Xerox Docutech 128 Technical manual

Finishing
Solutions
Planning
Guide
Supported Printers:
• Xerox DocuTech61xx
• Xerox DocuTech1xx HighLight Color (HLC)
• Xerox DocuPrint1xx
• Xerox iGen3Digital Production Press
• Xerox Nuvera100 / 120 Digital Production System
July 13, 2005
Rev. E
C.P. Bourg Document Finisher (BDFx)
with optional Cover Feeder,
Square Edge Module and Sheet Rotato
r

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,
Xerox iGen3Digital Production Press and Xerox NuveraDigital Production System 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 ............................................................................................................... 1-5
Environmental Requirements...................................................................................................... 1-6
Estimated Installation Time ......................................................................................................... 1-6
Operating Supplies ....................................................................................................................... 1-6
Floor Load...................................................................................................................................... 1-7
Floor Level ..................................................................................................................................... 1-7
Unique Features Set ........................................................................................................................ 1-8
Saddle Stitch.................................................................................................................................. 1-8
Edge / Top / Corner Stitch ........................................................................................................... 1-8
2. XEROX DOCUTECH61XX............................................................................................................. 2-1
Performance Specifications (DT61xx) ........................................................................................... 2-1
Performance Specifications (DT61xx with XSIS kit).................................................................... 2-1
Limitations.......................................................................................................................................... 2-2
System Dependencies and Prerequisites ..................................................................................... 2-2
Configuration Guide.......................................................................................................................... 2-2
Productivity Guide............................................................................................................................. 2-3
3. XEROX DOCUTECH1XX HIGHLIGHT COLOR (HLC) ................................................................... 3-1
Performance Specifications (DT1xx HLC) .................................................................................... 3-1
Limitations.......................................................................................................................................... 3-2
System Dependencies and Prerequisites ..................................................................................... 3-2
Configuration Guide.......................................................................................................................... 3-3
Productivity Guide............................................................................................................................. 3-3
4. XEROX DOCUPRINT1XX .............................................................................................................. 4-1
Performance Specifications (DP180)............................................................................................. 4-1
Performance Specifications (DP180 with XSIS kit) ..................................................................... 4-2
Limitations.......................................................................................................................................... 4-2
System Dependencies and Prerequisites ..................................................................................... 4-3
Configuration Guide.......................................................................................................................... 4-3
Productivity Guide............................................................................................................................. 4-4
5. XEROX IGEN3DIGITAL PRODUCTION PRESS .............................................................................. 5-1
Performance Specifications............................................................................................................. 5-1
Limitations.......................................................................................................................................... 5-2
System Dependencies and Prerequisites ..................................................................................... 5-2
Configuration Guide.......................................................................................................................... 5-2
Productivity Guide............................................................................................................................. 5-3
6. XEROX NUVERA100 / 120 DIGITAL PRODUCTION SYSTEM ....................................................... 6-1
Performance Specifications............................................................................................................. 6-1
Limitations.......................................................................................................................................... 6-2
System Dependencies and Prerequisites ..................................................................................... 6-2
Configuration Guide.......................................................................................................................... 6-3
Productivity Guide............................................................................................................................. 6-3
7. CUSTOMER AGREEMENT................................................................................................................. 7-5
Devices............................................................................................................................................... 7-5
Primary Customer Applications ...................................................................................................... 7-5
Special Considerations / Limitations .............................................................................................. 7-5

Table Of Contents

C.P. Bourg Document Finisher (BDFx)
Introduction
This Solutions Planning Guide contains information on how to
prepare for the installation of the C.P. Bourg Document Finisher
(BDFx) together with:
• Xerox DocuTech61xx
• Xerox DocuTech1xx HighLight Color (HLC)
• Xerox DocuPrint1xx
• Xerox iGen3Digital Production Press
• Xerox Nuvera100 / 120 Digital Production System
This guide also contains information on the optional C.P. Bourg
Cover Feeder (BCFx), SquareEdge Module (SQEDG) and C.P.
Bourg Sheet Rotator (BSR).
About this guide
This guide will provide the Analyst and the coordinating
Customer with common BDFx specifications and specific pre-
installation tasks for the Xerox printer (DocuTech 61xx,
DocuTech 1xx HighLight Color (HLC), DocuPrint 1xx, Xerox
iGen3 Digital Production Press and Nuvera100 / 120 Digital
Production System) to which the BDFx is to be installed with.
Contents
This section lists the contents of this guide:
• Introduction - provides information about the use of this
Guide.
• Product Overview– provides Installation Planning, including
Space requirements, Floor Load and Level, Electrical and
Environmental requirements, Installation Time and Operating
Supplies.
• Xerox DocuTech (DT 61xx) – provides information about
Limitations, System Dependencies, Configuration Guide and
Unique Features Set.
• Xerox DocuTech (DT 1xx HighLight Color (HLC)) – provides
information about Limitations, System Dependencies,
Configuration Guide and Unique Features Set.
• Xerox DocuPrint (DP1xx) – 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.
I

C.P. Bourg Document Finisher (BDFx)
• Customer Agreement – contains the Customer Agreement
form.
II

Introduction
This Solutions Planning Guide contains information on how to
prepare for the installation of the C.P. Bourg Document Finisher
(BDFx) together with:
• Xerox DocuTech61xx
• Xerox DocuTech1xx HighLight Color (HLC)
• Xerox DocuPrint1xx
• Xerox iGen3Digital Production Press
• Xerox Nuvera100 / 120 Digital Production System
This guide also contains information on the optional C.P. Bourg
Cover Feeder (BCFx), SquareEdge Module (SQEDG) and C.P.
Bourg Sheet Rotator (BSR).
About this guide
This guide will provide the Analyst and the coordinating
Customer with common BDFx specifications and specific pre-
installation tasks for the Xerox printer (DocuTech 61xx,
DocuTech 1xx HighLight Color (HLC), DocuPrint 1xx, Xerox
iGen3 Digital Production Press and Nuvera100 / 120 Digital
Production System) to which the BDFx is to be installed with.
Contents
This section lists the contents of this guide:
• Introduction - provides information about the use of this
Guide.
III

C.P. Bourg Document Finisher (BDFx)
1. Product Overview
Cover Feeder
(BCFx)
Booklet Maker
(BDFx)
Square Edge
(SQEDG)
The C.P. Bourg BDFx is a fully automated signature booklet maker,
which produces high quality saddle stitched booklets in-line. The
optional cover insertion module (BCFx) can feed preprinted cover
stock up to 300 gsm excluding window cutouts (the BCFx is not
available for iGen3).
The new Square Edge (SQEDG) Module option further expands its
capability by offering an optional square edge spine.
The BDFx can top or corner stitch from 2 to 50 sheets and it can
also be used in the fold only mode.
The Bourg Sheet Rotator (BSR) enables maximimum small Booklet
productivity on Xerox printers that are not equipped with an internal
rotator. (Not shown.) The BSR is mandatory when the BDFx is
installed with the iGen3Digital Production Press.
1-1

C.P. Bourg Document Finisher (BDFx)
Install Planning
This Install Planning guide will help you prepare for the installation
of the C.P Bourg Document Finisher (BDFx) together with:
• Xerox DocuTech61xx
• Xerox DocuTech1xx HighLight Color (HLC)
• Xerox DocuPrint1xx
• Xerox iGen3Digital Production Press
• Xerox Nuvera100 / 120 Digital Production System
Device Configurations
The Bourg Document Finisher components are:
• BDFx with Conveyor and 2 Cassette Stitch Heads
• Bourg Cover Feeder X (BCFx), optional (not available with
iGen3)
• Square Edge Module (SQEDG), optional
• Bourg Sheet Rotator (BSR), optional (mandatory with iGen3)
• Hohner or Cassette Stitch Heads (2 –4 heads total), optional
Note: The BDFx is delivered with 2 stitch heads. A third and / or
forth stitch head must be ordered and installed with the machine.
Space Requirements
The space requirements illustration provides machine footprint as
well as the overall operating and maintenance area.
In addition to the diagram below, there should be a minimum of 82
inches (2.083 mm) clearance from the floor to the nearest overhead
obstruction.
1-2

C.P. Bourg Document Finisher (BDFx)
Powe
r
35 inches
889 mm
Bourg Document
Finisher X
(BDFx)
94 inches
2391 mm
24 inches
613 mm Conve
y
or 35 inches
889 mm
68 inches
1736 mm
36 inches
914 mm
35 inches
889 mm
139 inches
3539 mm
Powe
r
35 inches
889 mm
Bourg Document
Finisher X
(BDFx)
Conve
y
or
BSR 94 inches
2391 mm
35 inches
889 mm
31.5 inches
805 mm
68 inches
1736 mm
36 inches
914 mm
35 inches
889 mm
170.5 inches
4344 mm
1-3

C.P. Bourg Document Finisher (BDFx)
Powe
r
35 inches
889 mm
94 inches
2391 mm
35 inches
889 mm
24 inches
613 mm
Bourg Document
Finisher X
(BDFx)
BCFx SQEDG
68 inches
1736 mm
19.7 inches
500 mm
40.1 inches
1020 mm
35 inches
889 mm
162.8 inches
4145 mm
Powe
r
35 inches
889 mm
Bourg Document
Finisher X
(BDFx)
BCFxBSR
24 inches
613 mm SQEDG
94 inches
2391 mm
35 inches
889 mm
68 inches
1736 mm
40.1 inches
1020 mm
31.5 inches
805 mm 19.7 inches
500 mm
35 inches
889 mm
194.3inches
4950 mm
Note: The space requirements diagram for the BDFx and the
optional devices are representations only and not drawn to scale.
1-4

C.P. Bourg Document Finisher (BDFx)
Dimensions Bourg Document Finisher Square Edge Module
(optional)
Bourg Cover Feeder
(optional,)
Width x Depth x Height 104.3” * x 24” x 71”
2650 x 739 x 1803 mm
*- Including Conveyor
40.1” x 24.25” x 49”
1020 x 616 x 1242 mm
26.75” * x 27” x 52”
680 x 687 x 1242 mm
*- 19.7” (500 mm) actual
floor space.
Shipping Dimensions
Width x Depth x Height
77” x 30” x 73”
1950 x 750 x 1850 mm
47.2” x 35.8” x 63”
1200 x 910 x 1600 mm
51” x 31.5” x 59”
1300 x 800 x 1500 mm
Weight 992 lbs (450 kg) 198 lbs (90 kg) 291 lbs (132 kg)
Shipping Weight 1235 lbs (560 kg) 507 lbs (230 kg) 264 lbs (120 kg)
Operator Clearance Minimum 24” (609.6mm) in
front of the device
Minimum 24” (609.6mm) in
front of the device
Minimum 24” (609.6mm) in
front of the device
Service Clearance Minimum 35” on all sides of
the device
Minimum 35” on all sides of
the device
Minimum 35” on all sides of
the device
Dimensions Bourg Sheet Rotator (optional,
mandatory with iGen3)
Width x Depth x Height 31.5” x 28.5” x 38.5”
805 mm x 720 mm x 980 mm
Shipping Dimensions
Width x Depth x Height
34.6” x 32.7” x 49.2”
880 mm x 830 mm x 1250 mm
Weight 298 lbs (135 kg)
Shipping Weight 353 lbs (160 kg)
Operator Clearance Minimum 24” (609.6mm) in front of the
device
Service Clearance Minimum 30” (763 mm) on all sides of
the device
Electrical Requirements
Nema # for all the devices listed below: 5R-15
Device North America Europe
BDF-X Power 120 VAC (+/- 10%), 60 Hz, 10A 230 VAC (+/- 10%), 50 Hz, 7A
BCF-X Power 120 VAC (+/- 10%), 60 Hz, 5A 230 VAC (+/- 10%), 50 Hz, 3A
SQEDG Power 120 VAC (+/- 10%), 60 Hz, 5A 230 VAC (+/- 10%), 50 Hz, 3A
Device North America Europe
BSR 110VAC (+/- 10%), 60 Hz, 4A 220VAC, (+/- 10%), 50 Hz, 2A
Note: For power cord locations on each device please refer to the
space diagrams in the Space Requirements section.
1-5

C.P. Bourg Document Finisher (BDFx)
Environmental Requirements
Environment BDFx / BCFx / SQEDG
Temperature 41 - 85°F (5 - 29°C)
Humidity 50 - 85%
Heat Emission BDFx: 2560 btu / hr
BCFx: 1590 btu / hr
SQEDG: 2400 btu / hr
Sound Emission 72 db
Altitude -100 ft. (-31m) to 4,000 ft. (1,219 m)
Environment BSR
Temperature 41 - 85°F (5 - 29°C)
Humidity 50 – 85%
Heat Emission 1,535 btu / hr
Sound Emission 55 db
Altitude -100 – 4,000 ft (-31 – 1,219 m)
Estimated Installation Time
C.P. Bourg installs the BDFx (including BCFx and SQEDG) and the
estimated installation time is 4 – 8 hours.
Installation and customer training will require approximately 2 days
total.
Operating Supplies
Each Bourg Document Finisher is delivered with 2 stitch heads. The
machine can be equipped with 1 or 2 additional stitch heads (any
additional stitch heads must be ordered when the machine is
ordered as this is not an upgrade that can be done in the field).
There are no operating supplies for the BSR.
Supply No. Description. Quantity / Unit
9158017 Wire Cassette (Acme Stitch Heads) 50, 0000 stitches / cassette
(2 cassettes / box)
9158018 Wire Spool (Hohner Stitch Heads) 50, 0000 stitches / spool
You can reach C.P. Bourg Customer Service using the following
phone number:
• United States and Canada: 1-508-998-2171
For Europe, please visit the C.P. Bourg web site and select your
region:
http://www.cpbourg.com
1-6

C.P. Bourg Document Finisher (BDFx)
Floor Load
Device Uniform load Point load
BDFx 68 lbs / sq.ft. (326 kg / sq. m) Casters A: 4,840 lbs / sq.in. (340 kg / sq.cm)
Casters B: 3,957 lbs / sq.in. (279 kg / sq.cm)
BCFx 30 lbs / sq.ft. (148 kg / sq. m) Casters: 1,053 lbs / sq.in. (75 kg / sq.cm)
SQEDG Module 44 lbs / sq.ft. (212 kg / sq. m) Casters: 2,680 lbs / sq.in. (190 kg / sq.cm)
BSR 48 lbs / sq.ft. (233 kg / sq. m) Casters: 1,585 lbs / sq.in. (112 kg / sq.cm)
Caster
BSR BCFx BDFx
ASQEDG B
Floor Level
BSR BDFx SQEDG
X4
X2
X3
X1
Configuration Measurement Specification
X1 5 ft (1.52 m) 3/16 in./ ft (4.77 mm / m)
X2 7.75 ft (2.36 m) 1/8 in./ ft (3.175 mm / m)
X3 7.5 ft (2.28 m) 1/8 in./ ft (3.175 mm / m)
X4 10 ft (3.05 m) 3/32 in./ ft (2.4 mm / m)
Note:The floor level is based on a printer paper exit height above
the floor of 34” (860 mm) for DP1xx, DT1xx, iGen3 and 40.2” (1021
mm) for DT61xx and Nuvera.
1-7

C.P. Bourg Document Finisher (BDFx)
Unique Features Set
Listed below are diagrams of the various stitch positions that the
BDF-X can produce.
Note: The BDFx is delivered with 2 stitch heads. A third and forth
stitch head must be ordered and installed with the machine to
enable the 3 and 4 stitch options shown in the diagrams below.
For high volume machines, it is recommended to use the Hohner
(Spool) Stitch Heads.
Saddle Stitch
Edge / Top / Corner Stitch
1-8

C.P. Bourg Document Finisher (BDFx)
2. Xerox DocuTech61xx
Performance Specifications (DT61xx)
Listed below are the Performance Specifications for the C.P.
Bourg Document Finisher, Cover Feeder and SquareEdge
Module.
Stapling / Folding Specifications
Paper Type /
Weight
BDFx / SQEDG: Uncoated Stock, 16 lbs Bond – 110 lbs Index (60 - 200 gsm)
BCFx: Uncoated Cover Stock, 20 lbs Bond – 10 pt cover stock (80 – 300 gsm∗)
∗- for all cover stocks, excluding window cutouts
Paper Size BDFx: 8 x 10” – 14 x 17” (203 x 254 mm – 364 x 432 mm)
BDFx w / BCFx in bypass mode: 8 x 10” – 12.25 x 17” (203 x 254 mm – 310 x 432 mm)
BDFx w / BCFx feeding covers: 8 x 10” – 11.75 x 17” (203 x 254 mm – 298 x 432 mm)
Booklet Sizes BDFx: 8 x 5” – 14 x 8.5” (203 x 127 mm – 364 x 216 mm)
BDFx w / BCFx in bypass mode: 8 x 5” – 12.25 x 8.5” (203 x 127 mm – 310 x 216 mm)
BDFx w / BCFx feeding covers: 8 x 5” – 11.75 x 8.5” (203 x 127 mm – 298 x 216 mm)
Edge Stapling BDFx: 8 x 10 – 11.7 x 14 (203 x 254 mm – 298 x 356 mm)
BDFx w / BCFx: 8 x 10 - 11.7 x 12.25 (203 x 254 mm – 298 x 310 mm)
Face Trim 0 – ¾” (0 – 19 mm)
Stitch Head Two to four stitch heads (Hohner or Acme)
Sheet Capacity
(Stitching)
Edge / Top / Corner Stitching: 2 – 50 sheets
Saddle Stitching: 2 – 22 sheets (20 lb Bond / 80 gsm)
Input Height 34” (860 mm) and 40.2” (1021 mm)
Performance Specifications (DT61xx with XSIS kit)
Stapling / Folding Specifications
Paper Size BDFx: 7 x 10” – 14 x 19.2” (178 x 254 mm – 364 x 488 mm)
BDFx w / BCFx in bypass mode: 8 x 10” – 12.25 x 17” (203 x 254 mm – 364 x 432 mm)
BDFx w / BCFx feeding covers: 8 x 10” – 11.75 x 17” (203 x 254 mm – 298 x 432 mm)
Booklet Sizes BDFx: 8 x 5” – 14 x 8.5” (203 x 127 mm – 364 x 216 mm)
BDFx w / BCFx in bypass mode: 8 x 5” – 12.25 x 8.5” (203 x 127 mm – 364 x 216 mm)
BDFx w / BCFx feeding covers: 8 x 5” – 11.75 x 8.5” (203 x 127 mm – 298 x 216 mm)
Edge Stapling BDFx: 8 x 10 – 11.7 x 14 (203 x 254 mm – 298 x 356 mm)
BDFx w / BCFx: 8 x 10 - 11.7 x 12.25 (203 x 254 mm – 298 x 310 mm)
Face Trim 0 – ¾” (0 – 19 mm)
2-1

C.P. Bourg Document Finisher (BDFx)
Limitations
• The BDFx can only be guaranteed to work to its maximum
book thickness when feeding (8.5 x 11 / A4) paper if the
paperweight is 90 gsm or less. (Long grain paper with a
weight above 90 gsm should be tested with the customer
paper and application before selling the BDFx.)
• Use of short grain paper is highly recommended for 11 x 17”
/ A3 sized paper.
System Dependencies and Prerequisites
Listed below are the dependencies and prerequisites for
installing the BDFx, BCFx and SQEDG module.
• The DT61xx 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 currently supported.
IOT INTERPOSER
DS5000 BDFx
BDFx
BYPASS
TRANSPORT BCFx BDFx SQEDG
BCFx BDFx
DS5000 BCFx BDFx
DS5000 SQEDG
BCFx BDFx
DS5000 BDFx DS5000 BCFx BDFx
DS5000 SQEDG
BCFx BDFx
DS5000 DS5000
DS5000
Printer Configurations Finisher Configurations
2-2

C.P. Bourg Document Finisher (BDFx)
Productivity Guide
The calculated productivity for the BDFx is based on host
machine running duplex job.
Set Size /
8.5 x 11” (A4)
1 sheet 2 sheets 3 sheets 4 sheets 5 sheets 10 sheets 15 sheets 22 sheets
Booklets / Hour 2700 2195 1538 1385 1037 523 338 239
Set Size /
11 x 17” (A3)
1 sheet 2 sheets 3 sheets 4 sheets 5 sheets 10 sheets 15 sheets 22 sheets
Booklets / Hour 1540 1179 675 588 451 237 153 108
2-3

C.P. Bourg Document Finisher (BDFx)
2-4