GBC DocuColor 6060 Technical manual

GBC Fusion Punch II with
Offset and Bypass Stacker
Finishing
Solutions
Planning
Guide
Supported Printers:
• Xerox DocuTech 61xx
• Xerox iGen3®Digital Production Press
• Xerox Nuvera™100 / 120 Digital Production System
• Xerox DocuColor 6060 / 7000 / 8000 Digital Color Press
June 29, 2005
Rev. A

Xerox Corporation
Global Knowledge & Language Services
800 Philips Road Bldg. 845 – 17S
Webster, NY 14580
Copyright ©2004 Xerox Corporation. All rights reserved.
Printed in the United States of America.
Please contact Xerox Feeding and Finishing with any comments or suggestions regarding the content
within this document:
[email protected]
Copyright protection claimed includes all forms and matters of copyrighted material and information now
allowed by statutory or judicial law of hereinafter granted, including without limitation, material generated
from the software programs that are displayed on the screen such as styles, icons, screen displays,
looks, etc.
Xerox®, The Document Company®, the digital X®, the Xerox DocuTech®, the Xerox DocuPrint®, the
Xerox iGen3®Digital Production Press, Xerox Nuvera™Digital Production System and Xerox
DocuColor 6060 / 7000 / 8000 Digital Color Press are trademarks of, or licensed to, Xerox Corporation.
Other product names used herein are trademarks of their respective owners.

Table Of Contents
INTRODUCTION ..........................................................................................................................................I
About this guide ....................................................................................................................................I
Contents.................................................................................................................................................I
1. PRODUCT OVERVIEW......................................................................................................................1-1
Install Planning..................................................................................................................................1-2
Device Configurations..................................................................................................................1-2
Space Requirements....................................................................................................................1-2
Electrical Requirements...............................................................................................................1-4
Environmental Requirements......................................................................................................1-4
Estimated Installation Time.........................................................................................................1-4
Operating Supplies....................................................................................................................... 1-4
Floor Load......................................................................................................................................1-5
Floor Level.....................................................................................................................................1-5
Unique Features Set ........................................................................................................................1-6
2. XEROX DOCUTECH 61XX................................................................................................................2-1
Performance Specifications.............................................................................................................2-1
Limitations..........................................................................................................................................2-1
System Dependencies and Prerequisites..................................................................................... 2-2
Configuration Guide..........................................................................................................................2-2
Productivity Guide............................................................................................................................. 2-2
3. XEROX IGEN3®DIGITAL PRODUCTION PRESS..............................................................................3-1
Performance Specifications.............................................................................................................3-1
Limitations..........................................................................................................................................3-1
System Dependencies and Prerequisites..................................................................................... 3-1
Configuration Guide..........................................................................................................................3-2
Productivity Guide............................................................................................................................. 3-2
4. XEROX NUVERA™100 / 120 DIGITAL PRODUCTION SYSTEM.......................................................4-1
Performance Specifications.............................................................................................................4-1
Limitations..........................................................................................................................................4-1
System Dependencies and Prerequisites..................................................................................... 4-2
Configuration Guide..........................................................................................................................4-2
Productivity Guide............................................................................................................................. 4-2
5. XEROX DOCUCOLOR 6060 / 7000 / 8000 DIGITAL COLOR PRESS..............................................5-1
Performance Specifications.............................................................................................................5-1
Limitations..........................................................................................................................................5-1
System Dependencies and Prerequisites..................................................................................... 5-2
Configuration Guide..........................................................................................................................5-2
Productivity Guide............................................................................................................................. 5-2
6. CUSTOMER AGREEMENT FORM......................................................................................................6-1
Devices...........................................................................................................................................6-1
Primary Customer Applications.................................................................................................. 6-1
Special Considerations / Limitations..........................................................................................6-1
I

Table Of Contents
II

GBC Fusion Punch II with Offset and Bypass Stacker
Introduction
This Solutions Planning Guide contains information on how to
prepare for the installation of the GBC Fusion Punch II (FP II)
together with:
• Xerox DocuTech®61xx
• Xerox iGen3®Digital Production Press
• Xerox Nuvera™100 / 120 Digital Production System
• Xerox DocuColor 6060 / 7000 / 8000 Digital Color Press
About this guide
This guide will provide the Analyst and the coordinating
Customer with common FP II specifications and specific pre-
installation tasks for the specific Xerox printer to which the FP II
is to be installed with.
Contents
This section lists the contents of this guide:
• Introduction - provides information about the use of this
Guide and it also lists the different printers.
• Product Overview– provides Installation Planning, including
Space requirements, Floor Load and Level, Electrical and
Environmental requirements, Installation Time and Operating
Supplies.
• Xerox DocuTech– provides information about Limitations,
System Dependencies, Configuration Guide and Unique
Features Set.
• Xerox iGen3®Digital Production Press – provides
information about Limitations, System Dependencies,
Configuration Guide and Unique Features Set.
• Xerox Nuvera™100 / 120 Digital Production System –
provides information about Limitations, System
Dependencies, Configuration Guide and Unique Features
Set.
• Xerox DocuColor 6060 / 7000 / 8000 Digital Color Press –
provides information about Limitations, System
Dependencies, Configuration Guide and Unique Features
Set.
• Customer Agreement – contains the Customer Agreement
form.
I

GBC Fusion Punch II with Offset and Bypass Stacker
II

GBC Fusion Punch II with Offset and Bypass Stacker
1. Product Overview
Fusion Punch Offset Stacker
The GBC Fusion Punch II provides in-line printer punching
combining printing and punching into one step. Single sheets are
punched and emerge ready to be finished into lay flat
documents. These types of documents are typically bound with
coil, wire or plastic comb binding and will lay flat when opened.
The Fusion Punch II can punch the long edge of an 8.5” x 11 /A4
or the short edge of an 11” x 17” / (279 mm x 432mm) / A3
sheet. A wide variety of hole-punch patterns are available. The
die sets are lightweight, do not require setup adjustment time
when changed and can be easily replaced by the operator.
The attached stacker can offset stack up to 2,500 sheets
preparing each document for immediate binding.
The Fusion Punch II can also be equipped with an optional
Bypass Stacker (the Bypass Stacker is currently not available
with the iGen3). This allows the operator to empty one stacker
while the other stacker is in use.
1-1

GBC Fusion Punch II with Offset and Bypass Stacker
Install Planning
This Install Planning guide will help you prepare for the
installation of the GBC Fusion Punch II.
Device Configurations
The GBC Fusion Punch II components are:
• GBC Fusion Punch II
• Offset Stacker
• Bypass Stacker, optional (not available with iGen3)
Note: The GBC Fusion Punch II with dual Stacker is currently
NOT supported with the Xerox iGen3
® Digital Production Press.
Space Requirements
The space requirements diagram provides machine footprint as
well as the overall operating and maintenance area.
In addition to the diagram below, there should be a minimum of
78 inches (1,981mm) clearance from the floor to the nearest
overhead obstruction.
Powe
r
36 inches
(914 mm)
Offset
Stacker
GBC Fusion Punch II
104 inches
(2641 mm)
24 inches
(610 mm)
54 inches
(1372 mm) 27 inches
(686 mm)
36 inches
(914 mm)
105 inches
(2668 mm)
1-2

GBC Fusion Punch II with Offset and Bypass Stacker
Powe
r
36 inches
(914 mm)
GBC Fusion
Punch II Bypass Stacker Offset Stacker 104 inches
(2641 mm)
24 inches
(610 mm)
54 inches
(1372 mm) 27 inches (686 mm) 27 inches (686 mm)
36 inches
(914 mm)
132 inches
(3354 mm)
Note: The space requirements diagram for the FP II is a
representation only and not drawn to scale.
Dimensions Fusion Punch Bypass Stacker Offset Stacker
Width x Depth x
Height 54” x 32” x 46”
(1372 x 813 x 1168 mm)
27” x 32” x 46”
(686 x 813 x 1168 mm)
27” x 32” x 46”
(686 x 813 x 1168 mm)
Shipping Dimensions
Width x Depth x
Height
60 5/8” x 41” x 57 1/4”
(1535 x 1041 x 1452 mm)
39” x 35 3/4” x 52 1/2”
(990 x 905 x 1333 mm)
39” x 35 3/4” x 52 1/2”
(990 x 905 x 1333 mm)
Weight 620 lbs (281 kg) 520 lbs (236 kg) 270 lbs (123 kg)
Shipping Weight 920 lbs (417 kg) 720 lbs (326 kg) 470 lbs (213 kg)
Operator Clearance Minimum 24” (610 mm) in front of
the device Minimum 24” (610 mm) in front of the device Minimum 24” (610 mm) in front of the device
Service Clearance Minimum 36” (914 mm) on all
sides of the device Minimum 36” (914 mm) on all sides of the device Minimum 36” (914 mm) on all sides of the device
1-3

GBC Fusion Punch II with Offset and Bypass Stacker
Electrical Requirements
Device North America Europe
Punch Power 115V, 60 Hz, 4.7A 230V, 50 Hz, 6.8A
Stacker Power 115V, 60 Hz, 1.0A 230V, 50 Hz, 0.25A
Environmental Requirements
Temperature 41 - 104°F (5 - 40°C)
Humidity 30 – 95% (non-condensing)
Heat Emission
(Punch & Stacker)
1198 btu / hr. (115V / 60Hz)
2150 btu / hr. (230V / 50Hz)
Sound Emission 64.7 db (Idling)
73.7 db (Running both Punch/Stacker)
Altitude Maximum: 3280 ft. (1000m)
Estimated Installation Time
GBC personnel install the Fusion Punch II and the estimated
installation time is 4 - 8 hours.
GBC also provides customer training that is approximately 4 – 8
hours.
Operating Supplies
The Fusion Punch II is not delivered with a specific die set (refer
to die set diagrams under Unique Features Set). A die set must
be ordered when ordering the machine.
Supply No. Description Quantity
0131000000 PB Plastic Bind (Plastic Coil) 1 set
0131060000 PB Plastic Bind Oversized (Plastic Coil) 1 set
0131020000 W2 Wire Rectangle - 2 holes/inch (Twin Loop) 1 set
0131010000 W3 Wire Square - 3 holes/inch (Twin Loop) 1 set
0131140000 W2 Wire Round - 2 holes/inch (Twin Loop) 1 set
0131050000 C4 Coil Round - 4 holes/inch (Color Coil) 1 set
0131190000 C4 Coil Oval - 4 holes/inch (Color Coil) 1 set
0131030000 3-5-7 Ring Binder (Looseleaf) 1 set
You can reach GBC Customer Service using the following phone
number:
• United States 1-847-272-3700
For Canada and Europe, please visit the GBC web site and
select your region:
http://www.GBC.com
1-4

GBC Fusion Punch II with Offset and Bypass Stacker
Floor Load
Device Uniform load Point load
Fusion Punch II 51.67 lbs / sq.ft. (253 kg / sq. m) Casters A: 108.5 lbs / sq.in. (7.63 kg / sq. cm)
Casters B: 201.5 lbs / sq.in. (14.2 kg / sq. cm)
Bypass Stacker 53 lbs / sq.ft. (259 kg / sq. m) Casters: 80 lbs / sq.in. (5.62 kg / sq. cm)
Offset Stacker 45 lbs / sq.ft. (219 kg / sq. m) Casters: 67.5 lbs / sq.in. (4.75 kg / sq. cm)
Fusion Punch II
Bypass
Stacker Offset Stacker
Caste
r
Feet
Note: The leveling feet on the Fusion Punch II and the Bypass /
Offset Stackers are only used to lock the solution in place after
installation. The casters will carry the entire load at all times and
therefore there are is no point load for the leveling feet.
Floor Level
X1
X2
Fusion Punch II
Offset
Stacker
Bypass
Stacker
Configuration Measurement Specification
X1 9 ft (2.74 m) 2 “ (50.8 mm) over entire length, or 0.22 in./ ft (15.2 mm / m)
X2 6.75 ft (2.1 m) 1.48 “ (37.6 mm) over entire length, or 0.22 in./ ft (15.2 mm / m)
Note: The floor level is based on a printer paper exit height
above the floor of 34” (860 mm).
1-5

GBC Fusion Punch II with Offset and Bypass Stacker
Unique Features Set
The following are diagrams of the die set configurations, which
are available for the Fusion Punch ll. These pictures do not
reflect sheet size limitations, rather provide a visual for the die
set configuration. Refer to specifications for sheet size
capabilities.
For Plastic Coil Binding choose from:
1 #0130000000 21
PB Plastic Bind Hole Size: .313” L x .125” W (7.95 x 3.175 mm) Center to Center Hole Spacing: .5625” (14.29 mm)
1 #0131060000 21
PB Plastic Bind Oversized Hole Size: .313” L x .188” W (7.95 x 4.77 mm) Center to Center Hole Spacing: .5625” (14.29 mm)
For Twin Loop Binding choose from:
1 #0131020000 23
W2 Wire Rectangle - 2 holes/in. (25.4 mm) Hole Size: .250” L x .214” W (7.95 x 5.44 mm) Center to Center Hole Spacing: .5” (12.7 mm)
1 #0131140000 23
W2 Wire Round - 2 holes/in. (25.4 mm) Hole Size: .250” Diameter (6.35 mm) Center to Center Hole Spacing: .5” (12.7 mm)
1 #0131010000 34
W3 Wire Square - 3 holes/in. (25.4 mm) Hole Size: .156” L x .156” W (3.96 x 3.96 mm) Center to Center Hole Spacing: .333” (8.46 mm)
For Color Coil Binding choose from:
1 #0131050000 47
C4 Coil Round - 4 holes/in. (25.4 mm) Hole Size: .172” Diameter (4.37 mm) Center to Center Hole Spacing: .2475” (6.29 mm)
1 #0131190000 47
C4 Coil Oval - 4 holes/in. (25.4 mm) Hole Size: .158” L x 197” (4 x 5 mm) Center to Center Hole Spacing: .2475” (6.29 mm)
For Looseleaf Binding:
1 #0131030000 7
3-5-7 Ring Binder – U.S. (Standard Looseleaf Pattern) Hole Size: .312 Diameter” (7.92mm)
1-6

GBC Fusion Punch II with Offset and Bypass Stacker
2. Xerox DocuTech 61xx
Performance Specifications
Listed below are the Performance Specifications for the Fusion
Punch II.
Punch / Stacker Specifications
Paper Size / Weight Paper Size: 7” x 10” (178 x 254 mm) – 11” x 17” (279 x 432 mm) / A3
Paper Weight: 16 lbs (60 gsm) – 110 lbs index, 250 gsm (12 pt.)
Stacker Capacity Stacker 2,500 sheets
Input Heights 34” (860 mm) and 40.2” (1021 mm)
Limitations
• Punching is limited to 7” x 10” (178x 254 mm) size up to 8.5”
x 11” / A4, long edge only including tabs and 11” x 17” / (279
mm x 432mm) / A3 can by punched short edge only.
• Clear covers and acetates are not supported.
• Depending on media characteristics, 11” x 17” / (279 mm x
432mm) / A3 may have stacking limitations.
2-1

GBC Fusion Punch II with Offset and Bypass Stacker
System Dependencies and Prerequisites
Listed below are the dependencies and prerequisites for
installing the Fusion Punch II.
• The DT6180 must be equipped with a Bypass Transport to
enable In-line Finishing.
Configuration Guide
The Configuration Guide contains diagrams over the various
Finishing Solutions that are available.
Printer Configurations Finisher Configurations
IOT INTERPOSER BYPASS FPII OFFSET
STACKER FPII BYPASS STACKER OFFSET STACKER
DS5000 FPII OFFSET
STACKER DS5000 FPII BYPASS STACKER OFFSET STACKER
DS5000 DS5000 FPII OFFSET
STACKER
*- The following inline devices are available:
• BDFx
• Book Factory
• Book Factory with Gateway
• SQFBM
DS5000 DS5000 FPII BYPASS
STACKER OFFSET STACKER
FPII INLINE
DEVICE *
BYPASS
STACKER FPII INLINE
DEVICE *
BYPASS
STACKER
BYPASS
STACKER
INLINE
DEVICE *
DS5000 FPII BYPASS
STACKER
DS5000 DS5000 FPII BYPASS
STACKER INLINE
DEVICE*
DS5000 DS5000 FPII BYPASS
STACKER BYPASS STACKER INLINE
DEVICE*
Productivity Guide
The Fusion Punch II does not require skip pitches and does not
affect the base printers output speed.
2-2

GBC Fusion Punch II with Offset and Bypass Stacker
3. Xerox iGen3®Digital Production Press
Performance Specifications
Listed below are the Performance Specifications for the Fusion
Punch II.
Punch / Stacker Specifications
Paper Size / Weight Paper Size: 7” x 10” (178 x 254 mm) – 11” x 17” (279 x 432 mm) / A3
Paper Weight: 16 lbs (60 gsm) – 110 lbs index, 250 gsm (12 pt.)
Stacker Capacity Stacker 2,500 sheets
Input Heights 34” (860 mm) and 40.2” (1021 mm)
Limitations
• Punching is limited to 7” x 10” (178x 254 mm) size up to 8.5”
x 11” / A4, long edge only including tabs and 11” x 17” / (279
mm x 432mm) / A3 can by punched short edge only.
• The validated configuration is limited to the Fusion Punch II
with a single Offset Stacker. This limitation will cause a stop
in production for as long as 10 minutes every time the
operator needs to empty the stacker. (The Fusion Punch II
with Bypass Stacker is not an available option on iGen3.)
• Although the maximum sheet weight capability of the iGen3
is 350 gsm, the Fusion Punch II is limited to 110 lbs index,
250 gsm (12 pt.).
• Clear covers and acetates are not supported.
• Depending on media characteristics, 11” x 17” / (279 mm x
432mm) / A3 may have stacking limitations.
System Dependencies and Prerequisites
• If installing a new FP II on an existing iGen3 installation, a
Xerox iGen3 Finishing Interface kit (product code UYR) must
be ordered.
• The Fusion Punch II requires an iGen3 Upgrade Kit, part
number: 7610528.
3-1

GBC Fusion Punch II with Offset and Bypass Stacker
Configuration Guide
The Configuration Guide contains diagrams over the various
Finishing Solutions that are currently supported.
Printer Configurations Finisher Configurations
FEEDER FEEDER PRINT
ENGINE OUTPUT MODULE INSERTER STACKER STACKER FPII OFFSET STACKER
The diagram above is only an example. The
Xerox iGen3 Digital Production Press can have
the following configurations:
• Up to 6 Feeders
• 1 inserter
• Up to 4 Stackers
Productivity Guide
The Fusion Punch II does not require skip pitches and does not
affect the base printers output speed.
3-2

GBC Fusion Punch II with Offset and Bypass Stacker
4. Xerox Nuvera™100 / 120 Digital Production System
Performance Specifications
Listed below are the Performance Specifications for the Fusion
Punch II.
Punch / Stacker Specifications
Paper Size / Weight Paper Size: 7” x 10” (178 x 254 mm) – 11” x 17” (279 x 432 mm) / A3
Paper Weight: 16 lbs (60 gsm) – 110 lbs index, 250 gsm (12 pt.)
Stacker Capacity Stacker 2,500 sheets
Input Heights 34” (860 mm) and 40.2” (1021 mm)
Limitations
• A Finisher Transport Module is required for in-line
connectivity to the printer.
• A Xerox Document Stacker 5000 is recommended for
stacking paper weights greater than 203 gsm and sizes
smaller than 8.5” x 11” (216 x 279 mm) or larger than 11” x
17” (279 x 432 mm).
• Punching is limited to 7” x 10” (178x 254 mm) size up to 8.5”
x 11” / A4, long edge only including tabs and 11” x 17” / (279
mm x 432mm) / A3 can by punched short edge only.
• Clear covers and acetates are not supported.
• Depending on media characteristics, 11” x 17” / (279 mm x
432mm) / A3 may have stacking limitations.
4-1

GBC Fusion Punch II with Offset and Bypass Stacker
System Dependencies and Prerequisites
Listed below are the dependencies and prerequisites for
installing the Fusion Punch II.
• The Finisher Transport Module is required for in-line
connectivity to the printer.
• A Xerox Document Stacker 5000 is recommended for
stacking paper weights greater than 203 gsm and sizes
smaller than 8.5” x 11” (216 x 279 mm) or larger than 11” x
17” (279 x 432 mm).
• If there is a transition of an existing FP II to a Nuvera Digital
Production System, the FP II will require an upgrade.
Note: In case the floor at the customer site is very uneven, it is
recommended that the Nuvera IOT is installed and leveled with a
Caster Leveling Kit (kit number 498K07900).
Configuration Guide
The Configuration Guide contains diagrams over the various
Finishing Solutions that are available.
Printer Confi
g
urations Finisher Confi
g
urations
SFM IOT FTM FPII OFFSET
STACKER FPII BYPASS STACKER OFFSET STACKER
SFM SFM IOT FTM OFFSET
STACKER OFFSET STACKER
BYPASS
STACKER
FPIIFPIIDS5000 DS5000
SFM IOT INS FTM DS5000 DS5000 FPII OFFSET
STACKER
SFM SFM IOT INS FTM DS5000 DS5000 FPII BYPASS
STACKER OFFSET STACKER
Productivity Guide
The Fusion Punch II does not require skip pitches and does not
affect the base printers output speed.
4-2

GBC Fusion Punch II with Offset and Bypass Stacker
5. Xerox DocuColor 6060 / 7000 / 8000 Digital Color Press
Performance Specifications
Listed below are the Performance Specifications for the Fusion
Punch II.
Punch / Stacker Specifications
Paper Size / Weight Paper Size: 7” x 10” (178 x 254 mm) – 11” x 17” (279 x 432 mm) / A3
Paper Weight: 16 lbs (60 gsm) – 110 lbs index, 250 gsm (12 pt.)
Stacker Capacity Stacker 2,500 sheets
Input Heights 34” (860 mm) and 40.2” (1021 mm)
Limitations
• Punching is limited to 7” x 10” (178x 254 mm) size up to 8.5”
x 11” / A4, long edge only including tabs and 11” x 17” / (279
mm x 432mm) / A3 can by punched short edge only.
• Clear covers and acetates are not supported.
• Depending on media characteristics, 11” x 17” / (279 mm x
432mm) / A3 may have stacking limitations.
5-1

GBC Fusion Punch II with Offset and Bypass Stacker
System Dependencies and Prerequisites
Listed below are the dependencies and prerequisites for
installing the Fusion Punch II.
• An Enhanced High Capacity Stacker is required for in-line
connectivity to the printer. .
• A DFA Enablement Kit (675K11272) is required to connect
the FPII with the Xerox DocuColor 6060 / 7000 / 8000.
• A Feeding & Finishing Interface Unit kit (FFIU kit
497K02331) is required to connect the FPII with the Xerox
DocuColor 6060 / 7000 / 8000.
Configuration Guide
The Configuration Guide contains diagrams over the various
Finishing Solutions that are available.
Printer Confi
g
urations Finisher Configurations
TRAY 1-2 IOT EHCS /
HCS80 OFFSET STACKER OFFSET STACKER
BYPASS
STACKER
FPII FPII
TRAY 3-4 TRAY 1-2 IOT EHCS /
HCS80
Productivity Guide
The Fusion Punch II does not require skip pitches and does not
affect the base printers output speed.
5-2