user manual Binding, Crimping & Cooling machine

Thank you for buying the PELEMAN INDUSTRIES nv BCC10 machine. Please read the operating instructions carefully to install and use your Binding, Crimping & Cooling machine properly. Keep your manual in a safe place for future reference.

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Please note that in this manual dimensions are expressed in millimetres, weights in kilograms and air pressure in bar. To convert millimeters into inches, multiply by 0.03937. To convert kilograms into pounds, multiply by 2.20462. To convert bar into Psi, multiply by 14.50377.

user manual Binding, Crimping & Cooling machine

Table of contents
1 - Safety precautions - pg 4
1.1 - Warnings 1.2 - Ambient operation and storage environments 1.3 - Electrical specifications 1.4 - Compressed air specifications 1.5 - Installation conditions 1.6 - Compliance

2 - Installation instructions - pg 6 3 - Operating instructions - pg 8 4 - Display settings - pg 10 5 - Maintenance - pg 11 6 - Disclaimers - pg 11

User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved - 

1 - Safety precautions
1.1 - WARNINgS
This BCC10 is intended for indoor use only and therefore needs to be protected from water and dust. Never operate the system in a humid environment. Never clean the BCC10 with plenty of water or another liquid as this could result in electrocution or could cause a short circuit. Always use a soft cloth to clean the product. Avoid using rough materials to clean the BCC10 since these could scratch the surface of it. Use a non-aggressive cleansing agent to remove stains. Never use aggressive cleansing agents, scouring products or thinner. Never expose the BCC10 to heavy shocks. Should this ever happen, have it checked by a qualified technician before using it again. The BCC10 is equipped with an air pressure regulating device. This device has been set to the nominal working air pressure of 6 Bar (87 Psi) in the factory before shipping. To prevent injury to the user, damage to the pneumatic components inside the product or malfunctioning of the product, make sure that the air pressure setting is never altered and that the air compressor (which is not a part of the product) attached to the BCC10 has been set to the correct air pressure (6 Bar / 87 Psi) before switching it on. Never set the air pressure of the compressor higher than 8 bar (120 Psi). Make sure that all electrical plugs and connectors as well as all pneumatic connections are connected correctly and firmly before switching on the air compressor and the BCC10. Never use the BCC10 for other purposes other than those described in this manual. Never insert any other object in the BCC10 than PhotoBooks or SteelBooks from Unibind. The spine dimensions the BCC tool can handle are 3, 5, 7, 9, 12 mm. Never insert hands or other body parts in the product. Failing to do so may result in serious injury. Always immediately remove a finished PhotoBooks or SteelBook from the BCC10. Never leave (un)finished covers (and certainly not any other object) inside the system for a prolonged time. Never expose the BCC10 to flammable or explosive gasses. Only trained technicians are allowed to open and/or service the electricity box of the BCC10. Never try to open, service or modify anything inside the electricity box yourself.

 - User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved

1.2 - AMBIENT OPERATION AND STORAgE ENvIRONMENTS

OPERATINg STORAgE HUMIDITy 0C to +40C -20C to +80C 35% to 90% Relative Humidity (no icing or condensation)

1.3 - ELECTRICAL SPECIFICATIONS

vOLTAgE CURRENT POWER CONSUMPTION 120 VAC / 50-60Hz 16,5 Amp (max) 1500 Watt (max)

1.4 - COMPRESSED AIR SPECIFICATIONS

NOMINAL PRESSURE MAxIMUM PRESSURE ALLOWED AIR qUALITy 6 bar (87 Psi) 8 bar (120 Psi) WARNINg ! do not alter the initial setting (6 Bar) of the air pressure regulator on the product Dried compressed air, lubricated or unlubricated

1.5 - INSTALLATION CONDITIONS

The BCC10 has been designed for indoor use only and can only operate at locations with a complete protection from dust and humidity. In case of structural damage to the BCC10, the machine has to be revised entirely before using it again. The revision (as well mechanically as electrically) has to happen by a competent person. Upstream, the electrical installation must have a differential switch. Make sure the sensitivity of this switch is according to the local regulations for machinery. The conditional short circuit rating (Icc) of the differential switch must be adjusted to the short circuit power of the place of operation. Upstream, the electrical installation needs to be secured with an automatic fuse. The sensitivity of the fuse has to be equal to 16A. If the main voltage would exceed the normal levels at the place of operation (by industrial activity in the surroundings or by atmospheric phenomena), all necessary risk reducing measures have to be taken.

1.6 - COMPLIANCE

User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved - 

2. Installation instructions
1. Cut all the straps from the box with an appropriate tool. 2. Open the wooden box by unscrewing the screws and removing the nails from the front, top and right side panel of the box. 3. Remove the transport immobilizing anchors attached to the four legs of the BCC10 by unscrewing both the bolt in the floor of the box and the bolt in the BCC10 for every anchor. 4. Lift the BCC10 out of the box with a forklift. 5. Screw in the BCC10 feet completely (until it stops). 6. gently place the BCC10 on the ground in its final position. The surface has to be solid, flat and horizontal. In case of a slight inclination, the height of the four feet has to be adjusted (use a level) so that the BCC10 can stand horizontally. 7. Place the machine in a way so that it cant obstruct people or vehicles. 8. Do not discard the bolts and the anchors or the rest of the packaging material. Just in case the BCC10 might have to be returned to Peleman Industries Nv (for repair/control). 9. Remove all the straps and packaging materials from the machine. The grey plastic caps on the top of the clamping arm look like parts of the machine, but theyre not. Please remove these caps so that the arm can slide freely from the left to the right. 10. Attach the handle to the book inserting slide on the left side of the machine. 11. Attach the handle to the center cover in the middle of the machine. 12. Connect the product to an air compressor that is capable of delivering the correct air pressure and the correct amount of compressed air that is needed for the BCC10 (minimum 600 liter/hour at 6 Bar/87 psi). The compressor and air hose are not a part of the machine and have to be provided by the client. The BCC10 is equipped with a 12 mm push in the fitting and can therefore only be connected to a 12 mm air hose (according to DIN-74324). 13. Make sure the compressor is set at the correct output pressure (6 bar/87 Psi) before switching it on. Also watch over it that the output air pressure of the compressor never exceeds the value of 8 bar (120 Psi) to avoid injury to the operator and/or damages to the BCC10. 14. Connect a suitable electric power plug to the end of the electric cable of the BCC10 or hard wire the cable directly into a fixed fuse box. In case a power plug is used, make sure it meets the minimum requirements of 120v and 16Amp. The color code used for connecting the BCC10 is the following: Brown Blue green/yellow Line Neutral Earth

15. No matter how the BCC10 is connected to the electricity net (hard wired or plugged), make sure that upstream the electrical installation is equipped with a differential switch with the correct rating according to the local regulations AND that it is secured with an automatic fuse with a rating of 16A. 16. When powering up the machine, its prior to use air to blow off any dust or particles in or around the machine. Then use Isopropyl Alcohol and lint free rags to thoroughly clean the unit. Tip: wrap a rag around a Book, secure the rag with tape, saturate the end of the rag in a cleaner and use the Book as cleaning tool). The plate of the machine where the spine of the Book touches is often very dirty from transport and the assembly process
 - User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved

17. Put on the air compressor and wait until the preset air pressure has been built up in the compressor. 18. Put on the product by turning the main power switch to position 1. The main power switch is located on the right side of the BCC10; the product is now ready for use. 19. Make sure that all cables as well as the air hose can not obstruct the passage or make people stumble!

Note: If the machine is not going to be used for a longer period (days or weeks), make sure it is completely emptied and powered down by turning the main power switch to the 0 position. The air compressor has to be switched off AND the air pressure, built up in the compressor, has to be released.

User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved - 

3. Operating instructions
1. Make sure that the air compressor is powered on and that the necessary air pressure has been built up in the compressor. 2. Power on the BCC10 by turning its main power switch to position 1. 3. Adjust the clamping arm to the correct height, which is very important to run the machine. you can adjust the clamping arm (raise and lower) with a wheel in the centre compartment. 4. Load 1-10 books in the input unit on the left side of the machine, spine facing downward. (Note! One book per compartment) 5. Press the reset button. The reset button will now light up. 6. Slide the Book(s) into position 1 by moving the handle of the input unit towards the machine. Make sure you push the handle until it cant go any further and then fully retract the input unit. (The entry slide doors should close automatically now) Tip: If the input unit doesnt go back to the start position, the machine will not operate. 7. Wait for about 10 minutes for the heating plate inside the BCC 10 to reach its working temperature. This warming up time is only required for the first book run or after an extended period of time for which the machine has set idle. The temperature setting and the actual temperature of the heating plate can be observed by reading the temperatures on the two temperature displays located on the right side of the BCC 10. Temperature is preset at 120C/248F. 8. Reload 1-10 books in the input unit with the spine facing downward. (Note! One Book per compartment) 9. Note! Make sure that you remove all the books from the exit tray before you insert additional books. 10. If the BCC10, after loading the input unit, does not automatically restart a new processing cycle, you should check the following steps: a. Check the display for an error message (In case of error messages, check chapter 4: display settings). b. Check if the light from the reset button is burning, if not: press the reset button. c. Make sure the input trey is returned to the start position. d. Make sure the centre door is closed. e. Make sure that, since the start of the previous cycle, more than 90 seconds have elapsed. At its best, the machine can only start a new processing cycle every 90 seconds. This is implemented to make sure that the Books stay long enough on the heating plate for a good binding of the pages. Note that the machine will also automatically start a new cycle after 90 seconds when there are still Books in the heating, crimping and/or cooling unit of the BCC10. f. Make sure the output unit of the BCC10 is empty. g. Make sure the emergency stop is not pressed. h. Make sure machine is powered on. i. Make sure the air pressure is adequate. j. visually inspect the machine for anything that may jam movements. 11. Make sure that after every working day both the BCC10 and the compressor are powered down.
 - User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved

WARNINg !
Make sure not to abandon the BCC10 (eg: at the end of the day or for lunch) if there are still Books inside the machine. It takes the heating plate a long time to cool down, even with the BCC10 powered down, and this could cause the Books (in the machine) to catch fire!

Note: By default, after 10 minutes of inactivity of the BCC10, its heating plate is automatically disabled for safety precautions and to save energy. If the BCC10 is restarted again, depending on the temperature of the heating plate at that moment, up to 10 minutes can be needed for the machine to start a processing cycle.

User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved - 

4. Display settings
1. ERRORS All occurring errors will be described on the display. When more than one error occurs, you can show the other errors on the display by pressing the buttons up or down. Just check every part of the machine with an error. When an error occurs, the light from the reset button will go out (with exception for the temp out of range message). TyPES OF ERRORS No pressure: This message appears when the pressure drops below 5,5 bar / 80 Psi, the machine will stop operating. The machines working pressure is 6 bar / 87 Psi. Temp out of range: The heating plate has not reached its working temperature yet. When the reset button is burning, the machine will start automatically as soon as the working temperature is reached. When necessary you can watch the actual temperature of the heating plate by pressing the Clear-button, all errors will then be removed from the display for about 5 seconds. 2. CHANgINg SETTINgS To change a value, just press the F-key of the setting that you want to change. The numbers from the chosen setting will now be marked. you can now move the blinking cursor to the number you want to change and press up or down to adjust. After adjusting, simply press the enter key. All settings can be shown on the display again by going to the top of the menu by pressing the button up. Temperature: This allows changing the preset temperature of the heating plate by pressing the button temp. on the display. The temperature is preset at 120C / 248F. The maximum temperature allowed is 140C / 284F. Warning: Use of too high temperatures can cause damage to the spine of the Book! Crimping time: Can be preset between 1,44 and 1,80 seconds. Cycle time: It is important to never change this setting! The cycle time is preset at 90 seconds. A change of this setting can cause malfunctioning of the machine.

10 - User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved

5. Maintenance
If the BCC10 is used within the given specifications for storage and operation temperature as well as air pressure and electrical specifications, only the following maintenance will be needed on the product: 1. LUBRICATION To make sure the machine can work optimally, some of the moving parts need to be lubricated. There are 12 lubrication points on the machine as shown in figure ???. Lubrication must be carried out using the lubrication nipples. To reach some of the lubrication points, disassembly of a few plates is needed as shown in figure ???. For this disassembly a socket wrench 5 is needed. Always move the carriages during lubrication. Lubrication intervals: Max. 12 months if grease lubrication is used. Lubrication quantity: If grease lubrication is used, continue greasing the carriage until new grease appears. Initial grease quantity is about 1,4 g. 2. CLEANINg For a good operation of the BCC10, make sure to keep it clean and free of strange objects at all times. If you dont use the machine for a long time, use air to blow off any dust or particles in or around the machine. Then use Isopropyl Alcohol and lint free rags to thoroughly clean the unit. Be careful when cleaning the partitions to prevent damage or deformation. Tip: wrap a rag around a Book, secure the rag with tape, saturate the end of the rag in cleaner and use the Book as a cleaning tool.

6. Disclaimers
PERFORMANCE DATA Performance data given in this manual are provided as a guide for the user in determining suitability and do not constitute a warranty. It may represent the result of PELEMAN INDUSTRIES nvs test conditions, and the users must correlate it to actual application requirements. CHANgE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons. Consult with your PELEMAN INDUSTRIES nv representative at any time to confirm the actual specifications of the purchased product.

User Manual - Bind, Crimp & Cooling tool BCC10 - 2008 Peleman Industries nv. All rights reserved - 11

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