The BOURG BINDER 3001 is a perfect binder designed for the off-line production of bound booklets. This manual serves as a guide to operate the BOURG BINDER 3001, providing instructions for excellent service and finishing on demand systems. It emphasizes safety information, including labels and data sheets, and outlines the machine's system description, control panel, binding parameters, timer use, cover station, milling depth adjustment, glue, binder setup, output unit, binding condition, and cycle description. Maintenance, mechanical troubleshooting, common glueing defects, environmental compliance, and an appendix with additional information are also covered.
Function Description
The BOURG BINDER 3001 is designed for automatic perfect binding. The binding process involves several steps:
- Automatic process with cover: In this mode, the machine handles the entire binding process including jogging, milling, notching, and glueing, with the cover being fed automatically.
- Automatic process without cover evacuation: bottom: This mode performs jogging, milling, notching, and glueing, but without evacuating the cover from the bottom.
- Automatic process without cover evacuation: top: Similar to the previous mode, this performs jogging, milling, notching, and glueing, but without evacuating the cover from the top.
The machine features a carriage that moves to the loading area and stands by. The carriage opening is pre-adjusted to match the thickness of the previous book. The control panel allows for precise adjustments of various parameters, including clamping duration, lateral clamping pressure, suction level, spine pressure, and cover clamping duration.
Important Technical Specifications
The BOURG BINDER 3001 has the following key specifications:
- Model: BB 3001
- Description: Glue binder
- Max. process speed: Maximum 500 cycles/hour
- Dimensions & Weight:
- Length: 1.88 m (6.17 ft)
- Width: 1.16 m (3.8 ft) (with the possibility to split machine to have 695 mm (2.28 ft) width for narrow way)
- Height: 1.06 m (3.48 ft)
- Weight: 400kg (882 lbs)
- Voltage: 208V/220V/230V/240V/3P, 220V/230V/240V/3P, 380V/400V/415V/3P+N
- Frequency: 60 Hz, 50 Hz, 50 Hz
- Current, rated: 20 A, 20 A, 20 A
- Power consumption, stand by: 1500 W
- Power consumption, operation: 3000 W
- Power consumption, maximum: 3500 W
- Mains connection: Cable with fixed connection and separation switch
- Safety class: I (IEC 536) Protective earth connection
- Protection class: IP 20 (IEC 529)
- Sound pressure level: Standby (55 dB(A)), In operation (76 dB(A))
- Radio interference: Complies with Directive 89/336/EEC
- Radiation: Not applicable
- Radiant heat: 10224 Btu/hour
- Ozone emission: Not applicable
- Room volume: Recommendation: 95 m³ (7 x 4.5 x 3 m) 3336 ft³ (23x14.8x9.8 ft)
- Room ventilation: Recommendation: min. 47.5 m³/h (natural ventilation)
- Dust concentration: For heat evacuation at continuous binding extra ventilation may be necessary (0.04 mg/m³ at continuous operation (TLV for nuisance dust = 10 mg/m³))
- Additional safety information: To avoid higher sound pressure levels than given above, the machine should be installed in a room with at least minimum room volume and favourable acoustical properties.
Book Dimensions:
- Max. book dimensions (max - min): See the illustration above
- Cover types: Glossy paper, with cutouts, with transparent front, "kromekote", etc.
- Cover weight: 80-250 gsm (may require creasing)
- Cover weight: 30-90 lb cover
- Paper weight: 60-160 gsm
- Paper weight: 15-40 lb bond
Features:
- Cover pile height: 60 mm (2.4 in.)
- Mist detector: Yes
- Speed max.: Up to 500 cycles/hour.
- Glue temperature: From 140° C to 165° C (284° F to 392° F)
- Milling + notching: Yes
- Paper waste collection: Yes
- Book counter: Yes
- Start up timer: Optional
- Fume extractor: Optional
- Fume extractor with active charcoal filter: Optional
- Outdoor fume exhaust: Optional
Machine Dimensions:
- Dimensions (l x w x h): 1.88 m x 1.16 m x 1.06 m (6.17 ft x 3.8 ft x 3.48ft)
Weight:
- Binder: 400 kg (882 lbs)
- Output Unit (optional): 55 kg (121 lbs)
Electrical supply:
- 208V/220V/230V/240V (60Hz): Δ -20A
- 220V/230V/240V (50Hz): Δ -20A
- 380V/400V/415V (50Hz): Y -20A
Radiant heat: 10224 Btu/hour
Noise level (Lpa): 76 dB (A) (at operator position)
Usage Features
The BOURG BINDER 3001 is designed for user-friendly operation with several adjustable features:
- Control Panel: The control panel allows operators to close the carriage, adjust clamping duration, lateral clamping pressure, suction level, and select various menus and programs. It also provides options to toggle drum rotation, glue tank heating, stop all operations, open the carriage, jogger ON/OFF, carriage normal or large pre-opening, fixed speed ON/OFF, and Liquid Crystal Display for menus and messages.
- Timer Operation: An optional timer allows for scheduled operation. The timer has a dial to set time in 1-minute units and brackets for ON/OFF settings. The knob rotates clockwise to set the time, and the brackets are inserted into grooves to define ON/OFF periods.
- Cover Station: The cover station includes separators, magnetic side guides, rear guides, and cover loads. It supports different binding modes:
- Mode by default: For an optimal production.
- Mode for special applications: For specific binding needs.
- Mode for symmetrical cover: For booklets with notes on the spine of the cover.
The cover station allows for lateral adjustment and squaring of covers to ensure precise binding. Suction cups and cover separators are adjustable for optimal cover separation.
- Milling Depth Adjustment: A knurling wheel adjusts the jogger height, which in turn controls the milling depth. The cursor indicates the jogger level according to the milling blade. The jogger height can be adjusted up to 2.5 mm (0.1 in.) of material removal from the spine. "O" means "no milling".
- Glue System: The glue drum temperature is controlled by a knob, with recommended temperatures between 140°C and 165°C. The glue level is monitored, and an overflow will fill a tank with glue granules. The system includes a glue film spreader and a thumbwheel for adjustment.
- Binder Setup: This involves selecting and clipping carriage jaws extensions, loading the cover station, selecting proper book size, side cover clamping pressure, suction level, spine pressure, cover clamping duration, and jogger height.
- Output Unit (optional): This unit delivers bound booklets. It features an emergency stop, reset button, resettable fuses, and spine adjustment.
Maintenance Features
Regular maintenance is crucial for the optimal performance and longevity of the BOURG BINDER 3001. The manual provides a detailed maintenance schedule:
-
Daily Maintenance:
- Vibrating table: Check and clean.
- Dust bag: Check and replace if necessary.
- Milling housing: Check and clean.
-
Weekly Maintenance:
- Glue tank: Check and purge glue.
- Suction cup: Check.
- Cover gripping plate: Check.
- Evacuation guide: Check.
- Nippers: Check.
- Pre-clamping guard nipping station: Check.
-
Monthly Maintenance:
- Vibrating table: Clean.
- Dust bag: Clean.
- Milling housing: Clean.
- Glue tank: Purge glue.
- Suction cup: Replace as necessary.
- Cover gripping plate: Check state Teflon covering.
- Evacuation guide: Check from the top with clamping station fully open.
- Nippers: Check.
- Pre-clamping guard nipping station: Remove glue strings.
-
Dust Bag Replacement: The dust bag should be replaced approximately every 20 hours of binding, or when the glue could be ruined. The manual provides illustrations for easy replacement. A pressure switch detects the "Replace dust bag" situation.
-
Glue Smell Suppression (optional): When smell neutralization decreases, it is time to replace the filters.
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Troubleshooting: The manual includes a comprehensive section on mechanical troubleshooting and common glueing defects, providing symptoms, probable causes, and remedies for issues such as:
- Cover not square on paper offset.
- Cover too far on the right/left.
- Insufficient glue on the back of the book.
- Warped pages where glue is applied.
- Covers suffer from nail head.
- Poor ejection and nipping.
- Book buckles when cover is applied.
- Cover does not show a sharp crease on the spine.
- Gaps in glue film.
- Feather on book spine.
- Nail head.
- Honeycomb film.
- Uneven glue line.
- Cavity spine.
- Cover register.
The BOURG BINDER 3001 is a robust and efficient perfect binder, designed for reliable operation and high-quality output, with clear guidelines for safe and effective use and maintenance.
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