Duplo KB-501 User manual
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PERFECT BINDER KB-501
INSTRUCTION MANUAL
Duplo USA Corporation.
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Introduction
Thank you for purchasing the perfect binder K-BINDER501.After the printed matter that is output from
devices (such as an electrophotographic printer or ink jet printer) is set on the K-BINDER501, the
equipment automatically aligns the printed matter, perfect-binds it, and then ejects the bound book.
This manual is intended for beginner operators and describes operational procedures, daily maintenance,
and safety precautions related to the K-BINDER501.
In order to fully utilize its functions and performances, and to use the K-BINDER501 for many years to
come, please make sure to read this manual thoroughly before operating the K-BINDER501.
Even after reading this manual, please take good care of this manual so that it can be used whenever
required.
Although we have made every attempt to make this manual as clear and accurate as possible, if you notice
any omissions, or any section that is unclear or erroneous, please contact the place of purchase.
When exporting the K-BINDER501
International transfer of the K-BINDER501, any of its parts and/or components must be carried out in
compliance with the relevant laws and ordinances of the country of export and the country of equipment
end-use. We do not assume any responsibility or liability for equipment transferred without regard to
proper export/import regulations or procedures.
Liability
Be aware that it is possible that a portion of this manual may not match exactly with your K-BINDER501
due to some reason such as changes in the specifications.
Duplo USA Corp. accepts no responsibility for any damage that occurs to the K-BINDER501 due to
situations that it has no control over, such as remodeling, disassembly, misuse, or inadequate environment
provided by or performed by the customer.
Duplo USA Corp. will bear absolutely no responsibility for any lost profits or damages resulting from the
operation of the K-BINDER501.
Safety Information
U.S.A only
NOTE
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant
to Part 15 of the Fcc Rules.
These limits are designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.
WARNING
The design and production of this unit conform to FCC regulations, and any changes or modifications
must be registered with the FCC and subject to FCC control.
Any changes made by the purchaser or user without first contacting the manufacturer will be subject to
penalty under FCC regulations.
Canada only
This ClassAdigital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.
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Europe only
CE Marking
We declare under our sole responsibility that the printer and option to which this declaration relates
is in conformity with the specifications below.
This declaration is valid for the area of the European Union (EU) only.
Product Type PERFECT BINDER
Product Name K-BINDER501
Standard Safety:IEC60950/1999
: Safety of information technology equipment, including electrical
business equipment
EMC:
EMI:EN61000-6-3/2001
:Electromagnetic compatibility (EMC)
Part6-3:Generic standards-Emission standard for residential,
commercial and light-industry environments.
EN55022(Class B)/1998
:Limits and method for measurement of radio disturbance
characteristic of information technology equipment(ITE)
EN61000-3-2(Class A)/1995/A1:1998/A2:1998/A14:2000
:Electromagnetic compatibility (EMC)-Part 3:Limits
Section 2:Limits for harmonic currents emissions
(equipment input current <=16A per phase)
EN61000-3-3/1995
:Electromagnetic compatibility (EMC)-Part 3:Limits
Section 3:Limitation of voltage fluctuations and flicker in low-
voltage supply systems for equipment with rated current<=16A
EMS:EN61000-6-1/2001
:Electromagnetic compatibility (EMC)
Part6-1:Generic standards-Immunity for residential, commercial
and light-industrial environments.
EN61000-4-2/1995
:Electrostatic discharge immunity
EN61000-4-3/1996
:Radiated, radio-frequency, electromagnetic field immunity
EN61000-4-4/1995
:Electric fast/transient/burst immunity
EN61000-4-5/1995
:Surge immunity
EN61000-4-6/1996
:Conducted disturbances induced by radio-frequency fields
Immunity
EN61000-4-8/1993
:Power-frequency magnetic field
EN61000-4-11/1994
:Voltage dips, short interruptions and voltage variations immunity
EC Directive Safety:73/23/EEC
EMC:89/336/EEC
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For safe use of the K-BINDER501
Please make sure to read this section completely before operating the K-BINDER501.
Alert symbols, signal words, and other symbols used in this manual are shown below.
This signal word indicates an immediately hazardous situation where
death or serious injury to the user will result if this indication is
ignored and the K-BINDER501 is used improperly. (However, as
standard operation of the K-BINDER501 is unlikely to result in
situations rated at the DANGER level, this signal word is not used in
this manual.)
This signal word indicates a potentially hazardous situation where
death or serious injury to the user could result if this indication is
ignored and the K-BINDER501 is used improperly.
This signal word indicates a potentially hazardous situation where
injury to the user or damage to materials may result if this indication
is ignored and the K-BINDER501 is used improperly.
This symbol indicates items that will cause improper operation if
performed. These items must never be performed.
This symbol indicates items that must be performed for proper
operation. These items must always be performed.
A description with this symbol indicates precautions for K-
BINDER501 operation. Make sure to follow the instructions, if any.
A description with this symbol indicates useful information and
supplemental explanations to enhance understanding of the K-
BINDER501.
[ ] This symbol indicates the button name of the operation panel.
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Precautions when installing and moving the K-BINDER501
CAUTION
Do not install the K-BINDER501 at locations with high temperature and high
humidity or at locations with dust and insufficient ventilation. This may result in
fire or electric shock.
Do not install the K-BINDER501 at locations close to heating devices such as a
stove or heater. This may result in fire.
Do not install the K-BINDER501 at locations directly exposed to sunlight. This
may result in failure of the K-BINDER501.
Temperature and humidity of the room where the K-BINDER501 is installed
should be kept within the following range with little fluctuation.
Operating temperature: 15°C to 30°C or 59°F to 86°F (no drastic changes)
Operating humidity: 25% to 70% (no condensation and no drastic changes)
Installation and moving of the K-BINDER501 must be performed by a Kyokko
Seiko appointed service company and service technician. Kyokko Seiko bears
absolutely no responsibility for any damage, breakdowns, or malfunctioning
resulting from installation or moving by anyone other than a Kyokko Seiko
appointed service company and service technician, and Kyokko Seiko extends
no guarantees regarding safety in such a case. If you need to have the K-
BINDER501 installed or moved, consult the place of purchase.
To allow escape in the event of danger and to enable access for operation and
maintenance of the K-BINDER501 and replacement of consumable items, leave
the installation space as shown in the figure below. Keep the floor free of
obstacles.
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Space required for installation
1000mm
1240mm600mm
735mm
600mm 600mm
23.6inch
23.6inch
23.6inch
48.8inch 39.4inch
29inch
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Precautions regarding power supply and ground connections
WARNING
Insert the power plug into an outlet capable of supplying power of 1500W or
more at ±10% of the rated supply voltage. Do not use an outlet with a starburst
connection. This may result in fire or electric shock due to heating.
Never touch the power plug with wet hands. This may result in electric shock.
When the K-BINDER501 is in the following conditions, immediately stop
operating the K-BINDER501, turn OFF the main switch and remove the power
plug from the outlet. Then, please contact the place of purchase.
• When smoking occurs from the K-BINDER501 or the exterior cover of the
K-BINDER501 is heated abnormally.
• When abnormal sound or smell is perceived.
• When water enters the interior of the K-BINDER501.
If you notice anything that might indicate damage to the power cable, such as
unusual deformations or surface abrasion, immediately turn OFF the main
switch of the K-BINDER501 and please contact the place of purchase to have
the parts replaced. If you continue to use the K-BINDER501 in such a
condition, it may result in fire or electric shock.
Do not step on or forcefully pull a power cable
CAUTION
As for the power cable to be connected to the K-BINDER501, make sure to
use the one that conforms to the local standards and regulations of the country
of installation.
When removing the power cable from the outlet, make sure to hold the power
plug. If the power cord is held and pulled, the cord may be damaged and it
may result in fire and electric shock.
Before cleaning or performing maintenance work on the K-BINDER501, turn
OFF the main switch and make sure to remove the power plug from the outlet.
If you clean or perform maintenance work on the K-BINDER501 without
turning OFF the main switch and removing the plug, it may result in electric
shock.
When the K-BINDER501 will not be operated for a long period during
consecutive holidays, turn OFF the main switch and make sure to remove the
power plug from the outlet for safety.
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Precautions for use
WARNING
Do not place containers with water (such as a vase, flowerpot, or glass) on the
K-BINDER501.
If the water is spilled into the K-BINDER501, it may result in fire or electric
shock.
Do not place metal objects on the K-BINDER501.
If metal objects such as a clip or staple fall inside the K-BINDER501 through a
gap, a short circuit may occur inside the K-BINDER501 and it may result in fire
or electric shock.
In the case when foreign matter (such as bits of metal, water, or any liquid)
enters the K-BINDER501, turn OFF the main switch and remove the power
plug from the outlet. Then, please contact the place of purchase. If you use the
K-BINDER501 without removing them, it may result in fire or electric shock.
Do not modify the K-BINDER501. This may result in fire or electric shock.
Never detach screws and covers unless otherwise instructed in this manual.
Accessing a high-voltage or high-temperature part or area inside the K-
BINDER501 may result in electric shock or burns.
When operating the K-BINDER501 for an extended period of time in a poorly
ventilated room or performing a high volume of bookbinding, in some cases,
an unpleasant odor generated by the glue may be noticed. (Note that this odor
has no effect on the human body.) Ensure that the operation room is ventilated
sufficiently in order to maintain a comfortable working environment.
CAUTION
Be aware of areas around the label that warns you of high temperature. Never
touch the areas or it may result in burns.
As you may get injured, be careful not to fall over the delivery section while it is
open.
Do not place things on the book supply shutter. They may fall inside the K-
BINDER501 when the book supply shutter is opened.
When you are not going to use the equipment for more than 4 hours, be sure
to turn OFF the main switch, as it will affect the durability of the glue used in
the equipment.
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Handling of alert labels
The alert labels are attached to parts of the K-BINDER501 that are potentially dangerous to operators and
maintenance personnel. There are three types of alert label (DANGER, WARNING, and CAUTION) that
are rated according to the level of danger, and instructions are indicated on each label. However, as
standard operation of the K-BINDER501 is unlikely to result in situations rated at the DANGER level,
DANGER labels cannot be seen during normal operation.
Observe the following safety rules when operating or performing maintenance work on the K-
BINDER501.
Do not peel off or tear the alert labels.
When an alert label has peeled off or is dirty, replace it with a new label.
If you need a new alert label, place an order with the place of purchase. It is very dangerous if the alert
label is left in such a condition.
As for the locations of any alert labels to be attached, refer to “Attachment locations of alert labels” on
page x.
Make sure to read and understand the description of danger and avoidance measures related to an area
where an alert label is attached.
About alert labels
The types of alert label (CAUTION) and their indications are described below. While operating or
cleaning the K-BINDER501, make sure to follow the instructions on each alert label.
• CAUTION label for moving parts
This label indicates that serious injuries, such as getting your hands
caught, may result when handling the section where this label is
attached.
Do not put your fingers or hands into the rotating, driving
or operating section.
• CAUTION label for extremely hot area
The area where this label is attached is extremely hot. It indicates
that you may be burned if your body touches the area.
Do not touch the area with bare hands immediately after
the K-BINDER501 is halted.
When you have to touch the area, make sure to wear
heat insulation gloves. When gloves are not available,
check that the area is sufficiently cooled down before
touching the area.
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Attachment locations of alert labels
The attachment locations of alert labels (CAUTION) are shown below.
The types of alert label (WARNING) and their attachment locations are described below.
• WARNING label
120 V Type 230 V Type
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Precautions when disposing of the K-BINDER501
When disposing of the K-BINDER501, consult the dealer from which you purchased the equipment or
entrust the disposal to a waste reclamation trader to ensure the procedure is environmentally safe.
About this manual
This manual describes precautions for safety and operational procedures of the K-BINDER501.
Although we have made every attempt to make this manual as clear and accurate as possible, if you notice
any omissions, or any section that is unclear or erroneous, please contact the place of purchase.
This manual consists of eight chapters as shown below.
Chapters 1 through 4: These chapters contain information required for usual operation and useful tips.
Make sure to read these chapters before operating the K-BINDER501.
Chapters 5 through 8: These chapters contain the daily maintenance procedure, troubleshooting
assistance, and technical information. Read each chapter as required.
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CONTENTS
Chapter 1 Equipment overview....................................................... 1
1. Name and function of each component...................................................1
Chapter 2 Before operating the K-BINDER501............................... 6
1. Setting a glue sheet roll...........................................................................6
2. Loading covers......................................................................................10
2.1 About covers .................................................................................10
2.2 How to load covers........................................................................11
Chapter 3 Before starting bookbinding.......................................... 14
1. Turning ON the power..........................................................................14
2. Turning OFF the power ........................................................................15
Chapter 4 Bookbinding operation.................................................. 16
1. Loading a book block ...........................................................................16
1.1 About a book block.......................................................................16
1.2 How to load a book block .............................................................16
2. Bookbinding workflow.........................................................................18
2.1 About the cool down mode ...........................................................18
3. Adjusting a bound book........................................................................19
3.1 How to change to the adjustment mode ........................................19
3.2 Adjustment procedure...................................................................20
3.3 How to return to the standby mode...............................................21
Chapter 5 Daily maintenance........................................................ 22
1. Daily maintenance ................................................................................22
1.1 Molding unit..................................................................................22
1.2 Delivery block...............................................................................23
2. Cut off waste disposal...........................................................................24
3. Filter replacement.................................................................................25
Chapter 6 Error codes................................................................... 26
1. Warning related errors..........................................................................26
2. Jam related errors..................................................................................27
3. Cover open related errors......................................................................27
4. Errors that require maintenance by service personnel ..........................28
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Chapter 7 Troubleshooting............................................................ 29
1. Book block jam.....................................................................................29
1.1 When error code J2 is shown on the COUNT display ..................29
2. Cover jam..............................................................................................30
2.1 When error code J3 is shown on the COUNT display ..................30
2.2 When error code J4 is shown on the COUNT display ..................31
2.3 When error code J5 is shown on the COUNT display ..................31
2.4 When error code J6 is shown on the COUNT display ..................32
3. Bound book jam....................................................................................33
3.1 When error code J7 is shown on the COUNT display ..................33
4. When a power failure occurs during bookbinding................................33
5. When it is not possible to supply power to the equipment ...................33
Chapter 8 Technical information.................................................... 34
1. Specifications........................................................................................34
2. Consumable items.................................................................................35
3. Outline drawing ....................................................................................36
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Chapter 1 Equipment overview
1. Name and function of each component
[Main unit]
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2
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1. Main switch
Turns ON/OFF the power of the K-BINDER501.
2. Book supply shutter
When the warm-up has completed (warm-up will take about 13 minutes after turning ON the power),
the book supply shutter automatically opens. This condition is called the “standby mode”.
The book supply shutter closes under the conditions shown below.
[1] When bookbinding starts
[2] When the main switch is turned OFF*
[3] When the cover open condition is detected (error codes C1 to C7)*
[4] When a jam is detected (error codes J1 to J7)
[5] When an error that requires maintenance by service personnel occurs (error codes E01 to E99)
[6] When the mode changes to the cool down mode*
[7] When the cover empty condition is detected*
[8] When the glue sheet empty condition is detected*
[9] When the glue empty condition in the roller unit tank is detected*
The conditions marked with an asterisk (*) only apply when there is no book block in the K-
BINDER501.
3. Sub clamp unit
Used when loading a book block.
4. Operation panel
Consists of buttons required for K-BINDER501 operation, lamps, and an indicator.
5. Paper jogging space
Used when jogging a book block.
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6. Filter cover
Opened when attaching/detaching the filter.
7. Filter
Absorbs the vaporized material generated inside the K-BINDER501 when glue is heated and its
smell.
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8. Pasting cover
Opened when setting a glue sheet roll.
9. Delivery cover
Ejects a bound book from the K-BINDER501. Open this cover when executing bookbinding.
10. Front cover 3
Opened when cleaning the molding unit.
11. Front cover 2
Opened when correcting a jam.
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12. Molding unit
Bonds a book block to a cover and drops the bound book on the delivery block.
13. Scraps tray
Collects waste that is generated after cutting covers.
14. Total counter
Indicates a total number of books bound (total count).
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15. Knob
Rotated when correcting a cover jam.
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16. Glue sheet unit
Used when setting a glue sheet roll.
17. Cassette unit
Used when loading covers.
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18. Upper feed cover
Opened when correcting a cover jam.
19. Lower feed cover
Opened when correcting a cover jam.
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120 V Type 230 V Type
20. Inlet
Connects the power cable.
21. Fuse (only for 120 V type)
Shuts OFF the power source when a short circuit is detected.
22. Circuit breaker 1 (only for 230 V type)
Automatically shuts OFF the power source when a short circuit is detected.
23. Circuit breaker 2 (only for 230 V type)
Automatically shuts OFF the power source when a short circuit is detected.
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[Operation panel] (Photo shown Europe 230V version)
1237
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1. START button
Used when executing bookbinding.
2. COUNT display
Indicates the total number of books bound from when the power was turned ON until now. Also
indicates a relevant error code when an error occurs to the K-BINDER501.
3. TROUBLE lamp
Lights up when an operation error (such as cover jam or book block jam) occurs in the K-
BINDER501.At the same time, a relevant error code is indicated on the COUNT display.
4. RESET button
Used when clearing the indication displayed on the COUNT display.
5. GLUE SHEET lamp
Lights up when a glue sheet roll has run out. When this lamp lights up, set a new glue sheet roll
referring to the procedures described in “1. Setting a glue sheet roll” in chapter 2.
6. COVER lamp
Lights up when covers have run out.
When this lamp lights up, supply covers referring to the procedures described in “2.2 How to load
covers” in chapter 2.
7. Cover size lamps
The lamp of the relevant cover size that is set lights up.
The cover size lamp is lit regardless of whether there is a cover in the K-BINDER501
or not.
Table of contents
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