JBI Wire-O WOB3500 MK2 User manual

ALPHA/OM/1 ©JBI 2000
67 Rue du Docteur Blaizot
BP 134
61304 L’Aigle Cedex
France
Tel: [phone]
Fax: [phone]
JBI James Burn Int.
®
®
®
Binding Machine
Wire-O®, Lhermite®and
UniCoil®are registered
Trademarks of
James Burn International
Patent Pending
Operating
Instructions
(Modèle WOB3500 MK2)
Version : 200-240Vac 50/60Hz Single phase
Issue : 2
Serial number WOB2.211 onwards
(starting January 2009)
To: Installation Agent
After installing this machine, always
leave this manual on the machine .

WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
Section Title - Topic Section Page
Contents
Introduction Welcome 1
Contact addresses and telephone
numbers
2
1.Using your binding machine safely Safety information 1 3
Safety warning signs on you binding
machine
1 4
Safety Instructions 1 5
Handle heavy equipment properly 1 6
Wear safe clothing 1 6
Protect children 1 6
Keep safety labels clean and in good
condition
1 7
Be prepared for emergencies 1 7
A note to all employers 1 7
Keep this manual with the binding
machine
1 8
If you need this manual in any other
language
1 8
Warning signs on and around your
binding machine
1 9
2.Installation of your binding
machine
Installation of your binding machine 2 10
Choosing a location for your binding
machine
2 10
Floor plan 2 10
Power points 2 10
Unpacking your binding machine 2 10
Unpacking your binding machine
continued
2 11
Warning 2 11
Unpacking your binding machine
continued
2 11
Technical data 2 12
3.How to select the correct size of
Wire-O
Wire sizes 3 13
Using the following formulae 3 13
Example 3 13
Table of recommended maximum book
thickness
3 14
Table of punched holes for each paper
size
3 14
4.Running your Binding Machine Display opening : selection 4 15
Initialization 4 16
Work display (final) 4 16
Lifting and loading a Wire-O spool 4 17
Lifting and loading a Wire-O spool 4 18
Lifting and loading a Wire-O spool 4 19
Bring the wire to the spool unwinder 4 19
Wire feeding in the wheel 4 20
Wire adjustment 4 20
Wire modification 4 21
Reception adjustment
4 21
Contents

WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
Section Title - Topic Section Page
5. Hanger feed using Hanger feed option 5 22
6. Henger spool installation Loading an hanger spool 6 23
7.Maintaining your binding machine General maintenance 7 24
Daily maintenance 7 24
Weekly maintenance 7 24
Annual maintenance 7 24
Ongoing maintenance 7 24
8. Spare parts Spare parts 8 25
9.Selling, transferring or disposing
of your binding machine
Selling or transferring your binding
machine
9 26
Disposing of your binding machine 9 26
10.Fault finding chart Fault finding chart 10 27
11.Technical data about your
binding machine
General data 11 29
Machine performance 11 29
Electrical data 11 30
Protection devices (fuses) 11 30
12.Amendments Issue no 1 12 31
13.Warranty James Burn International warranty 13 33
14. EC Declaration Declaration of conformity 14 34
Drawings – Circuit Diagram
Drawing no Title Page
No
0704-01-00 Glossary
0704-01-01 For supply 200-240 Vac
0704-01-02 Safety 24Vcc
0704-01-03 Board card 24V
0704-01-04 PLC inputs
0704-01-05 PLC outputs
0704-01-06 Sanyo card 3A-24Vcc : M1-M2-M3-M4
0704-01-07 Inverter book transport : M5 V : 200-240 Vac
0704-01-08 Inverter cutter assy : M6 : V : 200-240 Vac
0704-01-09 Inverter spool : M8 : V : 200-240 Vac
0704-01-10 Inverter closing : M9 : V : 200-240 Vac
0704-01-11 Terminal XB2-YB1
0704-01-12 Settling electric assy

Introduction
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
1
Thank you for purchasing a WOB3500 Binding Machine from James Burn International. This
instruction manual has been prepared to help you get the most from your new binding machine.
NOTICE
Read this manual carefully before installing your binding machine.
It is essential that you read all the instructions to ensure a safe and correct manner
for operating the machine.
This manual contains recommendations and instructions for installing, adjusting,
operating and maintaining your binding machine.
Failure to read this manual and operate the machine correctly could result in
damage to your equipment, or even personal injury.
This manual is a necessary and permanent part of your binding machine. Always
return the manual to its pocket holder, on the machine.
Note
This manual gives you general guideline for installing and operating your binding machine. It does not cover every
question you may have or cover every situation that can occur If in doubt please contact your supplier. Due to ongoing
efforts to improve the machine, James Burn International reserves the right to carry out changes to this machine.
The machine identification plate is found on the rear of the machine. ALWAYS confirm the serial number when
contacting James Burn International for spares or service.
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

1. Using your Binding Machine Safely
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
3
Safety Information
Learn to recognise safety information, and always follow recommended precautions and
safe operating practices.
This is the safety alert symbol:
When you see this symbol on your binding machine, or in this manual, be alert to the
potential for injury or property damage.
The manual uses the words DANGER, WARNING, CAUTION and NOTICE to accompany
the safety alert symbol. The words are defined as follows:
DANGER: You will cause severe personal injury or death if you ignore this
message.
WARNING:You may cause severe personal injury and/or substantial
damage to equipment or property if you ignore this message.
CAUTION: You may cause minor personal injuries or substantial damage to
equipment if you ignore this message.
NOTICE:This is important installation, operation or maintenance
information that should not be ignored.

1. Using your Binding Machine Safely
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
4
Safety Warning Signs on your Binding Machine
This section lists the safety warnings that you should be familiar with before you
install or operate your binding machine.
DANGER
Electrical shock hazard
DO NOT TOUCH THE CLOSING TOOLS IN
YOUR BINDING MACHINE.
Use a long screw driver or bar to clear jams in the
Closing Head.
Serious injury may occur if your fingers come into
contact with the closing tools while the machine is
operating.
NEVER PERFORM ANY REPAIR OR MAINTENANCE
ON YOUR BINDING MACHINE WHILE IT IS
OPERATING
Always remember to switch off the machine and
disconnect its electrical and air supply.
STOPPING THE BINDING MACHINE IN AN
EMERGENCY
Know where the emergency stop switch is located on
your binding machine.
The emergency stop switch is a red mushroom headed
push button, left side (respect to operator side).

1. Using your Binding Machine Safely
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
5
SHEAR HAZARD
Keep hands clear of Cutter. Turn power OFF before servicing.
Safety Instructions
DO NOT OPERATE THE BINDING MACHINE IF THE GUARDS ARE NOT
IN PLACE
All guards MUST be in place before you start the binding machine.
DO NOT ADJUST THE GUARD OPENINGS WHILE THE MACHINE IS
SWITCHED ON
Servicing must not be carried out with the machine switched ON.
DO NOT BYPASS THE INTERLOCK SWITCHES ON YOUR BINDING
MACHINE
Never use your binding machine unless the Interlock Switches are in proper
working order

1. Using your Binding Machine Safely
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
6
HANDLE HEAVY EQUIPMENT PROPERLY
Always handle heavy equipment with a suitable
mechanical lifting device.
Always position the weight of the machine on your lifting
device so that it is stable when lifted. Know the weight
of the equipment before attempting to lift it. (N.B. This
machine weighs 277kg (610lbs)
Never try to lift equipment that is heavier than the
maximum rating of your lifting device.
A minimum of 2 people is required when moving this
machine. The correct pallet and covers as supplied
should always be used.
WEAR SAFE CLOTHING
Secure all loose clothing - such as neckties or scarves
whilst operating your binding machine, and keep loose
hair tied back.
Safety footwear should always be worn when moving
this machine.
PROTECT CHILDREN
Keep children away from your binding machine. Never
allow children to operate your binding machine.

1. Using your Binding Machine Safely
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
7
KEEP SAFETY LABELS CLEAN AND IN GOOD
CONDITION
Do not remove any safety labels from your binding
machine. Keep all labels clean and legible. Replace
any missing or damaged labels.
BE PREPARED FOR EMERGENCIES
Be prepared for fires, injuries or other emergencies.
Keep a first aid kit and a fire extinguisher handy. Keep
emergency numbers of doctors, ambulance services,
hospitals and the fire department handy. Acquaint
yourself with the company fire procedure.
A NOTE TO ALL EMPLOYERS
Know your responsibilities as an employer.
Make sure your employees know how to operate the
binding machine safely and ensure they read this
manual.
Make sure your employees are aware of the safety
warnings displayed on the binding machine and
illustrated in this manual.
Make sure the binding machine is in proper working
condition. Unauthorised modifications may impair the
function and safety of the binding machine.

1. Using your Binding Machine Safely
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
8
KEEP THIS MANUAL WITH THE BINDING MACHINE
This manual is an important part of your binding
machine. Always keep this manual where it belongs -
with the binding machine.
IF YOU NEED THIS MANUAL IN ANY OTHER
LANGUAGE
If you need this manual in a language other than
English, contact James Burn International.

1. Using your Binding Machine Safely
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
9
Warning Signs on your Binding Machine
Identification
Plate
2 Adjustable feet
to keep the
machine stead
y
Adjusting square
paper format
Reception

2. Installation of your Binding Machine
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
10
Installation of your Binding Machine
Installation of your binding machine will depend on how you plan to use it and the
resources available in your bindery.
Therefore, the installation information should be considered as a guideline and
recommendation rather than exact instructions. Contact James Burn International if
you have any queries about installing the machine.
Choosing a Location for your Binding Machine
You should choose a site within the office that is solid, level and rigid enough to keep
the machine accurately aligned, even while it is running, and place it in a position
which ensures the most efficient work flow.
Floor Plan
The approximate floor area that is required for the binding machine is 2.5 x 1.0
metres.
Power Points
You should ensure that 16 amp electric connection points with earth are provided
nearby.
WARNING
Ensure that the voltage setting on your binding machine conforms
to the supply rating. See Electrical Installation Notes at the end of
this section. 2 Versions 100-120 Vac 50/60Hz or 200-240 Vac
50/60Hz, 16 Amps with Earth singlephase.

2. Installation of your Binding Machine
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
11
Unpacking your Binding Machine
The binding machine is packed in a wooden case. To unpack:
Unbolt the top and sides of the case and remove them.
Check to see if any damage has occurred to the machine during transportation.
Notify James Burn International and the carrier immediately regarding any
damaged parts.
Unwrap the protective film.
Check for quantity against list.
1 off Instruction services and spares parts manual.
1 off Footswitch.
WARNING
Avoid violent or sudden movement when moving the machine, otherwise
it may fall causing property damage and/or personal injury. Therefore
when you are moving the machine check that it is stable. The machine
weights 277Kg (610lbs).
Unbolt the retaining straps holding the machines feet to the base. At least 4
persons are required to removing the machine from the pallet. All the coach
bolts at the appropriate end of the pallet should be removed. The support
underneath the base can now be carefully removed, and the pallet tilted to
allow the machine to be slowly rolled off the now sloping base. The pallet
should be retained for future use.
Place the Wire-O Bind in situ.
Plug in the IEC mains cable and the footswitch. Switch on the WOB3500
using the black isolator switch on the right hand side of the machine. The
screen should illuminate and display the opening screen.

2. Installation of your Binding Machine
WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais
12
Technical Data
Standards And Application Conditions
Conformity Machine directive EMC directive
Approvals CE
Vibration Resistance Acceleration Resistance up to 2g (Germanischer Lyoyd, general
conditions).
Climatic Conditions Class 3K3 to EN50178 (Without Condensation, Average Relative Humidity 85%)
Packaging Dust Packaging
Permissible Temperature Range t t = -10ºC….+40ºC
t = 40ºC….+55ºC With Forced Air Cooling. Expect 30% Speed Reduction.
Permissible Installation Height h h = <1000m above mean sea level
General Electrical Data
Noise Emission
Noise Immunity Requirements to EN 61800-3
Insulation Strength Overvoltage Category iii to VDE 0110
Discharge Current to Potential Earth >3.5mA
Protection Measures Against Short circuit, Over-voltage, Motor over-temperature and Over-current
Type of Protection IP20
Electrical Installation IMPORTANT Notes
Protection of persons
Operators’ safety with RCCBs, RCDs and Circuit breakers.
Definitions- In the following text ‘RCCB’ is used for ‘Residual Current Circuit
Breaker’, RCD is used for Residual Current Device and CB is used for Circuit Breaker.
Protection of persons and animals –
The Inverter Drives, Programmable Logic Controllers and Switch Mode Power
Supplies, all use high value capacitors in their internal circuit design. This fact may
cause false tripping on power up. It is highly recommended that “Pulse current
sensitive RCCD” and “Type C” circuit breakers be fitted in your mains power
distribution panels, to protect the machine, operators and service staff and to reduce
false tripping to a minimum.

3. How to Select the Correct Size of Wire-O


WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais 13
Wire-Ois supplied in eleven different sizes for the WOB3500 binding machine. These
range from 1/4” and 11/4” sizes and are available in a variety of finishes and colours.
Request a brochure from James Burn International or your agent for the complete range.
Wire Sizes
The wires are numbered according to their size in sixteenths of an inch, e.g. wire
size 9 corresponds to 9/16” and wire size 6 corresponds to 3/8”.
The size of the wire required is obtained in the following manner.
Using the Following Formulae:
Imperial:
All 3:1 Pitch Wire Size = Book Thickness in inches + 1/16”
(and 5/8 wire)
All 2:1 Pitch Wire Size = Book Thickness in inches + 1/8”
(except 5/8 wire)
or
Metric:
All 3:1 Pitch Wire Size = Book Thickness in mm + 1.6mm
(and 5/8 wire) 25.4
All 2:1 Pitch Wire Size = Book Thickness in mm + 3.2mm
(except 5/8 wire) 25.4
Where the precise size is not available the nearest oversize wire can be used.
Example:
A book has a total thickness of 6mm, adding 1.6mm and dividing by 25.4 gives
0.3 inch. Therefore, No.5 - 5/16” - (8mm) wire can be used. (see table below).

3. How to Select the Correct Size of Wire-O


WOB3500/MesDocuments/Corinne/Notices/WOB3500/Anglais 14
Table of Recommended Maximum Book Thickness for each Wire Size
Wire Size
Recommended
Maximum
Book Thickness
Wire No. Mm ins
Pitch of
Wire
(Inches) mm ins
4 6.4 ¼ 3:1 4.6 3/16
5 7.9 5/16 3:1 6.2 ¼
6 9.5 3/8 3:1 7.8 5/16
7 11.1 7/16 3:1 9.5 3/8
8 12.7 ½ 3:1 11.0 7/16
9 14.3 9/16 3:1 12.5 ½
10 16.0 5/8 2:1 14 9/16
12 19.0 ¾ 2:1 16.0 5/8
14 22.0 7/8 2:1 19.0 ¾
16 25.4 1 2:1 22.0 7/8
18 28.57 11/18 2:1 25.3 1
20 31.8 1¼ 2:1 28.0 1 1/8
Table of Punched Holes for each Paper Size
The table below shows the maximum number of punched holes recommended for
various paper sizes being used.
Maximum Number of Punched Holes
3:1 Pitch 2:1 PitchPaper
Format Long Edge Short Edge Long Edge Short Edge
A6 17 12 11 8
A5 24 17 16 11
A4 34 24 23 16

4. Running Your Binding machine.
WOB3500/Corinne/MesDocuments/Notices/WOB3500/Anglais
15
Spool or Cut length
To come back to
p
revious screen
To
g
o to next screen
Cancel the initialization
NOTA : If you select n°18 or n°20, put the bar
u nder the jaws, fix it on the pusher, just clip the bar.
Don’t for
g
et to remove it when
y
ou select under n°18
It is highly recommended that only original James Burn International Wire-O
®
spools are use with your WOB3500
binding machine.
Switch on the WOB3500.
On the opening screen using the ‘change switch’ select ‘spool’.
NOTA : Pressing the ‘change switch’ alternates between ‘Spool’ and ‘Cut Lengths’.
‘Cut Lengths’ should only be selected if you are using Wire-O in cut lengths supplied by James Burn International.
Select the wire-o size (see chart page 14)
select the number of loops
select the number of cut lengths
select the jump length between the cut lengths
In 3/1 pitch number of loops from 8 to 41, number of cut lengths 1 to 4, jump length 03 to 25 (loops)
In 2/1 pitch number of loops from 5 to 28, number of cut lengths 1 to 4, jump length 02 to 18 (loops)
After selection validate your choice by the key
New : WARNING
The screen displays
If you see this symbol (with buzzer) you must Remove the bar under the jaw.
Replace the wire, if necessary, from the dented wheel/cut assembly, press on to continue and initialize the machine
The screen displays
Engineer menu
Validate

4. Running Your Binding machine.
WOB3500/Corinne/MesDocuments/Notices/WOB3500/Anglais
16
Cancel the initialization
Return to the
p
revious screen
In case of spool without
hanger option
In case of spool with hanger
option
In case of cut lengths with
hanger option
In case of cut lengths without
hanger option
To
g
o to next screen
4 POSSIBLE SITUATIONS
The screen displays
The screen displays
c
d
e
f

4. Running Your Binding machine.
WOB3500/Corinne/MesDocuments/Notices/WOB3500/Anglais
17
To Load a Spool of Wire-O
®
Open the Wire caddy door. Ensure that no wire remains under the wire lift drive
.
Carefully remove the spool from the shipping carton and remove the protective film. Ensure that the wire spool is
aligned as shown in the photo below.
Pull the spool cart out fully. Turn the spool support shaft, by hand, until the drive cam pin is at 9 o’clock.
Nicking
p
a
p
er.
Plastic
inserts.
Drive cam pin
Spool support shaft.
Wire caddy
door.
Wire lift
drive.
Nicking paper
removal rollers.
S
p
ool cart.

4. Running Your Binding machine.
WOB3500/Corinne/MesDocuments/Notices/WOB3500/Anglais
18
Position the spool in front of the machine with the Wire-O rolled-up clockwise, carefully lift the spool onto the spool
support shaft.
Turn the spool by hand until you feel drive cam pin engages in the spool.
Important : push the spool end cap in further so that the cup hole engages into the groove of the spool shaft.
Next, carefully remove the plastic packing clips from the wire-o
spool. Gently turn the spool and feed the nicking paper
through the nicking paper removal rollers.
Grove in
spool shaft.
Cup hole.
Plastic
retaining
cli
p
s.
Nicking paper
removal
rollers.
Nicking
p
a
p
er.
The spool is correctly mounted