RIGO PERFECT BINDER 420 HM User Manual
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RIGO PERFECT BINDER 420 HM User Manual

Professional binding machine, automatic model
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PERFECT BINDER 420 HM
Professional binding machine
Automatic model
User's manual

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Summary of Contents for RIGO PERFECT BINDER 420 HM

  • Page 1 PERFECT BINDER 420 HM Professional binding machine Automatic model User’s manual...

  • Page 2: Table Of Contents

    Table of Content 1. Introduction ..................3 2. Safety Manual ..................7 2.1 Installation ..................8 2.1.1. Room/Area ..................8 2.1.2 Fire and Explosion Hazard ..............8 2.1.3 Power Supply .................. 8 2.2 User/Operator .................. 10 2.3 During process/Operation .

  • Page 3: Introduction

    1. Introduction Thanks for attesting trustfulness towards us when you purchased our Perfect Binder 420 bookbinder machine and we congratulate for your exellent decision. We hope that the Perfect Binder 420 bookbinder machine will satisfy Your needs successfully for a long period of time. The Perfect Binder 420 is hot-melt bookbinder machine, which is suitable for binding books sized maximum 420x420x50 mm.
  • Page 5 DECLARATION OF CONFORMITY Herewith the RIGO Ltd. (Headquarter: H-1221 Budapest, Orsovai út 3., Production place: H-5435 Martfű, Lenin út 1.) declares that the following product: Datas of the machine: Producer: RIGO Tool and Mould Production Ltd. Type of machine: Perfect Binder 420HM Bookbinder machine...
  • Page 6 Disposal Electrical & Electronic Eliminación de residuos de aparatos eléctricos y Equipment. This symbol (the symbol of the electrónicos. Este símbolo (un cubo de basura tachado) crossed out wheeled bin) indicates that in indica que en los países europeos este producto no European countries this product should not be deberá...

  • Page 7: Safety Manual

    2. Safety Manual Warning signals applied on the Perfect Binder 420 HM Ignoring this mark could result in the possibility of serious injury or even death. Ignoring this mark could result in the possibility of injury or physical damage. Pay Attention – hot surface Warning for the danger of electric shock Danger!–...

  • Page 8: Installation

    2.1 Installation 2.1.1 Room/area The room in which the machine is installed has to be well aerated and dry and the temperature range is between 5 and 35°C. Do not use the machine in humid (the humidity range is between 10 and 85% RH), wet, dusty or explosive environment.
  • Page 9 The cross-section of the settled power cable has to be minimum 5 x 2,5 mm². To protect the machine against too much power consumption, use single-phase C 25 circuit/contact breaker. Carefully check the rotation of the motors. At an occurred failure of the fuses change them just to the specified value, the bridging of them or causing their short circuit is forbidden.

  • Page 10: User/Operator

    2.2 User/ Operator Only one person can use the machine at the time, in order to avoid any danger to the health. The machine can be handled just by a person who is educated, knows the instructions written in the user manual and is in appropriate state for safe working. Never stand or sit on the machine.

  • Page 11: During Process/Operation

    2.3 During Process/Operation 2.3.1 General terms Before start up, check if there is no other person in danger zone. Before start up, check not have any metal or easily-combustible object inside the working area. Do not place metal objects or vessels containing liquids on top of the unit. Keep this unit and the power cord away from heaters and heater vents and hanging objects.

  • Page 12: Milling Unit

    Attach a fume exhaust hose to the fume exhaust of this unit so that the fumes can be exhausted outdoors or to a well-ventilated place. 2.3.4 Milling unit Do not touch the milling blade at anytime! Do not remove any cover of the milling unit. Do not put your hands inside of the working area until the milling unit has been completely stopped and the cover is completely closed.

  • Page 13: Binding Unit

    2.3.6 Binding/Nipping unit Do not touch the nipping/binding unit while the machine is in operation. 2.3.7 Compressed air system Before opening the pneumatic system, make sure that it is unpressurized. The binding cycle is optimal in case of permanent existing of 6 bar compressed air pressure.

  • Page 14: Frint Door Safety Switch

    2.3.10 Front Door Safety switch The front door safety switch is responsible to protect the operator during operation; it is not responsible for stopping the machine in case of Emergency. Do not stop the operation process by activating the door safety switch.

  • Page 15: Maintenance

    2.4 Maintenance Disconnect the power plug from the power outlet before attempting to move this unit. Do not damage the power cord or power plug. Do not touch the power switch with wet hands. Do not remove the cover or back panel. Do not disassemble, modify or repair this unit.
  • Page 16 The rotation direction of the milling unit must be checked. The right direction is clockwise (from top view). In case the rotation direction is not appropriate, please change two phases in the socket or in the plug. If the machine is turned off in any case it can be restarted after minimum 2 minutes.

  • Page 17: Specification

    3. Specifications Type of the machine PERFECT BINDER 420 Dimensions of the machine (l x w x h mm) 2580 x 1040 x 1350 (l x w x h inch) 101,6” x 40,9” x 53,1” Dimensions of the packaging (l x w x h mm) 2830 x 1130 x 1560 (l x w x h inch) 111,4”...

  • Page 18: Unit And Operation Points Of The Machine

    The number of practical number of the working cycles depends on:thickness of the document to be bound, volume of the paper dust to be milled from document spine, binding time essential for the technology, ability of the operator. 4. Units and operation points of the machine 1.

  • Page 19: Description Of The Units Of The Machine

    5. Description of the units of the machine The Perfect Binder 420 can be separated by units to ease the understanding and sevicing of the machine. The units are the following: 5. 1. Frame of the machine 5. 2. Starting steel plate unit There is a jogger motor in this unit, this helps the accurate and quick jogging for the binding.
  • Page 20 find this in the 8. 4. SETUP screen at the point of 14. Value of the thickness of the cover sheet. The carriage clamp is at the upper position basicly. It goes from the starting steel plate up to the binding unit during the binding period. It goes down here, and presses the spine of the book to the cover sheet.
  • Page 21 5. 5. Vacuuming unit This unit serves to vacuum the paper dust created during the milling and the vapour of the glue. The daily cleaning and maintaining of the unit is very important in respect of the working of the vacuum. Blow out the dust sack by air after emptying at least once a week.
  • Page 22 5. 6. Glue tank unit Spine glue tank Sideglue tank This unit applies the glue on the spine of the document. There are three rollers in the pot, two for apply the glue and one for pull off and align the glue.
  • Page 23 5.6.1. Draining of the glue pot The glue tank has to be heated up and the glue has to be totally liquid. By pushing either the red Stop button or the emergency stop the glue rollers stop. The reason why the moving parts must not move is that the glue has greasing function and in the lack of glue the parts can be damaged.
  • Page 24 5.7.1. Regulation of the pressing power of the binding unit It is possible to regulate the pressing power of the binding unit in case of binding of different thick paper sheets. The way of it: the carriage clamp together with the book block has to be at the right end position and the nipping unit must be closed.
  • Page 25 We put a safety sensor to know if the cover is picked up or not. If yes, cover feeding is executed. This sensor is covered by a metal plate. When the suction arm picks the cover up, the cover moves this plate up also, and in this case the cover is transported over the binding unit.
  • Page 26 machine feeds a cover. When the machine runs out of cover page the cover holder table goes down automatically (Vacuum error message appears ont he display and by clicking on this message it disappears and binding job can be resumed). At this time the cover can refilled and then manually –...
  • Page 27 5.10.1. Adjusting of the scoring depth At the end of the feeder table an adjusting turning knob can be found which is to adjust the depth of the scoring. By turning this know clockwise the scoring depth can be increased (the gap between the scoring wheels is less) and by turning the know counter clockwise the scoring depth can be decreased (the gap between the wheels is more) according to the thickness and quality of the cover.

  • Page 28: Delivery, Installation

    6. Delivery, installation During delivery of the Perfect Binder 420 pay attention to protec the safety of it The forming of the machine and its packaging are to be able to move the machine easily with traditional lifting equipments (fork-lift, manual palette transporter). You have to note the centre of the gravity of the machine due to the danger of the tilt.
  • Page 29 3. Remove the packaging plastic foil, take the stacker and the vacuuming unit off. Turn the machine on the palette to be able to lift it at the two end with two palette transporters. After lifting take the palette off. Before lowering the machine, place the feet.

  • Page 30: Working And Actuation Of The Machine

    5. Release the carriage by removing the blocking plate. 6. Connect the network plug of the machine into the socket (3P + N+ PE) NOTICE! The machine can be connected into grounded 400V 25 A socket being in appropriate condition. The type of the settled power cable must be minimum 5 x 25 mm .
  • Page 31 Everytime before starting the work integrity of the cover and the locking accuracy of the closing items has to be checked by watching them. Tel: +45 36173363, e-mail: info@rich-ebbesen.dk...
  • Page 32 In that case if the plexi cover is open „Door is open” text appears on the display. Because of safety reason every functional parts stop. The error message disappears and the machine can be run further when the cover is closed. The working of the machine can be divided up several processes as following: 7.2 Startup process Putting in operation the Perfect Binder 420 starts with charging of the machine.
  • Page 33 - As long as the above functional parts are setup to the previously adjusted state „Wait” text appears showing that the machine is not in working order. “Wait” text disappears and the startup process of machine finished after few seconds, the main menu appears.
  • Page 34 7.2.1 Heating process This process starts when the machine is turned on. The electronic controller unit begins the heating of the machine and it takes approx. 90 minutes to heat the glue in the glue tank. The time of the heating up depends on the amount of the glue in glue tank usage...
  • Page 35 7.3 “START” screen The previous adjusted values can be seen on the screen. 1. Glue length application (upper value means the top the lower value means the bottom of the spine) 2. Value of the fine adjustment of the distance of the side glueing rollers 3.
  • Page 36 The “START” screen is an information tool during the work. The main data of your work are displayed here. The values can’t be modified on this screen. 7.4 “SETUP” screen This is where the values of the different settings of the machine can be modified. Also the thickness of the book block is to be measured here to enable the machine to set the distance of the side gluing rollers and the scoring wheels.
  • Page 37 3. Value of the fine adjustment of the distance of the scoring wheels Here can be fine adjusted the distance of the scoring wheels. The minimum value is 0 to not have more distance than the measured. The maximum value is 99 mm. Attention! The machine can bind 4-50 mm thick book.
  • Page 38 9. Display of temperature of the sideglue The real (measured) temperature of the gluecan be read here. Display of the setted temperature of the sideglue The temperature of glue wanted (setted) can be read here. Maximum value is 180 ºC. Relative glue temperature indicator This icon can be one of the following: Shows that the temperature of the glue is lower than the setted value.
  • Page 39 Value of cover page thickness The thickness of the cover can be adjusted here. By increasing the value, the gap between the spine of the book block and the steel plate of the binding unit can be increased. We can use this adjustment possibility to increase the thickness of the glue and cover sheet.
  • Page 40 higher quality of binding. When the close-forward button is pressed, the jogger stops and it will start again when the carriage clamp arrives back to initial position. Padding mode When activated the binding plates are out of order, the book can be binded without the cover and without by the pressing of the binding plates.
  • Page 41 7.5 Bookbinding process If the glue has reached the setted value; instead of “HEATING” text “READY” text appears, the working process can be started. The working process is composed of working cycles. The sequence of a working (or binding) cycle is the following: - put the document to bind into the carriage clamp (the clamp stays at the left side).
  • Page 42 - the glue roller applies the glue on the spine of the book. There are 3 rollers in the glue tank. Two big rollers and one small roller. The first roller is upper than the second one. This is because the role of the first roller is to put the glue in the holes made on the spine by the slitting knives.
  • Page 43 The machine is equiped with job memory space, which means that the operator can save the frequently occurent binding jobs. In the PLC screen there is a separate menu called ’SAVED DATA’. When the operator goes into this menu, the user first must push ’FROM PLC’...
  • Page 44 The service menu can be accessed with giving of the service code. The service code XXXXX. For further information contact the local RIGO dealer. Functions of service menu:...
  • Page 45 1. Testing of milling height. 2. Moving of the cover page thickness regulator. 3. Up and down moving of the carriage clamp. (vice) Process: By clicking on the icon its outline will be red. Now the clamp can be moved with the opening and closing buttons forward and backward.

  • Page 46: Maintenance

    8. Maintenance 8.1 Mechanical maintenance Lubrication points : points marked with 1 have to be oiled monthly points marked with 2 have to be oiled every third month 6.3. Carriage clamp (vice) 6.2. Starting steel plate unit 6.7. Binding unit 6.6.
  • Page 47 6.9. Cover page table 6.10. Scoring unit You have to care for the outer wires of the cover-lifter, you have to avoid to place any object into the area under the cover-lifter because the up and down moving cover-lifter can do harm on it or the mechanics itself can be harmed as well.
  • Page 48 Sensors, microswitches The appropriate working of sensors and microswitches is key matter. The primary respect when we chose them was the reliability and durability. The essential condition of the convenience working is the perfect contact, for this it is necessary the cleanness of the sensors.
  • Page 49 Warning: The plug of the machine is always allowed to pull out in when the machine is not under power (when the main switch is switched off). Cooling ventilators The cooling ventilators must be checked when the machine is switched off if dust gathering can be seen or not.
  • Page 50 8.3 Maintenance of the pneumatic Air supply The proper air supply is very important concerning the working and maintenance of the machine. The inconvenient air flow influences the performance of the machine. Quality of the air The quality of the air supply is very important. The air must be clean and dry. The humidity and chips soil the valve system which leads to the problems of the machine performance and maintenance.

  • Page 51: Error Messages

    9. Error messages The Perfect Binder 420 can control the state of the binding cyle procedures and it indicates if any problem occurs during binding process or with any unit of the machine. 9.1. Temperature sensor 1 broken: Electrical check: Control the Zone 1 cable connection points, and if the connections are ok, ...
  • Page 52 9.6. Analog module error: Electrical check: Check the PLC analog module connection with the PLC.  Check the cable connection of the measuring sensors to the analog module.  Mechanical check: Look for any mechanical damage.  9.7. Carriage clamp error: Electrical check: Check the clamp close micro-switch connection points.
  • Page 53 9.11. Obstacle in: Electrical check: Check the cable connection of the light-curtain, when active look the PLC X2.4  port for red LED light. Mechanical check: Remove everything from the light-curtain area (hand, book, obstacle etc.). In  normal condition green LED light shows that the light-curtain is in function, in case of red light appears on the light-curtain, it needs to be recalibrated.
  • Page 54 9.16. Cover feeder error: Electrical check: Check the functionality and connection points of the inductive sensor. When  activated yellow LED light is on. Mechanical check: Check the vacuum ejector and its’ choke.  9.17. Scoring error: Electrical check: Re-set the book thickness once again, because the thickness measuring sensor ...

  • Page 55: Data Table

    9.21. Book finished sensor error: Electrical check: Check the book finished sensor functionality and its’ connection points.  Mechanical check: Check sensor position.  9.22. Binding time error: Electrical check: Check the reed sensors and micro-switch positions and connections of the ...
  • Page 56 10. The data tables of the Perfect Binder 420:...

  • Page 57: Paper And Types

    11. Paper and types: The paper has its own characteristics during production, like weight, glossy or matt, cardboard type or not, grain direction etc. At your company the paper goes through further processes, which might change the characteristics of the paper, like warnishing, or laminating not mentioning the type of your printengine.
  • Page 58 5. Please prepare the book block well, and when you insert the book into the clamp make sure that it is standing stable on the sarting plate and the side sheets won’t fall between the clamp and the starting plate. As well as, to check the inside sheets are not standing out, if it happens can cause that the sheets are falling out from the book.
  • Page 59 MEMO Tel: +45 36173363, e-mail: info@rich-ebbesen.dk...
  • Page 60 Officially Blank...

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