Important Information

Transcription

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2 BQ-270 PERFECT BINDER Important Information This manual is designed to help you to install, operate and maintain the BQ-270 Perfect Binder. Please read and understand this manual, and keep it in a safe and convenient place. Do not operate the BQ-270 until you read and understand the instructions in this manual. Horizon International Inc. shall not be liable for incidental consequential damages resulting from: improper or inadequate maintenance by the customer unauthorized modification or misuse, or operation outside of the environmental specifications for the product. Horizon International Inc. pursues a policy of continuing improvement in design and performance of the product. Therefore, the product design and specifications are subject to change without prior notice and without our legal obligation. All rights are reserved. No part of this manual may be photocopied, reproduced or translated to another language without the prior written consent of Horizon International Inc. 0603/BQ270/E/HS, TM, HH, HS UM

3 Safety precautions are indicated in this manual as follows: Safety Precautions The term WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. The term CAUTION indicates a potentially hazardous situation which, if not avoided, may result in serious injury, or damage to the machine. This symbol indicates a note which includes important information. Follow the note to operate the machine safely. This symbol indicates a prohibited action. Do not perform any prohibited action. This symbol indicates an essential procedure. Follow the procedure to operate the machine safely. Important Attention Note Additional Information This lists the range of acceptable values and operating conditions. This information will help you to avoid problems with the machine or help you learn how to operate the machine. Refer to this note when you operate the machine. This explains a mechanism in the machine.

4 Safety Operation Precautions WARNING Do not touch the melt tank while the power switch is turned on. Melt tank is heated to 200 degrees Celsius (400 Fahrenheit), and may cause severe skin burn. Work alone when you maintain and lubricate the machine. Letting someone else operate the machine may cause severe personal injury. Do not touch the moving part. Otherwise it may cause severe personal injury. Turn off the power switch before adjusting the machine. If the start button is pressed, it may cause severe personal injury. Do not touch the milling cutter and roughening cutter. Otherwise it may cause severe personal injury. Be careful not to pinch your hands when inserting the book block into the clamp. Disconnect the power cable from the socket when recovering the breaker. BQ-270 weighs 900 kg (,980 lb). Transport and install the machine safely, and keep the weight of the unit in mind. CAUTION When turning off the power switch and on again, wait a dozen of seconds. Otherwise, the board may be damaged. When the milling guide and the nipper are set narrower than the clamp width, do not move the clamp. Otherwise, the lower part of the clamp may hit the guide and be damaged. Do not insert book block into clamp and drive the machine while chanover. Otherwise, tha machine may be damaged. Make sure to tighten the lock screw of milling cover brush. Otherwise the brush may fall out when the clamp passes over. Do not drive the application drum when the glue is not melted completely. Othewise, the machine may be damaged. When using optional weekly timer, the melt tank is heated up in the set up day, at the set up time. Check the machine when the melt tank is heated up for safe. Use the lubrication grease recommended by Horizon. If the ingredient of the grease changes, the life of the machine may be shortened or the machine may be damaged.

5 Important Information Safety Precautions Safety Operation Precautions CONTENTS. Machine Description... - Machine Description Safety Functions Parts Descriptions Carriage Clamp Section Level Plate Section Milling Section Melt Tank Section Nipping Section Cover Feed Section Delivery Section Touch Screen Screen Descriptions Job Settings on Touch Screen Entering the Job Information Using the Setting Screens... 9 Binding Mode Screen... 0 Start Mode Screen... Book Block Size Screen... 2 Cover Sheet Size Screen... 3 Function Screen... 4 Milling and Nipping Screen... 5 Gluing Screen Part... 6 Gluing Screen Part Gluing Screen Part Gluing Screen Part Bind the Books Using the Binding Screens... 8 Binding Screens Test Milling and Gluing...20 Test Milling and Gluing Screen Fine Adjustment...2 Clamp and Milling Fine-Adjust Screen... 2 Glue Fine-Adjust Screen Part Glue Fine-Adjust Screen Part Glue Fine-Adjust Screen Part Nipping Fine-Adjust Screen Scoring Fine-Adjust Screen Cover Sheet Fine-Adjust Screen Part Cover Sheet Fine-Adjust Screen Part Cover Sheet Fine-Adjust Screen Part Cover Sheet Fine-Adjust Screen Part Cover Sheet Fine-Adjust Screen Part Saving or Recalling or Deleting Job Settings Using the Single Operation Screen Single Operation Screen Part Single Operation Screen Part Single Operation Screen Part Home Positioning Screens Milling Brake Release Screen Information Screen... 33

6 2-8 Error Screen Numeric Keypad Screen Starting the Binding Operation Turn On the Power Switch Safety Function Check Enter the Job Information Using the Setting Screens Setting the Main Binding Screen Setting the Scoring Rollers Setting the Scraper (For Padding Only) Setting the Side Glue Rollers Start Binding Adding More Cover Sheets Removing the Bound Booklets Saving and Recalling the Job Information Adding More Glue Finishing the Binding Operation Parts Adjustments Changing the Spine Glue Amount and Position Adjusting the Side Glue Amount Changing the Nipping Setting Changing the Cover Feeding Settings Changing the Scoring Position Changing the Carriage Clamp Opening and Milling Guide Width Milling Depth Adjustment Glue Temperature Adjustment Side Glue Amount Adjustment (Far Side) Nipper Height Adjustment Nipper Angle Adjustment Cover Sheet Angle Adjustment Blower Air Adjustment Double Feed Stop Pad Height Adjustment Feed Table Height Adjustment Scoring Roller Pressure Adjustment Maintenance Cleaning the Book Block Path Cleaning the Sensors Lubrication Book Support Plate Replacement Milling Cutter Replacement Roughening Cutter Replacement Glue Replacement Double Feed Stop Pad Replacement Transport Belt Replacement Troubleshooting Problems with Booklet Quality Error Codes If a Circuit Breaker Trips If a Message Screen Appears Optional Device Weekly Timer... 97

7 8. Installation Installation Installation of Extractor (Option) Installation of Weekly Timer (Option) Appendix Specifications Accessories Consumable Parts Option Index...5

8 . Machine Description - Machine Description Touch Screen Used to input necessary information and operate the machine. Carriage Clamp Clamps the book block. Milling Section Mills the book spine. Melt Tank Section Applies glue to the book spine. Level Plate Registers the bottom of the sheet block. Nipping Section Pastes the cover sheet on the book spine and forms the spine. PERFECT BINDER BQ-270 Cover Feed Section Feeds the cover sheet to the nipping section. Trimmings Bag Collects the trimmings. Delivery Section Stacks the bound booklets vertically. Power Switch Glue Temperature Adjusting Knob Adjusts the glue temperature from 20 to 80 (248 to 356 ). Milling ON/OFF Lever Turns the milling operation ON or OFF. Turn the lever to the right to select milling ON. Turn to the left to select milling OFF. -2 Safety Functions Area Sensors The machine stops if this light between the sensors are cut. Safety Cover (left) The machine stops if this cover is opened. Safety Cover (right) The machine stops if this cover is opened. Emergency Stop Button The machine stops if this button is pressed. PERFECT BINDER BQ-270 Lower Nipper Door The machine stops if this door is opened.

9 -3 Parts Descriptions -3- Carriage Clamp Section PERFECT BINDER BQ-270 Grease Nipples Lubricate with grease here. Book Block Insert Section Insert the book blocks here, aligning to the right. Emergency Stop Button Press this button to stop the machine. Turn the button clockwise to release the emergency stop. Start Buttons When using the manual starting mode, press both buttons to start the binding operation Level Plate Section Level Plate The level plate moves forward to hold each book block as it is inserted. It moves back when delivering the booklet. Level Plate Slide Guide Regularly lubricate with grease. Delivery Section Each booklet is delivered here. 2

10 -3 Parts Descriptions -3-3 Milling Section PERFECT BINDER BQ-270 Rear Milling Guide WARNING Upper Knife This guide holds the book spine while the milling operation is done. Front Milling Guide This guide holds the book spine while the milling operation is done. Brake Release Button This button is used when replacing the milling cutter. This button works only after pressing the brake release Guide Block button on Touch Panel Screen. This block transports the power from the motor to the front milling guide. Milling Select Lever When milling the book spine, this lever is used to turn the milling operation ON or OFF. Set the lever to the left to turn off the milling operation. 3

11 -3 Parts Descriptions -3-4 Melt Tank Section PERFECT BINDER BQ-270 Glue Temperature Adjusting Knob The glue temperature can be adjusted from 20 to 80. (248 to 356 ) Wiper 2 Side Glue Roller This drum is used to apply the glue on the lower side of the book block. Glue Amount Adjusting Plate If too little glue is applied to the side glue roller, or too much glue is applied, adjust the glue amount by moving this plate. CAUTION Do not touch the melt tank after the power is turned on. The melt tank is heated to 200 degrees Celsius (400 Fahrenheit) and may cause severe skin burn. Lubrication Point Refer to [5-3] for details. Glue Level Upper Limit Keep the glue level lower than this line. The lower limit of the glue level is 8 mm (0.3") lower position below the upper limit line. Application Drum 2 This drum is used to put the glue on the book spine. Scrape Roller This roller scrapes the extra glue off of the spine. Adjust according to the glue amount applied here. Glue Supply Section Add more glue here when the glue level is low. Wiper The distance of glue penetration into the spine depends on the wiper opening. 0 Application Drum This drum is used to provide the glue that penetrates into the spine. Positioning Plate - Side Glue Roller (far side) This plate is used to adjust the position of the side glue roller on the far side of the machine. Turn the plate counterclockwise, and the roller moves forward to approach to the book block. (Normally set to 0.) 4

12 -3 Parts Descriptions -3-5 Nipping Section Upper Cover Guide Set to match the cover sheet size. Rear Jog Guide Before the cover sheet is fed, the side guide waits 3 mm (0.2") away from the edge of the sheet. It registers the cover with the front side guide before the nipping operation. Rear Nipper This forms the book spine with the front nipper. Transport Belts Transport the cover sheets. Registration Stopper Registers the cover sheets to the right. Front Nipper Front Jog Guide Before the cover sheet is fed, the side guide waits 3 mm (0.2") away from the edge of the sheet. It registers the cover with the rear side guide before the nipping operation. PERFECT BINDER BQ-270 Registration Stopper Angle Adjusting Lever This lever is used to adjust the cover sheet angle. Refer to [4-2] for details. Nipper Angle Adjusting Block Refer to [4-] for details. Nipper Height Adjusting Ring This ring is used to adjust the book spine sharpness. Refer to [4-0] for details. 5

13 -3 Parts Descriptions -3-6 Cover Feed Section Scoring Roller Pressure Adjusting Knob Adjust to produce the correct scoring line. Fixed Scoring Roller Adjustable Scoring Roller Transport Roller Feed Table Height Adjusting Knob Adjusts the height to feed the cover sheet. Cover Sheet Detect Sensor on Feed Table Detects the cover sheets on the feed table. End Guide Feed Table Pad Height Adjusting Lever This adjusts the height of the double feed stop pads. If the pad is worn or double feeding occurs frequently, raise the pads. Refer to [4-4] for details. Blower Air Adjusting Lever Refer to [4-3] for details. Positioning Guide Feed Rotor This feeds the cover sheets using suction and friction. Double Feed Detect Sensor This detects double feeding by measuring the light that penetrates the sheet. Double Feed Stop Pads 6

14 -3 Parts Descriptions -3-7 Delivery Section Push Plate This plate pushes the delivered booklets forward. Stopper Set this stopper next to the push plate. The stopper will be pushed forward as the booklets are stacked Touch Screen Touch Screen Refer to Section 2 for details on the screens. BQ-270 7

15 -4 Screen Descriptions The BQ-270 has five kinds of screens. Refer to Section 2 [Job Settings on Touch Panel] for details. (See page 9.) Setting Screens These screens are used to input the necessary job information. Refer to [2-]. Memory Screen This screen is used to save or recall the job settings. Refer to [2-5]. Binding Screens These screens are used to display the current job information during the binding operation. The can also be used to make fine adjustments. Refer to [2-2]. Single Operation Screens These screens are used during maintenance (cleaning or parts replacement). They can also be used to check the function of each section. Refer to [2-6]. Service Screen Information Screen This screen is used to show the ROM version and the total binding number. Refer to [2-7]. Function Setting Screen This screen is used to select the table movement when the double feeding occurs, milling function, and the delivery section full detection ON/OFF. 8

16 2. Job Settings on Touch Screen 2- Entering the Job Information Using the Setting Screens Input the necessary job information such as the binding type, sheet size and other functions. The Setting Screen can cover the following seven functions: Setting Screens P. P. 2 P. 3 P Binding Mode Screen Start Mode Screen Book Block Size Screen Cover Sheet Size Screen Function Screen Milling, Nipping Screen Gluing Screen Part Gluing Screen Part 2 Gluing Screen Part 3 Gluing Screen Part 4 Press the box, and the Numeric Keypad Screen appears. Input the setting value on the Numeric Keypad Screen in increments of 0.mm (0.004"). 9

17 2- Entering the Job Information Using the Setting Screens - - Binding Mode Screen : Binding with cover sheets. Select when binding with cover sheets. When this button is selected, the side glue rollers should be moved into their working positions. Refer to [3-6] on page 44. The side glue roller on the near side is controlled by the computer. The side glue roller on the far side must be set manually. : Binding without cover sheets. Select when binding without cover sheets. When this button is selected, the side glue rollers should be moved out of their working positions. Refer to [3-6] on page 44. The side glue roller on the near side is controlled by the computer. The side glue roller on the far side must be set manually. Also, when this button is selected, the support plate should be installed. Refer to [3-3] on page 36. OK button. Each of the Setting Screens has an OK button. Press this button to input the setting and go to the next screen. 0

18 2- Entering the Job Information Using the Setting Screens Start Mode Screen Return to the home position during every changeover. Normally, select. : Each part of the machine goes back to the home position before moving to a new set position. : Each part of the machine moves to the set position directly. Select the start mode. : Normal Start mode. Binding operation starts with start buttons. : Auto Start mode. Binding operation starts after the time set in 3. Start waiting time Input the time after the book block is inserted into the carriage clamp till the binding operation starts in increments of 0.. Input range is 0.0 to 9.9.

19 2- Entering the Job Information Using the Setting Screens 3 - Book Block Size Screen 2 2 Input the book block thickness. Measure the actual book block thickness using the attached caliper and input the value. The input range is 0.3 to 50 mm (0.00 to ). Input the book block length. Measure the actual book block length and input the value. The input range is 35.0 to mm (5.35 to ). 2

20 2- Entering the Job Information Using the Setting Screens Cover Sheet Size Screen 3 2 Input the cover sheet length in increments of 0. mm (0.005 ). The input range is to mm (9.055 to ). Input this setting first on this screen. 2 Input the length between the cover sheet rear edge and the spine (using either edge, or the center of the spine). The input range is shown in illustration below. or : Either edge of the spine Fixed Side Scoring (Rear Side) Downstream Movable Side Scoring (Front Side) 35 to 320 (5.32" to 2.60") 0 to to 350 (4.33" to 2.20) (4.72" to 3.77") 230 to 660 (9.05" to 25.98") mm(inch) If the dimension is out of this range, the front or rear guides may not reachthe cover sheet edge. : Center of the spine. 3 Input the cover sheet width in increments of 0. mm (0.005 ). The input range is 35.0 to mm (5.35 to ). When measuring the distance to the center of the spine, use the accessory alignment plate. think think automation. automation think automation. Alignment Plate Center of the Spine 3

21 2- Entering the Job Information Using the Setting Screens Function Screen (ON): Use the double feed detecting function. (OFF): Do not use the double feed detecting function. If the machine produces false indications of double-feeding because of an image on the cover sheet, turn this function OFF. 4

22 2- Entering the Job Information Using the Setting Screens 6 - Milling and Nipping Screen 2 - Nipping with milling Nipping without milling Nipping without cover Turn the milling operation ON or OFF. : Milling ON : Milling OFF 2 2 : 2- : If the milling set lever is set incorrectly, an error message screen will appear. - When Milling OFF is selected, the Insert Shim message appears. Insert the shims, referring to the message screen and [4-7] on page 59. Select this when doing milling. The nipper raises, then closes. Select this when nipping without milling. The nipper closes as it raises to prevent the spine from swelling. 2 : 2-3 If this mode is selected when the milling operation is done, the spine will become round. Select this when binding without cover sheets. The nipper will not operate. The machine will wait until the glue on the spine hardens, then the booklet will be delivered. 5

23 2- Entering the Job Information Using the Setting Screens 7 P. - - Gluing Screen Part 2 2 : The glue amount, wiper opening, nipping time and the nipping delay time is set automatically depending on the book block thickness. : The spine glue amount is set on the Gluing Part 2 and Gluing Part 4 screens. : Side glue will be applied. If you select, set the glue amount using the Gluing Screen Part 3. : Side glue will not be applied. 8 P Gluing Screen Part 2 (Available when selecting on Gluing Screen Part ) Adjust the spine glue thickness in increments of 0.mm (0.005 ). The adjustment range is 0 to +4.0 mm (0.55 ). Adjust the starting point to apply the spine glue. The adjustment range is mm to mm ( to ). Adjust the end point for the spine glue. The adjustment range is mm to mm ( to ). 6

24 2- Entering the Job Information Using the Setting Screens 9 P Gluing Screen Part 3 CAUTION The side gluing roller distance should not be used for adjustment of the side glue amount. This adjust the side gluing roller to correct position depending on the booklet thickness. Adjust the side gluing roller distance in increments of 0. mm (0.005 ). The input range is -.0 mm to +5.0 mm ( to ). 0 P Gluing Screen Part Adjust the wiper opening of application drum. Press once, and the opening increases by 0. mm (0.005 ). The glue will penetrate farther into the spine. The adjustment range is +0. to +2.0 mm ( to ). Adjust the wiper opening of application drum 2. Press once, and the opening increases by 0. mm (0.005 ). More glue will be applied to the spine. The adjustment range is +0. to +2.0 mm ( to ). CAUTION The wiper opening adjustment should not be used to adjust the spine glue thickness. But when the opening is set 0.5 mm (0.02 ) or less, glue may not be applied to the book spine at all. 7

25 2-2 Bind the Books Using the Binding Screens The Binding Screens can cover the following three functions: Binding Screens P. P. 2 P. 3 P. P. 2 P Main Binding Screen Test Milling and Gluing Screen Clamp and Milling Fine-Adjust Screen Glue Fine-Adjust Screen, Part Glue Fine-Adjust Screen, Part 2 Glue Fine-Adjust Screen, Part 3 Nipping Fine-Adjust Screen Scoring Fine-Adjust Screen Cover Sheet Fine-Adjust Screen, Part Cover Sheet Fine-Adjust Screen, Part 2 Cover Sheet Fine-Adjust Screen, Part 3 P. 4 2 Cover Sheet Fine-Adjust Screen, Part 4 P. 5 3 Cover Sheet Fine-Adjust Screen, Part 5 Press the box and the Numeric Keypad Screen appears. The value can be input using the Numeric Keypad Screen. 8

26 2-2 Bind the Books Using the Binding Screens - Main Binding Screen The current job information and the production conditions are displayed here Binding Counter Pre-set Counter C Binding Counter/Pre-set Counter. Press C to clear the counter. To change to the pre-set counter, press the counter box and input the new pre-set number using the Numeric Keypad Screen. Press the right part of the pre-set counter ( ) and input 0 to return to the binding counter. See figure above This adjusts the production speed (carriage clamp moving speed) in five steps. : Slow down : Speed up This indicates the book block thickness already entered on the Setting Screen. This indicates the distance between the cover sheet edge and the spine already entered on the Setting Screen. When using a saved job, the job number appears here. When not using a saved job or the read memory has been changed, 0 is indicated here. This area displays the production conditions. Press this button to lower the feed table. Press this button to feed one cover sheet. The machine memorizes the cover sheet thickness in order to detect the double feeding. This button is used to stop the motor on each unit after the binding operation. (Before the motor drives, start icon is indicated.) Press this button before switching the power off. Status Monitor : This symbol will appear when the cover sheet is fed to the nipping section, and the book block is put in the carriage clamp. :This symbol will appear if a cover sheet is not fed automatically to the nipping section. Feed a cover sheet by pressing both start buttons. Booklet is not delivered within 2 seconds after the carriage clamp has opened. Double feeding Misfeeding In operation Delivery section full No cover sheet on the feed table. Set the cover sheets. Insert Book Block ### OK Pre-set number of binding is finished. Milling ON/OFF lever Error Remove cover sheet on nipper. Press start button to drive the motor. Remove cover sheet at double feed detect sensor. 9

27 2-3 Test Milling and Gluing 2 - Test Milling and Gluing Screen The test milling and test gluing operations can be performed using this screen Test Milling Button. Press this button, and only the milling operation is performed and the booklet is delivered from the delivery section. Use this function to check milling depth. Test Gluing Button. Press this button to perform milling and gluing operation. The booklet stops above the nipping section with no cover sheet and stays there until the start button is pressed. Wait until the glue hardens, and check the applied glue amount. Press start buttons to deliver the booklet. Use this function to check the glue amount on the booklet. Test Binding Button. Press this button to perform a single binding with a cover sheet. The machine does not feed the next cover sheet. appears here, the test milling or the test gluing opera- Condition Monitor. When tions can be started. This button is used to stop the motor on each unit after the binding operation. (Before the motor drives, start icon is indicated.) Press this button before switching the power off. Press this button to feed one cover sheet. The machine memorizes the cover sheet thickness in order to detect the double feeding. Press this button to lower the feed table. 20

28 2-4 Fine Adjustment Clamp, Milling Width Adjustment Clamp and Milling Fine-Adjustment Screen You can use this screen to make fine adjustments to the carriage clamp width and the milling guide width. 2 Adjust the carriage clamp opening amount so that the book block is inserted smoothly. Unless you make this adjustment, the carriage clamp opens just the same amount as the book block thickness. Increase the opening to match the type of the book block. The input range is 0 to +5.0 mm ( ). : Makes the carriage clamp width wider. (Use this when using signatures.) : Makes the carriage clamp width narrower. (Use this when using sheets which crease or tear easily.) Adjust the opening so that the book block can move into the carriage clamp easily without being disturbed. After the adjustment, check that there is enough carriage clamp pressure by pressing the Carriage Clamp Close button on the Single Operation Screen. 2 Adjust the milling guide width. The input range is 0 to mm ( ). This adjustment may be necessary when using signatures. (Signatures can cause the spine of the book block to swell and hit the milling guide.) : Make the milling guide wider. : Make the milling guide narrower. When using signatures, make the milling guide wider to give the spine a good finish. However, if the guide is set too wide, the spine will be allowed to expand too much. 2

29 2-4 Fine Adjustment Glue Amount Adjustment 4 P Glue Fine-Adjust Screen Part This screen allows for fine adjustment of the spine glue This adjusts the spine glue thickness in increments of 0.mm (0.005 ). The adjustment range is 0 to +4.0 mm (0.55 ). This adjusts the starting point for the spine glue. The adjustment range is mm to mm ( to ). This adjusts the end point for the spine glue. The adjustment range is mm to mm ( to ). 5 P Glue Fine-Adjust Screen Part 2 This adjusts the side gluing roller distance in increments of 0. mm (0.005 ). The adjustment range is -.0 mm to +5.0 mm ( to ). CAUTION The side gluing roller distance should not be used for adjustment of the side glue amount. This adjust the side gluing roller to correct position depending on the booklet thickness. 22

30 2-4 Fine Adjustment Glue Amount Adjustment 6 P Glue Fine-Adjust Screen Part This adjusts the wiper opening for application drum. Press once, and the opening increases by 0. mm (0.005 ). More glue will penetrate into the spine of the book. The adjustment range is +0. to +2.0 mm ( to ). This adjusts the wiper opening for application drum 2. Press once, and the opening increases by 0. mm (0.005 ). More glue will be applied. The adjustment range is +0. to +2.0 mm ( to ). CAUTION The wiper opening adjustment should not be used to adjust the spine glue thickness. But when the opening is set 0.5 mm (0.02 ) or less, glue may not be applied to the book spine at all. 23

31 2-4 Fine Adjustment Nipping Operation Adjustment Nipping Fine-Adjust Screen This allows for adjustment of the nipping delay time, nipping time and nipper width. 2 3 Nipping delay time : Increase the nipping delay time. : Decrease the nipping delay time. Normally set to 0. The adjustment range is 0 to 30.0 sec. Nipping Delay Time: The nipping delay time is the delay from the moment the book block is transported above the nipper until the nipping operation starts. If the glue squeezes out, set the nipping delay time longer so that the glue will harden before the nipping operation. If the glue squeezes out even if the nipping delay time is increased, decrease the spine glue thickness. 2 When binding with cover sheet Nipping operating time. When binding a thick book block, make this longer. When binding without cover sheet The carriage clamp is returned after waiting above the nipper during the nipping operating time.(the glue on the spine hardens well, and then the booklet will be delivered.) The adjustment range is 0 to 30.0 sec. with either binding mode. 3 : Increase the nipper width : Decrease the nipper width Usually, the squareness of the spine depends on the nipper height. If the spine quality is poor even if the nipper height has been adjusted, adjust the nipper width. If the spine is too round, make the nipper width narrower. If the spine is too sharp, make it wider. The adjustment range is -0.5 to +.0 mm ( to ). 24

32 2-4 Fine Adjustment Scoring Operation Adjustment Scoring Fine-Adjust Screen 2 : The fixed scoring rollers move to the rear (far side). : The fixed scoring rollers move to the front (operator side). The adjustment range is -.0 mm to +.0 mm ( to ). The fixed rollers actually do not move. If the fixed scoring roller position is adjusted on the screen, the stack of cover sheets actually moves to compensate. 2 : The adjustable scoring rollers move to the rear (far side). : The adjustable scoring rollers move to the front (operator side). The adjustment range is -0.0 mm to +0.0 mm ( to ). Fixed Scoring Rollers Adjustable Scoring Rollers 25

33 2-4 Fine Adjustment Cover Feed Position Adjustment 9 P Cover Sheet Fine-Adjust Screen Part This allows for fine adjustment of the nipper against the cover sheet. Registration Position 2 Cover Sheet 3 4 Original Position Cover Sheet 3mm (0.2") 3mm (0.2") Press this button to move the nipper against the cover sheets. Normally, step 2 through 4 cannot be performed because the jog guides are not pressed against the cover sheet. Before doing the other adjustments (step 2 through 4), press button to bring the jog guides up against the cover sheet. After the adjustments, press the button again to return the jog guides to their original positions Press the button to move the stack of sheets position to the right (cover feeder side) by 0.2 mm (0.008 ). The input range is -3.0 mm to +3.0 mm (-0.0 to +0.0 ). This changes the jog guide spacing by 0. mm (0.005 ). The input range is -0.0 mm to mm ( to ). Press the button to move the cover sheet position to the rear by 0. mm (0.005 ). The input range is -0.0 mm to +0.0 mm ( to ) If you make this adjustment, make sure to adjust the position of the stack of cover sheets by the same amount. 26

34 2-4 Fine Adjustment Cover Pile Position Adjustment 0 P Cover Sheet Fine-Adjust Screen Part 2 This allows for fine adjustment of the cover sheet stack position. : This increases the positioning guide spacing on the feed table. : This decreases the positioning guide spacing on the feed table. These can be set by 0. mm (0.005 ). The input range is -0.0 mm to +0.0 mm ( to ). P Cover Sheet Fine-Adjust Screen Part 3 Transport Belt Registration Stopper 2 2 This sets the pressure produced by the transport belts. After the cover sheets are fed by the feed rotor, the transport belts feed the covers back to the registration stopper. The pressure of the transport belt is adjustable in five steps. Normally, use a loose setting when using thin sheets and use a tight setting when using thick sheets. The standard setting is. This adjusts the vacuum to the feed rotor when feeding the stacked sheets. If doublefeeding occurs often, make the vacuum weaker. If mis-feeding occurs often, make the vacuum stronger. The standard setting is. 27

35 2-4 Fine Adjustment Cover Feed Function Adjustment 2 P Cover Sheet Fine-Adjust Screen Part 4 2 This sets the light strength of the sensor using and. Select for normal use. If using thick or dark cover sheet, or if fault detection of double feeding occurs, select. Oppositely, if fault detection of mis-feeding occurs, select. 2 This sets the sensitivity of the double feeding detect sensor using (high), (middle), and (low) P. 5 Cover Sheet Fine-Adjust Screen Part 5 Cover Sheet Sensor Rear Registration 58mm This sets the number of the window (hole) on the cover sheets. The sensor which detects the window on the cover is located 58 mm rear side from the rear registration position. When not entering the number of the window, reposition the cover sheet and the book block so that the window does not pass over the sensor. Input range is 0 to 9. 28

36 2-5 Saving or Recalling Job Settings The Memory Screen is used to save or recall job settings. 2 6 Milling Operation ON Nipping with Milling This area indicates the job settings saved for the selected job number. (In this example, the screen shows that job number 0 includes : milling operation ON and nipping with milling.) This shows the status of each job number. White ( ): empty Gray ( 5 ): saved job Black ( 0 ): now selected This is the save button. Press this button to save the present settings to memory. Select the job number, then press the save button. Press OK on the Write OK Screen, and the present setting will be stored to the selected job number. This is the read out or recall button. Press the job number you want to read out, the press this button. Press OK on the Read Out OK Screen and go back to the Binding Screen. Press OK on the Changeover OK Screen, and all parts of the machine will move to the set (read out) positions. This is the Delete button. Select the job number to delete and press this button. The selected memory will be deleted. This is the Current Settings button. Press this button to indicate the current settings. 29

37 2-6 Using the Single Operation Screens These screens are used to maintain the machine and to check the function of each section. The Single Operation Screen can cover the following four functions: Single Operation Screens P. P. 2 2 Single Operation Screen Part Single Operation Screen Part 2 P. 3 3 Single Operation Screen Part Home Positioning Screen Milling Brake Release Screen P. - - Single Operation Screen Part Press to rotate the glue application drums This is the Application Drum button. Press to lower the right side of the melt tank when draining the glue. The tank returns to the original position when changeover is performed. Jammed Booklet Delivery Button. Press this button to open the clamp to release the jammed booklet. Carriage Clamp Close Carriage Clamp Open This triggers the booklet delivering motion: the level plate moves back and the carriage clamp opens. This is the Carriage Clamp Move button. Press this button and then press the Start buttons. The carriage clamp rail rises and the carriage clamp moves above the nipper. This button is used when setting the milling depth, or when replacing the carriage clamp support plate. 8 is shown while the car- Instruction for the next step to move the carriage clamp. riage clamp is moving. 30

38 2-6 Using the Single Operation Screens 2 P Single Operation Screen Part CAUTION The upper adjustable scoring roller will not move if it presses too tightly against the lower adjustable scoring roller : The nipper moves up. : The nipper moves down. The nipper moves down and opens completely. This button is used when cleaning the nipping section. The lower adjustable scoring roller moves next to the fixed scoring rollers. This button is used to bring the upper and lower adjustable scoring rollers together. This moves the lower adjustable scoring roller to the set position. : Opens the milling guide to the limit. : Moves the milling guide to the set position. 3 P Single Operation Screen Part : Press this button once, and the carriage clamp opens by 0 mm (0.395 ). Use this button when the book block is caught on the carriage clamp. :Press this button to reposition the delivery section after cleaning. :The delivery section moves back. This button is used when cleaning the delivery section. 3

39 2-6 Using the Single Operation Screens 4 - Home Positioning Screen Press the button for the section which you want to send to the home position. (There are conditions which could cause part of the machine to lose its home position.) 5 - Milling Brake Release Screen This is the brake release button for the milling motor. The milling motor can not be released by pressing the brake release button on the machine until this button is pressed. Use this button when replacing the milling cutter or the roughening cutter. 32

40 2-7 Information Screen These screens are used to set some machine operating functions. And also you can access the Information Screen which shows the ROM version and the total binding number from this screen. When you call your local dealer to service the machine, our operator may ask the ROM version or total binding number. In that case, refer to the Information Screen The control ROM version is indicated here. The panel ROM version is indicated here. The total binding number is indicated here. : The feed table is lowered when double feeding is detected. : The feed table is not lowered when double feeding is detected. : When changing the binding mode, the milling operation is set automatically depending on the selected binding mode. : When changing the binding mode, the milling operation is set manually by operator. The full detection function is use/ is not use at delivery section. : The jog guides are opened when the cover sheet is moved back to the registration stopper. : The jog guides are closed when the cover sheet is moved back to the registration stopper. 33

41 2-8 Error Screen The cover is open. Close the cover. The emergency stop button is pressed. Turn the emergency stop button clockwise. Light between area sensors is blocked. Remove the hand or object between sensors. An error code may appear here. See Section 6 [Troubleshooting] on page 90. This is the OK button. Use this to recover from an error condition. Press this button to go back to the Binding Screen. 2-9 Numeric Keypad Screen This screen is used to enter or input values. Input the value, then press ent ( enter ). If you enter an improper value, the value will not be accepted, and an E will appear on the screen. Press to return to the previous screen without entering a new value. 34

42 3. Starting the Binding Operation 3- Turn On the Power Switch Turn on the power switch. WARNING Do not touch the melt tank after the power is turned on. The melt tank is heated to 200 degrees Celsius (400 Fahrenheit), and may cause severe skin burns. Also be careful of the melt tank cover. Turn on the power switch. The glue inside the tank melts 40 to 50 minutes after the power is turned on. Press while Warm-Up Screen is indicated. The Warm-Up Screen disappears after the glue is melted completely, then the Changeover Confirmation Screen appears. PERFECT BINDER B Warm-Up Screen - Turn the power switch to the right. - After the Initial Screen appears, the Warm-Up Screen appears. Power Switch CAUTION When the warm up has completed, the glue temperature does not necessarily rise to the set temperature, therefore it can be warm enough for the application drum to rotate. 3-2 Safety Function Check The BQ-270 includes safety functions which protect the user from dangerous situations. Check these safety functions: - Emergency stop button - Right safety cover - Left safety cover - Lower nipper door All of these must work properly. Operate the cover, or press the button, and check the error icons on the Error Screen. If the Error Screen appears, the safety function is working properly. If the Error Screen does not appear, there is a problem with the safety circuit. Stop using the machine and call your local dealer. Emergency Stop Button Area Sensor Left Safety Cover Lower Nipper Door Right Safety Cover 35

43 3-3 Enter the Job Information Using the Setting Screens This section explains the steps necessary to input the job information. Select the binding type. - Select the binding type on the Binding Mode Screen. Decide whether the machine should home all parts on every changeover, and the starting mode. : Binding with cover sheets : Binding without cover sheets - Turn the home positioning feature ON or OFF on the Start Mode Screen. : Reset the guides to the home position on every changeover. - If you select binding without cover sheets, the side glue rollers should be moved out of the working positions. Refer to page 44. The side glue roller on the operator side is controlled by the computer. The side glue roller on the far side must be set manually. - If you select binding without cover sheets, the support plate and the shims ( mm) should be installed. (Refer to page 59 to install the shim.) If the support plate is not installed, the bound book will fall on the stacker and separate. : Reset the guides to the home position on the first changeover. The guide moves directly to the set position from the second changeover. - Select the operation starting mode on the Start Mode Screen. : Binding operation starts with start buttons. : Binding operation starts when the time which has been set on the box passes after the book block is inserted into the carriage clamp. When selecting, input the start waiting time. Input the book block size. - Input the book block size using the Book Block Size Screen. Refer to page 2. 36

44 3-3 Enter the Job Information Using the Setting Screen Select the spine gluing and side gluing settings. - Input the spine glue and side glue settings using the Glue Screen. Refer to page 6. - If you are using spine glue or the side glue, adjust the glue amount using Part 2, 3 and 4 of the Gluing Screen. Refer to pages 6 and 7. (The glue amounts can also be adjusted using the Fine-adjust Screens.) Input the milling and nipping settings. - Select the type of milling and nipping using the Milling, Nipping Screen. Refer to page 5. Input the cover sheet size. - Input the cover sheet length and width, and the distance between the cover edge and the spine. Refer to page 3. - To select milling OFF, select. Also check that the milling ON/OFF lever is set to the left (OFF). - To select milling OFF, select. Also check that the milling ON/OFF lever is set to the right (ON). - When using saved job information, go to page 49. Milling Select Lever PERFECT Turn the double feeding detect function ON or OFF. - Turn the double feeding detect function ON or OFF using the Function Screen. Refer to page 4. Without Milling With Milling 37

45 3-3 Enter the Job Information Using the Setting Screen Select the Binding Screen. - Changeover OK Screen appears. Message Screens shown while changeover Press OK to start the changeover. - Press, and the changeover is canceled and the previous screen appears. - While the changeover, Changeover Screen appears. This screen appears when there is a cover sheet left on the nipper while changeover. Remove the cover sheet and press OK. If is pressed, the changeover is canceled and the previous screen appears. This screen appears when there is a book block left in the clamp while changeover. Remove the book block and press OK. If is pressed, the changeover is canceled and the previous screen appears. This screen appears when there is a cover sheet left on the cover table while changeover. Remove the cover sheet and press OK. If is pressed, the changeover is canceled and the previous screen appears. 38

46 3-3 Enter the Job Information Using the Setting Screen This screen appears when there is a cover sheet left on the nipper and the cover table while changeover. Remove the cover sheet and press OK. If is pressed, the changeover is canceled and the previous screen appears. This screen appears when milling function ON/OFF is changed. If the level plate height is set correctly, press OK. If the level plate height is not set correctly, press to move the clamp and set the level plate height correctly referring to page 59, then press OK. If is pressed, the changeover is canceled and the previous screen appears. These screens appear when the binding mode which is set on the screen and the milling lever setting does not match. Refer to page 37 to set the milling lever correctly and press OK. If is pressed, the changeover is canceled and the previous screen appears. 39

47 3-4 Setting the Main Binding Screen This section explains the steps necessary to set the production speed and the counter function. Go to the Main Binding Screen. When using the cover sheet with window or hole, enter the number of the window (hole) using Cover Sheet Fine-adjust Screen Part5. Binding counter This area can display both the binding counter and the pre-set counter. When using the pre-set counter, press. - The Numeric Keypad Screen appears. Input the pre-set number and press ent. - Press the right part of to change the pre-set number using the Numeric Keypad Screen. - There is a sensor which detects the window (hole) at 58 mm rear side from the rear registrating position. - Enter the number of the window (hole) or reposition covers and book block so that the window (hole) on the cover does not pass over the sensor. sensor When the machine reaches the pre-set number of bindings, it will stop feeding the next cover sheets. This prevents the machine from scoring additional cover sheets once it reaches the pre-set number. Window 58mm Cover Sheet The settings on this screen are now complete. Select the production speed. Go to the [Scoring Roller Setting] on next page. - The production speed can be selected from five steps. - When binding thick book blocks, use a slower setting. If you are binding a thick book block and the production speed is set too fast, the milling can not be completed properly. On the other hand, if the production speed is set too slow, the side glue will dry and the binding quality will deteriorate. 40

48 3-5 Setting the Scoring Rollers Adjust the gap between the upper and lower scoring rollers by turning the scoring roller pressure knob. Binding without Scoring Binding with Scoring Open the left safety cover. Loosen the scoring roller pressure knob. Press the (standard) button for the scoring roller on the Single Operation Screen Part 2. - The lower adjustable scoring roller moves next to the fixed scoring rollers. - Turn the knob counterclockwise until the upper adjustable scoring roller is free. Adjustable Scoring Roller Scoring Roller Pressure Knob Upper Adjustable Scoring Roller CAUTION If the safety cover is opened while the scoring roller is moving, the scoring roller will stop at the wrong position. Check that the scoring roller has finished moving before opening the cover. Open the right safety cover. Fixed Roller Lower Adjustable Scoring Roller Move the upper adjustable scoring roller by hand until it touches the fixed scoring roller. - The upper scoring roller should be set above the lower scoring roller. 4

49 3-5 Setting the Scoring Rollers Lower the upper scoring roller. - Turn the knob clockwise to lower the upper scoring roller. - To reach the standard setting, turn the knob one rotation counterclockwise from the stop. Press the (Setting Position) button on the Single Operation Screen. - The adjustable scoring rollers move to the setting positions. Adjust so that there is a small gap between the upper and lower adjustable scoring rollers. You should be able to move the upper adjustable roller a bit with your finger. Upper Adjustable Scoring Roller Standard Gap Lower Adjustable Scoring Roller CAUTION If the scoring pressure is so strong so that the scoring roller does not rotate, the machine may be damaged when performing a changeover. Before each changeover, check with your finger to ensure that the scoring rollers rotate smoothly. Close the right safety cover. 42

50 3-6 Setting the Scraper (For Padding Only) Set the scraper manually if you select padding. The scraper levels the glue even. CAUTION - The set position differs depending on the spine glue thickness set on the screen. Select (Manual) on the Gluing Screen Part, and raise the scraper gradually checking the glue scraping condition. Do not raise the scraper too much, otherwise the scraper hits the booklet and be damaged. - Scraper is very hot. Wear thick gloves when setting the scraper. Press on the Gluing Screen Part 2 and set the glue thickness to.0 mm. [How to adjust] - Loosen the lock screw using the wrench, and move the scraper holding the lever. - First begin at the lower position. Raise it gradually. - Tighten the lock screw after adjustment. If the spine glue thickness is set to.2mm, and when the scraper hits the stopper, glue will be actually left a little on the spine after scraping. (It differs depending on each machine or other settings.) Set the desired glue thickness on the Gluing Screen Part 2. Gluing Screen Part 2 Open the safety cover (right). Find the lowest position where the scraper can level the glue even by repeating the test padding. Perform the binding operation. Lever Lock Screw Stopper Scraper CAUTION - When performing the binding with cover sheets, make sure to reposition the scraper at lowest position. Otherwise, the scraper hits the booklet and be damaged. - If the glue is burned, the scraper can not be smoothly adjusted. Make sure to wipe off the extra glue on the scraper after the operation, so that it can be adjusted in anytime. 43

51 0 3-7 Setting the Side Glue Rollers When you change the binding type, (binding with covers or binding without cover on the Binding Mode Screen, the screen with the message reminding you to set or release the side glue rollers will appear. Set or dislocate the side guide rollers according to the binding type. When binding with covers When binding without covers The screen will tell you to dislocate the side glue roller on the far side. The screen will tell you to set the side glue roller on the far side. Before dislocating the roller, make sure to memorize the original setting position. Turn off the power switch and open the left safety cover. CAUTION Wear thick gloves during this operation. The melt tank may be heated to 200 degrees Celsius (400 Fahrenheit) and may cause severe skin burns. To adjust the side gluing roller on the far side, loosen the locking screw on the positioning plate and turn the plate counterclockwise to the memorized position. Turn off the power switch and open the left safety cover. CAUTION Wear thick gloves during this operation. The melt tank may be heated to 200 degrees Celsius (400 Fahrenheit) and may cause severe skin burns. To adjust the side gluing roller on the far side, loosen the locking screw on the positioning plate and turn the plate clockwise to the stop. Side Gluing Roller (far side) Side Gluing Roller (far side) Allen Wrench Allen Wrench 0 Positioning Plate Locking Screw Locking Screw Positioning Plate Tighten the locking screw. Tighten the locking screw. - The pre-sets for the binding operation are complete. Start the binding operation, referring to [Start Binding] on next page. 44

52 3-8 Start Binding When 0 minutes has passed after the drum is stopped, message to rotate the drum appears. Press the button on the Single Operation Screen Part to check that the glue is heated to the setting temperature and melted completely. Press both start buttons to rotate the milling cutter. - The drum motor starts turning. WARNING - Do not put your hand inside the machine when the carriage clamp is operating. This part can cause severe personal injury. - When feeding a book block, remove your hand from the carriage clamp before it moves. This part can cause severe personal injury. Binding Operation Flow Insert book block inside the carriage clamp. Insert a book block in the carriage clamp and push it to the right. Start the binding operation. - Press both Start buttons. If the milling operation is turned ON, the book spine is milled here. Glue is applied to the book block by the melt tank. The nipping section presses the book spine and the cover sheet. After the carriage clamp comes back above the level plate, the booklet is delivered to the delivery section and stacked. 45

53 3-8 Start Binding Stop Binding Press the (Stop) button on the Binding Screen. - The machine stops. - If a cover sheet has been fed, open the right safety cover and remove the cover, and clear the error. Prepare for the next job. 46

54 3-9 Adding More Cover Sheets As the stack of cover sheets is reduced during the job, add more cover sheets. Press the Stop button on the Binding Screen. - The machine stops and the feed table lowers. Move the end guide against the right edge of the stack. Press both Start buttons. - The milling cutter rotates, and the feed table rises. Restart the binding operation. Move the end guide to the right. End Guide Feed Table Stack more cover sheets on the feed table. - Separate the cover sheets well before stacking. If the cover sheets are not separated, this can cause double feeding, or the cover sheets may be partially fed. - If it is difficult to stack the cover sheets, remove the end guide on the right. - Place the sheets in the correct orientation. 47

55 3-0 Removing the Bound Booklets Remove the booklet before the stacker is full. WARNING Press the Emergency Stop button before removing the booklets. If you do not do this, the machine may start suddenly and cause severe personal injury. Pull the stopper to the front. How to use the delivery chute -Use the chute when the book spine is scratched or bound book size is very large or small. -Hook the chute on the delivery section. -Place a suitable box at the exit to receive the delivered book without scratch or stain. How to install the delivery chute Remove the stacked booklets..move the stopper back. Stopper Stopper Push the stopper to the rear. 2.Hook the chute. -Hook the chute on the three square holes of the delivery guide. Delivery Guide Delivery Chute 48

56 3- Saving, Recalling, Deleting the Job Information The BQ-270 has a memory function which can save and recall the job information. This section explains the procedures necessary to write and read out the job information using the Memory Screen. Saving the Job Information Select the Memory Screen. Press the button. - The selected job number turns black and the Write OK Screen appears. Select the job number on which you want to write the job information. - White ( ): Empty - When selecting the memory with saved job (Gray), Replace OK Screen appears. - Gray ( 5 ): Saved job - Black ( 0 ): Now selected OK Press. - The present settings are saved in the selected job number. 49

57 3- Saving, Recalling, Deleting the Job Information Recalling the Job Information Select the Memory Screen. Recall the job information. - Press the (Read Out) button. - The Read Out OK Screen appears. Press the button for the job number you want to recall. Refer to page Each job number which is gray already has saved information. - Press the job number, and the saved job information will be shown in the left part of the screen. Press OK. - The Memory Screen appears. Select the Binding Screen if you want the machine to start the changeover right now. - The Changeover OK Screen appears. - Press OK, and the machine performs the changeover and the Binding Screen appears. The recall of the job information is now complete. 50