Operator Manual SDD BGB3202 Perfect Binder DBCB-0609-0001-V004
Content of this documentation has a confidential nature and remains the exclusive property of c.p. bourg s.a. / SDD B.V. 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 s.a. prior agreement in writing, disclosure to third party and/or reproductions as well as changes are prohibited.
TABLE OF CONTENTS 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 Safety Introduction...............................................................................................8 1.3 Warning pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.4 Instructions for safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.
.3.1 Accessing the automatic menu:........................................................................................ 35 4.3.2 Programming the automatic menu:................................................................................... 35 4.4 COUNTER menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.4.1 UNIT mode:....................................................................................................................... 41 4.4.2 SERIES mode:.....
. Preparing the binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.1 Loading the cover station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.2 Adjusting the cover position on the book . . . . . . . . . . . . . . . . . . . . . 74 5.3 Cover picking and separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 5.3.1 Suction and Blowing suction level:..............................................................
10 . Using the binder with the BBC . . . . . . . . . . . . . . . . . . . . . . . . . 92 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 10. General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 11. Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 11.1 Perfect Binding Mode (Online) . . . . . . . . . . . . . . . . . . . . . . . . 94 11.
INTRODUCTION Foreword This Operator Manual is for the SDD BGB3202. This perfect binder, which is attached online to a Canon/Océ printer, is a combination of the BB3002 offline binder and the BBC Book Compiler module. Thus, in this manual, you will see the name BGB3202 as well as the common engine name: the BB3002. The SDD BGB3202 is a single clamp thermal binder designed in a user-friendly way to create perfect bound books. Adjustments can quickly and easily be made via the touch screen (GUI).
SAFETY INFORMATION 1.2 Safety Information Please read the safety instructions carefully before using your equipment. This manual contains all the information you need to use your thermal binder safely. Pay particular attention to the warning notices on the machine. They indicate places presenting particular risks, and advise you to take appropriate precautions. All the details contained in this publication are based upon the most recently available information at the time of going to press.
1. Warning pictograms Please pay special attention to the description of the following pictograms : This label is located near the wheel-work, the chain and belt. It indicates a high risk of injury to your fingers if they get stuck between the wheel-work, the chain and belt. 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.
On the cover: MODEL : BB3002 EVA 3P+PE 60 Hz 208/220/230/240 V 12 A 3P+PE 12 A 50 Hz 230/240/380/400/415 V Refer to specifications in Installation Manual MADE IN BELGIUM BY B-1340 Ottignies - rue des Technologies, 22 Tel : +32 (0)10/62 22 11 Fax : +32 (0)10/61 36 38 9139727C This device complies with part 15 of the FCC Rules.
Inside the power rack: L 3 L 2 L 1 Power supply connection 9.139.
1.4 Instructions for safe use All products are tested according to the strictest safety standards in compliance with international law. To ensure that your work is carried out under the safest possible conditions, please observe the following instructions: Installation and movement: • Do not move the machine yourself - contact our technical team. he machine should only be connected to the electricity supply by qualified personnel in •T accordance with the installation manual.
1.5 Technical specifications Model BGB3202 D Glue binder D Length: 2,02 m (6.62 ft) Width: 2,4 m (7.9 ft) Height: 1,5 m (4.92 ft) Binder: 650 kg (1430 lbs) - BBR 80 Kg (176 lbs) 2.02m (6.62ft) 0.86m (2.86ft) 1.35m (4.43) 0.8m (2.6ft) 0.75m (2.46ft) 2.41m (7.9ft) 57,5mm (2.26”) 85mm (3.34”) 57,5mm (2.26”) 0.8m (2.6ft) 185mm (7.28”) 0.8m (2.6ft) External paper dust collector 0.8m (2.6ft) 0.60m (1.
2. GENERAL DESCRIPTION Perfect Binding mode Padding mode (without cover) MAX 60mm (2.36") MIN 1mm (0.04") 90 to 320mm (3.54" to 12.60") ) m " 5m .15 38 15 o o t t 60.36" (2 Glossy paper, with cutouts, with transparent front etc. Cover weight: 80-300 gsm 20-110 lb Lamination, grain and thickness of covers may disturb the clamping/nipping of books. Paper weight: 60-160 gsm 15-40 lb bond Features: Max. operating speed: Up to 600 cycles/hour (operator dependent and based on A4 - 8.
Operator Manual Page 15 5 6 7 4 2 1 2.2 General description of the binder 13 12 8 9 10 11 1. Main power switch. 2. Manual loading area. 3. N.A. 4. Pedal 5. Safety barriers. 6. Indicator lights. 7. Emergency stop button. 8. Front panel. 9. Cover station. 10. Intermediate conveyor. 11. Output conveyor - BBR (optional). 12. UI - graphical interface. 13. Push buttons.
2.3 Dof the gluing process • Place a set of sheets in the carriage jaws. • Start a gluing cycle, withdrawing your hands outside the loading area.
2.4 Dof various parts of the binder 2.4.1 "Vibrating" module (jogger): The vibration of the jogger plate re-aligns the block of paper to be bound. 2.4.2 Milling module: The milling module notches the spine of the bundle of paper to be bound. This improves glue adherence to paper material. The paper dust in extracted by external vacuum pump to a high capacity collection tank.
2.4.3 Glue tank: The glue tank contains the glue to be applied in a film to the spine of the book. The glue tank consists of 2 gluing cylinders: The first cylinder causes the glue to penetrate the notches made in notching and milling, while the second cylinder applies a larger quantity of glue to fix the cover. In "BLOCK" mode (padding, no cover), the first cylinder is deactivated so that the pages are easily detached.
2.4.4 Cover clamp: The cover clamp module places the cover over the book's spine. The cover clamp jaws apply the cover centrally in relation to the book so as to obtain a straight book with a square spine. Procedure: 1. The cover is first applied to the spine of the book (pressure along the spine). 2. The cover is then pressed to the side, folding it around the edges of the book (lateral pressure). 2.4.
2.4.6 Cover loading: The cover station suction bar picks up the cover and transfers it to the cover clamp module.
2.4.7 Binder output: The output baffle plate has a movable roller which aligns and slows down the book before its output. Output roller 2.4.8 Reception of books in the BBR module (optional): The bound books are finally received and stored in a high-capacity module, the BBR. Note: Risk of injury to your fingers if you take the booklets in this area.
3. USING THE BINDER 3.1 erating procedure 3.1.1 Powering up the binder: • The first operation is to power up the machine by turning the on/off switch to the ON1 position. icon at the bottom of the graphical interface screen to begin warming • Next press the the glue tank. • Wait for the glue to reach the correct temperature. For further details about see chapter "3.2 Powering up the binder and heating the glue tank", page 24. 3.1.
3.1.5 Starting the Dust Collator • Open the cover (1). • Push the button "I" (2). • Do not close the cover (1) (close the cover = stop emergency). After a stop emergency, push the button ”I” (2) again. 2 1 3.1.6 Switching the binder off: • To switch off the machine, turn the on/off switch to the 0 position: "power off". The glue tank heater can be programmed to switch on or off automatically with no input from the operator. To enter this mode, turn the binder's main switch to the ON2 position.
3.2 Powering up the binder and heating the glue tank On the front of the binder is a main switch with 3 positions: 1- Binder OFF. The first position of the switch cuts off all power to the machine: "POWER OFF". 2- Powering up the binder - ON1. The second position provides power to the machine: "POWER ON". 3- Placing the binder on stand-by - ON2. The third position corresponds to the "TIMER" mode. In this mode, the binder is on stand-by.
3.2.1 Heating the glue tank - main switch at ON1: Preliminary notes: -T he tank temperature is close to the gluing temperature. It is however slightly less, to avoid the glue oxidising too quickly. This temperature can be adjusted by a qualified technician to low or high temperature. •S et the switch in UP position for glue with working temperature greater than or equal to 160°C (Planatol).
3.2.2 Starting the TIMER - main switch in ON2 position: The "TIMER" menu can be programmed to start and stop the glue tank heater automatically with no input from the operator. In this way, the glue tank can begin to heat up before the operator arrives and the glue will be at the right temperature when the operator starts work. Here is a sample timetable: To access the "TIMER" menu: • Turn the binder's main switch to the ON2 position.
3.3 The binder controls The binder's controls are as follows: 1. A colour touch-screen used to program jobs (UI). 2. Black and green buttons on the loading console. 3. Pedal. 4. Emergency stop button. 5. Indicator lights. 6. Safety barriers. 3.3.1 Function of the buttons on the loading console: Emergency stop button Indicator lights Safety barrier Touch screen Push buttons Main switch Pedal Black button - opening the carriage jaws: 1.
3.3.2 Function of the pedal: The pedal closes the carriage jaws so that the space where the book to be bound is inserted can be reduced. 3.3.3 Indicator light above the loading area: Above the loading area is a strip of indicator lights. The operator can see at a glance the status of the binder from the indicator's various colours: - Green light: A green light indicates that the machine is ready for use and that the glue has reached the required temperature.
3.3.5 Emergency stop button: To stop the machine quickly (if the operator is in danger, for example), press the emergency stop button. 3.3.6 Reinitialising the binder: To reinitialise the binder, release the emergency stop button (if it has been pressed) and press the green button on the loading console. If necessary, remove the paper and cover. Note: The machine also performs an emergency stop if a panel is opened.
4. GRAPHICAL INTERFACE (UI) 4.1 General description of the graphical interface The graphical interface enables the binder to be used easily and intuitively. The touch-sensitive screen is divided into 4 parts: Zone C. Zone A. 1 2 3 4 Zone D. 5 6 7 Zone B. Zone A: Access to the various menus in the graphical interface: 1. "AUTOMATIC" menu: For automatic job programming. 2. "ADVANCED" menu: For programming the binding parameters for the cover. 3. "JOB" menu: For accessing settings during use. 4.
Zone B: Machine status icons: 1 6 2 3 4 5 1. CP Bourg logo. Pressing this button displays information relating to the version of the UI software installed. 2. Display of the number of bindings carried out and the total number in the current job. Pressing this button toggles between the "series" mode, “semi-series” mode and the "unit" mode. For more details on this subject, see chapter "4.4 COUNTER menu", page 40. 3.
Zone C: Current job display and warning messages: This zone displays the current job and various warning messages. This indicates the binder's status to the operator at all times. Current job name Warning messages When an error occurs, a red message scrolls on the screen. Display of the current job is then deleted. Error messages Warning messages Zone D: Dialogue area: This space is used for dialogue between the user and the binder. It enables the user to configure the binder to achieve the desired effect.
4.2 "PREFERENCES " menu This menu enables the binder to be configured according to the operator's preferences. Settings such as the language, units of measurement, start-up mode etc. are defined here. icon to the right of the screen. The "PREFERENCES" menu is accessed by pressing the Note: If the BBL/BBC is installed, this menu is in the TOOLS menu. Choice of language: V arious languages are available. The operator can easily switch from one to another by selecting the corresponding flag.
Default paper size. The binder needs to know the height of the book. When starting the machine or creating a new job, the format selected in this menu will be offered as the default. The operator can select from the most commonly used formats: - A4 (height = 210 mm/8.3"), US Letter (height = 216 mm/8.5"), B4J (height = 257 mm/10.1"), or enter a custom height. Start-up mode: automatic or manual. To produce a book, the operator must place the paper to be bound in the carriage jaws.
4.3 AUTOMATIC " menu On start-up, the automatic menu appears. The automatic menu enables the operator to bind standard jobs using settings with default values. The automatic menu facilitates the operator's job - he does not need to set the cover binding and cover clamp parameters, as they are determined directly according to the book to be bound. -> The BB3002 binder is therefore ready for use immediately. The operator can place the paper to be bound directly in the carriage jaws and begin a gluing cycle.
4. Three settings can be altered: Activation/deactivation of the jogger + adjustment of the amplitude of the vibration: The vibration of the jogger plate straightens the sheets in the paper bundle into a properly squared-off block. or By pressing the jogger plate. , the operator can activate or deactivate the vibration of Using the bar graph vibration. , the user can modify the amplitude of the Cover suction level: Using the bar graph be changed.
5. T he machine is now ready for operation using the "AUTO " parameters. The operator can now place the paper to be bound in the carriage jaws and begin a gluing cycle. Note: When loading the paper, place the back of the last page of the book to be bound, facing you. In brief: T he automatic menu enables easy use of the binder. No programming is required to configure the binder settings. The binding and cover clamp settings are automatically adapted according to the book to be bound.
Overview of the gluing and cover clamp parameters with and without the AUTO menu : Parameters set with the “AUTO ” menu Parameters set automatically according to the book to be bound. Parameters set without the “AUTO ” menu Parameters set manually by the operator. For further details on gluing and cover clamp parameters, see chapter "4.8 “JOB" menu", page 59.
List of default parameters in the automatic menu: To reset the gluing and cover clamp parameters to their "AUTO" values, press the icon in the automatic menu. • Binding parameters: - Carriage speed: fast. - Milling activated. - Milling depth: 1 mm - 3/64". - Temperature at which glue is applied (working temperature of the glue). - Both gluing cylinders activated + lateral gluing (if option installed). - Glue cut-off on front: 5 mm - 13/64". - Glue cut-off on back: 5 mm - 13/64".
4.4 menu The operator can access the counter menu by pressing the the screen. button at the bottom of The binder can work in unit mode, series mode or semi-series mode. "UN IT" mode is used when the operator wishes to produce books with different thicknesses or formats. This is the default mode. "SERIES " mode is used when the operator wishes to produce a series of books with identical thicknesses and formats.
4.4.1 UNIT mode: "UN IT" mode is used when the operator wishes to produce books with different thicknesses or formats. This is the default mode. 1 5 2 3 4 his first counter displays the total number of jobs completed since the 1. T machine was first put in service. 2. P ressing this icons changes the binder from "series" or "semi-series" mode to "unit" mode. The icon indicates that unit mode has been selected. 3. T his running counter shows the number of books completed in the current job.
4.4.2 SERIES mode: There are two types of series mode: - "continuous series" mode: To bind an undefined series of identical books. The series mode is permanently selected. - "preset series" mode: For a defined number of identical books. The series mode is selected for a defined number of jobs (configurable via the UI). 4.4.2.1 A. "CONTINUOUS SERIES" mode: 1 3 2 4 5 1. T he first counter displays the total number of jobs completed since the machine was first put in service. 2.
4.4.2.2 B. “PRESET SERIES" mode: 1 3 4 2 6 5 his first counter displays the total number of jobs completed since the 1. T machine was first put in service. 2. P ressing this icon changes the binder from "series" or "semi-series" mode to "unit" mode. The icon indicates that series mode has been selected. his running counter shows the number of books completed in the current 3. T job. The value of this counter is also displayed at the bottom of the screen. 4.
4.4.3 “SEMI-SERIES” mode: Like the series mode, there are two types of semi-series mode: - "continuous semi-series" mode: To bind an undefined series of identical books. The series mode is permanently selected. - "preset semi-series" mode: F or a defined number of identical books. The series mode is selected for a defined number of jobs (configurable via the UI).
4.5 " menu This menu provides access to various binding and cover clamp parameters, making it possible to produce personalised books which call for specific parameters. Accessing the advanced menu: 1. Press the icon (1) to access the advanced menu . 2. T o enter the parameters to the advanced menu, first clear the selection of the "AUTO " function. Press the key (2) . To return to the "AUTO" menu, press the same button again.
Cover suction level: This button modifies the suction level for the cover to be picked up. Two operating modes are possible, depending on whether or not the "AUTO" function is active. • If the "AUTO" function is active: The suction level is automatically adjusted according to the cover. • If the "AUTO" function is inactive: Activate/deactivate the "AUTO" function. The operator can modify the suction level manually.
4.6 menu: Managing parameters for cover clamping This menu enables you to set the parameters for cover clamping of the book. 4.6.1 Selecting "with cover" or "without cover" mode ("BLOCK" mode): Pressing this button activates with cover mode. Pressing this button activates without cover mode (Block mode). With cover mode is selected by default. Note: If Block mode is activated, the unused parameters relating to cover handling can no longer be selected.
4.6.2 In "WITH COVER" mode: 4.6.2.1 Cover positioning modes: There are three different ways in which the cover can be cased in: • N /1 mode: Default mode. The edge of the front cover is positioned at the edge of the first page to be glued. Paper path When the paper is loaded into the carriage jaws, the operator must place the back of the last page of the book facing him. -> Books with cover wings only available in this mode.
4.6.2.2 Selection and positioning of creases (optional module): As indicated above, the creasing options and cover parameters to enter depend on whether N/1, CENTRE or FIRST/N mode has been selected. • With N/1 mode: Note: Covers with folding wings are only available in this mode. 3 1 2 When the paper is loaded into the carriage jaws, the operator must place the back of the last page of the book to be bound facing him.
Selection of available creases: Six creases are available in this mode. Each one can be selected upwards, downwards or selected. Press the icon representing the desired crease to change the crease shape. 6 5 1 2 3 4 reases 2 and 3 are positioned automatically according to the •C thickness of the book. When selected, they are positioned downwards by default. •C reases 1 and 4 (courtesy creases) can be positioned as the operator wishes. A default values of 6 mm positioned upwards is proposed.
Books with folding wings: Books with folding wings are only available in N/1 mode. If the operator wishes to produce books with folding wings, creases 5 and 6 must be selected using the or icon. The operator must also specify the following widths: •T he width of the front wing (width 3), which is set to 90 mm by default. The width of the back wing, depending on the length of the cover. •T he width of the front cover (1) and back cover (2).
• With CENTRE mode: This mode enables the cover to be centred in relation to the book's spine. Symetric ath p er p Pa It is used to centre inscriptions on the spine of the book. As long as the inscriptions are in the centre of the cover, they will always be positioned on the spine, whatever be the thickness of the book. 1 2 When the paper is loaded into the carriage jaws, the operator must place the back of the last page of the book facing him. Cover wings are not available.
• With 1/N mode: 1 3 2 In this mode, the edge of the front cover is positioned on the edge of the first page to be bound. When the paper is loaded into the carriage jaws, the operator must place the front of the first page of the book facing him. Cover wings are not available. 1 N t on r e ap th pa N Fr 1 P The values to enter are: 1. The total length of the cover. 2. T he position of the courtesy creases (creases 1 and 4), which are set to 6 mm from the book's spine by default. 3.
4.6.3 In "WITHOUT COVER" mode: Pressing activates without cover mode (Block mode). In this mode, no cover parameters need to be entered.
4.7 : Managing binding parameters This menu enables you to set the parameters for milling and gluing the cover on the book. 1 2 3 7 8 4 6 5 4.7.1 Setting the carriage movement speed: Automatic carriage movement speed. Depending on the thickness of the book and the milling depth, the binder automatically calculates the carriage movement speed. Slow carriage movement. Regardless of the thickness of the book, slow carriage movement enables maximum notching of the spine, giving the best adhesion.
4.7.3 Selecting milling and the milling depth: Pressing or activates or deactivates the milling of the book's spine. When milling is activated, the operator can modify the milling depth (between 0 and 3 mm depending on paper type and format). • If the operator does not activate the rotation of the milling blade: -> No notching and no milling. In this case, the machine automatically with draws the notching tools to keep them out of the way of the paper.
4.7.4 Setting front and back glue cut-offs: Glue cut-offs enable you to stop applying the glue film at the front and back of the book's spine. • I n this case, the glue cut-offs are set at 15 mm - 0.6" from the edges of the book. The arrows and modify this value. Maximum value: 130 mm - 5.1". Default value: 5 mm - 0.2". • I f the operator reduces the value below 0", the glue cut-off will be beyond the edges of the book. Glue will thus be applied to the whole spine of the book. Maximum value: 60 mm - 2.
4.7.7 Setting the thickness of the glue film: bargraph, the operator can increase or decrease the Using the thickness of the glue film applied to the spine of the book. Diagram of the button Activate/deactivate the "AUTO" function. Activate/deactivate the "AUTO" function. When the "AUTO" function is deactivated, the operator can modify the thickness of the glue film applied to the spine of the book.
4.8 “JOB " menu This menu enables the operator to access a series of fine settings. These settings make it possible to get the most out of your BGB3202 for delicate and/or specific jobs. 1 3 5 10 2 4 6 11 7 8 9 12 Note: When a new job is created, settings 1, 2, 3, 4, 5, 6 and 9 are given their "AUTO" values. This means that these parameters are automatically adjusted according to the book to be bound. The operator still has the option of setting these parameters manually.
4.8.1 Correction of the paper pile thickness to be bound 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. This is frequent when using light paper (60 gsm - 15lb bond) or pre folded paper and increase with the paper pile thickness.
4.8.2 Setting the thickness of the glue film: Using this button you can modify the thickness of the glue film applied to the spine of the book. Two operating modes are possible, depending on whether or not the "AUTO" function is active. When the "AUTO" function is active, the thickness of the glue film is automatically adjusted according to the book to be bound. When the "AUTO" function is inactive, the operator can change the thickness of the glue film manually. 4.8.
• In "block" mode: This time corresponds to the glue drying time before the book is output. It is advisable to make this time as long as possible. The value can range from 6 seconds to 26 seconds in steps of 2 seconds. Default value: 16 seconds. 4.8.6 Setting the glue drying time during cover nipping: This button makes it possible to modify the glue drying time during cover nipping. Two operating modes are possible, depending on whether or not the "AUTO" function is active.
4.8.9 Book output mode: Before being directed on to the conveyor, the book can be realigned by the cover clamps and the stop before being output. 4 modes for the output of the book on to the conveyor are possible: 1. In this mode, the book falls on the clamps and on the stop before being output on the conveyor. This mode is the "AUTO" mode for book thickness of 15 to 60 mm. In this mode, the book falls on the stop before being output on the conveyor. 2.
4.8.11 Adjusting the creasing position: With this button the position of the creases on the front and back can be adjusted separately. For example, in the case of a book with folding wing flaps, there may be 3 creases on the back: 1. Crease on the spine of the book. 2. Courtesy crease. 3. Crease for the wing. 3. The operator can move these 3 creases at the same time so that the crease on the spine (crease 1 on the diagram) can be positioned exactly on the edge of the book's spine. ar 1 Re 2. 1.
4.9 "FILE" menu The BGB3202's graphical interface provides an easy and powerful way to manage your jobs. A job can be created (1), opened (2), saved (3) or deleted (4) simply by pressing the corresponding icons. 50 jobs can be saved in memory of the graphical interface. To access the FILE menu, press the button. A B 1 2 3 4 4.9.1 To create and save a new job: icon to create a new job. All the binding and cover clamp parameters for ress the •P the new job will be set to their "AUTO" values.
4.9.2 To open an existing job: • The operator can open an existing job, making it the current job. Saved jobs can be selected from a list that appears on the screen, in alphabetical order. he operator selects the required job by pressing the •T icon. The name of the job is then displayed at the top of the screen. • I f the operator wishes to modify a job, it must first be opened as explained above. The job that has been opened becomes the current job. The required changes can then be made.
4.10 "TIMER" menu The "TIMER" menu can be programmed to start and stop the glue tank heater automatically with no input from the operator. In this way, the glue tank can begin to heat up before the operator arrives, and the glue will be at the right temperature when the operator starts work. When the tank heater starts, the tank enters stand-by mode. The target temperature is set to Min or Max temperature. To access the "TIMER" menu, turn the binder's main switch to the third position (ON 2).
4.11 " menu The "ALARM" menu is accessed by pressing the icon to the right of the screen. This displays the warning and error messages that have occurred since the machine was last switched on, in chronological order. The errors and warnings can be selected to give further information about each message. Move the cursor up by using the button “1” or down by using the button “2”. 1 2 • The flashing indicates that the error and/or warning messages are current.
4.12 "TOOLS" menu To acces the Tools menu, you must press the key The header window enables to : - - on the right of the screen. Restart the binder. Set date and time. Open and close the cover clamps. Know the thickness of the last booklet bound. Push this button to lock the U.I. The screen saver starts. Enter the password 1234 to unlock the U.I. OR ATTENTION : The buttons of this menu are used for maintenance, cleaning, dejam,... DO NOT PUSH THE BUTTONS OF THIS MENU WHEN THE MACHINE IS RUNNING. 4.
4.12.2 Opening/closing the cover clamps: These two buttons open and close the cover clamps. This is useful for cleaning, removing films of glue from the non-stick cover clamp plate. Note: As a safety measure, clean the plate with the interlock open. 4.12.3 Restarting the graphical interface, the PLC and communication between them: In the event of problems, it is possible to: • Restart the touch-screen (UI). To completely reinitialize the UI software. •R estart the binder's computer (PLC).
4.12.5 Accessing the advanced menu: Press the icon to access the technicians' advanced menu. An alphanumeric keyboard will appear on the screen, and a password will be requested. Only qualified technicians will know this password, giving access to the advanced menu. 4.12.6 Exit roller mode: OR These controls are used to clean the output baffle of the Binder. Commande to lower the stop. Commande to lift the stop.
4.12.7 Checking the opening/closing the BBR or Start/Stop the conveyor: Using this function, the BBR initial opening can be adjusted before the book arrives. The BBR can open 5, 10, 15, 20 mm wider than the thikness of the book. Note: The maximum opening is 60 mm. The operator can modify the opening by pressing on left of the button to reduce the value or on right to increase the value. This button is only available if a BBR is connected to the binder.
5. Preparing the binder 5.1 Loading the cover station Suction bar Cover registration guide Front guides Magnetic side guide Cover station extension 1 2 The cover station must be reloaded when there are no more covers on the tray. To do this: • Raise the suction bar. This command is carried out when a pause is requested using the UI (press the button at the bottom right of the screen). • Remove the magnetic side guides. • Place the pile of covers against the front guides and the cover registration guide.
5.2 Adjusting the cover position on the book Front guides 1 Cover registration guide 2 Using the cover guide mounted on the cover station tray, the position of the cover on the book can be adjusted. 1 2 2 knobs on the cover station enables the following adjustments: • The lateral position of the cover in relation to the book. Adjust the position of the cover registration guide using the knurled knob (1) to align the cover correctly on the document. 1 turn of the knob moves the guide 1 mm.
• Lateral position of the cover in the relation to the book : View of book on the conveyor Conveyor drive belt Button correction (1) • Straightening the cover on the book : View of book on the conveyor Conveyor drive belt Button correction (2) • 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. 1 turn of the knob moves the guide 1 mm - 3/64".
5.3 Cover picking and separators 5.3.1 Suction and Blowing suction level: Suction and Blowing can be adjusted together in the UI using the icon menu (see chapter "4.5 ADVANCED" menu", page 45). in the "JOB" With the “AUTO” mode, the suction and blowing level is automatically adjusted according to the cover. It is also possible to adjust manually the suction and blowing level. See the tab below to set manually the suction and blowing level according to the cover paper weight and cover paper width.
5.3.2 Cover separators: Cover separators Registration guide S Rigid separator 9404146 • • Flexible separator 9403785 Adjust the position, number and type of the separators to optimize cover separation. By default, 3 separators 9403785 are installed. To improve the cover picking and avoid miss feed, adjust the position of the separators more to the RH side (close to the registration guide). 5.3.
5.3.4 Cover suction: According to the width of the cover, the operator must adjust the position of the cursor (1) to ensure that the covers are picked up correctly. Cursor (1) Plastic stud (2) The cover leaves the letter D visible Example: Place the covers on the cover station tray. In the above example, the cover leaves the letter "D" visible. Turn cursor (1) counterclockwise and adjust its position so that the letter "D" appears.
5.4 Glue tank 5.4.1 Setting the glue temperature: By default, the gluing temperature is set to 155°C. A technician is able to change the gluing temperature by default according to the used glue (from 130°C to 180°C). However, the operator has the option of adjusting the gluing temperature of ± 15°C using the icon (see chapter "4.6 ADVANCED menu: Managing parameters for cover clamping", page 47.
5.5 easing depth adjustment Adjust the depth of the crease depending on the used cover. For that purpose, use the lever (1). •L ower the lever (1) to increase the pressure in order to obtain sufficient deep notch in the cover. • Raise the lever (1) to decrease the pressure when the cover stays in the matrix.
6. Thanks to the technology used for the BGB3202, some customised bindings using special parameters can be created. 6.1 Bof sewed book In sewed mode, a cover can be applied on a sewed book. The jogger plate is slightly lower than in non-sewed mode and milling is disabled. The edge of the book to be bound is closer to the gluing cylinders; this helps the glue adhere to the paper better. - Accessing the sewed mode : In the advanced menu, clear the selection of the milling function.
6.2 Bof top stitched brochures If the staple is at a distance of 7 mm - 0.27" from the edge, 2mm 0.08" can be milled. 6.3 5mm after milling Binding of top stitched brochures can be made if the distance between the staple and the paper edge AF TER MILL IN G is superior or equal to 5 mm - 0.2". Lgluing only one face For very special applications, a glue film can be applied on one lateral face only. To do this, enter the JOB menu and increase to the maximum the correction of the thickness pile.
6.4 Multicreasing mode The BGB3202 is the first binder on market equipped with a creasing system punch matrix allowing execution of 13 creases on cover. This multi-creasing system is available only if the option is installed on the machine. If the option is installed, the use of Automatic and Advanced menu does not change but 2 icons are added on the screen: - Multi-creasing application. - Doctor booklet application (see chapter "6.5 “Doctor” booklet application", page 85).
• Multi-creasing mode: 13 creases are available in this mode. Each one can be selected to position upwards, downwards or deselected. Length of the front cover Crease on spine of the book Crease in the middle of the spine book Multi-creasing mode Note: - In mode N/1 or 1/N, the length of the front cover has to be clearly notified through the operator. - Keep to position specifications for creases on cover (see chapter "4.6.2.2 Selection and positioning of creases (optional module):", page 49.
6.5 “Doctor” booklet application If option multi-creasing is installed, the BGB3202 can create special applications, like “Doctor” booklets. They are booklets with 3 folding wings: - The first folding wing is inward. - The second corresponds to the booklet thickness. - The third folding wing folds back against the first one and closes the booklet. To access the “Doctor” booklet application, you have to: - Enter the advanced menu of cover nipping then select the module N/1 and 2 creases of the cover.
7. 7.1 Preventive maintenance Daily: - Carriage: Check the condition of the jaws, remove any trace of glue. - Glue tank: Check the glue level before switching on the machine. heck the condition of the clamps and the black non-stick plate: remove - Cover clamp: C any trace of glue. - Output unit: C heck that the baffle plates and guides are clean. Remove any trace of glue. - External waste collector : Shake the filter (cloth bag). Weekly: - General cleaning of the machine.
7.2 Rthe dust bag Note: - The message "Replace the dust bag" appears on the screen. This is a warning message, which means that the binder can continue to operate, but you are strongly advised to replace the bag to avoid adverse binding quality. - Shake the filter (cloth bag) every day to avoid that the message appears untimely. Plastic bag External waste collector 1.19159566 Plastic bag for D elta US 117 V D iam 340mm 1.
7.3 Emptying and refilling the glue tank When the glue starts to oxidise (turning brown), the contents of the tank must be replaced. There is a draining valve under the tank for this purpose. Preliminaries: • The glue must be at the right temperature (depending of glue) and the cylinders must be rotating. • First empty the tank, and then refill it. Emptying: • Raise the top panel and open the door on the front.
Filling: • Close the valve using the key designed for the purpose (CPB ref.: 9403843). • Fill the tank (via both filling areas). Glue Type CP Bourg Ref PLANATOL HM9925 9195046 5005666 9195035 RELIMELT F1 COOLBIND 3730 20 Kg 25 Kg 20 Kg WARNING: When the glue has completely melted, the level should always be between the maximum and minimum levels.
8. S The cover is not square on the paper offset (skewed). The cover is too far on the right. The cover is too far on the left. There is not enough glue on the back of the book. The pages are warped where the glue is applied (spread out). The covers suffer from nail head. Probable cause The cover is not cut square. The cover station and paper pile are not square to the machine. The glue spreader is too high. The paper is too weak for notching. The cover nipping is too hard.
9. GLUING DEFECTS Gaps in glue film Check: - Glue and roller temperature. - Running temperature. - Adhesive level in tank. Honeycomb film Check: - Glue and roller temperature. - Level of adhesive in the tank. - Moisture in the cover or book stock. Feather on book spine Adhesive and/or roller temperature too low. Uneven glue line Insufficient adhesive applied. Nail head Check: - Cover press too tight. - Height of back pressure. Cavity spine Cover press too tight. Sharpen the knife.
BBC Operator Manual Page 92
10. General description The SDD BGB3202 is an online device consisting of two modules: a modified BB3002 Perfect Binder and a Book Compiler (BBC) that compiles sheets or single fold signatures coming from previous device into a stack.
.Omodes Perfect Binding Mode (Online) Covers are printed and manually loaded into the BGB3202 cover feeder. Book blocks are printed sheet by sheet and stacked in the compiling section, then transferred to the BGB3202 clamp, and finally bound in the BGB3202, one book per bind cycle. Book blocks consist of individual cut sheets or signatures. If signatures are used the milling depth must be adapted. Note: In nearline mode, sheets are fed from the BSF instead of a printer. .
Electrical specifications (BBCBBC - Voltage/ Frequency: 1 20 V - 60 Hz (1 phase) 230 V - 50 Hz (1 phase) - Ampere: 2 A at 230 Vac input voltage 4 A at 120 Vac input voltage 9139854A MODEL : BBC 100 - 240 4-2 : 50/60 VOLTS : A Hz : - Power consumption: 500 W 1706 BTU/h Refer to specifications in Installation Manual MADE IN BELGIUM BY B-1340 Ottignies - rue des Technologies, 22 Tel : +32 (0)10 62 22 11 Fax : +32 (0)10 61 36 38 11.4 9139854A ace requirements 0.8m (2.
11.5 Paper size BOOKLET DIMENSIONS S Thickness Min : 195 x 139 mm (7.7 x 5.5") Max : 370 x 320 mm (14.5 x 12.6") 1 to 60 mm ( 0.04 to 2.36") (including “stuff & fluff” – book unevenness). The minimum thickness may be increase depending upon printer timing requirements, or when using very heavy covers or rigid paper. MAX 60mm (2.36") MIN 1mm (0.04") 139 to 320mm (5.5" to 12.60") mm 0 7 5") o 314. t 5 o 19.7" t (7 Note: Specifications for cover are the same as for the BGB3202, see chapter "2.
BBC Input - paper velocity : Input - feed rate : Up to 2000 mm/s Up to 300 sheets per minute (A4 format) Note: Using sheet flipper for all sheets may reduce maximum input rate. Productivity: Up to 300 books per hour Note: May be negatively impacted by printer, by number of creases, or by number of sheets per book. These productivity calculations are carried out under optimum conditions (configuration, paper type, adjustments ,...).
12. USER INTERFACE MENU FOR BBC Main screen 1) Use this button to view the BBC’s main configuration screen. 9 1 8 7 6 5 4 3 2 2) Job validation When the job parameters are defined, this button sends the setup information to the machine. The button is blinks to warnthe user that the setup displayed on the screen is different to the current setup of the machine. In this case, the user has to confirm the new setup to alter the settings in the machine.
5) Sheet thickness Select the approximate sheet thickness (20, 60 or 200 x 1/100mm). This parameter will be used for the Transfer Clamp pre-opening and to adjust the front stop position. • • • The first value should beselected when using normal sheets. The second value should be selected when using perforated and folded sheets. The third value should be selected when using folded sheets without a perforation on the fold, or very heavy sheets.
8) Loading mode Allows the operator to select the BBC’s loading mode: • Online means that book blocks are made sheet by sheet in the BBC compiler and then transferred to the Binder. The manual insertion cover (2) must be closed. (1) (2) Note: In order to work in online mode, the off-line baffle must be removed and replaced by the online baffle (1) supplied with the machine. • Offline means that book blocks are manually loaded into the Binder.
Sheet flipper description: In mode 1toN simplex, sheets are sent face down to the compiler, then transferred to the clamp with the trail edge becoming the book spine (glued side). If desired, the flipper can be activated, so that the leading edge of the sheet becomes the trail edge. If the device before the BBC is cutting the (long) sheets into 2 smaller size ones, flipping every second (sub) sheet will result in the white (unprinted) edge of the sheet being the lead edge for both sub sheets.
Below, some examples regarding the use of the flip function. (see illustrations on following pages). printed with blank lead and trail edges and cut in the middle should be stacked 1 Sheets in the same direction. In this case, the first sheet is not flipped and the second sheet is flipped in order to have the sheets stacked in the same direction. delivered in the wrong direction will be flipped to avoid manual intervention.
Page 103 1 VERSO RHHRHRESHHMIUJKFJ SEHHHHS SRHHHSH SRHHRYRYUKLIIO UKKYUKLKLUY YULLLLLTIK 2 1 FLIP OFF 2 FLIP AREA (Diverter) 1 1 ZERETPGFGZRGZEGGGERGRGHHRG IIEZOOGOO ZEGIPPGIP EFOPFZEGG RECTO 1 2 1 1 1 ZEGIPPGIP 1 EXAMPLE 1 ZERETPGFGZRGZEGG- EFOPFZEGG IIEZOOGOO GERGRGHHRG ZERETPGFGZRGZEGGZEGIPPGIP IIEZOOGOO GERGRGHHRG ZERETPGFGZRGZEGGZEGIPPGIP IIEZOOGOO GERGRGHHRG ZEGIPPGIP IIEZOOGOO RECTO EFOPFZEGG RECTO RECTO EFOPFZEGG ZERETPGFGZRGZEGGEFOPFZEGG RECTO GERGRGHHRG 2 COMPILER AREA Resul
Operator Manual Page 104 1 FLIP OFF FOLDED SHEET FLIP AREA (Diverter) COMPILER AREA Result EXAMPLE 3 EDGE BOUND
Operator Manual Page 105 1 FLIP ON FOLDED SHEET FLIP AREA (Diverter) COMPILER AREA Result EXAMPLE 4 EDGE BOUND
Operator Manual Page 106 2 FLIP ON 2 FLIP OFF 1 1 FOLDED SHEET 2 1 FLIP AREA (Diverter) 2 COMPILER AREA Result 1 2 1 2 1 2 1 2 1 EXAMPLE 5 EDGE BOUND
Operator Manual Page 107 2 1 FLIP ON FLIP OFF 2 FOLDED SHEET 2 1 FLIP AREA (Diverter) 2 COMPILER AREA Result 1 2 1 2 1 2 1 2 1 EXAMPLE 6 EDGE BOUND
12.2 "TOOLS menu To access the "TOOLS" menu, you must use the key The header window is displayed on the screen. on the right of the screen. ATTENTION : The buttons of this menu are used for maintenance, cleaning, dejam,... DO NOT PUSH THE BUTTONS OF THIS MENU WHEN THE MACHINE IS RUNNING. BBC When a BBC is installed, the following actions in this menu can be carried out: This button allows the activation of the purge of the BBC when the process is stopped while a book block is transferring to the binder.
12.3 "PREFERENCES " menu of the BBC This menu enables the binder to be configured according to the operator's preferences. Settings such as the language, units of measurement, start-up mode etc are defined here. Note: When the binder is configured in BBC mode, access to the "PREFERENCES" menu is via the "TOOLS" menu. For this menu, the functions of the binder are described in chapter "4.2 "PREFERENCES" menu", page 33. The only specific function dedicated to the BBC is the paper size used by default.
12.4 "ALARR When an alarm message is displayed on the screen, press the Alarm button. A screen with different messages appears. By pressing the Log button, access to the saved error messages for the BBC or BGB3202 is enabled. Press the blue arrow to return to the current message screen.
. . Magnetic corrugating bars (for machines with Tag 5) The magnetic corrugating bars improve stacking of curled sheets and reduce jams during ejection of thin booklets with curl. The magnetic corrugating bars supplied with the machine, can be used for books less than 45mm thick or curled light paper. Location for storing the bars 13.2 CCguide (B By using both screws (1), adjust the Compiler top guide (2) position so that it is not in contact with the baffle below.
14. JAM CLEARANCE FOR BBC In case of a jam or other problems you can open the Top Cover (1) in order to reach the compiling area. Then open baffle (A), (B) and (C). Baffle (B) must be opened before baffle (C). The cover (2) allows access to the area where the book block is held by the Transfer Clamp. 14.
14.2. Jam clearance in flip area You can also use the knurled Knob (3) to clear the paper path.
14.3 Jam clearance in the Transfer C This button in the TOOLS menu allows the BBC transfer clamp to be opened to remove a book block.
15. TROUBLESHOOTING FOR BBC Printer warning “Empty the external finisher” when the BBC is stopping A FULL signal is sent to the upstream device (printer, BSF,...) when the BBC is cycled down. In this way, tit ensures that the printer will not start because the full signal is active. So, during the BBC cycle down, the message shown on the printer is “Empty the external finisher” during ± 1 second. Note: To enable this function, set to 8 in the BBC tech menu/configuration/option.
15.2 Mechanical troubles for BBC SYMPTOM Paper jams during book block transfer in the clamp. PROBLEM CAUSE The squareness of the side joggers is not correct (side joggers are tighter on the top than on the bottom of the compiler). Paper jams when running light or curled paper. 'Dog ear' on the spine of the book or paper jams when transferring book block to the carriage clamp of the Binder.
ENVIRONMENTAL COMPLIANCE Product reRand diD ENGLISH: Application of this symbol on your equipment is confirmation that you must dispose of this equipment in compliance with agreed national Procedures. In accordance with European legislation dealing with "end of life electrical and electronic equipment", equipment subject to disposal must be managed within agreed procedures. Prior to disposal please contact your local representative for end of life take back information.
DEUTSCH: Geräte die dieses Symbol tragen, müssen den nationalen Richtlinien gemäß entsorgt werden. Den europäischen Bestimmungen zum Umgang mit elektrischen und elektronischen Altgeräten ist Folge zu leisten. Bei der Entsorgung des Geräts den Partner kontak-tieren. ITALIANO: Questo simbolo applicato sulla macchina indica la necessità di smaltire il prodotto in conformità con le normative nazionali vigenti.
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