C.P.Bourg BB3002 PUR Manuel utilisateur

OPERATOR

MANUAL

Initial issue: 05/08

Latest revision: 12/14

9.134.089

For BB3002, BB3102 and BB3202

with PUR VersaPail system and PUR Compact system

Operator Manual

Page 2

Initial issue: 05/08

Latest revision: 11/08

Content of this documentation has a confidential nature and remains the exclusive

property of c.p. bourg s.a. 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.

Operator Manual

Page 3

Initial issue: 05/08

Latest revision: 12/14

TABLE OF CONTENTS

Introduction ...............................................

BB3002

1.1 Warning pictograms .................................... BB3002 10

1.2 Instructions for safe use ................................. BB3002 13

1.3 Specifications for BB3002 with PUR VersaPail System......... BB3002 14

1.4 Specifications for BB3002 with PUR Compact System ......... BB3002 15

1.5 Space requirements for BB3002 with PUR .................. BB3002 16

1.6 What is PUR? ......................................... BB3002 17

1.7 Working with PUR...................................... BB3002 17

2. General description .............................BB3002 18

2.1 Specifications ......................................... BB3002 18

2.2 General description of the binder .......................... BB3002 19

2.3 Description of the gluing process .......................... BB3002 20

2.4 Description of various parts of the binder.................... BB3002 21

2.4.1 "Vibrating" module (jogger): ............................................................................... BB3002 21

2.4.2 Milling module: ................................................................................................... BB3002 21

2.4.3 Glue gun: ........................................................................................................... BB3002 22

2.4.4 Cover clamp: ...................................................................................................... BB3002 22

2.4.5 Creasing module (optional): ............................................................................... BB3002 23

2.4.6 Cover loading: .................................................................................................... BB3002 23

2.4.7 Binder output:..................................................................................................... BB3002 24

2.4.8 Reception of books in the BBR module (optional):............................................ BB3002 24

2.5 PUR C Glue consumption ............................... BB3002 25

3. Using the binder................................BB3002 26

3.1 Operating procedure.................................... BB3002 26

3.1.1 Powering up the binder: ..................................................................................... BB3002 26

3.1.2 Configuring the binder:....................................................................................... BB3002 26

3.1.3 Preparing the binder:.......................................................................................... BB3002 26

3.1.4 Binding a book:................................................................................................... BB3002 26

3.1.5 Switching the binder off:..................................................................................... BB3002 26

3.1.6 To start the Dust Collator .................................................................................. BB3002 27

3.2 Powering up the binder and heating the glue gun . . . . . . . . . . . . . BB3002 28

3.2.1 Heating the glue/gun: ......................................................................................... BB3002 29

3.2.2 Starting the TIMER - main switch in ON2 position:............................................ BB3002 30

3.3 The binder controls ..................................... BB3002 31

3.3.1 Function of the buttons on the loading console: ................................................ BB3002 31

3.3.2 Function of the pedal:......................................................................................... BB3002 32

3.3.3 Indicator light above the loading area: ............................................................... BB3002 32

3.3.4 Safety barriers:................................................................................................... BB3002 32

3.3.5 Emergency stop button: ..................................................................................... BB3002 33

Operator Manual

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Initial issue: 05/08

Latest revision: 12/14

3.3.6 Reinitialising the binder:..................................................................................... BB3002 33

4. Graphical Interface (UI) .......................... BB3002 34

4.1 General description of the graphical interface ................ BB3002 34

4.2 "PREFERENCES" menu ................................ BB3002 37

4.3 AUTOMATIC" menu .................................... BB3002 39

4.3.1 Accessing the automatic menu: ......................................................................... BB3002 39

4.3.2 Programming the automatic menu: .................................................................... BB3002 39

4.4 COUNTER menu ...................................... BB3002 44

4.4.1 UNIT mode:........................................................................................................ BB3002 45

4.4.2 SERIES mode: ................................................................................................... BB3002 46

4.4.3 “SEMI-SERIES” mode:....................................................................................... BB3002 48

4.4.4 Additional functions for PUR C .......................................................................... BB3002 49

4.5 ADVANCED" menu..................................... BB3002 50

4.6 ADVANCED menu: Managing parameters for cover clamping ... BB3002 52

4.6.1 Selecting "with cover" or "without cover" mode ("BLOCK" mode): .................... BB3002 52

4.6.2 In "WITH COVER" mode:................................................................................... BB3002 53

4.6.3 In "WITHOUT COVER" mode: ........................................................................... BB3002 59

4.7 ADVANCED MENU: Managing binding parameters ........... BB3002 60

4.7.1 Setting the carriage movement speed: .............................................................. BB3002 60

4.7.2 Selecting milling and the milling depth:.............................................................. BB3002 61

4.7.3 Setting front and back glue cut-offs:................................................................... BB3002 62

4.7.4 Setting the thickness of the glue film: ................................................................ BB3002 62

4.8 “JOB" menu .......................................... BB3002 63

4.8.1 Correction of the paper pile thickness to be bound ........................................... BB3002 64

4.8.2 Setting the thickness of the glue film: ................................................................ BB3002 65

4.8.3 Setting lateral pressure: ..................................................................................... BB3002 65

4.8.4 Setting the spine pressure: ................................................................................ BB3002 65

4.8.5 Setting the glue drying time before cover nipping:............................................. BB3002 65

4.8.6 Setting the glue drying time during cover nipping:............................................. BB3002 66

4.8.7 Activation/deactivation of the jogger + adjustment of the amplitude of the vibration:BB3002 66

4.8.8 Activation/deactivation of milling + selection of milling depth:............................ BB3002 66

4.8.9 Book output mode: ............................................................................................. BB3002 67

4.8.10 Configuring front and back glue cut-offs: ......................................................... BB3002 67

4.8.11 Adjusting the creasing position: ....................................................................... BB3002 68

4.8.12 Adjusting the cover position: ............................................................................ BB3002 68

4.9 "FILE" menu .......................................... BB3002 69

4.9.1 To create and save a new job:............................................................................ BB3002 69

4.9.2 To open an existing job:...................................................................................... BB3002 70

4.9.3 To delete an existing job:.................................................................................... BB3002 70

4.10 "TIMER" menu ....................................... BB3002 71

4.11 ALARM" menu ....................................... BB3002 72

4.12 "TOOLS" menu ....................................... BB3002 73

4.12.1 Setting the date and time: ................................................................................ BB3002 73

4.12.2 Opening/closing the cover clamps: .................................................................. BB3002 74

4.12.3 Restarting the graphical interface, the PLC and communication between them:BB3002 74

Operator Manual

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Initial issue: 05/08

Latest revision: 12/14

4.12.4 Thickness value of the last booklet bound: ...................................................... BB3002 74

4.12.5 Accessing the advanced menu: ....................................................................... BB3002 75

4.12.6 Exit roller mode: ............................................................................................... BB3002 75

4.12.7 Checking the opening/closing the BBR or Start/Stop the conveyor:................ BB3002 76

5. Preparing the binder ............................ BB3002 77

5.1 Loading the cover station ............................... BB3002 77

5.2 Adjusting the cover position on the book .................... BB3002 78

5.3 Cover picking and separators............................. BB3002 80

5.3.1 Separators:......................................................................................................... BB3002 80

5.3.2 Cover suction:..................................................................................................... BB3002 81

5.4 Not available .......................................... BB3002 82

5.5 Creasing depth adjustment............................... BB3002 83

6. Special applications.............................BB3002 84

6.1 Binding of sewed book .................................. BB3002 84

6.2 Binding of a top stitched brochures ........................ BB3002 85

6.3 Not available .......................................... BB3002 85

6.4 Multicreasing mode..................................... BB3002 86

6.5 “Doctor” booklet application .............................. BB3002 88

7. Using the PUR C Melter..........................BB3002 89

7.1 Refilling the PUR C Melter ............................... BB3002 89

7.1.1 Opening.............................................................................................................. BB3002 89

7.1.2 Closing ............................................................................................................... BB3002 89

7.1.3 Operation with the lid closed.............................................................................. BB3002 89

7.1.4 Extended production stop .................................................................................. BB3002 89

7.2 Purging System Sequence ............................... BB3002 90

7.3 Adjusting the pressure for PUR C Melter .................... BB3002 94

8. Maintenance ...................................BB3002 95

8.1 Preventive maintenance ................................. BB3002 95

8.2 Replacing the dust bag.................................. BB3002 96

8.3 Supplies and Accessories................................ BB3002 97

8.4 Adjusting Temperature on PUR C Melter.................... BB3002 98

8.5 Tips for successful operation:............................. BB3002 99

9. Guides ....................................... BB3002 100

10. Mechanical troubleshooting .................... BB3002 101

11. Common glueing defects ...................... BB3002 102

BBL

12. Using the Binder with the BBL ..................... BBL 104

12.1 Introduction ............................................ BBL 104

Operator Manual

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Initial issue: 05/08

Latest revision: 12/14

12.2 Warning pictograms ..................................... BBL 104

12.3 Ergonomics ............................................ BBL 105

12.4 Easy and flexible operation ............................... BBL 105

12.5 Daily productivity........................................ BBL 105

12.6 Electrical specifications................................... BBL 105

12.7 Space requirements ..................................... BBL 106

12.7.1 BB3102 with EVA System .................................................................................... BBL 106

12.7.2 BB3102 with PUR Compact System.................................................................... BBL 106

12.8 Paper size............................................. BBL 107

12.9 BBL performances ...................................... BBL 108

12.10 BBL loading .......................................... BBL 109

13. User Interface MENU FOR BBL .................... BBL 111

13.1 Main screen ........................................... BBL 111

13.2 "TOOLS" menu ......................................... BBL 113

13.3 "PREFERENCES" menu of the BBL ........................ BBL 114

13.4 "ALARM" menu......................................... BBL 115

14. Troubleshooting Guide BBL ....................... BBL 116

BBC

15. Using the Binder with the BBC.....................BBC 121

15.1 Introduction ............................................BBC 121

15.2 General description......................................BBC 122

15.3 Operation modes .......................................BBC 123

15.3.1 Perfect Binding Mode (On - line)......................................................................... BBC 123

15.3.2 Perfect Binding Mode (Near - line)...................................................................... BBC 123

15.3.3 Stacking/Compiling mode.................................................................................... BBC 123

15.3.4 Padding Mode - (Not available in PUR version).................................................. BBC 123

15.4 Electrical specifications (BBC) .............................BBC 124

15.5 Paper size.............................................BBC 124

15.6 Space requirements .....................................BBC 125

15.6.1 BB3202 with EVA System ................................................................................... BBC 125

15.6.2 BB3202 with PUR Compact System................................................................... BBC 125

15.7 BBC performances ......................................BBC 126

16. User Interface menu for BBC ......................BBC 127

16.1 Main screen ...........................................BBC 127

16.2 "TOOLS" menu ......................................... BBL 135

16.3 "PREFERENCES" menu of the BBC ........................ BBL 136

16.4 "ALARM" menu......................................... BBL 137

17. Jam clearance for BBC ...........................BBC 138

BB3002 with PUR Compact System Operator Card ............140

Operator Manual

Page 7

Initial issue: 05/08

Latest revision: 11/08

Environmental compliance ................................141

Operator Manual

Page 8

Initial issue: 05/08

Latest revision: 11/08

INTRODUCTION

Foreword

On behalf of everyone at CP Bourg, we would like to thank you for choosing a BOURG product

and congratulate you for your choice.

The Bourg Binder 3002 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 touch screen (GUI).

The machine automatically adapts to book thickness (from 1to 60 mm - 0.04" to 2.36") and

ensures a constant productivity of on demand books. Its cover creasing system is

performed by a “knives/matrix” method which guarantees both quality and flexibility.

The BB3002 binder together with the automatic Bourg Book Loader (BBL) form the complete

BB3102 unit. This ergonomic option enables automatic book block feeding into the binder.

See chapter "12. Using the Binder with the BBL", page 104.

The BB3002 binder together with the Bourg Book Compiler (BBC) form the complete

BB3202 unit. This module allows using the BB3002 in in-line mode behind a printer or

nearline behind a sheet feeder.

See chapter "15. Using the Binder with the BBC", page 121.

This manual is a guide to the use of the BB3002/BB3102/BB3202 binder.

Follow the instructions carefully, and you shall obtain years of excellent service from your book

binding system.

Should you have any difficulty using your equipment, please contact us at the addresses given

at the end of the manual to ask for technical assistance. We will be delighted to help.

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 the appropriate precautions.

All the details contained in this publication are based on the most recently available information

at the time of going to press.

We reserve the right to modify the content of this publication at any time, without notice.

Operator Manual

BB3002 Page 9

Initial issue: 05/08

Latest revision: 11/08

BB3002

Operator Manual

BB3002 Page 10

Initial issue: 05/08

Latest revision: 11/08

1.1 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 gun and near the valve for the draining

of the glue gun.

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.

ATTENTION: These safety alert symbols are for your personnal safety.

Never operate without all safety covers in place.

An emergency stop switch (red) located on the top cover allows

the operator to stop the machine at any time or any incident.

ATTENTION: - The room must be equipped with a chimney to evacuate the fume/

vapors outside of the room.

- Compressed air of 6bar (0.6MPa/87psi) is necessary.

- For more information about the glue, see Henkel Purmelt QR3317

Safety Data Sheet.

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