Perfect Binder PB-600S

Product Guide
Draft revision 01 (Sept 2011)

Perfect binding system model PB-600S for the

production of perfect bound books in-line
with a Digital Web printer

This Guide is revision 01 is not yet released ..

To ensure you are using the most up-to-date version of this Guide check the
‘download’ page on IBIS’s web site [Link] to view the latest revision.

[Link]

PB-600S Product and Application Guide rev.00 1

 Document Revision History
Rev Date Description of main changes made at each release
00 14/0910 First release.

Product specifications and / or appearance are subject to change without notice.

2 PB-600S Product and Application Guide rev.00

Contents

1 Press release from the Smart-binder initial product release at the Drupa
exhibition, 2004.................................................................................................................. 7
2 IBIS Product Range Summary ................................................................................. 8
3 Smart-binders SB-1, 2, 3 and 4 : Main user-features and benefits ......................... 8
4 Smart-binder system description and options .......................................................... 9
4.1 Process description ............................................................................................. 9
Smart-binder system layout ............................................ Error! Bookmark not defined.
4.1.1 Producing booklets up to 10mm (0.39”) thickError! Bookmark not defined.
4.1.2 Wire stitched booklets - SB-1, SB-2, SB-3 and SB-4. .............................. 10
4.1.3 ISG cold-glued booklets – SB-1G, SB1-G4, SB-3 and SB-4 onlyError! Bookmark not de
4.1.4 Producing hot-glued (square-back) books 5-60 mm thick (0.2-2.36”)Error! Bookmark not
4.1.5 SCF (Sheet collector and feeder) and Hot-melt binder (model BB3002)
as used on the SMART-BINDER model SB-4. .......... Error! Bookmark not defined.
4.2 Book output options .............................................. Error! Bookmark not defined.
4.3 Feeding Covers and Insert Sheets ........................ Error! Bookmark not defined.
4.4 Producing varying thickness booklets ................................................................ 13
4.5 Producing saddle-bound booklets up to 10mm thick .......................................... 13
4.6 Book and sheet integrity checking ..................................................................... 13
4.7 Three-knife trimming .......................................................................................... 13
4.8 Optional equipment............................................................................................ 14
4.8.1 Optional modules which may be supplied with the Smart-binderError! Bookmark not def
4.8.2 Ancillary features which may be fitted to the Smart-binder. ..................... 14
4.9 Feeding sheets off-line from a pile feeder ............. Error! Bookmark not defined.
4.9.1 SB-095 Direct-connected pile feeder for off-line operation onlyError! Bookmark not defi
4.9.2 SB-096 Pile feeder on the side (+ roller table) for combined off-line and
in-line operation ........................................................ Error! Bookmark not defined.
4.10 Trimmer Centre- Knife (Options CKN-100, 101 and 102)Error! Bookmark not defined.
4.11 Trimmer waste removal ........................................ Error! Bookmark not defined.
4.12 Additional Sheet Folding ....................................... Error! Bookmark not defined.
4.12.1 Sheet Folder option F-100 or F-101 ........... Error! Bookmark not defined.
4.12.2 Sheet rotator and folder option RF-100 ...... Error! Bookmark not defined.
4.13 Lightweight paper stocks ...................................... Error! Bookmark not defined.
4.14 Producing books with ‘loop’ stitches (Option LST-100)Error! Bookmark not defined.
4.15 Producing books with holes (Options HPM-100 and HDM-100)Error! Bookmark not defined.
4.16 Covers and inserts ................................................ Error! Bookmark not defined.
4.17 DMP-100 Sheet dynamic micro-perforation option Error! Bookmark not defined.
4.18 BSS-11 book stacker option ................................. Error! Bookmark not defined.
4.19 Spine squaring module Option SM-100 ................ Error! Bookmark not defined.
4.20 Pile Loading Trolley system Option PLT -100 ..... Error! Bookmark not defined.
4.21 Smart-binder Production Rates .......................................................................... 15
4.21.1 Sheet infeed rates ................................................................................... 15

PB-600S Product and Application Guide rev.00 3

 4.21.2 Book Production Rates, A4 saddle-bound books from 4-page sheets
(with no separately-fed cover) ................................................................................ 16
4.21.3 Different Booklet Format sizes ................... Error! Bookmark not defined.
5 Specifications ............................................................ Error! Bookmark not defined.
5.1 Smart-binder Specifications ............................................................................... 18
5.2 Rotator/folder RF100 Specifications: .................... Error! Bookmark not defined.
5.3 BS11 Stacker specifications ................................. Error! Bookmark not defined.
5.4 SM-100 Spine squarer specifications .................... Error! Bookmark not defined.
5.5 BB3002 perfect binder specifications (when used as part of the SB-4 system
and fed from the SCF-100) .......................................................................................... 20
5.6 CMT-330 trimmer specifications (when used as part of the SB-4 system in-line
with the BB3002 binder ) ............................................................................................. 22
6 Smart-binder Configurations ..................................... Error! Bookmark not defined.
6.1 Example Configurations for common applications. Error! Bookmark not defined.
6.1.1 In-line configuration - wide or narrow web .. Error! Bookmark not defined.
6.1.2 In-line configuration - narrow web to make full size booksError! Bookmark not defined.
6.1.3 In-line configuration with rotator/ folder to make small size books .Error! Bookmark not d
6.1.4 In-line / off-line configuration ...................... Error! Bookmark not defined.
6.1.5 In-line with extra F-100 folder to allow higher web speeds or lighter
paper stock ............................................................... Error! Bookmark not defined.
6.1.6 In-line with cut-sheet printer ....................... Error! Bookmark not defined.
6.1.7 Off-line operation from a pile feeder ........... Error! Bookmark not defined.
6.2 Selecting a configuration (In-line, near-line of off-line)Error! Bookmark not defined.
6.2.1 Running the Smart-binder ‘in-line’ with a digital printer:Error! Bookmark not defined.
6.2.2 Running the Smart-binder ‘near-line’ from a pre-printed roll unwinder
and cutter.................................................................. Error! Bookmark not defined.
6.2.3 Running the Smart-binder ‘off-line’ from a deep pile sheet feeder:Error! Bookmark not d
6.2.4 In-line/ off-line configuration (Option SB-096)Error! Bookmark not defined.
6.2.5 Choosing between an in-line or an off-line Smart-binder systemError! Bookmark not def
6.3 Selecting upstream modules as part of an in-line system................................... 24
6.3.1 Web Cutters ............................................................................................ 24
6.3.2 Web Moisturiser. ..................................................................................... 25
7 Print impositioning schemes ..................................... Error! Bookmark not defined.
7.1 Example impositions ............................................. Error! Bookmark not defined.
7.1.1 A4 or 8 ½ x 11” finished format size ........... Error! Bookmark not defined.
7.1.2 A5 Portrait or Digest (8½ x 5½”) without pre- foldingError! Bookmark not defined.
7.1.3 A5 landscape (or 8 ½ x 5 ½” oblong) finished sizeError! Bookmark not defined.
7.1.4 CD booklets (120mm square) from narrow web or pile feederError! Bookmark not define
7.1.5 A5 Portrait (or 8 ½ x 5 ½”) finished size ..... Error! Bookmark not defined.
7.1.6 A6 Landscape (or 4 ¼” x 5 ½” oblong) finished sizeError! Bookmark not defined.
7.2 Printing barcodes ............................................................................................... 25
7.2.1 Bar code locations...................................... Error! Bookmark not defined.
7.2.2 Format of barcodes .................................... Error! Bookmark not defined.
7.2.3 Bar codes when using the optional rotator /folderError! Bookmark not defined.
7.2.4 Running without barcodes (in off-line mode only)Error! Bookmark not defined.
4 PB-600S Product and Application Guide rev.00
 7.2.5 Reverse order barcodes ............................. Error! Bookmark not defined.
7.2.6 Job IDs....................................................... Error! Bookmark not defined.
7.2.7 Example of normal “scheme 0” bar coding for saddle-bound books .Error! Bookmark not
7.3 Image creep due to spine ‘wrap round’ ................. Error! Bookmark not defined.
8 Using the Smart-binder .......................................................................................... 26
8.1 Operating the Smart-binder ............................................................................... 26
8.1.1 Thickness changes ................................................................................. 26
8.1.2 Format changes ...................................................................................... 26
8.1.3 Stitch Spacing, standard Stitching (not loop stitching).Error! Bookmark not defined.
8.1.4 Using the Cover/Insert Feeder option CIF-100 ........................................ 26
8.1.5 Working with Paper rolls, or stacks of sheets .......................................... 27
8.1.6 Changing between wire stitching and ISG cold-gluingError! Bookmark not defined.
8.1.7 Using the optional ‘Spine-squaring’ unit SM-100Error! Bookmark not defined.
8.2 Maintaining the Smart-binder ............................................................................. 27
8.2.1 Spare Parts ............................................................................................. 27
8.2.2 Scheduled Maintenance .......................................................................... 28
8.2.3 Consumable parts ................................................................................... 28
9 Planning an installation .......................................................................................... 29
9.1 Installation schedule (SB-1, 2 and 3) ................................................................ 29
9.2 Preparing the site Refer to the Smart-binder Installation Questionnaire for full
list of all site preparation issues ................................................................................... 29
9.3 Layout of basic Smart-binder ............................................................................. 30
9.4 Layout of Off-line version Smart-binder................. Error! Bookmark not defined.
9.5 Layout of in-line Smart-binder with SB-096 pile feeder optionError! Bookmark not defined.
9.6 Layout of in-line Smart-binder SB-4 (layout option A)Error! Bookmark not defined.
9.7 Layout of RF100 rotator/folder option.................... Error! Bookmark not defined.
9.8 Layout of Optional CMT-330 trimmer ................................................................. 31
9.9 Services ............................................................................................................. 31
9.9.1 Electrical power requirement ................................................................... 31
9.9.2 Compressed air supply requirement ........................................................ 32
9.9.3 Air conditioning ....................................................................................... 32
9.9.4 Radiant heat output ................................................................................. 32
9.9.5 Trimmer waste (trim-off) removal systems............................................... 32
9.10 Connection to upstream/downstream equipment ............................................... 32
9.11 Installation, Commissioning and Training ........................................................... 32
9.11.1 Unloading ................................................................................................ 32
9.11.2 Machine module weights and sizes (crated) (approximate) ..................... 33
9.11.3 Smart-binder Module Weights and Sizes: uncrated (approximate)Error! Bookmark not d
9.11.4 Size of largest module (stitcher module), excluding packing. .................. 34
9.11.5 The Operator Training Course................................................................. 34
9.11.6 The Smart-binder Maintenance training course ....................................... 36
10 Frequently asked questions ................................................................................... 36
10.1 In-line or off-line operation? .................................. Error! Bookmark not defined.
10.2 In-line and off-line operation? ............................... Error! Bookmark not defined.
PB-600S Product and Application Guide rev.00 5
 10.3 Maximum and minimum book thicknesses ............ Error! Bookmark not defined.
10.4 System Operating Speeds and Efficiencies .......... Error! Bookmark not defined.
10.5 Perfect-Bound books ............................................ Error! Bookmark not defined.
10.6 Producing small format books in-line with a web printerError! Bookmark not defined.
10.7 Light weight paper stock. ...................................... Error! Bookmark not defined.
10.8 Maximum speed. .................................................. Error! Bookmark not defined.
10.9 Personalised books .............................................. Error! Bookmark not defined.
10.10 Personalised covers (or covers with cut-out windows).Error! Bookmark not defined.
10.11 ISG cold glue. ....................................................... Error! Bookmark not defined.
10.12 Multiple covers and insert-sheets.......................... Error! Bookmark not defined.
10.13 Perforated sheets. ................................................ Error! Bookmark not defined.
10.14 Hole punching and drilling..................................... Error! Bookmark not defined.
10.15 Loop Stitching. ...................................................... Error! Bookmark not defined.
10.16 Book Stacking, wrapping and/or banding. ............. Error! Bookmark not defined.
10.17 Book squaring....................................................... Error! Bookmark not defined.
10.18 Two-up production ................................................ Error! Bookmark not defined.
10.19 Minimum book format sizes. ................................ Error! Bookmark not defined.
10.20 Trimmer waste removal. ....................................... Error! Bookmark not defined.
10.21 Electrical power supply voltage. ............................ Error! Bookmark not defined.
10.22 Spine corner tearing on thick books. ..................... Error! Bookmark not defined.
10.23 In-line connection to cut-sheet printers. ................ Error! Bookmark not defined.
11 Appendices ............................................................................................................ 36
11.1 Power Distribution Networks (according to UL1950 and EN60950) ................... 36
11.2 IBIS SCHEDULED MAINTENANCE PACKAGE (SMP) ..................................... 37
11.2.1 Frequency of visits .................................................................................. 38
11.2.2 Duration of visits ..................................................................................... 38
11.2.3 SMP Price ............................................................................................... 38
11.2.4 Scheduling of SMP visits ......................................................................... 38
11.2.5 Replacement parts .................................................................................. 38
11.3 Conversion Charts For Stock Weights ............................................................... 39
11.4 Tools and Special Equipment Required for Service and Maintenance ............... 40
11.5 Smart-binder (SB) Application Questionnaire for Digital Print Applications. ....... 41

6 PB-600S Product and Application Guide rev.00

 1 Press release.
PERFECT BOUND BOOKS ON-DEMAND IN-LINE WITH DIGITAL
PRINTERS
The UK manufacturer IBIS Integrated Bindery Systems has launched a family of perfect
binding systems which may be used in-line with digital web or cut-sheet printers for the
production of high quality , soft-cover Perfect-Bound books up to 60mm thick.

SSF-100 or
BB3002
SCF-100
Sheet input perfect binder
feeder
from Digital
printer

Cover feeder

Folder wire
stitcher Perfect Bound
book delivery
(ready for
PB-600 system trimming)
operator controls

The IBIS PB-600 system Smart-binder incorporates the BB3002 perfect binder manufactured by CP
Bourg. To adapt this binder to run in-line with digital printers, IBIS has developed two different feeder
modules: the SSF-100 and the SCF-100.

The SSF-100 (as used on the PB-600S) receives piles of sheets from a sheet stacker (i.e as used in
connection with web cutters) and places these sheet piles directly into the BB3002 binder clamp. The
SCF-100 (as used on the PB-600C) receives a stream of digitally printed sheets (or folded
signatures), collects these sheets/sigs into loose book blocks and places these book blocks into the
binder clamp. An optional 3-side book trimmer is available to connect directly to the binder delivery.

The PB-600 systems mark the transition into a new era of low-cost ‘perfect binding’ systems that can
be used in-line with Digital Printers. The BB3002 can be supplied with either hot-melt gluing or PUR
gluing.
All IBIS products may be used in-line with a digital printer or fed off-line from a pre-printed roll or
sheet pile feeder.
IBIS PB-600S : THE ULTIMATE FINISHING SOLUTION
PB-600S Product and Application Guide rev.00 7
 2 IBIS Perfect Binder Product Range Summary

Max book
thickness
Max Max
Model

Binding
Input Output Cover feeding Key Features
method (s)
Speed speed
Perfect binding in-line
with digital cut-sheet
Perfect-binder

printers
400 pages/min
PB-600C

Auto-setting
Off-line hand feeding
Perfect Binding only

600 position.
books/hour Low pile feeder Optional in-line
Square-back
(incorporated trimmer for square-
‘perfect binding’
into the perfect bound books
only
binder)
(400 Hot-melt glue or Perfect binding in-line
approx 2400 with extra

books/hr for PUR with digital web

Perfect binder

Option for up to
1220 pages/min (or

optimum printers
6 cover creases
PB-600S

quality) Auto-setting
Off-line hand feeding
position.
Optional in-line
folder)

trimmer for square-

bound books

3 PB-600S in-line perfect binder : Main user-features

and benefits

 Range of different system configuration options

Can run in-line with a high-speed digital web printer, or off-line/near-line operation from
either a pre-printed reel or sheet pile feeder.
Variable-length accumulation conveyors available.
All in-line connected PB-600 systems may also be used off-line by manually feeding
book blocks into the binder clamp, if required, without an modules having to be moved..
May be fitted with in-line (or off-line) 3-side book trimmer : two different types of trimmer
are available.
High quality finished books
The BB3002 includes book block vibration, 3-roller gluing, 2-wheel side gluing and up to
6 cover creases, all for highest possible book quality.
 On-demand operation
The PB-600S can change book thicknesses on-the-run. It can also change book format
sizes automatically (simple operator touch screen input of required book dimensions)
 Performance
The PB-600S can run in-line with the highest speed digital web printers . The BB3002
outputs up to 400 books/hour.

8 PB-600S Product and Application Guide rev.00

 4 PB-600S perfect binder system description,
specifications, performance and options
4.1 PB-600S Process description
For a video and presentation of the PB-600S (with in-line CMT -330 trimmer) go to
[Link]

The PB-600S is used in-line with digital web

printers which are fitted with a web cutter and
stacker. The web cutter is used to slit and cut
the web into the required book size and to
output piles of cut sheets: each pile
representing one complete book-block.
Book-blocks travel horizontally along a
Shuttleworth accumulator conveyor and are
stopped at the end of this conveyor by a
reciprocating gate.
The gate releases one book at a time into the
SSF-100 sheet set feeder when the SSF-100
is ready to receive a book.
The SSF-100 clamps the sheet set, rotates it to vertical and pushes into the BB3002
binder clamp from the side.
The BB3002 vibrates the sheets into correct register, clamps the sheets and then
moves the sheets through the binding process which includes: sheet edge milling, hot
glue application (3-roller tank) side glue wheel application, cover feed with up to 6
creases, cover application and pressing, book delivery into optional stacker, or
optional in-line 3-side book trimmer
If the SSF or BB3002 stops, then the book stacks accumulate on the accumulator
conveyor. This allows the printer to keep running for some time until the accumulator
conveyor fills up. When the SSF/BB3002 restarts, then the number of accumulated
books on the conveyor is reduced providing the SSF/BB3002 runs faster than the
printer. The accumulator conveyor therefore reduces the number of printer stops.

Perfect Binder model PB-600S in-line with a high speed web printer :

Sheet stacker High speed web printer

Shuttleworth accumulator
roller conveyor
Perfect bound book delivery Web cutter (typically Hunkeler or
Lasermax)
In-line trimmer

Reciprocating ‘gate’
SSF
-100
BB3002

Optional book trimmer : either CMT

4.2
or FS trimmer
Perfect binderProduct
PB-600S (with hot and
melt glue or
Application Guide rev.00 9
PUR)
 4.3 PB-600S picture

Binder clamp
Cover
(may be Hot glue
SSF-100 Spine application
loaded by applicator
feeder hand) milling tank
BB3002
perfect binder

Sheet stack
input from
Digital printer
and web
cutter/stacker

Cover feeder and

cover creasing
(can add up to 6
crease lines)

Perfect Bound
book delivery
(ready for
PB-600S system trimming)
operator controls

4.4 Optional in-line trimmer

An optional 3-side book trimmer may be provided to run in-with the BB3002 binder
delivery, or off-line (hand fed). Two different trimmer options are available (CMT-130,
or FST) each of which are designed for on-demand book finishing.

10 PB-600S Product and Application Guide rev.00

 In-line version CMT -130 (Book trimmer option 1)
EASY VIEWING WINDOWS

Optional vertical stacker

(trimmed book output)

Untrimmed book
input direct from
BB3002 binder
delivery

Cooling elevator

The CMT 130 finishes soft-cover, perfect bound books at a rate of up to 500
books per hour by trimming piles of 1, 2 or 3 books at a time (number of books in
the pile depends on book thickness).. note max recommended throughput of
BB3002 binder is 400 books/hour.
The in-line version shown above connects directly to the BB3002 binder outlet, and
includes a multi-stage book cooling elevator to allow time for the hot-melt glue to cool
before trimming.
The CMT-130 has a maximum book thickness limit of 51mm (2“)
Book format size changes and thickness changes may be made automatically
(optional bar code detection available for auto changes).
The optional vertical stacker allows up to 24” / 609 cm of books to be delivered

PB-600S Product and Application Guide rev.00 11

 In-line version Fast-set trimmer (Book trimmer option 2)
Shown with optional book cooler transfer

The Fast-set trimmer finishes soft-cover, perfect bound books at a rate of up to

700 cycles per hour (700 books/hr if trimming 1-up, 1400 books/hr if trimming 2-up,
2100 books/hr if trimming 3-up).
The in-line version shown above connects directly to the BB3002 binder outlet, and
includes a multi-stage book cooling conveyor (with 20 book-stop positions) to allow
time for the hot-melt glue to cool before trimming.
The Fast-set has a maximum book thickness limit of 60mm (2.36“).
Book format size changes and thickness changes may be made automatically.
Power supply needed : 400V 3 phase, + neutral 6A, 50/60 cycles 1,25 kW.
Compressed air supply needed : 8 bar.

4.5 Paper flow diagram Sheets

stacked into
‘book piles
Sheets slit
Finished perfect- and ejected.
into 2 (or 3)
bound (ready sheets Sheets smaller
Cover Sheets Web cut into
feeder for trimming) collected
sheets
pressed sheets
cover together Sheets
together
feeder into delivered
Score,
signatures
fold and Scoreto Smart-
and
collate fold binder in
sheets sequence
sheets
Sheet stacks travel (and
Cover is along roller cover)
pressed accumulator
around the Sheet sets conveyor ISG cold
book Hot melt
glue applied received by gluing inside Sheet
Signatures
SSF-100 sheet (on stream
clamped Stacks are stopped by ‘gate’fold
andline)
module and input
together in released into SSF as needed.
BB3002 rotated to
binder and vertical
12 spinePB-600S
folds Product and Application Guide rev.00
milled off.
4.6 Binder process description
The BB3002 binder uses two glue applicator rollers and a reverse spinner roller to
accurately control the glue layer. Side rollers are also fitted to apply glue to each side
of the book, close to the book- spine. Spine preparation (milling) is done using a multi-
tipped rotating saw.

Optional
Signatures wing- fold
or sheets available

Cover sheet

Side glue Side glue

Hinge crease
Layer of hot-melt
Spine crease
glue

The BB3002 cover feeder applies multiple crease lines to each cover to assist it to
bend around the book and to open easily (including optional ‘gate-fold’ or ‘wing-fold’
creasing). A creasing-knife is used, instead of scoring wheels, that reduces cracking of
colour toner printed covers.
Signatures or sheets may be loaded into the clamp by hand if not wishing to use the
SCF (signature collector and feeder), or SSF (sheet set feeder).

4.7 Producing varying thickness booklets

Book thicknesses (number of pages in the book) may be changed without stopping the
line. The SSF measures the book thickness and provides a signal to the BB3002 to
adjust automatically to this thickness. The maximum throughput rate of the system is
reduced if continually changing book thickness

4.8 Book and Cover integrity checking

The PB-600S relies on only good book piles being delivered by the web cutter/stacker.
In this case any bad book piles must be detected by the stacker and pushed out in a
different direction (reject lane)
An optional bar code checking system is available for the cover feeder to ensure
that personalised covers ‘match’ the book block to which each cover is being applied.

PB-600S Product and Application Guide rev.00 13

 4.9 Optional equipment

4.9.1 Optional modules which may be supplied with the PB-600S

Item Part Description Function For more
no. no. info see
section.
1 SAC- Shuttleworth accumulator Allows books to accumulate in
101 conveyor with timing gate between the stacker and
Length 2 metres (6.56ft) SSF/BB3002 (so printer does not
need to stop immediately the
SSF/BB3002 stops) .
2 SAC- Additional 2 metre (6.56ft) May be used to increase
100 length of Shuttleworth accumulation capacity .
accumulator conveyor
(without timing gate)
3 CMT- CMT130 3-side trimmer Use for final 3-side trim of perfect
130-OL (hand fed) bound books up to 51mm thick (off-
line: hand fed)
4 CMT- CMT130 3-side trimmer Use for final 3-side trim of perfect
130-IL (in-line connected with bound books up to 51mm thick (in-
book cooling elevator . line connected: no hand feed
Includes delivery stacker) needed)
5 FST- Fast-set trimmer in-line Use for final 3-side trim of perfect
100 connected without 20- bound books up to 55mm thick (in-
station book cooling line connected: no hand feed
conveyor needed). Select this option if book is
cool enough for trimming when it
enters the trimmer
6 FST- Fast-set trimmer in-line Use for final 3-side trim of perfect
101 connected with 20-station bound books up to 55mm thick (in-
book cooling conveyor line connected: no hand feed
needed). Select this option if book
needs additional cooling time before
trimming.
7 TWC- Trimmer waste removal Used to remove trimmed-off paper if
100 system for Fast-set no pneumatic waste extraction
trimmer system is available.
8 TDC- Trimmer delivery conveyor Extra length trimmer delivery
100 conveyor (for use with FST
trimmers)
9 TFR- Voltage transformer for For use when the factory supply
105 PB-600S main power voltage is outside the 380 – 415
supply range (e.g. for installations outside
Europe)
10 PUR- PUR (polyurethane Select this option if PUR gluer
100 reactive glue) option for preferred to normal EVA glue
BB3002 binder
11 CMS- Cover matching system Select this option if applying
100 for BB3002 binder personalised book covers (with bar
coded I/D number on covers and
14 PB-600S Product and Application Guide rev.00
 sheets.
12 CMS- System to automatically Select this option if wishing to auto-
101 control CMT trimmer size adjust the CMT130 trimmer based
change on bar coded book size information
on each book.
10 SPK- Essential PB-600S spare Includes all parts that must be held
100 parts kit close to the machine to support
normal operation. Refer to IBIS for
spare parts relating to optional
modules.
11 SPK- Basic PB-600S Spare Includes all parts recommended to
101 Parts Kit be held close to the machine. Refer
to IBIS for spare parts relating to
optional modules.
12 SPK- Extended PB-600S Spare Includes all parts recommended to
102 parts kit be held by distributors in each
country when the installed base
exceeds 3 units. Refer to IBIS for
spare parts relating to optional
modules
13 SKK- Spare set of trimmer front It is recommended to hold two spare
105 and side knives for CMT- sets of knives for each machine
130 (one ready to fit and one being
reground).
14 SKK- Spare set of trimmer front It is recommended to hold two spare
106 and side knives for FST- sets of knives for each machine
100 (one ready to fit and one being
reground).

4.10 PB-600S performance

4.10.1 Sheet infeed rates

Production in-line with a Digital printer, or ‘near line from a pre-printed roll.
When running in-line with a digital web printer (or pre-printed roll), the sheet arrival rate
depends on web velocity and sheet cut-off dimension. The maximum web speed is
dictated by the type of printer and in-line web cutter/stacker which is used. It is also
dictated by the number of sheets in the book since the rate of thin book production
cannot exceed wither the eject cycle rate of the web cutter of the maximum book
production rate of the BB302 binder (approx 400 books/hour)

PB-600S Product and Application Guide rev.00 15

4.10.2 Maximum printer web speeds
When using the in-line connected PB-600S system then the maximum printer web
speed is linked to the number of sheets in the book and the maximum binding speed
which is 6.66 books/min (assuming that rate that maximum rate the stacker can eject
book piles exceeds 6.66 books/min).
[Link] The following table shows maximum printer speeds for different book
thicknesses, assuming 6 x 9” pages, printed with the 6” dimension 3-
across the web.

Number
of 2-page Number of Maximum Printer Maximum Printer
sheets 6 x 9” pages web speed (feet web speed (metres
in book in book /min) /min) Book output rate
(excluding (excluding Assuming 600 Assuming 183 ft/min (books/min)
separately-fed separately-fed ft/min is the is the printer
cover) cover) printer maximum maximum
Number
10 20 17.59 5.36 6.66
20 40 35.18 10.72 6.66

30 60 52.77 16.08 6.66

40 80 70.36 21.45 6.66
50 100 87.95 26.81 6.66

70 140 123.13 37.53 6.66

90 180 158.31 48.25 6.66

120 240 211.08 64.34 6.66

150 300 263.85 80.42 6.66
200 400 351.80 107.23 6.66

250 500 439.75 134.04 6.66

300 600 527.70 160.84 6.66

350 700 600.00 182.88 6.49

400 800 600.00 182.88 5.68
450 900 600.00 182.88 5.05

500 1000 600.00 182.88 4.54

550 1100 600.00 182.88 4.13

600 1200 600.00 182.88 3.79

Notes on book production rates

 The web cutter/stacker must have an eject cycle rate of at least 2.22 cycles /min.
Each eject delivers 3 book stacks assuming the 6 x 9” pages are printed 3-across
the web.
 A web buffer must be used between the printer and the web cutter to allow the
stacker to go through its eject cycle without stopping the printer.

16 PB-600S Product and Application Guide rev.00

 Actual running is never continuous. On a CF web system, time is needed to change
paper rolls periodically, and there are stops due to printers and the web
cutter/stacker . The BB3002 system needs to be stopped periodically for cover
loading and glue tank filling. When book size changes, time is needed to adjust the
system for the new size. These stops must be taken into account when estimating
production capacity.

[Link] The following table shows maximum printer speeds for different book
thicknesses, assuming 8 1/2 x 11” pages, printed with the 8 ½ ”
dimension 2-across the web.

Number
Number of
of 2-page Maximum Printer Maximum Printer
8 ½ x 11” web speed web speed
sheets
pages Book output rate
in book (feet /min) (metres /min) (books
in book
(excluding Assuming 600 Assuming 183 m/min
(excluding /min)
separately-fed ft/min is the is the printer
cover) separately-fed printer maximum maximum
cover)
Number
10 20 6.66
20 40 6.66

30 60 6.66
40 80 6.66

50 100 6.66
70 140 6.66
90 180 6.66

120 240 6.66

150 300 6.66

200 400 6.66

250 500
300 600

350 700
400 800

450 900
500 1000
550 1100

600 1200

Notes on book production rates

 The web cutter/stacker must have an eject cycle rate of at least 3.33 cycles /min.
Each eject delivers 2 book stacks assuming the 8 ½ x 11” pages are printed 2-
across the web.
 A web buffer must be used between the printer and the web cutter to allow the
stacker to go through its eject cycle without stopping the printer.
PB-600S Product and Application Guide rev.00 17
 Actual running is never continuous. On a CF web system, time is needed to change
paper rolls periodically, and there are stops due to printers and the web
cutter/stacker . The BB3002 system needs to be stopped periodically for cover
loading and glue tank filling. When book size changes, time is needed to adjust the
system for the new size. These stops must be taken into account when estimating
production capacity.

4.11 PB-600S Specifications

Speed
Maximum speed (books/hour)
600 (400 recommended for optimum book bind quality)

Note : higher speeds are possible without cover scoring.(but nor recommended for
book quality reasons)

Sheet Sizes (untrimmed) as presented to the PB-600S

Sheet Input Size Leading edge (long edge) Side edge (short edge)
Maximum 320mm (12.6”) 230mm (9.1”)
Minimum 200mm (7.9”) 110mm (4.3”)
Refer to IBIS is sizes are required outside the above range.
The size of sheets being fed into the PB-600S should not vary by more than 0.5mm
(0.020”) during running, unless changing jobs.

Cover Sizes (for BB3002 binder)

Cover input size Leading edge (short edge) Side edge (long edge)
Maximum 395mm 710mm
Minimum 100mm 200mm
The BB3002 binder can accept a cover size which may be outside the max/min range
of the SSF.
The cover may overlap the front edge of the book after it is applied. This overlap may
be removed by the trimmer front knife, providing this is within the specification of the
trimmer.

Finished Book Sizes (after trimming)

a) Using CMT-130 trimmer

Spine to Fore-edge book
Description Spine length
width
Maximum 304.8mm (12”) 228.6mm (9”)
Minimum 148mm (5.82”) 101.6mm (4”)

18 PB-600S Product and Application Guide rev.00

 a) Using FST trimmer
Spine to Fore-edge book
Description Spine length
width
Maximum 305mm (12”) 229 mm (9”)
Minimum 150mm (5.9”) 105mm (4.1”)

Trim off

A) Using CMT-130 trimmer

Maximum Minimum
Front trim

Side trim

*Note: A trim off between 0 and 3mm (1/8”) is not recommended.

A) Using FST trimmer

Maximum Minimum
Front trim 140mm (5.5”) 2.5mm (0.1”)

Side trim 2.5mm (0.1”)

*Note: A trim off between 0 and 2.5mm (0.1”) is not recommended.

Book Thickness
Maximum Minimum
Using CMT-330 Limited by bind quality:
50.8mm (2”)
trimmer approx 2mm
Using Fast-Set Limited by bind quality:
60mm (2.4”)
trimmer approx 2mm

Paper Weight Specification

Description Paper stock weight Cover stock weight

160gsm / 108 lbs offset / 43 300gsm

Maximum
lbs bond 111lbs/500 sheets (20 x 26”)
50 gsm / 34 lbs offset/ 13 80gsm
Minimum
lbs bond * 30 lbs/500 sheets (20 x 26”)

PB-600S Product and Application Guide rev.00 19

* Note: refer to IBIS if wanting to run stock weight lower than 50 gsm

Note that web printer and web cutter/stacker must also be able to handle selected
stock weights

Glue specification
Description Glue type Application
Layer approx 0.5 mm thick on
BB3002 Hot-melt EVA hot melt (refer to IBS for
signature spines + thinner
glue recommended specification)
layer on book sides.
.

4.12 BB3002 perfect binder specifications (book format sizes

assume use without SSF connected.. i.e. hand- fed
operation)

Maximum throughput rate : 400 books/hour (exact speed depends on book thickness
and book quality requirements)
Just insert the book block and the BB3002 will take care of the binding, no setting required.
The Bourg Binder BB3002 is the most efficient perfect binder available in the industry for cut
sheet and signatures.

A unique design based on total automation and touch screen controls results in a user friendly
system.

Books up to 60 mm - 2.36” thick are processed immediately.

A set up time reduced to a benchmark figure ensures a productivity of up to 600 cycles/hour.

The 3-cylinder glue tank equipped with a side gluing device and the scoring unit make the
BB3002 the ideal binder to produce not only state of the art perfect bound books but also
‘winged books’ of durable professional quality.

No tools are required for any of the operator adjustments.

See also
BB3002 PUR with vertical book stacker and Nordson Polyurethane reactive application

20 PB-600S Product and Application Guide rev.00

 Advantages
 Totally automated binder.
 Full Color touch sensitive screen.
 3-cylinder glue tank.
 Side gluing device.
 Powerful milling wheel with slitting.
 On-line cover creasing.
 Up to 13 positive or negative creases.
 Winged books can be made.
 Binds from 1 mm to 60 mm - 0.04” to 2.36”.

Specifications
COVER SIZE
MAX 710 mm x 395 mm - 28” x 15.6”
MIN 200 mm x 100 mm - 8” x 4”

COVER WEIGHT
80-300 gsm - 20 lb Bond – 110 lb Index

TEMPERATURE
MAX GLUING TEMPERATURE 180°C - 356°F
MIN GLUING TEMPERATURE 115°C - 239°F
SENSITIVITY ± 2°C - 4°F

BBR STACKING CAPACITY

680 mm – 26.4”

RECEPTION SIZE
MAX 385 mm x 320 mm - 15.15” x 12.6”
MIN 100 mm x 100 mm - 3.9” X 3.9”

CYCLES/HR
Up to 500

NOISE LEVEL
76dB (A) at operator position

ELECTRICAL RATINGS
Power required
- 208/220 V, 60Hz, 3 phases delta,12 A
- 220/230 or 240 V, 50 Hz, 3 phases delta 12A
- 380/400 or 415 V, 50 Hz, 3 phases star, no neutral needed, 12 A
Power consumption 4 Kw

RADIANT HEAT
13648 BTU/h

PB-600S Product and Application Guide rev.00 21

4.13 CMT-130 trimmer specifications
Specifications

Minimum Book Size: 4" x 6" / 101.6 mm x 152.4 mm

Maximum Book Size: 9.5" x 13" / 241 mm x 330 mm

Maximum Book Thickness: 2" / 51 mm

Maximum Trim - Top: 6.0" / 152 mm

Maximum Trim - Bottom: 3.5" / 89 mm

Maximum Trim - Face 5.5" / 140 mm

Minimum Trim - All Sides: 0.100" / 2.5 mm

Up to 200 books per hour (single book)

Speed
Up to 500 books per hour (multi-book)

Memory: 99 Book Jobs

Set-up Time for Book Size Change: Approximately 10 Seconds

DIMENSIONS

Overall Height 60" / 1524 mm

Overall Width 52" / 1321 mm

Overall Length 57" / 1448 mm

Net Weight (approximate) 1500 lbs / 680 kg

Shipping Weight (approximate) 1800 lbs / 816 kg

ELECTRICAL

3 Phase, 60 Hz, AC
208/230 Volts, 25 Amps (service size 40 Amps)

COMPRESSED AIR REQUIREMENTS

The CMT-130 requires 80-90 PSI regulated, dry, non-lubricated compressed air at a
minimum of 5 cubic feet per minute (at 80-90 PSI). The required minimum air quality
rating is ISO 8573.1 Class 2.4.2 (solids < 1 micron, pressure dew point < 38°F @100psig,
and oil content < .08 ppm)

The following 2 compressor systems are commonly used with the CMT-130. Other
equivalent systems may be used also. The compressor system must include an air dryer
capable of ISO Class 4 or better (pressure dew point < 38°F @100psig). Failure to use dry,
non-lubricated compressed air that meets or exceeds the above requirements may cause
damage to the machine and will result in THE WARRANTY BEING VOIDED.

System 1 - Traditional piston type compressor.

Powerex AS0203 - 2 hp climate control compressor with built-in refrigerated dryer,
electronic auto drain and starter.

System 2 - Rotary scroll type compressor. The advantage to this type is minimum
maintenance and very quiet operation (49-51db)
Powerex SES0308-208v with ACO100010 factory installed refrigerated dryer and auto drain.

Available from Air Technologies. Phone: 616-281-9500 or [Link]

22 PB-600S Product and Application Guide rev.00

 Note: An optional control system CMS-101 is available to automatically control
CMT-130 book size changes based on bar coded data on each book.

4.14 FST 60/700 Three-knife Trimmer Specifications

The 60/700 Three-knife Trimmer is capable of matching a digital printer's make-ready
speed, flexibility and productivity. Specifically designed for book on demand print
production, the 60/700 three knife trimmer operates with equal efficiency inline or
offline.

Control technology, all-round performance and functional efficiency are state of the art.
Changing the trim size is fully automatic and takes only 5-10 seconds when the data
matrix barcode reader is deployed. Standard, regularly produced book sizes can be
stored in the Fastset’s memory.

High Quality Finished Product

Wilstead Digital Finishing fully appreciates that our customers require a finished
product of the highest quality. The 60/700 Three-knife Trimmer achieves this in two
ways. Firstly, by carefully controlled book block handling throughout the trimming
process, so as to preserve the spine quality of the finished book. Secondly and unlike
some other three-knife trimmers, by trimming the book square to the spine. We believe
that the trimming accuracy and quality of finished product achieved by the Fastset
60/700 Three-knife Trimmer is in a class of its own.

Key features

 Maximum book thickness: 60mm

 Minimum book size 150mm x 105mm x 2mm thick

 Maximum book size

234mm x 156mm (9.21" x 6.14") x 60mm thick
297mm x 210mm (11.7" x 8.27") x 50mm thick
305mm x 229mm (12" x 9") x 20mm thick

 Cycles per hour: 700

 Typical output: 2,700 books per hour when trimming multiple book blocks.

 Hydraulic cutting and clamping to ensure precise and clean trimming quality.

 Automated transfer of books from perfect binder and insertion into Fastset
Dryer/Feeder, ensuring full inline operation.

 Automatic trim size change in as little as 5 sec's with data matrix barcode
reader.

 Ethernet/serial link to users IT system for the reporting of production

information.

 Compatible with all popular single and multi-clamp, PUR and hot melt perfect
binding machines including those manufactured by Tecnograf, Jud Ecamo,
Horizon, CP Bourg, The adjacent photographs show the Fastset 60/700 Three-
PB-600S Product and Application Guide rev.00 23
 knife Trimmer operating inline with the following binders, Horizon BQ-470, CP
Bourg BB3002 and Jud Ecamo Quadrimax

4.15 Selecting upstream modules as part of an in-line system

(when the Smart-binder is running in-line with web printers or near-line from pre-
printed roll)

4.15.1 Web Cutters

[Link] Cut-sheet length

The web cutter must give accurate sheet cut length, even when the system is
accelerating or decelerating on system start-up or stop. Any inaccuracy in cut sheet
length will be apparent in the finished book when checking the distance of the print to
the trimmed edge.

If there is any possibility that the cutter may produce incorrect length sheets (for
example on system start and stop) then the cutter should be fitted with an automatic
sheet reject gate. This reject gate may also be useful to reject a certain number of
sheets every time the system starts up if there is a risk that these sheets may be
unacceptably curled due to tensioner rollers in the cutter or festoon web buffer (see
also paragraph below on sheet rejection) .

[Link] Rejection of ‘bad’ books

The cutter must reject any sheets which are not correctly printed and it must then
automatically reject the pile (by pushing it in a different direction) instead of delivering
this sheet pile to the PB-600S system. This is essential to ensure that only good book
piles enter the PB-600S.

Refer to IBIS if the PB-600S Shuttle-worth conveyor system needs to be fitted with an
automatic pile reject capability.

[Link] Stacker eject rate

The stacker eject cycle rate must be considered to ensure that this does not restrict the
planned maximum book production rate. If printing 2-across the web then the stacker
eject rate can be half the maximum planned book production rate. If printing 3-across
the web then the stacker eject rate can be half the maximum planned book production
rate.
[Link] Stack quality
The stacker must give sheet register (within each pile) to within 0.5mm (.02”) in order to
ensure good register of the print to the edge of the finished book.

[Link] Web buffers

A web accumulator (festoon buffer) is needed between the printers and the cutter to
allow the printer to continue running while a stack is being ejected from the stacker.
When this is the case, the cutter may be set to run faster when there is more than a
preset amount of paper in the buffer. The buffer should be kept empty (i.e.: with the
minimum amount of paper in it) and the cutter maximum speed set very close to the
actual printer web speed. Stopping the line with excess paper in a web buffer (under
24 PB-600S Product and Application Guide rev.00
tension) introduces ‘curl’ into the paper in the buffer which can give problems with sheet
handling in the stacker and PB-600S.

[Link] Anti-static equipment for web cutters

Web cutters should be fitted with anti-static bars to, as far as possible, assist stacking
and eliminate static charge on the sheets delivered to the PB-600S. This is particularly
important when running with lightweight paper.

[Link] Different types of Web Cutters

The following web cutters are recommended for use with the PB-600S.

Hunkeler , Lasermaxroll , Tecnau, Bowe, Kern, Iram, Ehret

4.15.2 Web Moisturiser.

Web moisturisers (such as the Weko Rfdi) are sometimes used in digital print lines to
help control web humidity (affecting curl, paper handling and expansion / contraction
after adhesive binding). It is not usually needed for PB-600S operation, but can
sometimes help reduce static generation as the paper passes along the line. It can be
helpful when running lightweight papers.
The moisturiser unit can sometimes offer some assistance in helping to run very
difficult lightweight paper stock by adding a small amount of silicon oil to the
moisturising water.

4.16 Printing barcodes

The PB-600S does not require sheets to be printed with bar codes, and is not fitted
with any bar code readers as standard, unless the optional cover matching system is
selected (see 4.16) .
However, bar codes or print marks are needed on the web to enable the web cutter to
function and to ensure that the web cutter ejects each pile to be a correct and complete
set of sheets representing complete books. Refer to the web cutter manufacture for
information on required bar codes.

4.17 Optional Cover matching system CMS-100

An optional cover matching system CMS-100 is available, This system will
automatically stop the PB-600S binder if the cover bar coded I/D number does not
match the I/D number on the inside sheets. Refer to IBIS for more details.

PB-600S Product and Application Guide rev.00 25

5 Using the PB-600S system
5.1 Operating the PB-600S

5.1.1 Thickness changes

Changes in book thickness (number of pages) may be made automatically by the web
cuter/stacker (under bar code control) and the PB-600S will process changes in book
thickness without stops or pauses.
For large changes in book thickness it may be necessary to stop the PB-600S system
to change cover sizes. However note that a certain amount of cover overlap is
acceptable (and can be removed by the trimmer front knife) when varying book
thickness

Cover overlap
Cover

Thick book Thin book (showing cover

overlap, if cover size is not
reduced)
5.1.2 Book format size changes
Small book format size changes can be made by simply and quickly varying the
amount of trim off (using the CMT or FST trimmer)
Large changes in book format sizes require the printer to be stopped so that changes
can be made to each part of the system.

5.1.3 Cover creasing

The BB3002 can be adjusted to provide up to 6 cover creases. Four creases and
normally used in order to provide a square back to the book and (in conjunction with
the BB3002 side glue facility) to provide a hinge point to easily open the cover.
The 5th or 6th crease may be used to provide a wing-folded flap (requires manual
folding after binding) .
Gate fold crease #5
Gate fold crease #6
Optional
wing- fold
Signatures available
or sheets
Cover sheet
Side glue
Side glue

Hinge crease #4 Hinge crease #1

Spine crease #3 Spine crease #2

26 PB-600S Product and Application Guide rev.00
Covers should be flat and should be stored covered or wrapped in the same
environment as the PB-600S (temperature and humidity). Covers with damaged or
curled edges will not feed reliably.

5.1.4 Working with Paper rolls, or stacks of sheets

Paper rolls (reels) should be stored carefully, in the environment in which they will be
used and sealed in plastic film prior to use, to ensure that they are in optimum condition
for use. The outside part of any new reel should be discarded before use to avoid
damaged or dirty paper going through the line.
Toner should be properly fused to all digitally printed sheets. If not it will transfer from
the paper onto parts of the PB-600S and cause book marking. If toner does transfer to
PB-600S guides or belts, clean them using a cloth soaked in alcohol, or soap and
water.

5.2 Maintaining the PB-600S

5.2.1 Spare Parts

[Link] Trimmer knives

[Link] Spares Kits

Spare parts kits are available in either Essential, Basic or Extended forms:

Essential Spare Parts Kits

Essential spare parts kit

Additional Essential Spare Parts for PB-600S optional modules

Basic Spare Parts Kits

Basic spare parts kit

Additional Essential Spare Parts for PB-600S optional modules

Extended Spare Parts Kits

Extended Spare Parts kit

Extended Spare Parts for PB-600S optional modules

The ‘Essential’ spare parts kits contain components that are likely to be needed during
normal operation. The ‘Basic’ spare parts kit contains additional components that might
be damaged in the event of a severe jam or parts to repair other general machine
malfunctions. It is recommended that this kit is held at sites where time -critical jobs
are being run.

PB-600S Product and Application Guide rev.00 27

An ‘Extended’ spare parts kit contains components that can fail but are not commonly
required. This kit is primarily intended for re-sellers who are offering a maintenance
service, but may also be justified to be held at any site with several PB-600S systems.

5.2.2 Scheduled Maintenance

Scheduled maintenance kits are available as required. These contain parts that are
needed to carry out the scheduled maintenance programme for the PB-600S system .
It is recommended that all PB-600S scheduled maintenance is carried out by IBIS or
CP Bourg according to the Scheduled Maintenance Programme

5.2.3 Consumables
[Link] Glue
The PB-600S is supplied with a small quantity of EVA glue, sufficient for the initial
machine commissioning and test period. Refer to IBIS for recommended glue to be
used in the BB3002 binder. Only the correct (IBIS -specified) glue is used to avoid glue
application problems.
Based on a normal glue film thickness of 0.5mm, the PB-600S uses 3cc (cubic
centimetres) of EVA hot- melt glue to make one 300mm long book which is 20mm
thick. Glue usage for other book sizes and volumes may be calculated using this
information.

[Link] Trimmer knives

The knives require sharpening at intervals depending on machine usage. Sharpening
is best carried out by a local specialist.
Knives must only be changed or adjusted by a trained technician. IBIS (or CP Bourg for
the CMT trimmer) will provide this training as part of PB-600S service engineer
maintenance training course.

We recommend that at least two extra sets of trimmer upper knife blades are
purchased in addition to the set supplied with the machine. This allows for one set to
be in use on the machine, one set to be away for regrinding and one set ready to install
if the knives in use are damaged.

Additional lower knife ‘sticks’ are also recommended to be held in stock.

One spare set of knives is included in the basic spares kits; additional sets can be
purchased from IBIS (or CP Bourg for the CMT trimmer).

28 PB-600S Product and Application Guide rev.00

6 Planning an installation
When planning installation and commissioning, allow 2 days to install the PB-600S
and 5 days for system commissioning and operator training, prior to the start of live
production. This assumes that the PB-600S is being added to an existing web printer
and web cutter/stacker which is already installed and operational.

6.1 Installation schedule

Day Activity
1 Unpacking, checking shipment and moving into position
2 Assembling PB-600S modules , connecting power and compressed air
3-4 Commissioning: requires printed work and covers available from day 3.
5-7 Operator training and pre-production tests
In particular connection of power (day 2), the availability of printed work (day 3) and the
availability of trainees (days 5- 7) are critical to meeting this schedule.

6.2 Preparing the site Refer to the PB-600S Installation Questionnaire for full
list of all site preparation issues

Access:
Ensure that there is sufficient space to manoeuvre the largest PB-600S module into
the final position (see 9.10.4 for module dimensions). This is particularly important
where this unit must pass through doorways.

Floor:
The machine should be sited on a substantial floor, which is level over the total area of
the machine to within 10mm (3/8”). The floor must be able to withstand the loads
applied by the PB-600S without damage or movement.

Space around the machine: Allow adequate space for:

 All the doors and guards to be fully opened.
 Operators to move freely in the working areas around the binder and
trimmer .
 Access to all sides of the machine for maintenance.
 Emptying the trimmer waste collection bin, if a vacuum waste removal
system is not used.
 Electrical voltage transformer

The following layouts show space requirements for the PB-600S system.

PB-600S Product and Application Guide rev.00 29

 6.3 Layouts of PB-600S

Plan of in-line PB-600S perfect binding system (with optional CMT-130 trimmer):

Sheet stacker Sheets from in-line high

Perfect bound book
speed web printer
delivery stacker

Shuttleworth
Book accumulator
cooling
roller conveyor
elevator
Web cutter (typically
2000mm Hunkeler or Lasermax)
In-line
990mm (variable)
CMT-130
book Gate
trimmer Cover
feeder

1350 SSF
mm BB3002 perfect -100
binder 850mm

Approx 2540mm
2700mm

Plan of in-line PB-600S perfect binding system (with optional FST trimmer):

Sheet stacker
Perfect bound FST Sheets from in-line high
book delivery Trim- speed web printer
mer
xxxxmm

Web cutter (typically Hunkeler or

Book cooling Lasermax)
conveyor (20 2000mm
vertical pockets) (variable) Shuttleworth accumulator
roller conveyor
Cover
feeder Gate

1350 SSF
mm BB3002 perfect -100
binder 850mm

2540mm

30 PB-600S Product and Application Guide rev.00

Detailed layout of Optional CMT-130 trimmer

6.4 Services

6.4.1 Electrical power requirement

[Link] European voltage range: 3-phase 380-420 volt input supply
For PB-600S excluding trimmer
380 – 415Volts, 3 phase and earth, 50Hz, xxx Amps
Additional supply for CMT-130 trimmer
380 – 415Volts, 3 phase and earth, 50Hz, xx Amps
Additional supply for FST trimmer
380 – 415Volts, 3 phase and earth, 50Hz, xx Amps
[Link] USA 3-phase 195- 215 volt input supply

For PB-600S excluding trimmer

195- 215 Volts, 3 phase and earth, 60Hz, xxx Amps
Additional supply for CMT-130 trimmer
195- 215 Volts, 3 phase and earth, 60Hz, xx Amps
Additional supply for FST trimmer
195- 215 Volts, 3 phase and earth, 60Hz, xx Amps

PB-600S Product and Application Guide rev.00 31

Consult IBIS if input voltage is not listed above
Consult IBIS for power requirement of other optional modules.

Residual current devices (RCD) and Ground Fault Interrupters (GFI) must not be fitted
to the power supply as leakage currents from the PB-600S could cause nuisance trips.

6.4.2 Compressed air supply requirement

The PB-600S requires a high pressure (filtered) air supply for the Shuttleworth
conveyor stop gate: This must be a regulated between 4 and 5 bar pressure (60 – 77
psi). This uses a negligible volume of air .
If the optional CMT-330 book trimmer is selected then this requires 198 litres/min (7
cfm) air supply at minimum 5.8 bar (90 psi)
If the optional FST book trimmer is selected then this requires xxxlitres/min (xx cfm) at
8.0bar (120 psi) air supply

6.4.3 Air conditioning

The environment should be controlled to reduce variability in the behaviour of the
paper. This will result in more consistent, reliable operation.
Maintain relative humidity within the range 40-60% and temperature between 18 and
25ºC (64 and 77ºF)

6.4.4 Radiant heat output

Heat output from the BB3002 binder is 13648 BTU/hour.

6.4.5 Trimmer waste (trim-off) removal systems

If the end-user has a centralised vacuum extraction systems for waste paper, then this
service can be used to remove waste paper from the PB-600S trimmer.
Consult IBIS for routing and dimensions of ducts.
Alternatively, the trimmer (CMT or FST) can be supplied with its own Waste removal
system.

6.5 Interface to upstream web stacker

The infeed height above the factory floor of the Shuttleworth conveyor is 850mm. The
exit height of the web stacker must therefore also be 850mm.

6.6 Installation, Commissioning and Training

6.6.1 Unloading
- All PB-600S modules will be delivered on wooden pallets, and either covered or
crated, depending on the method of shipment. See below for dimensions and weights
of these crates.

32 PB-600S Product and Application Guide rev.00

- A Fork Lift Truck, capable of lifting 2.5 Tons (2500kg/5500lb) is required for lifting the
modules off the pallets.
- See 9.10.4 for the dimensions of the largest unit. Ensure that doors, etc. are large
enough for this module.

6.6.2 Machine module weights and sizes (crated) (approximate)

The basic in-line PB-600S is delivered in 4 separate sections (Note: if exact weights
and dimensions are needed then information should be obtained from IBIS at the time
the machine is shipped)
Module Description Size (L x W x H) Weight
Cm Inches Kg lb
1 Shuttle worth 100 x 60 x 85
conveyor 1m
2 Shuttle worth 100 x 60 x 85
conveyor 1m
3 SSF-100 85 x 54 x 120
4 BB3002 binder 200 xxx xxxx

CMT-330 trimmer
Module Description Size (L x W x H) Weight
CMT-130 trimmer Cm Inches Kg lb
1 CMT 130 trimmer 214 x 88 x xxx
2 Cooling elevator

FST trimmer
Module Description Size (L x W x H) Weight
FST trimmer Cm Inches Kg lb
1 Infeed cooling
conveyor
2 FST trimmer
3 Optional waste
extraction

PB-600S Product and Application Guide rev.00 33

6.6.3 Size of largest modules, excluding packing.

2050mm 1448mm xxxmm

BB3002 binder CMT-130 FST trimmer

xxxmm trimmer 1321mm

Note: all new installation sites should be checked to ensure that there is room to move
these modules into position

6.6.4 The Operator Training Course

Machine operators who have previous experience of Perfect binders will learn to
operate the new PB-600S system more quickly than operators without this experience.
Knowledge of operating hot glue application, trimming knives and all issues relating to
perfect bound book quality will be of particular value in operating the PB-600S.
The training program is divided into four sessions. Each session lasts approximately
four hours. It is recommended that the course be spread over a xxxx day period

A. Introduction Session
A.1. Introduction to IBIS and the PB-600S system.
A.2. Distribution of Operator manuals.
A.3. Introduction to Safety issues in general.

B. The PB-600S System

B.1. Identification of all elements of the PB-600S system.
B.2. Glossary of terms used in operating the machine.
B.3. Overview of general operation of the PB-600S system.
B.4. Review of Safety Issues related to actual machine operation.
B.5. How to start/stop the system.
B.6. Running demonstration of the PB-600S in operation.
Review important factors relating to the presentation of sheets from the
B.7. upstream equipment.

C. Make-ready adjustments
C.1.
C.2.
C.3. Review safety issues relating to PB-600S operation.

34 PB-600S Product and Application Guide rev.00

C.4.
C.5.
C.6.
C.7.
C.8.
C.9.
C.10.
C.11.

F. Operator maintenance
F.1. Review safety issues.
F.2. Carry out trimmer knife adjustment to produce good quality trim.
F.3. Lubrication
F.4.
F.5.
F.6. Cleaning sensors.

G. Fault Finding and resolution

G.1. Review possible book quality problems, causes and rectification.
Review possible paper jam conditions, causes, and prevention and jam
G.2. clearance.
G.3. Review fault messages on touch screen.

H. Review of PB-600S System operation

H.1. Review all machine adjustments needed to control finished book quality.
Run the complete system with a range of different book thicknesses and
H.2. sizes.
H.3. Demonstrate that commercially acceptable book quality can be achieved.
Demonstrate that the operator trainees have been adequately trained and
are capable of operating the ystem in a live production situation (run a
H.4. typical job, at an adequate quality and efficiency).
H.5. Issue training certificates to operator trainees.

PB-600S Product and Application Guide rev.00 35

6.6.5 PB-600S maintenance training course

A Service-Engineer maintenance training course (3 Days) is available for the BB-3002

binder and CMT trimmer

7 Frequently asked questions

8 Appendices
8.1 Power Distribution Networks (according to UL1950 and
EN60950)
1. TN POWER SYSTEM: A power distribution system having one point directly earthed, the
exposed conductive parts of the installation being directly connected to that point by
protective earth conductors. Three types of TN POWER SYSTEM are recognized according
to the arrangement of neutral and protective earth conductors, as follows:
i. TN-S system: having separate neutral and protective earth conductors throughout the
system;
ii. TN-C-S system: in which neutral and protective functions are combined in a single
conductor as part of the system;
iii. TN-C system: in which neutral and protective functions are combined in a single
conductor throughout the system;

2. TT POWER SYSTEM: A power distribution system having one point directly earthed, the
exposed conductive parts of the installation being connected to earth electrodes electrically
independent of the earth electrodes of the power system.

L1
L2
L3
N

Power system
earth
Protective Earth
Exposed conductive
parts

3. IT POWER SYSTEM: A power distribution system having no direct connection to

earth the exposed conductive parts of the installation being earthed.

L1
L2
L3
N
36 PB-600S Product and Application Guide rev.00

Impedance

Power
 8.2 IBIS SCHEDULED MAINTENANCE PACKAGE (SMP)

We are pleased to announce that IBIS is now offering a new Scheduled Maintenance
Program (SMP) for all IBIS products. This SMP is based upon scheduled visits by
IBIS to the end-customer site.

Why use us to help look after your IBIS equipment?

Our aim is that your IBIS system will always provide the best possible performance and
finished book quality. During each scheduled visit we will firstly replace all parts which
are recommended to be changed at specified intervals as part of Preventative
Maintenance (PM). Doing this prevents unscheduled machine down-time at a later
date. At the same time our experienced IBIS technicians will check the machine over
generally to see whether any other parts need replacing or adjusting.

During each visit we will inform you about the latest performance upgrades, discuss
with the machine operators any specific issues they have and provide advice and
assistance in these areas.

The SMP package includes all scheduled visits, software upgrades and all PM parts.

Scope of the IBIS SMP program

During each SMP visit the IBIS technician will:

 Replace all parts which should be changed at regular time intervals (Smart-binder
preventative maintenance).

 Check over the machine generally, ensure everything is correctly set up and
adjusted and identify whether any other parts need replacement.

 Install any software upgrades in order to keep the Smart-binder up-to-date and
discuss the availability of possible hardware upgrades.

 Ensure that the machine is performing correctly and meeting the customer’s
requirements.

 Provide additional help that may be required by the machine operators.

 Discuss any additional requirements that the customer may have.

PB-600S Product and Application Guide rev.00 37

8.2.1 Frequency of visits
It is recommended that an IBIS technician visits each PB-600S system every 3, 4 or 6
months. This choice of visit frequencies is offered to suit different customer needs.

8.2.2 Duration of visits

The standard SMP pricing assumes a normal duration of 2 days for the 3,000 hr, 6000
hr and 9,000 hr visits, with some additional days added on for the 12,000 hr visit (for
fitment of the extra preventative maintenance parts needed).

8.2.3 SMP Price

The SMP pricing assumes an annual payment made in advance at the start of each
year.
The SMP cost is higher for some years compared with others (due to the different parts
needed to be fitted at different intervals), but for simplicity the price is averaged over
the 4 year period commencing at the time of new machine installation.
This annual price includes all travel costs, technician’s time and replacement parts
(preventative maintenance) for the standard in-line PB-600S system (not including any
extra optional modules). Worn or damaged parts which are not part of the normal
maintenance kit (see Appendix A attached) are not included. If additional parts are
needed to be fitted during the SMP visit then these must be ordered in advance.

The SMP pricing assumes a machine usage up to about 3,000 hours a year. Prices
may vary slightly if usage is significantly higher than this, or if the machine includes
extra optional modules. Always refer to IBIS to confirm exact SMP price at the start of
each SMP year. The SMP price for machines installed outside the Europe, USA or
Canada is higher because of additional travel costs and time.

Refer to IBIS for a price quote

8.2.4 Scheduling of SMP visits

SMP visit dates must be agreed between IBIS and the customer at least one month in
advance. If this visit date is changed by the customer within one month of the
scheduled visit date then we will attempt to accommodate this change, where possible.
However, any extra costs relating to re-scheduling may be charged to the customer.

8.2.5 Replacement parts

Components will be changed as part of IBIS’s published preventative maintenance
schedule. The maintenance parts list may be modified by IBIS based on additional field
feedback in future. The parts required for each SMP visit (for pre-planned replacement)
will be sent by IBIS, at IBIS’s expense, to be on the customer’s site before the arrival of
the IBIS technician (or parts will be hand carried by the IBIS technician).

38 PB-600S Product and Application Guide rev.00

8.3 Conversion Charts For Stock Weights

BOND BOOK OR OFFSET COVER METRIC

lb/500 sheets lb/500 sheets lb/500 sheets Grams/metre2
17” X 22” 25” X 38” 20” X 26” (gsm)
11 27 15 40
12 30 17 45
13 34 18 50
16 41 22 60
19 47 26 70
21 54 30 80
24 61 33 90
27 68 37 100
35 88 48 130
43 108 59 160

Stock weight as a function of the number of pages in the

finished book

Stock Weight Approximate number of pages

gsm Pounds Pounds 40mm thick 20mm thick 10mm thick
Offset Bond book book book
60 40.6 16 928 464 232
70 47.3 18.6 800 400 200
80 54.0 21.3 704 352 176
90 61.0 24.0 624 312 156
Number of pages excludes outside covers.
High volume (low density) paper stock will give a thicker book.

PB-600S Product and Application Guide rev.00 39

8.4 Tools and Special Equipment Required for Service and
Maintenance

Routine Service and Maintenance Operations:

Allen Keys - 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10mm ball ended
Combination (ring and open ended) spanners - 6, 7, 8, 10, 13, 16, 17, 19, 24 A/F
hexagon
Adjustable spanner, about 200mm, 8” long
Plastic faced hammer
Side cutters (small, flush cutting)
Screwdrivers
Very small flat bladed (about 2mm, 5/64” tip)
Small flat bladed (about 3mm, ⅛” tip, parallel shank)
Medium flat bladed (about 5mm, 3/16” tip)
Very large flat bladed (about 12mm, ½” tip)
Small Philips (number 1)
Medium Philips (number 2)
Craft knife and blades
Fine nose pliers
Normal pliers (medium)
Circlip pliers (inside and outside)
Steel rule (300mm/12”)
Tape measure (3m, 10’)
Torch
Inspection mirror
Emery paper (medium, fine and very fine)
Fine files (square, flat, round and half round, about 200mm, 8” long)

Electrical Fault Finding and Repairs:

Multi-meter
Wire strippers
Small soldering iron and solder

Software or Control System Problems:

PC keyboard and mouse (with USB or PS2 type connectors)
USB memory key (64MB or larger)
The following equipment is only needed for certain rare fault conditions: It is not
needed for routine maintenance or rectifying any common faults.
Laptop PC with CD drive, serial port and network adapter
USB 2 Cable, Standard USB A to USB B connectors.
Special cable to connect PC serial port to Siemens servo drives (plus Siemens servo
drive software which is supplied with machine)
Crossover network cable to connect laptop to PC (RJ45 connectors, cat. 5 UTP cable)

40 PB-600S Product and Application Guide rev.00

8.5 PB-600S Application Questionnaire for Digital Print
Applications.
This Questionnaire may be used to help determine suitability and specification of PB-
600S for a digital print finishing application.

1. Will the PB-600S be running in-line with a digital printer ? If so, what type of
printer and what type of web cutter/stacker will be used?
What will be the maximum printer web speed and the maximum rate at which book
locks are ejected from the web cutter into the PB-600S system?

2. If running in-line with a web printer, then what is the width of the paper web (or max
sheet width) to be used, and how many pages will be printed across the web?

3. What type of books/booklets need to be produced by the PB-600S ? Provide as

much information as possible.

4. What is the maximum, minimum and average format size of the book blocks that
will be fed into the PB-600S and the required finished book sizes. How often will
the machine need to be changed to a different format size?

5. What is the range of paper stock weights to be used (max/min)?

6. What is the maximum, minimum and average number of pages in the required
finished books? What is the expected maximum book thickness? How frequently
will the book thickness change?

7. Will jobs with different page-count books be run sequentially, without system stop? If
so, then what are the expected maximum, minimum and average print job run-
lengths?

8. What will be the range of cover stock weights to be fed? Will these be digitally or
offset printed? Is there anything unusual about the covers (cut-out windows, gate-
folds etc)?

9. Is the binder to use EVA (hot melt glue) or PUR glue?

10. Is the factory temperature and humidity controlled?

11. What are the customer’s productivity expectations regarding number of books (of
stated average thickness) to be produced in a stated time period?

12. Is the trimmer to be fitted with its own waste removal system, or will the trimmer
waste be removed by the customer’s own vacuum extract system?

PB-600S Product and Application Guide rev.00 41

13. Is the binder cover matching system needed?

14. Is the automatic trimmer format size set up system needed?

15. Are any other optional modules needed

42 PB-600S Product and Application Guide rev.00

 NOTES

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

 NOTES

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

Produced by:

IBIS Integrated Bindery Systems Ltd.,

9 The Gateway Centre , Cressex Business Park,
High Wycombe,
Buckinghamshire,
UK.
HP12 3SU
Tel +44 (0) 1494 561 950
Fax +44 (0) 1494 561 951
E-mail: mail@[Link]
Web: [Link]

© Copyright IBIS Integrated Bindery Systems Ltd. 2010

[Link]

PB-600S Product and Application Guide rev.00 45