Booklet Maker for XEROX DocuTech family of copiers

and 4XXX and DT61XX printers.

OV
c.p.

ER
RI
bou

DE
rg
S.A.
N.V.
INSTALLATION
MANUAL
c.p.
bou
rg
S.A.
N.V. BI
ND
ER

BY
PA
SS

BP
Bou
rg
Rota Perf
ting orat
and ing
RF
Fold
ing
X
BO
UR
G BIN
DIN
G SY
ST
EM

c.p. bourg S.
N.

is

e rti f i ed b
C

Initial issue : 09/99

Latest revision : 04/00
ISO 9001 9.133.278
 TABLE OF CONTENTS

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1 - Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 - Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 - Location of the power supply cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Unpacking of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Installation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Prior to install your machine . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Installation of the BPRFx to the Printer . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Dip switches configuration . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Speed and frequency verification . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Connection to the main and to upstream devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Upstream devices configuration . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Installation Manual Initial issue : 09/99

Page 8 - 2 Latest revision : 04/00
 WARNINGS
Warning:
NEVER REMOVE THE POWER PLUG WHILE THE MACHINE IS RUN-
Prior to the installation: NING.
Check that your electrical mains corresponds to one of the following
three configurations:
USA 120V AC +/- 10% - 60Hz
EUROPE 230V AC +/- 10% - 50Hz
JAPAN 230V AC +/- 10% - 60Hz
MEXICO 140V AC +/- 10% - 60 Hz (Tag 10)

THE LABEL APPLIED ON YOUR MACHINE INDICATES CONFIGU-

RATIONS THE MACHINE IS SET UP FOR.

Check your environmental conditions.

This machine is designed for the following environment:

Storage and transport:

Temperature: -34°C through 60°C / -30°F through 140°F
Relative humidity: 5 through 90% RH
Altitude: -31m through 12192 m / -100 ft through 40,000 ft
Atmospheric pressure: ≥ 56 kPa (420 mm Mercury)

Work environment:
Temperature: 5 through 35°C (41 through 95°F)
Relative humidity: 40 through 85% RH

Power consumption: 920 Watts

BTU output: 3240BTU/H
Noise level: TBD db

Installation Manual Initial issue : 09/99

Page 8 - 3 Latest revision : 04/00
 INTRODUCTION
The information provided in this manual are based on the most recent
Thank you for having chosen a Bourg product. information available at the time of editing.

These instructions provide a guide for the installation of the automatic

BPRF system.

THIS MANUAL IS INTENDED TO BE USED EXCLUSIVELY BY

QUALIFIED TECHNICAL PERSONNEL.

The BOURG PERFORATING ROTATING & FOLDING (BPRF) machi-

ne is a finishing equipment intended to be incorporated in the Bourg
Binding Factory system.

The system consists in three operations:

- Perforating.
- Rotating.
- Folding.

CAUTION: Please follow the installation instructions before connec-

ting the system to the mains.

If you follow these instructions carefully, the machine will provide an

excellent service for years.

In case of failures when you use your equipment, please refer to the
addresses listed at the end of these instructions and ask for technical
assistance. It will be our pleasure to provide you with this assistance.

Installation Manual Initial issue : 09/99

Page 8 - 4 Latest revision : 04/00
 CHARACTERISTICS b. With 860 mm (33.9 in.) height the use of a machine without standoff
is mandatory.

1 - Configurations

The possible BPRF configurations are different according to the paper

output height of the upstream accessory.
Printer 860
Two heights are commonly used: 1021 mm (40.2 in.) and 860 mm (33.9
4135
in.).
4635 BPRFx
DP180
a. With 1021 mm (40.2 in.) height the use of standard machine (with
standoff) is mandatory. Bourg Binder By Pass

1021
DocuTech BPRFx
135, 6135
6180
Standoff
Bourg Binder By Pass

Installation Manual Initial issue : 09/99

Page 8 - 5 Latest revision : 04/00
2 - Space requirements 3 - Location of the power supply cord

Input
Power cord
Left side

Rear

(13 in.)
33 cm
BP
Bou
rg
Rota Perf
ting orat
and ing
RF
Fold
ing
X
BO
UR
G BIN

78 cm (31 in.)
DIN
G SY
ST
EM

c.p.
bou
rg
S.A.
N.V.

OV
ER
RI
DE

c.p.
bou
rg
S.A.
N.V. BI
ND
ER

BY
PA
SS

BPRF
(13 in.)

(13 in.)
33 cm

33 cm

162 cm (64 in.)

Operator side
Front Output
Right side

Height with upper cover closed: 1290 mm (51 in.)

Height with upper cover lifted: 1850 mm (73 in.)

Installation Manual Initial issue : 09/99

Page 8 - 6 Latest revision : 04/00
 UNPACKING OF THE MACHINE

1st step The machine can be moved (on a pallet) either:

- with a pallet truck, or with a fork-lift truck.
Above all:
CHECK CONDITION OF SHOCK AND TIP INDICATORS. The machine with its packaging weights 300 kg (661.5 lb).

Label “TIP-N-TELL”: In case of a temporary installation, please save the packaging in order
Blue grains in the arrow indicate that the machine has been upside to facilitate the repackaging.
down or heavily tilted.
HANDLE
WITH CARE

Label “WARNING”:
If the small indicator has turned red, it indicates that the machine has RED INDICATES ROUGH HANDLING IF
RED, NOTE ON BILL OF LOADING
INSPECTION MAY BE WARRANTED

been mishandled.

What to do if a label has been “triggered”: TIP-N-TELL

BLUE BEADS IN ARROW
SHOWS CONTAINER WAS
TIPPED OR MISHANDLED

Describe the conditions of the goods on the delivery note. Identify and
list, together with the driver, all externally visible damage. INDEX PACKAGING, INC.

When unpacking, evaluate the damage and contact the insurance com-
UNION, NH
TEL 800-662-3626
FAX 603-652-9279

pany of the shipping company.

LL
-TE OW
-N IN
ARR
WAS
TIP DS ER
BEA TAIN LED
E
BLU CON AND
WS MISH
SHO OR
ED
TIPP

INC.
ING,
KAG
PAC NH
X N,
INDE UNIO 3626
662-
800- 9279
TEL 652-
603-
FAX

Precautions to be taken during shipping:

The machine can be unpacked by two person.

If the machine shall be installed in a narrow room that prevents 180°

rotation, mind the operator side to enter the room with the correct orien-
tation.

Installation Manual Initial issue : 09/99

Page 8 - 7 Latest revision : 04/00
2nd step:
4
6
1. Cut the tape holding the box on the wooden pallet.
2. Remove the top of cardboard box.
3. Remove the cardboard sides from the machine.
2 c.p.

OVERRID
bourg

E
S
N. A
. V .
.

c.p.
bourg

S
N. A
. V .
.
BINDER

BYPASS

BP
Bourg

BOUR
Perforati
Rotating
and ng
Folding

G BIND
RF
ING
SYST
X

EM
5

3
OV
c.p.

ER
bourg

R ID
E
S.
N A.
. V
. 7. Lift the top cover.
8. Open the baffles A, B and C. Remove protective plastics out of
c.p.
bourg

S.
N A.
BI
. V ND
.
ER

BY
PA
SS

BP
Bourg
Perforat
Rotating
and ing
RF
X

baffles.
Folding
BOU
RG
BIND
ING
SYST
EM

9. Remove tape from finger input switch.

7
B C
1 9
A c.p.

OVERRID
bourg

E
N
. A
S. V
.
.

BINDER

BYPASS

.
. A .
S. V
N

bourg
c.p.

.
. A .
S. V
N

bourg
c.p.

4. Loose holding doors straps.

E

RF
X
OVERRID

BINDER
BP ng
Perforati
Folding
EM
BYPASS
Bourg and SYST
Rotating ING
G BIND
BOUR
.
. A .
S. V
N

bourg
c.p.

5. Remove protection corners. RF

X

BP ng
Perforati
Folding
EM
Bourg and SYST
Rotating ING
G BIND
BOUR

6. Remove protective plastic from the machine. 8

Installation Manual Initial issue : 09/99

Page 8 - 8 Latest revision : 04/00
 10. Free safety connecting rods from the doors (two doors 11. Remove front panel, secured with two quarter turn fastener.
operator side and one on the opposite): 12. Remove rear panel, secured with three quarter turn fastener.
- Loosen screw (a) and nut (b).
- Remove washer (c) and spacer (d).
Note: When safety connecting rod is free, place spacer and
washer around screw and secure it on different doors to
avoid to lose it. 12

10 a

11
d
.
A
S. V .
N.

bourg
c.p.

DE
RI
ER
OV

b c c.p.
bourg
A
.
S. V .
N.
B IN

BY
PA
DE

SS
R

BP
Bourg

Rotati
Perfor
ating
RF
ng
and
Foldin
X
BOU g
RG
BIN
DIN
G SYS
TEM

.
A
S. V .
N.

bourg
c.p.

I DE
OVERR

BINDER

BYPASS

.
A
S. V .
N.

bourg
c.p.

BP
Bourg
RotatinPerfora
g and ting
RF
Foldin
g
X
BOU
RG
BIND
ING
SYS
TEM

Installation Manual Initial issue : 09/99

Page 8 - 9 Latest revision : 04/00
 13. Close upper cover.
To be performed by riggers.
Remove brackets fastening machine on wooden pallet:
14. Remove the 8 screws (bracket on pallet fastening screws).
15. Remove the 8 screws (bracket on machine fastening screws). 18. Remove machine from wooden pallet using a forklift.
16. Lift the unit with castors to free both brackets.
17. Remove brackets from under the unit.

13
.
. A .
S. V
N

bourg
c.p.

RIDE
OVER

0
00
ER
00
BIND

S
BYPAS

.
. A .
S. V
N

bourg
c.p.

X16

X17
X18
X13
X15

X14

INP cs 0708
9422055

.
. A .
S. V
N

bourg
c.p.

E
ID
RR
O VE

0
00
ER
00
ND
BI

SS
PA
BY
9422156

.
. A .
S. V
N

bourg
c.p.

15
X16

X17
X18
X13
X15

X14
INP cs 0708

9422055

9422156

16
14

Note: Do not reinstall front and rear panels. They will be placed at
installation end.

17

Installation Manual Initial issue : 09/99

Page 8 - 10 Latest revision : 04/00
3 - Packaging material list
(for possible repackaging)
Item Quantity Elements cp bourg code no a
a 1 Complete cardboard, consisting of 9159273

a top panel and a panel for sides

.
. A .
S. V
N

bourg
c.p.

OVERRID

BINDER

BYPASS

.
. A .
S. V
N

bourg
c.p.

b 1 Wooden pallet 9159274

BP
Bourg
Rotating

BOUR
and
ng
Perforati

G BIND
RF
Folding

ING
SYST
X

EM

c 2 Mounting brackets 9403288

c.p.
bourg

S.
N A.
. V
.

OV
ER
RI
DE

c.p.
bourg

S.
N A.
BI
. V ND
.
ER

BY
PA
SS

d 8 Screws M8x30 (to secure bracket 9190437 k BP

j
Bourg
Perforat
Rotating
and ing
RF
Folding X
BOU
RG
BIND
ING
SYST
EM

to pallet) g
e b
e 8 Screws M8x20 (to secure bracket 9190436

to BPRF)

f 8 Lock washers 9172008 c

g 16 Flat washers 9172002

h 8 Special nuts 9135081 l

i Bubble plastic sheet 9159143

j 1 Protective plastic sheet 9159075 d

k Plastic strapping 9159141 f
g c.p.

OVERRID
bourg

E
S
N. A
. V .
.
m
l 2 Strapping Clips 9159142 c.p.
bourg

S
N. A
. V .
.
BINDER

BYPASS

BP
Bourg
Perforati
Rotating
RF
and ng
Folding X
BOUR
G BIND
ING
SYST
EM

m 10 Protection corners 9159074 h

Installation Manual Initial issue : 09/99

Page 8 - 11 Latest revision : 04/00
 INSTALLATION OF THE MACHINE 2- Adjust the height of the casters with the tools supplied with the
finishing device:
• Adjust casters to align the paper exit of the printer with the entrance
Prior to install your machine of the BPRFx.
• Make certain that the BPRFx is level.
• Check your paper output height. If 860 mm (34 in) height, you
have to remove BPRFx standoff.

• The outlet part of printer must be properly levelled by a Xerox

technician. The jack that is to be found under the printer final
module must be place under the rail in order to avoid later com-
pressing.
.
. A .
S. V
N

bourg
c.p.

.
. A .
S. V
N IDE
bourg
c.p. OVERR

0 ER
RI
DE

00 OV

R 00
BINDE

S
BYPAS

ER
ND
BI

S
PAS
BY
.
. A .
S. V
N

bourg
c.p.
.

Installation of the BPRFx to the Printer

. A .
S. V
N

bourg
c.p.

1 - Align the docking pins (a) with the holes in the docking plate of the X18

X15

X14
X17

X13
X16

INP cs 0708
9422055

printer (b). Lock with lever (c). 9422156

X16

X17
X18
X13
X15

X14
INP cs 0708

9422055

9422156

b
The sheet at printer exit must touch the top of the reclined part of the
bottom baffle.
c

Printer BPRF
Exit Entrance
a

Deflectors
Paper
a
Installation Manual Initial issue : 09/99
Page 8 - 12 Latest revision : 04/00
If necessary, this adjustment can be corrected. 3- Verify the lateral position.
Adjust the input conveyor position with both cams. • Lift the upper cover of the BPRFx.
• Loosen the four securing screws a. Caution: It is difficult to determine in advance where the sheet is
• Turn cam nuts to obtain an optimal adjustment. going to exit from the printer. The lateral position is only
• Tighten the four securing screws a. know when the sheets are actually output. A coarse set-
ting is done first, and it is refined when the first sheets
Note: Used angular adjustment of the small conveyor (situated before come out of the printer.
the BPRF perforating tool) only for minor corrections. Test machine alignment by having the test sheet of align-
The machine performance increase when the input conveyor and ment go forward with the help of driving pulley situed at
the rotator conveyor are levelled one to another. the end of the printer conveyor (exit sheet side) opposite
The height adjustment must be principally achieved by setting feet side of the registration.
and castors. When pushing sheet without driving them, we can not
have a reliable reference because of waving sheets.
Take care during operation, to press the printer exit
conveyor down (against its stops), to avoid its uprising
when the upper panel is open.
a Rear frame
Previous
device
BPRF
S
b H
E
E
T

Front frame

a 6 mm (1/4")
The right edge of the sheet must be 6 mm (1/4”) from the regis-
b tration edge element. If not, release the locking lever (c), sepa-
rate the machines and move the docking plate (b) by means of
four 2 mm allen screws (d) to compensate for the difference.
Repeat docking procedures (1 - 2 - 3).

Installation Manual Initial issue : 09/99

Page 8 - 13 Latest revision : 04/00
 Perforation counter adjustment.

From factory, the perforation position counter is adjusted in millimeters

c (figure 1). Both gears ref. b are used.

If customer wants to work in inches (figure 2):

b • Bring the counter to 178 mm (for example) with the knurled knob.
• Loosen screws ref. a.
a • Move counter bracket to disengaged any gear each one to other.
• Display 07.01 in. (by means of knurled knob) on the counter
without changing the setting.
• Mate both gears C.
• Tighten both screws ref. a.
a
Be careful, reading is different following chosen unit:
d
1 - For millimeter,
• The number inside the first box is always “1” or “2”.
• Separation between units and decimals is situated between the
Note: when level adjustment is done, drive the feet down to the third and fourth box (reading direction).
floor. When stability is correct, lift the castors (approximately
one centimeter - 3/8”).
Figure 1.
Place one sheet on the output. Before going out, this sheet had to be
registred (put it on rotator conveyor against registration, select “no rota- a
tion”). Install the accessory following in installation manual.

1 7 8 ,0
b c
= 1 or 2
b c

Installation Manual Initial issue : 09/99

Page 8 - 14 Latest revision : 04/00
2 - For inches, Dip switches configuration
• The number inside the first box is always “0”.
• Separation between units and decimals is situated between the This label with this chart is affixed close to the switches.
second and third box (reading direction).
Dip switch in upper position, ON.
Figure 2. Dip switch in lower position, OFF.
a
Table for BPRF Dip-Switches
n. FUNCTION ON OFF

0 7.0 1 7
8 1. Printer
2. All selections override
4xxx
Enabled
61xx
Disabled
b c ON 5
6 3. 0 to 3 ADC steps allowed...
...binary coded
4 4. ...between perf and folder
=0
3 5. ADC Calibration mode Selected Not Sel'

9.139.422
2 6. ADC Selection Folder Perfo
b c 1 7. Cycle Up Supported Not Sup'
8. Jam Detection Enabled Disabled

ON

OFF
Dip switches functions:

• Dip switch 1

ON for 4890, 4135, 4635 or DP180.

OFF for DT135, 6135 or 6180.

Installation Manual Initial issue : 09/99

Page 8 - 15 Latest revision : 04/00
• Dip switch 2 • Dip switches 5 and 6

OFF is normal setting enabling 4 different modes. ADC = Analog to Digital Converter.
Used for calibration only,while machine is working, both switches
Note: ON is used to work with any combinations of perf / rotation need to be OFF.
and fold.).
• Dip switch 7
Applications: - Demo: possibility to show all the possibilities with
no restrictions. With DT135, switch 7 must be turned OFF because there is no
- Rotation when connected on a DT135 or 6xxx cycle-up signal on the DT135.
with build in rotator: BPRF rotator can rotate 10” x With all the other printers, switch 7 must be ON.
14” sheets.
- Custom application. • Dip switch 8

• Dip switches 3 and 4 In normal mode, always ON.

The use of switch 8 in OFF position is only to allow the process of
Used for setting only. In normal mode it is recommended to have sheets fed by hand for test purpose.
both switches OFF Caution : if switch 8 is in OFF position, no DFA signal will be sent
A bigger relative position clearance between perforation and fold is to the following device.
allowed. If dip switch 3 and 4 are ON, see chart :

4 3
0 0 minimum relative clearance
0 1
1 0
1 1 maximum relative clearance

Installation Manual Initial issue : 09/99

Page 8 - 16 Latest revision : 04/00
Speed and frequency verification Two speeds and two frequency are available. They are determined by
the upstream devices and country.
Figure 1 Figure 3
50Hz pulley - 60Hz pulley - Tensioner position.
Ø73.5mm (2" 7/8) Ø59mm (2" 5/16) When the position of the pulley changes the position of the tensioner
Position 180 s./min. Position 180 s./min. must be checked.

• Figure 1.
Tensioner Tensioner 50Hz European unit - input paper speed: 180 sheets / 1 minute.
The belt is placed inside the biggest grooves ( ø 73.5 mm) of the
pulley 922408. Tensioner is placed in lower hole.

• Figure 2.
50Hz European unit - input paper speed: 135 sheets / 1 minute.
The belt is placed inside the smallest grooves ( ø 56 mm) of the
Main motor pulley Main motor pulley pulley 9222408. Tensioner is placed in central hole.

• Figure 3.
Figure 2 Figure 4 60Hz American unit - input paper speed: 180 sheets / 1 minute.
50Hz pulley - 60Hz pulley - The belt is placed inside the biggest grooves ( ø 59 mm) of the
Ø56mm (2" 3/16) Ø45mm (1" 3/4) pulley 9222410. Tensioner is placed in central hole.
Position 135 s./min. Position 135 s./min.
• Figure 4.
60Hz American unit - input paper speed: 135 sheets / 1 minute.
Tensioner Tensioner The belt is placed inside the smallest grooves ( ø 45 mm) of the
pulley 9222410. Tensioner is placed in upper hole.

Main motor pulley Main motor pulley

Installation Manual Initial issue : 09/99
Page 8 - 17 Latest revision : 04/00
Connection to the main and to upstream devices

Before making electrical connections, reinstall front and rear covers. Do

not forget to fasten the securing rods of the doors.

PRECAUTIONS FOR THE CONNECTION TO THE MAINS.

In order to prevent any danger during the installation, the use or the Rear view
maintenance of the equipment, the connecting point to the mains must
be located near the equipment and be accessible at any time.
To printer or pre-
t
No d
us
e vious devices
M
RO
/F S
TO U
A VIO E
DF RE VIC
P E
D
M
RO
/F
TO T
A EX E
DF N VIC
DE
M
RO
/F ER
T OI N D S S
B PA
BY

To binder.
See BB2005 Install
Manual.

To binder bypass key.

To mains See BB2005 Install Manual.

Installation Manual Initial issue : 09/99

Page 8 - 18 Latest revision : 04/00
Upstream devices configuration

Xerox 6180 /6135 Device Profiles

REVISION : I 17/03/00

HOW TO USE THIS CHART:

Example:
Installed machines: Xerox DT6180 + BBF2005 with bypass + BDFX.
If the job is delivered to the binder, the profile to use is found in the column “BBF2005 bypass”.
If the job is delivered to the BDF, the profile to use is found in the column “ Bypass + BDF”

Remark:
There must be one specific profile for each mode of finishing.
For a specified finishing device, the recommended profile is depending on the presence of other devices.
Example: profile for a BDF is not the same if a BBF2005 bypass is fit ( column to apply is “Bypass + BDF) or if the BDF is connected directly to
the printer ( column to apply is “BDF”)

Revision list:
Rev.A : 17/05/99 MODIFICATIONS FOR BPRF.
Rev.B : 9/06/99 corrections BPRF
Rev. C : 18/06/99 corrections on timings + additional columns.
Rev. D : 23/06/99 correction C0 delivery start adjust for BPRF+BBF2005BYPASS
Rev. E : 10/08/99 « cycle down delay » added on timings + « sheet compiler processing time » et « max. set processing time » replaced by «
sheet jam time » andt « set jam time » en P.3.
Rev. F : 23/08/99 stacker software : 3.5.2 for DFA,INPUT and DRIVER BOARDS.
Rev.G : 13/10/99 Properties and default limits for 6135; BDF parameters; general update.
Rev. H: 13/03/00 Remark 5 added; correction on remark 3; maximum sheet width modified 364 ‡ 432 when BPRF is used together with
BBF2005.
Rev. I; 17/03/00 corrections for BDF+BCFX ; Bypass2005 + BDF +BCFX ; BPRF + Bypass2005 + BCFX + BDF.

Installation Manual Initial issue : 09/99

Page 8 - 19 Latest revision : 04/00
PROPERTIES
AND
XEROX DT 6180/6135
DEFAULT
LIMITS
Name BBF2005 BBF2005 BPRF+ BPRF+BBF BDF BDF+BCFX Bypass Bypass BPRF BPRF
bypass BBF2005 BBF2005 +BDF +BDF +Bypass +Bypass
+BCFX +BDF +BCF+BDF
Type External External External External External External External External External External
Function 1 Line off Line off Line off Line off Line off Line off Line off Line off Line off Line off
Function 2 Line off Line off Line off Line off Line off Line off Line off Line off Line off Line off
Sheet 1 -> N and 1 -> N and 1 -> N and 1 -> N and 1 -> N and 1 -> N and 1 -> N and 1 -> N and 1 -> N and 1 -> N and
sequence N -> 1 N -> 1 N -> 1 N -> 1 N -> 1 N -> 1 N -> 1 N -> 1 N -> 1 N -> 1
Side 1 Face up and Face up and Face up and Face up and Face up and Face up and Face up and Face up and Face up and Face up and
direction face down face down face down face down face down face down face down face down face down face down
Rotate Never Never Never Never Never or Never or Never or Never or Never or Never or
N.B.: N.B.: N.B.: N.B.: Always Always Always Always Always Always
Rotation Rotation Rotation Rotation depending on depending on depending on depending on depending on depending on
needed if glue needed if glue needed if glue needed if glue job. job. job. job. job. job.
must be must be must be must be
applied on applied on applied on applied on
short edge. short edge. short edge. short edge.
Min.sheet 254 254 254 254 254 B.P.: Cover 254 B.P.: Cover 254 B.P.: Cover
length (mm) 254 254 254 254 254 254
Max.sheet 356 356 356 356 364 B.P.: Cover 364 B.P.: Cover 364 B.P.: Cover
length (mm) 364 297 364 297 364 297
Min.sheet 203 203 203 203 203 B.P.: Cover 203 B.P.: Cover 203 B.P.: Cover
width (mm) 203 254 203 254 203 254
Max. sheet 364 364 432 432 432 B.P.: Cover 432 B.P.: Cover 432 B.P.: Cover
width (mm) 432 432 432 432 432 432
Max. sheet 200 200 200 200 200 200 200 200 200 200
weight ( gsm)
Min.sheet 60 60 60 60 60 60 60 60 60 60
weight (gsm)
Min. set size 15 15 15 15 1 1 1 1 1 1
(Nbr. Of sheets)
Max. set size 350 350 350 350 55 55 55 55 55 55
(Nbr of sheets) N.B.: Max. 125 N.B.: Max. 125
sheets if Perf./Rot sheets if Perf./Rot
and fold is used. and fold is used.

Installation Manual Initial issue : 09/99

Page 8 - 20 Latest revision : 04/00
TIMINGS XEROX DT 180
Finisher BBF2005 BBF2005 BPRF+ BPRF+BBF BDF BDF+BCFX Bypass2005 Bypass2005 BPRF BPRF
name with bypass BBF2005 2005 with +BDF +BDF +Bypass2005 +Bypass2005
bypass +BCFX +BDF +BCF+BDF
Timing 0 0 0 0 0 0 0 0 0 0
between
sheets (ms)
Sheet jam 1000 1000 2000 2000 1700 2000 3993 4293 4993 5293
time (ms)
Set compiler 2000 2000 2000 2000 600 700 600 700 600 700
processing
time (ms)
Max. set 15000 15000 15000 15000 600 2400 600 2400 600 2400
processing
time (ms)
Set jam time 32760 32760 32760 32760 7168 7468 9461 9761 10461 10761
(ms)
Time to cycle 0 0 0 0 0 0 0 0 0 0
up (ms)
Statuses S0,S1,S2 S0,S1,S2 S0,S1,S2 S0,S1,S2 S0,S1,S2, S0,S1,S2, S0,S1,S2, S0,S1,S2, S0,S1,S2, S0,S1,S2,
supported recommended recommended recommended recommended S3,S4 S3,S4 S3,S4 S3,S4 S3,S4 S3,S4
(S3/S4 on (S3/S4 on (S3/S4 on (S3/S4 on
request) request) request) request)
Delivery Trail. Trail. Trail. Trail. Lead Lead Lead Lead Lead Lead
signal type Edge Edge Edge Edge Edge Edge Edge Edge Edge Edge
Delivery start 60 200 60 200 120 0 200 200 200 200
adjust (ms)
Delivery end 60 60 60 60 50 50 60 60 60 60
adjust (ms)
End of set 30 30 30 30 30 10 30 30 30 30
offset (ms)
Recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery
behaviour
Finisher 0 0 0 0 10 0 10 0 10 0
capacity (set)
Cycle Down 0 0 0 0 0 0 0 0 0 0
Delay (ms)

Installation Manual Initial issue : 09/99

Page 8 - 21 Latest revision : 04/00
TIMINGS XEROX DT 135
Finisher BBF2005 BBF2005 BPRF+ BPRF+BBF BDF BDF+BCFX Bypass2005 Bypass2005 BPRF BPRF
name with bypass BBF2005 2005 with +BDF +BDF +Bypass2005 +Bypass2005
bypass +BCFX +BDF +BCF+BDF
Timing 0 0 0 0 0 0 0 0 0 0
between
sheets (ms)
Sheet jam 1000 1000 2312 2312 1700 2093 4704 5103 6022 6415
time (ms)
Set compiler 2000 2000 2000 2000 600 700 600 700 600 700
processing
time (ms)
Max. set 15000 15000 15000 15000 600 2400 600 2400 600 2400
processing
time (ms)
Set jam time 32760 32760 32760 32760 7168 7562 10183 10577 11498 11892
(ms)
Time to cycle 0 0 0 0 0 0 0 0 0 0
up (ms)
Statuses S0,S1,S2 S0,S1,S2 S0,S1,S2 S0,S1,S2 S0,S1,S2, S0,S1,S2, S0,S1,S2, S0,S1,S2, S0,S1,S2, S0,S1,S2,
supported recommended recommended recommended recommended S3,S4 S3,S4 S3,S4 S3,S4 S3,S4 S3,S4
(S3/S4 on (S3/S4 on (S3/S4 on (S3/S4 on
request) request) request) request)
Delivery Trail. Trail. Trail. Trail. Lead Lead Lead Lead Lead Lead
signal type Edge Edge Edge Edge Edge Edge Edge Edge Edge Edge
Delivery start 79 262 79 262 120 0 262 262 262 262
adjust (ms)
Delivery end 60 60 60 60 50 50 60 60 60 60
adjust (ms)
End of set 30 30 30 30 30 10 30 30 30 30
offset (ms)
Recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery Set recovery
behaviour
Finisher 0 0 0 0 10 0 10 0 10 0
capacity (set)
Cycle Down 0 0 0 0 0 0 0 0 0 0
Delay (ms)

Installation Manual Initial issue : 09/99

Page 8 - 22 Latest revision : 04/00
N.B. :
1. IF ONE OR MORE STACKER IS USED, DON’T FORGET TO ADD 656 mS. ON THE « SHEET JAM TIME » AND « SET JAM TIME » VALUES
FOR EACH STACKER. WHEN CONNECTED ON A 6180.
ADD 861mS. WHEN CONNECTED ON A 6135.
2. STACKER SOFTWARE MUST BE 3.5.2 (DFA+INPUT+DRIVER) TO SUPPORT CYCLE-UP AND T.E. SIGNALS FROM PRINTER 3.04 softwa-
re can be disturbed by « not announced » sheets delivered by the printer after a jam.
3. BPRF+BBF2005 : control of milling motor by BPRF requires :
-Cycle -up from printer + BPRF ready in « perf. mode » if connected on a 6100/35/80 ( PLC input X17 « on » ).
OR
-BPRF ready in « perf. mode » if connected on a DT135 ( BBF2005 PLC inputs X17/18/19 « off »).
4. Delivery End Adjust : to allow the BPRF to determine if C0/C1 are trigged « lead « or « trail » edge, the maximum C0 pulse duration in « trail »
edge must be limited at 60 msec. In « lead » edge mode, the C0 pulse duration is a function of the sheet size ( process direction at printer out-
put) and is always longer than 100 msec.
5. Min. set size ( number of sheets/ set in binder mode):
If “maximum set processing time parameter” is set at 15000 ms, the min set size can be reduced if relative “stiffness” of printed sheets matches
the type of cover
( cover stiffness, weight and grain orientation). THE ONLY RISK IS PURELY MECHANICAL.TO BE CAREFULLY VERIFIED ON SITE BY FIELD
ENGINEER

Installation Manual Initial issue : 09/99

Page 8 - 23 Latest revision : 04/00
 c.p. bourg S. A.
N. V. c.p. bourg S.A.

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 / 332447
Fax: + 32 (0) 10 / 61 69 03 Fax: 352 / 331999
Telex: 2844

c.p. bourg G.M.B.H.

c.p. bourg Inc.

Balinger Strasse 80 Samuel Barnet Bd.

D-72336 Balingen (Germany) New Bedford
Tel.: +497433991680 Massachussets 02745 USA
Fax: +497433991686 Tel.: 1/508.9982171
Service-Tel: 0800-85 35 950 Fax: 1/508.9982391

c.p. bourg S.A.

SILIC 410
32, rue des Gémeaux
F-94573 Rungis (France)
Tel.: 33 / 1.46873214
Fax: 33 / 1.46875217
Telex: 260577

ified b
er t
C

ISO 9001
Installation Manual Initial issue : 09/99
Page 8 - 24 Latest revision : 04/00