Service Manual BB 3002 11 05 - A4

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 Initial issue: 02/04

Page 0 - ii 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

Page 0 - 1 Latest revision: 12/04
This page is intentionally left blank.

LISTE DE CONTRÔLE DES RÉVISIONS
Page Rev. Page Rev. Page Rev. Page Rev. Page Rev. Page Rev. Page Rev.
0-i 11a/05 4-2 06/05 4-30 11/04 4-58 11/04 4-86 11/04 4-114 11/04 4-142 11/04
0-ii 09/03 4-3 06/05 4-31 11/04 4-59 11/04 4-87 11/04 4-115 11/04 4-143 11/04
0-1 09/03 4-4 06/05 4-32 11/04 4-60 12/04 4-88 11/04 4-116 11/04 4-144 11/04
0-2 09/03 4-5 06/05 4-33 11/04 4-61 12/04 4-89 11/04 4-117 11/04 4-145 11/04
0-3 11/05 4-6 11/04 4-34 11/04 4-62 12/04 4-90 01/05 4-118 11/04 4-146 08/05
0-4 11/05 4-7 11/04 4-35 11/04 4-63 06/05 4-91 11/04 4-119 11/04 4-147 11/04
0-5 11a/05 4-8 11/04 4-36 11/04 4-64 11/04 4-92 11/04 4-120 12/04 4-148 11/04
4-9 11/04 4-37 11/04 4-65 06/05 4-93 11/04 4-121 12/04 4-149 11/04
1-i 06/05 4-10 11/04 4-38 11/04 4-66 12/04 4-94 12/04 4-122 11/04 4-150 11/04
1-ii 10/03 4-11 11/04 4-39 11/04 4-67 12/04 4-95 11/04 4-123 11/04 4-151 11/04
1-1 10/03 4-12 11/04 4-40 11/04 4-68 11/04 4-96 12/04 4-124 11/04 4-152 11/04
1-2 10/03 4-13 11/04 4-41 11/04 4-69 12/04 4-97 11/04 4-125 11/04 4-153 11/04
1-3 10/03 4-14 11/04 4-42 11/04 4-70 12/04 4-98 11/04 4-126 11/04 4-154 11/04
1-4 06/05 4-15 11/04 4-43 11/04 4-71 06/05 4-99 11/04 4-127 11/04 4-155 11/04
1-5 06/05 4-16 11/04 4-44 06/05 4-72 11/04 4-100 11/04 4-128 12/04 4-156 11/04
1-6 10/03 4-17 11/04 4-45 11/04 4-73 09/05 4-101 11/04 4-129 11/04 4-157 11/04
1-7 04/05 4-18 11/04 4-46 11/04 4-74 09/05 4-102 11/04 4-130 11/04 4-158 11/04
1-8 10/03 4-19 11/04 4-47 11/04 4-75 11/04 4-103 11/04 4-131 11/04 4-159 11/05
4-20 11/04 4-48 11/04 4-76 11/04 4-104 11/04 4-132 11/04 4-160 11/04
2-i 10/03 4-21 04/05 4-49 11/04 4-77 11/04 4-105 11/04 4-133 11/04 4-161 11/04
2-ii 10/03 4-22 04/05 4-50 11/04 4-78 11/04 4-106 11/04 4-134 11/04 4-162 11/04
4-23 11/04 4-51 11/04 4-79 11/04 4-107 09/05 4-135 11/04 4-163 06/05
3-i 10/03 4-24 11/04 4-52 11/04 4-80 09/05 4-108 11/04 4-136 11/04 4-164 11/04
3-ii 10/03 4-25 11/04 4-53 11/04 4-81 11/04 4-109 09/05 4-137 11/04 4-165 11/04
4-26 11/04 4-54 11/04 4-82 11/04 4-110 09/05 4-138 11/04 4-166 11/04
4-i 11/05 4-27 11/04 4-55 11/04 4-83 11/04 4-111 11/04 4-139 11/04 4-167 11/04
4-ii 11/04 4-28 08/05 4-56 11/04 4-84 11/04 4-112 09/05 4-140 11/04 4-168 11/04
4-1 06/05 4-29 08/05 4-57 11/04 4-85 11/04 4-113 09/05 4-141 11/04 4-169 11/04
Modifications Initial issue: 02/04

4-170 11/04 5-4 11/05 5-32 09/04 5-60 08/05 5-88 09/04 5-116 11/05 6-4 01/04
4-171 11/04 5-5 06/05 5-33 03/05 5-61 09/04 5-89 01/05 5-117 11/05 6-5 06/05
4-172 11/04 5-6 09/04 5-34 08/05 5-62 09/04 5-90 09/04 5-118 11/05 6-6 08/05
4-173 12/04 5-7 09/04 5-35 08/05 5-63 09/04 5-91 09/04 5-119 11/05 6-7 11/05
4-174 12/04 5-8 03/05 5-36 09/04 5-64 11/04 5-92 09/04 5-120 11/05 6-8 05/05
4-175 12/04 5-9 09/04 5-37 09/04 5-65 10/05 5-93 09/04 5-121 11/05 6-9 01/05
4-176 12/04 5-10 09/04 5-38 03/05 5-66 09/04 5-94 09/04 5-122 11/05 6-10 02/05
4-177 11/04 5-11 01/05 5-39 09/05 5-67 09/04 5-95 09/04 5-123 11/05 6-11 02/05
4-178 12/04 5-12 09/04 5-40 11/05 5-68 06/05 5-96 09/04 5-124 11/05 6-12 01/05
4-179 12/04 5-13 12/04 5-41 11/05 5-69 09/04 5-97 09/04 5-125 11/05 6-13 01/05
4-180 11/04 5-14 09/04 5-42 01/05 5-70 09/04 5-98 06/05 5-126 11/05 6-14 01/04
4-181 11/04 5-15 01/05 5-43 09/05 5-71 09/04 5-99 11/05 5-127 11/05 6-15 01/04
4-182 11/04 5-16 01/05 5-44 11/05 5-72 09/04 5-100 08/05 5-128 11/05 6-16 01/04
4-183 11/04 5-17 09/04 5-45 11/05 5-73 09/04 5-101 11/04 5-129 11/05 6-17 01/05
4-184 11/04 5-18 09/04 5-46 11/04 5-74 06/05 5-102 09/04 5-130 11/05 6-18 01/05
4-185 11/04 5-19 09/04 5-47 03/05 5-75 09/05 5-103 09/04 5-131 11/05 6-19 01/05
4-186 11/04 5-20 10/05 5-48 03/05 5-76 05/05 5-104 09/04 5-132 11/05 6-20 01/05
4-187 11/04 5-21 09/04 5-49 11/05 5-77 05/05 5-105 11/05 5-133 09/04 6-21 01/05
4-188 11/04 5-22 09/04 5-50 03/05 5-78 09/04 5-106 10/05 5-134 06/05 6-22 01/05
4-189 11/04 5-23 03/05 5-51 09/04 5-79 09/05 5-107 11/05 5-135 09/04 6-23 01/05
4-190 11/04 5-24 09/04 5-52 09/04 5-80 09/05 5-108 11/05 5-136 09/04 6-24 01/05
4-191 11/04 5-25 09/04 5-53 09/04 5-81 09/04 5-109 11/05 5-137 09/04 6-25 01/05
5-26 09/04 5-54 09/04 5-82 08/05 5-110 11/05 6-26 01/05
5-i 11/05 5-27 09/04 5-55 09/04 5-83 08/05 5-111 11/05 6-i 11/05 6-27 01/05
5-ii 09/04 5-28 09/04 5-56 09/04 5-84 08/05 5-112 11/05 6-ii 01/04 6-28 01/05
5-1 11/05 5-29 09/04 5-57 09/04 5-85 08/05 5-113 11/05 6-1 08/05 6-29 06/05
5-2 11/05 5-30 09/04 5-58 08/05 5-86 09/05 5-114 11/05 6-2 01/04 6-30 01/05
5-3 11/05 5-31 09/04 5-59 09/04 5-87 09/04 5-115 11/05 6-3 08/05 6-31 03/04
Modifications Initial issue: 02/04

6-32 01/04 7-24 11/04 7-52 06/05 7-80 06/05 7-108 06/05 8-ii 01/04 8-28 09/04
6-33 01/04 7-25 06/05 7-53 06/05 7-81 06/05 7-109 06/05 8-1 06/05 8-29 12/04
7-26 11/04 7-54 06/05 7-82 06/05 7-110 06/05 8-2 01/04 8-30 03/04
7-i 11a/05 7-27 11/04 7-55 06/05 7-83 06/05 7-111 08/04 8-3 03/04 8-31 03/04
7-ii 08/04 7-28 11/04 7-56 06/05 7-84 06/05 7-112 06/05 8-4 01/04 8-32 03/04
7-1 11/04 7-29 11/04 7-57 11/04 7-85 06/05 7-113 08/04 8-5 03/04 8-33 03/04
7-2 06/05 7-30 06/05 7-58 11/04 7-86 06/05 7-114 08/04 8-6 06/05 8-34 06/05
7-3 11/05 7-31 06/05 7-59- 11/04 7-87 06/05 7-115 08/04 8-7 06/05
7-4 11/05 7-32 06/05 7-60 11/04 7-88 06/05 7-116 08/04 8-8 03/04
7-5 06/05 7-33 11/04 7-61 11/04 7-89 06/05 7-117 08/04 8-9 03/04
7-6 06/05 7-34 11/04 7-62 06/05 7-90 06/05 7-118 08/04 8-10 10/04
7-7 11/04 7-35 11/04 7-63 11/04 7-91 08/04 7-119 08/04 8-11 03/04
7-8 11/04 7-36 11/04 7-64 11/04 7-92 08/04 7-120 08/04 8-12 09/04
7-9 11/04 7-37 11/04 7-65 11/04 7-93 08/04 7-121 11a/05 8-13 03/04
7-10 11/04 7-38 11/04 7-66 11/04 7-94 08/04 7-122 08/04 8-14 03/04
7-11 06/05 7-39 11/04 7-67 11/04 7-95 08/04 7-123 06/05 8-15 10/04
7-12 06/05 7-40 11/04 7-68 11/04 7-96 08/04 7-124 06/05 8-16 10/04
7-13 11/04 7-41 11/04 7-69 11/04 7-97 06/05 7-125 06/05 8-17 03/04
7-14 11/04 7-42 06/05 7-70 11/04 7-98 08/04 7-126 06/05 8-18 10/04
7-15 11/04 7-43 06/05 7-71 06/05 7-99 08/04 7-127 06/05 8-19 03/04
7-16 11/04 7-44 11/04 7-72 06/05 7-100 08/04 7-128 06/05 8-20 03/04
7-17 09/05 7-45 11/04 7-73 06/05 7-101 08/04 7-129 06/05 8-21 03/04
7-18 06/05 7-46 11/04 7-74 06/05 7-102 08/04 7-130 06/05 8-22 03/04
7-19 11/04 7-47 11/04 7-75 09/05 7-103 08/04 7-131 03/05 8-23 03/04
7-20 11/04 7-48 06/05 7-76 09/05 7-104 08/04 7-132 08/04 8-24 03/04
7-21 11/04 7-49 06/05 7-77 06/05 7-105 06/05 7-133 08/04 8-25 03/04
7-22 06/05 7-50 06/05 7-78 06/05 7-106 08/04 8-26 03/04
7-23 06/05 7-51 06/05 7-79 06/05 7-107 08/04 8-i 06/05 8-27 03/04

Page 0 - 5 Latest revision: 11a/05
Section 2 :
STATUS INDICATOR RAPS
BLE
ILA
AVA
OT
N
RAPs indication état Initial issue: 02/04

Status indicator RAPs Initial issue: 02/04

Section 3 :
QUALITY RAPS
LE
AB
AIL
AV
T
NO
Quality RAPs Version initiale: 09/03

Page 3 - 0 Dernière révision: 10/03
Quality RAPs Initial issue: 02/04

Section 4:
ADJUSTMENT/REPLACEMENT PROCEDURES
Adjustment/Replacement procedures Initial issue: 06/03


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

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 of the end of travel flag for closure of the cover clamp ...........................................................................81
8.2 Adjustment pre-positioning flag for the cover clamp ..................................................................................................82
8.3 Adjustment of the cover clamp gripping “home” flag .................................................................................................83
8.4 Adjustment of cover clamp parallel alignment ...........................................................................................................84
8.5 Adjustment 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

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

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

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


Mechanical and
electromechanical adjustments


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

travel guides
Purpose : 2
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 : Fig.1
Open the top panel.
Remove the rear panels from the machine.
2
Connect the technician control box to release the brake on REAR VIEW
the movement motor.
Detail A
Procedure : 1
4
1. Position of the “carriage movement”
1
Jogger-side guide : see Fig.1.
• Place a bundle of paper (1) in the carriage clamp
against the “jogger guide” (4).
• 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
3 mm
REAR VIEW

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”.
144mm+/-1
Fig.2

1.2 Adjusting the theoretical position of the Jogger-
side switch (36S01p)
3. Then adjust the support position (2).
Purpose : The switch should operate 10 mm before the carriage
reaches the guide.
This switch sends a signal to the automatic control system to
indicate that the carriage is in the loading position.
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).
Warning : The switch must not be depressed fully. Fig.2
1
10 mm
Clic + 1mm
2 1 Fig.3
93mm+/-1 Fig.1

1.3 Adjustment of the drive-belt tension
Purpose :
Procedure :
The carriage drive belt must be under sufficient tension to
• Tighten the drive belt tensioner bolts (1).
ensure that correct positioning of the carriage is obtained.
• Loosen the three pulley support bolts (2).
Prerequisites :
Initialise the binder; the carriage must be above the jogger • Loosen the three lock-nuts (4) and adjust the drive belt
module. using the bolts (3).
Open the top panel. The drive belt should be tensioned to a value of 475N.
Remove the rear panels from the machine. 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.
24mm
• Then tighten the lock-nuts (4) so that the adjustment is set.
5 kg • Return the binder to normal operating conditions.
24mm+/-3mm
Fig.1
1 2
Fig.2

1.4 Technical features
Braking torque adjustment.
Purpose :
Braking torque is proportional to compression of springs 22;
The movement motor brake is used to stop the carriage such compression can be varied by acting on nuts 23
rapidly when the interlock circuit is opened. (loosen to decrease, tighten to increase).
Compression of the three springs must be uniform.
Prerequisites : Bracking torque : 4Nm.
• Initialise the binder - the carriage must be above the jogger 25 22 23 19
module. +/- 10.5mm

• 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. 0.3mm 40 2
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. 1
Once magnetic gap has been adjusted check that nuts have
been correctly tightened.

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 :
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.
Fig.1

2. JOGGER MODULE
2.1 Adjustment of the jogger plate position

Procedure :
Purpose : • Using the locking bolts (3), lock the electromagnetic core
The air-gap between the core and the vibrating plate of the (1) of the jogger as high up as possible, at the end of the
electromagnet should be 0.4 mm in order to ensure correct slots.
operation of the jogger electromagnet.
• Using the locking bolts (4), adjust the height of the plate (2)
Preliminaries : relative to the core. The air-gap between the core and the
• The interlock must be open or there must be no power electromagnet vibrating plate should be 0.4 mm.
supply to the machine.
• Disconnect the MNL connector from the jogger. • Re-connect the MNL connector.
2 +0.1
2 +0.1
+0 +0
0.4mm 0.4mm
1
4
3
3
1 4

2.2 Positioning of “jogger plate height” flag
• Loosen the pressure bolts on the notched pulley (2).
Purpose : • Turn the notched pulley (2) to align the right edge of the flag
The “Jogger Home” flag determines the lowest point of the with the edge of the sensor (when the roller is against the
jogger plate. cam guide).
Prerequisites : • Then tighten the pressure bolts on the notched pulley (2).
• Remove the rear panels from the machine, plus the right • Return the binder to normal operating conditions.
lateral panel.
• Press the emergency stop button to prevent power
reaching the jogger lift motor. LEFT SIDE VIEW
Procedure :
4
• Manually turn the jogger plate lift shaft until the roller is
against the cam guide (1). When the roller (4) is on
the guide, align the right
1 edge of the flag (5) with
the sensor (3).
4
1
5
4 2
5 3
3
2
Fig.2
1
3
Fig.1

2.3 Adjustment of the drive-belt tension
• Check the drive belt tension by holding it between the
Purpose : thumb and index finger and exerting torsion on it.
This procedure determines the drive belt tension to be The drive belt should pivot through 90° over a distance of
applied to lift the jogger plate. 100 mm (Fig.2).
Prerequisites : • Return the binder to normal operating conditions.

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

2.4 Adjustment of the Jogger plate position
Purpose : • Raise the jogger plate by reducing the milling depth to zero.
When at its highest possible position, the jogger plate should
be at the same height as the top tooth on the milling blade. Warning : The teeth on the milling blade are very sharp.
The jogger plate must also be square to the carriage jaw.
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

The jogger module is fitted to the binder chassis using 3 threaded Pre-adjustment of the jogger plate lateral position :
rods (1). Use these three threaded rods to adjust : • Place the aquare (ref CPB 9941021000) underneath the
• The horizontal position of the jogger plate relative to the jaw on the carriage clamps (as shown in Fig.2).
carriage.
• Adjust the position of the jogger plate using the three
• The height of the jogger plate relative to the top tooth of the threaded rods (1) (Fig.1) so that the shoulder of the jogger
milling blade. plate is set back 1.5 mm in relation to the jaw on the
• The straightness of the jogger plate relative to the carriage carriage clamps.
jaw.
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
1.5 mm
Pre-adjustment of the jogger plate position :
This procedure is used to obtain an approximate setting of
1.5 mm
the jogger plate quickly.
Fig.2

Pre-adjustment of the straightness of the jogger plate :
• Place the square (ref CPB 99941021000) as shown in Fig. 3. • Move the carriage towards the loading zone and measure
• Adjust the position of the jogger plate using the three the height of the jogger plate.
threaded rods (1) (Fig.1) in order to adjust the straightness • The jogger module is fitted to the chassis using 3 threaded
of the jogger plate relative to the jaw on the carriage clamps. rods (Fig.1). Use these three threaded rods to adjust:
Precise adjustment of the jogger plate position : - The height of the jogger plate.
This must be at the same height as the top tooth on
This procedure is used to achieve a precise setting of the position the milling blade (0 mm tolerance: +0 / +0.05 mm).
of the jogger plate.
• Mount two comparators in the carriage clamps as shown in - Straightness of the jogger plate relative to the carriage
(Fig.1). 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.
Fig.1 10+/-1mm
1
10+/-1mm
• Manually turn the milling blade so that the top tooth 1.5 mm
(marked during manufacture) is to the left, on the jogger 1.5 mm
side.
• Zero the two comparators on the top tooth of the milling
blade. Fig.2 Fig.3

3. CARRIAGE
3.1 Adjustment of mobile carriage jaw
Purpose :
• This adjustment will ensure that the paper bundle is Fig.1
gripped correctly when it is being bound.
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 TOP VIEW
correct orientation (Fig.1).
The fact that the jaws are not parallel improves
the grip on large formats, especially during milling
operations.
1
Prerequisites :
• Open the top panel. Fig.2
brake on the movement motor.
• Manually move the carriage over the glue tank to improve
accessibility. 2
• Disconnect the connector (1) from the jaw closure motor. 2.7mm+/-0.2mm
2.7mm+/-0.2mm
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
3
obtained between the grips (2) and the mobile jaw (3) of 4 4
the clamp. 4
• Close the clamps manually.

• The two jaws of the clamp should not appear to be parallel. • Move manually the carriage over the cover clamp module.
On the right hand side of the clamp there should be a • Loosen the screws (5).
distance of 2 mm ± 0.3 mm between the grips of the fixed • Place a gange of 2 mm between the two jaws of the clamp
jaw and the grips of the mobile jaw (Fig.3). If not proceed to on the right side and close the clamps.
procedure #2. • 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).
Note : It is important that they are not parallel, so that a
• Reconnect the motor, close the panel and re-initialise the
good grip of the paper can be achieved. If they
binder.
are not within tolerance, the position of the grips
must be corrected (2).
• Reconnect the motor, close the panel and re-initialise the
binder.
2mm+/-0.3mm
0mm
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 5
5 Fig.4
break on 1.
3.2 Adjustment of the position of the “bundle thickness Paper path direction
measurement” magnetic sensor (33B04p)
Purpose :
Insert 5 sheets of 80 gsm
A linear encoder is fitted to the carriage.
This is used to measure the thickness of the bundle of paper
+0.5 +/- 2mm
in the carriage jaw.
Prerequisites :
Fig.1
brake on the movement motor. Magnetic tape
• Manually move the carriage over the glue tank to improve
accessibility. <1° <3°
Insert 5 sheets of
• If necessary, remove the rear panels from the machine. 80 gsm
Procedure :
• Adjust the position of the linear encoder and magnetic strip
as shown in the figures below.
Maximum default value for alignment Fig 2

<3°
Maximum default value for alignment Fig.3
TOP VIEW

3.3 Mounting the carriage on the beam
Purpose :
Warning : Do not lubricate the beam guide rails.
The carriage is mounted and guided on the beam by means
of 4 rollers. The lower 2 rollers are at a fixed height and
provide a reference setting. The upper rollers are adjustable,
and are used to ensure that there is neither play nor 1
interference between the guide rails and the beam.
The upper roller supports are fitted on cams so that their

1
height may be adjusted. A hole in the supports facilitates
adjustment on the beam.
Prerequisites :
• Connect the technician control box to release the milling
blade and movement brakes.
Procedure :
• If the carriage has been removed, replace the carriage on
the beam :
Fig.1
- Loosen the upper rollers and using the cams raise the
rollers to their maximum height (separate the upper
and lower rollers so that the carriage may be inserted
onto the beam). Note : The correct adjustment is obtained when the rail
- Insert the carriage onto the beam. / roller play is zero and when it is possible to turn
the roller by hand whilst preventing the carriage
• For adjustment of the carriage on the beam: from moving.
- Place a small pin (D 5 mm) (1) in the upper roller
supports and use the cams to reduce the play • Return the binder to normal operating conditions.
between the rollers and the guide rails of the beam.
Once properly adjusted, tighten the roller supports on
the carriage.
4. MILLING
4.1 Adjusting the height of the milling blade
Purpose :
The milling motor must be mounted so that the top tooth of
the milling blade (marked during manufacture) is aligned at
the same height as the jogger plate (at its highest position).
Prerequisites :
• Connect the technician control box in order to bypass the
interlock.
Warning : The teeth on the milling blade are very sharp.
Procedure :
1. Raise the jogger plate to its highest position.
In the technician “STATUS” menu, select the
“JOGGER” module and reduce the height of the milling
to 0 mm.
Fig.1
2. Place one comparator in the carriage clamp (Fig.1).
3. Zero the comparator on the jogger plate.
set to 0

4. Using the technician control box :
- Release the milling blade and movement motor
brakes.
- Open the interlock loop.
5. Manually turn the milling blade so that the top-most tooth

is on the “JOGGER” side.
6. Move the carriage over the milling blade and measure the
separation between the top tooth on the milling blade and
the jogger plate.
The jogger plate must be higher than the top tooth: by
distance of 0 to 0.05 mm.
If necessary, adjust the height and straightness of
the milling blade :
• Loosen the 4 bolts (1).
• Alter the height of the milling blade using the 2
bolts (2) in order to obtain a difference of 0 to 1
0.05 mm.
1
• Also align the milling blade so that it is square to
the carriage. Place a square against the fixed
grips of the carriage (Fig.2) and adjust the
square using the bolts (2).
• Re-tighten the 4 bolts (1).
1 1 Fig.2
2
2

0 -1.1 10. Return the binder to normal operating conditions.
Painted teeth +0.05 -1.15 Painted teeth
Notes : Each component has been fitted and adjusted
on the chassis during manufacture.
There is no need to alter the adjustment of the
threaded rods that have been painted.
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 fitting and alignment of the assemblies on
the chassis must be adjusted by qualified
personnel using suitable tools (micrometers,
comparators, stands etc.).
Fig.3
7. Manually turn the milling blade so that the top tooth is on

the “CASING-IN” side.
8. Measure the distance between the top tooth of the milling

blade and the jogger plate.
- The jogger plate must be higher than the top tooth :
by a distance of 1.1 to 1.15 mm.
- If necessary, adjust the inclination of the milling blade
in order to obtain a difference of 1.1 to 1.15 mm. This
adjustment is made using bolt (1) (Fig.3).
9. Re-check by repeating the procedure from point 4

onwards.

4.2 Adjustment of the counter-cut
6
Purpose : 30
19 3
mm
The distance between the counter-cut and milling blade
should be adjusted to obtain good milling of the spine of the
book.
If this is done, the paper waste produced will be smaller and 2
3
more easily extracted to the waste bag. 8
Prerequisites :
• Open the front panel. 5 1
• Connect the technician control box to release the milling
blade and movement motor brakes (interlock open).
6 Procedure :
30
19 3
mm A. Horizontally :
1. Loosen bolts (1), (2) and (3).
2. Slide the runner (5) to the left, to the end of the slots.
2 3. Check that the counter-cut (6) and fixed grips (8) of the
3
8 clamp are in the -0,3mm now.
If they are not, move the counter-cut laterally in the slots
(3).
5 1 4. Release the milling blade motor brake.

Fig.1 Manually rotate the milling blade in an anti-clockwise
direction and check that the notching tools fit correctly into
the counter-cut notches provided for this purpose.

Warning : The distance between the counter-cut (6) and
the shaft of the motor must be equal to 30
mm ± 1 mm - See Fig.1. If this distance is 1
incorrect, the motor must be moved by 3
loosening the bolts (1) and the position of the
4 2
motor altered using the adjustment bolts (2) -
See Fig.2.
3
Fig.1
1 1
• Feel whether the counter-cut is brushing against the
milling blade by placing an Allen key in the centre bolt
of the milling blade and turning it manually in an anti-
1 1 • Raise the counter-cut by slowly unscrewing bolts (3)
Fig.2 and (1) and by tightening the three bolts (4) until they
2
just come into contact with the top tooth of the milling
blade.
B. Vertically : • Check for contact by slowly turning the milling blade in

This procedure involves adjusting the height of the counter- an anti-clockwise direction (using the Allen key).
cut relative to the milling blade using the bolts (4) (Fig.1).
• Now adjust the tightness of bolts (4) and tighten bolts
• Slightly loosen bolt (1) and bolt (3). (1) and (3) so that the milling blade no longer touches
the counter-cut (2).
• Slowly bring the counter-cut (2) against the milling
blade by gradually unscrewing the three bolts (4) and • Check that the milling blade turns freely after
by tightening bolts (3) and (1). adjustment.

• Adjustment of the slide.
• Bring the slide (1) as close as possible to the milling blade
(2) without touching it.
• Tighten bolts (3) and check that there is no interference

with the milling blade (manually turn the milling blade in an
anti-clockwise direction using an Allen key).
3
1 2
Fig.1

4.3 Adjustment of the height of the notching tools
Purpose : Procedure :
The height of the notching tools must be adjusted so that the • Commence a binder start cycle by loading the clamp with a
spine of the book is scored to provide better adhesion of the bundle of paper with a thickness of 40 mm.
glue. • As soon as part of the book has been notched, press the
emergency stop button.
Preliminaries :
• Connect the technician control box to bypass the interlock
• The counter cut should be adjusted relative to the milling and to release the milling blade and movement motor
blade. brakes.
• The brush and its support must be unscrewed from the • Cautiously open the carriage clamp using the black button
milling blade housing beforehand (right side of the milling on the control console.
blade) (Fig.1).
• Take the bundle out of the clamp and examine the notched
spine of the book. Notches are made using two different
tools. The notches should be 0.8 mm in depth (Fig.2).
0.8 mm
.03 in.
Fig.2
Fig.1

• In order to adjust notching depth :
- Depress the emergency stop button.
- Using a 2 mm Allen key, slacken the pressure bolts
(1). There is lateral access to the pressure bolts on
the hub of the milling blade (Fig.3). 3
- Turn the adjustment bolt (2) in a clockwise direction to
3 2
reduce the depth of notching and in the opposite
direction to increase the depth of notching. 1
- After adjustment, tighten the pressure bolt (1) and 2
check that the notching tools (3) still pass into the Fig.3
notch in the counter-cut (especially if the notching
depth on the paper is more than 0.8 mm).
Notes : The notching tools have two sharpened faces.

They can be reversed when one face has
become worn.
• Re-fit the brush and its support on the milling blade

housing.

4.4 Adjustment of the milling panel
Procedure :
Purpose :
The milling panel is a safety component which protects the
operator against accidents when the milling blade is rotating. • Remove the 3 fixing bolts (1) from the milling blade housing
It also stops waste from the milling blade housing from (Fig.2).
reaching the exterior of the machine during milling of the • Recover the milling panel assembly (2).
book.
The milling panel, when in its closed position, should be 2

mm from the counter-cut (Fig.1). 1
2m
m
1 2
Fig.1
Warning : The teeth on the milling blade are very sharp. Fig.2

• Remove the base panel (3) (Fig.3) of the milling panel
assembly using the 4 bolts (4).
• Adjust the position of the rubber stop (5) so that there is a
gap of 2 mm between the milling panel and the counter-cut.
2m
m
• In order to check the position of the panel, place the unit
(1) without the base panel on the milling blade housing and
measure the gap between the milling blade housing and
the milling panel (Fig.4).
1
3
4
Fig.4
5
Fig.3

4.5 Adjustment of air-gap in the milling motor brake
• Remove the cover (1) that supports the main switch and
Purpose: the door interlock key.
The milling motor is provided with a safety brake that stop

the milling blade in case of an emergency stop.
At power OFF, the brake is activated.
A 24V command allows releasing the brake.
The aim of this procedure is to set the existing air-gap

between the disc Ferodo and the brake jaws.
Procedure N°1 : Checking the air-gap value :

• Open the front door and the top panel.
• Remove the rear covers.
• For safety measures, unplug the milling motor (4x6)
connector.
4X6

• Remove the motor joint (2).
• When brake is activated (at power OFF), measure the air-
gap value between the mobile jaw and the electromagnet.
The air-gap value should be between 0.2 and 0.3 mm all
along the circumference.
• Re-install the motor joint, re-install all covers, plug the 4 x 6
connector and restore the binder to operating conditions.

Procedure N°2 : Changing the air-gap value :
To set the air-gap, remove the milling motor from the binder.
The adjustment screws access can not be gained when the motor • To set the air-gap value :
is inside the machine. - Loosen slightly the screw (1) and adjust the thread rod
(2) depth.
When the motor is removed from the machine : - Tighten the threaded rod (CW) to increase the air-gap
• Remove the notching tool indexation assembly by removing value and loosen the threaded rod (CCW) to decrease
the central screw. the value.
• When the brake is activated (at power OFF), measure the - Tighten the screw (1).
air-gap value between the mobile jaw and the
electromagnet. • Repeat this adjustment for the three threaded rods (2).
The air-gap value should be between 0.2 and 0.3 mm all • With a 24 VDC power supply, energize the brake.
along the circumference.
• Rotate manually the milling blade and check that the
Ferodo disc does not keep sticking against the brake jaws.
The milling blade must be totally free.
• Re-install the joint, re-install the notching tool indexation
assembly and re-install the motor inside the binder.
• Re-install all covers, plug the 4 x 6 connector of the milling
motor and restore the binder to operating conditions.
• Proceed to the adjustment of the notching tool indexation
(Adjustment of the notching tool indexation).
Adjust the height of different modules (jogging plate, drums
of the glue tank, Cover clamp module).

4.6 Adjustment of the notching tool indexation
• Remove the guard plate (2) of the electronic rack.
Purpose:
When the operator does not want to mill the book, the
notching tools are indexed to clean the paper path from
milling tools.
This procedure defines the position of a perforated disc
mounted on the same axis as the milling blade.
The 42B04i sensor detects the position of the notching tool
indexation.
1
Procedure :
• Open the front door and the top panel.
• Remove the rear covers.
• For safety measures, unplug the milling motor (4x6) • Remove the front closure panel (3) from the rack.
connector. • To gain access easily to the adjustment screws of the
• Remove the cover (1) that supports the main switch and notching tool indexation, the plate (4) can be removed from
the door interlock key. inside the electronic rack.
4X6
3

• In the technician menu, “STATUS” menu, select the “Milling
module”. Proceed to the indexation of the notching tools by • If not, adjust the disc (1) position in order to have the (Fig.
2) notching tools at the right position as illustrated on Fig.1.
pressing the 42M02i key.
• The notching tools are indexed to clear the paper path from
the tools see Fig.1.
1
Fig.2
• Press the 42M02i again to check the position of the

tools.
m
• Re-install all covers and panels, plug the 4 x 6 connector of
70m
70mm the milling motor and restore the binder to operating
conditions.
Fig.1

4.7 Replacement of the milling blade
8. Also check the height of the top tooth of the milling blade
Purpose : relative to the jogger plate - see “Adjustment of the height of
Once the milling blade becomes worm it will no longer cut. the milling blade”.
It must then be replaced. 9. Return the binder to normal operating conditions.
Procedure :
1

1. Open the front panel (interlock open).
2. Remove the milling panel assembly using the three bolts 3
(1) - See Fig.1. 2 4
7 6
3. Remove the counter-cut (6) (Fig.2).
• Remove the tube and connectors from the pressure
sensor (7).
4
• Unscrew bolts (3) and (4) and remove the “counter-
cut” assembly.
4. Remove the milling blade. 3
• Unscrew bolts (8) and (5) and remove the milling

blade.
5. Replace the worn milling blade with a new one.
Pay attention to the direction of the milling blade.
Fix the milling blade in place using new bolts (8) and (5).
6. Locate the top tooth (See “Identifying the top tooth of the
milling blade”). 8
7. Refit the counter-cut by tightening bolts (3) and (4). Place 8

the counter-cut correctly relative to the milling blade as 5
indicated in the chapter “Adjustment of the counter-cut”.
Fig.1 Fig.2

4.8 Identifying the top tooth of the milling blade
Purpose : • Place an Allen key on the centre bolt of the milling blade to
This procedure involves identifying the top tooth. turn it manually in an anti-clockwise direction and to sense
This tooth is the reference zero-point for alignment of the when the counter-cut is slightly touching the milling blade.
various modules on the chassis.
• Raise the counter-cut by slowly unscrewing bolts (3) and
Preliminaries : (1) and by tightening the three bolts (4) until they only come
Open the front panel. into contact with one single tooth, the top-most tooth of the
milling blade.
Procedure :
• Slightly loosen bolt (1) and bolt (3). • Mark the tooth.
• Slowly bring the counter-cut (2) against the milling blade by

• Review the adjustments :
gradually unscrewing the three bolts (4) and by tightening
bolts (3) and (1). “Adjustment of the height of the milling blade”.
“Adjustment of the counter-cut”.
“Adjustment of the height of the notching tools”.
“ SUMMARY: ALIGNMENT OF THE VARIOUS MODULES ON THE
BB3002 CHASSIS”.
1
3
Take care not to damage the teeth on the milling blade.
4 2

4.9 Pressure sensor adjustment
Procedure :
5.6.1 Internal dust bag full :
Purpose :
The pressure sensor (45S01p) detects a dust bag nearly full
and sends a message to the touch screen to warn the
operator.
A membrane that warps itself under pressure makes the
pressure sensor. An electrical contact is open or closed
depending on the distortion of the membrane.
The pressure sensor is installed at upstream bag and
measures the air pressure in the bag.
It operates with pressure.

If the dust bag is empty:
The turbine air goes out easily through the bag.
-> There is a low pressure in the sensor.
• In the technical menu, enter the milling module status.
-> It means that electrical contact is open.
• Remove the rear panels.
If the dust bag is full: • Remove the waste bin with the bag (1) (Fig.1).
The turbine air goes out with difficulty.
-> There is a high pressure in the sensor. • Ensure that the extraction waste tube is clear from paper
-> It means that electrical contact is closed. dust.
• Install the perforated jig (2) on the extraction tube not of the
Prerequisite : waste bin.
• Check that the flexible tube is properly connected on the • Run the motors 42M01p and 45M01p by pressing the key
‘HIGH’ entry of the pressure sensor. • Unplug the “faston” terminals (3) (Fig.2) from the pressure
sensor and plug a multimeter instead. Set the multimeter
on ohmmeter and sound signal.

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 Note: Turn the sensor adjustment screw CW in order to
signal from the ohmmeter). On the milling status close the contact earlier.
screen, the signal 45S01p should be illuminated .
• Remove the jig, install the waste bin, connect the pressure
- Remove your(s) finger(s) from the jig. The contact sensor and restore the binder to operating conditions.
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.
2
1
Fig.1 Fig.2

4.9.2 Milling exhaust vent obstructed
7. Go to the technician menu/milling module status (if you do not
Purpose:
used a multimeter).
The pressure sensor (42S01p) detects if the milling exhaust vent 8. Turn the adjustment screw in order to close the contact (sound
is obstructed by paper dust. signal from the ohmmeter).
In this case a message is sent to the touch screen to warn the On the milling status screen the signal 42S01p should be
operator.
Caution: DO NOT BLOW OR SUCK INTO THE illuminated .
SENSOR. Turn the adjustment screw in order to open the contact (sound
RISK TO DAMAGE THE SENSOR. signal).
1. Unplug the flexible tube from the sensor. On the milling statusscreen, the signal 42S01p should be OFF .
2. Put 14 mm of water in the tube. 9. Remove the flexible tube from the sensor and remove the
For that purpose, immerse the tube in the water, then adjust the water.
amount of water by releasing the surplus.
10. Reinstall the tube on the sensor and milling blade housing.
3. Position the water in the middle of the tube.
11. check the adjustment: Run the milling motor, the signal 42s01p
4. Plug the tube on the sensor (on adjustment screw side).
Attention: Only one part of water should be inside the should be illuminated (green) .
tube (see illustration).
Stop the milling motor, the signal 42s01p should be OFF (gray) .
Unplug the “faston” terminal from the pressure sensor and
connect the multimeter.
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.

5. GLUE TANK
Procedure :
5.1 Gluing cylinder height 1. Remove the jogger plate :
In the technician menu’s “STATUS” menu, select the
Purpose : “JOGGER” module and reduce the height of the milling to
The height of the gluing cylinders must be adjusted precisely 0 mm.
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.
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).
• Connect the technician control box in order to bypass the set to 0
interlock.

2. Place 2 comparators in the carriage clamps. 4. Move the carriage over the glue tank and measure the
3. Zero the two comparators on the top tooth of the milling distance between the gluing cylinders and the top tooth of
blade (marked during manufacture). 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
-0.15 mm -1.8mm
1 Fig.1
cylinder 1 cylinder 2
1
Fig.2

5. To adjust the height of the cylinders :
- Slacken off bolts (2) (Fig.3). 6. Also adjust the straightness of the cylinders relative to the
- Loosen the nuts (3). fixed grips of the carriage using bolt 2.
- Using a size 19 open ended spanner adjust the height Re-start at (4) if necessary.
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). ATTENTION: Each component has been fitted and
adjusted on the chassis during
3 manufacture.
There is no need to alter the adjustment
4 of the threaded rods locked using a spot
of colour.
1 If the quality of books produced should
start to fall, attempts should be made to
resolve the problem without altering the
3 adjustment of the various assemblies on
4 the chassis.
The fitment and alignment of the
assemblies on the chassis must be
1 adjusted by qualified personnel using
suitable tools (micrometers, comparators,
Fig.3 stands etc.).
2
7. When the height and square alignment of the cylinders is
correct, return the binder to normal operating conditions.
4 4
Fig.4 Fig.5

5.2 Calibration of the SPINNER height
Procedure :
Purpose :
• Enter the “GLUE TANK SPINNER” menu of the technician
The spinner is the component that determines the thickness
menu.
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.
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.
and to release the milling blade and movement motor
brakes.

Pre-adjustment of the spinner height.
• Place a comparator in the carriage clamp. • Then adjust the straightness of the spinner relative to the
• Move the carriage over the milling blade and zero the grips of the fixed clamp on the carriage.
comparator on the top tooth of the milling blade (on the - Place the square (Ref. CPB 9941021000) on the
jogger side). cylinder of the spinner.
• Then move the carriage over the glue tank and using the - Turn the cam (2) to adjust the straightness of the
comparator measure the height distance between the cylinder relative to the fixed grips of the clamp on the
spinner cylinder and the top tooth of the milling blade. carriage.
• Carry out a mechanical pre-adjustment of the height of the Adjusting the height of the spinner.
spinner using cams (1) and (2).
Adjust the spinner height to 0 mm +/- 1 mm relative to the The height of the spinner can be adjusted very precisely using the
top tooth of the milling blade. spinner calibration menu.
• Using the comparator (zeroed on the top tooth of the milling
Adjusting the square alignment of the spinner. blade) measure the spinner height.
• Leave the comparator in the carriage clamp and move the
carriage slightly towards the cover clamp module. • 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.
Cam 1
Cam 2

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 2
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).
Fig.1

5.4 Fitment of cylinder temperature sensors
Purpose :
The temperature sensors at cylinders 1 and 2 must be fitted
2
correctly in order that they can measure the glue 3
temperature.
Prerequisites :
2 1
• Open the top panel. 3
4
interlock.
1
• The binder must be ready : Green indicator lit (glue up to 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).
Fig.1
• 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). 30mm 3
• Re-tighten the bolt (4).
0.1mm
1
WARNING: The sensor must never touch the cylinder 2 4
(this could activate the safety system of the

“GLUETANK” card).
• Once the correct adjustment has been set, return the
binder to normal operating conditions.
Fig.2 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. WARNING : To avoid any possibility of receiving burns,
• When the tank is empty, close the drain valve and refill the wait until the aluminium container has
tank with fresh glue. 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 Max level
pressing the green button on the loading console.
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.

5.6 Adjustment of pre-scrapers
Purpose :
scraper
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 scraper pin
amount of glue pumped by the cylinder.
Prerequisites :
• The glue tank must be hot.
• Scrapers (5) and (6) must be removed to allow better
access (Fig.2).
Procedure : pre-scraper
• 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. pre-scraper 1 pre-scraper 2
6
It must be parallel to the cylinder. 5
1.5mm 7.5mm
• On cylinder N°2 : 1
3
- Slacken off the bolts (3) and adjust the position of the
pre-scraper so that a distance of 7.5 mm is left cylinder 1 cylinder 2
between the cylinder and the pre-scraper.
It must be parallel to the cylinder.
2 4
Fig.2

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 cut- Fig.1 Front cut off

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.
interlock.
• The glue must be hot and the cylinders must be rotating.

For the first gluing cylinder :
Procedure : • Push on the core by hand to simulate activation of the
- Adjustment of scraper. electromagnet. Measure the distance between the
• When the scraper is raised (electromagnet scraper and the gluing cylinder.
deactivated), measure the distance between the For cylinder 1 : Distance = 0 mm (when glue is hot) - the
scraper and the gluing cylinder. scraper must be against the cylinder (Fig.3).
For cylinder 1 : Distance = 0.5 mm (when glue is hot) (Fig.3). To adjust this distance, slacken off nut (3) and adjust the
depth of the threaded rod (4) (Fig.2).
In order to adjust this distance, slacken off nut (1) and adjust When adjustment is correct, re-tighten the nut (3).
the depth of the threaded rod (2) (Fig.2).
Electromagnet deactivated. Electromagnet activated.

Distance between scraper Distance between scraper
and cylinder = 0.5 mm. and cylinder = 0 mm.
3
4 0. 0m
1 5m m
m
2
Fig.2
Fig.3

- 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
1
electromagnets: - for the second gluing cylinder.
2 - lateral gluing.
• 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).

For the second gluing cylinder :
• Push on the core of the electromagnet by hand to simulate
Procedure : the activation of the electromagnet.
- Adjustment of scraper : Measure the distance between the scraper and the gluing
• When the scraper is raised (electromagnet deactivated) cylinder.
measure the distance between the scraper and the gluing
cylinder. For cylinder 2 : Distance = 1 mm (when glue is hot).
For cylinder 2 : Distance = 5 mm (when glue is hot). In order to adjust this distance, slacken off nut (3) and adjust the
depth of the threaded rod (4).
In order to adjust this distance, slacken off nut (1) and adjust the When the adjustment is correct, re-tighten the nut (3).
depth of the threaded rod (2).
Electromagnet activated. Electromagnet deactivated.

Distance between scraper and cylinder Distance between scraper and cylinder
= 1 mm. = 5 mm.
3
5m
1m
m
4 1
2

5.8 Lateral glue wire
in )
Purpose :
(.02
When lateral gluing is not fitted, a wire is placed just behind
mm
the second gluing cylinder. 1
0 .5
The effect of this wire is to increase the amount of glue on
the two lateral edges of the spine of the booklet.
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 With wire set to the right

5.9 Mounting of glue level sensors
Purpose :
Two sensors, placed at the rear of the tank, check the level
of glue in the tank.
Prerequisites :
The glue must be fully melted (±145°C) and the cylinders
48B02s
48B01s
must be rotating. 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).

Procedure : Electrical Adjustment :
A potentiometer located on the "GLUE TANK" card is used to 48-B01S Min glue level
set the temperature threshold for detecting whether or not 48-B02S Max glue level
the sensors are immersed in glue. 48-B03P Cylinder 1 Temperature
48-B04P 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
48-B04S 1-2
48-B03S
48-B02S
48-B01S
48-B04
S
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 Potentiometer R 102 is used to set the temperature threshold
010 into the rack at the "GLUE TANK" card location and for both glue level probes (minimum level and maximum
connect the "GLUE TANK" card to the extension. 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: Interlock OK.
Yellow led: Glue High Level.
Yellow led: Glue Low Level.
Red Led: Error Drum 1
Red Led: Error Drum 2.
R102
Test point

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

5.10 Adjustment of the position of the sensor for TOP VIEW
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 : Fig.1
8mm+/-1 Screw 1
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.
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 - Bracket (2)
and move to the rear to view the signal on the
paper. Fig.2

6. LATERAL GLUING
• Bind a book without cover and lateral gluing activated.
6.1 Adjusting the fixed cylinder position of the lateral
gluing • 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
Glue
pushed to the
high.
0.5 +/-0.1 1
Correct
2
adjustment
2
Cylinder too far or

0.5 +/-0.1 not enough glue.
1 Lack of glue.
2 Bad moving
speed -> Lack of
glue on the first
1 book (See chapter
“Calibration of
- Loosen both nuts (2). lateral gluing”
- Turn the threated rod (1) to adjust the fixed cylinder (calibration)).
position in order that it is 0.5mm behind the fixed
jaw of the carriage. Proceed to adjutment Adjusting the home sensor 48B09i
Turn the nuts CW to increase the gap. position of the lateral gluing.
Turn the nuts CCW to decrease the gap.

6.2 Synchronization of the lateral glue cut-off on the Procedure #1 : Cut-off Synchronization.
gluing cylinders
1
Purpose :
The aim of this procedure is to synchronize the glue cut-off
on the lateral gluing cylinders. 2
There is only one command for the opening and closing of
the lateral gluing scrapers.
7
On the lateral gluing cylinders : 3
- You should obtain a gap of 0.5 mm between the
6
scraper and the cylinder when the scrapers are open.
- And the scrapers should be in contact with the
cylinders when they are closed. 5
8
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 Fig.2
4
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). • On the lateral gluing fixed head, loosen the middle screw
(1) remove the roller (8), extract the stainless steel cap (2)
1
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.
Fig.1 • Push manually on the solenoid core to simulate a glue cut-off.

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 Screwdriver
the core inside the solenoid, tighten the screws (3) and
install the stainless steel cap (2) and the middle screw (1)
(Fig.2).
• The adjustment is correct if :

- When the solenoid is inactive and the cylinders are
rotating, the amount of glue on cylinders is equal.
5
- When the solenoid is activated, the glue on cylinders
is interrupted. 3
7
Fig.3

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)
5 Fig.4
(Fig.5).
4 2
• In order to adjust this distance, loosen the nut (1) and
3 5
adjust the depth of the threated rod (2) (Fig.4).
• Push on the core by hand to simulate activation of the

solenoid (Fig.4).
1
The scraper should be in contact with the cylinder.
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).
6
Procedure #3 : Solenoid adjustment (see Adjustment of
gluing cylinder glue cut-off scrapers).
End of procedure. 0.5
mm
• Install both small plates (5) above the lateral gluing cylinder
(see Fig.4).
• Attach the spring (6).
• Restore the binder in normal operating conditions.
Fig.5

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 :
1
• Connect the technician control box in order to bypass the Fig.1
interlock.
• The binder must be ready : Green indicator lit (glue up to 1
Procedure :
• Remove the top covers (3) to visualise the glue flow. 2
• By slackening off the bolts (1) (fig.1), it is possible to move
2
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.
Fig.2
• When the adjustment is correct, re-tighten the bolts (1).

Glue surface should be convex
Notes : This procedure should be carried out when the
cylinders are rotating and temperature correct,
Fig.3
in order that the supply of glue to lateral gluing
may be visually observed.

6.4 Separation of lateral gluing cylinders Procedure :
See Preventative and Corrective Maintenance via the U.I.->
Purpose : Advanced Menu : “CALIBRATIONS”->
Technicians can correct the separation distance between the Calibration of lateral gluing
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

6.5 Adjusting the home sensor 48B09i position of the 2. Press the button to do a homing then press the
lateral gluing button to separate the cylinders to the maximum.
3. Use a screwdriver to check that the cylinder support block
Purpose : (1) is not against the glue tank (detail 1).
• If there is a gap between the block and the glue tank,
The home sensor 48B09i limits the displacement of fixed
go to step 5.
cylinder in order to not have the cylinder in contact with the
• If not move the sensor bracket (2) to the rear of the
glue tank.
machine.
Prerequisites : 4. Do the procedure from the step 2 again.
• The binder must be ready: Green indicator lit (glue 5. Restore the binder to operating conditions.
temperature reached, cylinders 1
rotating).
• The following adjustments should be done:
Detail 1
Adjusting the fixed cylinder position of the lateral gluing
Advanced menu :”Calibrations” 3. Calibration of lateral
gluing.
Procedure:
1. Enter the technician menu -> Advanced menu -> Glue
tank.
Detail 2

7. COVER CLAMP
7.1 Adjustment of cover clamp position relative to Prerequisites :
the position of the carriage and to the milling • Open the top panel, open the door at the front, remove the
blade lateral and rear panels.
Purpose :
interlock.
The zero level of the machine is the level of the top tooth on
the milling blade. • Remove the protective panel fitted to the carriage.
There are three adjustments to be carried out in order to
correctly position the cover clamp module relative to the
milling blade :
• 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.

Procedure N°1 : Pre-positioning of the cover clamp module in
the machine 4. Raise the cover clamp unit and open the cover clamp.
1. Re-initialize the binder by pressing the green button on the
loading console. 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
In the technician menu’s “STATUS” menu, select the of 3 times on the icon.
“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).

7. Fix the gauge in the internal threads (5) on the side of the 10. Then carry out pre-adjustment of the cover clamp module :
sides 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.

4
These must both be against the carriage fixed clamp
jaw (see Fig.1).
3 5 1
2
4 To align the cover clamp module clamps with the carriage
3
clamps :
- Loosen the nuts (1) (the upper ones).
- Adjust the alignment using the bolts (2).
Fig.1 - Re-tighten the nuts (1).
5
8. Once the gauge is fixed to the cover clamp module,

remove the pins.
9. Using the technician control box, release the movement 1

motor brake and move the carriage over the cover clamp 3
module. 2
3 1
1 3 Fig.2
Warning : Do not apply excessive force if the jaw of the
fixed clamp on the carriage rub against the
gauge guides. Note : The cover clamp module must be in position

10.2. Carry out pre-adjustment of the cover clamp module 10.3. At the same time, place the square against the fixed
height using the square 99 410 21 000 - see Fig.3. jaw of the carriage clamp (see Fig.3 detail B).
Square 99 410 21 000 has a shoulder of 10 mm. Straighten the non-stick tray of the cover clamp module
It must be possible to insert the shoulder on the square relative to the fixed jaw of the carriage using nuts (1)
between the fixed jaw of the carriage and the non-stick and (3) - See Fig.2.
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).
Detail A
10mm
Detail B
Fig.3

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 - Move the carriage so that it is above the loading area.
height. This operation is carried out using 2 comparators - Using nuts (1) and (2) (See Fig.2) :
fitted in the carriage clamp.
- Release the emergency stop button. - Adjust the height of the cover clamp module so
- Move the carriage so that it is above the loading area. that the non-stick plate is 0.8 mm lower than the
- Lower the cover clamp module to its lowest position. jogger plate level (height of cover clamp module:
- Remove the gauge. ).
- Raise the cover clamp module into position . - Also adjust the square alignment of the cover
- Depress the emergency stop button. clamp module relative to the jaw of the fixed
- Place the two comparators in the carriage clamp and clamp of the carriage.
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

- Release the emergency stop button.
- Once this procedure is complete, lower the cover clamp
- Adjust the cover clamp module heights and check all module once more to its lowest position and bring the
heights on the UI : carriage over the loading area.
- Cover clamp module in position : 0.2 mm.
(when the glue drum is warm)

-0.1mm
-0.2mm

+0mm Zero level -1.7mm
-1.8mm
+0.05mm (coloured tooth)
+0.75 +- 0.05
+10mm up : -0.2mm
-1.1mm 0 (from the
-1.15mm technician menu) down : -1.7mm

Procedure N°3 : Checks on the alignment of cover clamp and
creasing modules relative to the carriage 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
1. Raise the cover clamp unit and open the jaw. clamp module holes.
In the technician menu’s “STATUS” menu, select the 4
“COVERCLAMP” module. 5 1
3
2
4
3
• Raise the cover clamp module to height “3”
by pressing on the icon.
• Open the cover clamp jaw by pressing a maximum of

5
3 times on the icon.
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.

6. Also check the alignment of the creasing module
relative to the carriage. Warning : Do not apply excessive force if the jaw of the
- Depress the emergency stop button. fixed carriage rub against the gauge guides.
- Draw back the cover clamp + gauge to the rear. When both gauge guides are against the fixed carriage jaw,
- Release the emergency stop button. both front edges of the gauge must be against the punch of
- In the technician menu’s “STATUS” menu, select the the creasing module (see Fig.2 and 3).
“CREASING” module and lower the creasing punch.
Warning : Do not crush the gauge with the creasing
punch.
Fixed jaws of carriage
- Bring the cover clamp + gauge against the creasing
punch.
- Using the technician control box, release the
movement motor brake and move the carriage over
Fig.2
The gauge is
against the
creasing punch.
Fig.3

• 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
1 Fig.4
18
Fig.5
2

8. COVER CLAMPS
8.1 Adjustment of the end of travel flag for closure of
the cover clamp 1. Open the cover clamp :
Purpose : In the technician menu’s “STATUS” menu, select the

“COVERCLAMP” menu and open the cover clamps by
Fitted to the rear cover clamp is a flag which, by means of a
pressing once.
sensor, indicates the end of travel for closure of the cover
clamps. Adjustment of this flag is achieved by means of 2
2. Place a 3 mm wedge between the cover clamp.
slots in the rear clamp, to which access may be gained from
above.
3. Close the cover clamp manually.
Prerequisites :
• Open the top panel. 4. Adjust the position of the “close clamp” flag so that the
• Connect the technician control box in order to bypass the status of sensor 54B03p changes when there is a 3 mm
interlock. gap between the jaw.
• Reinitialising the binder.
Move the flag (3) laterally in the slots (5) for this
Procedure : adjustment.
3m
m

8.2 Adjustment pre-positioning flag for the cover
clamp
1. Pre-opening the cover clamp :
Purpose : In the technician menu’s “STATUS” menu, select the
There is a flag which is used for pre-opening the cover clamp “COVERCLAMP” module and pre-open the cover clamp
jaw in accordance with the thickness of the book. by pressing the button.
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
Prerequisites : slackening the bolts (4).
interlock.
• Reinitialising the binder.
40
m
m
Procedure :
4
3
3. Re-initialise the binder and once more press button to

check the pre-opening distance of the cover clamp .

8.3 Adjustment of the cover clamp gripping “home” 1. Open the cover clamp :
flag In the technician menu’s “STATUS” menu, select the
“COVERCLAMP” menu and open the cover clamp by
Purpose : pressing button once.
Cell 54B01p indicates to the automatic control system 2. Depress the emergency stop button.
whether or not the cover clamp module is in the “home”
position. 3. Close the clamps manually so that there is a distance of 2
mm between the jaws of the cover clamp.
The cover clamp is in the “Home” position when: 4. Move the “clamps + panel” assembly until the sensor
- The clamp is closed, 54B01p (1) changes state. When this occurs, the distance
- The “clamps + panel” assembly is set back towards between the clamp and the aluminium blocks (2) should be
the rear of the machine. 3 mm.
Prerequisites : 5. If this distance is not correct, correct the position of the
• Open the top panel. flag (3) by slackening the bolts (4).
interlock. 2 3m
• Reinitialising the binder. m
Procedure : 4 3
1 2m
m+
/-1
2
6. Re-initialise the binder and check the 3 mm distance

between the jaws cover clamp.

8.4 Adjustment of cover clamp parallel alignment
Purpose :
The cover clamp must be mounted in parallel in order to 3. Place both Ø5 cylindrical pins (6) in the holes in the
ensure that cover clamp the cover is performed the same gripping panel provided for this purpose.
pressure along the entire length of the book. 4. Loosen bolts (1) and (2). This releases racks (4) and (5).
Tools :
• Technician’s control box.
• 2 Ø5 cylindrical pins (9231152).
Procedure :
6
1. Open the top panel, remove the right lateral and rear
panels.
2. Open the cover clamp :
1
“COVERCLAMP” module and open the cover clamp by 3
pressing once on . 4
6 2
Fig.1

5. Close the cover clamp : 6. The clamp then closed gently and first come into contact
In the technician menu’s “STATUS” menu, select the with the left pin.
“COVERCLAMP” module and close the cover clamp by
pressing once.
Select 6
1. Drying Time maximum 7
2. Pressure force minimum
In this case, the cover clamp remains closed 1
for 25 sec (time necessary to apply steps
3
6,7,8 and 9). 4
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. 1.

8.5 Adjustment of height of cover clamp relative to
the non-stick plate
Purpose : 2. Remove the upper panel and connect the technician
To prevent premature wear of the cover clamp panel and in control box in order to bypass the interlock.
order to ensure that there is correct gripping of the paper, the 3. On the front clamp (6) :
maximum play between the panel and the clamps must be - Loosen the 4 M4 fixing bolts (1).
0.1 mm. - Adjust the height of the clamp using the two M8 grub
Prerequisites : screws (2). There must be a maximum of 0.1 mm play
between the panel and the jaw over the entire length
• The cover clamp must be parallel.
of the jaw.
• Tools : 0.1 mm thickness gauge. - Tighten the four M4 fixing bolts (1) to set the
Procedure : adjustment.
1. Open the cover clamp to about 50 mm : 4
“COVERCLAMP” module and open the cover clamp by 7 3 1
5
pressing once on the button.
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.

9. COVER CLAMP AND OUTPUT GUIDE LIFT
9.1 Adjustment of the cover clamp lift “HOME”

position
Purpose : • Re-initialize the binder by pressing the green button on the

The “home” position of the cover clamp lift corresponds to loading console.
the position : - Cover clamp module lowered. • Remove the right lateral panel and the rear panel.
- Outlet guide lowered.
• Disconnect the cover clamp lift motor connector.
On the control rod for the cover clamp lift, there is a rotation
• This adjustment is carried out from the rear of the machine
zone of 16°. In this neutral zone, rotation of the shaft does
on the cover clamp side.
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).
Prerequisites :
1
1

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
• The adjustment is carried out by moving the sensor support 4
(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
4
3

9.2 Adjustment of the various heights of the cover
clamp lift
2. Remove the main panel, remove the right lateral and rear
Purpose : panels.
The cover clamp module can be raised to various heights in 3. Connect the technician control box in order to bypass the
order for it to be pressed with more or less force against the interlock.
spine of the book being bound. 4. Disconnect the cover clamp lift motor connector. Manually
Cell 54B05p (5) and a 6-position flag (4) are used to indicate turn the cover clamp lift shaft (1) and align the first cover
the cover clamp height. clamp height marker with the roller (3).
The aim of this procedure is to get the height of the cover
clamp module to correspond to the position of the flag in 5. Re-connect the motor connector to stop the shaft rotating.
sensor 54B05p. 6. Adjust the position of the "cover clamp height flag"
Procedure : (54B05p) so that the first height marker on the cams
corresponds to the first side of the flag.
1. Raise the cover clamp module to height N°1 :
In the technician menu's "STATUS" menu, select the 7. Return the binder to normal operating conditions.
"COVERCLAMP" menu and raise the cover clamp
module to the first height setting by pressing
4 Centre sensor 54B05p
on the first side of the flag.
3
2
3 4
4 1
6 2
5
5 6
3.5 +/- 0.5 mm

9.3 Checking the “Home” and “Cover clamp height”
flags 3. Check the position of the flags in cells 54B04p (cover clamp lift
Home) and 54B05p (cover clamp height).
The aim of this procedure is to check adjustments :
- “Home” position of the cover clamp lift. When the outlet guide (1) is lifted and the roller (2) of the cover
- Height of the cover clamp lift. clamp module is against the cam (3) :
- The “home” flag (4) is still in sensor 54B04p (cover clamp
Procedure N°1 : module lowered).
1. Remove the main panel, remove the right lateral and rear - One side of the flag (5) is in sensor 54B05p to show that
panels. Connect the technician control box in order to the outlet guide (1) is raised.
bypass the interlock. - Both leds are OFF
2. Raise the outlet guide :

1
“COVERCLAMP” menu and raise the cover clamp 2
outlet guide by pressing once on the key.
2 4
5
4
54B04p 54B05p

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
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.

9.4 Adjustment cover clamp lift guide
Purpose : “COVERCLAMP” module and raise the cover clamp
On the cover clamp plate, the guide (4) prevents the cover module to the maximum height by pressing the
clamp module from moving beyond the maximum height and icon .
so falling to the low position.
• Adjust the position of the guide (4) by unscrewing bolts (6)
and leaving a 5 mm gap between the guide (4) and the
Prerequisites : cam (5).
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”.
Procedure :
• Open the top panel, remove the right lateral and rear
panels.
5
interlock.
• Raise the cover clamp module (maximum height).
6
4
4
6
5mm

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. 3
Procedure :
• Re-initialize the binder by pressing the green button on the 1
loading console.
The cover clamp module and the outlet guide initialise in
the “Home” position. 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).
m
1m
4mm 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.
• Push the core (7) (Fig.2) down to the bottom of the Fig.1
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 1
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) 3
when the clamp is opened to 6 mm (using the wedge).
• Return the binder to normal operating conditions. 2
6
7
4
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. 2
• Tighten the shafts (1) onto the sides of the cover clamp
module using bolts (2). 1
• Return the binder to normal operating conditions. 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.
Procedure :
1
6mm
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.

• In order to adjust this setting, slacken off the bolts (1) 4. Carry out an adjustment of the height of the sensor.
and move the sensor support laterally. Once the Cell 60B01p must detect the presence of light and dark
sensor is correctly located, re-tighten bolts (1) to set coloured covers.
the adjustment. 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 The height at which sensor 60B10p is positioned must
and creasing must be calibrated from the therefore be :
technician menu’s “CREASING” menu (see
Calibration of creasing positions) to adjust - Low enough to detect dark coloured covers.
the value of creasing position (theoretical - Take care, however, as if the sensor is too low it
value of 86). 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.
2
8 m
m
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 2
(interlock open).
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 1
resistance.
• Refit the panels and return the binder to normal operating
conditions.
1

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 : 6 5
1. Using the lever (6), adjust the height of the punch to its 3 4
lowest point (Fig.1). Turn the lever (6) in the anti-clockwise 2
direction to adjust the height of the punch at the lowest 1
point. 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 Fig.1
the creasing module.

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 2
1
Fig.2 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) 4
deactivated” position.
• Using the cam (3), align the punch in the matrix

7
(section AA).
A 5
• Re-tighten the bolts (9) to lock the adjustment. Creasing

nip point
9 1 AA
• In order to adjust creasing depth : 1
- Raise the punch (1) by turning the motor shaft (4) 1
3 Creasing
manually. nip point
A
- On each side of the creasing module, loosen both 7
bolts (7) and raise the punch (1) by means of the 2
5
cams (5). 2
- Place a large format sheet of 80 gsm paper 9
between the punch (1) and the matrix (2).
8
- Raise the punch (1) by turning the motor shaft (4) 2
manually to bottom dead centre.
- Lower the punch by simultaneously turning both
cams (5) until resistance is felt.
- Re-tighten the bolts (7) to lock the adjustment.
Fig.4

- Leave the punch in the matrix (at bottom dead - Raise the punch by turning the motor shaft (3)
centre), bring the rear guide shaft (1) against the manually (Fig.6).
matrix (Fig.5). - Lower the punch (1) by manually turning the motor
- Tighten the fixing bolts (2). 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.
2
- 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
2
Fig.5 X X
Fig.6

7. Adjust the punch when the matrix is in the “electro-magnet
activated” position (Fig.7). - If top and bottom creasing is identical, point # 8 is not
necessary.
• Switch the matrix over to the electromagnet activated
position. Turn the motor shaft manually to bring the punch
into the matrix (section AA). Sheet of 80gsm
Fig.8
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 AA
Fig. 9
A
2
Fig.7
1
• In the electromagnet activated position, determine whether Fig.10

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
2
the same in both directions of creasing (Fig.8 & 9).

8. Adjusting the inclination of the punch relative to the matrix : 2
Fig.11 Sheet of 80gsm
1
• Switch the matrix back to the “electromagnet deactivated” 3
position and bring the punch into the matrix.
• 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 :
1
- If the “electromagnet activated” creasing was shallower
Creasing at top Creasing at bottom
than that obtained using “electromagnet deactivated”
electromagnet electromagnet
(Fig.11 & 12), incline the punch forwards towards the activated
deactivated Fig.12
front of the machine.
Fig.13 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 Creasing at bottom
electromagnet electromagnet
deactivated activated Fig.14

• Lower the punch (1) by manually turning the motor shaft so 9. Check the punch matrix height from # 7.
that only a strip of light remains between the punch (1) and 10. Carry out a paper test and check that the creasing depth is the
the matrix (2) and visually check that the two are parallel same in both positions of the matrix.
(Fig.15). Creasing should be quite deep with 80 gsm paper.
• Tighten the four fixing bolts (1) for the two guide panels (2) If the punch height is raised to a maximum using the lever
(Fig.12 & 14). (Fig.1), the creasing should be much lighter.
X X
Fig.15

11.2 Adjustment of the position of the creasing
module relative to the cover clamp module • Raise the cover clamp module fully by
pressing on the icon .
Purpose : • Open the cover clamp jaw by pressing a maximum on
The creasing module must be correctly aligned with the the icon.
carriage so that the cover creasing obtained is parallel with
the length of the book.
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.
4
interlock.
• Remove the protective panel fitted to the carriage. 3 5 1
Procedure : 2
4
3
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.
5
3. Raise the cover clamp unit and open the jaw.
In the technician menu’s “STATUS” menu, select the Fig.1
“COVERCLAMP” module.

4. In the STATUS menu of the technical menu, select the 9. Adjust the alignment of the creasing module relative to the
CREASING module and raise fully the creasing punch. cover clamp module.
5. Using the technician control box, release the milling blade When both gauge guides are against the fixed carriage
brake and the translation carriage brake. 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 The jig is against the fixed
(Fig.1). 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

• Slacken off the four bolts (3) and adjust the distance 10. Adjust the height of the creasing module relative to the
between the creasing module and the punch using the cover transport clamp.
cam (1) - See Fig.4 and 5.
• Adjust the alignment of the creasing module relative to The creasing matrix (1) must be parallel with and 2 mm
the gauge using the cam (1) - See Fig.4 and 5. 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 .
- Move the cover transport clamp towards the creasing
module.
2
3
1 Fig.4
Fig.5

- 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.
1
3
Fig.6 3 3 Fig.7
3
Stiffener
2mm
Fig.8
1

11.3 Procedure for removal of the creasing module
Purpose : Procedure :
The creasing module can be easily removed from the binder
chassis. This enables technicians :
module.
- to replace the module easily or • Remove all electrical connectors from the creasing module
(motor, electro-magnets, cells).
- 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).
Note : To remove the creasing module, it is not • In order to refit the creasing module, tighten the bolts (1),
necessary to de mount the cover station. (2) and (3) and return the binder to normal operating
conditions.
1 2
2
1
3
3
Fig.1 Fig.2
Fig.3

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
Procedure :
1mm
module.
• Manually turn the creasing module drive shaft and lift the
punch to top dead center.
• Adjust the lateral position and height of the slide (2):
2 1mm
- 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). 7 3
2
- Laterally : - Loosen the bolts (5). 1
- Move the support (4) so that
1mm
the panel (7) is guided correctly in a 6

lateral direction by the slides (2).

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).
2
1

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

12. COVER STATION
12.1 Adjusting the position of the cover station Prerequisites :
• The cover clamp module must be correctly fitted relative to
Correct fitting of the cover station is important as it produces the milling blade and the carriage.
correct cover clamp of the cover on a book.
• Loosen the bolts (5) to release the (2) puller from the pre-
Three adjustment procedures must be carried out in order ensure feed.
that there is correct fitment : • 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
2
above the cover transport clamp.
5
- Straightness : The cover station must be mounted square
The fitment must also allow the suction bar
to carry out the transfer of the cover to the 6
cover transport clamp in a correct manner.
- Inclination : The cover station tray must be fixed

horizontally.
Fig.1

Procedure : Perpendicularity of the registration guide relative to the station tray.
• Open the top panel, the right lateral panel and the panel • Move the magnetic guides against the cover station
above the pre-feed and the creasing module. registration guide.
• Connect the technician control box in order to bypass the • Adjust the straightness of the registration guide relative to
interlock. the station tray.
• Initialise the binder by pressing the emergency stop button,
by releasing it just afterwards and by pressing the green - Loosen the bolts (1).
button on the loading panel. - 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

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 5
4
by rotating the cam (8).
7
3. Re-tighten the cam and bolts (7) and (10).
The correct height of the cover station is :
4mm
- The pre-feed suction ramp must be able to pass between 6
the punch and the matrix of the creasing module (punch
raised to top dead centre). 8
- The pre-feed suction bar suction cups must be 4 mm Fig.1

above the cover transport clamp (Fig.1).
A more precise adjustment can also be performed by 9
altering the position of the pre-feed chain guide.
6
- The station must be level. Use level (9) to carry out this
adjustment.
7 8
10
10
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 +/-12.5
5
6
7
B
2
3
4 +/-12.5
5
6
7
Fig.4
1
A

3. Slacken off bolts (1), (3) and (4) and the cams (5) (Fig. 5 Adjustment of the inclination of the station :
& 6). Using the cams (5), adjust the inclination of the cover station tray
4. Using the cams (2), adjust the squareness of the station so that it is fixed horizontally.
relative to the cover clamp module so that :
• The suction pads on the suction bar can travel further 1. Loosen bolts (3) and (4).
than the upper jaw of the cover transport clamp. 2. Adjust the inclination of the cover station tray using the
• Distances (C) and (D) between the front strut of the cams (5).
cover clamp module and the upper tray of the station Use levels (6) and (7) to carry out this adjustment.
are equal (+/- 677 mm) (Fig.6). 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
5
4
5 3
Fig.5
Fig.6
4

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.
- Re-tighten the bolts (6). 2
5
Fig.7

12.2 Adjustment of the cover station register guide
• Button (1) is used to adjust the lateral position of the cover
Purpose : relative to the book.
Using the register guide mounted on the cover station tray, Adjust the position of the register guide using the
the position of the cover on the book can be adjusted. knurled knob (1) to align the cover correctly on the
2 knobs on the cover station allow the following adjustments to be document.
carried out (Fig.1) : View of book on the conveyor
- Squareness of the cover on the book. Fig.2

- The lateral position of the cover relative to the book. 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

1
knurled knob (2) to square the cover correctly relative
to the book.
2
In N/First and Centred modes, straighten the cover as
shown in the diagram (3).
In First/N mode, the correction is reversed.

Prerequisites :
• The cover station must be fitted correctly see “Adjustment
of the position of the cover station”. Offset of covers
• Place covers in the cover station. button (1)
1 mm/turn
Procedure :
1. Start a binder cycle by placing a bundle of paper in the
carriage clamp.
2. Recover the glued book. 1
3. Examine the positioning of the cover on the book (Fig.4) :
- Adjust the offset of the cover relative to the book Screws
using knob (1).
- Straighten the cover on the book using the knob (2). 1
1
Straightening of covers
Note: During transfer of the cover from the pre-feed to button (2)
the cover clamp module, check that the cover
moves in parallel with the cover station register
guide.
2 2
If it does not, the pre-feed and/or cover station 1
vertical guide shafts must be realigned (See 2
Screws
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 2
indexes). If it is not possible, adjust the carriage mechanical
stop. 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

5. Vertically.
During the prefeed lift, the cover path should be observed in 6. Check the procedure by carrying out another cover pick-
order to check that the cover is moved in parallel with the up (press button in the CREASING menu).
register guide (3).
If this is not so, then the prefeed must be re-aligned relative During the pick-up of a cover and its movement using the
to the cover station guide (3). cover transport clamp, the cover should move in parallel
with the cover station register guide.
- Loosen the bolts (1). Adjustment of the register setting may perhaps be
necessary (see chapter : Adjustment of the cover
- Move the prefeed laterally using the tie-rod (2). station register guide). If, despite this adjustment, the
- Re-tighten the bolts (1). 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).
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 8. Re-fit the panels and return the binder to normal operating

3 conditions.

12.4 Cover picking and separators
2. Cover suction :
1. Separators :
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.
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

Procedure :
• Press the button at the bottom of the UI screen to
raise the blower bar.
• Place the covers in the cover station against the register
2
guide.
• Unscrew the cursor (2) and adjust its position to the same
letter as shown on the cover station just next to the cover.
D
• 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

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. A
B
Note : To remove the cover station, it is not necessary
to de-mount the creasing module. F
Prerequisites :
• The binder must be switch OFF.
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. (C), (D), (E)
• 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).

Procedure :
• Remove the four screws (G). • Apply the same procedure in reserve order to re-fit the
cover station.
The cover station is hung by 2 hooks (H) and rests on the Check the height, straightness and inclination of the cover
frame. 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
• Two persons are required to lift up the cover station from its
2 points (H) and then pull it out from the binder.

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
1mm

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

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.

13.3 Adjustment of the suction bar safety switch Procedure :
• Loosen the bolts (1) (Fig.2).
During creasing of a cover, the suction bar is located in front of
the creasing panel cover opening. Any intrusion through this • Move support (2) in the slots until the “CLICK” of the
opening is therefore impossible; there is therefore no possibility of switches (3) is heard when the rollers of the latter fall into
an accident occurring during the creasing of a cover (safety OK). the notch in the rail (4).
The “home” position of the suction bar is the position of the • Re-tighten the bolts (1).
suction bar when it is located in front of the creasing panel
opening. In this position, two cut-off switches activate a safety • Re-fit the panels and return the binder to normal operating
relay supplying the creasing motor. In any position the creasing conditions.
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. 4
Prerequisites : 3 2
• Remove the right lateral panel and the panel above the 1
prefeed.
• Re-initialize the binder by pressing the green button on the
loading console.
4 1
3
Fig.1
2 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 72B03p
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.
Sensor signal = 0 72B02i
Prerequisites :
• Remove the upper closure panel from the BBR head by to
loosening the screws (1).
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 : 1
Pre-positioning of the BBR head in accordance with the 1 Fig.1
thickness of the book by counting of impulses for
sensor 72B03p.

• In the technical menu, enter in the BBR status page.
The icon means that the level is high -> Sensor signal = 1
The icon means that the level is low ->

Sensor signal = 0

Procedure :
Adjusting the head “Home” position : • Loosen the screws of the flag (1) and move it until 72B02i
• Move manually the BBR head until the head baffle is at 10 is illuminated .
mm from the book separator harrow (the BBR head should • Tighten the screws of the flag (1).
not be vertical).
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
10 mm strippers.
• 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 End of procedure :
• Reconnect the motor 72M01p and install the upper closure
panel of the BBR head

14.2 Adjustment of the BBR head vertical position
switch 72S03s
Procedure :
Purpose : This actually involves adjustment of the depression of the
This procedure defines the position of switch 72S03s which switch pin.
detects when the head is vertically aligned.
To do this : - Manually incline the head of the BBR so that it
Prerequisites : is vertical.
- Move the support by loosening screws (2)
• Remove the upper closure panel from the BBR by
laterally until the switch is heard to engage.
loosening the screws (1).
- Move it further 1 mm and fix it in place.
• Unplug the motor 72M01p.
Attention: The switch pin must not be depressed fully.
Finish the procedure by plugging the 72M01p motor and installing

1 the upper closure panel from the BBR.
72S03s
1
2
Clic + 1mm

14.3 Adjusting the BBR book separator harrow end
of travels : bottom dead centre position 72S02s
Purpose : Adjustment of the switch bracket position :

When the BBR book separator harrow is at bottom dead • Move the book separator harrow to the bottom dead
centre, a switch is activated to send a signal to the BBR centre.
automatic control system-it indicates that the book separator The book separator harrow should be 5 mm lower
harrow is lower than the level of the stacking table. than the level of the stacking table.
This involves a safety switch which, when activated, cuts off • Loosen the screws (1) and adjust the switch bracket
the supply to the head movement motor. position so that it is activated when the book separator
harrow is at bottom dead centre.
Procedure : 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”.
72B06i The switch rod must not be depressed fully.
Clic +1mm
72S02s
1

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
72B06i
8m
m
1

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

-0.1mm
-0.2mm

+0mm Zero level -1.7mm
+0.05mm -1.8mm
(coloured tooth)
+0.75 +- 0.05
+10mm up : -0.2mm
-1.1mm 0 (from the
-1.15mm technician menu) down : -1.7mm

Preventative and Corrective
Maintenance via the U.I.


1. INTRODUCTION
This manual will enable you to carry out preventative and • Part Two : CALIBRATIONS :
corrective maintenance on the BB3002 binder.
- Calibration of glue cut-off, jogger vibration frequency etc.
The technician menu used in the graphical user interface (UI) of - Adjustments of specific settings of the binder (gluing
the binder will allow you, for example to : temperature, creasing etc.).
- Calibrate glue cut-off, calibrate the jogger vibration

frequency,… • Part Three : VARIOUS :
- Adjust gluing temperatures. - Configuration of the machine : - Selection of optional

installed elements,...
- Start an endurance test. - Configuration of gluing
- Test some electrical elements of the machine (sensors, AUTO parameters,...
motors,….). - Starting an endurance
-… test,...
The header window of the technician menu is accessible both to Detailed explanations of these three parts are given in the
you and to the operator. It provides options for reinitialising the following chapters.
binder and for setting the date and time.
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….)

2. TECHNICIAN MENU : HEADER WINDOW
2.1 Setting the time and date
To access the technician menu, press the button on the right
of the screen. • To change the time, press the hours, minutes or
The header window is then displayed on the screen. seconds.
A numeric keypad will then appear on the screen.
This header window may be accessed by anyone. The correct time may then be entered.
No password is required in order to access it.
1) To check the time.
The header window is used to 2
2) To cancel the operation.
- Re-initialise the binder,
- Alter the time and date, 3 3) To delete the last number.
- Open and close the cover clamp,
- (To) know the thickness of the last booklet bound. 1
• The operation for changing the date is identical.

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. In the event of problems, it is possible to :
1. Restart the touch screen (UI).
This reinitialises completely the UI software.
This function is useful for cleaning, and for removing
films of glue from the non-stick cover clamp plate. 2. Restart the binder’s computer (PLC).
This reinitialises completely the binder software.
Notes : As a safety measure, clean the plate with the Attention: A power OFF/ON does not reinitialize the
interlock open. 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.

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.

2.5 Accessing the advanced menu
Moves the cursor to the left.
To access the technician menu’s advanced menu, press the
icon.
Moves the cursor to the right.
An alphanumeric keyboard then appears on the screen.
Deletes the character highlighted by the cursor.
You must then enter the password correctly to be allowed to enter
the advanced menu.
Cancels the operation and returns to the header
window of the technician menu.
When the correct password has been entered, you then have
access to the advanced menu.
Validating the password.
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.

2.6 The Structure of the Technician Menu
2.6.1 Accessing the header page of the technician menu : 2.6.3 Password entry :
Press to access the header page of the technician menu.

Enter the password and validate it by pressing .
2.6.2 Accessing the technician menu’s advanced menu :

2.6.4 Entering the advanced technician menu :
Press to access the advanced technician menu.

You can then access all adjustments on the BB3002 binder.

3. ADVANCED MENU OF THE TECHNICIAN MENU
Once the technician menu password has been correctly validated, • Part Three : VARIOUS :
the following window is displayed on the screen.
- 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.).

3.1 Advanced Menu : “STATUS”
The “STATUS” section is used to check that operational status is The different modules of the binder are as follows :
correct : - Covers,
- Carriage,
- for inputs (sensors, switches etc.) and - Jogger module,
- for outputs (by electrically controlling certain motors and - Milling module,
electromagnets).
- Glue tank,
- Carriage movement,
- Cover clamp,
- Cover loading,
- Scoring,
- Cover transport clamps,
- Output unit + conveyor,
- BBR.
This menu is very useful for :

- 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,
Press key 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.

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 :

Note : To return to the general window from the
The icon means that the signal level is high. advanced menu, press icon .
The icon means that the signal level is low.
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.

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 to initialise the clamp.
- 33B02p : Carriage paper presence detector.
- 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.

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.
- 39B01p : Jogger Home sensor.
- 39Y02p : Vibrator.
-> Press to make the jogger plate vibrate.

3.1.4 Milling module :
- 42M01p : Milling motor.
- 45M01p : Waste suction turbine motor.
- 42M02i : Notching tools indexing motor.
- 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).

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.
- 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).

Inventory of outputs :
- 48M01p : Cylinder rotation motor.
Note : - At rest, the activation command for
-> Cylinder rapid rotation command . electromagnets is .
-> Cylinder slow rotation command . - When an electromagnet is activated, the
command changes to .
- Warning , maximum 3 seconds activation of
- 48M02b : Lateral gluing setup motor. electromagnet.
-> Lateral gluing return home command.
- 48E02p : Cylinder 1 heating resistance.
-> Lateral gluing cylinder maximum separation
distance command. - 48E03p : Cylinder 2 heating resistance.
-> Bring lateral gluing cylinders together command.
Note : Press the icon at the bottom of the screen
- 48M03i : Spinner height setup motor. to heat the cylinders.
-> Rise or fall of spinner cylinder command.
-> Spinner home command. - 48E01p + 48E05p : Cylinder 1 resistance command.

In normal use conditions, the heating of
the glue tank bottom is always
- 48Y01p : Control of activation of cylinder 1 glue cut- activated.
off.
Notes : Wait until the glue is hot before activating
- 48Y02p : Control of activation of lateral gluing glue outputs.
cut-off.
- 48Y03p : Control of activation of cylinder 2 glue cut-

off.

3.1.6 Carriage Movement :
- 36B03p : Movement encoder.
- 36B04p : Book length detection sensor.
- 36S01p : Movement upstream end of travel.
- 36M01p : Carriage movement motor.
-> Command for moving carriage to the left - slow
speed.
-> Command for moving carriage to the right -
slow speed.
-> Carriage home position command.

3.1.7 Cover clamp :
- 54M02p : Clamp motor.
-> 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

Inventory of inputs : mm.
- 54B01p : Cover clamp Home sensor.
- 54B06p : Pre-positioning of cover clamp.
- 54M03p : Cover clamp positioning motor.
- 54B03p : Cover clamp closed sensor.
-> Home positioning command for cover clamp
- 54B05p : Detection of cover clamp + outlet roller raised (“ready to discharge a book” position).
positions.
-> Cover clamps movement command in centred
- 54B04p : Cover clamp Home sensor. position.
Inventory of outputs : -> Cover clamps movement command in position.

- 54M01p : Cover clamp module lift and roller lift motor.
-> Cover clamp lift command.

Cover clamp module testing :
-> Cover clamp descent command. - Command to start an endurance test.
-> Roller lift command. - Command to stop an endurance test.
-> Roller descent command.

3.1.8 Cover picking :
- 57M02p : Suction turbine motor.
-> Turbine start and stop command.
-> Suction increase or decrease command.
- 57Y01p : Blowing bar lifting electromagnet.

-> Electromagnet activation command.
(0) : Electromagnet deactivated.
(1) : Electromagnet activated
Warning : Maximum 3 second activation of the

electromagnet.
- 57Y02p : Turbine solenoid valve.

-> Solenoid activation command.
At rest (0) -> suction is produced using the

Inventory of inputs : suction bar.
- 57B01p : Cover picking home sensor. When activated (1) -> suction is switched to the
- 57B02p : Cover pick-up detection. surrounding air.
Inventory of outputs : Warning : Maximum 3 seconds activation of the

- 57M01p : Cover pick-up drive motor. electromagnet.
-> Cover picking return home command.
-> Cover picking simulation command.

3.1.9 Scoring :
- 57Y01p : Reverse Scoring direction electromagnet.

(1) : Electromagnet activated
Warning : - 3 seconds maximum activation of

electromagnet.
- Do not reverse the creasing direction when
the motor is running.
- 63B01p : Scoring punch position 1 sensor.
- 63M01p : Scoring motor.
-> 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.

3.1.10 Cover Transport :
- 60Y01p : Clamp opening electromagnet.
(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 : No cover (Miss).

- 60B01p : Cover detection in the transport clamp.
- 60B02p : Cover transport clamp home sensor.
- 60B03p : Detection of zone where there is no 1 cover.
interference of the cover transport with the
carriage.
Inventory of outputs : 2 covers (Double).

- 60M01p : Scoring motor.
-> Command for forward movement of clamp.
-> Command for backward movement of clamp.
-> Command for Cover transport clamp home
position.

3.1.11 Outlet and conveyor :
- 69B01p : Book ejection detection.
- 79B01p : Detection of presence of book on output
conveyor.
- 79M01p : Output conveyor drive motor.
-> Motor start and stop command.

3.1.12 BBR :
- 72M01i : BBR head positioning and drive depending on
Software
version thickness of the book.
implement -> Command for backward movement of head
ed in
BBR.
(Thick books).
-> Command for forwards movement of head
(Thin books).
- 72M02p : Book separator harrow lift/descent drive

(separation of books).
-> Book separator harrow lift command.
-> Book separator harrow descent command.
- 79M01p : Output conveyor drive motor.
- 79B01p : Detection of presence of book on output
conveyor. -> Motor start and stop command.
- 72B01p : Book at inlet to BBR detection sensor.
- 72B02i : Head Home position sensor. BBR testing :
- 72B03p : Head positioning sensor - Command to start an endurance test.
(depending on thickness).
- 72B06i : Book separator harrow TDC detection. - Command to stop an endurance.
- 72B08p : Full detection. - Command for BBR home position.
- 72S01s : Emergency stop switch.

- 72S02s : Switch. Book separator harrow BDC detection
Notes : This screen is only available if a BBR is
switch.
connected to the binder.
- 72S03s : Book brought to vertical detection.

3.2 Advanced Menu : “CALIBRATIONS”
6. Calibration of carriage braking.

7. Calibration and adjustment of screen brightness.
1 4 We shall look again at each of these menus in greater detail later.

2 5
3 6
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.

3.2.1 Setting the gluing temperature :
• Enter the “GLUE TEMPERATURE” menu of the technician This allows you to :
menu. 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.
2. Add some extra heating time to ensure that the glue

temperature is homogeneous throughout the tank.
The following image will then appear on the screen. 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.

3.2.2 Calibration of the SPINNER height : Procedure :
• Enter the “GLUE TANK SPINNER” menu on the technician
The spinner is the component that determines the thickness of the menu.
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.
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
brakes. The following screen is displayed.

Mechanical pre-adjustment of the spinner height : Adjusting the height of the spinner :
• Place a comparator (PN 9 591 153) in the carriage clamp. Eccentric 1
• 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 Eccentric 2
cylinder and the highest tooth of the milling blade.
• 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 height of the spinner can be adjusted very precisely using the
the fixed clamp on the carriage. spinner calibration menu.
- 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).

• 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.

3.2.3 Calibration of glue cut-offs :
Each of these calibrations can be further divided into three modes :
This calibration is used to cut off the film of glue on the spine of 5. “Notched and variable speed” mode.
the book in accordance with the glue cut offs required by the 6. “Un-notched and high speed” mode.
operator.
7. “Notched and low speed” mode.
To enter the glue cut-off calibration menu, press the key “GLUE
TANK SCRAPERS”. 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 6 7
Calibration of glue cut-off is divided into four parts :

1. Calibration of lateral gluing.
2. Calibration of the first cylinder. Correction of glue cut-offs.
3. Calibration of the second cylinder.
4. Calibration of cylinders 1 + 2. 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.

Sign convention for correction of glue cut-off :
Example: - Front cut off : measured = 20 mm.
During calibration, the distance between the glue-cut-off and the Desired cut-off: 15 mm.
edge of the book must be 15 mm , both to the front and
rear. Reduce the glue cut-off length
-> correction = -5.
If this is not the case, a correction must be made in order that cut-
off takes place at the correct location. - Rear cut-off : measured = 12 mm.
Desired cut-off : 15 mm.
The purpose of this calibration is simply to determine the
corrections to be made to ensure that cut-off occurs at the Increase the glue cut-off length
required point. -> correction = 3.
Front glue cut off : 20mm

Negative correction : - 5mm
15 15
Correction of glue cut-offs.

12 Rear glue cut off : 12mm 20
Positive correction: Increases the glue-cut-off length. Positive correction : + 3mm
Negative correction: Reduces the glue-cut-off length.

Elements that influence the glue cut-off :
So - In the “un-notched and variable speed” mode, the
The following elements influence glue cut-off : speed of carriage movement is always at a
• Carriage movement speed. maximum. A single calibration using a 5 mm
booklet is required.
• The amount of glue to be applied to the spine of the book
(will vary depending on the thickness of the book). - In the “notched at slow speed” mode, the speed
The thicker book, the more glue that is to be applied to the of carriage movement is always at a minimum.
spine. A single calibration using a 5 mm booklet is
required.
The speed of movement of the carriage itself varies depending on
the thickness of the book. (See calibration of lateral gluing).
The carriage speed decrease with the increasing

of the booklet thickness
Carriage speed
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.

Procedure to follow for calibration of glue cut-offs :
Prerequisites : - In notched and variable speed mode :
• The binder must be ready : Green indicator lit (glue up to
temperature, cylinders rotating). • Press key to enter “Notched and variable speed”
• Connect the technician control box to bypass the interlock mode.
brakes. • Take a bundle of paper of 5 mm thickness and place it in
• Open the top panel. the carriage clamp.
• The height and straightness of the spinner must be correct • Begin a gluing cycle. The gluing mode will then be in
(see Calibration of the SPINNER height). “BLOCK mode”, notched and the carriage will move at a
variable speed.
1. Calibration of the first gluing cylinder
• To reduce book drying time above cover clamp, press the
• Press key to access calibration of the first cylinder. 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.

- In un-notched and variable speed mode : - In notched and low speed mode :
• Press key to enter “un-notched and maximum • Press key to enter “Notched and minimum speed”
speed” mode. mode.
• Take a bundle of paper of 5 mm thickness and place it in • Take a bundle of paper of 5 mm thickness and place it in
the carriage clamp. Withdraw your hands from the loading the carriage clamp. Withdraw your hands from the loading
area and start a gluing cycle. The gluing mode will then be area and start a gluing cycle. The gluing mode will then be
in “BLOCK mode”, un-notched and the carriage will move in “BLOCK mode”, notched and the carriage will move at
at maximum speed. minimum speed.
• Release the book that is produced and correct the glue cut- • Release the book that is produced and correct the glue cut-
off length if necessary. Front and rear glue cut-offs must be off length if necessary.
15 mm from the edge of the booklet. 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 • Repeat the operation using bundles of paper of 25 mm and
only). 45 mm thickness (Correction on the rear glue cut-off only).

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

3. Calibration of lateral gluing
A. Separation of lateral gluing cylinders : Changing the lateral gluing cylinder separation gap correction
value :
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 To validate.
You may correct the lateral gluing cylinder separation gap : Notes : For correct lateral gluing, adjust the gap
separating the cylinders so that once the
When booklets are being glued the cylinders are separated by : key is pressed, both of the films of glue on each
the thickness of the book + the correction made by a technician.
of the cylinders just touch one another.

B. Separation of lateral gluing cylinders according to the booklet • When the correction is zero :
thickness :
The distance between the lateral gluing cylinders is
When the carriage clamp closes, the bottom of the pile (not equal to the measured paper pile thickness at closing of
gripped in the clamp) to be bound is larger than the paper the carriage.
thickness in the clamp.
• When the correction is different than zero :
To take this situation into account, a correction on the lateral The distance between the lateral gluing cylinders is
gluing cylinders separation can be done for each booklet equal to :
The measured paper pile thickness at closing of the

thickness by using icon . carriage.
+
A correction depending on the measured thickness.
When correction = 1 :
if measured thickness is 0 mm -> correction is 0.0 mm.
When correction = 2 :
61
60
Correction +1
Cylinders gap
30.5
30
Correction 0
Book thickness
30 60

C. Adjustment of displacement speed for the lateral qluing cylinder In this case, decrease the speed of the cylinder movement by
When books of different thicknesses are bound, the mobile using the icon (value by default : 10).
cylinder moves depending on the new book thickness to be
bound.
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

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

speed” mode.
or key - to enter “Notched and minimum speed”

mode.
• 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 to enter “Notched and variable speed”

mode.
• Calibration of lateral gluing then follows the usual

procedure using bundles of paper of 5, 25 mm thickness.

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.

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.
5. Remove the cover from the clamp and

5 cm
measure the distance between the score and
6 the edge of the cover.
Enter this value in the UI (see 5).
The value in grey (86.0) is the theoretical
5 value.
6. The final operation involves correcting the position of creasing

Cover with creasing centred on the spine of the book.
relative to cover clamp 3 4 - If the correction is zero, the creasing on the spine will be
spaced at the thickness of the booklet.
1. Press key . - If there is a positive correction, the space between creasing
The binder then automatically picks up and scores the cover. will be greater than the thickness of the booklet.
The creasing on the cover is then centred relative to the - If there is a negative correction, the space between
cover clamp. 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
3. Align the cover clamp with the fixed carriage clamps. the spine of the booklet.
Adjust the alignment using key .

3.2.5 Calibration of the Jogging vibration frequency :
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 self-
adhesive 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.

3.2.6 Calibration of carriage braking :
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.

3.2.7 Parameterisation of the touch-screen :
In order to gain access to the touch screen, press the “TOUCH Two adjustments may be carried out :
SCREEN” key.
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.

3.3 Advanced Menu : “VARIOUS”
This menu is used to adjust some of the binder’s parameters.
3. Save the current “Calibrations” menu settings in memory
in the technician menu.
To access the “VARIOUS “ menu, press button .
When done after glue cutt-off calibration, this operation
define the AUTO parameters to save these
adjustments.
1 5 4. Delete the current settings in the “Calibrations” menu in

order to restore the settings saved in (3).
2 6
A confirmation message appears to delete the current
3 7
settings and restore the saved settings.
4 8
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.).
This menu allows you to : 7. Change the machine counter.
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).

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.

3.3.2 Define parameters of the AUTOMATIC menu:
In the ‘AUTO’ menu or during the creation of a new task (by • The following window will then appear on the screen.
pressing key ), the parameters for cover clamp and gluing will The technician can now define the ‘AUTO’ parameter
be reinitialized to their ‘AUTO’ values. values.
This menu defines the value of the ‘AUTO’ parameters. These parameter values will then be used during creation of a
new task or in the AUTOMATIC menu.
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.

The 6 parameters that change with the booklet thickness are the These are for each parameter, the recommended ‘AUTO’ value to
followings: be entered :
- Thickness of the glue film.
- Cover clamp dorsal pressure. Thickness of the glue film.
- Padding drying time.
- Drying time before cover clamp.
- Drying time during cover clamp.
For each parameter, the technician should defined its value:

- For a thickness from 0 to 15 mm.
- For the default value, i.e. the parameter value when
operator switches from ‘AUTO’ mode to manual mode.
Cover clamp lateral pressure.

Cover clamp dorsal pressure. Drying time before cover clamp.
Padding drying time.

Drying time during cover clamp.

To return to the first window from the ‘AUTO’ parameters
definition, press key .

3.3.3 Selection of optional items :
You will then be able to select the optional elements that are
At installation of the binder at the client’s premises you should installed on the binder.
select the optional items fitted to the machine.
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.

3.3.4 Binder counter :
The binder is provided with a counter that totals the numbers of The screen will then display the total number of bindings carried
bindings carried out. out.
This counter may be accessed at any time.
Make entries into the counter that is displayed to change the
In order to access the binder counter, press “MACHINE counter value.
COUNTER”.
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.

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 .


Section 5 :
SPARE PARTS
Spare Parts Initial issue: 05/03


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
3. Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
PL3.1 Carriage (part 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4. Jogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
PL4.1 Jogger (part 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
PL4.2 Jogger (part 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

PL4.3 Jogger (part 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5. Notching/Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
PL5.1.1 Notching/Milling (without Tag 19) (part 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
PL5.1.2 Notching/Milling (with Tag 19) (part 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
PL5.2 Notching/Milling (part 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
PL5.3 Notching/Milling (part 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
6. Glue tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

PL6.1 Glue tank (part 1 of 14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
PL6.3 Glue tank - lateral gluing (optional) (part 3 of 14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
PL6.10 Glue tank (part 10 of 14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
7. Cover nipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

PL7.1 Cover nipping (part 1 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

PL7.10 Cover nipping (part 10 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
8. Cover transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

PL8.1 Cover transport (part 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
9. Suction bar drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

PL9.1 Suction bar drive system (part 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
10. Cover station (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

PL10.1 Cover station (part 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
11. cover suction / blower turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

PL11.1 cover suction / blower turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
12. Scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

PL12.1 Scoring (part 1 of 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
PL12.8 Creasing (part 8 of 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
13. Output & conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

PL13.1 Output & conveyor (part 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
PL13.2 Output & conveyor (part 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

14. Output unit (bottom) optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
PL14.1 Output unit (bottom) optional (part 1 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
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

INTRODUCTION This symbol means item 4 is a painted part.
All part numbers corresponding to parts which are
4 painted in different colors depending on machine ver-
Symbols and legends sion do require a “color” suffix.
3 This symbol refers to a spare with exact description

and part number listed on the page.
- AF For blue machines
S10
This symbol refers to common hardware. List, descrip-
W8 tiption and part numbers of common hardware is in a
separate section at the end of the spare parts manual.
N16
This symbol means item 4 is affected by a configura- For example, to order the front door assy 9403883, you should
tion change described by tag-3. order the part 9403883-AF.
4 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).
This symbol means item 5 is to be used when tag-3

5 3 is not crossed.(For tag description see "tag significa-
tion" section 6).
This symbol means that replacement of part 10

10 3.9 requires an adjustment. It is available on section 4
chapter 3.9 in the service manual.

1. COVERS
See PL1.1
See PL1.3
See PL1.1
See PL1.2
Spare parts Initial issue: 05/03

PL1.1 Covers (part 1 of 10)
7 1 9146339 Emergency button

1 2 9422990
3 9422991
4 9146354
6 9413733 Quarter turn lock assy
7 9139707
8 9230354
For the blue machines
5 9403885-AF
9 9403897-AF
4
N006 W185 8
N006 W185 8 8
8
3
8 8
9 C431 S377

OR
S377
S377
S377
5 1 1
S378
2
S378
1 9146373 Actuator black IP40
2 9432557 Safety curtain assembly
S377 3 NA
5 9422996 Dual button board
6 9199448 Rubber bumper
S551
S551
4 9403925-AF Loading area extension
S551 6
4
W186 S441
W186 S551
S551 S441

See PL1.4
1
2
2
W185
S464
See PL1.5
1
2
2
W185
S464
1 9201665 Actuator shaft
2 9261139 Actuator shaft spacer

1 9115031
S378 2 9422990
S472 3 9199985 Gas spring
6 9261850
5 1 7 9203754
4 For the blue machines
S378 4 9231000-AF
5 9403886-AF
S378
S472
1
W187
W185
2
S464 S163 S464
W187 S481
W187
W185
7
S464 S163 6
3
S481
W187
W185
S464 6

2
S377
S469 S472
W185 See PL1.4
N006
3
R431 S516
1
W003
S472 N005
See PL1.4
S377 Plexi cover can

not be replaced
W003
1 9146366 Interlock switch

2 9413733 Quarter turn lock assy N005
4 9104114
4
3 9414070-AF
S374
W187

See PL1.7
See PL1.7
See PL1.9
See PL1.9
See PL1.7
See PL1.8
See PL1.10
See PL1.9

S377
S377
S378
S377 7
2
R431
5 R431
5 R431
4
S378
W182
R431
S378 N005
S378
S378
8 5
S462
S461 S377 6
9
8 9
9 6
S377
R431
6 3 S377
1 5 9413733 Quarter turn lock assy
S377 C431 6 9199448 Rubber stop
7 9199807 Rubber stop D15
8 9150065 Microswitch
9 9260831 microswitch bracket
6
S377
1 9414058-AF
S377 2 9414064-AF
3 9414063-AF
4 9414062-AF
S377

4 2
S467
W185 S516
S467
W185
S516
1
S377
S377
S515
3
S515
S377
S377
S378
7
S378
9
1 9115026 Hinge 100D + spring 5
2 9115027 Hinge arm
3 9146379
4 9146366 Interlock switch
5 9104106 Verschlub BDF
6 9104105 Snapin handle
9 9261039 Rubber distance 5mm
7 9403883-AF
8 9414066-AF
9 6


6 2985276

1 9230967-AF
2 9414056-AF
3 9231072-AK
S304 4 9403879-AF
S304
S304
S304
R431 4
5 R431
6
S377
R431
S459
2
S459 S377
W185
S459
W185 W185
S459
W185
S377
S377 3
S377
S377

S472
W186 3
2
S472
S472
S472 W186
W186
W186
R431
S377
S472
R431
W185
S377 W186 S464
1
W185
S464

3 9403882
S377
2 9414060-AF
S377

2. DRIVE SYSTEM

PL2.1 Drive system (part 1 of 3)
W188
S393
3
3 W188
3
W187
S483
1
4 2
1 9126449
2 9413909
3 9190394
4 9261853

N008
S483 7
11 1 W187
11
11 9 W187
S473
W186
W187
11
10 W005
11 W188
S374
8 5
S461 S482 S382
3
6
S483
S457
W184
N106
11 4
W187
11
1 9260831 Microswitch bracket
11
2 9261853
S482 3 9422841
2
4 9413908
12 N012 5 9222599
S435 W187
6 9413906
S483
7 9413907
8 9203273
9 9432351
11 9190394
12 9413909

1
1
S607
S607
W187
W006 1 9190394
8 2 9432447
W187 W187 2
7 9 3 9432350
S607 4 9116005 Shaft key DIN 6885A
S569 5 9203275
5 6 068850602000
7 9215512
6 8 9203278
4 9 9151922
4
W187
S569
8

3. CARRIAGE

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 9414004
W187
S374
W187
S374
W187
S482

6
S474
W041
Spring washer sequence
7 W034
S922
1
S922
W034
S922
W034
S922
2
W034
2
N001 2
W034
N001
W041
1 9230605 Mobile jaw
N001 S377
3 2 9108062 Locking saddle
S474 3 9422774 Emitter board
4 9175010 Roller 625ZZ
5 9203362 Carriage closure guide
W186
6 9422773 Receiver board
7 9230604 Fixe jaw
S471
R002

S548
W188
N004
S548 W002
W188 1
W200
1
W188
S548
N004
1 9175082 Roller
W002
W200
W188
W200
S548 W188
S613
W200
W188
S613

5 S471
W186
6 S460
6
S471
W186
4
3
2
1
W186
1 9432331
2 9414038 Pinion
3 9203365
4 9422843
5 9108027 Locking saddle
6 9108070 Wire routing clamp
S472 W186

S378
W188 W188
S374
W187
See PL2.1
S489
W188
S441
1
S377 W186
S441
1
W186
W186
1 9414004
W187
S374
W187
S374
W187
S482

7
4 3
S482
W187
3
W187
S374 6
S374
2
W187 W187
S243
S374
S490
S490
W188
W188
1 9414076
2 9414077
W187
3 9108060 Flat tie holder blind hole
4 9107061
S482
5 9230609
6 9414078
7 9414079
W187
1
S546
W187
1

4. JOGGER
1 2081998 Jogging foot lever

PL4.1 Jogger (part 1 of 3)
S473
6
W186 5 5
1
S471
W186
S473
W186 W186 S471

W186
5 S471
5
W186
See PL4.3
1 9222620
2 9203318
3 9175089 Bearing
W186 4 9230583-AK
W186 5 9182065
S472 W186
4 6 9432425
S472
7 9413915
R024 3
S472 R024
7 3 R024
2
W186 7
2
W186 W186
W186
S471
S471 S471
S471

W187 6
S233 1
10
S464 6 W187
W185
13
S502 8 S481
11
W187
N006 W187
S502 S233
7 9
W187
N006
S460
S453 7 S377 S453

N046 W004 3
14
W190 2
N046
W190 S377
N046 S377
W190 W190
1 9403737
2 9107063 Optical switch
W175 3 9107062 Photosensor
W190 S592 12 W175 4 9166277
N046 N046 N046 5 9211455 Fly whl washer primary shaft
S592 W175 W175 6 9175089 Bearing
W175
W187
7 9413916
W187 8 9126326 Belt
S243 S243 12 9 9431932 Stepping motor + hex. shaft
W187 10 9413917
W187
S243
11 9413522 Pulley assy
4 S243
12 9230581
5 13 9203317
W187 4 14 9203744
S374
5 W190
W187
S374 S592

S377
N152
10 N152
S377
N152
N152
S371 S371 S471 S471
S371 8 W185 W185
W186 W186
W185
3
5
S453 S371
3
7 N054 W185
W185 S471 S471

W186
W186
S471 2 3
5
6 W186
9
3 3
W186 3
S471 W186
1
3 1 9413913
2 9230576
S471
3 9157011 o-ring
3
4 9230582
W186 1 5 9230579
5 6 9230578
4 S471
7 9166292
8 9203319
9 9413914
10 9199889
4

5. NOTCHING/MILLING

PL5.1.1 Notching/Milling (without Tag 19) (part 1 of 4)
A: N002
S536
S122 S551
S472
S472 B: N002 8
W186
B W186
W186 16 12 11
16
A
12
A S453
S471 1 S536 W185
S523
2
S562
S371
W186
S523 N054
W185 14
14 9 3
7
7
6 6
15 4 13
1 9230805 Stationary knife
S009 3
2 9230802 Stationary sliding block
13 W163 3 9203555 Connecting plate
15 4 9166164 Spring
N006
10 5 9199999 Milling blade
5
6 9199998 Notching knife (2 std / 4 opt)
S009 7 2990125 Cutter adjusting screw
8 9222738 milling shutter
10 9165075 Edge moulding
11 2082806 Teflon strip
12 9403915 Abrasive tools (option)
13 9127039 Nylon sleeve
S378 14 9203552 Milling shutter pivot
S378 15 9203551 cutter brushing
16 9203895 Station knife adj. washer

PL5.1.2 Notching/Milling (with Tag 19) (part 2 of 4)
S472
S472
W186
W186 A: N002
B S536
16 A 16 S122 S551
1
A
S464 S514 B: N002 8
W039 W186
W185 12 11
18
12
2 S453
17 S471
W186 S536 W185
S462 21 S523 1 9231361 Stationary knife
S184 2 9231360 Stationary sliding block
S562
20 3 9203555 Connecting plate
19 S371 4 9166164 Spring
22 S523 N054 5 9404141 + 9204100 Milling blade assembly
S471 14
W185 6 9199998 Notching knife (2 std / 4 opt)
W186
7 7 2990125 Cutter adjusting screw
6
6 14 9 3 8 9222738 milling shutter
15 7
W005 10 9165075 Edge moulding
N008 23 15
4 13 11 2082806 Teflon strip
S009 3 12 9403915 Abrasive tools (option)
13 9127039 Nylon sleeve
13 W163
14 9203552 Milling shutter pivot
N006 15 9203551 cutter brushing
10
16 9203895 Station knife adj. washer
5
S009 17 9204120 Roller pivot
18 9240378 Bronze roller
19 9107074 Pressure Sensor
20 9199678 Nozzle
21 9199666 Pressure sensor tube
22 9157033 Rubber O Ring
23 9204100 Centering washer
S378
S378

PL5.2 Notching/Milling (part 3 of 4)
S570 S570
S570 19 S570 19 S489
S489
W003 W003
19 W003 W003
3 3 W044
W044
6 6 6 6
S489 S489 S514
W185 S514
1
S489 S489 S489 S489 W185
S462
W551
W044 W044 1
W044 W044
6 6
S551
6 6
10
S462 10
N008
2
3
7
4
N008
1 9198003 Brush
2 9165023 Cable grommet
3 9222351 Tube fix
4 9261250 Pressure sensor tube
5 NA
6 9198011 Brush
7 9199678 Nozzle
8 NA
9 NA
10 9107074 with tag 6 Pressure sensor
9591161 without Tag 6 Upgrade Kit Tag 8

PL5.3 Notching/Milling (part 4 of 4)
2 S437
W188
S437
W188
S607
S607
S458
N150
N002 1 S378
W190 3
9 S474
N150
W175 11
S465 3
W211 N002
1 9432373
W175 S474 2 9151916
N008
S592
4 9414035
W186 5 9222652
6 9126161 Belt D4x412
S479 7 9175012 Bearing
8 9175100
W186 9 9230661
S479 10 009310806506
W186 11 9203448
W185 7
8 W185
S479
S514
5
4
7
S042
W200
W188 6
10

6. GLUE TANK

PL6.1 Glue tank (part 1 of 14)
N078
W189
N078
W189
S191 1 9203632
2 9230889
3 9203631

N009 W188
S472
W192
S377 5 W002
N009
W192 1 S377
S474 2
5
3
N009
W188
W002 N009
N009
W002
10
9 S465
W467 W004
6
S465
S465
1 9135095 S465 4 Sealing paste

2 9172212
3 9230880
8
4 9170402
5 9183135
6 9147004
7 9432392 S465
7
8 9196027
9 9166285
10 9203681 7 S465

PL6.3 Glue tank - lateral gluing (optional) (part 3 of 14)
1 See P.L. 6.4
S138 W007
N002
4
S371 2
W185
N012
1 9432339 Lateral gluing assy 8

2 9414054 Gear Z10 assy S484
3 9230927 Gear N012
4 9140079 Pin S484
5 9432396 Solenoid assy S377
6 9140008 Spring pin 7
7 9166286 Spring 5 6
8 9203647 Connecting plate
9 9107063 Optical switch S377
10 009330500806 Screw
W186
9
10
S378

3
W027 8
C013
4 13
W026
W030
C012
W207
2
8
6
11
3 13
C158
S051
7 W207
S464 W007
W207
W191
13 9
1 9157042 O ring
W026
2 9172207 Spirawave washer
11
3 9261834 Washer
4 9591179 Lateral screw kit
5 9403992 Recover glue plate
10 13
6 9204091 Half screw fixed head
S377
7 9204090 Half screw mobil head
8 9140079 Pin
S464
9 9204098 Spring int. support W002
1
10 9204097 Spring ext support S296
1
11 9172213 Spiraware washer N002

S343
S343
S465
7
6
S465
W191 S522
S522 W191
W186
W186
5 9
5 8
2 1
3
8
3
S542
8
W191
4
S542
6 W191
do not demount do not demount
1 9215509
2 9215510
W185 W185 3 9174011 W185 W185
4 9204047 lateral gluing cylinder
S542 5 9414195
S542 S542
S542 6 9414198 S542
W006 7 9414199 W006
W187 8 9172208 W187
S543 9 9240361 S543

S374
S374 W187
W185
S464 S371
W187
W191
1 4
5
S481
S481
W187
3
W187 1 9432403
3 2 9183135
3 9147007
4 9111110
5 9111026 Master link 8mm

Chain path
1 1 9111108
W192
7 2 9111026 Master link 8mm
S474
5 3 9230900
W192 4 9203741
5 9414045
3 6 9210630 Spacer
7 9142004
3
2
1
W007
W186
S441
S454
4 W187
4
S454
W187
S574 6
W187
W175
N150 6
N150 S503
W187
W211
W187
S503
W211 N150
W175

1
S441
W192
W007
3
R006
S473
14
W186
12
R012
13
10
S243
W187
1 9111109 11
W006
2 9230900
7
3 9230901 S473 W186
4 9403928 W186 N002
5 9166284 S473
6 9414041 R153
2
7 9230903 W187 W007
8 9111002 Chain link S607 N001 W186 S465 4
9 9151180 W187 W185
S441
10 9116012 Shaft key DIN6885A 5x5x20
11 9116009 Shaft key DIN6885A 5x5x25 S374 5 W001
12 9116007 Shaft key DIN6885A 4x4x14 W187
Chain path N012
13 9116040
W191
14 9142004 S465
W028 S435
R010 6
W001

W011 S465
S374 W001 W191
4
S377
W187
S465
S482
S672 W191
9
W001
S502 W011
28 W187 S374
12
S009 W185
8
S482 9
W187 7 W187 5 S465
S482
6 14
3 W111
2
1 9432458
R016 2 9175110
S482
3 9230881
W187 4 9432391
11 13
8
6 9140080
10 7 9166282
15 8 9240354
9 9203621
11
10 9222714
11 9147010
2
W209 12 9204092
R012
13 9240353
14 9261831
1
15 9166283
W185
S466 W187
N012

N002
S296
N002 S296
S465
S465
S296
S296
W185
S465
S465 S453
W185
W191
11 S378
11 8
1
10
S457
S457
S457
W105
S514
S378
W186 W186
S470
W185 S441 3
N012
4 S470 1 9203646
S470 N012 3 2
2 9166286
10 W186
5 S484 3 9203647
W186 2
4 9203648
6 S484 9 5 9261832
6 9203649
9 7 7 9432396
8 9203737
7 9 9140008 Spring pin
10 9203650
11 9240359

S466
W185
W185 S466
3 W185
S377 6 2
S471 7
W186 S378
S378
W007
R052 S464
W185
W186
S496
S465
W186
R023
S465
W186
5 2
R023
5 2
1 9414055 W186
2 9230890 Lateral wire 1.5
S474
3 9230891 Lateral wire 2
W186
4 9147007
5 9222729 Solenoid bracket spacer S474
6 9203638
7 9203639 S377
S474
W186
W186
S474

S468
W185
1 2
13
14
S382
S009
14
115°
7
S382
145° 14
S009 14
6 1! 9422980
OR 6
2! 9422981
3! 9422982
16 4
145° 4! 9432440
S457
W184 5! 9423007
15 8
165° 6! 2983952! Thermostat 145°
7! 2983951! Thermostat 115°
10 5 8! 9432439
9! 9147006
9
10! 9147005
11! 9230884
12
12! 9230883
11
W193 13! 9403844
S454 14! 9147007
W193
15! 9124191! Thermostat 165°
W193 16! 9156001!
S454 W193
W193
S454
S454
S454

2 1 9199821 Funnel
2 004390001902 Nut
3 2985185 Draining plug
3
4 9403843 Spaner
5 9199883 Aluminium container

S378
2 3
S378
N152
5
4
2 9231253
4 9151046 Cooling fan
1 9404064-AK
3 9404063-AK
5 9231254-AK
S517
S378

7. COVER NIPPING

PL7.1 Cover nipping (part 1 of 10)
See PL7.2 to PL 7.7
S544 1
2
3
W187
W187
S559
1 9210630 Washer
S544
3 2 9260003 Holder side cover plate
1 W188 3 9413939
See PL7.10
2
W188
S559
S471
S471
S471 S471
See PL7.8, 7.9

See PL7.3
See PL7.4
See PL7.7
1
1 9432355

S466
S466
S469
S469
W191
W191
W191
W191 S415
S466 1
S466
W191 W191
S415 2
1 9222602
2 9413931
4
3 9166082 Spring
W186 4 9230555
5 9203801
S471 5
2 S371
5
W185
4
W186
S471
N152
3
S453
S469

S343
S465
W185 S464
1 S243
S243 W187
W191
W187 S466
S465
W191
W185
S464
W191
1 9230560
5 4 2 9203802
5 3 9230559
4 9413935
4
5 9413936
6 9203286
6
7
7 S378
S378 W185
S464 See PL7.5
S464
W185
S371 2
W039
R002

S243
W187
S243 See PL7.6

W187
See PL7.6
S243
W187
See PL7.6
1
See PL7.6
W185
W185
1 9203293
S464
S464
W187
S374
W186
See PL7.6
S441
W186
S441
W186
S441

S470
S243 W186
W187 5 9
21 11 8
6
10
1 9
W186
R161 S470
3
S377
W163
3
7 21
2
S481
S481
1 9413937 Gear assembly
W187 W187
2 9230562 Gear M1 Z101
3 9175087 Ball bearing
4 9151136 DC lift gearmotor
10 5 9203293 Shutter pivot
6 9413938 Nipping gear assembly
W187 7 9204140 Motor gear Z24
8 9403733 Gear assembly
S374 9 9175091 Ball bearing
10 9212069 Lower ejection spacer
4 21 11 9591201 Gear motor kit

1 9222603
S415 2 9230575
S453
3 9230555
W191 4 9230558
S466 1 5 9413934
S415 W191 6 9413933
7 9166082 Spring
5 S453
W191
W191 2
N152 S453
7 6
S453 N001
S469
W001
W035
W035
W035
W191
S453
S465
S442
N002
3
W191
W193
S481

5
6
20 7
S481
5 W187
R016
9
8
W185 W185
2
S371 20 4
S371
20 3

2 9175006 Bearing
2 3 9151136 DC lift gearmotor
S453
4 9231362 Gear Z24
W187 5 9231090 Guide
S481 6 9403735 Lift shaft assembly
1
7 9591200 Gearmotor kit
8 9203342 Home flag
9 9203313 Flag height
1 W187
S502
W188
W187
N006 S573
W187 S243
S502
W188
S573

S376 W200 S566

3 W002
2 N009
4 W188
W190
S566 1
W002 N046
3
S376 N009 W190 W187 N046
4 W188 N046
W200 W190
S574 W190 S480
1 N046
W187 W190
S481
W190
N046
W190
W122
1 9203306
W122
W007 2 9260889 Plastic bumper
W007 S574
S470 3 9230571
S470 4 9203296
W190
See PL7.8 N046
W190
S574

S441
S441
W186
W186
S614
W187
W630
S453
1 3
N152 N152 6
1
N152
9
8 10
4 W630
W187
S454
S465 N012
W193 S495 5 W187 S504
N012 W186
S454
1 9175070 Bearing
W187 2 9203300
W186 S495 4 9432357
7 6 9413940
5 7 9203603
10 8 9203298
9
9 9203304
10 9203305
W187
S454
W187
S454
S504 N012
1
W187

8. COVER TRANSPORT

PL8.1 Cover transport (part 1 of 3)
Detail A
W001 10
S435
S466 W001
6
R001 2
N152
N187
N006 S378
8 10
W185 3
N012
S464
N001 See detail A S470
W185
1
9
S614 N001
W006
W001
12 4
11
12
W186
11 S441
W001
N001
See detail A
W185 W006
9 S614
S614
S470
W006
S378
2 3
1 9403739
11 2 9230589
W001
3 9111105
12
4 9111104
N001
5 9432356
6 9413948
4 7
7 9230594
W163
8 9166237 Spring
9 9203803
5 10 9261701
11 9413948
S466 12 9203398

17
16
8
ITE
63
CT
LO
S371
S667 W185
W185
14
4 N006
N152 S522
N152 6
5 S378 W186
C001 S537
S382
S472
2
13
15 9
N002
S377
S377 S377
S377 8
N152
1 9422850 PNP sensor
W186 2 9203745 Shaft
3 9403980 CT plate sensor
S371 4 9261861 Foam
W185 5 9403738 Upper nip assy
S377 6 9166279 Spring
S522
7 9203315 LH bracket
10
S377 8 9432446 Solenoid
9 9230588 Lower nip plate
10 9403740 Transl. bearing assy
13 3 12 11 9203334 Chain fast. block
7 12 9203327 Flag
S377
1 11 13 9127001 Bushing
S460 14 9403742 Joint support assy
S514
10 15 9403751 Nipping lover assy
16 9104107 Lever
17 9195016 Glue
S371
S371
11

FRONT VIEW
N005
1 9111004 Master link
2 9432480 Nipping harness plate assy
3 9422860 Cable DB 9
4 9203334 Fix. chain block
REAR VIEW
1
1 16
4
S371
12
S471
5 W186
5
1
2
1
S371
N005
S093
S093

9. SUCTION BAR DRIVE SYSTEM

PL9.1 Suction bar drive system (part 1 of 3)
N152 3
1
S517
13
R158
5

2 9261715
14 S377 3 9222658
S377
15 4 17 4 9127021 Bush 8-12-12 bronze/graphite
5 9127002 Oilite bushing
N006 7 6 9261822
6 9 8
7 2980118 Nylon bearing
7
10 8 9203429
R002 R002
9 9203874
10 9166045 Lower spring
7
11 9203426
6 12
12 9403981
13 9139737
16 7
14 9203878
11
15 9104113
S377 16 9260633
17 9422942

S464
W185 2
3 3
S378
See PL9.1
4
1 9230654
2 9414030
3 9230652
4 9101003 Compact magnet
5 9414029
5
5
2
W185
W185
1
S464
S464
W185
W185
W185
S464

5
12
W185 S465
6 S453
11
10
S481 N054
R001 W004
S270 S519
W187
8
S464
W187 S378
S614
N152
W001
W185
W001 S371 W187
S481 S614
N152
N001
S481
W187 W187
W001 W185
4 8
1 N001
2 7
N152
S453
N006 W187
1 9203418
3 2 9111106
S481
W001 8 N008 3 9261711
N001 4 9166094 Spring
S464 5 9403770
6 9432357
8 9413948
9 W185
9 10 9127001 Bushing
S463
11 9203399
12 9203417

10. COVER STATION (2)

PL10.1 Cover station (part 1 of 4)
S539
S481
2 2
W187
S374
W187 W187
S243
2 1
W187
S243
S374
W187
W187
1
S243
S483
S243 S374
1 W187
W187
W187 S481
S243
S243
W187
W187 1 9203385
1
2 9414105
S539
S243 W187
S243
S374
W187
S481
S243
W187
1
S481
W187

W186
S471
W186 W186
S523
N005 W186
W186 S471
N005
S523 N005
W186 W186
1
W186
W175
S523
1
S523
W186 W175
S377
S377
2
S377 1 9166172
S377 2 9261721
R026
2
R026 R026
S471 For the blue machines

3 9403769-AF
R026
W186
S471
W186

S533
W163 S453
N006
W004
S465 4
S533 2 W191
3
S527
W163
N152
N005
5
1 9166247 Traction spring
2 9139740 Area label
3 9139739 Tray adjustment label
6
9
4 9261714 Position adjust. nut
5 9414047 Driving tray shaft
W002 6 9261865 Bushing
R013 N007
N005 7 9410563 Knob assy
8 9414048 Tray transl. screw shaft
11 7 S527
N002 9 9139752 Angle adjust label
W186 10 9139753 Lateral adj. label
6 N007
W185 11 9139154 Knob label
1
10 N054
8
S378
R013
W002
11 7 W191
S453

4 16
16 3 S471
16 20 W186
21
21
21
2
2 5
2
1
S377
S471
W186 7
9
16
17
1 9203887
19 2 9404146
22
3 9403784
7 S441 4 9104093 Knurled knob
8
12 W186 5 9203452
6 9414026
W184 7 9414025
S378 S441 W191 8 9432383
W186 S457 9 9140036
11 S371 10 9166203 Spring for tray TDS
6
11 9230669
10 S371
W191 12 9230668
13 9157011 O-ring 12x4
14 9203889
W186 13
15 2085322
18
16 9230801
13 14
S471 17 9261870
15 18 9261871
W186 W186 19 9260652 Suction plug transport modulen
20 9404145
S471 S471 21 9403785
22 9166121 Spring

11. COVER SUCTION / BLOWER TURBINE

PL11.1 cover suction / blower turbine
20
18
1
2
18
3
18
S471
7 5
S377
W186 19
3 S471
2
W186
4 S472 1! 9432364
S471 2! 9222644
W186 3! 9157022! O Ring
4! 9203421! Filter corcom Iovni
18 5! 9120189
6 6! 9260346! Prelift tube 70mm lg
W186
7! 9151145
S472 18 8 8! 9260871
16
16 9! 9183131
10! 9430876! Solenoid assy
8 17
11! 9166027! Spring
S471 12! 9261712
S470 W186 9
13! 9157010! O-Ring
W186 14
15 14! 9108010! Tiewraps
8
S603 15! 9432378
9
11 16! 9261845
10 14 17! 9165130
13 18! 9199843
12
19! 9261873
N006 20! 9261872

12. SCORING

PL12.1 Scoring (part 1 of 8)
S473 2
S441
2
W186 S464
18 3
W185
S464
4 18 W185
S441
W186
S472
W186
S471
3 W186
S473 W186
See PL11.4
S441
S471 1 9403767 Punch assembly
W186
2 9260379 Knife holder slides
2 2 3 9203405 Pivot eccentric
W186 4 9204139 with Tag 18
9591188 witout Tag 18
S441 S464
W185

Optional
W186
R024
W186
10 S470 11 1
W187
S470 S163
7 S374
5
W017
9 S374
W187 W187
2
R024
3
S571 S374
S571
7
1
7 W187
W187 W186
S374 W017 S470
5
6
4
W186 4
W185
7 8 S396
W187
S470 S374
W187
1 9127063 Bushing
2 9104107 Knob
3 9203756 Lever axis
S374 W187 4 9261851 Stop
5 9230636 Cam
6 9203381 Spacer
7 9261710 Ring
8 9203406 Spacer axis
9 9423086 Double detect sensor
10 9204043 Sensor bracket
11 9591169 Double detect sensor kit

S453
N054
2
S472
N054
S453 W186
1 9175091
2 9166082 Spring
2
3 9203391
4 9403732
S371 For the blue machines

W185
S523 1 5 9231169-AF
W003
W003
S377
N005
3
N002 5
S474
W186
S472
1
W185
S377 S377
S371

1 17
17 11
S464
W185
10
S514
2 S371
W185
8 17
1 17 3
7
17
5
4
4
4
7
4
4
2 1 9166074 Spring (with Tag 17)
S009 4 2 9127043 Nylon bushing 6mm
17
4
4 7006046000 Paper feed friction roller
12 4 6 5 9203378 Upper shaft
14 6 9414022 Roller shaft assy
7 9240144 Door pivot
13 8 9404152 Cover support bracket (with Tag 17)
9 9 9403758 LH connecting plate
W185 10 9403759 RH connecting plate
11 9166074 2X +9404152 1X (without Tag 17)
S464
12 9240377 Bearing
15
13 9204117 Stop
3
14 9166299 Spring
W185 15 9204118 Bearing
17
S371
S514

See PL12.6
1 9413945
See PL12.7

W019 R007 W186

S522
N005
W041 See PL 12.5
N006
N054
R011
W029
S453
2
S009
S452 N005
7
9 1
W187 10 22
S233
S474
See PL 12.5 1 9414005 Connecting rod assembly
W007
2 9240077 Eccentric for transr. bar
3 NA
S377 8 22 4 9116005 Idler
W163 5 9230647 Gear Z 48
S008
4 6 NA
7 9140016 Precision taper pin
8 9231363 Gear Z 48
9 9175089 Bearing
10 9151136 DC lift gearmotor
11 9591202 Gearmotor kit
22 11

S453
See 12.5
4 S453
N006 3
S452
4
N006
S453
4
S473
W007
N054
N006
W041
N005
See 12.5
S378
1 9414005
2 9240077 Eccentric for transr. bar
S378 3 9175027 Bearing
5 9140016 Precision taper pin
N005
S009 5
R007
W186 1
S471
2
W029

PL12.8 Creasing (part 8 of 8)
W187 S374
W187
S502
W187
S502
W185
S464
W187
S464 S502
W185
S374
W187
2 W187
S482
1
S481
W187
W186
S374 2 S472
S482 6 18
W187 S453
S502 W186
N054 S472
5 W187 18
S502
W185
W187
1! 9230642! Matrix
S371
2! 9127063! Bushing
R024 3! 9166298! Spring
3 4! 9432362! Solenoid assy
W185 4 5! 9203385! Eccentric
W187 S464 6! 9204138! with Tag 18
S482
! 9591188 ! without Tag 18
5

13. OUTPUT & CONVEYOR

PL13.1 Output & conveyor (part 1 of 2)
1
S378
W186
7 S523
2
S523
W186
11
S441 W186
S378 S522
13 3
10 8
12 W027
12
W027
S441 S475 5
W003
W186 W186 S522
N002 S484
14
S441 6 W001 15 W001
W191
14 N001
15
W001
W007 N001 S465
W186 W163
W163 N006
14 W191
14
S484 N006 1 9404111-AK
W017 S441 S465 2 9199448 Rubber stop
R024
4 3 9231315-AK
W007 4 9261719
W186 5 9404110-AK
S441 6 9261857
4 7 9107064
8 9403964-AK
9 9231133-AK
10 9203840
11 9203841
R024 12 9175081 Ball bearing
W017 13 9203566
9 14 9261858
15 9261295 Pivot bearing

PL13.2 Output & conveyor (part 2 of 2)
11
11
11
1 R014 11 S243
1
1
1
9 13
8
12 R159
11
11 3
S516
11
11
12 R014
8 14
9
S243
R159
S516
10
2 14 1 9126445
3 13
2 9413859 Pulley assy
S502 4 9126319 Belt 10T5 640mm BDF
5 5 9151136 DC lift gearmotor
2 6 9199898
W187 7 9199896
8 9261846
4 9 9175015 Ball bearing
10 9107064
11 9261255 Molded pulley conveyor
16 12 2097307
W185 13 9261221 Injected housing
S464 14 014750402200
15 9403947
16 9403948
15

14. OUTPUT UNIT (BOTTOM) OPTIONAL

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

5 2 9231128
3 9203826
5 9165008
6 9199897
5
5 8 9199898
1 9 9178062
10 9203825

3 W187
5 1 9231129-AF
2 4 9231130-AF
7 9231124-AF
S481 W187 3
3
4
S481
7 5
10
7 N005 5
W186
W186
S478 6
9 5
W186
W186 8
S471
S471 6

See Pl 13.4
5 W187
S377
S481
4
2
W185
S377
2 1 NA
2 9261900
S377 4 3 9104114
4 S465
4 9261717
5 9403957
S465 6 9231110
S377
W185 7 9107063 Optical switch
8 9203815
S524 9 9414152
N106
9
S377
S524
9 S523
S377 9 W186
N106
8 N106 6
W186
S471
S524 W186 6 S464
S471 W185
N106
S524 S453
W187
N006 7 S481
W187
S481

1 1
R010
2
3
2
R010 6
S441
N006
W186
W185
N006 1 9261187 Green handle for baffle

2 2980069 Bushing
W185
3 9166246 Spring
4 9403956
5 9231132-AK
W186
6 9166074 Clutch lock spring
S441

S505
W187
4
1 9166291
2 9203817
W186 3 9261201 Spacer
1 4 9261855
3 3
S441
4
3
N001
N001
3
N001

7
8
W186 4 1 9261255 Molded pulley conveyor

R014 S441 2 9126453
S377 3 9414151
4 9230609
6 3 5 9203830
S377 6 9203814
3
1 7 9261876
5 S471
1 8 9203828
7 W186
1 8
S441 S471
W186
W186 3
W186
2 R014
W186
2 W187
S471 S471
2
S481
W186
S471
1
1
1
W186
S471

S378
S490
10
N001
13 5 S549
S377 W188
S453 7 W004 11
W004 11 11
S471 S233
5 5
1
S551 N006
S523 S463
S471 6 8
9
12 9
2
9
N004
S471
11 N008
12
2 S490
W188
3 5
5
4 W185
3 1 9231112
2 9414151
3 9231113
4 9222784
S464 5 9203822
6 9430937 Motor assy
10 9203823
11 9175091
12 9157011 O-ring
W185 13 9203821
S464

S371
S371 W185
For machines without TAG 15 15
If replacing item 1,5 or 17, all 3 parts need R007
to be replaced at the same time then mark
off TAG 15. 9
10
9
17 15 R007
W185
11
2 R007
3 1 15 9 8
9 8
2 R007 11
10
5 15 N106 7
7
N106
N005
N005
N106
6
6 1 9404144-AF BBR upper cover (with Tag 15)
S523
W186 4 2 9199807 Rubber stop
3 9260889 Plastic bumper
4 9231103-AF BBR rear cover
S523 5 9404143 BBR uppper baffle (with Tag 15)
16 S371 6 9107064 Photosensor
W186
12 7 9403953 Pusher part A
14
S523 W185 15 8 9403952 Pusher part B
9 9261877 Bushing
N005
10 9203810 Pivot
N005 12 11 9203811 Shaft
S523 12 9166237 Spring
S523 14 13 9203829 Stop
S474
15 14 9261039 Rubber distance
W186
12 15 9421685 Grounding braid
S522
16 9420702 Grounding braid
12 13 17 9198017 Contact blade
S474
N005

S502
1 2
N001
4
W187
3 11
S481
W187
S377
S481 1 9430937 Motor assy

S481 S377
W187 2 9231096 Gear
W187 11
3 9423XXX BBR board (see Software history in the
General Procedure in the Service Manual)
4 9199878 Spacer
N008 5 9203805 Sensor bracket
6 9146339 Emergency button
6 8 7 9150073 Microswitch
7
N152 8 9260831 Microswitch bracket
S460
9 9231107 Shaft
5 9 10 9107063 Optical switch
11 9146340 Base for emerg. button
9 10
10
S453

15. EXTERNAL SYSTEM FOR COLLECTING WASTE
1 9107074 Pressure sensor
2 9432539 Collector assembly
3 7500295 Clamping ring
6 2985284 Magnet
13 19 8 9104105 Snapin handle
9 9159566 Plastic bag
10 NA-
11 NA
12 9432540 Collector control box
13 9261897 Sleeve
19 14
3 14 7500297 Clamping ring
15 9151188 Clamp for dust bag
S371 W184 N008 5
S462 4 W185
S548 S453 7 9403979-AF
W163 1
W184
W185 N008
W185
15 W188
S453 S453
W185 6
W184 S461 7
6
9
12

16. INTERNAL SYSTEM FOR COLLECTING WASTE (OPTION)
W184
S489
W184 N008
1
S462 W188
S473
W186
2
S471
3
3
W188
N005
S473
11 W186
W184 10 W188
3
S462 3
N008 5
1 W185 1 9107074
4
S548 S453 2 9151917
S371 3 7500295 Clamping ring
W184 4 9150065 Microswitch
N008
W185 9 5 9260831 Microswitch bracket
W163 6 2985284 Magnet
W188 8 9104105 Snapin handle
9 9198895
S453 S453
W185 10 9165023 Cable grommet
W185 11 9222351
6
W184 S461 7
6
7 9403979-AF

17. U.I.

17.1 U.I.
10
S464 S441
W186
S464
W185
3
2
8
N006
S515
N006
S515 1 9423 UI (see Software history in the General
Procedure in the Service Manual)
2 9183129
4
3 9203951
4 9432387
S008 5 9403856
6 9261836
7
6 7 9203683
8 9138094
9 9 9165129
W187 10 9423 Industrial flash (see Software history in the
W190 5 General Procedure in the Service Manual)
7
W187 6
S552
S574

18. ELECTRICAL

PL 18.1 Electrical (part 1 of 2)
4
3 5
7 24
6
1 9132024 Digital out 1X8 module DO 435

8
2 9103049 Power supply with Tag 4
9103049+9423077 Power supply without Tag 4
3* 9423xxx Frequency driver translation
4 9182066 Auto transfo
5 9120180 Filter triphase
4 2 6 9423082 Isolation board assy
7 9422962 Power board
4 8 9423005 Harness
9 9422856 Drive board
13 12 10 9422928 Interlock board
4 15 11
13 11 9422894 Dispatch board
14 10
9 12 9422868 Glue tank board
9
13 9431627 Blower assy
14 9170380 Resistor
15 9423077 Capacitor assembly
16* 9423xxx CPU
25
17 9132021 Digital OUT 1X4 module DO 135
18 9132022 Digital IN 1X10 module DI 140
16 19 9132025 Motor bridge module MM432
1
18 22 20 9132027 Combination module CM 211
21 21 9132023 Digital IN module 1X16 DI 439
20
20
22 9132026 Motor module MM 424
26***
19 24* 9423xxx Frequency driver glue tank
U
N
E
M
R
TE
N
E
25** 9199845 Battery CR 2477N
17 17 17
26*** 9132019 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

PL 18.2 Electrical (part 2 of 2)
Power board A20 - Fuses + Relays
A20 : F11 & F12 - 6.25A
A20 : F7 & F8 - 6.25A
Protection Power supply
220V power supply protection A20 : F3 & F4 - 6.25A
220VAC -> 24 - 36 VDC
Glue tank frequency converter 1 Glue tank resistor
1 1 protection Dispatch Board A4 : Fuses.
1
A20 : F9 & F10 - 6.25A
1
220V power supply protection
Translation frequency converter A20 : F1 & F2 - 6.25A
Glue drum resistor
protection
2
A20 : F5 & F6 - 4A
220V power supply
protection
Prefeed blower suction
A4 - F1 (500mA) A4 - F2 (1A)
Protection 24V converter 24 VDC - 5 VDC Protection 24V Sensor
3 4
General fuses and relays of the BB3002

F3 Reset button in case
3p of milling motor over T°
K0
42
F2
2p
F1 K0
6 42
10 9 1 9124016
2 9124008
3 9124024
5
4 9124028
5 9124194
8 6 9169907 Relay omron
7 9169084 Contact 3NO +1NC
11 7 8 9177051 Base
Fuses 12A Milling motor
9 9124093 Therm relay
Power supply of the BB3002 Over T° intern dust process relay
collector relay 10 9169122 Contact 2NO + 2NC
11 9164011 fuse holder

19. INDEX
First Aid Kit

Bourg Nr Color Description P.L. Page Ref.
9591136
2081998 Jogging foot lever 28 1 4.
2082806 Teflon strip 33 11 5.1.1
2082806 Teflon strip 34 11 5.1.2
2085322 75 15 10.4
2097307 89 12 13.2
2980069 Bushing 94 2 14.4
2980118 Nylon bearing 68 7 9.1
2983951 Thermostat 115° 49 7 6.12
2983952 Thermostat 145° 49 6 6.12
2985185 Draining plug 50 3 6.13
2985276 15 6 1.9
2985284 Magnet 100 6 15.
2985284 Magnet 101 6 16.
2990125 Cutter adjusting screw 33 7 5.1.1
2990125 Cutter adjusting screw 34 7 5.1.2
7500295 Clamping ring 100 3 15.
7500295 Clamping ring 101 3 16.
7500297 Clamping ring 100 14 15.
9101003 Compact magnet 69 4 9.2
9103049 Power supply with Tag 4 105 2 18.1
9104093 Knurled knob 75 4 10.4
9104105 Snapin handle 14 6 1.8
9104105 Snapin handle 100 8 15.
9104105 Snapin handle 101 8 16.
9104106 Verschlub BDF 14 5 1.8
9104107 Knob 80 2 12.2
9104107 Lever 65 16 8.2
9104113 68 15 9.1
9104114 93 3 14.3
9107061 27 4 3.6
9107062 Photosensor 30 3 4.2

First Aid Kit
9591136
9107063 Optical switch 60 1 7.8
X
9107063 Optical switch 99 10 14.9
9107064 Photosensor 98 6 14.8
9107064 88 7 13.1
9107064 89 10 13.2
9107074 Pressure sensor 100 1 15.
9107074 101 1 16.
9107074 with tag 6 Pressure sensor 35 10 5.2
9107074 Pressure Sensor 34 19 5.1.2
9108010 Tiewraps 77 14 11.1
9108027 Locking saddle 25 5 3.4
9108060 Flat tie holder blind hole 27 3 3.6
9108062 Locking saddle 23 2 3.2
9108070 Wire routing clamp 25 6 3.4
9111002 Chain link 45 8 6.8
9111004 Master link 66 1 8.3
9111026 Master link 8mm 44 2 6.7
9111026 Master link 8mm 43 5 6.6
9111104 64 4 8.1

First Aid Kit
9591136
9111105 64 3 8.1
9111106 70 2 9.3
9111108 44 1 6.7
9111109 45 1 6.8
9111110 43 4 6.6
9115026 Hinge 100D + spring 14 1 1.8
9115027 Hinge arm 14 2 1.8
9115031 10 1 1.4
9116005 Shaft key DIN 6885A 20 4 2.3
9116005 Idler 84 4 12.6
9116007 Shaft key DIN6885A 4x4x14 45 12 6.8
9116009 Shaft key DIN6885A 5x5x25 45 11 6.8
9116012 Shaft key DIN6885A 5x5x20 45 10 6.8
9116040 45 13 6.8
9120180 Filter triphase 105 5 18.1
9120189 77 5 11.1
9124008 106 2 18.2 X
9124016 106 1 18.2 X
9124024 106 3 18.2 X
9124028 106 4 18.2 X
9124093 Therm relay 106 9 18.2
9124191 Thermostat 165° 49 15 6.12
9124194 106 5 18.2 X
9126161 Belt D4x412 36 6 5.3 X
9126319 Belt 10T5 640mm BDF 89 4 13.2 X
9126326 Belt 30 8 4.2
9126445 89 1 13.2 X
9126449 18 1 2.1
9126453 96 2 14.6
9127001 Bushing 70 10 9.3
9127001 Bushing 65 13 8.2

First Aid Kit
9591136
9127002 Oilite bushing 68 5 9.1
9127021 Bush 8-12-12 bronze/graphite 68 4 9.1
9127039 Nylon sleeve 33 13 5.1.1
9127039 Nylon sleeve 34 13 5.1.2
9127043 Nylon bushing 6mm 82 2 12.4
9127063 Bushing 80 1 12.2
9127063 Bushing 86 2 12.8
9132019 Kbd to prg ABB freq.diver 105 26 18
9132021 Digital OUT 1X4 module DO 135 105 17 18.1
9132022 Digital IN 1X10 module DI 140 105 18 18.1
9132023 Digital IN module 1X16 DI 439 105 21 18.1
9132024 Digital out 1X8 module DO 435 105 1 18.1
9132025 Motor bridge module MM432 105 19 18.1
9132026 Motor module MM 424 105 22 18.1
9132027 Combination module CM 211 105 20 18.1
9135095 39 1 6.2
9138094 103 8 17.1
9139154 Knob label 74 11 10.3
9139707 7 7 1.1
9139737 68 13 9.1
9139739 Tray adjustment label 74 3 10.3
9139740 Area label 74 2 10.3
9139752 Angle adjust label 74 9 10.3
9139753 Lateral adj. label 74 10 10.3
9140008 Spring pin 40 6 6.3
9140008 Spring pin 47 9 6.10
9140016 Precision taper pin 85 5 12.7
9140016 Precision taper pin 84 7 12.6
9140036 75 9 10.4
9140079 Pin 40 4 6.3
9140079 Pin 41 8 6.4
9140080 46 6 6.9

First Aid Kit
9591136
9142004 44 7 6.7
9142004 45 14 6.8
9146339 Emergency button 7 1 1.1
9146339 Emergency button 99 6 14.9
9146340 Base for emeg.button 99 11 14,9
9146354 7 4 1.1
9146366 Interlock switch 11 1 1.5
9146366 Interlock switch 14 4 1.8
9146373 Actuator black IP40 8 1 1.2
9146379 14 3 1.8
9147004 39 6 6.2
9147005 49 10 6.12
9147006 49 9 6.12
9147007 43 3 6.6
9147007 48 4 6.11
9147007 49 14 6.12
9147010 46 11 6.9
9150065 Microswitch 100 4 15.
9150065 Microswitch 101 4 16.
9150065 Microswitch 13 8 1.7 X
9150065 Microswitch 70 9 9.3
9150065 Microswitch 19 10 2.2
9150073 Microswitch 99 7 14.9
9150073 Microswitch 97 8 14.7
9151046 Cooling fan 51 4 6.14
9151136 DC lift gearmotor 60 3 7.8
X
9151145 77 7 11.1
9151180 45 9 6.8
9151188 Clamp for dust bag 100 15 15.

First Aid Kit
9591136
9151916 36 2 5.3
9151917 101 2 16.
9151922 20 9 2.3
9156001 49 16 6.12
9157010 O-Ring 77 13 11.1
9157011 o-ring 31 3 4.3
9157011 O-ring 97 12 14.7
9157011 O-ring 12x4 75 13 10.4
9157022 O Ring 77 3 11.1
9157033 Rubber O Ring 34 22 5.1.2
9157042 O ring 41 1 6.4
9159566 Plastic bag 100 9 15.
9164011 fuse holder 106 11 18.2
9165008 92 5 14.2
9165023 Cable grommet 35 2 5.2
9165023 Cable grommet 101 10 16.
9165075 Edge moulding 33 10 5.1.1
9165075 Edge moulding 34 10 5.1.2
9165129 103 9 17.1
9165130 77 17 11.1
9166027 Spring 77 11 11.1 X
9166045 Lower spring 68 10 9.1 X
9166074 Spring (with Tag 17) 82 1 12.4
X
9166074 Clutch lock spring 94 6 14.4
9166082 Spring 81 2 12.3
9166082 Spring 55 3 7.3 X
9166082 Spring 59 7 7.7
9166094 Spring 70 4 9.3 X
9166121 Spring 75 22 10.4 X
9166164 Spring 33 4 5.1.1
X
9166164 Spring 34 4 5.1.2

First Aid Kit
9591136
9166172 73 1 10.2 X
9166203 Spring for tray TDS 75 10 10.4 X
9166237 Spring 64 8 8.1
X
9166237 Spring 98 12 14.8
9166246 Spring 94 3 14.4
9166247 Traction spring 74 1 10.3 X
9166277 30 4 4.2 X
9166279 Spring 65 6 8.2 X
9166282 46 7 6.9 X
9166283 46 15 6.9 X
9166284 45 5 6.8 X
9166285 39 9 6.2 X
9166286 47 2 6.10
X
9166286 Spring 40 7 6.3
9166291 95 1 14.5
9166292 31 7 4.3 X
9166298 Spring 86 3 12.8 X
9166299 Spring 82 14 12.4
9169084 Contact 3NO +1NC 106 7 18.2
9169122 Contact 2NO + 2NC 106 10 18.2
9169907 Relay omron 106 6 18.2
9170380 Resistor 105 14 18.1
9170402 39 4 6.2
9172207 Spirawave washer 41 2 6.4
9172208 42 8 6.5
9172212 39 2 6.2
9172213 Spiraware washer 41 11 6.4
9174011 42 3 6.5
9175006 Bearing 60 2 7.8
9175010 Roller 625ZZ 23 4 3.2
9175012 Bearing 36 7 5.3

First Aid Kit
9591136
9175015 Ball bearing 89 9 13.2
9175021 Ball bearing 62 5 7.10
9175027 Bearing 85 3 12.7
9175070 Bearing 62 1 7.10
9175081 Ball bearing 88 12 13.1
9175082 Roller 24 1 3.3
9175087 Ball bearing 58 3 7.6
9175087 Ball bearing 89 3 13.2
9175089 Bearing 29 3 4.1
9175089 Bearing 30 6 4.2
9175089 Bearing 84 9 12.6
9175091 81 1 12.3
9175091 Ball bearing 58 9 7.6
9175091 97 11 14.7
9175094 Ball bearing 82 3 12.4
9175100 36 8 5.3
9175110 46 2 6.9
9177051 Base 106 8 18.2
9178062 92 9 14.2
9182065 29 5 4.1 X
9182066 Auto transfo 105 4 18.1
9183129 103 2 17.1
9183131 77 9 11.1
9183135 43 2 6.6
9183135 39 5 6.2
9190394 20 1 2.3
9190394 18 3 2.1
9190394 19 11 2.2
9195016 Glue 65 17 8.2
9196027 39 8 6.2
9198003 Brush 35 1 5.2 X

First Aid Kit
9591136
9198011 Brush 35 6 5.2
9198017 Contact blade 98 17 14.8
9198895 101 9 16.
9199067 Rubber bumper 33 9 5.1.1
9199067 Rubber bumper 34 9 5.1.2
9199448 Rubber stop 88 2 13.1
9199448 Rubber bumper 8 6 1.2
9199448 Rubber stop 13 6 1.7
9199666 Pressure sensor tube 34 21 5.1.2
9199678 Nozzle 35 7 5.2
9199678 Nozzle 34 20 5.1.2
9199807 Rubber stop 98 2 14.8
9199807 Rubber stop D15 13 7 1.7
9199821 Funnel 50 1 6.13
9199843 77 18 11.1
9199845 Battery CR 2477N 105 25** 18.1
9199878 99 4 14.9
9199883 Aluminium container 50 5 6.13
9199889 31 10 4.3
9199896 89 7 13.2
9199897 92 6 14.2
9199898 89 6 13.2
9199898 92 8 14.2
9199985 Gas spring 10 3 1.4
9199998 Notching knife (2 std / 4 opt) 33 6 5.1.1
X
9199998 Notching knife (2 std / 4 opt) 34 6 5.1.2
9199999 Milling blade 33 5 5.1.1
9201665 Actuator shaft 9 1 1.3
9203273 19 8 2.2
9203275 20 5 2.3
9203278 20 8 2.3

First Aid Kit
9591136
9203286 56 6 7.4
9203293 57 1 7.5
9203293 Shutter pivot 58 5 7.6
9203296 61 4 7.9
9203298 62 8 7.10
9203300 62 2 7.10
9203304 62 9 7.10
9203305 62 10 7.10
9203306 61 1 7.9
9203313 Flag height 60 9 7.8
9203315 LH bracket 65 7 8.2
9203317 30 13 4.2
9203318 29 2 4.1
9203319 31 8 4.3
9203327 Flag 65 12 8.2
9203334 Fix. chain block 66 4 8.3
9203334 Chain fast. block 65 11 8.2
9203342 Home flag 60 8 7.8
9203362 Carriage closure guide 23 5 3.2
9203365 25 3 3.4
9203378 Upper shaft 82 5 12.4
9203381 Spacer 80 6 12.2
9203385 72 1 10.1
9203385 Eccentric 86 5 12.8
9203391 81 3 12.3
9203398 64 12 8.1
9203399 70 11 9.3
9203405 Pivot eccentric 79 3 12.1
9203406 Spacer axis 80 8 12.2
9203417 70 12 9.3
9203418 70 1 9.3

First Aid Kit
9591136
9203421 Filter corcom Iovni 77 4 11.1
9203426 68 11 9.1
9203429 68 8 9.1
9203448 36 11 5.3
9203452 75 5 10.4
9203551 cutter brushing 33 15 5.1.1
9203551 cutter brushing 34 15 5.1.2
9203552 Milling shutter pivot 33 14 5.1.1
9203552 Milling shutter pivot 34 14 5.1.2
9203555 Connecting plate 33 3 5.1.1
9203555 Connecting plate 34 3 5.1.2
9203566 88 13 13.1
9203603 62 7 7.10
9203621 46 9 6.9
9203631 38 3 6.1
9203632 38 1 6.1
9203638 48 6 6.11
9203639 48 7 6.11
9203646 47 1 6.10
9203647 47 3 6.10
9203647 Connecting plate 40 8 6.3
9203648 47 4 6.10
9203649 47 6 6.10
9203650 47 10 6.10
9203681 39 10 6.2
9203683 103 7 17.1
9203737 47 8 6.10
9203741 44 4 6.7
9203744 30 14 4.2
9203745 Shaft 65 2 8.2
9203754 10 7 1.4

First Aid Kit
9591136
9203756 Lever axis 80 3 12.2
9203801 55 5 7.3
9203802 56 2 7.4
9203803 64 9 8.1
9203805 99 5 14.9
9203810 Pivot 98 10 14.8
9203811 Shaft 98 11 14.8
9203814 96 6 14.6
9203815 93 8 14.3
9203817 95 2 14.5
9203821 97 13 14.7
9203822 97 5 14.7
9203823 97 10 14.7
9203825 92 10 14.2
9203826 92 3 14.2
9203828 96 8 14.6
9203829 Stop 98 13 14.8
9203830 96 5 14.6
9203840 88 10 13.1
9203841 88 11 13.1
9203874 68 9 9.1
9203878 68 14 9.1
9203887 75 1 10.4
9203889 75 14 10.4
9203895 Station knife adj. washer 33 16 5.1.1
9203895 Station knife adj. washer 34 16 5.1.2
9203951 103 3 17.1
9204043 Sensor bracket 80 10 12.2
9204047 lateral gluing cylinder 42 4 6.5
9204090 Half screw mobil head 41 7 6.4
9204091 Half screw fixed head 41 6 6.4

First Aid Kit
9591136
9204092 46 12 6.9
9204097 Spring ext support 41 10 6.4
9204098 Spring int. support 41 9 6.4
9204100 Centering washer 34 23 5.1.2
9204117 Stop 82 13 12.4
9204118 Bearing 82 15 12.4
9204120 Roller pivot 34 17 5.1.2
9204138 with Tag 18 86 6 12.8
9204139 with Tag 18 79 4 12.1
9204140 Motor gear Z24 58 7 7.6
9210630 Washer 53 1 7.1
9210630 Spacer 44 6 6.7
9211455 Fly whl washer primary shaft 30 5 4.2
9212069 Lower ejection spacer 58 10 7.6
9215509 42 1 6.5
9215510 42 2 6.5
9215512 20 7 2.3
9222351 Tube fix 35 3 5.2
9222351 101 11 16.
9222599 19 5 2.2
9222602 55 1 7.3
9222603 59 1 7.7
9222620 29 1 4.1
9222644 77 2 11.1
9222652 36 5 5.3
9222658 68 3 9.1
9222714 46 10 6.9
9222729 Solenoid bracket spacer 48 5 6.11
9222738 milling shutter 33 8 5.1.1
X
9222738 milling shutter 34 8 5.1.2
9222784 97 4 14.7

First Aid Kit
9591136
9230354 7 8 1.1
9230555 59 3 7.7
9230555 55 4 7.3
9230558 59 4 7.7
9230559 56 3 7.4
9230560 56 1 7.4 X
9230562 Gear M1 Z101 58 2 7.6
9230571 61 3 7.9
9230575 59 2 7.7
9230576 31 2 4.3
9230578 31 6 4.3
9230579 31 5 4.3
9230581 30 12 4.2
9230582 31 4 4.3
9230583-AK AK 29 4 4.1
9230588 Lower nip plate 65 9 8.2
9230589 64 2 8.1
9230594 64 7 8.1
9230604 Fixe jaw 23 7 3.2
9230605 Mobile jaw 23 1 3.2
9230609 96 4 14.6
9230609 27 5 3.6
9230636 Cam 80 5 12.2
9230642 Matrix 86 1 12.8
9230647 Gear Z 48 84 5 12.6
9230652 69 3 9.2
9230654 69 1 9.2
9230661 36 9 5.3
9230668 75 12 10.4
9230669 75 11 10.4
9230801 75 16 10.4

First Aid Kit
9591136
9230802 Stationary sliding block 33 2 5.1.1
9230805 Stationary knife 33 1 5.1.1
9230880 39 3 6.2
9230881 46 3 6.9
9230883 49 12 6.12
9230884 49 11 6.12
9230889 38 2 6.1
9230890 Lateral wire 1.5 48 2 6.11
9230891 Lateral wire 2 48 3 6.11
9230900 45 2 6.8
9230900 44 3 6.7
9230901 45 3 6.8
9230903 45 7 6.8
9230927 Gear 40 3 6.3
9230967-AF AF 15 1 1.9
9231000-AF AF 10 4 1.4
9231072-AK AK 15 3 1.9
9231090 Guide 60 5 7.8
9231096 99 2 14.9
9231103-AF AF BBR rear cover 98 4 14.8
9231107 99 9 14.9
9231110 93 6 14.3
9231112 97 1 14.7
9231113 97 3 14.7
9231124-AF AF 92 7 14.2
9231128 92 2 14.2
9231129-AF AF 92 1 14.2
9231130-AF AF 92 4 14.2
9231132-AK AK 94 5 14.4
9231133-AK AK 88 9 13.1
9231169-AF AF 81 5 12.3

First Aid Kit
9591136
9231253 51 2 6.14
9231254-AK AK 51 5 6.14
9231315-AK AK 88 3 13.1
9231360 Stationary sliding block 34 2 5.1.2
9231361 Stationary knife 34 1 5.1.2
9231362 Gear Z24 60 4 7.8
9231363 Gear Z 48 84 8 12.6
9240077 Eccentric for transr. bar 84 2 12.6
9240077 Eccentric for transr. bar 85 2 12.7
9240144 Door pivot 82 7 12.4
9240353 46 13 6.9
9240354 46 8 6.9
9240359 47 11 6.10
9240361 42 9 6.5
9240377 Bearing 82 12 12.4
9240378 Bronze roller 34 18 5.1.2
9260003 Holder side cover plate 53 2 7.1
9260346 Prelift tube 70mm lg 77 6 11.1
9260379 Knife holder slides 79 2 12.1
9260633 68 16 9.1
9260652 Suction plug transport modulen 75 19 10.4
9260831 Microswitch bracket 19 1 2.2
9260831 Microswitch bracket 100 5 15.
9260831 Microswitch bracket 101 5 16.
9260831 microswitch bracket 13 9 1.7
9260871 77 8 11.1
9260889 Plastic bumper 61 2 7.9
9260889 Plastic bumper 98 3 14.8
9261039 Rubber distance 5mm 14 9 1.8

First Aid Kit
9591136
9261039 Rubber distance 98 14 14.8
9261139 Actuator shaft spacer 9 2 1.3
9261187 Green handle for baffle 94 1 14.4
9261201 Spacer 95 3 14.5
9261221 Injected housing 89 13 13.2
9261250 Pressure sensor tube 35 4 5.2
9261255 Molded pulley conveyor 96 1 14.6
9261255 Molded pulley conveyor 89 11 13.2
9261295 Pivot bearing 88 15 13.1
9261701 64 10 8.1
9261710 Ring 80 7 12.2
9261711 70 3 9.3
9261712 77 12 11.1
9261714 Position adjust. nut 74 4 10.3
9261715 68 2 9.1 X
9261717 93 4 14.3
9261719 88 4 13.1
9261721 73 2 10.2
9261822 68 6 9.1 X
9261831 46 14 6.9
9261832 47 5 6.10 X
9261834 Washer 41 3 6.4
9261836 103 6 17.1
9261845 77 16 11.1
9261846 89 8 13.2
9261850 10 6 1.4
9261851 Stop 80 4 12.2
9261853 19 2 2.2
9261853 18 4 2.1
9261855 95 4 14.5
9261857 88 6 13.1

First Aid Kit
9591136
9261858 88 14 13.1
9261861 Foam 65 4 8.2
9261865 Bushing 74 6 10.3
9261870 75 17 10.4
9261871 75 18 10.4
9261872 77 20 11.1
9261873 77 19 11.1
9261876 96 7 14.6
9261877 Bushing 98 9 14.8
9261897 Sleeve 100 13 15.
9261900 93 2 14.3
9403732 81 4 12.3
9403733 Gear assembly 58 8 7.6
9403735 Lift shaft assembly 60 6 7.8
9403737 30 1 4.2
9403738 Upper nip assy 65 5 8.2
9403739 64 1 8.1
9403740 Transl. bearing assy 65 10 8.2
9403742 Joint support assy 65 14 8.2 X
9403751 Nipping lover assy 65 15 8.2
9403758 LH connecting plate 82 9 12.4
9403759 RH connecting plate 82 10 12.4
9403767 Punch assembly 79 1 12.1
9403769-AF AF 73 3 10.2
9403770 70 5 9.3
9403784 75 3 10.4
9403785 75 21 10.4
9403843 Spaner 50 4 6.13
9403844 49 13 6.12
9403856 103 5 17.1
9403879-AF AF 15 4 1.9

First Aid Kit
9591136
9403882 16 3 1.10
9403883-AF AF 14 7 1.8
9403885-AF AF 7 5 1.1
9403886-AF AF 10 5 1.4
9403897-AF AF 7 9 1.1
9403915 Abrasive tools (option) 33 12 5.1.1
9403915 Abrasive tools (option) 34 12 5.1.2
9403925-AF AF Loading area extension 8 4 1.2
9403928 45 4 6.8
9403947 89 15 13.2
9403948 89 16 13.2
9403952 Pusher part B 98 8 14.8
9403953 Pusher part A 98 7 14.8
9403956 94 4 14.4
9403957 93 5 14.3
9403964-AK AK 88 8 13.1
9403979-AF AF 100 7 15.
9403979-AF AF 101 7 16.
9403980 CT plate sensor 65 3 8.2
9403981 68 12 9.1
9403992 Recover glue plate 41 5 6.4
9404063-AK AK 51 3 6.14
9404064-AK AK 51 1 6.14
9404110-AK AK 88 5 13.1
9404111-AK AK 88 1 13.1
9404143 BBR uppper baffle (with Tag 15) 98 5 14.8
9404144-AF AF BBR upper cover (with Tag 15) 98 1 14.8
9404145 75 20 10.4
9404146 75 2 10.4
9404152 Cover support bracket (with Tag 17) 82 8 12.4
9410563 Knob assy 74 7 10.3

First Aid Kit
9591136
9413522 Pulley assy 30 11 4.2 X
9413733 Quarter turn lock assy 16 1 1.10
9413733 Quarter turn lock assy 13 5 1.7 X
9413859 Pulley assy 89 2 13.2
9413906 19 6 2.2
9413907 19 7 2.2
9413908 19 4 2.2
9413909 18 2 2.1
9413909 19 12 2.2
9413913 31 1 4.3
9413914 31 9 4.3
9413915 29 7 4.1
9413916 30 7 4.2
9413917 30 10 4.2
9413931 55 2 7.3
9413933 59 6 7.7
9413934 59 5 7.7
9413935 56 4 7.4
9413936 56 5 7.4
9413937 Gear assembly 58 1 7.6
9413938 Nipping gear assembly 58 6 7.6
9413939 53 3 7.1
9413940 62 6 7.10
9413945 83 1 12.5
9413948 64 6 8.1
9413948 70 8 9.3
9413948 64 11 8.1
9414004 22 1 3.1

First Aid Kit
9591136
9414004 26 1 3.5
9414005 Connecting rod assembly 84 1 12.6
9414005 85 1 12.7
9414022 Roller shaft assy 82 6 12.4
9414025 75 7 10.4
9414026 75 6 10.4
9414029 69 5 9.2
9414030 69 2 9.2
9414035 36 4 5.3
9414038 Pinion 25 2 3.4
9414041 45 6 6.8
9414045 44 5 6.7
9414047 Driving tray shaft 74 5 10.3
9414048 Tray transl. screw shaft 74 8 10.3
9414054 Gear Z10 assy 40 2 6.3
9414055 48 1 6.11
9414056-AF AF 15 2 1.9
9414058-AF AF 13 1 1.7
9414060-AF AF 16 2 1.10
9414062-AF AF 13 4 1.7
9414063-AF AF 13 3 1.7
9414064-AF AF 13 2 1.7
9414066-AF AF 14 8 1.8
9414070-AF AF 11 3 1.5
9414076 27 1 3.6
9414077 27 2 3.6
9414078 27 6 3.6
9414079 27 7 3.6
9414105 72 2 10.1
9414151 97 2 14.7
9414151 96 3 14.6

First Aid Kit
9591136
9414152 93 9 14.3
9414195 42 5 6.5
9414198 42 6 6.5
9414199 42 7 6.5
9420702 Grounding braid 98 16 14.8
9421685 Grounding braid 98 15 14.8
9422773 Receiver board 23 6 3.2 X
9422774 Emitter board 23 3 3.2 X
9422841 19 3 2.2 X
9422843 25 4 3.4
9422850 PNP sensor 65 1 8.2 X
9422856 Drive board 105 9 18.1 X
9422860 Cable DB 9 66 3 8.3
9422868 Glue tank board 105 12 18.1
9422894 Dispatch board 105 11 18.1 X
9422928 Interlock board 105 10 18.1 X
9422942 68 17 9.1 X
9422962 Power board 105 7 18.1 X
9422980 49 1 6.12
9422981 49 2 6.12
9422982 49 3 6.12
9422990 7 2 1.1
9422990 10 2 1.4
9422991 7 3 1.1
9422996 Dual button board 8 5 1.2 X
9423005 Harness 105 8 18.1
9423007 49 5 6.12
9423077 Capacitor assembly 105 15 18.1
9423082 Isolation board assy 105 6 18.1
9423086 Double detect sensor 80 9 12.2
9430876 Solenoid assy 77 10 11.1 X

First Aid Kit
9591136
9430937 Motor assy 99 1 14.9
9430937 Motor assy 97 6 14.7
9431627 Blower assy 105 13 18.1 X
9431932 Stepping motor + hex. shaft 30 9 4.2
9432331 25 1 3.4
9432339 Lateral gluing assy 40 1 6.3
9432350 20 3 2.3
9432351 19 9 2.2
9432355 54 1 7.2
9432356 64 5 8.1
9432357 62 4 7.10
9432357 70 6 9.3
9432362 Solenoid assy 86 4 12.8 X
9432364 77 1 11.1
9432373 36 1 5.3 X
9432378 77 15 11.1
9432383 75 8 10.4 X
9432387 103 4 17.1
9432391 46 4 6.9
9432392 39 7 6.2 X
9432396 Solenoid assy 40 5 6.3
X
9432396 47 7 6.10
9432403 43 1 6.6
9432425 29 6 4.1
9432439 49 8 6.12 X
9432440 49 4 6.12 X
9432446 Solenoid 65 8 8.2 X
9432447 20 2 2.3
9432458 46 1 6.9 X
9432480 Nipping harness plate assy 66 2 8.3
9432539 Collector assembly 100 2 15.

First Aid Kit
9591136
9432540 Collector control box 100 12 15.
9432557 Safety curtain assembly 8 2 1.2
9591161 without Tag 6 Upgrade Kit Tag 8 35 5.2
9591169 Double detect sensor kit 80 11 12.2
9591179 Lateral screw kit 41 4 6.4
9591188 witout Tag 18 79 12.1
9591188 without Tag 18 86 12.8
9591200 Gearmotor kit 60 7 7.8
9591201 Gear motor kit 58 11 7.6
9591202 Gearmotor kit 84 11 12.6
4390001902 Nut 50 2 6.13
7006046000 Paper feed friction roller 82 4 12.4
9310806506 36 10 5.3
9330500806 Screw 40 10 6.3
14750402200 89 14 13.2
68850602000 20 6 2.3
9103049+942
Power supply without Tag 4 105 18.1
3077
9104114 11 4 1.5
9166074 2X
(without Tag 17) 82 11 12.4
+9404152 1X
9404141 +
Milling blade assembly 34 5 5.1.2
9204100
UI (see Software history in the General
9423… 103 1 17.1
Procedure in the Service Manual)
9423… BBR board (see Software history in the 99 3 14.9
Industrial flash (see Software history in
9423… the General Procedure in the Service 103 10 17.1
Manual)
9423xxx CPU 105 16* 18.1
9423xxx Frequency driver glue tank 105 24* 18.1
9423xxx Frequency driver translation 105 3* 18.1

20. FIRST AID KIT
First Aid Kit 9591136

Bourg Number Quantity Description
9103049 1 Power Supply 900W 24V+36V
9107063 3 Photosensor
9124008 2 Fuse 4A T 6,3X32
9124016 6 Fuse 6,25A T 6,3X32
9124024 1 Fuse 0,5A T 5X20
9124028 1 Fuse 1A T 5X20
9124187 2 Fuse 3,75A
9124194 3 Fuse 12A T
9126161 1 Belt D4X412
9126319 1 Belt 10T5 640MM
9126445 2 Belt 1446 X40
9132026 1 PLC module MM432
9150065 2 Microswitch+roller+open.
9151136 1 Motor
9166027 1 Release Spring
9166045 1 Spring
9166082 4 Tension Spring
9166121 1 Spring
9166172 2 Spring
9166203 1 Spring
9166277 2 Spring
9166279 1 Spring
9166282 1 Spring
9166283 3 Spring
9166284 1 Spring
9166285 1 Spring
9166286 3 Spring
9166292 1 Spring
9182065 4 Jogger blade spring
9198003 2 Milling brush

First Aid Kit 9591136
Bourg Number Quantity Description
9199883 5 Aluminium bowl
9199998 2 Notching tool
9199999 1 Milling blade
9222738 1 Milling shutter
9230560 1 Teflon plate
9261715 1 Succion bar flag
9261822 8 Flat cup
9261832 2 Drum 1 Scraper
9403742 1 Cover clamp with foam
9413522 1 Pulley 10T5
9413733 2 1/4 turn screw assy
9414098 1 Jig for nipping adj.
9422492 1 Cable DB9M-DB9M
9422773 1 Carriage receiver board
9422774 1 Carriage emitter board
9422841 1 Encoder
9422850 1 PNP sensor
9422856 1 Stepper driver board
9422894 1 Timer + Dispatch board
9422928 1 Interlock board
9422962 1 Power board
9422969 1 Isolation board
9422996 1 Dual button board
9430876 1 Solenoid 9136026+conn. assy
9431627 1 Fan 9151133+conn. assy
9432362 1 Solenoid 9136083+Led assy
9432373 1 Motor 9151123+conn. assy
9432383 1 Solenoid 9136075+Led+conn.
9432392 1 Glue tank drum assy
9432439 1 Heating resistor 300W
9432440 1 Heating resistor 1000W
9432458 1 Spinner resistor 50W assy

21. HARDWARE
6PCC DIN912 ZINC 6PCC DIN 912 + TUFLOCK ST DIN 913 BLK ST DIN 916 BLK. TH DIN 933 ZINC.
M3 M4 M5 M6 M8 M5 M6 M8 M8 M3 M4 M5 M8 M4 M5 M6 M8 M10 M12
6 S457 8 S392 20 S185 5 S042 S009 10 S495
8 S458 S371 S470 S480 16 S569 35 S186 10 S122 12 S496 S233
10 S464 S441 S163 30 S490 12 S571 S415 16 S452 S502 S559
12 S459 S465 S471 S481 20 S296 20 S396 S454
16 S460 S453 S472 S374 S548 30 S138 25 S270 S573
20 S461 S466 S473 S243 S489 50 S566 30 S503 S437
25 S462 S467 S474 S482 35 S614
30 S463 S468 S483 45 S435
35 S469 S484 S393 70 S574
45 S546 75 S504
50 S549 80 S592
60 S479 S613 90 S505
100 S376
TFF DIN 963 ZINC. CHTB ULS ZINC. 6PCC DIN 7984 ZINC. 6PCF DIN7991 Screw with washer
M3 M4 M5 M6 M4 M5 M6 M4 M5 M6 M8 M4 M6
8 S343 8 S514 10 S542 S543 8 S304 8 S377
12 S093 10 S515 S522 12 S570 10 S537 12 S378
12 S516 S523 16 S544 12 S551 20 S382 S607
16 S517 S524 45 S922 16 S539
20 S525 20 S562
25 S519 25 S536
30 S527
Spring loaded set screw

M5
12 S442
To order Sxxx,
“S” should be replaced by the number 9190.
Example:
for a S163, you should order the item 9190163.

WASHER - 9172xxx
D:2 D:3 D:4 D:5 D:6 D:8 D:10 D:12 D:12.5 D:15 D:17 D:18
DIN 125 ZINC. W005 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 W211
DIN 988 (0.2) W028 W017 To order Wxxx,

DIN 988 (0.5) W039 W027 W029 “W” should be replaced by the number 9172.
MEDIUM CONTACT W184 W185 W186 W187 W188 W189 W190
Example:
A PICOTS W191 W192 W193 W194
for a W193, you should order the item 9172193.
ROND. RESS. GRIFFES W182
6797 IZ W044
NUT - 9135xxx
M2,5 M3 M4 M5 M6 M8 M10 M12
DIN 546 N106
DIN 934 N054 N002 N012 N009 N046

To order Nxxx,
DIN439 N078
“N” should be replaced by the number 9135.
DIN 985 N008 N006 N005 N001 N004 N150
+ SPRING N152 Example:

for a N152, you should order the item 9135152.

CIRCLIPS - 9117xxx
D:4 D:6 D:7 D:9 D:10 D:12 D:14 D:15 D:17 D:19 D:32 D:35
DIN 471 R158 R011 R007 R153 R012 R026
DIN 472 R0159 R006 R016
DIN6799 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.

NOTES
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Section 6 :
GENERAL PROCEDURES
General Procedures Initial issue: 06/04

Page 6 - i Latest revision: 09/05

Page 6 - ii 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


Page 6 - 2 Latest revision: -
SPECIALITY TOOLS KIT 9591182
Extension board for glue tank board Cover clamp jig Digital comparator kit
(96 pins connector) 9423010
9414098
9926012
9926011
9231152 9926009
9591153
9926010
Jogger label 99 133 04000
1,0
0,9
0,8
0,7
0,6 9210582
0,5 Jogger adjustment square 9941021000
0,4 9414167
0,3
0,2
0,1
0 9204035
Serial cable RS232 9138096
Feeler gauge 9929348 Technician box 9432545

Ethernet cable 9138093
Keyboard to program ABB

frequency driver 9132019
Serial cable 9422187
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TAG MATRIX LOCATION
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PROGRAMMED PARTS AND SOFTWARE HISTORY
Part UI Industrial flash BBR Part Frequency Frequency

description CPU with software programmed board CD description driver for glue tank driver for translation
with Software
TAG
Software Software
version version
V02.00.04 9423093 - 9423138 - 9423092 -

14 9425003 B V01.00.01 9423091 9423090
V00.00.12 9423006 E
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.

TAG INFO
TAG 1 : TAG 10 :
Software version 02.00.00.
Machines equipped with interlock boards 9422928C.
TAG 11 :
TAG 2 :
New BBR board to correct mode RUN/DOWNLOAD problem
Machines equipped with moulded glue tank.
9423006B to 9423006C (AM 031).
TAG 3 : TAG 12 :
Machines equipped with a moulded milling blade housing (volute). Machines equipped with new feeding system for lateral gluing.
TAG 4 : TAG 13 :
Add capacitor assy to reduce current and use COSEL power supply. New threaded rod (in two parts) for lateral gluing cylinders -
Kit 9591179.
TAG 5 :
Machine pre-equipped with double detection harness. TAG 14 :
Kit Upgrade BBR 9591181.
TAG 6 : Addition of springs (to avoid marking on booklets) and grounding
Hole in the milling blade housing + cover clamp shaft replacement braid (to avoid BBR frequently stops).
and prefeed gear assembly replacement).
TAG 15 :
TAG 7 : New BBR cover (9404144) and new upper baffle for BBR head
Lateral gluing modification (glue cut off index + driving). (9404143).
TAG 8 : TAG 16 :
Kit 9591161 (software version 02.00.00 + pressure sensor + New suction ramp, removal of the knurled knob.
sleeve + lateral gluing cylinders + insulation washer removal +
BBR book separator harrow replacement + polishing of the TAG 17 :
baffles). Creasing module: Springs 9166280 replaced by springs 9166074.
TAG 9 :
Cover station panel.

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

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.

Step 2 : Install the BB3002 Software on your How to remove the BB3002 Software Manager
computer Press “Start “ / “Settings “ / “Control Panel “.
- In the Control Panel, double click on “ Add/Remove
- Insert the CD-ROM in the CD-Reader.
Programs “ (or select “Add/ Remove Programs “, click
- Double click “My Computer“ to access the CD-Reader and on “ file/open “).
open its respective drive (or select the drive, click on
- Select the program BB 3002 Software Manager then
“file/open“).
press “ Add/Remove “, press the Yes button to confirm
- Double click on the file “ Setup “ (or select “ Setup “, click the removal.
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”. - Leave your computer connected to the mains when
download.
Note 1: (Only for Windows XP) - Check that hibernate or power off mode are not activated
If the software is already installed on your (Start / Control panel / Power option).
computer you have the possibility to modify, - Restart the computer.
repair or remove it. Make your choice and click
the “Next” button.
Note 2: (For the other O.S.): If the software is already

installed on your computer you have to remove
the installed version.

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

CASE 2 : Using the serial cable 9138096
- Time : 1 hour 30 minutes.
- Only if the download with the Ethernet cable is not - To update the U.I, connect the UI to the PC through
possible (no Ethernet board, TCP IP failure). 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.
9138096 Node rotary switches

Left
Right
From PC
From PC
Fig.4B
Fig.4C

Step 4 : Updating the binder A- Backup
Power ON the binder. Click on Backup BB3002 Settings. Read the checklist.
On your computer, click on “Start”, select “All programs” then If you use a serial cable, you have to specify a port
“CP Bourg/BB3002 Software Manager/ Version XX.XX.XX”. COM number (following your configuration) (Fig.6).
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

Fig.5 ( If serial cable only)
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”.

B- Update TAG
Click on “Update BB3002” (Fig.5) and follow instructions. Marf off The TAG number corresponding to the installed software
Click on “Yes” button. (for example TAG 10 for the software version 02.00.00) see CD label.
Wait until the message “BB3002 transfer OK” appears (25
Version TAG
minutes).
02.00.00 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.
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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

Fig.6
Step 6 : Updating the BBR The window (Fig.10) appears. Follow the instructions tehn
click on “OK”.
Time : 2 minutes.
Binder must be ON and BBR connected.
Follow
On your computer, click on “Start”, select “All programs” then instructions
“CP Bourg/BB3002 Software Manager/ Version XX.XX.XX”.
A window “Software Manager V02.00.04” will pop up (Fig.8).
Fig.8
Fig.10
Click on “Update BBR” (Fig.8).
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).

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 TAG
02.00.00 10
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ANNEXE : Menu Help
Both the UI and PLC are closely interlinked and are
BB3002 Software Manager connected to each other through a crossed serial cable. The
This CDROM contains all the files for the updating and installing software versions need to be compatible for the
of the C.P.Bourg BB3002 Software Manager. Please install this communication in between the two. Make sure the both
sofware running setup.exe. software versions have the same XX.YY (Version XX.YY.ZZ),
the ZZ is unimportant for the communication.
Hardware
The updating or installation of the software requires either a
1. Ethernet crossed cable - reference: 9138093. crossed serial cable or a crossed ethernet cable. Only the
2. Serial crossed cable - reference: 9138096. 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
The BB3002 Update to a new version
have a serial port, there are some USB-serial port adapters
1. Updating the BB3002. on the market.
2. Settings or Alarms: Backup, Restore, View.
Here are the options
Please Backup your settings before any action and Restore them
1. Updating the BB3002
at the end. After Installation you will need to check:
4. Updating the UI software
1. The date and time.
5. Reinstalling the PLC software
2. The glue heat up timer (it may assume the glue tank 6. Reinstalling the UI software
needs reheating). 7. Settings or Alarms: Backup, Restore, View
3. The machine counter (recoverable from the mechanical
reading in the machine).
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.
BB3002 Update the RIGHT rotary switch to 0 (see figure 3C). When
rebooting the UI "Mode/Node=02" will appear.
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

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.

sing a crossed ethernet cable
Checklist:

Interface.
194.10.200.70).
connexion.

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.

Connection
UI Update can be done in two ways:

serial cable).
Using a crossed serial cable

computer.
3. Remember to reconnect the BB3002 serial cable after
installation.

Using a crossed ethernet cable
Checklist:

Interface.

194.10.200.70).

connexion.

the RIGHT rotary switch to 0 (see figure 3C). When

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:

serial cable).
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

computer (COM1 or COM2).
end of your cable directly into the PLC.
3. Launch the installation program and specify COM port.
installation.

Installing the PLC software using a crossed ethernet cable
Using a crossed ethernet cable
Checklist:

Interface.

194.10.200.70)
connexion.

the RIGHT rotary switch to 0 (see figure 3C ). When

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

computer (COM1 to COM8).
3. Launch the installation program.
installation.

ALARM MESSAGES
Alarm Messages Messages d'alarme

English Français
2 Please press the green button on the machine Veuillez appuyer sur le bouton vert
4 Please press the glue tank heating button Veuillez appuyer sur la chauffe de colle
8 Glue tank too cold - please wait La colle chauffe - Veuillez patienter
16 Glue tank too hot - please wait La colle est trop chaude - Patientez
32 Book in the machine - please remove it Veuillez retirer le livre de la machine
64 Cover in the machine - please remove it Veuillez retirer la couverture de la machine
128 BBR full - please empty it BBR rempli - Veuillez le vider
256 Technician mode Mode Technicien
512 Emergency stop activated - please deactivate Arrêt d'urgence enclenché
1024 Life test running Test de durée de vie en cours
2048 Book Binder needs rebooting - please reboot Veuillez éteindre et allumer la machine
4096 Double click the green button to start Faites un double click sur le bouton vert
8192 Automatic start upon insertion of the book Auto démarrage dès l'introduction du livre
16384 Glue tank level too low - please add glue Niveau de colle trop bas
32768 Glue tank level too high - please remove Niveau de colle trop haut
65536 The waste bag is full - please empty it Sac à copeaux plein - Veuillez le vider
131072 The cover level is low - please refill Niveau de couverture bas
524288 Glue tank heating cycle not completed Attente de la chauffe du bac à colle
1048576 Interlock active - please release Interlock actif - veuillez le relacher
2097152 The book dimensions are out of limits ! Paramètres du livre hors limites !
4194304 Book width must be Epaisseur doit être
66666 Book thickness out of specifications Epaisseur du livre hors spécifications

77777 Emergency stop - Barrier detection during cycle Arrêt d'urgence - Détection des mains dans la barrière
88888 Emergency stop - Caused by exit from technician page Arrêt d'urgence - Sortie d'une page technicien
99999 Interlock activated - Maybe a door is open or an interlock switch is active Interlock actif - Porte ouverte ou interlock actif
33010 Carriage - Please remove any paper from the carriage clamp Chariot - Veuillez retirer le papier dans le chariot
33040 Carriage - Timed out trying to reach the fully closed position Chariot - La pince n'a pas su atteindre position fermée
33060 Carriage - Reset failed Chariot - Réinitialisation a échoué
33080 Carriage - Timed out while switching to PWM mode Chariot - Pince: Echec lors du basculement vers le mode PWM
33090 Carriage - Timed out trying to reach the fully open position Chariot - La pince n'a pas su atteindre sa position maximale
33110 Carriage - Carriage position out of bounds Chariot - Position du chariot hors limites
33130 Carriage - Timed out trying to reach the initialisation position Chariot - Pince n'a pas su atteindre sa position d'initialisation
33210 Carriage - Book thickness out of range (negative or bigger than 60 mm) Chariot - Epaisseur en dehors des spécifications (épaisseur < 0 mm ou > 60 mm)
33240 Carriage - No book in the clamp during the cycle Chariot - Absence de livre dans la pince durant le process

English Français
33333 Carriage - Motor overheating protection activated Chariot - Protection de surchauffe du moteur activé
33350 Carriage - Timed out while closing the clamp with 4 Amps Chariot - Fermeture impossible à 4 Ampères
33910 Carriage - Carriage buttons: current mode during the switch to PWM Chariot - Boutons du Chariot: mode courant lors de basculement PWM
33980 Carriage - Carriage buttons: forced current mode Chariot - Boutons du Chariot: mode courant non demandé
36048 Translation - Variator error Translation - Erreur variateur
36049 Translation - Left position switch error Translation - Switch de détection Chariot à Gauche ne répond pas
39001 Jogger - Too many active steppers - Please reboot the machine Taquage - Trop de moteurs pas à pas actifs - Veuillez redémarrer la machine
39002 Jogger - TPU DIRRESPONSE - Please reboot the machine Taquage - TPU DIRRESPONSE - Veuillez redémarrer la machine
39005 Jogger - TPU ERROR - Please reboot the machine Taquage - ERREUR TPU - Veuillez redémarrer la machine
39106 Jogger - Did not find the cell - Is the cell badly adjusted ? Taquage - N'a pas trouvé sa cellule - Cellule mal ajustée ?
39107 Jogger - Did not stop in the cell - Is the cell badly adjusted ? 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
42050 Milling - Motor direction test failed ! Wrong direction or motor not turning
tourne pas
42100 Milling - Exhaust vent blocked Fraisage - Bourrage copeaux
42300 Milling - Milling motor temperature too high Fraisage - Surchauffe du moteur de fraisage
42500 Milling - No milling bag in BB3002 Fraisage - Pas de sac à copeaux dans BB3002
42600 Milling - Please check the milling bag is not full Fraisage - Bac à copeaux plein
42700 Milling - Current overload Fraisage - Courrant trop important
42800 Milling - Not running Fraisage - Ne tourne pas
48002 Glue tank - Variator error Bac à colle - Erreur de variateur
48100 Glue tank - Cylinder 1 and Cylinder 2 temperature difference too high Bac à colle - Différence de températures cylindres 1 et 2 trop grande
48160 Glue tank - Side glue mechanism did not reach its cell Bac à colle - Le mechanisme de l'encollage latéral n'a pas atteint sa cellule
48201 Glue tank - Side glue - Too many active steppers - Please reboot Bac à colle - Encollage latéral - Trop de moteurs actifs - Veuillez redémarrer
48202 Glue tank - Side glue - TPU (dirresponse) - Please reboot Bac à colle - Erreur TPU de l'encollage latéral (dirresponse) - Veuillez redémarrer
48205 Glue tank - Side glue TPU error - Please reboot Bac à colle - Erreur TPU de l'encollage latéral - Veuillez redémarrer
48206 Glue tank - Scraper TPU error - Please reboot Bac à colle - Erreur TPU des scrapers - Veuillez redémarrer
48300 Glue tank - Spinner out of range Bac à colle - Le spinner n'est pas dans la plage tolérée
48301 Glue tank - Spinner - Too many active steppers - Please reboot Bac à colle - Spinner - Trop de moteurs actifs - Veuillez redémarrer
48302 Glue tank - Spinner - TPU (dirresponse) - Please reboot Bac à colle - Spinner - TPU (dirresponse) - Veuillez redémarrer
48305 Glue tank - Spinner - TPU error - Please reboot Bac à colle - Spinner - Erreur TPU - Veuillez redémarrer
48600 Glue tank - Relay on temperature board needs resetting Bac à colle - Thermique carte bac à colle déclenché
48700 Side glue option is present but not declared in the UI Encollage latéral présent mais déclaré absent dans l'UI
54001 Cover Transport - Too many active steppers - Please reboot the machine Transport Couverture - Trop de moteurs actifs - Veuillez redémarrer la machine
54002 Cover Transport - TPU DIRRESPONSE - Please reboot the machine Transport Couverture - TPU DIRRESPONSE - Veuillez redémarrer la machine
54005 Cover Transport - Timed out turning left Transport Couverture - Timeout en tournant à gauche
54106 Book Clamp Up/Down - Timed out turning left Emboitage - Timed out en tournant à gauche
54107 Book Clamp Up/Down - Timed out turning right Emboitage - Timeout en tournant à droite
54110 Book Clamp Up/Down - Failed to reach the down position Emboitage - Echec lors du retour à la position basse
54120 Book Clamp Up/Down - Failed to reach the up position Emboitage - Echec lors du retour à la position haute
54160 Book Clamp Up/Down - Failed to leave the cell Emboitage - Incapacité de quitter la cellule

English Français
54210 Book Clamp Nipping - Failed to close Emboitage Pinçage - Echec de fermeture
54320 Book Clamp Nipping - Failed to reach the requested current Emboitage Pinçage - Incapable d'atteindre le seuil de courant demandé
54400 Book Clamp Nipping - Failed to reach the requested book thickness position Emboitage Pinçage - Incapable d'atteindre la position pour l'épaisseur du livre
54500 Book Clamp Nipping - Failed to reach the requested position Emboitage Pinçage - Incapable d'atteindre la position demandée
54600 Book Clamp Nipping - Failed to reopen Emboitage Pinçage - Incapable de se réouvrir
57005 Cover Feeder - Initialisation error - Failed to leave the home cell Prise couverture - Pas sorti de sa cellule lors de l'initialisation
57016 Cover Feeder - Failed to collect the cover even after several tries Prise couverture - Echec même après quelques essais
57017 Cover Feeder - Cover lost while waiting for the transfer Prise couverture - Perte couverture en attente du transfer
57018 Cover Feeder - Cover lost during the fast part of the transfer Prise couverture - Perte couverture pendant le transfert rapide
57019 Cover Feeder - Cover lost during the slow part of the transfer Prise couverture - Perte couverture pendant le tranfert lent
57020 Cover Feeder - Cover lost while transferring into the clamp (breaking) Prise couverture - Perte couverture pendant le transfert - freinage
57022 Cover Feeder - Cover lost in cover clamp Prise couverture - Perte couverture dans la pince couverture
57027 Cover Feeder - Process error even after several retries Prise couverture - Perte couverture après plusieurs essais
57028 Cover Feeder - Double cover detected Prise couverture - Double couverture
57029 Cover Feeder - Cover sensor did not respond Prise couverture - capteur présence papier ne répond pas
57101 Cover Feeder - Too many active steppers - Please reboot Prise couverture - Trop de moteurs actifs - Veuillez redémarrer
57102 Cover Feeder - TPU (dirresponse) - Please reboot Prise couverture - TPU (dirresponse) - Veuillez redémarrer
57105 Cover Feeder - TPU error - Please reboot Prise couverture - Erreur TPU - Veuillez redémarrer
60002 Cover Clamp - Initialisation error - Cover present: please remove manually Transport Couverture - Veuillez retirer la couverture de la pince
60014 Cover Clamp - Cover lost after being loaded into the clamp Transport Couverture - Couverture perdue après transfert
60015 Cover Clamp - Creasing distance out of range - Bad book format ? Transport Couverture - Distance de rainage hors spécifications - Format du livre ?
60016 Cover Clamp - Clamping position out of range - Bad book format ? Transport Couverture - Position d'emboitage hors spécifications - Format du livre ?
Transport Couverture - Perte de couverture en positionnant pour rainage ou
60023 Cover Clamp - Lost the cover while positioning for creasing or book reception
emboitage
60024 Cover Clamp - Lost the cover while waiting for the book clamping Transport Couverture - Perte de couverture en attendant l'emboitage
60025 Cover Clamp - Lost the cover during the book clamping Transport Couverture - Perte de couverture en emboitage
60026 Cover Clamp - Lost the cover with the creasing mechanism up Transport Couverture - Perte de couverture avec rainage en position haute
60101 Cover Clamp - Too many active steppers - Please reboot Transport Couverture - Trop de moteurs actifs - Veuillez redémarrer
60102 Cover Clamp - TPU (dirresponse) - Please reboot Transport Couverture - TPU (dirresponse) - Veuillez redémarrer
60105 Cover Clamp - TPU error - Please reboot Transport Couverture - Erreur TPU - Veuillez redémarrer
63000 Creasing - Too many covers ? Try lowering the suction level Rainage - Impossible de rainer - Trop de couvertures ?
63020 Creasing - Prepositioning timed out Rainage - Timeout du prépositionnement du rainage
63030 Creasing - Creasing cell badly connected Rainage - Mauvaise connexion de la cellule de rainage
63040 Creasing - Timed out while trying to reach the home position Rainage - Impossible d'atteindre la position d'initialisation
63060 Cover Clamp - Creasing home cell badly connected ? Cover Clamp - Mauvaise connexion de la cellule de rainage ?
85000 BBR - Unknown error BBR - Erreur inconnue
85001 BBR - CAN initialisation error BBR - Erreur pendant l'initialisation du CAN
85002 BBR - CAN write error BBR - Erreur pendant écriture du CAN
85021 BBR - Error during initialisation BBR - Erreur pendant l'initialisation
85026 BBR - Error during the return home of the BBR 'head' BBR - Erreur pendant le 'homing' de la tête

English Français
85032 BBR - Error opening BBR 'head' for homing BBR - Erreur ouverture de tête allant en home
85037 BBR - Error the BBR 'head' didn't reach its home cell BBR - Erreur la tête n'arrive pas à la cellule home
85038 BBR - The head is detecting the 'squeeze' BBR - La palette de la tête se trouve déja relevée
85039 BBR - The head is detecting the 'squeeze' too early BBR - Relevée de la palette de la tête détectée trop tot
85048 BBR - Error while the book is entering the BBR BBR - Erreur lors de la réception du livre
85053 BBR - Error while waiting for the opening of the 'head' BBR - Erreur en attente de la préouverture de la tête
85058 BBR - Error during the opening of the 'head' BBR - Erreur lors de la preouverture de la tête
85064 BBR - Error while checking the book reception BBR - Erreur en vérifiant la réception du livre
85069 BBR - Error while setting the incoming book delay parameter BBR - Erreur pendant le paramètrage du délai de livre rentrant
85074 BBR - Error while waiting for the book BBR - Erreur en attente du livre
85085 BBR - Error while squeezing the book BBR - Erreur en pressant le livre
85090 BBR - Timed out while squeezing the book BBR - Timeout en pressant le livre
85096 BBR - Error while asking the fork to go down BBR - Erreur demande herse vers le bas
85101 BBR - Error while waiting for the fork to go down BBR - Erreur en attente de la herse en position basse
85106 BBR - Error asking for the 'head' overrun BBR - Erreur demandant surcourse de la tête
85112 BBR - Error while checking the 'head' overrun BBR - Erreur attendant surcourse de la tête
85117 BBR - Error while asking the fork to go up BBR - Erreur demandant herse de remonter
85122 BBR - The fork failed to go up BBR - La herse n'a pas su remonter
85128 BBR - Error asking the 'head' to return BBR - Erreur demandant à la tête de reculer
85133 BBR - Error waiting for the 'head' to return BBR - Erreur en attendant le retour de la tête
85144 BBR - Emergency stop detected BBR - Arrêt d'urgence enclenché
85241 BBR - Full - Please empty the BBR BBR - Plein - Veuillez vider le BBR
85245 BBR - Stop button pushed BBR - Bouton d'arrêt enclenché
85246 BBR - Book stuck on the BBR head BBR - Livre arrêté sur la tête du BBR
99000 BB3002 Timeout - Unknown error Timeout BB3002 - Erreur inconnue
99033 BB3002 Timeout - Carriage clamp did not respond Timeout BB3002 - La pince chariot ne répond pas
99036 BB3002 Timeout - Translation did not respond Timeout BB3002 - La translation ne répond pas
99136 BB3002 Timeout - Translation did not respond while testing the encoder Timeout BB3002 - Translation ne répond pas pendant le test de l'encodeur
99039 BB3002 Timeout - Jogger did not respond Timeout BB3002 - Le taquage ne répond pas
99042 BB3002 Timeout - Milling did not respond Timeout BB3002 - Fraisage ne répond pas
99048 BB3002 Timeout - Glue tank did not respond Timeout BB3002 - Bac à colle ne répond pas
99148 BB3002 Timeout - Spinner did not respond Timeout BB3002 - Spinner ne répond pas
99248 BB3002 Timeout - Side glue did not respond Timeout BB3002 - L'encollage latéral ne répond pas
99057 BB3002 Timeout - Cover feeder did not respond Timeout BB3002 - Prefeed ne répond pas
99060 BB3002 Timeout - Cover clamp did not respond Timeout BB3002 - Le transport couverture ne répond pas
99063 BB3002 Timeout - Book clamp did not respond Timeout BB3002 - l'emboitage ne répond pas
99065 BB3002 Timeout - Creasing mechanism did not respond Timeout BB3002 - Le rainage ne répond pas
99099 BB3002 Timeout - Paper lost in carriage clamp Timeout BB3002 - Perte de papier dans la pince chariot
99142 BB3002 Timeout - Milling could not be indexed Timeout BB3002 - Fraisage incapable de s'indexer
99090 BB3002 Timeout - Milling could not be indexed Timeout BB3002 - Fraisage incapable de s'indexer

English Français
99160 Process - Changed cover mode while in process Process - Changement de mode couverture pendant le cycle
99242 BB3002 Timeout - Jogger too low - risk of collision with milling Timeout BB3002 - Taquage trop bas - risque de collision avec la fraise
99260 BB3002 Timeout - Cover not in safe area Timeout BB3002 - Couverture n'est pas en position de sécurité
99833 BB3002 Timeout - Carriage clamp not in emergency stop status Timeout BB3002 - La pince chariot n'est pas en arrêt d'urgence
99836 BB3002 Timeout - Translation not in emergency stop status Timeout BB3002 - La translation n'est pas en arrêt d'urgence
99839 BB3002 Timeout - Jogger not in Emergency Stop Status Timeout BB3002 - Le taquage n'est pas en arrêt d'urgence
99855 BB3002 Timeout - Milling not in Emergency Stop Status Timeout BB3002 - Le fraisage n'est pas en arrêt d'urgence
99856 BB3002 Timeout - Book clamp not in emergency stop status Timeout BB3002 - L'emboitage n'est pas en arrêt d'urgence
99857 BB3002 Timeout - Cover feeder not in emergency stop status Timeout BB3002 - Le prefeed n'est pas en arrêt d'urgence
99858 BB3002 Timeout - Glue tank not in emergency stop status Timeout BB3002 - Le bac à colle n'est pas en arrêt d'urgence
99860 BB3002 Timeout - Cover clamp not in emergency stop status Timeout BB3002 - Le Transport Couverture n'est pas en arrêt d'urgence
99890 BB3002 Timeout - Conveyor not in emergency stop status Timeout BB3002 - Convoyeur n'est pas en arrêt d'urgence
99900 BB3002 - Power loss in 5v cells BB3002 - Perte de la tension des cellules 5v
Undocumented error - Erreur non documentée -
200000 * Book Binder switched on * * Machine sous tension *
200001 * Book Binder switched off * * Machine éteinte *

NOTES

NOTES

Section 7:
WIRING DIAGRAMS
Wiring Diagrams Initial issue: 04/04


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
1.8 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
1.17 Carriage clamp (part 1 of 2) ........................................................................................................................................17
1.18 Carriage clamp (part 2 of 2) ........................................................................................................................................18
1.19 Translation (part 1 of 3)...............................................................................................................................................19
1.22 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
1.31 Glue tank (part 7 of 8) .................................................................................................................................................31
1.32 Glue tank (part 8 of 8) .................................................................................................................................................32
1.33 Book clamp (part 1 of 2)..............................................................................................................................................33
1.34 Book clamp (part 2 of 2)..............................................................................................................................................34
1.35 Prefeed (part 1 of 2)....................................................................................................................................................35
1.36 Prefeed (part 2 of 2)....................................................................................................................................................36
1.37 Cover clamp ................................................................................................................................................................37
1.38 Creasing ......................................................................................................................................................................38
1.39 Can..............................................................................................................................................................................39
1.40 Conveyor .....................................................................................................................................................................40
1.41 Signalling lighting ........................................................................................................................................................41
1.42 BBR Power supply and interlock (part 1 of 4).............................................................................................................42
1.43 BBR Head motor (part 2 of 4) .....................................................................................................................................43
1.44 BBR Inputs sensor (part 3 of 4) ..................................................................................................................................44
1.45 BBR Fork motor (part 4 of 4) ......................................................................................................................................45
1.46 External dust extractor and option ..............................................................................................................................46
1.47 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

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

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 variators-
Version 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

1. WIRING DIAGRAMS
1.1 Diagram block

1.2 Interlock connections (part 1 of 2)

1.3 Interlock connections (part 2 of 2)

1.4 Power parts single-LINE representation (part 1 of 4)




1.8 Main supply

1.9 Interlock board

1.10 Interlock by pass

1.11 Interlock power supply 36V

1.12 Interlock power supply 24V (part 1 of 5)





1.17 Carriage clamp (part 1 of 2)

1.18 Carriage clamp (part 2 of 2)

1.19 Translation (part 1 of 3)



1.22 Jogger

1.23 Milling (part 1 of 2)

1.24 Milling (part 2 of 2)

1.25 Glue tank (part 1 of 8)








1.33 Book clamp (part 1 of 2)

1.34 Book clamp (part 2 of 2)

1.35 Prefeed (part 1 of 2)

1.36 Prefeed (part 2 of 2)

1.37 Cover clamp

1.38 Creasing

1.39 Can

1.40 Conveyor

1.41 Signalling lighting

1.42 BBR Power supply and interlock (part 1 of 4)

1.43 BBR Head motor (part 2 of 4)

1.44 BBR Inputs sensor (part 3 of 4)

1.45 BBR Fork motor (part 4 of 4)

1.46 External dust extractor and option

1.47 Cover detection

2. GRAPHICAL SYMBOLS FOR DIAGRAMS

3. COMPONENT LIST
Name Part Type FNC Reference Bourg Number Page

-A1 9422856 STEPPER_BOARD -A1 14, 22, 34, 35
-A2 9422856 STEPPER_BOARD -A2 14, 27, 37
-A3 9422928 Main interlock for selv circuit -A3 9, 11, 12, 13, 15, 16, 17, 19
-A4 9422894B Dispatch board -A4 10, 13, 18, 19, 22, 24, 29, 33, 34, 35, 36, 37, 38
-A5 9422868_GLUE_TANK_BOARD Glue tank control -A5 29, 30, 31
-A7 9423006 BBR board -A7 42, 43, 44, 45
-A8 9103048_36V+24V_1000W Power supply 36V and 24V 1000W -A8 11
-A20 9422962 Power board for primary circuit and brakes -A20 11, 21, 22, 23, 26, 28, 32, 36
-A30 9422969 Isolation board for variable frequency driver -A30 20, 23, 25
-AT 9432258_BOITIER_BY-PASS Technician box -AT 10, 16
-AUI 9138094 Graphic user interface PP120 -AUI 39
-CH1 MAIN_SAFETY_GROUND Main safety ground -CH1 8
-CH2 SEC_SAFETY_GROUND Secondary safety ground -CH2 23
-CH9 SECONDARY_GND GND 39
-CH10 SECONDARY_GND 28
-E1 9120180_FILTRE_3X415V_20A Triphase input filtre -E1 8
-E2 9120189_FILTRE_10VN1 Blower suction filter -E2 36
-F1 9164011 Main fuse. 12AM -F1 8
-F2 9164011 Main fuse. 12AM -F2 8
-F3 9164011 Main fuse. 12AM -F3 8
-T1 9182066_TRANSFO_3X208..415V_5.2KVA Main transformer -T1 8
-TCAN1 9422912 Terminator CAN TCAN1 39
-TCAN2 9422912 TERMINATOR CAN TCAN2 40
-X11 9121363+9121461 TBD 23
1X1 9121973+9121974 Linking from flexible cable to carriage 33-X1 17, 18
1X4 9121973+9121974 Linking from main frame to flexible cable 33-X4 17, 18
1X6 9121363+9121461 Linking from main frame to flexible cable 33-X6 17
2X1 MODU10P_9121836+9121837 Linling from main frame to translation part 36-X1 19
4X1 MNL3POS_9121352 Connector for outside dust collector 42-X1 23
4X3 9121326+9121327 TBD TBD 23
4X5 MNL4POS_9121853+9121767 TBD TBD 23
5X1 WAGO4X(1+1) Linking for cylinder resistors 48-X1 32
6X1 9121471+9121470 Linking from main frame to book clamp 54-X1 33, 34, 37
6X3 9121949+9121950 Linking from flat cable to clamping area 54-X5 33, 34
6X5 9121949+9121950 Linking from flat cable to clamping area 54-X5 33, 34

6X6 9121469+9121468 Linking from main frame to book clamp 54-X6 34, 37
7X1 MNL9POS_9121481+9121478 Linking from main frame to glue tank 57-X1 35, 38
7X3 9121481+9121478 Linking from main frame to glue tank 57-X3 35
13X3 9121326+9121327 Security barrier for clamping area 66-X3 15
33-B01P 9422774 Carriage emitter 33-B01p 18
33-B02P 9422773 Cariage receptor 33-B02p 18
33-B04P 9422843 Carriage clamp tichickness gauge 33-B04p 17
33-M01P 9432331 Carriage clamping Motor 33-M01p 17
33-R1 9170380_RES44R_50W Limiting current resistor 33-R1 17
36-B03P 9422841+9422842 Carriage translation encoder 36-B03p 19
36-B04P 9422850 Book edges detection 36-B04p 19
36-M01P 9151915_3X220V_D Carriage translation motor 36-M01p 21
36-S01P 9150065 Translation end switch left 36-S01p 19
36-U1P 9132014_ABB Translation variable frequency driver 36-U1p 21
39-B01P 9107063 Jogger home position 39-B01p 22
39-M01P 9431932 Jogger positioning stepper 39-M01p 22
39-Y02P 9432425 Jogger coil 39-Y02p 22
42-B04I 9107063 Phases reporting + notching tools 42-B04i 24
42-B05I 9107063 Phases order reporting 42-B05i 24
42-K02P 9169084_3NO+1NF+2NO+THERM Milling motor process relay 42-K02p 23
42-K03P 9169907+9177051_1NO+1NF_24VDC Over temperature dust collector relay 42-K03p 23
42-M01P 9151916_3X380V_Y Milling motor 42-M01p 23
42-M02I 9432373_MOTOR_24VDC Notching tools indexing 42-M02i 16
42-S01S 9107046_DIFF_PRESSURE_SENSOR Milling exhaust blocked d tection 42-S01s 24
45-M01P 9151917_3X380V_Y Dust collector motor 45-M01p 23
45-S01S 9107046_DIFF_PRESSURE_SENSOR Dust collector full d tection 45-S01s 24
45-S02S 9150065 Dust collector in place d tection 45-S02s 24
48-B01S 9422980_SINGLE_PTC1000 Min glue level 48-B01s 29
48-B02S 9422981_SINGLE_PTC1000 Max glue level 48-B02s 29
48-B03P 9422982_DUAL_PTC1000 Cylinder 1 temperature 48-B03P 30
48-B04P 9422982_DUAL_PTC1000 Cylinder 2 temperature 48-B04P 30
48-B05P 2983951_SWITCH_TH_NC_115¡C Glue tank 115¡c thermostatic control 48-B05p 31
48-B08I 9124180_SWITCH_TH_NO_170¡C+MNL6P Clixon glue tank over heating control 48-B08i 31
48-B09I 9107063 Side glueing home position 48-B09i 29
48-B10I 9107063 Spinner home position 48-B10i 29
48-B11P 2983952_SWITCH_TH_NC_145¡C Glue tank 145¡c thermostatic control 48-B11p 31
48-E01P 9432440 Glue tank resistor 1Kw 48-E01p 32
48-E04P 9170399_RES Spiner resistor 24V/50w 48-E04p 32
48-E05P 9432439 Glue tank resistor 0,3Kw 48-E05p 32
48-M01P 9151180_3X220V_D Glue tank cylinders motor 48-M01p 26
48-M02B 9431251 Side glueing positioning stepper 48-M02b 27
48-M03I 9431251 Spinner positioning stepper 48-M03i 27
48-U01P 9132014_ABB Glue tank variable frequency driver 48-U01p 26

48-Y01P 9432396_ELECTRO Cylinder 1 scraper coil 48-Y01p 28
48-Y02P 9432396_ELECTRO Cylinder 2 scraper coil 48-Y02p 28
48-Y03P 9432396_ELECTRO Side glueing scrapper coil 48-Y03p 28
51-M01P 9151046+WAGO Smoke evacuation motor 51-M01p 36
54-B01P 9107063 Book clamp home position 54-B01p 33
54-B03P 9107063 Book clamp fully close 54-B03p 33
54-B04P 9107063 Book clamp up / down home position 54-B04p 33
54-B05P 9107063 Book clamp / exit backstop positions 54-B05p 33
54-B06P 9107063 Book clamp pr opening 54-B06p 34
54-M01P 9151136_MOTOR_24VDC_90T Book clamp up/down motor 54-M01p 34
54-M02P 9151136_MOTOR_24VDC_90T Book clamping motor 54-M02p 34
54-M03P 9431251 Book clamp positioning stepper 54-M03p 34
57-B01P 9107063 Prefeed home position 57-B01p 35
57-B02P 9107063+CAB_PREFEED_BB3002 Cover prefeed detection 57-B02p 36
57-M01P 9432356 Prefeed positioning stepper 57-M01p 35
57-M02P 9151145 Prefeed blower suction 57-M02p 36
57-S01P 9150026 Crunching unit motor safety switch 57-S01p 38
57-S02P 9150026 Crunching unit motor safety switch 57-S02p 38
57-Y01P 9432383 Blower manifold up coil 57-Y01p 35
57-Y02P 9430876 Prefeed suction valve 57-Y02p 35
60-B01P 9422850 Cover d tection in cover clamp 60-B01p 37
60-B02P 9107063 Cover clamp home position 60-B02p 37
60-B03P 9107063 Cover clamp safe area detection 60-B03p 37
60-M01P 9432356 Cover clamp positioning stepper 60-M01p 37
60-Y01P 9430876 Cover clamp nipping coil 60-Y01p 37
63-B01P 9107063 Creasing home position 63-B01p 38
63-B02P 9107063 Creasing cell 2 63-B02p 38
63-B03P 9107063 Creasing cell 3 63-B03p 38
63-M01P 9151136_MOTOR_24VDC_90T Creasing motor 63-M01p 38
63-Y01P 9432362_ELECTRO Creasing up / down selection coil 63-Y01p 38
66-B01P 9107903+9107904+SUBD Security barrier for loading area 66-B01p 15
66-H1 9422991 Signalisation red and green 66-H1 41
66-H2 9422990 Upper cover lighting 66-H2 41
66-H3 9422990 Glue tank lighting 66-H3 41
66-H4 9422990 Book clamp lighting 66-H4 41
66-H5 9422996_ENS_CIRC_DUAL_BUTTON Switches board 66-H5 41
66-S03P 2081998_FOOTSWITCH_NO+MNL Carriage clamp nipping pedal 66-S03p 10
66-S04S 9146379_ROT_OFF+ON1+ON2_3NO+1NO+1NMain primary switch 66-S04s 8
66-S05S 9146354+9146339_1NC+COUT_DE_POING Emergency switch 66-S05s 10
66-S06S 9146308_INTERLOCK_SWITCH_2XNC Cover interlock switch 66-S06s 10
66-S08S 9146308_INTERLOCK_SWITCH_2XNC Door interlock switch 66-S08s 10
69-B01P 9107064 Book out of binder detection 69-B01p 33
72-B01P 9107064 Book incomming detection sensor 72-B01p 44

72-B02I 9107063 Head home position sensor 72-B02i 44
72-B03P 9107063 Head positioning sensor 72-B03p 44
72-B06I 9107063 Fork up position sensor 72-B06i 45
72-B08P 9107063 BBR full sensor 72-B08p 44
72-M01P 9151136_MOTOR_24VDC_90T Head motor 72-M01p 43
72-M02P 9151136_MOTOR_24VDC_90T Fork motor 72-M02p 45
72-S01S 9146354+9146339_1NC+COUT_DE_POING Emergency BBR switch 72-S01S 42
72-S02S 9150079 Security switch fork down sensor 72-S02S 43
72-S03S 9150073 Security switch book press sensor 72-S03S 43
72-X2 CPC14POS_REV_9121579 BBR connector 72-X2 42
79-B01P 9107064 Book out of convoyor detection 79-B01p 40
79-M01P 9151136_MOTOR_24VDC_90T Reception convoyor 79-M01p 40
CM211-S3 CM211 S3+4 14, 20, 23, 24, 25, 30, 41
CM211-S5 CM211 S5+6 9, 10, 14, 15, 22, 27, 29, 31, 34, 35, 36, 37
CPU0 CPU_2003 Programmable logic controler CPU0 13, 39
DI140-S0 DI140 S0.4 13, 19, 33, 37
DI439-7- DI439SOURCE S7+8 13, 18, 22, 29, 33, 34, 35, 36, 38, 40
DO135-S0 DO135 S0.1 13, 22, 27, 34
DO135-S0 DO135 S0.2 13, 22, 28, 35, 37
DO135-S0 DO135 S0.3 13, 20, 28
DO435-S1 DO435 S12 12, 35, 37, 38, 41
MM424-S1 MM424 S11 12, 16, 34, 38
MM432-S1 MM432 S1+2 8, 10, 14, 17, 19, 24, 34, 37
X2 CPC14POS_REV_9121580+9121579 TBD TBD 40
XS1 9123011_BORNIER Main connector -- 8
XUI 9121949+9121950 Linking form binder to user interface 39

4. DESCRIPTION OF ELECTRICAL COMPONENTS
4.1 Numbering of BB3002 binder modules 4.2 Covers
66 Covers.
33 Carriage.
36 Carriage movement.
39 Jogger module.
42 Milling module.
45 Waste suction.
48 Glue tank.
54 Cover clamp.
57 Cover picking.
60 Cover transport clamp.
63 Creasing.
69 Binder Output.
79 Output conveyor.
72 BBR.
Number Description PLC Connection Page
85 UI extension arm.
66-B01p Security barrier for loading area Module CM 211 – X131 : 11 15
66-H1 Red signal (*) Module DO 435 – X171 : 8 41
66-H2 Green Signal +Upper cover lighting (*) Module DO 435 – X171 : 7 41
66-H4 Book clamp lighting Connected on Power board A20 41
66-S01p Green Button Module CM 211 – X121 : 10 41
66-S02p Black button Module CM 211 – X121 : 11 41
66-S03p Carriage clamp nipping pedal Module MM432 – X112 : 13 10
66-S04s Main primary switch Module MM432 – X112 : 14 2-4-8
66-S05s Emergency stop switch Module CM211 – X131 : 12 10
66-S06s Cover interlock switch Module CM211 – X131 : 12 10
66-S08s Door interlock switch Module CM211 – X131 : 12 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.

4.3 Carriage
33-B01p Carriage emitter Dispatch card - 5V 18
33-B02p Paper detection Module DI439 – X141 : 3 18
33-B04p Carriage clamp thickness gauge Module MM432 – X112 : 5 & 5 17
33-B05p Fixed clamp jaw detection (On line) Module DI439 – X141 : 4 18
33-B06p Moving clamp jaw detection (On line) Module DI439 – X141 : 4 18
33-R1 Limiting current resistor 17

33-M01p Carriage clamping Motor Module MM432 – X11 : 3 & 4 17

4.4 Jogger module

39-B01p Jogger home position Module DI439 – X141 : 8 22
39-M01p Jogger positioning stepper Clock : Module DO135 – X101 : 2 22
Direction : Module CM211 – X132 : 5 22
39-Y02p Jogger coil Clock : Module DO135 – X102 : 7 22

4.5 Milling module
42k02p
42k03p
42-S01s Milling exhaust blocked detection Module CM211 – X121 : 7 24
42-B04i Phases Reporting + notching tools Module MM432 – X112 : 10 24
42-B05i Phases order Reporting Module MM432 – X112 : 11 24
45-S01s Dust collector full detection Module MM432 – X112 : 17 24
45-S02s Dust collector in place detection Module CM211 – X121 : 12 24
42-M01p Milling motor Module CM211 – X121 : 9 23
42-M02i Notching tools indexing Module MM424 – X161 : 7 16
45-M01p Dust collector motor Module CM211 – X121 : 9 23
Various :
42-M01p-Brake Milling motor Brake No Reporting PLC 23
42-M01p-Protection Milling motor Protection No Reporting PLC 23
42-K02p Milling motor process relay Module CM211 – X121 : 9 23
42-K03p Over Temperature dust collector relay Module CM211 – X122 : 10 23
45-M01p-Protection Intern dust collector motor Protection No reporting PLC 23

4.6 Glue tank
48-B01s Min glue level Module CM211 – X131 : 5 29
48-B02s Max glue level Module CM211 – X131 : 6 29
48-B03p Cylinder 1 Temperature Module CM211 – X121 : 14 30
48-B04p Cylinder 2 Temperature Module CM211 – X121 : 17 30
48-B05p Glue tank Low temp thermostatic control Module CM211 – X131 : 7 31
48-B08i Clixon glue tank over heating control Module CM211 – X131 : 10 31
48-B09i Side glueing home position Module DI439 – X141 : 10 29
48-B10i Spinner home position Module DI439 – X141 : 11 29
48-B11p Glue tank High temp thermostatic control Module CM211 – X131 : 7 31


48-E01p Glue tank resistor 1Kw Regulation with clixon 48B05p or 48B11p 32
48-E02p Cylinder 1 resistor 0.3Kw Module CM211 – X122 : 11 30
48-E03p Cylinder 2 resistor 0.3Kw Module CM211 – X122 : 12 30
48-E04p Spinner resistor 24V/50w No command 32
48-E05p Glue tank resistor 0.3Kw Regulation with clixon 48B05p or 48B11p 32
48-M01p Glue tank cylinders motor Glue tank variable frequency driver 26
48-M02b Side glueing positioning stepper Clock : Module DO135 – X101 : 4
Direction : Module CM 211 – X132 : 6 27
48-M03i Spinner positioning stepper Clock : Module DO135 – X101 : 7
48-U01p Glue tank variable frequency driver Start fwd : Module CM211 – X122 : 8
Consigne 0-10V : Module CM211 – X122 : 17 26
48-Y01p Cylinder 1 scraper coil Module DO135 – X102 : 9 28
48-Y02p Cylinder 2 scraper coil Module DO135 – X103 : 2 28
48-Y03p Side glueing scrapper coil Module DO135 – X102 : 4 28

4.7 Carriage movement

36-B03p Carriage translation encoder Signal A : Module DI140 – X104 : 4 19
Signal B : Module DI140 – X104 : 3 19
36-B04p Book edges detection Module DI140 : X104 : 1 19
36-S01p Translation end switch left Module MM432 – X112 : 15 19
36-M01p Carriage translation motor Translation variable frequency driver 21
36-U1p Translation variable frequency driver Start FWD : Module CM211 – X122 : 5 21
Start REV : Module CM 211 – X122 : 7 21
Speed 5Hz : Module DO 135 – X103 : 7 21
Speed : Module CM211 – X122 : 14 21

4.8 Cover clamp module

4-B01p Book clamp home position Module DI439 – X141 : 12 33
54-B03p Book clamp fully close Module DI439 – X141 : 14 33
54-B04p Book clamp up / down home position Module DI439 – X141 : 15 33
54-B05p Book clamp / exit backstop positions Module DI140 – X104 : 2 33
54-B06p Book clamp pre opening Module DI439 – X141 : 16 34

54-M01p Book clamp up/down motor Module MM424 : X161 : 3 & 4 34
54-M02p Book clamping motor Module MM432 : X111 : 7 & 8 34
54-M03p Book clamp positioning stepper Clock : Module DO135 – X101 : 9

4.9 Cover picking

57-B01p Pre-feed home position Module DI439 : X141 : 17 35
57-B02p Cover pre-feed detection Module DI439 : X141 : 18 36
57-B03p Double cover detection Not yet determined /
57-S02p Creasing unit motor safety switch / 38
57-S01p Creasing unit motor safety switch / 38
57-M01p Prefeed positioning stepper Clock : Module DO135 – X101 : 9
57-M02p Prefeed blower suction Module CM211 – X132 : 14 & 15 36
57-Y01p Blower manifold up coil Module DO435 – X171 : 3 35
57-Y02p Prefeed suction valve Module DO435 – X171 : 4 35

4.10 Creasing
63-B01p Creasing home position Module DI439 - X141 : 5 38
63-B02p Creasing cell 2 Module DI439 - X141 : 6 38
63-B03p Creasing cell 3 Module DI439 - X141 : 7 38

63-M01p Creasing motor Module MM424 – X161 : 5 & 6 38
63-Y01p Creasing up / down selection coil Module DO435 – X171 : 6 38

4.11 Cover transport

60-B01p Cover detection in cover clamp Module MM432 – X112 : 18 37
60-B02p Cover clamp home position Module DI140 – X104 : 5 37
60-B03p Cover clamp safe area detection Module DI140 – X104 : 6 37

60-M01p Cover clamp positioning stepper Clock : Module DO135 – X102 : 4
60-Y01p Cover clamp nipping coil Module DO435 - X171 : 5 37

4.12 Output and conveyor

69-B01p Book out of binder detection Module DI439 – X141 : 13 33
79-B01p Book out of conveyor detection Module DI439 – X141 : 9 40

79-M01p Reception conveyor Module MM424 – X161 : 8 40

4.13 BBR
Software
revision of
the BBR
72-B01p 9107064 Book incoming detection sensor
72-B02i 9107063 Head home position sensor
72-B03p 9107063 Head positioning sensor
72-B06i 9107063 Fork up position sensor
72-B08p 9107063 BBR full sensor
72-S01s 9146354+9146339_1NC+COUT_DE_POING Emergency BBR switch
72-S02s 9150079 Security switch fork down sensor
72-S03s 9150073 Security switch book press sensor
79-B01p 9107064 Book out of conveyor detection
72-M01p 9151136_MOTOR_24VDC_90T Head motor
72-M02p 9151136_MOTOR_24VDC_90T Fork motor
79-M01p 9151136_MOTOR_24VDC_90T Reception conveyor

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. To the front of the electronics rack.
The principal items are the programmable B & R automatic control • Programmable Logic Controller PLC - B&R.
system and some 7 electronic cards. • Electronics cards.
Electronic boards
DO 435
PLC B&R MM 424
DI 439
CM 211-2
CM 211-1
MM 432
CPU 474

Connector locations.
CPU 474 MM 432 CM 211-1 CM 211-2 DI 439 MM 424 DO 435
X143
X161
X173
X112
X122
X132
X142
X172
X141
X171
X111
X121
X131
DO135-X101
DO135-X102
DO135-X103
DI140-X104
To the rear of the electronics rack.
16
11 1. Current limiting resistor for the carriage clamp
15
closure motor (inside the rack).
2. Connector 4X3 to the internal turbine supply.
3. Connector 4X5 to the milling motor supply.
1
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) ->
10
42K02p
7. Over-temperature relay for the internal turbine
12 -> 42K03p.
13 8. Connector for command of external waste
14 2 suction.
3
4 9. Fuses F1, F2, F3 (12A) for three-phase supply to
5 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.
6 16. 1000W, 24V - 36V supply.
7

5.2 Relays and fuse holders
At the rear of the rack there are : Notes: In the event of the milling motor overheating, a
thermal fuse operates and cuts off supply to the
1. Command relays for the milling blade and waste extraction motor.
suction (internal or external) To re-set the motor, press the red button on
-> 42K02p. relay 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

5.3 B&R Modules
5.3.1 CPU 474 :

The CPUs CP474/CP774 have four slots for screw-in
The CPU is operated on the far left hand side of the module module. The screw-in modules are plugged into the CP
rack. interface as required, and are attached using the fastening
There are status LEDs and the connection sockets for an screws.
RS232 and a CAN interface on the module.
The interface modules can be installed in slots 1, 2 and 3.
2 4 6 2 4 6
0 8 0 8
E C A E C A
Alimentation 24V (++ --) + ground
Serial port to UI
CAN port to BBR
DO 135
DO 135 Conn X103 DO 140
Conn X101 Conn X104
DO 135
Conn X102

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
2) Discharge electrostatic energy by touching the mounting rail or battery (sticking out in
the ground connection (not the power supply !). front of battery).
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). 6) Place the free end oof the battery removal strip under the
Pick up the battery by the flat sides (don’t pick up the battery by battery so that it doesn’t hang out of the battery compartment.
the edges). An isolated tool can also be used to remove the 7) Replace the battery compartment cover. Make sure that the slot
battery. for the screwdriver is facing upwards.
The left side of the battery compartment cover is placed in the
Right: Wrong: 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.
Battery: CR2477N
Hazardous Components
5) Insert the battery with the proper polarity. Place battery over the Battery Fluid: Propylenecarbonate (69%)
removal strip with the “+” side facing the back. Ethyleneglycoldimethylether (25%)
The battery removal strip must be routed behind the battery Lithiulperchlorate (6%)
(sticking out in front of the battery) in order to be able to Metallic Lithium
removed it again.

5.3.2 Module DO 135 :
Connector X102 (slot 2).
The DO135 is a 4 channel
Pin assignment
output module. 1 Shield
The type of operation can be 57M01b_clock : Prefeed positionning
2 Output 1
1
1 stepper
2
set for each output 3 GND
3
4
DO 135 4 Output 2 60M01p_clock : Cover clamp
5
separately. It is used for TPU
6
Conn X103 positionning stepper
7
5 Shield
8
operation (for example for the DO 135 6 Shield
clock of the steppers motors). Conn X102 7 Output 3 39Y02p : PWM signal for jogger coil
9 10 11 12
DO 135 12
Conn X101 8 GND
TB712
9 Output 4 48Y01p : Cylinder 1 scraper coil
Connections 10 Shield
11 +12bis +24 VDC Alim 24V logic
12 GND GND
Connector X101 (Slot 1).
Pin assignment Connector X103 (slot 3).
1
1
2
1 Shield
3
39M01b_clock : Jogger positionning
4
2 Output 1
5
stepper
6
7
3 GND
8
4 Output 2 48M02b_clock : Side glueing positionning
stepper Pin assignment
5 Shield
9 10 11 12
12 1 Shield
6 Shield 48Y02p : Cylinder 2 scraper coil
2 Output 1
1
TB712 7 Output 3 48M03i_clock : Spinner positionning 1
2
stepper 3 GND
3
8 GND
4
4 Output 2 48Y03p : Side glueing scraper coil
9 Output 4 54M03b_clock : Book clamp 5
6
7
positionning stepper 5 Shield

8
10 Shield
6 Shield
7 Output 3 36M01p_break : Carriage translation break
9 10 11 12
12 GND 12
GND
8 GND
TB712
9 Output 4 Virtual : Virtual variable for glue cutting
10 Shield
12 GND 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 DO 140
functionality. The module is also equipped Conn X104
with supply voltage monitoring.
Connector X104 (Slot 4).
Pin assignment
1 Input 1 (TPU) B36B04p : Book edges detection (voltage)

2 Input 2 (TPU) B54B05p : Book clamp/exit backstop positions
1
1
2
3 Input 3 (TPU) B36B03p : Carriage translation encoder_B
3
4
4 Input 4 (TPU) B36B03p : Carriage translation
5
6
B60B02p : Cover clamp home position
7
5 Input 5 Encoder Channel A / Event counter 1
8
6 Input 6 Encoder Channel B / Event counter 2 B60B03p : Cover clamp safe area
7 Input 7 / Reference Pulse
9 10 11 12
12
8 Input 8 / Reference Enable
TB712
9 Input 9
10 Input 10
11 + 24 VDC supply for inputs Alim 24V logic
12 GND GND
DI140 - pin assignment

5.3.4 Module MM432 :
The motor bridge module MM432 is used to control two DC Connections
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.
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. status LEDS
Motor control takes place using a 16 kHz PWM signal and is
therefore mostly noise-free.
Connector X111 (Slot 1 of module MM432).
A local processor provides the required intelligence and is
used for communication with the higher level CPU.
1 2 3 4 5 6 7 8 9 10
It handles the preparation of the ABR inputs and normal Power Element X1
digital input, the control of both motors (each with a PWM Pin assignment TB710
signal) and the Analog measurements.
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 (+)
X111 9 Not assigned

10 Not assigned
X112

Connector X112 (Slot 2 of module MM432).
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X2
Digital inputs
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
Phases order reporting + notching
10 ABR encoder 2 : A-Signal 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

5.3.5 Module CM 211 :
CM 211 - 1.
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, Connector X 121.
• 8 transistor outputs, 24 VDC, 0.5 A, comparator
1 18
function, short-circuit protection,
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
• 2 inputs, ±10 V / 0-20 mA, 12 bit, X2

• 2 outputs, ±10 V, 12 bit.
Terminal Block X1
1 + 24VDC Alim. 24V Logique

2 + 24VDC
3 + 24VDC
4 n.c.
5 Digital Input DI1 36M01p_error : Carriage translation drive error
X121
6 Digital Input DI2 48M01p_error : Glue tank cylinders driver error
X122
7 Digital Input DI3 42S01p : Milling exhaust blocked detection
8 Digital Input DI4 57B04p : Miss cover detection
9 Digital Input DI5 42E01p : Milling motor overcurrent + themostat
Repoting
10 Digital Input DI6 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

Connector X 122.
1 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X2
Terminal Block X2
1 GND GND
2 GND
3 GND
4 n.c.
36M01p_start_fwd : Carriage translation start
5 Digital Output DO1 (to right)
6 Digital Output DO2
7 Digital Output DO3 36M01p_start_rev : Carriage translation start
(to left)
8 Digital Output DO4 48M01p_start : Glue tank cylinder start
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+ 36M01p_speed : Carriage translation speed
setting (+)
15 Analog Output 1 GND (OGND) 36M01p_speed : Carriage translation speed
Shield setting (GND)
16 Glue tank cylinders speed setting shield
17 Analog Output AO2+ 48M01p_speed : Glue tank cylinder speed
setting (+)
18 Analog Output 2 GND (OGND) 48M01p_speed : Glue tank cylinder speed
setting (+)

CM 211 - 2.
Connector X 131.
1 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X131
Terminal Block X1
X132
1 + 24VDC Alim. 24V Logique
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)

Connector X 132.
1 18
1 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)

5.3.6 Module DI 439 :
Source connection.
Digital input modules are used to convert binary signals for a Inputs are wired as source connections :
process to the internal signal level required for the PCC. When an input is active the signal is earthed.
The states of the digital inputs are shown using Status LEDs.
Characteristics relevant for input modules :

- Number of Inputs : 16.
- Input Voltage : 24 VDC.
- Input delay : 1 ms.
X141
X142
X143
status LEDS

Module DI 439 : Connector X141.
1 18
1 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

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
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
status LEDS
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
1 2 3 4 5 6 7 8 9 10
X1
TB710

5.3.8 Module DO 435 : Connector X171.
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
2
X172
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 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X1
TB710
status LEDS

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
5 optoelectronic cells and to send 24V
4 signals from the cells to the automatic
3 control system.
2
5. Glue Tank Card - A5 : This card is controls the heating of the
1
glue tank:
- 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.

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
Relays and fuse holde
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.

5.4.1 DRIVER Card - A1 :
Front view Front face
Clock
Direction
Power (36V)
Motor 54M03
Motor 57M01
Motor 39M01
24V - 5V not used
Connector A1 - X14
A1 - X14
Connector A1 - X11
A1 - X11
Connector A1 - X12
Handle

5.4.2 DRIVER Card - A2 :
Clock
Direction
Power (36V)
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

5.4.3 INTERLOCK Card - A3 :
Top part.
Barrier Cells OK
Power indicator
Reporting interlock
36V
24V
A3 - X38: Connector A3 - X38: Connector

Bottom part.
A3 - K3: Interlock relay A3 - X32: Connector
A3 - X36:
Connector
A3 - K7: Carriage in loading

area position relay Connector A3 - X36
A3 - K4: Interlock relay to A3 - K1 & K2: Loading area lights

entry module curtains relay
A3 - K8 & K9: Bookclamp lights curtains

relay (not used)
A3 - K11: Technical box relay
A3 - X31: Connector

5.4.4 DISPATCH Card - A4 :
Top part.
Set counter 888 888

Set counter
Hour counter Hour counter 888 888
Connector A4 - X46
Connector A4 - X46
1 hour
1/10 hour

Bottom part.
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) A4 - F2 (1A)
Protection 24V converter 24 VDC - 5 VDC Protection 24V sensor

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. High temp.

Low 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.

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 Connector X303: Command signals to

the frequency variator for the translation motor. the frequency variator for the glue tank motor.

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 - X204: A20 - X203: glue tank
connector for solenoid + jogger command
220V power supply
Power board A20 - X211
A20 - 36K5: interlock relay
carriage clamp
A20 - F5 & F6: Translation brake
220V power supply
protection A20 - 42K7:
Prefeed blower suction interlock relay - 2
Milling motor
A20 - X215: A20 - X201: process and
connector for interlock command
fumes extractor
power supply 220V
A20 - X205:
connector for prefeed
blower suction prefeed A20 - 42K6:
power supply 220V interlock relay - 1
Milling motor
A20 - X223:
connector for isolation
board power supply 24V A20 - X210: milling motor
power supply 380V
glue drum rotation motor A20 - K1: interlock relay
A20 - X217: glue tank Glue drums resistor
carriage clamp translation motor A20 - X222: glue tank resistance resistor connection
power supply 1KW A20 - U2: static relay
A20 - X221: glue tank resistance Glue drum 2 resistor
power supply 0.3 KW A20 - U1: static relay
A20 - U3: static relay Glue drum 1 resistor
Glue tank resistor
A20 - U2: interlock relay
Glue tank resistor

List of components: Power card
Fuses : Relays :
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 A20 – 42K6 : Milling motor relay interlock.
variator. A20 – 42K7 : Second milling motor relay interlock.
A20 - F10 : 6.25A fuse - Protects movement frequency A20 – 48K6 : Cylinder rotation motor relay interlock.
variator.
A20 - F11 : 6.25A fuse - Protects 24-36V power supply.
A20 - F12 : 6.25A fuse - Protects 24-36V power supply.

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 Connector A7-X1

List of components: BBR Card A7 - K2 : Safety relay.
Safety relay that only allows the BBR head to pass
Fuses : when the book separator harrow is lowered.
A7 - F3 : Protects BBR 24V supply.
If fuse A7 - F3 is open there is no longer 24V to the Safety :
card and Led A7-B2 turns off. A7 - S2 : Selector: “run” mode/“download” mode.
Relays : - Selector down: “RUN” mode:

A7 - K1 : BBR card interlock relay. normal use of BBR.
Relay open if BBR emergency shut-down or
BB3002 Interlock. - 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.

6.2 Interlock circuit
Différent cases : - During loading :
• First level interlock. Carriage clamp current is reduced.
The first level interlock corresponds to the cover and All movements of carriage are disabled. -> Safety OK
will stop all dangerous elements like translation motor, The milling and the glue tank are
milling motor, clamping, creasing and the glue tank (see protected by mechanical parts.
electric diagrams p.2).
- During carriage movement :
• Second level interlock. Intrusion of anything between barrier cell,
If the glue Temperature increase dangerously, a security the carriage, milling and the glue tank
switch activate a security relay and disabled all the main motor are stopped. -> Safety OK.
motorizations except the rotation of the glue tank to
homogenate the glue Temperature
(see electric diagrams p.3). • Fourth level and Creasing.
The pre-feed ramp must be located in a right place to
• Third level and Current limiting by RESISTOR. allow the creasing process. In this position, a double
During the paper loading, a resistor connected in series security switch activates a security relays and the
with the motor limits the clamping motor current. creasing motor is powered.
This resistor activated by the barrier cell and the
In all other position, the motor is disabled. Some
resulting force corresponding to the limited current is
mechanical parts are design to prevent finger
about 80N with a permanent 24V power supply
introduction.
(See electric diagrams p.17 and 18).
The fourth interlock level must stop this motor.
The milling and the glue tank main motor are not
interlocked by the secondary level in loading paper Different cases : - During the movement of pre feed :
position, in other position, all intrusion in the barrier The creasing motor is not powered
cells stop the milling motor and the glue tank. For this and the movement of -> Safety OK
one switch is located on the translation and correspond pre feed is not dangerous.
to the loading zone, we need a double direction contact
to switch between the two states (loading zone, - In the position to allow creasing :
translation). The contact switch NC must be only used The creasing motor can rotate,
like a security contact and than the switching must be but it’s not possible to introduce
realised by a security relay supply through the NC fingers. ->Safety OK
switch-loading zone. (see electric diagrams p.2 and 3) (See electric diagrams p.38).

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.

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

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).

6.6 Interlock Diagram
See page 7 - 2

7. THERMAL CONTROL OF GLUE HEATING
7.1 Technical description

Cylinder heating :
Two separate circuits regulate the tank and cylinder heating :
The cylinders are heated when the icon is activated (at
Tank heating : the bottom of the UI screen).
Two elements at the bottom of the tank are used to heat the
Two sensors (Pt 1000) measure the temperature of the glue
glue in the tank.
at the cylinders. These are connected to two inputs of the
automatic control system.
These elements are supplied :
- Continuously when the binder is powered up (main
The automatic control system regulates the glue
switch position ON1).
temperature.
- When the binder is in “TIMER” mode (main switch
position ON2).
• Heating of the tank and cylinders is protected by a thermal
Notes : There is still power supplied to the elements at sensor when the glue temperature exceeds 170°C.
the bottom of the tank even during an
emergency shut-down. • 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.

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 + Glue tank board 3. Cylinder 3 heating device : 50 W; 24 V DC; without regulation.
4. Cylinder 1 temperature managing device : 2 x PT1000 (a and b).
9
24 VDC 5. Cylinder 2 temperature managing device : 2 x PT1000 (c and d).
Outputs Inputs
6. Glue tank heating device : 1000 W; 230 VAC; with regulation.
300 W; 230 V AC; with regulation.
Error bit 7. Glue tank thermostat.
Temperature
8. Glue tank safety thermostat (can be reset manually).
Digital setting
9. Regulation and safety device :
Digital 4 analog. inputs Error if : - difference between a and b temperatures too
important,
- difference between c and d temperatures too
important,
- over temperature.
State relay
230 VAC
State relay
4 5 24 VDC
1 2 7
24 VDC
8
Timer
6
State relay 230 VAC

7.3 Diagram of tank heating
Additional heating
T (c°) Heating time out: 55 min. Drums
delay setted
heating Binder waiting start
on the UI
Glue T° setted on the UI

CYLINDERS T°
Glue Tank T° : High - Low GLUE TANK T°
Glue T° setted on the UI - 40°C
CYLINDERS ROTATION
ON 1 Switch opening Check glue level : if OK => continue

if KO => Stop cylinders + stop heating + return a
(Hardware) 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”.

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.

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.
High temp
Low temp
Glue tank temperature

switch: Min - Max
A5 - F1: Thermal breaker in case
of over temperature

8. ABB FREQUENCY VARIATOR
8.1 Connection
COMMAND connection terminal block :
Power connection terminal block :

8.2 List of parameters
Note : Ensure fmin < fmax.
8.2.1 GROUP 2: Motor data and limit values :
• 201 Unom : Nominal motor voltage as shown on
identification plate. • 208 Verrou sens : Backward rotation can be locked.
U nom is the maximum voltage applied to the 1 = AV/ ARR
motor by the ACS 100. 2 = AV only
F nom is the frequency at which the output • 209 Bruit moteur: Control of motor noise level
voltage is equal to Unom. 0= standard (switching frequency 4 kHz)
The ACS 100 can supply a voltage that is greater 1= reduced noise (switching frequency 8 kHz)
than the mains supply voltage to the motor. 2 = silent (switching frequency 16 kHz)
See Figure 3.
• 202 fnom : Nominal motor frequency as shown on Note : When the “reduced noise” (8 KHz) setting is
identification plate (field attenuation value). used, the maximum load capacity of the ACS
See Figure 3. 100 is I2 at an ambient temperature of 30°C or
• 203 Inom : Nominal motor current as shown on 0.9 x I2 at 40°C. When the “Silent” (16 kHz)
identification plate. setting is used, the maximum load capacity is
0.75 * I2 at an ambient temperature of 30°C.
Note : This parameter is only used when the motor
thermal protection function is in service.
See parameter 502 (f lim). See Figure 5. 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.

8.2.2 GROUP 3 : Command characteristics :
• 301 Arrêt Shut down mode : 1 = free wheel clutch. Note : RI compensation must be as low as possible.
2 = on ramp.
See also parameter 307 (Temps inj. cc).
• 307 Temps inj cc Time of c.c. injection after modulation
• 302 Rampe Shape of ramp : 0 = Linear stops. If freewheel shut down occurs, the
1 = Rapid S-shaped ramp ACS 100 uses braking by injection of c.c.
2 = Medium S-shaped ramp If ramped shut down occurs, the ACS 100
3 = Slow S-shaped ramp uses braking by maintenance of the c.c.
after the ramp.
Figure 2 : Output frequency.
• 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).

8.2.3 GROUP 4 : Inputs and outputs :
• 401 EA mini Scaling of analogue input.
Note : After changing switch power off and then on
0 % = 0 mA (or 0 V) and 100 % = 20 mA
again to confirm the change.
(or 10 V) on input.
• 402 EA maxi Scaling of analogue input. • 406 Vitesse const. Constant speed. May be called through
0 % = 0 mA (or 0 V) and 100 % = 20 mA a logic input.
(or 10 V) on 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:

Note : In alternate operation the variator will shut off if
1 = standard ABB config.
EL1 and EL2 are activated at the same time.
2 = 3-wire control.
3 = alternate operation.
8.2.4 GROUP 5 : Supervision and faults :
• 501 EA Fault Supervision of analogue input • 503 Verrou param Locking out of access to parameters.
0 = no supervision. 0 = START/STOP keys and DIRECTION
1 = if the analogue input value is OF ROTATION keys locked, no
less than the parameter value. 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.
• 502 flim Threshold frequency for motor thermal protection. 2 = Modified values not stored in
permanent memory.
Flim and Inom (param. 203) define the safe
operating range of the motor in continuous • 504 Blocage démarrage Start-up function locked. A locked
operation. start-up means that a start-up
order has not been executed:
0 Hz = motor thermal protection deactivated. • 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 re-
set of a fault or a change of
command mode when a start-up
command is received.

1 = Yes -> Start-up un-lock function There is a constant number of re-set attempts (5) and the
activated. time period is constant (30 secs).
The variator will not start up after re-set At time “A” there are three faults, with the following fault
of a fault or a change of command being the fourth. The variator is re-set because the number
mode. of attempt is less than 5.
In order to re-activate the variator, a
new start-up command must be given.
• 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 re-
sets 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.

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). • The values in the table on page 1 must be entered into
parameters 201 to 205 in this way.
• Press “menu” to gain access to the various groups of
parameters. • Once these parameters have been input, press twice on
“menu“ to leave any application.
• Using the up and down arrows to select “DL” and press
“ENTER” for 3 seconds to download the parameters from • Terminate programming by pressing “enter+menu”.
the keyboard to the variator. The variator is then in “REMOTE“ mode.
The automatic control system and not the keyboard will
therefore be in control of the variator.

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.

8.4 Parameterisation of frequency variators-
Version 01.00.01 “Glue Tank” parameters
DI 1 DI 2 DI 3 ACTION P201 = 230 P202 = 50 P203 = 1.5 P204 = 2830 P205 = 2.1 P206 = 60
0 0 0 Stop 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
1 0 0 Start FWD
P402 = 100 P403 = 0 P404 = 60 P405 = 3 P406 = 5 P501 = 0
0 1 0 Start REV
P502 = 60 P503 = 1 P504 = 0 P505 = 1 P506 = 0
1 1 0 Stop
1 0 1 FWD at 5 Hz Notes : After changing parameter P405, the variator must be shut
down and re-started to confirm the change.
0 1 1 REV at 5 Hz
If P306 increases, braking will be more violent and vice
0 0 1 Stop versa.
1 1 1 Stop Remote Mode : Automatic control system in control.
DI 1 : Start Fwd.
Local Mode : Keyboard control - motor can be
DI 2 : Start Rev. controlled manually using the keyboard.
DI 3 : Set frequency = 5 Hz.
Press “Enter+Menu” at the same time to change from one
DC Com connected to GND. Terminal 7 linked to terminal 9. mode to the other.
AGND connected to 0V of the automatic control system.
Download : Save everything from the keyboard onto the
variator.
0-10V analogue input on the AI terminal (2). Upload: Save everything from the variator onto the keyboard.
0V at terminal (3) AGND. Be in local mode to carry out this operation.
With download or upload, data is transferred except for

“Movement” parameters : parameters 201 to 205 (motor parameters).
P201 = 230 P202 = 50 P203 = 1.8 P204 = 2780 P205 = 4.5 P206 = 60
The keyboard screen will display the variator parameters
P207 = 0 P208 = 1 P209 = 0 P301 = 2 P302 = 0 P303 = 0.1 (never the keyboard parameters).
P304 = 0.4 P305 = 1 P306 = 20 P307 = 0 P308 = 1 P401 = 0
Alternative ABB Config. Parameter 405 at 3.
P402 = 100 P403 = 0 P404 = 60 P405 = 3 P406 = 5 P501 = 0
P502 = 80 P503 = 1 P504 = 0 P505 = 1 P506 = 0

8.5 Error messages
Errors :
Alarms : Code Description
FL 1 Excess current:
Code Description - Possible mechanical problem.
CF 0 – CF 9 Position of selector S1 - Acceleration / deceleration times may be too short.
Some parameters can only be modified if S1 = FL 2 Over-voltage c.c.
- Circuit voltage too high.
0.
- Deceleration time may be too short.
AL1 Loading (read/write) has failed. FL 3 ACS 100 overheating.
AL 2 Action forbidden with variator functioning. - Ambient temperature too high.
- Serious overload.
AL 3 Action not allowed in remote mode (REM) or FL 4 * Fault current: output earth fault or short circuit.
local mode (LOC). FL 5 Output overload.
AL 4 Rotation direction key locked. Locking activated FL 6 Under-voltage cc.
FL 7 Analogue input fault (see parameter 501)
(parameter 208). FL 8 Motor overheating (see parameter 502)
AL 5 RUN key on micro-console locked. FL 9 Micro-console disconnected in LOCAL mode.
Logical input configured for 3-wire commands Note: If FL 9 is displayed when power switched off, the ACS 100
and EL 2 not connected. will start in remote command mode (REM) when power is
switched on.
AL 6 Action not allowed. Locking activated FL10 Inconsistency between parameters.
(parameter 503). Check that EA mini (Fmin) is not greater than EA maxi
(Fmax).
AL 10 * Excess current regulator activated.
FL11 * cc bus ripple too high.
AL 11 * Over-voltage regulator activated. Check supply circuit.
AL 12 * Under-voltage regulator activated. FL 12 Reserved. Contact your supplier.
FL 13 - FL 14 * Equipment fault. Contact your supplier.
AL 13 Reserved. Contact your supplier. FL 15 * Analogue input outside value range.
AL 14 Attempt to go to remote mode (REM) when Check AI level.
locking is activated (parameter 208). FL 16 - FL 19 * Equipment fault. Contact your supplier.
Any display Series connection fault.
AL 15 – AL 16 Reserved. Contact your supplier. flashing . Connection fault between micro-console and ACS 100.
Note : Alarm codes (*) will be displayed Note : Faults (*) where the red diode flashes are re-set by
only if parameter 506 is set to 1 (Yes). switching power off and then switching it back on. Other
faults are re-set by pressing on the START/STOP button.

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 : Open if there is a fault or the drive

is off.
OV : I/O common OV
Ai 1 : Voltage analog input Analog input : 0-5V or 0-10V
+5V : Power supply Reference potentiometer : 2.2 to
10kΩ (Max current available : 10 mA).
DO : Output which can be configured as
analog or logic input.
Li 1 – Li 2 - Li 3 – Li 4 : Programmable logic inputs. Power supply +15 V (max 30V)
State 0 if < 5V - State 1 if > 11V.
+15V : Logic input power supply

9.1.3 Wiring diagrams :
• Power Supply :
• Inputs and Outputs :

To the PLC
To the PLC

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 50 (E range)
or or
60 Hz 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 0.1 s to 99.9 s 3
Range: 0 Hz to motor nominal frequency FrS (parameter in drC menu).
ESC
1st level dEC Deceleration ramp time 0.1 s to 99.9 s 3
bFr adjustment Range: motor nominal frequency FrS (parameter in drC menu) to 0 Hz.
parameters Low speed 0 Hz to HSP 0
LSP
Motor frequency to 0.
ESC HSP High speed LSP to 200 Hz = bFr
Menu: Motor control Motor frequency to max. reference.
drC Check that this setting is appropriate for the motor and the application.
ItH Motor thermal current 0 to 1.5 In (1) According to drive
ESC
rating
Menus
Menu: Application functions Fun 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.
ESC
Menu: Monitoring SUP SP2 2nd preset speed (2) 0.0 to 200 Hz 10
SP3 3rd preset speed (2) 0.0 to 200 Hz 25
SP4 4th preset speed (2) 0.0 to 200 Hz 50
Ait Configuration of the analog input 5U, 10U, 0A, 4A 5U
- 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.

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 Adjustment range Factory setting
U n S Nominal motor voltage marked on the rating plate. 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 20
stopped
1 to 100% when
Value Motor nominal cosine ϕ operating
Value too high: lengthening of response time
Value too low: overspeed, possible instability.
F L G Frequency loop gain 0 to 100% when 20
stopped
1 to 100% when
operating
Value too high: overspeed, instability.
Value too low: lengthening of response time
UFr IR compensation 0 to 200% 50
Used to optimise the torque at very low speed, or to
adapt to special cases (example: for motors connected
in parallel, lower UFr).
nCr Nominal motor current marked on the rating plate 0.25 to 1.5 In (1) Acc. to rating
CLI 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 0.50 to 1.00 Acc. to rating
(1) In = nominal drive current

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 Description Factory setting

tCC Type of control
A C t 2 C = 2-wire control 2C
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:
ENT ESC LI1: forward
Type of control LIx: reverse
FUn tCC 3-wire control (pulse control): a "forward" or "reverse" pulse is sufficient to
ESC ENT
command starting, a "stop" pulse is sufficient to command stopping.
Example of wiring: +15 V LI1 LI2 LIx
ESC ESC LI1: stop
FCS Reminder of the configuration LI2: forward [ [ [
ENT 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 if tCC = 2C: LI2
n O : function inactive if tCC = 3C: LI3
LII to L I 4 : choice of the input assigned to the reverse command
PS2 Preset speeds
If LIA and LIb = 0: speed = reference on AI1
If LIA = 1 and LIb = 0: speed = SP2
Assignment of input LIA if tCC = 2C: LI3
- n O : function inactive if tCC = 3C: LI4
- L I I to L I 4 : choice of the input assigned to LIA
Assignment of input LIb if tCC = 2C: LI4
- n O : function inactive if tCC = 3C: nO
- 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) 10
S P 3 3rd preset speed, adjustable from 0.0 to 200 Hz (1) 25
S P 4 4th preset speed, adjustable from 0.0 to 200 Hz (1) 50
(1) The preset speeds can also be accessed in the 1st level adjustment parameters.

FLr Catch on the fly nO
rSF Fault reset nO Enables a smooth restart if the run command is maintained after the
- n O : function inactive following events:
- L I I to L I 4 : choice of the input assigned to this function - loss of line supply or disconnection
- fault reset or automatic restart
The reset takes place at a transition on the input (rising edge: 0 to 1). It is
- freewheel stop.
only authorised if the fault has disappeared. The motor resumes from the estimated speed at the time of the restart
rP2 Second ramp then follows the ramp to the reference speed.
LI Assignment of the 2nd ramp control input nO This function requires 2-wire control (tCC = 2C) with tCt = LEL or PFO.
n O : function inactive
- n O : function inactive
Y E S : function active
- L I I to L I 4 : choice of assigned input The function intervenes at each run command, resulting in a slight delay
AC2 and dE2 are only accessible if LI is assigned. (1 second max.).
A C 2 2nd acceleration ramp time, adjustable from 0.1 to 99.9 s 5.0 If continuous automatic injection braking has been configured (Ct) this
function cannot be activated.
d E 2 2nd deceleration ramp time, adjustable from 0.1 to 99.9 s 5.0
dO Analog/logic output DO
StP Controlled stop on loss of line supply nO A C t Assignment rFr
- n O : locking of the drive and freewheel stopping of the motor - n O : not assigned
- F r P : stop according the valid ramp (dEC or dE2) - O C r : analog output = current in the motor. The full signal corresponds
- Y E S : fast stop, the stopping time depends on the inertia and the braking to 200% of the nominal drive current.
ability of the drive. - r F r : analog output = motor frequency. The full signal corresponds to
100% HSP.
brA Deceleration ramp adaptation YES - F t A : logic output = frequency threshold reached, closed (state 1) if the
- n O : function inactive motor frequency exceeds the adjustable threshold Ftd.
- Y E S : This function automatically increases the deceleration time, if this - S r A : logic output = reference reached, closed (state 1) if the motor
has been set at too low a value for the inertia of the load, thus avoiding the frequency is equal to the reference.
overvoltage fault. - C t A : logic output = current threshold reached, closed (state 1) if the
motor current exceeds the adjustable threshold Ctd.
AdC Automatic DC injection Ftd is only accessible if ACt = FtA, Ctd is only accessible if ACt = CtA.
A C t Operating mode YES F t d frequency threshold, adjustable from 0 to 200 Hz = bFr
- n O : function inactive C t d current threshold, adjustable from 0 to 1.5 In (In = nominal drive current) In
- Y E S : DC injection on stopping, duration adjustable via tdC, when Atr Automatic restart nO
operation is no longer controlled and the motor speed is zero. The value - n O : function inactive
of this current can be adjusted via SdC. - Y E S : Automatic restart, after locking on a fault, if the fault has disappeared
- C t : Continuous DC injection on stopping, when operation is no longer and the other operating conditions permit the restart. The restart is performed
controlled and the motor speed is zero. The value of this current can be by a series of automatic attempts separated by increasingly long waiting
adjusted via SdC. periods: 1 s, 5 s, 10 s, then 1 min for the following periods. If the restart has
In 3-wire control the injection is only active when LI1 is at 1. not taken place after 6 min, the procedure is aborted and the drive remains
locked until it is disconnected and then reconnected.
tdC is only accessible if ACt = YES, SdC if ACt = YES or Ct. The following faults permit this function: OHF, OLF, ObF, OSF, PHF.
t d C Injection time on stopping, adjustable from 0.1 to 30.0 s 0.5 The drive fault relay remains activated if this function is active. The speed
S d C Injection current, adjustable from 0 to 1.2 In (In = nominal drive current) 0.7 In reference and the operating direction must be maintained.
This function is only accessible in 2-wire control (tCC = 2C) with tCt = LEL
SFt Switching frequency or PFO.
A C t Frequency range LF Check that an accidental start does not present any danger to
- L F r : random frequency around 2 or 4 kHz according to SFr personnel or equipment.
- L F : fixed frequency of 2 or 4 kHz according to SFr bFr Motor frequency 50 (E range)
- H F : fixed frequency of 8, 12 or 16 kHz according to SFr (Same as bFr 1st level adjustment parameter) or
Set to 50 Hz or 60 Hz, taken from the motor rating plate. 60 (U range)
S F r Switching frequency: 4
- 2 : 2 kHz (if ACt = LF or LFr) (if ACt = LF or LFr) IPL Line phase loss fault configuration YES
- 4 : 4 kHz (if ACt = LF or LFr) 12 This parameter is only accessible on 3-phase drives.
- n O : inhibition of the line phase loss fault
- 8 : 8 kHz (if ACt = HF) (if ACt = HF) - Y E S : monitoring of the line phase loss fault
- 12 : 12 kHz (if ACt = HF)
- 16 : 16 kHz (if ACt = HF) SCS Configuration backup nO
When SFr = 2 kHz, the frequency automatically changes to 4 kHz at high - Y E S : saves the current configuration to the EEPROM memory. SCS
speed. automatically switches to nO as soon as the save has been performed.
When SFt = HF, the selected frequency automatically changes to the This function is used to keep another configuration in reserve, in addition
lower frequency if the thermal state of the drive is too high. It automatically to the current configuration. When drives leave the factory the current
returns to the SFr frequency as soon as the thermal state permits. configuration and the backup configuration are both initialised to the
factory configuration.

9.2.4 Monitoring Menu : SUP
Code Description Factory setting ENT ESC
SUP FrH Value Frequency reference

FCS Reminder of the configuration nO ESC ENT
- r E C : the current configuration becomes identical to the backup
ESC ESC
configuration previously saved by SCS. rEC is only visible if the backup Drive thermal state
has been carried out. FCS automatically switches to nO as soon as this tHd Value
ENT
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 When the drive is running, the value displayed is that of one of the monitoring parameters. The default value
performed. which is displayed is the motor reference (parameter FrH).
For rEC and InI to be taken into account the ENT key must be
held down for 2 s. 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.
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%.

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 • Ramp too short, check the settings.
overcurrent • Inertia or load too high, check the size of the motor/drive/load.
• Mechanical locking, check the state of the mechanism.
SCF • Check the cables connecting the drive to the motor, and the insulation of the motor.
motor short-circuit,
insulation fault
InF • Check the environment (electromagnetic compatibility).
internal fault • Replace the drive.
CFF • Return to factory settings or call up the backup configuration, if it is valid. See
configuration fault parameter FCS in the FUn menu.
SOF • Instability, check the motor, gain and stability parameters.
overspeed • Driving load too high, add a braking module and resistor and check the size of the
motor / drive / load.
OHF • Check the motor load, the drive ventilation and the environment. Wait for the drive to
drive overload cool before restarting.
OLF • Check the setting of the motor thermal protection, check the motor load. Wait for the
motor overload drive to cool before restarting.
OSF • Check the line voltage.
overvoltage
ObF • Braking too harsh or driving load. Increase the deceleration time, add a braking
overvoltage resistor if necessary and activate the brA function if it is compatible with the
during deceleration application.
PHF This protection only operates with the drive on load.
line phase failure • 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 • Check the voltage and the voltage parameter.
undervoltage
CrF • Replace the drive.
charging circuit

9.4 Programmation of the frequency driver
LI 1 - Fwd LI 2 - Rev LI 3 - X1 ACTION

0 0 0 Stop Glue tank motor :
1 0 0 Start FWD
0 1 0 Start REV Acc = 0.1 Dec = 0.2 Lsp = 0 Hsp = 60
1 1 0 Ith = 1.3 SP2 = 10 Ait = 10 Uns = 230
1 0 1 FWD à 5 Hz Frs = 50 Sta = 12 Flg = 25 Ufr = 50
0 1 1 REV à 5 Hz Ncr = 1.2 Cli = 3 Nsl = 2.8 Slp = 100
0 0 1 Stop Cos = 0.76 Act = 2C Tct = trn Rrs = Li 2
1 1 1 Ps 2 : LIA = Li3 ; LIB = LI4
Note : The others parameters are adjusted with factory

LI 1 : Start Fwd settings.
LI 2 : Start Rev
LI 3: Constant frequency = 5 Hz.
Attention : The frequency inverter does not stop if LI 1 and

LI 2 = 1.
Translation motor :
Acc = 0.1 Dec = 0.2 Lsp = 0 Hsp = 60
Ith = 1.5 SP2 = 5 Ait = 10 Uns = 230
Frs = 50 Sta = 12 Flg = 25 Ufr = 50
Ncr = 2.3 Cli = 4.5 Nsl = 3.6 Slp = 100
Cos = 0.77 Act = 2C Tct = trn Rrs = Li 2
Ps 2 : LIA = Li3 ; LIB = LI4

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Section 8 :
INSTALLATION MANUAL
Installation manual Initial issue: 02/04


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 . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .16
2. Binder levelling . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .17
3 Kit Contenant . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .18
4. Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .19
5. Output unit (BBR) (optional) . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .21
6. User Interface Installation . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .23
7. Paper dust bag collector installation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .24
8. Extension installation . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .25
9. Foot switch installation . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .27
10. Dust collector installation . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . .28
5. Connecting the power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

1. Introduction . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2. Power Network Voltage ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3. Installing the power cord .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4. System power up . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32


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

2. Warning pictograms
Please pay special attention to the description of the following
pictograms :
ATTENTION : These safety alert symbols are for your
personnal safety. Never operate without
WARNING all safety covers in place.
High leakage current
earth connection essential before
9.139.163A
connecting supply An emergency stop switch (red) located
ATTENTION on the top cover allows the operator to
Courant de fuite élevé stop the machine at any time or any
Raccordement à la terre indispensable
avant le raccordement au réseau 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

On the cover : Inside the power rack :
MODEL : BB3002
SER. N¡ :
60 Hz 208 / 220 / 230 / 240 V
3P+PE
12 A
LISTED
I.T.E.
E125337
1
L
2
L
3
L
50 Hz 230 / 240 / 380 / 400 / 415 V
3P+PE
12 A
WARNING
gepr fte Refer to specifications High leakage current
Sicherheit
in Installation Manual.
earth connection essential befo
MADE IN BELGIUM BY c.p. bourg S.A.
B-1340 Ottignies - rue des Technologies, 22 connecting supply
Tel : +32 / 10 / 62 22 11 Fax : +32 / 10 / 61 36 38 B
9139727A ATTENTION
Courant de fuite lev
Raccordement la terre indispe
avant le raccordement au r sea
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 : On the back (inside) :

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.

1. Site specification
Dimensions in meter (& foot).
External paper dust collector
Height : 1.50 m (4.92 ft.).
0.8m (2.6ft)
0.8m (2.6ft) 2.02m (7.22ft)
0.8m
0.65m
(2.13ft)
(2.6ft)
0.86m (2.86ft)
1.35m (4.43)
0.75m
(2.46ft)
2.41m (7.9ft)
Top view
0.60m
(1.96ft)
0.5m (1.64ft)

2. Specification Room ventilation Recommendation: min. 47,5 m3/h
(natural ventilation)
Model BB 3002
For heat evacuation at continuous binding
Description Glue binder
extra ventilation may be necessary
Max. cycles / hour Up to 600 cycles
(operator dependent and based on A4 Dust concentration 0,04 mg/m3 at continous operation
format) (TLV for nuisance dust = 10 mg/m3)
Dimensions Length: 2.02 m (7.22 ft) Additionnal safety information To avoid higher sound pressure levels
Width: • without BBR 1.350 m (4.43 ft) than given above, the machine should be
• with BBR 2.410m (7.9 ft) installed in a room with at least minimum
Height: 1.50 m (4.92 ft) room volume (see above) and favourable
acoustical properties.
Power required - 208/220 V, 60Hz
3 phases delta, 12A
Weight
- 220/230 or 240V, 50 Hz, Binder 650kg 1433lbs
3 phases delta 12A Output Unit (optional) 80kg 176lbs
- 380/400 or 415V, 50Hz
3 phase star, no neutral
needed, 12A
Power consumption, stand by 1500W
Power consumption, operation 4000 W
¤
Power consumption, maximum 5500W MODEL : BB3002
Mains connection Field-wiring 3 phases connection + ground SER. N¡ :

60 Hz 208 / 220 / 230 / 240 V
3P+PE
12 A
Safety class I (IEC 536) Protective earth connection LISTED
I.T.E.
E125337
Protection class IP 20 (IEC 529)

50 Hz 230 / 240 / 380 / 400 / 415 V
3P+PE
12 A
Radio interference Complies with Directive 93 / 68 / EEC
Radiation Not applicable
gepr fte Refer to specifications
Sicherheit
Radiant heat 13648 BTU/h in Installation Manual.
MADE IN BELGIUM BY c.p. bourg S.A.
B-1340 Ottignies - rue des Technologies, 22
Tel : +32 / 10 / 62 22 11 Fax : +32 / 10 / 61 36 38 B
Noise level (Lpa) Maximum 76 dB (A) (at operator position) 9139727A
Ozone emission Not applicable

Room volume Recommendation: 95 m3 (7 x 4,5 x 3 m)
3336 ft3 (23x14.8x9.8 ft)

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
BLUE BEADS IN ARROW
• “Warning” label: SHOWS CONTAINER WAS
TIPPED OR MISHANDLED
Red indicates rough handling.

If indicator is red, ALWAYS accept shipment, note activation
on bill of lading, and inspect shipment for damage.
INDEX PACKAGING, INC.
UNION, NH
TEL 800-662-3626
FAX 603-652-9279
TIP-N-TEL
BLUE
BEADS
SHOWS L
IN
ARROW
CONTAINER
TIPPED
OR
WAS
MISHANDLED
INDEX
PACKAGING,
UNION,
INC.
TEL NH
800-662-3626
FAX
603-652-9279
IF
TIP
PACKAGE(N)
TELL
OVER ARROW
MAKE HAS
IN
FOR NOT BEEN POINT
TRANSIT.
DAMAGE.ON ON
DEPEND BILL ITS IS BLUE
OF SIDE
ON ANY LADING OR THIS
THIS CLAIMS TIPPED
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
TION BILL HANDLI
MAY OF NG
LOADIN IF
BE
WARRA
G
NTED
HANDLE
WITH
CARE
RED
INDICATES
ROUGH
RED,
If indicator
NOTE HANDLING
ON accept
INSPECTION BILL IF
OF is
LOADING red,
MAY on chipment,
BE bill ALWAYS
WARRANTED
shipmentof
lading, note
for and activation

damage.inspect
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 HANDLE
WITH CARE
If indicator is red, ALWAYS
DEPEND ON THIS NOTATION
accept shipment, note activation
RED INDICATES ROUGH HANDLING IF on bill of lading, and inspect
RED, NOTE ON BILL OF LOADING
INSPECTION MAY BE WARRANTED
TIP N shipment for damage.
TELL
PATENT NO. 3,926,144
PRINTED IN USA.

2. Handling
The pallet can be lifted only from one side (as illustrated).
6 in) 21
70
4.7
(6 mm
Weight 1010 Kg (2220lbs). mm (8
45 5.4
16 3i
n)
1660 mm (65.35 in)

LI
FT
HE
RE

3. Unpacking the Binder
The package contains:

• The Binder unit (a).
• 1 ramp (g). a
• 1 bag of glue granules (b).
• 1 accessory box (c).
• 1 user interface (e).
• 1 dust collector (d).
• 1 output unit (f). c
Unpacking : b Fig.3
• Remove the staples fastening the cardboard to the wooden
side panel and frame (Fig.1). e g f
• Remove the cardboard (Fig.2). d
• 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).
Straps
f
c
b Fig.5
Fig.4 d g
e g
Fig.1
Fig.2

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.

5. Undocking the Binder from the pallet
1. Remove the screws fastening the docking support bracket 6. Install correctly the ramp against the pallet (Fig.6).
to the binder and to the pallet. There are 8 screws (4 on The binder wheels must go through the cuts of the pallet.
the front and 4 on the rear).
2. Rotate the height adjustment legs clockwise to raise the Attention: Minimum 2 persons are required to remove
binder off the docking support brackets. the binder from the pallet.
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.
Top view
Binder
Ramp
1 1 4
4
1 3
1 2 5
2
Fig.5 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

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.

3. Kit Content
a Operator manual
REF ITEM NUMBER Description i

a 9414078 Large and high guides
b 9414077 Short and high guides
c 9414076 Off line guides b
d 9414079 Large and low guides
e 9403843 Spanner for draining the glue tank
f 9199883 Aluminium container c j
g 9414105 Magnetic stop
h 2081998 Foot switch
i 9133729 operator manual d
j 9230665-AF Cover table extension
k 9403925-AF Loading area extension k
l 9432430-AF Conveyor
e
l
f

4. Conveyor Conveyor installation
• Raise the baffle (1) (Fig.2).
Unpacking of the conveyor • Position the rollers (2) on the guides (3).
• Unpack the conveyor from the box. • Adjust the conveyor height by using the foot (4).
• Install the foot (1) on the conveyor with the screws (2) and • Lock the conveyor position with the levers (5) (Fig.3 on next
washers (Fig.1). page).
2
1
3
2
Fig.1
4 4 Fig.2

Connection
• Connect the cable (6) to the binder.
• Install the terminator plug (7).
Fig.3
5
5

5. Output unit (BBR) (optional)
1
Installation 2
• 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. D
• Manually push the BBR head towards the binder (hold the
385mm
BBR base in place). B

A
• Insert the docking pin (C) inside the hole located under the D Fig.1
conveyor as shown on figure 2.
D
• 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.
2 C
Note: Make sure The Levers (D) are in the down
position so the conveyor can move freely within B
the guides (3).
1
Fig.2
3 A
D
D
Fig.3

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.

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
7 3
4
8 5
3
2
6
1

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.
Fig. 1

8. Extension installation
Loading area extension
Install the extension as illustrated.

Cover table extension
Install the extension as illustrated.

9. Foot switch installation
Connect the foot switch in the connector (1) located under the
binder.

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 red
2 black
3 yellow
4 white
Warning : for the connection, only use the orange connector
Red 1 Black 2
1 3 2 4
120V Yellow 3 White 4
Single phase orange connector orange connector
White (network) Red (network)
110V
1 3 2 4 Red 1 White 4 Black 2

230V
Single phase orange connector orange connector orange connector
Red (network) White (network) Yellow 3
220V

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
7 9
2
6
1
5
8
3 9
4

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.

2. Power Network Voltage
Prerequisites :
Procedure :
Remove the left rear panel and the electrical box cover (see
drawing on previous page). • Connect the wires L1, L2, L3 on the transformer to the
Use a voltmeter to verify the supply voltage. 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 4 4 3 3 2 2 2 2 2 4 4 3 3 2 2 2 2 2 Input of the transformer

1 0 8 8 4 3 3 2 0 1 0 8 8 4 3 3 2 0 1 0 8 8 4 3 3 2 0
5 0 0 0 0 0 0 0 8 5 0 0 0 0 0 0 0 8 5 0 0 0 0 0 0 0 8
Output of the transformer
L13 L12 L23 L22 L33 L32

L1 L2 L3
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 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
1
L
2
L
3
L

3. Installing the power cord 4. System power up
Warning: Do not plug the power cord in the wall • Connect the power cord to the wall outlet.
outlet. • Turn the main switch to the ON 1 position.
• The BB3002 is starting up.
• Remove the insulation on the end of all the wires of the • After a few seconds, if the following message appears on
power cord as required. the U.I.: 42050 “Milling motor direction test failed” :
• Fit a terminator lug (1) on the ground wire (green / yellow). • Switch the binder OFF.
• Insert the cable in the hole as shown on Fig.1. • Disconnect the power cord from the wall outlet.
• First, connect the ground wire on screw (1). • Invert the position of 2 wires on the connector (2) rack.
• Then, connect the 3 wires of the network in the wago • Connect the power cord to the wall outlet.
connector (2). • Switch the binder ON.
There is no neutral wire.
• Tighten nut A (under the machine). • When the installation is complete reinstall the covers.
1
L
2
L
3
L
1
A
HiWAR
c ear gh NI
C AT onneth colneakNa G
o T ct n g
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


S. A. S.A.
c.p. bourg N. V. c.p. bourg
rue des Technologies, 22 rue Millewee, B.P. 85
B-1340 Ottignies (Belgium) L-7201 Walferdange (Luxembourg)
Tel.: + 32 (0) 10 / 62 22 11 Tel.: 352 / 33 24 47
Fax: + 32 (0) 10 / 61 69 03 Fax: 352 / 33 19 99
e-mail: export.be@cpbourg.com e-mail: cpbourg@pt.lu
web: www.cpbourg.com
G.M.B.H. Inc.
c.p. bourg c.p. bourg
Schweizertrasse 70 / 1 50 Samuel Barnet Bd.
D-72336 Balingen (Deutschland) New Bedford Industrial Park
Tel.: +49 7433 998 1680 Massachussets 02745 (USA)
Fax: +49 7433 998 1686 1285 New Bedford
e-mail: cpbourg_germany@cpbourg.com Tel.: 1/508.9982171
Fax: 1/508.9982391
e-mail: cpbourg@worldnet.att.net
S.A.
c.p. bourg
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: cpb_france@cpbourg.com
http: //www.cpbourg.com


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SERVICE

Initial issue: 02/04

Changes Initial issue: 02/04

Changes Initial issue: 02/04

Changes Initial issue: 02/04

Modifications Initial issue: 02/04

Modifications Initial issue: 02/04

Changes Initial issue: 02/04

STATUS INDICATOR RAPS

RAPs indication état Initial issue: 02/04

Status indicator RAPs Initial issue: 02/04

Quality RAPs Version initiale: 09/03

Quality RAPs Initial issue: 02/04

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

Mechanical and electromechanical adjustments ........................................7

2. Jogger module ........................................................................................................................................15

5. Glue tank .................................................................................................................................................45

Adjustment/Replacement procedures Initial issue: 06/03

6. Lateral gluing ..........................................................................................................................................65

7. Cover clamp ............................................................................................................................................72

8. Cover clamps ..........................................................................................................................................81

9. Cover clamp and output guide lift ........................................................................................................87

Adjustment/Replacement procedures Initial issue: 06/03

11. Cover Creasing .....................................................................................................................................99

12. Cover station .........................................................................................................................................112

13. Pre-feed ..................................................................................................................................................127

14. Adjustment procedures : BBR ............................................................................................................130

Adjustment/Replacement procedures Initial issue: 06/03

3. Advanced Menu of the Technician Menu .............................................................................................145

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

1.1 Adjustment of the position of the carriage end-of-

• Adjust the position of the carriage movement guide (2)

Adjustment/Replacement procedures Initial issue: 06/03

3. Return the binder to normal operating conditions.

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

• Open the top panel.

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

2.1 Adjustment of the jogger plate position

• Return the binder to normal operating conditions.

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

Prerequisites : • Return the binder to normal operating conditions.

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

Adjustment/Replacement procedures Initial issue: 06/03

16 Belleville washers are placed on each of the 4

Adjustment/Replacement procedures Initial issue: 06/03

Maximum default value for alignment Fig 2

Maximum default value for alignment Fig.3

Adjustment/Replacement procedures Initial issue: 06/03

The upper roller supports are fitted on cams so that their

2. Place one comparator in the carriage clamp (Fig.1).

3. Zero the comparator on the jogger plate.

Adjustment/Replacement procedures Initial issue: 06/03