Xerox DocuPrint 75, DocuColor 6060, DocuPrint 90, Nuvera 100, Nuvera 120 Planning Manual

Finishing

Xerox Document Binder 120-D

(DB120-D)

Solutions

Planning

Guide

Supported Printers:

• Xerox DocuColor 2045 / 2060 / 5252 / 6060 / 7000 / 8000
Digital Color Press

• Xerox DocuPrint 75 / 90 & DocuTech 75 / 90

• Xerox Nuvera 100 / 120 Digital Production System

July 13, 2005
Rev. E

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:

[e-mail]

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 DocuColor and the Xerox Nuvera Digital Production System are trademarks of, or licensed to,
Xerox Corporation.
Classic Series Cover is a registered trademark of Coverbind.
Other product names used herein are trademarks of their respective owners.

Table Of Contents

INTRODUCTION .......................................................................................................................................... I

About this guide .................................................................................................................................... I

Contents................................................................................................................................................. I

Contact Information .........................................................................................................................II

1. PRODUCT OVERVIEW ...................................................................................................................... 1-1

Performance Specifications............................................................................................................. 1-2

Install Planning.................................................................................................................................. 1-3

Device Configurations .................................................................................................................. 1-3

Space Requirements.................................................................................................................... 1-3

Electrical Requirements................................................................................................................... 1-5

Environmental Requirements...................................................................................................... 1-5

Estimated Installation Time ......................................................................................................... 1-5

Operating Supplies ....................................................................................................................... 1-6

2. XEROX DOCUCOLOR 2045 / 2060 / 5252 / 6060 / 7000/ 8000 DIGITAL COLOR PRESS........... 2-1

Limitations.......................................................................................................................................... 2-1

System Dependencies and Prerequisites ..................................................................................... 2-1

Configuration Guide.......................................................................................................................... 2-1

Productivity Guide............................................................................................................................. 2-2

3. XEROX DOCUPRINT 75 / 90 & DOCUTECH 75 / 90....................................................................... 3-1

Limitations.......................................................................................................................................... 3-1

System Dependencies and Prerequisites ..................................................................................... 3-1

Configuration Guide.......................................................................................................................... 3-1

Productivity Guide............................................................................................................................. 3-1

4. XEROX NUVERA 100 / 120 DIGITAL PRODUCTION SYSTEM....................................................... 4-1

Limitations.......................................................................................................................................... 4-1

System Dependencies and Prerequisites ..................................................................................... 4-1

Configuration Guide.......................................................................................................................... 4-2

Productivity Guide............................................................................................................................. 4-2

5. CUSTOMER AGREEMENT FORM ...................................................................................................... 5-1

Devices............................................................................................................................................... 5-1

Primary Customer Applications ...................................................................................................... 5-1

Special Considerations / Limitations.............................................................................................. 5-1

I

Table Of Contents

II

Xerox Document Binder 120-D (DB120-D)

Introduction

About this guide

Contents

The purpose of this document is to describe the features and
operation of the Xerox Document Binder 120-D (DB120-D) when
used inline with validated Xerox printers. It also provides
information to be used when planning the installation of this
solution.

This guide will provide the Analyst and the Customer with
common DB120-D specifications and pre-installation tasks
based on the actual Xerox printer model attached to the
DB120-D.

Note: The DB120-D’s capability of running Letter size and A4
paper is hardware dependent. Reference is made to both USA
(Lettersize/115V) and Europe (A4/230V) when applicable data
and specifications differ between the two.

This section lists the contents of this guide:

• Introduction - provides information about the use of this
Guide.

• Product Overview–provides Performance Specifications and
Installation Planning including Space, Electrical,
Environmental requirements, Installation Time and Operating
Supplies.

• Xerox DocuColor 2045/2060/5252/6060/7000/8000 Digital
Production Press – provides information about Limitations,
System Dependencies and Configuration Guide.

• Xerox DocuPrint 75 / 90 & DocuTech 75 / 90 - provides
information about Limitations, System Dependencies and
Configuration Guide.

• Xerox Nuvera 100 / 120 Digital Production System –
provides information about Limitations, System
Dependencies and Configuration Guide.

• Customer Agreement – contains the Customer Agreement
form.

I

Xerox Document Binder 120-D (DB120-D)

Contact Information

Coverbind is Bindomatic’s US subsidiary. For support in the
United States, please contact:

Coverbind

3200 Corporate Drive, Wilmington, NC 28405

Phone [phone] & 910-799-4116, Fax [phone]

E-mail [e-mail]

For support in Europe, please contact:

Bindomatic AB

Box 42101, SE-126 14 Stockholm, Sweden

Phone [phone], Fax [phone]

E-mail [e-mail]

II

Xerox Document Binder 120-D (DB120-D)

1. Product Overview

DB120-D

Document Binder

The Document Binder DB120-D uses a unique perfect binding
technology combined with pre-formed covers to create a high
quality professionally bound document. The DB120-D binds 8.5”
x 11” (A4 in Europe) documents up to 120 pages in a variety of
ready available, wide range of standard covers. The DB120-D
standard covers always display a transparent plastic front page.

You can custom order imprinted covers with your logo or a
particular design. The pre-formed cover wraps around the
internal pages to produce a perfect bound document with a
commercial look and feel. The document pages fit neatly and
uniformly into the bind for the perfect bound look. Trimming is not
needed.

The spine is scored in four places allowing each sheet of paper
to hinge. The adhesive in the spine is reinforced with a mesh
cloth that strengthens the book’s spine. The result is a perfect
bound book that lies flat when open and won’t fall apart.

1-1

Xerox Document Binder 120-D (DB120-D)

Performance Specifications

Binding US Specifications European Specifications

Paper Size / Weight 8.5” x 11” (216 x 279 mm)

Cover Sizes

Spine Width / Approx. # of
sheets

Tray Capacity Input Tray: 2 pre-loaded cassettes

Warm-up Time Approx. 2 minutes Approx. 2 minutes

Input Height 34” (860 mm) and 40.2” (1021 mm) 34” (860 mm) and 40.2” (1021 mm)

Listed below are the Performance Specifications for the
Document Binder 120-D.

A4 (210 x 297 mm)

Note: A conversion kit allowing for usage
of A4 / 115V is available. These kits
would be applicable on some specific
markets and special applications.

20 lbs (75 gsm) – 32 lbs index (120 gsm)
bond and flush cut tabs.

Weights above 32 lbs. (120 gsm) should
be used only as dividers or inserts.

Based on 20 lbs (75 gsm) paper

1/16” / 2 – 15 sheets (∗)

1/8” / 16 – 30 sheets

1/4" / 31 – 60 sheets

3/8” / 61 – 90 sheets

1/2" / 91 – 120 sheets

(∗) Minimum sheets for 1/16” dependent
on connected printer. In walk-up mode
however, 1 – 15 sheets are allowed
regardless of connected printer.

containing 150 covers each

Output Tray: 20 – 100 finished sets
depending on spine width.

Note: A conversion kit allowing for usage
of Letter size / 230V is available. These
kits would be applicable on some specific
markets and special applications.

20 lbs (75 gsm) – 32 lbs index (120 gsm)
bond and flush cut tabs.

Weights above 32 lbs. (120 gsm) should
be used only as dividers or inserts.

Based on 80 gsm paper

1.5 mm / 2 – 13 sheets (∗)

3 mm / 14 – 28 sheets

6 mm / 29 – 55 sheets

9 mm / 56 – 84 sheets

13 mm / 85 – 120 sheets

(∗) Minimum sheets for 1.5 mm dependent
on connected printer. In walk-up mode
however, 1 – 15 sheets are allowed
regardless of connected printer.

Input Tray: 2 pre-loaded cassettes
containing 150 covers each

Output Tray: 20 – 100 finished sets
depending on spine width.

1-2

Xerox Document Binder 120-D (DB120-D)

Install Planning

Device Configurations

Space Requirements

This Install Planning guide will help you prepare for the
installation of the DB 120-D.

The Document Binder 120-D components are:

• Document Binder 120-D

The space requirements illustration provides machine footprint
as well as the overall operating and maintenance area.

In addition to the diagram, there should be a minimum of 78
inches (1,981mm) clearance from the floor to the nearest
overhead obstruction.

17 inches
432 mm

Document Binder 120 –D

(DB120-D)

56 inches
1422 mm

30 inches
763 mm

73inches
1854 mm

24 inches
610 mm

17 inches
432 mm

71 inches
1805 mm

1-3

Xerox Document Binder 120-D (DB120-D)

17 inches
432 mm

75 / 90

Finisher

75 / 90

Bypass

Transport

23 inches
584 mm

Document Binder 120 –D

(DB120-D)

56 inches
1422 mm

96 inches
2438 mm

30 inches
763 mm

24 inches
610 mm

17 inches
432 mm

Note: The space requirement diagrams for the DB 120-D are
representations only and not drawn to scale.

Dimensions Document Binder 120-D DocuPrint DocuTech 75/90 Bypass

Width x Depth x Height 56” x 24” x 50 1/2”

1422 mm x 610 mm x 1283 mm

Shipping Dimensions

Width x Depth x Height

Weight 462 lbs (210 kg) 99.2 lbs (45 kg)

Shipping Weight 542 lbs (246.4 kg) N/A

Operator Clearance Minimum 24” (610 mm) in front of the

Service Clearance Minimum 30” (763 mm) in front, 17”

66.5” x 31” x 53.25”

1689 mm x 787 mm x 1352 mm

device

(432 mm) behind and to the right of the
device

23” x 25” x 42”

584 mm x 635 mm x 1067 mm

N/A

Minimum 24” (610 mm) in front of the
device

Minimum 30” (763 mm) in front, 17”
(432 mm) behind the device

Transport

71 inches
1805 mm

1-4

Xerox Document Binder 120-D (DB120-D)

Electrical Requirements

Device North America Europe

Document Binder120-D 115 VAC, 60 Hz, 7A

DocuPrint DocuTech 75/90
Bypass Transport

Environmental Requirements

The recommended location of the electrical wall outlet, mounted
on a rear wall is to be no more than 6 feet (1,829mm) away from
the rear center of the Document Binder 120-D.

220VAC, 50 Hz, 3.5A

Power cord: 6 - 8 ft (1,829 –
2,438 mm)

105 - 127 VAC 60 Hz, 2 A N/A

Device Document Binder120-D

Temperature

Humidity 10 – 85% (non-condensing)

Heat Emission 108 btu / hr. (Energy Saver mode)

Sound Emission Standby: 46 dB

Altitude 0 – 13,000 ft. (0 – 4,000 m)

50 - 90° F (10 - 32°C)

809 btu / hr. (Standby mode)

1106 btu / hr. (Operating mode)

4 sheets binding: 68 dB

30 sheets binding: 66 dB

100 sheets binding: 66 dB

Power cord: 6 - 8 ft (1,829 –
2,438 mm)

Estimated Installation Time

In North America, the CoverBind personnel install the DB120-D
and the estimated installation time is 2 hours. CoverBind
personnel also provides an initial 2 – 4 hour customer training.

In Europe, Bindomatic personnel install the DB120-D and the
estimated installation time is 2 hours. Bindomatic personnel also
provides an initial 2 – 4 hour customer training..

To contact Bindomatic and / or Coverbind, please go to:

Contact Information

1-5

Xerox Document Binder 120-D (DB120-D)

Operating Supplies

Covers specific to USA Reorder #

Classic Series

Impression Series A non-glare / frosted transparent plastic front

Custom Wrap around covers with customized color

Each DB20-D is delivered with a sample/install package of
covers. These install packs differ slightly between USA and
Europe but the purpose is the same – to provide installation
technician with covers for install purposes and customer with
covers for initial testing.

There are several styles of covers available. Below you will find
listings of the various covers / market:

A non-glare / frosted, transparent plastic front
side with satin spine and back side.

Available in:

White, Black, Burgundy, Navy Blue, Royal
Blue, Red & Green

side with linen embossed chlorine free
uncoated coloured graphical board spine and
backside.

Available in:

White, Black, Red, Gray, Blue

printing, foil stamping or die cutting*.

White 3R8860 – 3R8864

Black 3R8865 - 3R8869

Burgundy 3R8880 - 3R8884

Green 3R8885 - 3R8889

Navy Blue 3R8875 - 3R8879

Red 3R8870 - 3R8874

Royal Blue 3R8890 - 3R8894

Aqua 3R8895 - 3R8899

White 3R6843 - 3R6847

Black 3R6833 - 3R6837

Blue 3R6838 - 3R6842

Red 3R6849 - 3R6853

Gray 3R6854 - 3R6858

* - For custom covers, contact your Xerox sales representative

(or visit http://www.xerox.com, and select Supplies) for more
information.

1-6

Xerox Document Binder 120-D (DB120-D)

Covers specific to Europe Reorder #

Royal Series A non-glare/frosted transparent plastic front

Impression Series A non-glare / frosted transparent plastic front

Xerox Generic Xerox Generic Customized / Logo Cover

side with linen embossed chlorine free
uncoated coloured graphical board spine and
back side.

Available in:

White, Black, Dark Green, Burgundy, Grey,
Blue, Graphite & Dark Blue

side with linen embossed chlorine free
uncoated coloured graphical board spine and
backside.

Available in:

White, Black, Red, Grey, Blue

“Frog”

White 3R93676 - 3R93680

Black 3R93701 - 3R93705

Graphite 3R97650 - 3R97654

Burgundy 3R93691 - 3R93695

Dark Blue 3R93696 - 3R93700

Grey 3R93681 - 3R93685

Dark Green 3R93686 - 3R93690

Blue 3R97645 - 3R97649

White 3R97700 - 3R97704

Black 3R97705 - 3R97709

Blue 3R97710 - 3R97714

Red 3R97715 - 3R97719

Grey 3R97720 - 3R97724

3R97657 – 3R97659 *

(* - Available in 1.5, 3 and 6 mm
only.)

Covers range in spine width from 1/16" (1.5mm) - 1/2" (13mm)
and there are three cassettes of 150 covers per cassette and
three cassettes per master box. There is only one spine width
per cassette.

The Xerox Supplies Marketing Center is available for ordering
Xerox supplies, including paper and other throughput material.
You can reach the Xerox Supplies Marketing Center using the
following toll-free phone number:

• United States 1-800-822-2200

• Canada 1-800-668-0199

For Europe, please visit the Xerox web site and select your
country:

http://www.xerox.com

1-7

Xerox Document Binder 120-D (DB120-D)

1-8

Xerox Document Binder 120-D (DB120-D)

2. Xerox DocuColor 2045 / 2060 / 5252 / 6060 / 7000/ 8000
Digital Color Press

Limitations

System Dependencies and Prerequisites

• When connected inline with a printer, the minimum binding
capacity is 3 sheets / 2045, 4 sheets / 2060 and 2 sheets /
5252, 6060, 7000 and 8000 using 20lbs (75 gsm) bond
paper. (In walk-up manual mode, the minimum binding
capacity is 1 sheet 20 lbs (75 gsm) bond paper.)

• The DB120-D is compatible with 8.5 x 11” (A4 in Europe)
paper in weights ranging from 20 – 110 lbs (75 – 200 gsm)
bond and flush cut tabs.

Note: Weights above 32 lbs (120 gsm) should only be used as
covers, dividers or inserts.

Listed below are the dependencies and prerequisites for
installing the DB120-D.

• A High Capacity Stacker / Enhanced High Capacity Stacker
is needed to connect the DB120-D inline with the Xerox
DocuColor 2045 / 2060 / 5252 / 6060 / 7000 / 8000.

• A DFA Enablement Kit (675K11272) is required to connect
the DB120-D with the Xerox DocuColor 2045 / 2060 / 5252 /
6060 / 7000 / 8000.

• A Feeding & Finishing Interface Unit kit (FFIU kit
497K02331) is required to connect the DB120-D with the
Xerox DocuColor 2045 / 2060 / 5252 / 6060 / 7000 / 8000.

Configuration Guide

The Configuration Guide contains diagrams over the various
Finishing Solutions that are available.

2-1

Xerox Document Binder 120-D (DB120-D)

Printer Configurations Finisher Configurations

DocuColor 6060

Tray 3-4 Tray 1-2 IOT

Tray 3-4 Tray 1-2 IOT EHCS

DocuColor 7000 / 8000

Tray 1-2 IOT HCS80

Tray 3-4 Tray 1-2 IOT HCS80

DB120-D

Productivity Guide

The DB120-D will keep up with the rated speed of the printer.

2-2

Xerox Document Binder 120-D (DB120-D)

3. Xerox DocuPrint 75 / 90 & DocuTech 75 / 90

Limitations

System Dependencies and Prerequisites

• When connected inline with a printer, the minimum binding
capacity is 5 sheets for 75 PPM and 6 sheets for 90 PPM
using 20lbs (75 gsm) bond paper. (In walk-up manual mode,
the minimum binding capacity is 1 sheet 20 lbs (75 gsm)
bond paper.

• The DB120-D is compatible with 8.5 x 11” (A4 in Europe)
paper in weights ranging from 20 – 110 lbs (75 – 200 gsm)
bond and flush cut tabs.

Note: Weights above 32 lbs (120 gsm) should only be used as
covers, dividers or inserts.

A Bypass Transport is required for in-line connectivity to the
printer.

Configuration Guide

The Configuration Guide contains diagrams over the various
Finishing Solutions that are available.

Printer Configurations Finisher Configurations

FINISHER DB120-DIOT

Productivity Guide

The DB120-D will keep up with the rated speed of the printer.

BYPASS

TRANSPORT

3-1

Xerox Document Binder 120-D (DB120-D)

3-2

Xerox Document Binder 120-D (DB120-D)

4. Xerox Nuvera 100 / 120 Digital Production System

Limitations

• A Finisher Transport Module is required for in-line
connectivity to the printer.

• Coated paper is functional with the 860mm input height but
not recommended for the 1021mm input height. However,
binding test could be done and binding strength
confirmed/checked before start of job/production.

• When connected inline with a printer, the minimum binding
capacity is 2 sheets of 20 lbs (75 gsm) bond paper. (In walk­up manual mode, the minimum binding capacity is 1 sheet
20 lbs (75 gsm) bond paper.

• The DB120-D is compatible with 8.5 x 11” (A4 in Europe)
paper in weights ranging from 20 – 110 lbs (75 – 200 gsm)
bond and flush cut tabs.

Note: Weights above 32 lbs (120 gsm) should only be used as
covers, dividers or inserts.

System Dependencies and Prerequisites

Listed below are the dependencies and prerequisites for
installing the DB120-D.

• The Finisher Transport Module is required for in-line
connectivity to the printer.

• Currently, a Xerox Document Stacker 5000 must be installed
in-line with the printer and the DB120-D.

• If the DB120-D is installed in-line with another Finishing
Device (such as a DS5000), the 1021 Height Kit must be
installed (unit is shipped with 860 Height Kit installed).

• If there is a transition of an existing (stand alone or from a
different printer) DB120-D to a Nuvera Digital Production
System, the DB120-D 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).

4-1

Xerox Document Binder 120-D (DB120-D)

s

A

Configuration Guide

Printer Configurations Finisher Configurations

The Configuration Guide contains diagrams over the various
Finishing Solutions that are available.

SFM IOT FTM

SFM SFM IOT

SFM IOT INS

SFM SFM IOT

DB120D

FTM

DS5000 DB120D

FTM

INS FTM

Note: This option i

currently not supported.

DS5000 is required.

DS5000 DB120DDS5000

Productivity Guide

The DB120-D will keep up with the rated speed of the printer.

4-2

Xerox Document Binder 120-D (DB120-D)

5. Customer Agreement Form

Devices

As a final step in the install planning you must complete the
Customer Agreement form.

Check off the modules that will be part of this install:

• Xerox Document Binder 120-D

• DocuPrint / DocuTech 75 / 90 Bypass Transport

• A4 / 115V Conversion Kit

• Letter size / 230V Conversion Kit

• 1021 Height Kit (Nuvera)

Primary Customer Applications

Record the primary customer applications:

Special Considerations / Limitations

Record any special considerations and / or limitations identified
by Xerox and agreed to by the customer:

I have reviewed the solution expectations and understand the specifications and
limitations for each of the modules that will be installed: (Signature and Date)

Customer

Xerox Sales Representative

Xerox Analyst Representative

Xerox Service Representative

Coverbind Representative

For installations made in the US and Canada, a copy of the signed Customer Agreement must
be:

A) Attached to the XOA / Customer purchase order and faxed to SPA: 1-800 –407-8430.
B) Scanned and emailed to [e-mail]

427-3140 (8*227-3140).

, or faxed to Phil Schmelzlen (585)

5-1

Xerox Document Binder 120-D (DB120-D)