BUSKRO BK7IB-2 User manual
BK7IB-2 Inline Base
Part No. 9105171 User’s Guide V1.0
BK7IB-2 Inline Base User’s Guide
Published by:
Buskro Ltd.
1738 Orangebrook Court, Unit #1
Pickering, ON, L1W 3G8
Canada
Tel.: (905) 839-6018
Fax: (905) 839-6023
All Rights Reserved. No part of this book may be used or reproduced in any form or by
any means, electronic or mechanical, or stored in a database or retrieval system,
without prior written permission of Buskro Ltd. except in case of brief quotations
embodied in critical articles or reviews. Making copies of any part of this book for any
purpose other than your own personal use is a violation of copyright laws.
Copyright © 2009, Buskro Ltd.
First Edition, 2009
Printed in Canada
This manual is sold as is, without warranty of any kind, either express or implied,
respecting the contents of this manual, including but not limited to implied warranties for
the manual’s quality, performance, merchantability, or fitness for any particular purpose.
Neither Buskro Ltd. nor its dealers or distributors shall be liable to the purchaser nor any
other person or entity with respect to any liability, loss, or damage caused or alleged to
be caused directly or indirectly by this manual.
Manual History
Version Date Description ECO No.
1.0 27-Feb-09 Manual Released. N/A
Buskro Ltd. BK7IB Inline Base
BK7IB-2 Inline Base
Buskro Ltd. BK7IB Inline Base
Table Of
Contents
1.0 General Information.............................................................................1-0
1.1 Description ............................................................................................................ 1-1
1.2 Features ................................................................................................................. 1-2
1.2.1 Vacuum Table Belts......................................................................................... 1-2
1.2.2 Complete Instrument Panel.............................................................................. 1-2
1.2.3 BK1600 Series Conveyor Compatibility......................................................... 1-3
1.2.4 Tabber Compatibility....................................................................................... 1-3
1.2.5 Auxiliary Feeder Compatibility....................................................................... 1-3
1.2.6 Maintenance Considerations............................................................................ 1-4
1.2.7 Print Quality Considerations............................................................................ 1-4
1.3 Specifications......................................................................................................... 1-5
1.4 System Drawings................................................................................................... 1-6
2.0 Operator Instructions...........................................................................2-0
2.1 Instrument Panel Functions ................................................................................ 2-1
2.1.1 Rocker Switches .............................................................................................. 2-1
2.1.2 Production Dial................................................................................................ 2-2
2.1.3 Machine and Conveyor Function Pushbuttons................................................ 2-2
2.1.3 Resettable Piece Counter................................................................................. 2-4
2.2 Material Side Guide Adjustments....................................................................... 2-4
2.3 Upstream Compatibility ...................................................................................... 2-6
2.3.1 BK720 Friction Feeder .................................................................................... 2-6
2.4 Downstream Compatibility.................................................................................. 2-7
2.5 Maintenance Schedule.......................................................................................... 2-8
3.0 BK7IB Integration.................................................................................3-0
3.1 Introduction .......................................................................................................... 3-1
3.2 Physical Location.................................................................................................. 3-1
3.3 Cable Connections................................................................................................ 3-2
4.0 Electrical System...................................................................................4-0
4.1 Introduction .......................................................................................................... 4-1
4.2 The Base Control Board....................................................................................... 4-1
4.2.1 Troubleshooting the Base Control Board and Peripheral Circuitry................. 4-6
4.3 Start/Stop Control ................................................................................................ 4-9
4.4 Transport Speed ................................................................................................... 4-9
4.5 Conveyor Speed .................................................................................................. 4-10
4.6 “Universal Speed Control” (Optional) ............................................................. 4-10
4.7 Electrical Troubleshooting and Installation Problems................................... 4-11
General Information
Buskro Ltd. BK7IB Inline Base
Chapter 1
1.0 General Information
Chapter 1 General Information Page 1-1
1.1 Description
The Buskro BK7IB-2 Inline Base is a mailpiece transportation system and features a
transport mechanism that is controlled via a centrally located operator control panel. The
system was specifically designed as a flexible and reliable platform whose purpose is to
optimize the performance of an inkjet imaging system. The BK7IB-2, in conjunction with
Buskro Controllers, produces some of the highest quality imaging within one of the
simplest and most efficient operating environments.
The mailpiece transport system, designed for the inkjet process, consists of vacuum
equipped table belts with an electronic variable pitch control technology that permits
regulation of the belt movement to adjust to the mailpieces size. In addition, an alignment
section with side guides is present at the input of the base to reduce mailpiece skew prior
to entry into the inkjet imaging area. A shaft encoder mounted on the transport belt
provides sequencing of the inkjet process.
Operator control of the BK7IB-2 is provided by a series of electrical switches and buttons
displayed on a clear, unhindered control panel centrally positioned at the front of the base.
The control panel consists of rocker switches for the Main and Vacuum power; a
resettable LCD piece totalizing counter; potentiometers for the conveyor speed, stack
speed, base speed, and pitch control; Start/Stop/Jog pushbutton controls for machine
operation; and an On/Off/Auto selector for the conveyor.
All these features, in addition to the manufacturing quality and innovative product design,
add up to an extremely functional inkjet base capable of years of reliable operation.
In order to fulfill the specific needs of the customer, different configurations of the
BK7IB-2 are available. From an electrical standpoint, a 200VAC Japanese and a standard
220-240 VAC model are available. In addition, the BK7IB-2 is available in a “right”
running machine (product travel left to right from the operator’s perspective) or “left”
running machine (product travel right to left).
The common version is designed for 220 - 240 VAC, 50/60 Hz operations but also has
115 VAC power outlets. This version was designed to be used at any location where the
Buskro Ltd. BK7IB Inline Base
Chapter 1 General Information Page 1-2
power is 230 VAC, 50 or 60 Hz. The machine is equipped with an internal 230 VAC to
115 VAC isolation transformer rated at 1 kVA. The transformer powers the 115 VAC
outlets at the rear of the machine to accommodate any peripheral equipment designed for
the North American line voltage standard (e.g. a BK720 Friction Feeder).
A special Japanese version is also available, designed for operating at 200 - 240 VAC, 50
or 60 Hz. This version has an internal isolation transformer, rated at 2 kVA. It has
primary taps at 200, 208, 220, 230 and 240 Volts and a secondary 230 Volt winding,
tapped at 115 Volts. The transformer generates the 230 VAC needed internally for the
BK7IB-2. In addition, it provides 115 VAC for those peripherals, which need that
voltage.
1.2 Features
1.2.1 Vacuum Table Belts
The table belts, which transport the mailpieces past the inkjet imaging region, are
equipped with vacuum to provide positive adhesion to the base. This helps to ensure
accurate placement of the image on the mailpiece. The BK7IB-2 also provides adjustable
outer belts to accommodate different size mailpieces.
1.2.2 Complete Instrument Panel
All necessary controls required to operate the BK7IB-2 are easily accessible to the
operator on a central instrument panel. The control panel comes complete with rocker
switches, large pushbuttons for all machine/conveyor functions, variable speed
potentiometers for machine/conveyor speed regulation, and a resettable piece counter.
Buskro Ltd. BK7IB Inline Base
Chapter 1 General Information Page 1-3
1.2.3 BK1600 Series Conveyor Compatibility
The BK7IB-2 is fully compatible with any BK1600 series conveyor model. Connection to
the conveyor is made through a 7-pin round connector located at the rear of the base. A
DC-speed controller mounted inside the base comes with a speed potentiometer, located
on the front panel, for complete control of the conveyor's belt speed. A second
potentiometer allows the operator to set the increased speed required during “stack”
operation.
1.2.4 Tabber Compatibility
The inkjet base is compatible with all Buskro Tabbers. This allows for full integration
between the Tabber and base controls such that the controls on either system can directly
stop and/or start the entire system. Connection to the Tabber is made through a connector
located at the rear of the base. The Tabber may be operated either upstream or
downstream from the BK7IB-2.
1.2.5 Auxiliary Feeder Compatibility
The inkjet base is equipped with a 14-pin connector for control of a BK720 feeder. The
feeder may be installed using an optional flip-up table, which is attached to the base, or
using a separate stand. Its start/stop operation can be controlled from the base.
A BK425 feeder may also be used and would be connected to the upstream control
connector of the BK7IB-2.
Buskro Ltd. BK7IB Inline Base
Chapter 1 General Information Page 1-4
1.2.6 Maintenance Considerations
The BK7IB-2 is designed to facilitate maintenance should it be required. All electrical
components are contained in two main panels at the front and rear of the base. Removal
of a small number of screws provides easy access to the main electronics of the system. In
terms of mechanical access, removal of the front door provides access to the blower while
removal of the transport tabletop provides access to the motor assembly.
1.2.7 Print Quality Considerations
The BK7IB-2 has been specifically designed for the printing process. As a result, it
incorporates certain unique features to optimize print quality. Included are a smooth
mechanical transport, an encoder, vacuum-assisted transport belts, and a sturdy cabinet
construction.
Buskro Ltd. BK7IB Inline Base
Chapter 1 General Information Page 1-5
Buskro Ltd. BK7IB Inline Base
1.3 Specifications
1.3.1 Product handling
Minimum 3.0” x 5.0” 76 mm x 127 mm
Maximum 16.0” x 17.0” 406 mm x 432mm
Thickness Single Sheet to 1 1/8” Up to 28 mm
1.3.2 Physical
Weight (crated) 530 lbs 240 kg
1.3.3 Production rate
Belt Speed 0 to 600 ft/min 0 to 3.05 m/s
Conveyor Speed 0 to 26.0” in/s 0 to 0.7 m/s
1.3.4 Electrical requirements
Line Voltage 200 or 220 ±15% VAC
Line Current 5 Amps
Power 1.2 kVA
1.3.5. Operator controls
Circuit-Breaker Switch Main, Vacuum
Machine Pushbuttons Start, Stop, Run/Jog
Conveyor Selector On/Off/Auto
Potentiometers Production, Conveyor
Counter 8-digit resettable
Chapter 1 General Information Page 1-6
1.4 System Drawings
120 VAC OUTLETS
JP1
JB4
JB5 JB3
JB8
Table 1-1: BK7IB-2 Features and Interface Specifications (BK7IBR-2 Shown)
Item Description Reference
1 Instrument Panel Assembly Buskro P/N, 9104908A
2 115 VAC Receptacle (Quantity 2)
3 Base BK7IB-2, Rear View
4 Photocue Sensor Connector (3-pin female)
5 I/O Connector (26-pin male)
6 Base Mounting Foot (Quantity 4)
7 Cycle Sensor Connector (3-pin female)
8 Jam Sensor Connector (3-pin female)
9 Guide, Belt BK7IB Enhanced, 30 in Lg. Buskro P/N, 9103791
10 Material Guide Assembly, BK7IB, 19” Buskro P/N, 9103585A
JB3 Auxiliary Feeder Connector (17-14 CPC female)
JB4 Downstream Connector (23-57 CPC female)
JB5 Conveyor Connector (23-7 CPC female)
JB8 Upstream Connector (23-37 CPC female)
JP1 Base Power IEC Connection (220 VAC)
Items 7, 8, JB3, JB4, JB5, and JB8 are on opposite ends of the base in the BK7IBL
Buskro Ltd. BK7IB Inline Base
Chapter 1 General Information Page 1-7
O.H.
X1
O.W.
Y1
Z1
FRONT
REAR
LEFT
RIGHT
O.L.
Z2
Table 1-2: BK7IB-2 Overall Dimensions
Symbol Description Dimensions
O.W. Overall Width 33.9” 861 mm
O.L. Overall Length 55.75” 1422 mm
O.H. Overall Height 37.90” 962 mm
X1 Leveling Foot Length 46.68” 1186 mm
Y1 Tabletop Height 32.6” to 40.5” 902 to 940 mm
Z1 Leveling Foot Width 27.50” 699 mm
Z2 Tabletop Width 23.75” 603 mm
Buskro Ltd. BK7IB Inline Base
Operator Instructions
Buskro Ltd. BK7IB Inline Base
Chapter 2
2.0 Operator Instructions
Chapter 2 Operator Instructions Page 2-1
2.1 Instrument Panel Functions
The Buskro BK7IB-2 Inkjet base is equipped with a centrally located instrument panel
(Figure 2-1) that displays all the necessary controls to operate the base. The controls can
be sub-divided into the following six distinct functions:
• Power Switches (main and vacuum)
• Transport Control
• System Speed and Mode
• Conveyor Speed and Mode
• Feeder Control
• Piece Counter
FEED ENABLE
PIECE COUNTER
START PUSHBUTTON
JOG/RUN SELECTOR
EMERGENCY STOP PUSHBUTTON
SPEED CONTROL CONNECTION
POWER ROCKER SWITCH
VACUUM POWER ROCKER SWITCH
PRESET STACK POTENTIOMETER
CONVEYOR SPEED CONTROL DIAL
ON/OFF/AUTO CONVEYOR SELECTOR
PRODUCTION SPEED DIAL
FEED ENABLE START STOP SPEED CONTROL PRODUCTIONJOG RUN POWER
VACUUM
CONVEYOR CONTROL
SPEED
OFF
AUTO ON STACK
Figure 2-1: Base Instrument Panel
2.1.1 Rocker Switches
The two rocker switches located to the right of the piece counter provide power to the
inkjet base and the transport blower.
The Power Rocker Switch turns on the main power to the inkjet base. When the “I” is
pressed down, power is on and the switch is lit. Otherwise, when the “O” is pressed
down, power is off.
Buskro Ltd. BK7IB Inline Base
Chapter 2 Operator Instructions Page 2-2
Note: When working on the BK7IB-2 electrical components, disconnect the power plug
for complete safety. Turning the Power rocker switch OFF will not disengage all
220 VAC circuitry.
The Vacuum Rocker Switch turns the transport blower on and provides vacuum to the
transport tabletop. When the switch is ON, it should illuminate Green.
2.1.2 Production Dial
The production dial controls the speed of the transport belts on the BK7IB-2 base. A
clockwise rotation corresponds to a speed increase while a counter-clockwise rotation
results in a speed decrease.
2.1.3 Machine and Conveyor Function Pushbuttons
The pushbuttons and selector knobs located on the instrument panel permit control of the
machine and conveyor operation. The Start (green) and Stop (red) pushbuttons allow
engagement and suspension of the inkjet operation while the Run/Jog (black) selector sets
the system to run continuously (RUN) when the Start button is momentarily depressed, or
intermittently (JOG) while the Start button remains depressed.
The conveyor is equipped with its own control in the form of an On/Off/Auto selector
knob (black), which determines the operating mode of the conveyor. It can be operated
continuously, in conjunction with the base, or turned off completely.
Stop Pushbutton
The red stop button stops the transport belts.
Buskro Ltd. BK7IB Inline Base
Chapter 2 Operator Instructions Page 2-3
Start Pushbutton
The green start pushbutton will cause the transport belts to run. It will only activate the
transport if there is no STOP input currently applied to the base, in which case the red
indicator light in the Stop button will be lit.
Run/Jog Selector
The Run/Jog selector is a 2-position rotary switch that permits a choice between
continuous and intermittent machine operation. When the Run mode has been selected
and the Start button is pressed, the machine will operate continuously. In the Jog mode,
the machine will cycle only as long as the Start button remains pressed.
• Run Mode - Machine will operate when the momentary Start button is pressed.
• Jog Mode - Machine will operate only while the Start button is pressed.
On/Off/Auto Selector
The conveyor On/Off/Auto selector determines the operating mode of the conveyor.
When set on auto, the conveyor is on when the transport base is on, and off when the base
is off. In on mode, the conveyor runs continuously and independently of the operating
mode of the base. Finally, an off selection suspends the conveyor’s operation altogether.
Buskro Ltd. BK7IB Inline Base
Chapter 2 Operator Instructions Page 2-4
2.1.3 Resettable Piece Counter
The counter located on the left side of the instrument panel monitors and totalizes the
number of mailpieces that are detected by the Photocue sensor. The counter can be reset
to zero by pressing the reset button located on the front of the counter.
00000008
Reset button
8-Digit Display
Figure 2-2: Resettable Piece Counter
2.2 Material Side Guide Adjustments
Proper adjustment of the material side guides shown in Figure 2-3 will permit dependable
and accurate feeding of the mailpieces so that they are correctly aligned when presented
under the printhead(s). The objective of this section of the transport base is to straighten
out any mailpiece that may come out of the feeder in a skewed manner. This will ensure
that the image is properly placed on the piece. When adjustment of the side guides is
performed, it is imperative that they not squeeze and retard the advancing mailpiece as
this would result in incorrect print positioning.
Buskro Ltd. BK7IB Inline Base
Chapter 2 Operator Instructions Page 2-5
Left Side
Material Guide
Right Side
Material Guide
Mailpiece
Material Jam Switch
Side Guide Knob (4)
Figure 2-3: Material Side Guides on the BK7IB-2
The material side guides, must be set correctly to ensure that the mailpieces are directed in
a straight fashion into the inkjet imaging area. In order to properly adjust the side guides,
the following steps are recommended:
1. Loosen and remove the guide fastening knob(s) on each material side guide.
2. Slowly feed a mailpiece onto the transport belts. Stop the transport base when
the mailpiece is between the side guides.
3. Place the left and right side guides about 1/16" to 1/8" from the corresponding
edge of the mailpiece. Ensure that the guides do not pinch the mailpiece
anywhere along its edges.
4. Replace the fastening knob(s) in the nearest threaded holes located in the base's
tabletop and tighten them to secure the guides.
5. Slowly dispense another mailpiece onto the transport belts and check that the
mailpieces path is unobstructed by the material side guides. If so, repeat steps 1
to 4.
Note: If the material side guides are improperly set, the mailpiece may become trapped
between them and/or cause a jam at the output of the feed rollers. If the material
side guides are incorrectly set, the Material Jam switch may be activated resulting
in a system stoppage.
In some cases, the side guides will need to be secured with one knob each (as
opposed to two) depending on the size of the mailpiece.
Buskro Ltd. BK7IB Inline Base
Chapter 2 Operator Instructions Page 2-6
2.3 Upstream Compatibility
The BK7IB-2 was designed to be a part of a flexible system in which one or more units
can precede or follow it in the process stream. Possible units, which may be placed
upstream from the printing base, would be a feeder (e.g. a BK425) or a tabber (BK730).
The required communication with an upstream device is carried out over the BK7IB-2’s
upstream connector (JB8, at the rear of the machine).
The functions found on this connector are: Start and Stop signals from the BK7IB-2 to the
upstream device and Start and Stop signals from the upstream device to the BK7IB-2. The
UPSTREAM connector of the BK7IB-2 is configured to communicate with the
DOWNSTREAM connector of the upstream unit.
A separate 14-pin connector (JB3, on the rear of the machine) is provided for a BK720
Friction Feeder.
To be able to stop and start the system from any location (Emergency Stop), the Stop and
Start functions are linked to the next unit via connections on the Upstream and
Downstream connectors of the BK7IB-2.
2.3.1 BK720 Friction Feeder
The BK720 Friction Feeder differs from other equipment in a system configuration since
it is a “table-top” unit, rather than the normal floor-standing units.
To accommodate this feeder, the BK7IB-2 can be equipped with an optional flip-up table.
This table has the right height and dimensions to match the BK720 to the BK7IB-2 base.
The BK720 Feeder has been designed to work with the BK7IB-2. Although the feeder
can function as a stand-alone unit with its own ON/OFF switch and speed control
potentiometer, its operating mode can be switched so that the Run function is under the
control of the BK7IB-2. An interface cable with the appropriate connectors is provided to
connect the BK720 to connector JB3 at the back of the BK7IB-2.
Buskro Ltd. BK7IB Inline Base
Chapter 2 Operator Instructions Page 2-7
Note:The stop function is not incorporated in the BK720 and therefore DIP switch S1-2 has to be
set to Disable when a BK720 is used as a feeder.
2.4 Downstream Compatibility
Possible units, which may be placed downstream from the printing base, would be an
extension table (BK703), a tabber (BK730) or even another printing base. The required
communication with a downstream device is carried out over the BK7IB-2’s downstream
connector (JB4, at the rear of the machine).
The functions found on the downstream connector are basically the same as for the
upstream connector, although the configuration is different. The DOWNSTREAM
connector of the BK7IB-2 is configured to communicate with the UPSTREAM connector
of the downstream unit. The control signal for a downstream drier is also provided on this
connector.
A separate 7-pin connector (JB5 at the rear of the BK7IB-2) is provided for a Buskro
Conveyor. This connector only has a provision for a Stop signal from the conveyor to the
BK7IB-2. However, the speed control circuit for the conveyor is actually part of the
BK7IB-2 and thus the drive voltage for the conveyor motor also has to be sent over the
connector. This permits the BK7IB-2 to provide such features as Stack Control (i.e.
providing gaps between certain stacks of mailpieces for sorting or bundling purposes).
If there is no unit downstream from the BK7IB-2, other than a conveyor, then the sensing
circuit for the Stop button has to be set to DISABLE, or the BK7IB-2 cannot run. This
function is performed by switch S1-3 on the Base Control Board.
The same function for the conveyor is provided by S1-1, the CONV DISABLE/ENABLE
switch. If a conveyor is not present in the system, S1-1 has to be set to DISABLE.
Buskro Ltd. BK7IB Inline Base
Table of contents
