Xerox Document Binder 120 User manual

XEROX
Xerox Document Binder 120
Operator Manual
January 1999
701P99911

Xerox Corporation
Multinational Customer & Service Education
780 Salt Road
Webster, New York 14580
©1998, 1999 by Xerox Corporation. All rights reserved.
XEROX®, The Document Company®, the stylized X, and all Xerox
products mentioned in this publication are trademarks of XEROX
CORPORATION.
XEROX®, The Document Company®, the stylized X, and all Xerox
products mentioned in this publication are trademarks of Xerox
Corporation and Xerox Canada Ltd is the licensee of the trademarks.

NOTICES
XEROX DOCUMENT BINDER 120 OPERATOR MANUAL iii
Approvals and certification
Safety
United States This equipment is listed by the Underwriters Laboratories Inc., to
UL1950.
Canada Approved by Underwriters Laboratories Inc., to Canadian National
Standard C22.2 No. 950-93.
Radio Frequency Emissions
United States This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and used in
accordance with the Operator Manual, may cause harmful
interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference in which
case the user will be required to correct the interference at his or her
own expense.
Changes or modifications to this equipment not specifically approved
by the Xerox Corporation may void the user’s authority to operate
this equipment.
Xerox Limited
The CE marking applied to this product symbolizes Xerox Limited Declaration of
conformity with the following applicable Directives of the European Union as of
the dates indicated:
January 1, 1995: Council Directive 73/23/EEC amended by Council Directive
93/68/EEC, approximation of the laws of the member states related to low
voltage equipment.
January 1, 1996: Council Directive 89/336/EEC, approximation of the laws of the
member states related to electromagnetic compatibility.
A full declaration, defining the relevant directives and referenced standards can
be obtained from your Xerox Limited representative.
WARNING
This is a Class A product. In a domestic environment this product may cause
radio interference in which case the user may be required to take adequate
measures.
WARNING
In order to allow this equipment to operate in proximity to Industrial, Scientific,
and Medical (ISM) equipment, the external radiation from ISM equipment may
have to be limited or special mitigation measures taken.
Changes or modifications to this equipment not specifically approved
by the Xerox Limited Corporation may void the user’s authority to
operate this equipment.

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL v
Table of contents
1. Introduction 1-1
Team Xerox Support for service and supplies 1-1
Organization and content of this manual 1-2
Terminology used in this manual 1-3
Conventions used in this manual 1-3
Safety Statements 1-4
Location of your Binder 120 1-6
Product orientation 1-8
Information sources 1-8
2. Getting to know the Binder 120 2-1
Main components 2-2
Control Panel 2-4
Interface Module 2-7
Manual Feeder 2-8
Cover Trays 2-9
Output Tray and Book Guide 2-10
Book path through the Binder 120 2-11
3. Preparing the Binder 120 for on-line and off-line operation 3-1
Modes of operation 3-2
On-line 3-2
Stand-by 3-2
Off-line 3-2
Connecting to a Xerox 5100 3-3
Checklist for connecting to a Xerox 5100 3-10
Connecting to a Xerox 5800 or 5895 3-11
Checklist for connecting to a Xerox 5800 or 5895 3-18
Connecting to a Xerox 5680/5892 3-19
Checklist for connecting to a Xerox 5680/5892 3-26
Connecting to a Xerox 5890 3-27
Checklist for connecting to a Xerox 5890 3-33
Disconnecting from a host machine 3-34
Checklist for disconnecting from a host machine 3-42
Switching to a different host machine 3-43
Switching from on-line to stand-by mode 3-44
Switching from stand-by to on-line mode 3-45

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 1-1
1. Introduction
The Xerox Document Binder 120 Operator Manual is for the use of
operators trained on the Binder 120 during machine installation. It
describes the operation and maintenance of the Binder 120 as an
automatic book-maker accessory to the Xerox 5100, 5800 family,
and 5680/5892 products or as a stand-alone, manual-feed book
maker. It accepts copy sets in either 8.5 by 11 inch (United States
and Canada) or A4 (Xerox Limited) sizes. It uses specially designed
Xerox covers to produce bound books.
Team Xerox support for service and supplies
Xerox has a professional team in place to help you if you have any
questions. You will need the following information when you call for
assistance:
Customer number: ___________________________________
Machine type: Xerox Document Binder 120
Serial number: ___________________________________
Software version: ___________________________________
Host machine type: ___________________________________
Customer
Support
Representative: ___________________________________
The Binder 120 requires the use of specially designed Xerox covers.
The covers are contained in cassettes that have a capacity of 150
covers. A variety of standard and custom covers is available.
Contact your Sales Representative for more information.
Record the telephone numbers in the spaces below for quick
reference when you need to contact a member of Team Xerox
support.
Sales: __________________________________________
Service: __________________________________________
Supplies: __________________________________________

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 2-1
2. Getting to know the Binder 120
This chapter introduces the Xerox Binder 120, illustrates its major
components, and provides you with information you will need to
begin making books.

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 3-1
3. Preparing the Binder 120 for
on-line and off-line operation
This chapter describes the modes of operation of the Binder 120. It
also explains how to set up the Binder 120 for both on-line
(automatic) and off-line (manual) operation. It includes procedures for
the following situations:
•Connecting to a host machine
Use this procedure to connect the Binder 120 to a host machine.
After doing so, the Binder 120 will be in the on-line mode for
automatic binding of books.
•Disconnecting from a host machine
Use this procedure to disconnect the Binder 120 from a host
machine. After doing so, the Binder 120 will be in the stand-
alone mode for manual binding of books.
•Switching to a different host machine
Use this procedure to disconnect the Binder 120 from one host
machine and connect it to a different one. After doing so, the
Binder 120 will remain in the on-line mode for automatic binding
of books.
•Switching from on-line to stand-by mode
Use this procedure to disconnect the Interface Module of the
Binder 120 from the Output Tray of the host machine. After
doing so, the Binder 120 will remain in the on-line configuration,
but will be in the stand-by mode. Both machines can then
operate independently.
•Switching from stand-by to on-line mode
Use this procedure to connect the Interface Module of the Binder
120 to the Output Tray of the host machine. After doing so, the
Binder 120 will be in the on-line mode for automatic binding of
books.

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 3-47
Connecting to a Xerox 5388
Use this procedure to connect the Binder 120 from the stand-alone
mode to a Xerox 5388 host machine.
1. Press the Binder 120 Power Switch to the Off (O) position.
2. Unplug the Binder 120 Power Cord from the electrical wall outlet
and the Binder 120.
•Set the Power Cord on top of the Binder 120.

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 4-1
4. Making the books
This chapter provides an overview of books. It also lists and explains
the steps in the book-making process.
Book overview
A book consists of one or more sheets, referred to as a copy set,
bound into a specially designed Xerox cover. The covers are
available in a variety of spine widths ranging from 1/16 inch (1.5 mm)
to 1/2 inch (13 mm). The appropriate spine width for a book
depends on the paper weight and number of sheets being bound.
The number of sheets that can fit into a specified spine width varies
according to the weight of the paper. For 20 lb, 24 lb or 80 gsm
Xerox paper, refer to the Spine Width/Sheet Capacity table in
chapter 8, “Technical data.”
If the Binder 120 detects the use of a non-Xerox cover, a “Please
Feed Set Using a Xerox Cover - Press Reset to Continue.”
message will appear in the Message Display of the Control Panel of
the Binder 120. The Binder 120 will stop processing. You must
perform a jam clearance to remove the copy set and cover from the
Binder 120. See chapter 7, “Problem solving,” for further information
about jam clearance.
The covers are contained in recyclable cardboard cassettes.
Cassettes are packaged in cases of three. Each cassette contains
150 covers with a total of 450 covers per case.
The cassettes are loaded into the Cover Trays of the Binder 120.
Each cassette has a bar code that the Binder 120 reads to
determine the cover type, color, and spine width. This is the
information that appears in the Cover Supply Contents Display of the
Control Panel of the Binder 120.

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 5-1
5. Customizing your Binder 120
The Binder 120 provides a number of Customer Tools features that
you can customize or program to meet your specific needs. These
features are as follows:
?Energy Saver
?Spine Width Units Display
?Attention Lamp
?Sound Tone
?Electronic Counter
?Security Code
?Software Version
This chapter describes these Customer Tools features and explains
how to change them.

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 6-1
6. Care
This chapter contains helpful hints for caring for your Binder 120 and
for ordering supplies, instructions for storing cover cassettes, and
information about cleaning your Binder 120.
Helpful hints
Care of your Binder 120
?Do not place heavy objects on any surface of the Binder 120.
?Do not place liquids on the Binder 120.
?Avoid placing paper clips or staples on the Binder 120 surface.
?Do not apply cleaning liquids or sprays directly to the Binder
120; apply them to a cloth first.
?Store the cover cassettes according to the directions provided in
this chapter.
Ordering supplies
The Binder 120 requires the use of specially designed Xerox covers.
The covers are contained in cassettes that have a capacity of 150
covers. The cassettes are ordered in cases of three. A variety of
standard and custom covers is available. Contact your Xerox Sales
Representative for more information.
To order cassettes, call the Xerox number that you recorded in
chapter 1, “Introduction,” at the beginning of this manual.

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 7-1
7. Problem solving
This chapter provides instructions for resolving the various problems
that can occur during the operation of the Binder 120. It includes
detailed procedures for resolving specific problems, as well as a
general problem-solving table. If you are unable to correct the
problem, follow the procedure for calling for service at the end of the
chapter.

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 8-1
8. Technical data
This chapter provides the product specifications and paper/cover
specifications for your Binder 120. It also includes the sheet
capacities for the various spine widths, a copy paper satisfaction
guide, and the book cool-down times.

TECHNICAL DATA
8-2XEROX DOCUMENT BINDER 120 OPERATOR MANUAL
Product specifications
The table below contains the product specifications for the Binder
120.
Automatic operation Capable with Xerox 5100, 5800 family, and 5680/5892 host machines. The Binder
120 is shipped with a Third Party Enablement Kit. When installed on a Xerox
5100, 5800 family, or 5680/5892 product, the kit enables the Binder 120 to operate
as an accessory to the host machine. Each kit is for one host machine only.
Additional host machines require additional kits.
Binding speed Accepts approximately one copy set per 2 seconds
Book output time Approximately 2.0 minutes from the time of entrance of a copy set into the Binder
120 until the book is available in the Output Tray
Book capacity ?On-line: 5 to 100 sheets
?Manual: 1 to 120 sheets
Output Tray capacity 20 to 80 books depending on the spine width
Cover Tray capacity ?Cover Tray 1: 1 cover cassette (150 covers)
?Cover Tray 2: 1 cover cassette (150 covers)
Warm-up time ?From the Off position: Approximately 2 minutes
?From the Energy Saver mode: Approximately 2 minutes
Electrical requirements ?Standard office outlet
?United States/Xerox Canada Limited: 115 VAC, 60 HZ
?Xerox Limited: 230 VAC, 50 HZ
Environmental requirements ?Minimum: 50?F (10?C) at 15% relative humidity
?Maximum: 90?F (32?C) at 85% relative humidity
Machine dimensions ?Height to Output Tray: 38 inches (965 mm)
?Height to top of Output Tray cover: 48 inches (1200 mm)
?Width: 23 1/2 inches (597 mm)
?Length with Interface Module down: 47 inches (1194 mm)
?Length with Interface Module up: 59 1/4 inches (1505 mm)

TECHNICAL DATA
XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 8-3
Machine weight Approximately 475 lbs (216 kg) with cassettes
Noise level ?Stand-by: 43.4 decibels
?Run: 62.3 decibels
Power consumption ?Warm up: 800 watts
?Standby: 237 watts
?Operation: 324 watts
?Energy Saver: 31 watts
Heat output ?Warm up: 2730 BTU per hour
?Standby: 809 BTU per hour
?Operation: 1106 BTU per hour
?Energy Saver: 108 BTU per hour

TECHNICAL DATA
8-4XEROX DOCUMENT BINDER 120 OPERATOR MANUAL
Paper/cover specifications
The table below contains the paper/cover specifications for the
Binder 120.
Paper size Either 8.5 x 11 inch (US/XCL) or A4 (XL)
Paper weight ?20 lb (80 gsm) to 110 lb (200 gsm) for tabs, inserts, and title sheets (the tabs,
inserts, and title sheets must be the same size as the sheets in the copy set)
?20 lb (80 gsm) to 32 lb (120 gsm) for all other types
Cover type Specially designed Xerox covers
Cover cassette capacity 150 covers per cassette (3 cassettes per case)

TECHNICAL DATA
XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 8-5
Spine width/sheet capacity
The table below contains the minimum/maximum sheet capacities
for the various spine widths.
Spine width Number of sheets allowed1
Inches Millimeters 20 lb 24 lb 80 gsm
1/1621.5 min - 15 min - 12 min - 13
1/8 316 -30 13 - 25 14 - 28
1/4 631 - 60 26 - 50 29 - 55
3/8 961 - 90 51 - 75 56 - 84
1/2 13 91 - 120 76 - 100 85 - 120
1The binding capacity and reliability will decrease with extremes of paper characteristics, such as curl, static,
temperature, humidity, and paper brand. The capacities listed are minimums/maximums for Xerox paper.
2Minimum sheets allowed in manual mode is 1. Minimum sheets allowed in automatic mode is 5.

TECHNICAL DATA
8-6XEROX DOCUMENT BINDER 120 OPERATOR MANUAL
Copy paper guide for reliable Binder 120 operation
For more reliable Binder 120 operation, Xerox recommends that you
use the following guide when selecting copy papers.
Copy Paper Excellent Good Not Recommended
Size 8.5 x 11 (A4) Any other sizes
Weight 20 - 24 lb (75 - 90 gsm) 25 - 110 lb (91 - 200 gsm) <20 lb (80 gsm)
>110 lb (200 gsm)
Copy Paper Type and
Condition Xerographic copy paper
Preprinted forms
Recycled paper
Less than 0.25 inch (6
mm) curl
Less than 0.5 inch (13
mm) curl Tabs
Plastic reinforced paper
Synthetic paper
Labels, coated and
carbonless stock
Window stock
Transparencies
Greater than 0.5 inch (13
mm) curl

TECHNICAL DATA
XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 8-7
Book cool-down time
The table below lists the recommended cool-down time for the glue
in the book cover spines to reach almost full strength.
When the books exit the Binder 120, you can handle and browse
through them. You should not, however, allow them to lie open until
the recommended cool-down time.
Spine width
(inches/millimeters) Cool-down time (in minutes)1
1/16 (1.5) 10
1/8 (3) 15
1/4 (6) 25
3/8 (9) 35
1/2 (13) 45
1The times indicated are for stacks of books consisting of copy sets fed
into the Binder 120 from the host machine. Individual books will cool
down in approximately half the time shown. Books consisting of
cooled-down copy sets fed through the Manual Feeder will also cool
down in half the time shown.

TECHNICAL DATA
8-8XEROX DOCUMENT BINDER 120 OPERATOR MANUAL
Notes: