bourg_binding.pdf

BB3000

Service Manual

Model discontinued in January 2001

C

ertified by

ISO 9001

Revision November 2003

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Service Manual BB 3000

BB3000 Service manual

Contents November 2001

1 / TheoryMachine description (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 1Machine description (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 2Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 3Micro Control Unit - inputs / outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 4Functional diagram (1 / 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 5Functional diagram (1 / 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 6Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 7Glue consumption (EUR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 8Glue consumption (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 9

2 / DiagramsWiringSensors description & location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 1Sensors to PLC inputs (32 to 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 2Power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 3Wiring to the mains + Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 4Interlocks circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 5Power path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 6General wiring diagram 1 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 7General wiring diagram 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 8Electrical drawer (Rack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 9 Carriage shifting and drum rotation motor control (front rack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 10Power board 1/2 (electrical diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 11Heating circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 12Control Panel (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 13Book detectors in carriage and delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 14BBR damped book chute - Motor control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 15Carriage - cover nipping motors torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 16BBR-X 4 relays (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 17BBR 3 relays (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 18

InstallationInstallation summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 19Component location fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 20Programmable logic unit / (Re) programming instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 21

3 / AdjustmentsElectricalMain motor speed (re)adjustment (Kbic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 3 / 1Carriage shifting and drum rotation motor control (front rack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 3 / 2Cover clamp motor torque limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 3 / 3Suction bar speed control (power board 2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 3 / 4

MechanicalCover clamp clutch spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 3 / 5Procedure to re-time gears on the cover station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 3 / 6Adjustment of the position of the stationary knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 3 / 7Alignment of the sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 3 / 8

4 / Spare parts listGuards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 1Fuses & relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 2Switches - Cells - Buttons thermostats - PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 3Motor & solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 4Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 5Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 6Carriage drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 7Jogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 8Notching & milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 9Gluing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 10Cover clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 11Cover station - suction bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 12Suction bar drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 13Suction air cut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 14BBR (output unit - bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 15BBR (output unit - up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 16Index & recommended parts for one year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 22

5 / MaintenanceDust bag replacement frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 5 / 1Main drive motor brushes life expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 5 / 2

6 / Trouble shootingNon stop test procedureWarm-up period shortening (for service purpose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 6 / 1Power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 6 / 2Heating circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 6 / 3Nipping motor torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 6 / 4

7 / HistoryDevelopments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 7 / 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 7 / 7Wiring instructions for the replacement of the B.B.C. / ASEA P.L.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 7 / 8

8 / Useful, translated and obsolete itemsMaschine Beschreibung (D, 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 8 / 1Maschine Beschreibung (D, 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 8 / 2Description machine (F, 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 8 / 3Description machine (F, 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 8 / 4Réglage fraise et contre-lame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 8 / 5

TheoryMachine description (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 1Machine description (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 2Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 3Micro Control Unit - inputs / outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 4Functional diagram (1 / 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 5Functional diagram (1 / 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 6Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 7Glue consumption (EUR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 8Glue consumption (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 9

May 1999

ON

OFF

c.p. bourg S. A.N. V.

I

1

TH

EO

RY

Service manual BB3000 Machine description GB (1) Jan.1997

Carriage brake

Carriage openingclosure Suction bar

in-out allow

Carriage slow down( left - right )

Tank thermostat selector ( 115 / 145¡C )

Scraper

Tank thermostats

Carriage atright end

Shutter opening closure

Shutter closure detector

Y01 Booklet counter

X44 X55Drum temperature adjustment

Tank heating resistor

Cooling fan

Carriage slow down( right - left )

Automatic carriagespeed adjustment

Carriage clutchengagement

Mainmotor

Book presence detector

Carriage homedetector

Cell amplifiercard

Carriage fullopening detector

Jogging tableupper position

detector

Jogger magnet

X15 Process start ( green ) X14( To press and release simultaneously

with same button at opposite end )

X13 Carriage opening ( blue )

Suction level adjustment

X14 Proces start ( green )X15 ( To press and release simultaneouslywith same button at opposite end )

X03 Emergency

Drum temperature regulator sensor

Scraper height adjustment

Drum heating resistor

Foot switch

Carriageclosuredetector

X8 Roughing close - normal

Clamping down

Clamping up and suction valve control

Roughing andpaper chipsextractionmotor

X10 Narrow / wide carriage opening + ejection mode

X7 Notching / milling on - off

X12 Drum heating on - off ( rotation starts when warm )

Jogger on - off

Side clamping pressure adjustment

Clamping duration adjustmentX2, X5, X9, X11

Program mode selector X6, X4

X38X40

X49

X41

X42

X48

X47

Y12Y13Y12Y13X46

X45

X52X50

X53

X39

Y32Y32

Y43

X51X511/1

K21Cover clamping

Service manual BB3000 Machine description GB (2) May 1999

F1F2F3F4F5F6F7F8F9F10F11F12F13F14F15F16F17F18

F20

-

+

2,5ATT3,2ATT4 ATT2,5ATT3,2ATT2,5ATT2,5ATT7 ATT2,5ATT5 ATT1 ATT6,3ATT

20AT20AT20AT

15 AT2 ATT1 ATT

Adjustab.

Panel, PLC outputs - turbineClutch - brake - air valveSuction bar transferSuction bar up / downShutter opening closing motorCarriage clamping motorDrum heating resistorTransformer primary - cooling fanMain motorTank heating resistorJoggerCover clamping motor (torque limiter board)Mains: phase L1Mains: phase L2Mains: phase L3Power supply low voltageScraper heating resistorPLC ( 24 v )

Roughing motor 220V: 6,7ARoughing motor overload 380V: 4A

F12

F13 F14F15

F16F17

F18

F7F1F2

F4

F5F6

F8F9

F10F11

F3

D.C. power supply

Main motorspeed control

Fuses Rating Protected circuitry

Tank heating hours counter

Main switch

Power interfacing /+ suction bar speed

Logiccontrol

Transfo

Clamping motortorque limiting

T = time lagTT = super time lag

ONOFFK1K2K3K4K5K6K7K8K9K10K11K12K13K14K15

Air24V to PLC at safeguardings offSuction bar slow motionSuction bar in - outSuction bar out - inSuction bar up - downShutter openingShutter closureCarriage openingCarriage closureAir shut-off valveCarriage clutch - brakeMain motor speed controlMain motor speed controlDrum rotation ( off = inhibit )

K20Drum heating

K19K18K17K16

Main motorGlue tank heatingJoggerMotor brake

Roughing motor relay

Resetableroughing motoroverloadF20

Connection tobinder of parts

located in cover

Shutter openingclosing motor

Fume extractor(second fan with regenerating

filter option)

Safety on perspex guard

Air shut-offsolenoid

Cell amplifiercard

Air shut-off valve

Bookpresencedetector

ClampingLifting (+ closure)Lowering (+ opening)

Suction bar position detector (over clamping)

Cover pickingdetector

Suction barlifting / lowering

motor

Connector forjogger pedal

Cover separation barautomatic lowering

Cover suction / separation air turbine

Y08 Y09

Y06

X43

Y10 Y11

Y15

X33

X34

X32

X36

X37

Y45Y45

Y46

Safety onupper guard

X35

Suction bar upperposition detector

X54CN1 connectorfor BBR delivery

conveyer

Suction bar transferring

motor

Suction barposition detector ( over cover pile )

Suction bar slow down (out-in)

Suction barslow down ( in-out )

1/2

INPUTS0

Y OUT

15

15X IN

0

OUTPUTSY47

Y32

C4

C5

C6

C1

C2

C3J73

J21

1 40

36

4

5

8

1

9

33

C6

Drawing ref.:

Date: Index

Supersedes: Superseded by:

July 1997 A B

A

Index B: description complement

BB 3000 BLOCK DIAGRAM

J5

J1

J6

Powersupplyof PLC

C1 ➞ C5 to power components(see pg 2/7 - 2/8 wiring diagrams andpg 2/6 power path)

From sensors X32 ➞ X55(see pg 2/2 specific diagram)

Power boardPLC

J22

Main motor Tank therm.Jog pedal.

Control panel

3 PH

1 PH1 PH

Cover nippingAir valveCarr. open/cl.suction barClutch/brake

Milling motor relayand breaker

Interlock

BBR

J11

J12

J13

Drum and tank heating

J6

J10 J3J9

Speedcontrol

PCB

OUTPUT

IN IN

OUTPUT

J73 J21J72

J70

J71

C6J7

J8

X02

X15

Y0

Y15

Y32

Y47

X32

X55

J5

J4

C1

C2

C5

ONOFF

J6

J1

J5

J4

J2

J8

J9J10

J11

J12J3

J7

J22

J15

J14

Operatorcontrolpanel

KBICmain motor

speed control

Cover clampingmotor torque

limitJ40

34

1

1

1

34

1

1

30

34

1

1

1

3

8

1

1

12

1

J131

6

Cover nipping motorTorque limiterboard

J15 J14

J2

J1

1/3

INPUTS0

Y OUT

15

15X IN

0

OUTPUTSY47

Y32

iN.H

J21

J1J5

BB3000 Micro Control Unit

Sensors

Controls

Powered parts

Connectors

262524232221201918171615

6543

36353433323130292827262516151413121110

98765

X00X01X02X03X04X05X06X07X08X09X10X11X12X13X14X15

X32X33X34X35X36X37X38X39X40X41X42X43X44X45X46X47X48X49X50X51X52X53X54X55

✖✔✖✖✖

♠✖♠✖

✔✔

✔✔✔✔✔

✔✔✔

✔

✔✔

greenredredred

greenredredred

greenredredred

greenredredred

greenredredred

greenredredred

greenredredred

greenredredred

greenredredred

greenredredred

Not availableNot availableClamping/drying durationPLC enable (knob or guard not actived)Binding mode selectionClamping/drying durationBinding mode selectionMilling notching ON/OFF activatedCarriage at constant speedClamping/drying durationCarriage wide pre-openingClamping/drying durationDrum heating ON/OFF activatedCarriage opening (blue) knob pushedLeft (green) carriage closure knob pushedRight (green) carriage closure knob pushed

No cover on suction cupsSuction bar upSuction bar not fully outNo (brief) suction bar in/out slow down instructionNo (brief) suction bar out/in slow down instructionSuction bar is not fully inwardsClamping not in upper positionMilling motor temperature is satisfactoryCover clamping is in lower positionShutter is fully open Shutter is closedNo book in shutter (output)Drum rotation request (pointers: black over green)Carriage home (left limit)Carriage right/left slow down (brief pulse)Suction bar allow (brief pulse)Carriage left/right slow down (brief pulse)Carriage at right limitCarriage not fully openCarriage closedNo book in carriageJogger upBBR full or stoppedDrum temperature too low

30 p

ins

J5

conn

ecto

r40

pin

s J2

1 co

nnec

tor

34 p

ins

J6 c

onne

ctor

34 p

ins

J1 c

onne

ctor

#To

From

LEDcolour Description

Input signals (LED is illuminated when description is true)

302928262524231413121110

987

3028241413121110

987

Y00Y01Y02Y04Y05Y06Y07Y08Y09Y10Y11Y12Y13Y14Y15

Y32Y34Y38Y40Y41Y42Y43Y44Y45Y46Y47

✔

✔

✔✔✔✔✔

✔

✔ illuminated when binder ready

greenredred

greenredredred

greenredredred

greenredredred

greenredred

greenredredred

greenredredred

Green carriage closure buttons (blinking illumination)Book counter incrementBlue carriage opening button illuminationMain motor speed coded instruction relay (K14)Suction bar slow speed relay (K3)Suction bar up/down relay (K6)Main motor speed coded instruction relay (K13)Suction bar out/in relay (K5)Suction bar in/out relay (K4)Shutter closure relay (K8)Shutter opening relay (K7)Carriage closure relay (K10)Carriage opening relay (K9)Carriage translation clutch relay (K12) (associated brake is active when clutch is not powered)Suction air shut-off valve relay (K11)

Milling/notching relayBBR control pulseDrum heating relay (K20)Drum + main motor rotation relay (K15)Drum heating/rotation key selected (but enabled-disabled by X55/X44)Cover feeder suction/blowing relay (K1)+24 V to jogger relay (K17) side opposite to pedalCarriage translation slow down relay (K16) (resistor across motor)Cover clamping lowering

to torque limit board via J2Cover clamping liftingTorque limit inhibit

#LED

colour Controlled power element (via power board, see diagr. 4.74.71.1450)

Service manual BB3000 February 1999

-

-

-

-

-

-

I

-

-

-

-

I

-

-

I

I

-

I

-

-

-

I

I

-

-

I

-

I

-

I

I

I

I

-

-

-

I

-

I

-

1Duration selector steps

2 3 4 5 6 7 8 9 10

0 0,8 1,6 2,4 3,2 4 4,8 5,6 6,4 7,2

5 10 15 20 25 30 35 40 45 50

(M I + II )

(M III )

Combinations

Constant: close notchingHigh: carriage return/milling offLow: idleBook thickness dependant (if milling on)

Speed

-

-

-

I

I

-

I

I

X04

X06

X02

X05

Y04

Y07

Binding modes

-

-

I

-

-

I

I

I

I II III IV

Seconds

32

36

40

44• • •

• • •• • •

• • •Y OUT

32

36

40

44• • •

• • •• • •

• • •

48

52• • •

• • • X IN

J6Output instructions to power board (LED is illuminated at output high (24V) )

F

Y15

X43

X36X37

Y45

X33X35

X34

Y06

Y08Y09Y05

Y32

24HTimer

X53

X44X55

Y46X32

Y10Y11

Safety on upper guard

Safety onperspex

Cell amplif.card

C7

J41

P36

J30

J33

J29

J42

X45

Y32

X39

Y43

X53

X52

X46

X47

X48

X49

X40

X38

X42

X41

X44 X55

C1C2

C3C4

C5C6

C7

Y12Y13

Chipsextractor

Y38

Y14

Y44

Y04Y07

Y42

X50

Cellampli. board

X51X51

J28

J33

J30

X54

POWER BOARD

✔ illuminated when binder ready✖ selectors position dependant ♠ illuminated when selected

50

› 40¡C

250

Red pointerselected temp

Black pointeractual drum temp.

Greenpointer

1/4

1/5

POWER "ON"

INITIATED ?

STAND BY(GREEN LIGHTS ON)

CLAMPINGLIFTING ANDCLOSURE

CLAMPINGLIFTING ONLY

YES

(M1 + M2) +

MODE 1 MODE 2

CARRIAGESTART, TRAVELSLOW DOWN

CLAMPINGLOWERING SHUTTER

OPENINGCARRIAGEOPENING

40 5141

INITIAL COVER PICKING

LEGEND

PROCESS STEP

49

OR

ALTERNATIVE ROUTES

SIMULTANEOUS STEPS

43 52

AND

INITIAL CONDITIONS

M1 M2+

(M3 + M4)

(M1 + M2)

SPINE DRYING

MODE 3 MODE 4

STAND - BY

51 52

GLUING

CLAMPING OR DRYING ( SELECTED DURATION: SEE LEDS 02/05/09 AND 11 )

SIMULTANEOUS 14 15SIMULTANEOUS 14 15

SIMULT. 14 15

SIMULT. 14 15

CONDITION FOR TRANSIT TO NEXT STEP( LED # X49 IS ALIGHT )

CARRIAGE OPENING(BLUE KNOB)

SIMULT. 14 15SIMULT. 14 15

EMERGENCY KNOB PRESSED OR

PERSPEX GUARD LIFTED (AT ANY TIME)

+

NO

BLUE KNOB AND BOOK REMOVAL

CONDITION IS AS DESCRIBED ONRESPECTIVE LINE OF TABLE BELOW

49

CONDITION IS OPPOSITE TO DESCRIPTIONON RESPECTIVE LINE

M1 = MODE 1M2 = MODE 2M3 = MODE 3M4 = MODE 4

: BINDING WITH COVER: BINDING WITH GAUZE: GLUE PADDING : GLUE PADDING + MANUAL REMOVAL

49

(32 + 34)

51 32 37 51 34

( 53 + Y32 )

55 44 Y40

45 51 40 42 33 34

( 45 + 40 + 42 + 33 + 34 ) ( 51 )

CONDITION FOR TRANSIT TO NEXT STEP( LED # X49 IS SPENT )

1/6

- X - X - X - X - X

- - X X - - X X - -

-

- - - X X X X - -

X09

BOOK DROPPINGACKNOWLEDGMENT

SUCTION BARIN OUT

SUCTION BARLOWERING

SUCTION BAR AND COVER LIFTING

COVER TRANSFEROUT IN

SHUTTERCLOSURE

CARRIAGERETURN

(43 52 OVER 0,5 sec)

(WITHIN 0,5 sec)

CLAMPING / DRYING DURATION SELECTOR (SECONDS)

SEL. POSITION

MODE 1 + 2

MODE 3

1 2 3 4 5 6 7 8 9 10

0,8 1,6 2,4 3,2 4 4,8 5,6 6,4 7,2

5 10 15 20 25 30 35 40 45 50

- - -

-

- - - - X X

X = LED ON

= LED OFF-

COVER IS POSITIONNEDFOR NEXT BINDING

BB3000/9 FUNCTIONAL DIAGRAM( Simplified )

JAN 1993

0

M1 + M2 M3 + M4

SIMULT.

SIMULT.

AWAITING INITIALCOVER REQUEST

SIMULT. 14 15

LATE DROPPING

COVER MISSED

JAMMED BOOK REMOVAL

M1 + M2 + M3

ROUGHING MOTOR "ON"

DRUM ROTATION MOTOR "ON"

X

X

Y32

Y40

POWER ACTUATORS

X04

BINDING MODE SELECTOR

MOD.1LED OFF

LED OFF

LED ON

LED OFF

LED OFF

LED ON

LED ON

LED ONMOD.2 MOD.3 MOD.4

SENSORS / KNOBS / LEDS

CARRIAGE IS IN HOME POSITION (LEFT)

SUCTION BAR IS NOT FULLY IN

RIGHT CARRIAGE CLOSURE KNOB PRESSED

PROCESS INHIBIT (DRUM t¡ <= required temp. )

LEFT CARRIAGE CLOSURE KNOB PRESSED

CORRESPONDING LED IS ALIGHT WHEN:#

X11

X05

X02

X06

DRUM ROTATION ALLOW ( 40¡C. BELOW

SELECTED TEMPERATURE )

SHUTTER IS NOT FULLY OPEN

JOGGER IS IN UPPER POSITION

THERE IS NO BOOK IN DROPPING AREA

CARRIAGE IS EMPTY

NO COVER ON SUCTION CUPS

SUCTION BAR IN-OUT TRANSFER IS ALLOWED

CLAMPING IS NOT FULLY DOWN

SHUTTER IS FULLY OPEN

X45

X37

X15

X55

X14

X44

X42

X53

X43

X52

X32

X47

X40

X41

SUCTION BAR IS NOT FULLY OUT

SUCTION BAR IS IN UPPER POSITION

X34

X33

CARRIAGE IS AT RIGHT ENDX49

CARRIAGE IS CLOSEDX51

14 + 15

32 33

32 + 33

37

34

47

32 3342

47 45

14 15

14 15

43 + 52

43 52

( JAM )

43 52

IN O

PP

OS

ITE

CO

ND

ITIO

N (

i.e. X

) C

OR

RE

SP

ON

DIN

G L

ED

IS T

UR

NE

D O

FF

1/7

Cover types Glossy paper, with cutouts, with transparent front,"kromekote", etc.

Cover weight 80-250 gsm (20 lb.- 65 bond) may require creasing

Cover pile max. 70 mm 2 3/4"

Miss detector on cover feeder Yes

Speed max. 500 cycles/hour (A4 size - spine long side - thickness 1 cm)

Glue temperature From 115¡ C to 200¡ C

Milling and/or notching Yes

Paper waste collection Yes

Book counter Yes

24 hour start up timer Optional

Fume extractor Yes

Outdoor fume exhaust Optional

Dimensions: ( l x w x h ) 1,88 m x 1,1 m x 1 m (74" x 43 1/2" x 39 1/2" ) w/o cover 1,81 m x 0,65 m x 0,95 m (71 1/4" x 25,6" x 371/2" ) Weight 440 Kg (970 lbs)

Electrical supply 50 Hz: 220V/230V or 240V60 Hz: 208V or 240V

Y 380V/400V or 415V

Power consumption 3kW

Noise level ( Lpa ) 75 dB(A)

Radiant heat 9540 B.T.U. /hour

320 mm(12.6")

Book dimensions

min

MAX

Max: 45 mm (13/4") (– 400 sheets, 80 gsm (20 lb))Min: 2 sheets (theoretical)

p

BB3000 September 1997Rev. minimum length

385 mm(15.16")

100 mm(4")

90 mm(3.55")

75 mm(3")

100 mm(4")

Restricted to binding mode IV

Padding

Reducible to 0,65 m (25.6")for narrow passage way

1/8

Glue consumption (chart established using our glue quality)

Exp

ecta

ble

num

ber

of A

4 bi

ndin

gs (

glue

d le

nght

way

s) b

etw

een

succ

essi

ve g

lue

refil

ls

There is one Kg (2.2 lbs) of glue between tank max. and min. level indicators. Level check takes place at drum stopped.Glueing defects are likely in the vicinity of the mark minimum. Tank full capacity is 1.35 kg (50 oz) of glue. August 1997

Book thickness (mm)2 4 6 8 101 3 5 7 9

400

600

800

1000

1200

1400

1600

1800

500

700

900

1100

1300

1500

1700

2000

1900

Detail ofthe chart

Book thickness (mm)

10

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

20 30 40 50 60

Max BB2000

Max BB3000Max BB3000


Thickest glue film

Thinnest glue film

1/9

10

1000

500

600

700

800

900

1100

1200

1300

100

200

300

400

20 30 50 60

1"1/2"1/4" 3/4" 2"11/2"11/4" 13/4" 23/4"

4040(mm)

Book thickness

(Inches)

Book thickness

Glue consumption(chart established using our glue quality)

Approxim

ate

numberof81/ 2"x11"bindings(gluedlenghtways)betweensuccessivegluerefills

There is one Kg (2.2 lbs) of glue between tank max. and min. level indicators. Level check takes place at drum stopped.

Glueing defects are likely in the vicinity of the mark minimum. Tank full capacity is 1.35 kg (50 oz) of glue. August 1997

axBB2000BB4000

MaxBB2000BB4000



2 4 6 101(mm)

(inches)

3 5 7 9

1000

2000

1/4" 5/16"3/16"1/16" 3/8"1/8"

1100

1200

1300

1400

1500

1600

1700

1800

1900

2100

400

500

600

700

800

900

Detail of

the chart

88

Thinnest glue film

Thickest glue film

DiagramsWiring

Sensors description & location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 1Sensors to PLC inputs (32 fi 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 2Power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 3Wiring to the mains + Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 4Interlocks circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 5Power path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 6General wiring diagram 1 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 7General wiring diagram 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 8Electrical drawer (Rack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 9 Carriage shifting and drum rotation motor control (front rack) . . . . . . . . . . . . . . . . . . . .pg 2 / 10Power board 1/2 (electrical diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 11Heating circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 12Control Panel (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 13Book detectors in carriage and delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 14BBR damped book chute - Motor control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 15Carriage - cover nipping motors torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 16BBR-X 4 relays (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 17BBR 3 relays (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 18

InstallationInstallation summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 19Component location fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 20Programmable logic unit / (Re) programming instructions . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 21

October 2001

I

2

ON

OFF


DIA

GR

AM

S

2 / 1

X43

X33X33

X34

X32X32

X36X37X37

X35X35

X53X53

X50X50

X45X45

X46X46

X47X47

X48X48

X49X49

X51X51

Service manual BB3000 Sensors description & location Jan.1997

Cover on suction cupsSuction bar upper position detect.Suction bar outer limit detectorSuction bar slow down (in-out)Suction bar slow down (out-in)Suction bar inner limit (over clamping = in)Clamping upMilling motor is overheated (detector inside)Clamping downShutter openShutter closedBook in ejection area receiver assemblyBook in ejection area emitter assembly

2983886915001429838522983852298385229838529150014298113491500149150014915001494207309420707

X32X33X34X35X36X37X38X39X40X41X42

X43RX43E

Drum rotation start (tank temperature ok)Carriage homeCarriage in transfer position Carriage in transfer positionCarriage in transfer positionCarriage over cover clampsCarriage opening limit Carriage closedBook presence detectorBook presence detectorJogger up (milling disabled)Drum temperature regulation

298326491500149150014915001491500149150014915001429837169420705942070691500142983264

X44X45X46X47X48X49X50X51

X52RX52E

X53X55

X41

X38

X40

X52

X44X55

X42

X39X39

2 / 2

PLC

Drawing ref.:

Date: Index


Oct. 1996 AD

BE

D

C

BB 3000Sensors - PLC inputs 32 to 55

(+ interfacing C6 - J21)

Index E: X45 & S8, wiring and state of switch corrected

C1

C2

C3

C4

C5

C6

J73

J5 (X02 ➞ X15 described on MCU + inputs/outputs page 1/4)

J21

1 40

36

4

5

8

1

3

15

131

9

33

J21 C6

2K2 1/2W 2K2 1/2W

ZD 24V 0.5 W

26/30/34

3533

429

825362132172813

241020

616

918

514

112

2

3/7/11/15/19/22/23/27/31

1K 1/4 W

C60

Y OUT

X IN15

0

15

INPUTS

32

36

40

44• • •

• • •• • •

• • •

48

52• • •

• • •

1

iN.H

OUTPUTS

Drum temp low ( therm. pointers: black below red )

BBR full or stopped

Jogger up (milling disabled)

Book in carriage

Carriage is closed

Carriage is fully open

Carriage is at right limit

Carriage left/right slow down (brief closure)

Suction bar allow (brief closure)

Carriage right - left slow down (brief closure)

Carriage home (left limit)

Drum rotation request (pointers: black over green)

Book is still in shutter (output)

Shutter is closed

Shutter is fully open

Cover clamp in lower position

Milling motor is overheated (detector inside)

Cover clamp motor torque limiter request

Suction bar is fully inwards

Suction bar out/in slow speed request (brief opening)

Suction bar in/out slow speed request (brief opening)

Suction bar out

Suction bar up

No cover on suction bar

n.c.

n.c

n.c.

n.o.

n.o.

n.o.

n.c.

n.c.

n.c.

n.c.

n.c.

n.c.

n.o.connector

n.c.

n.o.

n.o.

n.o.

n.c.

n.c.

n.c.

n.c.

n.c.

n.o.

X55

S8 (BBR)

n.o. X53

X52 (Cell) X51

X50 (H)

X49

X48

X47

X46

X45 (H)

X44 (H)

X42 (H)

X41

X40 (H)

X39

X38

X37(Reed)X36

(Reed) X35(Reed)X34 (H)

(Reed) X33 (H)

X32 (H)

X43 (Cell)

24 V

(H) = Home position

The condition shown for the sensors corresponds to the description

Leds turn on when corresponding input is high (24v)

Upper rowGreen

J73Leds

0V

Flatcable

0V

+

X55X54X53X52X51X50X49X48X47X46X45X44

X43X42X41X40X39X38X37X36X35X34X33X32

PLC

REDREDRED

GREENREDREDRED

GREENREDREDRED

GREEN

REDREDRED

GREENREDREDRED

GREENREDREDRED

GREEN

#Colour

0V

F181A

24V

SensorsX32 ➞ X55

Please disregard any previousversion of this diagram

123456789

10111213141516171819202122232425262728293031323334353637383940

2 / 3

INPUTS

OUTPUTS 36

4

5

8

19

33

C6

BBR II

ON

OFF

15

14

13

L3

L2

L1

Fuses Rating(Slow blow)

BB 3000 Power distribution

1

Suction bar up/down (M13)

Shutter (M15)

Clamp open / close (M5)

MCU outputs (layer 1 + 2)

Tank thermostat

Control panel

2

3

4

5

6

7

8

10

11

9

Power board

T1

-

+

F12F13

F14F15

F19 F16F17

F18

F7

F1

F8F9

F10F11

ONOFF

F20

Powerboard

M14 Trq.limit.

Frontrack

MCU

T1

17

18

16

19

19 V

24V24V

19 V

230 V

20

Milling motor

Drum

M1/M10/M21

Tank

Vibrator

Start up timer

Fan

Turbine(M9)

(No F19 for early 120 v brushless M9)

N (L3)

MCU

12Torque limiter board

Glue

spreader

Clutch (L5)

Brake (L7)

Air valvek2

J40n.o.

Cover nipping (M14)

1 2,5 A 2 3,2 A 3 4 A 4 2,5 A 5 3,2 A 6 2,5 A 7 2,5 A 8 7 A 9 3,2 A10 5 A11 1 A12 6,3 A13 20 A14 20 A15 20 A16 15 A17 2 A18 1 A19 4 A20 4/6,7 A

F3F2

Suction bar in - out transfer motor

F6

F5F4

3

7

11

15

19

23

27

31

X53

X44 - X55

X39

X50 - X51 - X52 em - rec

X45 - X46 - X47 - X48 - X49

X38 - X40 - X41 - X42 - X43

X32 - X33 - X34 - X35 - X36 - X37

BBR

SensorsC6

july 2001

J21

J73

J21

J73

J27

J27

2 / 4

Drum heatingresistor

KbicL2


Jog.coil

Turbine

Milling motor

L3k19

L2

L1

N

Powerboard

J12

J11

J10

RED19V

BLK

MCU

BBR

Spreaderheatingresistor

342

339

336

345

333

332

331

334

ON

OFF

208V

220V

230V

240V

400 V

415 V

380 V

Main switchJ208

6

4

2

7

5

3

1

k18 k17F15

F14

F13BLUEBLUE

5 wires ( 3 + N + )

4 wires ( 3 + )

320321

BLU

0V

OR

AW

HT

GR

YR

ED

BR

NB

LK22

0V

190V

200V

210V

230V

240V

250V

YE

LV

IO

Cooling fans

Transfo

Wire 301 is to connect to:

- appropriate terminal if

- 220V if 380V230V if 400V240V if 415V

228

229

230

028029

030

344341

338

Trip323

322

20A

L3

L2

L1

N

C1

n.b. heavy damage will occur if neutral is omitted in wiring

120V

3

F16 15A

F20

: turn to max (6,7A): set for 4A

T3 T2 T1

T3

T2

T1

A2

F18 1A

F17 2A

C3

J18

J17

RC

+

19V

1

2

3

4

4 C1

C4C3

8

9

11

10

13

5

3

J13

1

F72,5A

F8

7A F92,5A

F105A

F111A

3 14 2

6

5

J40: 320 ➞ L2

321 ➞ L1346 ➞ Jumper N = L3

: 320 ➞ L3321 ➞ N346 ➞ no jumper

Wiring J12 J11

k20

319 N

004

046

033

058

059

002001

032

045

003C5

C2

2C7

1

2

J14

J41

8

9

J3

344341

338

Reset

*

*

J19

1224h timer(option)

125 4

111312

11 7 6 5 4 312 8

301

036

035

56 89

C3

Drawing ref.:

Date: Index


January 1999 A B C

BB 3000 WIRING TO THE MAINSPOWER SUPPLY

Index C: Addition of F19

ON

OFF

BBR II

-

+

C4C5

C1C2

C3

39

15

F13 F14

F20

F8F9

F10F11

ONOFF

K19

K18

K17

F15 F19

F16F17 F18

K20

1

12

1

1

1

6

Mainswitch

F7

J13

J40

J14J3

J12

J11

J10

J19

J20

J18

J17

RC

Tr

KBIC

C7

Emergencystop unit(EUR only)

L2L1

Auto reset emerg.stop unit A2

A1

13 +

—

—

X1

X2J37

J107

346346

Kbic / L1

12

3

F19

2

1

4

3

2 / 5

Safety ontop cover

EmergencySafety onperspex

C5

J29

24V

PLC

0V

F18F1

J3

8

9

J404 3

Date:

Supersedes: Superseded by: Drawing ref.:

IndexJune 2001 A B

¤

BB3000 INTERLOCKS CIRCUIT

K2c

K2b

K2K2

K19K19

F9

To main motorcontrol board (Kbic)

POWERBOARD

J13

3

4

J29

4

3

J4

25

20

J22

25

20

L1 N

J115 ➞ 18

J112 1

J1078

Powerto PLCoutputs

J615 ➞ 1831 ➞ 34

X3 (low = PLC disabled)J5

23

J37

J107

J401

2

GS Emerg.stop control

13

A1

23

14

A2

5

6

C5

Emergency

Topcover

Perspex

On european models only

F18

INPUTS

OUTPUTS

PLC

J6J1

Kbic

Frontrack

F1F3

K19

F4

F5F6

F9

K2

J13 J3

J1

J7

J5J6

J4J40

J22

J10

J11

Millingmotorrelay

Emerg.stopcntrl

To milling motor relay

L1

T1

L2

T2

L3

T3

F6

Suctionbar in/outmotor

F5

Suction barup / downmotorF4

Shuttermotor

F3

Carriageopen/closemotor

J7

1

4

5/6

7/8

Suctionbar

in/outin/out

up / downup / down

ShutterShutter

Carriageopen /close

Carriageopen /close

Index B: Disregard may 1999 version

2 / 6

9

7

Operatorcontrolpanel

Sensors 32 ➞ 55

A -

P2

KBIC

P3

Y4 high: 1K over P2.P3

A +

P1

Shutteropening/closure

Cover clamping and lifting

Air shut-off valve solenoid

Suction bar lifting /lowering

Suction bar translation

Milling/notching

Solid statespeed

regulationboard

Cooling fans

24H timer(option)

Carriagebrake

Carriage clutch

Carriage translation and drum rotation

Carriage speedadjustment

Carriageopen/close

Jogger solenoid

Tank heating

Spreader heating

C55

12

10

C29

15

11

12

2

3/4

5

C35

811

123

C4

1

C5

C6

6

13

11

C210

3

14

13

1

4/3 1/2

6

7 8

6/5

8/7

4

2/1

5/6

7/8

+ 24V

-

-

1k11

k12

2

3

K2

K18

K8

K10

4K

5

8

10

K6

K12

K11

K7

K9

K19

3

2

5

2/341

2

28

3999 74 8 Y46

Y8/9

Y10/11

Y12/13

Y45

Y15

Y14

Y6

Y8/9

Y11/10

Y13/12

L3 L2 L1

L1

8

C1

6

9

11

4

C1

7

10

3

1 2

11

12

5

7

3

C36

912

13

C4

2

Upper guard

Emergency

Thermostat145¡C

Therm. 115¡C

Therm. select

Perspex guard

Drumheating

KBIC

L2L1

K14

K13

Y4

Y7

POWER PATHBB3000 September 2001

F2

F1719V

F1

F4

F3

F5

F6

k20

k18

k17

k19

F7

F10

F11

F9

F8

F13

F14

F15

L3( ) N( )

Inputs Inputs

Outputs (Y)

MCU X32

➞ X

55

X02

➞ X

15

5K

4

P2 between P1 P3 variableP2 = P1 minimumP2 = P1 (1K //Pot) constantP2 = P3 maximum

Speed

L1( )

N( )L3( )

L2( )

Speed instructions

1/6

3/4

40V to 180V

19V

C4C5

C6

C1C2

C3

ONOFF

J6

J1

J5

J4

J8J9

J10

J11

J3

J7J7

J22

J15J14

Controlpanel

KBICmain motor

speed control


limit

34

1

1

1

34

1

1

30

341

1

18

1

1

12

1

Wire identification # on general wiring diagram

Rel

ay

k2n.o.

6

8

4

L2

KBIC

J21

J2

J12

J40

J1316

J9J9

J7

J10 J10

J12 J12

J11

J12

J19

J7

J8

J3

J2

J1

J2

J1

J3

J3

J4 J5J22

J15 J15

J14 J14

J21

J13J134 3

190¡C

190¡CAuto Reset

2 / 7

C1C2

C3

C4

C5

C61 40

36

45

8

19

33

13

23

14

1512

1

C3-8

C3-9

C3-10

C5-5

C5-6

C3-13

C3-11

C3-12

C3-14

035

036

037YEL/GRN

055

056

040

038

039

041

1

2

3

4

5

6

7

9

10

035

036

055

038

039

041

037

040

056

YEL/GRN

5

3

4

N

L2

L2

Transfo

N

034YEL/GRN

12 14

11n.c. 13

12

43 Safety on

upper guard

654

32

441YEL/GRN

24 hoursTimer

C6-11

C6-16

C3-1

C3-4

X39

+24v

C3-2

C3-3

T3

T2

T1

C3-7

C3-6N

C3-5L2

380 / 415 V

200 / 208 / 230 / 240 V031YEL/GRN

YEL/GRN

032

033

YEL/GRN

Lower framecooling fan

Milling motor overload

X39 X39

Upper guard coolingfan or fumes extractor

Safety onperspex guard

Loom

034YEL/GRN

031YEL/GRN

439

440

438

L2

INPUTS

3940

INPUTS = X

12

MCU

Externalbridge

030

029

028

116111

111

116

028

029

030

436435

437

033

032

435

436

455

438

439

441

437

440

456

460455

456

C6-23

C2-15

123

027

C6-30 130

C2-14 026

+24V

0V

C6-24 124

C2-10 022

0V

X43

C6-20 120X41

C6-10 110X42

C6-9 109X38

C6-6 106X40

C2-9 021

C2-6 018

C2-5 017

1

13

2

12

3

11

4

5

6

7

10

9

8

K

A

A

K

C

E

E

C

BLK

BLK

RED

RED

RE

D

BLK

8 7 6 5 4 3 2 1

BLK

RE

D

EMITTER

RECEIVER

X43

Cell amplifierboard

Binding detector cellsunder shutter

RE

D

BLK

WT

H

RED

RED

REDRED

RED

BLK

WHT

BLK

BLK

BLK

BLK

GRN

BRN

WHT

RED

0 V

RED

RED

RED

RED

BLK

BLK

BLK

BLK

GRNBRN

WHTRED

X41 Open shutter detector

X42 Closed shutter detector

X38 Nipping upperposition detectorand torque limiter

X40 Nipping lowerposition detector

Y10 & Y11 Shutter opening closure

Y45 & Y46 Jaw clamping and lifting

Y15 Air shut-off valvesolenoid

123

027

130

026

124

022

120

110

109

106

021

018

017

C6-27 127

C6-12 112

+24V

X33

C6-14 114X35

C6-1 101X34

C6-5 105X36

C6-18 118X37

C6-2 102X32

127

112

114

101

105

118

102

1

2

3

4

5

6

7

8

9

10

11

12

13

C2-1 013

C2-2 014

C2-3 015

C2-4 016

013

014

015

016

C5-7 057

C5-8 058+ 24V

C5-9 0590V

C6-31 131+ 24V

C6-33 133X54

127

112

114

101

105

118

102

013

014

015

016

511

512

6

5 3

2

1

4

112

127

114101

015

016

015

013

105118

511

BRN

GRN

RED

GRN

REDBLKWHT

X33 Suction bar upper limit

X34 Suction bar outer limit

X35 Suction bar slow down

Y06 Suction bar lifting /lowering motor

Y08 & Y09 Suctionbar translation

X37 Suction bar inner limit

X32 Cover detector on suction bar

BBR

X36 Suction bar slow down

IN ➞ OUT

OUT ➞ IN

Lo

cati

on

on

pag

e 2/

8

Full

n.c.

n.c.

n.c.

n.c.

n.c.

Date:


SuffixNov. 1997

¤

BB3000 WIRING DIAGRAM 1/2

Y34

A

n.o.

B

F

Suffix G: ❊ wiring corrected

CC

513

137

015

057

058

059

131

133

D EG

Upperguard

Milling / notching

Cover feed

Cover clamping

J21

J21

J33

J21

J41

P36

J14

J7

J7

J8

F

Y15

X43

X36X37

Y45Y45

X33X35

X34

Y06

Y08Y09Y05

Y32

24HTimer

X53X53

X44X55

Y46Y46

X32

Y10Y11


Safety onperspex

Cell amplif.card

C7

J41

P36

J30

J33

J29J21

J21

J42

ONOFF

Controlpanel

Kbic

Cover clampingmotor torquelimit board


J7J10

J14

J15

J9J8

J2

J4

❊

n.o.

J21

J13

J13

J13

J17

See p. 2/2 See

p. 2/2

See . 2/9

See p. 2/9

2 / 8

See p 2 / 13

C6-15 115

C6-26 126

+24V

0V

C6-29 129X52

C6-25 125X50

C6-8 108X51

C1-9 009

C1-10 010

C2-8 020

C2-7 019

C1-11 011

1

2

3

4

5

6

7

8

K

A

A

KGRYWTH

GR

Y

WH

T

1 2 3 4 5 6 7 8

530

531

EMITTERX52

Cell amplifierboard

Fix jaw emitter cells

532

534

524

530

Carriage variablespeed adjustment

115

126

019

020

010

108

125

129

C6-19 119

C2-13 025

+24V

0V

C2-12 024

C6-36 136X49

C6-21 121X48

C6-32 132X47

C6-17 117X46

1

2

3

4

5

6

7

8

009

011

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

EC1

EC2

EC2

527531

528532533

529534

535

536

521

522

523

524

525

526

1

2

1

2

3

4

533

525

527

528

529

526

523

522

521

535

536

X45

X39

Y43

X53

X52

X46

X47

X48

X49

X40

X38

X42

X41

X44 X55

C

E

E

CGRYWHT

RECEIVER

BRNBLU

GRN

BRN

X50 Full opening detector

Y12, Y13Carriage open/close

motor

Mobile jaw receiving cells

Jaw full closure detectorConnection baron mobile jaw

C2-11 023

C6-28 128X45

2

3

4

5

6

7

9

8

RED

RED

436

421

432

417

428

025

023

024

136

121

132

128

117

1

RED

107

421

432

417

428

113

504

RED

REDRED Carriage shift brake

Carriage shift clutch

X49 Carriage right limit

X48 Carriage left-right slow down

X47 Suction bar IN-OUT allow

X46 Carriage right-left slow down

X45 Carriage home position

Carriage shift

115¡C

145¡C9139028

C7-1

C7-2

C6-3

C6-4

C1-1 001

C1-2 002

C1-4 004

C5-10 060

C5-11 061

C5-12 062

C5-13 063

C6-35 135

C6-13 113

C1-3 003

C6-7 107

1001

003

060

061

062

063

135

12

8

118

117

C4-6

C5-1 051

C5-2 052

65

047 YEL/GRN1

2

C4-1

C4-2

C4-3

044YEL/GRN

044YEL/GRN

C4-4 045

C4-5 046

Jogger pedal

Jogger upper position

Suction turbine( + cover separation blast )



Spreader heating resistor

Tank thermostat (145¡ C)

Tank thermostat (115¡ C)

Tank thermostat selector

X44 X55 Drumtemperature regulator

Jogger solenoid

Flat cableconnection

boards

Fla

t ca

ble

12345678

45678

123

EC112345678

45678

123

X52

X51

436504

C1-5 005YEL/GRN

C2

C3C4

C5C6

X53

YEL/GRN 047

KBIC A +

KBIC A -

+24v

n.o.

n.o.

120v

Y12Y13 n.c.

n.c.

n.o.

n.o.

n.o.

n.o.

n.o.

Chipsextractor

Y38

Y14

Y44

Y04Y07

Y42

X50

Cellampli.board

Y43

Y42

Y38

Sensor

Y44

Y14

Y04 - Y07

1

3

2

503

503502

502501

501

043

042043042

104103

104

103

045046

052

051(0v < V < 10v)

BB3000 WIRING DIAGRAM 2/2 November 1997

X51X51

BB3000

3

5

6

7

8

11

12

+24V

X44

X55

J3

J3

J3J33

J30

J9

J7

J21

J16

J21

J21J28

J10

J21

Carriage shifting

Carriage

Jogger

Gluing section

0V

Cover picking

0V

19v

N

N/L1

L2/L3

L1

N

J8

J30

J46

J28

P32

P32

P31

P31

5

1 23

46 C1-8

008YEL /GRN

C1-7

007

C1-6

006

008

007

006

BRNRackchassis

BLU

13

12

10

1119 419

004 4

10

190¡C

002190¡C

2

AUTO RESET

AUTO RESET

9

C7

C1

Y32

See p 2 / 12

¥

¥

2 / 9

-

+

39

15

ONOFF

F16F17

F18

1

12

1

1

1

6

J19

J16

J18

J17

J21

RC

Tr

KBIC

Torquelimiterboard

Torquelimiterboard

C7

C4C5

C6

C1

C2C3

J19

C5251

252253

254255

256257

258259

260261

262263

2

4

6

8

10

12

14

1

3

5

7

9

11

13

15

C4242

243244

245246

247248

249250

067

169

348

2

4

6

8

10

12

14

13

5

7

9

11

13

15

C3228

229230

238232

231232

233234

235236

237238

239240

241

2

4

6

8

10

12

14

1

3

5

7

9

11

13Timer

15

C2213

214215

216217

218219

220221

222223

224225

226227

2

4

6

8

10

12

14

1

3

5

7

9

11

13

15

C1201

202203

204205

206207

209

211

208

210

2

4

6

8

10

12

14

1

35

7

9

11

13

15

24

13

R

C C

262

263

307

307

P3-

7 308

309 25

1

253

2 4 6 8 10 12

1 3

203

204

320Bridge 346 for

No bridge 346 for

3

240

11

1

4

12

310

34

312

311

56

314

313

210

209

211

78

319

12

067

910

317

7

318

348

8

201

5

202

6

242

3

243

4

315

1

316

2

2

310

312

5 7 9

J15K21

J14

J1

J16

J2

F16

F17

J3J4

J7

J8

J9J10

J11J12J40

J13

F126,3 A

2

10

Cover clamping motor torque limiter

Main motor speed regulation

401

260

F18

AF

18A

304

11

R19

R17 +FA+ L1 L2

F-

A-

I1IR CL

I2MIN

ACCELP2

P3MAX

WHITE REDP1

323322

255256

257

5

3

1

311

329

328

326 327

6

4

2

PLC

3

1

4

2

215

214

217

216

213

218219

220

227223

224

318

329324

2

1

3

1

2

34

325

221222

317

5

3

1

67

8

4

2

23

1

314

313

405

402

406

407

301235

J5

To PLCinput

J6

FromPLC

output

From J2Power board

Origin, interconnectiondestination on

page 2 / 2

To PLC inputsX32 ➞ X55

To J15

torquelimiter

From PLC

outputTo/from J22

Control panel

Power board

328327

326

316

206

315

402

404

403

401

207

302245248

303239249236246233304252

254208

247244250241237231234305306205

1

335307

To millingmotor control

21

2

3

4

5

319BLU303

ORAWHTGRYREDBRNBLK 301

302

YELVIO

190V120V

200V210V220V230V240V250V

3

5

7

2

4

6

89

1

6

7

8

9

10

258407

324308405

226335

259225330325309402

403

404

RED

BLK

261

406

1

2

3

4

5

6

7

Transfo

Drawing ref.:

Date: Index


Nov. 1997

BB 3000WIRING DIAGRAM

ELECTRICAL DRAWER ( RACK )

F18 1

F18

A

F18

A

J3-7

2345

Jogger

+

260

19V

1

313

15

To connect to: - appropriate terminal if - 220V if 380V

230V if 400V240V if 415V

R

ON

OFF

BBR II

J18

L2

L1

N

L3

J17C7

321

346346

Cpedal

J21

C6

2 / 10

F9

F2

K15

K12

12 13 11

206207

67

R

262

263

307

P3-

7 308

309 25

1

253

2 4 6 8 10 12

1 3

240

11 12

310

34

312

311

56

314

313

78

319

12

067

910

317

7

318

348

8

201

5

202

6

242

3

243

4

315

1

316

2

310

312

5 7 9

F2

F9

L3

L2

L1

N


board

304

11

R19

R17 +FA+ L1 L2

F-

A-

I1IR CL

I2MIN

ACCELP2

P3MAX

WHITE REDP 1

311

329

328

326 327

215

214

217

216

213

218219

220

227223

224

318

329

2

1

3

317

5

3

1

67

8

4

2

23

1

314

313

To J15

torquelimiter

From PLC

outputTo/from J22

Control panel

Power board

328327

326

316

206

315

225

207

1

2

3

4

1

313

15

209

210

211

4K7 6

7

M10

M 10

Carriage translationbrake clutch

DrivemotorCarriage

variable speed

223224

22512

11

13

C1

C2

C

March 2002

BB3000 Carriage shifting and drum rotation motor control (front rack)

(Re) adjustmentsee page 3 / 1

J11

J1J2

J3J4

To PLCinput

J5

FromPLC

output

J6

J7

J8

J13

J40 J12

J10

J16

J9

J1078

12

J978

1/62

3/45

L1L2

I2I1 P3 P1 P2

21

L1N (L3)

J11

J1

10

14

23

26

8J6

J30

243

Y4

0110

Y7

1100

D.C. V(AT A+)

40V63V

180VPot.dept.

I (Amp.)(in 329)

0,40,610,4 < I < 1

Speed*

MinConstantMaxVariable

131211

C2

J162

1

3

6

7

C1

32

J8

L5

Clutch

L7Brake

Clutch safetyPower board

MCU

* According to the (de) energizing of K13 (Y7) and K14 (Y4)

K16

K19

K13

K14

Y7

Y4

Y14

X44

S44

Y44(M10slow)

Y40(M10on-off)

317318

225224223

313314

209 312

310211311

315

316

328

329

206

327326

207

036

037

P503P103

+

47 25W

A +

A —

Main motor speed regulation board

K13

K14

K15

K16

K19

K12WIRING

ELECTRICAL

Run

Leave trimpots "IR","CL", "ACCEL", like illustrated.i.e. fully c.w. ( )

(high for black pointer over green one)

4K7

Clutch /Brake

2 / 11

K3

K4

K5

Y5

Y9

Y8

in - out

out - in

F3

k3

k5

C2

5

6

Shutter open

Shutter close

4 Suction bar up / down

3

8

7

Carriage clamp.close

Carriage clamp.open

F5

F4

F6

F18

k2

F2

F1

3

2

1

Brake

Clutch

Air shut offvalve

K7

K8

Y11

Y10

K6Y6

K10Y12

K9Y13

K12Y14

K11Y15

K13Y7

K14Y4

K15Y40

K16Y44

61

3

2

4

P3

P1

5 P2

1K

7

8

I2

I1

L2L1

1

2Mainmotor

To

mai

n m

oto

r sp

eed

co

ntr

ol b

oar

d

On

car

riag

e

Suction barmotion

k4R10 8,2‰

47‰

Brake

FET

k7

k8

k6

k10

k9

k12

k11

7 8 915/1617/1823 26 28 30

6

19/2021/22

1 2 5 345+6

7+8

9+10

3+4

2

1

34 32 30

30 29 28

15 16 182 4 3 1 6 5 8 7 10 9 12 11 17 1413 20 27 29 31

7 15 12 11 10 2

Deadstop

6

3 4 5 6 15 16 17 18 19 20 21 22 23 25 2624

Covers

15-1831-34

Y47MCU OUTPUTSSee pg 1/4 - 2/6

Y46Y45

Y39 Y36 Y34 Y32 Y0 Y1 Y20V

X15X14

X13X12

X11X10

X9X8

X7

X6

X5

X4

X6 X4Bindingmode

0 00 11 01 1

X2X3

X1 X0MCUINPUTS

Date:


IndexAugust 2001

¤

BB3000POWER BOARD ELECTRICAL DIAGRAMCOMPONENTS LOCATION / FUNCTION

13

Y41

33

9 8

2324

0V 24V

2526

2122

K1

K17

11

Y43

12

Y42

3/45/6

65

4

4K7

N

L1

K 2K 19

3

TankThermostat

K18

4 A

3.2 A

2.5 A

1 A

2.5

A

3.2 A

2.5 A

3F9

2,5 A4

5F10

5 A6

7F11

1 A8

11F8

7 A12

k19

k18

k17

L2

L3

208 or 220Vonly

Turbines

Coil

Jogger

Glue tank heating

F7 2.5 A

Static

Drum heatingresistor

MCU

K20

Y38 C1

L1

L2

24

5V Hourscount

470 F

Pedal

Y40101

Y70110

SpeedVariableConstantMinimumMaximum

ONOFF

J1

J5

J4J2

J8

J9J10

J11

J12J3

J13

J7

J40

J22

J15

J14

C7

C5

580

C4

C1

Controlpanel

Kbic


limit

J1

J5

J6

X

Y

1

6

34

1

1

1

34

1

1

30

34

1

1

1

3

8

1

1

12

1

F12

F7F1F2

F4

F5F6

F8F9

F10F11

F3


Tank heatinghours counter

Main switch


ONOFF

K1K2K3K4K5K6K7K8K9K10K11K12K13K14K15


K20 Drum heating

K19K18K17K16

Kbic 230V supplyGlue tank heatingJoggerMain motor brake

K21 Cover clamping

There is a surge protection diode on each relay coil.

C71

Applicable from S.N. 8.700 through 61.10.4.0001 and up4.74.71.1450

R9

TZ1/2

1 2 3 4

3 4

NL3 1

2

25

13

14

11

12

24

10

9

8

7

23

26

3

4

Static

A B C

14

10

1

2

3

4 TransfoJ19

5

1

2

4

KBIC +

-

1

2

A+

A-

9

11

10

See pg 3/4

5+6

7+8

9+10

3+4

2

1

See pg 1/4 - 2/2

3

4

5

6

2

1

8

7

12

11

15

13/14

J15 J2

J1

J12 J13

J5

J6

J3

J4

J6 J7

J8

J9

J10

J1

J11

J40

InputSee pg 3/4

2 / 12

Tank resistor

ThermostatSelector

Drum

145¡C115¡C

190¡C

S44S55

Needs to be positioned 0.1mm away from drum

Greenpointer

Red pointer(selected

temp)

Black pointer(actual drum temper)190¡C

BB 3000Heating circuitry

Resistors (tank - drum - spreader)

-

+

ONOFF

MCU

T1

J5

J4

J1

J12

J17

J73

J72

F16R

F17

F7

K20

F1

K18

F10

1

1

J134

J3

J11J10

¥

¥

Controlpanel

(see pg 2/13)

19v

F16

F1

J17

19v+ 24v DC

R

S44 S55

Bindingdisabled

Drumrotationdisabled

S44 closes when black pointer reaches green pointerS55 opens when black pointer reaches red pointer

12C5

145¡C

145¡C

Thermostatselector

115¡C

115¡C

F13 F15

C1

C5

J5

J21

8

2

190¡C

190¡C

26

1

J4

J134

7

35

13

C6

38

16

5

J21

5

16

X55J73

6 X12

Y38

J71

MCU

J3 3

J10 2 J17

J11

K 20

K 18Solid state

Solid state

24

F15 F13

F10

F17

F7J12 4

13C5

L 3 L 1 L 2 N(Y) / L3( )

J10 5

8

11C3

T1

10

11

1

3

6

7

1

3

9

10

2

4

J28

Spreader

Drum

C5

C1 J10 6

J12 2

Tank heatingresistor

J28

1

36

4

5

8

1

9

33

C6

50 250

= 40¡C

J11 1

C1

2

4

1

3

15

13

J3

BBR II

ON

OFF

X44

J72

From secondary winding of T1

NOVEMBER 2001

– 23 ‰ cold

– 65 ‰ cold

– 150‰ cold

J5 6

J28

J28

6

7

1

3

9

10

2

4

J28

J28127 13 8

Auto reset

Auto reset

5

16

X55

X44

J73

66 X12

Y38

J71J72

MCU

MCUJ73

J72

J5

J1

C1

C5

36

4

5

8

1

9

33

C6

J5

24

24

J1

7

35

13

38

16

5

J21

C6

12

13

1110

11

C5

1

3

C1 C1

2

4

J21

J5

36

4

5

8

1

9

33

C6C5

C1

J21

J1

J71

2 / 13

Date:


IndexSept. 1996 A

Applicable from S.N. 8700 trough 61.10.4.0001 and up¤

BB3000 CONTROL PANEL(ELECTRICAL & WIRING)

2 / 14

Date:


IndexAugust 1997

3.74.71.0906

¤

BB3000 BOOK DETECTORS INCARRIAGE AND DELIVERY

LED1Red

LD271

K

A

LD271

K

A

3

2

1

6

5

4

7

E

C

TR1

E

C

C1100 F63V

ZD112V

+

ZD1

LED1

R4

R3R6

R5

R1

R2

8

C1

+TR1

KA

EMITTER

ec

RECEIVER

Detector Cell assy amplifierLocation emitter receiver board R1

Carriage X52 9420706 9420705 9420996 1K2Delivery X43 9420707 9420730 9420696 560

X52

X43

Cellampli.board

Cellampli.board

Cellampli.board

Cellampli.board

R22K2

R4100K

R1

R310K

R510K

R63K3

24V

0V

OUT

Books: 0VNo books: 24V

LEDS OFFAT BEAM INTERRUPTED

2 / 15

Date:


IndexJan. 1997 A

From S.N. 68.02.0.0001 onwards ¤

BBR DAMPED BOOK CHUTEMOTOR CONTROL PCB

2 / 16

2 / 17

K1

F

S4noco

nc

S5noco

nc

S8noco

nc

S6 noco

nc

S7no co

nc

K3

029

3

146 7

82

5

S9

2

16

5

4

3

S11

no

co

nc 3

146 7

82

53

146 7

82

5

K2

P2 ( BBR-X upper part )

2

1

65

43

S2noco

nc

S1noco

nc

S3noco

nc

12

34

56

78

9

S10

M1 M2

21

6

54

3

P 1to Binder

J2

J4 J5

J3

026

028

023

024

026

028

027

025

024

038

040

030

032

031

041 04

2

040

039

033

034

031

032

037034

033

035

039

041

022

036030

045

046

055

056

GRNBRN GRNBRN

002

003004

005

006

007

D1

D2

D3

K4

3

146 7

82

5 D4

002

003

004

005

Date:


IndexJan. 1997

May 1995 A

A B¤

BBR-XELECTRICAL - WIRING DIAGRAMSSTROMLAUF - VERDRAHTUNGSPL NESCHEMAS ELECTRIQUE ET CABLAGE

014

013012

015

010

014

048

043

050

047

053

052

051

035

054

037036

060059

058

044

046

059

058

017

009

013

018

042

048

050

021

053

043

051022

038

010

011

006

018

020047

052

056057

060

057

049

049

021

016015

008

00900

7

055

054

008

008

044

012

011

017

019

016

020

045

6547

1 2

TH1 TH2

2 1

3 4

029027

023

025

L

6547

1 2

001

F

S8

24 V

0V

S9

S10

1 LK2

7

6

7

6

7

4 5

63

2

8

6

1

4

4

1

1

4

3

3

3

8

6

5

8

6 55

1

4

D1

P1

Contacts are illustrated BBR-X in position of rest

Contacts are illustrated BBR-X in position of rest

Index B: BBR-X applicability limits

S1S2S3S4S5S6S7S8S9S10S11

K1K2K3K4

TH1TH2

F

P1P2

M1M2

L

D

StartBook detector on pusher headBook detector on pusher headActuated by chain when pushers " IN "Actuated by chain when pushers " OUT "Actuated when blades UPActuated when blades DOWNBBR fullEmergency stopResetSafety

Power interrupt and memoryM1 ON/OFFM2 ON/OFFM1 direction + brake

Motor 1 overload ( 1,8 A )Motor 2 overload ( 1,8 A )

Power protection ( 7 AT )

Plug to binderInterconnection

Pushers IN-OUT drive motorBlades UP-DOWN drive motor

Cycle interrupt lamp

General purpose diodes

Relay pin #

12

TH1

TH2

34

1-2-3-....

2K2

7

D2

J2/P2

nc noS1

3K

K3

K4

K2

2

7

D34K2

7

D4TH2

1 2M2

TH1

1

2M1

2

6

nc no

S2 nc no

S11

no nc

S5S6

nc no

S4

ncno

S7

nc no

S3

nc no

1

3 4

S8

nc

co

no

nc

co

no

nc

co

no

nc

co

no

S1

S2

S3

S5

S9

S10L

S6

S7

S11

M1

M2

P2

P1

K1

TH1

F

ncno

co

K2 K3K4

TH2

S4

J3

DIAGRAM APPLICABLE TO BBR-X UP TO S.N. 68.20.0.9999

2 / 18

K1

F

S4noco

nc

S5noco

nc

S8noco

nc

S6 noco

nc

S7no co

nc

029

3

14

6 7

8

2

5

S9

2

16

5

4

3

2

16

54

3

S2no co

nc

S1no co

nc

S3no co

nc

1

2

3

4

5

6

7

8

9M1 M2

026

028

023

024

026

028

027

025

024

038

039

030

032

031

033

034

031

032

037034

033

035

039

040

022

036030

045 046 055 056

GRNBRN GRNBRN

006

007

D1

K3314

6 7

8

2

5 D3

K2314

6 7

8

2

5 D2 002

003

004

005

014

010

014

048

043

047

053 035

054

037036

059

058

044

046

059

058

017

009

013

018

021

053

043022

038

010

011

006

018

020047

056057

057

021

012

016

013

009007

055

054

008008044

012

011

017019

020

045

6547

1 2

TH1 TH2

2 1

4 3

029027

023

025

6547

1 2

F

S8

24 V

0V

S9

S10

1 LK2

7

6

7

6

7

4 5

63

2 1

8

1

4

4

1

3

3

8

6 5

1

4

D1

Contacts are illustrated output unit in position of rest

12

TH2

TH1

3 4

2K2

7

D2 D3

nc noS1

3KK3

K2

2

7

TH2

1 2M2

TH1

1

2M1

2

6

nc no

S2

no nc

S5S6

nc no

S4

ncno

S7

nc no

S3

nc no

1

3 4

S5

S9

S10L

S6

S7

M1

M2

K1

TH1F

K2

K3

TH2

S4

J3

J2

J4

P1

P2J2

J5

J3

J41

P2

5

TH3

M3 control P.C.B(see specific electrical diagram)

1

M3Chute rollers

J2/P2

Tobinder

P1J1

P41

P2

from PLC (Y34)

S1S2S3S4S5S6S7S8S9S10

K1K2K3

TH1TH2TH3

F

P1P2

M1M2M3

L

D

StartBook detector on pusher headBook detector on pusher headActuated by chain when pushers " IN "Actuated by chain when pushers " OUT "Actuated when blades UPActuated when blades DOWNDelivery conveyer fullEmergency stopReset

Power interrupt and memoryM1 ON/OFFM2 ON/OFF

Motor 1 overload ( 1,8 A )Motor 2 overload ( 1,8 A )Motor 3 overload ( 1,8 A )

Power protection ( 7 AT )

Plug to binderInterconnection

Pushers IN-OUT drive motorBlades UP-DOWN drive motorChute rollers drive motor

Cycle interrupt lamp

General purpose diodes

S8

S2

S3

Tobinder

S1TH3

L

S10

Date:


IndexJan. 2000

C

A B CD

¤

BBRDELIVERY UNIT

WIRING & ELECTRICAL DIAGRAMMOTORIZED DAMPED BOOK CHUTE / 3 RELAYS

To upper part(damped chute)

002003

004005

21

6

54

21

6

54

J1

P41

+

+

+

J1 / P1P41

001

001

2 / 19

J18

BLU0V

ORAWHTGRYREDBRNBLK

220V

190V200V210V

230V240V250V

YELVIO

RED

BLK

Transfo

333

332

331

334

BLUE

342

340320

337

345

343

343

340

337

345

339

336

345

342

339

336

345

319

333

332

331

334

ON

OFF

ON

OFF

J20 F15

F14

F13

L3

L2

L1

T3 T2 T1

T3 T2 T1

N

8

6

4

2

7

5

3

1No wirehere

50 Hz

60 Hz

380 V

400 V

415 V

220 V

230 V

208 V

240 V

Main switch

Main switch

Power board Milling motorElectrical Mechanical

Transformer Mainsfrequence

Selection of proper pulley under milling motor for dust extractor

Ballast forjogger

InputCurrentdistributingnetwork

J20

L3

L2

L1

N

8

6

4

2

7

5

3

1

J11

L3

L2

L1

N

3 1

4 2

J12

F15

F14

F13

J11

L3

L2

L1

N

3 1

4 2

J12

346

BLUE

✸ bridge 346 does not exist ( must be removed ) for power distribution.

✸ Seven mandatory checks.

To connectto appropriate

terminal

4 wires ( 3 + )

5 wires ( 3 + N + )

320

321

321

1

2

3

4

1

2

3

4

fl 80 mm3 1/4"

BB3000 InstallationNovember 1997

fl 100 mm4"

J18

BLU0V N

319 N

301 L2

301 L2

ORAWHTGRYREDBRNBLK

220V

190V200V210V

230V240V250V

YELVIO

RED

BLK

Transfo To connect to220V if Y 380V230V if Y 400V240V if Y 415V

228229

230

L3L2L122A1322

T3T2T122A2

C3344341

338

323

12

3

P13-6

T3T2T1

96

228229

230

L3L2L122A1322

T3T2T122A2

C3344341

338

323

12

3

P13-6

T3T2T1

96

set for 4 A.

✸

✸✸

set for 6,7 A ( fully clockwise ).✸

✸✸

✸

✸

✸

✸✸

✸

✸

✸

20A

20A

ON

OFF

BBR

2 / 20

Pupitre de commande - sorties automate - commande turbineEmbrayage - frein - soupape aspirationMoteur translation rampe succionMoteur ascension/descente rampeMoteur ouverture/fermeture voletMoteur ouverture / fermeture chariotR sistance chauffe cylindreTransfo. alimention et ventilateursMoteur principalR sistance chauffe bac colleVibreurLimiteur de couple mot. emboit. couv.Secteur: phase L1Secteur: phase L2Secteur: phase L3Alimentation basse tensionR sistance chauffe r partiteurAutomate programmable

Protection moteur fraisage / gr cquage en 220V: 6,7AProtection moteur fraisage / gr cquage en 380V: 4A

Attention : ne jamais remplacer que par des fusibles de m me type et de m me valeur.

F1F2F3F4F5F6F7F8F9F10F11F12F13F14F15F16F17F18

F20

-

+

2,5A3,2A4 A2,5A3,2A2,5A2,5A7 A2,5A5 A1 A6,3A20A20A20A

15 A2 A1 A

Adjust

Panel, PLC outputs - turbineClutch - brake - air valveSuction bar transferSuction bar up / downShutter opening closing motorCarriage closing motorDrum heating resistorTransformer primary - cooling fanMain motorTank heating resistorJoggerCover nipping motor (torque limiter board)Mains: phase L1Mains: phase L2Mains: phase L3Power supply low voltageSpreader heating resistorPLC ( 24 v )

Roughing motor 220V: 6,7ARoughing motor overload 380V: 4A

F12

F13 F14F15

F16F17

F18

F7F1F2

F4

F5F6

F8F9

F10F11

F3

D.C. power supply


Fuses

On

po

we

r b

oa

rd

Rating Protected circuitry Circuit / composant prot g Abgesicherte Teile

Tank heatinghours counter

Main switch

Power interfacing /+ suction bar speed

Logiccontrol

Transfo


Warning : For continued protection against fire hazard replace only with fuses of same type and rating.

ONOFF

K1K2K3K4K5K6K7K8K9K10K11K12K13K14K15


K20Drum heating

K19K18K17K16

Main motorGlue tank heatingJoggerMotor brake

Roughing motor relay

Resetableroughing motor

overload

K21Cover clamping

VORSICHT : nur durch Sicherungen gleichen Typs und Werten ersetzen.

Steuerpult - Autom. Ausg nge - SaugmotorKupplung - Bremse - LuftventilSaugergest nge, herein - herausSaugergest nge, hoch - tiefAuswurfklappe, MotorTransportschlitten, ffnung - Verschlu§LeimwalzenheizungTrafo ( prim re Wicklung ) - K hlventilatorHauptmotorTankheizungR ttlerDrehmomentbegrenzungsplatineNetz: L1Netz: L2Netz: L324V StromversorgungHeizung LeimabstreiferPLC Automat

Fr semotor berlast-Sicherung bei 220V: 6,7AFr semotor berlast-Sicherung bei 380V: 4A

Air24V automate ( s curit s au repos )Rampe ( translation lente )Sortie de la rampeRentr e de la rampeAscension - descente rampeOuverture voletFermeture voletOuverture chariotFermeture chariotSoupape air aspirationEmbrayage - Frein chariotR gulation vitesse moteur principalR gulation vitesse moteur principalRotation cylindre ( retir = moteur inhib )

Luft24V zu PLC, ( Sicherheitshaube unten )Saugergest nge, langsamSaugergest nge, innen - au§enSaugergest nge, au§en - innenSaugergest nge, auf - abAuswurfklappe, offenAuswurfklappe, geschlossenTransportschlitten, offenTransportschlitten, geschlossenLuftventil, offen - geschlossenTransportschlitten, Kupplung-BremseHauptmotor, Geschwindigkeit-KontrolleHauptmotor, Geschwindigkeit-KontrolleLeimtrommel, Drehung ( aus= verhindert )

BB3000

Service manual BB3000 Component location fuses and relays July 2001

F20

F DGB

2 / 21

BB3000

To transfer the contents of the programmed EPROM to the internal RAM:

1. Switch OFF the power.2. Align the IC pins with the width of the memory socket.3. Insert the chip with the proper orientation.4. If mode is switched to run, switch ON power.

( if mode is switched to prog, move to run )

The transfer of the contents of the EPROM to the RAM is automatic, and takes – 3 minutes.

Up to you to leave or to recover the chip to further program blankPLC's, but if you recover, switch off prior to remove the chip.

Model

Control EPROM #(programmed)*

9422025

PLC #(not programmed)

9132011

Rev. 03-98 Life of battery9133093

Programmable logic unit.

Identification

(Re)programming instructions.

* Supplied with this instruction sheet

Off1234

16171819

PLC

Prog

Run

Run indicator

IN.H

Inputs ( X )

Inputconnector

Supply ofnext boards

External 24V DCpowersupply

Outputs ( Y )GreenRed

LEDS

Control board (top)- Backup batteryunder this cornerof top board. Negative facing board.

- To replace at leastevery 7 years.

- Battery shape:coin IEC #: CR 2032

- Insert new battery within 5 minutes fromremoval to keep theprogram save.

- Flashes during oneweek when it is timeto replace the battery.

15

12

12

GND5V

0V DC

1 AT

24V

8

4

0

Alarmbattery

Description

On

AdjustmentsElectricalMain motor speed (re)adjustment (Kbic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 1Carriage shifting and drum rotation motor control (front rack) . . . . . . . . . . . . . . . . . . . .pg 3 / 2Cover clamp motor torque limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 3Suction bar speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 4

MechanicalCover clamp clutch spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 5Procedure to re-time gears on the cover station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 6Adjustment of the position of the stationary knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 7Alignment of the sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 8

May 1999

ON

OFF


I

3

AD

JUS

TM

EN

TS

3 /1

12 13 11

Service manual BB3000 May 1999

ONOFF

Controlpanel

Kbic





J1

J10

J9J8

Carriage drive motor speed (re)adjustmentn.b. the boards are adjusted in the factory prior to their shipment.

Why?¥ To reach the optimum operating speed

When?¥ Never, under normal circumstances.¥ When the carriage bangs at limits (after running in period?).¥ When the production rate gets lower than usual.¥ When motor or speed regulation boards has been replaced.

Procedure¥ Leave all trimpots like illustrated as a basic adjustment. (accel. is fully C.C.W)¥ Connect voltage meter between A+ & A—¥ Remove J8 or F2 to disable the carriage drive clutch

Minimum speedThe reading should be 40V D.C. when idling. If the reading differs, turn trimpot "min" until reading is 40V D.C.

Maximum speedSwitch off millling motor ( )Start binding cycle (catch and tap missfeed detector actuator). The reading should be 180V D.C.If the reading differs, turn trimpot "max" for 180V D.C. reading.

¥ Double check the voltages. Adjustments are interdependant.

¥ Restore the binder to an operating condition.

206207

211210

6

10

7

11

R

262

263

307

P3-

7 308

309 25

1

253

2 4 6 8 10 12

1 3

240

11 12

310

34

312

311

56

314

313

210

209

211

78

319

12

067

910

317

7

318

348

8

201

5

202

6

242

3

243

4

315

1

316

2

310

312

5 7 9

J1

J16

J2J3

J4

J7F2

J8

J9J10

J11

L3

L2

L1

N

J12J40

J13


board

304

11

R19

R17 +FA+ L1 L2

F-

A-

I1IR CL

I2MIN

ACCELP2

P3MAX

WHITE RED

P1

311

329

328

326 327

215

214

217

216

213

218219

220

227223

224

318

329

2

1

3

317

5

3

1

67

8

4

2

23

1

314

313

J5

To PLCinput

J6

FromPLC

output

To J15

torquelimiter

From PLC

outputTo/from J22

Control panel

POWER BOARD

328327

326

316

206

315

207

225

1

2

3

4

1

313

15

F2

ON

OFF

BBR II

Y4 Y7Carriage speeds (k14) (k13) Volts

- minimum = idle 0 1 40V- variable = milling "ON" 0 0 40 < V < 180- constant = close notching 1 1 63V- maximum = milling "OFF" 1 0 180V

6

7

M


Drivemotor

223224

22512

11

13

C1

C2

C

341

2

PROGR. 12

3

45 6

7

8

9

10

Control panel

ON

OFF

K14 K13

3 /2

F9

F2

K15

K12

12 13 11

206207

67

R

262

263

307

P3-

7 308

309 25

1

253

2 4 6 8 10 12

1 3

240

11 12

310

34

312

311

56

314

313

78

319

12

067

910

317

7

318

348

8

201

5

202

6

242

3

243

4

315

1

316

2

310

312

5 7 9

F2

F9

L3

L2

L1

N


board

304

11

R19

R17 +FA+ L1 L2

F-

A-

I1IR CL

I2MIN

ACCELP2

P3MAX

WHITE REDP 1

311

329

328

326 327

215

214

217

216

213

218219

220

227223

224

318

329

2

1

3

317

5

3

1

67

8

4

2

23

1

314

313

To J15

torquelimiter

From PLC

outputTo/from J22

Control panel

Power board

328327

326

316

206

315

225

207

1

2

3

4

1

313

15

209

210

211

4K7 6

7

M10

M 10


DrivemotorCarriage

variable speed

223224

22512

11

13

C1

C2

C

March 2002

BB3000 Carriage shifting and drum rotation motor control (front rack)

(Re) adjustmentsee page 3 / 1

J11

J1J2

J3J4

To PLCinput

J5

FromPLC

output

J6

J7

J8

J13

J40 J12

J10

J16

J9

J1078

12

J978

1/62

3/45

L1L2

I2I1 P3 P1 P2

21

L1N (L3)

J11

J1

10

14

23

26

8J6

J30

243

Y4

0110

Y7

1100

D.C. V(AT A+)

40V63V

180VPot.dept.

I (Amp.)(in 329)

0,40,610,4 < I < 1

Speed*

MinConstantMaxVariable

131211

C2

J162

1

3

6

7

C1

32

J8

L5

Clutch

L7Brake

Clutch safetyPower board

MCU

* According to the (de) energizing of K13 (Y7) and K14 (Y4)

K16

K19

K13

K14

Y7

Y4

Y14

X44

S44

Y44(M10slow)

Y40(M10on-off)

317318

225224223

313314

209 312

310211311

315

316

328

329

206

327326

207

036

037

P503P103

+

47 25W

A +

A —

Main motor speed regulation board

K13

K14

K15

K16

K19

K12WIRING

ELECTRICAL

Run

Leave trimpots "IR","CL", "ACCEL", like illustrated.i.e. fully c.w. ( )

(high for black pointer over green one)

4K7

Clutch /Brake

3 /3

Service manual BB3000 May1999

ONOFF

Controlpanel

Kbic



J1

J7J10

J14J15

J22

J9J8

J2

J4

F126,3A

K21

9421204

max

minTorqueadjust

TP min

TP max

R22

R23

R19

R20

R21

1002M2

100

4

3

2

1

J14

2

10

J15J2

Clamppressure

knob

Coverclampmotor

J4J22

J1MCU

10K

Y47Y47Y46Y46

Y45Y45

C2

M

Cover clamp motor torque limiter adjustmentPurpose: the torque limiter must be adjusted for the proper clamping pressure range of the cover clamp.

Preliminaries¥ The binder must be operational in the binding mode # I.¥ Open the upper and front panels.¥ Tape the cover detection switch X32 to the top of the suction bar.

Procedure: two alternative adjustments are possible.

1. Current measurement

Requires a 10 amps DC meter to measure the actual current through the motor.Requires a little time to make the adjustment (turn duration POT. to maximum)

Minimum torque adjustment

¥ Remove the wire from pin # 4 of J14 on the torque limiter PCB.¥ Connect a 10 amp meter between wire # 4 and pin # 4.¥ With the clamp pressure knob at minimum, start a "book" cycle with the two green buttons.¥ When the clamp comes up and just closes, the meter should read between 1 and 1.75 amp.¥ Adjust the minimum pot if necessary.

Note: the rear and front nippers must close completely and smoothly when minimum pressure is selected, after the adjustment is made.

Maximum torque adjustment

¥ Repeat the above adjustment with the pressure knob on maximum.¥ The reading should be 5 amps maximum.¥ Adjust the maximum pot if necessary.

2. Voltage measurement

Control the logic function of the PCB up to the power stage.

Minimum torque adjustment

¥ Connect a voltage meter between R19 and ground.¥ With the clamp pressure knob at minimum start, a "book" cycle with the two green buttons.¥ When the clamp comes up and just closes, the meter should read between 0.1 and 0.175 VDC.¥ Adjust the minimum pot if necessary.

Note: the rear and front nippers must close completely and smoothly when minimum pressure is selected, after the adjustment is made.

Maximum torque adjustment

¥ Move the positive probe to R22.¥ Repeat the above adjustment with the pressure knob on maximum.¥ The reading should be 0.5 VDC maximum for cover clamp¥ Adjust the maximum pot if necessary.

10

9

max

minTorqueadjust

R22

R23

R19

R20

R21

1002M2

100

TP min

TP max0V

0V

3 /4

Date:


IndexJuly 1996 A B

¤

BB3000POWER BOARD ELECTRICAL DIAGRAMSUCTION BAR SPEED CONTROL

Applicable from S.N. 8.700 through 61.10.4.0001 and upIndex B: identification for the suction bar detector 4.74.71.14514.74.71.1451 A

K3

1

2

3

4

in - out

out - inF3 k5

J7 C2k4

R10

FET

4 AT

Full speed adjust. Slow speed adjust.

C1

C2

ZDR1

R2

R3

C3

IC1

IC2 IC2

D22R4

C4C5

R5

D23TRP1 TRP2

D24R7

R6

C6

IC3J625

IC11

5

IC21

5

IC31

5

K3 K4

K5

K6

TRP1

TRP2

C2

C1

FET1

D22

C3

R1R5R6

R2

R3

R8R7

R4

C5C4

ZDD24

D2

3

C6

R10

J6J51

30

1

34

12V

Bar motion

2/2

24V from k2( see diagram 4.74.71.1450 )

OUT

CVGND

VCC 1

23

6

7

5

2

34

+

7

6

TRIGTRES

DISRES

F3

F4

F5

C8

Y5MCU bar

slow motion

instruction

R8

C8

J7

R1R2R3R4R5R6R7R8R10

FET

D22

470220

11002K22K21001008,2

IRF540

BAT85

‰K‰‰K‰‰‰K‰K‰‰ 10W

C1C2C3C4C5C6C8

ZD

IC1IC2IC3

100220

10,10,1100,1

12V

NE55540107

CA3160

FFnFF cerF cerpF cerF cer

*

1

2

3

4

5

6

7

SUCTION BARMOTION MOTOR

(IN - OUT / OUT - IN)

SUCTION BARSLOW DOWN(OUT - IN)

SUCTION BAR INNERLIMIT DETECTOR

COVER PICKINGDETECTOR

SUCTION BAR

X36

X37

*

( Fierce starts can result in cover versus suction cups slipping )

( Accuracy of home andinner bar position )

Important ! Read complete procedure beforemaking the following actions

Suction bar full and slow speed adjustment.

Purpose: for the fast and smoothy transfer and the accurate positionning of the cover.

Preliminaries:- Select binding mode I or II.- Check that the suction bar is home ( fully out )- Lock ( tape ) the actuator of the switch at the end of the suction bar in activated condition.- Disconnect one of the bar motion motor feed wires. ( J71 or J72 )

Procedure:- Depress the green buttons to start a binding cycle.- The suction bar obviously stays in home position ( its motor being disconnected )- Trim TRP1 for 8V between and- Pull the chain of the suction bar until its flag is between sensors X36 and X37. Trim TRP 2 for 8V over motor terminals ( J71 and J72 )

- Rewire the loose motor wire within one minute to prevent slow down resistor R10 from overheating.

3 /5

Cover clamping clutch

1. Spring tension check

1.1. Check that the cover clamping is in lowest position. Lower if necessary

1.2. Unlock (3 mm allen key) the adjustment collar.

1.3. Check that the front nipper can move forwards only (a couple of millimeters backlash is however acceptable).

1.4. To move the front nipper backwards, it is necessary to turn the adjustment collar by hand 15° to 20° in clockwise direction.If the front nipper can move in both directions, the clutch is ok !

n.b.: if the collar is not held manually, the clutch is engaged and only the clo-sing movement of the front nipper is possible (like a ratchet).

2. Spring tension adjustment

The following procedure is required after any cleaning or replacement of the clutch spring. It is valid only provided the timing of the gears is correct.

2.1. Make sure that the cover clamping is still in lower position.Remove the guard of the feeding unit to get access.

2.2. Loosen the adjustment collar.

2.3. Move the front nipper fully forwards (in closed position).

2.4. Move it backwards (the gap is restricted because the clutch does not allow the maximum opening).

2.5. While holding the bushing, turn the adjustment collar in C.C.W. direction until its catch touches the stop pin.

2.6. Put a mark on the bushing in line with the adjustment collar edge (1).

2.7. Put a second mark (2) on the bushing 5 mm further in C.C.W. direction.

2.8. Move the front nipper inwards, so that the bushing turns in C.W. direction.

2.9. Turn the collar to align the second mark (2) and tight the collar screw.

2.10.Check the front nipper movement.

n.b. there are no situations where the front nipper movement is impossiblein both direction, except if the nipper is already closed (full inwardstravel).

2.11. If the result is not OK, repeat the procedure from § 2.7. with a third mark5 mm further, ifthis is still notenough, re-timethe gears.

1

2

5 mm

Adjustment collar

Catch

BushingStop pin

Service manual BB2005 / BB3000 — Rev. April 1997

3 /6

Procedure to re-time gears of the cover stationNecessary in case of overtravel of rear nipper cam 34 and subsequent cover station blocking.Remove the suction bar drive system.

1. Close shutter (2) manually, if it is open. (Disconnecting J7 facilitates the closure)

2. Loosen the two headless screws and remove keys in motor movement transmission unit. (13)

3. Remove nylon gear (8) and small gear (6).

4. Rollers (3) of rear nipper should be where illustrated on cams (34), not in cutout.

5. Move the nippers 105 mm apart manually.

6. Replace nylon gear (8).

7. Replace gear (6) with its pin fully clockwise without moving neither gear (5) nor cam (34).

8. Pull the rear nipper forward, mark this position on teflon plate (2) and release rear nipper. Put a second mark 45 mm further in the direction of the front nipper.

9. Turn motor transmission unit by hand until front and rear nipper nippers reach the two marks simultaneously.

10. - If front nipper aligns with the second mark before rear nipper reaches first mark, loosen set screw in collar (4f) on front nipper clutch assembly and turn collar counter clockwise and tighten screw.

- If front nipper is delayed, turn collar (4f) clockwise.

11. Replace key in motor movement transmission unit (13) and tighten set screws. Restore the binder to working condition.

ON

OFF

4f

8

6

34

5

34

33

OPERATOR SIDE

FRONTNIPPER

REARNIPPER

13

2

Service manual 3000Rev. April 1997

34

BB3000

3 /7

BB3000 # 61.10.4.5569 and upBB2005 # 64.20. . and up

Oct. 1997

The clearance between milling blade and stationary knife needs adjustment when strips of chips are collected in the waste bag instead of small pieces of paper dust.

Preliminaries (retrofit only)- Slide block to the utmost left (slots-screw 1 ).- Lay stationary knife on support plate (screws 4 protrude)- Line-up close long edge of stationary knife with

carriage fixed jaw (screws 3 and machinist scale caution: fragile threads in alloy).

Adjustment of the position of the stationary knife

Horizontally: slide the stationary knife to allow the notching knife to pass freely in cut out (nuts 2 ).

Vertically: Adjust screws 4 for a minimum gap between stationary knife and blade.n.b. - The gap is not visible - proceed acoustically*

- The rear screw 4 tilts the stationary knife- Loosen the locking nut of screws 4 enough to turn them freely.

Slide now block back. Lock 1 when it just clears any point around the blade* .* Rotate blade with carefulness in C.C.W. direction to reveal and eliminate any audible rubbing.

A couple of adjustments can interfere - check and readjust as required.

2

1

3

4

5*

ST. KNIFE

Highest tooth(coloured) ofmilling blade

Notchingknife

1

ST. KNIFE

SUPPORT PLATE

CARRIAGE(FIXED JAW)

4 4

1

4

44

2

14

382

3

1

2,5

8

44

3STATIONARY

KNIFE

KNIFESUPPORT

PLATE

Millingblade

11

44

4

3

3

3

3

2

2

23

3 /8

Zero level (jogger fully up: 0,0 mm)

(jogger fully down: -2,2 mm)

- 1,1 mm

Spreader bladelevel adjustAdjust when glue is at 140¡C (coolbind)

Adjust when glue is at 160¡C (1122R)

+ 0,8 mm

Jogger

¥ Tolerance on distances: 0,05 mm (comparator) unless otherwise specified.

* Applicable for the viscosity of the glue we supply (cool bind).Lift drum to -0,8 mm and reduce scraper gap to 3 mm for glue 9.195.025 (1122R)

Important: these are very critical interdependant adjustments which are only to be changed when absolutely necessary.Careless readjustment or loss of references would involve a mandatory complete relevelling of each section.

Cover plate

Mingap

Cover plate

Maxgap

Drum scraperMax gap= 3,5 mm

Drum- 1,5 mm*

Angle : 30¡Position : fully up

Nipping upLever up : - 0,2 mmLever down : - 1,3 mm

Gluetank

Solenoid

0 mm + 0— 0,05

3

10

19

Locking2

Knife Adjustment(slotted)

19

Notching / milling

Spreader

17

19

fl 1.5 mm*

17

*

Date:


IndexApril 2000

¤

BB3000 ALIGNMENT OF THE SECTIONS(IN OPERATING CONDITIONS)

A B C

Zero level(Colouredtooth)

Spare parts listGuards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 1Fuses & relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 2Switches - Cells - Buttons thermostats- boards . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 3Motor & solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 4Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 5Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 6Carriage drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 7Jogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 8Notching & milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 9Gluing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 10Cover clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 11Cover station - suction bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 12Suction bar drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 13Suction air cut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 14BBR (output unit - bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 15BBR (output unit - up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 16Index & recommended parts for one year . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 22

November 2003

ON

OFF


I

4

SP

AR

E P

AR

TS

4 /1

BBR

1 2087994 (Assy)2 2086978 (Little model)

2086979 (Big model)3 2087701 (Plexi)4 2083110 (Funnel)5 20877026 94018497 20871018 20871709 940218010 208710211 208199812 208043413 9195025 (1122 - R 20 kg)14 2080997 (One pair)

2985286 (Wheel only)15 298527916 298528317 298528218 919943119 208099820 9139434

9139000 (version 2)21 919947622 913902923 919947524 208499825 2086815 (Protection band)26 913904427 919950428 913943330 2087998 (Tool box)

2083995 (Side gluing kit)

Date:


IndexDec. 2000

11C

¤

BB3000 ILLUSTRATED SPARE PARTS LISTGUARDS

Index D: Item # 13 corrected

A B CD

ON

OFF

Glue20 Kg

Applicable to BB3000 from S.N. 61.10.0.0001 and up

09139029

-

+

9199504

+

+

-

-

-9199475

9199476

c.p. bourg

TOOL BOX

Guards quarter turn fastener

1122

R

Option

18

1615

121

3

22228

27

20

4

5

26

23

17

9

10

25

12

78

13

19

11

6

14

14

Option(pg. 15 & 16)

2430

4 /2

-

+

F12 F13 F14 F20F7

F1F2 F4F3

F5

F8F9

F10F11

F3F4

All fuses are slow blow

ON

OFF

K1

K2

K3

K4

K5

K6

K7

K8

K9

K10

K11

K12

K13

K14

K15

K16

K17

K18*

K19

K20*

K21

* Static relay 5A 380v (See pg.6/2)Solder type

¥

¥

¥

¥

¥

¥

Air valve

24V to PLC

Suction bar slow motion

Suction bar in - out

Suction bar out - in

Suction bar up - down

Shutter opening

Shutter closure

Carriage opening

Carriage closure

Air shut-off valve

Carriage clutch

Main motor speed control

Main motor speed control

Drum rotation (off = inhibit)

Motor brake

Jogger

Glue tank heating

Main motor

Drum heating

Cover clamping

9169016

9169085

9169907

9169907

9169907

9169907

9169907

9169907

9169907

9169907

9169907

9169907

9169906

9169906

9169906

9169907

9169907

9169092

9169087

9169092

9169047

Fuses RelaysRating Protected circuitryPart # Controlled componentPart #F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

F17

F18

F19

F20

2,5 A

3,2 A

4 A

2,5 A

3,2 A

2,5 A

2,5 A

7 A

2,5 A

5 A

1 A

6,3 A

20 A

20 A

20 A

15 A

2 A

1 A

4 A

Panel, PLC outputs - turbine

Clutch - brake - air valve

Suction bar transfer

Suction bar up / down

Shutter opening / closing motor

Carriage clamping motor


Transformer primary - cooling fan

Main motor


Jogger

Cover clamping motor torque limiter card

Mains: phase L1 230V or 380V



Power supply low voltage

Scraper heating resistor

MCU

Turbine

Milling motor

9124035

9124017

9124008

9124035

9124017

9124035

9124035

9124094

9124035

9124018

9124030

9124016

9124080

9124080

9124080

9124031

9124026

9124030

9124008

9124093

Drawing ref:

Date: Index


May 1999

BB 3000 ILLUSTRATED PARTS LISTFUSES & RELAYS

A

2

ON

OFF

BBR

K13K14K15

¥ K19

¥ K2

¥ K20*

¥ K18*

K17

K16

K21

¥ K1

Index A: New rating for F2 & F5

From S.N. 61.10.4.0147 onwards

Set to 4 A for 380V

Set to 6,3A for 230VAdjustable

F15

F16 F17 F18F16 F17 F18

K3K4K5K6K7K8K9K10K11K12

F6F6

F19

916908491690849169090

4 /3

Drawing ref.:

Date: Index


May 1999

BB 3000ILLUSTRATED PARTS LIST

SWITCHES - CELLS BUTTONS THERMOSTATS BOARDS

AD

Index D: Item # 36 added

B

33C

C

1 9150014 2 9420996 3 9420706 4 9420705 5 2983716 6 9146183 (green)

9146184 (blue) 7 9102033 8 9146182 9 914600610 914606811 9146024 (momentary)12 9146025 (push on/off)13 914617914 9162034 (10K)

9162035 (47K)15 9104070

+ 9104069+ 9104072

16 942069317 2983264

18 2983952 (145¡C)19 2983951 (115¡C)20 9124163 (190¡C)21 298399122 208199823 915004624 298390825 942069626 942073027 942070728 298388629 298385230 914618131 298357432 298328633 9422506 (10A)34 943066835 942195436 9170156 (47‰ 50w)

X45

X52

X53

X51

X46

X47

X48

X49

X40

X38

X42

X41

X44X55Cell

ampli.board

Cellampli.board

X43

X36X37

X33

X35X34

X32


Safety onperspex

Cellamplifier

board

Cellamplifier

board

11

21

1

17

1

2 3 4

6

5

7

8

1

20

9

19 18

10

22

23

24353625

11 1213

14

15

16

26

29

27

29

2929

130

3132

33

34

28

4 /4

Drawing ref.:

Date: Index


March 2002

BB 3000 ILLUSTRATED PARTS LISTMOTORS & SOLENOIDS

A

Index D: items # 12 added

B

44B

C

Y08Y09

Y06Y06

Y10 Y11

Y12 Y13

Y15Y15

Y45 Y46

1 91510462 91360653 94309374 2085819 (120v brushless)5 29811246 20840097 2984114 (rubber)8 9431259 (suction bar in-out)9 9430937 (sction bar up-down)

10 299039011 943093712 2981131 (motor: up to 61.10.4.5391)

9151128 (motor: 61.10.4.5392 and up)2983985 (one brush)*

13 298410614 913702215 915114016 915104617 2985276

* ! watch life expectancy15

17

11

10

16

13 14

4

8

9

5

6

7

3

2

1

12

4 /5

-

Index D: split of item 12 (Matsushita / ABB-ASEA)

Drawing ref.:

Date: Index


Dec. 2002

BB 3000 ILLUSTRATED PARTS LISTOTHERS

55C

AD

B C

1 9260854 2 9412138 3 2086815 4 9119001 5 2081998 6 9430957 7 2085009 8 2085127 9 912020610 916700411 9421236

12 9132011 (small MCU - not programmed)9421782 (eprom)

9132010 (ABB - ASEA 24v - not programmed)2970019 (eprom prog. 23)Reminder: 230v model is no longer available

13 9170156 (47‰ 50w)14 2985276

1

14

2

3

4

12

10 9

6

78

5

1113

4 /6

Date:


IndexMay 1999 A B

¤

BB3000 ILLUSTRATED SPARE PARTS LISTCARRIAGE

From S.N. 61.10.0.0001 and up

6

BBR II

ON

OFF

Home

Operatorside

X50

Y12Y13

X51

X52

X52

1 2086978 (short) 2086979 (long) 2 9117005 3 2980128 4 2086330 5 2086817 6 2086012 7 9420705 (one pair: R.) 8 9420706 (one pair: Em.) 9 298397810 916205111 942099612 915001413 2086977 (elastic)14 2088893 (flat cable)15 942111916 298206817 911700718 943093719 298206020 9175084

Carriage assembly: 2086999

Index B: carriage assy # corrected

4

6 19

17

1820

810 13

11 12

5

3

2

1

1

7

14

15

16

9

4 /7

Date:


IndexOct. 1996

7 B

A B C¤

BB3000 ILLUSTRATED SPARE PARTS LISTCARRIAGE DRIVE SYSTEM

1 9137022 2 2086303 3 2086819 4 2083809 5 2086822 6 2981131 (motor: up to 61.10.4.5391)

9151128 (motor: 61.10.4.5392 and up)2983985 (one brush)*

7 2086991 8 2086010 9 298410610 2980117 11 2086820

9111002 (connecting link)12 942111913 9111061 (161 links)

9111059 (5 links + stud)14 208889315 299024716 299024817 208697718 208601119 208630720 208632521 208630422 298001223 00439080000624 208600125 2984006 (connecting link)

From S.N. 61.10.0.0001 and up

Index C: different # for item 11

To drum

ON

OFF

BBR

7

* ! watch life expectancy

4

6 5

2

13

110

7

9

8

18

19

23

20

2221

10

14

1617

15

12 11

24

325

4 /8

1 2981411 2 2980125 3 2982061 4 2990389 (50 Hz: 4 each

60 Hz: 2 each) 5 2990390 6 2080998 7 2990228

Date:


IndexJuly 1997

8

¤

BB3000 ILLUSTRATED SPARE PARTS LISTJOGGER

Index A: item # 7 added


A

BBR II

ON

OFF

3

7

3

1

6 2

4

5

4 /9

Date:


IndexMarch 2001

®

BB3000 ILLUSTRATED SPARE PARTS LISTNOTCHING /MILLING + CHIPS EXTR.

1 9151140 2 2984123 3 2082700 4 2082803 5 2990126 6 2082802

+2082801 7 2082422 8 2082416 (50Hz)

9221843 (60Hz) 9 941213810 208240011 299024312 921865913 921865814 208231215 208210416 2082809

17 208280618 298533019 208281020 299012521 299012422 009160400823 208270224 941213625 9190599 (4x)26 919056227 926085428 921742429 940183330 M 2083989 (option)

2083803 (coal filter)2083804 (tissue filter)

31 298002932 298000933 941261534 208212435 2985284

From S.N. 61.10.4.5578 and up

AD

BE

CF

Index F: add the new item 34 and 35

99E

BBR II

ON

OFF

Optional outdoor fumesexhaust kit: M 2083988

19

18 34

1

8

9

7

24

31

32

3

6

6

11

1013

23

29

27

28

16

35

5

4

25

26

20 2122

30

12

2

15

17

33

14

4 /10 To clutch(Pg. 7)

Side gluing retrofit kit: 2083995

Tank + drum assembly #2083999 / 10From S.N. 61.10.0.0001 and up

Index F: items 40 / 41 / 42 addedDate:


IndexOctober 2003

¤

BB3000 ILLUSTRATED SPARE PARTS LISTGLUING SECTION

1

A B CD E F

1010 E

2083990 assy(items 27, 40,

41, 42 incl.)

14 2983952 (145¡C)15 2983951 (115¡C)16 298385717 299032718 914602019 208314820 208330621 208330722 2083800 (grad. band)23 2083310 (wheel)24 2083412 (¿ 2mm) STD

2083416 (¿ 1,5mm) T. kit25 2083152 (scraper)26 208380927 208380728 2086822

ON

OFF

Fume / smellsextractorpage 9

* ! watch life expectancy

29 2981131 (motor: up to 61.10.4.5391)9151128 (motor: 61.10.4.5392 and up)2983985 (one brush)*

30 208370031 915104632 9124163 (190¡C)33 0000002999 (¿ 2mm)

0000001599 (¿ 1,5mm)

1 2985102 (3 units) 2 2983991 (resistor)

2083002 (spreader)

2

19

21

23

20

22

34

3

38

6

7

9

10

111213

27

36

4140

42

8

5

4

26

30

33

32

16

14

24

15

33

28

18

35

25

17

35

39

29

31

37

3 2983264 4 2990355 5 2980132 6 2083000 7 2990315 8 2985263 9 298526210 299031911 208370112 298007613 2083806

34 298526135 208315336 917507837 298527638 298341739 298002640 004720047041 299021342 2083104

9111002 (3/8")

4 /11

Date:


Index

Nov. 2001

®

BB3000 ILLUSTRATED SPARE PARTS LISTCOVER NIPPING

1 2084427 2 2084420 3 2980128 4a 2084337 4b 9166058 4c 2980138 4d 2084338 4e 9401991 5 2084805 6 2084802 7 2980124 8 2084806 9 912703610 942069611 208440012 298012813 298411414 208897015 2084009 assy16 2084814 + 911100217 208480918 2084992 M1419 2085819 M9 (117v)20 9260216 (2x)21 2981120 M1522 208481623 208897224 2088973

25 208481726 208482227 299017828 2084330

33 208482534 208443835 208442636 208401337 298207838 298012639 208401440 941224241 941224342 208400243 9101003

29 208482130 208416831 2084402 32 2084801OPERATOR SIDEOPERATOR SIDE

ON

OFF

BBR

A B C

1111B

See pg. 3

See pg. 3See pg. 3

Index C: item # 4c and 4e corrected

42

3

4e

7

9

8

618

13

1617

14

19

1211

21 36

23

24

22

15

4b4a

38

4c

4d

31

32

26

34

34

25

20

33 10

27

40

2829

30

35

3943

37

5

12

43

41

41

4 /12

Date:


IndexJan. 2003

®

BB3000 ILLUSTRATED SPARE PARTS LISTCOVER STATION - SUCTION BAR

12

A B C

BBR II

ON

OFF

Index C: new assy # 36

16 208541817 208522418 922185119 208521920 208535021 926063322 299023723 208542724 208443025 208416026 208599627 208543428 298600129 943161830 208581231 208581032 299033933 2982073 spring34 208532235 208581336 9413930

Applicable to BB3000 from S.N. 61.10.0.0001 and upApplicable to BB3000 from S.N. 61.10.0.0001 and up

"T" 9260503"Clip" 9199843

1 2085009 2 9261101 3 2085127 blade 4 2986048 5 2983886 6 2982066 7 2986057 8 2084335 9 208443110 298604811 208599012 208533413 941056414 208533215 2085425

2

3

4

5

29

30

35

1

34

6

731

25

24

32

1213

1415

16

3320

22

28

36

26

26

21

8

27

11

9

19

18

18

17

23

10

4 /13

208581420858032085802943125994309372985287942203329838522085112

123456789

101112131415161718

20851069175010913101320853472980133208543020853012085816 (Teflon)2085808

Date:


IndexNov. 2000

®

BB3000 ILLUSTRATED SPARE PARTS LISTSUCTION BAR DRIVE SYSTEM

282930313233343536373839

4041

208501420854002085311208540729820692085700208099820858052980012915001429903312085403 (17 incl.)20850109200933

42434445464748

2085983 (assy)9161082298411029841092085987 (assy)91610842984109

1313B

A B C


192021222324252627

208530620858012980075298011820851132085300917508420858019217422

ON

OFF

BBR II

Index C: items # 42 to 48 added

Seepg. 12

Suctionbar

•

•

•

•

••

4

5

2

3

22

22

34

426

43

43

44

45

46 47

48

1

8

11

25

2627

28

2930

31

25

33

41

35

36

40

18

23

12

20

39

37

24

15

17

16

16

1314

12 32

2319 20

21

38

227

8

9

10

4 /14

1 9.200.385* 2 9.157.001* 3 9.200.386 4 9.140.008 5 9.260.692 6 9.166.052 7 9.260.693 8 9.136.065* 9 9.216.10210 9.216.10011 9.190.10312 9.172.00313 9.260.667*14 9.260.668*15 9.216.10316 9.190.16617 9.172.00418 9.216.10119 9.135.00620 9.260.67121 9.190.42622 9.200.405*23 9.157.025*24 9.260.66925 9.221.64026 9.190.165

ASSEMBLY # 9.430.957

* Subject to wear

Applicable to MOD"S" from S.N. 413.000to BB3000/9 from S.N. 8.700

Date:


IndexFEB. 1993

¤

BB3000 ILLUSTRATED SPARE PARTS LISTAIR CUT OFF

1414

4 /15

nc

co

M1

M2

Assy9580115

Detailedpage 16

Steel

Nylon

P1

Binder

P2

8 9150053 (Switch only)9261117 (Actuator)

9 9150073 (Switch only)10 800310700011 P80100060012 800101100013 700202100014 943093715 299029716 913504617 208043418 913507819 916900120 9124094 (7 AT)

9164004 (Fuse holder)21 9008007800 (Switch only)

9008006400 (Yellow cap)9008004100 (Bulb)

22 9146067 (Contacts only)23 800203500024 800201600025 941260926 800202100027 800201800028 800201900029 800202400030 800202300031 800200700032 800200600033 9177065

Index E: Update of the item # 2

Drawing ref.:

Date: Index


November 2003

BB 3000 ILLUSTRATED PARTS LISTBBR - OUTPUT UNIT (BOTTOM)

1515 D

A B CD E F

ON

OFF

1 9012004200 (Assy) 2 9121043 (Plug)

9121042 (Female) 3 8002103000 4 3304014000 5 8003010000 6 3602012000 7 9124165 (1,8 A)

12 3

5

4

6

98

2

2

14

15

16

17

1819

33

10

1

1111

1213

720

3231

21221

25

27

2829 30

26

2324

4 /16

Drawing ref.:

Date: Index


November 2003

BB 3000 ILLUSTRATED PARTS LISTBBR - OUTPUT UNIT (TOP)

161616

A B

ON

OFF

1 9126234 2 9175040 3 9222270 4 9261116 5 9222271 6 9201475 7 2980024 8 9218613 9 940210910 921862011 912104212 920147413 940236614 921861615 942200716 922226917 943093718 9124157 (1,8 A)19 921861720 926005821 921861522 941056323 298006924 921861425 920147626 916500127 926111728 208432929 915005330 9121043

P1

Binder

P2

1 23

4

4

6

56 7

9

10

8

1213

11

30

26

27

29

28

23

15

14

1416

17

20

21

23

25

24

22

1819

9

INDEX A: Uptade of the item # 11

4 /17

Index BB3000

Article Page Item Depot Article Page Item Depot

2080434 1 12 2083809 7 4

2080434 15 17 2083809 10 26

2080997 1 14 2083990 10 Assy

2080998 1 19 2083995 1 30

2080998 8 6 2084002 11 42

2080998 13 34 2084009 4 6

2081998 1 11 2084009 11 15

2081998 3 22 2084013 11 36

2081998 5 5 2084014 11 39

2082104 9 15 2084160 12 25

2082124 9 34 2084168 11 30

2082312 9 14 2084329 16 28

2082400 9 10 2084330 11 28

2082416 9 8 2084335 12 8

2082422 9 7 2084337 11 4a

2082700 9 3 2084338 11 4d

2082702 9 23 2084400 11 11

2082801 9 6 2084402 11 31

2082802 9 6 2 2084420 11 2 1

2082803 9 4 1 2084426 11 35

2082806 9 17 1 2084427 11 1

2082809 9 16 2084430 12 24

2082810 9 19 2084431 12 9

2083000 10 6 2084438 11 34

2083002 10 2 2084801 11 32

2083104 10 42 2084802 11 6

2083110 1 4 2084805 11 5

2083148 10 19 2084806 11 8

2083152 10 25 2084809 11 17

2083306 10 20 2084814 11 16

2083307 10 21 2084816 11 22

2083310 10 23 2084817 11 25

2083412 10 24 2084821 11 29

2083416 10 24 2084822 11 26

2083417 10 38 2084825 11 33

2083700 10 30 2084992 11 18

2083701 10 11 2084998 1 24

2083800 10 22 2085009 5 7

2083803 9 30 2085009 12 1

2083804 9 30 2085010 13 40

2083806 10 13 2085014 13 28

2083807 10 27 2085106 13 10

Illustrated Illustrated Qty 1 rst aid

Qty 1 rst aid

7/11/03

4 /18

Index BB3000



Qty 1 rst aid

2085112 13 9 2086010 7 8

2085113 13 23 2086011 7 18

2085127 5 8 1 2086012 6 6

2085127 12 3 2086153 10 35

2085219 12 19 2086303 7 2

2085224 12 17 2086304 7 21

2085300 13 24 2086307 7 19

2085301 13 16 2086325 7 20

2085306 13 19 2086330 6 4

2085311 13 30 2086815 1 25

2085322 12 34 2086815 5 3

2085332 12 14 2086817 6 5

2085334 12 12 2086819 7 3

2085347 13 13 2086820 7 11

2085350 12 20 2086822 7 5

2085400 13 29 2086822 10 28

2085403 13 39 2086977 6 13

2085407 13 31 2086977 7 17 1

2085418 12 16 2086978 1 2

2085425 12 15 2086978 6 1

2085427 12 23 2086979 1 2

2085430 13 15 2086979 6 1

2085434 12 27 2086991 7 7

2085700 13 33 2086999 6 Assy

2085801 13 20 2087101 1 7

2085801 13 26 2087102 1 10

2085802 13 3 2087170 1 8

2085803 13 2 2087701 1 3

2085805 13 35 2087702 1 5

2085808 13 18 2087994 1 1

2085810 12 31 2087998 1 30

2085812 12 30 2088893 6 14

2085813 12 35 2088893 7 14

2085814 13 1 2088970 11 14

2085816 13 17 2088972 11 23

2085819 4 4 2088973 11 24

2085819 11 19 2980009 9 32

2085983 13 42 2980012 7 22

2085987 13 46 2980012 13 36

2085990 12 11 2980024 16 7

2085996 12 26 2980026 10 39

2086001 7 24 2980029 9 31

7/11/03

4 /19

Index BB3000



Qty 1 rst aid

2980069 16 23 2983952 10 14 1

2980075 13 21 2983978 6 9

2980076 10 12 2 2983985 4 12

2980117 7 10 2983985 7 6

2980118 13 22 2983985 10 29

2980124 11 7 2983991 3 21

2980125 8 2 2983991 10 2

2980126 11 38 1 2984006 7 25

2980128 6 3 2984106 4 13

2980128 11 3 2984106 7 9

2980128 11 12 2984109 13 45

2980132 10 5 1 2984109 13 48

2980133 13 14 2984110 13 44

2980138 11 4c 2984114 4 7 1

2981120 11 21 2984114 11 13 1

2981124 4 5 1 2984123 9 2

2981131 7 12 2985102 10 1 5

2981131 7 6 2985261 10 34

2981131 10 29 2985262 10 9 1

2981131 4 12 2985263 10 8 1

2981411 8 1 2985276 4 17

2982060 6 19 2985276 5 14

2982061 8 3 2985276 10 37

2982066 12 6 2985279 1 15

2982068 6 16 2985282 1 17

2982069 13 32 2985283 1 16

2982073 12 33 2985284 9 35

2982078 11 37 2985286 1 14

2983264 3 17 2985287 13 6

2983264 10 3 1 2985330 9 18 1

2983286 3 32 2986001 12 28

2983574 3 31 2986048 12 4

2983716 3 5 2986048 12 10

2983852 3 29 2 2986057 12 7

2983852 13 8 2 2990124 9 21 2

2983857 10 16 2990125 9 20 2

2983886 3 28 1 2990126 9 5 2

2983886 12 5 1 2990178 11 27

2983908 3 24 2990213 10 41

2983951 3 19 1 2990228 8 7

2983951 10 15 1 2990237 12 22

2983952 3 18 1 2990243 9 11

7/11/03

4 /20

Index BB3000



Qty 1 rst aid

2990247 7 15 9124163 3 20 2

2990248 7 16 9124163 10 32 2

2990297 15 15 9124165 15 7

2990315 10 7 9126234 16 1

2990319 10 10 1 9127036 11 9

2990327 10 17 9131013 13 12

2990331 13 38 9132011 5 12

2990339 12 32 9135006 14 19

2990355 10 4 1 9135046 15 16

2990389 8 4 9135078 15 18

2990390 4 10 9136065 4 2

2990390 8 5 9136065 14 8

9101003 11 43 9137022 4 14

9102033 3 7 9137022 7 1

9104069 3 15 9139000 1 20

9104070 3 15 9139029 1 22

9104072 3 15 9139044 1 26

9111002 7 11 9139433 1 28

9111002 11 16 9139434 1 20

9111059 7 13 9140008 14 4

9111061 7 13 9146006 3 9

9117005 6 2 9146020 10 18

9117007 6 17 9146024 3 11

9119001 5 4 9146025 3 12

9120206 5 9 9146067 15 22

9121043 15 2 9146068 3 10

9121043 16 30 9146179 3 13

9121042 15 2 9146181 3 30

9121042 16 11 9146182 3 8

9124008 2 F3 40 9146183 3 6

9124016 2 F12 9146184 3 6

9124017 2 F2, F5 9150014 3 1 2

9124018 2 F10 40 9150014 6 12

9124026 2 F17 20 9150014 13 37 2

9124030 2 F11,18 20 9150046 3 23

9124031 2 F16 20 9150053 15 8

9124035 2 F 40 9150053 16 29

9124080 2 F 9150073 15 9

9124093 2 F20 9151046 4 1

9124094 2 F8 9151046 4 16

9124094 15 20 9151046 10 31

9124157 16 18 9151128 7 6

7/11/03

4 /21

Index BB3000



Qty 1 rst aid

9151128 10 29 9199475 1 23

9151128 4 12 9199476 1 21

9151140 4 15 9199504 1 27

9151140 9 1 9199843 12 " Clip "

9157001 14 2 9200385 14 1

9157025 14 23 9200386 14 3

9161082 13 43 9200405 14 22

9161084 13 47 9200933 13 41

9162034 3 14 9201474 16 12

9162035 3 14 9201475 16 6

9162051 6 10 9201476 16 25

9164004 15 20 9216100 14 10

9165001 16 26 9216101 14 18

9166052 14 6 9216102 14 9

9166058 11 4b 9216103 14 15

9167004 5 10 9217422 13 27

9169001 15 19 9217424 9 28

9169016 2 K1 9218613 16 8

9169047 2 K21 9218614 16 24

9169085 2 K2 9218615 16 21

9169087 2 K19 9218616 16 14

9169092 2 K18,20 9218617 16 19

9169906 2 K 9218620 16 10

9169907 2 K 9218658 9 13

9170156 3 36 9218659 9 12

9170156 5 13 9221640 14 25

9172003 14 12 9221843 9 8

9172004 14 17 9221851 12 18

9175010 13 11 9222269 16 16

9175040 16 2 9222270 16 3

9175078 10 36 9222271 16 5

9175084 6 20 9260058 16 20

9175084 13 25 9260216 11 20

9177065 15 33 9260503 12 " T "

9190103 14 11 9260633 12 21

9190165 14 26 9260667 14 13

9190166 14 16 9260668 14 14

9190426 14 21 9260669 14 24

9190562 9 26 9260671 14 20

9190599 9 25 9260692 14 5

9195025 1 13 9260693 14 7

9199431 1 18 9260854 5 1

7/11/03

4 /22

Index BB3000



Qty 1 rst aid

9260854 9 27 9430937 4 9

9261101 12 2 9430937 4 11

9261116 16 4 9430937 6 18

9261117 15 8 9430937 13 5

9261117 16 27 9430937 15 14

9401833 9 29 9430937 16 17

9401849 1 6 9430957 5 6

9401991 11 4e 9430957 14 Assy

9402109 16 9 9431259 4 8 1

9402180 1 9 9431259 13 4

9402366 16 13 9431618 12 29

9410563 16 22 9580115 15 Assy

9410564 12 13 3304014000 15 4

9412136 9 24 3602012000 15 6

9412138 5 2 7002021000 15 13

9412138 9 9 8001011000 15 12

9412242 11 40 8002006000 15 32

9412243 11 41 8002007000 15 31

9412609 15 25 8002016000 15 24

9412615 9 33 8002018000 15 27

9413930 12 36 8002019000 15 28

9420693 3 16 8002021000 15 26

9420696 3 25 1 8002023000 15 30

9420696 11 10 1 8002024000 15 29

9420705 3 4 8002035000 15 23

9420705 6 7 8002103000 15 3

9420706 3 3 1 8003010000 15 5

9420706 6 8 8003107000 15 10

9420707 3 27 1 9008004100 15 21

9420730 3 26 1 9008006400 15 21

9420996 3 2 9008007800 15 21

9420996 6 11 9012004200 15 1

9421119 6 15 0000001599 10 33

9421119 7 12 0000002999 10 33

9421236 5 11 004390800006 7 23

9421782 5 12 0047200470 10 40

9421954 3 35 0091604008 9 22

9422007 16 15 2083999 / 10 10 Assy

9422033 13 7 M2083988 9

9422506 3 33 M2083989 9 30

9430668 3 34 P801000600 15 11

9430937 4 3

7/11/03

MaintenanceDust bag replacement frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 5 / 1Main drive motor brushes life expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 5 / 2

June 2001

ON

OFF


I

5

MA

INT

EN

AN

CE

5 / 1

0 0.5 1 1.5 2 2.5

5

10

15

20

25

30

35

40

45

50

Millions of mm3 of dust

Max.BB3000

Milling depth ( mm )

BB3000 Dust bag replacement frequency

Warning: paper dust will ruin the glue and clog the machine if bag is not replaced in time

2

3

4

5

1. Spot the number of millions of mm3 of dust corresponding tothe milling depth.

2. Divide this number by the length of the spine ( expressed in mm )

3. Divide the result by the thickness of the book (expressed in mm )

The result is the number number of books between bag exchanges.

Examples: 1. 0.5 mm milled off the 297 mm (A4) long spine of a 10 mm thick book

2. 0.5 mm milled off the 279 mm (11") long spine of a 12,7 (1/2") mm thick book

3. 2.2 mm milled off the 385 mm long spine of a 45 mm thick book

Rev. August 1997

9.500.000

297 x 10= 3200 books per bag ( 1 replacement every 12 3/4 hour:

BB3000 full speed )

2.200.000

385 x 45

Ex: 1, 2

= 127 books per bag ( 1 replacement every 1/2 hour:BB3000 full speed, max thickness, max length )

9.500.000

279 x 12,7= 2680 books per bag ( 1 replacement every 10 3/4 hour:

BB3000 full speed )

Ex: 3

5 / 2

TECHNICAL BULLETIN: ABOUT: Top range ENCLOS:TECHNICHES RUNDSCHREIBEN: 99-05-01 BETRIFFT: binders ANLAGE: BULLETIN TECHNIQUE: CONCERNE: ANNEXE:

Motor : 9151128One brush : 298 3985

Applicable to :

BB2005BBF2005BB2006BB2008BB3000

This page will be in next version of service manual

Inspection: 1rst after 100 hours2nd after 300 hours

n.b. ¥ Wear limit: 6mm¥ Always replace the set

MaintenanceRemove the brushes and blow compressed air in their seat to clean the inside whenever inspecting or at least every 500 h.This provides for a brush life expectancy between 1500 and 3000 hours.

This bulletin contains new and upgraded documents about:


Preventive maintenance

Trouble shootingNon stop test procedureWarm-up period shortening (for service purpose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 6 / 1Power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 6 / 2Heating circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 6 / 3Nipping motor torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 6 / 4

June 2001

ON

OFF


I

6

TR

OU

BLE

SH

OO

TIN

G

6 / 1

ONOFF

X03 Emergency

Main switch

X12 Drumheating on - off

X15 Process start(green)

X14 Process start(green) X32

X13 Carriage opening (blue)

Service manual BB3000 February 1997

To deliberately shorten the time that the binder requires to be operational (to reduce unproductive waiting periods during machine maintenance or repair).

- Wait for the blinking of the green lights ( X14 and X 15 )

- Press X13 and switch off the main switch simultaneously

- Press X14 and switch on the main switch- Press X12 within the next two seconds

to operate the binder.

Switch the binder OFF/ON to return to the normal operation mode (for quality bindings).

For a trouble free observation of the working of components remote from the control panel or for an intensive check of a suspected part, the BB3000’s are fitted as a standard with an ingenious feature allowing for their automatic non-stop operation without the need of sheets, covers or tools.

Procedure: - Simulate the picking of a cover sheet on the suction bar (scotch the actuator of its microswitch X32 to the suction bar).

- Press right hand adjacent blue and green buttons ( X13 and X15 ) simultaneously and turn off main switch.

- Press left hand green button ( X14 ) while turning on the main switch.- Switch on the drum heating key ( X12 ) within the next 5 seconds.- Press now the two green start buttons ( X14 and X15 ) simultaneously.

The continous repetition of binding cycles is started up.

n.b.: the process would automatically stop and the binder return to standby (with glue cooling down) 15 seconds after any clamping failure.

Trouble shooting

6 / 2

TECHNICAL BULLETIN: # 6 ABOUT: ENCLOS:TECHNISCHES RUNDSCHREIBEN: Sept. 01 BETRIFFT: Top ranger ANLAGE: BULLETIN TECHNIQUE: CONCERNE: Binders ANNEXE:

TROUBLE SHOOTING

- Old style power boards (machines where TAG 23 is not crossed / our T.B. 00-12-04 refers) were fitted with slim 5A Crydom static relays K18 and K20 to control the heating resistors.

- K20 switches the power of the drum easily, but K18 is a little underrated for the tank resistor, and gets hot.Some K18 have indeed burned out a hole in the board.

- Considering the cost of a replacement board, we suggest that youcheck the board whenever servicing a binder to ascertain that

they do not get brown around the area where K18 is soldered.

- If there are signs of over heating and if the board is not dammaged, we further suggest to swap this relay with the next model 9169106 (10A with cooler).As this model is too thick to fit between K17 and K19 , some pin extension is to provide for.Insulation of the pins must be secured because two of them are at a potential of 230V


C

ertified by

ISO 9001A.M.

ONOFF

K20 Drum heating

K19K18K17

Glue tank heating

6 / 3

Tank resistor Thermostat

Selector

Drum

145¡C115¡C

190¡C

S44S55

Needs to be positioned 0.1mm away from drum

Greenpointer

Red pointer(selected

temp)

Black pointer(actual drum temper)190¡C

BB 3000Heating circuitry

Resistors (tank - drum - spreader)

-

+

ONOFF

MCU

T1

J5

J4

J1

J12

J17

J73

J72

F14

F16R

F17

F7

F1

K18

F10

1

1

J134

J3

J11J10

¥

¥

Controlpanel

19v

T1

F16

F1

J17

19v+ 24v DC

R

S44 S55

Bindingdisabled

Drumrotationdisabled

S44 closes when black pointer reaches green pointerS55 opens when black pointer reaches red pointer

12C5

7

145¡C

145¡C

Thermostatselector

115¡C

115¡C

J28

F13 F15

C1

C5

J5

J21

8

2

190¡C

190¡C

812 13

26

1

J4

J134

7

35

13

C6

38

16

5

J21

5

16

X55J73

6 X12

Y38

J71

MCU

J3 3

J10 2 J17

J11

K 20

K 18Solid state

Solidstate

24

F15 F13

F10

F17

F7J12 4

13C5

L 3 L 1 L 2 N(Y) / L3( )

J10 5

8

11C3

T1

10

11

1

3

6

7

1

3

9

10

2

4

J28Spreader

Drum

C5

C1 J10 6

J12 2

Tank heatingresistor

J28

1

36

4

5

8

1

9

33

C6

50 250

= 40¡C

J11 1

C1

2

4

1

3

15

13

J3

BBR II

ON

OFF

X44

TROUBLE SHOOTINGSeptember 2001

- Kindly note that any breakage in the tank heating circuit is neither notified nor evident to notice.- The heat developped by the sole drum resistor being sufficient to enable S44 and even S55, bindings can be performed, in degraded mode however (longer warm-up, curdled glue, unefficient glue cut-

off etc...).-If you where to experiment such defects, always start your investigations with the supply of the tank heating resistor(F10, K18, etc...)

– 23 ‰ cold

– 65 ‰ cold

– 150‰ cold

7

J28

12 13 8

J28

6

7

1

3

9

10

2

4

J28

5

16

X55

X44

J73

X12

Y38

J71

MCU

MCUJ73

J71

J72

J5

C1

C5

36

4

5

8

1

9

33

C67

35

13

38

16

5

J21

C6

12

13

1110

11

C5

1

3

C1 C1

2

4

36

4

5

8

1

9

33

C6C5

C1

J21

K20

J71J72J5 6

66

J71J72J5

J5

J1

J1 24

24

6 / 4

Service manual BB3000 March 2002

Cover nipping motor torque limiter board

Problem: Fuse F12 of board blows repeatedly

position of X38 (Nipping station in upper position detector) is likely to be involved or anything(dried glue - shutter, etc... ) that works against the lifting and closing of the station.The board is OK most of the time.

Test is easy:- Disconnect one wire on X38- Proceed to one binding cycle- The motor should not even be strong enough to lift the nipping station IF IT DOES, TORQUE LIMITER BOARD IS DEFECTIVE

Trouble shooting

X39

X38

BB3000

ONOFF

Controlpanel

Kbic


Cover nippingmotor torquelimit board

J1

J7J10

J14J15

J22

J9J8

J2

J4

F126,3A

K21

9421204

max

minTorqueadjust

TP min

TP max

R22

R23

R19

R20

R21

1002M2

100

4

3

2

1

J14

2

10

J15J2

Clamppressure

knob

Coverclampmotor

J4J22

J1MCU

10K

Y47Y47Y46Y46

Y45Y45

C2

M 10

9 0V

HistoryDevelopments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 7 / 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 7 / 7Wiring instructions for the replacement of the discontinued 230v B.B.C. / ASEA P.L.C . .pg 7 / 8

June 2001

ON

OFF


I

7

HIS

TO

RY

7 /1

8001 PLC Progr.15

8006 PLC Progr. 16 = Progr.15 + longer pulse for counter + safety if switch 05 is out of order.

8026 PLC Progr.17 = Progr. 16 + diff. control of green lights + safety if switch 01 is out of order.

8051 Cover Mechanical modification :clamping - Seat in cast iron parts catalogueassembly - Different shaft pages 120 to 134

- Different gears- Different front and rear clamps retrofit kit #- Different bracket ( for micro switch ) 208.4991- Different shutter toothed rack - Five positions for spine pressure instead of four.

Jogger Different electro magnet ( suitable for 50 and 60 Hz ) part #:298.1130assembly Different jogging plate ( with weights for jogging vibrations amplitude adjustement ). part #:299.0228e

8075 PLC Progr. 18 = Prog. 17 + Techn. bull. 89.09.09.Change of waiting time in stand by ( operational within 2 hours instead of 5 minutes )Low speed also possible without milling selected.

Glue tank Tank thermostats moved from tank rear to left side to reduce interference with Techn. bull. 89.10.10.drum temperature.

8091 Glue tank Different tank thermostats support Techn. bull. 89.10.10.also 8073 ( not compatible with previous model )

8091 Power Adaptation of slow down circuitry ( R5 = 8,2 W / 20W instead of 22 W / 10 W ) of Resistor part #:also 8084 board suction bar " out-in" drive motors which specs. have changed as from S.N. 8051 9 170 168

for a more accurate cover deposit. Retrofit installation on machines 8050< S.N.<8091 requires suction bar slow speedreadjustment ( trim 1 on power board ).

BB 3000 - Developments Page 106/04/95

Starting Section Purpose / description Details / illustration/ with S.N. retrofit form

7 /2

8091 Cover feed Modification of coding finder.("in" position - for cell 22, 23 )also 8084 Modification of suction bar holder ( T ).

8101 Cover Installation of protection plate over left side cover clamping shaft. to prevent Part # 208.4152clamping glue from dropping on the shafts.

Drive motor New sprocket to match 3/8" (9.5mm ) motor-drum chain pitch ( instead of 1/2" ).

8104 Glue drum Heating resistor not molded anymore. Part # unchanged.Rica model ( new ) has black connection wires.Old models have orange wires. Old models discontinued

8141 PLC Progr. 19 = modified Progr.18 for better positionning of first cover.

8162 Carriage Locking of screws on braket pins. ( loctite 638 )Carriage opening cam: reinforcement of its locking by a screw.

Carriage Different front carriage support: cylindrical instead of square.translation.

8164 Carriage Front carriage clamp prepared to receive ejection plate

8186 PLC Progr. 20 = modified Progr. 19 for delivery

Delivery Socket for optional BBR delivery. T.B. 90.07.03 +T.B. 90.10.01retrofit kit form:

Erroneous wiring up to S.N. 8204 T.B.90.10.03 208.8898

Carriage Front clamp fitted with 5 round pushers actuating paper detection switch for straight T.B.90.07.03 +book dropping. T.B.90.10.04

Retrofit kit form:#208.6983



7 /3

8186 Carriage Different main motor and sproket . Parts.catal. Page 46transfer

Stronger spring: 298.2068 ( Bolt lever mechanism ) Item 48, page 152 ofparts catalogue

Glue drop Hengstler counter instead of Zenith Up to S.N. 8050: fi Retrofit:assy 208.6985adjustment For 8050 < S.N. <8186: fi Retrofit assy 208.6986

Glue tank Mounting of hexagonal holder glue wave for side glueing.

Cover feed Different spring ( suction bar bolt mechanism ) for more accurate stop position. Part # 298.2069

Cover Washer for travel limitation of blower ramp. Part # 299.0363station

Cover Protection tube over shutter shaft ( no longer risk of glue dropping on shaft ) Retrofit kit 208.4989clamping Retrofit kit + tool box

208.4988

8195 PLC Progr.21 = modified Progr.20 for binding inhibit at BBR delivery full.( blue lamp will flash )

8205 Milling Motor brake removed for better paper dust evacuation. Pedal for jogger control+ 8202,8099 motor ( Brake wiring and supports are still left in place ). is no longer an option.

8209 PLC Progr. 22: different control of dust extractor motor for better paper dust evacuation+8205,8206, - With notching only: the vacuum motor runs longer than before.

8099 - With notching and milling: the vacuum motor runs continuously unless one doesnot bind for more than 10 sec.

Glue film Modification of mechanism. Retrofit kit 208.6982length ( 208.6981 up to

S.N. 8050 )Delivery Modification of the wiring of the socket for the optional BBR T.B.90.10.03.A



7 /4

8215 PLC Progr. 23 = modified Progr. 22 for a different ejection sequence.( straight book drop )Now ( 23 ): clamping down + carriage opening before shutter opening.Up to ( 22 ): clamping down + shutter opening before carriage opening.N.B. interconnecting input 26 and +24 v automat of a PLC fitted with programme 23 will result in a book ejection like that provided by programme 22.This is usefull to prevent the contact of a wet spine with the shutter in glueing mode 3 . ( padding + ejection )

Delivery One wire added from rack connector IV to delivery socket . T.B. 90.10.03

8239 Milling Milling wheel inclined instead of horizontal. Fix blade should have motor changed at the same time but remains old style until S.N. 8261

8260 Fuses The rating, the size or the reaction time of twelve fuses is modified to conform with The index of corres-international rules of technical reasons. ponding drawingsF6 / 9 / 12 / 13 / 17 / 18 / 19 / 20 / 21 / 22 / 23 / 24 are involved. is incremented .

PLC Progr. 24 = automatic mixing of above mentionned progr. 23 and 22 according to Retrofit possibilitythe status of the wide ( progr 23 ) / narrow ( progr 22 ) carriage opening selector on only after connectioncontrol panel. Progr. 24 = control of air valve solenoid. of input 27 to + 24 v

Cover feed The air valve is driven by a solenoid instead of being driven by the rear clamp.A new card ( located under the valve ) drives this solenoid.The suction is not stopped at each cycle anymore.

Blower - New control PCB ( # 9420867 without timer as the need for a blower running later Diagr.than the suction is no longer there ). This card does not match earlier binders. 1.74.71.1263- Rating of F 24 decreased to 2,5 A.

Cover Hand adjustable symmetrical working of the clamps to eliminate the " nailhead ". T.B. 90.12.02clamping This change required a new torque limit control PCB assembly ( # 9420862 ) No retrofit

providing for a short braking of the motor between lifting and clamping movement. Diagr.1.74.71.12631.74.71.0900 B



7 /5

8260 Glueing The scraper works at a higher temperature than before for a better removal of theexcess of glue. Its heating element is increased to 15 W.

A piece of wire over the drum creates a wave of glue like on our lower range bindersand the drum turns at higher speed than before for a better glue deposit.

8262 Milling Modified fix blade ( see page 4 ) for a better milling of first sheets on non Part # 208.2408 (EUR) operators side as well. ( interchangeable with

previous model )

8500 Adjustment Longer shaft to conform to safety requirements Short model does no(USA) hand wheel longer match

8270 Power Relays K 3 / 5 / 6 / 8 / 9 / 11 / 12 / 13 / 14 are changed into plug in model with(EUR) interface retaining clips for service facility

8500 (USA) Connectors Orange connectors on PC boards and harnesses are substituted by higher

specifications green ones.

8285 Photo cell Reduction of power of emitter beam ( R1 on board 9.420.996 = 560 W · 1,2 KW ) Diagram. :in loading to discriminate 2 sheets from a dozen of sheets and eliminate possible undesirable 3.74.71.0906 Aarea carriage home returns.

2 models of cell amplifying boards. 9.420.696 in cover clamping area difference9.420.996 in loading area is value of R1 only

8302 Drum Different model fits binders, it displays ( window ) the drum temperature Retrofit kit # :(EUR) thermostat ( black pointer ) and the drum requested temperature ( red pointer ). 208.3992

8500 thru The green pointer indicates the drum rotation start temperature ( 40°C colder - this former model is no8519 difference is still not adjustable ). longer available.

(USA)



7 /6

8334 Cover Stronger front clamp limit TB 92.01.01clamping

8500 PLC - Different model ( identical look but powered in 24 V D.C. ) DiagramsN.B. : - U.S. models of BB 3000 were already fitted with 24 V PLC for U.L. 1.74.71.0903 C

approval purpose since Nov 1990 but with progr. 24 3.74.71.0904 B- It is hard to notice the difference between the two models. ( ≠ labels only ) 1.74.71.0910 B- PLC is no longer destroyed in case of erroneous wiring to the mains 1.74.71.1263 A- PLC is no longer electronically protected against short circuit of its inputs 1.74.71.1268

but external F25 would blow. published in june 1991- Progr. 25 superseeds progr. 24 in march 1992 for PLC insensitiveness to are applicable.

parasitic pulses which might accidentally open the shutter for a couple of mm.Modification in the field is not necessary.

8536 Carriage The grey cable ( with 10 black wires ) connecting the carriage to the frame of the TB 92.0binder ( item 102 on page 92 of illustrated parts catalogue ) is replaced by a flatflexible conductor cable for a longer life expectancy

Please specify on the order form, whether kit is for BB3000 with S.N. < 8261 Retrofit kit # 2.08.6976or with S.N. between 8261 and 8535.

Repro- To benefit from the latest upgradings, an updated eprom can be inserted from Eprom order # :gramming outside the PLC ( no matter whether 220V or 24V model )

8700

61.10.4.000 No retrofit on(Recognizable from paper waste bag on rear panel instead of separated earlier model

and up vacuum cleaner). possible



NEW STYLE BB3000

7 /7

8700 through PLC Different (smaller) model (Matsushita) - different logic / power interface61.10.4.000 Power supply Toroïdal transformers No retrofit onand up Cover feed New single brushless turbine for both cover picking and separation earlier model is(model identified Chips extract. In built turbine driven by the milling motor possibleas BB3000/9) Dust bag at the rear of the binder - no longer vacuum cleaner

61.10.4.0058 PLC Software upgrading for longer life expectancy of relays K4 and K5. ( suction baroutwards and inwards motion )Retrofit to binders back to S.N. 8700 is advisable, easy and cheap. Eprom prog BB3004



7 /8

EINGANG

AUSGANG

00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17

20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37

41 42 43 44 45 46 4740 HZ HR

NETZ STARUN

50 51 52 53 54 55 56 57 60 61 62 63 64 65 66 67

71 72 73 74 75 76 7770

HR474543413735333127

HZ4644424036343230

252321

242220 26

1715131107050301

1614121006040200

0VSTOSTA

0VRUN

220V

24V

7776575744737271703W WW

07 KR 264 BBC

6766656421 63626160 WW575655540 53525150W

EINGANG

AUSGANG

(INPUTS)

(OUTPUTS)

PROGRAMMABLELOGIC CONTROL

EINGANG

AUSGANG

00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17

20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37

41 42 43 44 45 46 4740 HZ HR

NETZ STARUN

50 51 52 53 54 55 56 57 60 61 62 63 64 65 66 67

71 72 73 74 75 76 7770

HR474543413735333127

HZ4644424036343230

252321

242220 26

1715131107050301

1614121006040200

0VSTOSTA

0VRUN

+ 24V —

24V

7776575744737271703W WW

07 KR 264 BBC

6766656421 63626160 WW575655540 53525150W

EINGANG

AUSGANG

(INPUTS)

(OUTPUTS)

PROGRAMMABLELOGIC CONTROL

9133241Oct. 1997

Wiring instructions for the replacement of the B.B.C. / ASEA P.L.C. in a BB3000 with serial number below 8500

9132007(discontinued

model)

220 V

Originalwiring

Cooling fans

9132010(NOT programmed)

2,5 A2983260

2983874

Transformer

Rectifier

OPERATORSIDE

OPERATORSIDE

0 VDifferent wiringrequired for thesupply of low voltage PLC

- Do not reconnect the wires withthe 220 V to the P.L.C. any more.

- Leave them feeding the cooling fans.

+—

RUN

220V

RUN

+ 24V —

Useful, translated and obsolete itemsMaschine Beschreibung (D, 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 1Maschine Beschreibung (D, 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 2Description machine (F, 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 3Description machine (F, 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 4Réglage fraise et contre-lame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 5

June 2001

ON

OFF


I

8

US

EF

UL

Bremse Transportschlitten

Motor für Transportschlitten( öffnen/schließen )

Saugergestängeinnen/außen

Erlaubnis

Schlittenbremsung ( links/rechts )

Wahlschalter Tankthermostat( 115 / 145°C )

Abstreifer

Tank-Thermostate

Transportschlitten Endschalter, rechts

Auswurfklappe, Schalter für Öffnung

Auswurfklappe, Schalter für Verschluß

Y01 Auflagenzähler

Tankheizung, Wiederstand

Kühlventilator

X8 Abstand -Frässchlitze

( eng/normal )

X7 Fräsmotor,Ein - Aus

Schlittenbremsung(rechts/links)

Automatischer TransportschlittenGeschwindigkeitsEinstellung

Kupplung,Transportschlitten

Hauptmotor

Taster für eingelegten Buchblock

Transportschlitten, Endschalter,

Grundposition

VerstärkerPlatine

Transportschlitten,Endschalter fürmax. Öffnung

TransportschlittenFühler für

Obererposition

Rüttler - Magnet

X13 Schlittenöffnung ( Lampe blau )

Saugluft-Einstellung

Umschlag, seitliche Anpressung

X2, X5, X9, X11 Umschlagstation Anpressdruckdauer

X6, X4 Programm-Wahlschalter

X14 Start - Arbeitszyklus ( grüne

Lampen ) X15 gleichzeitig betätigen

X10 Schlittenöffnung ( eng/weit )

X12 Trommelheizung, An - AusAutomatische Drehung wenn Temperatur erreicht

X03 Not-Stop

Thermostatfühler für Temperatur Leimtrommel

Leimabstreifer, Einstellung

Trommelheizung

Fußschalter

Transportschlitten,Fühler für

SchließungRüttler, An - Aus

Umschlagpresse unten

Umschlagpresse hoch und Saugluft Abschaltung

X44 X55

X38

X40

X49

X41

X42

X48

X47

Y12Y13X46

X45X52

X50

X53

Y43

X51

Y32

X39

Fräse Motorund PapierspäneAbsaugung

Leimwalzen TemperaturEinstellung

X15 Start - Arbeitszyklus ( grüne

Lampen ) X14 gleichzeitig betätigen

Service manual BB3000 — Machine Beschreibung (D,1)— Jan. 1997

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

F17

F18

F20

-

+

2,5ATT

3,2ATT

4 ATT

2,5ATT

3,2ATT

2,5ATT

2,5ATT

7 ATT

2,5ATT

5 ATT

1 ATT

6,3ATT

20AT

20AT

20AT

15 AT

2 ATT

1 ATT

Adjust

F12

F13F14

F15

F16

F20

F17

F18

F7

F1F2

F4

F5F6

F8F9F10

F11

F3

Dunstabzug

( 2. K�hlventilator mit

aktivem Kohlefilter Option )

Sicherheitsschalter

( Plexiglas )

Magnet f�r Luftventil

( auf/geschlossen )

Verst�rker

Platine

Luftventil

Taster f�r

eingelegten

Buchblock

Umschlagpresse

Heben + Schlie§en

Senken + �ffnen

Taster, Saugergest�nge

�ber Umschlagpresse

Umschlagansaug

tasterGleichstrom

Versorgung

Motor f�r

Saugergest�nge,

Anheben und Senken

Sicherung Wert Gesch�tzte Bestandteile

Tankheizung

Stundenz�hler

Hauptschalter

Leistung + Saugergest�nge

Geschwindigkeitsplatine

VORSICHT: nur durch Sicherungen

gleichen Typs und Werten ersetzen

PLC

Automat

Trafo

B�chse f�r

Fu§schalter

Autom. Senkung von

Umschl�ge Separatoren

Gebl�se f�r

Saug-und

Blasluft

T = Tr�ge

TT = Supertr�ge

Y08

Y09

Y06

X43

Y10

Y11

Y15

X33

X34

X32

X36

X37

Y45

Y46

Sicherheitschalter

( Haube )

X35

Saugergest�nge, Endschalter

obere Position

X54

CN1, Elektr.Anschlu§ f�r

StehendauslageBBR

ONOFF

K1 LuftK2 24V zu PLC, ( Sicherheitshaube unten )K3 Saugergest�nge, langsamK4 Saugergest�nge, innen - au§enK5 Saugergest�nge, au§en - innenK6 Saugergest�nge, auf - abK7 Auswurfklappe, offenK8 Auswurfklappe, geschlossenK9 Transportschlitten, offenK10 Transportschlitten, geschlossenK11 Luftventil, offen - geschlossenK12 Transportschlitten, Kupplung-BremseK13 Hauptmotor, Geschwindigkeit-KontrolleK14 Hauptmotor, Geschwindigkeit-KontrolleK15 Leimtrommel, Drehung ( aus= verhindert )

K20Trommelheizung

K19 HauptmotorK18 TankheizungK17 R�ttlerK16 Motor Bremse

Fr�se motor

Steuerrelais

K21Seitenpressung,

Umschlag

Saugergest�nge, Schalter -

Startposition ( Ansaugung Umschalg )

Saugergest�nge,

langsam ( innen/au§en)

Steuerpult - Autom. Ausg�nge - Saugmotor

Kupplung - Bremse - Luftventil

Saugergest�nge, herein - heraus

Saugergest�nge, hoch - tief

Auswurfklappe, Motor

Transportschlitten, �ffnung - Verschlu§

Leimwalzenheizung

Trafo ( prim�re Wicklung ) - K�hlventilator

Hauptmotor

Tankheizung

R�ttler

Drehmomentbegrenzungsplatine

Netz: L1

Netz: L2

Netz: L3

24V Stromversorgung

Heizung Leimabstreifer

PLC Automat

Fr�semotor �berlast-Sicherung bei 220v: 6,7A

Fr�semotor �berlast-Sicherung bei 380v: 4A

R�ckstellbar

�berlast -

Sicherung

Motor f�r

Seitenpressung

�ffen und Schlie§en

Hauptmotor

Geschwindigkeitsplatine

Motor f�r

Saugergest�nge

Transport

( hinein/heraus)

Saugergest�nge,

langsam (innen/au§en )

Umschlagpres-

sungmotor

Drehmomentbe-

grenzungsplatine

Service manual BB3000 Ñ Maschine Beschreibung (D, 2) Ñ Jan. 1997

Frein chariot

Ouverture / fermeture

chariot

Autorisation

sortie rampe

aspiration

Ralentisseur chariot

( gauche - droite )

S�lecteur de thermostat

r�servoir � colle ( 115 / 145¡C )

R�partiteur chauff�

Thermostats r�gulation

temp�rature bac � colle

Fin de course

droite

D�tecteur pleine ouverture volet

D�tecteur fermeture volet

Y01 Compteur de reliures

Thermostat r�gulation

temp�rature cylindre

R�sistance chauffage

bac � colle

Ventilateur

X8 S�lection densit�

gr�cage

X7 Fraisage - gr�cage

marche - arr�t

Ralentisseur chariot

(droite - gauche)Auto r�gulation

vitesse chariot

Embrayage

chariot / cha�ne

Moteur

principal

D�tecteur

pr�sence

de feuilles

Fin de course

gauche

Amplificateur

cellule

D�tecteur pleine

ouverture chariot

D�tecteur position

haute taqueur

Electro aimant

taqueur

Moteur

fraisage

gr�cage

�vacuation

copeaux

X15Fermeture chariot + prise couverture

( deux boutons � pousser et rel�cher

simultan�ment )

X13 Ouverture chariot ( bleu )

R�glage niveau aspiration

R�glage pression emboitage couverture

X2, X5, X9, X11 R�glage dur�e emboitage couverture

X6, X4 S�lecteur du mode de travail

X14 Fermeture chariot + prise couverture

( deux boutons � pousser et rel�cher

simultan�ment )

X10 S�lecteur pr�-ouverture chariot : forte / faible + mode d'�jection

X12 Chauffage cylindre marche - arr�tX03 Arr�t d'urgence

Sonde r�gulateur temp�rature cylindre

Variateur hauteur r�partiteur

R�sistance chauffage cylindre

P�dale commande

taqueur

D�tecteur

fermeture

chariot

Taqueur

marche - arr�t


basse emboitage


haute emboitage

X44 X55

X38X40

X49

X41

X42

X48

X47

X46

X45

X50

X53

Y43

X51

Y32

X39

Notice technique BB3000 Ñ Description machine (F, 1) Ñ Jan. 1997

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

F17

F18

F20

-

+

2,5ATT

3,2ATT

4 ATT

2,5ATT

3,2ATT

2,5ATT

2,5ATT

7 ATT

2,5ATT

5 ATT

1 ATT

6,3ATT

20/15AT

20/15AT

20/15AT

15 AT

2 ATT

1 ATT

Adjust

Pupitre de commande - sorties automate - commande turbine

Embrayage - frein - soupape aspiration

Moteur translation rampe succion

Moteur ascension/descente rampe

Moteur ouverture/fermeture volet

Moteur ouverture / fermeture chariot

R�sistance chauffe cylindre

Transfo. alimention et ventilateurs

Moteur principal

R�sistance chauffe r�servoir � colle

Vibreur

Limiteur de couple mot. emboit. couv.

Secteur: phase L1

Secteur: phase L2

Secteur: phase L3

Alimentation basse tension

R�sistance chauffe r�cleur

Automate programmable

Protection moteur fraisage/gr�cquage en 220V: 6,7A

Protection moteur fraisage/gr�cquage en 380V: 4A

F12

F13F14

F15

F20

F16

F17

F18

F7

F1F2

F4

F5F6

F8F9F10

F11

F3

Ouverture

fermeture

volet

Extracteur d'air vici�

( deux si filtre � r�g�n�ration )

S�curit� fen�tre

plexi ferm�e

Electro-aimant

commande soupape

Amplificateur

celluleSoupape

de coupure

d'aspiration

D�tecteur

pr�sence

reliure

Emboitage couverture

- Mont�e + fermeture

- Descente + ouverture

D�tecteur rampe au

droit de l'emboitage

D�tecteur de

prise de couverture

Alimentation basse tension

Translation rampe

d'aspiration

Mont�e / descente

rampe d'aspiration

Ralentisseur rampe

en sortie

Carte r�gulation

vitesse moteur

principal

Fusible Valeur Circuit prot�g�

Compteur d'heures

de mise sous tension

Carte interface logique /

puissance+ vitesse rampe

Transformateur

Connecteur pour

p�dale vibreur

Descente automatique

s�parateurs couvertures

Ralentisseur rampe

� la rentr�e

Turbine

aspiration

ventilation

couvertures

Limiteur du couple

du moteur d'emboitage

Attention : ne jamais remplacer que par

des fusibles de m�me type et de m�me valeur.

Notice technique BB3000 Ñ Description machine (F, 2) Ñ Jan. 1997

Y08

Y09

Y06

X43

Y10

Y11

Y15

X33

X34

X32

X36

X37

Y45

Y46

S�curit�

capot ferm�

X35

D�tecteur rampe au

droit des couvertures


sup�rieure rampe

X54

Connecteur CN1pour convoyeurgrande capacit�

(BBR )

ONOFF

K1 AirK2 24V automate ( s�curit�s au repos )K3 Rampe ( translation lente )K4 Sortie de la rampeK5 Rentr�e de la rampeK6 Ascension - descente rampeK7 Ouverture voletK8 Fermeture voletK9 Ouverture chariotK10 Fermeture chariotK11 Soupape air aspirationK12 Embrayage - Frein chariotK13 R�gulation vitesse moteur principalK14 R�gulation vitesse moteur principalK15 Rotation cylindre ( retir� = moteur inhib� )

K19 Moteur principalK18 Chauffe bac � colleK17 VibreurK16 Frein moteur

Relais moteur

fraisage / gr�cage

K21 Emboitagecouverture

T = fusion lente

TT= fusion tr�s lente

Coupe circuit

g�n�ral

K20 Chauffe cylindre

Automate

programmable

Protection moteur

fraisage / gr�cage

( � r�armement )

BB3000 S.N. 61.10.4.5569 and up

BB2005 S.N. 64.20. . and up

Oct. 1997

82

3

1

2,5

8

4

4

3

1

1

4

4

4

3

3

3

3

2

2

23

R�glage de la distance entre fraise et contre-lame

Ce r�glage est � refaire lorsque le sac r�colteur de d�chets

contient des bandelettes au lieu de poussi�re de papier.

Pr�liminaires (uniquement en cas de remplacement)

- Glisser le blochet vers la gauche (vis 1 ).

- Appliquer les vis 4 de la contre-lame contre la t�le support.

- Aligner le long bord avant de la contre-lame et la

m�choire fixe du chariot (trois vis 3 + r�glette).

R�glage de la position de la contre-lame

Horizontalement: la glisser pour permettre le libre passage des couteaux dans leur d�coupe (�crous 2 ).

Verticalement: le jeu entre contre-lame et fraise doit �tre minimum. R�gler les trois vis 4 .

n.b. - La vis 4 qui est seule, agit aussi sur l’inclinaison de la contre-lame.- Les vis 4 doivent être libres pour monter / descendre la contre-lame,

débloquer leur écrou.

Rapprocher ensuite le blochet de la lame jusquÕ� affleurer la dent la plus longue* 1 .

* Tourner délicatement la fraise dans le sens anti-horlogique pour “entendre” et éliminer tout frottement.Des interactions existent entre les différents réglages / blocages. Les vérifier et retoucher si nécessaire.

14

2

1

3

4

4

4

CONTRELAME

TïLE

SUPPORT

LAME

CONTRE LAME

Dent la plushaute (color�e)de la fraise

Couteau degr�cquage

1

CONTRE LAME

TïLE SUPPORT

MåCHOIRE

FIXE DU

CHARIOT

4 4

2

1

3

4

5*


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SILIC 41032, rue des G meaux

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c.p. bourg S.A.

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Tel.: 352 / 33 24 47Fax: 352 / 33 19 99


c.p. bourg Inc.

50 Samuel Barnet Bd.New Bedford Industrial ParkMassachussets 02745 (USA)

1285 New BedfordTel.: 1/508.9982171Fax: 1/508.9982391


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