 9175110 9230881 9432391 9107063 9140080 9166282 9240354 9203621 9222714 9147010 9204092 9240353 9261831 9166283

Optical switch

PL6.10 Glue tank (part 10 of 14) N002 N002 S296 S465 W185

S296 S465 S296

S296 S465

W185 S465

S453 W191

S378

11 11

8 1 10

S457

S457 S457 W105 S514 S378 W186

W186 S441

W185 4

3

N012 S470 3

N012 W186

S470 5

S470

10 W186

2 S484

2

6

9 7

Spare parts Page 5 - 47

9

S484

Initial issue: 05/03 Latest revision: 09/04

7

1 2 3 4 5 6 7 8 9 10 11

9203646 9166286 9203647 9203648 9261832 9203649 9432396 9203737 9140008 9203650 9240359

Spring pin

PL6.11 Glue tank (part 11 of 14) S466 W185 S466

W185

3 6

S377

W185

2 7

S471 W186

S378

S378 W007

R052

S464 W185 W186 S496 1 S465 W186 R023

S465 W186 5

2

R023 5

1 2 3 4 5 6 7

9414055 9230890 9230891 9147007 9222729 9203638 9203639

2 W186

Lateral wire 1.5 Lateral wire 2

S474 W186

Solenoid bracket spacer

S474 S377 W186

W186 S474

Spare parts Page 5 - 48

Initial issue: 05/03 Latest revision: 03/05

S474

PL6.12 Glue tank (part 12 of 14) S468 W185 1

2

13

3

14 S382 S009 14

3

115° 7 S382

145°

14 S009

6

OR

6

4

145°

16 15

14

W184

8

165°

S457

5

10 9

12

11 W193 W193

S454 W193

W193

S454

W193

S454 S454 S454

Spare parts Page 5 - 49

Initial issue: 05/03 Latest revision: 11/05

1! 9422980 2! 9422981 3! 9422982 4! 9432440 5! 9423007 6! 2983952! Thermostat 145° 7! 2983951! Thermostat 115° 8! 9432439 9! 9147006 10! 9147005 11! 9230884 12! 9230883 13! 9403844 14! 9147007 15! 9124191! Thermostat 165° 16! 9156001!

PL6.13 Glue tank (part 13 of 14)

1

1 2 3 4 5

2

3

4

5

Spare parts Page 5 - 50

Initial issue: 05/03 Latest revision: 03/05

9199821 004390001902 2985185 9403843 9199883

Funnel Nut Draining plug Spaner Aluminium container

PL6.14 Glue tank (part 14 of 14) S378

1

S378

3

2

N152 5 4

2 9231253 4 9151046 Cooling fan For the blue machines 1 3 5

9404064-AK 9404063-AK 9231254-AK

S378

Spare parts Page 5 - 51

Initial issue: 05/03 Latest revision: 09/04

S517

7. COVER NIPPING

Spare parts Page 5 - 52

Initial issue: 05/03 Latest revision: 09/04

PL7.1 Cover nipping (part 1 of 10) See PL7.2 to PL 7.7

S544

1 2 3

W187 W187 S544

1 9210630 2 9260003 3 9413939

S559

3 1

W188

See PL7.10 2

W188

S559

S471

S471

S471

S471

See PL7.8, 7.9

Spare parts Page 5 - 53

Initial issue: 05/03 Latest revision: 09/04

Washer Holder side cover plate

PL7.2 Cover nipping (part 2 of 10)

See PL7.3

See PL7.4

See PL7.7 1

1

Spare parts Page 5 - 54

Initial issue: 05/03 Latest revision: 09/04

9432355

PL7.3 Cover nipping (part 3 of 10) S466 S466 S469 S469 W191 W191 S415

W191 W191

S466

1

S466 W191

W191

S415

2

4

W186 S471 2

S371 W185

5

5 4

W186 S471 N152 3

S453 S469

Spare parts Page 5 - 55

Initial issue: 05/03 Latest revision: 09/04

1 2 3 4 5

9222602 9413931 9166082 9230555 9203801

Spring

PL7.4 Cover nipping (part 4 of 10)

S343

S465 W185

S464

S243

1

W187

S243

W191 S466

W187 S465

W191

W185 S464 W191

5

1 2 3 4 5 6 7

4

5 5 4

6 7 7

S378

S378

W185 S464

See PL7.5

S464 W185 3 S371

2

W039 R002

Spare parts Page 5 - 56

Initial issue: 05/03 Latest revision: 09/04

9230560 9203802 9230559 9413935 9413936 9203286 9107063

Optical switch

PL7.5 Cover nipping (part 5 of 10) S243 W187 S243

See PL7.6

W187 See PL7.6

S243 W187 See PL7.6 1

See PL7.6

W185 W185

S464

S464

W187 S374

W186 See PL7.6 S441

W186

S441

W186 S441

Spare parts Page 5 - 57

Initial issue: 05/03 Latest revision: 09/04

1

9203293

PL7.6 Cover nipping (part 6 of 10)

S470 S243 W187

W186 9

5

21

8

11

6

10

1

9 W186

R161

S470

3 S377 W163

3

21

7

2

S481 W187

S481 W187

10 W187 S374 4

Spare parts Page 5 - 58

Initial issue: 05/03 Latest revision: 08/05

21

1 2 3 4 5 6 7 8 9 10 11

9413937 9230562 9175087 9151136 9203293 9413938 9204140 9403733 9175091 9212069 9591201

Gear assembly Gear M1 Z101 Ball bearing DC lift gearmotor Shutter pivot Nipping gear assembly Motor gear Z24 Gear assembly Ball bearing Lower ejection spacer Gear motor kit

PL7.7 Cover nipping (part 7 of 10) 1 2 3 4 5 6 7

S415 S453 S466 S415

W191

1

W191

S453

5

9222603 9230575 9230555 9230558 9413934 9413933 9166082

Spring

W191

W191 N152

2

S453

7 S453

6 N001 W001 W035

S469

W035 W035

W191 S453 S465

S442 N002

3

W191

4

W193

S481

Spare parts Page 5 - 59

Initial issue: 05/03 Latest revision: 09/04

PL7.8 Cover nipping (part 8 of 10)

5

6

20

7 S481

5

R016

9

W187

8 W185

W185

2

20

S371

4

S371

20

2

3

S453

W187 S481

1

1

W187 S502 W188 W187 N006 W187

S573 S243

S502 W188

S573

Spare parts Page 5 - 60

Initial issue: 05/03 Latest revision: 08/05

1 2 3 4 5 6 7 8 9

9107063 9175006 9151136 9231362 9231090 9403735 9591200 9203342 9203313

Optical switch Bearing DC lift gearmotor Gear Z24 Guide Lift shaft assembly Gearmotor kit Home flag Flag height

PL7.9 Cover nipping (part 9 of 10)

2 S376

S566 W002

W200 3

2 4 W190 S566 W002

3 S376 4

W200

N009 W188 1

N009 W188 1

N046 W190 N046 W190 N046

S574

W187

N046 W190

S480

W190

W187

S481 W190 N046 W190 W122 W007

W122 W007

S470

S470 W190

See PL7.8

N046 W190 S574

Spare parts Page 5 - 61

Initial issue: 05/03 Latest revision: 09/04

S574

1 2 3 4

9203306 9260889 9230571 9203296

Plastic bumper

PL7.10 Cover nipping (part 10 of 10) S441 S441 W186

W186

S614 W187 W630

S453 3

1 2 N152

N152

6 1

N152 W630

4

10

8

W187 N012

S465 W193 N012

9

S454 S495 5 W186

W187

S504

S454 W187 W186

S495

7 5 10

9

W187 S454 W187 S454 S504

1

N012 W187

8 6

Spare parts Page 5 - 62

Initial issue: 05/03 Latest revision: 09/04

1 2 3 4 5 6 7 8 9 10

9175070 9203300 9107063 9432357 9175021 9413940 9203603 9203298 9203304 9203305

Bearing Optical switch Ball bearing

8. COVER TRANSPORT

Spare parts Page 5 - 63

Initial issue: 05/03 Latest revision: 09/04

PL8.1 Cover transport (part 1 of 3) Detail A

W001 W001

S466

10

S435

6 R001

2

N152 N006

N187 S378

8

10

W185 N012 N001

3

S464

S470 W185

See detail A

1

9 W006

S614

N001 W001

4

12 11

12

W186

11

S441

W001 N001 See detail A W185

9

S614

S470

2

3

W006

S378

11 W001

12 N001

4

7 W163

5 S466

Spare parts Page 5 - 64

W006 S614

Initial issue: 05/03 Latest revision: 11/04

1 2 3 4 5 6 7 8 9 10 11 12

9403739 9230589 9111105 9111104 9432356 9413948 9230594 9166237 9203803 9261701 9413948 9203398

Spring

PL8.2 Cover transport (part 2 of 3) 17 S371

ITE CT 8 LO 63

16 S667 W185

W185

14 4

N006 N152

5

N152

6

S522 W186

S378 C001

S382

S537

2

S472

13 9

15

N002 S377 S377

S377

8

S377

N152

W186 S371 W185 S377

S522

10

S377

13 S377

3

12

7 1

S514

11 S460

10 S371

Spare parts Page 5 - 65

S371

11

Initial issue: 05/03 Latest revision: 10/05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

9422850 9203745 9403980 9261861 9403738 9166279 9203315 9432446 9230588 9403740 9203334 9203327 9127001 9403742 9403751 9104107 9195016

PNP sensor Shaft CT plate sensor Foam Upper nip assy Spring LH bracket Solenoid Lower nip plate Transl. bearing assy Chain fast. block Flag Bushing Joint support assy Nipping lover assy Lever Glue

PL8.3 Cover transport (part 3 of 3) FRONT VIEW N005

1 2 3 4 5

9111004 9432480 9422860 9203334 9107063

Master link Nipping harness plate assy Cable DB 9 Fix. chain block Optical switch

REAR VIEW

1 1

16

4

S371 12

S471 W186

5

3

5

1

2 4 1 S371 N005

S093

S093

Spare parts Page 5 - 66

Initial issue: 05/03 Latest revision: 11/05

9. SUCTION BAR DRIVE SYSTEM

Spare parts Page 5 - 67

Initial issue: 05/03 Latest revision: 09/04

PL9.1 Suction bar drive system (part 1 of 3)

2

N152

3

1

S517

13

R158

5

14 15

6 10

R002

S377

9

S377 4

8

7

R002

12

16

7 11

Spare parts Page 5 - 68

7

N006

7 6

17

S377

Initial issue: 05/03 Latest revision: 06/05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

9107063 9261715 9222658 9127021 9127002 9261822 2980118 9203429 9203874 9166045 9203426 9403981 9139737 9203878 9104113 9260633 9422942

Optical switch

Bush 8-12-12 bronze/graphite Oilite bushing Nylon bearing

Lower spring

PL9.2 Suction bar drive system (part 2 of 3) S464

2

W185

1

3

3 S378

See PL9.1

4

1 2 3 4 5 5

5

2 W185 W185 1

S464 S464 W185 W185

W185 S464

Spare parts Page 5 - 69

Initial issue: 05/03 Latest revision: 09/04

9230654 9414030 9230652 9101003 9414029

Compact magnet

PL9.3 Suction bar drive system (part 3 of 3) 5 12

W185 S465 6

S453

11 10

N054 W004

S481

R001

S270

S519

W187

8

S464

S378

W187

S614

N152 W001 W185 S371

W001

W187 S481

N152

N001

S614

S481 W187

W187 W001 N001

4

1 2

W185

8

7

N152 N006

S453 W187

3 8

W001

S481 N008

N001 S464

9

S463

Spare parts Page 5 - 70

W185

9

Initial issue: 05/03 Latest revision: 09/04

1 2 3 4 5 6 7 8 9 10 11 12

9203418 9111106 9261711 9166094 9403770 9432357 9107063 9413948 9150065 9127001 9203399 9203417

Spring

Optical switch Microswitch Bushing

10. COVER STATION (2)

Spare parts Page 5 - 71

Initial issue: 05/03 Latest revision: 09/04

PL10.1 Cover station (part 1 of 4) S539 S481 2

2 W187 S374 W187 2

W187 S243 S243 S374 W187

1 W187

W187 1 S243

S483

S243

1

W187

W187

S481

W187 S243

S243 W187

S539

S243

S243 W187

1 2

W187

1

W187 S374 S481

S243 W187 1 S481 W187

Spare parts Page 5 - 72

Initial issue: 05/03 Latest revision: 09/04

9203385 9414105

S374

PL10.2 Cover station (part 2 of 4)

W186 S471

S523

W186

W186 N005

W186 N005

S471

W186 N005 W186

S523 W186

1

W186 S523

W175 1

S523 W175

W186

S377 S377 2 S377

1 2

S377

9166172 9261721

R026 2 R026

R026 S471

R026

W186

2 2 S471 W186

Spare parts Page 5 - 73

Initial issue: 05/03 Latest revision: 09/04

For the blue machines 3 9403769-AF

PL10.3 Cover station (part 3 of 4) S533

S453

W163 N006 W004

4

S465 S533

2

W191

3 S527 W163 N152 N005

5

6 9 W002 R013

N007 N005

11

7

S527 N002 W186 6

N007 10

8

W185 N054

1

S378 R013 W002

11

Spare parts Page 5 - 74

7

W191 S453

Initial issue: 05/03 Latest revision: 10/05

1 2 3 4 5 6 7 8 9 10 11

9166247 9139740 9139739 9261714 9414047 9261865 9410563 9414048 9139752 9139753 9139154

Traction spring Area label Tray adjustment label Position adjust. nut Driving tray shaft Bushing Knob assy Tray transl. screw shaft Angle adjust label Lateral adj. label Knob label

PL10.4 Cover station (part 4 of 4) 16

4

16 16

S471

3

W186

20

21 21 21 2 2

5

2 1

S377 S471 7

W186

9

16 17 19

22 7

S441 W186

8 12

S441

S378

W186

W184 W191 S457 S371

11

6

10

W186

W191

S371

13

18 13

S471

14

15

Spare parts Page 5 - 75

W186

W186

S471

S471

Initial issue: 05/03 Latest revision: 09/05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

9203887 9404146 9403784 9104093 9203452 9414026 9414025 9432383 9140036 9166203 9230669 9230668 9157011 9203889 2085322 9230801 9261870 9261871 9260652 9404145 9403785 9166121

Knurled knob

Spring for tray TDS

O-ring 12x4

Suction plug transport modulen

Spring

11. COVER SUCTION / BLOWER TURBINE

Spare parts Page 5 - 76

Initial issue: 05/03 Latest revision: 05/05

PL11.1 cover suction / blower turbine 20 18

18

1

2 3

18 S471

7

5 S377

W186

19

S471

3

2 W186 S472 S471 W186

4

18 6

W186 S472

18

8

16

16

17

8 S470 15

W186

S471 W186

10

9

11

8

S603

12

9 13

14

N006

Spare parts Page 5 - 77

Initial issue: 05/03 Latest revision: 05/05

14

1! 2! 3! 4! 5! 6! 7! 8! 9! 10! 11! 12! 13! 14! 15! 16! 17! 18! 19! 20!

9432364 9222644 9157022! 9203421! 9120189 9260346! 9151145 9260871 9183131 9430876! 9166027! 9261712 9157010! 9108010! 9432378 9261845 9165130 9199843 9261873 9261872

O Ring Filter corcom Iovni Prelift tube 70mm lg

Solenoid assy Spring O-Ring Tiewraps

12. SCORING

Spare parts Page 5 - 78

Initial issue: 05/03 Latest revision: 09/04

PL12.1 Scoring (part 1 of 8) S473 S441

2 2

W186

S464

3

18

W185 S464 4

18

W185 S441 W186

S472 W186

1

S471 W186

3 S473

W186

See PL11.4

S441 S471 W186 2

2 W186 S441

S464 W185

Spare parts Page 5 - 79

Initial issue: 05/03 Latest revision: 09/05

1 2 3 4

9403767 Punch assembly 9260379 Knife holder slides 9203405 Pivot eccentric 9204139 with Tag 18 9591188 witout Tag 18

PL12.2 Scoring (part 2 of 8) Optional

W186

R024

W186 10 S470

11

S470 7

1

W187 S163

S374 5 W017

9

S374

W187

W187

2 R024 3 S571

7

S374

S571 1

W187

7

W186

W187 W017

S374

S470

5 6

4 4

W186

8

7

S396

W185

W187 S470

S374 W187

S374

Spare parts Page 5 - 80

W187

Initial issue: 05/03 Latest revision: 09/05

1 2 3 4 5 6 7 8 9 10 11

9127063 9104107 9203756 9261851 9230636 9203381 9261710 9203406 9423086 9204043 9591169

Bushing Knob Lever axis Stop Cam Spacer Ring Spacer axis Double detect sensor Sensor bracket Double detect sensor kit

PL12.3 Scoring (part 3 of 8) S453 N054 2

S472

N054 S453

W186

1 2 3 4

2

W185 S523

W003

5

1 S377

N005 3

4 N002

S474 S472

5

W186

1 W185 S371

Spare parts Page 5 - 81

S377

S377

Initial issue: 05/03 Latest revision: 09/04

Spring

For the blue machines

S371

W003

9175091 9166082 9203391 9403732

9231169-AF

PL12.4 Scoring (part 4 of 8) 17

1

17

11 S464 10

W185 S514 S371

2

W185

17

8

17

1

3

7

17 5

4 4 4

7

4 4

2

17

S009

4 4 4

12

6

14 13 9 W185 S464 15 3 W185

17

S371 S514

Spare parts Page 5 - 82

Initial issue: 05/03 Latest revision: 08/05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

9166074 Spring (with Tag 17) 9127043 Nylon bushing 6mm 9175094 Ball bearing 7006046000 Paper feed friction roller 9203378 Upper shaft 9414022 Roller shaft assy 9240144 Door pivot 9404152 Cover support bracket (with Tag 17) 9403758 LH connecting plate 9403759 RH connecting plate 9166074 2X +9404152 1X (without Tag 17) 9240377 Bearing 9204117 Stop 9166299 Spring 9204118 Bearing

PL12.5 Scoring (part 5 of 8)

1

See PL12.6

1 See PL12.7

Spare parts Page 5 - 83

Initial issue: 05/03 Latest revision: 08/05

9413945

PL12.6 Scoring (part 6 of 8) W019 R007 W186 N005 W041 N006 N054

S522

See PL 12.5 R011 W029

S453 2 S009 N005

S452 9

7 1

10

W187

22

S233 5

S474

See PL 12.5 W007

8

S377

22

W163

S008 4

22

Spare parts Page 5 - 84

11

Initial issue: 05/03 Latest revision: 08/05

1 2 3 4 5 6 7 8 9 10 11

9414005 9240077 NA 9116005 9230647 NA 9140016 9231363 9175089 9151136 9591202

Connecting rod assembly Eccentric for transr. bar Idler Gear Z 48 Precision taper pin Gear Z 48 Bearing DC lift gearmotor Gearmotor kit

PL12.7 Scoring (part 7 of 8) S453

See 12.5 4

S453

N006

3 S452 4 N006 S453

4

S473 W007

N054 N006 W041 N005

See 12.5

S378 S378

N005 S009

R007

5

1

W186 S471 2 W029

Spare parts Page 5 - 85

Initial issue: 05/03 Latest revision: 08/05

1 2 3 4 5

9414005 9240077 9175027 9107063 9140016

Eccentric for transr. bar Bearing Optical switch Precision taper pin

PL12.8 Creasing (part 8 of 8) W187 S502

S374

W187

W187 S502 W185 S464

S464

S502

W187

W185

S374 W187 2

W187 S482

1

S481

S374

2

S482 S453 S502 N054

W187 5

W187 W186 S472 W186 S472

W187 S502

6

18 W185

W187 S371 R024 3 W185 W187

S482

4

S464

5

Spare parts Page 5 - 86

18

Initial issue: 05/03 Latest revision: 09/05

1! 2! 3! 4! 5! 6! !

9230642! Matrix 9127063! Bushing 9166298! Spring 9432362! Solenoid assy 9203385! Eccentric 9204138! with Tag 18 9591188 ! without Tag 18

13. OUTPUT & CONVEYOR

Spare parts Page 5 - 87

Initial issue: 05/03 Latest revision: 09/04

PL13.1 Output & conveyor (part 1 of 2) 1

S378

7

W186 S523 2

S523 W186 11

12

10

12 W027 S441

S441 S378 13 W027 S475 W003 W186 N002 S441

W186

W186 3 8

5 S522 14

6

N001

15 W007 W186

14 14 4

W017 S441 R024

S484 N006

N001 W163 W191 S465

W007 W186 S441 4

R024 W017 9

Page 5 - 88

S484 W001 W191

15

W001

14

Spare parts

S522

Initial issue: 05/03 Latest revision: 09/04

N006

W001 W163 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

S465

9404111-AK 9199448 9231315-AK 9261719 9404110-AK 9261857 9107064 9403964-AK 9231133-AK 9203840 9203841 9175081 9203566 9261858 9261295

Rubber stop

Ball bearing

Pivot bearing

PL13.2 Output & conveyor (part 2 of 2) 11

11 11 1

1

1

1 R014

S243

11

12

8

9

13 R159 11

S516

11 3

11 11

R014

12 9

8

14

S243 R159 S516 10 3 13

14

2

S502 5 2 W187 4

16 W185 S464

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

9126445 9413859 9175087 9126319 9151136 9199898 9199896 9261846 9175015 9107064 9261255 2097307 9261221 014750402200 9403947 9403948

15

7 6

Spare parts Page 5 - 89

Initial issue: 05/03 Latest revision: 01/05

Pulley assy Ball bearing Belt 10T5 640mm BDF DC lift gearmotor

Ball bearing Molded pulley conveyor Injected housing

14. OUTPUT UNIT (BOTTOM) OPTIONAL

Spare parts Page 5 - 90

Initial issue: 05/03 Latest revision: 09/04

PL14.1 Output unit (bottom) optional (part 1 of 9) See PL 14.8 &14.9

See PL 14.3

See PL 14.5, 14.6 & 14.7

See PL 14.2

Spare parts Page 5 - 91

Initial issue: 05/03 Latest revision: 09/04

PL14.2 Output unit (bottom) optional (part 2 of 9) 2 3 5 6 8 9 10

5

5

5 1

W187

3

3

9231128 9203826 9165008 9199897 9199898 9178062 9203825

For the blue machines

5

1 4 7

2

S481

W187

9231129-AF 9231130-AF 9231124-AF

3

3 4

5 S481 7 10 7 W186 S478 W186 S471

9

5 5

N005 W186 6 W186 8

S471 6 8

Spare parts Page 5 - 92

Initial issue: 05/03 Latest revision: 09/04

5

PL14.3 Output unit (bottom) optional (part 3 of 9) See Pl 13.4

3

5

W187 S481

S377

4 2 W185 S377

1 2 3 4 5 6 7 8 9

2 S377

4

4

S465

S465

S377 W185

9

S524

N106

NA 9261900 9104114 9261717 9403957 9231110 9107063 9203815 9414152

Optical switch

S377 S377

9 9

S524

S523 W186

N106 8 S524 N106

W186 S471

N106 W186 S471 6

6

S464

W185 S453

S524 N006

7 W187 S481

Spare parts Page 5 - 93

Initial issue: 05/03 Latest revision: 09/04

W187 S481

PL14.4 Output unit (bottom) optional (part 4 of 9) 1

1

R010 2

5 3 2 6

R010 6 6

S441 N006

W186

W185

1 2 3 4 5 6

N006 W185

W186 S441 4

4

Spare parts Page 5 - 94

Initial issue: 05/03 Latest revision: 09/04

9261187 2980069 9166246 9403956 9231132-AK 9166074

Green handle for baffle Bushing Spring

Clutch lock spring

PL14.5 Output unit (bottom) optional (part 5 of 9)

S505 W187

2

4

1 2 3 4

W186 1

3

3

S441 4

2 3 N001 N001 3 N001

Spare parts Page 5 - 95

Initial issue: 05/03 Latest revision: 09/04

9166291 9203817 9261201 9261855

Spacer

PL14.6 Output unit (bottom) optional (part 6 of 9) 7 8 4

W186 R014

S441 S377 6 S377

1

3 5

1

7 8

1 S441

3 S471 W186

1 2 3 4 5 6 7 8

9261255 Molded pulley conveyor 9126453 9414151 9230609 9203830 9203814 9261876 9203828

S471 W186 W186

3

3 W186 2 2 2

R014 S471

W187

S471

S481 W186 S471

1 1 1 W186 S471

Spare parts Page 5 - 96

W186

Initial issue: 05/03 Latest revision: 09/04

PL14.7 Output unit (bottom) optional (part 7 of 9) S378

S490

10 N001

7

S453 W004 S233

S471

5

13

S377 W004

S549 W188

11 11

11 5

5

1 N006

S551

S523

S463 6

S471

8 9

12

9

2 N004

S471

11

12

N008 S490 W188

2 3 4

5

9

5 W185

3

S464

W185 S464

Spare parts Page 5 - 97

Initial issue: 05/03 Latest revision: 11/05

1 2 3 4 5 6 7 8 9 10 11 12 13

9231112 9414151 9231113 9222784 9203822 9430937 9107063 9150073 9260831 9203823 9175091 9157011 9203821

Motor assy Optical switch Microswitch

Microswitch bracket O-ring

PL14.8 Output unit (bottom) optional (part 8 of 9) For machines without TAG 15 If replacing item 1,5 or 17, all 3 parts need to be replaced at the same time then mark off TAG 15. 17

S371 W185

S371 15

R007 9

10 9

15

W185

2 3

R007 11

R007 1

15

9

2

R007

10 5

9

8

11

N106

15

8

7 7

N106 N005 N005 N106 S523 W186

6 6

4

16

W186 14

S523

S523 S371 12 W185 15 N005

N005

S523 S523

12

14

S474

15 W186 S522

12 13

12 S474 N005

Spare parts Page 5 - 98

Initial issue: 05/03 Latest revision: 06/05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

9404144-AF 9199807 9260889 9231103-AF 9404143 9107064 9403953 9403952 9261877 9203810 9203811 9166237 9203829 9261039 9421685 9420702 9198017

BBR upper cover (with Tag 15) Rubber stop Plastic bumper BBR rear cover BBR uppper baffle (with Tag 15) Photosensor Pusher part A Pusher part B Bushing Pivot Shaft Spring Stop Rubber distance Grounding braid Grounding braid Contact blade

PL14.9 Output unit (bottom) optional (part 9 of 9) S502 2

1

N001 4 3

W187

11

4

S481 W187 S377

S481 W187

S377

S481 W187

11

N008 6

7 S460

8 N152 5

9

9

10 10 S453

Spare parts Page 5 - 99

Initial issue: 05/03 Latest revision: 11/05

1 2 3

9430937 9231096 9423XXX

4 5 6 7 8 9 10 11

9199878 9203805 9146339 9150073 9260831 9231107 9107063 9146340

Motor assy Gear BBR board (see Software history in the General Procedure in the Service Manual) Spacer Sensor bracket Emergency button Microswitch Microswitch bracket Shaft Optical switch Base for emerg. button

15. EXTERNAL SYSTEM FOR COLLECTING WASTE

13

19

1 2 3 4 5 6 8 9 10 11 12 13 14 15

19

14

3 S371

W184

N008

3

4

S462

S548

1

W163

5

9107074 9432539 7500295 9150065 9260831 2985284 9104105 9159566 NANA 9432540 9261897 7500297 9151188

Pressure sensor Collector assembly Clamping ring Microswitch Microswitch bracket Magnet Snapin handle Plastic bag

Collector control box Sleeve Clamping ring Clamp for dust bag

For the blue machines W185 S453

7

9403979-AF

W184 N008

W185

W185

15

W188 S453

S453 W185 W184

S461

6 6

7

9

8

12

Spare parts Page 5 - 100

Initial issue: 05/03 Latest revision: 08/05

16. INTERNAL SYSTEM FOR COLLECTING WASTE (OPTION) W184 W184

S489 N008

1

S462

W188

S473

W186 2

S471

3

3 W188 N005 S473 11 S462

W186 10

W184

3 N008

1

W188

3 5 4

S548

1 2 3 4 5 6 8 9 10 11

W185 S453

S371 W184 N008

W185 W163

9

W188 S453

S453 W185 W184

S461

W185 6

6

Cable grommet

For the blue machines

8

Page 5 - 101

Clamping ring Microswitch Microswitch bracket Magnet Snapin handle

7

7

Spare parts

9107074 9151917 7500295 9150065 9260831 2985284 9104105 9198895 9165023 9222351

Initial issue: 05/03 Latest revision: 11/04

9403979-AF

17. U.I.

Spare parts Page 5 - 102

Initial issue: 05/03 Latest revision: 09/04

17.1 U.I.

10

1

S441

S464

W186

S464

W185 3 2 8

N006

S515 N006 S515 4

S008 7

6 9

W187 W190

5 7 6

W187 S552 S574

Spare parts Page 5 - 103

Initial issue: 05/03 Latest revision: 09/04

1

9423

2 3 4 5 6 7 8 9 10

9183129 9203951 9432387 9403856 9261836 9203683 9138094 9165129 9423

UI (see Software history in the General Procedure in the Service Manual)

Industrial flash (see Software history in the General Procedure in the Service Manual)

18. ELECTRICAL

Spare parts Page 5 - 104

Initial issue: 05/03 Latest revision: 09/04

PL 18.1 Electrical (part 1 of 2)

4 5

3 7

24 6

1 2

8

4

2

4 4

12

13

15

11

13

14

9

9

10

25

16

1

18

22 21 20 20

26***

17 17 17

E N TE R

M E N U

19

3* 4 5 6 7 8 9 10 11 12 13 14 15 16* 17 18 19 20 21 22 24* 25** 26***

9132024 9103049 9103049+9423077 9423xxx 9182066 9120180 9423082 9422962 9423005 9422856 9422928 9422894 9422868 9431627 9170380 9423077 9423xxx 9132021 9132022 9132025 9132027 9132023 9132026 9423xxx 9199845 9132019

Digital out 1X8 module DO 435 Power supply with Tag 4 Power supply without Tag 4 Frequency driver translation Auto transfo Filter triphase Isolation board assy Power board Harness Drive board Interlock board Dispatch board Glue tank board Blower assy Resistor Capacitor assembly CPU Digital OUT 1X4 module DO 135 Digital IN 1X10 module DI 140 Motor bridge module MM432 Combination module CM 211 Digital IN module 1X16 DI 439 Motor module MM 424 Frequency driver glue tank Battery CR 2477N Kbd to prg ABB freq.chiver

* See section 6 General procedures ** See section 7 5.3.1 CPU474 for replacement Programmed parts and software history *** See section 6 Speciality tools

Spare parts Page 5 - 105

Initial issue: 05/03 Latest revision: 11/05

PL 18.2 Electrical (part 2 of 2) Power board A20 - Fuses + Relays A20 : F11 & F12 - 6.25A Protection Power supply 220VAC -> 24 - 36 VDC

A20 : F7 & F8 - 6.25A 220V power supply protection Glue tank frequency converter

1

A20 : F3 & F4 - 6.25A Glue tank resistor protection

1

1

Dispatch Board A4 : Fuses.

1 A20 : F9 & F10 - 6.25A 220V power supply protection Translation frequency converter

1 A20 : F1 & F2 - 6.25A Glue drum resistor protection

2 A20 : F5 & F6 - 4A 220V power supply protection Prefeed blower suction

A4 - F1 (500mA) Protection 24V converter 24 VDC - 5 VDC

3

General fuses and relays of the BB3002 F3

Reset button in case of milling motor over T°

3p K0 42

F2

p

F1

02

K 42

6

10

9

5 8 11 Fuses 12A Power supply of the BB3002

Spare parts Page 5 - 106

7 Over T° intern dust collector relay

Milling motor process relay

Initial issue: 05/03 Latest revision: 10/05

1 2 3 4 5 6 7 8 9 10 11

9124016 9124008 9124024 9124028 9124194 9169907 9169084 9177051 9124093 9169122 9164011

Relay omron Contact 3NO +1NC Base Therm relay Contact 2NO + 2NC fuse holder

A4 - F2 (1A) Protection 24V Sensor

4

19. INDEX Bourg Nr 2081998 2082806 2082806 2085322 2097307 2980069 2980118 2983951 2983952 2985185 2985276 2985284 2985284 2990125 2990125 7500295 7500295 7500297 9101003 9103049 9104093 9104105 9104105 9104105 9104106 9104107 9104107 9104113 9104114 9107061 9107062

Spare parts Page 5 - 107

Color

Description Jogging foot lever Teflon strip Teflon strip

Bushing Nylon bearing Thermostat 115° Thermostat 145° Draining plug Magnet Magnet Cutter adjusting screw Cutter adjusting screw Clamping ring Clamping ring Clamping ring Compact magnet Power supply with Tag 4 Knurled knob Snapin handle Snapin handle Snapin handle Verschlub BDF Knob Lever

Photosensor

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

28 33 34 75 89 94 68 49 49 50 15 100 101 33 34 100 101 100 69 105 75 14 100 101 14 80 65 68 93 27 30

1 11 11 15 12 2 7 7 6 3 6 6 6 7 7 3 3 14 4 2 4 6 8 8 5 2 16 15 3 4 3

4. 5.1.1 5.1.2 10.4 13.2 14.4 9.1 6.12 6.12 6.13 1.9 15. 16. 5.1.1 5.1.2 15. 16. 15. 9.2 18.1 10.4 1.8 15. 16. 1.8 12.2 8.2 9.1 14.3 3.6 4.2

First Aid Kit 9591136

Bourg Nr 9107063 9107063 9107063 9107063 9107063 9107063 9107063 9107063 9107063 9107063 9107063 9107063 9107063 9107063 9107064 9107064 9107064 9107074 9107074 9107074 9107074 9108010 9108027 9108060 9108062 9108070 9111002 9111004 9111026 9111026 9111104

Spare parts Page 5 - 108

Color

Description Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Optical switch Photosensor

Pressure sensor with tag 6 Pressure sensor Pressure Sensor Tiewraps Locking saddle Flat tie holder blind hole Locking saddle Wire routing clamp Chain link Master link Master link 8mm Master link 8mm

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

60 68 30 36 62 85 46 66 56 70 93 97 40 99 98 88 89 100 101 35 34 77 25 27 23 25 45 66 44 43 64

1 1 2 3 3 4 5 5 7 7 7 7 9 10 6 7 10 1 1 10 19 14 5 3 2 6 8 1 2 5 4

7.8 9.1 4.2 5.3 7.10 12.7 6.9 8.3 7.4 9.3 14.3 14.7 6.3 14.9 14.8 13.1 13.2 15. 16. 5.2 5.1.2 11.1 3.4 3.6 3.2 3.4 6.8 8.3 6.7 6.6 8.1

First Aid Kit 9591136

X

Bourg Nr 9111105 9111106 9111108 9111109 9111110 9115026 9115027 9115031 9116005 9116005 9116007 9116009 9116012 9116040 9120180 9120189 9124008 9124016 9124024 9124028 9124093 9124191 9124194 9126161 9126319 9126326 9126445 9126449 9126453 9127001 9127001

Spare parts Page 5 - 109

Color

Description

Hinge 100D + spring Hinge arm Shaft Idler Shaft Shaft Shaft

key DIN 6885A key DIN6885A 4x4x14 key DIN6885A 5x5x25 key DIN6885A 5x5x20

Filter triphase

Therm relay Thermostat 165° Belt D4x412 Belt 10T5 640mm BDF Belt

Bushing Bushing

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

64 70 44 45 43 14 14 10 20 84 45 45 45 45 105 77 106 106 106 106 106 49 106 36 89 30 89 18 96 70 65

3 2 1 1 4 1 2 1 4 4 12 11 10 13 5 5 2 1 3 4 9 15 5 6 4 8 1 1 2 10 13

8.1 9.3 6.7 6.8 6.6 1.8 1.8 1.4 2.3 12.6 6.8 6.8 6.8 6.8 18.1 11.1 18.2 18.2 18.2 18.2 18.2 6.12 18.2 5.3 13.2 4.2 13.2 2.1 14.6 9.3 8.2

First Aid Kit 9591136

X X X X

X X X X

Bourg Nr 9127002 9127021 9127039 9127039 9127043 9127063 9127063 9132019 9132021 9132022 9132023 9132024 9132025 9132026 9132027 9135095 9138094 9139154 9139707 9139737 9139739 9139740 9139752 9139753 9140008 9140008 9140016 9140016 9140036 9140079 9140079 9140080

Spare parts Page 5 - 110

Color

Description Oilite bushing Bush 8-12-12 bronze/graphite Nylon sleeve Nylon sleeve Nylon bushing 6mm Bushing Bushing Kbd to prg ABB freq.diver Digital OUT 1X4 module DO 135 Digital IN 1X10 module DI 140 Digital IN module 1X16 DI 439 Digital out 1X8 module DO 435 Motor bridge module MM432 Motor module MM 424 Combination module CM 211

Knob label

Tray adjustment label Area label Angle adjust label Lateral adj. label Spring pin Spring pin Precision taper pin Precision taper pin Pin Pin

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

68 68 33 34 82 80 86 105 105 105 105 105 105 105 105 39 103 74 7 68 74 74 74 74 40 47 85 84 75 40 41 46

5 4 13 13 2 1 2 26 17 18 21 1 19 22 20 1 8 11 7 13 3 2 9 10 6 9 5 7 9 4 8 6

9.1 9.1 5.1.1 5.1.2 12.4 12.2 12.8 18 18.1 18.1 18.1 18.1 18.1 18.1 18.1 6.2 17.1 10.3 1.1 9.1 10.3 10.3 10.3 10.3 6.3 6.10 12.7 12.6 10.4 6.3 6.4 6.9

First Aid Kit 9591136

Bourg Nr 9142004 9142004 9146339 9146339 9146340 9146354 9146366 9146366 9146373 9146379 9147004 9147005 9147006 9147007 9147007 9147007 9147010 9150065 9150065 9150065 9150065 9150065 9150073 9150073 9151046 9151136 9151136 9151136 9151136 9151145 9151180 9151188

Spare parts Page 5 - 111

Color

Description

Emergency button Emergency button Base for emeg.button Interlock switch Interlock switch Actuator black IP40

Microswitch Microswitch Microswitch Microswitch Microswitch Microswitch Microswitch Cooling fan DC lift gearmotor DC lift gearmotor DC lift gearmotor DC lift gearmotor

Clamp for dust bag

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

44 45 7 99 99 7 11 14 8 14 39 49 49 43 48 49 46 100 101 13 70 19 99 97 51 60 58 89 84 77 45 100

7 14 1 6 11 4 1 4 1 3 6 10 9 3 4 14 11 4 4 8 9 10 7 8 4 3 4 5 10 7 9 15

6.7 6.8 1.1 14.9 14,9 1.1 1.5 1.8 1.2 1.8 6.2 6.12 6.12 6.6 6.11 6.12 6.9 15. 16. 1.7 9.3 2.2 14.9 14.7 6.14 7.8 7.6 13.2 12.6 11.1 6.8 15.

First Aid Kit 9591136

X

X

Bourg Nr 9151916 9151917 9151922 9156001 9157010 9157011 9157011 9157011 9157022 9157033 9157042 9159566 9164011 9165008 9165023 9165023 9165075 9165075 9165129 9165130 9166027 9166045 9166074 9166074 9166082 9166082 9166082 9166094 9166121 9166164 9166164

Spare parts Page 5 - 112

Color

Description

O-Ring o-ring O-ring O-ring 12x4 O Ring Rubber O Ring O ring Plastic bag fuse holder Cable grommet Cable grommet Edge moulding Edge moulding

Spring Lower spring Spring (with Tag 17) Clutch lock spring Spring Spring Spring Spring Spring Spring Spring

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

36 101 20 49 77 31 97 75 77 34 41 100 106 92 35 101 33 34 103 77 77 68 82 94 81 55 59 70 75 33 34

2 2 9 16 13 3 12 13 3 22 1 9 11 5 2 10 10 10 9 17 11 10 1 6 2 3 7 4 22 4 4

5.3 16. 2.3 6.12 11.1 4.3 14.7 10.4 11.1 5.1.2 6.4 15. 18.2 14.2 5.2 16. 5.1.1 5.1.2 17.1 11.1 11.1 9.1 12.4 14.4 12.3 7.3 7.7 9.3 10.4 5.1.1 5.1.2

First Aid Kit 9591136

X X X

X X X X

Bourg Nr 9166172 9166203 9166237 9166237 9166246 9166247 9166277 9166279 9166282 9166283 9166284 9166285 9166286 9166286 9166291 9166292 9166298 9166299 9169084 9169122 9169907 9170380 9170402 9172207 9172208 9172212 9172213 9174011 9175006 9175010 9175012

Spare parts Page 5 - 113

Color

Description

Spring for tray TDS Spring Spring Spring Traction spring Spring

Spring

Spring Spring Contact 3NO +1NC Contact 2NO + 2NC Relay omron Resistor Spirawave washer

Spiraware washer Bearing Roller 625ZZ Bearing

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

73 75 64 98 94 74 30 65 46 46 45 39 47 40 95 31 86 82 106 106 106 105 39 41 42 39 41 42 60 23 36

1 10 8 12 3 1 4 6 7 15 5 9 2 7 1 7 3 14 7 10 6 14 4 2 8 2 11 3 2 4 7

10.2 10.4 8.1 14.8 14.4 10.3 4.2 8.2 6.9 6.9 6.8 6.2 6.10 6.3 14.5 4.3 12.8 12.4 18.2 18.2 18.2 18.1 6.2 6.4 6.5 6.2 6.4 6.5 7.8 3.2 5.3

First Aid Kit 9591136 X X X

X X X X X X X X

X X

Bourg Nr 9175015 9175021 9175027 9175070 9175081 9175082 9175087 9175087 9175089 9175089 9175089 9175091 9175091 9175091 9175094 9175100 9175110 9177051 9178062 9182065 9182066 9183129 9183131 9183135 9183135 9190394 9190394 9190394 9195016 9196027 9198003

Spare parts Page 5 - 114

Color

Description Ball bearing Ball bearing Bearing Bearing Ball bearing Roller Ball bearing Ball bearing Bearing Bearing Bearing Ball bearing Ball bearing

Base

Auto transfo

Glue Brush

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

89 62 85 62 88 24 58 89 29 30 84 81 58 97 82 36 46 106 92 29 105 103 77 43 39 20 18 19 65 39 35

9 5 3 1 12 1 3 3 3 6 9 1 9 11 3 8 2 8 9 5 4 2 9 2 5 1 3 11 17 8 1

13.2 7.10 12.7 7.10 13.1 3.3 7.6 13.2 4.1 4.2 12.6 12.3 7.6 14.7 12.4 5.3 6.9 18.2 14.2 4.1 18.1 17.1 11.1 6.6 6.2 2.3 2.1 2.2 8.2 6.2 5.2

First Aid Kit 9591136

X

X

Bourg Nr 9198011 9198017 9198895 9199067 9199067 9199448 9199448 9199448 9199666 9199678 9199678 9199807 9199807 9199821 9199843 9199845 9199878 9199883 9199889 9199896 9199897 9199898 9199898 9199985 9199998 9199998 9199999 9201665 9203273 9203275 9203278

Spare parts Page 5 - 115

Color

Description Brush Contact blade Rubber bumper Rubber bumper Rubber stop Rubber bumper Rubber stop Pressure sensor tube Nozzle Nozzle Rubber stop Rubber stop D15 Funnel Battery CR 2477N Aluminium container

Gas spring Notching knife (2 std / 4 opt) Notching knife (2 std / 4 opt) Milling blade Actuator shaft

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

35 98 101 33 34 88 8 13 34 35 34 98 13 50 77 105 99 50 31 89 92 89 92 10 33 34 33 9 19 20 20

6 17 9 9 9 2 6 6 21 7 20 2 7 1 18 25** 4 5 10 7 6 6 8 3 6 6 5 1 8 5 8

5.2 14.8 16. 5.1.1 5.1.2 13.1 1.2 1.7 5.1.2 5.2 5.1.2 14.8 1.7 6.13 11.1 18.1 14.9 6.13 4.3 13.2 14.2 13.2 14.2 1.4 5.1.1 5.1.2 5.1.1 1.3 2.2 2.3 2.3

First Aid Kit 9591136

X

Bourg Nr 9203286 9203293 9203293 9203296 9203298 9203300 9203304 9203305 9203306 9203313 9203315 9203317 9203318 9203319 9203327 9203334 9203334 9203342 9203362 9203365 9203378 9203381 9203385 9203385 9203391 9203398 9203399 9203405 9203406 9203417 9203418

Spare parts Page 5 - 116

Color

Description

Shutter pivot

Flag height LH bracket

Flag Fix. chain block Chain fast. block Home flag Carriage closure guide Upper shaft Spacer Eccentric

Pivot eccentric Spacer axis

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

56 57 58 61 62 62 62 62 61 60 65 30 29 31 65 66 65 60 23 25 82 80 72 86 81 64 70 79 80 70 70

6 1 5 4 8 2 9 10 1 9 7 13 2 8 12 4 11 8 5 3 5 6 1 5 3 12 11 3 8 12 1

7.4 7.5 7.6 7.9 7.10 7.10 7.10 7.10 7.9 7.8 8.2 4.2 4.1 4.3 8.2 8.3 8.2 7.8 3.2 3.4 12.4 12.2 10.1 12.8 12.3 8.1 9.3 12.1 12.2 9.3 9.3

First Aid Kit 9591136

Bourg Nr 9203421 9203426 9203429 9203448 9203452 9203551 9203551 9203552 9203552 9203555 9203555 9203566 9203603 9203621 9203631 9203632 9203638 9203639 9203646 9203647 9203647 9203648 9203649 9203650 9203681 9203683 9203737 9203741 9203744 9203745 9203754

Spare parts Page 5 - 117

Color

Description Filter corcom Iovni

cutter brushing cutter brushing Milling shutter pivot Milling shutter pivot Connecting plate Connecting plate

Connecting plate

Shaft

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

77 68 68 36 75 33 34 33 34 33 34 88 62 46 38 38 48 48 47 47 40 47 47 47 39 103 47 44 30 65 10

4 11 8 11 5 15 15 14 14 3 3 13 7 9 3 1 6 7 1 3 8 4 6 10 10 7 8 4 14 2 7

11.1 9.1 9.1 5.3 10.4 5.1.1 5.1.2 5.1.1 5.1.2 5.1.1 5.1.2 13.1 7.10 6.9 6.1 6.1 6.11 6.11 6.10 6.10 6.3 6.10 6.10 6.10 6.2 17.1 6.10 6.7 4.2 8.2 1.4

First Aid Kit 9591136

Bourg Nr 9203756 9203801 9203802 9203803 9203805 9203810 9203811 9203814 9203815 9203817 9203821 9203822 9203823 9203825 9203826 9203828 9203829 9203830 9203840 9203841 9203874 9203878 9203887 9203889 9203895 9203895 9203951 9204043 9204047 9204090 9204091

Spare parts Page 5 - 118

Color

Description Lever axis

Pivot Shaft

Stop

Station knife adj. washer Station knife adj. washer Sensor bracket lateral gluing cylinder Half screw mobil head Half screw fixed head

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

80 55 56 64 99 98 98 96 93 95 97 97 97 92 92 96 98 96 88 88 68 68 75 75 33 34 103 80 42 41 41

3 5 2 9 5 10 11 6 8 2 13 5 10 10 3 8 13 5 10 11 9 14 1 14 16 16 3 10 4 7 6

12.2 7.3 7.4 8.1 14.9 14.8 14.8 14.6 14.3 14.5 14.7 14.7 14.7 14.2 14.2 14.6 14.8 14.6 13.1 13.1 9.1 9.1 10.4 10.4 5.1.1 5.1.2 17.1 12.2 6.5 6.4 6.4

First Aid Kit 9591136

Bourg Nr 9204092 9204097 9204098 9204100 9204117 9204118 9204120 9204138 9204139 9204140 9210630 9210630 9211455 9212069 9215509 9215510 9215512 9222351 9222351 9222599 9222602 9222603 9222620 9222644 9222652 9222658 9222714 9222729 9222738 9222738 9222784

Spare parts Page 5 - 119

Color

Description

Spring ext support Spring int. support Centering washer Stop Bearing Roller pivot with Tag 18 with Tag 18 Motor gear Z24 Washer Spacer Fly whl washer primary shaft Lower ejection spacer

Tube fix

Solenoid bracket spacer milling shutter milling shutter

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

46 41 41 34 82 82 34 86 79 58 53 44 30 58 42 42 20 35 101 19 55 59 29 77 36 68 46 48 33 34 97

12 10 9 23 13 15 17 6 4 7 1 6 5 10 1 2 7 3 11 5 1 1 1 2 5 3 10 5 8 8 4

6.9 6.4 6.4 5.1.2 12.4 12.4 5.1.2 12.8 12.1 7.6 7.1 6.7 4.2 7.6 6.5 6.5 2.3 5.2 16. 2.2 7.3 7.7 4.1 11.1 5.3 9.1 6.9 6.11 5.1.1 5.1.2 14.7

First Aid Kit 9591136

X

Bourg Nr 9230354 9230555 9230555 9230558 9230559 9230560 9230562 9230571 9230575 9230576 9230578 9230579 9230581 9230582 9230583-AK 9230588 9230589 9230594 9230604 9230605 9230609 9230609 9230636 9230642 9230647 9230652 9230654 9230661 9230668 9230669 9230801

Spare parts Page 5 - 120

Color

Description

Gear M1 Z101

AK Lower nip plate

Fixe jaw Mobile jaw

Cam Matrix Gear Z 48

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

7 59 55 59 56 56 58 61 59 31 31 31 30 31 29 65 64 64 23 23 96 27 80 86 84 69 69 36 75 75 75

8 3 4 4 3 1 2 3 2 2 6 5 12 4 4 9 2 7 7 1 4 5 5 1 5 3 1 9 12 11 16

1.1 7.7 7.3 7.7 7.4 7.4 7.6 7.9 7.7 4.3 4.3 4.3 4.2 4.3 4.1 8.2 8.1 8.1 3.2 3.2 14.6 3.6 12.2 12.8 12.6 9.2 9.2 5.3 10.4 10.4 10.4

First Aid Kit 9591136

X

Bourg Nr 9230802 9230805 9230880 9230881 9230883 9230884 9230889 9230890 9230891 9230900 9230900 9230901 9230903 9230927 9230967-AF 9231000-AF 9231072-AK 9231090 9231096 9231103-AF 9231107 9231110 9231112 9231113 9231124-AF 9231128 9231129-AF 9231130-AF 9231132-AK 9231133-AK 9231169-AF

Spare parts Page 5 - 121

Color

Description Stationary sliding block Stationary knife

Lateral wire 1.5 Lateral wire 2

Gear AF AF AK Guide AF

BBR rear cover

AF AF AF AK AK AF

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

33 33 39 46 49 49 38 48 48 45 44 45 45 40 15 10 15 60 99 98 99 93 97 97 92 92 92 92 94 88 81

2 1 3 3 12 11 2 2 3 2 3 3 7 3 1 4 3 5 2 4 9 6 1 3 7 2 1 4 5 9 5

5.1.1 5.1.1 6.2 6.9 6.12 6.12 6.1 6.11 6.11 6.8 6.7 6.8 6.8 6.3 1.9 1.4 1.9 7.8 14.9 14.8 14.9 14.3 14.7 14.7 14.2 14.2 14.2 14.2 14.4 13.1 12.3

First Aid Kit 9591136

Bourg Nr 9231253 9231254-AK 9231315-AK 9231360 9231361 9231362 9231363 9240077 9240077 9240144 9240353 9240354 9240359 9240361 9240377 9240378 9260003 9260346 9260379 9260633 9260652 9260831 9260831 9260831 9260831 9260831 9260831 9260871 9260889 9260889 9261039

Spare parts Page 5 - 122

Color

Description

AK AK Stationary sliding block Stationary knife Gear Z24 Gear Z 48 Eccentric for transr. bar Eccentric for transr. bar Door pivot

Bearing Bronze roller Holder side cover plate Prelift tube 70mm lg Knife holder slides Suction plug Microswitch Microswitch Microswitch Microswitch microswitch Microswitch

transport modulen bracket bracket bracket bracket bracket bracket

Plastic bumper Plastic bumper Rubber distance 5mm

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

51 51 88 34 34 60 84 84 85 82 46 46 47 42 82 34 53 77 79 68 75 19 100 101 99 13 97 77 61 98 14

2 5 3 2 1 4 8 2 2 7 13 8 11 9 12 18 2 6 2 16 19 1 5 5 8 9 9 8 2 3 9

6.14 6.14 13.1 5.1.2 5.1.2 7.8 12.6 12.6 12.7 12.4 6.9 6.9 6.10 6.5 12.4 5.1.2 7.1 11.1 12.1 9.1 10.4 2.2 15. 16. 14.9 1.7 14.7 11.1 7.9 14.8 1.8

First Aid Kit 9591136

Bourg Nr 9261039 9261139 9261187 9261201 9261221 9261250 9261255 9261255 9261295 9261701 9261710 9261711 9261712 9261714 9261715 9261717 9261719 9261721 9261822 9261831 9261832 9261834 9261836 9261845 9261846 9261850 9261851 9261853 9261853 9261855 9261857

Spare parts Page 5 - 123

Color

Description Rubber distance Actuator shaft spacer Green handle for baffle Spacer Injected housing Pressure sensor tube Molded pulley conveyor Molded pulley conveyor Pivot bearing Ring

Position adjust. nut

Washer

Stop

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

98 9 94 95 89 35 96 89 88 64 80 70 77 74 68 93 88 73 68 46 47 41 103 77 89 10 80 19 18 95 88

14 2 1 3 13 4 1 11 15 10 7 3 12 4 2 4 4 2 6 14 5 3 6 16 8 6 4 2 4 4 6

14.8 1.3 14.4 14.5 13.2 5.2 14.6 13.2 13.1 8.1 12.2 9.3 11.1 10.3 9.1 14.3 13.1 10.2 9.1 6.9 6.10 6.4 17.1 11.1 13.2 1.4 12.2 2.2 2.1 14.5 13.1

First Aid Kit 9591136

X

X X

Bourg Nr 9261858 9261861 9261865 9261870 9261871 9261872 9261873 9261876 9261877 9261897 9261900 9403732 9403733 9403735 9403737 9403738 9403739 9403740 9403742 9403751 9403758 9403759 9403767 9403769-AF 9403770 9403784 9403785 9403843 9403844 9403856 9403879-AF

Spare parts Page 5 - 124

Color

Description

Foam Bushing

Bushing Sleeve

Gear assembly Lift shaft assembly Upper nip assy Transl. bearing assy Joint support assy Nipping lover assy LH connecting plate RH connecting plate Punch assembly AF

Spaner

AF

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

88 65 74 75 75 77 77 96 98 100 93 81 58 60 30 65 64 65 65 65 82 82 79 73 70 75 75 50 49 103 15

14 4 6 17 18 20 19 7 9 13 2 4 8 6 1 5 1 10 14 15 9 10 1 3 5 3 21 4 13 5 4

13.1 8.2 10.3 10.4 10.4 11.1 11.1 14.6 14.8 15. 14.3 12.3 7.6 7.8 4.2 8.2 8.1 8.2 8.2 8.2 12.4 12.4 12.1 10.2 9.3 10.4 10.4 6.13 6.12 17.1 1.9

First Aid Kit 9591136

X

Bourg Nr 9403882 9403883-AF 9403885-AF 9403886-AF 9403897-AF 9403915 9403915 9403925-AF 9403928 9403947 9403948 9403952 9403953 9403956 9403957 9403964-AK 9403979-AF 9403979-AF 9403980 9403981 9403992 9404063-AK 9404064-AK 9404110-AK 9404111-AK 9404143 9404144-AF 9404145 9404146 9404152 9410563

Spare parts Page 5 - 125

Color

Description

AF AF AF AF

AF

Abrasive tools (option) Abrasive tools (option) Loading area extension

Pusher part B Pusher part A

AK AF AF CT plate sensor Recover glue plate AK AK AK AK AF

BBR uppper baffle (with Tag 15) BBR upper cover (with Tag 15)

Cover support bracket (with Tag 17) Knob assy

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

16 14 7 10 7 33 34 8 45 89 89 98 98 94 93 88 100 101 65 68 41 51 51 88 88 98 98 75 75 82 74

3 7 5 5 9 12 12 4 4 15 16 8 7 4 5 8 7 7 3 12 5 3 1 5 1 5 1 20 2 8 7

1.10 1.8 1.1 1.4 1.1 5.1.1 5.1.2 1.2 6.8 13.2 13.2 14.8 14.8 14.4 14.3 13.1 15. 16. 8.2 9.1 6.4 6.14 6.14 13.1 13.1 14.8 14.8 10.4 10.4 12.4 10.3

First Aid Kit 9591136

Bourg Nr 9413522 9413733 9413733 9413733 9413733 9413733 9413859 9413906 9413907 9413908 9413909 9413909 9413913 9413914 9413915 9413916 9413917 9413931 9413933 9413934 9413935 9413936 9413937 9413938 9413939 9413940 9413945 9413948 9413948 9413948 9414004

Spare parts Page 5 - 126

Color

Description Pulley assy Quarter turn Quarter turn Quarter turn Quarter turn Quarter turn Pulley assy

lock lock lock lock lock

assy assy assy assy assy

Gear assembly Nipping gear assembly

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

30 16 11 13 15 7 89 19 19 19 18 19 31 31 29 30 30 55 59 59 56 56 58 58 53 62 83 64 70 64 22

11 1 2 5 5 6 2 6 7 4 2 12 1 9 7 7 10 2 6 5 4 5 1 6 3 6 1 6 8 11 1

4.2 1.10 1.5 1.7 1.9 1.1 13.2 2.2 2.2 2.2 2.1 2.2 4.3 4.3 4.1 4.2 4.2 7.3 7.7 7.7 7.4 7.4 7.6 7.6 7.1 7.10 12.5 8.1 9.3 8.1 3.1

First Aid Kit 9591136 X

X

Bourg Nr 9414004 9414005 9414005 9414022 9414025 9414026 9414029 9414030 9414035 9414038 9414041 9414045 9414047 9414048 9414054 9414055 9414056-AF 9414058-AF 9414060-AF 9414062-AF 9414063-AF 9414064-AF 9414066-AF 9414070-AF 9414076 9414077 9414078 9414079 9414105 9414151 9414151

Spare parts Page 5 - 127

Color

Description

Connecting rod assembly Roller shaft assy

Pinion

Driving tray shaft Tray transl. screw shaft Gear Z10 assy AF AF AF AF AF AF AF AF

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

26 84 85 82 75 75 69 69 36 25 45 44 74 74 40 48 15 13 16 13 13 13 14 11 27 27 27 27 72 97 96

1 1 1 6 7 6 5 2 4 2 6 5 5 8 2 1 2 1 2 4 3 2 8 3 1 2 6 7 2 2 3

3.5 12.6 12.7 12.4 10.4 10.4 9.2 9.2 5.3 3.4 6.8 6.7 10.3 10.3 6.3 6.11 1.9 1.7 1.10 1.7 1.7 1.7 1.8 1.5 3.6 3.6 3.6 3.6 10.1 14.7 14.6

First Aid Kit 9591136

Bourg Nr 9414152 9414195 9414198 9414199 9420702 9421685 9422773 9422774 9422841 9422843 9422850 9422856 9422860 9422868 9422894 9422928 9422942 9422962 9422980 9422981 9422982 9422990 9422990 9422991 9422996 9423005 9423007 9423077 9423082 9423086 9430876

Spare Parts Page 5 - 128

Color

Description

Grounding braid Grounding braid Receiver board Emitter board

PNP sensor Drive board Cable DB 9 Glue tank board Dispatch board Interlock board Power board

Dual button board Harness Capacitor assembly Isolation board assy Double detect sensor Solenoid assy

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

93 42 42 42 98 98 23 23 19 25 65 105 66 105 105 105 68 105 49 49 49 7 10 7 8 105 49 105 105 80 77

9 5 6 7 16 15 6 3 3 4 1 9 3 12 11 10 17 7 1 2 3 2 2 3 5 8 5 15 6 9 10

14.3 6.5 6.5 6.5 14.8 14.8 3.2 3.2 2.2 3.4 8.2 18.1 8.3 18.1 18.1 18.1 9.1 18.1 6.12 6.12 6.12 1.1 1.4 1.1 1.2 18.1 6.12 18.1 18.1 12.2 11.1

First Aid Kit 9591136

X X X X X

X X X X

X

X

Bourg Nr 9430937 9430937 9431627 9431932 9432331 9432339 9432350 9432351 9432355 9432356 9432357 9432357 9432362 9432364 9432373 9432378 9432383 9432387 9432391 9432392 9432396 9432396 9432403 9432425 9432439 9432440 9432446 9432447 9432458 9432480 9432539

Spare Parts Page 5 - 129

Color

Description Motor assy Motor assy Blower assy Stepping motor + hex. shaft Lateral gluing assy

Solenoid assy

Solenoid assy

Solenoid

Nipping harness plate assy Collector assembly

Initial issue: 05/03 Latest revision: 11/05

P.L.

Page

Ref.

99 97 105 30 25 40 20 19 54 64 62 70 86 77 36 77 75 103 46 39 40 47 43 29 49 49 65 20 46 66 100

1 6 13 9 1 1 3 9 1 5 4 6 4 1 1 15 8 4 4 7 5 7 1 6 8 4 8 2 1 2 2

14.9 14.7 18.1 4.2 3.4 6.3 2.3 2.2 7.2 8.1 7.10 9.3 12.8 11.1 5.3 11.1 10.4 17.1 6.9 6.2 6.3 6.10 6.6 4.1 6.12 6.12 8.2 2.3 6.9 8.3 15.

First Aid Kit 9591136

X

X X X

X X

X X X X

Bourg Nr 9432540 9432557 9591161 9591169 9591179 9591188 9591188 9591200 9591201 9591202 4390001902 7006046000 9310806506 9330500806 14750402200 68850602000 9103049+942 3077 9104114 9166074 2X +9404152 1X 9404141 + 9204100 9423… 9423… 9423… 9423xxx 9423xxx 9423xxx

Spare Parts Page 5 - 130

Color

Description Collector control box Safety curtain assembly without Tag 6 Upgrade Kit Tag 8 Double detect sensor kit Lateral screw kit witout Tag 18 without Tag 18 Gearmotor kit Gear motor kit Gearmotor kit Nut Paper feed friction roller Screw

Power supply without Tag 4

P.L.

Page

Ref.

100 8 35 80 41 79 86 60 58 84 50 82 36 40 89 20

12 2

15. 1.2 5.2 12.2 6.4 12.1 12.8 7.8 7.6 12.6 6.13 12.4 5.3 6.3 13.2 2.3

11 4

7 11 11 2 4 10 10 14 6

105

18.1

11

4

1.5

(without Tag 17)

82

11

12.4

Milling blade assembly

34

5

5.1.2

103

1

17.1

99

3

14.9

103

10

17.1

105 105 105

16* 24* 3*

18.1 18.1 18.1

UI (see Software history in the General Procedure in the Service Manual) BBR board (see Software history in the Industrial flash (see Software history in the General Procedure in the Service Manual) CPU Frequency driver glue tank Frequency driver translation

Initial issue: 05/03 Latest revision: 11/05

First Aid Kit 9591136

20. FIRST AID KIT First Aid Kit 9591136 Bourg Number 9103049 9107063 9124008 9124016 9124024 9124028 9124187 9124194 9126161 9126319 9126445 9132026 9150065 9151136 9166027 9166045 9166082 9166094 9166121 9166164 9166172 9166203 9166237 9166247 9166277 9166279 9166282 9166283 9166284 9166285 9166286 9166292 9182065 9198003

Spare parts Page 5 - 131

Quantity 1 3 2 6 1 1 2 3 1 1 2 1 2 1 1 1 4 1 1 1 2 1 3 1 2 1 1 3 1 1 3 1 4 2

Description Power Supply 900W 24V+36V Photosensor Fuse 4A T 6,3X32 Fuse 6,25A T 6,3X32 Fuse 0,5A T 5X20 Fuse 1A T 5X20 Fuse 3,75A Fuse 12A T Belt D4X412 Belt 10T5 640MM Belt 1446 X40 PLC module MM432 Microswitch+roller+open. Motor Release Spring Spring Tension Spring Tension Spring Spring Tension Spring Spring Spring Tension Spring Tension Spring Spring Spring Spring Spring Spring Spring Spring Spring Jogger blade spring Milling brush

Initial issue: 05/03 Latest revision: 11/05

First Aid Kit 9591136 Bourg Number 9199883 9199998 9199999 9222738 9230560 9261715 9261822 9261832 9403742 9413522 9413733 9414098 9422492 9422773 9422774 9422841 9422850 9422856 9422894 9422928 9422962 9422969 9422996 9430876 9431627 9432362 9432373 9432383 9432392 9432396 9432439 9432440 9432446 9432458

Spare parts Page 5 - 132

Quantity 5 2 1 1 1 1 8 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description Aluminium bowl Notching tool Milling blade Milling shutter Teflon plate Succion bar flag Flat cup Drum 1 Scraper Cover clamp with foam Pulley 10T5 1/4 turn screw assy Jig for nipping adj. Cable DB9M-DB9M Carriage receiver board Carriage emitter board Encoder PNP sensor Stepper driver board Timer + Dispatch board Interlock board Power board Isolation board Dual button board Solenoid 9136026+conn. assy Fan 9151133+conn. assy Solenoid 9136083+Led assy Motor 9151123+conn. assy Solenoid 9136075+Led+conn. Glue tank drum assy Solenoid 9136026+conn. assy Heating resistor 300W Heating resistor 1000W Solenoid 9136084+conn. assy Spinner resistor 50W assy

Initial issue: 05/03 Latest revision: 11/05

21. HARDWARE 6PCC DIN912 ZINC 6 8 10 12 16 20 25 30 35 45 50 60

8 12

M3 M4 S457 S458 S371 S464 S459 S465 S460 S453 S461 S466 S462 S467 S463 S468 S469

M5

6PCC DIN 912 + TUFLOCK M6

S470 S441 S471 S472 S473 S474

M8

S480 S163 S481 S374 S548 S243 S489 S482 S483 S484 S393 S546 S549 S479 S613

M5 8 16 30

M6

M8 S392

S569

20 35

ST DIN 913 BLK

ST DIN 916 BLK.

M8 S185 S186

M3 M4 S042 S009

5 10 12 20 30 50

S490

M5 S122

S571

S415 S296 S138 S566

TFF DIN 963 ZINC.

CHTB ULS ZINC.

6PCC DIN 7984 ZINC.

6PCF DIN7991

M3 S343 S093

M4 M5 S514 S515 S522 S516 S523 S517 S524 S525 S519 S527

M4 S542

M4 S304

8 10 12 16 20 25 30

M6 10 12 16 45

M5

M6 S543

S570 S544 S922

8 10 12 16 20 25

TH DIN 933 ZINC. M8

M5

M6

M4 10 12 16 20 25 30 35 45 70 75 80 90 100

M5 S495 S496 S452

S396

M6

M8

M10

M12

S233 S502 S559 S454 S270 S573 S503 S437 S614 S435 S574 S504 S592 S505 S376

Screw with washer M8 8 12 20

S537 S551

M4 M6 S377 S378 S382 S607

S539 S562 S536

Spring loaded set screw 12

M5 S442

To order Sxxx, “S” should be replaced by the number 9190. Example: for a S163, you should order the item 9190163.

Spare parts Page 5 - 133

Initial issue: 05/03 Latest revision: 06/05

WASHER - 9172xxx D:2 DIN 125 ZINC.

D:3

D:4

D:5

D:6

D:8

D:10

W005

D:12 D:12.5 D:15 D:17

D:18

W175

DIN 125 POLYAM.

W041

DIN 126 ZINC.

W004 W003 W001 W002

DIN 127 ZINC.

W105

W011

DIN 137B

W045 W122

DIN 2093A

W034

DIN 2093B

W035

DIN 9021

W163 W007 W006 W200

DIN 988 (0.2)

W211

To order Wxxx, “W” should be replaced by the number 9172.

W028 W017

DIN 988 (0.5)

W039

MEDIUM CONTACT

W027 W029

W184 W185 W186 W187 W188 W189 W190

A PICOTS

Example: for a W193, you should order the item 9172193.

W191 W192 W193 W194

ROND. RESS. GRIFFES

W182

6797 IZ

W044

NUT - 9135xxx M2,5

M3

M4

M5

DIN 546 DIN 934

M6

M8

+ SPRING

Spare parts Page 5 - 134

M12

N106 N054 N002

N012 N009

DIN439 DIN 985

M10

N046 N078

N008 N006 N005 N152

N001 N004

To order Nxxx, “N” should be replaced by the number 9135.

N150

Example: for a N152, you should order the item 9135152.

Initial issue: 05/03 Latest revision: 09/04

CIRCLIPS - 9117xxx D:4 DIN 471

D:6

D:7

D:9

R158

D:10

D:12

R011 R007

D:14

D:15

D:17

R002

R013 R010

R024 R014

To order Rxxx, “R” should be replaced by the number 9117. Example: for a R159, you should order the item 9117159.

Spare parts Page 5 - 135

Initial issue: 05/03 Latest revision: 09/04

D:32

D:35

R0159

R006

R016

R153 R012 R026

DIN 472 DIN6799

D:19

NOTES .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Spare parts Page 5 - 136

.......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Initial issue: 05/03 Latest revision: 09/04

NOTES .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Spare parts Page 5 - 137

.......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Initial issue: 05/03 Latest revision: 09/04

NOTES .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Spare parts Page 5 - 138

.......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Initial issue: 05/03 Latest revision: 09/04

Section 6 :

GENERAL PROCEDURES

General Procedures Page 6 - i

Initial issue: 06/04 Latest revision: 09/05

This page is intentionally left blank.

General Procedures Page 6 - ii

Initial issue: 06/04 Latest revision: -

TABLE OF CONTENT Table of content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Speciality tools Kit 9591182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Tag matrix location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Programmed parts and software history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Tag info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Download procedure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Step 1 : Tool requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Step 2 : Install the BB3002 Software on your computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Step 3 : Connecting PC to binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Step 4 : Updating the binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Step 5 : Connecting PC to BBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Step 6 : Updating the BBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 ANNEXE : Menu Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

General Procedures Page 6 - 1

Initial issue: 06/04 Latest revision: 08/05

This page is intentionally left blank.

General Procedures Page 6 - 2

Initial issue: 06/04 Latest revision: -

SPECIALITY TOOLS KIT 9591182 Extension board for glue tank board (96 pins connector) 9423010

Cover clamp jig

Digital comparator kit

9414098 9926012 9926011 9231152

9926009

9591153 Jogger label

9926010

99 133 04000

1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0

Jogger adjustment square

9210582

9941021000

9414167 9204035

Serial cable RS232

9138096

Technician box

Feeler gauge 9929348 Ethernet cable

9422187

Keyboard to program ABB frequency driver 9132019 M

E N

U

Serial cable

9138093

R

TE

EN

General Procedures Page 6 - 3

Initial issue: 06/04 Latest revision: 08/05

9432545

TAG MATRIX LOCATION

SE R IA L

N U M BE R

:

SERIAL NUMBER

General Procedures Page 6 - 4

Initial issue: 06/04 Latest revision: -

PROGRAMMED PARTS AND SOFTWARE HISTORY

Part description

CPU

UI with software

Industrial flash programmed

BBR board

CD

with Software

Part description

Frequency driver for glue tank

Frequency driver for translation

TAG Software version

14

V02.00.04

Software version

9423093 -

V00.00.12

9423138 -

9423092 9425003 B 9423006 E

V01.00.01

Note : • The letter (A, B, C, etc…) means that it is the minimum sofware version corresponding to its respective part. • Some differences can be observed between the label on the board and the software present in the board due to an upgrade using a CD Rom. • If there is any problem present or an upgrade needs to be done, kindly mention the Tag number for the correct reference level.

General Procedures Page 6 - 5

Initial issue: 06/04 Latest revision: 06/05

9423091

9423090

TAG INFO TAG 1 : Machines equipped with interlock boards 9422928C.

TAG 10 : Software version 02.00.00.

TAG 2 : Machines equipped with moulded glue tank.

TAG 11 : New BBR board to correct mode RUN/DOWNLOAD problem 9423006B to 9423006C (AM 031).

TAG 3 : Machines equipped with a moulded milling blade housing (volute).

TAG 12 : Machines equipped with new feeding system for lateral gluing.

TAG 4 : Add capacitor assy to reduce current and use COSEL power supply.

TAG 13 : New threaded rod (in two parts) for lateral gluing cylinders Kit 9591179.

TAG 5 : Machine pre-equipped with double detection harness. TAG 6 : Hole in the milling blade housing + cover clamp shaft replacement and prefeed gear assembly replacement).

TAG 14 : Kit Upgrade BBR 9591181. Addition of springs (to avoid marking on booklets) and grounding braid (to avoid BBR frequently stops). TAG 15 : New BBR cover (9404144) and new upper baffle for BBR head (9404143).

TAG 7 : Lateral gluing modification (glue cut off index + driving). TAG 8 : Kit 9591161 (software version 02.00.00 + pressure sensor + sleeve + lateral gluing cylinders + insulation washer removal + BBR book separator harrow replacement + polishing of the baffles).

TAG 16 : New suction ramp, removal of the knurled knob. TAG 17 : Creasing module: Springs 9166280 replaced by springs 9166074.

TAG 9 : Cover station panel.

General Procedures Page 6 - 6

Initial issue: 06/04 Latest revision: 08/05

TAG 18 : Creasing module: - New punch with stiffener - New matrix with stiffener - Kit 9591188. TAG 19 : Milling blade housing (volute) and counter-cut modifications kit 9591199. TAG 20 : Cover nipping motor gear replacement (lift). Kit 9519200 (AM 065). TAG 21 : Cover nipping motor gear replacement (opening). Kit 9591201 (AM 065). TAG 22 : Scoring motor gear replacement. Kit 9591202 (AM 065). TAG 24 : Replacement of ball bearings in the glue tank (150°C to 200°C). 9175107 replaced by 9175109 9175106 replaced by 9175110

General Procedures Page 6 - 7

Initial issue: 06/04 Latest revision: 11/05

DOWNLOAD PROCEDURE One serial cable (RS232) (also called null-modem serial cable) - item number 9138096 (DB9F-DB9F) (Fig.2).

Step 1 : Tool requirements Laptop with standard Windows 95 and up (excepted Millenium). One Ethernet board (preferably). One serial port. One Ethernet crossed cable - item number 9138093 (Fig.1).

Fig.2

One serial cable (DB9-4 pins) for download BBR item number 9422187 (Fig.3).

Fig.3

Fig.1

Note: These cables are not supplied with the machine.

General Procedures Page 6 - 8

Initial issue: 06/04 Latest revision: 05/05

How to remove the BB3002 Software Manager

Step 2 : Install the BB3002 Software on your computer - Insert the CD-ROM in the CD-Reader. - Double click “My Computer“ to access the CD-Reader and open its respective drive (or select the drive, click on “file/open“).

Press “Start “ / “Settings “ / “Control Panel “. - In the Control Panel, double click on “ Add/Remove Programs “ (or select “Add/ Remove Programs “, click on “ file/open “). - Select the program BB 3002 Software Manager then press “ Add/Remove “, press the Yes button to confirm the removal.

- Double click on the file “ Setup “ (or select “ Setup “, click on “ file/open “)

- When done, close the “Add/Remove “ window (press on the cross in the top right corner) and then the “Control Panel “ window.

- The installation will now start and a welcome window “BB3002 Software Manager “ will pop up. - Click on the “Next” button then “Next” again, “Install” and “Finish”. Note 1: (Only for Windows XP) If the software is already installed on your computer you have the possibility to modify, repair or remove it. Make your choice and click the “Next” button.

- Leave your computer connected to the mains when download. - Check that hibernate or power off mode are not activated (Start / Control panel / Power option). - Restart the computer.

Note 2: (For the other O.S.): If the software is already installed on your computer you have to remove the installed version.

General Procedures Page 6 - 9

Initial issue: 06/04 Latest revision: 01/05

Step 3 : Connecting PC to binder CASE 1 : Using the Ethernet cable 9138093 - Time : 25 minutes. - Allow to update the PLC and the UI at the same time. - Connect the U.I. to the PC through the cable (9.138.093) as illustrated on Fig.4A.

9138093

From PC Fig.4A

General Procedures Page 6 - 10

Initial issue: 06/04 Latest revision: 02/05

CASE 2 : Using the serial cable 9138096 - Time : 1 hour 30 minutes. - Only if the download with the Ethernet cable is not possible (no Ethernet board, TCP IP failure).

- To update the U.I, connect the UI to the PC through the cable (9138096) as illustrated on Fig.4C.

- To update the PLC, connect the PLC to the PC through the cable (9138096) as illustrated on Fig.4B.

U.I. Node rotary switches

9138096

Left Right

From PC

From PC

Fig.4B Fig.4C

General Procedures Page 6 - 11

Initial issue: 06/04 Latest revision: 02/05

A- Backup

Step 4 : Updating the binder

Click on Backup BB3002 Settings. Read the checklist.

Power ON the binder.

If you use a serial cable, you have to specify a port COM number (following your configuration) (Fig.6).

On your computer, click on “Start”, select “All programs” then “CP Bourg/BB3002 Software Manager/ Version XX.XX.XX”.

If you use a Ethernet cable, set the IP adress of the UI as discribed on point 2 and 3 of the backup settings window (Fig.6).

Backup folder name

Port COM number ( If serial cable only)

Fig.5 A window “BB3002 Software Manager” will pop up (Fig.5).

Fig.6

When the backup is finished, the message Backup OK appears, click “OK” then “Close”.

General Procedures Page 6 - 12

Initial issue: 06/04 Latest revision: 01/05

B- Update

TAG

Click on “Update BB3002” (Fig.5) and follow instructions. Click on “Yes” button. Wait until the message “BB3002 transfer OK” appears (25 minutes).

Marf off The TAG number corresponding to the installed software (for example TAG 10 for the software version 02.00.00) see CD label. Version 02.00.00

TAG 10

Click on “Close”. The update is now finished. Close all windows and disconnect the cable.

In case of difficulties, select “Help” (Fig.5) and follow the instructions (attached hereafter). Note : If you used an Ethernet cable, you can update the PLC and UI software at the same time (BB3002 update). If you used a serial cable, you have to update the PLC then the U.I. SE R IA L

N U M BE R

:

SERIAL NUMBER

General Procedures Page 6 - 13

Initial issue: 06/04 Latest revision: 01/05

Step 5 : Connecting PC to BBR Note : If the BBR has not the Tag 11 marked off (board 9423006 C and up) install the kit # 9591161. - Connect the BBR board (connector X2) to the PC through the cable (9.422.187) as illustrated on Fig.7.

9423006-C and up

To pc

9422187

Fig.7

General Procedures Page 6 - 14

Initial issue: 06/04 Latest revision: Fig.6

The window (Fig.10) appears. Follow the instructions tehn click on “OK”.

Step 6 : Updating the BBR Time : 2 minutes. Binder must be ON and BBR connected. On your computer, click on “Start”, select “All programs” then “CP Bourg/BB3002 Software Manager/ Version XX.XX.XX”.

Follow instructions

A window “Software Manager V02.00.04” will pop up (Fig.8).

Fig.8 Click on “Update BBR” (Fig.8).

Fig.10 When the download is completed. Follow instructions again then click “OK”. Close all windows and disconnect the cable.

Port COM number

Fig.9 Select the port COM number (following your configuration) (Fig.9) Click on “Yes” button (Fig.9).

General Procedures Page 6 - 15

Initial issue: 06/04 Latest revision: -

TAG Marf off The TAG number corresponding to the installed software (for example TAG 10 for the software version 02.00.00) see CD label. Version 02.00.00

TAG 10

SE R IA L

N U M BE R

:

SERIAL NUMBER

General Procedures Page 6 - 16

Initial issue: 06/04 Latest revision: -

ANNEXE : Menu Help BB3002 Software Manager This CDROM contains all the files for the updating and installing of the C.P.Bourg BB3002 Software Manager. Please install this sofware running setup.exe. Hardware 1. Ethernet crossed cable - reference: 9138093. 2. Serial crossed cable - reference: 9138096.

Both the UI and PLC are closely interlinked and are connected to each other through a crossed serial cable. The software versions need to be compatible for the communication in between the two. Make sure the both software versions have the same XX.YY (Version XX.YY.ZZ), the ZZ is unimportant for the communication. The updating or installation of the software requires either a crossed serial cable or a crossed ethernet cable. Only the crossed serial cable is capable of doing all the operations. The BB3002 Complete update, hawever needs to be done using the crossed ethernet cable. If your laptop does not have a serial port, there are some USB-serial port adapters on the market.

The BB3002 Update to a new version 1. Updating the BB3002. 2. Settings or Alarms: Backup, Restore, View. Please Backup your settings before any action and Restore them at the end. After Installation you will need to check: 1. The date and time. 2. The glue heat up timer (it may assume the glue tank needs reheating). 3. The machine counter (recoverable from the mechanical reading in the machine).

Here are the options 1. Updating the BB3002 4. Updating the UI software 5. Reinstalling the PLC software 6. Reinstalling the UI software 7. Settings or Alarms: Backup, Restore, View

Advanced Features The Book Binder has two pieces of hardware requiring software: • User Interface (UI) which is in fact the touch screen on which the user interacts with the machine . • Programmable Logic Controller (PLC) which is situated inside the machine.

General Procedures Page 6 - 17

Initial issue: 06/04 Latest revision: 01/05

the RIGHT rotary switch to 0 (see figure 3C). When rebooting the UI "Mode/Node=02" will appear.

BB3002 Update BB3002 Update needs to be done using Ethernet Crossed cable reference: 9138093. Checklist: 1. Use Ethernet crossed cable between Laptop and BB3002. 2. Please set IP Adress on BB3002 to xxx.xxx.xxx.xxx. (IP is given by the software). The IP Adress is calculated by the BB3002 Software Manager: It asks you to put an IP adress in the User Interface. (The Adress calculated is the last digit of your computer IP + 1 For example: if the computer has 194.10.200.71 then the software asks you to enter in the UI: 194.10.200.72. If it was 194.10.200.79 it would ask you to enter in UI: 194.10.200.70) 3. To Set IP adres on UI: go in the Tech menu -> various -> connexion. 4. Then YOU MUST RESTART UI ! (To validate IP). 5. Time: 15 to 20 min. 6. If Ethernet connection fails check UI node adress = 02. The node adress is displayed on the black startup screen of the UI: "Mode/Node=02". If it is not correct it needs to be changed using a screwdriver on the UI (remove metal plate) WARNING ! THE NUMBERS ARE INVERTED ! when looking at the UI set the LEFT rotary switch to 2 and

General Procedures Page 6 - 18

Initial issue: 06/04 Latest revision: 01/05

Settings or Alarms: Backup, Restore, View

3. Remember to reconnect the BB3002 serial cable after installation.

Backup Settings The user has to specify the directory name for the settings and Alarms are to be saved. Restore Settings The user will be promped to select BB3002.cfg file in the directory where the settings ares saved. View Settings Settings are viewed in a window selecting a BB3002.cfg file. This window can be saved into a .csv file to archive the information in Excell, for example. The Alarms are saved and restored at the same time as the settings and can be viewed and exported to *.csv in the same way as the settings. Connection The backup, restore operation can be done in two ways, by using a: 1. CROSSED serial cable (RS232) (also called null-modem serial cable). 2. CROSSED ethernet cable (RJ45 - TCP/IP). Using a crossed serial cable 1. Connect one end of the cable to the serial port on your computer (COM1 or COM2). 2. Disconnect the BB3002 serial cable and connect the other end of your cable directly into the UI.

General Procedures Page 6 - 19

Initial issue: 06/04 Latest revision: 01/05

sing a crossed ethernet cable Checklist: 1. Use Ethernet crossed cable between Laptop and BB3002. 2. Please set IP Adress on BB3002 to xxx.xxx.xxx.xxx. (IP is given by the software). The IP Adress is calculated by the BB3002 Software Manager: It asks you to put an IP adress in the User Interface. (The Adress calculated is the last digit of your computer IP + 1 For example: if the computer has 194.10.200.71 then the software asks you to enter in the UI: 194.10.200.72. If it was 194.10.200.79 it would ask you to enter in UI: 194.10.200.70). 3. To Set IP adres on UI: go in the Tech menu -> various -> connexion. 4. Then YOU MUST RESTART UI ! (To validate IP). 5. If Ethernet connection fails check UI node adress = 02. The node adress is displayed on the black startup screen of the UI: "Mode/Node=02". If it is not correct it needs to be changed using a screwdriver on the UI (remove metal plate) WARNING ! THE NUMBERS ARE INVERTED ! when looking at the UI set the LEFT rotary switch to 2 and the RIGHT rotary switch to 0 (see figure 3C). When rebooting the UI "Mode/Node=02" will appear.

General Procedures Page 6 - 20

Initial issue: 06/04 Latest revision: 01/05

Connection UI Update can be done in two ways: 1. CROSSED serial cable (RS232) (also called null-modem serial cable). 2. CROSSED ethernet cable (RJ45 - TCP/IP). Using a crossed serial cable 1. Connect one end of the cable to the serial port on your computer. 2. Disconnect the BB3002 serial cable and connect the other end of your cable directly into the UI. 3. Remember to reconnect the BB3002 serial cable after installation.

General Procedures Page 6 - 21

Initial issue: 06/04 Latest revision: 01/05

Using a crossed ethernet cable Checklist: 1. Use Ethernet crossed cable between Laptop and BB3002. 2. Please set IP Adress on BB3002 to xxx.xxx.xxx.xxx. (IP is given by the software). The IP Adress is calculated by the BB3002 Software Manager: It asks you to put an IP adress in the User Interface. (The Adress calculated is the last digit of your computer IP + 1 For example: if the computer has 194.10.200.71 then the software asks you to enter in the UI: 194.10.200.72. If it was 194.10.200.79 it would ask you to enter in UI: 194.10.200.70). 3. To Set IP adres on UI: go in the Tech menu -> various -> connexion. 4. Then YOU MUST RESTART UI ! (To validate IP). 5. If Ethernet connection fails check UI node adress = 02. The node adress is displayed on the black startup screen of the UI: "Mode/Node=02". If it is not correct it needs to be changed using a screwdriver on the UI (remove metal plate) WARNING ! THE NUMBERS ARE INVERTED ! when looking at the UI set the LEFT rotary switch to 2 and the RIGHT rotary switch to 0 (see figure 3C). When rebooting the UI "Mode/Node=02" will appear.

General Procedures Page 6 - 22

Initial issue: 06/04 Latest revision: 01/05

PLC software installation instructions The software installed contains both the operating system and book binder software for the PLC. The software can be installed in two ways, by using a: 1. CROSSED serial cable (RS232) (also called null-modem serial cable). 2. CROSSED ethernet cable (RJ45 - TCP/IP). Both connection are approximately the same speed but the serial connection is the easiest to set up and the most reliable. We recommed using the crossed serial connection. Installing the PLC software using a crossed serial cable 1. Connect one end of the cable to the serial port on your computer (COM1 or COM2). 2. Disconnect the BB3002 serial cable and connect the other end of your cable directly into the PLC. 3. Launch the installation program and specify COM port. 4. Remember to reconnect the BB3002 serial cable after installation.

General Procedures Page 6 - 23

Initial issue: 06/04 Latest revision: 01/05

Installing the PLC software using a crossed ethernet cable Using a crossed ethernet cable Checklist: 1. Use Ethernet crossed cable between Laptop and BB3002. 2. Please set IP Adress on BB3002 to xxx.xxx.xxx.xxx. (IP is given by the software). The IP Adress is calculated by the BB3002 Software Manager: It asks you to put an IP adress in the User Interface. (The Adress calculated is the last digit of your computer IP + 1 For example: if the computer has 194.10.200.71 then the software asks you to enter in the UI: 194.10.200.72. If it was 194.10.200.79 it would ask you to enter in UI: 194.10.200.70) 3. To Set IP adres on UI: go in the Tech menu -> various -> connexion. 4. Then YOU MUST RESTART UI ! (To validate IP). 5. If Ethernet connection fails check UI node adress = 02. The node adress is displayed on the black startup screen of the UI: "Mode/Node=02". If it is not correct it needs to be changed using a screwdriver on the UI (remove metal plate) WARNING ! THE NUMBERS ARE INVERTED ! when looking at the UI set the LEFT rotary switch to 2 and the RIGHT rotary switch to 0 (see figure 3C ). When rebooting the UI "Mode/Node=02" will appear.

General Procedures Page 6 - 24

Initial issue: 06/04 Latest revision: 01/05

UI software installation instructions The software installed contains both the operating system and book binder software for the UI. The software can be installed using a CROSSED serial cable (RS232) (also called null-modem serial cable).

Since this is the full installation, ALL the data on the UI will be lost !!! The settings can be backed up using the utility provided on the cd. Installing the UI software using a crossed serial cable 1. Connect one end of the cable to the serial port on your computer (COM1 to COM8). 2. Disconnect the BB3002 serial cable and connect the other end of your cable directly into the UI. 3. Launch the installation program. 4. Remember to reconnect the BB3002 serial cable after installation.

General Procedures Page 6 - 25

Initial issue: 06/04 Latest revision: 01/05

ALARM MESSAGES Alarm Messages 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192 16384 32768 65536 131072 524288 1048576 2097152 4194304 8388608 16777216 66666 77777 88888 99999 33010 33040 33060 33080 33090 33110 33130 33210 33240

Messages d'alarme

English

Français

Please press the green button on the machine Please press the glue tank heating button Glue tank too cold - please wait Glue tank too hot - please wait Book in the machine - please remove it Cover in the machine - please remove it BBR full - please empty it Technician mode Emergency stop activated - please deactivate Life test running Book Binder needs rebooting - please reboot Double click the green button to start Automatic start upon insertion of the book Glue tank level too low - please add glue Glue tank level too high - please remove The waste bag is full - please empty it The cover level is low - please refill Glue tank heating cycle not completed Interlock active - please release The book dimensions are out of limits ! Book width must be Book width must be Book width must be

Veuillez appuyer sur le bouton vert Veuillez appuyer sur la chauffe de colle La colle chauffe - Veuillez patienter La colle est trop chaude - Patientez Veuillez retirer le livre de la machine Veuillez retirer la couverture de la machine BBR rempli - Veuillez le vider Mode Technicien Arrêt d'urgence enclenché Test de durée de vie en cours Veuillez éteindre et allumer la machine Faites un double click sur le bouton vert Auto démarrage dès l'introduction du livre Niveau de colle trop bas Niveau de colle trop haut Sac à copeaux plein - Veuillez le vider Niveau de couverture bas Attente de la chauffe du bac à colle Interlock actif - veuillez le relacher Paramètres du livre hors limites ! Epaisseur doit être Epaisseur doit être Epaisseur doit être

Book thickness out of specifications Emergency stop - Barrier detection during cycle Emergency stop - Caused by exit from technician page Interlock activated - Maybe a door is open or an interlock switch is active Carriage - Please remove any paper from the carriage clamp Carriage - Timed out trying to reach the fully closed position Carriage - Reset failed Carriage - Timed out while switching to PWM mode Carriage - Timed out trying to reach the fully open position Carriage - Carriage position out of bounds Carriage - Timed out trying to reach the initialisation position Carriage - Book thickness out of range (negative or bigger than 60 mm) Carriage - No book in the clamp during the cycle

Epaisseur du livre hors spécifications Arrêt d'urgence - Détection des mains dans la barrière Arrêt d'urgence - Sortie d'une page technicien Interlock actif - Porte ouverte ou interlock actif Chariot - Veuillez retirer le papier dans le chariot Chariot - La pince n'a pas su atteindre position fermée Chariot - Réinitialisation a échoué Chariot - Pince: Echec lors du basculement vers le mode PWM Chariot - La pince n'a pas su atteindre sa position maximale Chariot - Position du chariot hors limites Chariot - Pince n'a pas su atteindre sa position d'initialisation Chariot - Epaisseur en dehors des spécifications (épaisseur < 0 mm ou > 60 mm) Chariot - Absence de livre dans la pince durant le process

General Procedures Page 6 - 26

Initial issue: 06/04 Latest revision: 01/05

Alarm Messages 33333 33350 33910 33980 36048 36049 39001 39002 39005 39106 39107

Messages d'alarme

English

Français

Carriage - Motor overheating protection activated Carriage - Timed out while closing the clamp with 4 Amps Carriage - Carriage buttons: current mode during the switch to PWM Carriage - Carriage buttons: forced current mode Translation - Variator error Translation - Left position switch error Jogger - Too many active steppers - Please reboot the machine Jogger - TPU DIRRESPONSE - Please reboot the machine Jogger - TPU ERROR - Please reboot the machine Jogger - Did not find the cell - Is the cell badly adjusted ? Jogger - Did not stop in the cell - Is the cell badly adjusted ?

Chariot - Protection de surchauffe du moteur activé Chariot - Fermeture impossible à 4 Ampères Chariot - Boutons du Chariot: mode courant lors de basculement PWM Chariot - Boutons du Chariot: mode courant non demandé Translation - Erreur variateur Translation - Switch de détection Chariot à Gauche ne répond pas Taquage - Trop de moteurs pas à pas actifs - Veuillez redémarrer la machine Taquage - TPU DIRRESPONSE - Veuillez redémarrer la machine Taquage - ERREUR TPU - Veuillez redémarrer la machine Taquage - N'a pas trouvé sa cellule - Cellule mal ajustée ? Taquage - Ne s'est pas arrêté dans sa cellule - Cellule mal ajustée ? Fraisage - Echec du test de direction du moteur. Mauvaise direction ou le moteur ne tourne pas Fraisage - Bourrage copeaux Fraisage - Surchauffe du moteur de fraisage Fraisage - Pas de sac à copeaux dans BB3002 Fraisage - Bac à copeaux plein Fraisage - Courrant trop important Fraisage - Ne tourne pas Bac à colle - Erreur de variateur Bac à colle - Différence de températures cylindres 1 et 2 trop grande Bac à colle - Le mechanisme de l'encollage latéral n'a pas atteint sa cellule Bac à colle - Encollage latéral - Trop de moteurs actifs - Veuillez redémarrer Bac à colle - Erreur TPU de l'encollage latéral (dirresponse) - Veuillez redémarrer Bac à colle - Erreur TPU de l'encollage latéral - Veuillez redémarrer Bac à colle - Erreur TPU des scrapers - Veuillez redémarrer Bac à colle - Le spinner n'est pas dans la plage tolérée Bac à colle - Spinner - Trop de moteurs actifs - Veuillez redémarrer Bac à colle - Spinner - TPU (dirresponse) - Veuillez redémarrer Bac à colle - Spinner - Erreur TPU - Veuillez redémarrer Bac à colle - Thermique carte bac à colle déclenché Encollage latéral présent mais déclaré absent dans l'UI Transport Couverture - Trop de moteurs actifs - Veuillez redémarrer la machine Transport Couverture - TPU DIRRESPONSE - Veuillez redémarrer la machine Transport Couverture - Timeout en tournant à gauche Emboitage - Timed out en tournant à gauche Emboitage - Timeout en tournant à droite Emboitage - Echec lors du retour à la position basse Emboitage - Echec lors du retour à la position haute Emboitage - Incapacité de quitter la cellule

42050 Milling - Motor direction test failed ! Wrong direction or motor not turning 42100 42300 42500 42600 42700 42800 48002 48100 48160 48201 48202 48205 48206 48300 48301 48302 48305 48600 48700 54001 54002 54005 54106 54107 54110 54120 54160

Milling - Exhaust vent blocked Milling - Milling motor temperature too high Milling - No milling bag in BB3002 Milling - Please check the milling bag is not full Milling - Current overload Milling - Not running Glue tank - Variator error Glue tank - Cylinder 1 and Cylinder 2 temperature difference too high Glue tank - Side glue mechanism did not reach its cell Glue tank - Side glue - Too many active steppers - Please reboot Glue tank - Side glue - TPU (dirresponse) - Please reboot Glue tank - Side glue TPU error - Please reboot Glue tank - Scraper TPU error - Please reboot Glue tank - Spinner out of range Glue tank - Spinner - Too many active steppers - Please reboot Glue tank - Spinner - TPU (dirresponse) - Please reboot Glue tank - Spinner - TPU error - Please reboot Glue tank - Relay on temperature board needs resetting Side glue option is present but not declared in the UI Cover Transport - Too many active steppers - Please reboot the machine Cover Transport - TPU DIRRESPONSE - Please reboot the machine Cover Transport - Timed out turning left Book Clamp Up/Down - Timed out turning left Book Clamp Up/Down - Timed out turning right Book Clamp Up/Down - Failed to reach the down position Book Clamp Up/Down - Failed to reach the up position Book Clamp Up/Down - Failed to leave the cell

General Procedures Page 6 - 27

Initial issue: 06/04 Latest revision: 01/05

Alarm Messages 54210 54320 54400 54500 54600 57005 57016 57017 57018 57019 57020 57022 57027 57028 57029 57101 57102 57105 60002 60014 60015 60016

Messages d'alarme

English

Français

Book Clamp Nipping - Failed to close Book Clamp Nipping - Failed to reach the requested current Book Clamp Nipping - Failed to reach the requested book thickness position Book Clamp Nipping - Failed to reach the requested position Book Clamp Nipping - Failed to reopen Cover Feeder - Initialisation error - Failed to leave the home cell Cover Feeder - Failed to collect the cover even after several tries Cover Feeder - Cover lost while waiting for the transfer Cover Feeder - Cover lost during the fast part of the transfer Cover Feeder - Cover lost during the slow part of the transfer Cover Feeder - Cover lost while transferring into the clamp (breaking) Cover Feeder - Cover lost in cover clamp Cover Feeder - Process error even after several retries Cover Feeder - Double cover detected Cover Feeder - Cover sensor did not respond Cover Feeder - Too many active steppers - Please reboot Cover Feeder - TPU (dirresponse) - Please reboot Cover Feeder - TPU error - Please reboot Cover Clamp - Initialisation error - Cover present: please remove manually Cover Clamp - Cover lost after being loaded into the clamp Cover Clamp - Creasing distance out of range - Bad book format ? Cover Clamp - Clamping position out of range - Bad book format ?

Emboitage Pinçage - Echec de fermeture Emboitage Pinçage - Incapable d'atteindre le seuil de courant demandé Emboitage Pinçage - Incapable d'atteindre la position pour l'épaisseur du livre Emboitage Pinçage - Incapable d'atteindre la position demandée Emboitage Pinçage - Incapable de se réouvrir Prise couverture - Pas sorti de sa cellule lors de l'initialisation Prise couverture - Echec même après quelques essais Prise couverture - Perte couverture en attente du transfer Prise couverture - Perte couverture pendant le transfert rapide Prise couverture - Perte couverture pendant le tranfert lent Prise couverture - Perte couverture pendant le transfert - freinage Prise couverture - Perte couverture dans la pince couverture Prise couverture - Perte couverture après plusieurs essais Prise couverture - Double couverture Prise couverture - capteur présence papier ne répond pas Prise couverture - Trop de moteurs actifs - Veuillez redémarrer Prise couverture - TPU (dirresponse) - Veuillez redémarrer Prise couverture - Erreur TPU - Veuillez redémarrer Transport Couverture - Veuillez retirer la couverture de la pince Transport Couverture - Couverture perdue après transfert Transport Couverture - Distance de rainage hors spécifications - Format du livre ? Transport Couverture - Position d'emboitage hors spécifications - Format du livre ? Transport Couverture - Perte de couverture en positionnant pour rainage ou emboitage Transport Couverture - Perte de couverture en attendant l'emboitage Transport Couverture - Perte de couverture en emboitage Transport Couverture - Perte de couverture avec rainage en position haute Transport Couverture - Trop de moteurs actifs - Veuillez redémarrer Transport Couverture - TPU (dirresponse) - Veuillez redémarrer Transport Couverture - Erreur TPU - Veuillez redémarrer Rainage - Impossible de rainer - Trop de couvertures ? Rainage - Timeout du prépositionnement du rainage Rainage - Mauvaise connexion de la cellule de rainage Rainage - Impossible d'atteindre la position d'initialisation Cover Clamp - Mauvaise connexion de la cellule de rainage ? BBR - Erreur inconnue BBR - Erreur pendant l'initialisation du CAN BBR - Erreur pendant écriture du CAN BBR - Erreur pendant l'initialisation BBR - Erreur pendant le 'homing' de la tête

60023 Cover Clamp - Lost the cover while positioning for creasing or book reception 60024 60025 60026 60101 60102 60105 63000 63020 63030 63040 63060 85000 85001 85002 85021 85026

Cover Clamp - Lost the cover while waiting for the book clamping Cover Clamp - Lost the cover during the book clamping Cover Clamp - Lost the cover with the creasing mechanism up Cover Clamp - Too many active steppers - Please reboot Cover Clamp - TPU (dirresponse) - Please reboot Cover Clamp - TPU error - Please reboot Creasing - Too many covers ? Try lowering the suction level Creasing - Prepositioning timed out Creasing - Creasing cell badly connected Creasing - Timed out while trying to reach the home position Cover Clamp - Creasing home cell badly connected ? BBR - Unknown error BBR - CAN initialisation error BBR - CAN write error BBR - Error during initialisation BBR - Error during the return home of the BBR 'head'

General Procedures Page 6 - 28

Initial issue: 06/04 Latest revision: 01/05

Alarm Messages 85032 85037 85038 85039 85048 85053 85058 85064 85069 85074 85085 85090 85096 85101 85106 85112 85117 85122 85128 85133 85144 85241 85245 85246 99000 99033 99036 99136 99039 99042 99048 99148 99248 99057 99060 99063 99065 99099 99142 99090

Messages d'alarme

English

Français

BBR - Error opening BBR 'head' for homing BBR - Error the BBR 'head' didn't reach its home cell BBR - The head is detecting the 'squeeze' BBR - The head is detecting the 'squeeze' too early BBR - Error while the book is entering the BBR BBR - Error while waiting for the opening of the 'head' BBR - Error during the opening of the 'head' BBR - Error while checking the book reception BBR - Error while setting the incoming book delay parameter BBR - Error while waiting for the book BBR - Error while squeezing the book BBR - Timed out while squeezing the book BBR - Error while asking the fork to go down BBR - Error while waiting for the fork to go down BBR - Error asking for the 'head' overrun BBR - Error while checking the 'head' overrun BBR - Error while asking the fork to go up BBR - The fork failed to go up BBR - Error asking the 'head' to return BBR - Error waiting for the 'head' to return BBR - Emergency stop detected BBR - Full - Please empty the BBR BBR - Stop button pushed BBR - Book stuck on the BBR head BB3002 Timeout - Unknown error BB3002 Timeout - Carriage clamp did not respond BB3002 Timeout - Translation did not respond BB3002 Timeout - Translation did not respond while testing the encoder BB3002 Timeout - Jogger did not respond BB3002 Timeout - Milling did not respond BB3002 Timeout - Glue tank did not respond BB3002 Timeout - Spinner did not respond BB3002 Timeout - Side glue did not respond BB3002 Timeout - Cover feeder did not respond BB3002 Timeout - Cover clamp did not respond BB3002 Timeout - Book clamp did not respond BB3002 Timeout - Creasing mechanism did not respond BB3002 Timeout - Paper lost in carriage clamp BB3002 Timeout - Milling could not be indexed BB3002 Timeout - Milling could not be indexed

BBR - Erreur ouverture de tête allant en home BBR - Erreur la tête n'arrive pas à la cellule home BBR - La palette de la tête se trouve déja relevée BBR - Relevée de la palette de la tête détectée trop tot BBR - Erreur lors de la réception du livre BBR - Erreur en attente de la préouverture de la tête BBR - Erreur lors de la preouverture de la tête BBR - Erreur en vérifiant la réception du livre BBR - Erreur pendant le paramètrage du délai de livre rentrant BBR - Erreur en attente du livre BBR - Erreur en pressant le livre BBR - Timeout en pressant le livre BBR - Erreur demande herse vers le bas BBR - Erreur en attente de la herse en position basse BBR - Erreur demandant surcourse de la tête BBR - Erreur attendant surcourse de la tête BBR - Erreur demandant herse de remonter BBR - La herse n'a pas su remonter BBR - Erreur demandant à la tête de reculer BBR - Erreur en attendant le retour de la tête BBR - Arrêt d'urgence enclenché BBR - Plein - Veuillez vider le BBR BBR - Bouton d'arrêt enclenché BBR - Livre arrêté sur la tête du BBR Timeout BB3002 - Erreur inconnue Timeout BB3002 - La pince chariot ne répond pas Timeout BB3002 - La translation ne répond pas Timeout BB3002 - Translation ne répond pas pendant le test de l'encodeur Timeout BB3002 - Le taquage ne répond pas Timeout BB3002 - Fraisage ne répond pas Timeout BB3002 - Bac à colle ne répond pas Timeout BB3002 - Spinner ne répond pas Timeout BB3002 - L'encollage latéral ne répond pas Timeout BB3002 - Prefeed ne répond pas Timeout BB3002 - Le transport couverture ne répond pas Timeout BB3002 - l'emboitage ne répond pas Timeout BB3002 - Le rainage ne répond pas Timeout BB3002 - Perte de papier dans la pince chariot Timeout BB3002 - Fraisage incapable de s'indexer Timeout BB3002 - Fraisage incapable de s'indexer

General Procedures Page 6 - 29

Initial issue: 06/04 Latest revision: 06/05

Alarm Messages

Messages d'alarme

English 99160 99242 99260 99833 99836 99839 99855 99856 99857 99858 99860 99890 99900

Français

Process - Changed cover mode while in process BB3002 Timeout - Jogger too low - risk of collision with milling BB3002 Timeout - Cover not in safe area BB3002 Timeout - Carriage clamp not in emergency stop status BB3002 Timeout - Translation not in emergency stop status BB3002 Timeout - Jogger not in Emergency Stop Status BB3002 Timeout - Milling not in Emergency Stop Status BB3002 Timeout - Book clamp not in emergency stop status BB3002 Timeout - Cover feeder not in emergency stop status BB3002 Timeout - Glue tank not in emergency stop status BB3002 Timeout - Cover clamp not in emergency stop status BB3002 Timeout - Conveyor not in emergency stop status BB3002 - Power loss in 5v cells Undocumented error 200000 * Book Binder switched on * 200001 * Book Binder switched off *

General Procedures Page 6 - 30

Process - Changement de mode couverture pendant le cycle Timeout BB3002 - Taquage trop bas - risque de collision avec la fraise Timeout BB3002 - Couverture n'est pas en position de sécurité Timeout BB3002 - La pince chariot n'est pas en arrêt d'urgence Timeout BB3002 - La translation n'est pas en arrêt d'urgence Timeout BB3002 - Le taquage n'est pas en arrêt d'urgence Timeout BB3002 - Le fraisage n'est pas en arrêt d'urgence Timeout BB3002 - L'emboitage n'est pas en arrêt d'urgence Timeout BB3002 - Le prefeed n'est pas en arrêt d'urgence Timeout BB3002 - Le bac à colle n'est pas en arrêt d'urgence Timeout BB3002 - Le Transport Couverture n'est pas en arrêt d'urgence Timeout BB3002 - Convoyeur n'est pas en arrêt d'urgence BB3002 - Perte de la tension des cellules 5v Erreur non documentée * Machine sous tension * * Machine éteinte *

Initial issue: 06/04 Latest revision: 01/05

NOTES

General Procedures Page 6 - 31

Initial issue: 06/04 Latest revision: -

NOTES

General Procedures Page 6 - 32

Initial issue: 06/04 Latest revision: -

Section 7:

WIRING DIAGRAMS

Wiring Diagrams Page 7 - 0

Initial issue: 04/04 Latest revision: 11a/05

This page is intentionally left blank.

Wiring Diagrams Page 7 - ii

Initial issue: 04/04 Latest revision: 08/04

TABLE OF CONTENTS 1. Wiring diagrams .........................................................................................................................................1 1.1 Diagram block .................................................................................................................................................................1 1.2 Interlock connections (part 1 of 2)...................................................................................................................................2 1.3 Interlock connections (part 2 of 2)...................................................................................................................................3 1.4 Power parts single-LINE representation (part 1 of 4) .....................................................................................................4 1.5 Power parts single-LINE representation (part 2 of 4) .....................................................................................................5 1.6 Power parts single-LINE representation (part 3 of 4) .....................................................................................................6 1.7 Power parts single-LINE representation (part 4 of 4) .....................................................................................................7 1.8 Main supply .....................................................................................................................................................................8 1.9 Interlock board ................................................................................................................................................................9 1.10 Interlock by pass .........................................................................................................................................................10 1.11 Interlock power supply 36V .........................................................................................................................................11 1.12 Interlock power supply 24V (part 1 of 5) .....................................................................................................................12 1.13 Interlock power supply 24V (part 2 of 5) .....................................................................................................................13 1.14 Interlock power supply 24V (part 3 of 5) .....................................................................................................................14 1.15 Interlock power supply 24V (part 4 of 5) .....................................................................................................................15 1.16 Interlock power supply 24V (part 5 of 5) .....................................................................................................................16 1.17 Carriage clamp (part 1 of 2) ........................................................................................................................................17 1.18 Carriage clamp (part 2 of 2) ........................................................................................................................................18 1.19 Translation (part 1 of 3)...............................................................................................................................................19 1.20 Translation (part 2 of 3)...............................................................................................................................................20 1.21 Translation (part 3 of 3)...............................................................................................................................................21 1.22 Jogger .........................................................................................................................................................................22 1.23 Milling (part 1 of 2) ......................................................................................................................................................23 1.24 Milling (part 2 of 2) ......................................................................................................................................................24 1.25 Glue tank (part 1 of 8) .................................................................................................................................................25 1.26 Glue tank (part 2 of 8) .................................................................................................................................................26 1.27 Glue tank (part 3 of 8) .................................................................................................................................................27 1.28 Glue tank (part 4 of 8) .................................................................................................................................................28 1.29 Glue tank (part 5 of 8) .................................................................................................................................................29 1.30 Glue tank (part 6 of 8) .................................................................................................................................................30

Wiring Diagrams Page 7 - 1

Initial issue: 04/04 Latest revision: 02/05

1.31 1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 1.40 1.41 1.42 1.43 1.44 1.45 1.46 1.47

Glue tank (part 7 of 8) .................................................................................................................................................31 Glue tank (part 8 of 8) .................................................................................................................................................32 Book clamp (part 1 of 2)..............................................................................................................................................33 Book clamp (part 2 of 2)..............................................................................................................................................34 Prefeed (part 1 of 2)....................................................................................................................................................35 Prefeed (part 2 of 2)....................................................................................................................................................36 Cover clamp ................................................................................................................................................................37 Creasing ......................................................................................................................................................................38 Can..............................................................................................................................................................................39 Conveyor .....................................................................................................................................................................40 Signalling lighting ........................................................................................................................................................41 BBR Power supply and interlock (part 1 of 4).............................................................................................................42 BBR Head motor (part 2 of 4) .....................................................................................................................................43 BBR Inputs sensor (part 3 of 4) ..................................................................................................................................44 BBR Fork motor (part 4 of 4) ......................................................................................................................................45 External dust extractor and option ..............................................................................................................................46 Cover detection ...........................................................................................................................................................47

2. Graphical symbols for diagrams ............................................................................................................48 3. Component list .........................................................................................................................................53 4. Description of electrical components ....................................................................................................57 4.1 Numbering of BB3002 binder modules ........................................................................................................................57 4.2 Covers ...........................................................................................................................................................................57 4.3 Carriage ........................................................................................................................................................................59 4.4 Jogger module .............................................................................................................................................................60 4.5 Milling module ..............................................................................................................................................................61 4.6 Glue tank ......................................................................................................................................................................62 4.7 Carriage movement ......................................................................................................................................................64 4.8 Cover clamp module ....................................................................................................................................................65 4.9 Cover picking ...............................................................................................................................................................66 4.10 Creasing .....................................................................................................................................................................67 4.11 Cover transport ...........................................................................................................................................................68

Wiring Diagrams Page 7 - 2

Initial issue: 04/04 Latest revision: 02/05

4.12 Output and conveyor ..................................................................................................................................................69 4.13 BBR ............................................................................................................................................................................70

5. General Description of the electronics rack .........................................................................................71 5.1 General schematic for the electronics rack ..................................................................................................................71 5.2 Relays and fuse holders ..............................................................................................................................................74 5.3 B&R Modules ...............................................................................................................................................................75 5.3.1 CPU 474 : .........................................................................................................................................................75

Exchanging the battery of the CPU ...........................................................................................................76 5.3.2 Module DO 135 : ..............................................................................................................................................77 5.3.3 Module DI 140 : ................................................................................................................................................78 5.3.4 Module MM432 : ...............................................................................................................................................79 5.3.5 Module CM 211 : ..............................................................................................................................................81 5.3.6 Module DI 439 : ................................................................................................................................................85 5.3.7 Module MM424 : ...............................................................................................................................................87 5.3.8 Module DO 435 : ..............................................................................................................................................88 5.4 Electronics cards ..........................................................................................................................................................89 5.4.1 DRIVER Card - A1 : .........................................................................................................................................91 5.4.2 DRIVER Card - A2 : ..........................................................................................................................................92 5.4.3 INTERLOCK Card - A3 : .................................................................................................................................93 5.4.4 DISPATCH Card - A4 : .....................................................................................................................................95 5.4.5 GLUE TANK Card - A5 : ...................................................................................................................................97 5.4.6 ISOLATION Card - A30 : ...................................................................................................................................98 5.4.7 POWER Card - A20 : ........................................................................................................................................99 5.4.8 BBR Card - A7 : ...............................................................................................................................................101

6. Interlock Circuit ......................................................................................................................................102 6.1 General presentation ..................................................................................................................................................102 6.2 Interlock circuit ...........................................................................................................................................................103 6.3 Timer ..........................................................................................................................................................................104 6.4 Technical box .............................................................................................................................................................105 6.5 Thermal protection of the milling motor .....................................................................................................................106 6.6 Interlock Diagram ........................................................................................................................................................107

Wiring Diagrams Page 7 - 3

Initial issue: 04/04 Latest revision: 02/05

7. Thermal control of glue heating ...........................................................................................................108 7.1 Technical description ..................................................................................................................................................108 7.2 “Heating tank” electrical diagram ................................................................................................................................109 7.3 Diagram of tank heating .............................................................................................................................................110 7.4 Making the system safe in the event that temperature is exceeded ..........................................................................111 7.5 Temperature at bottom of tank ...................................................................................................................................112

8. ABB frequency variator .........................................................................................................................113 8.1 Connection .................................................................................................................................................................113 8.2 List of parameters .......................................................................................................................................................114 8.2.1 GROUP 2: Motor data and limit values : ..........................................................................................................114 8.2.2 GROUP 3 : Command characteristics : ...........................................................................................................115 8.2.3 GROUP 4 : Inputs and outputs : ......................................................................................................................116 8.2.4 GROUP 5 : Supervision and faults : ................................................................................................................117 8.3 Programming ..............................................................................................................................................................119 8.3.1 Menu structure : ...............................................................................................................................................119 8.3.2 Procedure to be followed : ...............................................................................................................................119 8.3.3 Manual control of motors : ................................................................................................................................120 8.4 Parameterisation of frequency variatorsVersion 01.00.01 ........................................................................................................................................................121 8.5 Error messages ..........................................................................................................................................................122

9. TELEMECANIQUE Frequency driver ...................................................................................................123 9.1 Connections ...............................................................................................................................................................123 9.1.1 Power Terminals : .............................................................................................................................................123 9.1.2 Control Terminals : ...........................................................................................................................................123 9.1.3 Wiring diagrams : .............................................................................................................................................124 9.2 Parameters of the frequency driver ............................................................................................................................125 9.2.1 First level adjustment parameters : ..................................................................................................................125 9.2.2 Motor Control Menu : drC..................................................................................................................................126 9.2.3 Application functions menu : Fun ......................................................................................................................127 9.2.4 Monitoring Menu : SUP .....................................................................................................................................129 9.3 Faults - Causes - Remedies .......................................................................................................................................130

Wiring Diagrams Page 7 - 4

Initial issue: 04/04 Latest revision: 02/05

1. WIRING DIAGRAMS 1.1 Diagram block

Wiring Diagrams Page 7 - 1

Initial issue: 04/04 Latest revision: 11/04

1.2 Interlock connections (part 1 of 2)

Wiring Diagrams Page 7 - 2

Initial issue: 04/04 Latest revision: 06/05

1.3 Interlock connections (part 2 of 2)

Wiring Diagrams Page 7 - 3

Initial issue: 04/04 Latest revision: 11/04

1.4 Power parts single-LINE representation (part 1 of 4)

Wiring Diagrams Page 7 - 4

Initial issue: 04/04 Latest revision: 11/04

1.5 Power parts single-LINE representation (part 2 of 4)

Wiring Diagrams Page 7 - 5

Initial issue: 04/04 Latest revision: 06/05

1.6 Power parts single-LINE representation (part 3 of 4)

Wiring Diagrams Page 7 - 6

Initial issue: 04/04 Latest revision: 06/05

1.7 Power parts single-LINE representation (part 4 of 4)

Wiring Diagrams Page 7 - 7

Initial issue: 04/04 Latest revision: 11/04

1.8 Main supply

Wiring Diagrams Page 7 - 8

Initial issue: 04/04 Latest revision: 11/04

1.9 Interlock board

Wiring Diagrams Page 7 - 9

Initial issue: 04/04 Latest revision: 11/04

1.10 Interlock by pass

Wiring Diagrams Page 7 - 10

Initial issue: 04/04 Latest revision: 11/04

1.11 Interlock power supply 36V

Wiring Diagrams Page 7 - 11

Initial issue: 04/04 Latest revision: 06/05

1.12 Interlock power supply 24V (part 1 of 5)

Wiring Diagrams Page 7 - 12

Initial issue: 04/04 Latest revision: 06/05

1.13 Interlock power supply 24V (part 2 of 5)

Wiring Diagrams Page 7 - 13

Initial issue: 04/04 Latest revision: 11/04

1.14 Interlock power supply 24V (part 3 of 5)

Wiring Diagrams Page 7 - 14

Initial issue: 04/04 Latest revision: 11/04

1.15 Interlock power supply 24V (part 4 of 5)

Wiring Diagrams Page 7 - 15

Initial issue: 04/04 Latest revision: 11/04

1.16 Interlock power supply 24V (part 5 of 5)

Wiring Diagrams Page 7 - 16

Initial issue: 04/04 Latest revision: 11/04

1.17 Carriage clamp (part 1 of 2)

Wiring Diagrams Page 7 - 17

Initial issue: 04/04 Latest revision: 09/05

1.18 Carriage clamp (part 2 of 2)

Wiring Diagrams Page 7 - 18

Initial issue: 04/04 Latest revision: 06/05

1.19 Translation (part 1 of 3)

Wiring Diagrams Page 7 - 19

Initial issue: 04/04 Latest revision: 11/04

1.20 Translation (part 2 of 3)

Wiring Diagrams Page 7 - 20

Initial issue: 04/04 Latest revision: 11/04

1.21 Translation (part 3 of 3)

Wiring Diagrams Page 7 - 21

Initial issue: 04/04 Latest revision: 11/04

1.22 Jogger

Wiring Diagrams Page 7 - 22

Initial issue: 04/04 Latest revision: 06/05

1.23 Milling (part 1 of 2)

Wiring Diagrams Page 7 - 23

Initial issue: 04/04 Latest revision: 06/05

1.24 Milling (part 2 of 2)

Wiring Diagrams Page 7 - 24

Initial issue: 04/04 Latest revision: 11/04

1.25 Glue tank (part 1 of 8)

Wiring Diagrams Page 7 - 25

Initial issue: 04/04 Latest revision: 06/05

1.26 Glue tank (part 2 of 8)

Wiring Diagrams Page 7 - 26

Initial issue: 04/04 Latest revision: 11/04

1.27 Glue tank (part 3 of 8)

Wiring Diagrams Page 7 - 27

Initial issue: 04/04 Latest revision: 11/04

1.28 Glue tank (part 4 of 8)

Wiring Diagrams Page 7 - 28

Initial issue: 04/04 Latest revision: 11/04

1.29 Glue tank (part 5 of 8)

Wiring Diagrams Page 7 - 29

Initial issue: 04/04 Latest revision: 11/04

1.30 Glue tank (part 6 of 8)

Wiring Diagrams Page 7 - 30

Initial issue: 04/04 Latest revision: 06/05

1.31 Glue tank (part 7 of 8)

Wiring Diagrams Page 7 - 31

Initial issue: 04/04 Latest revision: 06/05

1.32 Glue tank (part 8 of 8)

Wiring Diagrams Page 7 - 32

Initial issue: 04/04 Latest revision: 06/05

1.33 Book clamp (part 1 of 2)

Wiring Diagrams Page 7 - 33

Initial issue: 04/04 Latest revision: 11/04

1.34 Book clamp (part 2 of 2)

Wiring Diagrams Page 7 - 34

Initial issue: 04/04 Latest revision: 11/04

1.35 Prefeed (part 1 of 2)

Wiring Diagrams Page 7 - 35

Initial issue: 04/04 Latest revision: 11/04

1.36 Prefeed (part 2 of 2)

Wiring Diagrams Page 7 - 36

Initial issue: 04/04 Latest revision: 11/04

1.37 Cover clamp

Wiring Diagrams Page 7 - 37

Initial issue: 04/04 Latest revision: 11/04

1.38 Creasing

Wiring Diagrams Page 7 - 38

Initial issue: 04/04 Latest revision: 11/04

1.39 Can

Wiring Diagrams Page 7 - 39

Initial issue: 04/04 Latest revision: 11/04

1.40 Conveyor

Wiring Diagrams Page 7 - 40

Initial issue: 04/04 Latest revision: 11/04

1.41 Signalling lighting

Wiring Diagrams Page 7 - 41

Initial issue: 04/04 Latest revision: 11/04

1.42 BBR Power supply and interlock (part 1 of 4)

Wiring Diagrams Page 7 - 42

Initial issue: 04/04 Latest revision: 06/05

1.43 BBR Head motor (part 2 of 4)

Wiring Diagrams Page 7 - 43

Initial issue: 04/04 Latest revision: 06/05

1.44 BBR Inputs sensor (part 3 of 4)

Wiring Diagrams Page 7 - 44

Initial issue: 04/04 Latest revision: 11/04

1.45 BBR Fork motor (part 4 of 4)

Wiring Diagrams Page 7 - 45

Initial issue: 04/04 Latest revision: 11/04

1.46 External dust extractor and option

Wiring Diagrams Page 7 - 46

Initial issue: 04/04 Latest revision: 11/04

1.47 Cover detection

Wiring Diagrams Page 7 - 47

Initial issue: 04/04 Latest revision: 11/04

2. GRAPHICAL SYMBOLS FOR DIAGRAMS

Wiring Diagrams Page 7 - 48

Initial issue: 04/04 Latest revision: 06/05

Wiring Diagrams Page 7 - 49

Initial issue: 04/04 Latest revision: 06/05

Wiring Diagrams Page 7 - 50

Initial issue: 04/04 Latest revision: 06/05

Wiring Diagrams Page 7 - 51

Initial issue: 04/04 Latest revision: 06/05

Wiring Diagrams Page 7 - 52

Initial issue: 04/04 Latest revision: 06/05

3. COMPONENT LIST Name -A1 -A2 -A3 -A4 -A5 -A7 -A8 -A20 -A30 -AT -AUI -CH1 -CH2 -CH3 -CH4 -CH5 -CH6 -CH7 -CH8 -CH9 -CH10 -CH11 -E1 -E2 -F1 -F2 -F3 -T1 -TCAN1 -TCAN2 -X11 1X1 1X4 1X6 2X1 4X1 4X3 4X5 5X1 6X1 6X3 6X5

Part Type 9422856 9422856 9422928 9422894B 9422868_GLUE_TANK_BOARD 9423006 9103048_36V+24V_1000W 9422962 9422969 9432258_BOITIER_BY-PASS 9138094 MAIN_SAFETY_GROUND SEC_SAFETY_GROUND SEC_SAFETY_GROUND SEC_SAFETY_GROUND SEC_SAFETY_GROUND SEC_SAFETY_GROUND SEC_SAFETY_GROUND SEC_SAFETY_GROUND SECONDARY_GND SECONDARY_GND SEC_SAFETY_GROUND 9120180_FILTRE_3X415V_20A 9120189_FILTRE_10VN1 9164011 9164011 9164011 9182066_TRANSFO_3X208..415V_5.2KVA 9422912 9422912 9121363+9121461 9121973+9121974 9121973+9121974 9121363+9121461 MODU10P_9121836+9121837 MNL3POS_9121352 9121326+9121327 MNL4POS_9121853+9121767 WAGO4X(1+1) 9121471+9121470 9121949+9121950 9121949+9121950

Wiring Diagrams Page 7 - 53

FNC STEPPER_BOARD STEPPER_BOARD Main interlock for selv circuit Dispatch board Glue tank control BBR board Power supply 36V and 24V 1000W Power board for primary circuit and brakes Isolation board for variable frequency driver Technician box Graphic user interface PP120 Main safety ground Secondary safety ground Secondary safety ground Secondary safety ground Secondary safety ground Secondary safety ground Secondary safety ground Secondary safety ground

Reference -A1 -A2 -A3 -A4 -A5 -A7 -A8 -A20 -A30 -AT -AUI -CH1 -CH2 -CH3 -CH4 -CH5 -CH6 -CH7 -CH8 GND

Secondary safety ground Triphase input filtre Blower suction filter Main fuse. 12AM Main fuse. 12AM Main fuse. 12AM Main transformer Terminator CAN TERMINATOR CAN TBD Linking from flexible cable to carriage Linking from main frame to flexible cable Linking from main frame to flexible cable Linling from main frame to translation part Connector for outside dust collector TBD TBD Linking for cylinder resistors Linking from main frame to book clamp Linking from flat cable to clamping area Linking from flat cable to clamping area

-CH5 -E1 -E2 -F1 -F2 -F3 -T1 TCAN1 TCAN2 33-X1 33-X4 33-X6 36-X1 42-X1 TBD TBD 48-X1 54-X1 54-X5 54-X5

Initial issue: 04/04 Latest revision: 06/05

Bourg Number

Page 14, 22, 34, 35 14, 27, 37 9, 11, 12, 13, 15, 16, 17, 19 10, 13, 18, 19, 22, 24, 29, 33, 34, 35, 36, 37, 38 29, 30, 31 42, 43, 44, 45 11 11, 21, 22, 23, 26, 28, 32, 36 20, 23, 25 10, 16 39 8 23 21 26 36 11 28 8 39 28 36 8 36 8 8 8 8 39 40 23 17, 18 17, 18 17 19 23 23 23 32 33, 34, 37 33, 34 33, 34

Name 6X6 7X1 7X3 13X3 33-B01P 33-B02P 33-B04P 33-M01P 33-R1 36-B03P 36-B04P 36-M01P 36-S01P 36-U1P 39-B01P 39-M01P 39-Y02P 42-B04I 42-B05I 42-K02P 42-K03P 42-M01P 42-M02I 42-S01S 45-M01P 45-S01S 45-S02S 48-B01S 48-B02S 48-B03P 48-B04P 48-B05P 48-B08I 48-B09I 48-B10I 48-B11P 48-E01P 48-E04P 48-E05P 48-M01P 48-M02B 48-M03I 48-U01P

Part Type 9121469+9121468 MNL9POS_9121481+9121478 9121481+9121478 9121326+9121327 9422774 9422773 9422843 9432331 9170380_RES44R_50W 9422841+9422842 9422850 9151915_3X220V_D 9150065 9132014_ABB 9107063 9431932 9432425 9107063 9107063 9169084_3NO+1NF+2NO+THERM 9169907+9177051_1NO+1NF_24VDC 9151916_3X380V_Y 9432373_MOTOR_24VDC 9107046_DIFF_PRESSURE_SENSOR 9151917_3X380V_Y 9107046_DIFF_PRESSURE_SENSOR 9150065 9422980_SINGLE_PTC1000 9422981_SINGLE_PTC1000 9422982_DUAL_PTC1000 9422982_DUAL_PTC1000 2983951_SWITCH_TH_NC_115¡C 9124180_SWITCH_TH_NO_170¡C+MNL6P 9107063 9107063 2983952_SWITCH_TH_NC_145¡C 9432440 9170399_RES 9432439 9151180_3X220V_D 9431251 9431251 9132014_ABB

Wiring Diagrams Page 7 - 54

FNC Linking from main frame to book clamp Linking from main frame to glue tank Linking from main frame to glue tank Security barrier for clamping area Carriage emitter Cariage receptor Carriage clamp tichickness gauge Carriage clamping Motor Limiting current resistor Carriage translation encoder Book edges detection Carriage translation motor Translation end switch left Translation variable frequency driver Jogger home position Jogger positioning stepper Jogger coil Phases reporting + notching tools Phases order reporting Milling motor process relay Over temperature dust collector relay Milling motor Notching tools indexing Milling exhaust blocked d tection Dust collector motor Dust collector full d tection Dust collector in place d tection Min glue level Max glue level Cylinder 1 temperature Cylinder 2 temperature Glue tank 115¡c thermostatic control Clixon glue tank over heating control Side glueing home position Spinner home position Glue tank 145¡c thermostatic control Glue tank resistor 1Kw Spiner resistor 24V/50w Glue tank resistor 0,3Kw Glue tank cylinders motor Side glueing positioning stepper Spinner positioning stepper Glue tank variable frequency driver

Reference 54-X6 57-X1 57-X3 66-X3 33-B01p 33-B02p 33-B04p 33-M01p 33-R1 36-B03p 36-B04p 36-M01p 36-S01p 36-U1p 39-B01p 39-M01p 39-Y02p 42-B04i 42-B05i 42-K02p 42-K03p 42-M01p 42-M02i 42-S01s 45-M01p 45-S01s 45-S02s 48-B01s 48-B02s 48-B03P 48-B04P 48-B05p 48-B08i 48-B09i 48-B10i 48-B11p 48-E01p 48-E04p 48-E05p 48-M01p 48-M02b 48-M03i 48-U01p

Initial issue: 04/04 Latest revision: 06/05

Bourg Number

Page 34, 37 35, 38 35 15 18 18 17 17 17 19 19 21 19 21 22 22 22 24 24 23 23 23 16 24 23 24 24 29 29 30 30 31 31 29 29 31 32 32 32 26 27 27 26

Name 48-Y01P 48-Y02P 48-Y03P 51-M01P 54-B01P 54-B03P 54-B04P 54-B05P 54-B06P 54-M01P 54-M02P 54-M03P 57-B01P 57-B02P 57-M01P 57-M02P 57-S01P 57-S02P 57-Y01P 57-Y02P 60-B01P 60-B02P 60-B03P 60-M01P 60-Y01P 63-B01P 63-B02P 63-B03P 63-M01P 63-Y01P 66-B01P 66-H1 66-H2 66-H3 66-H4 66-H5 66-S03P 66-S04S 66-S05S 66-S06S 66-S08S 69-B01P 72-B01P

Part Type FNC 9432396_ELECTRO Cylinder 1 scraper coil 9432396_ELECTRO Cylinder 2 scraper coil 9432396_ELECTRO Side glueing scrapper coil 9151046+WAGO Smoke evacuation motor 9107063 Book clamp home position 9107063 Book clamp fully close 9107063 Book clamp up / down home position 9107063 Book clamp / exit backstop positions 9107063 Book clamp pr opening 9151136_MOTOR_24VDC_90T Book clamp up/down motor 9151136_MOTOR_24VDC_90T Book clamping motor 9431251 Book clamp positioning stepper 9107063 Prefeed home position 9107063+CAB_PREFEED_BB3002 Cover prefeed detection 9432356 Prefeed positioning stepper 9151145 Prefeed blower suction 9150026 Crunching unit motor safety switch 9150026 Crunching unit motor safety switch 9432383 Blower manifold up coil 9430876 Prefeed suction valve 9422850 Cover d tection in cover clamp 9107063 Cover clamp home position 9107063 Cover clamp safe area detection 9432356 Cover clamp positioning stepper 9430876 Cover clamp nipping coil 9107063 Creasing home position 9107063 Creasing cell 2 9107063 Creasing cell 3 9151136_MOTOR_24VDC_90T Creasing motor 9432362_ELECTRO Creasing up / down selection coil 9107903+9107904+SUBD Security barrier for loading area 9422991 Signalisation red and green 9422990 Upper cover lighting 9422990 Glue tank lighting 9422990 Book clamp lighting 9422996_ENS_CIRC_DUAL_BUTTON Switches board 2081998_FOOTSWITCH_NO+MNL Carriage clamp nipping pedal 9146379_ROT_OFF+ON1+ON2_3NO+1NO+1NMain primary switch 9146354+9146339_1NC+COUT_DE_POING Emergency switch 9146308_INTERLOCK_SWITCH_2XNC Cover interlock switch 9146308_INTERLOCK_SWITCH_2XNC Door interlock switch 9107064 Book out of binder detection 9107064 Book incomming detection sensor

Wiring Diagrams Page 7 - 55

Reference 48-Y01p 48-Y02p 48-Y03p 51-M01p 54-B01p 54-B03p 54-B04p 54-B05p 54-B06p 54-M01p 54-M02p 54-M03p 57-B01p 57-B02p 57-M01p 57-M02p 57-S01p 57-S02p 57-Y01p 57-Y02p 60-B01p 60-B02p 60-B03p 60-M01p 60-Y01p 63-B01p 63-B02p 63-B03p 63-M01p 63-Y01p 66-B01p 66-H1 66-H2 66-H3 66-H4 66-H5 66-S03p 66-S04s 66-S05s 66-S06s 66-S08s 69-B01p 72-B01p

Initial issue: 04/04 Latest revision: 06/05

Bourg Number

Page 28 28 28 36 33 33 33 33 34 34 34 34 35 36 35 36 38 38 35 35 37 37 37 37 37 38 38 38 38 38 15 41 41 41 41 41 10 8 10 10 10 33 44

Name 72-B02I 72-B03P 72-B06I 72-B08P 72-M01P 72-M02P 72-S01S 72-S02S 72-S03S 72-X2 79-B01P 79-M01P CM211-S3 CM211-S5 CPU0 DI140-S0 DI439-7DO135-S0 DO135-S0 DO135-S0 DO435-S1 MM424-S1 MM432-S1 X2 XS1 XS2 XS3 XUI

Part Type 9107063 9107063 9107063 9107063 9151136_MOTOR_24VDC_90T 9151136_MOTOR_24VDC_90T 9146354+9146339_1NC+COUT_DE_POING 9150079 9150073 CPC14POS_REV_9121579 9107064 9151136_MOTOR_24VDC_90T CM211 CM211 CPU_2003 DI140 DI439SOURCE DO135 DO135 DO135 DO435 MM424 MM432 CPC14POS_REV_9121580+9121579 9123011_BORNIER 9123011_BORNIER 9123011_BORNIER 9121949+9121950

Wiring Diagrams Page 7 - 56

FNC Head home position sensor Head positioning sensor Fork up position sensor BBR full sensor Head motor Fork motor Emergency BBR switch Security switch fork down sensor Security switch book press sensor BBR connector Book out of convoyor detection Reception convoyor

Programmable logic controler

TBD Main connector Main connector Main connector Linking form binder to user interface

Reference 72-B02i 72-B03p 72-B06i 72-B08p 72-M01p 72-M02p 72-S01S 72-S02S 72-S03S 72-X2 79-B01p 79-M01p S3+4 S5+6 CPU0 S0.4 S7+8 S0.1 S0.2 S0.3 S12 S11 S1+2 TBD ----

Initial issue: 04/04 Latest revision: 06/05

Bourg Number

Page 44 44 45 44 43 45 42 43 43 42 40 40 14, 20, 23, 24, 25, 30, 41 9, 10, 14, 15, 22, 27, 29, 31, 34, 35, 36, 37 13, 39 13, 19, 33, 37 13, 18, 22, 29, 33, 34, 35, 36, 38, 40 13, 22, 27, 34 13, 22, 28, 35, 37 13, 20, 28 12, 35, 37, 38, 41 12, 16, 34, 38 8, 10, 14, 17, 19, 24, 34, 37 40 8 8 8 39

4. DESCRIPTION OF ELECTRICAL COMPONENTS 4.2 Covers

4.1 Numbering of BB3002 binder modules 66 33 36 39 42 45 48 54 57 60 63 69 79 72 85

Covers. Carriage. Carriage movement. Jogger module. Milling module. Waste suction. Glue tank. Cover clamp. Cover picking. Cover transport clamp. Creasing. Binder Output. Output conveyor. BBR. UI extension arm.

Wiring Diagrams Page 7 - 57

Number 66-B01p 66-H1 66-H2 66-H4 66-S01p 66-S02p 66-S03p 66-S04s 66-S05s 66-S06s 66-S08s

Description Security barrier for loading area Red signal (*) Green Signal +Upper cover lighting (*) Book clamp lighting Green Button Black button Carriage clamp nipping pedal Main primary switch Emergency stop switch Cover interlock switch Door interlock switch

Initial issue: 04/04 Latest revision: 11/04

PLC Connection Module CM 211 – X131 : 11 Module DO 435 – X171 : 8 Module DO 435 – X171 : 7 Connected on Power board A20 Module CM 211 – X121 : 10 Module CM 211 – X121 : 11 Module MM432 – X112 : 13 Module MM432 – X112 : 14 Module CM211 – X131 : 12 Module CM211 – X131 : 12 Module CM211 – X131 : 12

Page 15 41 41 41 41 41 10 2-4-8 10 10 10

Notes : - 66S05p -> 66S08p: Interlock reporting. Interlock key at: - Emergency shut-down button. - Top panel. - Front door. - Binder CPC connector to output conveyor. - CPC Connector from output conveyor to BBR. - CPC Connector to ON line module (3502) in the electronics rack. - Interlock Card. - Safety barrier disturbance.

Wiring Diagrams Page 7 - 58

Initial issue: 04/04 Latest revision: 11/04

4.3 Carriage

Inventory of inputs : Number

Description

PLC Connection

Page

33-B01p 33-B02p 33-B04p 33-B05p 33-B06p 33-R1

Carriage emitter Paper detection Carriage clamp thickness gauge Fixed clamp jaw detection (On line) Moving clamp jaw detection (On line) Limiting current resistor

Dispatch card - 5V Module DI439 – X141 : 3 Module MM432 – X112 : 5 & 5 Module DI439 – X141 : 4 Module DI439 – X141 : 4

18 18 17 18 18 17

Description

PLC Connection

Page

Carriage clamping Motor

Module MM432 – X11 : 3 & 4

17

Inventory of drives : Number

33-M01p

Wiring Diagrams Page 7 - 59

Initial issue: 04/04 Latest revision: 11/04

4.4 Jogger module

Inventory of inputs : Number

39-B01p

Description

PLC Connection

Page

Jogger home position

Module DI439 – X141 : 8

22

Inventory of drives : Number

Description

PLC Connection

Page

39-M01p

Jogger positioning stepper

39-Y02p

Jogger coil

Clock : Module DO135 – X101 : 2 Direction : Module CM211 – X132 : 5 Clock : Module DO135 – X102 : 7

22 22 22

Wiring Diagrams Page 7 - 60

Initial issue: 04/04 Latest revision: 11/04

4.5 Milling module

42k02p 42k03p

Inventory of inputs : Number 42-S01s 42-B04i 42-B05i 45-S01s 45-S02s

Description Milling exhaust blocked detection Phases Reporting + notching tools Phases order Reporting Dust collector full detection Dust collector in place detection

PLC Connection Module CM211 – X121 : 7 Module MM432 – X112 : 10 Module MM432 – X112 : 11 Module MM432 – X112 : 17 Module CM211 – X121 : 12

Page 24 24 24 24 24

PLC Connection Module CM211 – X121 : 9 Module MM424 – X161 : 7 Module CM211 – X121 : 9

Page 23 16 23

Inventory of drives : Number 42-M01p 42-M02i 45-M01p

Description Milling motor Notching tools indexing Dust collector motor

Various : Number 42-M01p-Brake 42-M01p-Protection 42-K02p 42-K03p 45-M01p-Protection

Wiring Diagrams Page 7 - 61

Description Milling motor Brake Milling motor Protection Milling motor process relay Over Temperature dust collector relay Intern dust collector motor Protection

PLC Connection No Reporting PLC No Reporting PLC Module CM211 – X121 : 9 Module CM211 – X122 : 10 No reporting PLC

Initial issue: 04/04 Latest revision: 11/04

Page 23 23 23 23 23

4.6 Glue tank

Inventory of inputs : Number

48-B01s 48-B02s 48-B03p 48-B04p 48-B05p 48-B08i 48-B09i 48-B10i 48-B11p

Description

PLC Connection

Page

Min glue level Max glue level Cylinder 1 Temperature Cylinder 2 Temperature Glue tank Low temp thermostatic control Clixon glue tank over heating control Side glueing home position Spinner home position Glue tank High temp thermostatic control

Module Module Module Module Module Module Module Module Module

29 29 30 30 31 31 29 29 31

Wiring Diagrams Page 7 - 62

CM211 – X131 : 5 CM211 – X131 : 6 CM211 – X121 : 14 CM211 – X121 : 17 CM211 – X131 : 7 CM211 – X131 : 10 DI439 – X141 : 10 DI439 – X141 : 11 CM211 – X131 : 7

Initial issue: 04/04 Latest revision: 06/05

Inventory of outputs : Number

Description

PLC Connection

Page

48-E01p 48-E02p 48-E03p 48-E04p 48-E05p 48-M01p 48-M02b

Glue tank resistor 1Kw Cylinder 1 resistor 0.3Kw Cylinder 2 resistor 0.3Kw Spinner resistor 24V/50w Glue tank resistor 0.3Kw Glue tank cylinders motor Side glueing positioning stepper

Regulation with clixon 48B05p or 48B11p Module CM211 – X122 : 11 Module CM211 – X122 : 12 No command Regulation with clixon 48B05p or 48B11p Glue tank variable frequency driver Clock : Module DO135 – X101 : 4 Direction : Module CM 211 – X132 : 6 Clock : Module DO135 – X101 : 7 Direction : Module CM 211 – X132 : 7 Start fwd : Module CM211 – X122 : 8 Consigne 0-10V : Module CM211 – X122 : 17 Module DO135 – X102 : 9 Module DO135 – X103 : 2 Module DO135 – X102 : 4

32 30 30 32 32 26

48-M03i

Spinner positioning stepper

48-U01p

Glue tank variable frequency driver

48-Y01p 48-Y02p 48-Y03p

Cylinder 1 scraper coil Cylinder 2 scraper coil Side glueing scrapper coil

Wiring Diagrams Page 7 - 63

Initial issue: 04/04 Latest revision: 11/04

27 27 26 28 28 28

4.7 Carriage movement

Inventory of inputs : Number

Description

PLC Connection

Page

36-B03p

Carriage translation encoder

36-B04p 36-S01p

Book edges detection Translation end switch left

Signal A : Module DI140 – X104 : 4 Signal B : Module DI140 – X104 : 3 Module DI140 : X104 : 1 Module MM432 – X112 : 15

19 19 19 19

PLC Connection

Page

Inventory of outputs : Number

36-M01p 36-U1p

Description

Carriage translation motor Translation variable frequency driver

Wiring Diagrams Page 7 - 64

Translation variable frequency driver Start FWD : Module CM211 – X122 : 5 Start REV : Module CM 211 – X122 : 7 Speed 5Hz : Module DO 135 – X103 : 7 Speed : Module CM211 – X122 : 14 Initial issue: 04/04 Latest revision: 11/04

21 21 21 21 21

4.8 Cover clamp module

Inventory of inputs : Number

Description

4-B01p 54-B03p 54-B04p 54-B05p 54-B06p

Book Book Book Book Book

clamp clamp clamp clamp clamp

PLC Connection

home position fully close up / down home position / exit backstop positions pre opening

Module Module Module Module Module

DI439 DI439 DI439 DI140 DI439

Page

– – – – –

X141 X141 X141 X104 X141

: : : : :

12 14 15 2 16

33 33 33 33 34

Inventory of outputs : Number

Description

PLC Connection

Page

54-M01p 54-M02p 54-M03p

Book clamp up/down motor Book clamping motor Book clamp positioning stepper

Module MM424 : X161 : 3 & 4 Module MM432 : X111 : 7 & 8 Clock : Module DO135 – X101 : 9 Direction : Module CM 211 – X132 : 8

34 34

Wiring Diagrams Page 7 - 65

Initial issue: 04/04 Latest revision: 11/04

34

4.9 Cover picking

Inventory of inputs : Number

Description

PLC Connection

Page

57-B01p 57-B02p 57-B03p 57-S02p 57-S01p

Pre-feed home position Cover pre-feed detection Double cover detection Creasing unit motor safety switch Creasing unit motor safety switch

Module DI439 : X141 : 17 Module DI439 : X141 : 18 Not yet determined / /

35 36 / 38 38

Inventory of outputs : Number

Description

PLC Connection

Page

57-M01p

Prefeed positioning stepper

Clock : Module DO135 – X101 : 9 Direction : Module CM 211 – X132 : 8 Module CM211 – X132 : 14 & 15 Module DO435 – X171 : 3 Module DO435 – X171 : 4

35 36 35 35

57-M02p 57-Y01p 57-Y02p

Prefeed blower suction Blower manifold up coil Prefeed suction valve

Wiring Diagrams Page 7 - 66

Initial issue: 04/04 Latest revision: 11/04

4.10 Creasing

Inventory of inputs : Number

Description

PLC Connection

Page

63-B01p 63-B02p 63-B03p

Creasing home position Creasing cell 2 Creasing cell 3

Module DI439 - X141 : 5 Module DI439 - X141 : 6 Module DI439 - X141 : 7

38 38 38

Inventory of outputs : Number

Description

PLC Connection

Page

63-M01p 63-Y01p

Creasing motor Creasing up / down selection coil

Module MM424 – X161 : 5 & 6 Module DO435 – X171 : 6

38 38

Wiring Diagrams Page 7 - 67

Initial issue: 04/04 Latest revision: 11/04

4.11 Cover transport

Inventory of inputs : Number

Description

PLC Connection

Page

60-B01p 60-B02p 60-B03p

Cover detection in cover clamp Cover clamp home position Cover clamp safe area detection

Module MM432 – X112 : 18 Module DI140 – X104 : 5 Module DI140 – X104 : 6

37 37 37

Inventory of outputs : Number

Description

PLC Connection

Page

60-M01p

Cover clamp positioning stepper

60-Y01p

Cover clamp nipping coil

Clock : Module DO135 – X102 : 4 Direction : Module CM 211 – X132 : 10 Module DO435 - X171 : 5

37 37

Wiring Diagrams Page 7 - 68

Initial issue: 04/04 Latest revision: 11/04

4.12 Output and conveyor

Inventory of inputs : Number

Description

PLC Connection

Page

69-B01p 79-B01p

Book out of binder detection Book out of conveyor detection

Module DI439 – X141 : 13 Module DI439 – X141 : 9

33 40

Inventory of outputs : Number

Description

PLC Connection

Page

79-M01p

Reception conveyor

Module MM424 – X161 : 8

40

Wiring Diagrams Page 7 - 69

Initial issue: 04/04 Latest revision: 11/04

4.13 BBR Software revision of the BBR

Inventory of inputs : 72-B01p 72-B02i 72-B03p 72-B06i 72-B08p 72-S01s 72-S02s 72-S03s 79-B01p

9107064 9107063 9107063 9107063 9107063 9146354+9146339_1NC+COUT_DE_POING 9150079 9150073 9107064

Book incoming detection sensor Head home position sensor Head positioning sensor Fork up position sensor BBR full sensor Emergency BBR switch Security switch fork down sensor Security switch book press sensor Book out of conveyor detection

Inventory of outputs : 72-M01p 72-M02p 79-M01p

9151136_MOTOR_24VDC_90T 9151136_MOTOR_24VDC_90T 9151136_MOTOR_24VDC_90T

Wiring Diagrams Page 7 - 70

Head motor Fork motor Reception conveyor Initial issue: 04/04 Latest revision: 11/04

5. GENERAL DESCRIPTION OF THE ELECTRONICS RACK

5.1 General schematic for the electronics rack

This section describes the location of the various components found in the BB3002 electronics rack. The principal items are the programmable B & R automatic control system and some 7 electronic cards.

To the front of the electronics rack. • Programmable Logic Controller PLC - B&R. • Electronics cards.

Electronic boards

DO 435 MM 424

PLC B&R DI 439 CM 211-2 CM 211-1 MM 432

CPU 474

Wiring Diagrams Page 7 - 71

Initial issue: 04/04 Latest revision: 06/05

Connector locations.

Wiring Diagrams Page 7 - 72

Initial issue: 04/04 Latest revision: 06/05

DO 435

X171

X172 X173

MM 424

X161

X142 X143 X141

X131

X121

DI 439

X132

CM 211-2

X122

CM 211-1

X112

MM 432

X111

DO135-X101 DO135-X102 DO135-X103 DI140-X104

CPU 474

To the rear of the electronics rack. 16

11 15

1

10

12 13 2 3 4

14

5

6 7

8

9

Wiring Diagrams Page 7 - 73

Initial issue: 04/04 Latest revision: 06/05

1. Current limiting resistor for the carriage clamp closure motor (inside the rack). 2. Connector 4X3 to the internal turbine supply. 3. Connector 4X5 to the milling motor supply. 4. Spare connector. 5. CPC Connector to the ON line module (3502). 6. Command relay for the milling blade and waste extraction suction (internal or external) -> 42K02p 7. Over-temperature relay for the internal turbine -> 42K03p. 8. Connector for command of external waste suction. 9. Fuses F1, F2, F3 (12A) for three-phase supply to the binder. 10. Transformer. 11. Three-phase input filter. 12. Frequency variator for the movement motor. 13. Frequency variator for the glue tank motor. 14. “POWER - A 20” card. 15. Card for isolation of command signals for frequency variators - A6. 16. 1000W, 24V - 36V supply.

5.2 Relays and fuse holders At the rear of the rack there are : 1. Command relays for the milling blade and waste extraction suction (internal or external) -> 42K02p. 2. Internal turbine over-temperature relays -> 42K03p. 3. Connector for command of external waste suction. 4. Fuses F1, F2, F3 (12A) for three-phase supply to the binder. Note : Only replaced by a fuse of same type and rating. 5. Re-activation of the 42K02p relay (command for the milling blade and waste extraction suction).

5 1 2

3 4

Wiring Diagrams Page 7 - 74

Initial issue: 04/04 Latest revision: 06/05

Notes: In the event of the milling motor overheating, a thermal fuse operates and cuts off supply to the motor. To re-set the motor, press the red button on relay 42K02p.

5.3 B&R Modules 5.3.1 CPU 474 : The CPU is operated on the far left hand side of the module rack. There are status LEDs and the connection sockets for an RS232 and a CAN interface on the module.

2 4 6 8 0 E C A

The CPUs CP474/CP774 have four slots for screw-in module. The screw-in modules are plugged into the CP interface as required, and are attached using the fastening screws. The interface modules can be installed in slots 1, 2 and 3.

2 4 6 8 0 E C A

Alimentation 24V (++ --) + ground Serial port to UI CAN port to BBR DO 135 Conn X101

DO 135 Conn X103

DO 140 Conn X104

DO 135 Conn X102

Wiring Diagrams Page 7 - 75

Initial issue: 04/04 Latest revision: 09/05

EXCHANGING THE BATTERY OF THE CPU 1) Remove voltage to power supply. ATTENTION: Data is lost when the battery is exchanged !

The battery removal strip must be routed behind the battery (sticking out in front of battery).

2) Discharge electrostatic energy by touching the mounting rail or the ground connection (not the power supply !). 3) Open the battery compartment cover with the help of a screwdriver. 4) Remove the battery from the battery compartment using the removal ribbon (don’t touch the battery with uninsulated tools -> short circuit). Pick up the battery by the flat sides (don’t pick up the battery by the edges). An isolated tool can also be used to remove the battery. Right:

Wrong:

6) Place the free end oof the battery removal strip under the battery so that it doesn’t hang out of the battery compartment. 7) Replace the battery compartment cover. Make sure that the slot for the screwdriver is facing upwards. The left side of the battery compartment cover is placed in the battery compartment and the right side is pressed into place. 8) Return voltage to power supply. ATTENTION: Lithium batteries are considered hazardous waste ! Please dispose of batteries according to the guidelines in your area.

5) Insert the battery with the proper polarity. Place battery over the removal strip with the “+” side facing the back. The battery removal strip must be routed behind the battery (sticking out in front of the battery) in order to be able to removed it again.

Wiring Diagrams Page 7 - 76

Battery: Hazardous Components Battery Fluid:

Metallic Lithium

Initial issue: 04/04 Latest revision: 09/05

CR2477N Propylenecarbonate (69%) Ethyleneglycoldimethylether (25%) Lithiulperchlorate (6%)

5.3.2 Module DO 135 : Connector X102 (slot 2). The DO135 is a 4 channel output module. The type of operation can be set for each output separately. It is used for TPU operation (for example for the clock of the steppers motors).

Pin assignment

Output 1

3

2

57M01b_clock : Prefeed positionning stepper

GND

3 4

DO 135 Conn X103

5

4

Output 2

6 7

5

Shield

60M01p_clock : Cover clamp positionning stepper

8

6

9 10 11 12

DO 135 Conn X102 DO 135 Conn X101

12

TB712

Connections

Shield

7

Output 3

8

GND

9

Output 4

10

Shield

11

+12bis +24 VDC

12

Connector X101 (Slot 1).

GND

39Y02p :

PWM signal for jogger coil

48Y01p :

Cylinder 1 scraper coil

Alim 24V logic GND

Connector X103 (slot 3).

Pin assignment 1

1

Shield

2 1

1

1

2

Shield

2

Output 1

3

1

4 5

39M01b_clock : Jogger positionning stepper

6 7

3

GND

8 9 10 11 12

12

4 5 6

Shield

Shield

2

Output 1

12

9 10 11 12

Alim 24V logic GND

3 4

TB712

5 6 7

Page 7 - 77

48Y03p : Side glueing scraper coil

Shield

Initial issue: 04/04 Latest revision: 06/05

Shield Output 3

8

GND

9

Output 4

10

Shield

11

+12bis +24 VDC

12

Wiring Diagrams

GND Output 2

8

GND

54M03b_clock : Book clamp positionning stepper

7

+12bis +24 VDC

12

48Y02p : Cylinder 2 scraper coil

6

Shield

5

Output 4

1

4

GND

11

1

3

8

48M03i_clock : Spinner positionning stepper

2

Output 3

10

Pin assignment

Shield

7

9

48M02b_clock : Side glueing positionning stepper

1

TB712

Output 2

GND

36M01p_break : Carriage translation break

Virtual : Virtual variable for glue cutting Alim 24V logic GND

5.3.3 Module DI 140 : The DI140 digital input module is a screw-in module for the B&R SYSTEM 2003 and for the B&R Power Panel. It has 10 inputs for 24 VDC, four of which are equipped with counter functions. The counter inputs can be configured either as encoder or event counter inputs. The DI140 supports TPU functionality. The module is also equipped with supply voltage monitoring.

DO 140 Conn X104

Connector X104 (Slot 4).

Pin assignment

Input 1 (TPU)

B36B04p : Book edges detection (voltage)

2

Input 2 (TPU)

B54B05p : Book clamp/exit backstop positions

3

Input 3 (TPU)

B36B03p : Carriage translation encoder_B

4

Input 4 (TPU)

B36B03p : Carriage translation

5

Input 5 Encoder Channel A / Event counter 1

B60B02p : Cover clamp home position

6

Input 6 Encoder Channel B / Event counter 2

B60B03p : Cover clamp safe area

7

Input 7 / Reference Pulse

8

Input 8 / Reference Enable

9

Input 9

10

Input 10

11

+ 24 VDC supply for inputs

Alim 24V logic

12

GND

GND

1

1

1

2 3 4 5 6 7 8 9 10 11 12

12

TB712

DI140 - pin assignment

Wiring Diagrams Page 7 - 78

Initial issue: 04/04 Latest revision: 06/05

5.3.4 Module MM432 : The motor bridge module MM432 is used to control two DC motors with a nominal voltage of 10 - 24 VDC at a nominal current up to 4 A. The module is also equipped with two ABR channels as well as six normal digital inputs for creating positioning tasks which are not too complex.

Connections

Each motor is controlled with a full-bridge (H-bridge). Therefore the motors can be moved in both directions. Each bridge branch has its own supply voltage. The advantage of this is that two different motors with different voltages can be used. Each channel has current measurement, supply voltage measurement, and short circuit recognition to ground and to the positive supply voltage. Motor control takes place using a 16 kHz PWM signal and is therefore mostly noise-free. A local processor provides the required intelligence and is used for communication with the higher level CPU. It handles the preparation of the ABR inputs and normal digital input, the control of both motors (each with a PWM signal) and the Analog measurements.

X111 X112

Wiring Diagrams Page 7 - 79

status LEDS

Connector X111 (Slot 1 of module MM432). Power Element

X1

Pin assignment

1

2

3

4

5

6

7

8

9 10

TB710

1

+ DC supply for motor 1

Alim. 24V Logique

2

- DC supply for motor 1

GND

3

+ motor output motor 1

33M01p : Carriage clamping motor (+)

4

- motor output motor 1

33M01p : Carriage clamping motor (GND)

5

+ DC supply for motor 2

Alim. 24V puissance

6

- DC supply for motor 2

GND

7

+ motor output motor 2

54M02p : Book clamping motor (+)

8

- motor output motor 2

54M02p : Book clamping motor (+)

9

Not assigned

10

Not assigned

Initial issue: 04/04 Latest revision: 06/05

Connector X112 (Slot 2 of module MM432).

X2

1

2

3

4

5

Digital inputs

6

7

8

9 10

11 12 13 14 15 16 17 18

TB718

Pin Assignment 1

+ 24VDC supply for inputs and incremental

Alim. 24V Logique

2

GND

GND

3

ABR encoder 1 : +24 VDC Supply

33B04p : Carriage clamp thickness (A)

4

ABR encoder 1 : GND

33B04p : Carriage clamp thickness (A)

5

ABR encoder 1 : A-Signal

6

ABR encoder 1 : B-Signal

7

ABR encoder 1 : R-Signal

8

ABR encoder 2 : +24 VDC Supply

9

ABR encoder 2 : GND

10

ABR encoder 2 : A-Signal

Phases order reporting + notching 42B04i : tools index

11

ABR encoder 2 : B-Signal

42B05i : Phases order reporting

12

ABR encoder 2 : R-Signal

13

Digital input 1 (reference enable 1[sre1])

66S03p : Carriage clamp nipping pedal

14

Digital input 2 (limit switch 1 left [sel1])

66S04s : Timer mode activation

15

Digital input 3 (limit switch 1 right [ser1])

36S01p : Translation end switch left

16

Digital input 4 (reference enable 2[sre2])

57B03p : Double cover detection

17

Digital input 5 (limit switch 2 left [sel2])

45S01p : Dust collector full detection

18

Digital input 6 (limit switch 2 right [ser2])

60B01p : Cover detection in cover clamp

Wiring Diagrams Page 7 - 80

Initial issue: 04/04 Latest revision: 06/05

5.3.5 Module CM 211 : The CM 211 module is a Combination Module : • 8 inputs, 24 VDC, 4 ms, sink, 3 one channel or 2 two channel counters or 2 incremental encoders, 20 kHz, • 8 transistor outputs, 24 VDC, 0.5 A, comparator function, short-circuit protection, • 2 inputs, ±10 V / 0-20 mA, 12 bit, • 2 outputs, ±10 V, 12 bit.

CM 211 - 1. Connector X 121. 1 X2

1

18 2

3

4

5

6

7

8

9 10

11 12 13 14 15 16 17 18

Terminal Block X1

X121 X122

+ 24VDC

2

+ 24VDC

3

+ 24VDC

4

n.c.

5

Digital Input DI1

36M01p_error : Carriage translation drive error

6

Digital Input DI2

48M01p_error : Glue tank cylinders driver error

7

Digital Input DI3

42S01p : Milling exhaust blocked detection

8

Digital Input DI4

57B04p : Miss cover detection

9

Digital Input DI5

10

Digital Input DI6

42E01p : Milling motor overcurrent + themostat Repoting 66S01p : Carriage clamp nipping button

11

Digital Input DI7

66S02p : Carriage clamp opening button

12

Digital Input DI8

45S02p : Dust collector in place detection

13

Shield

14

Analog Input AI1+

48B03p : Cylinder 1 temperature (+)

15

Analog Input 1 GND (AGND)

48B03p : Cylinder 1 temperature (GND)

16

Shield

17

Analog Input AI2+

48B04p : Cylinder 2 temperateur (+)

18

Analog Input 2 GND (AGND)

48B04p : Cylinder 2 temperateur (GND)

status LEDS

Wiring Diagrams Page 7 - 81

Alim. 24V Logique

1

Initial issue: 04/04 Latest revision: 06/05

Connector X 122.

1 X2

1

18 2

3

4

5

6

7

8

9 10

11 12 13 14 15 16 17 18

Terminal Block X2 GND

1

GND

2

GND

3

GND

4

n.c.

5

Digital Output DO1

6

Digital Output DO2

7

Digital Output DO3

8

Digital Output DO4

9

Digital Output DO5

10

Digital Output DO6

42M01p : Milling dust collector command

11

Digital Output DO7

48E02p : Cylinder 1 resistor command

12

Digital Output DO8

48E03p : Cylinder 2 resistor command

13

Shield

Carriage translation speed setting shield

14

Analog Output AO1+

15

Analog Output 1 GND (OGND)

16

Shield

36M01p_speed : Carriage translation speed setting (+) 36M01p_speed : Carriage translation speed setting (GND) Glue tank cylinders speed setting shield

17

Analog Output AO2+

18

Analog Output 2 GND (OGND)

Wiring Diagrams Page 7 - 82

36M01p_start_fwd : Carriage translation start (to right) 36M01p_start_rev : Carriage translation start (to left) 48M01p_start : Glue tank cylinder start

48M01p_speed : Glue tank cylinder speed setting (+) 48M01p_speed : Glue tank cylinder speed setting (+)

Initial issue: 04/04 Latest revision: 06/05

CM 211 - 2.

Connector X 131. 1 1

18 2

3

4

5

6

7

8

9 10

11 12 13 14 15 16 17 18

X131

Terminal Block X1

X132

Alim. 24V Logique

1

+ 24VDC

2

+ 24VDC

3

+ 24VDC

4

n.c.

5

Digital Input DI1

48B01s : Min glue level

6

Digital Input DI2

48B02s : Max glue level

7

Digital Input DI3

48E07s : Glue tank thermostat reporting

8

Digital Input DI4

9

Digital Input DI5

10

Digital Input DI6

48E06s : Glue tank temperature error

11

Digital Input DI7

66B01p : Safety light curtain reporting

12

Digital Input DI8

66S : Interlock reporting

13

Shield

14

Analog Input AI1+

15

Analog Input 1 GND (AGND)

16

Shield

17

Analog Input AI2+

18

Analog Input 2 GND (AGND)

Wiring Diagrams Page 7 - 83

Initial issue: 04/04 Latest revision: 06/05

Connector X 132. 1 1

18 2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18

Terminal Block X2 1

GND

GDN

2

GND

3

GND

4

n.c.

5

Digital Out put D01

39M01b_direction jogger stepper direction

6

Digital Out put D02

48M02b_direction Side glueing stepper direction

7

Digital Out put D03

48M02b_direction Spinner stepper direction

8

Digital Out put D04

54M03b_direction Book clamp stepper direction

9

Digital Out put D05

57 M01b_direction Prefeed stepper direction

10 Digital Out put D06

60M01b_direction Cover clamp stepper direction

11 Digital Out put D07

30E01s Book binding counter

12 Digital Out put D08

48V01p Glue tank heating enable with timer

13 Shield 14 Analog Output A01+

57M02p_level Prefeed blower succion level (+)

15 Analog Output 1 GND (OGND)

57M02_level Prefeed blower succion level (GND)

16 Shield 17 Analog Putput A02+ 18 Analog Output 2 GND (OGND)

Wiring Diagrams Page 7 - 84

Initial issue: 04/04 Latest revision: 06/05

5.3.6 Module DI 439 : Digital input modules are used to convert binary signals for a process to the internal signal level required for the PCC. The states of the digital inputs are shown using Status LEDs.

Source connection. Inputs are wired as source connections : When an input is active the signal is earthed.

Characteristics relevant for input modules : - Number of Inputs : 16. - Input Voltage : 24 VDC. - Input delay : 1 ms.

X141 X142 X143

status LEDS

Wiring Diagrams Page 7 - 85

Initial issue: 04/04 Latest revision: 06/05

Module DI 439 : Connector X141. 1 1

18 2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18

Terminal Block X1 1 2 3

Digital Input DI1

33B02p Carriage clamp paper detection

4

Digital Input DI2

33B05s - 33B06s Fixed & &moving clamp jam detection

5

Digital Input DI3

63B02p Creasing home position

6

Digital Input DI4

63B02p Creasing cell 2

7

Digital Input DI5

63B03p Creasing cell 3

8

Digital Input DI6

39B01p Jogger home position

9

Digital Input DI7

79B01p Book out of conveyor detection

10 Digital Input DI8

48B09i Side glueing home position

11 Digital Input DI9

48B10i Spinner home detection

12 Digital Input DI10

54B01p Book clamp home position

13 Digital Input DI11

69B01p Book out of binder detection

14 Digital Input DI12

54B03p Book clamp fully closed

15 Digital Input DI13

54B04p Book clamp up/down home position

16 Digital Input DI14

54B06p Book clamp pre opening

17 Digital Input DI15

57B01p Prefeed home position

18 Digital Input DI16

57B02p Cover prefeed detection

Wiring Diagrams Page 7 - 86

Initial issue: 04/04 Latest revision: 06/05

5.3.7 Module MM424 : The motor module MM424 is used for digital control of up to 4 DC motors with a nominal voltage of 24 VDC at a nominal current of max. 2 A. Unlike the motor bridge module MM432, the motor module MM424 can only digitally switch the 24 VDC supply voltage to the respective motor. X161 Connector X 161.

Pin assignment

status LEDS

1

GND

GND

2

+24 VDC supply for inputs for motors

Alim. 24V Logique interlock

3

Motor 1 (-), Movement in Left Direction

54M01p_R : Book clamp down motor

4

Motor 1 (+), Movement in Right Direction

54M01p_L : Book clamp down motor

5

Motor 2 (-), Movement in Left Direction

63M01p_R : Creasing motor

6

Motor 2 (+), Movement in Right Direction

63M01p_L : Creasing motor

7

Motor 3 (-), Movement in Left Direction

42M02i : Notching tools indexing

8

Motor 3 (+), Movement in Right Direction

79M01p : Reception convoyor

9

Motor 4 (-), Movement in Left Direction

10

Motor 4 (+), Movement in Right Direction

X1

1

2

3

4

5

6

7

8

TB710

Wiring Diagrams Page 7 - 87

Initial issue: 04/04 Latest revision: 06/05

9 10

Connector X171.

5.3.8 Module DO 435 : Digital output modules are used to control external loads (relays, motors, solenoids). The states of the digital outputs are indicated with status LEDs.

Terminal Block X1 1

X171 X172

2

X173

3

Digital Ouput DO1

57Y01i Blower manifold up coil

4

Digital Ouput DO2

57Y02p Prefeed suction valve

5

Digital Ouput DO3

60Y01p Cover clamp nipping coil

6

Digital Ouput DO4

63Y01p Creasing up/down selection coil

7

Digital Ouput DO5

66H01s_green Green light

8

Digital Ouput DO6

66H01s_red Red light

9

Digital Ouput DO7

10 Digital Ouput DO8 1 X1

1

18 2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18

TB710

status LEDS

Wiring Diagrams Page 7 - 88

Initial issue: 04/04 Latest revision: 06/05

5.4 Electronics cards To the front of the electronics rack.

4. Dispatch card - A4 : This card is used to provide a 5V supply to optoelectronic cells and to send 24V signals from the cells to the automatic control system.

5 4 3 2

5. Glue Tank Card - A5 : This card is controls the heating of the glue tank:

1

- Management of min and max glue levels in the tank, - Regulation of the temperature of cylinders 1 and 2, - Protection against over-heating etc.

1. Driver Card - A1 : This is the power driver for supplies to stepper motors. It has three outputs per card to supply three motors. For each motor the B & R PLC provides the clock and direction to the driver. 2. Driver Card - A2 : Idem driver card 1. 3. Interlock Card - A3 : This card is used to control the machine’s safety loop. In the event of an emergency shut-down the interlock card opens the safety loop and cuts off the power supply to all motors.

Wiring Diagrams Page 7 - 89

Initial issue: 04/04 Latest revision: 06/05

To the rear of the electronics rack. Isolation board for frequency converter

Power Supply 24V-36V

Translation frequency converter Glue Tank frequency converter Power board

Isolation Card - A6 : This card is used to provide galvanic isolation for frequency variator command signals. Power card - A 30 : On this card are mounted the various relays supplying the movement motor, glue tank heating elements, transistors for activation of glue-cut-off solenoids etc.

Wiring Diagrams Page 7 - 90

Initial issue: 04/04 Latest revision: 06/05

Relays and fuse holde

5.4.1 DRIVER Card - A1 : Front face Clock Direction Power (36V)

Front view

Motor 54M03 Motor 57M01 Motor 39M01 24V - 5V not used Connector A1 - X14

A1 - X14

Connector A1 - X11 A1 - X11

Connector A1 - X12 Handle

Wiring Diagrams Page 7 - 91

Initial issue: 04/04 Latest revision: 08/04

5.4.2 DRIVER Card - A2 : Front face Clock Direction Power (36V)

Front view

Green lights Motor 60M01 Motor 48M03 Motor 48M02 24V - 5V not used Connector A2 - X24

A2 - X24

Connector A2 - X21 A2 - X21

Connector A2 - X22 Handle

Wiring Diagrams Page 7 - 92

Initial issue: 04/04 Latest revision: 08/04

5.4.3 INTERLOCK Card - A3 :

Top part.

Front face

Front view

Barrier Cells OK Power indicator Reporting interlock

36V 24V A3 - X38: Connector

A3 - X38: Connector

A3 - X39: Connector

A3 - X39: Connector

A3 - X37: Connector

A3 - X37: Connector

Wiring Diagrams Page 7 - 93

Initial issue: 04/04 Latest revision: 08/04

Bottom part. Front face

Front view A3 - K3: Interlock relay

A3 - X32: Connector

A3 - X36: Connector

A3 - K7: Carriage in loading area position relay

Connector A3 - X36 A3 - K1 & K2: Loading area lights curtains relay

A3 - K4: Interlock relay to entry module A3 - K8 & K9: Bookclamp lights curtains relay (not used) A3 - K11: Technical box relay

A3 - X31: Connector

Wiring Diagrams Page 7 - 94

Initial issue: 04/04 Latest revision: 08/04

5.4.4 DISPATCH Card - A4 : Top part.

Front view

Front face

Set counter

Set counter

Hour counter

Hour counter

888 888

888 888

Connector A4 - X46 Connector A4 - X46 1 hour 1/10 hour

Wiring Diagrams Page 7 - 95

Initial issue: 04/04 Latest revision: 08/04

Bottom part.

Front view

Front face 24V Logic 24V Sensor OFF when A4-F2 released 5V Sensor OFF when A4-F1 released Connector A4 - X41

Connector A4 - X43

A4 - F1 (500mA) Protection 24V converter 24 VDC - 5 VDC

Wiring Diagrams Page 7 - 96

A4 - F2 (1A) Protection 24V sensor

Initial issue: 04/04 Latest revision: 08/04

5.4.5 GLUE TANK Card - A5 : Connector A5 - X52

Green Led: Interlock OK Yellow Led: Glue High Level Yellow Led: Glue Low Level Red Led: Error Cylinder 1 Red Led: Error Cylinder 2 High temp. Low temp.

High temp. Low temp. Glue tank temperature switch: Min - Max

A5 - K1: Interlock over temperature A5 - R102: Glue level potentiometer Handle

A5 - F1: Thermal breaker in case of over temperature

Notes: When an error occurs K1 opens and sends a large current to breaker A5 - F1. This in turn opens after a certain time in order to record the appearance of a fault (problem with temperature regulation, fault at klixon etc.). The “Glue High Level” and “Glue Low Level” level LED’s are lit if the probes are immersed in the glue, and vice versa.

Wiring Diagrams Page 7 - 97

Initial issue: 04/04 Latest revision: 06/05

5.4.6 ISOLATION Card - A30 : Connector X301: Command signals from the B&R PLC.

Connector X304: Board power supply 220VAC.

Connector X302: Command signals to the frequency variator for the translation motor.

Wiring Diagrams Page 7 - 98

Connector X303: Command signals to the frequency variator for the glue tank motor.

Initial issue: 04/04 Latest revision: 08/04

5.4.7 POWER Card - A20 : A20 - X219: connector for A20 - F3 & F4: fuse 6.25A A20 - X12: Connector for A20 - X207: board 24V 220V power supply protection Glue tank resistor protection rack ventilation power supply Glue tank frequency converter A20 - F7 & F8: 6.25A A20 - X218: A20 - X214: conn for 220V for A20 - F1 & F2: fuse 6.25A A20 - X213: lighting 200V power supply protection Power supply 24 - 36V Glue drum resistor Translation frequency converter Protection Power supply protection A20 - F11 & F12: 6.25A A20 -X206: 24V to BBR A20 - R1: Polyswitch 3.75A Jogger power supply 24V Red Led: Jogger error A20 - X203: glue tank solenoid + jogger command

A20 - X204: connector for 220V power supply Power board

A20 - X211 A20 - 36K5: interlock relay carriage clamp Translation brake A20 - 42K7: interlock relay - 2 Milling motor A20 - X201: process and interlock command

A20 - F5 & F6: 220V power supply protection Prefeed blower suction A20 - X215: connector for fumes extractor power supply 220V A20 - X205: connector for prefeed blower suction prefeed power supply 220V

A20 - 42K6: interlock relay - 1 Milling motor

A20 - X223: connector for isolation board power supply 24V

A20 - X210: milling motor power supply 380V

A20 - 48K6: interlock relay glue drum rotation motor A20 - 36K4: interlock relay carriage clamp translation motor

Wiring Diagrams Page 7 - 99

A20 - X222: glue tank resistance power supply 1KW A20 - X221: glue tank resistance power supply 0.3 KW A20 - U3: static relay Glue tank resistor A20 - U2: interlock relay Glue tank resistor

A20 - X217: glue tank resistor connection A20 - U2: static relay Glue drum 2 resistor A20 - U1: static relay Glue drum 1 resistor

Initial issue: 04/04 Latest revision: 08/04

A20 - K1: interlock relay Glue drums resistor

List of components: Power card Relays :

Fuses : A20 - F1 : 6.25A fuse - Protects tank cylinder elements.

A20 – U1 : Static relay for cylinder 1 heating element.

A20 - F2 : 6.25A fuse - Protects tank cylinder elements.

A20 - U2 : Static relay for cylinder 2 heating element.

A20 - F3 : 6.25A fuse - Protects elements at bottom of tank.

A20 - U3 : Static relay for heating element at bottom of tank.

A20 - F4 : 6.25A fuse - Protects elements at bottom of tank. A20 - F5 : 4 A fuse - Protects cover suction - feed.

A20 – K1 : Cylinder heating element relay interlock.

A20 - F6 : 4 A fuse - Protects cover suction - feed.

A20 – K2 : Bottom of tank heating element relay interlock.

A20 - F7 : 6.25A fuse - Protects glue tank frequency variator.

A20 – 36K4 : Carriage movement motor relay interlock.

A20 - F8 : 6.25A fuse - Protects glue tank frequency variator.

A20 – 36K5 : Movement brake relay interlock.

A20 - F9 : 6.25A fuse - Protects movement frequency variator.

A20 – 42K6 : Milling motor relay interlock.

A20 - F10 : 6.25A fuse - Protects movement frequency variator.

A20 – 48K6 : Cylinder rotation motor relay interlock.

A20 – 42K7 : Second milling motor relay interlock.

A20 - F11 : 6.25A fuse - Protects 24-36V power supply. A20 - F12 : 6.25A fuse - Protects 24-36V power supply.

Wiring Diagrams Page 7 - 100

Initial issue: 04/04 Latest revision: 08/04

5.4.8 BBR Card - A7 : A7-F3 Fuse 500 mA

Relay A7-K1 Relay A7-K1

Connector A7-X7 For communication CAN with PLC BB3002

Green led A7-B1 Blinking in RUN mode

Switch A7-S2 RUN mode / Download mode Connector A7-X2 Serial connector for microprocessor download

Connector A7-X1

List of components: BBR Card Fuses : A7 - F3 : Protects BBR 24V supply. If fuse A7 - F3 is open there is no longer 24V to the card and Led A7-B2 turns off.

Connector A7-X1

A7 - K2 : Safety relay. Safety relay that only allows the BBR head to pass when the book separator harrow is lowered. Safety : A7 - S2 : Selector: “run” mode/“download” mode.

Relays : A7 - K1 : BBR card interlock relay. Relay open if BBR emergency shut-down or BB3002 Interlock.

Wiring Diagrams Page 7 - 101

Initial issue: 04/04 Latest revision: 08/04

-

Selector down: “RUN” mode: normal use of BBR.

-

Selector up: “DOWNLOAD” mode: for the Microcontroller.

6. INTERLOCK CIRCUIT 6.1 General presentation The interlock circuit will be composed of 4 levels : • The first level corresponds to the cover and will stop all dangerous power features. • The second level is used to stop all movement except the rotation of the glue tank when a over Temperature has occurred. • The third level is activated during the loading of paper in off line mode. • The fourth level is used for the creasing. It’s enabled by a switch when the prefeed is located in a right position.

Wiring Diagrams Page 7 - 102

Initial issue: 04/04 Latest revision: 08/04

6.2 Interlock circuit • First level interlock. The first level interlock corresponds to the cover and will stop all dangerous elements like translation motor, milling motor, clamping, creasing and the glue tank (see electric diagrams p.2). • Second level interlock. If the glue Temperature increase dangerously, a security switch activate a security relay and disabled all the motorizations except the rotation of the glue tank to homogenate the glue Temperature (see electric diagrams p.3). • Third level and Current limiting by RESISTOR. During the paper loading, a resistor connected in series with the motor limits the clamping motor current. This resistor activated by the barrier cell and the resulting force corresponding to the limited current is about 80N with a permanent 24V power supply (See electric diagrams p.17 and 18). The milling and the glue tank main motor are not interlocked by the secondary level in loading paper position, in other position, all intrusion in the barrier cells stop the milling motor and the glue tank. For this one switch is located on the translation and correspond to the loading zone, we need a double direction contact to switch between the two states (loading zone, translation). The contact switch NC must be only used like a security contact and than the switching must be realised by a security relay supply through the NC switch-loading zone. (see electric diagrams p.2 and 3)

Wiring Diagrams Page 7 - 103

Différent cases : - During loading : Carriage clamp current is reduced. All movements of carriage are disabled. -> Safety OK The milling and the glue tank are protected by mechanical parts. - During carriage movement : Intrusion of anything between barrier cell, the carriage, milling and the glue tank main motor are stopped. -> Safety OK.

• Fourth level and Creasing. The pre-feed ramp must be located in a right place to allow the creasing process. In this position, a double security switch activates a security relays and the creasing motor is powered. In all other position, the motor is disabled. Some mechanical parts are design to prevent finger introduction. The fourth interlock level must stop this motor. Different cases : - During the movement of pre feed : The creasing motor is not powered and the movement of -> Safety OK pre feed is not dangerous. - In the position to allow creasing : The creasing motor can rotate, but it’s not possible to introduce fingers. ->Safety OK (See electric diagrams p.38).

Initial issue: 04/04 Latest revision: 08/04

6.3 Timer To be able to use a GUI software timer based, we have a 3 positions rotary main switch to energize the main glue tank resistor. The 3 position are : • OFF. • ON 1 : the main use of this machine. • ON 2 or timer mode : The main interlock loop is open and the resistors are energized through a static relay placed on the glue tank control board. At this time the static relay is drive by the GUI timer.

Wiring Diagrams Page 7 - 104

Initial issue: 04/04 Latest revision: 08/04

6.4 Technical box CPB part number 9432545, for field engineers use only. • The switch is used to by pass the covers interlock and allows engineer to see what append in a running machine. • The push button is use to energise the 2 brakes used in the machine and allows engineers to manually move translation and milling motors.

9432545

Wiring Diagrams Page 7 - 105

Initial issue: 04/04 Latest revision: 06/05

6.5 Thermal protection of the milling motor If the current in the milling motor increase dangerously, a thermal protection is activated and disable all the motorizations. After a few minutes, the technician can restart the machine by pushing on the red button on the relay support (see p.23 and 74).

Wiring Diagrams Page 7 - 106

Initial issue: 04/04 Latest revision: 08/04

6.6 Interlock Diagram

See page 7 - 2

Wiring Diagrams Page 7 - 107

Initial issue: 04/04 Latest revision: 08/04

7. THERMAL CONTROL OF GLUE HEATING 7.1 Technical description

Cylinder heating :

Two separate circuits regulate the tank and cylinder heating : Tank heating : Two elements at the bottom of the tank are used to heat the glue in the tank. These elements are supplied : - Continuously when the binder is powered up (main switch position ON1). - When the binder is in “TIMER” mode (main switch position ON2). Notes : There is still power supplied to the elements at the bottom of the tank even during an emergency shut-down.

The cylinders are heated when the the bottom of the UI screen).

Two sensors (Pt 1000) measure the temperature of the glue at the cylinders. These are connected to two inputs of the automatic control system. The automatic control system regulates the glue temperature.

• Heating of the tank and cylinders is protected by a thermal sensor when the glue temperature exceeds 170°C. • A heating element is also installed in the spinner. The spinner temperature is not regulated.

The elements at the bottom of the tank may be set to two different temperatures. A switch located on the “Glue tank” card is used to select the required temperature. For National Coolbind, select a tank bottom temperature of 115°C. The temperatures are regulated using a thermal sensor (klixon) fixed to the tank.

Wiring Diagrams Page 7 - 108

icon is activated (at

Initial issue: 04/04 Latest revision: 06/05

7.2 “Heating tank” electrical diagram • Diagram Legend : 1. Cylinder 1 heating device : 300 W; 230 VAC; with regulation. 2. Cylinder 2 heating device : 300 W; 230 VAC; with regulation.

PLC

+ 9

Outputs

3. Cylinder 3 heating device : 50 W; 24 V DC; without regulation.

Glue tank board

4. Cylinder 1 temperature managing device : 2 x PT1000 (a and b).

Inputs

Error bit

24 VDC

6. Glue tank heating device : 1000 W; 230 VAC; with regulation. 300 W; 230 V AC; with regulation.

Temperature setting

Digital 4 analog. inputs

Digital

5. Cylinder 2 temperature managing device : 2 x PT1000 (c and d).

State relay

7. Glue tank thermostat. 8. Glue tank safety thermostat (can be reset manually). 9. Regulation and safety device : Error if : - difference between a and b temperatures too important, - difference between c and d temperatures too important, - over temperature.

230 VAC State relay 4

24 VDC

5 3

1

2

7

24 VDC

8 Timer 6 State relay

Wiring Diagrams Page 7 - 109

Initial issue: 04/04 Latest revision: 06/05

230 VAC

7.3 Diagram of tank heating T (c°)

Drums heating

Heating time out: 55 min.

Additional heating delay setted on the UI

Glue T° setted on the UI

Binder waiting start

CYLINDERS T°

Glue Tank T° : High - Low

GLUE TANK T°

Glue T° setted on the UI - 40°C

CYLINDERS ROTATION

ON 1

Switch opening (Hardware)

Check glue level : if OK => continue if KO => Stop cylinders + stop heating + return a Error

1. Power on (main switch at ON 1) -> Tank bottom heaters start automatically when power is applied. The glue temperature is regulated at temperature corresponding to switch position. -> A 55 minute time delay is activated. 2. If the operator presses the green button -> All setup manoeuvres are carried out except for those that require the glue to be hot. 3. If the operator presses icon

-> Cylinder heating is activated. -> The temperature of the glue on the cylinders is regulated at 40°C below the gluing temperature.

4. When the 55 minute time delay has expired and if the

icon has been activated : -> Cylinder rotation. -> Rise in cylinder temperature until gluing temperature is reached.

5. When the temperature of the glue reaches gluing temperature, the glue tank set-up alone will be automatically carried out. From that time on the glue levels will be (continually) controlled. 6. A further heating delay period, set using the UI, may be added in order to make sure that the glue temperature is uniform throughout the tank (optional). 7. The green signal light on the loading zone comes on to indicate that the machine is ready to start -> “Binder waiting start”.

Wiring Diagrams Page 7 - 110

Initial issue: 04/04 Latest revision: 06/05

7.4 Making the system safe in the event that temperature is exceeded In order to meet international standards, the glue temperature is maintained at a temperature that is 20°C below the flash-point temperature of the glue. A thermal fuse (which can be reset manually) operates in the event of this temperature being exceeded. In the event that the glue temperature exceeds 190°C: • The thermal fuse A5 - F1 operates. • Tank and cylinder heating is stopped immediately through 3 safety relays. • The machine shuts down completely except for the cylinders, which continue to turn in order to maintain the glue at a uniform temperature. • An error message appears on the screen: “Glue temperature too high” The machine will remain shut down as long as fuse A1 - F1 has not been reinstated. In order to re-start the machine, it is necessary to wait until the glue temperature falls below 130°C before re-setting the fuse. Technicians must therefore wait approximately 15 minutes before they can re-initialise the machine.

Wiring Diagrams Page 7 - 111

Initial issue: 04/04 Latest revision: 08/04

7.5 Temperature at bottom of tank The elements at the bottom of the tank may be set to two different temperatures. A switch located on the “Glue tank” card is used to change from one temperature setting to the other.

Front view

Front face

High temp Low temp

Glue tank temperature switch: Min - Max A5 - F1: Thermal breaker in case of over temperature

Wiring Diagrams Page 7 - 112

Initial issue: 04/04 Latest revision: 06/05

8. ABB FREQUENCY VARIATOR 8.1 Connection Power connection terminal block :

Wiring Diagrams Page 7 - 113

COMMAND connection terminal block :

Initial issue: 04/04 Latest revision: 08/04

8.2 List of parameters 8.2.1 GROUP 2: Motor data and limit values : • 201 Unom : Nominal motor voltage as shown on identification plate. U nom is the maximum voltage applied to the motor by the ACS 100. F nom is the frequency at which the output voltage is equal to Unom. The ACS 100 can supply a voltage that is greater than the mains supply voltage to the motor. See Figure 3. • 202 fnom : Nominal motor frequency as shown on identification plate (field attenuation value). See Figure 3. • 203 Inom : Nominal motor current as shown on identification plate. Note : This parameter is only used when the motor thermal protection function is in service. See parameter 502 (f lim). See Figure 5.

Note : Ensure fmin < fmax. • 208 Verrou sens : Backward rotation can be locked. 1 = AV/ ARR 2 = AV only • 209 Bruit moteur: Control of motor noise level 0= standard (switching frequency 4 kHz) 1= reduced noise (switching frequency 8 kHz) 2 = silent (switching frequency 16 kHz) Note : When the “reduced noise” (8 KHz) setting is used, the maximum load capacity of the ACS 100 is I2 at an ambient temperature of 30°C or 0.9 x I2 at 40°C. When the “Silent” (16 kHz) setting is used, the maximum load capacity is 0.75 * I2 at an ambient temperature of 30°C. Figure 1 : F min and F max parameters to limit the output frequency.

• 204 Vitesse nom : Nominal motor speed as shown on identification plate. • 205 Imax : Maximum current supplied to the motor by the ICS 100. • 206 fmax : Maximum frequency applied to the motor by the ICS 100. Figure 1: Parameterisation of fmin and fmax to limit output frequency. • 207 fmin: Minimum frequency applied to the motor by the ACS 100.

Wiring Diagrams Page 7 - 114

Initial issue: 04/04 Latest revision: 08/04

8.2.2 GROUP 3 : Command characteristics : • 301 Arrêt Shut down mode : 1 = free wheel clutch. 2 = on ramp. See also parameter 307 (Temps inj. cc). • 302 Rampe Shape of ramp : 0 = Linear 1 = Rapid S-shaped ramp 2 = Medium S-shaped ramp 3 = Slow S-shaped ramp Figure 2 : Output frequency.

Note : RI compensation must be as low as possible. • 307 Temps inj cc Time of c.c. injection after modulation stops. If free- wheel shut down occurs, the ACS 100 uses braking by injection of c.c. If ramped shut down occurs, the ACS 100 uses braking by maintenance of the c.c. after the ramp. • 308 Ucmax Control of over-voltage regulator. Select 0, if braking choppers are connected. 0 = no over-voltage regulation of the intermediate circuit. 1 = over-voltage regulation in service Figure 3 :Output voltage.

• 303 Acc Time to accelerate from frequency of zero to max. frequency (0 - fmax). • 304 Déc Time to decelerate from max. frequency to frequency of zero (fmax - 0). • 305 Loi U/f U/f at attenuation point: 1 = Linear (curves A and C) 2 = Quadratic (curves B and D) Linear is preferable for constant torque applications and for pumping application (centrifugal fans). • 306 Comp RI compensation value (application of an additional voltage between 0 Hz and fnom).

Wiring Diagrams Page 7 - 115

Initial issue: 04/04 Latest revision: 08/04

8.2.3 GROUP 4 : Inputs and outputs : • 401 EA mini Scaling of analogue input. 0 % = 0 mA (or 0 V) and 100 % = 20 mA (or 10 V) on input. • 402 EA maxi Scaling of analogue input. 0 % = 0 mA (or 0 V) and 100 % = 20 mA (or 10 V) on input.

Note : After changing switch power off and then on again to confirm the change. • 406 Vitesse const. Constant speed. May be called through a logic input.

Note : EA mini < EA maxi. • 403 Réf mini Reference value corresponding to minimum AI. • 404 Réf maxi Reference value corresponding to maximum AI. Figure 4 :

• 405 Config EL Configuration of logical inputs: 1 = standard ABB config. 2 = 3-wire control. 3 = alternate operation.

Wiring Diagrams Page 7 - 116

Note : In alternate operation the variator will shut off if EL1 and EL2 are activated at the same time.

Initial issue: 04/04 Latest revision: 08/04

8.2.4 GROUP 5 : Supervision and faults : • 501 EA Fault Supervision of analogue input 0 = no supervision. 1 = if the analogue input value is less than the parameter value.

• 503 Verrou param Locking out of access to parameters. 0 = START/STOP keys and DIRECTION OF ROTATION keys locked, no parameters may be changed. Only display of parameters is possible.

401 (EA mini), display of a fault code and free-wheel shut-down of the ACS 100.

1 = Access to parameters not locked. 2 = Modified values not stored in permanent memory.

• 502 flim Threshold frequency for motor thermal protection. Flim and Inom (param. 203) define the safe operating range of the motor in continuous operation. 0 Hz = motor thermal protection deactivated.

• 504 Blocage démarrage Start-up function locked. A locked start-up means that a start-up order has not been executed: • in the event of a fault being re-set or during a change of command mode (local -> remote).

Figure 5 : 0 = No -> Start-up lock function deactivated. The variator will start-up after reset of a fault or a change of command mode when a start-up command is received.

Wiring Diagrams Page 7 - 117

Initial issue: 04/04 Latest revision: 08/04

1 = Yes -> Start-up un-lock function activated. The variator will not start up after re-set of a fault or a change of command mode. In order to re-activate the variator, a new start-up command must be given.

There is a constant number of re-set attempts (5) and the time period is constant (30 secs). At time “A” there are three faults, with the following fault being the fourth. The variator is re-set because the number of attempt is less than 5.

• 505 Automatic re-set This function can be used to re-set the variator automatically after an over-voltage fault. It defines the number of automatic resets that are allowed (5) in a given period of time (30 secs). 0 secs = function deactivated If a value greater than 0 s is selected, the over-voltage fault is automatically re-set after the set delay. If 0 is selected, the fault is not automatically re-set. Figure 6 : Operation of the automatic re-set function.

Wiring Diagrams Page 7 - 118

Initial issue: 04/04 Latest revision: 08/04

8.3 Programming • Press on the menu to enter the parameter groups.

8.3.1 Menu structure :

• Using the up and down arrows, select “02” and press “ENTER” to access the group 2 parameters. Parameter 201 is then selected. • When “ENTER” is pressed rapidly, the variator will display the selected parameter for 1 second. • By pressing on “ENTER” for longer, the selected parameter value can be altered using the up and down arrows. Press “enter” once more to confirm the value. Example : parameter P304.

8.3.2 Procedure to be followed : • Apply voltage to the variator. • Place the keyboard on the variator. • Go to “LOCAL” mode (press “enter + menu” at the same time to change from “REMOTE” mode to “LOCAL” mode and vice versa). • Press “menu” to gain access to the various groups of parameters. • Using the up and down arrows to select “DL” and press “ENTER” for 3 seconds to download the parameters from the keyboard to the variator.

Wiring Diagrams Page 7 - 119

• The values in the table on page 1 must be entered into parameters 201 to 205 in this way. • Once these parameters have been input, press twice on “menu“ to leave any application. • Terminate programming by pressing “enter+menu”. The variator is then in “REMOTE“ mode. The automatic control system and not the keyboard will therefore be in control of the variator.

Initial issue: 04/04 Latest revision: 08/04

8.3.3 Manual control of motors : Manual control of motors is possible through the keyboard. In “LOCAL” mode, pressing “start / stop” will cause the motor to run. Pressing on it once more will stop the motor. The rotation speed of the motor may be altered. Press “enter” and increase the frequency using the up and down arrows. Confirm the frequency by pressing “enter”.

Pressing the up and down arrows will display the current frequency or the electrical current passing through the motor. Terminate the test by pressing “start / stop” to stop the motor.

Wiring Diagrams Page 7 - 120

Initial issue: 04/04 Latest revision: 08/04

8.4 Parameterisation of frequency variatorsVersion 01.00.01

“Glue Tank” parameters P201 = 230 P202 = 50

P203 = 1.5 P204 = 2830 P205 = 2.1 P206 = 60

P207 = 0

P208 = 1

P209 = 0

P301 = 2

P302 = 0

P303 = 0.1

P304 = 0.4

P305 = 1

P306 = 20

P307 = 0

P308 = 1

P401 = 0

P402 = 100 P403 = 0

P404 = 60

P405 = 3

P406 = 5

P501 = 0

P502 = 60

P504 = 0

P505 = 1

P506 = 0

DI 1

DI 2

DI 3

ACTION

0

0

0

Stop

1

0

0

Start FWD

0

1

0

Start REV

1

1

0

Stop

1

0

1

FWD at 5 Hz

0

1

1

REV at 5 Hz

0

0

1

Stop

If P306 increases, braking will be more violent and vice versa.

1

1

1

Stop

Remote Mode : Automatic control system in control.

DI 1 : Start Fwd. DI 2 : Start Rev. DI 3 : Set frequency = 5 Hz.

0-10V analogue input on the AI terminal (2). 0V at terminal (3) AGND.

P201 = 230 P202 = 50 P203 = 1.8 P204 = 2780 P205 = 4.5 P206 = 60 P207 = 0

P208 = 1

P209 = 0

P301 = 2

P302 = 0

P303 = 0.1

P304 = 0.4

P305 = 1

P306 = 20

P307 = 0

P308 = 1

P401 = 0

P402 = 100 P403 = 0

P404 = 60

P405 = 3

P406 = 5

P501 = 0

P502 = 80

P504 = 0

P505 = 1

P506 = 0

Page 7 - 121

Press “Enter+Menu” at the same time to change from one mode to the other. Download : Save everything from the keyboard onto the variator. Upload: Save everything from the variator onto the keyboard. Be in local mode to carry out this operation. With download or upload, data is transferred except for parameters 201 to 205 (motor parameters).

“Movement” parameters :

Wiring Diagrams

Notes : After changing parameter P405, the variator must be shut down and re-started to confirm the change.

Local Mode : Keyboard control - motor can be controlled manually using the keyboard.

DC Com connected to GND. Terminal 7 linked to terminal 9. AGND connected to 0V of the automatic control system.

P503 = 1

P503 = 1

The keyboard screen will display the variator parameters (never the keyboard parameters). Alternative ABB Config. Parameter 405 at 3.

Initial issue: 04/04 Latest revision: 11a/05

8.5 Error messages Errors : Alarms : Code CF 0 – CF 9

Description Position of selector S1 Some parameters can only be modified if S1 = 0. AL1 Loading (read/write) has failed. AL 2 Action forbidden with variator functioning. AL 3 Action not allowed in remote mode (REM) or local mode (LOC). AL 4 Rotation direction key locked. Locking activated (parameter 208). AL 5 RUN key on micro-console locked. Logical input configured for 3-wire commands and EL 2 not connected. AL 6 Action not allowed. Locking activated (parameter 503). AL 10 * Excess current regulator activated. AL 11 * Over-voltage regulator activated. AL 12 * Under-voltage regulator activated. AL 13 Reserved. Contact your supplier. AL 14 Attempt to go to remote mode (REM) when locking is activated (parameter 208). AL 15 – AL 16 Reserved. Contact your supplier. Note : Alarm codes (*) will be displayed only if parameter 506 is set to 1 (Yes).

Wiring Diagrams Page 7 - 122

Code FL 1

Description Excess current: - Possible mechanical problem. - Acceleration / deceleration times may be too short. FL 2 Over-voltage c.c. - Circuit voltage too high. - Deceleration time may be too short. FL 3 ACS 100 overheating. - Ambient temperature too high. - Serious overload. FL 4 * Fault current: output earth fault or short circuit. FL 5 Output overload. FL 6 Under-voltage cc. FL 7 Analogue input fault (see parameter 501) FL 8 Motor overheating (see parameter 502) FL 9 Micro-console disconnected in LOCAL mode. Note: If FL 9 is displayed when power switched off, the ACS 100 will start in remote command mode (REM) when power is switched on. FL10 Inconsistency between parameters. Check that EA mini (Fmin) is not greater than EA maxi (Fmax). FL11 * cc bus ripple too high. Check supply circuit. FL 12 Reserved. Contact your supplier. FL 13 - FL 14 * Equipment fault. Contact your supplier. FL 15 * Analogue input outside value range. Check AI level. FL 16 - FL 19 * Equipment fault. Contact your supplier. Any display Series connection fault. flashing . Connection fault between micro-console and ACS 100.

Note : Faults (*) where the red diode flashes are re-set by switching power off and then switching it back on. Other faults are re-set by pressing on the START/STOP button.

Initial issue: 04/04 Latest revision: 08/04

9. TELEMECANIQUE FREQUENCY DRIVER Frequency driver used : TELEMECANIQUE ATV11 PU12M2E (9132017)

9.1.2 Control Terminals :

- Output nominal current = 3A. - Output maximum current = 4.5A. - Maximum power = 550 W.

9.1 Connections 9.1.1 Power Terminals : 9.1.1.1 Power Terminals :

RC – RA :

Fault relay contact :

OV : Ai 1 : +5V :

I/O common Voltage analog input Power supply

DO :

Wiring Diagrams Page 7 - 123

Li 1 – Li 2 - Li 3 – Li 4 :

Programmable logic inputs.

+15V :

Logic input power supply

Initial issue: 02/05 Latest revision: -

Open if there is a fault or the drive is off. OV Analog input : 0-5V or 0-10V Reference potentiometer : 2.2 to 10kΩ (Max current available : 10 mA). Output which can be configured as analog or logic input. Power supply +15 V (max 30V) State 0 if < 5V - State 1 if > 11V.

9.1.3 Wiring diagrams : • Power Supply :

• Inputs and Outputs : To the PLC

To the PLC

Wiring Diagrams Page 7 - 124

Initial issue: 02/05 Latest revision: -

9.2 Parameters of the frequency driver 9.2.1 First level adjustment parameters :

Code

Description

Adjustment range

Factory setting

bFr

Motor frequency

50 Hz or 60 Hz

50 (E range) or 60 (U range)

This parameter is only visible the first time the drive is switched on. It can be modified at any time in the FUn menu.

Displays the drive status

XXX

A C C Acceleration ramp time ESC

bFr

0.1 s to 99.9 s

3

Range: 0 Hz to motor nominal frequency FrS (parameter in drC menu).

1st level adjustment parameters

dEC

Deceleration ramp time

0.1 s to 99.9 s

3

Range: motor nominal frequency FrS (parameter in drC menu) to 0 Hz. LSP

Low speed

0 Hz to HSP

0

LSP to 200 Hz

= bFr

Motor frequency to 0. HSP

ESC

Menu: Motor control

Motor frequency to max. reference. Check that this setting is appropriate for the motor and the application.

drC ESC

Menu: Application functions

Fun

ItH

Motor thermal current

0 to 1.5 In (1)

According to drive rating Current used for motor thermal protection. Set ItH to the nominal current marked on the motor rating plate. The memory of the motor thermal state returns to zero when the drive is switched off.

SP2

2nd preset speed (2)

0.0 to 200 Hz

10

SP3

3rd preset speed (2)

0.0 to 200 Hz

25

4th preset speed (2)

0.0 to 200 Hz

50

Configuration of the analog input

5U, 10U, 0A, 4A

5U

Menus

ESC

Menu: Monitoring

SUP

High speed

SP4 Ait

- 5 V : voltage 0 - 5 volts (internal power supply) - 1 0 V : voltage 0 - 10 volts (external power supply) - 0 A : current 0 - 20 mA - 4 A : current 4 - 20 mA (1) In = nominal drive current (2) The preset speeds only appear if the corresponding function has remained at the factory setting or has been reconfigured in the FUn menu.

Wiring Diagrams Page 7 - 125

Initial issue: 02/05 Latest revision: -

9.2.2 Motor Control Menu : drC The parameters in clear boxes can only be modified when the drive is stopped and locked. Parameters in shaded boxes can be modified with the drive operating or stopped.

Value

Nominal motor voltage Drive performance can be optimised by entering the values marked on the motor rating plate Code

Description

U n S Nominal motor voltage marked on the rating plate.

Value

Adjustment range

Factory setting

100 to 500 V

Acc. to rating

FrS

Nominal motor frequency marked on the rating plate.

40 to 200 Hz

50 / 60Hz dep. on bFr

StA

Frequency loop stability

0 to 100% when stopped 1 to 100% when operating

20

0 to 100% when stopped 1 to 100% when operating

20

Motor nominal cosine ϕ Value too high: lengthening of response time Value too low: overspeed, possible instability. F L G Frequency loop gain

Value too high: overspeed, instability. Value too low: lengthening of response time UFr

IR compensation 0 to 200% Used to optimise the torque at very low speed, or to adapt to special cases (example: for motors connected in parallel, lower UFr).

50

nCr CLI

Nominal motor current marked on the rating plate

0.25 to 1.5 In (1)

Acc. to rating

Limiting current

0.5 to 1.5 In (1)

1.5 In

nSL

Nominal motor slip

0 to 10.0 Hz

Acc. to rating

Calculate using the formula: nSL = parameter FrS x (1 - Nn/Ns) Nn = nominal motor speed marked on the rating plate Ns = motor synchronous speed SLP

Slip compensation

0 to 150% (of nSL)

100

Used to adjust the slip compensation around the value set by the nominal motor slip nSL, or to adapt to special cases (example: for motors connected in parallel, lower SLP). C O S Nominal motor cosine j marked on the rating plate (1) In = nominal drive current

Wiring Diagrams Page 7 - 126

Initial issue: 02/05 Latest revision: -

0.50 to 1.00

Acc. to rating

9.2.3 Application functions menu : Fun The parameters in clear boxes can only be modified when the drive is stopped and locked. Parameters in shaded boxes can be modified with the drive operating or stopped.

Code tCC

ENT

FUn

ESC

Type of control

tCC ENT

ESC

ESC

ESC

FCS

Reminder of the configuration

ENT

Description

Factory setting

Type of control 2C A C t 2 C = 2-wire control 3 C = 3-wire control 2-wire control: The open or closed state of the input controls the running or stopping. +15 V LI1 LIx Example of wiring: LI1: forward LIx: reverse 3-wire control (pulse control): a "forward" or "reverse" pulse is sufficient to command starting, a "stop" pulse is sufficient to command stopping. Example of wiring: +15 V LI1 LI2 LIx LI1: stop LI2: forward [ [ [ LIx: reverse To change the assignment of tCC press the "ENT" key for 2 s. This causes the following functions to return to factory setting: rrS, tCt, Atr, PS2 (LIA, LIb). t C t Type of 2-wire control trn (parameter can only be accessed if tCC = 2C): L E L : state 0 or 1 is taken into account for running or stopping. t r n : a change of state (transition or edge) is necessary to initiate operation, in order to prevent accidental restarts after a power supply interruption. P F O: same as LEL, but the "forward" input always takes priority over the "reverse" input.

rrS

Reverse n O : function inactive to L I 4 : choice of the input assigned to the reverse command LII

PS2

Preset speeds If LIA and LIb = 0: speed = reference on AI1 If LIA = 1 and LIb = 0: speed = SP2 If LIA = 0 and LIb = 1: speed = SP3 If LIA = 1 and LIb = 1: speed = SP4 Assignment of input LIA - n O : function inactive - L I I to L I 4 : choice of the input assigned to LIA Assignment of input LIb - n O : function inactive - L I I to L I 4 : choice of the input assigned to LIb SP2 is only accessible if LIA is assigned, SP3 and SP4 if LIA and LIb are assigned. S P 2 2nd preset speed, adjustable from 0.0 to 200 Hz (1) S P 3 3rd preset speed, adjustable from 0.0 to 200 Hz (1) S P 4 4th preset speed, adjustable from 0.0 to 200 Hz (1)

(1) The preset speeds can also be accessed in the 1st level adjustment parameters.

Wiring Diagrams Page 7 - 127

Initial issue: 02/05 Latest revision: -

if tCC = 2C: LI2 if tCC = 3C: LI3

if tCC = 2C: LI3 if tCC = 3C: LI4 if tCC = 2C: LI4 if tCC = 3C: nO

10 25 50

Code

Description

rSF

nO Fault reset - n O : function inactive - L I I to L I 4 : choice of the input assigned to this function The reset takes place at a transition on the input (rising edge: 0 to 1). It is only authorised if the fault has disappeared.

rP2 LI

Second ramp Assignment of the 2nd ramp control input - n O : function inactive - L I I to L I 4 : choice of assigned input AC2 and dE2 are only accessible if LI is assigned.

A C 2 2nd acceleration ramp time, adjustable from 0.1 to 99.9 s d E 2 2nd deceleration ramp time, adjustable from 0.1 to 99.9 s

Factory setting

brA

YES Deceleration ramp adaptation - n O : function inactive - Y E S : This function automatically increases the deceleration time, if this has been set at too low a value for the inertia of the load, thus avoiding the overvoltage fault.

SFt

Automatic DC injection YES A C t Operating mode - n O : function inactive - Y E S : DC injection on stopping, duration adjustable via tdC, when operation is no longer controlled and the motor speed is zero. The value of this current can be adjusted via SdC. - C t : Continuous DC injection on stopping, when operation is no longer controlled and the motor speed is zero. The value of this current can be adjusted via SdC. In 3-wire control the injection is only active when LI1 is at 1. tdC is only accessible if ACt = YES, SdC if ACt = YES or Ct.

Switching frequency A C t Frequency range - L F r : random frequency around 2 or 4 kHz according to SFr - L F : fixed frequency of 2 or 4 kHz according to SFr - H F : fixed frequency of 8, 12 or 16 kHz according to SFr S F r Switching frequency: - 2 : 2 kHz (if ACt = LF or LFr) - 4 : 4 kHz (if ACt = LF or LFr) - 8 : 8 kHz (if ACt = HF) - 12 : 12 kHz (if ACt = HF) - 16 : 16 kHz (if ACt = HF) When SFr = 2 kHz, the frequency automatically changes to 4 kHz at high speed. When SFt = HF, the selected frequency automatically changes to the lower frequency if the thermal state of the drive is too high. It automatically returns to the SFr frequency as soon as the thermal state permits.

Wiring Diagrams Page 7 - 128

nO Catch on the fly Enables a smooth restart if the run command is maintained after the following events: - loss of line supply or disconnection - fault reset or automatic restart - freewheel stop. The motor resumes from the estimated speed at the time of the restart then follows the ramp to the reference speed. This function requires 2-wire control (tCC = 2C) with tCt = LEL or PFO. n O : function inactive Y E S : function active The function intervenes at each run command, resulting in a slight delay (1 second max.). If continuous automatic injection braking has been configured (Ct) this function cannot be activated.

5.0 5.0

nO Controlled stop on loss of line supply - n O : locking of the drive and freewheel stopping of the motor - F r P : stop according the valid ramp (dEC or dE2) - Y E S : fast stop, the stopping time depends on the inertia and the braking ability of the drive.

t d C Injection time on stopping, adjustable from 0.1 to 30.0 s S d C Injection current, adjustable from 0 to 1.2 In (In = nominal drive current)

Description

FLr

nO

StP

AdC

Code

dO

Analog/logic output DO rFr A C t Assignment - n O : not assigned - O C r : analog output = current in the motor. The full signal corresponds to 200% of the nominal drive current. - r F r : analog output = motor frequency. The full signal corresponds to 100% HSP. - F t A : logic output = frequency threshold reached, closed (state 1) if the motor frequency exceeds the adjustable threshold Ftd. - S r A : logic output = reference reached, closed (state 1) if the motor frequency is equal to the reference. - C t A : logic output = current threshold reached, closed (state 1) if the motor current exceeds the adjustable threshold Ctd. Ftd is only accessible if ACt = FtA, Ctd is only accessible if ACt = CtA. F t d frequency threshold, adjustable from 0 to 200 Hz = bFr C t d current threshold, adjustable from 0 to 1.5 In (In = nominal drive current) In

Atr

nO Automatic restart - n O : function inactive - Y E S : Automatic restart, after locking on a fault, if the fault has disappeared and the other operating conditions permit the restart. The restart is performed by a series of automatic attempts separated by increasingly long waiting periods: 1 s, 5 s, 10 s, then 1 min for the following periods. If the restart has not taken place after 6 min, the procedure is aborted and the drive remains locked until it is disconnected and then reconnected. The following faults permit this function: OHF, OLF, ObF, OSF, PHF. The drive fault relay remains activated if this function is active. The speed reference and the operating direction must be maintained. This function is only accessible in 2-wire control (tCC = 2C) with tCt = LEL or PFO. Check that an accidental start does not present any danger to personnel or equipment.

bFr

Motor frequency (Same as bFr 1st level adjustment parameter) Set to 50 Hz or 60 Hz, taken from the motor rating plate.

50 (E range) or 60 (U range)

IPL

Line phase loss fault configuration This parameter is only accessible on 3-phase drives. - n O : inhibition of the line phase loss fault - Y E S : monitoring of the line phase loss fault

YES

SCS

nO Configuration backup - n O : function inactive - Y E S : saves the current configuration to the EEPROM memory. SCS automatically switches to nO as soon as the save has been performed. This function is used to keep another configuration in reserve, in addition to the current configuration. When drives leave the factory the current configuration and the backup configuration are both initialised to the factory configuration.

0.5 0.7 In LF

4 (if ACt = LF or LFr) 12 (if ACt = HF)

Factory setting

Initial issue: 02/05 Latest revision: -

9.2.4 Monitoring Menu : SUP Code

Description

FCS

nO Reminder of the configuration - n O : function inactive - r E C : the current configuration becomes identical to the backup configuration previously saved by SCS. rEC is only visible if the backup has been carried out. FCS automatically switches to nO as soon as this action has been performed. - l n l : the current configuration becomes identical to the factory setting. FCS automatically switches to nO as soon as this action has been performed. For rEC and InI to be taken into account the ENT key must be held down for 2 s.

Factory setting

ENT

SUP

ESC

FrH

Value

Frequency reference

ENT

ESC

ESC

ESC

tHd

Value

Drive thermal state

ENT

When the drive is running, the value displayed is that of one of the monitoring parameters. The default value which is displayed is the motor reference (parameter FrH). While the value of the required new monitoring parameter is being displayed, the "ENT" key must be pressed a second time to confirm the change of monitoring parameter and to store it. From then on the value of this parameter will be displayed during operation (even after the drive has been switched off). If the new choice is not confirmed by pressing the "ENT" key for a second time, the drive will return to the previous parameter after it has been switched off. The following parameters can be accessed, with the drive stopped or running.

Wiring Diagrams Page 7 - 129

Code

Parameter

Unit

FrH

Display of the frequency reference (factory configuration)

Hz

rFr

Display of the output frequency applied to the motor

Hz

LCr

Display of the motor current

A

ULn

Display of the line voltage

V

tHr

Display of the motor thermal state: 100% corresponds to the nominal thermal state. % Above 118%, the drive trips on an OLF fault (motor overload). It can be reset below 100%.

tHd

Display of the drive thermal state: 100% corresponds to the nominal thermal state. % Above 118%, the drive trips on an OHF fault (drive overheating). It can be reset below 80%.

Initial issue: 02/05 Latest revision: -

9.3 Faults - Causes - Remedies Starter does not start, no fault displayed • Check that the run command input(s) have been actuated in accordance with the chosen control mode. • When the drive is switched on, at a manual fault reset, or after a stop command, the motor can only be powered once the "forward" and "reverse" commands have been reset. If they have not been reset, the drive will display "rdY" or ìnStî but will not start.

Faults displayed The cause of the fault must be removed before resetting. Faults SOF, OHF, OLF, OSF, ObF, and PHF can be reset via a logic input if this function has been configured. Faults OHF, OLF, OSF, ObF, and PHF can be reset via the automatic restart function, if this function has been configured. All faults can be reset by switching the drive off then on again. Fault

Remedy

OCF overcurrent

• Ramp too short, check the settings. • Inertia or load too high, check the size of the motor/drive/load. • Mechanical locking, check the state of the mechanism.

SCF motor short-circuit, insulation fault

• Check the cables connecting the drive to the motor, and the insulation of the motor.

InF internal fault

• Check the environment (electromagnetic compatibility). • Replace the drive.

CFF configuration fault

• Return to factory settings or call up the backup configuration, if it is valid. See parameter FCS in the FUn menu.

SOF overspeed

• Instability, check the motor, gain and stability parameters. • Driving load too high, add a braking module and resistor and check the size of the motor / drive / load.

OHF drive overload

• Check the motor load, the drive ventilation and the environment. Wait for the drive to cool before restarting.

OLF motor overload

• Check the setting of the motor thermal protection, check the motor load. Wait for the drive to cool before restarting.

OSF overvoltage

• Check the line voltage.

• Braking too harsh or driving load. Increase the deceleration time, add a braking ObF overvoltage resistor if necessary and activate the brA function if it is compatible with the during deceleration application.

Wiring Diagrams Page 7 - 130

PHF line phase failure

This protection only operates with the drive on load. • Check the power connection and the fuses. • Reset. • Check the line supply / drive compatibility. • If there is an unbalanced load, inhibit the fault via IPL = nO (FUn menu).

USF undervoltage

• Check the voltage and the voltage parameter.

CrF charging circuit

• Replace the drive.

Initial issue: 02/05 Latest revision: -

9.4 Programmation of the frequency driver LI 1 - Fwd 0 1 0 1 1 0 0 1

LI 2 - Rev 0 0 1 1 0 1 0 1

LI 3 - X1 0 0 0 0 1 1 1 1

ACTION Stop Start FWD Start REV FWD à 5 Hz REV à 5 Hz Stop

Glue tank motor : Acc = 0.1 Ith = 1.3 Frs = 50 Ncr = 1.2 Cos = 0.76 Ps 2 : LIA = Li3 ; LIB = LI4

Attention : The frequency inverter does not stop if LI 1 and LI 2 = 1. Translation motor :

Wiring Diagrams Page 7 - 131

Dec = 0.2 SP2 = 5 Sta = 12 Cli = 4.5 Act = 2C

Lsp = 0 Ait = 10 Flg = 25 Nsl = 2.8 Tct = trn

Hsp = 60 Uns = 230 Ufr = 50 Slp = 100 Rrs = Li 2

Note : The others parameters are adjusted with factory settings.

LI 1 : Start Fwd LI 2 : Start Rev LI 3: Constant frequency = 5 Hz.

Acc = 0.1 Ith = 1.5 Frs = 50 Ncr = 2.3 Cos = 0.77 Ps 2 : LIA = Li3 ; LIB = LI4

Dec = 0.2 SP2 = 10 Sta = 12 Cli = 3 Act = 2C

Lsp = 0 Ait = 10 Flg = 25 Nsl = 3.6 Tct = trn

Hsp = 60 Uns = 230 Ufr = 50 Slp = 100 Rrs = Li 2

Initial issue: 02/05 Latest revision: 03/05

NOTES .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Wiring Diagrams Page 7 - 132

.......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Initial issue: 04/04 Latest revision: 08/04

NOTES .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Wiring Diagrams Page 7 - 133

.......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... .......................................................................................................... ..........................................................................................................

Initial issue: 04/04 Latest revision: 08/04

Section 8 :

INSTALLATION MANUAL

Installation manual Page 8 - 1

Initial issue: 02/04 Latest revision: 06/05

This page is intentionally left blank.

Installation manual Page 8 - 2

Initial issue: 02/04 Latest revision: -

TABLE OF CONTENTS 1. Preliminary instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1. Prior to the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 2. Warning pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2. Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1. Site specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 2. Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3. Unpacking the Binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 1.Check the stickers on containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 2. Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 3. Unpacking the Binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 4. Unpacking the output unit (BBR) (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 5. Undocking the Binder from the pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4. Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

1. Preliminary . . . . . . . . . . . . . . . . . . . . . . . . . 2. Binder levelling . . . . . . . . . . . . . . . . . . . . . . 3 Kit Contenant . . . . . . . . . . . . . . . . . . . . . . . . 4. Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Output unit (BBR) (optional) . . . . . . . . . . . . . 6. User Interface Installation . . . . . . . . . . . . . . . 7. Paper dust bag collector installation (optional) 8. Extension installation . . . . . . . . . . . . . . . . . . 9. Foot switch installation . . . . . . . . . . . . . . . . . 10. Dust collector installation . . . . . . . . . . . . . .

5. Connecting the power 1. 2. 3. 4.

Introduction . . . . . . . . . Power Network Voltage Installing the power cord System power up . . . . .

Installation manual Page 8 - 3

. . . . . .

. . . . . . . .. .. ..

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

........ ........ ........ ........ ........ ........ ........ ........ ........ ........

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

.16 .17 .18 .19 .21 .23 .24 .25 .27 .28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 ... ... .. ...

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

Initial issue: 02/04 Latest revision: -

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

.30 .31 .32 .32

This page is intentionally left blank.

Installation manual Page 8 - 4

Initial issue: 02/04 Latest revision: -

1. PRELIMINARY INSTRUCTIONS 1. Prior to the installation Check the environmental conditions of your area. This machine is designed for the following environment : Intermediate storage and transport: Temperature: -34°C + 60°C / -30°F + 140°F Relative humidity: 5 - 90% RH Altitude: -31m - 12192m / -100ft - 40000ft Air pressure: > 56kPa (420mm Hg) Operating environment : Temperature: 5 -35°C / 41°F - 95°F Relative humidity: 10 - 85% RH

Installation manual Page 8 - 5

Initial issue: 02/04 Latest revision: -

2. Warning pictograms Please pay special attention to the description of the following pictograms : 9.139.163A

WARNING High leakage current earth connection essential before connecting supply ATTENTION Courant de fuite élevé Raccordement à la terre indispensable avant le raccordement au réseau

An emergency stop switch (red) located on the top cover allows the operator to stop the machine at any time or any incident.

This label is located near the wheel-work of the chain. It indicates a high risk of injury to your fingers if they get stuck between the wheel-work and the chain.

This label is located near the glue tank and near the valve for the draining of the glue tank. It indicates a high burning risk if you touch the hot glue.

This label is located near the milling blade. It a high risk of injury to your hands if you touch indicates the rotating tools

Installation manual Page 8 - 6

ATTENTION : These safety alert symbols are for your personnal safety. Never operate without all safety covers in place.

Initial issue: 02/04 Latest revision: 06/05

On the cover :

Inside the power rack :

¤

MODEL : BB3002 SER. N¡ : 3P+PE

60 Hz

208 / 220 / 230 / 240 V 12 A

230 / 240 / 380 / 400 / 415 V 12 A

gepr fte Sicherheit

3

50 Hz

L

3P+PE

L

2

L

1

LISTED I.T.E. E125337

WARNING High leakage current earth connection essential befo connecting supply ATTENTION Courant de fuite lev Raccordement la terre indispe avant le raccordement au r sea

Refer to specifications in Installation Manual.

c.p. bourg S.A.

MADE IN BELGIUM BY B-1340 Ottignies - rue des Technologies, 22 Tel : +32 / 10 / 62 22 11 Fax : +32 / 10 / 61 36 38

B 9139727A

HigWAR coenarth h le NING CoATT necticonnakag avRa acc uranENTIO ng suectioe nt orde t de N pplyn le r m fu acc ent ite ord la le em ter v ent re in au rs

Inside the Binder :

Installation manual Page 8 - 7

On the back (inside) :

Initial issue: 02/04 Latest revision: 06/05

2. INTRODUCTION THIS MANUAL IS INTENDED TO BE USED EXCLUSIVELY BY QUALIFIED TECHNICAL PERSONNEL. Thank you for having choosen a Bourg product. The BOURG BINDER 3002 is a perfect binder destined for the off-line production of bound booklets. The system consists of 2 units: 1. Perfect Binder. 2. Output Unit (optional). This manual is a guide to their installation.

IMPORTANT: Please read and follow these instructions carefully before connecting the system to the mains and you should obtain years of excellent service from your system.

All information in this publication is based on the latest information available at the time of approval for printing.

Installation manual Page 8 - 8

Initial issue: 02/04 Latest revision: -

Dimensions in meter (& foot).

0.8m (2.6ft)

1. Site specification External paper dust collector

Height : 1.50 m (4.92 ft.). 2.02m (7.22ft)

0.65m (2.13ft)

2.41m (7.9ft)

1.35m (4.43)

0.8m (2.6ft)

0.75m (2.46ft)

0.86m (2.86ft)

0.8m (2.6ft)

0.60m (1.96ft)

Installation manual Page 8 - 9

Initial issue: 02/04 Latest revision: -

0.5m (1.64ft)

Top view

2. Specification Model Description Max. cycles / hour

Dimensions

Room ventilation BB 3002 Glue binder Up to 600 cycles (operator dependent and based on A4 format) Length: 2.02 m (7.22 ft) Width: • without BBR 1.350 m (4.43 ft) • with BBR 2.410m (7.9 ft) Height: 1.50 m (4.92 ft)

Power required

- 208/220 V, 60Hz

Power consumption, stand by Power consumption, operation Power consumption, maximum Mains connection Safety class Protection class Radio interference Radiation Radiant heat Noise level (Lpa)

3 phases delta, 12A - 220/230 or 240V, 50 Hz, 3 phases delta 12A - 380/400 or 415V, 50Hz 3 phase star, no neutral needed, 12A 1500W 4000 W 5500W Field-wiring 3 phases connection + ground I (IEC 536) Protective earth connection IP 20 (IEC 529) Complies with Directive 93 / 68 / EEC Not applicable 13648 BTU/h Maximum 76 dB (A) (at operator position)

Ozone emission Room volume

Installation manual Page 8 - 10

Dust concentration Additionnal safety information

Recommendation: min. 47,5 m3/h (natural ventilation) For heat evacuation at continuous binding extra ventilation may be necessary 0,04 mg/m3 at continous operation (TLV for nuisance dust = 10 mg/m3) To 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.

Weight Binder Output Unit (optional)

¤

MODEL : BB3002 SER. N¡ : 3P+PE

60 Hz

208 / 220 / 230 / 240 V 12 A LISTED I.T.E. E125337

3P+PE

50 Hz

230 / 240 / 380 / 400 / 415 V 12 A

gepr fte Sicherheit

Refer to specifications in Installation Manual.

c.p. bourg S.A.

MADE IN BELGIUM BY B-1340 Ottignies - rue des Technologies, 22 Tel : +32 / 10 / 62 22 11 Fax : +32 / 10 / 61 36 38

Not applicable Recommendation: 95 m3 (7 x 4,5 x 3 m) 3336 ft3 (23x14.8x9.8 ft)

Initial issue: 02/04 Latest revision: 10/04

B 9139727A

650kg 1433lbs 80kg 176lbs

3. UNPACKING THE BINDER 1. Check the stickers on containers • TIP-N-Tell label: Blue beads in arrow shows container was tipped or mishandled. TIP-N-TELL

• “Warning” label: Red indicates rough handling. If indicator is red, ALWAYS accept shipment, note activation on bill of lading, and inspect shipment for damage.

BLUE BEADS IN ARROW SHOWS CONTAINER WAS TIPPED OR MISHANDLED

INDEX PACKAGING, INC. UNION, NH TEL 800-662-3626 FAX 603-652-9279 TIP-N-TEL BLUE BEADS SHOWS TIPPED

L

IN ARROW CONTAINER OR

WAS MISHANDLED

INDEX PACKAGING, UNION, TEL

INC. NH 800-662-3626

FAX 603-652-9279

IF TIP (N) PACKAGE TELL OVER ARROW MAKE HAS IN BEEN POINT TRANSIT. FOR NOT ON ON DAMAGE. DEPEND BILL ITS IS BLUE SIDE OF ANY LADING OR THIS ON TIPPED THIS CLAIMS NOTATION AND FOR CHECK TIPPING

TIP

N TELL PATENT NO. PRINTED 3,926,144 IN

USA.

HAN WIT H DLE CAR E RED INDICAT RED, ES NOTE ROUGH INSPEC ON BILL HANDLI TION OF MAY NG LOADIN IF BE WARRA G NTED

HANDLE WITH CARE RED INDICATES

If indicator

ROUGH RED, HANDLING

NOTE ON INSPECTION

BILL

accept is red, chipment, on ALWAYS bill of shipment lading, note and activation for damage.inspect

IF OF LOADING

MAY BE WARRANTED

HANDLE WITH CARE

RED INDICATES ROUGH HANDLING IF RED, NOTE ON BILL OF LOADING INSPECTION MAY BE WARRANTED

IF TIP (N) TELL ARROW POINT IS BLUE THIS PACKAGE HAS BEEN ON ITS SIDE OR TIPPED OVER IN TRANSIT. MAKE NOT ON BILL OF LADING AND CHECK FOR DAMAGE. ANY CLAIMS FOR TIPPING DEPEND ON THIS NOTATION

TIP N TELL PATENT NO. 3,926,144 PRINTED IN USA.

Installation manual Page 8 - 11

Initial issue: 02/04 Latest revision: -

HANDLE WITH CARE

RED INDICATES ROUGH HANDLING IF RED, NOTE ON BILL OF LOADING INSPECTION MAY BE WARRANTED

If indicator is red, ALWAYS accept shipment, note activation on bill of lading, and inspect shipment for damage.

2. Handling The pallet can be lifted only from one side (as illustrated).

6 4.7

4

16

21

70

mm

(8

5.4

3i

n)

1660 mm (65.35 in)

Weight 1010 Kg (2220lbs).

m 5m

(6

in)

LI FT

Installation manual Page 8 - 12

HE RE

Initial issue: 02/04 Latest revision: 09/04

3. Unpacking the Binder The package contains: • The Binder unit (a). • 1 ramp (g). • 1 bag of glue granules (b). • 1 accessory box (c). • 1 user interface (e). • 1 dust collector (d). • 1 output unit (f).

a

c

Unpacking : • Remove the staples fastening the cardboard to the wooden side panel and frame (Fig.1). • Remove the cardboard (Fig.2). • Remove the wooden side panel and frame (Fig.2). • Remove the plastic wrap (Fig.4). • Cut the straps. • Remove the ramp and the 4 boxes (glue, accessories, user interface and dust collector) (Fig.5).

b

Fig.3 e

f

g

d

Straps

a

f c

Fig.4

Fig.5

b d

g

e

Fig.1

Installation manual Page 8 - 13

Fig.2 Initial issue: 02/04 Latest revision: -

g

4. Unpacking the output unit (BBR) (optional) • Remove the screws fastening the docking support brackets (1) to the pallet and to the BBR. • Move the BBR further away from the binder in order to use the ramp when the binder will be lowered from the pallet.

1

Installation manual Page 8 - 14

Initial issue: 02/04 Latest revision: -

5. Undocking the Binder from the pallet 1. Remove the screws fastening the docking support bracket to the binder and to the pallet. There are 8 screws (4 on the front and 4 on the rear). 2. Rotate the height adjustment legs clockwise to raise the binder off the docking support brackets. 3. Remove the docking support brackets. 4. Rotate the height adjustment legs counterclockwise until the binder is resting on the wheels. 5. Do steps 1-4 for the other support bracket.

6. Install correctly the ramp against the pallet (Fig.6). The binder wheels must go through the cuts of the pallet. Attention: Minimum 2 persons are required to remove the binder from the pallet.

Top view

Binder

Ramp 1 1

1 1 2

4

4 3

5

2

Fig.5

Installation manual Page 8 - 15

Initial issue: 02/04 Latest revision: 10/04

Fig.6

4. INSTALLATION 1. Preliminary • Move the binder to its final location. • Cut the tie wrap and open plexi top cover (Fig.1). • Cut and remove : - the two tie wraps on the cover transport and the cover feeder (Fig.2). - the two tie wraps on the cover clamp (Fig.2).

Fig.1 Fig.2

Installation manual Page 8 - 16

Initial issue: 02/04 Latest revision: 10/04

2. Binder levelling Note : It is essential that the Binder be levelled. Several water gauge levels are installed on the chassis of the binder to assist the levelling. Rotate the legs to adjust the level of the binder by using the water bubble gauges.

Installation manual Page 8 - 17

Initial issue: 02/04 Latest revision: -

3. Kit Content a REF a b c d e f g h i j k l

ITEM NUMBER 9414078 9414077 9414076 9414079 9403843 9199883 9414105 2081998 9133729 9230665-AF 9403925-AF 9432430-AF

Description Large and high guides Short and high guides Off line guides Large and low guides Spanner for draining the glue tank Aluminium container Magnetic stop Foot switch operator manual Cover table extension Loading area extension Conveyor

Operator manual

i

b

j

c

d k e l f

g

h

Installation manual Page 8 - 18

Initial issue: 02/04 Latest revision: 10/04

4. Conveyor Unpacking of the conveyor • Unpack the conveyor from the box. • Install the foot (1) on the conveyor with the screws (2) and washers (Fig.1).

Conveyor installation • Raise the baffle (1) (Fig.2). • Position the rollers (2) on the guides (3). • Adjust the conveyor height by using the foot (4). • Lock the conveyor position with the levers (5) (Fig.3 on next page).

2 2

1

1 2 3 3 2

4

Fig.1 4

Installation manual Page 8 - 19

Initial issue: 02/04 Latest revision: -

4

Fig.2

Connection • Connect the cable (6) to the binder. • Install the terminator plug (7).

Fig.3

5

5 7

6

Installation manual Page 8 - 20

Initial issue: 02/04 Latest revision: -

5. Output unit (BBR) (optional) 1

Installation • Elevate the foot (B) off the ground so that the conveyor rests on the output unit Fig.1. • Adjust the BBR height by using the feet (A) Fig.1. • Manually push the BBR head towards the binder (hold the BBR base in place). • Insert the docking pin (C) inside the hole located under the conveyor as shown on figure 2. • Unlock the levers (D) and push the BBR and the conveyor fully towards the binder Fig.3. • The rollers should be positioned as illustrated on figure 3.

D B

A

D

385mm

2

Fig.1

D

2

Note: Make sure The Levers (D) are in the down position so the conveyor can move freely within the guides (3).

C

B 1

A A

3

Fig.2

D D

Fig.3

Installation manual Page 8 - 21

Initial issue: 02/04 Latest revision: -

Connection • On the conveyor, remove the terminator plug located under the conveyor. Store it in a safe place. • Connect the cable (1) to the conveyor.

1

Installation manual Page 8 - 22

Initial issue: 02/04 Latest revision: -

6. User Interface Installation • Carrefully unpack the UI from its box . • Remove the screw (1) and washers (2) and (3) from the bracket. • Slightly loosen both screws (8) to easily insert the arm. • Insert the end of the arm in the bracket (7) with a washer (3) on each side of the spacer (5). • Replace the screw (1) and washer (2). • Tighten the screws (8). • Tighten the screw (1). • Plug in the connector (6).

8 3

7

5

8

4

3 2

6

1

Installation manual Page 8 - 23

Initial issue: 02/04 Latest revision: -

7. Paper dust bag collector installation (optional) • Open the paper dust box (drawer). • Correctly slot the bag opening (1) into the guide (2). • Replace the paper dust box.

1

2

Fig. 1

Installation manual Page 8 - 24

Initial issue: 02/04 Latest revision: -

8. Extension installation Loading area extension Install the extension as illustrated.

2

3

4

5

1

Installation manual Page 8 - 25

Initial issue: 02/04 Latest revision: -

Cover table extension Install the extension as illustrated.

1

2

Installation manual Page 8 - 26

Initial issue: 02/04 Latest revision: -

9. Foot switch installation Connect the foot switch in the connector (1) located under the binder.

1

Installation manual Page 8 - 27

Initial issue: 02/04 Latest revision: -

10. Dust collector installation 1. Unpack the dust collector. 2. Refer to the enclosed instructions to assemble the dust collector. The motor is not connected. 3. Remove the screw to open the electrical box. Warning : Ensure that the power cord is not plugged to the mains. 4. Connect the wires as illustrated. 5. Tighten the screw to correctly close the electrical box.

Connection of the motor according to the network voltage single phase:

1 2 3 4

red black yellow white

Warning : for the connection, only use the orange connector 120V

1

3

2

4

Single phase

Black 2

Red 1 Yellow 3

orange connector

White 4

White (network)

Red (network)

Red 1

White 4

orange connector

110V

1

3

2

4

Black 2

230V Single phase

orange connector 220V

Installation manual Page 8 - 28

Red (network)

orange connector White (network)

Initial issue: 02/04 Latest revision: 09/04

orange connector Yellow 3

6. Install the sleeve (8) with the fiving ring (9). Pay attention to not dostruct the holes. 7. Connect the dust exhaust pipe (1) to the sleeve using a fixing ring (2). 8. Put the magnetic power box (3) on the binder. 9. Plug the MNL connector (4) of the power box to the connector (5) located under the machine. 10. Plug the power cable (6) of the dust collector to the power box. 11. Connect the box power (7) cord to the mains.

8 9

7 2

6

1 5

8 9

3 4

2

Installation manual Page 8 - 29

Initial issue: 02/04 Latest revision: 12/04

5. CONNECTING THE POWER 1. Introduction The BB3002 is a permanently connected and field wiring machine. It must be connected to the mains with harmonized cable outer diameter from 9mm to 16mm with a minimum cross section area of conductors of 2,5mm2 (maximum 4mm2) or 12AWG. The Power cord must have 3 phases and earth (yellow/green) wire. The cable is not supplied with the binder. The binder is designed to be connected to the following power network: - 208/220 V, 60Hz 3 phases delta, 12A - 220/230 or 240V, 50 Hz, 3 phases delta 12A - 380/400 or 415V, 50Hz 3 phases star, no neutral needed, 12A Attention: • The network line to the binder must be protected by a 20A breaker. • No neutral is needed.

Installation manual Page 8 - 30

Initial issue: 02/04 Latest revision: -

2. Power Network Voltage Prerequisites : Remove the left rear panel and the electrical box cover (see drawing on previous page). Use a voltmeter to verify the supply voltage.

4 4 3 3 2 2 2 2 2 1 0 8 8 4 3 3 2 0 5 0 0 0 0 0 0 0 8

4 4 3 3 2 2 2 2 2 1 0 8 8 4 3 3 2 0 5 0 0 0 0 0 0 0 8

Procedure : • Connect the wires L1, L2, L3 on the transformer to the corresponding voltage tap. For example : if the network voltage between 2 phases is 380V, connect L1, L2, L3 on 380V. • Check that the wires L12, L22, L32 are connected on 230V. • Check that the wires L13, L23, L33 are connected on 380V. 4 4 3 3 2 2 2 2 2 1 0 8 8 4 3 3 2 0 5 0 0 0 0 0 0 0 8

Input of the transformer Output of the transformer

L13

L12

L23

L1

L22

L2

4 1 4 5 0 3 0 8 3 0 8 2 0 4 2 0 3 2 0 3 2 0 2 2 0 8 0

4 1 4 5 0 3 0 8 3 0 8 2 0 4 2 0 3 2 0 3 2 0 2 2 0 8 0

L

3

L

2

L

1

4 1 4 5 0 3 0 8 3 0 8 2 0 4 2 0 3 2 0 3 2 0 2 2 0 8 0

L33 L3

Installation manual Page 8 - 31

Initial issue: 02/04 Latest revision: -

L32

3. Installing the power cord

4. System power up • Connect the power cord to the wall outlet. • Turn the main switch to the ON 1 position. • The BB3002 is starting up. • After a few seconds, if the following message appears on the U.I.: 42050 “Milling motor direction test failed” : • Switch the binder OFF. • Disconnect the power cord from the wall outlet. • Invert the position of 2 wires on the connector (2) rack. • Connect the power cord to the wall outlet. • Switch the binder ON.

Warning: Do not plug the power cord in the wall outlet. • Remove the insulation on the end of all the wires of the power cord as required. • Fit a terminator lug (1) on the ground wire (green / yellow). • Insert the cable in the hole as shown on Fig.1. • First, connect the ground wire on screw (1). • Then, connect the 3 wires of the network in the wago connector (2). There is no neutral wire. • Tighten nut A (under the machine).

• When the installation is complete reinstall the covers.

L

3

L

2

L

1

2

1

A

Installation manual Page 8 - 32

Initial issue: 02/04 Latest revision: -

HiWAR c ear gh NI AT onneth colneakNa G C ct n g o T avRa acc uranENTI ing suectioe nt orde t deON pplyn le r m fu acc ent ite ord la le em ter v ent re in au rs

This page is intentionally left blank.

Installation manual Page 8 - 33

Initial issue: 02/04 Latest revision: -

c.p. bourg

c.p. bourg

S. A. N. V.

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] web: www.cpbourg.com

rue Millewee, B.P. 85 L-7201 Walferdange (Luxembourg) Tel.: 352 / 33 24 47 Fax: 352 / 33 19 99 e-mail: [email protected]

c.p. bourg

c.p. bourg

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]

c.p. bourg

S.A.

http: //www.cpbourg.com

Page 8 - 34

Inc.

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]

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]

Installation manual

S.A.

Initial issue: 02/04 Latest revision: 06/05