C.P.Bourg BB3002 PUR Operator's Manual
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C.P.Bourg BB3002 PUR Operator's Manual

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For BB3002, BB3102 and BB3202
with PUR VersaPail system and PUR Compact system
OPERATOR
MANUAL
Initial issue: 05/08
Latest revision: 12/14
9.134.089

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Summary of Contents for C.P.Bourg BB3002 PUR

  • Page 1 For BB3002, BB3102 and BB3202 with PUR VersaPail system and PUR Compact system OPERATOR MANUAL Initial issue: 05/08 Latest revision: 12/14 9.134.089...
  • Page 2 Content of this documentation has a confidential nature and remains the exclusive property of c.p. bourg s.a. It is only put at the user (including without limitation: Renter or Purchaser or their employees) disposal within the exclusive scope of using and servicing the product.

  • Page 3: Table Of Contents

    Table of conTenTs Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bb3002 1.1 Warning pictograms .
  • Page 4 3.3.6 Reinitialising the binder: ..................BB3002 4 . Graphical Interface (UI) . . . . . . . . . . . . . . . . . . . . . . . . . . bb3002 4.1 General description of the graphical interface .
  • Page 5 4.12.4 Thickness value of the last booklet bound: ............BB3002 4.12.5 Accessing the advanced menu: ............... BB3002 4.12.6 Exit roller mode: ....................BB3002 4.12.7 Checking the opening/closing the BBR or Start/Stop the conveyor: ....BB3002 5 . Preparing the binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . bb3002 5.1 Loading the cover station .
  • Page 6 12.2 Warning pictograms ........BBL 12.3 Ergonomics .
  • Page 7 environmental compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Manual Initial issue: 05/08 Latest revision: 11/08...

  • Page 8: Introduction

    InTRodUcTIon foreword On behalf of everyone at CP Bourg, we would like to thank you for choosing a BOURG product and congratulate you for your choice. 3002 The Bourg Binder is a single clamp thermal binder designed in a user-friendly way to create perfect bound books.
  • Page 9 bb3002 Operator Manual Initial issue: 05/08 Latest revision: 11/08 BB3002 Page 9...

  • Page 10: Warning Pictograms

    1 .1 Warning pictograms Please pay special attention to the description of the following pictograms : This label is located near the wheel-work, the chain and belt. It indicates a high risk of injury to your fingers if they get stuck between the wheel-work, the chain and belt.
  • Page 11 On the cover: ® MODEL BB3002 SER. N° 60 Hz 208 / 220 / 230 / 240 V 3P+PE 12 A LISTED I.T.E. E125337 50 Hz 230 / 240 / 380 / 400 / 415 V 3P+PE 12 A Refer to specifications geprüfte Sicherheit in Installation Manual.
  • Page 12 Inside the power rack : Power supply connection WARNING High leakage current earth connection essential before connecting supply ATTENTION Courant de fuite élevé Raccordement à la terre indispensable avant le raccordement au réseau On the back (inside) : BBR : Note: Risk of injury to your fingers if you take the booklets in this area.

  • Page 13: Instructions For Safe Use

    • To avoid any risk of creating potential hazards, no Bourg equipment should be modified except by qualified technical personnel. • Always use materials recommended by C.P.Bourg and developed for Bourg machines. Unsuitable materials may damage the equipment. • Do not use the machine if it makes unusual noises. Disconnect the machine from the electricity supply and contact the Maintenance Service.

  • Page 14: Specifications For Bb3002 With Pur Versapail System

    Operator Manual Initial issue: 05/08 Latest revision: 06/13 BB3002 Page 14...

  • Page 15: Specifications For Bb3002 With Pur Compact System

    Operator Manual Initial issue: 05/08 Latest revision: 09/14 BB3002 Page 15...

  • Page 16: Space Requirements For Bb3002 With Pur

    1 .5 space requirements for bb3002 with PUR Dimensions in meter (& foot). PUR VERSAPAIL SYSTEM Caster load for BB3002: Front LH 110 kg (242.5 lbs) Rear LH 110 kg (242.5 lbs) External paper dust collector Front RH 220 kg (485 lbs) Rear RH 200 kg (441 lbs) 2.02m (6.62ft) 0.8m (2.6ft)

  • Page 17: What Is Pur

    1 .6 What is PUR? PUR (polyurethane) is a reactive hot melt material that is melted and processed like conventional hot melt adhesive. It binds in a hot–cold process and cross-links under the influence of moisture, thus achieving its final solidity. The original plastic film thus becomes elastic and very flexible, and it can no longer be melted or dissolved.

  • Page 18: General Description

    2 . GeneRal descRIPTIon 2 .1 specifications Padding mode (without cover) Perfect Binding mode MAX 60mm (2.36") MIN 1mm (0.04") 90 to 320mm (3.54" to 12.60") 5 " 5 . 1 " t . 3 6 Cover types: Glossy paper, with cutouts, with transparent front etc.
  • Page 19 Operator Manual Initial issue: 05/08 Latest revision: 06/13 BB3002 Page 19...

  • Page 20: Description Of The Gluing Process

    2 .3 description of the gluing process • Place a set of pages in the carriage jaws. • Start a gluing cycle, withdrawing your hands outside the loading area. Automatic process with cover Cover clamping Glueing Milling Roughing Jogging Glueing Automatic process without cover Jogging...

  • Page 21: Description Of Various Parts Of The Binder

    2 .4 description of various parts of the binder 2.4.1 "Vibrating" module (jogger): The vibration of the jogger plate re-aligns the block of paper to be bound. 2.4.2 Milling module: The milling module roughs the edge of the bundle of paper to be bound. This helps the glue adhere to the paper better.

  • Page 22: Glue Gun

    2.4.3 Glue gun: The adhesive flows from a bulk melter through a heated hose then a filter (3) and into the application head. The adhesive is applied to the spine from underneath as soon as the control module Application module (4) is triggered (opened).

  • Page 23: Creasing Module (Optional)

    2.4.5 Creasing module (optional): The creasing module can create folds in the cover to make it easier to open the book. It also makes it possible to obtain bindings with folding wings. 2.4.6 Cover loading: The cover station suction bar picks up the cover and transfers it to the cover clamp module.

  • Page 24: Binder Output

    2.4.7 Binder output: The output baffle plate has a movable roller which aligns and slows down the book before its output. Output roller 2.4.8 Reception of books in the BBR module (optional): The bound books are finally received and stored in a high-capacity module, the BBR. Note: Risk of injury to your fingers if you take the booklets in this area.

  • Page 25: Pur C Glue Consumption

    2 .5 PUR c Glue consumption - Consumption for a glue spine length of 297mm. - The amount of glue used for purging is not taken into account. - This graph is valid for glue PLANATOL 2880, JOWAT 600-37 and HENKEL 3317. - This document is for rough calculation only (Exact quantities may be slightly different).

  • Page 26: Using The Binder

    3 . UsInG The bIndeR 3 .1 operating procedure 3.1.1 Powering up the binder: • The first operation is to power up the PUR C System (if installed) then the machine by turning the on/off switch to the ON1 position. See chapter "3.2 Powering up the binder and heating the glue gun", page 28.

  • Page 27: To Start The Dust Collator

    3.1.6 To start the Dust Collator • Open the cover (1). • Push the button ”I” (2). • Do not close the cover (1) (close the cover = stop emergency). After a stop emergency, push the botton ”I” (2) again. Operator Manual Initial issue: 05/08 Latest revision: 11/08...

  • Page 28: Powering Up The Binder And Heating The Glue Gun

    3 .2 Powering up the binder and heating the glue gun On the front of the binder is a main switch with 3 positions: 1- Binder OFF. The first position of the switch cuts off all power to the machine: "POWER OFF".

  • Page 29: Heating The Glue/Gun

    3.2.1 Heating the glue/gun: 3.2.1.1 VersaPail System Preliminary notes: This temperature can be adjusted by a qualified technician to low or high temperature. The operator can vary this temperature by ± 15°C using the graphical interface from the VersaPail. Procedure for starting heating: 1) Turn ON the VersaPail.

  • Page 30: Starting The Timer - Main Switch In On2 Position

    3.2.2 Starting the TIMER - main switch in ON2 position: The "TIMER" menu can be programmed to start and stop the glue gun heater automatically with no input from the operator. In this way, the glue gun can begin to heat up before the operator arrives and the glue will be at the right temperature when the operator starts work.

  • Page 31: The Binder Controls

    3 .3 The binder controls The binder's controls are as follows: 1. A colour touch-screen used to program jobs (UI). 2. Black and green buttons on the loading console. 3. Pedal. 4. Emergency stop button. 5. Indicator lights. 6. Safety barriers. 3.3.1 Function of the buttons on the loading console: Emergency stop button Indicator lights...

  • Page 32: Function Of The Pedal

    3.3.2 Function of the pedal: The pedal closes the carriage jaws so that the space where the book to be bound is inserted can be adjusted. 3.3.3 Indicator light above the loading area: Above the loading area is a strip of indicator lights. The operator can see at a glance the status of the binder from the indicator's various colours: - Green light: A green light indicates that the machine is ready for use and that the glue...

  • Page 33: Emergency Stop Button

    3.3.5 Emergency stop button: To stop the machine quickly (if the operator is in danger, for example), press the emergency stop button. 3.3.6 Reinitialising the binder: (*) To reinitialise the binder, release the emergency stop button (if it has been pressed) and press the green button on the loading console.

  • Page 34: Graphical Interface (Ui)

    4 . GRaPhIcal InTeRface (UI) 4 .1 General description of the graphical interface The graphical interface enables the binder to be used easily and intuitively. The touch-sensitive screen is divided into 4 parts: Zone C. Zone A. Zone D. Zone B. Zone A: Access to the various menus in the graphical interface: 1.
  • Page 35 Zone B: Machine status icons: 1. CP Bourg logo. Pressing this button displays information relating to the version of the UI software installed. 2. Display of the number of bindings carried out and the total number in the current job. Pressing this button toggles between the "series"...
  • Page 36 Zone C: Current job display and warning messages: This zone displays the current job and various warning messages. This indicates the binder's status to the operator at all times. Current job name Warning messages When an error occurs, a red message scrolls on the screen. Display of the current job is then deleted.

  • Page 37: Preferences" Menu

    4 .2 "PRefeRences" menu This menu enables the binder to be configured according to the operator's preferences. Settings such as the language, units of measurement, start-up mode etc. are defined here. The "PREFERENCES" menu is accessed by pressing the icon to the right of the screen. choice of language: Various languages are available.
  • Page 38 default paper size . The binder needs to know the height of the book. When starting the machine or creating a new job, the format selected in this menu will be offered as the default. The operator can select from the most commonly used formats: - A4 (height = 210 mm), - US Letter (height = 216 mm), - B4J (height = 257 mm),...

  • Page 39: Automatic" Menu

    4 .3 aUToMaTIc" menu On start-up, the automatic menu appears. The automatic menu enables the operator to bind standard jobs using settings with default values. The automatic menu facilitates the operator's job - he does not need to set the cover binding and cover clamp parameters, as they are determined directly according to the book to be bound.
  • Page 40 4. Three settings can be altered: Activation/deactivation of the jogger + adjustment of the amplitude of the vibration: The vibration of the jogger plate straightens the sheets in the paper bundle into a properly squared-off block. By pressing , the operator can activate or deactivate the vibration of the jogger plate.
  • Page 41 5. The machine is now ready for operation using the "aUTo" parameters . The operator can now place the paper to be bound in the carriage jaws and begin a gluing cycle. Note: When loading the paper, place the back of the last page of the book to be bound, facing you.
  • Page 42 Overview of the gluing and cover clamp parameters with and without the AUTO menu : Parameters set with the “aUTo” menu Parameters set automatically according to the book to be bound. Parameters set without the “aUTo” menu Parameters set manually by the operator.
  • Page 43 List of default parameters in the automatic menu: To reset the gluing and cover clamp parameters to their "AUTO" values, press the icon in the automatic menu. • Binding parameters: - Carriage speed: fast. - Milling activated. - Milling depth: 1 mm. - Glue cut-off on front: 5 mm.

  • Page 44: Counter Menu

    4 .4 coUnTeR menu The operator can access the counter menu by pressing the button at the bottom of the screen. The binder can work in unit mode, series mode or semi-series mode. only foR PUR c "UnIT" mode is used when the operator wishes to produce books with different thicknesses or formats.

  • Page 45: Unit Mode

    4.4.1 UNIT mode: "UnIT" mode is used when the operator wishes to produce books with different thicknesses or formats. Thus, bind one by one. This is the default mode. only foR PUR c 1. This first counter displays the total number of jobs completed since the machine was first put in service.

  • Page 46: Series Mode

    4.4.2 SERIES mode: There are two types of series mode: - "continuous series" mode: To bind an undefined series of identical books. The series mode is permanently selected. - "preset series" mode: For a defined number of identical books. The series mode is selected for a defined number of jobs (configurable via the UI).
  • Page 47 4.4.2.2 “PRESET SERIES" mode: only foR PUR c 1. This first counter displays the total number of jobs completed since the machine was first put in service. 2. Pressing this icon changes the binder from "series" or "semi-series" mode to "unit"...

  • Page 48: Semi-Series" Mode

    4.4.3 “SEMI-SERIES” mode: Like the series mode, there are two types of semi-series mode: - "continuous semi-series" mode: To bind an undefined series of identical books. The series mode is permanently selected. - "preset semi-series" mode: For a defined number of identical books. The series mode is selected for a defined number of jobs (configurable via the UI).

  • Page 49: Additional Functions For Pur C

    4.4.4 Additional functions for PUR C A calculation method based on glue consumption has been developed. An estimate of the number of books that can be bound is calculated according to the remaining glue ( ) or air height in the Melter ( When the minimum level is reached ( ), the machine stops.

  • Page 50: Advanced" Menu

    4 .5 adVanced" menu This menu provides access to various binding and cover clamp parameters, making it possible to produce personalised books which call for specific parameters. Accessing the advanced menu: 1. Press the icon (1) to access the advanced menu 2.
  • Page 51 Cover suction level: This button modifies the suction level for the cover to be picked up. Two operating modes are possible, depending on whether or not the "AUTO" function is active. • If the "AUTO" function is active: The suction level is automatically adjusted according to the cover. •...

  • Page 52: Advanced Menu: Managing Parameters For Cover Clamping

    4 .6 adVanced menu: Managing parameters for cover clamping This menu enables you to set the parameters for cover clamping of the book. 4.6.1 Selecting "with cover" or "without cover" mode ("BLOCK" mode): Pressing this button activates with cover mode. Pressing this button activates without cover mode (Block mode).

  • Page 53: In "With Cover" Mode

    4.6.2 In "WITH COVER" mode: 4.6.2.1 Cover positioning modes: There are three different ways in which the cover can be cased in: • N / FIRST mode: Default mode. The edge of the front cover is positioned at the edge of the first page to be glued.
  • Page 54 4.6.2.2 Selection and positioning of creases (optional module) As indicated above, the creasing options and cover parameters to enter depend on whether N/FIRST, CENTRE or FIRST/N mode has been selected. • With N/FIRST mode: Note: Covers with folding wings are only available in this mode. When the paper is loaded into the carriage jaws, the operator must place the back of the last page of the book to be bound facing him.
  • Page 55 Selection of available creases: Six creases are available in this mode. Each one can be selected upwards, downwards or selected. Press the icon representing the desired crease to change the crease shape. • Creases 2 and 3 are positioned automatically according to the thickness of the book.
  • Page 56 Books with folding wings: Books with folding wings are only available in N/FIRST mode. If the operator wishes to produce books with folding wings, creases 5 and 6 must be selected using the icon. The operator must also specify the following widths: •...
  • Page 57 • With CENTRE mode: This mode enables the cover to be centred in relation to the book's spine. Symetric a t h It is used to centre inscriptions on the spine of the book. As long as the inscriptions are in the centre of the cover, they will always be positioned on the spine, whatever be the thickness of the book.
  • Page 58 • With FIRST/N mode: In this mode, the edge of the front cover is positioned on the edge of the first page to be bound. When the paper is loaded into the carriage jaws, the operator must place the front of the first page of the book facing him.

  • Page 59: In "Without Cover" Mode

    4.6.3 In "WITHOUT COVER" mode: Pressing activates without cover mode (Block mode). In this mode, no cover parameters need to be entered. Operator Manual Initial issue: 05/08 Latest revision: 11/08 BB3002 Page 59...

  • Page 60: Advanced Menu: Managing Binding Parameters

    4 .7 adVanced MenU: Managing binding parameters This menu enables you to set the parameters for milling and gluing the cover on the book. 4.7.1 Setting the carriage movement speed: Automatic carriage movement speed. Depending on the thickness of the book and the milling depth, the binder automatically calculates the carriage movement speed.

  • Page 61: Selecting Milling And The Milling Depth

    4.7.2 Selecting milling and the milling depth: Pressing activates or deactivates the milling of the book's spine. When milling is activated, the operator can modify the milling depth (between 0 and 3 mm depending on paper type and format). • If the operator does not activate the rotation of the milling blade: ->...

  • Page 62: Setting Front And Back Glue Cut-Offs

    4.7.3 Setting front and back glue cut-offs: Glue cut-offs enable you to stop applying the glue film at the front and back of the book's spine. • In this case, the glue cut-offs are set at 15 mm from the edges of the book.

  • Page 63: Job" Menu

    4 .8 “Job" menu This menu enables the operator to access a series of fine settings. These settings make it possible to get the most out of your BB3002 for delicate and/or specific jobs. are given their "AUTO" Note: When a new job is created, settings values.

  • Page 64: Correction Of The Paper Pile Thickness To Be Bound

    4.8.1 Correction of the paper pile thickness to be bound When the carriage clamp closes, the bottom of the pile (not gripped in the clamp) to be bound is larger than the paper thickness in the clamp. This is frequent when using light paper (60 gsm) or pre folded paper and increase with the paper pile thickness.

  • Page 65: Setting The Thickness Of The Glue Film

    4.8.2 Setting the thickness of the glue film: Using this button you can modify the thickness of the glue film applied to the spine of the book. Two operating modes are possible, depending on whether or not the "AUTO" function is active. When the "AUTO"...

  • Page 66: Setting The Glue Drying Time During Cover Nipping

    • In "block" mode: This time corresponds to the glue drying time before the book is output. It is advisable to make this time as long as possible. The value can range from 6 seconds to 26 seconds in steps of 2 seconds. Default value: 16 seconds.

  • Page 67: Book Output Mode

    4.8.9 Book output mode: Before being directed on to the conveyor, the book can be realigned by the cover clamps and the exit roller before being output. 4 modes for the output of the book on to the conveyor are possible: In this mode, the book falls on the clamps and then the exit roller before being output on the conveyor.

  • Page 68: Adjusting The Creasing Position

    4.8.11 Adjusting the creasing position: With this button the position of the creases on the front and back can be adjusted separately. For example, in the case of a book with folding wing flaps, there may be 3 creases on the back: 1. Crease on the spine of the book. 2.

  • Page 69: File" Menu

    4 .9 "fIle" menu The BB3002's graphical interface provides an easy and powerful way to manage your jobs. A job can be created (1), opened (2), saved (3) or deleted (4) simply by pressing the corresponding icons. 50 jobs can be saved in memory of the graphical interface. To access the FILE menu, press the button.

  • Page 70: To Open An Existing Job

    4.9.2 To open an existing job: • The operator can open an existing job, making it the current job. Saved jobs can be selected from a list that appears on the screen, in alphabetical order. • The operator selects the required job by pressing the icon.

  • Page 71: Timer" Menu

    4 .10 "TIMeR" menu The "TIMER" menu can be programmed to start and stop the glue gun heater automatically with no input from the operator. In this way, the glue gun can begin to heat up before the operator arrives, and the glue will be at the right temperature when the operator starts work.

  • Page 72: Alarm" Menu

    4 .11 alaRM" menu The "ALARM" menu is accessed by pressing the icon to the right of the screen. This displays the warning and error messages that have occurred since the machine was last switched on, in chronological order. The errors and warnings can be selected to give further information about each message. Move the cursor up by using the button “1”...

  • Page 73: Setting The Date And Time

    4 .12 "Tools" menu To acces the Tools menu, you must press the key on the right of the screen. The header window enables to : - Restart the binder. - Set date and time. - Open and close the cover clamps. - Know the thickness of the last booklet bound.

  • Page 74: Opening/Closing The Cover Clamps

    4.12.2 Opening/closing the cover clamps: These two buttons open and close the cover clamps. This is useful for cleaning, removing films of glue from the non-stick cover clamp plate. Note: As a safety measure, clean the plate with the interlock open. 4.12.3 Restarting the graphical interface, the PLC and communication between them: In the event of problems, it is possible to: •...
  • Page 75 4.12.5 Accessing the advanced menu: Press the icon to access the technicians' advanced menu. An alphanumeric keyboard will appear on the screen, and a password will be requested. Only qualified technicians will know this password, giving access to the advanced menu. 4.12.6 Exit roller mode: These controls are used to clean the BBR.
  • Page 76 4.12.7 Checking the opening/closing the BBR or Start/Stop the conveyor: Using this function, the BBR initial opening can be adjusted before the book arrives. The BBR can open 5, 10, 15, 20 mm wider than the thikness of the book. Note: The maximum opening is The operator can modify the opening by pressing on left of the button to reduce the value or on right to increase the value.
  • Page 77 5 . PRePaRInG The bIndeR 5 .1 loading the cover station Suction bar Cover guide Front guides Cover station extension The cover station must be reloaded when there are no more covers on the tray. To do this: • Raise the suction bar. This command is carried out when a pause is requested using the UI (press the button at the bottom right of the screen).
  • Page 78 5 .2 adjusting the cover position on the book Front guides Cover registration stop Using the cover guide mounted on the cover station tray, the position of the cover on the book can be adjusted. 2 knobs on the cover station enables the following adjustments: •...
  • Page 79 • Lateral position of the cover in the relation to the book : View of book on the conveyor Conveyor drive belt Button correction (1) • Straightening the cover on the book : View of book on the conveyor Conveyor drive belt Button correction (2) •...
  • Page 80 5 .3 cover picking and separators 5.3.1 Separators: Cover separators Flexible cover Rigid cover separator separator 9404146 9403785 • Suction and blowing can be adjusted together in the UI using the icon in the "JOB" menu (see chapter"4.8 “JOB" menu", page 63). •...
  • Page 81 5.3.2 Cover suction: According to the width of the cover, the operator must adjust the position of the cursor (1) to ensure that the covers are picked up correctly. Cursor (1) Plastic stud (2) The cover leaves the letter D visible Example: Place the covers on the cover station tray.
  • Page 82 5 .4 not available Operator Manual Initial issue: 05/08 Latest revision: 11/08 BB3002 Page 82...
  • Page 83 5 .5 creasing depth adjustment Adjust the depth of the crease depending on the used cover. For that purpose, use the lever (1). • Lower the lever (1) to increase the pressure in order to obtain sufficient deep notch in the cover.
  • Page 84 6 . sPecIal aPPlIcaTIons Thanks to the technology used for the BB3002, some customised bindings using special parameters can be created. 6 .1 binding of sewed book In sewed mode, a cover can be applied on a sewed book beforehand. The jogger plate is slightly lower than in non-sewed mode.
  • Page 85 6 .2 binding of a top stitched brochures Binding of a top stitched brochures can be made if the distance between the staple and the paper edge afTeR MIllInG is superior or equal to 5 mm. If the staple is at a distance of 7 mm from the edge, 2mm can be milled. 6 .3 not available Operator Manual Initial issue: 05/08...
  • Page 86 6 .4 Multicreasing mode The BB 3002 is the first binder on market equipped with a creasing system punch matrix allowing execution of 13 creases on cover. This multi-creasing system is available only if the option is installed on the machine. If the option is installed, the use of Automatic and Advanced menu does not change but 2 icons are added on the screen: - Multi-creasing application - Doctor booklet application (see chapter...
  • Page 87 • Multi-creasing mode: 13 creases are available in this mode. Each one can be selected to position upwards, downwards or deselected. Length of the front cover Crease in the Crease on middle of the spine of spine book the book Multi-creasing mode Note: - In mode N/...
  • Page 88 6 .5 “doctor” booklet application If option multi-creasing is installed, the BB3002 can create special applications, like “Doctor” booklets. They are booklets with 3 folding wings: - The first folding wing is inward. - The second corresponds to the booklet thickness. - The third folding wing folds back against the first one and closes the booklet.
  • Page 89 7 . UsInG The PUR c MelTeR 7 .1 Refilling the PUR c Melter WaRnInG: RISK OF BURNS ! Wear safety glasses and heat protective gloves. 7.1.1 Opening • To open the lid, turn the handle ( ) counter-clockwise. Make sure to turn the handle until it goes no further (about rotations).
  • Page 90 7 .2 Purging system sequence aTTenTIon: In case of purge of cleaner, Setpoint temperature should be adjusted to °c (see chapter "8.4 Adjusting Temperature on PUR C Melter", page 98. Purge System daily to remove grease and left over PUR material from previous day before beginning production.
  • Page 91 Warning : Risk of burns. Wear safety glasses and heat protective gloves. Close the covers (pay attention to the wheel handle). PUR c VersaPail Operator Manual Initial issue: 05/08 Latest revision: 09/14 BB3002 Page 91...
  • Page 92 4. Close access door and cover and then press the purge button on the touch screen. Glue will begin to fill cup reservoir. Fill cup until glue is fresh and without air. Releasing purge button will stop the flow of adhesive. 5.
  • Page 93 6. Clean the excess of glue. Close door and cover and press the button to exit the menu. 7. When the purge cup has been removed, press "yes" to confirm. 8. Purge sequence is complete. Reinitialise the binder by pressing the green button.
  • Page 94 7 .3 adjusting the pressure for PUR c Melter 1. Main pressure (minimum required pressure 6 bars). 2. Dry compressed air (inside the Tank). 3. Static pressure (depending on the viscosity of the glue and the thickness of the book). Adjust the pressure by turning the appropriate button.
  • Page 95 8 . MaInTenance 8 .1 Preventive maintenance WaRnInG: Risk of burns. Wear safety glasses and heat protective gloves ! Daily: - carriage: Check the condition of the jaws, remove any traces of glue. Use spray cleaner 9195053. - Glue gun: Purge the system and clean the excess of glue by opening then closing the gun to the maximum.
  • Page 96 8 .2 Replacing the dust bag Note: - The message "Replace the dust bag" appears on the screen. This is a warning message, which means that the binder can continue to operate, but you are strongly advised to replace the bag to avoid adverse binding quality.
  • Page 97 8 .3 supplies and accessories Note: Emptying and refilling the VersaPail System See VersaPail Manual. 9196037 3317 2 Glue Purmelt HENKEL QR Kg (PUR C) 9196034 2880 2 Glue Planatol Kg (PUR C) 9195048 3317 20 Glue Purmelt HENKEL QR Kg (VersaPail) 9590023 For PUR VersaPail...
  • Page 98 8 .4 adjusting Temperature on PUR c Melter For the Melter Press and hold the Tank key (1) for three seconds. The (A) display flashes (value=1). Press an arrow in (B) area, the display flashes. Use the arrows to modify the value or the keypad to enter the setpoint temperature recommended by the manufacturer of the hot melt.
  • Page 99 8 .5 Tips for successful operation: Adjusting Component Temperatures (Glue QR3317) Parameter Value Description T° Tank 110°C Setpoint temperature T° Hose 120°C Setpoint temperature T° Gun 130°C Setpoint temperature Note: Valid for Glue type HENKEL QR 3317. Adjusting Component Temperatures (Purmelt cleaner 2) Parameter Value Description...
  • Page 100 9 . GUIdes 4 types of guides are supplied with the machine. Use the most appropriate guides in order that the sheets are effeciently held up in the carriage and the operator can easily guide the book block into position. GUIDES QUANTITY CP BOURG #...
  • Page 101 10 . MechanIcal TRoUbleshooTInG symptom Probable cause Remedy The cover is not square on The cover is not cut square. Check the covers. the paper offset (skewed). The cover station and paper Check the squareness with pile are not square to the respect to the nippers.
  • Page 102 11 . coMMon GlUeInG defecTs Gaps in glue film Feather on book spine Nail head Check: Check: Adhesive and/or roller - Glue and roller temperature. temperature too low. - Cover press too tight. - Running temperature. - Height of back pressure. Honeycomb film Uneven glue line Cavity spine...
  • Page 103 Operator Manual Initial issue: 09/13 Latest revision: - BBL Page 103...
  • Page 104 12 . UsInG The bIndeR WITh The bbl 12 .1 Introduction On behalf of everyone at CP Bourg, we would like to thank you for choosing a BOURG product and to congratulate you on your choice. 3002 The BB is designed in a user-friendly way to create perfect bound books. Adjustments can quickly and easily be made via a touch screen (GUI).

  • Page 105: Ergonomics

    12 .3 ergonomics The BBL’s loading area consists of a m long conveyor belt, equipped with multiple separators. The operator places these where he wants and then places the book blocks in-between the separators. The conveyor belt can hold anywhere up to blocks ensuring autonomy of up to minutes, depending on the thickness of the book blocks.

  • Page 106: Space Requirements

    12 .7 space requirements 12.7.1 BB3102 with EVA System 12.7.2 BB3102 with PUR Compact System 2.02m (6.62ft) 2.02m (6.62ft) 0.8m 0.8m 0.30m (2.6ft) (2.6ft) (1ft) 0.80m 0.8m (2.6ft) (2.6ft) 0.8m 0.8m (2.6ft) (2.6ft) 0.60m (1.96ft) 0.60m (1.96ft) Operator and Service clearance Operator and Service clearance Operator Manual Initial issue: 09/13...

  • Page 107: Paper Size

    12 .8 Paper size booKleT dIMensIons size Min : mm ( in.) Max : mm ( in.) Thickness mm ( in.) MAX 60mm (2.36") MIN 1mm (0.04") 139 to 320mm (5.5" to 12.60") . 5 " . 7 " 3002 Note: Specifications for cover are the same as for the BB , see chapter "2.

  • Page 108: Bbl Performances

    12 .9 bbl performances 3002 number of available bbl capacity booklet pockets productivity with thickness gsm – max paper size) (includes security zone) PUR glue pockets booklets/h 1207 pockets booklets/h 1207 pockets booklets/h 1811 pockets booklets/h 1610 pockets booklets/h 1509 pockets booklets/h 1811...

  • Page 109: Bbl Loading

    12 .10 bbl loading Adjust the position of the separators in order to obtain the appropriate size for the book block. A maximum of holes can be left free between consecutive separators. Make sure that each separator is correctly placed into its slot. Load the book blocks in the BBL against the registered table on the operator side, placing the side that has to be bound at the bottom, according to the selected mode ( to N, centered or N...
  • Page 110 The use of lateral brushes allows the binder to handle light papers and/or papers which have little consistency. Adjust the brushes’ position so that they slightly touch the book blocks. Brush Progress direction Book block Brush - (operator side) When the book loader is in standby, a pedal can be used to manually move the conveyor belt forward and therefore easily load the BBL.

  • Page 111: User Interface Menu For Bbl

    13 . UseR InTeRface MenU foR bbl 13 .1 Main screen ) Press this button to view the BBL’s main configuration screen. 2) loading mode Allows the operator to select the BBL’s loading mode: - On-line corresponds to the BBL’s new loading method. - Off-line corresponds to the BB3002’s traditional loading method.
  • Page 112 6) Vibration time This function enables the operator to adjust the vibration time to jog the book block against the 3002 “stop” in the BB ’s carriage clamp. Two operating modes are available: the ‘Auto’ mode turned on or off. - ‘Auto’...

  • Page 113: Tools" Menu

    13 .2 "Tools" menu To access the "TOOLS" menu, you must press the key on the right of the screen. The header window is displayed on the screen. aTTenTIon: The buttons of this menu are used for maintenance, cleaning, dejam,... DO NOT PUSH THE BUTTONS OF THIS MENU WHEN THE MACHINE IS RUNNING.

  • Page 114: Preferences" Menu Of The Bbl

    13 .3 "PRefeRences" menu of the bbl This menu enables the binder to be configured according to the operator's preferences. Settings such as the language, units of measurement, start-up mode ... are defined here. Note: When the binder is configured in BBL mode, the access to the menu "PREFERENCES"...

  • Page 115: Alarm" Menu

    13 .4 "alaRM" menu When an alarm message is displayed on the screen, press the Alarm button. A screen with different messages appears. Press , an animation shows the way to resolve the error. Refer to"14. Troubleshooting Guide BBL", page 116 for more details.

  • Page 116: Troubleshooting Guide Bbl

    14 . TRoUbleshooTInG GUIde bbl BBL - SIDE COVER OPEN Close the interlock closing the side cover. Close the interlock closing the top cover. BBL - TOP COVER OPEN BBL - MANUAL LOADING Close the interlock closing the manual loading cover. COVER OPEN BBL - MAIN INTERLOCK OPEN Release the emergency stop button or the portico of protection placed on the lateral cover.
  • Page 117 BBL - PUSHER TICKNESS HOMING Open the side cover and check that the forks of the lift are free in depth. FAILED BBL - PUSHER HOMING FAILED Open the side cover and check that the forks of the lift are free vertically. BBL - OPEN/ CLOSE CLAMP Open the top cover and check that the opening and closing of the clamp is not obstructed by HOMING FAILED...
  • Page 118 BBL - TRANSFER CLAMP NOT ON Open the top cover and check that the translational movement of the clamp is not obstructed TARGET by an obstacle. The clamp can be moved manually. BBL - CONVEYOR REGISTRATION Open the side cover and check that the translational movement of the clamp is not obstructed NOT ON TARGET by an obstacle.
  • Page 119 BBL - REMOVE PAPER BLOCK FROM Open the side cover and remove 1or2 blocks of sheet from the separation area in order that PROCESS AREA the BBL may perform a full reset. BBL - CONVEYOR BLOCKED Open the side cover and check that there is not too much pressure on the side baffles result of a paper jam, for example Open the side cover and insert an extra separator in the separation area of sheet blocks if the gap is too large...
  • Page 120 Operator Manual Initial issue: 09/13 Latest revision: - BBC Page 120...

  • Page 121: Using The Binder With The Bbc

    15 . UsInG The bIndeR WITh The bbc 15 .1 Introduction On behalf of everyone at CP Bourg, we would like to thank you for choosing a BOURG product and to congratulate you for your choice. 3002 The Bourg Binder is a single clamp thermal binder designed in a user-friendly way to create perfect bound books.

  • Page 122: General Description

    15 .2 General description 3202 3002 The BB is an in-line device consisting of two modules: a modified Bourg BB Perfect Binder (with Tag ) and a Bourg Book Compiler (BBC) that compiles sheets or single fold signatures coming from previous device into a stack and transfers the stack into the modified Binder.

  • Page 123: Operation Modes

    15 .3 operation modes 15.3.1 Perfect Binding Mode (On - line) 3002 Covers are printed and manually loaded into the BB cover feeder. Book blocks are 3002 printed sheet by sheet and compiled in compiling section, then transferred to BB clamp, 3002 and finally bound in BB...

  • Page 124: Electrical Specifications (Bbc)

    15 .4 electrical specifications (bbc) 9139854 - Voltage/ Frequency: 120 V - 60 Hz (1 phase) 230 V - 50 Hz (1 phase) MODEL : - Ampere: 1,5 A at 230 Vac input voltage 100 - 240 VOLTS : 3 A at 120 Vac input voltage 4 - 2 50/60 - Power consumption: 500 W...

  • Page 125: Space Requirements

    15 .6 space requirements 1450 1500 Height : mm - Depth : mm - Length : 15.6.1 BB3202 with EVA System 2.02m (6.62ft) 0.85m (2.8ft) 0.8m (2.6ft) 0.8m (2.6ft) 0.60m (1.96ft) Operator and Service clearance 15.6.2 BB3202 with PUR Compact System 2.02m (6.62ft) 0.85m 0.30m...

  • Page 126: Bbc Performances

    15 .7 bbc performances 2000 Input - paper velocity : Up to mm/s Input - feed rate : Up to sheets per minute (A format) Note: Using sheet flipper for all sheets may reduce maximum input rate. Productivity: Up to books per hour Note: May be impacted by printer, by number of creases, by number of sheets per book.

  • Page 127: User Interface Menu For Bbc

    16 . UseR InTeRface MenU foR bbc 16 .1 Main screen ) Press this button to view the BBC’s main configuration screen. 2) sheet flipper Potentially needed for specific printing modes, especially when sheet processing device is 3202 connected between IOT and BB that requires to flip sheets to invert lead and trail edges or face up &...
  • Page 128 5) clamp opening 3002 In the case of curly sheets, an extra-opening of the BB carriage clamp can be justified. This extra opening can be adjusted in incremental steps of mm - " (from 0 to 40mm - 1.6"). Usual value is mm - ".
  • Page 129 Sheet flipper description: There are options available Waste bin: When the waste bin is selected with a number of sheets (N) to be send to the waste bin, the (N) first sheets of the set will be sent to the waste bin before compiling sheets.
  • Page 130 Operator Manual Initial issue: 09/13 Initial issue: 08/13 Latest revision: - BBC Page 130 Latest revision: 12/14...
  • Page 131 Operator Manual Initial issue: 09/13 Initial issue: 08/13 Latest revision: - BBC Page 131 Latest revision: 12/14...
  • Page 132 Operator Manual Initial issue: 09/13 Initial issue: 08/13 Latest revision: - BBC Page 132 Latest revision: 12/14...
  • Page 133 Operator Manual Initial issue: 09/13 Initial issue: 08/13 Latest revision: - BBC Page 133 Latest revision: 12/14...
  • Page 134 Operator Manual Initial issue: 09/13 Initial issue: 08/13 Latest revision: - BBC Page 134 Latest revision: 12/14...

  • Page 135: Tools" Menu

    16 .2 "Tools" menu To access the "TOOLS" menu, you must press the key on the right of the screen. The header window is displayed on the screen. aTTenTIon: The buttons of this menu are used for maintenance, cleaning, dejam,... DO NOT PUSH THE BUTTONS OF THIS MENU WHEN THE MACHINE IS RUNNING.

  • Page 136: Preferences" Menu Of The Bbc

    16 .3 "PRefeRences" menu of the bbc This menu enables the binder to be configured according to the operator's preferences. Settings such as the language, units of measurement, start-up mode ... are defined here. Note: When the binder is configured in BBC mode, the access to the menu "PREFERENCES"...

  • Page 137: Alarm" Menu

    16 .4 "alaRM" menu When an alarm message is displayed on the screen, press the Alarm button. A screen with different messages appears. Operator Manual Initial issue: 09/13 Latest revision: 08/14 BBC Page 137...

  • Page 138: Jam Clearance For Bbc

    17 . JaM cleaRance foR bbc In case of a jam or other problems you can open the Top Cover ( ) in order to reach the compiling area then open baffle (A), (B) and (C). Baffle (B) must be open before baffle (C). The cover ( ) allows reaching the area where the book block is held by the Transfer Clamp.
  • Page 139 You can also use the knurled Knob ( ) to clear the paper path. Operator Manual Initial issue: 09/13 Latest revision: - BBC Page 139...
  • Page 140 bb3002 WITh PUR coMPacT sysTeM oPeRaToR caRd Operator Card BB3002 with PUR Compact System Consult material manufacturer’s safety data sheet and product manual for safe handling and operating instructions! Start Up Switch on the binder to start the heat of the glue Wait 30 min so the glue is melted Open the slot nozzle Remove grease from slot nozzle...
  • Page 141 enVIRonMenTal coMPlIance Product Recycling and disposal ENGLISH: Application of this symbol on your equipment is confirmation that you must dispose of this equipment in compliance with agreed national Procedures. In accordance with European legislation dealing with "end of life electrical and electronic equipment", equipment subject to disposal must be managed within agreed procedures.
  • Page 142 DEUTSCH: Geräte die dieses Symbol tragen, müssen den nationalen Richtlinien gemäß entsorgt werden. Den europäischen Bestimmungen zum Umgang mit elektrischen und elektronischen Altgeräten ist Folge zu leisten. Bei der Entsorgung des Geräts den Partner kontak-tieren. ITALIANO: Questo simbolo applicato sulla macchina indica la necessità di smaltire il prodotto in conformità...

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