Service Manual: Model Discontinued in January 2001 Revision November 2003

BB3000
Service Manual
f i ed b
er t i
Revision November 2003
C
ISO 9001 Model discontinued in January 2001

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Service Manual BB 3000

BB3000 Service manual
Contents November 2001
1 / Theory
Machine description (1) . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 1
Machine description (2) . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 2
Block diagram . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 3
Micro Control Unit - inputs / outputs ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 4
Functional diagram (1 / 1) . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 5
Functional diagram (1 / 2) . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 6
Specifications . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 7
Glue consumption (EUR) . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 8
Glue consumption (USA) . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 1/ 9
2 / Diagrams
Wiring
Sensors description & location . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 1
Sensors to PLC inputs (32 to 55) . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 2
Power distribution . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 3
Wiring to the mains + Power supply . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 4
Interlocks circuit . . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 5
Power path . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 6
General wiring diagram 1 / 2 . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 7
General wiring diagram 2 / 2 . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 8
Electrical drawer (Rack) . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 9
Carriage shifting and drum rotation motor control (front rack) . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 10
Power board 1/2 (electrical diagram) . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 11
Heating circuitry . . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 12
Control Panel (wiring and electrical) . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 13
Book detectors in carriage and delivery . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 14
BBR damped book chute - Motor control PCB . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 15
Carriage - cover nipping motors torque limiter . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 16
BBR-X 4 relays (wiring and electrical) . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 17
BBR 3 relays (wiring and electrical) . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .pg 2 / 18
Installation
Installation summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 19
Component location fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 20
Programmable logic unit / (Re) programming instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 21
3 / Adjustments
Electrical
Main motor speed (re)adjustment (Kbic) . . . . . . . . . . . . . . . .................................. . . . pg 3 / 1
Carriage shifting and drum rotation motor control (front rack) ................................. . . . pg 3 / 2
Cover clamp motor torque limit . . . . . . . . . . . . . . . . . . . . . . .................................. . . . pg 3 / 3
Suction bar speed control (power board 2/2) . . . . . . . . . . . . .................................. . . . pg 3 / 4
Mechanical
Cover clamp clutch spring tension . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . pg 3 / 5
Procedure to re-time gears on the cover station ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . pg 3 / 6
Adjustment of the position of the stationary knife .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . pg 3 / 7
Alignment of the sections . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . pg 3 / 8
4 / Spare parts list
Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 1
Fuses & relays . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 2
Switches - Cells - Buttons thermostats - PC Boards .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 3
Motor & solenoids . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 4
Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 5
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 6
Carriage drive system . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 7
Jogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 8
Notching & milling . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4/ 9
Gluing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 10
Cover clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 11
Cover station - suction bar . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 12
Suction bar drive system . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 13
Suction air cut-off valve . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 14
BBR (output unit - bottom) . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 15
BBR (output unit - up) . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 16
Index & recommended parts for one year . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 17
....... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 4 / 22
5 / Maintenance
Dust bag replacement frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 5 / 1
Main drive motor brushes life expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 5 / 2
6 / Trouble shooting
Non stop test procedure
Warm-up period shortening (for service purpose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . pg 6 / 1
Power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . pg 6 / 2
Heating circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . pg 6 / 3
Nipping motor torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . pg 6 / 4
7 / History
Developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 7 / 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 7 / 7
Wiring instructions for the replacement of the B.B.C. / ASEA P.L.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg 7 / 8
8 / Useful, translated and obsolete items

Maschine Beschreibung (D, 1) ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . pg 8 / 1
Maschine Beschreibung (D, 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . pg 8 / 2
Description machine (F, 1) . . . . ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . pg 8 / 3
Description machine (F, 2) . . . . ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . pg 8 / 4
Réglage fraise et contre-lame . ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . pg 8 / 5
THEORY
Theory
Machine description (1) . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 1
Machine description (2) . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 2
Block diagram . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 3
Micro Control Unit - inputs / outputs ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 4
Functional diagram (1 / 1) . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 5
Functional diagram (1 / 2) . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 6
Specifications . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 7
Glue consumption (EUR) . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 8
Glue consumption (USA) . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 1/ 9
ON
OFF
1
c.p. bourg S. A.
N. V.
May 1999
Carriage at
right end
X49
Carriage brake Carriage slow down
( left - right )
X48
Shutter closure detector
Shutter opening closure
Carriage opening X42
closure Suction bar
in-out allow Tank thermostats
X41
X47 X40
Automatic carriage Carriage clutch X38 Clamping down
Carriage slow down
speed adjustment engagement Clamping up and suction valve control
( right - left )
Main
X46 Y12 motor
Carriage home Y13
detector Scraper
Drum temperature regulator sensor
X45 Roughing and Scraper height adjustment
Book X52 paper chips Drum heating resistor
X50 presence extraction
Y32 Tank thermostat selector ( 115 / 145¡C )
detector motor
Cell amplifier Tank heating resistor
card X39
X51
1/1
Cooling fan
Carriage full Y01 Booklet counter
opening detector Jogger magnet X44 X55
Y43 Suction level adjustment Drum temperature
Jogging table adjustment
X53
upper position Carriage Side clamping pressure adjustment
detector closure
detector Clamping duration adjustment
X2, X5, X9, X11 X15 Process start ( green ) X14
( To press and release simultaneously
Program mode selector X6, X4
with same button at opposite end )
X13 Carriage opening ( blue )

X03 Emergency
X8 Roughing close - normal
X10 Narrow / wide carriage opening + ejection mode
X7 Notching / milling on - off
X12 Drum heating on - off ( rotation starts when warm )
Jogger on - off
X14 Proces start ( green )
X15 ( To press and release simultaneously
Foot switch with same button at opposite end )
Service manual BB3000 Machine description GB (1) Jan.1997

Fuses Rating Protected circuitry
F1 2,5ATT Panel, PLC outputs - turbine
F2 3,2ATT Clutch - brake - air valve
F3 4 ATT Suction bar transfer Safety on
upper guard
F4 2,5ATT Suction bar up / down
Connection to
F5 3,2ATT Shutter opening closing motor binder of parts Safety on
F6 2,5ATT Carriage clamping motor located in cover perspex guard
F7 2,5ATT Drum heating resistor
F8 7 ATT Transformer primary - cooling fan Fume extractor
(second fan with regenerating Cell amplifier
F9 2,5ATT Main motor filter option) Cover suction /
Air shut-off Y15 card separation
F10 5 ATT Tank heating resistor Air
solenoid air turbine
shut-off
F11 1 ATT Jogger
valve
F12 6,3ATT Cover clamping motor (torque limiter board) Shutter opening
closing motor Clamping
F13 20AT Mains: phase L1
Lifting (+ closure)
F14 20AT Mains: phase L2 Lowering (+ opening)
Y10
F15 20AT Mains: phase L3
Y11
F16 15 AT Power supply low voltage Connector for
jogger pedal X32 Y45
F17 2 ATT Scraper heating resistor
Book
F18 1 ATT PLC ( 24 v ) X43 presence
detector Y46
Suction bar position
F20 Adjustab. Roughing motor 220V: 6,7A X37 detector (over clamping)
Roughing motor overload 380V: 4A Cover picking
X36 Suction bar slow down (out-in)
detector
1/2
T = time lag
TT = super time lag
D.C. power supply +
F16 Resetable
-
Transfo F17 roughing motor Suction bar
F20 F18 overload Cover separation bar
Main motor transferring
speed control motor automatic lowering
Clamping motor Roughing Y08
torque limiting F15 motor relay
K21 F14 CN1 connector X54 Y09
F13
Cover clamping for BBR delivery
Logic conveyer X33
control X35 Suction bar
Tank heating hours counter
slow down ( in-out )
Power interfacing / Suction bar Y06
Suction bar upper
+ suction bar speed lifting / lowering position detector
F12
motor
F7 X34 Suction bar
position detector
K20 F1F2 F3
( over cover pile )
Drum heating
F4 K1 Air
OFON
Main switch F K2 24V to PLC at safeguardings off
K3 Suction bar slow motion
F5 K4 Suction bar in - out
K19 Main motor F6 K5 Suction bar out - in
K18 Glue tank heating K6 Suction bar up - down
K17 Jogger K7 Shutter opening
F8 K8 Shutter closure
K16 Motor brake F9 K9 Carriage opening
F10 K10 Carriage closure
F11 K11 Air shut-off valve
K12 Carriage clutch - brake
K13 Main motor speed control Service manual BB3000 Machine description GB (2) May 1999
K14 Main motor speed control
K15 Drum rotation ( off = inhibit )
34
KBIC J22
main motor Operator
1
speed control control
panel
J15
34 J1 J21
J2 J14 15 Power
6
J13 15 X IN supply C6 1 40
1 1 Cover clamping
motor torque
of PLC
J40 1 J3 J4 Y OUT 0
limit C5
0 TS C6
J12 PU 36
30 J5 IN C4
1
TS 8 33
Y47
TPU C3
4
OF
ON
J6 OU
F 1
34
Y32 J73 C2
1
9
5
1
1
1
J5
J7
J11 12
J9 J1
1
J10 8 C1 C1 ➞ C5 to power components
1
1 (see pg 2/7 - 2/8 wiring diagrams and
1/3
J8 pg 2/6 power path)

J6
3
Power board
PLC
Milling motor relay Control panel
and breaker
J22
Interlock
C5
BBR
J13 J4
Cover nipping X02 X32
J7 From sensors X32 ➞ X55
J72
Air valve J5 IN IN J73 J21 C6
Carr. open/cl. (see pg 2/2 specific diagram)
suction bar C2 X15 X55
Clutch/brake J8 J70 Y0
J6 OUTPUT
Y15
3 PH J11 Index B: description complement
1 PH
Y32 Index
Date:
J71
J12 J1 OUTPUT July 1997

Y47
A B
Drum and
C1 J10 J9 J3 J2
tank heating
Torque
BB 3000 BLOCK DIAGRAM
Speed Tank therm. J15 limiter J14 Cover nipping motor Supersedes: Superseded by: Drawing ref.:
Main motor PCB board A
control Jog pedal.
BB3000 Micro Control Unit 24H Safety on
Timer upper guard
Input signals (LED is illuminated when description is true)
LED J29
To # colour Description Safety on
Duration selector steps perspex
26 X00 green Not available
1 2 3 4 5 6 7 8 9 10
Sensors X53
25 X01 red Not available Binding modes
24 X02 ✖ red Clamping/drying duration
I II III IV
X02 - - - - - - - - I I Controls
23 X03 ✔ red PLC enable (knob or guard not actived)
J33 Y15
30 pins J5 connector
22 X04 ✖ green Binding mode selection X04 - I - I

Powered parts
21 X05 ✖ red Clamping/drying duration X05 - - - - I I I I - - J42
20 X06 ✖ red Binding mode selection X06 - - I I J30
19 X07 red Milling notching ON/OFF activated Connectors Cell amplif.
card
18 X08 ♠ green Carriage at constant speed X44 Y10
17 X09 ✖ red Clamping/drying duration Y11
- I - I - I - I - I X55
16 X10 ♠ red Carriage wide pre-opening Y45
15 X11 ✖ red Clamping/drying duration - - I I - - I I - - X32
6 X12 green Drum heating ON/OFF activated X43
C7 Y46
5 X13 red Carriage opening (blue) knob pushed (M I + II ) 0 0,8 1,6 2,4 3,2 4 4,8 5,6 6,4 7,2 F
4 X14 red Left (green) carriage closure knob pushed Seconds
(M III ) 5 10 15 20 25 30 35 40 45 50
3 X15 red Right (green) carriage closure knob pushed X37
36 X32 ✔ green No cover on suction cups X36
35 X33 ✔ red Suction bar up ✔ illuminated when binder ready
Y32
34 X34 red Suction bar not fully out ✖ selectors position dependant
33 X35 ✔ red No (brief) suction bar in/out slow down instruction ♠ illuminated when selected ••
•52
32 X36 ✔ green No (brief) suction bar out/in slow down instruction ••
31 X37 ✔ red Suction bar is not fully inwards •48 X IN P36
•• Y08
30 X38 ✔ red Clamping not in upper position •44 Y09
•• J41 Y05
29 X39 ✔ red Milling motor temperature is satisfactory •40
28 X40 green Cover clamping is in lower position •• X33
•36
27 X41 red Shutter is fully open •• X35

26 X42 red Shutter is closed •32
iN.H
Y06
25 X43 ✔ red No book in shutter (output) 15
16 X44 ✔ green Drum rotation request (pointers: black over green) X IN X34
15 X45 ✔ red Carriage home (left limit)
Y OUT 0 X54
14 X46 red Carriage right/left slow down (brief pulse)
15
13 X47 red Suction bar allow (brief pulse) 0 TS
PU
1/4
12 X48 green Carriage left/right slow down (brief pulse) IN Red pointer
11 X49 red Carriage at right limit
U TS X49
Green selected
10 X50 ✔ red Carriage not fully open Y47
TP pointer temp
9 X51 red Carriage closed OU
8 X52 ✔ green No book in carriage Y42 ¡C
› 40
Y32
7 X53 ✔ red Jogger up •• X48
•44 J33
6 X54 red BBR full or stopped ••
5 X55 red Drum temperature too low •40 X42
•• J21 Y44
Y OUT •36
•• X41
•32 X40
Output instructions to power board (LED is illuminated at output high (24V) ) X47
J5
LED
J1 J6 X46 Y14 X38 50 250
From # colour Controlled power element (via power board, see diagr. 4.74.71.1450)
30 Y00 green Green carriage closure buttons (blinking illumination) Y12
X45 Y04
29 Y01 red Book counter increment Combinations Y13
28 Y02 ✔ red Blue carriage opening button illumination POWER BOARD
Y07 Black pointer
J30 Y38
J28 actual drum temp.
26 Y04 green Main motor speed coded instruction relay (K14) Y04 - - I I Cell
25 Y05 red Suction bar slow speed relay (K3) ampli. board
24 Y06 red Suction bar up/down relay (K6) X52
23 Y07 ✔ red Main motor speed coded instruction relay (K13) Y07 - I - I Speed Chips
Y32
extractor X44 X55
14 Y08 green Suction bar out/in relay (K5) X50
Constant: close notching X51
13 Y09 red Suction bar in/out relay (K4)
High: carriage return/milling off X39
12 Y10 red Shutter closure relay (K8)
Low: idle
11 Y11 red Shutter opening relay (K7)
Book thickness dependant (if milling on)
10 Y12 green Carriage closure relay (K10) Y43
9 Y13 red Carriage opening relay (K9)
8 Y14 red Carriage translation clutch relay (K12) (associated brake is active when clutch is not powered) X53
7 Y15 red Suction air shut-off valve relay (K11)
C6 C5
30 Y32 green Milling/notching relay
28 Y34 red BBR control pulse C4 C3
24 Y38 ✔ red Drum heating relay (K20) C2

14 Y40 ✔ green Drum + main motor rotation relay (K15) C1
13 Y41 ✔ red Drum heating/rotation key selected (but enabled-disabled by X55/X44)
12 Y42 ✔ red Cover feeder suction/blowing relay (K1) C7
11 Y43 ✔ red +24 V to jogger relay (K17) side opposite to pedal
10 Y44 green Carriage translation slow down relay (K16) (resistor across motor)
9 Y45 red Cover clamping lowering
to torque limit board via J2
8 Y46 red Cover clamping lifting
7 Y47 ✔ red Torque limit inhibit Service manual BB3000 February 1999
✔ illuminated when binder ready
EMERGENCY KNOB PRESSED OR
POWER "ON"
LEGEND PERSPEX GUARD LIFTED (AT ANY TIME)
PROCESS STEP
55 44 Y40 INITIAL CONDITIONS
45 51 40 42 33 34
49 CONDITION FOR TRANSIT TO NEXT STEP
( LED # X49 IS ALIGHT ) INITIATED ?
SIMULTANEOUS 14 15 CARRIAGE OPENING
SIMULTANEOUS 14 15 (BLUE KNOB)
YES NO
CONDITION IS AS DESCRIBED ON
RESPECTIVE LINE OF TABLE BELOW ( 53 + Y32 ) ( 45 + 40 + 42 + 33 + 34 ) + ( 51 )
49 CONDITION FOR TRANSIT TO NEXT STEP

( LED # X49 IS SPENT ) STAND BY
(GREEN LIGHTS ON)
CONDITION IS OPPOSITE TO DESCRIPTION
ON RESPECTIVE LINE
INITIAL COVER PICKING SIMULT. 14 15
43 52
51 32 37 (M1 + M2) + 51 34 (M3 + M4)
1/5
AND SIMULT. 14 15
M1 + M2 CARRIAGE
OR
(32 + 34) (M1 + M2)
START, TRAVEL GLUING
SLOW DOWN
49
ALTERNATIVE ROUTES
MODE 1 MODE 2 MODE 3 MODE 4
CLAMPING
CLAMPING SPINE STAND - BY
LIFTING AND
SIMULTANEOUS STEPS LIFTING ONLY DRYING
CLOSURE
BLUE KNOB AND BOOK REMOVAL

CLAMPING OR DRYING
( SELECTED DURATION: SEE LEDS 02/05/09 AND 11 ) 51 52
SIMULT. 14 15
SIMULT. 14 15
CLAMPING
M1 = MODE 1: BINDING WITH COVER SHUTTER CARRIAGE
LOWERING
M2 = MODE 2: BINDING WITH GAUZE OPENING OPENING
M3 = MODE 3: GLUE PADDING
M4 = MODE 4: GLUE PADDING + MANUAL REMOVAL 40 41 51
SENSORS / KNOBS / LEDS
AWAITING INITIAL BOOK DROPPING
# CORRESPONDING LED IS ALIGHT WHEN: COVER REQUEST ACKNOWLEDGMENT
X14 LEFT CARRIAGE CLOSURE KNOB PRESSED
X15 RIGHT CARRIAGE CLOSURE KNOB PRESSED
SIMULT. 14 15 43 + 52 ( JAM )
X32 NO COVER ON SUCTION CUPS
IN OPPOSITE CONDITION (i.e. X ) CORRESPONDING LED

LATE DROPPING JAMMED BOOK REMOVAL
43 52
X33 SUCTION BAR IS IN UPPER POSITION (43 52 OVER 0,5 sec)
43 52
X34 SUCTION BAR IS NOT FULLY OUT (WITHIN 0,5 sec)
SIMULT. 14 15
X37 SUCTION BAR IS NOT FULLY IN
SIMULT. 14 15
X40 CLAMPING IS NOT FULLY DOWN
IS TURNED OFF
X41 SHUTTER IS FULLY OPEN
X42 SHUTTER IS NOT FULLY OPEN

CARRIAGE
X43 THERE IS NO BOOK IN DROPPING AREA M1 + M2 M3 + M4 M1 + M2 + M3
RETURN
X44 DRUM ROTATION ALLOW ( 40¡C. BELOW
SELECTED TEMPERATURE ) 47 47 45
X45 CARRIAGE IS IN HOME POSITION (LEFT)

SUCTION BAR
X47 SUCTION BAR IN-OUT TRANSFER IS ALLOWED IN OUT
X49 CARRIAGE IS AT RIGHT END
34
1/6
X51 CARRIAGE IS CLOSED
X52 CARRIAGE IS EMPTY
X53 JOGGER IS IN UPPER POSITION 14 + 15 SUCTION BAR SHUTTER

LOWERING CLOSURE
X55 PROCESS INHIBIT (DRUM t¡ <= required temp. )
32 33 32 + 33
CLAMPING / DRYING DURATION SELECTOR (SECONDS) 42
SEL. POSITION 1 2 3 4 5 6 7 8 9 10 COVER MISSED
SUCTION BAR AND
MODE 1 + 2 0 0,8 1,6 2,4 3,2 4 4,8 5,6 6,4 7,2 COVER LIFTING
MODE 3 5 10 15 20 25 30 35 40 45 50
- - - - - - - - X X 32 33
X02
X05 X = LED ON - - - - X X X X - - COVER TRANSFER

X09 - = LED OFF - X - X - X - X - X OUT IN
X11 - - X X - - X X - - 37
COVER IS POSITIONNED
BINDING MODE SELECTOR
FOR NEXT BINDING
X06 LED OFF LED OFF LED ON LED ON
MOD.1 MOD.2 MOD.3 MOD.4
X04 LED OFF LED ON LED OFF LED ON
POWER ACTUATORS
Y32 ROUGHING MOTOR "ON" X BB3000/9 FUNCTIONAL DIAGRAM
Y40 DRUM ROTATION MOTOR "ON" X ( Simplified )
JAN 1993
p
MAX
Book dimensions
min
Padding
320 mm
(12.6")
90 mm
(3.55") 100 mm 385 mm
(4") (15.16")
75 mm 100 mm
(3") (4")
Restricted to
binding mode IV Max: 45 mm (13/4") (– 400 sheets, 80 gsm (20 lb))
Min: 2 sheets (theoretical)
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

Reducible to 0,65 m (25.6")
Outdoor fume exhaust Optional for narrow passage way
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 240V

60 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

BB3000 September 1997
Rev. minimum length
1/7
1300
Expectable number of A4 bindings (glued lenghtways) between successive glue refills Glue consumption
(chart established using our glue quality)
1200
Book thickness (mm)

1 2 3 4 5 6 7 8 9 10
1100 2000
1900
1000 1800
1700
Detail of 1600
900
the chart
1500
800 1400
1300
700 1200
1100
600 1000
900
500 800
700
400 600
500
300 Thickest glue film 400
200
Thinnest glue film
100
Max BB2005
Max BB2000
Max BB3000
Book thickness
(mm)
10 20 30 40 50 60
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
1/8
Approximate number of 8 1/2" x 11" bindings (glued lenghtways) between successive glue refills Glue consumption
(chart established using our glue quality)
1300
Book thickness
1200
1/ 1/ 3/ 1/ 5/ 3/
(inches) 16" 8" 16" 4" 16" 8"
2100
(mm) 1 2 3 4 5 6 7 8 9 10
2000
1100
1900
1800
1000
Detail of
1700
the chart
1600
900
1500
1400
800
1300
1200
700
1100
1000
600
900
800
500
700
600
400
500
Thickest glue film

400
300
Thinnest glue film
200
100
Max BB2005
BB2000
Max BB3000 Max
ax
BB4000
(mm)
10 20 30 40 50 60
Book thickness
(Inches)
1/ 1/ 3/ 1 1 /4 " 1 1 /2 " 1 3 /4 " 2 3 /4 "
4" 2" 4" 1" 2"
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
1/9
DIAGRAMS
Diagrams
Wiring
Sensors description & location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 1
Sensors to PLC inputs (32 fi 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 2
Power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 3
Wiring to the mains + Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 4
Interlocks circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 5
Power path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 6
General wiring diagram 1 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 7
General wiring diagram 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 8
Electrical drawer (Rack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2/ 9
Carriage shifting and drum rotation motor control (front rack) . . . . . . . . . . . . . . . . . . . .pg 2 / 10
Power board 1/2 (electrical diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 11
Heating circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 12
Control Panel (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 13
Book detectors in carriage and delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 14
BBR damped book chute - Motor control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 15
Carriage - cover nipping motors torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 16
BBR-X 4 relays (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 17
BBR 3 relays (wiring and electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 18
Installation
Installation summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 19
Component location fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 20
Programmable logic unit / (Re) programming instructions . . . . . . . . . . . . . . . . . . . . . . .pg 2 / 21
ON
OFF
October 2001
2
c.p. bourg S. A.
N. V.
X49
X48
X42
X47
X41
X46 X40
X45 X38
X52 X43
X32
X37
X50 X39 X36
X44
X51
X53 X55
X33
2/1
X35
X34
X32 2983886 Cover on suction cups X44 2983264 Drum rotation start (tank temperature ok)
X33 9150014 Suction bar upper position detect. X45 9150014 Carriage home
X34 2983852 Suction bar outer limit detector X46 9150014 Carriage in transfer position
X35 2983852 Suction bar slow down (in-out) X47 9150014 Carriage in transfer position
X36 2983852 Suction bar slow down (out-in) X48 9150014 Carriage in transfer position
X37 2983852 Suction bar inner limit (over clamping = in) X49 9150014 Carriage over cover clamps
X38 9150014 Clamping up X50 9150014 Carriage opening limit
X39 2981134 Milling motor is overheated (detector inside) X51 2983716 Carriage closed
X40 9150014 Clamping down X52R 9420705 Book presence detector
X41 9150014 Shutter open X52E 9420706 Book presence detector
X42 9150014 Shutter closed X53 9150014 Jogger up (milling disabled)
X43R 9420730 Book in ejection area receiver assembly X55 2983264 Drum temperature regulation
X43E 9420707 Book in ejection area emitter assembly
Service manual BB3000 Sensors description & location Jan.1997

PLC J21 C6 The condition shown for the sensors corresponds to the description
Leds J73 1 0V
2 26/30/34 n.c. X55
Colour # 3 Drum temp low ( therm. pointers: black below red )
4 n.o. S8 (BBR)
RED X55 5 35 connector BBR full or stopped
RED X54 6 33
n.o. X53
RED X53 7 4 Jogger up (milling disabled)
GREEN X52 8 29
RED X51 9 8 n.c X52
10 25
Book in carriage
RED X50 (Cell)
RED X49 11 36 n.c. X51
GREEN X48 12 21 Carriage is closed
RED X47 13 32
n.c. X50 (H)
RED X46 14 17 Carriage is fully open
RED X45 15 28
16 13 n.o. X49
GREEN X44
17
Carriage is at right limit
Flat 18 n.o. X48
cable 19 2K2 1/2W 2K2 1/2W Carriage left/right slow down (brief closure)
20 n.o. X47
0V 21 Suction bar allow (brief closure)
22 X46
23 ZD 24V 0.5 W n.o. Carriage right - left slow down (brief closure)
24
RED X43 25 24 n.o. X45 (H)
RED X42 26 10
Carriage home (left limit)
RED X41 27 20 n.o. X44 (H)
GREEN X40 28 6 Drum rotation request (pointers: black over green)
RED X39 29
1K 1/4 W
16
n.c. X43
RED X38 30 9 Book is still in shutter (output)
RED X37 31 18 (Cell)
32 5 n.c. X42 (H)
GREEN X36
33 14
Shutter is closed
RED X35
RED X34 34 1 n.c. X41
RED X33 35 12 Shutter is fully open
GREEN X32 36 2 n.c. X40 (H)
37 + Cover clamp in lower position
2/2
38 3/7/11/15/19/22/23/27/31 X39
39 n.c. Milling motor is overheated (detector inside)
40
n.c. X38
Cover clamp motor torque limiter request
n.c. X37
Suction bar is fully inwards
F18 (Reed)
n.c. X36
1A Suction bar out/in slow speed request (brief opening)
(Reed)
0V n.c. X35
Suction bar in/out slow speed request (brief opening)
24V (Reed)
Leds turn on n.c. X34 (H)
Suction bar out
•• when corresponding (Reed)
•52 input is high (24v) n.o. X33 (H)
Upper row •••
Suction bar up
48•
• Green n.c. X32 (H)
•44 No cover on suction bar
•• J21 (H) = Home position
•40
15 iN.H ••
•36
PLC 15 X IN ••
•32
C6 1 40 Please disregard any previous
13
Y OUT 0 1 24 V version of this diagram
1
TS
C5
0 U C6
INP 36
C4 Index E: X45 & S8, wiring and state of switch corrected
S
P UT 4
8 33
UT J73 C3 Date: Index
O
15 Sensors Oct. 1996
C2 A B C
3 9 X32 ➞ X55
5
C1 Sensors - PLC inputs 32 to 55 D E
1
BB 3000 (+ interfacing C6 - J21)
J5 (X02 ➞ X15 described on
MCU + inputs/outputs page 1/4) Supersedes: Superseded by: Drawing ref.:
D
J21 Sensors Fuses Rating
C6 3 X53 (Slow blow)
BB 3000 Power distribution 7 X44 - X55 1 2,5 A
J73 2 3,2 A
11 X39 3 4 A
MCU 15 X50 - X51 - X52 em - rec 4 2,5 A
MCU outputs (layer 1 + 2) 5 3,2 A
Power board J27 19 X45 - X46 - X47 - X48 - X49
Tank thermostat 6 2,5 A
Clutch (L5) 18 23 X38 - X40 - X41 - X42 - X43
Control panel 1 7 2,5 A
Brake (L7)
J40 27 X32 - X33 - X34 - X35 - X36 - X37 8 7 A
Air valve 2 n.o. Torque limiter board 9 3,2 A
k2 31 BBR
Suction bar in - out transfer motor 3 Cover nipping (M14) 12 10 5 A
11 1 A
Suction bar up/down (M13) 4 Start up timer
12 6,3 A
Shutter (M15) 5 Fan 13 20 A
Clamp open / close (M5) 6 14 20 A
T1 24V 15 20 A
L3 15 7 Drum 16
16 15 A
L2 14 8 19 V 17 2 A
Glue
17 18 1 A
2/3
L1 13 9 M1/M10/M21
spreader (No F19 for early 120 v brushless M9) 19 4 A
10 Tank 19 V
20 20 4/6,7 A
11 Vibrator 19
Milling motor
230 V Turbine
N (L3)
(M9)
F20
F19 + F16 Front
F15
-
F17
F12 F14
T1 F18
rack J21
F13
J27
MCU
TS
PU
IN
U TS 36
TP
OU
J73 8
F1 F2 F3 33
4
OO C6
FFN
9
5
ON
1 OFF
F4 BB
R
II
F7 F5
F8
F9 F6 M14 Trq.
F10 limit.
F11 Power
board july 2001
T3 228 1 028
Milling
: turn to max (6,7A) T2 229 2 029
motor
: set for 4A 323
T1 230 3 030
Trip C3
F20
Reset * Wire 301 is to connect to:
Power
T3 T2 T1 A2 board - appropriate terminal if
— 6 J13 - 220V if 380V
322 5 230V if 400V
1 240V if 415V
4
344 338 X1
341 Auto reset emerg. 3 Wiring J12 J11
stop unit A2 — 2 : 320 ➞ L2
A1 1 J40 321 ➞ L1 346
13
J37 + 346 ➞ Jumper N = L3
F7
380 V 344 338
X2 2,5A k20 : 320 ➞ L3
341 321 ➞ N
400 V 5 wires Kbic / L1 J107 4 3 2 1 J12 346 ➞ no jumper
415 V (3+N+ )
320
321 J11
208V J20 Main switch F15
k19 k18 k17
220V L3 333 8 7
342 4 L3
F14 F8
230V 4 wires L2 332 6 5
339 3 L2
(3+ ) 7A F9 F10 F11
L1 4 3
240V 331 336 2 L1 2,5A 5A 1A
F13
BLUE N 334 2 1
345 1 N
ON
n.b. heavy damage will occur if 12 11 8 7 6 5 4 3 J10
neutral is omitted in wiring
OFF
20A
C1 4 3 24h timer C3 2 1 C1
(option) 12 13
F18 1A 004
11 Kbic 002
J41 C5 003 001
MCU J19 L2
5 058 8 Drum heating 301 * F19 Tank
resistor heating resistor
1 F16 15A
BBR 319
J14 8 + N
J3 C7 2
250V
240V
230V
220V
210V
200V
190V
120V
0V
3 059 9 J18 6 5 9 8 C3 5 4 2 1 C4
C2 13 C
R Jog.coil
WHT
GRY
ORA
BRN
RED
BLU
YEL
BLK
VIO
033 036
9 032 035
2 046
Cooling fans
045
Spreader 11 BLK
heating 19V 19V
resistor 10 RED Turbine
F17 2A
J17
R Transfo
+ C
Tr
-
F13 F14 F15 F19

F20 OFF
ON
BB
R
F17 J20 II
F18
F16
KBIC
L1 J18
L2
J17
J13 6
1
J40
J3 Emergency
F7 1 J14 stop unit
(EUR only)
J12
C5
K20 C4
OFON
F J19 C3
Main
switch C2 9
15
3
C1
C7 1
K19 12 Index C: Addition of F19

K18 F8 1
Date: Index
F9 January 1999
K17 J11 F10 A B C
J10 F11 WIRING TO THE MAINS
BB 3000 POWER SUPPLY
Supersedes: Superseded by: Drawing ref.:
2/4
PLC
J40
Milling
J3 4 3 motor
24V 8 J7 Suction relay
F18 Kbic J22
1 bar in/out
F1 F18
F3 motor
0V 9 J1
K2c Suction bar J13 F1
4 up / down J3
F3
F4 motor J40
J4 F4 PLC
Shutter K2 J5 PU
TS
5/ J6 Emerg.
IN
6 motor TP
U TS
F5 F5 stop OU
cntrl
Carriage F6
K19 J7
20 20 7/ open/close J11
8 motor
F6 J1 J6
J22 J4 F9 J10
Emergency
25 25 K2b J1 Front
15 ➞ 18 Power rack
2/5
J6 to PLC
Safety on
15 ➞ 18 outputs J29 top cover
3 5 4 Safety on
31 ➞ 34 Emergency perspex
J5
Perspex
23 X3 (low = PLC disabled)
K2
J29 C5 J13 Carriage
J3 To milling open /
7 13 14 motor relay close
Top GS
T1 T2 T3 C5
cover J40 Emerg.
4 6 3 1 A1 stop Shutter
control
K19 2 A2
POWER
BOARD F9 J10 L1 L2 L3 Suction in/out
7 23 bar
up / down
J11 J10 Index B: Disregard may 1999 version
2 1 8 7 On european models only
¤ Date: Index
June 2001 A B
L1 N To main motor
control board (Kbic)
BB3000 INTERLOCKS CIRCUIT
Outputs (Y)
J22 J4 J5 J21 C6
X02 ➞ X15
X32 ➞ X55
Operator
control Inputs Inputs Sensors 32 ➞ 55
panel MCU
Emergency J13 C5 Perspex guard

C5 J13 K
4 5 6 3 2
Upper guard K
+ 24V 19
Therm. 115¡C
J3
Thermostat K
8 2 12 13 3
145¡C 18
J3 F1 J3 Therm. select
Spreader
10 heating 11 19V
F17
19V
Cover clamping
J2 J14 C2 and lifting
C2 J14 J2
Y45 9 9 9 3 9 10 4 7 8 8 Y46
J1 J15 J15 J1
Air shut-off valve
Y15 K k11 1 15 14
11 solenoid
J8
Carriage
F2 2 11 clutch
Y14 K
12 Carriage 13
k12 3 12
k2 brake
n.o. Suction bar
Y6 K 4 2 1 3
6 F4 lifting /lowering
Carriage K
Y13/12 K9 F6 7/8 7 8 8/7 10 9 Y12/13
10 open/close
Suction bar
Y8/9 K5 F3 2/1 3/4
translation
4/3 1/2 K
45 Y8/9
4
Shutter
Y11/10 K7 F5 5/6 5 6 6/5 K
8 7 Y10/11
8 opening/closure
J7 J7
- K
14 Y4
Speed instructions
J9 C1 C1 K
13 Y7
P3 1/6 9 J9 -
Carriage speed
Solid state
10 2
adjustment Speed
speed P1 3/4 11 5 P2 P2 between P1 P3 variable
regulation P2 = P1 minimum
board KBIC KBIC P2 = P1 (1K //Pot) constant
40V to 180V Carriage translation P2 = P3 maximum
A+ 6 and drum rotation 7 A-
Y4 high: 1K over P2.P3
190¡C
J12 F7 J12 Auto Reset J12
L3( ) Drum N( )
1 k20 4 4 3 2/3
L2( ) heating L1( )
F10 J10 Tank J10
k18 5 1 heating
2 6
J11 190¡C
F11 Jogger
L1 2 k17 3 1 solenoid 2 4
F9 C4 KBIC C4
k19 7 8
L1 L2 N( )
C3 C3 L3( )
KBIC
34
J22 5 6
main motor Control Cooling
speed control 1
panel
fans L2
J15 8 9
34 J1
J14
J19 J21
J13 6 11 12 12
J2
1 1 Cover clamping
motor torque 24H timer F8
1
J3 J4 limit
(option) 13 11 C6
J40
1
30 J5 1
Relay
J12 C5
OF
ON
1 J6 2
F
34 Milling/notching C4
1
J7 3 C3
F15
F14
F13
1
1
C2
J11 12
L3 L2 L1 C1
J10 1 8
1
J9
1
J8 POWER PATH
Wire identification # on general wiring diagram BB3000 September 2001
2/6
See
RED
p. 2/2 See Cover clamping J33
INPUTS = X
24H
p. 2/2
RED
RED
❊ Cell amplifier
board
Binding detector cells
under shutter
MCU S Safety on +24V C6-23 123 123 1 RED
PU
T Timer RED
IN upper guard 8 7 6 5 4 3 2 1
1 J21
2 1 40 0V C6-30 130 130 2 BLK X43
RED
RED
BLK
BLK
J29
WTH
RED
BLK
J21 C6 K A
39 Safety on
perspex C6-24 124 124 3 WHT EMITTER
40 C5 X43 BLK A K
36
C4
8 33 J21 RED
See C3 X53 X41 C6-20 120 120 4 BLK C E

C2 RECEIVER
. 2/9 C1
4 J33 Y15 BLK E C
59 J42 X42 C6-10 110 110 5 BLK RED
1
J30
Cell amplif. X38 C6-9 109 109 6 BLK
card RED
13 X44 Y10 n.c. X41 Open shutter detector
BLK
Location on page 2/8

X55 Y11 X40 C6-6 106 106 7 BLK
14 RED
Y45
1 15 X32 BLK n.c. X42 Closed shutter detector
2 X43 C2-5 017 017 8 GRN
12 C7
3 Y46
F RED
X38 Nipping upper
X37
J7 C2-6 018 018 9 BRN BLK n.c. position detector
and torque limiter
X36
C2-9 021 021 10 WHT RED X40 Nipping lower
Y32 BLK n.c. position detector
J14 C2-10 022 022 11 RED

Y10 & Y11 Shutter opening
Milling / notching P36 GRN closure
+24v C6-11 111 Y08 BRN
Y09 0V C2-14 026 026 12
J21 J41 Y05
Milling motor overload
X39 C6-16 116 X33 Y45 & Y46 Jaw clamping
X35 J8 C2-15 027 027 13 WHT
RED
and lifting
111
X39 X39 Y06
T3 C3-1 028 116 P36 137
0V Y15 Air shut-off valve
2/7
X34 +24V C6-27 127 127 1 127

solenoid
T2 C3-2 029
028
X33 C6-12 112 112 2 112
T1 C3-3 030 029 Control
030 YEL/ panel
GRN X35 C6-14 114 114 3 114 112
Kbic J15 X33 Suction bar upper limit
C3-4 031
YEL/GRN
031
YEL/GRN
200 / 208 / 230 / 240 V J13 J21 127 n.o.
513
X34 C6-1 101 101 4 101
380 / 415 V See J14 Cover clamping
p. 2/9 J2 motor torque X34 Suction bar outer limit
L2 5 101
C3-5 032 032 limit board X36 C6-5 105 105 105
114 IN ➞ OUT
Lower frame J4
N C3-6 033 033 cooling fan
OFF
ON
X37 C6-18 118 118 6 118 X35 Suction bar slow down
034 J10 J7 X32 C6-2 102 102 7 102

C3-7 034 013 BRN Y06 Suction bar lifting /
YEL/GRN YEL/GRN
J9 lowering motor
015 GRN
J8 8
Cover feed
L2 C3-8 035 035 1 435
C2-1 013 013 9 013 016 RED Y08 & Y09 Suction
435 Upper guard cooling bar translation
N C3-9 036 036 2 436 436
437 YEL/GRN fan or fumes extractor C2-2 014 014 10 014
015 GRN
C3-10 037 055 3 455

YEL/GRN
11 Safety on
J7 C2-3 015 015 11 015
015 105 RED X36 Suction bar slow down
13
n.c. 118 BLK
C5-5 055 056 4 456 12 14 perspex guard OUT ➞ IN
Loom 12 511 WHT
C2-4 016 016 016 X37 Suction bar inner limit
J13 4
456 460
C5-6 056 040 5 440 455 511
J13
1
Safety on C5-7 057

Y34 13
3
n.o. X32 Cover detector on suction bar

upper guard 512
4
5 n.c.
2
L2 C3-13 040 038 6 438 + 24V C5-8 058
3 24 hours J17 J41 Suffix G: ❊wiring corrected

6 057
Transfo C3-11 038 039 7 439 438 0V C5-9 059 131
5 Timer ¤ Date: Suffix
440 4 1 Nov. 1997
Upper
L2
External 6 2
BBR A B C
N C3-12 039 041 9 441
guard 439 3
bridge + 24V C6-31 131 D E C
441
2
J21
058
Full
5
4
3 BB3000 WIRING DIAGRAM 1/2
G
C3-14 041 037 10 437 X54 C6-33 133
133 Supersedes: Superseded by: Drawing ref.:
YEL/GRN
YEL/GRN 059 F
X49
Carriage Cell amplifier
BB3000 X48
Y42 +24V C6-15 115
P32 EC1
530
board
J33 Jogger J21

1 1 527
1 2 3 4 5 6 7 8
2 2 531
X42 J3 C7-1 0V C6-26 126 528 Fix jaw emitter cells
Y44
WHT
GRY
532
530
531
3 3
534
524
532
115
533 K X52 A
X41 X40 4 4 EMITTER
0V C7-2 X52 C6-29 129 529
X47 n.o. GRY A K
126 5 5 534
WTH
X46 Y14 X38 6 6
X50 C6-25 125
Jogger pedal 019 7 7 535
Flat cable
Y12 533
Y04 +24v C6-3 103 020 8 8 536
X45 Y13 X51 C6-8 108 525 n.c. X50 Full opening detector
Y07
Cell J30 Y38 J21
ampli. C6-4 104 X53 P31
board J28 C1-9 009
011 1 1 521
103 Y12, Y13
X52 104 n.o. 010 2 2 522 535 2 GRN
Chips Carriage open/close
extractor Y32 X44 X55 J9 C1-10 010
009 3 3 523 536 1 BRN
motor
X50 X51
Jogger upper position 4 4
X39 C1-11 011
5 5 1
523
129 6 6 524 Carriage variable
Y43 522 2
C2-7 019 speed adjustment
125 7 7 525 521
X53 See p 2 / 13 J7 108 8 8 526
3
C2-8 020
C6 C5 EC2
C3 042
Mobile jaw receiving cells
C4 L1 C4-1 042
C2
043 J46 C E
RECEIVER
C1 N C4-2 043 044 Y43 87
65
P31 87
65
527 1 GRY E X52 C
YEL/GRN 528 WHT
43 43 2
C7 Jogger solenoid 21 21
529 X51
C4-3 044
YEL/GRN Flat cable
P32 EC2 EC1
3 BRN
BLU
n.c.
526 4
120v connection Jaw full closure detector
C4-4 045 87 87
Cover picking boards 65 65 Connection bar
43 43
045 6
21 21 on mobile jaw
2/8
N C4-5 046
046 5
Y42
051 2
YEL/GRN 047 (0v < V < 10v)
C4-6 Suction turbine J30
052 1 ( + cover separation blast ) Carriage shifting Y44
J3 C5-1 051
047 YEL/GRN
1 RED
Carriage shift brake
See p 2 / 12 RED
RED
J10 0V C5-2 052
J28 Gluing section
0V C2-13 025 025 2 RED
C1-1 001 001 1 Tank heating resistor C2-11 023 023 3 Y14
J8 RED Carriage shift clutch
C1-2 002 002 2 ¥ C2-12 024 024 4 RED
190¡C
AUTO RESET
N/L1 C1-3 003 003 3 X49 C6-36 136 136 5 436 436 n.o. X49 Carriage right limit
504
L2/L3 C1-4 ¥
X48 Carriage left-right
004 004 4
190¡C X48 C6-21 121 121 6 421 421 n.o.
504 slow down
AUTO RESET Y38 Drum heating resistor 503
005 X47 Suction bar
C1-5 060 5 X47 C6-32 132 132 7 432 432 n.o.
YEL/GRN
J21 503 IN-OUT allow
502
C5-10 060 061 6
X46 C6-17 117 117 8 417 417 n.o. X46 Carriage right-left
Spreader heating resistor
19v 502 slow down
501
C5-11 061 062 7 7 Tank thermostat (145¡ C) 428 428 n.o. X45 Carriage home position
11 X45 C6-28 128 128 9
501
8
C5-12 062 063 8 11 Tank thermostat (115¡ C) +24V C6-19 119 119 1 419
J3
C5-13 063 9 8 115¡C Tank thermostat selector 006 10 BRN
Rack
chassis
12
145¡C
9139028
KBIC A + C1-6 006 Carriage shift
Sensor
+24V C6-7 107
10
J16 007 12 BLU
C1-7 007
J21 KBIC A -
YEL /
11 008 13 Y04 - Y07
X44 C6-13 113 GRN
5 6 C1-8
135 4 008
12 107 X44 X55 Drum
X55 C6-35 135 1 3
2 temperature regulator
113 BB3000 WIRING DIAGRAM 2/2 November 1997
To PLC inputs
F18A
F18A
F18A
F18A
401
260
X32 ➞ X55
J3-7
R +
404 401
F18 54 3 2 1
C C F16
403 402 Origin, interconnection
PLC destination on
F17 260
page 2 / 2 J21
ON
OFF
405
406
407
402
J19 BB
R
II
232
235 1
238
301
C6
245 302
248 2
J17 239 303
258 3 249
407 C7
1 236 Cover clamping motor 1
324 335 2 Jogger 233 4 246 torque limiter
C
405 2 308 307 1 pedal 252 304 3
335 254 5 13
3 226 Main motor speed regulation
259 208
6 J15
225 247 2 K21
4 330 244 From J2 15 251 1
7 326 R 327 252 2
250
402 5
325
309 241 Power board 10
254
253
4
3 C5
8 237 255 5
403 256 6
6 261 231 A+ L1 L2 257 7
404 9 234 222 4 258 8
19V +F F-
4
R17
7 406 305 318 3 259 9
328 221 260 10
3
205 10 306 317 J14
BLK 325 2 261 11
2
R19 A- 262 12
324 1 263 13
1
Transfo RED
J18 329 14
ACCEL
I1
15
P2
303 J16 311
1 MAX MIN IR CL
BLU 319 P3 242 1
2 315 1 326 I2 F12 243 2
ORA
WHT 3
120V
190V
302
327
WHITE P1 RED
6,3 A 245
244
4
3 C4
GRY 4 200V 206 2 246 5
328
2/9
247 6
310
314
RED 5 210V 248 7
316
312
313
BRN 6 220V 3 329 249 8
BLK 7 230V 301 207 250 9
8 067 10
YEL 240V 348 11
VIO 9 250V 12
251
253
13
262
308
To connect to: 14
P3-7
To milling
307
263
307
309
11 304
- appropriate terminal if motor control
From To To From 169 15
PLC J15 To/from J22
10
12
PLC PLC
2
4
6
8
- 220V if 380V 228 1
torque Control 229 2
1
3
5
7
9
230V if 400V output limiter input output 230 3 C3
240V if 415V panel 231 4
R 232 5
C F16 233 6
Tr
+
323 6 J1 J3 J5 J6 235
234
8
7
-
322 5
F17 255 4 J2 J4 236 9
256 3 J13 237 10
257 2 238 11
F18 1 239 12 Timer
1 215 240 13
2 216 241 14
4 3 214 15
J18 3 4 213
KBIC 2 J40 J11 J7
J16 1 J12 5
6
217
218 213 1
J17 Power board 7 219 214 2
6
1
8 220
216
215
4
3 C2
Torque J21 L3
4
2
limiter 217 5
C6 320 218 6
3
1
1
board L2 Bridge 346 for 219 7
203
C5 346 220 8
C4 No bridge 346 for 221 9
OFON C3 L1 222 10
204
F J19 C2
1 227 223 11
9
15 321 J8 2 223 224 12
3
N 3 224 225 13
1 C1 226 14
C7
12
J10 J9 227 15
1
201 1
Date: Index 202 2
C1
12
10
203
8
2
3
8
6
4
2
Nov. 1997 204 4
11
7
5
3
1
205 5
WIRING DIAGRAM
319
348
318
202
243
316
206 6
314
312
310
210
BB 3000 ELECTRICAL DRAWER 208
207
8
7
240
067
317
201
242
315 209 9
313
311
211
209
( RACK ) 210 10
Supersedes: Superseded by: Drawing ref.: 211 11
12
13
14
15
BB3000 Carriage shifting and drum rotation
motor control (front rack)
Main motor
speed regulation (Re) adjustment
board
326 R 327
see page 3 / 1
A+ L1 L2
R17 +F F-
328 318
317
R19 A-
ACCEL
329
P2 I1 Leave trimpots "IR","CL",
311
225 MAX IR CL
J16 P3 MIN
"ACCEL", like illustrated.
I2
315 1 326 P1 i.e. fully c.w. ( )
WHITE RED
206 327
2
328
310
314
312
316 313
207
3 329 Carriage translation
brake clutch
251
253
262
308
P3-7
263
307
309
11 304
From To To From
PLC J15 To/from J22
10
12
PLC PLC
2
4
6
8
torque Control
12 13 11 C2
1
3
5
7
9
output limiter input output

panel 223 11
224 12
J1 J3 J5 J6 225 13
J2 J4
J13
Power board F2 1 215
2 216
3 214 1
J11 J7 4 213 C
J40 J12 5 217
6 218 3
7 219 13
8 220
4 L3 K19
K16
K15
K14
K13
3 L2 15
2 L1 C1
F9 1 227 206 6
WIRING 1 N K12 J8 2
3
223
224 207 7
J10 J9
Drive
12
10
8
6
4
2
11
209
9
Carriage motor
7
5
3
1
319
348
318
202
243
316
314
312
310
4K7
210 variable 6
speed
240
067
317
201
242
315
313
311
211 M10
7
ELECTRICAL
Main motor speed

J11 K19 J10 regulation board
F9 J16 C1
L1 2 7 317 L1
N (L3) 1 8 318 L2 A+ 328 2 206 6 036
315 1 326 47 327 M 10

1 25W
Y44 10 K16
(M10 2 316 A— 329 3 207 7 037
slow)
J1
J9 Y4 Y7 D.C. V I (Amp.) Speed*
Y40 Run
7 313 I2 (AT A+) (in 329)
(M10 14 K15
on-off) 8 314 I1 P3 P1 P2 0 1 40V 0,4 Min
1/6 209 312 1 1 63V 0,6 Constant
MCU
Y7 23
+ 2 4K7 1 0 180V 1 Max
K13
3/4 211 310 0 0 Pot. 0,4 < I < 1 Variable
F2 5 311 dept.
Y4 26 K14
225 13 2
Y14 8 K12 3 224 12 4 L7
Brake * According to the(de) energizing
Clutch / of K13 (Y7) and K14 (Y4)
J6 2 223 11 3 L5
Brake
X44 Power board J8 C2 P103 P50 J30 Clutch
3
Clutch safety March 2002
S44
(high for black pointer over green one)
2 / 10
L1 Drum heating
resistor k3
J6 R10 8,2‰ J7 C2
MCU OUTPUTS L2 MCU
Y47 Y45 K3 k4
See pg 1/4 - 2/6 L3 N C1 0V Y5 25 1 3
in - out
Y46 Y41 Y38 Y39 Y36 Y34 Y32 Y43 Y42 Y0 Y1 Y2 Input
3 4 See pg 3/4
Suction bar
K4 motion
Y9 13 FET 2 4
19/20 3/4 15/16 15-18 out - in
J1 7 8 9 13 24
21/22 5/6
23 26 28 30
17/18
11 12
31-34
30 29 28 k5
K5 See pg 3/4
Y8 14
F3
Covers K7 4A k7
Y11 11 F5 5 5 Shutter open
J15 J2 C5
5 6 3.2 A
K8 k8
5+6 5+6 Y10 12 6 6 Shutter close
1 2 3 4 6 1 2 5 4 3 F4
K6 k6
7+8 7+8 Y6 24 4 2 Suction bar
J12 J13 2.5 A
up / down
9+10 9+10
K1 F6
k2 3 1
2.5 A
3+4 3+4 F7 R9 580 K10 k10
2.5 A
Y12 10 8 8 Carriage clamp.
K20 K 19 close
2 2 K2 K9 F1 k9
Static 470 F Y13 9 7 7 Carriage clamp.
2.5 A J40
1 1 5V Hours open
count
3
K17
J8
4
3 12 Brake
25 21 23 K12
34 32 30 33 2 4 3 1 6 5 8 7 10 9 12 11 13 17 20 27 14 29 31 26 22 15 16 18 24 J4 Y14 8
F2
k12
K18 2 11 Clutch
Dead Static 3.2 A
stop K11
Y15 7 k11
4 7 5 6 12 1 11 10 2 3 9 8 J3 1 15 Air shut off
2 / 11
13/14 valve C1
1 C7
F18 6 P3
To main motor speed control board

Tank
J5
On carriage
3 4 5 6 15 16 17 18 19 20 21 22 24 23 25 26 1A 1 9
Pedal Thermostat
K13 4K7
Y7 23
Y4 Y7 Speed 2 10
MCU See pg 1/4 - 2/2 X15 X13 X11 X9 X7 X5 X2 X1 X0 0 0 Variable
INPUTS 1K 3 11
X14 X12 X10 X8 X3 1 1 Constant
X6 X4 0 1 Minimum 4 P1
34
J22 1 0 Maximum
1 Control Y4 26
Binding panel K14 5 P2
X6 X4 mode
Main motor
Clamping motor 0 0 Kbic
speed control
torque limiting
0 1 J15 0V 24V
1 0 J1 7 I2
K21 Cover clamping 1 1 K15
34 J1 Y40 14 I1
J13 J14 8
Tank heating J2 J4
F12 6 J9
hours counter
F7
J40 1
1 Cover clamping
motor torque
KBIC
K20 Drum heating F1
1 J3 limit
J10 47‰
F2 F3 K1 Air
A+
F4
K2 24V to PLC at safeguardings off J12 1
Brake
+
Main switch OF
F
ON
K3 Suction bar slow motion
1
30 J5 K16
F5
F6
K4
K5
K6
Suction bar in - out
Suction bar out - in
Suction bar up - down
ON J6
Y44 10
2 A-
Main
-
K19 Kbic 230V supply OF
F 1
K18 Glue tank heating K7 Shutter opening 34
N 1 motor
K17 Jogger K8 Shutter closure 1
F8 k19 F9
K16 Main motor brake F9
K9 Carriage opening J11 3 L1
F10 K10 Carriage closure 1
F11 K11 Air shut-off valve 2,5 A
4 L2
K12 Carriage clutch - brake 1 X k18
K13 Main motor speed control
J7 J5 F10
K14 Main motor speed control J11 12 L1 2 5 1
K15 Drum rotation ( off = inhibit ) C7 208 5A Glue tank heating
J10 1 J9 6 2
There is a surge protection diode on each relay coil. 8 J1 or 220V k17
1 F11
¤ Date: Index 1 only 7 1 Jogger
August 2001 J8 Y
A B C 3 J6
1A
8 2 Coil
POWER BOARD F8 TZ
BB3000 ELECTRICAL DIAGRAM 1/2
COMPONENTS LOCATION / FUNCTION
L2 3
7A
11
4
Turbines
Supersedes: Superseded by: Drawing ref.: L3 4 12 5
4.74.71.1450 Transfo
Applicable from S.N. 8.700 through 61.10.4.0001 and up J19
C4
NOVEMBER 2001
From
secondary L3 L1 L2 N(Y) / L3( )
19v
winding
of T1 J10 2 J17 C5
R F17 J28
C3 10 6 Spreader
F15 F13 11 – 23 ‰
115¡C 19v
+ 24v DC Thermostat
11
cold
selector 7
T1
F16 145¡C 4 J11 2 F10 Tank heating
J17 Red pointer
C5 J10 5 1 1 resistor 9 2 2 J11 1 Green (selected
190¡C pointer temp)
8 13 J3 3 K 18 – 65 ‰ Auto reset
C1
8 cold C1 J10 6 = 40
¡C
145¡C 115¡C Solid state F7
J3 F1 7 12 13 8
J12 4 3 3 10 4 4 J12 2
J28 Drum
190¡C
2 K 20 Auto reset
Solid state – 150‰ cold 50 250
J1
24 Needs to be
C5 190¡C positioned Black pointer
12 0.1mm away (actual drum temper)
190¡C from drum
2 / 12
J71 Drum
S44
J5
J56 J72 24
S55
Y38
J4
26 6 6 X12 115¡C
Control R J28
panel T1 +
F16 145¡C
(see pg 2/13)
-
1 MCU F17
J134
J134
F13 F15 Tank
1
J21 J17 J21 resistor

J72 Thermostat
38 F7 J1
MCU Selector
J73 C5
C6 36
S44 S55 7 J12 J4
J3 J71
¥ 8 33
C6 J73 K20 ON
J5 C1 4
OF
F
35 5 5 X55 F1 ¥ OFF
ON
Drum Binding 13 BB
R
1 9 II
rotation 5
disabled K18 J11
J5 1
disabled 13 16
16 16 X44 J10 1 J1 1
BB 3000
F10 15 Heating circuitry
S44 closes when black pointer reaches green pointer
S55 opens when black pointer reaches red pointer 3
Resistors (tank - drum - spreader)
2 / 13
Applicable from S.N. 8700 trough 61.10.4.0001 and up

¤ Date: Index
Sept. 1996 A
CONTROL PANEL
BB3000 (ELECTRICAL & WIRING)
24V
6 3
R1
R4
A C 100K
5 + C1
ZD1 100 F
LD271 12V TR1
63V
K E R3
10K 2
OUT
A C R5 R6
10K 3K3 Books: 0V
LD271
4 No books: 24V
K E R2 LED1
2K2 Red
7 1
0V
c Detector Cell assy amplifier

A
Location emitter receiver board R1
2 / 14
K e Carriage X52 9420706 9420705 9420996 1K2

EMITTER RECEIVER Delivery X43 9420707 9420730 9420696 560
8
R4 TR1
+
Cell
ampli. Cell R3 C1
board X52 ampli. R1 R6
board
X43 LED1
R2
R5 ZD1
¤ Date: Index
LEDS OFF August 1997
AT BEAM INTERRUPTED
BOOK DETECTORS IN
BB3000 CARRIAGE AND DELIVERY
3.74.71.0906
2 / 15
From S.N. 68.02.0.0001 onwards

¤ Date: Index
Jan. 1997 A
DAMPED BOOK CHUTE
BBR MOTOR CONTROL PCB
2 / 16
S1 Start
S2 Book detector on pusher head 2 1
S3 Book detector on pusher head 3 S9
S4 Actuated by chain when pushers " IN " 4
TH1
S5 Actuated by chain when pushers " OUT " 2
1
S6 Actuated when blades UP M1
S10 S4
S7 Actuated when blades DOWN S1 6
2
S8 BBR full nc no nc no 1 8
K2
S9 Emergency stop 5
S10 Reset 4 5 6 2 S11 3
4 6
K 1 D1 L
S11 Safety 1 1 8
1 8
nc no K4
7 S2 6
4
K1 Power interrupt and memory 7
nc no 3 5
K2 M1 ON/OFF TH2
K3 M2 ON/OFF 6 S3
K4 M1 direction + brake nc no
7
TH1 3 4
TH1 Motor 1 overload ( 1,8 A ) 6
TH2 Motor 2 overload ( 1,8 A ) F J2/P2 S5
S6
nc no
F Power protection ( 7 AT ) S8
no nc
S7
P1 Plug to binder
no nc
P2 Interconnection
24 V
M1 Pushers IN-OUT drive motor 4 5
M2 Blades UP-DOWN drive motor 0V 3 6 TH2
2
P1 D2 2 D3 2 D4 2
L Cycle interrupt lamp K 2 K 3 K 4 3 1
M2
7 7 7 1 2
D General purpose diodes 4 K3
1-2-3-.... Relay pin #
Contacts are illustrated BBR-X in position of rest
DIAGRAM APPLICABLE TO BBR-X UP TO S.N. 68.20.0.9999

S1
Contacts are illustrated BBR-X in position of rest
¤ Date: Index
Index B: BBR-X applicability limits Jan. 1997 A B
S5 S11 S2 ELECTRICAL - WIRING DIAGRAMS
S4 P2 BBR-X STROMLAUF - VERDRAHTUNGSPL NE

SCHEMAS ELECTRIQUE ET CABLAGE
S3 Supersedes: Superseded by: Drawing ref.:
May 1995 A
co co
no nc
no no
co
nc
nc
M1
co
S6 S8
no
nc
M2 P1 006
S7 nc
P1 to Binder co
no
co no
003
K2 K3 4 004 S8 nc 007
K1 3 5
S9 K4 002
001 005
S10 2 6
L F 1
TH1
TH2 042
5 4 3
8 1 2
052
046
056
045
055
J3
049 048
D4
039 049 050

J4 J5
K4
1 041
051
6
BRN GRN BRN GRN 060

J2 6
2 022 J3
021
5 3
8 9
M1 M2 053 035 053
5 4 3
8 1 2
4
043
030 036 057 054
022
D3
051
6 7
K3
032
060 038
6
059
039
034
042
040
005
co
041
no 037 010
038
S6 nc 033
004
037
5
nc no 043
5 4 3
8 1 2
035 036 011

co no
co 048 044
002 003
S4
4
nc 040 006
D2
S11 050 046

018
K2
047 059
6
058 020
030 047
2
co 033 nc 017 052

5 4 3
8 1 2
no 032 S7
S5 057
1
nc 031 034 no
co 009
010 056
D1
031 014 013

K1
015 058
6
018
025
028
co no 029
S2 nc 026
023 029 P2 ( BBR-X upper part ) S9

4
012
045
007
027
054
009
3 5
2 2 1
055
023
008
co 024
044
008
6
011
no 014 021
S1 nc 025 1 013 3 4 015
012 016
017
026
016
S10 F 1 2 1 2
024
co
6 547 6 547
no 028
S3 008
nc 027
020
019
L TH1 TH2
2 / 17
S1 Start
S2 Book detector on pusher head 2 1
S3 Book detector on pusher head S9

TH1
3 4
S4 Actuated by chain when pushers " IN " 2
S5 Actuated by chain when pushers " OUT " 1
M1
S6 Actuated when blades UP S10 S4
S1 6
2
S7 Actuated when blades DOWN nc no nc no 1 8
S8 Delivery conveyer full K2
4 2 6 5
S9 Emergency stop 5 4
L 3
K 1 D1
S10 Reset 1 8
1
7 S2
7 nc no
K1 Power interrupt and memory
TH1
K2 M1 ON/OFF 6 S3
K3 M2 ON/OFF nc no
7
TH2 3 4
TH1 Motor 1 overload ( 1,8 A ) 6
TH2 Motor 2 overload ( 1,8 A ) F J2/P2 S5
TH3 Motor 3 overload ( 1,8 A ) S6
nc no
S8
no nc
F Power protection ( 7 AT ) S7
J1 / P1 no nc
P1 Plug to binder P41
24 V
P2 Interconnection 4 5
TH2
0V 3 6
M1 Pushers IN-OUT drive motor 2 1 D2 2 D3 2
3 1
M2 Blades UP-DOWN drive motor K 2 K 3 M2
1 2
M3 Chute rollers drive motor 7 7 4 K3
L Cycle interrupt lamp
D General purpose diodes Contacts are illustrated output unit in position of rest
To
binder
TH3
J41
TH3 S1 from PLC (Y34) M3 control P.C.B
1
Chute
To
J2 (see specific M3 rollers binder
P2 S3 electrical diagram)
S4 P41
S2
S5
1
S8 6 2 J1
5
+ 4 P1
+ J1
M1
S6 To upper part
M2 (damped chute)
001
K1
K2 P1 002
P2
S7 003
K3 4 +
004
S9 005 5
001
S10 2 6
1 P41
L F
TH1
TH2 J3 045 046 055 056
006
J4 J5 co
no
039 S8 nc 007
BRN GRN BRN GRN
1 040 J3
6 022 021
J2 2
5 3 M1 M2 053 3 2 035 053 9
K3 043
4 057 4 1 054
022 8
030 036 5 D3 8
032
7 038 7
034
6 059
038
co no 037 010 6 005
S6 nc 033 037
025 co 035
043 3 K2 2 036
011 5 004
no
S4 4 1 044
024
028 nc 039 048 006 4 003
029 no co 5 D2 8 046
018 002
1 025 026 nc S2 047 6 7 059
058 020
3
6 030 047
2 023 023 2
5 3 co no 032 033 nc 3 2 017
P2 4 027 S7 K1 057
029 024 no co S5 nc 031 034 no
co 4 1 009 056 1
010
nc S1 031 014 5 D1 8 013
058
6 7 018
026
028 no co
027 nc S3
012 007 045 054 009
¤ Date: Index 2 1
014 021 011 044 008 008 055
L
Jan. 2000 A B C 4 3 013
020
012 017
DELIVERY UNIT D S9 019
BBR WIRING & ELECTRICAL DIAGRAM

MOTORIZED DAMPED BOOK CHUTE / 3 RELAYS
016
S10
1
6 547
2 1
6 547
2
F
Supersedes: Superseded by: Drawing ref.: TH1 TH2
C
2 / 18
Current Electrical Mechanical
distributing Input Power board Milling motor
network Transformer Mains Ballast for Selection of proper pulley under
milling motor for dust extractor
✸ set for 4 A. C3
frequence jogger
✸ 344
341
L3
L2
T3
T2
T3 228
T2 229
1
2
5 wires
338 L1 T1 T1 230 3
(3+N+ )
22 22
322 A1 A2 96 323 P13-6
ON
OFF
J12
20A J11
380 V
4
2
1
J20 Main switch F15
3
333
8 7 320
L3 342 343 4 L3
F14
6 5
400 V L2 332 339 340 3 L2 50 Hz
2 L1 T3 T2 T1
✸
L1 4 3 337
331 336
321
N 334 2 1
345
F13
345 1 N ✸
415 V
BLUE BLK ✸ ✸ fl 100 mm
4"
RED
J18 To connect to
Transfo 0V 319 N
BLU
220V if Y 380V
ORA 230V if Y 400V
WHT 190V 240V if Y 415V
GRY 200V 301 L2
RED 210V
BRN
BLK
220V
230V
✸
2 / 19
YEL 240V
VIO 250V
✸ set for 6,7 A ( fully clockwise ). C3

✸ 344
341
L3
L2
T3
T2
T3 228
T2 229
1
2
4 wires 338 L1 T1 T1 230 3
(3+ ) 22 22 OFF
ON
322 A1 A2 96 323 P13-6 BB

R
ON
208 V OFF J12

20A J11
✸
4
2
1
F15
3
J20 Main switch

7 L3
220 V L3 333
8
342 343 4
F14 320
5
L2 332 6 339 340 3 L2 346
T3 T2 T1
321
L1 4 3
337
2 L1
✸bridge 346 does
331 336
230 V F13 60 Hz
✸
1
No wire N 334 2 345 345 1
N
here
BLUE
✸ not exist ( must be
removed ) for
power distribution. fl 80 mm
240 V 3 1/4"
BLK
J18
RED 319 N
✸
0V
BLU To connect
ORA
WHT 190V to appropriate
GRY 200V 301 L2 terminal
RED 210V
BRN
BLK
220V
230V ✸
Transfo YEL 240V BB3000 Installation
VIO 250V
✸ Seven mandatory checks. November 1997
Fuses Rating GB Protected circuitry F Circuit / composant prot g D Abgesicherte Teile
BB3000
F1 2,5A Panel, PLC outputs - turbine Pupitre de commande - sorties automate - commande turbine Steuerpult - Autom. Ausg nge - Saugmotor
F2 3,2A Clutch - brake - air valve Embrayage - frein - soupape aspiration Kupplung - Bremse - Luftventil
On power board
F3 4 A Suction bar transfer Moteur translation rampe succion Saugergest nge, herein - heraus
F4 2,5A Suction bar up / down Moteur ascension/descente rampe Saugergest nge, hoch - tief
F5 3,2A Shutter opening closing motor Moteur ouverture/fermeture volet Auswurfklappe, Motor
F6 2,5A Carriage closing motor Moteur ouverture / fermeture chariot Transportschlitten, ffnung - Verschlu§
F7 2,5A Drum heating resistor R sistance chauffe cylindre Leimwalzenheizung
F8 7 A Transformer primary - cooling fan Transfo. alimention et ventilateurs Trafo ( prim re Wicklung ) - K hlventilator
F9 2,5A Main motor Moteur principal Hauptmotor
F10 5 A Tank heating resistor R sistance chauffe bac colle Tankheizung
F11 1 A Jogger Vibreur R ttler
F12 6,3A Cover nipping motor (torque limiter board) Limiteur de couple mot. emboit. couv. Drehmomentbegrenzungsplatine
F13 20A Mains: phase L1 Secteur: phase L1 Netz: L1
F16 15 A Power supply low voltage Alimentation basse tension 24V Stromversorgung
F17 2 A Spreader heating resistor R sistance chauffe r partiteur Heizung Leimabstreifer
F18 1 A PLC ( 24 v ) Automate programmable PLC Automat
F20 Adjust Roughing motor 220V: 6,7A Protection moteur fraisage / gr cquage en 220V: 6,7A Fr semotor berlast-Sicherung bei 220V: 6,7A
Roughing motor overload 380V: 4A Protection moteur fraisage / gr cquage en 380V: 4A Fr semotor berlast-Sicherung bei 380V: 4A
D.C. power supply +

2 / 20
F16 Warning : For continued protection against fire

Resetable
-
Transfo F17
roughing motor hazard replace only with fuses of same type and rating.
F20 F18
overload
Main motor Clamping motor Roughing
speed control torque limiting F15 motor relay
F14 Attention : ne jamais remplacer que par
F13
des fusibles de m me type et de m me valeur.
K21 Logic
Cover clamping control
Tank heating F12 VORSICHT : nur durch Sicherungen

hours counter gleichen Typs und Werten ersetzen.
K20 F7
Drum heating F1F2 F3
ON
F4 K1 Air Air Luft
Main switch OF
24V zu PLC, ( Sicherheitshaube unten )
F
K2 24V to PLC at safeguardings off 24V automate ( s curit s au repos )
K3 Suction bar slow motion Rampe ( translation lente ) Saugergest nge, langsam
F5 K4 Suction bar in - out Sortie de la rampe Saugergest nge, innen - au§en
K19 Main motor F6 K5 Suction bar out - in Rentr e de la rampe Saugergest nge, au§en - innen
K18 Glue tank heating K6 Suction bar up - down Ascension - descente rampe Saugergest nge, auf - ab
K17 Jogger K7 Shutter opening Ouverture volet Auswurfklappe, offen
K16 Motor brake F8 K8 Shutter closure Fermeture volet Auswurfklappe, geschlossen
F9 K9 Carriage opening Ouverture chariot Transportschlitten, offen
F10 K10 Carriage closure Fermeture chariot Transportschlitten, geschlossen
F11 K11 Air shut-off valve Soupape air aspiration Luftventil, offen - geschlossen
K12 Carriage clutch - brake Embrayage - Frein chariot Transportschlitten, Kupplung-Bremse
K13 Main motor speed control R gulation vitesse moteur principal Hauptmotor, Geschwindigkeit-Kontrolle
Power interfacing / K14 Main motor speed control R gulation vitesse moteur principal Hauptmotor, Geschwindigkeit-Kontrolle
K15 Drum rotation ( off = inhibit ) Rotation cylindre ( retir = moteur inhib ) Leimtrommel, Drehung ( aus= verhindert )
+ suction bar speed
Service manual BB3000 Component location fuses and relays July 2001
Programmable logic unit.
Identification Control PLC # EPROM #

Model (not programmed) (programmed) *
BB3000 9132011 9422025
Description
- Backup battery Control board (top)
under this corner PLC 1 AT
of top board. IN.H External 24V DC
Negative facing board. 15 power
0V DC supply
- To replace at least 24V
every 7 years. 5V Supply of
12 GND next boards
- Battery shape: Off On
coin IEC #: CR 2032 1 16
2 17
- Insert new battery 3 18
4 19
within 5 minutes from 8
removal to keep the Input
connector
program save.
- Flashes during one Run Alarm
week when it is time indicator battery 4
to replace the battery.
Inputs ( X )
0
LEDS
Prog Outputs ( Y )
Green
Run 12 Red
(Re)programming instructions.
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 blank

PLC's, but if you recover, switch off prior to remove the chip.
9133093 * Supplied with this instruction sheet Rev. 03-98 Life of battery
2 / 21
ADJUSTMENTS
Adjustments
Electrical
Main motor speed (re)adjustment (Kbic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3/ 1
Carriage shifting and drum rotation motor control (front rack) . . . . . . . . . . . . . . . . . . . .pg 3/ 2
Cover clamp motor torque limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3/ 3
Suction bar speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3/ 4
Mechanical
Cover clamp clutch spring tension . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 5
Procedure to re-time gears on the cover station ... . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 6
Adjustment of the position of the stationary knife .. . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 7
Alignment of the sections . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 3 / 8
ON
OFF
May 1999
3
c.p. bourg S. A.
N. V.
Carriage drive motor speed (re)adjustment
n.b. the boards are adjusted in the factory prior to their shipment.
Why?
¥ To reach the optimum operating speed OFF
ON
BB
R
II
When?
¥ Never, under normal circumstances.
¥ When the carriage bangs at limits (after running in period?).
¥ When the production rate gets lower than usual.
Main motor
¥ When motor or speed regulation boards has been replaced. speed regulation
Control
panel
Kbic
Procedure
J1
¥ Leave all trimpots like illustrated as a basic adjustment. (accel. is fully C.C.W) Cover clamping
motor torque
¥ Connect voltage meter between A+ & A— limit board
¥ Remove J8 or F2 to disable the carriage drive clutch ON
OF
F
F2
Minimum speed
The reading should be 40V D.C. when idling. J10
If the reading differs, turn trimpot "min" until reading is 40V D.C. J9
J8
Maximum speed
Switch off millling motor ( )
Start binding cycle (catch and tap missfeed detector actuator).
The reading should be 180V D.C.
2 3
If the reading differs, turn trimpot "max" for 180V D.C. reading. ON 1 4
3
4
5 6
7
OFF 2 9
¥ Double check the voltages. Adjustments are interdependant. PROGR. 1 10
¥ Restore the binder to an operating condition.

Control panel
Main motor
speed regulation
board
326 R 327
Y4 Y7
Carriage speeds (k14) (k13) Volts
A+ L1 L2 - minimum = idle 0 1 40V
R17 +F F-
318
- variable = milling "ON" 0 0 40 < V < 180
328
317 - constant = close notching 1 1 63V
R19 A-
- maximum = milling "OFF" 1 0 180V
ACCEL
329
225 P2 I1
311
MAX MIN IR CL
J16 P3
I2
315 1 326 P1
WHITE RED
206 2 327
328 Carriage translation
310
314
312
313
316
207
3 329 brake clutch
251
253
262
308
P3-7
263
307
309
11 304
From To From
To
To/from J22
12 13 11 C2
PLC J15
10
12
PLC PLC
2
4
6
8
torque Control
1
3
5
7
9
output limiter input output 223 11

224 12
panel 225 13
J1 J3 J5 J6
J2 J4
J13
1 215 1
2 216 C
F2 3
4
214
213 3
J40 J12 J11 J7 5 217 13
6 218
7 219
8 220
4 L3 15
3 L2 C1
206 6
2 L1 POWER BOARD K14 K13 207 7
1 227
J8 2 223
1 N 3 224 210 10
211 11
J10 J9
Drive
motor
12
10
8
6
4
2
11
7
5
3
1
6
319
348
318
202
243
316
314
312
310
210
M
240
067
317
201
242
315
313
311
211
209
Service manual BB3000 May 1999
3 /1
BB3000 Carriage shifting and drum rotation
motor control (front rack)
Main motor
speed regulation (Re) adjustment
board
326 R 327
see page 3 / 1
A+ L1 L2
R17 +F F-
328 318
317
R19 A-
ACCEL
329
P2 I1 Leave trimpots "IR","CL",
311
225 MAX IR CL
J16 P3 MIN
"ACCEL", like illustrated.
I2
315 1 326 P1 i.e. fully c.w. ( )
WHITE RED
206 327
2
328
310
314
312
313
316
207
3 329 Carriage translation
brake clutch
251
253
262
308
P3-7
263
307
309
11 304
From To To From
PLC J15 To/from J22
10
12
PLC PLC
2
4
6
8
torque Control
12 13 11 C2
1
3
5
7
9
output limiter input output

panel 223 11
224 12
J1 J3 J5 J6 225 13
J2 J4
J13
Power board F2 1 215
2 216
3 214 1
J11 J7 4 213 C
J40 J12 5 217
6 218 3
7 219 13
8 220
4 L3 K19
K16
K15
K14
K13
3 L2 15
2 L1 C1
F9 1 227 206 6
WIRING 1 N K12 J8 2
3
223
224 207 7
J10 J9
Drive
12
10
8
6
4
2
11
209
9
Carriage motor
7
5
3
1
319
348
318
202
243
316
314
312
310
4K7
210 variable 6
speed
240
067
317
201
242
315
313
311
211 M10
7
ELECTRICAL
Main motor speed

J11 K19 J10 regulation board
F9 J16 C1
L1 2 7 317 L1
N (L3) 1 8 318 L2 A+ 328 2 206 6 036
315 1 326 47 327 M 10

1 25W
Y44 10 K16
(M10 2 316 A— 329 3 207 7 037
slow)
J1
J9 Y4 Y7 D.C. V I (Amp.) Speed*
Y40 Run
7 313 I2 (AT A+) (in 329)
(M10 14 K15
on-off) 8 314 I1 P3 P1 P2 0 1 40V 0,4 Min
1/6 209 312 1 1 63V 0,6 Constant
MCU
Y7 23
+ 2 4K7 1 0 180V 1 Max
K13
3/4 211 310 0 0 Pot. 0,4 < I < 1 Variable
F2 5 311 dept.
Y4 26 K14
225 13 2
Y14 8 K12 3 224 12 4 L7
Brake * According to the(de) energizing
Clutch / of K13 (Y7) and K14 (Y4)
J6 2 223 11 3 L5
Brake
X44 Power board J8 C2 P103 P50 J30 Clutch
3
Clutch safety March 2002
S44
(high for black pointer over green one)
3 /2
Cover clamp motor torque limiter adjustment
Purpose: 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. J22
Control
panel
Maximum torque adjustment
Kbic J15
¥ Repeat the above adjustment with the pressure knob on maximum. J14
J1
¥ The reading should be 5 amps maximum. Cover clamping
¥ Adjust the maximum pot if necessary. J2 motor torque
limit board
J4
ON
OF
F
J2 J15
J22 J4
Clamp 9421204 J10 J7
10K
pressure 2
J9
knob
J8
Y47 10
Y46
Y45 K21
MCU J1
4 TP min
3 R19
100
2 J14 min
R20 Torque
Cover
clamp M
10 1 R21 adjust TP min
motor 9 0V max
2M2 R23
100
C2 R22
R19
TP max 100
F12 min
6,3A R20 Torque
R21 adjust
max
2M2 R23
100
2. Voltage measurement R22
Control the logic function of the PCB up to the power stage.
TP max
Minimum torque adjustment 0V
¥ 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. Service manual BB3000 May1999
3 /3
R1 470 ‰ 1 1
Suction bar full and slow speed adjustment.
R2 220 K‰ J5 J6
R3 1 ‰ 30 34 Purpose: for the fast and smoothy transfer and the
R4 100 K‰ accurate positionning of the cover.
R5 2K2 ‰
R6 2K2 ‰ Preliminaries:
R7 100 K‰ - Select binding mode I or II.
R10
R8 100 K‰ - Check that the suction bar is home ( fully out )
R10 8,2 ‰ 10W - Lock ( tape ) the actuator of the switch at the end of
R1 the suction bar in activated condition.
F3 C1
R2
R3
FET IRF540 R5
R6 K3 K4 J7 - Disconnect one of the bar motion motor feed wires.
D22 BAT85 ( J71 or J72 )
1
R4
5
C2 IC2 TRP
C1 100 F C8 Important ! Read complete procedure before
2
1
C2 220 F 2
F4 making the following actions
C3 1 nF K5 3
5
D23
C4 0,1 F cer D22 IC1 TRP IC3 C6
C5 0,1 F cer 1
Procedure:
1
4 - Depress the green buttons to start a binding cycle.
C6 10 pF cer C5 R8
C8 0,1 F cer F5 C4 R7 5 - The suction bar obviously stays in home position
D24
K6 ( its motor being disconnected )
ZD 12V ZD C3 6
- Trim TRP1 for 8V between and
IC1 NE555
FET1
7 *
- Pull the chain of the suction bar until its flag is
IC2 40107 between sensors X36 and X37.
IC3 CA3160 Trim TRP 2 for 8V over motor terminals ( J71 and J72 )
*
3 /4
- Rewire the loose motor wire within one minute to

12V
J625 2
prevent slow down resistor R10 from overheating.
C8 7 IC3
D22
R2 R4 R5 R6 3+ 6 COVER PICKING
R8 4 DETECTOR
ZD IC2 IC2 SUCTION
Y5 DIS
RES VCC 1 6
5
BAR
R1
MCU bar R3 TRES OUT 3
C2 2 7
slow TRIG IC1 C6
GND CV
motion C5 D23
TRP1 SUCTION BAR INNER
C4 TRP2 R7
instruction C1 C3 X37
LIMIT DETECTOR
D24
X36
SUCTION BAR
Full speed adjust. Slow speed adjust. SLOW DOWN
R10 ( Fierce starts can result in cover ( Accuracy of home and (OUT - IN)
versus suction cups slipping ) inner bar position ) SUCTION BAR
K3 MOTION MOTOR
J7 C2 (IN - OUT / OUT - IN)
k4 in - out
3
1
Bar motion
FET ¤ Date: Index
2 4 out - in July 1996 A B
F3 k5 POWER BOARD
2/2
4 AT
BB3000 ELECTRICAL DIAGRAM
SUCTION BAR SPEED CONTROL
24V from k2 Drawing ref.:
( see diagram 4.74.71.1450 )
Applicable from S.N. 8.700 through 61.10.4.0001 and up Supersedes: Superseded by:
Index B: identification for the suction bar detector 4.74.71.1451 A 4.74.71.1451

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 impossible
in both direction, except if the nipper is already closed (full inwards
travel).
2.11. If the result is not OK, repeat the procedure from § 2.7. with a third mark
5 mm further, if
Adjustment collar this is still not
1 enough, re-time
the gears.
2
5 mm
Bushing
Catch Stop pin
Service manual BB2005 / BB3000 — Rev. April 1997
3 /5
Procedure to re-time gears of the cover station
Necessary 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.
OPERATOR SIDE
BB3000 OFF
ON
FRONT
NIPPER
2
REAR
NIPPER
34 3
3
34
4f
34
5
6
8
13
Service manual 3000
Rev. April 1997
3 /6
3
2,5 2
The clearance between milling blade and stationary knife needs 4
adjustment when strips of chips are collected in the waste bag 2
4 8
instead of small pieces of paper dust.
Preliminaries (retrofit only) 3
- Slide block to the utmost left (slots-screw 1 ). 4 STATIONARY
2 KNIFE
- Lay stationary knife on support plate (screws 4 protrude)
- Line-up close long edge of stationary knife with 2 8 3
carriage fixed jaw (screws 3 and machinist 3 4
scale caution: fragile threads in alloy). 4
1
* 1
5 1
3
3
4
3 /7
Milling
blade 3
CARRIAGE
(FIXED JAW)
2
KNIFE 3
SUPPORT 4 4
1 PLATE
ST. KNIFE
SUPPORT PLATE
1
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 22 ).
ST. KNIFE
Vertically: Adjust screws 4 for a minimum gap between stationary knife and blade.
n.b. - The gap is not visible - proceed acoustically* Notching
- The rear screw 44 tilts the stationary knife Highest tooth knife
- Loosen the locking nut of screws 4 enough to turn them freely. (coloured) of
Slide now block back. Lock 1 when it just clears any point around the blade* . milling blade
BB3000 # 61.10.4.5569 and up
* Rotate blade with carefulness in C.C.W. direction to reveal and eliminate any audible rubbing. BB2005 # 64.20. . and up
A couple of adjustments can interfere - check and readjust as required. Oct. 1997
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.
Drum
- 1,5 mm* Spreader
Zero level Nipping up
+ 0,8 mm 0 mm + 0 Lever up : - 0,2 mm
(Coloured
tooth) - 1,1 mm Drum scraper — 0,05 Lever down : - 1,3 mm
Max gap Angle : 30¡
= 3,5 mm * Position : fully up
Zero level (jogger fully up: 0,0 mm)
Jogger Notching / m
illing Cover plate
Glue
tank
(jogger fully down: -2,2 mm)
17
Solenoid
Knife Adjustment e
(slotted) plat
v er
3 /8
Locking
Co
2
fl 1.5 mm*
3
19
19
10
Min
17 gap Max
19 gap
Spreader blade
Adjust when glue is at 140¡C (coolbind) level adjust
Adjust when glue is at 160¡C (1122R)
¤ Date: Index
April 2000 A B C
ALIGNMENT OF THE SECTIONS
¥ Tolerance on distances: 0,05 mm (comparator) unless otherwise specified. BB3000 (IN OPERATING CONDITIONS)
* Applicable for the viscosity of the glue we supply (cool bind). Supersedes: Superseded by: Drawing ref.:
Lift drum to -0,8 mm and reduce scraper gap to 3 mm for glue 9.195.025 (1122R)

SPARE PARTS
Spare parts list
Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 1
Fuses & relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 2
Switches - Cells - Buttons thermostats- boards . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 3
Motor & solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 4
Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 5
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 6
Carriage drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 7
Jogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 8
Notching & milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4/ 9
Gluing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 10
Cover clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 11
Cover station - suction bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 12
Suction bar drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 13
Suction air cut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 14
BBR (output unit - bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 15
BBR (output unit - up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 16
Index & recommended parts for one year . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 4 / 22
ON
OFF
4
November 2003
c.p. bourg S. A.
N. V.
Applicable to BB3000 from S.N. 61.10.0.0001 and up 1 2087994 (Assy)
2 2086978 (Little model)
2086979 (Big model)
3 2087701 (Plexi)
4 2083110 (Funnel)
25 5 2087702
3 4 6 9401849
26 7 2087101
28 22
2 8 2087170
Guards quarter 1 5 9 9402180
21
turn fastener 20 23 10 2087102
u rg
. bo 11 2081998
c.p
12 2080434
13 9195025 (1122 - R 20 kg)
18 -
+
-+
-
14 2080997 (One pair)
2985286 (Wheel only)
9199475
9 0
913902
17
15 2985279
16 27 919947
6
16 2985283
15 919
+
950
4
17 2985282
18 9199431
10 19 2080998
4 /1
19 20 9139434
9139000 (version 2)
9 6 21 9199476
ON
OFF
22 9139029
23 9199475
BB 24 2084998
R
25 2086815 (Protection band)
26 9139044
7 27 9199504
8 28 9139433
Option 30 2087998 (Tool box)
11 2083995 (Side gluing kit)
13 Option
(pg. 15 & 16)
12
1122R
Gl
u 14
20 e Index D: Item # 13 corrected
Kg 14 ¤ Date: Index
Dec. 2000
A B C
X
BO 24 ILLUSTRATED SPARE PARTS LIST D
30
OO
L BB3000 GUARDS
T Supersedes: Superseded by: Drawing ref.:
1C 1
+
-
F15
F19
F7 F12 F13 F14 F20 F16 F17 F18
K21
¥ K2 9169084
9169084
¥ K20*
9169090
¥ K1 F1
F2 F4
F3
F4
F3 F5
OF F6
F
ON
K3
K4
K5
K6
K7
¥ K19 K8
K9
¥ K18* K10
F8
K17 F9 K11
F10 K12
K16 F11 K13
K14
K15
Fuses Rating Part # Protected circuitry Relays Part # Controlled component
F1 2,5 A 9124035 Panel, PLC outputs - turbine ¥ K1 9169016 Air valve
F2 3,2 A 9124017 Clutch - brake - air valve ¥ K2 9169085 24V to PLC
F3 4 A 9124008 Suction bar transfer K3 9169907 Suction bar slow motion
F4 2,5 A 9124035 Suction bar up / down K4 9169907 Suction bar in - out
F5 3,2 A 9124017 Shutter opening / closing motor K5 9169907 Suction bar out - in
F6 2,5 A 9124035 Carriage clamping motor K6 9169907 Suction bar up - down
F7 2,5 A 9124035 Drum heating resistor K7 9169907 Shutter opening
F8 7 A 9124094 Transformer primary - cooling fan K8 9169907 Shutter closure
F9 2,5 A 9124035 Main motor K9 9169907 Carriage opening
F10 5 A 9124018 Tank heating resistor K10 9169907 Carriage closure
F11 1 A 9124030 Jogger K11 9169907 Air shut-off valve
F12 6,3 A 9124016 Cover clamping motor torque limiter card K12 9169907 Carriage clutch
F13 20 A 9124080 Mains: phase L1 230V or 380V K13 9169906 Main motor speed control
F14 20 A 9124080 Mains: phase L2 230V or 380V K14 9169906 Main motor speed control
F15 20 A 9124080 Mains: phase L3 230V or 380V K15 9169906 Drum rotation (off = inhibit)
F16 15 A 9124031 Power supply low voltage K169169907 Motor brake
F17 2 A 9124026 Scraper heating resistor K179169907 Jogger
F18 1 A 9124030 MCU ¥ K18* 9169092 Glue tank heating
F19 4 A 9124008 Turbine ¥ K19 9169087 Main motor
F20 Adjustable 9124093 Milling motor Set to 4 A for 380V ¥ K20* 9169092 Drum heating
Set to 6,3A for 230V K21 9169047 Cover clamping
All fuses are slow blow
* Static relay 5A 380v (See pg.6/2)
¥ Solder type
Index A: New rating for F2 & F5
Date: Index
May 1999
ON
A
ILLUSTRATED PARTS LIST
OFF
BB
R
BB 3000 FUSES & RELAYS
Supersedes: Superseded by: Drawing ref:
From S.N. 61.10.4.0147 onwards 2
4 /2
1 9150014
1
X49
2 9420996
3 9420706
X48 4 9420705
X42 1 5 2983716
1 6 9146183 (green)
X41 21 9146184 (blue)
X40
X47 20 7 9102033
X38
1 8 9146182
X46 6 X44
9 9146006
Cell 10 9146068
2 ampli. 3 4 7
X55 17
board X45 19 11 9146024 (momentary)
18
8 12 9146025 (push on/off)
X52
X51 13 9146179
14 9162034 (10K)
9162035 (47K)
1 5 16 15 9104070
X53
15 + 9104069
+ 9104072
16 9420693
9 14 17 2983264
10 13
11 12
22 Safety on
upper guard
23 Safety on
perspex
36 35 24
25
Cell
amplifier
board
18 2983952 (145¡C) 34
19 2983951 (115¡C) 26
X43
20 9124163 (190¡C) X32
21 2983991
33 29
22 2081998
23 9150046 X37
28 27
24 2983908 X36
25 9420696 29
26 9420730
27 9420707
28 2983886
29 2983852 30 X33
1
30 9146181
31 2983574 32 31 29
X35
32 2983286 29 X34
33 9422506 (10A)
34 9430668 Index D: Item # 36 added
35 9421954 Date: Index
May 1999
36 9170156 (47‰ 50w) A B C
BB 3000 SWITCHES - CELLS BUTTONS D
THERMOSTATS BOARDS
3C 3
4 /3
1
4
2 Y15
3 5
6
Y10
Y11 7
Y45
Y46
1 9151046 Y08
2 9136065 Y09
3 9430937 8
4 2085819 (120v brushless)
5 2981124 Y06
6 2084009
7 2984114 (rubber) 9
8 9431259 (suction bar in-out)
9 9430937 (sction bar up-down)
10 2990390
11 9430937
13 14 12 2981131 (motor: up to 61.10.4.5391)
9151128 (motor: 61.10.4.5392 and up)
12 2983985 (one brush)*
13 2984106
11 14 9137022
15 9151140
16 9151046
17 2985276
15
Y12 * ! watch life expectancy
Y13
17
10
16
Index D: items # 12 added

Date: Index
March 2002
A B C
BB 3000 MOTORS & SOLENOIDS
4B 4
4 /4
14
1
2
3 1 9260854
2 9412138
4
3 2086815
4 9119001
5 2081998
6 9430957
7 2085009
8 2085127
9 9120206
10 9167004
11 9421236
5
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
7
10 8
9
13 11
-
12 Index D: split of item 12 (Matsushita / ABB-ASEA)

Date: Index
Dec. 2002
A B C
ILLUSTRATED PARTS LIST D
BB 3000 OTHERS
5C 5
4 /5
From S.N. 61.10.0.0001 and up
8
Home 11 12
10 13
1 OFF
ON
X50 BB
R
II
7
1 2086978 (short)
9 2086979 (long)
X51
14 2 9117005
1 Y12 3 2980128
Y13 4 2086330
5 2086817
X52 15 6 2086012
2
Operator X52 7 9420705 (one pair: R.)
8 9420706 (one pair: Em.)
side 16
4 /6
9 2983978
10 9162051
11 9420996
12 9150014
13 2086977 (elastic)
14 2088893 (flat cable)
15 9421119
16 2982068
17 9117007
17 18 9430937
19 2982060
3 4 20 20 9175084
18
6 19 Index B: carriage assy # corrected
¤ Date: Index
May 1999 A B
5 Carriage assembly: 2086999
ILLUSTRATED SPARE PARTS LIST
BB3000 CARRIAGE
6
1 9137022
9 2 2086303
2 3 2086819
19 4 2083809
7 5 2086822
1 6 2981131 (motor: up to 61.10.4.5391)
ON
10 9151128 (motor: 61.10.4.5392 and up)
OFF
BB
R 2983985 (one brush)*
8 7 2086991
* ! watch life expectancy
8 2086010
12 11 9 2984106
10 2980117
14 11 2086820
9111002 (connecting link)
17 12 9421119
16 15
24 13 9111061 (161 links)
13 9111059 (5 links + stud)
14 2088893
4 /7
15 2990247
16 2990248
To drum 17 2086977
18 2086011
10
19 2086307
25 3
20 2086325
21 2086304
20 4
22 2980012
23 004390800006
24 2086001
21 25 2984006 (connecting link)
22
6 5
18 23
Index C: different # for item 11
From S.N. 61.10.0.0001 and up
¤ Date: Index
Oct. 1996 A B C
BB3000 CARRIAGE DRIVE SYSTEM
7B 7
1
6 2
ON
OFF
BB
R
II
1 2981411
2 2980125
4 3 2982061
4 2990389 (50 Hz: 4 each
60 Hz: 2 each)
4 /8
3 5 2990390
6 2080998
7 2990228
5
3
Index A: item # 7 added
¤ Date: Index
July 1997 A
BB3000 JOGGER
Applicable to BB3000 from S.N. 61.10.0.0001 and up
8
22 5
20 21 33
12
4 10
13
17
OFF
ON
25
BB
R
II
26 14
15
11 1 9151140 17 2082806
23 2 2984123 18 2985330
3 2082700 19 2082810
6 4 2082803 20 2990125
Optional outdoor fumes
3 5 2990126 21 2990124
exhaust kit: M 2083988 28 6 2082802 22 0091604008
+2082801 23 2082702
30
7 2082422 24 9412136
27 8 2082416 (50Hz) 25 9190599 (4x)
4 /9
9221843 (60Hz) 26 9190562

6 24 9 9412138 27 9260854
29
10 2082400 28 9217424
11 2990243 29 9401833
31 1 12 9218659 30 M 2083989 (option)
13 9218658 2083803 (coal filter)
7 14 2082312 2083804 (tissue filter)
8 15 2082104 31 2980029
19
35 16 2082809 32 2980009
32 33 9412615
34 2082124
35 2985284
2
Index F: add the new item 34 and 35
® Date: Index
9 March 2001 A B C
ILLUSTRATED SPARE PARTS LIST D E F
18 34
BB3000 NOTCHING /MILLING + CHIPS EXTR.
16 From S.N. 61.10.4.5578 and up Supersedes: Superseded by: Drawing ref.:
9E 9
1 2985102 (3 units) 2 2083990 assy 3 2983264 29 2981131 (motor: up to 61.10.4.5391)
2 2983991 (resistor) (items 27, 40, 4 2990355 9151128 (motor: 61.10.4.5392 and up)
2083002 (spreader) 41, 42 incl.) 5 2980132
Fume / smells 2983985 (one brush)*
20 6 2083000 30 2083700
extractor * ! watch life
7 2990315 31 9151046
page 9 expectancy
OFF
ON
8 2985263 32 9124163 (190¡C)

19 9 2985262 33 0000002999 (¿ 2mm)
10 2990319 0000001599 (¿ 1,5mm)
14 2983952 (145¡C) 34 11 2083701
15 2983951 (115¡C)
41 12 2980076
21
16 2983857 13 40 22 13 2083806
17 2990327 12 11
18 9146020
19 2083148
10
20 2083306 23
9111002 (3/8")
21 2083307 9
22 2083800 (grad. band) 8
23 2083310 (wheel) 7
26 1
24 2083412 (¿ 2mm) STD
2083416 (¿ 1,5mm) T. kit 27
25 2083152 (scraper) 3
4 /10
26 2083809
27 2083807 To clutch 36
28 2086822 (Pg. 7)
38
35 6
39 25 34 2985261
32 4
35 2083153
42 36 9175078
29 28
33 24 37 2985276
33 38 2983417
30 39 2980026
37 40 0047200470 5
35 41 2990213
Side gluing retrofit kit: 2083995
42 2083104
15 Index F: items 40 / 41 / 42 added
¤ Date: Index
14 October 2003 A B C
ILLUSTRATED SPARE PARTS LIST D E F
17 16 18 BB3000 GLUING SECTION
From S.N. 61.10.0.0001 and up Supersedes: Superseded by: Drawing ref.:
31 Tank + drum assembly #2083999 / 10 10 E 10
43 39 ® Date: Index
Nov. 2001 A B C
35 ILLUSTRATED SPARE PARTS LIST
BB3000 COVER NIPPING
OFF
ON
40
11B 11
BB
R 25 2084817 29 2084821
26 2084822 30 2084168
See 27 27 2990178 31 2084402
OPERATOR SIDE pg. 3 28 2084330 32 2084801
41 Index C: item # 4c and
25 24
4e corrected
43
23
2 26
1 41
See pg. 3
1 2084427 34 22
2 2084420 37
3 2980128 28
4a 2084337 3 29
4b 9166058 30
4 /11
4c 2980138
4d 2084338
4e 9401991
20
5 2084805
6 2084802 21 36
7 2980124 42
8 2084806 4c
9 9127036
33 10
10 9420696 4b
11 2084400
4a
12 2980128 4e
13 2984114
14 2088970 34
15 2084009 assy 32 33 2084825
19 34 2084438
16 2084814 17
35 2084426
+ 9111002 4d 16 36 2084013
17 2084809 5 37 2982078
18 2084992 M14 38 2980126
19 2085819 M9 (117v) 38 9 39 2084014
14
20 9260216 (2x) 6 11 12 40 9412242
21 2981120 M15 7 15 18 41 9412243
22 2084816 31 42 2084002
23 2088972 13 43 9101003
24 2088973
8
Applicable to BB3000 from S.N. 61.10.0.0001 and up
30
1 2085009
35 2 9261101
3 3 2085127 blade
"T" 9260503 4 2986048
2 "Clip" 9199843 5 2983886
29 6 2982066
32 7 2986057
5 8 2084335
6
9 2084431
10 2986048
36 11 2085990
28 12 2085334
13 9410564
22
11 14 2085332
1 21 15 2085425
7 34
4 31
8 25 26
26
24 10
9
16 2085418
23
17 2085224
18 9221851
19 2085219
20 2085350
21 9260633
22 2990237
14 23 2085427
20
33 15 24 2084430
27 25 2084160
26 2085996
27 2085434
16
28 2986001
29 9431618
30 2085812
13 31 2085810
12
32 2990339
33 2982073 spring
19 34 2085322
18 35 2085813
36 9413930
17
Index C: new assy # 36
18
® Date: Index
Jan. 2003
A B C
OFF
ON
BB
R
BB3000 COVER STATION - SUCTION BAR
II
12
4 /12
43 42 28 2085014 42 2085983 (assy)
6 29 2085400 43 9161082
43 30 2085311 44 2984110
•
• 31 2085407 45 2984109
•
44 32 2982069 46 2085987 (assy)
45 33 2085700 47 9161084
34 2080998 48 2984109
• 38 35 2085805
46 47 36 2980012
• 8
48 37 9150014
• 22
4 7 38 2990331
See 39 2085403
pg. 12 (17 incl.)
5 9
40 2085010
10 16 41 9200933
13 15
14
11 17
3
12 32
2 31
4 /13
23
19 20
39
30 29 18
34 8 25 20
22
16 21
1
33
25 23
1 2085814 10 2085106 19 2085306 40
22 28
2 2085803 11 9175010 20 2085801
3 2085802 12 9131013 21 2980075 12
Suction 4 9431259 13 2085347 22 2980118
bar 24
5 9430937 14 2980133 23 2085113 35
6 2985287 15 2085430 24 2085300 27
26 41
7 9422033 16 2085301 25 9175084
8 2983852 17 2085816 (Teflon) 26 2085801 36
9 2085112 18 2085808 27 9217422
Index
37
® Date: NO
FFO
Nov. 2000 A B C
ILLUSTRATED SPARE PARTS LIST Index C: items # 42 to 48 added
BB3000 SUCTION BAR DRIVE SYSTEM
R
II
BB
13B 13 Applicable to BB3000 from S.N. 61.10.0.0001 and up
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 9.216.102
10 9.216.100
11 9.190.103
12 9.172.003
13 9.260.667*
14 9.260.668*
15 9.216.103
16 9.190.166
17 9.172.004
18 9.216.101
19 9.135.006
20 9.260.671
21 9.190.426
22 9.200.405*
23 9.157.025*
24 9.260.669
25 9.221.640
26 9.190.165
* Subject to
wear
ASSEMBLY # 9.430.957
¤ Date: Index
FEB. 1993

BB3000 AIR CUT OFF
Applicable to MOD"S" from S.N. 413.000 Supersedes: Superseded by: Drawing ref.:
to BB3000/9 from S.N. 8.700 14 14
4 /14
8 9150053 (Switch only)
Detailed 9261117 (Actuator)
Binder
page 16 9 9150073 (Switch only)
10 8003107000
8 9 11 P801000600
P1
ON
12 8001011000
OFF
Assy P2
13 7002021000
9580115 6 2 14 9430937
15 2990297
10 16 9135046
17 2080434
29 30 5 18 9135078
28 1
19 9169001
4
27 Steel 20 9124094 (7 AT)
2 9164004 (Fuse holder)
2 3 21 9008007800 (Switch only)
1
Nylon 9008006400 (Yellow cap)
9008004100 (Bulb)
4 /15
26 22 9146067 (Contacts only)

23 8002035000
11 24 8002016000
11
nc
25 9412609
M1 13 12 1 9012004200 (Assy) 26 8002021000
2 9121043 (Plug) 27 8002018000
co
14 9121042 (Female) 28 8002019000

M2 3 8002103000 29 8002024000
4 3304014000 30 8002023000
33 5 8003010000 31 8002007000
25 6 3602012000 32 8002006000
24 7 9124165 (1,8 A) 33 9177065
23
15 Index E: Update of the item # 2
1 22 Index
16 Date:
21 November 2003
A B C
17 ILLUSTRATED PARTS LIST
20 BB 3000 D E F
32 7 19 18 BBR - OUTPUT UNIT (BOTTOM)
31 Supersedes: Superseded by: Drawing ref.:
15 D 15
Binder
1 9126234
2 9175040
P1
3 9222270
P2
6 7 4 9261116
8
5 OFF
ON
5 9222271
4 9 6 9201475
3
7 2980024
1 2
8 9218613
9 9402109
10 10 9218620
4 11 11 9121042
12 9201474
6 12 13 9402366
13 14 9218616
26 15 9422007
16 9222269
17 9430937
15 18 9124157 (1,8 A)
4 /16
27
9 19 9218617
30
20 9260058
21 9218615
29 22 9410563
23 2980069
14
28 24 9218614
23 25 9201476
26 9165001
20
27 9261117
14 28 2084329
16 29 9150053
30 9121043
21 25 INDEX A: Uptade of the item # 11
19 18 17
Date: Index
24 November 2003
A B
22 23
BB 3000 BBR - OUTPUT UNIT (TOP)
1616 16
Index BB3000
Illustrated Illustrated
Qty Qty
Article Page Item 1 rst Depot Article Page Item 1 rst Depot
aid aid
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
7/11/03
4 /17
Index BB3000
Qty Qty
aid 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 /18
Index BB3000
Qty Qty
aid 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 /19
Index BB3000
Qty Qty
aid 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 /20
Index BB3000
Qty Qty
aid 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 /21
Index BB3000
Qty Qty
aid 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
4 /22

MAINTENANCE
Maintenance
Dust bag replacement frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 5 / 1
Main drive motor brushes life expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 5 / 2
ON
OFF
June 2001
5
c.p. bourg S. A.
N. V.
BB3000 Dust bag replacement frequency
Millions of mm3
of dust Warning: paper dust will ruin the glue and clog the machine if bag is not replaced in time
50
1. Spot the number of millions of mm3 of dust corresponding to
the milling depth.
2. Divide this number by the length of the spine ( expressed in mm )

45
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
40
9.500.000
= 3200 books per bag ( 1 replacement every 12 3/4 hour:
297 x 10 BB3000 full speed )
2. 0.5 mm milled off the 279 mm (11") long spine of a 12,7 (1/2") mm thick book
9.500.000
= 2680 books per bag ( 1 replacement every 10 3/4 hour:
35 279 x 12,7 BB3000 full speed )
3. 2.2 mm milled off the 385 mm long spine of a 45 mm thick book
2.200.000
= 127 books per bag ( 1 replacement every 1/2 hour:
385 x 45 BB3000 full speed, max thickness, max length )
30
5
25
20
15 3 Max.
BB3000
Ex: 3
10
Ex: 1, 2
2
0 0.5 1 1.5 2 2.5

Milling depth ( mm )
Rev. August 1997
5/1
TECHNICAL BULLETIN: ABOUT: Top range ENCLOS:
TECHNICHES RUNDSCHREIBEN: 99-05-01 BETRIFFT: binders ANLAGE:
BULLETIN TECHNIQUE: CONCERNE: ANNEXE:
This bulletin contains new and upgraded documents about:
Preventive maintenance
Motor : 9151128
One brush : 298 3985
Inspection: 1rst after 100 hours

2nd after 300 hours
n.b. ¥ Wear limit: 6mm
¥ Always replace the set
Maintenance
Remove 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.
Applicable to :
BB2005
BBF2005
BB2006
BB2008
BB3000
This page will be in next version of service manual
c.p. bourg S. A.
N. V.
5/2

TROUBLE SHOOTING
Trouble shooting
Non stop test procedure
Warm-up period shortening (for service purpose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 6 / 1
Power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 6 / 2
Heating circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 6 / 3
Nipping motor torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 6 / 4
ON
OFF
6
June 2001
c.p. bourg S. A.
N. V.
Trouble shooting
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.
X14 Process start

(green) X32
X15 Process start

(green)
X03
Emergency
X12 Drum
heating on - off
X13 Carriage
opening (blue)
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 )
OF
F
ON - 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.
Main switch Switch the binder OFF/ON to return to the normal
operation mode (for quality bindings).
Service manual BB3000 February 1997
6/1
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 you
check 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
K20 Drum heating
ON
OF
F
K19
K18 Glue tank heating
K17
f i ed b
er t i
C
c.p. bourg S. A.
N. V. A.M.
ISO 9001
6/2
T1 TROUBLE SHOOTING
L3 L1 L2 N(Y) / L3( ) September 2001
19v
J10 2 J17 C5
R F17 J28
C3 10 6 Spreader
F15 F13 11 – 23 ‰
115¡C 19v
+ 24v DC Thermostat
11
cold
selector 7
T1
F16 145¡C 4 J11 2 F
10 Tank heating
J17 Red pointer
C5 J10 5 1 1 resistor 9 2 2 J11 1 Green (selected
190¡C pointer temp)
8 12 13 8 13 J3 3 K 18 – 65 ‰
C1
8 cold C1 J10 6 = 40
¡C
145¡C 115¡C Solid state F7
J3 F1
J12 4 3 3 Drum 10 4 4 J12 2
J28 Solid 190¡C
2 state
K 20
J1 24 – 150‰ cold 50 250
- Kindly note that any breakage in the tank heating circuit is neither Needs to be
C5 notified nor evident to notice. 190¡C positioned Black pointer
12 7 - The heat developped by the sole drum resistor being sufficient to 0.1mm away (actual drum temper)
190¡C from drum
enable S44 and even S55, bindings can be performed, in degraded
mode however (longer warm-up, curdled glue, unefficient glue cut-
6/3
off etc...).
J71 Drum
S44
J5
J56 J72 24 -If you where to experiment such defects, always start your S55
Y38 investigations with the supply of the tank heating
J4 resistor(F10, K18, etc...)
26 6 6 X12 115¡C J28
R 145¡C
Control T1 +
F16
panel
-
1 MCU F17
J134
J134
F13 F15
F14
1
Tank
J21 J17 J21
J72 resistor Thermostat
38 F7 J1
MCU Selector
J73 C5
C6 36
S44 S55 7 J12 J4
J3 J71
¥ 8 33
C6 J73 K20 ON
J5 C1 4
OF
F
35 5 5 X55 F1 ¥ OFF
ON
Drum Binding 13 BB
R
1 9 II
rotation 5
disabled K18 J11
J5 1
disabled 13 16 16 X44 J10 1 J1 1
BB 3000
F10 15 Heating circuitry
S44 closes when black pointer reaches green pointer
S55 opens when black pointer reaches red pointer 3
Resistors (tank - drum - spreader)
Trouble shooting
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
BB3000
X38
X39
J22
Control
panel
Kbic J15
J14
J1
Cover
Coverclamping
nipping
J2 motor torque
limit board
J4
ON
OF
F
J2 J15
J22 J4
Clamp 9421204 J10 J7
10K
pressure 2
J9
knob
J8
Y47 10
Y46
Y45 K21
MCU J1
4 TP min
3 R19
100
2 J14 min
R20 Torque
Cover 10 1 R21 adjust
clamp
motor
M 9 0V max
2M2 R23
100
C2 R22
TP max
F12
6,3A
Service manual BB3000 March 2002
6/4

HISTORY
History
Developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 7 / 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 7 / 7
Wiring instructions for the replacement of the discontinued 230v B.B.C. / ASEA P.L.C . .pg 7 / 8
ON
OFF
7
June 2001
c.p. bourg S. A.
N. V.
Page 1
BB 3000 - Developments 06/04/95
Starting Section Purpose / description Details / illustration/

with S.N. retrofit form
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 catalogue
assembly - 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.
7 /1
Jogger Different electro magnet ( suitable for 50 and 60 Hz ) part #:298.1130

assembly 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 speed
readjustment ( trim 1 on power board ).
Page 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 # 208.4152
clamping 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.
7 /2
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. 90.10.01
retrofit 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
Page 3

8186 Carriage Different main motor and sproket . Parts.catal. Page 46
transfer
Stronger spring: 298.2068 ( Bolt lever mechanism ) Item 48, page 152 of
parts catalogue
Glue drop Hengstler counter instead of Zenith Up to S.N. 8050: fi Retrofit:assy 208.6985
adjustment 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 # 299.0363

7 /3
station
Cover Protection tube over shutter shaft ( no longer risk of glue dropping on shaft ) Retrofit kit 208.4989
clamping 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 does
not bind for more than 10 sec.
Glue film Modification of mechanism. Retrofit kit 208.6982

length ( 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
Page 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-
7 /4
international rules of technical reasons. ponding drawings

F6 / 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 possibility
the status of the wide ( progr 23 ) / narrow ( progr 22 ) carriage opening selector on only after connection
control 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. 90.12.02
clamping 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.1.74.71.1263
1.74.71.0900 B
Page 5

8260 Glueing The scraper works at a higher temperature than before for a better removal of the
excess 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 binders
and 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
7 /5
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 A
area carriage home returns.
2 models of cell amplifying boards. 9.420.696 in cover clamping area difference
9.420.996 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 no
8519 difference is still not adjustable ). longer available.
(USA)
Page 6

8334 Cover Stronger front clamp limit TB 92.01.01
clamping
8500 PLC - Different model ( identical look but powered in 24 V D.C. ) Diagrams
N.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.
7 /6
8536 Carriage The grey cable ( with 10 black wires ) connecting the carriage to the frame of the TB 92.0
binder ( item 102 on page 92 of illustrated parts catalogue ) is replaced by a flat
flexible conductor cable for a longer life expectancy
Please specify on the order form, whether kit is for BB3000 with S.N. < 8261 Retrofit kit # 2.08.6976
or 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
NEW STYLE BB3000
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
Page 7

8700 through PLC Different (smaller) model (Matsushita) - different logic / power interface
61.10.4.000 Power supply Toroïdal transformers No retrofit on
and 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 possible
as 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 bar
outwards and inwards motion )
Retrofit to binders back to S.N. 8700 is advisable, easy and cheap. Eprom prog BB3004
7 /7
Wiring instructions for the replacement of the B.B.C. /
ASEA P.L.C. in a BB3000 with serial number below 8500
220 V Cooling fans
Original
wiring
RUN 24V 0V 00 02 04 06 10 12 14 16 20 22 24 26 30 32 34 36 40 42 44 46 HZ
220V STA STO 0V 01 03 05 07 11 13 15 17 21 23 25 27 31 33 35 37 41 43 45 47 HR
EINGANG
(INPUTS) EINGANG
00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17
RUN PROGRAMMABLE
20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37
40 41 42 43 44 45 46 47 HZ HR
220V LOGIC CONTROL

9132007 NETZ RUN STA
50 51 52 53 54 55 56 57 60 61 62 63 64 65 66 67
(discontinued 70 71 72 73 74 75 76 77
model) (OUTPUTS)
AUSGANG
AUSGANG 07 KR 264 BBC
W 0 50 51 52 53 54 55 56 57 W 1 60 61 62 63 W 2 64 65 66 67 W 3 70 71 72 73 W 4 74 75 W 5 76 77
OPERATOR
SIDE
Different wiring - Do not reconnect the wires with

0V required for the
the 220 V to the P.L.C. any more.
supply of low - Leave them feeding the cooling fans.
voltage PLC
RUN 24V 0V 00 02 04 06 10 12 14 16 20 22 24 26 30 32 34 36 40 42 44 46 HZ
+ 24V — STA STO 0V 01 03 05 07 11 13 15 17 21 23 25 27 31 33 35 37 41 43 45 47 HR
2,5 A EINGANG
(INPUTS)
2983260 00 01 02 03 04 05 06 07
EINGANG
10 11 12 13 14 15 16 17
RUN 20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37
PROGRAMMABLE
+ 24V — LOGIC CONTROL
40 41 42 43 44 45 46 47 HZ HR
NETZ RUN STA
50 51 52 53 54 55 56 57 60 61 62 63 64 65 66 67
70 71 72 73 74 75 76 77
2983874 9132010 (OUTPUTS)

AUSGANG
(NOT programmed) AUSGANG 07 KR 264 BBC
W 0 50 51 52 53 54 55 56 57 W 1 60 61 62 63 W 2 64 65 66 67 W 3 70 71 72 73 W 4 74 75 W 5 76 77
OPERATOR
+ SIDE
Rectifier
—
Transformer
9133241
Oct. 1997
7 /8

USEFUL
Useful, translated and obsolete items
Maschine Beschreibung (D, 1) ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 1
Maschine Beschreibung (D, 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 2
Description machine (F, 1) . . . ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 3
Description machine (F, 2) . . . ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 4
Réglage fraise et contre-lame . ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg 8 / 5
ON
OFF
c.p. bourg S. A.
N. V.
June 2001 8
Transportschlitten Endschalter, rechts
Bremse Transportschlitten
Schlittenbremsung X49
( links/rechts )
X48 Auswurfklappe, Schalter für Verschluß
Motor für Transportschlitten
( öffnen/schließen ) X42 Auswurfklappe, Schalter für Öffnung
Saugergestänge
innen/außen
Erlaubnis Tank-Thermostate
X41 X40
X47
Umschlagpresse unten
Automatischer Transportschlitten Kupplung,
GeschwindigkeitsEinstellung Schlittenbremsung Transportschlitten X38
(rechts/links) Umschlagpresse hoch und Saugluft Abschaltung
Hauptmotor
Y12
Transportschlitten, X46 Y13 Abstreifer
Endschalter,
Grundposition Thermostatfühler für Temperatur Leimtrommel
Leimabstreifer, Einstellung
X45 Fräse Motor
Trommelheizung
Taster für X52 und Papierspäne
Absaugung Wahlschalter Tankthermostat X44 X55
X50 eingelegten Y32 Leimwalzen Temperatur
Buchblock ( 115 / 145°C )
Einstellung
Verstärker
Platine Tankheizung, Wiederstand
X39
X51
Y01 Auflagenzähler
Kühlventilator
Transportschlitten, X8 Abstand - X15 Start - Arbeitszyklus ( grüne
Endschalter für Frässchlitze Lampen ) X14 gleichzeitig betätigen
Rüttler - Magnet
max. Öffnung Y43 ( eng/normal )
Transportschlitten X7 Fräsmotor, X13 Schlittenöffnung ( Lampe blau )

X53
Fühler für Transportschlitten, Ein - Aus
Obererposition Fühler für Rüttler, An - Aus
Saugluft-Einstellung
Schließung
Umschlag, seitliche Anpressung
X2, X5, X9, X11 Umschlagstation Anpressdruckdauer
X6, X4 Programm-Wahlschalter
X10 Schlittenöffnung ( eng/weit )
X03 Not-Stop X12 Trommelheizung, An - Aus

Automatische Drehung wenn Temperatur erreicht
X14 Start - Arbeitszyklus ( grüne

Lampen ) X15 gleichzeitig betätigen
Fußschalter
Service manual BB3000 — Machine Beschreibung (D,1)— Jan. 1997
Sicherung Wert Geschtzte Bestandteile
F1 2,5ATT Steuerpult - Autom. Ausgnge - Saugmotor

Sicherheitschalter
F2 3,2ATT Kupplung - Bremse - Luftventil
( Haube )
F3 4 ATT Saugergestnge, herein - heraus
F4 2,5ATT Saugergestnge, hoch - tief Sicherheitsschalter
F5 3,2ATT Auswurfklappe, Motor ( Plexiglas )
F6 2,5ATT Transportschlitten, ffnung - Verschlu§
F7 2,5ATT Leimwalzenheizung Dunstabzug

( 2. Khlventilator mit
F8 7 ATT Trafo ( primre Wicklung ) - Khlventilator
aktivem Kohlefilter Option ) Verstrker
F9 2,5ATT Hauptmotor
Platine Geblse fr
F10 5 ATT Tankheizung
Magnet fr Luftventil Y15 Saug-und
( auf/geschlossen ) Luftventil
F11 1 ATT Rttler Blasluft
F12 6,3ATT Drehmomentbegrenzungsplatine
F13 20AT Netz: L1 Motor fr

Umschlagpresse
Seitenpressung
F14 20AT Netz: L2 Heben + Schlie§en
ffen und Schlie§en
F15 20AT Netz: L3 Y10 Senken + ffnen
F16 15 AT 24V Stromversorgung Y11

F17 2 ATT Heizung Leimabstreifer Bchse fr
Y45
F18 1 ATT PLC Automat
Fu§schalter X32 Taster fr
X43 eingelegten
F20 Adjust Frsemotor berlast-Sicherung bei 220v: 6,7A Buchblock Y46
Frsemotor berlast-Sicherung bei 380v: 4A Taster, Saugergestnge
X37 ber Umschlagpresse
T = Trge
Umschlagansaug X36 Saugergestnge,
taster langsam ( innen/au§en)

TT = Supertrge
Gleichstrom
+
Versorgung - F16
Rckstellbar
Umschlagpres- Trafo F17
berlast -
sungmotor F20 F18
Sicherung Motor fr
Drehmomentbe- Autom. Senkung von
Frse motor Saugergestnge
Hauptmotor
grenzungsplatine F15 Steuerrelais Transport Umschlge Separatoren
Geschwindigkeitsplatine
F13
F14 ( hinein/heraus) Y08
K21
PLC X54 Y09
Seitenpressung, Automat
Umschlag X33 Saugergestnge,
CN1, Elektr. X35
Anschlu§ fr langsam (innen/au§en )
Tankheizung F12
Stundenzhler
Stehendauslage Y06
BBR Saugergestnge, Endschalter
F7 obere Position
K20 X34
F1
Trommelheizung F2 F3
Saugergestnge, Schalter -
O
F4 Startposition ( Ansaugung Umschalg )
Hauptschalter
N
O
F
F
Motor fr
K1 Luft
K2 24V zu PLC, ( Sicherheitshaube unten ) Saugergestnge,
F5
K3 Saugergestnge, langsam Anheben und Senken
F6
K19 Hauptmotor K4 Saugergestnge, innen - au§en
K18 Tankheizung K5 Saugergestnge, au§en - innen
K17 Rttler K6 Saugergestnge, auf - ab
K16 Motor Bremse F8 K7 Auswurfklappe, offen
F9 K8 Auswurfklappe, geschlossen VORSICHT: nur durch Sicherungen
F10 K9 Transportschlitten, offen gleichen Typs und Werten ersetzen
F11
K10 Transportschlitten, geschlossen
K11 Luftventil, offen - geschlossen
K12 Transportschlitten, Kupplung-Bremse
Leistung + Saugergestnge K13 Hauptmotor, Geschwindigkeit-Kontrolle
Geschwindigkeitsplatine K14 Hauptmotor, Geschwindigkeit-Kontrolle Service manual BB3000 Ñ Maschine Beschreibung (D, 2) Ñ Jan. 1997
K15 Leimtrommel, Drehung ( aus= verhindert )
Fin de course
droite
Frein chariot
Ralentisseur chariot
X49
( gauche - droite )
X48 Dtecteur fermeture volet
X42 Dtecteur pleine ouverture volet

Autorisation
Ouverture / fermeture
sortie rampe
chariot
aspiration Thermostats rgulation
X41
temprature bac colle
X47
Dtecteur position
Embrayage
Ralentisseur chariot X40
basse emboitage
Auto rgulation chariot / chane X38
(droite - gauche)
vitesse chariot
Moteur Dtecteur position
principal haute emboitage
Fin de course X46 Rpartiteur chauff
gauche
Sonde rgulateur temprature cylindre
Moteur
Variateur hauteur rpartiteur

fraisage
X45
grcage Rsistance chauffage cylindre
Dtecteur
vacuation Slecteur de thermostat X44 X55
X50 prsence
Y32 copeaux rservoir colle ( 115 / 145¡C )
Thermostat rgulation
de feuilles
Amplificateur temprature cylindre
cellule Rsistance chauffage

X39
X51 bac colle
Y01 Compteur de reliures
Ventilateur
Dtecteur pleine
ouverture chariot X8 Slection densit

X15Fermeture chariot + prise couverture
Electro aimant
grcage
Y43 ( deux boutons pousser et relcher
taqueur
simultanment )
Dtecteur position
X7 Fraisage - grcage
X53
marche - arrt X13 Ouverture chariot ( bleu )
haute taqueur Dtecteur
fermeture Taqueur
Rglage niveau aspiration
chariot marche - arrt
Rglage pression emboitage couverture
X2, X5, X9, X11 Rglage dure emboitage couverture
X6, X4 Slecteur du mode de travail
X10 Slecteur pr-ouverture chariot : forte / faible + mode d'jection
X03 Arrt d'urgence

X12 Chauffage cylindre marche - arrt
X14 Fermeture chariot + prise couverture
( deux boutons pousser et relcher
simultanment )
Pdale commande
taqueur
Notice technique BB3000 Ñ Description machine (F, 1) Ñ Jan. 1997

Fusible Valeur Circuit protg
F1 2,5ATT Pupitre de commande - sorties automate - commande turbine Scurit
F2 3,2ATT Embrayage - frein - soupape aspiration capot ferm
Scurit fentre
F3 4 ATT Moteur translation rampe succion
plexi ferme
F4 2,5ATT Moteur ascension/descente rampe
F5 3,2ATT Moteur ouverture/fermeture volet

F6 2,5ATT Moteur ouverture / fermeture chariot Extracteur d'air vici
( deux si filtre rgnration )

F7 2,5ATT Rsistance chauffe cylindre
Amplificateur Turbine
F8 7 ATT Transfo. alimention et ventilateurs
Y15 cellule aspiration

Electro-aimant
Soupape
F9 2,5ATT Moteur principal ventilation
commande soupape
de coupure
F10 5 ATT Rsistance chauffe rservoir colle couvertures
d'aspiration
F11 1 ATT Vibreur
Ouverture
F12 6,3ATT Limiteur de couple mot. emboit. couv. Emboitage couverture
fermeture
- Monte + fermeture
F13 20/15AT Secteur: phase L1
volet
- Descente + ouverture

Y10
Connecteur pour
F16 15 AT Alimentation basse tension
Y11 Y45
F17 2 ATT Rsistance chauffe rcleur
pdale vibreur
X32
Dtecteur
F18 1 ATT Automate programmable

X43 prsence
reliure
Y46
Dtecteur rampe au
F20 Adjust Protection moteur fraisage/grcquage en 220V: 6,7A
X37 droit de l'emboitage
Protection moteur fraisage/grcquage en 380V: 4A
X36
Alimentation basse tension
+ Dtecteur de Ralentisseur rampe
F16
prise de couverture la rentre
-
Protection moteur
T = fusion lente Transformateur F17
fraisage / grcage
TT= fusion trs lente F20 F18
( rarmement )
Limiteur du couple Relais moteur

Carte rgulation
F15
du moteur d'emboitage fraisage / grcage
vitesse moteur
F14
F13 Descente automatique
principal Translation rampe
sparateurs couvertures
Y08
Automate d'aspiration
K21 Emboitage
programmable
Y09
couverture
X54
Compteur d'heures
X33
F12
de mise sous tension
X35
Ralentisseur rampe
Connecteur CN1 en sortie

F7
K20 Chauffe cylindre

pour convoyeur
Y06
F1 grande capacit Dtecteur position
F3
F2
(BBR ) suprieure rampe
F4
Coupe circuit
X34
O
N
O
Monte / descente
F
F
gnral K1 Air Dtecteur rampe au

rampe d'aspiration
K2 24V automate ( scurits au repos )
F5 droit des couvertures
K3 Rampe ( translation lente )
F6
K19 Moteur principal K4 Sortie de la rampe
K18 Chauffe bac colle K5 Rentre de la rampe
K17 Vibreur K6 Ascension - descente rampe
K16 Frein moteur F8

K7 Ouverture volet
F9
K8 Fermeture volet
Attention
F10
K9 Ouverture chariot
F11 : ne jamais remplacer que par
K10 Fermeture chariot
K11 Soupape air aspiration des fusibles de mme type et de mme valeur.
K12 Embrayage - Frein chariot
Carte interface logique /
K13 Rgulation vitesse moteur principal
puissance+ vitesse rampe
K14 Rgulation vitesse moteur principal
K15 Rotation cylindre ( retir = moteur inhib ) Notice technique BB3000 Ñ Description machine (F, 2) Ñ Jan. 1997
3
2,5 2
Rglage de la distance entre fraise et contre-lame
Ce rglage est refaire lorsque le sac rcolteur de dchets 4

2
contient des bandelettes au lieu de poussire de papier. 4 8
Prliminaires (uniquement en cas de remplacement)
3
- Glisser le blochet vers la gauche (vis 1
1 ). CONTRE
4
- Appliquer les vis 4 de la contre-lame contre la tle support. LAME
2
- Aligner le long bord avant de la contre-lame et la
2 8
mchoire fixe du chariot (trois vis 3 + rglette). 3
3 4
4
1
*
1
5 1
3
3
4
MåCHOIRE
3
FIXE DU
CHARIOT
2
TïLE 3 4 4
1 SUPPORT
LAME CONTRE LAME
TïLE SUPPORT
1
Rglage de la position de la contre-lame
Horizontalement: la glisser pour permettre le libre passage des couteaux dans leur dcoupe (crous 2 ).
CONTRE LAME
Verticalement: le jeu entre contre-lame et fraise doit tre minimum. Rgler les trois vis 4 .
n.b. - La vis 44 qui est seule, agit aussi sur l’inclinaison de la contre-lame. Couteau de
- Les vis 4 doivent être libres pour monter / descendre la contre-lame, Dent la plus grcquage
débloquer leur écrou. haute (colore)
Rapprocher ensuite le blochet de la lame jusquÕ affleurer la dent la plus longue* 1
1 .
de la fraise BB3000 S.N. 61.10.4.5569 and up
* Tourner délicatement la fraise dans le sens anti-horlogique pour “entendre” et éliminer tout frottement. BB2005 S.N. 64.20. . and up
Des interactions existent entre les différents réglages / blocages. Les vérifier et retoucher si nécessaire. Oct. 1997
c.p. bourg S. A.
N. V. c.p. bourg S.A.
rue des Technologies, 22 rue Millewee, B.P. 85

B-1340 Ottignies (Belgium) L-7201 Walferdange (Luxembourg)
Tel.: + 32 (0) 10 / 62 22 11 Tel.: 352 / 33 24 47
Fax: + 32 (0) 10 / 61 69 03 Fax: 352 / 33 19 99
e-mail: export.be@cpbourg.com e-mail: cpbourg@pt.lu
web: www.cpbourg.com
c.p. bourg G.M.B.H.

c.p. bourg Inc.
Schweizertrasse 70 / 1 50 Samuel Barnet Bd.

D-72336 Balingen (Deutschland) New Bedford Industrial Park
Tel.: +49 7433 998 1680 Massachussets 02745 (USA)
Fax: +49 7433 998 1686 1285 New Bedford
e-mail: cpbourg_germany@cpbourg.com Tel.: 1/508.9982171
Fax: 1/508.9982391
e-mail: cpbourg@worldnet.att.net
c.p. bourg S.A.
SILIC 410
32, rue des G meaux
F-94573 Rungis (France)
Tel.: 33 / 1.46873214
Fax: 33 / 1.46875217
e-mail: cpb_france@cpbourg.com
http: //www.cpbourg.com
ified b
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ISO 9001

Service Manual: Model Discontinued in January 2001 Revision November 2003

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Service Manual: Model Discontinued in January 2001 Revision November 2003

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BB3000

ISO 9001 Model discontinued in January 2001

Service Manual BB 3000

Contents November 2001

8 / Useful, translated and obsolete items

X13 Carriage opening ( blue )

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

J8 pg 2/6 power path)

J12 J1 OUTPUT July 1997

22 X04 ✖ green Binding mode selection X04 - I - I

27 X41 red Shutter is fully open •• X35

24 Y38 ✔ red Drum heating relay (K20) C2

49 CONDITION FOR TRANSIT TO NEXT STEP

BLUE KNOB AND BOOK REMOVAL

IN OPPOSITE CONDITION (i.e. X ) CORRESPONDING LED

X42 SHUTTER IS NOT FULLY OPEN

X45 CARRIAGE IS IN HOME POSITION (LEFT)

X51 CARRIAGE IS CLOSED

X52 CARRIAGE IS EMPTY

X53 JOGGER IS IN UPPER POSITION 14 + 15 SUCTION BAR SHUTTER

X05 X = LED ON - - - - X X X X - - COVER TRANSFER

Cover pile max. 70 mm 2 3/4"

Miss detector on cover feeder Yes

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

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" )

Weight 440 Kg (970 lbs)

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

Power consumption 3kW

Noise level ( Lpa ) 75 dB(A)

Radiant heat 9540 B.T.U. /hour

Book thickness (mm)

300 Thickest glue film 400

Thickest glue film

Thinnest glue film

Service manual BB3000 Sensors description & location Jan.1997

F13 F14 F15 F19

K19 12 Index C: Addition of F19

Emergency J13 C5 Perspex guard

See C3 X53 X41 C6-20 120 120 4 BLK C E

Location on page 2/8

J14 C2-10 022 022 11 RED

X34 +24V C6-27 127 127 1 127

034 J10 J7 X32 C6-2 102 102 7 102

C3-10 037 055 3 455

Safety on C5-7 057

n.o. X32 Cover detector on suction bar

L2 C3-13 040 038 6 438 + 24V C5-8 058

3 24 hours J17 J41 Suffix G: ❊wiring corrected

J33 Jogger J21

output limiter input output

Main motor speed

315 1 326 47 327 M 10

To main motor speed control board

J21 J17 J21 resistor

Applicable from S.N. 8700 trough 61.10.4.0001 and up

c Detector Cell assy amplifier

K e Carriage X52 9420706 9420705 9420996 1K2

From S.N. 68.02.0.0001 onwards