Perfect Binder PB-600S Product Guide Draft revision 01 (Sept 2011)

Transcription

1 Perfect Binder PB-600S Product Guide Draft revision 01 (Sept 2011) Perfect binding system model PB-600S for the production of perfect bound books in-line with a Digital Web printer This Guide is revision 01 is not yet released.. To ensure you are using the most up-to-date version of this Guide check the download page on IBIS s web site to view the latest revision. PB-600S Product and Application Guide rev.00 1

2 Document Revision History Rev Date Description of main changes made at each release 00 14/0910 First release. Product specifications and / or appearance are subject to change without notice. 2 PB-600S Product and Application Guide rev.00

3 Contents 1 Press release from the Smart-binder initial product release at the Drupa exhibition, IBIS Product Range Summary Smart-binders SB-1, 2, 3 and 4 : Main user-features and benefits Smart-binder system description and options Process description... 9 Smart-binder system layout... Error! Bookmark not defined Producing booklets up to 10mm (0.39 ) thickerror! Bookmark not defined Wire stitched booklets - SB-1, SB-2, SB-3 and SB ISG cold-glued booklets SB-1G, SB1-G4, SB-3 and SB-4 onlyerror! Bookmark not de Producing hot-glued (square-back) books 5-60 mm thick ( )Error! Bookmark not SCF (Sheet collector and feeder) and Hot-melt binder (model BB3002) as used on the SMART-BINDER model SB Error! Bookmark not defined. 4.2 Book output options... Error! Bookmark not defined. 4.3 Feeding Covers and Insert Sheets... Error! Bookmark not defined. 4.4 Producing varying thickness booklets Producing saddle-bound booklets up to 10mm thick Book and sheet integrity checking Three-knife trimming Optional equipment Optional modules which may be supplied with the Smart-binderError! Bookmark not def Ancillary features which may be fitted to the Smart-binder Feeding sheets off-line from a pile feeder... Error! Bookmark not defined SB-095 Direct-connected pile feeder for off-line operation onlyerror! Bookmark not defi SB-096 Pile feeder on the side (+ roller table) for combined off-line and in-line operation... Error! Bookmark not defined Trimmer Centre- Knife (Options CKN-100, 101 and 102)Error! Bookmark not defined Trimmer waste removal... Error! Bookmark not defined Additional Sheet Folding... Error! Bookmark not defined Sheet Folder option F-100 or F Error! Bookmark not defined Sheet rotator and folder option RF Error! Bookmark not defined Lightweight paper stocks... Error! Bookmark not defined Producing books with loop stitches (Option LST-100)Error! Bookmark not defined Producing books with holes (Options HPM-100 and HDM-100)Error! Bookmark not defined Covers and inserts... Error! Bookmark not defined DMP-100 Sheet dynamic micro-perforation option Error! Bookmark not defined BSS-11 book stacker option... Error! Bookmark not defined Spine squaring module Option SM Error! Bookmark not defined Pile Loading Trolley system Option PLT Error! Bookmark not defined Smart-binder Production Rates Sheet infeed rates PB-600S Product and Application Guide rev.00 3

4 Book Production Rates, A4 saddle-bound books from 4-page sheets (with no separately-fed cover) Different Booklet Format sizes... Error! Bookmark not defined. 5 Specifications... Error! Bookmark not defined. 5.1 Smart-binder Specifications Rotator/folder RF100 Specifications:... Error! Bookmark not defined. 5.3 BS11 Stacker specifications... Error! Bookmark not defined. 5.4 SM-100 Spine squarer specifications... Error! Bookmark not defined. 5.5 BB3002 perfect binder specifications (when used as part of the SB-4 system and fed from the SCF-100) CMT-330 trimmer specifications (when used as part of the SB-4 system in-line with the BB3002 binder ) Smart-binder Configurations... Error! Bookmark not defined. 6.1 Example Configurations for common applications. Error! Bookmark not defined In-line configuration - wide or narrow web.. Error! Bookmark not defined In-line configuration - narrow web to make full size bookserror! Bookmark not defined In-line configuration with rotator/ folder to make small size books.error! Bookmark not d In-line / off-line configuration... Error! Bookmark not defined In-line with extra F-100 folder to allow higher web speeds or lighter paper stock... Error! Bookmark not defined In-line with cut-sheet printer... Error! Bookmark not defined Off-line operation from a pile feeder... Error! Bookmark not defined. 6.2 Selecting a configuration (In-line, near-line of off-line)error! Bookmark not defined Running the Smart-binder in-line with a digital printer:error! Bookmark not defined Running the Smart-binder near-line from a pre-printed roll unwinder and cutter... Error! Bookmark not defined Running the Smart-binder off-line from a deep pile sheet feeder:error! Bookmark not d In-line/ off-line configuration (Option SB-096)Error! Bookmark not defined Choosing between an in-line or an off-line Smart-binder systemerror! Bookmark not def 6.3 Selecting upstream modules as part of an in-line system Web Cutters Web Moisturiser Print impositioning schemes... Error! Bookmark not defined. 7.1 Example impositions... Error! Bookmark not defined A4 or 8 ½ x 11 finished format size... Error! Bookmark not defined A5 Portrait or Digest (8½ x 5½ ) without pre- foldingerror! Bookmark not defined A5 landscape (or 8 ½ x 5 ½ oblong) finished sizeerror! Bookmark not defined CD booklets (120mm square) from narrow web or pile feedererror! Bookmark not define A5 Portrait (or 8 ½ x 5 ½ ) finished size... Error! Bookmark not defined A6 Landscape (or 4 ¼ x 5 ½ oblong) finished sizeerror! Bookmark not defined. 7.2 Printing barcodes Bar code locations... Error! Bookmark not defined Format of barcodes... Error! Bookmark not defined Bar codes when using the optional rotator /foldererror! Bookmark not defined Running without barcodes (in off-line mode only)error! Bookmark not defined. 4 PB-600S Product and Application Guide rev.00

5 7.2.5 Reverse order barcodes... Error! Bookmark not defined Job IDs... Error! Bookmark not defined Example of normal scheme 0 bar coding for saddle-bound books.error! Bookmark not 7.3 Image creep due to spine wrap round... Error! Bookmark not defined. 8 Using the Smart-binder Operating the Smart-binder Thickness changes Format changes Stitch Spacing, standard Stitching (not loop stitching).error! Bookmark not defined Using the Cover/Insert Feeder option CIF Working with Paper rolls, or stacks of sheets Changing between wire stitching and ISG cold-gluingerror! Bookmark not defined Using the optional Spine-squaring unit SM-100Error! Bookmark not defined. 8.2 Maintaining the Smart-binder Spare Parts Scheduled Maintenance Consumable parts Planning an installation Installation schedule (SB-1, 2 and 3) Preparing the site Refer to the Smart-binder Installation Questionnaire for full list of all site preparation issues Layout of basic Smart-binder Layout of Off-line version Smart-binder... Error! Bookmark not defined. 9.5 Layout of in-line Smart-binder with SB-096 pile feeder optionerror! Bookmark not defined. 9.6 Layout of in-line Smart-binder SB-4 (layout option A)Error! Bookmark not defined. 9.7 Layout of RF100 rotator/folder option... Error! Bookmark not defined. 9.8 Layout of Optional CMT-330 trimmer Services Electrical power requirement Compressed air supply requirement Air conditioning Radiant heat output Trimmer waste (trim-off) removal systems Connection to upstream/downstream equipment Installation, Commissioning and Training Unloading Machine module weights and sizes (crated) (approximate) Smart-binder Module Weights and Sizes: uncrated (approximate)error! Bookmark not d Size of largest module (stitcher module), excluding packing The Operator Training Course The Smart-binder Maintenance training course Frequently asked questions In-line or off-line operation?... Error! Bookmark not defined In-line and off-line operation?... Error! Bookmark not defined. PB-600S Product and Application Guide rev.00 5

6 10.3 Maximum and minimum book thicknesses... Error! Bookmark not defined System Operating Speeds and Efficiencies... Error! Bookmark not defined Perfect-Bound books... Error! Bookmark not defined Producing small format books in-line with a web printererror! Bookmark not defined Light weight paper stock.... Error! Bookmark not defined Maximum speed.... Error! Bookmark not defined Personalised books... Error! Bookmark not defined Personalised covers (or covers with cut-out windows).error! Bookmark not defined ISG cold glue.... Error! Bookmark not defined Multiple covers and insert-sheets.... Error! Bookmark not defined Perforated sheets.... Error! Bookmark not defined Hole punching and drilling.... Error! Bookmark not defined Loop Stitching.... Error! Bookmark not defined Book Stacking, wrapping and/or banding.... Error! Bookmark not defined Book squaring.... Error! Bookmark not defined Two-up production... Error! Bookmark not defined Minimum book format sizes.... Error! Bookmark not defined Trimmer waste removal.... Error! Bookmark not defined Electrical power supply voltage.... Error! Bookmark not defined Spine corner tearing on thick books.... Error! Bookmark not defined In-line connection to cut-sheet printers.... Error! Bookmark not defined. 11 Appendices Power Distribution Networks (according to UL1950 and EN60950) IBIS SCHEDULED MAINTENANCE PACKAGE (SMP) Frequency of visits Duration of visits SMP Price Scheduling of SMP visits Replacement parts Conversion Charts For Stock Weights Tools and Special Equipment Required for Service and Maintenance Smart-binder (SB) Application Questionnaire for Digital Print Applications PB-600S Product and Application Guide rev.00

7 1 Press release. PERFECT BOUND BOOKS ON-DEMAND IN-LINE WITH DIGITAL PRINTERS The UK manufacturer IBIS Integrated Bindery Systems has launched a family of perfect binding systems which may be used in-line with digital web or cut-sheet printers for the production of high quality, soft-cover Perfect-Bound books up to 60mm thick. Sheet input from Digital printer SSF-100 or SCF-100 feeder BB3002 perfect binder Cover feeder Folder PB-600 system operator controls wire stitcher Perfect Bound book delivery (ready for trimming) The IBIS PB-600 system Smart-binder incorporates the BB3002 perfect binder manufactured by CP Bourg. To adapt this binder to run in-line with digital printers, IBIS has developed two different feeder modules: the SSF-100 and the SCF-100. The SSF-100 (as used on the PB-600S) receives piles of sheets from a sheet stacker (i.e as used in connection with web cutters) and places these sheet piles directly into the BB3002 binder clamp. The SCF-100 (as used on the PB-600C) receives a stream of digitally printed sheets (or folded signatures), collects these sheets/sigs into loose book blocks and places these book blocks into the binder clamp. An optional 3-side book trimmer is available to connect directly to the binder delivery. The PB-600 systems mark the transition into a new era of low-cost perfect binding systems that can be used in-line with Digital Printers. The BB3002 can be supplied with either hot-melt gluing or PUR gluing. All IBIS products may be used in-line with a digital printer or fed off-line from a pre-printed roll or sheet pile feeder. IBIS PB-600S : THE ULTIMATE FINISHING SOLUTION PB-600S Product and Application Guide rev.00 7

8 Perfect Binding only Perfect binder PB-600S 1220 pages/min (or approx 2400 with extra folder) Perfect-binder PB-600C 400 pages/min Model Max book thickness 2 IBIS Perfect Binder Product Range Summary Max Input Speed Max Output speed Binding method (s) Cover feeding Key Features Perfect binding in-line with digital cut-sheet printers 600 books/hour (400 books/hr for optimum quality) Square-back perfect binding only Hot-melt glue or PUR Low pile feeder (incorporated into the perfect binder) Option for up to 6 cover creases Off-line hand feeding position. Optional in-line trimmer for squarebound books Perfect binding in-line with digital web printers Auto-setting Auto-setting Off-line hand feeding position. Optional in-line trimmer for squarebound books 3 PB-600S in-line perfect binder : Main user-features and benefits Range of different system configuration options Can run in-line with a high-speed digital web printer, or off-line/near-line operation from either a pre-printed reel or sheet pile feeder. Variable-length accumulation conveyors available. All in-line connected PB-600 systems may also be used off-line by manually feeding book blocks into the binder clamp, if required, without an modules having to be moved.. May be fitted with in-line (or off-line) 3-side book trimmer : two different types of trimmer are available. High quality finished books The BB3002 includes book block vibration, 3-roller gluing, 2-wheel side gluing and up to 6 cover creases, all for highest possible book quality. On-demand operation The PB-600S can change book thicknesses on-the-run. It can also change book format sizes automatically (simple operator touch screen input of required book dimensions) Performance The PB-600S can run in-line with the highest speed digital web printers. The BB3002 outputs up to 400 books/hour. 8 PB-600S Product and Application Guide rev.00

9 In-line trimmer 4 PB-600S perfect binder system description, specifications, performance and options 4.1 PB-600S Process description For a video and presentation of the PB-600S (with in-line CMT -330 trimmer) go to The PB-600S is used in-line with digital web printers which are fitted with a web cutter and stacker. The web cutter is used to slit and cut the web into the required book size and to output piles of cut sheets: each pile representing one complete book-block. Book-blocks travel horizontally along a Shuttleworth accumulator conveyor and are stopped at the end of this conveyor by a reciprocating gate. The gate releases one book at a time into the SSF-100 sheet set feeder when the SSF-100 is ready to receive a book. The SSF-100 clamps the sheet set, rotates it to vertical and pushes into the BB3002 binder clamp from the side. The BB3002 vibrates the sheets into correct register, clamps the sheets and then moves the sheets through the binding process which includes: sheet edge milling, hot glue application (3-roller tank) side glue wheel application, cover feed with up to 6 creases, cover application and pressing, book delivery into optional stacker, or optional in-line 3-side book trimmer If the SSF or BB3002 stops, then the book stacks accumulate on the accumulator conveyor. This allows the printer to keep running for some time until the accumulator conveyor fills up. When the SSF/BB3002 restarts, then the number of accumulated books on the conveyor is reduced providing the SSF/BB3002 runs faster than the printer. The accumulator conveyor therefore reduces the number of printer stops. Perfect Binder model PB-600S in-line with a high speed web printer : Sheet stacker High speed web printer Shuttleworth accumulator roller conveyor Perfect bound book delivery Web cutter (typically Hunkeler or Lasermax) BB3002 SSF -100 Reciprocating gate 4.2 Optional book trimmer : either CMT or FS trimmer Perfect binder (with hot melt glue or PUR) PB-600S Product and Application Guide rev.00 9

10 4.3 PB-600S picture SSF-100 feeder Binder clamp (may be loaded by Spine hand) milling Hot glue applicator tank Cover application BB3002 perfect binder Sheet stack input from Digital printer and web cutter/stacker Cover feeder and cover creasing (can add up to 6 crease lines) PB-600S system operator controls Perfect Bound book delivery (ready for trimming) 4.4 Optional in-line trimmer An optional 3-side book trimmer may be provided to run in-with the BB3002 binder delivery, or off-line (hand fed). Two different trimmer options are available (CMT-130, or FST) each of which are designed for on-demand book finishing. 10 PB-600S Product and Application Guide rev.00

11 In-line version CMT -130 (Book trimmer option 1) EASY VIEWING WINDOWS Optional vertical stacker (trimmed book output) Untrimmed book input direct from BB3002 binder delivery Cooling elevator The CMT 130 finishes soft-cover, perfect bound books at a rate of up to 500 books per hour by trimming piles of 1, 2 or 3 books at a time (number of books in the pile depends on book thickness).. note max recommended throughput of BB3002 binder is 400 books/hour. The in-line version shown above connects directly to the BB3002 binder outlet, and includes a multi-stage book cooling elevator to allow time for the hot-melt glue to cool before trimming. The CMT-130 has a maximum book thickness limit of 51mm (2 ) Book format size changes and thickness changes may be made automatically (optional bar code detection available for auto changes). The optional vertical stacker allows up to 24 / 609 cm of books to be delivered PB-600S Product and Application Guide rev.00 11

12 In-line version Fast-set trimmer (Book trimmer option 2) Shown with optional book cooler transfer The Fast-set trimmer finishes soft-cover, perfect bound books at a rate of up to 700 cycles per hour (700 books/hr if trimming 1-up, 1400 books/hr if trimming 2-up, 2100 books/hr if trimming 3-up). The in-line version shown above connects directly to the BB3002 binder outlet, and includes a multi-stage book cooling conveyor (with 20 book-stop positions) to allow time for the hot-melt glue to cool before trimming. The Fast-set has a maximum book thickness limit of 60mm (2.36 ). Book format size changes and thickness changes may be made automatically. Power supply needed : 400V 3 phase, + neutral 6A, 50/60 cycles 1,25 kw. Compressed air supply needed : 8 bar. Cover is pressed around the book 4.5 Paper flow diagram Cover feeder 12 Hot melt glue applied Finished perfectbound (ready for trimming) Signatures clamped together in BB3002 binder and spine folds milled off. Sheet sets received by SSF-100 module and rotated to PB-600S Product and Application Guide Sheets stacked into book piles and ejected. Sheets pressed together Sheet stacks travel along roller accumulator conveyor ISG cold gluing inside sheet (on Stacks are stopped by gate fold and line) released into SSF as needed. Sheets slit into 2 (or 3) Sheets smaller collected Web cut into sheets together sheets Sheets into Score, delivered signatures fold and Score and fold sheets rev.00 Sheet stream input

13 4.6 Binder process description The BB3002 binder uses two glue applicator rollers and a reverse spinner roller to accurately control the glue layer. Side rollers are also fitted to apply glue to each side of the book, close to the book- spine. Spine preparation (milling) is done using a multitipped rotating saw. Signatures or sheets Optional wing- fold available Cover sheet Side glue Layer of hot-melt glue Side glue Spine crease Hinge crease The BB3002 cover feeder applies multiple crease lines to each cover to assist it to bend around the book and to open easily (including optional gate-fold or wing-fold creasing). A creasing-knife is used, instead of scoring wheels, that reduces cracking of colour toner printed covers. Signatures or sheets may be loaded into the clamp by hand if not wishing to use the SCF (signature collector and feeder), or SSF (sheet set feeder). 4.7 Producing varying thickness booklets Book thicknesses (number of pages in the book) may be changed without stopping the line. The SSF measures the book thickness and provides a signal to the BB3002 to adjust automatically to this thickness. The maximum throughput rate of the system is reduced if continually changing book thickness 4.8 Book and Cover integrity checking The PB-600S relies on only good book piles being delivered by the web cutter/stacker. In this case any bad book piles must be detected by the stacker and pushed out in a different direction (reject lane) An optional bar code checking system is available for the cover feeder to ensure that personalised covers match the book block to which each cover is being applied. PB-600S Product and Application Guide rev.00 13

14 Item no. 4.9 Optional equipment Optional modules which may be supplied with the PB-600S 14 Part no. 1 SAC SAC CMT- 130-OL 4 CMT- 130-IL 5 FST FST TWC TDC TFR PUR CMS- 100 Description Function For more info see section. Shuttleworth accumulator conveyor with timing gate Length 2 metres (6.56ft) Additional 2 metre (6.56ft) length of Shuttleworth accumulator conveyor (without timing gate) CMT130 3-side trimmer (hand fed) CMT130 3-side trimmer (in-line connected with book cooling elevator. Includes delivery stacker) Fast-set trimmer in-line connected without 20- station book cooling conveyor Fast-set trimmer in-line connected with 20-station book cooling conveyor Trimmer waste removal system for Fast-set trimmer Trimmer delivery conveyor Voltage transformer for PB-600S main power supply PUR (polyurethane reactive glue) option for BB3002 binder Cover matching system for BB3002 binder PB-600S Product and Application Guide Allows books to accumulate in between the stacker and SSF/BB3002 (so printer does not need to stop immediately the SSF/BB3002 stops). May be used to increase accumulation capacity. Use for final 3-side trim of perfect bound books up to 51mm thick (offline: hand fed) Use for final 3-side trim of perfect bound books up to 51mm thick (inline connected: no hand feed needed) Use for final 3-side trim of perfect bound books up to 55mm thick (inline connected: no hand feed needed). Select this option if book is cool enough for trimming when it enters the trimmer Use for final 3-side trim of perfect bound books up to 55mm thick (inline connected: no hand feed needed). Select this option if book needs additional cooling time before trimming. Used to remove trimmed-off paper if no pneumatic waste extraction system is available. Extra length trimmer delivery conveyor (for use with FST trimmers) For use when the factory supply voltage is outside the range (e.g. for installations outside Europe) Select this option if PUR gluer preferred to normal EVA glue Select this option if applying personalised book covers (with bar coded I/D number on covers and rev.00

15 12 CMS SPK SPK SPK SKK SKK- 106 System to automatically control CMT trimmer size change Essential PB-600S spare parts kit Basic PB-600S Spare Parts Kit Extended PB-600S Spare parts kit Spare set of trimmer front and side knives for CMT- 130 Spare set of trimmer front and side knives for FST- 100 sheets. Select this option if wishing to autoadjust the CMT130 trimmer based on bar coded book size information on each book. Includes all parts that must be held close to the machine to support normal operation. Refer to IBIS for spare parts relating to optional modules. Includes all parts recommended to be held close to the machine. Refer to IBIS for spare parts relating to optional modules. Includes all parts recommended to be held by distributors in each country when the installed base exceeds 3 units. Refer to IBIS for spare parts relating to optional modules It is recommended to hold two spare sets of knives for each machine (one ready to fit and one being reground). It is recommended to hold two spare sets of knives for each machine (one ready to fit and one being reground) PB-600S performance Sheet infeed rates Production in-line with a Digital printer, or near line from a pre-printed roll. When running in-line with a digital web printer (or pre-printed roll), the sheet arrival rate depends on web velocity and sheet cut-off dimension. The maximum web speed is dictated by the type of printer and in-line web cutter/stacker which is used. It is also dictated by the number of sheets in the book since the rate of thin book production cannot exceed wither the eject cycle rate of the web cutter of the maximum book production rate of the BB302 binder (approx 400 books/hour) PB-600S Product and Application Guide rev.00 15

16 Maximum printer web speeds When using the in-line connected PB-600S system then the maximum printer web speed is linked to the number of sheets in the book and the maximum binding speed which is 6.66 books/min (assuming that rate that maximum rate the stacker can eject book piles exceeds 6.66 books/min) The following table shows maximum printer speeds for different book thicknesses, assuming 6 x 9 pages, printed with the 6 dimension 3- across the web. Number of 2-page sheets in book (excluding separately-fed cover) Number Number of 6 x 9 pages in book (excluding separately-fed cover) Maximum Printer web speed (feet /min) Assuming 600 ft/min is the printer maximum Maximum Printer web speed (metres /min) Assuming 183 ft/min is the printer maximum Book output rate (books/min) Notes on book production rates The web cutter/stacker must have an eject cycle rate of at least 2.22 cycles /min. Each eject delivers 3 book stacks assuming the 6 x 9 pages are printed 3-across the web. A web buffer must be used between the printer and the web cutter to allow the stacker to go through its eject cycle without stopping the printer. 16 PB-600S Product and Application Guide rev.00

17 Actual running is never continuous. On a CF web system, time is needed to change paper rolls periodically, and there are stops due to printers and the web cutter/stacker. The BB3002 system needs to be stopped periodically for cover loading and glue tank filling. When book size changes, time is needed to adjust the system for the new size. These stops must be taken into account when estimating production capacity The following table shows maximum printer speeds for different book thicknesses, assuming 8 1/2 x 11 pages, printed with the 8 ½ dimension 2-across the web. Number of 2-page sheets in book (excluding separately-fed cover) Number Number of 8 ½ x 11 pages in book (excluding separately-fed cover) Maximum Printer web speed (feet /min) Assuming 600 ft/min is the printer maximum Maximum Printer web speed (metres /min) Assuming 183 m/min is the printer maximum Book output rate (books /min) Notes on book production rates The web cutter/stacker must have an eject cycle rate of at least 3.33 cycles /min. Each eject delivers 2 book stacks assuming the 8 ½ x 11 pages are printed 2- across the web. A web buffer must be used between the printer and the web cutter to allow the stacker to go through its eject cycle without stopping the printer. PB-600S Product and Application Guide rev.00 17

18 Actual running is never continuous. On a CF web system, time is needed to change paper rolls periodically, and there are stops due to printers and the web cutter/stacker. The BB3002 system needs to be stopped periodically for cover loading and glue tank filling. When book size changes, time is needed to adjust the system for the new size. These stops must be taken into account when estimating production capacity PB-600S Specifications Speed Maximum speed (books/hour) 600 (400 recommended for optimum book bind quality) Note : higher speeds are possible without cover scoring.(but nor recommended for book quality reasons) Sheet Sizes (untrimmed) as presented to the PB-600S Sheet Input Size Leading edge (long edge) Side edge (short edge) Maximum 320mm (12.6 ) 230mm (9.1 ) Minimum 200mm (7.9 ) 110mm (4.3 ) Refer to IBIS is sizes are required outside the above range. The size of sheets being fed into the PB-600S should not vary by more than 0.5mm (0.020 ) during running, unless changing jobs. Cover Sizes (for BB3002 binder) Cover input size Leading edge (short edge) Side edge (long edge) Maximum 395mm 710mm Minimum 100mm 200mm The BB3002 binder can accept a cover size which may be outside the max/min range of the SSF. The cover may overlap the front edge of the book after it is applied. This overlap may be removed by the trimmer front knife, providing this is within the specification of the trimmer. Finished Book Sizes (after trimming) a) Using CMT-130 trimmer Description Spine length Spine to Fore-edge book width Maximum 304.8mm (12 ) 228.6mm (9 ) Minimum 148mm (5.82 ) 101.6mm (4 ) 18 PB-600S Product and Application Guide rev.00

19 a) Using FST trimmer Description Spine length Spine to Fore-edge book width Maximum 305mm (12 ) 229 mm (9 ) Minimum 150mm (5.9 ) 105mm (4.1 ) Trim off A) Using CMT-130 trimmer Maximum Minimum Front trim Side trim *Note: A trim off between 0 and 3mm (1/8 ) is not recommended. A) Using FST trimmer Maximum Minimum Front trim 140mm (5.5 ) 2.5mm (0.1 ) Side trim 2.5mm (0.1 ) *Note: A trim off between 0 and 2.5mm (0.1 ) is not recommended. Book Thickness Using CMT-330 trimmer Using Fast-Set trimmer Maximum 50.8mm (2 ) 60mm (2.4 ) Minimum Limited by bind quality: approx 2mm Limited by bind quality: approx 2mm Paper Weight Specification Description Paper stock weight Cover stock weight Maximum Minimum 160gsm / 108 lbs offset / 43 lbs bond 50 gsm / 34 lbs offset/ 13 lbs bond * 300gsm 111lbs/500 sheets (20 x 26 ) 80gsm 30 lbs/500 sheets (20 x 26 ) PB-600S Product and Application Guide rev.00 19

20 * Note: refer to IBIS if wanting to run stock weight lower than 50 gsm Note that web printer and web cutter/stacker must also be able to handle selected stock weights Glue specification Description Glue type Application. BB3002 Hot-melt glue EVA hot melt (refer to IBS for recommended specification) Layer approx 0.5 mm thick on signature spines + thinner layer on book sides BB3002 perfect binder specifications (book format sizes assume use without SSF connected.. i.e. hand- fed operation) Maximum throughput rate : 400 books/hour (exact speed depends on book thickness and book quality requirements) Just insert the book block and the BB3002 will take care of the binding, no setting required. The Bourg Binder BB3002 is the most efficient perfect binder available in the industry for cut sheet and signatures. A unique design based on total automation and touch screen controls results in a user friendly system. Books up to 60 mm thick are processed immediately. A set up time reduced to a benchmark figure ensures a productivity of up to 600 cycles/hour. The 3-cylinder glue tank equipped with a side gluing device and the scoring unit make the BB3002 the ideal binder to produce not only state of the art perfect bound books but also winged books of durable professional quality. No tools are required for any of the operator adjustments. See also BB3002 PUR with vertical book stacker and Nordson Polyurethane reactive application 20 PB-600S Product and Application Guide rev.00

21 Advantages Totally automated binder. Full Color touch sensitive screen. 3-cylinder glue tank. Side gluing device. Powerful milling wheel with slitting. On-line cover creasing. Up to 13 positive or negative creases. Winged books can be made. Binds from 1 mm to 60 mm to Specifications COVER SIZE MAX 710 mm x 395 mm - 28 x 15.6 MIN 200 mm x 100 mm - 8 x 4 COVER WEIGHT gsm - 20 lb Bond 110 lb Index TEMPERATURE MAX GLUING TEMPERATURE 180 C F MIN GLUING TEMPERATURE 115 C F SENSITIVITY ± 2 C - 4 F BBR STACKING CAPACITY 680 mm 26.4 RECEPTION SIZE MAX 385 mm x 320 mm x 12.6 MIN 100 mm x 100 mm X 3.9 CYCLES/HR Up to 500 NOISE LEVEL 76dB (A) at operator position ELECTRICAL RATINGS Power required - 208/220 V, 60Hz, 3 phases delta,12 A - 220/230 or 240 V, 50 Hz, 3 phases delta 12A - 380/400 or 415 V, 50 Hz, 3 phases star, no neutral needed, 12 A Power consumption 4 Kw RADIANT HEAT BTU/h PB-600S Product and Application Guide rev.00 21

22 4.13 CMT-130 trimmer specifications S p e c i f i c a t i o n s Minimum Book Size: Maximum Book Size: Maximum Book Thickness: Maximum Trim - Top: Maximum Trim - Bottom: Maximum Trim - Face Minimum Trim - All Sides: Speed Memory: Set-up Time for Book Size Change: 4" x 6" / mm x mm 9.5" x 13" / 241 mm x 330 mm 2" / 51 mm 6.0" / 152 mm 3.5" / 89 mm 5.5" / 140 mm 0.100" / 2.5 mm Up to 200 books per hour (single book) Up to 500 books per hour (multi-book) 99 Book Jobs Approximately 10 Seconds DIMENSIONS Overall Height Overall Width Overall Length Net Weight (approximate) Shipping Weight (approximate) 60" / 1524 mm 52" / 1321 mm 57" / 1448 mm 1500 lbs / 680 kg 1800 lbs / 816 kg ELECTRICAL 3 Phase, 60 Hz, AC 208/230 Volts, 25 Amps (service size 40 Amps) COMPRESSED AIR REQUIREMENTS The CMT-130 requires PSI regulated, dry, non-lubricated compressed air at a minimum of 5 cubic feet per minute (at PSI). The required minimum air quality rating is ISO Class (solids < 1 micron, pressure dew point < 38 and oil content <.08 ppm) The following 2 compressor systems are commonly used with the CMT-130. Other equivalent systems may be used also. The compressor system must include an air dryer capable of ISO Class 4 or better (pressure dew point < 38 Failure to use dry, non-lubricated compressed air that meets or exceeds the above requirements may cause damage to the machine and will result in THE WARRANTY BEING VOIDED. System 1 - Traditional piston type compressor. Powerex AS hp climate control compressor with built-in refrigerated dryer, electronic auto drain and starter. System 2 - Rotary scroll type compressor. The advantage to this type is minimum maintenance and very quiet operation (49-51db) Powerex SES v with ACO factory installed refrigerated dryer and auto drain. Available from Air Technologies. Phone: or 22 PB-600S Product and Application Guide rev.00

23 Note: An optional control system CMS-101 is available to automatically control CMT-130 book size changes based on bar coded data on each book FST 60/700 Three-knife Trimmer Specifications The 60/700 Three-knife Trimmer is capable of matching a digital printer's make-ready speed, flexibility and productivity. Specifically designed for book on demand print production, the 60/700 three knife trimmer operates with equal efficiency inline or offline. Control technology, all-round performance and functional efficiency are state of the art. Changing the trim size is fully automatic and takes only 5-10 seconds when the data matrix barcode reader is deployed. Standard, regularly produced book sizes can be stored in the Fastset s memory. High Quality Finished Product Wilstead Digital Finishing fully appreciates that our customers require a finished product of the highest quality. The 60/700 Three-knife Trimmer achieves this in two ways. Firstly, by carefully controlled book block handling throughout the trimming process, so as to preserve the spine quality of the finished book. Secondly and unlike some other three-knife trimmers, by trimming the book square to the spine. We believe that the trimming accuracy and quality of finished product achieved by the Fastset 60/700 Three-knife Trimmer is in a class of its own. Key features Maximum book thickness: 60mm Minimum book size 150mm x 105mm x 2mm thick Maximum book size 234mm x 156mm (9.21" x 6.14") x 60mm thick 297mm x 210mm (11.7" x 8.27") x 50mm thick 305mm x 229mm (12" x 9") x 20mm thick Cycles per hour: 700 Typical output: 2,700 books per hour when trimming multiple book blocks. Hydraulic cutting and clamping to ensure precise and clean trimming quality. Automated transfer of books from perfect binder and insertion into Fastset Dryer/Feeder, ensuring full inline operation. Automatic trim size change in as little as 5 sec's with data matrix barcode reader. Ethernet/serial link to users IT system for the reporting of production information. Compatible with all popular single and multi-clamp, PUR and hot melt perfect binding machines including those manufactured by Tecnograf, Jud Ecamo, Horizon, CP Bourg, The adjacent photographs show the Fastset 60/700 Three- PB-600S Product and Application Guide rev.00 23

24 knife Trimmer operating inline with the following binders, Horizon BQ-470, CP Bourg BB3002 and Jud Ecamo Quadrimax 4.15 Selecting upstream modules as part of an in-line system (when the Smart-binder is running in-line with web printers or near-line from preprinted roll) Web Cutters Cut-sheet length The web cutter must give accurate sheet cut length, even when the system is accelerating or decelerating on system start-up or stop. Any inaccuracy in cut sheet length will be apparent in the finished book when checking the distance of the print to the trimmed edge. If there is any possibility that the cutter may produce incorrect length sheets (for example on system start and stop) then the cutter should be fitted with an automatic sheet reject gate. This reject gate may also be useful to reject a certain number of sheets every time the system starts up if there is a risk that these sheets may be unacceptably curled due to tensioner rollers in the cutter or festoon web buffer (see also paragraph below on sheet rejection) Rejection of bad books The cutter must reject any sheets which are not correctly printed and it must then automatically reject the pile (by pushing it in a different direction) instead of delivering this sheet pile to the PB-600S system. This is essential to ensure that only good book piles enter the PB-600S. Refer to IBIS if the PB-600S Shuttle-worth conveyor system needs to be fitted with an automatic pile reject capability Stacker eject rate The stacker eject cycle rate must be considered to ensure that this does not restrict the planned maximum book production rate. If printing 2-across the web then the stacker eject rate can be half the maximum planned book production rate. If printing 3-across the web then the stacker eject rate can be half the maximum planned book production rate Stack quality The stacker must give sheet register (within each pile) to within 0.5mm (.02 ) in order to ensure good register of the print to the edge of the finished book Web buffers A web accumulator (festoon buffer) is needed between the printers and the cutter to allow the printer to continue running while a stack is being ejected from the stacker. When this is the case, the cutter may be set to run faster when there is more than a preset amount of paper in the buffer. The buffer should be kept empty (i.e.: with the minimum amount of paper in it) and the cutter maximum speed set very close to the actual printer web speed. Stopping the line with excess paper in a web buffer (under 24 PB-600S Product and Application Guide rev.00

25 tension) introduces curl into the paper in the buffer which can give problems with sheet handling in the stacker and PB-600S Anti-static equipment for web cutters Web cutters should be fitted with anti-static bars to, as far as possible, assist stacking and eliminate static charge on the sheets delivered to the PB-600S. This is particularly important when running with lightweight paper Different types of Web Cutters The following web cutters are recommended for use with the PB-600S. Hunkeler, Lasermaxroll, Tecnau, Bowe, Kern, Iram, Ehret Web Moisturiser. Web moisturisers (such as the Weko Rfdi) are sometimes used in digital print lines to help control web humidity (affecting curl, paper handling and expansion / contraction after adhesive binding). It is not usually needed for PB-600S operation, but can sometimes help reduce static generation as the paper passes along the line. It can be helpful when running lightweight papers. The moisturiser unit can sometimes offer some assistance in helping to run very difficult lightweight paper stock by adding a small amount of silicon oil to the moisturising water Printing barcodes The PB-600S does not require sheets to be printed with bar codes, and is not fitted with any bar code readers as standard, unless the optional cover matching system is selected (see 4.16). However, bar codes or print marks are needed on the web to enable the web cutter to function and to ensure that the web cutter ejects each pile to be a correct and complete set of sheets representing complete books. Refer to the web cutter manufacture for information on required bar codes Optional Cover matching system CMS-100 An optional cover matching system CMS-100 is available, This system will automatically stop the PB-600S binder if the cover bar coded I/D number does not match the I/D number on the inside sheets. Refer to IBIS for more details. PB-600S Product and Application Guide rev.00 25

26 5 Using the PB-600S system 5.1 Operating the PB-600S Thickness changes Changes in book thickness (number of pages) may be made automatically by the web cuter/stacker (under bar code control) and the PB-600S will process changes in book thickness without stops or pauses. For large changes in book thickness it may be necessary to stop the PB-600S system to change cover sizes. However note that a certain amount of cover overlap is acceptable (and can be removed by the trimmer front knife) when varying book thickness Cover Cover overlap Thick book Thin book (showing cover overlap, if cover size is not reduced) Book format size changes Small book format size changes can be made by simply and quickly varying the amount of trim off (using the CMT or FST trimmer) Large changes in book format sizes require the printer to be stopped so that changes can be made to each part of the system Cover creasing The BB3002 can be adjusted to provide up to 6 cover creases. Four creases and normally used in order to provide a square back to the book and (in conjunction with the BB3002 side glue facility) to provide a hinge point to easily open the cover. The 5 th or 6 th crease may be used to provide a wing-folded flap (requires manual folding after binding). Gate fold crease #5 Gate fold crease #6 Signatures or sheets Side glue Optional wing- fold available Cover sheet Side glue 26 Hinge crease #4 Hinge crease #1 Spine crease #3 Spine crease #2 PB-600S Product and Application Guide rev.00

27 Covers should be flat and should be stored covered or wrapped in the same environment as the PB-600S (temperature and humidity). Covers with damaged or curled edges will not feed reliably Working with Paper rolls, or stacks of sheets Paper rolls (reels) should be stored carefully, in the environment in which they will be used and sealed in plastic film prior to use, to ensure that they are in optimum condition for use. The outside part of any new reel should be discarded before use to avoid damaged or dirty paper going through the line. Toner should be properly fused to all digitally printed sheets. If not it will transfer from the paper onto parts of the PB-600S and cause book marking. If toner does transfer to PB-600S guides or belts, clean them using a cloth soaked in alcohol, or soap and water. 5.2 Maintaining the PB-600S Spare Parts Trimmer knives Spares Kits Spare parts kits are available in either Essential, Basic or Extended forms: Essential Spare Parts Kits Essential spare parts kit Additional Essential Spare Parts for PB-600S optional modules Basic Spare Parts Kits Basic spare parts kit Additional Essential Spare Parts for PB-600S optional modules Extended Spare Parts Kits Extended Spare Parts kit Extended Spare Parts for PB-600S optional modules The Essential spare parts kits contain components that are likely to be needed during normal operation. The Basic spare parts kit contains additional components that might be damaged in the event of a severe jam or parts to repair other general machine malfunctions. It is recommended that this kit is held at sites where time -critical jobs are being run. PB-600S Product and Application Guide rev.00 27

28 An Extended spare parts kit contains components that can fail but are not commonly required. This kit is primarily intended for re-sellers who are offering a maintenance service, but may also be justified to be held at any site with several PB-600S systems Scheduled Maintenance Scheduled maintenance kits are available as required. These contain parts that are needed to carry out the scheduled maintenance programme for the PB-600S system. It is recommended that all PB-600S scheduled maintenance is carried out by IBIS or CP Bourg according to the Scheduled Maintenance Programme Consumables Glue The PB-600S is supplied with a small quantity of EVA glue, sufficient for the initial machine commissioning and test period. Refer to IBIS for recommended glue to be used in the BB3002 binder. Only the correct (IBIS -specified) glue is used to avoid glue application problems. Based on a normal glue film thickness of 0.5mm, the PB-600S uses 3cc (cubic centimetres) of EVA hot- melt glue to make one 300mm long book which is 20mm thick. Glue usage for other book sizes and volumes may be calculated using this information Trimmer knives The knives require sharpening at intervals depending on machine usage. Sharpening is best carried out by a local specialist. Knives must only be changed or adjusted by a trained technician. IBIS (or CP Bourg for the CMT trimmer) will provide this training as part of PB-600S service engineer maintenance training course. We recommend that at least two extra sets of trimmer upper knife blades are purchased in addition to the set supplied with the machine. This allows for one set to be in use on the machine, one set to be away for regrinding and one set ready to install if the knives in use are damaged. Additional lower knife sticks are also recommended to be held in stock. One spare set of knives is included in the basic spares kits; additional sets can be purchased from IBIS (or CP Bourg for the CMT trimmer). 28 PB-600S Product and Application Guide rev.00

29 6 Planning an installation When planning installation and commissioning, allow 2 days to install the PB-600S and 5 days for system commissioning and operator training, prior to the start of live production. This assumes that the PB-600S is being added to an existing web printer and web cutter/stacker which is already installed and operational. 6.1 Installation schedule Day Activity 1 Unpacking, checking shipment and moving into position 2 Assembling PB-600S modules, connecting power and compressed air 3-4 Commissioning: requires printed work and covers available from day Operator training and pre-production tests In particular connection of power (day 2), the availability of printed work (day 3) and the availability of trainees (days 5-7) are critical to meeting this schedule. 6.2 Preparing the site Refer to the PB-600S Installation Questionnaire for full list of all site preparation issues Access: Ensure that there is sufficient space to manoeuvre the largest PB-600S module into the final position (see for module dimensions). This is particularly important where this unit must pass through doorways. Floor: The machine should be sited on a substantial floor, which is level over the total area of the machine to within 10mm (3/8 ). The floor must be able to withstand the loads applied by the PB-600S without damage or movement. Space around the machine: Allow adequate space for: All the doors and guards to be fully opened. Operators to move freely in the working areas around the binder and trimmer. Access to all sides of the machine for maintenance. Emptying the trimmer waste collection bin, if a vacuum waste removal system is not used. Electrical voltage transformer The following layouts show space requirements for the PB-600S system. PB-600S Product and Application Guide rev.00 29

30 6.3 Layouts of PB-600S Plan of in-line PB-600S perfect binding system (with optional CMT-130 trimmer): Perfect bound book delivery stacker Sheet stacker Sheets from in-line high speed web printer In-line CMT-130 book trimmer Book cooling elevator Shuttleworth accumulator roller conveyor Cover feeder 990mm Gate 2000mm (variable) Web cutter (typically Hunkeler or Lasermax) 1350 mm BB3002 perfect binder SSF mm Approx 2700mm 2540mm Plan of in-line PB-600S perfect binding system (with optional FST trimmer): Perfect bound book delivery xxxxmm FST Trimmer Sheet stacker Sheets from in-line high speed web printer Book cooling conveyor (20 vertical pockets) Cover feeder 2000mm (variable) Web cutter (typically Hunkeler or Lasermax) Shuttleworth accumulator roller conveyor Gate 1350 mm BB3002 perfect binder SSF mm 2540mm 30 PB-600S Product and Application Guide rev.00

31 Detailed layout of Optional CMT-130 trimmer 6.4 Services Electrical power requirement European voltage range: 3-phase volt input supply For PB-600S excluding trimmer Volts, 3 phase and earth, 50Hz, xxx Amps Additional supply for CMT-130 trimmer Volts, 3 phase and earth, 50Hz, xx Amps Additional supply for FST trimmer Volts, 3 phase and earth, 50Hz, xx Amps USA 3-phase volt input supply For PB-600S excluding trimmer Volts, 3 phase and earth, 60Hz, xxx Amps Additional supply for CMT-130 trimmer Volts, 3 phase and earth, 60Hz, xx Amps Additional supply for FST trimmer Volts, 3 phase and earth, 60Hz, xx Amps PB-600S Product and Application Guide rev.00 31

32 Consult IBIS if input voltage is not listed above Consult IBIS for power requirement of other optional modules. Residual current devices (RCD) and Ground Fault Interrupters (GFI) must not be fitted to the power supply as leakage currents from the PB-600S could cause nuisance trips Compressed air supply requirement The PB-600S requires a high pressure (filtered) air supply for the Shuttleworth conveyor stop gate: This must be a regulated between 4 and 5 bar pressure (60 77 psi). This uses a negligible volume of air. If the optional CMT-330 book trimmer is selected then this requires 198 litres/min (7 cfm) air supply at minimum 5.8 bar (90 psi) If the optional FST book trimmer is selected then this requires xxxlitres/min (xx cfm) at 8.0bar (120 psi) air supply Air conditioning The environment should be controlled to reduce variability in the behaviour of the paper. This will result in more consistent, reliable operation. Maintain relative humidity within the range 40-60% and temperature between 18 and 25ºC (64 and 77ºF) Radiant heat output Heat output from the BB3002 binder is BTU/hour Trimmer waste (trim-off) removal systems If the end-user has a centralised vacuum extraction systems for waste paper, then this service can be used to remove waste paper from the PB-600S trimmer. Consult IBIS for routing and dimensions of ducts. Alternatively, the trimmer (CMT or FST) can be supplied with its own Waste removal system. 6.5 Interface to upstream web stacker The infeed height above the factory floor of the Shuttleworth conveyor is 850mm. The exit height of the web stacker must therefore also be 850mm. 6.6 Installation, Commissioning and Training Unloading - All PB-600S modules will be delivered on wooden pallets, and either covered or crated, depending on the method of shipment. See below for dimensions and weights of these crates. 32 PB-600S Product and Application Guide rev.00

33 - A Fork Lift Truck, capable of lifting 2.5 Tons (2500kg/5500lb) is required for lifting the modules off the pallets. - See for the dimensions of the largest unit. Ensure that doors, etc. are large enough for this module Machine module weights and sizes (crated) (approximate) The basic in-line PB-600S is delivered in 4 separate sections (Note: if exact weights and dimensions are needed then information should be obtained from IBIS at the time the machine is shipped) Module Description Size (L x W x H) Weight 1 Shuttle worth conveyor 1m 2 Shuttle worth conveyor 1m Cm Inches Kg lb 100 x 60 x x 60 x 85 3 SSF x 54 x BB3002 binder 200 xxx xxxx CMT-330 trimmer Module Description Size (L x W x H) Weight CMT-130 trimmer Cm Inches Kg lb 1 CMT 130 trimmer 214 x 88 x xxx 2 Cooling elevator FST trimmer Module Description Size (L x W x H) Weight FST trimmer Cm Inches Kg lb 1 Infeed cooling conveyor 2 FST trimmer 3 Optional waste extraction PB-600S Product and Application Guide rev.00 33

34 6.6.3 Size of largest modules, excluding packing. 2050mm 1448mm xxxmm BB3002 binder xxxmm CMT-130 trimmer 1321mm FST trimmer Note: all new installation sites should be checked to ensure that there is room to move these modules into position The Operator Training Course Machine operators who have previous experience of Perfect binders will learn to operate the new PB-600S system more quickly than operators without this experience. Knowledge of operating hot glue application, trimming knives and all issues relating to perfect bound book quality will be of particular value in operating the PB-600S. The training program is divided into four sessions. Each session lasts approximately four hours. It is recommended that the course be spread over a xxxx day period A. Introduction Session A.1. Introduction to IBIS and the PB-600S system. A.2. Distribution of Operator manuals. A.3. Introduction to Safety issues in general. B. The PB-600S System B.1. B.2. B.3. B.4. B.5. B.6. B.7. Identification of all elements of the PB-600S system. Glossary of terms used in operating the machine. Overview of general operation of the PB-600S system. Review of Safety Issues related to actual machine operation. How to start/stop the system. Running demonstration of the PB-600S in operation. Review important factors relating to the presentation of sheets from the upstream equipment. C. Make-ready adjustments C.1. C.2. C.3. Review safety issues relating to PB-600S operation. 34 PB-600S Product and Application Guide rev.00

35 C.4. C.5. C.6. C.7. C.8. C.9. C.10. C.11. F. Operator maintenance F.1. Review safety issues. F.2. Carry out trimmer knife adjustment to produce good quality trim. F.3. Lubrication F.4. F.5. F.6. Cleaning sensors. G. Fault Finding and resolution G.1. G.2. G.3. Review possible book quality problems, causes and rectification. Review possible paper jam conditions, causes, and prevention and jam clearance. Review fault messages on touch screen. H. Review of PB-600S System operation H.1. H.2. H.3. H.4. H.5. Review all machine adjustments needed to control finished book quality. Run the complete system with a range of different book thicknesses and sizes. Demonstrate that commercially acceptable book quality can be achieved. Demonstrate that the operator trainees have been adequately trained and are capable of operating the ystem in a live production situation (run a typical job, at an adequate quality and efficiency). Issue training certificates to operator trainees. PB-600S Product and Application Guide rev.00 35

36 Power PB-600S maintenance training course A Service-Engineer maintenance training course (3 Days) is available for the BB-3002 binder and CMT trimmer 7 Frequently asked questions 8 Appendices 8.1 Power Distribution Networks (according to UL1950 and EN60950) 1. TN POWER SYSTEM: A power distribution system having one point directly earthed, the exposed conductive parts of the installation being directly connected to that point by protective earth conductors. Three types of TN POWER SYSTEM are recognized according to the arrangement of neutral and protective earth conductors, as follows: i. TN-S system: having separate neutral and protective earth conductors throughout the system; ii. TN-C-S system: in which neutral and protective functions are combined in a single conductor as part of the system; iii. TN-C system: in which neutral and protective functions are combined in a single conductor throughout the system; 2. TT POWER SYSTEM: A power distribution system having one point directly earthed, the exposed conductive parts of the installation being connected to earth electrodes electrically independent of the earth electrodes of the power system. L1 L2 L3 N Power system earth Exposed conductive parts Protective Earth 3. IT POWER SYSTEM: A power distribution system having no direct connection to earth the exposed conductive parts of the installation being earthed. 36 L1 L2 L3 N PB-600S Product and Application Guide rev.00 Impedance

37 8.2 IBIS SCHEDULED MAINTENANCE PACKAGE (SMP) We are pleased to announce that IBIS is now offering a new Scheduled Maintenance Program (SMP) for all IBIS products. This SMP is based upon scheduled visits by IBIS to the end-customer site. Why use us to help look after your IBIS equipment? Our aim is that your IBIS system will always provide the best possible performance and finished book quality. During each scheduled visit we will firstly replace all parts which are recommended to be changed at specified intervals as part of Preventative Maintenance (PM). Doing this prevents unscheduled machine down-time at a later date. At the same time our experienced IBIS technicians will check the machine over generally to see whether any other parts need replacing or adjusting. During each visit we will inform you about the latest performance upgrades, discuss with the machine operators any specific issues they have and provide advice and assistance in these areas. The SMP package includes all scheduled visits, software upgrades and all PM parts. Scope of the IBIS SMP program During each SMP visit the IBIS technician will: Replace all parts which should be changed at regular time intervals (Smart-binder preventative maintenance). Check over the machine generally, ensure everything is correctly set up and adjusted and identify whether any other parts need replacement. Install any software upgrades in order to keep the Smart-binder up-to-date and discuss the availability of possible hardware upgrades. Ensure that the machine is performing correctly and meeting the customer s requirements. Provide additional help that may be required by the machine operators. Discuss any additional requirements that the customer may have. PB-600S Product and Application Guide rev.00 37

38 8.2.1 Frequency of visits It is recommended that an IBIS technician visits each PB-600S system every 3, 4 or 6 months. This choice of visit frequencies is offered to suit different customer needs Duration of visits The standard SMP pricing assumes a normal duration of 2 days for the 3,000 hr, 6000 hr and 9,000 hr visits, with some additional days added on for the 12,000 hr visit (for fitment of the extra preventative maintenance parts needed) SMP Price The SMP pricing assumes an annual payment made in advance at the start of each year. The SMP cost is higher for some years compared with others (due to the different parts needed to be fitted at different intervals), but for simplicity the price is averaged over the 4 year period commencing at the time of new machine installation. This annual price includes all travel costs, technician s time and replacement parts (preventative maintenance) for the standard in-line PB-600S system (not including any extra optional modules). Worn or damaged parts which are not part of the normal maintenance kit (see Appendix A attached) are not included. If additional parts are needed to be fitted during the SMP visit then these must be ordered in advance. The SMP pricing assumes a machine usage up to about 3,000 hours a year. Prices may vary slightly if usage is significantly higher than this, or if the machine includes extra optional modules. Always refer to IBIS to confirm exact SMP price at the start of each SMP year. The SMP price for machines installed outside the Europe, USA or Canada is higher because of additional travel costs and time. Refer to IBIS for a price quote Scheduling of SMP visits SMP visit dates must be agreed between IBIS and the customer at least one month in advance. If this visit date is changed by the customer within one month of the scheduled visit date then we will attempt to accommodate this change, where possible. However, any extra costs relating to re-scheduling may be charged to the customer Replacement parts Components will be changed as part of IBIS s published preventative maintenance schedule. The maintenance parts list may be modified by IBIS based on additional field feedback in future. The parts required for each SMP visit (for pre-planned replacement) will be sent by IBIS, at IBIS s expense, to be on the customer s site before the arrival of the IBIS technician (or parts will be hand carried by the IBIS technician). 38 PB-600S Product and Application Guide rev.00

39 8.3 Conversion Charts For Stock Weights BOND lb/500 sheets 17 X 22 BOOK OR OFFSET lb/500 sheets 25 X 38 COVER lb/500 sheets 20 X 26 METRIC Grams/metre 2 (gsm) Stock weight as a function of the number of pages in the finished book gsm Stock Weight Pounds Offset Pounds Bond 40mm thick book Approximate number of pages 20mm thick book 10mm thick book Number of pages excludes outside covers. High volume (low density) paper stock will give a thicker book. PB-600S Product and Application Guide rev.00 39

40 8.4 Tools and Special Equipment Required for Service and Maintenance Routine Service and Maintenance Operations: Allen Keys - 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10mm ball ended Combination (ring and open ended) spanners - 6, 7, 8, 10, 13, 16, 17, 19, 24 A/F hexagon Adjustable spanner, about 200mm, 8 long Plastic faced hammer Side cutters (small, flush cutting) Screwdrivers Very small flat bladed (about 2mm, 5 / 64 tip) Small flat bladed (about 3mm, ⅛ tip, parallel shank) Medium flat bladed (about 5mm, 3 / 16 tip) Very large flat bladed (about 12mm, ½ tip) Small Philips (number 1) Medium Philips (number 2) Craft knife and blades Fine nose pliers Normal pliers (medium) Circlip pliers (inside and outside) Steel rule (300mm/12 ) Tape measure (3m, 10 ) Torch Inspection mirror Emery paper (medium, fine and very fine) Fine files (square, flat, round and half round, about 200mm, 8 long) Electrical Fault Finding and Repairs: Multi-meter Wire strippers Small soldering iron and solder Software or Control System Problems: PC keyboard and mouse (with USB or PS2 type connectors) USB memory key (64MB or larger) The following equipment is only needed for certain rare fault conditions: It is not needed for routine maintenance or rectifying any common faults. Laptop PC with CD drive, serial port and network adapter USB 2 Cable, Standard USB A to USB B connectors. Special cable to connect PC serial port to Siemens servo drives (plus Siemens servo drive software which is supplied with machine) Crossover network cable to connect laptop to PC (RJ45 connectors, cat. 5 UTP cable) 40 PB-600S Product and Application Guide rev.00

41 8.5 PB-600S Application Questionnaire for Digital Print Applications. This Questionnaire may be used to help determine suitability and specification of PB- 600S for a digital print finishing application. 1. Will the PB-600S be running in-line with a digital printer? If so, what type of printer and what type of web cutter/stacker will be used? What will be the maximum printer web speed and the maximum rate at which book locks are ejected from the web cutter into the PB-600S system? 2. If running in-line with a web printer, then what is the width of the paper web (or max sheet width) to be used, and how many pages will be printed across the web? 3. What type of books/booklets need to be produced by the PB-600S? Provide as much information as possible. 4. What is the maximum, minimum and average format size of the book blocks that will be fed into the PB-600S and the required finished book sizes. How often will the machine need to be changed to a different format size? 5. What is the range of paper stock weights to be used (max/min)? 6. What is the maximum, minimum and average number of pages in the required finished books? What is the expected maximum book thickness? How frequently will the book thickness change? 7. Will jobs with different page-count books be run sequentially, without system stop? If so, then what are the expected maximum, minimum and average print job runlengths? 8. What will be the range of cover stock weights to be fed? Will these be digitally or offset printed? Is there anything unusual about the covers (cut-out windows, gatefolds etc)? 9. Is the binder to use EVA (hot melt glue) or PUR glue? 10. Is the factory temperature and humidity controlled? 11. What are the customer s productivity expectations regarding number of books (of stated average thickness) to be produced in a stated time period? 12. Is the trimmer to be fitted with its own waste removal system, or will the trimmer waste be removed by the customer s own vacuum extract system? PB-600S Product and Application Guide rev.00 41

42 13. Is the binder cover matching system needed? 14. Is the automatic trimmer format size set up system needed? 15. Are any other optional modules needed 42 PB-600S Product and Application Guide rev.00

43 NOTES PB-600S Product and Application Guide rev.00 43

44 NOTES 44 PB-600S Product and Application Guide rev.00

45 Produced by: IBIS Integrated Bindery Systems Ltd., 9 The Gateway Centre, Cressex Business Park, High Wycombe, Buckinghamshire, UK. HP12 3SU Tel +44 (0) Fax +44 (0) mail@ibis-bindery.com Web: Copyright IBIS Integrated Bindery Systems Ltd PB-600S Product and Application Guide rev.00 45