This document provides maintenance instructions for the MR720 PUR binding machine. It includes sections on operating the digital touchscreen and main functions of the machine, including setting end stop positions, adjusting the nipping station, feeding covers, and setting glue and binding parameters. Safety precautions are noted regarding keeping guards closed to prevent injury while the machine is operating.
This document provides maintenance instructions for the MR720 PUR binding machine. It includes sections on operating the digital touchscreen and main functions of the machine, including setting end stop positions, adjusting the nipping station, feeding covers, and setting glue and binding parameters. Safety precautions are noted regarding keeping guards closed to prevent injury while the machine is operating.
This document provides maintenance instructions for the MR720 PUR binding machine. It includes sections on operating the digital touchscreen and main functions of the machine, including setting end stop positions, adjusting the nipping station, feeding covers, and setting glue and binding parameters. Safety precautions are noted regarding keeping guards closed to prevent injury while the machine is operating.
This document provides maintenance instructions for the MR720 PUR binding machine. It includes sections on operating the digital touchscreen and main functions of the machine, including setting end stop positions, adjusting the nipping station, feeding covers, and setting glue and binding parameters. Safety precautions are noted regarding keeping guards closed to prevent injury while the machine is operating.
JUD ECAMO SARL au capital de 401 420 Le 20/07/2007
CONSTRUCTEUR DE MATERIEL ARTS GRAPHIQUES
Services Administratif et Commercial- 22 rue de la Roquette 75011 PARIS tel 01 47 00 85 95 fax 01 47 00 11 58 E-mail : jud@judecamo.com Site :www.judecamo.com BNP Paris Turenne n 21922849-RCS Lyon B317640902-SIREN 317 640 902 000 43- code TVA FR 53317640902- Code APE 295L SIEGE SOCIAL ET USINE : 19 Av Karl MARX -69120 VAULX EN VELIN- Tel 04 72 97 03 03- Fax 04 72 97 03 09 1/70 MR720 PUR Maintenance Manual Ntm.D.MR720 PUR.05.06.001 Le 20/07/2007 2/70 Index of modifications 1 Cration 02/05/2006 ER 2 Traduction 29/05/2006 GO 3 Mise jour MB 12/2006 ER 4 Traduction 12/2006 GO 5 Modif. Page 34/ Clamp initialization procedure 07/2007 GO Le 20/07/2007 3/70 Table of contents 1. General overview Page 7 2. Digital Touchscreen Page 8 3. Starting the machine Page 9 3.1 Main menu functions Page 10 4. Machine functions and settings Page 11 4.1 Switching on the binder Page 11 4.2 Opening the nozzle Page 11 4.3 Purging the hose and nozzle Page 11 4.4 Setting the end stop positions Page 13 4.4.1. Side gluing end stop position Page 15 4.4.2. Nipping end stop position Page 15 4.4.3. Scoring end stop Page 16 4.4.4. Cover feeder end stop Page 16 4.5. Setting the clamp Page 17 4.6. Setting the cover feeder Page 18 4.7. Setting the scoring depth Page 19 4.8. Setting the nipping station Page 20 4.8.1. Adjusting the nipping height Page 23 4.9. Feeding a cover Page 23 4.10. Setting the rotation time of the cover intake roller Page 24 4.11. Controll of the photocell on the nipping station Page 25 4.12. Setting the glue drying/ clamping time Page 25 4.13. Switching on the mill and the jogger Page 26 4.14. Jogger setting Page 27 4.15. Setting the gluing parameters Page 27 4.16. Setting the clamp speed Page 28 4.17. Checking the glue layer Page 28 4.18. Setting the mill Page 29 4.19. Auto binding mode Page 30 4.20. Setting the auto cycle start delay Page 31 5. Setting the time and date Page 32 6. Resetting the copy counter Page 33 Le 20/07/2007 4/70 7. Clamp Page 33 7.1. Initializing the measuring device on the clamp Page 34 8. Replacing parts on the mill Page 35 8.1. Changing a notching tooth Page 35 8.2. Changing the milling plate Page 36 8.3. Changing the mill Page 38 9. PUR Slot nozzle Page 40 9.1. Glue pressure regulation Page 40 9.2. Adjusting the nozzle height Page 41 9.3. Purging the glue application system Page 41 9.3.1. Purging the glue hose Page 41 9.3.2. Purging the slot nozzle Page 42 10. Initial end stop positions Page 43 10.1. Initial position of the nipping end stop Page 44 10.2. Initial position of the scoring wheel Page 45 10.3. Initial position of the cover feeder end stop Page 47 10.4. Zero position slot nozzle Page 48 11. Inertia compensation Page 50 11.1. Clamp inertia Page 51 11.2. Compensation the glue stop inertia Page 53 12. End stop limits Page 56 13. Changing the language and measurement parameters Page 57 14. Controlling the input/ output functions Page 58 14.1. Input functions Page 59 14.2. Output functions Page 61 15. Specifications Page 62 16. Connections Page 63 17. Required environment Page 64 18. Factory settings Page 65 18.1. Mill factory settings Page 65 18.2. Factory setting nozzle height Page 66 18.3. Factory setting nipping jaws Page 66 Le 20/07/2007 5/70 18.4. Factory setting scoring wheel Page 68 19. Pneumatic rack Page 68 20. Troubleshooting Page 69 21. Maintenance Page 70 21.1 Daily maintenance Page 70 21.2. Weekly maintenance Page 70 Le 20/07/2007 6/70 SAFETY ADVISAL ! The MR 720 complies to the CE safety regulations and grants full operator safety. DO NOT UNDER ANY CIRCUMSTANCE WHATSOEVER short-circuit, unplug or bridge the guard closing sensors to prevent major injury. Le 20/07/2007 7/70 1. General Overview Clamp Main switch Nipping station Slot nozzle Touchscreen Cover feeder Exit slide Mill Handwheel Le 20/07/2007 8/70 2. Digital Touchscreen The MR 720 features a digital control panel. If a key is highlighted, the corresponding function is enabled. E-Stop Start Button Touchscreen Screen switch Le 20/07/2007 9/70 3. Starting the machine Make sure the machine is supplied with compressed air. The pressure must be of 6 bar at least. Switch on the Durapail bulk melter. (see Nordsons operations manual) Turn the main power switch to On (see chapter 1). Switch on the control panel by turning the screen switch (See chapter 2). The following screen appears: The unit is operational once the bulk melter, the hose and the nozzle reached operating temperature. (see Nordson operation manual) Le 20/07/2007 10/70 3.1. Main Menu functions Clamp speed Lowest speed - reccomended when binding thick blocks Medim speed - reccomended when binding blocks of medium thickness High speed reccomended when binding thin blocks Mill control Book/ Blockbinding switch Cover feeder control Manual cover feeder key Jogger control Auto binding mode Current date/ Access date setting menu Current time/ Access time setting menu Access timing menu (Glue drying/ Clamping/ Auto cycle start delay/ Roller rotation time) Counter reset Access end stop position setting menu Access glue parameter/ purge menu Set glue drying/ nipping time End stop positions As soon as the end stops reached their target position (and the cycle can be launched) the circle will highlight. Le 20/07/2007 11/70 4. Machine functions and settings 4.1. Switch on the binder (see chapter 3) and the bulk melter. (see Nordsons operations manual) 4.2. Open the nozzle as much as possible by turning the hand wheel. Clean the nozzle of eventual grease remains. ATTENTION: GREASE AND CLOSE THE NOZZLE WHENEVER THE MACHINE IS NOT BEING USED. THE GLUE REMAINING IN THE NOZZLE MAY NEVER CURE. 4.3. Purging the hose and nozzle Hang the purge basin on the purge valve (see Nordson operations manual) Open the purge valve and wait until the basin is filled with glue. Tighten the screw and let the glue cool down/ cure in the basin. BE CAUTIOUS AS THE NOZZLE IS HOT. To purge the nozzle select: Purge valve on hose Le 20/07/2007 12/70 Manually open the nozzle by turning the hand wheel. Position the purge tank above the slot nozzle and close the side gluing blocks again. Make sure the purge receptacle is tightly held in place and that it sits correctly on the nozzle. Touch the Purge key until the purge tank is filled with glue. Manually open the slot nozzle by turning the hand wheel again and remove the purge tank. Do not leave the purge menu until the purge tank has been removed from the nozzle. After each manual slot nozzle opening/ closing, the side gluing end stop initializes automatically. If it doesnt, select: Le 20/07/2007 13/70 4.4. Setting the end stop positions Le 20/07/2007 14/70 The current end stop positions figure in the left column. To change those settings, select the value name to be changed in the right column. A keyboard will then appear on the touchscreen. Current end stop position To enter the new target position To individually initialize the end stop To enable/ disable the measuring device on the clamp. In case the auto function is on, the side gluing and scoring end stops automatically calibrate according to the thickness of the bookblock. To initialize all end stops. To confirm a new setting Digital Keyboard The Feeder and Nipping end stop positions always have to be identical. A new target position has to be confirmed by selecting , so the binder calibrates to the set position. To return to the main menu Le 20/07/2007 15/70 4.4.1. Side gluing end stop position The value name to be set in the Side gluing menu box corresponds to the thickness of the book block. The binder performs this setting automatically if the auto mode is on. 4.4.2. Nipping end stop position The value name to be set in the Nipping menu box corresponds to the distance between the border of the cover an the first bent of the spine. Motorized nozzle block Motorized cover positioning bar on nipping station Le 20/07/2007 16/70 4.4.3. Scoring end stop The value name to be set in the scoring menu box corresponds to the thickness of the document to be bound. The scoring distance is almost identical to the distance between the side gluing blocks. When running in auto mode, the binder performs this setting automatically. 4.4.4. Cover feeder end stop The nipping and feeder value names are always identical. (distance from the border of the cover to the first bent of the bookspine) End stop to position the cover stack Motorized scoring wheel Le 20/07/2007 17/70 4.5. Setting the clamp A measuring device installed on the clamp determines the book block thickness and calibrates the scoring wheel and the nozzle opening accordingly if the auto scoring function is active. Setscrew limiting the clamp opening Le 20/07/2007 18/70 Select if you want the scoring and side gluing end stops to calibrate automatically (recommended for producing single copies). If you whish to bind larger series of the same format, it is recommended to run the machine in manu mode. Set the according side gluing and scoring value names. When running in auto mode, the cover is loaded on the nipping station once the side gluing and scoring end stops moved to the appropriate position. 4.6. Setting the cover feeder Position the cover stock against the cover end stop finger once it moved to the appropriate position. Make sure the rear side of the cover stock is properly positioned against the cover stock end stops in front of the blower. (see following page) Position the loadstones and the side guides against the cover stock to ensure the covers are accurately transferred. Adjust the position of the suckers to the width of the cover stock. (eventually enable 3 or 5 suckers by turning the according switch see picture on following page) Never position the suckers in front of the cover forwarding wheels though, as this would obstruct the movement of the cover forwarding bar. The cover end stop finger must form an angle of 90 towards the cover stock end stops. Ensure this is the case by transferring a cover on the nipping station: Switch on the cover feeder by selecting in the main menu then activate twice the key. The scoring lines must run parallel to the the border of the cover. If they dont fine tune the position of the cover stack by turning the setscrews. (see on following picture) Loadstones to fix to fix the cover stack End stop finger for positioning the cover stack Sideguides Suckers Screws fixing the suckers on the cover forwarding bar Cover intake wheels Screw limiting the downward movement of the cover feeder arm. Le 20/07/2007 19/70 4.7. Setting the scoring depth The scoring depth has been preset. To obtain proper scoring results, lower the caliper lever and place a cover sample below the pressure adjustment wheel. The pressure can be fine tuned by loosening the nut and then by turning the wheel. Setscrews to fine tune the position of the cover stack Progressive cover intake Suction control Blower control Switch to enable either 3 or 5 suckers Rear end stops Caliper lever Pressure regulation wheel Nut Blower outlet Le 20/07/2007 20/70 4.8. Setting the nipping station To set the nipping station : Move the motorized nipping bar to the appropriate position (See chapter 4.4.2 and 4.4.4.) Prior to setting the front cover positioning bar, the nipping jaws must be raised. To this effect go: Rear cover positioning blocks. Prior to fixing these, ensure the cover forwarding fingers are up. . Motorized cover positioning bar Nipping plates Flap Cover forwarding bars Le 20/07/2007 21/70 The pneumatic cover positioner will activate. Lay the cover against the cover forwarding bars and the motorized cover positioning bar. The cover forwarding bars must be up and positioned at the nipping jaws. If they arent, ensure the cover feeder is on ( key in the main menu) and select the key. A cover will then be loaded on the nipping station. Loosen the fixing handle and position the front cover bar against the border of the cover. Mind the cover lies flat on the nipping station and that it is not bent. Then position the rear cover blocks against the rear side of the cover. Lower the nipping jaws again by selecting: Le 20/07/2007 22/70 The cover forwarding bars must run parallel to the motorized nipping bar. If they dont, loosen the screws holding the cover forwarding bars with an Allen wrench, move them to the correct position, and tighten the screws again. If the cover is not forwarded far enough (or too far) on the nipping station, the book block will not be aligned to the upper side of the cover. In this case adjust the stroke length of the cover forwarding bars. To this effect loosen the nut of the setscrew located in the exit slide as shown in above picture. Tighten the setscrew to move the cover further to the right, loosen Cover forwarding finger Set screw to adjust the stroke length of the the forwar- ding fingers Le 20/07/2007 23/70 the setscrew to move the cover further to the left. Once the appropriate position has been found, tighten the nut on the set screw. 4.8.1 Adjusting the nipping height Square spine. Round spine: Increase the nipping height by turning the thumbscrews anti-clockwise in steps of 90. Crushed spine: The nipping plates exert too much pressure. Lower the tables by turning cloclwise by 90. 4.9. Feeding a cover The covers are forwarded automatically into the nipping station when running the machine in standard mode. However it is also possible to load the cover manually, either by pushing the manual cover feeder button on the nipping station or by selecting the function on the main menu. (see chapter 4.6) Always ensure though the cover feeder is on. Setscrews to adjust the nipping height Le 20/07/2007 24/70 Check the cover position on the nipping station and eventually rectifiy. 4.10. Setting the rotation time of the cover intake roller To streamline the machine cycle it is possible to adjust the cycling time of the roller on the cover feeder. In fact, once the roller finished rotating, the cover forwarding fingers come up to push the cover on the nipping station. For covers with a short spine the roller cycling time can be reduced. Le 20/07/2007 25/70 Enter the rotation time and confirm the setting by selecting Enter. 4.11. Control of the photocell on the nipping station It is also possible to operate the binder in bookbinding mode even if the photocell on the nipping station is not covered. The operator has then though to check before every cycle that a cover is effectively present on the nipping station. 4.12. Setting the glue drying/ clamping time Le 20/07/2007 26/70 Select the setting you whish to change and enter the desired timing by means of the digital keyboard that will appear. Confirm your settings by selecting Enter. Timeframe during which the block and cover are being nipped. Glue drying time when binding blocks To return to the main menu 4.13. Switiching on the mill and the jogger Le 20/07/2007 27/70 4.14. Jogger setting The book blocks are being jogged before the milling 4.15. Setting the glue parameters Jogging intensity control Jogger Le 20/07/2007 28/70 To set the glue length on the spine To set the glue stop on top of the spine Enter the according value name and select to return to the main menu. 4.16. Setting the clamp speed Three clamp speeds are available. Lowest speed reccommended for binding thick documents Medium speed reccommended for binding documents of medium thickness High speed reccommended for binding thin documents 4.17. Checking the glue layer Ensure the and functions are off. Load the clamp, activate the foot pedal to close the clamp and push the yellow cycle start button. As the nipping table is not active, the document is only jogged, milled and glued. The document will be released on the exit slide once the set glue drying time elapsed. Check the quality of the glue layer and rectify if needed. Le 20/07/2007 29/70 4.18. Setting the mill By milling the document, the spine surface is being evened and prepared for the gluing. The notching teeth allow the glue to penetrate deeper into the paper fibers, thus ensuring increased bondage. ATTENTION: NEVER TRY TO MANUALLY OPEN THE FLAP OVER THE MILL Cycle start button Clamp Mill Milling plate Flap Notching teeth Le 20/07/2007 30/70 4.19. Auto binding mode Reset the copy counter in a first place. Then go into the end stop menu and enable the Manual mode. Knob to adjust the milling depth Le 20/07/2007 31/70 Return to the main menu. Enable the mill, the nipping station and the auto cycle mode. Once the operator passes his hand in front of the photocells on the loading station, the auto cycle start delay countdown begins. Once the set time elapsed, the clamp will close and the machine begins to cycle. Load the first cover manually by selecting the according key in the main menu. 4.20. Setting the auto cycle start delay Le 20/07/2007 32/70 Enter the desired cycle start delay by means of the digital keyboard and confirm the settings by selecting Enter. Once the photocells on the loading station have been cleared, the binder will wait for the set delay prior to starting the cycle automatically. 5. Setting the time and date Enter the weekday, day, month and year. Confirm your settings by selecting Enter. Return to the main menu to set the time. Set the time and confirm your settings by selecting Enter. Return to the main menu. Le 20/07/2007 33/70 6. Resetting the copy counter Select to reset the copy counter. 7. Clamp Setscrew limiting the clamp opening Le 20/07/2007 34/70 7.1. Initializing the measuring device on the clamp The access code is 9 9 9 9 9 9 9 9 confirm the settings by selecting Enter. Le 20/07/2007 35/70 Open the clamp as much as possible and determine the exact distance between the clamp and the carrier plate. Select and insert the determined value. Then close the clamp by activating the foot pedal and select ; open the clamp by releasing the foot pedal and select . A value name appears on the lower part of the screen. This value must be identical to the one appearing on . Return to the main menu by selecting . 8. Replacing parts on the mill 8.1. Changing a notching tooth STRICTLY RESPECT THE FOLLOWING PROCEDURE TO PREVENT SEVERE INJURY ENSURE THE GUARD ABOVE THE MILL IS CLOSED AND THAT NO OBJECTS LIE ON THE FLAP PROTECTING THE MILL . Turn the screw on the VF distributor by 90 (clockwise). The flap over the mill opens up. Open this guard Le 20/07/2007 36/70 B) PUSH THE E-STOP BUTTON ONLY NOW YOU MAY LIFT THE GUARD OVER THE MILL. Replace the notching tooth/ teeth. Ensure they are correctly oriented and tightened. Lift the tooth/ teeth until it/ they graze(s) the milling plate. Turn the mill manually by placing an Allen wrench in the screw fixing the mill. The notching tooth/ teeth will leave an imprint in the milling plate. Eventually adjust the height of the remaining notching teeth. Make sure all notching teeth are securely tightened. Close the flap over the mill again by turning the screw on the VF distributor anticlockwise, only then the E-Stop button may be unlocked. (see chapter 19) Check the notching height by binding a block (see chapter 4.17) and eventually adjust if needed. 8.2. Changing the milling plate Notching tooth Setscrew to adjust the notching height Loosen the screw to the side of the mill to extract the notching tooth. Open this guard Le 20/07/2007 37/70 STRICTLY RESPECT THE FOLLOWING PROCEDURE TO PREVENT SEVERE INJURY! ENSURE THE GUARD ABOVE THE MILL IS CLOSED AND THAT NO OBJECTS LIE ON THE FLAP PROTECTING THE MILL . PUSH THE E STOP BUTTON ONLY NOW THE GUARD OVER THE MILL MAY BE LIFTED. Turn the screw on the VF distributor by 90 (clockwise). The flap over the mill opens up. Le 20/07/2007 38/70 Lower the notching teeth (see chapter 8.1.). Position the new milling plate. Manually displace the carriage clamp over the milling station and align the milling plate to the inner side of the carriage. Return the carriage clamp to its home position. Raise one notching tooth so it grazes the milling plate. Place an Allen wrench in the screw fixing the mill. Let the mill rotate manually by turning the Allen wrench and gently tighten the screws fixing the milling plate. This will leave an imprint of the notching teeth on the milling plate. The milling plate is a wear and tear part and requires occasional replacement. Always ensure the plate is in contact with the notching teeth so the spine is held in place during the milling/ notching process. Once the milling plate has been replaced, close the flap over the mill again by turning the screw on the VF distributor anticlockwise, only then you may unlock the E-Stop button. (see chapter 19) 8.3. Changing the mill STRICTLY RESPECT THE FOLLOWING PROCEDURE TO PREVENT SEVERE INJURY! ENSURE THE GUARD ABOVE THE MILL IS CLOSED AND THAT NO OBJECTS LIE ON THE FLAP PROTECTING THE MILL . Milling plate Screw fixing the mill Open this guard Le 20/07/2007 39/70 B) PUSH THE E STOP ONLY NOW THE FLAP OVER THE MILL MAY BE OPENED. Screw fixing the mill Milling plate Notching tooth Setscrew to adjust the notching height Turn the screw on the VF distributor by 90 (clockwise). The flap over the mill opens up. Le 20/07/2007 40/70 In the first place determine the height of the notching teeth by means of a sliding gauge. Then uninstall the milling plate and the mill. Put aside the notching teeth as well as the setscrews that adjust the notching height. Whenever a mill replacement occurs, the milling plate must be changed as well. Install the mill and the notching teeth. Set the notching teeth at the same height than they were before. Fix the new milling plate as explained in the previous chapter. Test the notching/ milling and eventually adjust the notching height if required. Dont forget to tighten the notching teeth again. Once the required pieces have been replaced, close the flap over the mill again by turning the screw on the VF distributor anticlockwise, only then you may unlock the E-Stop button. (see chapter 19) 9. PUR Slot nozzle 9.1. Glue pressure regulation Increase/ decrease the glue pressure according to the cycling speed and the thickness of the book block. Pressure gauge Le 20/07/2007 41/70 9.2. Adjusting the nozzle height By turning the knob the nozzle can be raised or lowered. (see chapter 18.2.) 9.3. Purging the glue application system It is crucial to continually purge the system of eventual air remains. Purge the system whenever the machine has not been used over a longer stretch of time in order to ensure consistent glue viscosity. The glue remaining in the nozzle must never cure. 9.3.1.Purging the glue hose Hang the basin on the purge screw and loosen the screw. (See Nordson instruction manual). Wait until the basin is filled with glue and close the purge screw again. Wait until the basin cooled before taking it away. BE CAUTIOUS AS THE NOZZLE IS HOT. Knob to adjust the nozzle height Le 20/07/2007 42/70 9.3.2. Purging the slot nozzle Select: Purge screw Le 20/07/2007 43/70 Manually open the nozzle. Position the purge receptacle on the nozzle and close the nozzle again. Ensure the purge tank tightly sits on the nozzle. Touch the Purge key until the purge receptacle is filled with glue. Open the slot nozzle by turning the hand wheel again and remove the purge receptacle.Do not leave this menu until the purge receptacle has been removed from the nozzle. 10. Initial End stop positions A recap of these values is featured with every machine. The zero positions are defined through a contact. In the following the zero positions of the end stops can be determined and fine tuned. The access code is 1 2 3 4 5 6 7 8 , confirm by selecting Enter. Distance A Distanz C Distance C Le 20/07/2007 44/70 To switch between the screens To return to the main menu In a first place initialize the end stops by selecting , then measure the following distances: 10.1. Initial position of the nipping end stop Load a cover on the nipping station and bind a book. Measure the distance between the cover border and the first bent of the spine. If the determined distance doesnt correspond to the value name shown on the screen (for example determined value 188 mm and value name shown on screen 190 mm) go : Distance B Distance A : distance between the inner side of the carriage clamp and the inner side of the nipping bar. Distance D Le 20/07/2007 45/70 Select , once done select the Max opening menu box. Rectify the positions accordingly. (in above example zero position 2 mm). Confirm your settings by selecting Enter. Initialize the end stop again by selecting then and check the setting is now correct. Fine tune if necessary. 10.2. Initial position of the scoring wheel Value B : Distance between the grooves of the scoring wheels Fix scoring wheel Le 20/07/2007 46/70 The female groove of the lower (static) scoring wheel must be aligned to the inner side of the carriage clamp. (to the operators side) If it isnt, loosen the screws fixing the upper and lower scoring wheels and move them to the appropriate position. Then determine Value B as shown. The distance must correspond to the thickness of the book block. If it doesnt, refer to chapter 7.1. (Initializing the clamp.) If though the determined value corresponds to the thickness of the book block, but not to the value name shown on the screen (for instance scoring value name shown on screen 5 mm and book block thickness 4.5 mm) go: The access code is 1 2 3 4 5 6 7 8 , confirm by selecting Enter. Le 20/07/2007 47/70 Select , once the scoring wheel reached its initial position select Zero and rectify the zero value accordingly. (in above example zero position 0,5 mm). Confirm the settings by selecting Enter. Initialize the end stop again by selecting then . Check the settings are now correct and rectify if needed. 10.3. Initial position of the cover feeder end stop If the determined distance between the border of the cover and the scoring line does not correspond to the value name shown on the screen (for instance shown value name on screen 210 mm and determined distance 211 mm) go: Value C : Distance between the cover end stop finger and the marking on the cover feeder. The marking is aligned to the inner side of the carriage clamp, the edge of the rear niping jaw, and the and the female groove of the fix scoring wheel Le 20/07/2007 48/70 The access code is 1 2 3 4 5 6 7 8 , confirm by selecting Enter. Select . Once the end stop moved to its initial position select Max Opening. Rectify the value of the zero position accordingly. (In above example zero position +1 mm). Confirm the settings by selecting Enter. Initialize the end stop again by selecting , then and check if the setting is now correct. Fine tune if necessary. 10.4. Zero position slot nozzle Value D : Distance between the side gluing blocks Le 20/07/2007 49/70 The access code is 1 2 3 4 5 6 7 8 , confirm by selecting Enter. Select . Once the end stop moved to its initial position select Zero. Enter the determined value. Initialize the end stop again by selecting , then . For the time being the side gluning value is approximate. To fine tune switch the binder to padding mode and bind a block (see chapter 4.17) of the same thickness than the value name shown on the Le 20/07/2007 50/70 screen. If the front side gluing block applies a glue layer of approximately 0.3 mm thickness, the end stops are positioned correctly. If the glue layer is too thin, the set side gluing value name needs to be increased. If, on the other hand, there is glue on the spine but the book block is compressed and the front sheet is crumpled, the set side gluing value name must be decreased. 11. Inertia compensation A recap of these parameters is featured with every machine. By compensating the inertia, the binder displaces its braking ramp by the set value. This allows the binder to calibrate as closely as possible to the set end stop position. The inertia compensation is only required for the nipping and feeder end stops. The side gluing and scoring end stops are driven by brushless motors which operate with a precision to 1/100 th of a mm. The access code is 12345678 confirm by selecting Enter. Le 20/07/2007 51/70 If for example the target position of the nipping end stop is 210 mm and the according value name shown on the screen is of 210.3 mm, the inertia must be corrected by 0.3mm (The value name to be set is 210.3 0,3= 210 mm) Check the settings are correct and fine tune if necessary. 11.1. Clamp inertia The clamp transfer inertia parameters vary according to the set clamp speed. These parameters can be set to ensure the clamp always stops at the correct position when reaching the nipping station. (The clamp inertia parameters can be set for low and medium clamp speed only, the high clamp speed being the original factory setting.) Inertia nipping end stop drive Inertia cover feeder end stop drive Le 20/07/2007 52/70 The access code is 9 9 9 9 9 9 9 9 confirm the setting by selecting Enter. Clamp inertia at low speed Clamp inertia at medium speed Clamp inertia at high speed Le 20/07/2007 53/70 To return to the main menu To switch between the menues 11.2 Compensating the glue application inertia The distance photocell to nozzle and the glue application inertia values vary according to the set clamp speed. In order to achieve an accurate glue cut off at the end of the spine, the glue is sucked back into the nozzle once the end of the bypassing book block approaches. The timing at which the glue suction shall occur can be adjusted. (=Glue Application Inertia) The exact distance between the photocell and the nozzle is being determined through approximation. In a first place, set the glue stop to zero (see chapter 4.15), then measure the distance between the photocell and the nozzle. Set a value name which is actually bigger than the distance you actually determined. (for instance distance photocell to nozzle + 20 mm) Prepare several bookblocks with identical spine length. Set a value name in the glue application length menu box which is inferior to the actual spine length. (for instance bookspine length 40 mm). This ensures the glue is only being applied on the spine. (see also chapter 4.15) Distance photocell to nozzle Glue stop Inertia No glue application Glue application Le 20/07/2007 54/70 Bind several blocks and progressively reduce the photocell to nozzle distance value name until the glue application starts exactly on the top edge of the bookspine. Repeat the operation with the various clamp speeds. Measure the glue application length on the spine and compare with the value name shown on the screen. (see chapter 4.15) The difference between the determined values corresponds to the glue application inertia. Repeat the procedure with the various clamp speeds and enter the determined value names as shown on the following screenshots: No glue application Glue application Glue application length Distance photocell to nozzle Moving book block Le 20/07/2007 55/70 The access code is 9 9 9 9 9 9 9 9 confirm by selecting Enter. Glue stop inertia Distance Photocell nozzle at low speed Glue stop inertia Distance cell to nozzle at high speed Glue stop inertia Distance photocell nozzle at medium speed Le 20/07/2007 56/70 12. End stop limits A recap of these values is featured with every machine. The end stop limit defines the maximum and minimum limits between which the end stops may move. The access code is 12345678 confirm by selecting Enter. Le 20/07/2007 57/70 To enter the maximum opening To enter the minimum opening To return to the main menu 13. Changing the language and measurement parameters To change the language and measurement parameters: Le 20/07/2007 58/70 The access code is 9 9 9 9 9 9 9 9 confirm by selecting Enter. To switch from mm to inch. To switch the language parameters from english to french 14. Input/ Output function control Le 20/07/2007 59/70 The access code is 9 9 9 9 9 9 9 9 confirm by selecting Enter. 14.1. Input function control In this menu the operative status of the various machine parts can be tested. If for instance the foot pedal is activated, the according menu box will highlight. Select to get to the output function control menu.. Select To return to the main menu 0.00 Initial position side gluing 0.01 Side gluing end stop limit 0.02 Initial position scoring 0.03 Scoring end stop limit 0.04 0.05 0.06 Encoderinformation A cover feeder end stop 0.07 Encoderinformation B cover feeder end stop Le 20/07/2007 60/70 0.08 Encoderinformation A nipping end stop 0.09 Encoderinformation B nipping end stop 0.10 0.11 Encoderinformation B PUR 01.00 PUR nozzle control 01.01 Cover feeder end stop limit 01.02 Nipping end stop limit 01.03 Reserved counting/ interruption 01.04 Impulse side gluing end stop drive 01.05 Impulse scoring wheel end stop drive 01.06 01.07 Progressive cover feeding 01.08 01.09 Machine on 01.10 Cam on cover feeder 01.11 02.00 Detection clamp on loading station 02.01 Detection clamp on nipping station 02.02 Photocell exit slide 02.03 Photocell on loading station 02.04 Cover detection 02.05 Guard closing sensor 02.06 Foot pedal 02.07 Cycle start button 02.08 Low limit side gluing end stop 02.09 02.10 02.11 03.01 03.02 03.03 03.04 High limit side gluing end stop 03.05 03.06 03.07 03.08 03.09 03.10 03.11 Le 20/07/2007 61/70 14.2. Output function control The various output functions can be checked in this menu. Select the according menu box to chek a component is operative. To check for instance the suction pump select the 103.04 key. The pump will work for the time the key is being touched. NEVER TOUCH TWO KEYS AT THE SAME TIME. Select to return to the input function control menu Select to return to the main menu 100.00 Impulse Side gluing 1 100.01 Impulse Side gluing 2 100.02 Impulse Scoring 1 100.03 Impulse Scoring 2 100.04 Clutch control 100.05 Control cover intake roller Le 20/07/2007 62/70 100.06 Low limit cover feeder end stop (smallest position) 100.07 High limit cover feeder end stop (highest position) 101.00 Nipping end stop (smallest position) 101.01 Nipping end stop (highest position) 101.02 Reset side gluing end stop 101.03 Reset socring end stop 101.04 101.05 Jogger control 101.06 101.07 PUR nozzle control 102.00 Solenod valve clamp closing 102.01 Solenod valve clamp opening 102.02 Solenod valve high pressure 102.03 Solenod valve nipping plates up 102.04 Solenod valve nipping plates closed 102.05 Solenod valve cover forwarding fingers 102.06 Solenod valve milling flap 102.07 103.00 Paper waste suction control 103.01 Mill control 103.02 Cover feeder cycling control 103.03 Run brushless drive + Alarm reset 103.04 Vacuum pump control and blower 103.05 Relay control at low clamp speed 103.06 Relay control at medium clamp speed 103.07 15. Specifications Clamp 1 Mechanical speed 600 Cycles/ hour Estimated amperage consumption 13 A Power consumption 8 KW Power supply 1 for the binder one for the bulk melter Weight 700 Kg (Machine) & 340 kg (empty bulk melter) Machine dimensions (l x w x h) 2350 x 950 x 1350 mm Bulk melter dimensions (l x w x h) 1180 x 540 x 1268 mm Packing dimensions (lx w x h) 2510 x 1080 x 1400 mm (Binder) 1250 x 1000 x 1700 mm (Bulk melter) 670 x 470 x 500 mm (Paper suction) Le 20/07/2007 63/70 16. Connections Compressed air Conveyor plug Le 20/07/2007 64/70 17. Required environment Power 400 V three phased (or 220 V for USA) Frequency 50 Hz (or 60 Hz for USA) Maximum intensity 16 A Compressed air 6 bar and 100 l/min Compressed air/ low pressure 1 to 1.5 Bar Plug paper dust extractor Compressor plug Le 20/07/2007 65/70 18. Factory settings 18.1. Mill factory settings STRICTLY RESPECT THE FOLLOWING PROCEDURE TO PREVENT SEVERE INJURY A) ENSURE THE GUARD ABOVE THE MILL IS CLOSED AND THAT NO OBJECTS LIE ON THE FLAP PROTECTING THE MILL . Turn the screw on the VF distributor, the flap over the mill will open up. Open this panel Le 20/07/2007 66/70 B) Push the E-stop button ONLY THEN THE GUARD ABOVE THE MILL MAY BE OPENED. Ensure the jogger is perfectly plain. Load the clamp with a book block of approx. 40 mm Close the clamp by means of the setscrews. Manually displace the clamp over the mill. Ensure the notching teeth only graze the bookspine. Close the flap over the mill again by turning the screw on the VF distributor. Only then the E Stop button may be unlocked. (see chapter 19) 18.2. Factory setting nozzle height Position the (loaded) clamp above the opened nozzle. Set the distance between the bookspine and the nozzle to 0.3 mm by turning the gradual setscrew. (see chapter 9.2) 18.3. Factory setting nipping jaws Lift the nipping plates as follows Le 20/07/2007 67/70 Now position the clamp over the nipping station.. The edge of the rear nipping jaw must be aligned to the inner side of the carriage clamp. Set distance between the flap and the bookspine to 0,5 mm. (see chapter 4.8.1.) 18.4. Factory settings scoring wheels Align the groove of the static scoring wheel to the inner side of the carriage clamp. (see chapter 10.2) 19. Pneumatic rack PL: Solend valve closing the nipping plates M: Solenod valve lifting the nipping plates T: Solenod valve activating the cover forwarding fingers VF: Solenod valve opening the flap SF: Solenod valve closing the clamp HP/BP: Solenod valve controlling the high/ low pressure Turn the screw clockwise by 90 in order to activate the solenod valve Le 20/07/2007 68/70 20. Troubleshooting The machine doesnt start The machine is not plugged Plug the machine, ensure the line is supplied with power The main switch has not been turned on Set the main switch to I The E-Stop button has been pushed Check the machine and unlock the E-stop button. The start button next to the control panel has not been pushed Push the start button The clamp is in its initial position and doesnt move The clamp doesnt close Check the binder is supplied with compressed air and that there is enough pressure. ( 6 bar) A guard is opened Close the guard The clamp is over the nipping station and doesnt return to its home position. The book still lies on the exit slide. Clear the exit slide The exit slide is cleared. Pass your hand in front of the photocell located in the exit slide. The bookspine is crushed or round The jaws dont exert enough pressure on the spine Lift the jaws by turning the setscrews. (see chapter 4.8.1) The jaws exert too much pressure on the spine. Lower the jaws by turning the setscrews. (see chapter 4.8.1) No glueflow The bulk melter, the hose and the nozzle havent reached operating temperature. Wait until the system reached operating temperature (see Nordson instruction manual) The pump on the Durapail is off/ the melting plate is not lowered. Switch on the pump/ ensure the melting plate is down (see Nordsons operations manual) The book block is not holding on the cover The nozzle doesnt eject enough glue. Check the nozzle height and the glue pressure (see chapter 9.1& 9.2) The glue hasnt got appropriate viscosity Check the glue viscosity by purging the hose (see chapter 4.3) No glue ejection after having turned on the machine Purge the nozzle (see chapter 4.3) No glue ejection from the nozzle after having switched off the standby mode on the Durapail Shortly touch the Purge key in the glue parameter menu (see chapter 4.3) Le 20/07/2007 69/70 The scoring wheels cut the cover Excessive scoring pressure. Adjust the scoring depth. (see chapter 4.7) The cover is not conveyed onto the nipping station No cover stock Load a cover stock (see chapter 4.6.) The suckers dont pick up the cover Set the lowest point the suckers can reach (see chapter 4.6.) & set the suction intensity The cover of the bound book is not aligned to the book block. The cover is not correctly positioned on the nipping station. Adjust the stroke length of the cover forwarding bars (see chapter 4.8.) Make sure the cover forwarding bars are parallel to the motorized nipping bar. (see chapter 4.8.) The spine of the book block is round/ not well prepared. The notching teeth arent in contact with the milling plate. Adjust the milling depth (see chapter 4.18) and the height of the notching teeth. (See chapter 8.1) The dimensions of the book block/ document dont correspond to the values shown on the screen The zero positions of the end stops arent on the appropriate position. Adjust the initial positions of the end stops. (see chapter 10) The glue application length doesnt correspond to the entered value name. The set glue application inertia value name is incorrect. The entered distance photocell to nozzle is incorrect. Adjust the glue application inertia / the distance photocell to nozzle. (see 11.2) Le 20/07/2007 70/70 21. Maintenance Grease and close the nozzle as soon as the machine is no longer being used. (see chapter 4.2) This prevents the glue from curing prematurely. Purge the hose and nozzle once the machine is turned on. (see chapter 4.3) 21.1 Daily maintenance _Purge the hose and nozzle (see chapter 4.3) _Clean the nozzle of eventual grease remains _Clean the machine of eventual paper dust remains _ Clean the cover forwarding wheels _ Clean the machine _ Clean the nipping jaws and the active parts whenever needed. Never use a metallic tool for cleaning the jaws in order not to damage the coating of the nipping jaws. In order to reduce maintenance efforts, apply some silicone on the active parts. _ Clean the flap on the nipping station and regularly apply some silicone. _ Clean the exit slide _ Empty the paper dust bag 21.2. Weekly maintenance _ Grease the moving machine parts _ Drain the pneumatic circuit of eventual condensation remains