Industrial Roller Inserter Model PBS400

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1 Industrial Roller Inserter Model PBS400 Instruction Manual Manufactured By: Gateway Bookbinding Systems Ltd 385 DeBaets Street Winnipeg, Mb, Canada R2J 4J8 Ph. (204) Fax (204) Toll Free Ph Version: 1-2

2 Table of Contents Declaration of Conformity 2 Technical Specifications 3 Safety Information 4 Installation Information 5 Set-up and Operation 6 Maintenance 9 Electric Wiring Diagram 10 1

3 Declaration of Conformity According to the EC guidelines for Machines 98/37/EC and EMC Directive 89/336/EEC; amended by 93/31/EEC The construction of the machine: Model : PBS 400 / IRI Type : Roller Inserter Was developed, constructed, and produced in accordance with the EC guidelines 98/37/EC and Directive 89/336/EEC amended by 93/31/EEC and with the sole responsibility of: Company: Gateway Bookbinding Systems Ltd. 385 Debaets Street Winnipeg, Manitoba Canada The following harmonized specifications were applied: EN 1050 EN EN EN (Emissions) The following national norms, guidelines and specifications were applied: - A complete technical documentation as well as the relevant manual is available. In the original version In the following European languages: English The CE mark was first applied in 2008 Winnipeg, June 24, 2008 Chief Engineer Place and Date Signature Title 2

4 Technical Specifications Machine Size: Machine weight: 20 wide x 10 Deep x 7 High (50.8 cm x 25.4 cm x 17.8cm) 21.5 lbs. ( 9.75kgs.) Operating Voltages: Power Supply Input: VAC, 0.8A - Single phase 50/60 Hz Power Supply Output: 12VDC, 2.5A Major Components: A On-Off Switch B Power Connection C-Book Shaper D- Rollers D A B C E E Power Supply, complete with power supply cord suitable for specified country. Capabilities: 6mm 30mm diameter coil Note: It is recommended for coil diameters larger than 20mm that a larger pitch and hole size are used (Eg. 3:1 or 2.5:1 pitch with a 6.5 x 5.5mm oval hole) to keep productivity high by reducing insertion effort and time. 3

5 Safety Information General Description The PBS 400 is a roller inserter. The rollers are driven by a low voltage DC motor with the power being supplied by an external AC adapter power supply. The dimensions are: 20 W x 10 D x 7 H ( 50.8cm x 25.4cm x 17.8cm) The weight is 21.5lbs. ( 9.75kg) Safety information The maximum sound pressure level observed for the PBS 400 is less than 70 dba. Roller Hazard A rotating part/pinch hazard exists between the upper and lower rollers. When operating the equipment, do not put your fingers directly between the rollers. Also, keep hair, clothing, jewelry, or any other items that may be caught by the rollers away from the rollers. The PBS 400 is designed to insert plastic spiral binding. Under no circumstances should the unit be used with any other materials or for any other purpose. Use of other binding products (i.e. steel wire) could cause personal injury and damage to the equipment. 4

Installation When unpacking the PBS400, the power cord, power pack and cut and bend pliers will be located in the upper cardboard separator in the top of the carton.

6 Installation When unpacking the PBS400, the power cord, power pack and cut and bend pliers will be located in the upper cardboard separator in the top of the carton. Remove the cardboard separator and carefully lift the PBS400 out of the carton. To ease the removal of the PBS400 from the carton you may wish to tip the carton on its back and slide the unit out of the box on its back with the roller facing upwards. Place the TCB on a sturdy level work surface or table that positions the unit at a comfortable work height for operation. Ensure that the equipment is installed in an area with adequate lighting that is free of shadows and glare. The set-up and operational areas of the machine must be clearly visible. A B Plug the power cord D into the power pack C. Plug the small round connector from the power pack into the 12VDC power port on the right side of the PBS400 B. Plug the free end of the power cord D into the wall. D C The main power switch A, is located on the D right side of the inserter just above the power connection. Caution: Be certain that the rollers D are clear of any obstructions starting the inserter. A secondary disconnect is to disconnect the power pack from the 12VDC power jack on the side of the machine or disconnect the power plug from the wall outlet. Be certain to allow adequate clearance behind the PBS400 to allow easy disconnection of the power cord from the wall and the power plug from the side. When you are finished using the PBS400 the power supply should always be unplugged at the wall to prolong the life of the power pack, protect operators from accidentally operation of the PBS400 and to save power. 5

Set-up: Set-up and Operation Determining the Correct Coil Size The first step when using the PBS 400 is to determine the proper size Plastikoil binding to use on a document.

7 Set-up: Set-up and Operation Determining the Correct Coil Size The first step when using the PBS 400 is to determine the proper size Plastikoil binding to use on a document. Use the Koil Size Calculator included with the machine (see instructions on the Calculator) If an actual copy of the document is unavailable for measurement, the Plastikoil size can be estimated using the chart on the back of the Koil Size Calculator. This can be useful in cases where preordering the coil is desirable. Note: It is important to remember when ordering coil that it should be approximately 1 longer than the binding edge of the book being bound. (For example, a book with an 11 binding edge would require 12 coil) Once the proper coil has been selected, you can move to the insertion stage. 6

Set-up and Operation Operation: Place the book in the shaper on the front of the inserter. This will assist the coil in passing through the punched holes by pre-shaping the book.

Place the coil and book onto the rollers as shown below. Hold the book loosely to allow the coil to shape the book as it passes through the punched holes.

Best results are obtained when the coil is driven from the right hand end of the rollers and book is held slightly away from the rollers on the left hand side.

8 Set-up and Operation Operation: Place the book in the shaper on the front of the inserter. This will assist the coil in passing through the punched holes by pre-shaping the book. Start a pre-made coil into the first few holes of the book. Turn on the inserter using the switch on the right side of the cabinet. Place the coil and book onto the rollers as shown below. Hold the book loosely to allow the coil to shape the book as it passes through the punched holes. Use the support shelf as a guide to control the position of the book relative to the rollers. Best results are obtained when the coil is driven from the right hand end of the rollers and book is held slightly away from the rollers on the left hand side. This will allow the coil to find its way into the book without being forced or distorted. CAUTION: Roller Hazard A rotating part/pinch hazard exists between the upper and lower rollers. When operating the equipment, do not put your fingers directly between the rollers. Also, keep hair, clothing, jewelry, or any other items that may be caught by the rollers away from the rollers. 7

Set Up and Operation After the coil has been inserted into the book insert the special Plastikoil

enters the book on the right hand side (see photo).

Squeeze the pliers to cut and bend the end of the coil. The crimp keeps the coil from unwinding.

9 Set Up and Operation After the coil has been inserted into the book insert the special Plastikoil Cut and Bend pliers (with the red dot of the pliers facing UP) into the last loop of the coil as it enters the book on the right hand side (see photo). Keep the pliers at a 90-degree angle to the book spine. Squeeze the pliers to cut and bend the end of the coil. The crimp keeps the coil from unwinding. After you have finished one end of your book, flip the book over and repeat the same procedure to finish the opposite end. Note: Giving the pliers an extra twist of the wrist in the crimping process will result in a longer crimp. For higher volume applications, for sizes 6mm- 50mm we recommend the Total Cut and Bend automatic cut and crimp system to save time and increase productivity and quality. 8

Occasionally it may be necessary to open the cabinet to remove any debris or paper products that may have become ingested into the roller cabinet.

10 Maintenance Periodically, the rubber drive roller can be cleaned using Plastikoil Rubber Roller Rejuvenator. Dampen a cotton cloth with the roller solution and gently apply the solution to the rollers. Occasionally it may be necessary to open the cabinet to remove any debris or paper products that may have become ingested into the roller cabinet. Disconnect all power to the inserter before attempting any disassembly. Remove the Philips screws from the top and front of the cabinet and lift the top off the inserter. Clean out any debris that is present and inspect the condition of the roller belt. The rollers are driven by a simple single belt system. Confirm the belt is properly routed over the pulleys and around the backs of the rollers. Inspect the wire connectors to be certain that they firmly affixed to their connection points. A small amount of light machine oil (10wt) can be used on the end of the rollers to add additional lubrication if required. The bearings used are oil impregnated so lubrication should only be required in applications where a noticeable drop in roller performance has been observed. Following your inspection of the interior of the cabinet, replace the cover, and fasten all screws. 9

11 INDUSTRIAL ROLLER INSERTER 10

12 INDUSTRIAL ROLLER INSERTER PBS 400 Inserter Parts list Main cabinet body Motor drive pulley, 18mm pitch dia. x 4mm belt x 1/4" bore SSS M4-0.7 Pitch x 8mm lg Motor mounting bracket front support shelf/ book shaper Top panel Decal "Roller Hazard" "PBS" Logo, Small, Smooth 1.5" x 4.13" (4 colour, red, black, grey plus clear) Switch, C&K, 0.187" x.030" quick connect. (min 3 amp DC) Power jack (Switchcraft #722A) Power supply 12 VDC 2.5 Amps (30 W) Phihong #PSA31U-120R Rohs Power cord, North American SN sticker #8x1/2" long type B tapping screw Phillips Truss head, Zinc plated Rubber feet c/w washer (B741W) #8x1/2" long type B tapping screw Phillips Pan head Zinc plated Tinnerman clips for #8 SMS x 3/8" lg BHSCS #6 SAE Flatwasher DC motor 24V,3/16" terminals #8x3/8" long type B tapping screw Phillips Truss head, Zinc plated L&R rollers support assembly, c/w bearings inner crossmember Rubber roller Lower roller Assembly, Delrin, Black, 2" Nominal Diameter, c/w pins /16-18 Nut /16" Washer, 21/64 id x 5/8 od x.120 th zinc plated /16-18 x 1" HHCS Idler pulley c/w bearing 5/16" bore /16 Lockwasher, Helical Polycord drive belt 4 mm, 16.75" length driven pulley rubber roller SSS 6-32 x 3/8" /16" (.340")id x.740" od x 1/16" thick, Nylon Washer /16" id (.317") x 1/2" od x.031" th Nylon washer

13 INDUSTRIAL ROLLER INSERTER 12

14 INDUSTRIAL ROLLER INSERTER 13

HD4170 SETUP & OPERATOR MANUAL. Performance Design Inc East Braniff St. Boise, Idaho 83716

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