JBI Alpha-Doc Mk4 User manual

ALPHAM4/V1 JBI SEPT 2011
67 Rue du Docteur Blaizot
BP 134
61304 L’Aigle Cedex
France
Tel: [phone]
Fax: [phone]
2151
JBI James Burn Int.
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Automatic Punching Machine
Wire-O®, Lhermite®and
UniCoil®are registered
Trademarks of
James Burn International
Patent Pending
Operating
Instructions
Alpha-Doc Mk4 version 100-120V (us)
Issue : 1.1
Serial number AL4.022 onwards
(Starting May 2012)
To: Installation Agent
After installing this machine, always
leave this manual on the machine .

Page
Contents
ALPHAM4/V1 SEPT 2011
1
INTRODUCTION
Section 1 Installation Precautions
Section 2 General
2.1 Working Speed
2.2 Paper Tolerances
2.3 Paper Jams
Section 3 Switching On
Section 4 Buttons settling
Section 5 Operation
5.1 Changing Size
5.2 Setting the Punching Thickness
5.3 Setting Normal, Card or Index Selection
5.4 Tool Changing
5.5 Tool Raising
5.6 Loading and Modification of Personalised Formats
5.7 Use of the High Pile Feeder
5.8 Use of the High Pile Reception
Section 6 Options
6.1 Separator
6.2 Tab Option
6.3 Air Blower Unit
6.4 How to fit a Mk3 tool onto the Mk4 Alphadoc
Section 7 Troubleshooting
7.1 Troubleshooting when Switching On
7.2 Troubleshooting during Cycle
7.3 Remedy in case of troubleshooting
Section 8 Maintenance
Section 9 Selling, Transferring or Disposing of your punching machine
EC Machine Directive
Registration Card

Intro Page
Introduction
ALPHAM4/V1 SEPT 2011
1
Thank you for buying an αlpha-doc®Punching Machine from James Burn
International SA. This instruction manual has been prepared to help you get
the most from your new machine.
NOTICE
Read this manual thoroughly before installing your αlpha-doc®Punching Machine.
It is essential that you read all the instructions to ensure a safe and correct manner for
operating the machine. Misuse of the machine could be extremely dangerous and lead
to injury.
This manual contains recommendations and instructions for installing, adjusting,
operating and maintaining your punching machine.
Failure to read this manual could result in personal injury or damage to your
equipment, for which we accept no liability.
This manual is a necessary and permanent part of your punching machine and must be
kept with the machine.
Note:
This manual gives you general guidelines for installing and operating your punching
machine. It does not cover every question you may have or every situation that can
occur, in which case you should contact your agent or one of the JBI offices listed
overleaf.
Also in an ongoing effort to improve the quality and performance of this punching
machine, James Burn International S.A. reserves the right to carry out changes to the
machine.

Intro Page
Introduction
ALPHAM4/V1 SEPT 2011
2
If you have any questions about your Punching Machine or this manual, please contact your
local James Burn International agent or office shown below :
Your local James Burn International agent or office

Section 1 Page
1. Installation
ALPHAM4/V1 SEPT 2011
1
Important Precautions for Installation
1.1 Keep your machine away from the radiators and other sources of heat. The ambient
temperature has to be lower than 24°. Do not block the ventilation openings.
1.2 Do not place the machine against a wall : allow 0.5m minimum all around the machine
to facilitate tool changing.
1.3 Avoid locating the machine near other machines likely to transmit electro-magnetic
interference (for instance : welding outfit, radio, compressors, portable phones…).
1.4 Before switching the machine ON, read the operating instructions and before first time
use, read the precautions to be taken.
1.5 Power Supply : The machine needs to be connected to a 100-120 V (us) supply with
earth (imperative) to secure the electrical safety (Protection : circuit-breaker 16 A
curve C).
NOTE : Avoid neutral load on the installation, this is equipped with electronics generating
leakage current which can activate upstream protections.

Section 2 Page
2. General
ALPHAM4/V1 SEPT 2011
1
2.1 Working Speed and Mode
The machine is equipped with three working speeds and four working modes as
shown below and whose selection is possible on the keyboard of the machine.
a. Speed (90) : plain good quality copying paper 90 strokes per minute
b. Normal (80) : plain copying paper 80 strokes per minute
c. Card (70C) : plain copying paper with card board 70 strokes per minute
d. Index (70I) : tab sheets 70 strokes per minute
2.2 Paper Tolerances
2.2.1
G.S.M. BRACKET
(weight of the paper per square meter) Between 70gsm and 250gsm
MINIMUM SIZE OF PAPER 138mm x 138mm
MAXIMUM SIZE OF PAPER 350mm x 330mm
MAXIMUM TOLERANCE OF PAPER SIZE
IN THE SAME PILE 0.5 mm

Section 2 Page
2. General
ALPHAM4/V1 SEPT 2011
2
2.2.2 You will find below the different shapes of warping or any kind of out of
shape material which our machine can allow :
- 1 -
LOCATED ON THE SIDE OF THE
PICK-UP OF THE SHEET – CURVED
DOWNWARDS.
- 2 -
SPREAD OVER ALL THE SHEET –
CURVED UPWARDS.
- 3 -
SPREAD OVER ALL THE SHEET –
CURVED DOWNWARDS.
- 4 -
LOCATED ON THE SIDE OF THE
PICK-UP OF SHEET – CURVED
UPWARDS.
- 5 -
MIXED WARPING SPREAD OVER THE
SHEET.
CAUTION
It is possible to punch acetate or similar paper only if each sheet is
interleaved with 10 sheets minimum (plain copying paper) without
any responsibility on our part insofar as the acetate may have a
diversified composition. It is advisable to contact us and to send us
some samples before any trial. We will advise you on the feasibility
of its use.
N.B. Make sure that you are using antistatic acetate
L Inferior to L/2
2
10 10
5
L Inferior to L/2
5

Section 2 Page
2. General
ALPHAM4/V1 SEPT 2011
3
2.3 Paper Jams
If the paper jams repeatedly at the outlet :
2.3.1 Check the direction of the warping of the paper located in the feeder and
compare this with the tolerances mentioned in Section 2.2.2.
2.3.2 In case you have to cope with one or more situations, turn your paper so
that you obtain either case no. 1 or 3. It will improve both the pick-up of
the paper and the reception.
2.3.3 Check whether you meet the aforementioned restrictions (see Section
2.2).
2.3.4 Always use a paper of good quality if possible.
2.3.5 When the paper has just been photocopied, it is advisable to let it cool
down for a quarter of an hour before punching it.
CAUTION
The storage of the paper before punching is of great
importance : on cooling the paper may be susceptible
to warping, hence the importance of stacking the paper
correctly.

Section 3 Page
3. Switching On
ALPHAM4/V1 SEPT 2011
1
Normal
Operation ¾
Switching
on
¾The screen
lights up ¾
TEST
Message :
Booting
Loading Runtime
¾¾
Press to
initialize
Message :
INIT
¾
Possible
Troubles ¾
The screen
does not light
up
Maintenance
manual
Message :
“COVER OPEN”
Check the cover
Message :
“EMERGENCY
STOP”
Check the
emergency stop
button
The cover is closed
See the
maintenance
manual or
contact JBI’s
engineering
department
The button isn’t locked The button is locked
The cover is open
Twist off the
button for
unlocking
Close the
cover
Open the
cover
entirely and
then close it. The cover is closed

Section 4 Page
4. Buttons settling
ALPHAM4/V1 SEPT 2011
1
Plug
Machine
« ON » switch
Control display
« touch screen »
Button « ON »
Button
« STOP »
Emergency
STOP
button

Section 5 Page
5. Operation
ALPHAM4/V1 SEPT 2011
1
5.1 Changing Size
5.1.1 All paper sizes that can be selected :
1 : A4P 297.0X210.0
2 : A4L 210.0X297.0
3 : A5P 210.0X148.0
4 : A5L 148.0X210.0
5 : US/2P 215.9X137.7
6 : US/2L 137.7X215.9
7 : USP 279.4X215.9
8 : USL 215.9X279.4
9 : FLSP 330.2X215.9 NOTA : Don’t forget to retract the foot stops or the
10 : FLSL 215.9X330.2 head stops, located less than 7mm before the square
11 : CUST1 ***.*X***.* of lateral jogging respect to the paper size selected.
12 : CUST2 ***.*X***.*
13 : CUST3 ***.*X***.*
14 : CUST4 ***.*X***.*
5.1.2 Procedure
5.1.3. Check the punching
The punching tools are centered respect to the machine.
Press or (see the above screen) for adjusting the paper size.
From – 9,5mm to +7,5mm respect the “0” position
This adjustment has to be used for formats with uneven number of holes.
Example :
For an A4P format with 33 holes in 3:1” pitch press the key up to 4,2 to get the correct
position.
°°°°°°°°°°°°°°°°
Correct °°°°°°°°°°°°°°°° Wrong
°°°°°°°°°°° °°°°°°°°°°°
- 9.5mm + 7.5mm
To select the size
press or to
find the right size

Section 5 Page
5. Operation
ALPHAM4/V1 SEPT 2011
2
5.2 Setting the Punching Thickness
5.2.1 Thicknesses that can be selected
〉1.0
〉0.9
〉0.8
〉0.7
〉0.6
〉0.5
5.2.2 Procedure
To select the thick
press or to
find the thick

Section 5 Page
5. Operation
ALPHAM4/V1 SEPT 2011
3
5.3 Setting Speed (90), Normal (80), Card (70C) or Index (70I) Selection
5.3.1 Initial Menu
〉90 90 cycles/min
〉80 80 cycles/min
〉70C 70 cycles/min
〉70I 70 cycles/min + 3 solenoids TABS
5.3.2 Procedure
NOTE : By selecting the 70I Index mode you will activate the 3 solenoids located on the
square of the side lay gauge (if you have this option – see Section 6.1).
By selecting the 70C Card mode you will operate in low speed (70 strokes per minute),
useful for difficult work with card board or sensitive paper.
Then press on “INIT”
Launch the cycle, 2 possibilities :
1) Press : launch 1 cycle to validate the paper format
2) Press the “ON” button (see Section 4)
To stop the cycle press the “STOP” button (section Section 4)

Section 5 Page
5. Operation
ALPHAM4/V1 SEPT 2011
4
5.4 Tool Changing
5.4.1 Procedure
Press
Nearly whole the tool is lowering, you can change the tool :
- open the tool door
- remove the 3 screws on the tool base
- change the tool
- tighten the 3 screws by using a flat key
- close the tool door
When the tool changing is completed press
NOTE : The tool must be removed ONLY when it is in the lowered position.

Section 5 Page
5. Operation
ALPHAM4/V1 SEPT 2011
5
5.5 Tool Raising
5.5.1 Procedure
Press
Tool up
The tool is raising entirely : instructions to remove paper jam (if necessary) :
- open the PVC cover
- remove sheets by pulling slowly, check that no offcut paper remains
- close the PVC cover

Section 5 Page
5. Operation
ALPHAM4/V1 SEPT 2011
6
5.6 Loading and Modification of Personalised Formats
5.6.1 4 x Possibilities of Size
11 : CUST1 ***.*X***.*
12 : CUST2 ***.*X***.*
13 : CUST3 ***.*X***.*
14 : CUST4 ***.*X***.*
5.6.2 Procedure : select in first mm or inch
Press
ifmm if inch
Change value Change value

Section 5 Page
5. Operation
ALPHAM4/V1 SEPT 2011
7
5.7 Use of the High Pile Feeder
5.7.1 Procedure
Go into the feeder menu by pressing on
Press directly on the button ON or ON
To return to the READY menu press
NOTA : possible message

Section 5 Page
5. Operation
ALPHAM4/V1 SEPT 2011
8
5.8 Use of the High Pile Reception
5.8.1 Procedure
Go into the reception menu by pressing on
Press directly on the button ON or ON
To return to the READY menu press
Nota : possible message

Section 6 Page
6. Options
ALPHAM4/V1 SEPT 2011
1
6.1 Separator
How to select the separator ?
Go into starting position, tool in high position
OR
Press on the «CHANGEOVER OF TOOL» button on the keyboard
-Take a BTR key n°2
-Open the upper cover
-Unscrew the support of separator stop located in front of the feeder at pick-up level,
in front of the beak
To select the separator (for mixed papers or cards) :
Move the support to the left
To use only the beak (for standard paper only) :
Move the support to the right
NOTICE : if you experience troubles with sensitive paper or hard paper, you
can reduce the speed by selecting the mode Card «70C» (see section 5 page
3)

Section 6 Page
6. Options
ALPHAM4/V1 SEPT 2011
2
6.2 Tab Option
SIDE LAY GAUGE FOR TABS WITH THREE SOLENOIDS FOR ALPHA-DOC MK4
TECHNICAL SPECIFICATIONS
SHEET SIZE A4 P
US P 297 x 210 mm
279.4 x 215.9 mm
FEASIBILITY ONLY ON ROUND CORNERING TWO SIDES
MAXIMUM HEIGHT OF
TABS 13.5 mm
MINIMUM NUMBER OF
TABS 4
MINIMUM SIZE
of the margin from the edge
of the sheet 0 mm
UNFEASIBILITY ROUND CORNERING ONE SIDE
SIZE OF SHEETS
Sheets between each index card
must have the same sizes as the
basis of the tab (size X) and the
same length (dimension Y) with a
0.2mm bracket.
ADVANTAGES
The second solenoid has to be located in the middle of the sheet to balance the lay gauge.
The lay gauge with three solenoids is made posible by the low pressure of the solenoids,
which enables the sheets not to be damaged.
EXAMPLES
1
st sheet 2nd sheet 3rd sheet 4th sheet
Two solenoids must always be in jogging operation to ensure the pushing of
sheets.
Assembly : Remove the square of side lay gauge to replace by the Tab Option by using a
6-face key to remove the two screws. Connect the two electric wires on the tittle terminal
located on the support.
CAUTION
Disconnect the machine before operation.
Hmax.
X
Y
1
2
3