BB50H

BB50 & BB50/H Operating Instructions
Wire-O® Binding Machines
Series : 1
Issue : 1
May 2005
From serial no. 001 onwards
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67 rue du Docteur Blaizot
61300 L’AIGLE France
TEL: +33 (0)2.33.84.21.50

FAX: +33 (0)2.33.84.21.51
® ®
Wire-O , Lhermite and
®
UniCoil are
registered Trademarks of
James Burn International
BB500/01/1 © JBI 2005

Contents Page 1
Contents
Page
Introduction
Section 1. Using your Binding Machine Safely

1.1 Safety warning signs for your binding machine 2
1.2 Warning signs on your binding machine 7
Section 2. Installing your Binding Machine

2.1 Unpacking your Binding Machine 1
2.2 Choosing a suitable location for your binding machine 1
2.3 Installation 3
Section 3. Installing a Spool of Wire-O Wire onto the Spool Stand

3.1 How to select the correct size of Wire-O wire 1
3.2 Installing a spool of Wire-O wire 2
Section 4. Setting Up and Adjusting your Binding Machine

4.1 Installing/changing Wire-O wire feed starwheel 2
4.2 How to eject Wire-O wire remnants from feed belt 3
4.3 Changing feed on starwheels 3
4.4 How to adjust Wire-O wire feed guide 4
4.5 How to load Wire-O wire into the binding machine 5
4.6 How to set cutter to cut Wire-O wire centrally 7
4.7 Installing/changing inserts in the transfer bar 9
4.8 Preparing closing tools to suit your binding machine 10
4.9 Installing/changing closing tools 12
4.10 Wire-O wire pusher adjustments 14
4.11 Transfer bar adjustment 15
4.12 Binding table height adjustment 16
4.13 Control Panel 17
4.14 Wire-O wire pitch counter setting 20
4.15 Wire-O wire feed programming 21
4.16 Installation of side lay gauge 30
4.17 Adjustment of front perspex guard 32
4.18 Cross match adjustment of closing tools 33
Section 5. Operating your Binding Machine

5.1 Final check and installations 1
5.2 How to perform your first bind safely 2
5.3 Setting and operating hanger feed for calendar binding 3
5.4 Wire-O wire bind adjustment 7
5.5 How to set for skip bind of books 10
5.6 How to remove a jammed book/calendar or Wire-O wire 10
5.7 How to remove a jammed hanger in the hanger feed 11
5.8 Running your machine as a Wire-O spool wire cutter 11
BB50/01/1 2005
Contents Page 2
Contents
Section 6. Maintaining your Binding Machine

6.1 General Maintenance 1
6.2 How to empty slug bottle 2
6.3 How to align Wire-O wire feed belt 2
6.4 How to run your binding machine sequentially 2
6.5 Fault finding chart 3
6.6 Recommended spare parts for your binding machine 4
Section 7. Binding Machine Technical Data

7.1 General data 1
7.2 Electrical data 1
7.3 Compressed air data 2
7.4 Machine Performance 2
7.5 Electrical Circuit Diagrams 3
Warranty
CE Declaration of conformity
Registration Card
BB50/01/1 2005
Intro Page 1
Introduction
Thank you for buying a BB50 or BB50/H Wire-O book/calendar binding machine from
James Burn International. This instruction manual has been developed to help you get
the most from your new binding machine.
NOTICE
Read this manual carefully before installing your binding machine.
It is essential that you read all the instructions to ensure a safe and correct manner for
operating the machine. Misuse of the machine could be extremely dangerous and lead
to injury.
This manual contains recommendations and instructions for installing, adjusting,

operating and maintaining your binding machine.
Failure to read this manual could result in damage to your equipment, or even personal
injury.
This manual is a necessary and permanent part of your binding machine. Always
return the manual to its pocket holder on the machine
This manual consists of the following sections:
1. “Using your Binding Machine Safely” shows all the safety warnings that you should
be familiar with before you attempt to use your binding machine in a safe manner.
2. “Installing your Binding Machine” contains guidelines for locating, unpacking,

handling and installing your binding machine.
3. “Installing your Spool of Wire-O wire on the Spool Unwind Stand” describes how
spools of Wire-O wire are loaded/unloaded from the spool stand.
4. “Adjusting and setting up your Binding Machine” describes adjustments and settings
that are needed to the machine to enable it to bind various sizes of Wire-O wires
from 3/16” to 1” size with the matching book thicknesses. Other additional settings
will be required to perform calendar binding or skip binding.
5. “Stating and Operating your Binding Machine” describes how to check your binding
machine before it is switched on and how to make your first bind safely.
BB50/01/1 2005
Intro Page 2
Introduction
6. “Maintaining your Binding Machine” describes routine maintenance for your binding
machine. Also in this section, for subsequent use, there are electric circuit
diagrams, parts lists and lists of spares you may require.
7. “Selling, Transferring or Disposing of your Binding Machine” tells you what you
should do before you sell, transfer or dispose of your binding machine.
8. “Technical Data of your Binding Machine” describes the machine details, electrical
data, compressed air data and machine performance information.
Read all your documentation carefully and observe the recommended ways. The
complete documentation for your binding machine includes:
1. This manual
2. User guides for Mitsubishi controller and display.
3. Spares manual
NOTE: This manual gives you general guidelines for installing and operating your
binding machine. It does not cover every question you may have or every situation that
can occur. It you have any queries you should contact your local agent or one of the JBI
offices listed overleaf.
Also in an ongoing effort to improve the quality and performance of this binding machine
James Burn International reserves the right to carry out changes to this machine.
The identification plate shown below is found at the rear of the binding machine.
BB50/01/1 2005
Intro Page 3
Introduction
If you have any questions about your binding machine or this manual, please contact your
local James Burn International agent or office:
Your local JBI agent or office
BB50/01/1 2005
Section 1 Page 1
1. Using your Binding Machine Safely
Learn to recognise safety information, and always follow recommended precautions and
safe operating practices.
This is the safety alert symbol:
When you see this symbol on your binding machine, or in this manual, be alert to the
potential for injury or property damage.
The manual uses the words DANGER, WARNING, CAUTION and NOTICE to
accompany the safety alert symbol. The words are defined as follows:
DANGER: You will cause severe personal injury or death if you ignore this
message.
WARNING: You may cause severe personal injury and/or substantial

damage to equipment or property if you ignore this message.
CAUTION: You may cause minor personal injuries or substantial damage to

equipment if you ignore this message.
NOTICE: This is important installation, operation or maintenance

information that should not be ignored.
BB50/01/1 2005
Section 1 Page 2
1.1 Safety Warning Signs for your Binding Machine
This section lists the safety warnings that you should be familiar with before you
install or operate your binding machine.
DANGER
Electrical shock hazard
DO NOT TOUCH THE CLOSING TOOLS IN YOUR

BINDING MACHINE.
Serious injury may occur if your fingers come into

contact with the closing tools while the machine is
operating. Be sure that the front perspex guard is
suitably adjusted and is in place.
NEVER PERFORM ANY REPAIR OR MAINTENANCE

ON YOUR BINDING MACHINE WHILE IT IS
OPERATING
Always remember to switch off the machine and

disconnect its electrical supply.
STOPPING THE BINDING MACHINE IN AN

EMERGENCY
Know where the emergency stop switch is located on

your binding machine.
The emergency stop switch is a red mushroom headed

push button. It is positioned below the control box on
the right hand side machine cover.
BB50/01/1 2005
Section 1 Page 3
DO NOT OPERATE THE BINDING MACHINE IF THE

GUARDS ARE NOT IN PLACE
All guards MUST be in place before you start the
binding machine.
DO NOT ADJUST THE GUARD OPENINGS WHILE

THE MACHINE IS SWITCHED ON.
Settings must only be carried out while the machine is

switched OFF.
DO NOT BYPASS THE GUARD INTERLOCK

SWITCHES ON YOUR BINDING MACHINE
Never use your binding machine unless the guard

interlock switches are in proper working order.
NOTICE
Mechanical interlock switches are attached to the following guards:

A ) Front perspex guard
B) Lower hinged guard under the binding table
C) Hinged access guard to the wire feed area
D) Top perspex guard
E) Back perspex guard
All other guards are fixed to the machine with screws and should only be removed
and replaced by a qualified person such as a service engineer or maintenance
engineer.
BB50/01/1 2005
Section 1 Page 4
DO NOT OPERATE WITHOUT GUARDS IN PLACE.
HANDLE HEAVY EQUIPMENT PROPERLY
Always handle heavy equipment with a suitable

mechanical lifting device.
Always position the weight of the machine on your lifting

device so that it is stable when lifted. Know the weight
of the equipment before attempting to lift it.
Never try to lift equipment that is heavier than the

maximum rating of your lifting device.
WEAR SAFE CLOTHING
Secure all loose clothing - such as neckties or scarves

whilst operating your binding machine, and keep loose
hair tied back.
Safety footwear should always be worn when moving

this machine.
PROTECT CHILDREN
Keep children away from your binding machine. Never

allow children to operate your binding machine.
BB50/01/1 2005
Section 1 Page 5
KEEP SAFETY LABELS CLEAN AND IN GOOD

CONDITION
Do not remove any safety labels from your binding

machine. Keep all labels clean and legible. Replace
any missing or damaged labels.
BE PREPARED FOR EMERGENCIES.
Be prepared for fires, injuries or other emergencies.

Keep a first aid kit and a fire extinguisher handy. Keep
emergency numbers of doctors, ambulance services,
hospitals and the fire department handy. Aquaint
yourself with the company fire procedure.
A NOTE TO ALL EMPLOYERS
Know your responsibilities as an employer.
Make sure your employees know how to operate the

binding machine safely and ensure they read this
manual.
Make sure your employees are aware of the safety

warnings displayed on the binding machine and
illustrated in this manual.
Make sure the binding machine is in proper working

condition. Unauthorised modifications may impair the
function and safety of the binding machine.
BB50/01/1 2005
Section 1 Page 6
KEEP THIS MANUAL WITH THE BINDING MACHINE
This manual is an important part of your binding

machine. Always keep this manual where it belongs -
with the binding machine.
IF YOU NEED THIS MANUAL IN ANY OTHER

LANGUAGE
If you need this manual in a language other than

English, contact James Burn International.
BB50/01/1 2005
Section 1 Page 7
1.2 Warning Signs on your Binding Machine
Figure 1b Binding Machine Warning Signs
BB50/01/1 2005
Section 1 Page 8
Figure 1c Binding Machine Warning Signs
BB50/01/1 2005
Section 2 Page 1
2. Installing your Binding Machine
2.1 Unpacking your Binding Machine

The binding machine will usually arrive in a wooden case. Unbolt and remove the
top bracing cross members (not all crates have these) and sides. Unscrew the
clamps which secure the machine to the packing case base. Unpack the spool
stand and component pieces, such as closing tools and any specially ordered
spares.
The binding machine and its spool stand weighs 406kg (893lb) nett. It is
recommended that the machine be lifted off the base and positioned in the desired
location using a fork lift truck. The forks should be at least 1 metre long and
spaced 0.5 metres apart. Approach the machine from the rear, placing the forks
centrally under the bottom cross members of the framework. Raise the machine
carefully.
WARNING
Avoid violent or sudden movement when lifting to prevent the
machine toppling over.
Unpainted metal parts of the binding machine and spool stand are coated with a
paraffin-based rust inhibitor and should be cleaned off with a suitable solvent such
as while spirit.
As you unpack your binding machine and spool stand check to ensure that no
obvious damage has occurred during shipping. Notify James Burn International or
an agent immediately of any damaged parts.
2.2 Choosing a Suitable Location for your Binding Machine

You must choose a site within the factory that is solid, level and rigid enough for
the machine and position it such that it ensures the most efficient flow of work.
Installing your binding machine will depend on how you plan to use it and the
resources available in your binder. Therefore, the installation information in
Sections 2.2.1 and 2.2.2 should be considered as guidelines rather than exact
instructions.
BB50/01/1 2005
Section 2 Page 2
2.2.1 Floor Area
The approximate floor area required for the binding machine and spool
stand is 4.3mx3.3m (figure 2a).
Figure 2a Floor space
2.2.2 Power Points
You must ensure that electric and compressed air connection points are
provided nearby.
WARNING
Your binding machine requires clean dry compressed air.
Ensure that the air compressor has fitted an aftercooler,
filters and air-dryer. The machine operating pressure is
5.52 bar (80 psi), minimum supply capacity being 14.46
CFM (410 litres/min).
WARNING
Ensure that the voltage setting on your binding machine
conforms to the supply rating.
BB50/01/1 2005
Section 2 Page 3
2.3 Installation
2.3.1 Place the machine in the desired location allowing for the spool stand which
is to be positioned on the right hand side of the binding machine.
2.3.2 Level the binding machine by adjusting the feet as necessary.
2.3.3 Screw the three feet onto the underside of the spool stand base with the
countersunk bolts provided.
2.3.4 Place the spool stand next to the binding machine as shown in figure 2b.
The stand can be positioned in any orientation around the spool feed
monitor, provided that Wire-O wire is fed in a direct line off the spool.
Spool Stand
Binding Machine
Max. 90°
Max. 40°
Wire-O Feed Monitor
Figure 2b Spool Stand Orientation
2.3.5 Adjust the position of the spool feed monitor to suit the angle of the stand.
2.3.6 Place the foot pedal on the floor beneath the binding table such that it is
conveniently positioned to operate the machine. Connect the foot pedal
electrical lead into the socket on the right hand side of the machine.
2.3.7 After ensuring that the mains electrical supply is switched off, connect the
electric lead from the binding machine to the power socket.
BB50/01/1 2005
Section 2 Page 4
2.3.8 Connect the compressed air supply to the binding machine (left side) after
ensuring the connections are suitable.
2.3.9 Connect the machine power lead into the socket on the right hand side of
the binding machine.
Your binding machine is now ready to operate.
BB50/01/1 2005
Section 3 Page 1
3. Installing a Spool of Wire-O® Wire onto the Spool Stand
3.1 How to Select the Correct Size of Wire-O® Wire

Wire-O® wire is supplied in eleven different sizes for the BB50-BB/50H. These
range from 3/16” to 1” and are available in a variety of finishes and colours.
The required size of Wire-O® wire is obtained by either:
a) Using the following formulae:
Imperial
3:1” pitch Wire-O® wire size = Book Thickness in inches + 1/16”

(and 5/8” wire)
2:1” pitch Wire-O® wire size = Book Thickness in inches + 1/8”

(except 5/8” wire)
or
Metric
3:1” pitch Wire-O® wire size = Book Thickness in millimetres + 1.6mm

(and 5/8” wire) 25.4
2:1” pitch Wire-O® wire size = Book Thickness in millimetres + 3.2mm

(except 5/8” wire) 25.4
Where the precise size is not available the nearest oversize Wire-O® wire
should be used.
Example:
A book has a total thickness of 6mm, adding 1.6mm and dividing by 25.4 gives
0.299 inches. Therefore, No. 5 – 5/16” (8mm) Wire-O® can be used.
b) Measuring Card
Using a book measuring card available from James Burn International, the
correct Wire-O® wire necessary for binding is determined.
See also the size selection table overleaf (figure 3a).
BB50/01/1 2005
Section 3 Page 2
Wire-O® Size Selection Table
Pitch of Recommended Maximum

Wire-O® Wire Size Wire-O® Book Thickness
Wire-O® Wire
Wire No. Millimetres Inches Inches Millimetres Inches
3 4.8 3/16 3:1 3.2 1/8
4 6.4 1/4 3:1 4.8 3/16
5 7.9 5/16 3:1 6.4 1/4
6 9.5 3/8 3:1 7.9 5/16
7 11.5 7/16 3:1 9.5 3/8
8 12.7 1/2 3:1 11.1 7/16
9 14.3 9/16 3:1 12.7 1/2
10 16.0 5/8 2:1 14.3 9/16

12 19.0 3/4 2:1 16.0 5/8
14 22.0 7/8 2:1 19.0 3/4
16 25.4 1” 2:1 22.0 7/8
Figure 3a
3.2 Installing a Spool of Wire-O® Wire
3.2.1 Select the size of Wire-O® wire for the job.
3.2.2 Place the carton containing the Wire-O® wire spool next to the spool unwind
stand.
3.2.3 Open the carton flaps.
3.2.4 Lay the carton on its side.
3.2.5 Roll out the spool.
3.2.6 Discard the empty carton.
3.2.7 From the upper shaft of the spool stand, slacken off the screw knob (see
figure 3b).
3.2.8 Remove the spool retaining collar and spring (see figure 3b).
3.2.9 Lift the spool by holding it by the metal hubs and load it onto the upper
shaft in such a way that the Wire-O® wire is fed off the top towards the
binding machine.
BB50/01/1 2005
Section 3 Page 3
3.2.10 Push the spool up against the spool locating flange.
3.2.11 Replace the spring and retaining collar.
3.2.12 Secure the collar by tightening the knob so that the spring grips the spool,
so that the spool does not freewheel.
3.2.13 Remove the cling film and tape wrapping.
3.2.14 Slacken off the screw knob and remove the spool retaining collar from the
lower shaft of the spool stand.
3.2.15 Load an empty spool onto the lower shaft.
3.2.16 Push the spool up against the locating flange.
3.2.17 Replace the spring and retaining collar.
3.2.18 Lock it by tightening the knob so that the spring does not grip the spool
but enables it to freewheel.
Spring
Wire-O Spool
Screw Knob
Empty Spool
Spool Retaining Collar
Figure 3b Spool Stand
Proceed with setting up and adjusting your binding machine to the size of Wire-O®
wire selected. However, you will need to return to the spool stand at a later stage
(Section 4.5).
BB50/01/1 2005
Section 4 Page 1
4. Setting Up and Adjusting your Binding Machine
When changing between Wire-O wire sizes, or installing Wire-O wire for the first time, it
will be necessary to adjust and install various parts of the binding machine as described in
the following chapters. Refer to figure 4a for an illustration of the main parts of the
machine.
Control Box Top Perspex Guard Rear Perspex Guard
Left Hand Cover Right Hand Guard
Right Hand Hinged

Front Perspex Access Guard
Guard
Spool Speed Control Knob
Emergency Stop Button

Adjustable
Finger Guard Wire-O Feed Monitor
Proximity sensor
Binding Table
Foot Pedal
Lay Gauge Slug Bottle
Spool Unwind Stand

Main Isolator Switch
Figure 4a
BB50/01/1 2005
Section 4 Page 2
4.1 Installing/Changing Wire-O Wire Feed Starwheel

Once you have selected the correct Wire-O wire size, refer back to the table in
figure 3a to see which pitch the selected Wire-O wire conforms to. The selected
size of Wire-O wire determines whether a 2:1” or 3:1” pitch feed starwheel is used.
To install or change a starwheel refer to figure 4b and proceed as follows:
Feed Plate Feed Handle
Starwheel Feed Chute
Figure 8
Friction Drive Disc

Retaining Knob
Figure 4b. Wire-O Wire Feed Unit
BB50/01/1 2005
Section 4 Page 3
4.2 How to Eject Wire-O Wire Remnants from the Feed Belt
4.2.1 Switch ON the machine (refer to operating procedure in Section 5.2).
4.2.2 Ensure no further wire will feed in.
4.2.3 Use HOME function see section 4.13.1.3
4.2.4 Switch off machine.
4.3 Changing Feed on Starwheels: 3:1” and 2:1”

(see figure 4b)
4.3.1 Open the right hand hinged access guard.
4.3.2 Grip the Wire-O wire feed handle with right hand.
4.3.3 Whilst holding the feed handle unscrew the retaining knob.
4.3.4 Remove the friction drive disc.
4.3.5 Remove the starwheel by withdrawing it bottom first until it is free from its
location and clear of the shaft.
4.3.6 Insert the required starwheel.
4.3.7 Load the required starwheel on the mounting disc.
4.3.8 Engage it into the slots in the feed plate.
4.3.9 Replace the friction drive disc.
4.3.10 Replace the retaining knob.
NOTICE
Do not over tighten the knob, you may jam the starwheel.
4.3.11 Close the right hand hinged access guard.
BB50/01/1 2005
Section 4 Page 4
4.4 How to Adjust the Wire-O Wire Feed Guide
Clamp Lever
Clamping Screw
Feed Guide
Adjusting Lever
Wire-O
Chute
Feed Handle
Figure 4c Wire-O Wire Feed Guide
4.4.1 Open the right hand access door.
4.4.2 Slacken off the clamp lever.
4.4.3 Raise or lower the feed guide with the adjusting lever to set it to the required
Wire-O wire size (approximate).
4.4.4 Retighten the clamp lever.
4.4.5 Close the right hand access door.
BB50/01/1 2005
Section 4 Page 5
4.5 How to Load Wire-O Wire into the Binding Machine
4.5.1 Open the right hand access door.
4.5.2 Take the end of the Wire-O wire from the spool.
4.5.3 Unwind the spool by hand to form a dancing loop (see figure 4d).
NOTICE
Do not stretch Wire-O wire as this will damage it.
4.5.4 Temporarily let the interleaf paper gather on the floor.
4.5.5 Run the Wire-O wire between the upright pillars and under the floating
sensor tube of the feed monitor as shown in figure 4d. Set the height of
the floating sensor tube by repositioning the limit block. Refer to figure 4e
for recommended setting heights.
4.5.6 Place the Wire-O wire on the feed chute and push it up to the starwheel
(refer to figure 4b). Turn the feed handle to feed the Wire-O wire onto the
starwheel, ensuring that the Wire-O wire freely engages between the teeth.
Intake sufficient Wire-O wire to engage onto the first few teeth of the
starwheel (between 2 and 4 clicks).
4.5.7 Close the right hand door.
4.5.8 Find and attach the end of the interleaf paper to the hub of an empty spool
and gently turn it back by hand to take up the slack.
4.5.9 Reposition the retaining collars on both upper and lower spool stand shafts
so that the springs grip the spools to prevent free-wheeling. The spool
stand is now set up to dispense Wire-O wire although it may be necessary
to adjust the position of the retaining collars at a later stage if the grip is not
sufficient to drive either (especially the full) spool.
BB50/01/1 2005
Section 4 Page 6
Right Hand Access Door
Upright Pillars
Wire-O Wire
Spool
Feed Chute
Empty Spool
Dancing Loop
Floating Sensor
Tube
Recommended
Set heights: Figure 4d Loading Wire-O Wire into the Binding Machine
3:1 : 450mm
2:1 : 200mm
Figure 4e
Feed Monitor
Figure 4e Feed Monitor
BB50/01/1 2005
Section 4 Page 7
4.6 How to Set Cutter to Cut Wire-O Wire Centrally

(refer to figures 4c and 4f)
When the cutter cuts the wire it removes a section of wire (slug) centrally from the broad
loop. These slugs are collected into a slug collection bottle positioned under the right
hand cover. The cutter blade position will vary from 2:1” to 3:1” pitch Wire-O wire.
To set the cutter blade centrally in the broad loop:
4.6.1 Set the Wire-O wire pitch to the required pitch using the SET UP page.
See 4.13.1.3.
4.6.2 Open the right hand hinged access guard.
4.6.3 Check that the correct feed starwheel is in place (refer to Section 4.3).
4.6.4 Check Wire-O wire feed guide is set to selected Wire-O® wire size (refer to
Section 4.4).
4.6.5 Check Wire-O wire is loaded into the machine (refer to Section 4.5).
4.6.6 Check the Wire-O wire is running between the cutter blade and die. If
there is insufficient Wire-O wire, referring to figure 4c turn the feed handle
to intake more Wire-O wire.
4.6.7 Temporarily slacken the clamping screw with a 5mm hexagon key.
4.6.8 By hand, adjust the cutter on top the mark 2:1 or 3:1..
4.6.9 Tighten the clamping screw with the 5mm hexagon key.
4.6.10 Remove the hexagon key.
4.6.11 Close the right hand hinged access guard.
NOTICE
Empty the slug bottle regularly, check every four weeks (refer to
Section 6.2).
BB50/01/1 2005
Section 4 Page 8
Slug Cutter
Die
Slug Cutter
Wire-O Wire
Operating Lever
Slug Cutter
Blade
Cutter Blade and Die positioned

behind Mounting Block
Clamping Screw
Feed Handle
Figure 4f Cutter Unit
BB50/01/1 2005
Section 4 Page 9
4.7 Installing/Changing Inserts in Transfer Bar
The transfer bar (containing the book stop inserts) moves the cut length of Wire-O wire
from the conveyor belt to the closing tools. The book stop(s) on the inserts act as a
register for the book binding edge whilst the grooves longitudinally locate and guide the
Wire-O wire binding. It is therefore necessary to install inserts which correspond to the
size of Wire-O wire being bound.
To install inserts proceed as follows, referring to figure 4g.
Insert
Thumbscrew
Retaining Plate
Locating Pins
Thumbscrew
Thumbscrew
Transfer Bar
Figure 4f Transfer Bar
4.7.1 Raise the front perspex guard so that it latches in an open position.
4.7.2 Slacken the 6 thumbscrews along the length of the transfer bar so that the
3 retaining plates are released. Remove any present inserts.
BB50/01/1 2005
Section 4 Page 10
4.7.3 Select inserts which correspond to the size of Wire-O wire to be bound.
Starting at the cutter end, position inserts end-to-end along the transfer
bar, ensuring that they seat correctly on the locating pins.
Inserts are supplied in varying lengths, with different combinations of book

stop. 1” and 2” long inserts are available for Wire-O wire sizes 3, 4, and 5.
1” and 6” long inserts are supplied for Wire-O wire sizes 6, 7, 8, 9, 10, 12,
14 and 16. It is recommended that you bind with as many inserts with
book stops, spaced every 2” (50.8mm) as is possible.
NOTE: Ensure that book stops are always positioned outside the extreme
ends of the hanger.
4.7.4 Re-tighten the thumbscrews to secure the inserts on the transfer bar.
4.7.5 Close the front perspex guard.
4.8 Preparing Closing Tools to Suit your Binding Machine

The Wire-O closing tool are supplied in pairs consisting of an upper and lower jaw. It is
necessary to select and install a pair which correspond to the size of Wire-O wire to be
bound. For ease of identification each pair of tools is stamped with the size and whether
it is a top or bottom jaw (see figure 4h).
4.8.1 Select a top and bottom jaw of the appropriate size and pitch to
correspond to the size of Wire-O wire to be bound. For ease of
identification each pair of closing tools have their size and reference
number stamped on the sloping face of the tool, e.g., 1/4” TOP JAW
(BB044-STT4-0)
4.8.2 When calendar binding, select an appropriate size and type insert for the
hanger to be used (see figure 4h). Inserts are marked on the rear face as
below (1/4” size shown as an example):
BB50/01/1 2005
Section 4 Page 11
Insert
Item Ref. Applicable Hanger
Mark Size Jaw Type
8 1/4” T No.2
9 1/4” T Nos. 3 & 4
10 1/4” B Nos. 3 & 4
11 1/4” FT None (straight bind)
12 1/4” EH (either) EH 3 & EH 4
14 1/4” B No. 2
15 1/4” FB None (straight bind)
T = for use in top jaw only

B = for use in bottom jaw only
F = filler
EH = Eurohanger (for use in either jaw)
4.8.3 Clamp the appropriate inserts into the tools with the M4x6 socket head cap
screw provided.
M4x6 Screw
Position
Figure 4h Closing Tool Preparation
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4.9 Installing/Changing Closing Tools

The Wire-O wire closing tools are supplied in pairs consisting of an upper and lower jaw.
It is necessary to select and install a pair which correspond to the size of Wire-O wire to
be bound. For ease of identification each pair of tools is stamped with the size and
whether it is a top or bottom jaw.
4.9.1 Raise the front perspex guard so that it latches in an open position.
4.9.2 To remove previously fitted tools, support the upper jaw with one hand,
whilst unscrewing the two handscrews in the upper beam. Once
unscrewed, remove the jaw by freeing from its locating pegs.
Upper Beam
Handscrews
Upper Jaw
Lower Beam
Cross–Match
Screw
Lower Jaw
Figure 4i Closing Tool Installation
4.9.3 Removing the lower jaw is most easily done whilst the table is forward. To
do this, first open the guard below the table. Disengage both latches on the
underside of the table as shown in Figure 4j and pull the table towards you.
Ensure that the table latches in a forward position to prevent it slipping
back.
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Table Latches
Table Lock Collet
Table Handle
Bottom Guard
Figure 4j View of Underside of Table
4.9.4 As with the upper tool, unscrew the handscrews and remove the lower jaw.
4.9.5 To fit a new tool, with the table still in a forward latched position, as
described in 4.9.3, and with the front perspex guard raised, install the
selected lower jaw in the lower beam.
Ensure that the tool engages on the location pegs so that it lies flat on the
beam, and screw the handscrews through the beam to retain the jaw. Do
not over-tighten. Using a 3mm Allen key adjust the socket head cap screw
at either end of the bottom beam until the front edge of the jaw is flush with
the beam.
4.9.4 Locate the upper jaw on the location pegs in the upper beam and secure it
with the handscrews. Do not over-tighten. Using a 3mm Allen key adjust
the socket head cap screw at either end of the upper beam until the front
edge is flush with the beam
4.9.5 Disengage the table latches and return the binding table to its closed
latched position. Ensure that the latches re-engage to lock the table in
position.
NOTICE
It may be necessary to raise the table to enable it to re-
latch if it clashes with the bottom closing tool. Refer to
Section 4.12.
4.9.6 Close the front perspex guard and the guard below the table.
The closing tools are now installed, but will probably require adjusting to perform a correct
bind. This adjustment is known as cross-match and is described in Section 4.17.
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4.10 Wire-O Wire Pusher Adjustments

Depending on the Wire-O wire size you wish to bind it will be necessary to adjust the
pusher travel and pusher height accordingly.
4.10.1 Raise the front perspex guard.
4.10.2 Raise the pusher shield to its highest position by turning the thumbscrew
at either end of the pusher plate.
4.10.3 Using wire cutters, manually cut a full bind length (500mm) of Wire-O wire
and lay it on the conveyor belt.
4.10.4 Turn the thumbscrews to lower the shield so that it is just above, but does
not touch the Wire-O wire.
To adjust the pusher travel proceed as follows:

Thumbscrew
Pusher Shield
Wire-O
Push Stroke
Insert
Pusher Plates
Transfer Bar
Figure 4k
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NOTICE
Before adjusting the pusher travel it is necessary to ensure that the
transfer bar inserts installed correspond to the Wire-O wire size
selected. Refer to Section 4.7 for the procedure for installing and
changing inserts.
This adjustment is carried out manually, although slight adjustments may be

required when first operating the machine, described in Section 5.
4.10.5 Manually place the Wire-O wire strip cut in Section 4.10.3 centrally on
the transfer bar as shown in figure 4k.
4.10.6 From the back of the machine grip the pusher plate with one hand and
offer it up to the Wire-O wire strip so that it touches but does not move
the Wire-O wire.
NOTE: If the pusher cannot be offered up far enough to touch the

Wire-O wire, rotate the thumbscrew clockwise to offer the
pusher up, until it touches but does not move the Wire-O wire.
If this has been done the setting is complete, if not continue as
follows:
4.10.7 While holding the pusher at this position rotate the thumbscrew anti-
clockwise until the pusher begins to be drawn back as the control handle
limits the forward travel.
4.10.8 Remove and discard the Wire-O wire strip.
4.11 Transfer Bar Adjustment

It is necessary to adjust the transfer bar travel according to the selected Wire-O wire size.
The transfer bar should present the Wire-O wire into the closing tools so that it is gripped,
but not squashed, as shown in figure 4l.
NOTICE
Prevent collision of the transfer bar with closing tools, especially when
changing to a larger Wire-O wire size (e.g., 3/16” to 7/8”) by limiting the
transfer bar stroke to a minimum as a starting point for beginning
adjustment.
4.11.1 Rotate the handle labelled “transfer bar” at the rear of the machine to
alter the stroke of the forward travel, until the Wire-O wire is presented
correctly. The Wire-O wire should sit in the radii of the closing tools
such that its tips do not protrude to obstruct the insertion of sheets.
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This adjustment can be carried out manually, by sliding the transfer bar
forward by hand, but in practice is easiest done when operating the
machine as described in Section 5. You will therefore need to return to
this section at a later stage to make slight adjustments.
Upper Jaw
Transfer Bar
Lower Jaw
Figure 4l Wire-O Wire Presentation
4.12 Binding Table Height Adjustment

(refer to figure 4j)
It is necessary to set the height of the binding table to suit the selected size of Wire-O
wire, to enable smooth entry of the book into the closing tools. This is therefore carried
out once the closing tools have been installed, and with the table in a closed latched
position. Refer to figure 16 and proceed as follows:
4.12.1 Slacken off the table lock collet.
4.12.2 With the table latched so that it is closest to the closing tools, rotate the
table handle to set the height of the table. The top front edge of the
binding table should align with the top front edge of the bottom jaw.
4.12.3 Re-tighten the table lock collet.
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4.13 Control Panel
This section is to familiarise the operator with the functions of the touch screen only. For
instructions on operating the machine see Section 5.
4.13.1 This machine features a state of the art touch Screen display panel. The
machine set-up is simplified by the operator being presented with a
series of menus and the appropriate selection being made by touching
the indicated areas of the screen.
On powering up the machine, the operator will be presented with the

INTRODUCTION PAGE. This contains information such as the serial
number and contact details for James Burn.
For details of the pages hierarchy see figure 4m.
Figure 4m
SET UP PAGE START MENU AUTO CYCLE/READY TO RUN
SPOOL WIRE CUTTER STEP MODE
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4.13.2 Start Menu
To set up or run the machine, touch the START option box on the
screen.
If the machine is already set up for an operation proceed directly to the

AUTOMATIC CYCLE page by touching AUTOMATIC CYCLE option
box. (For details of use, see section 4.13.4)
If it is required to check or change the settings, go to the SET UP page

by touching the SET UP option box. (For details of use, see section
4.13.3).
To manually step the machine through the cycle enabling fine

adjustments to be made to the mechanical components, proceed to the
MANUAL CYCLE page by touching the MANUAL CYCLE option box.
SWC (spool wire cutter) is a special function for cutting predetermined

lengths of Wire O for other applications, and is not normally used when
binding with the BB43. See section 5.8
NOTE: This should only be done when the SET UP parameters have
been entered (for details of use, see section 4.13..5)
4.13.3 Set Up Page
From the START MENU, touch the SET UP option box.
To input the required values (NO. OF LOOPS, SKIP LENGTH and

NUMBER OF ELEMENTS) touch the appropriate option box. A key
pad will appear on the screen. Touch the appropriate keys to select the
value. Touch the ENT key to input the value.
For further details on these setting values, see the examples in section
4.15.
The HOME option is only required when changing wire ratio (pitch size
from 2:1 to 3:1 or vice versa). If a new value for wire ratio has been
entered, to run the machine through a homing cycle, touch the HOME
option box.
When the correct parameters have been entered, touch the EXIT
option box to exit to the AUTO CYCLE/READY TO RUN menu.
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4.13.4 Auto Cycle/Ready to Run Menu
When this page is displayed, if a book is placed over the proximity

sensor on the table the machine can be cycled by pressing the foot
pedal (see figure 4a).
Also on this page more experienced operators can fine tune settings
for optimum performance:
BELT SPEED ADJUSTMENT- is available because smaller wire sizes

can be transported through the machine faster than larger ones and
the binding format etc. To adjust the belt speed, touch the BELT
SPEED ADJUSTMENT option box. Coarse settings can be made by
touching the appropriate vertical bars.
PRESS TO HALT - This function provides a limited degree of

protection from tampering by unauthorised users. Touching this option
box will prevent the machine from being cycled, and lock out most of
machine functions. Touching the option box for a second time will
return the machine normal mode.
RESET BOOK COUNT - Touching this option box will reset the book
count for a new production run.
BOOK COUNT - Touching this option box will toggle between BOOK
COUNT ON and BOOK COUNT OFF.
HANGER -This option box will only be present if a hanger unit has
been fitted. Touching this option box Toggles between hanger feed on
and hanger feed off.
EXIT - Touching this option box will return the program to the START
MENU.
4.13.5 Manual Cycle
This mode should be used for making adjustments to the closing

mechanisms. To return to the START MENU, touch the RESET
MACHINE AND EXIT option box.
4.13.6 Other Pages
Other pages exist for use by James Burn Engineers only. They are
concealed from the operator to prevent parameters being altered.
Critical parameters are pass word protected. In the unlikely event that
an operator were to find themselves in the ENGINEERS menu pages it
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is important that no parameters are altered. The operator should return

to the main menu by selecting the EXIT options. Once back in the main
menu the machine should be switched off and left for thirty seconds,
before powering up again.
4.14 Wire-O Wire Pitch Counter Setting

When changing between 2:1” and 3:1” pitch Wire-O wire it is necessary to set the binding
machine to accept the new pitch, as follows:
4.14.1 Remove any Wire-O wire from the closing tools.
4.14.2 Reconnect the electrical supply and switch the isolator ON.
4.14.3 From the START MENU go to the SET UP page (see 4.13.3). Select
the correct pitch value using the WIRE 2:1 or WIRE 3:1 box.
Turn the pitch selector switch on the control panel to the required pitch, to
automatically change the closing tool carried gap to suit the Wire-O wire pitch
selected.
4.15 Wire-O Wire Feed Programming

(refer to Section 4.13 – Control Panel)
This machine is capable of straight binding or skip binding used for books or calendars.
The binding format consists of three programme variables, called NUMBER OF LOOPS,
NUMBER OF ELEMENTS and SKIP LENGTH located in the SET UP page (see 4.13.3).
These represent the Wire-O wire element lengths, the skip (gap) lengths and the number
of elements. The programme automatically presents the binding format to a central
position in the closing tools.
NOTICE
Ready-made tables showing various Wire-O wire feed programmes for
binding are provided with the machine. Alternatively, the programming
can be calculated in the following way (see following pages):
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4.15.1 Straight Binding (3:1”)
Example: To bind a book with an element of 24 loops
Number of loops = 24
Element length
Book length
3:1 Closing tool
1st loop
60th loop
Maximum number of binding loops = 60
On the SET UP page, set the variables to the following:
‘Number of loops’ = 24
‘Number of elements’ = 1
‘Skip Length’ = 0
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4.15.2 Calendar Binding (3:1”) with No.3 Hanger
Example: To bind a calendar with two elements of 16 loops each with a number
3 hanger (3 loop skip).
Calendar bind length
Skip length = 3
3:1 closing tool
60th loop
1st loop
Loops = 16 Loops = 16
Element length Element length
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4.15.3 Calendar Binding (3:1”) with No.2 Hanger
Example: To bind a calendar with two elements of 18 loops each with a number
2 hanger (2 loop skip).
Calendar bind length
Skip length = 2
3:1 Closing tool
60th loop 1st loop

18 loops 18 loops
Element length Element length
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4.15.4 Skip Binding with a Single Skip (3:1”)
Example: To bind a book with a single skip (gap) of 5 loops and 2 elements of 6
loops each.
Book binding length
Skip length = 5
3:1 closing tool
60th loop 1st loop
6 loops 6 loops
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4.15.4 Skip Binding with Two Skips (3:1”)
Example: To bind a book with two skips (gaps) of 5 loops and 3 elements of 8
loops each.
Book binding length
8 loops 8 loops 8 loops
3:1 Closing tool
60th loop 1st loop
Skip length = 5 Skip length = 5
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4.15.5 Straight Binding (2:1”)
Example: To bind a book with an element of 23 loops
Element length = 23 loops
Book length
2:1 Closing tool
1st loop
41st loop
‘Skip length’ = 0
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4.15.6 Skip Binding with a Single Skip (2:1”)
Example: To bind a book with a single skip (gap) of 8 loops and 2 elements of
13 loops each.
Book binding length
Skip length = 8
2:1 Closing tool
41st loop 1st loop
13 loops 13 loops
Number of loops Number of loops
On the SET UP page, set the variables to following:
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4.15.7 Skip Binding with Two Skips (2:1”)
Example: To bind a book with two skips (gaps) of 4 loops and 3 elements of 6
loops each.
Book binding length
6 loops 6 loops 6 loops
2:1 Closing tool
41st loop 1st loop
Skip length = 4 Skip length = 4
‘Skip length’ = 4
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4.16 Installation of Side Lay Gauge

A side lay gauge is required to longitudinally position the book in the Wire-O wire prior to
binding.
NOTE: Ensure that part holes are not punched at either end of the sheet. A margin of
at least 3mm to 4mm should be allowed between the first or last holes and the
edge of the sheet.
Two types of side lay gauge are supplied with the machine, only one is to be used at any
one time:
a. Lay gauge for ordinary books (where the sheets are the same size as the covers).
Follow instructions in Section 4.15.1.
b. Lay gauge for books with oversize covers. Follow instructions in Section 4.15.2.
NOTICE
It is necessary to position the side lay gauge after the binding table
height has been set.
For installing the lay gauge for ordinary books:
4.16.1 Run the machine so that the required cut length of Wire-O wire is held in the
closing tools (refer to Section 5 “Operating your Binding Machine”), and the
transfer bar is raised.
4.16.2 Insert a punched sample sheet or cover into the closing tool, up to the bookstops,
as shown in figure 4n. Align the sheet so that the gaps between the broad loops
in the bottom jaw are positioned centrally with the punched holes.
4.16.3 Position the ordinary lay gauge to either the left hand or right hand edge of the
sheet. Secure the body to the table with the two screws provided so that it is
parallel to the corresponding datum edge. Use a 4mm Allen key.
NOTICE
The ordinary lay gauge can be positioned along either the left
hand or right hand edge of the sheet, depending upon which
side you prefer to lay the book.
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Lay Gauge Arm
Book
Ordinary
Side Lay Gauge
Table
Figure 4n . Ordinary Side Lay Gauge
4.16.4 Without dislodging the sheet offer the adjustable datum arm up to the sheet by
adjusting the micrometer screw.
For installing the lay gauge for books with over-sized covers:
4.16.5 Run the machine so that the required cut length of Wire-O wire is held in the
closing tools (refer the Section 5 “Operating your Binding Machine”) and the
transfer bar is raised.
Book
Swivel Arm
Table
Figure 4o Oversized cover side laygauge
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4.16.6 Insert a punched sample cover into the closing tools, up to the bookstops. Align
the cover longitudinally so that the narrow loop tips in the bottom jaw are
positioned centrally in the punched holes.
4.16.7 Without dislodging the cover, offer the over-sized cover lay gauge body
(adjustable swivel arm raised) up to the left-hand cover edge, as shown in figure
4o. Secure it to the table with the two screws provided so that it is parallel to the
left hand edge.
NOTICE
The over-size cover lay gauge can only datum off the left—hand
book edge.
4.16.8 Replace the cover with a sample sheet, again alining the holes with the Wire-O
wire tips as it would be bound.
4.16.9 Without dislodging the sheet, lower the adjustable swivel arm and adjust its
position with the micrometer screw, so that it butts up against the edge of the
sheet.
4.16.10 Remove the sample sheet.
The oversize cover lay gauge is now set to register the covers and, using the swivel arm,
the inside sheets.
4.17 Adjustment of Front Perspex Guard

4.17.1 Ensure binding table has been set to correct height.
4.17.2 Ensure front perspex guard is fully closed.
4.17.3 Adjust height of front perspex guard extension so that the gap between the
bottom edge and the table allows a bound book to be withdrawn. As a guide this
gap should be equal to the size of Wire-O wire in sixteenths of an inch (1.6mm)
plus one sixteenth (1.6mm), to give a vertical height in inches.
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4.18 Cross-Match Adjustment of Closing Tools

Cross-match adjustment of the newly installed closing tools is necessary to ensure
correctly closed Wire-O wire. During cross-match adjustment the upper and lower closing
tools are moved relative to one another at either end. Referring to Section 5.4 adjust the
closing tools as follows:
To adjust the upper closing tool:
4.18.1 Slacken the hand screws to permit sliding adjustment of the closing
tool.
4.18.2 Insert the 3mm Allen key provided into the cross-match screw in the
upper beam corresponding to the end of the tool to be adjusted.
4.18.3 Rotate the Allen key anti-clockwise to move the tool back (into the
machine) and clockwise to move the tool forward (towards the
operator).
NOTE: It is only necessary to rotate a cross-match screw a small

amount to adjust the bind.
4.18.4 Tighten both handscrews to secure the upper tool.
To adjust the lower closing tool:
4.18.5 Referring to figure 4j, open the guard under the table. Disengage both
latches on the underside of the table and pull the table towards you.
Ensure that the table latches in a forward position to prevent it slipping
back.
4.18.6 Ensure that the handscrews in the lower beam are slackened to permit
sliding adjustment of the tool.
4.18.7 Insert the 3mm Allen key provided into the cross-match screw in the
lower beam corresponding to the end of the tool to be adjusted.
4.18.8 Rotate the Allen key anti-clockwise to move the tool back (into the
machine), and clockwise to move the tool forward (towards the
operator).
4.18.9 Tighten both handscrews to secure the lower tool.
4.18.10 Disengage the table latches and return the binding table to its closed
latched position. Ensure that the latches re-engage to lock the table in
position. Close the guards.
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5. Operating your Binding Machine
5.1 Final Check and Installations

Before operating your binding machine you must ensure that the procedures described in
previous sections have been completed and that you are familiar with the facilities and
features of the control panel (figure 5a).
5.1.1 Check that the following adjustment and setting up procedures have been
completed:
Installation of 2:1” and 3:1” Wire-O wire feed sprocket
Adjustment of Wire-O wire feed guide
Adjustment of Wire-O wire cutter
Installation of correct transfer bar inserts
Installation of correct closing tools
Adjustment of Wire-O wire pusher (travel and height)
Adjustment of transfer bar
Adjustment of table height
Selection of, and adjustment of, lay gauge
Setting of Wire-O wire pitch (SET UP page)
Setting of Book Count (AUTOCYCLE/READY TO RUN menu)
Adjustment of front perspex guard
Hanger feed set and loaded when calendar binding (refer to Section 5.3)
5.1.2 Check that the correct Wire-O wire size has been loaded.
5.1.3 Check that all machine guards are shut properly. Operator guards are
electrically interlocked and fixed guards are secured to the machine with
screws. Removal of guards which require the use of external tooling aids
(e.g. Allen key) should only be carried out by authorised personnel.
5.1.4 Check that the Wire-O wire pitch selector key on the control panel is set to
correspond to the pitch of Wire-O wire loaded.
5.1.5 Check that the spool speed control knob on the control panel is set to the
correct speed.
5.1.6 Check that the compressed air supply is connected to your binding
machine and restricted to 5.5 Bar (80 P.S.I.) pressure.
5.1.7 Check that the Wire-O wire fed into the machine is not taut causing the
floating sensor tube to be raised off the limit block and that the limit block is
set at a suitable height (see recommended position in figure 4e).
5.1.8 Connect the electrical supply lead into the machine and to the supply
socket.
5.1.9 Select the AUTOCYLCLE/READY TO RUN menu to enable one complete

machine cycle on operation to be performed (see section 4.13.4).
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Spool Speed
Control Knob
PRESS TO START
Option box (gives access to
the START MENU)
Emergency Stop
Switch
Figure 5a Operator Control Panel and WireO Wire Setting Up Panel
NOTE: The Electric Mains Isolator Switch is positioned on the front electrical enclosure
below the worktable. Provided all guards are shut, and the isolator switch is
ON, when a selection box in the START MENU page is touched, the
compressed air supply to the machine will be activated.
5.2 How to Perform your First Bind Safely

When you have completed all final checks and installations, proceed as follows:-
5.2.1 Switch ON the electric isolator. This will illuminate the touch screen.
5.2.2 Touch the PRESS TO START option box to activate the START MENU.
Touch the AUTOMATIC CYCLE option box to activate the
AUTOCYCLE/READY TO RUN menu. If the Wire-O wire (or Wire-O wire
and hanger when calendar binding) is present between the closing tools
then go to Section 5.2.5. If not, then proceed as follows:
5.2.3 Cover the book sensor with a sheet of paper or book to be bound. Begin
the machine cycle by depressing the foot pedal once only.
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5.2.4 Remove the sheet or book to be bound. This will activate the machine to
present the Wire-O wire (or Wire-O wire and hanger in the case of
calendar binding) into the closing tools ready for binding.
5.2.5 Place the book or calendar to be bound flat on the binding table with the
cover sheets on the bottom. Align its datum edge up to the side lay
gauge.
NOTE: In practice, books are bound with covers on the underside so

that after binding the rear cover can be turned around to
conceal the bind joint. This also ensures that the inner sheets
will never drop out as usually the covers are thicker than the
inside sheets.
5.2.6 Slide the book or calendar along the side lay gauge, under the perspex
guard and into the closing tools until it contacts the bookstops in the
transfer bar.
CAUTION
Never put fingers under the front perspex guard
5.2.7 Release the book or calendar.
5.2.8 Depress the foot pedal once to complete the bind.
5.2.9 Remove the book.
5.2.10 Inspect the circular shape of bind and check and the narrow loops are
tucked between the broad loops to ensure sheets cannot be removed.
NOTE: If you notice that the bound Wire-O wire is distorted or under or
over closed then refer to Section 5.4 “Wire-O Wire Bind
Adjustment”.
5.3 Setting and Operating the Hanger Feed for Calendar Binding
(refer to figure 5.3a)
5.3.1 Select the hanger style and length for the job.
5.3.2 Set the wire feed programme to suit the binding length of the calendar
(see Section 4.15 “Wire-O Wire Feed Programming)
5.3.3 Open the rear perspex guard.
5.3.4 Lift and remove the top perspex guard.
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5.3.5 Load the reel of hangers centrally on the spool support shaft located into
the slots at the rear top of the machine.
CAUTION
A full spool of hangers can weigh as much as 15kg.
5.3.6 Unwind about a 200mm long mat of hangers from the reel.
5.3.7 Adjust the hanger guides to support the hangers close to the tape take-off
point.
5.3.8 Position the tape take-off rollers, quantity as required, under the adhesive
tapes of the hangers.
5.3.9 Adjust the height of the central guide rod to maintain minimum clearance
with selected hanger loop.
NOTE: Height adjustment of the central guide rod is obtained by

releasing the locknut and rotating the knurled thumbwheel.
After correct adjustment is made tighten the locknut.
5.3.10 Pull the adhesive tape over the take-off rollers to feed hangers into the
magazine initially.
NOTE: Ensure that hangers stack evenly and centrally into the
magazine.
5.3.11 Advance adhesive tapes to the tape reelers.
5.3.12 Position the tape rollers to line up with the tapes.
5.3.13 Roll the end of the tape over the cardboard tubes.
5.3.14 Unwind and discard the plastic ribbon to the rear of the machine.
5.3.15 Replace the top perspex guard.
5.3.16 Close the rear perspex guard.
5.3.17 If still in the SET UP page, touch the EXIT option box to go to the
AUTOCYCLE/READY TO RUN menu.
5.3.18 Switch ON the hanger feed by touching the HANGER ON on/off option box.
5.3.19 Hangers will be automatically fed around the feed wheels until they arrive on
step before the pick and place unit.
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5.3.20 Cycle the machine to present hangers into the closing jaws.
NOTE: Check that the first hanger is gripped by the pick and place unit
and on the next cycle this hanger will be dropped into the Wire-
O wire on the transfer bar ready to be presented to the closing
tools for binding into the calendar.
5.3.21 When the hangers are exhausted from the reel, remove the empty hanger
reel from the machine.
5.3.22 Lift the roller containing the empty hanger reel away from the location slots
in the side plates.
5.3.23 Remove the empty hanger reel from the spool support shaft.
5.3.24 Load a new hanger reel onto the spool support shaft.
5.3.25 Relocate the roller back into the location slots in the side plates.
5.3.26 Remove the adhesive tape with cardboard rollers from the drive roller by
depressing against the compression spring and detaching it by swinging it
towards you from the opposite end.
5.3.27 Mount new cardboard rollers on the drive roller (quantity as required) and
load the drive roller back onto the machine by depressing against the
compression spring.
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Control Panel
Reel of Hangers
Central Guide Rod Binding Table
Knurled Thumbwheel
and Locknut
Plastic Ribbon
Adhesive Tape
Hanger
Cardboard Tubes
Tape Take-Off Rollers
Figure 5.3a
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5.4 Wire-O Wire Bind Adjustment

Wire-O wire can be distorted on binding if it is not presented correctly to the closing tools,
or if one of the closing tools is not correctly aligned in relation to the other. It is therefore
necessary to adjust the closing tool cross-match and make minor adjustments to the
Wire-O wire presentation to perform correct book binding. The following sections describe
remedies to these binding errors.
Refer to Section 6.6 for a complete fault finding guide.
Problem: Cause: Upper tool to far forward,

The narrow loops stick out above the relative to bottom closing
broad loops tool.
Remedy: Rotate cross-match

screw(s) anti clockwise to
move upper tool away
from operator. If bind is
too tight or squashed,
rotate cross match
screw(s) clockwise to
move lower tool towards
operator.
Cause: The lower tool is too far

Problem:
forward relative to the upper
The broad loops stick out above the
closing tool.
narrow loops.
Remedy: Rotate the cross-match
screw(s) anti-clockwise to
move the lower tool away
from the operator. If the
bind is too tight or
squashed, rotate the cross-
match screw(s) clockwise to
move the upper tool towards
the operator.
BB50/01/1 2005
Section 5 Page 8
Problem: Cause: Both the upper and lower closing

The narrow and broad loops tools are too far forward of the
line up but sheets are machine.
removable.
Remedy: Rotate all cross-match screws anti-
clockwise to move the tools away
from the operator.
Problem: Cause: The Wire-O wire is not presented into

The Wire-O wire is squashed in the radii of the closing tools.
the closing tools (showing both
tips). Remedy: Adjust the transfer bar travel as
required:
Anti-clockwise = towards operator
Clockwise = away from operator.
Problem: Cause: The Wire-O wire is

The Wire-O wire tips show in the presented incorrectly due to
top closing tool only. rolling on the transfer bar.
Remedy: Lower the pusher angle to

prevent the Wire-O wire
rolling as it is pushed
forward.
BB50/01/1 2005
Section 5 Page 9
Cause: The Wire-O wire is not presented into

Problem:
the radii of the closing tools.
The Wire-O wire is presented
into, but not held by the closing
Remedy: Increase the transfer bar travel by
tools.
adjusting the handle anti-clockwise at
the rear of the machine.
Problem: Cause: The Wire-O wire is not presented

The Wire-O wire is rushed into the radii of the closing tools.
into the book
Remedy: Adjust the transfer bar handle at
the rear to correct the pusher
travel.
Problem: Cause: Holes in the book do not line up with

The Wire-O wire is crushed into the Wire-O wire in the machine.
the book
Remedy: Adjust the lay gauge to reposition the
book so that the holes line up with the
Wire-O wire loops.
BB50/01/1 2005
Section 5 Page 10
5.5 How to Set for Skip Bind of Books

Skip binding of books can be done on this machine.
5.5.1 Refer to the tables for the recommended skip settings on standard binding
formats.
5.5.1 If non-standard formats are used for binding, refer to the formulae shown in
Section 4.15.
5.5.2 Set the Wire-O wire feed programme accordingly.
5.5.3 Depending upon the skip selection arrange to punch the paper accordingly.
5.5.4 Repeat all the stops from Sections 5.1 and 5.2.
5.6 How to Remove a Jammed Book, Calendar or Wire-O Wire
WARNING
Removal of a jammed book, calendar or Wire-O wire should be carried
out by a service or maintenance engineer. Before removing a jammed
book, calendar or Wire-O wire switch OFF and disconnect the electrical
supply for personal safety.
5.6.1 Find the location of the jammed book, calendar or Wire-O wire.
5.6.2 Temporarily remove or open the appropriate guard(s) to gain access to the
jammed item.
5.6.3 Remove the jammed book or Wire-O wire.
5.6.4 Replace or close the guard(s).
5.6.5 Restart the binding machine.
BB50/01/1 2005
Section 5 Page 11
5.7 How to Remove a Jammed Hanger in the Hanger Feed

BB50/H only
(refer to figures 4a and 5.3a)
CAUTION
Switch OFF and disconnect the electrical supply for personal safety.
5.7.1 Open the rear hinged door.
5.7.2 Remove the top perspex guard temporarily.
5.7.3 Cut off the adhesive tapes between the magazine and reelers.
5.7.4 Remove the hanger reel.
5.7.5 Empty the magazine.
5.7.6 Locate and remove the jammed hanger.
5.7.7 Reload the hanger (refer to Section 5.3).
5.7.8 Replace the top perspex guard.
5.7.9 Close the rear hinged door.
5.7.10 Restart the binding machine.
5.8 Running your Machine as a Spool Wire Cutter

5.8.1 Carry out all the instructions in Section 5 up to and including 5.1.8 and
proceed as follows:
5.8.2 Go to the SET UP page. Select the SWC option box. Touch the ENTER
NUMBER OF LOOPS. A keypad will appear. Type number of loops
required and press ENT.
5.8.3 Depress the foot pedal once to cut one binding length. The binding
lengths can be collected from the chute located in the left hand side
cover.
5.8.4 Touch the EXIT option box to return to the START menu.
BB50/01/1 2005
Section 6 Page 1
6. Maintaining your Binding Machine
6.1 General Maintenance

Although only limited maintenance is required, that which is required is important to
enable continually safe and good machine performance.
WARNING
All maintenance work should be carried out by authorised personnel
such as a maintenance or service engineer, or a qualified electrician.
Before commencing any maintenance work, switch OFF and

disconnect the electrical supply for personal safety.
The following daily maintenance is required:
6.1.1 Grease (LM or some other high quality lithium based grease) the needle
roller bearing at each end of the closing tool carriers.
6.1.2 Check all pivots for slackness. Should any slackness be found then re-
tighten them by using the right tool (correct size spanner or Allen key etc.).
6.1.3 Check that the cam arm, closing mechanism and supports are free of
obstruction and accumulated paper dust. Lightly smear working surfaces
with L.M. grease if needed.
6.1.4 Check that the guards and their interlocks operate correctly.
The following pneumatic maintenance is required at regular intervals:
6.1.5 Check that airline pipes are not damaged or leaking and replace where
necessary. 10mm, 8mm, 6mm and 4mm airline pipes are used in the
machine – ensure a replacement pipe is of the same diameter size.
6.1.6 Check that valves, cylinders and fittings are not leaking and rectify where
necessary. A loss of air pressure may impair the performance of the
machine.
6.1.7 Check that the pressure regulator gauge reading corresponds to a setting of
5.5 BAR (80 PSI).
BB50/01/1 2005
Section 6 Page 2
6.2 How to Empty the Slug Bottle

The slug bottle is positioned under the right hand guard at the rear of the machine.
Scraps of wire (slugs), after cutting, are collected into this bottle. When this bottle is full it
needs to be emptied.
To empty the bottle:
6.2.1 Unscrew the bottle.
6.2.2 Empty the bottle.
6.2.3 Replace the bottle.
NOTICE
Empty the slug bottle regularly, check every four weeks.
6.3 How to Align The Wire-O Wire Feed Belt

If the external teeth on the feed belt do not align with those on the yellow bridge inserts, it
is necessary to realign the belt to ensure that the binding lengths are presented correctly
to the closing tools.
6.3.1 On the control panel touch the HOME option box on the SET UP page
6.3.2 Continue binding production.
6.4 How to Run your Binding Machine Sequentially

(refer to figures 7 and 21)
When carrying out service or maintenance work on your binding machine it may be useful
to run the machine cycle step by step (sequentially).
WARNING
This operation should only be carried out by authorised personnel such
as a maintenance or service engineer or a qualified electrician.
6.4.1 Switch the isolator switch ON.
6.4.2 On the START MENU touch the MANUAL CYCLE option button
6.4.3 Depress the foot pedal. At every depression sequences the machine
through a step of its cycle. When the operation is finished press the EXIT
option button to go back to the START MENU.
BB50/01/1 2005
Section 6 Page 3
6.5 Fault Finding Chart
No. FAULT CAUSE REMEDY

1. - Touch screen not - Blown fuse - Examine the right hand electrical
illuminated. supply connector.
- Examine mains plug fuse. Check F1
and F2 (folio 1)
2. - Screen appears showing - Various - Follow advice on the screen and
Warning. proceed.
3. - Machine not starting when - Foot pedal switch not connected - Connect foot pedal.
foot pedal is depressed. - No air supply - Check air supply
- PLC main internal fuse blown - Replace fuse
(PLC power light off)
- PLC error light on - Switch power OFF to reset
4. - Spool drive not rotating - Speed setting set at minimum - Increase speed setting
during cycle. on control panel.
- Speed control PCB fuse blown - Replace fuse F4 (folio 7)
5. - Spool drive over-running - Locking handle loose - Tighten
6. - Intermittent machine - Defective / mis-aligned guard - Examine guard switches
stoppage switches.
- Wire feed monitor sensor set - Reset to lower position
too high
- Spool drive speed set too slow - Increase spool drive speed
potentiometer
7. - Large Wire-O sizes - Excessive stretch in feed gate - Raise feed gate sensor position
misfeeding - Feed in anvil setting too low - Adjust anvil height setting
- Spool drive setting too fast - Reduce speed potentiometer
- Spool stand too far away from - Move stand closer to biding machine.
machine - Slow belt speed. (from
- Transfer belt speed incorrect AUTOCYCLE / READY TO RUN
page.
8. - Feed belt alignment - Drive slip - Re home machine from the SET UP
position incorrect page.
9. - Wire-O intake sprocket - Sprocket locking solenoid - Check action of locking solenoid
misfeed to feed belt jammed - Check assembly for tight spots
- Clutch slip - Check for slug build up.
10. - Wire not cut centrally - Wrongly positioned cutter unit - Slacken clamping screw and adjust
- Wire jam in cutter slot cutter position
- Wire not being cut - Remove unit and clear
11. - Slugs not being removed - Wire jammed in cutter slot - Remove unit and clear
- Nylon tube not connected - Connect tube
- Nylon tube blocked - Clear out the tube
- Collection bottle full - Empty bottle
BB50/01/1 2005
Section 6 Page 4
6.6 Recommended Spare Parts and Tools for your Binding Machine
Part No. Description Quantity

BB023-68-102 3/16” Set of Transfer Bar Inserts 1 Set
BB023-68-112 1” Set of Transfer Bar Inserts 1 Set
BB050-11-005 Bridge Insert 6
111511-5B Air Filter Cartridge 1
630617 Mist Separator Cartridge 1
BB043-01-057 Transfer Belt 1
BB043-30-026 Timing Belt 1
X-TK019 Open Ended Spanner 19mm 1
X-TK028 Open Ended Spanner 13mm 1
X-TK100 Hexagonal Key Set 1 Set
X-TK010 Wire Cutters 1
XBB023-71-058B Set of Brushes for Spool Unwind Motor 1 Set
Fuse 20mm 10A Slow blow (folio 1) 2
Fuse 20mm 2A Slow blow (folio 3 and 4
7)
Fuse 20mm 4A Slow blow (folio 6) 2
BB50/01/1 2005
Section 7 Page 1
7. Binding Machine Technical Data
NOTICE
Your binding machine is constructed to a very high specification, details
of which are given below in Sections 8.1 to 8.4. These specifications
must be strictly adhered to at all times.
7.1 General Data

a) Binding Machine
Machine Size : 1.50m wide x 1.16m deep x 1.40m high
(59” x 46” x 56”)
Nett Weight : 346kg (761lbs)
Base Fitting : Adjustable Mounts
b) Spool Stand (vertical)

Stand Size : 500mm wide x 750mm deep x 1300mm high
(20” x 26” x 42”)
Nett Weight : 60kg (132lbs)
Base Fitting : Fixed Mounts
Loading : Standard Wire-O wire spools
7.2 Electrical Data
WARNING
Internal power circuits are 230V AC irrespective of the machine supply
voltage.
Power Consumption : 1 kW
Mains Supply : 230V 50/60Hz
Wire Feed Drive : (Servomotor)
Fuse Ratings:
F1 : Mains supply 10 Amp Slow Blow 20mm

F2 : 24V D.C. Switched 2 Amp Slow Blow 20mm
Mode Power Supply (Input)
F3 : Servo ampli 4 Amp Slow Blow 20mm
F4 : Spool Motor Drive 2 Amp Slow Blow 20mm
BB50/01/1 2005
Section 7 Page 2
7. Binding Machine Technical Data
7.3 Compressed Air Data

Air Supply : 5.52 bar (80psi) operating pressure
Air Consumption : 14.46 CFM (410 litres/minute) at maximum output

Non-lubricated
Air Input : Mains or dedicated compressor

Minimum capacity 15 CFM (425 litres/minute)
CAUTION
Your machine requires clean and dry compressed air, otherwise the
machine may be damaged.
Ensure that the air compressor has fitted an aftercooler, filters and
airdryer.
7.4 Machine Performance

Mechanical Speed : Maximum : 1800 items/hour
Binding Capacity : For 3/16” – 9/16” (3:1” pitch) Wire-O

Maximum : 60 loops
For 5/8” – 1” (2:1” pitch) Wire-O

Maximum : 41 loops
Calendar Binding : Minimum 4 loops (3:1”) on either side of the hanger

Maximum 28 loops (3:1”) on either side of the hanger
Hanger Style : No. 2 to No.4 and Eurohangers No 3 & 4.
NOTICE
Ensure when punching calendars that the gap in the middle is a whole
number of pitches.
BB50/01/1 2005
FOLIO DESCRIPTION DATE
01 Circuit de puissance - Power circuit 100-120Vac 04/04/2005
02 Circuit de sécurité - Safety circuit 04/04/2005
03 Circuit carte 24Vcc - Card circuit 24Vdc 04/04/2005 Machine à relier : BB50-US
04 Entrées Automate - PLC inputs 04/04/2005 JAMES BURN INTERNATIONAL
05 Sorties Automate - PLC Outputs 04/04/2005 BINDING Machine: BB50-US
06 Servo-ampli : MR-J2S-40A 04/04/2005
version 110Vac
07 Carte driver spool 04/04/2005
08 Bornier connections 04/04/2005
09 Implantation platine 04/04/2005
10 Circuit pneumatique 04/04/2005
11 Implantation capteurs 04/04/2005
12 Implantation actionneurs 04/04/2005
IND MODIFICATION DATE IND MODIFICATION DATE
DES. RESP. DATE ECH.
JAMES BURN INTERNATIONAL

67, rue du docteur Blaizot
61304 L'AIGLE cedex
CLIENT
N° AFFAIRE
0405US-01 INDICE A N° 87654321
CE PLAN NE PEUT ETRE COMMUNIQUE SANS AUTORISATION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
IG
T10A
T4A
F1
F3
Alimentation LL1 101
B L1 . .
103 111 111
Filtre: FR1
230Vac LL2
L2 102
104 112 112
PE PE
C
BOUTON Marche:
Filter AWG16 S=1,31mm² vert/jaune(green/yellow)
230Vac 60Hz
115Vac 60Hz
0-1
D
103 104
(3L2) (1L1)
XB2 TM1 TM2 TM3 TM4 TM5 TM6
F2 KM1
blue
E
brown
purple
Fusible Temporisé:T2A
yellow
(4T2) (2T1)
black
red
105 106 Temporize fuse
T1US F4
LV1
T2A
G
NV1
Auto-transfo 110Vac/230Vac F06 F06
1,1Kw réf:JE08020 F06
H
vers MR-J2S-40A
LV2
NV2
(L11) F06
F06
vers MR-J2S-40A
I (L21) F07
vers Sprint Electric

F07
J
F03 F03 F03

vers folio:03-02
M
(vers cartes 24Vcc)
(to cards 24Vdc)
DESSINE PAR: JH BB50-US version 110Vac JAMES BURN International Circuit de puissance:110Vac FOLIO
DATE: 04/04/2005 AFFAIRE N°0405US-01 Power circuit:110Vac 01
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A C+ blue S=0.8mm² C+ C+ C+
F11
XB12
C+ XB8 XB9 XB10
B C+ C+ C+ C+
. X16
SBAU1 .X16 US1: Sécurité couteau

C Cutter safety
US2: sécurité carter supérieur
(F05-17)
RY14
top cover safety
D
22 22 US3: sécurité supérieure reliure
13
14
XB24 Top bind safety
. .
US1 US1 US4: sécurité inférieure reliure
E
. . Bottom bind safety
XB25 XB30
. . 13 US5: sécurité carter arrière
US2 US2 RY13 Rear cover safety
F (F05-18)
By1+ . . 14
XB26 XB31
. . 13
SS1 (M8117)
US3 US3 RY7
sur PLC(F05605)
G (F05-18)
By1- . . 14
XB27 XB32
. .
US4 US4
H
. . M1
XB28 XB33
. .
C1
US5 US5
I
.
XB29 XB34
23 29
.X10
A1
F04-12
J
CR1
M1
KM1 EV1
C1
A2 V1
D-
K D- D-
XB14 D-
XB13 XB15 XB23
F11 D-
D- D- D- D- Blue S=0.8mm²
e
F O
n
oi
L
s io
t
urr
he
res
Co
F04-13 F01-11
roc
np
rc
ge
F01-11
e
teu
ya
se
bra
Mo
F04-10
Mi
M
Em
DESSINE PAR: JH BB50-US JAMES BURN International Circuit sécurité(safety circuit) FOLIO
DATE: 04/04/2005 AFFAIRE N°0405US-01 24Vcc(24Vdc) 02
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F
ALIM. 24Vdc
V1+ V1+ V1- V1- PE N L
106
105
C+ D-
K
F01-13
F03-01
L
F01-12
F03-02
F01-15
DESSINE PAR: JH AFFAIRE N°:0405US-01 JAMES BURN Circuit carte 24Vcc FOLIO
DATE: 04/04/2005 BB50US Circuit card 24Vdc 03
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F11
AWG20 bleue(blue) C+ C+ C+ C+ C+ C+ C+ C+ C+ C+
XB37
XB38
XB41
XB42
XB43
XB44
XB45
XB47
XB48
XB49
XB50
XB51
XB40
XB39
XB52
F11
XB8
AWG20 bleue(blue) D- D-
Carters(covers)
XB35 XB36
Brown
Hanger miss sensor

F01-10
Brown
XB37
11
XB40
.
PE KM1
.
F06-10(CN1B-18)
(F02-05)
12
4K7
X2
F06-10(CN1A-14)
US1
X15
Cell Table
30 XC1
Black
ZB1
XB39 hanger reel sensor

XB38
AU1
Brown
X3 US2 X16
31 X13 .
(F02-08)
Spool gate sensor
Emergency stop
US3
Capteur flottant
Black
32
Black
X21
Transfer bar limit
Brown
4K7
US4
33 .
pédale
(X5) US5 X20
ZB1 X14
.
Black
Pédale (foot pedal)
X10
KM1
TOP zéro
(F02-05)
Alarm servo
XB34
Ecran X6
D- D- X2 X3 X4 X5 X10 X11 X13 X14 X15 X16 X20 X21
(screen)
+24V
-0V
PE
S/S
X0
X2
X3
X4
X5
X6
X7
X10
X11
X12
X13
X14
X15
X16
X17
X20
X21
X22
X24
X25
X26
X27
X1
X23
T01
CAB1 PLC : FX1N-40MT-DSS24Vcc (PNP) PLC1 INPUT (Entrées)

PE - +
D-
C+
RS422
Cable: CAB1
DESSINE PAR: JH BB50US version 110Vac JAMES BURN Input Plc: FX1N-40MT-DSS 24Vcc FOLIO
DATE: 04/04/2005 AFFAIRE N°0405US-01 04
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
C.de carte dérouleur bobine

F07-07 BY0+
(Driver spool) S5
F07-07 BY0-
S4
F02-05
BY1+
22
SS1 (M8117)
F02-05 BY1-
23
Plc : FX1N-40MT-DSS24Vcc (PNP) PLC1 OUTPUT(sorties)
.
+V1
+V0
+V2
+V3
+V4
+V5
24V
Y10
Y11
Y12
Y13
Y14
Y15
Y16
Y17
0V
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7
.
C+
Hanger ratchet(rochet crochet)
Power delay
Hanger drive motor(moteur crochet)
Hanger slide(glissière crochet)
Hanger clamp(pince crochet)
XB56
Transfer bar
C+
Cutter(couteau)
GRIP
Pusher(pousseur)
Clutch(embrayage)
D- D-
Bind (reliure)
C+
XB54 XB55
Ajust 2:1
A1
XB53 Y14
C+
C+
Ajust 3/1
(F02-08D) A2
XB22
C+
F06-40(CN1B-5)
Y4 Y10
F06 (CN1A-3)
F06-20(CN1A-10)
D-
Y2
Y5 Y11
XB4 XB16
Relai statique
F06-20(CN1A-1)
XB3 Y3 XB5 Y6 XB17 Y12 Y16

D-
D-
F06-20(CN1B-15)
XB1
A1 A1
D-
D-
D-
XB2 Y7 (F02-13G) Y13 (F02-15F) Y17
D-
XB6 A2 XB18 A2 XB20
XB7 XB19 XB21

D-
D-
D-
D-
D-
D-
D-
DESSINE PAR: JH BB50-US version 110Vac JAMES BURN Output Plc: FX1N-40MT-DSS 24Vcc FOLIO
DATE: 04/04/2005 AFFAIRE N°0405US-01 (Sorties Plc) 05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F01-15 111
A
F01-15 112
B PE
C
MR-J2S-40A
Cable résolver
Moteur: HC-KFS43
E
CN1B
CN1A
F
CN2(ENC)
CN3
G
F01-13 NV1
H
F01-13 LV1
D
I
PE U W V
Prise moteur
C
L1 L2 L3
P
J U V W
L21
Vert(green)
Jaune(yellow)
Rouge(red)
112
CN1A-14
Marron(brown)
CN1A-10
L11
PE 111
Noir(Black)
K
CN1A-11
X0 U
Jaune(yellow)
(F04-17) V
Marron(brown)
Rouge(red)
D-(Y0)
CN1B-18
CN1A-3
L (F05-06) W
CN1B-15
Noir(Black)
CN1B-13
C+ RED(rouge)
CN1A-1
CN1B-5
X1 V0+ White(blanc)
M D-(Y0)(F04-18) (F05-05)
C+ (F05-07) D-(Y1) Black(noir)
(F05-08)
V1+
(F05-07)
DESSINE PAR: JH BB50-US version 110Vac JAMES BURN Servo-ampli : MR-J2S-40A FOLIO
DATE: 04/04/2005 AFFAIRE N°0405US-01 06
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B On Lamp
Max speed
C
Min speed
D
Ramp
Carte driver spool

E
FUSE: 6,3A
IR comp
F
Current
G
1 2 3 4 5 6 A+ A- F+ F- N L
S1 S2 S3 S4 S5 A+ A- F+ F-
H
Inducteur:2kohms
(field)
Induit:15ohms
LV2
(armature)
NV2
Run
10K
R1
I
F05-02
F01-18
J
F05-02
F01-18
K
DESSINE PAR: JH BB50-US version 110Vac JAMES BURN Carte c.de driver spool FOLIO
DATE: 04/04/2005 AFFAIRE N°0405US-01 07
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
3&
30
32
33
34
24
25
26
27
28
29
D-
C+
24
29
X10
Bornier: XB1
(Connection box)
DESSINE PAR: JH BB50-ER version 110Vac JAMES BURN Bornier- connection Box : XB1 FOLIO
DATE: 04/04/2005 AFFAIRE N°0405US-01 08
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
JE12200
A
JE12028
JMOT036
JE29054
B
JMOT037 CN1B-18
JE06081
F
CN1B-18 JE29051
G
JE29053
CN1B-18
H
JE08024
JE07033
I
J JE15029
JE25016
JE07067
M JE07005+JE07004
DESSINE PAR: JH BB50-US version 110Vac JAMES BURN Implantation platine FOLIO
DATE: 04/04/2005 AFFAIRE N°0405US-01 09
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
V1 : JH01069
BIND / Reliure GRIP/ pré-position V2 : JH01068
CAM Adjust HANGER OPTION
Ajustement cames Option crochets V3 : JH01067
V4 : JH01066
V9
V5 : JH01070
V6 : JH01071
V1 V1 V7 : JH01065
V8 : JH01073
V8
V9 : JH01072
V10 : JH01074
T5 : JH02032
V2 V3 R1 : JH10031
R3
R2 : JH05091
R3 : JH05089
V1 V1 V10 R4 : JH05090
Pusher
Pousseur
T4 : JH02027
R2 R2 Transfer-bar
V4 Barre de Transfert
R2 R2
Y4 R2 V6
Cutter
Y3 Couteau R4
R4
JH05085 JH05085 R2
ED3 V5
ED3
Y5
ED4
Y11 Y10 Y12 Y2 Y6
ED2 V7 JH05075
T3 : JH02028
ED5
Y16 Y17
FR1 : JH08017
JH05079 ED1 : JH10037
R1 R1 JH05081 JH05092 ED2 : JH10038
T2 : JH02030
ED3 : JH10039
JH05075
ED1 ED4 : JH10040
ED5 : JH10029
T1 : JH02031
FR1 JH05070
T2 : JH02030
Z1 : pression air = 6 Bars T1 : JH02031
T3 : JH02028
Air pressure = 6 Bars
FR1 T4 : JH02027
T5 : JH02032
DESSINE PAR: JH BB50-US version 110Vac FOLIO 10

JAMES BURN Circuit pneumatique
DATE: 04/04/2005 AFFAIRE N°0405US-01
N° Entrée DESCRIPTION Repère/folio
N° Input
X0 Libre / Free
X1 Libre / Free
X2 Cellule table / Cell on table F04-09
X3 Capteur flottant dévidoir / Flotting contact spool drive F04-10
X4 contacteur KM1 (NO) contactor F04-10
X5 Pédale / foot pedal F04-11
X6 Contact Barre de transfert / transfer-bar limit switch F04-11
X7 Libre / free
X10 Ligne de sécurité carters / Safety lign covers F04-12
X11 Contacteur KM1(NF) contactor F04-13
X12 Libre / Free
X13 Contact controle crochet / Contact control hanger F04-13
X14 Contact présence crochet / Contact on hanger F04-14
X15 Cellule controle bobine / Cell control spool F04-15
X16 Contact A.U. / Contact emergency stop F04-16
X17 LIbre / Free
X20 Top zero servo-moteur / Zero top servo-motor F04-17
X21 Alarme servo-moteur / Alarm servo-motor F04-18
X22 Libre / Free
X23 Libre / Free
X24 Libre / Free
X25 Libre / Free
X26 Libre / Free
X27 Libre / Free
FOLIO
11
N° actionneurs Repère/Folio
DESCRIPTION
N° output
Y0 Sorties pulses 100Hz / Output pulses F05-05
Y1 Validation Servo-moteur / Valid servo-motor F05-06
Y2 C.de barre de transfert F05-08
Y3 C.de reliure / Bind order F05-09
Y4 C.de pré-position reliure / Grip bind order F05-10
Y5 C.de couteau / Cutter order F05-11
Y6 C.de pousseur / Pusher order F05-11
Y7 C.de embrayage / Clutch order F05-12
Y10 C.de rochet / Ratchet order (crochets/hangers) F05-13
Y11 C.de bride / Clamp order (crochets/hangers) F05-14
Y12 C.de glissière / Slide order (crochets/hangers) F05-14
Y13 C.de moteur crochets / Hangers motor order F05-15
Y14 Validation pression air / Valid air pressure F05-17
Y15 Libre / Free
Y16 C.de ajustement 2:1 F05-17
Y17 C.de Ajustement 3:1 F05-18
FOLIO
12
Warranty Page 1
Warranty
Do not detach this Warranty Card
JAMES BURN WARRANTY
This Warranty is restricted to the provision of labour (including travel costs)

and the replacement of parts and components as defined below, which are
found to have been faulty. It expressly excludes claims due to misuse or bad
handling by employees of the customer or third parties.
The period of Warranty, for equipment supplied by James Burn International

(JBI), is twelve months for mechanical parts, and travel costs, and six months
for electrical components from the date of delivery to the customer’s site.
Consumable parts are excluded from the Warranty.
JBI or his distributor reserves the right to request the return of any faulty part
or component before a replacement is sent out on a free of charge basis.
Where this is impractical or the component has not yet been returned, JBI
will charge the replacement component and will issue a credit upon receipt of
the faulty part.

67 rue du Docteur Blaizot
61300 L’AIGLE
France
Tel : +33 (0)2 33 84 21 50
Fax: +33 (0)2 33 84 21 51
Website: www.jamesburn.com
BB50/01/1 2005

67 rue du Dr Blaizot, 61300 L’AIGLE, France
Tel: 33 (0)2 33 84 21 50 Fax: 33 (0)2 33 84 21 51
EC Declaration of Conformity
Machine Description Book and Calendar Binding Machine
Name, Type or Model BB50 BB50/H
Serial No.: …………………………………..
Standards used, including number, title, issue, date and other relevant documentation:
BS EN 60204-1 1993 Safety of machinery – electrical equipment of machines
BS EN 60950 1992 Safety of information technology equipment, including

electrical business equipment
BS EN 292-1-2 1991 Safety of machinery
BS EN 50081-1 1992 Electromagnetic compatibility
BS EN 50082-1 1992 Electromagnetic compatibility
BS EN ISO 11202:1996 Acoustics: Noise emitted by machinery and equipment
Name of authorised representative: Guy Vatome
Position of authorised representative: Managing Director
I declare as the authorised representative that the above information in relation to the supply and
manufacture of this machine complies with all the essential requirements of the EC Directives
(89/392/EEC and 89/336/EEC) and as amended and with the national laws and regulations adopting
these Directives.
Signature of authorised representative:
Date: 19/05/2005
BB50 2005
BB50 & BB50/H
Please retain this top part for your information. Should you, however, require
service under the terms of our warranty please return this card with a brief
description of the problem on the reverse side and send it to the address shown in
introduction page 3. A charge will be made for repairs carried out after the expiry
of the Warranty period.
SERVICE REQUEST CARD

BB50 & BB50/H WIRE-O BINDING MACHINES
Date of Purchase: ____________________________________________
Dealer’s Name & Address: ____________________________________________
Date Registration Card sent

to James Burn International: ____________________________________________
Machine Serial No.: ____________________________________________

BB43 & BB43/H
REGISTRATION CARD
PLEASE COMPLETE AND RETURN THIS PART WITHIN 7 DAYS OF RECEIPT OF MACHINE
(see Introduction of this Handbook for relevant JBI address)
Company Name:
Address:
Tel No.:
Type of Business:
Dealer’s Name & Address:
Date of Purchase: Machine Serial No.:
What made you aware of the

Wire-O Binding Machine? Exhibition Advertisement Other User
Your Name (Mr/Mrs/Miss)
Title:
Signature:

BB50 2005
Description of Fault:
BB50 2005

BB50H

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BB50 & BB50/H Operating Instructions

Wire-O® Binding Machines

From serial no. 001 onwards

TEL: +33 (0)2.33.84.21.50

BB500/01/1 © JBI 2005

Section 1. Using your Binding Machine Safely

Section 2. Installing your Binding Machine

Section 3. Installing a Spool of Wire-O Wire onto the Spool Stand

Section 4. Setting Up and Adjusting your Binding Machine

Section 5. Operating your Binding Machine

Section 6. Maintaining your Binding Machine

Section 7. Binding Machine Technical Data

Read this manual carefully before installing your binding machine.

This manual contains recommendations and instructions for installing, adjusting,

This manual consists of the following sections:

2. “Installing your Binding Machine” contains guidelines for locating, unpacking,

2. User guides for Mitsubishi controller and display.

Your local JBI agent or office

This is the safety alert symbol:

WARNING: You may cause severe personal injury and/or substantial

CAUTION: You may cause minor personal injuries or substantial damage to

NOTICE: This is important installation, operation or maintenance

1.1 Safety Warning Signs for your Binding Machine

Electrical shock hazard

DO NOT TOUCH THE CLOSING TOOLS IN YOUR

Serious injury may occur if your fingers come into

NEVER PERFORM ANY REPAIR OR MAINTENANCE

Always remember to switch off the machine and

STOPPING THE BINDING MACHINE IN AN

Know where the emergency stop switch is located on

The emergency stop switch is a red mushroom headed

DO NOT OPERATE THE BINDING MACHINE IF THE

DO NOT ADJUST THE GUARD OPENINGS WHILE

Settings must only be carried out while the machine is

DO NOT BYPASS THE GUARD INTERLOCK

Never use your binding machine unless the guard

Mechanical interlock switches are attached to the following guards:

DO NOT OPERATE WITHOUT GUARDS IN PLACE.

HANDLE HEAVY EQUIPMENT PROPERLY

Always handle heavy equipment with a suitable

Always position the weight of the machine on your lifting

Never try to lift equipment that is heavier than the

WEAR SAFE CLOTHING

Secure all loose clothing - such as neckties or scarves

Safety footwear should always be worn when moving

Keep children away from your binding machine. Never

KEEP SAFETY LABELS CLEAN AND IN GOOD

Do not remove any safety labels from your binding

BE PREPARED FOR EMERGENCIES.

Be prepared for fires, injuries or other emergencies.

A NOTE TO ALL EMPLOYERS

Know your responsibilities as an employer.

Make sure your employees know how to operate the

Make sure your employees are aware of the safety

Make sure the binding machine is in proper working

KEEP THIS MANUAL WITH THE BINDING MACHINE

This manual is an important part of your binding

IF YOU NEED THIS MANUAL IN ANY OTHER

If you need this manual in a language other than

1.2 Warning Signs on your Binding Machine

Figure 1b Binding Machine Warning Signs

Figure 1c Binding Machine Warning Signs

2.1 Unpacking your Binding Machine

2.2 Choosing a Suitable Location for your Binding Machine