Horizon Fitness BQ-150 User manual

I
BOOK BINDER
BQ-150
Important Information
- This manual is designed to help you to install, operate and maintain BQ-150 Book
Binder. Read, understand and keep this manual in a safe and convenient place.
- Do not operate BQ-150 until you have read and understood the instructions in this
manual.
- Horizon International Inc. shall not be liable for incidental consequential damages result-
ing from, improper or inadequate maintenance by customer, unauthorized modification or
misuse, 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 the manual may be photocopied, reproduced or trans-
lated to another language without the prior written consent of Horizon International Inc.
UM202013-05
060727/BQ150/05E/DV

II
Safety Precautions
- The signal word WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
- The signal word CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in damage on machines. It may also be used to alert against unsafe
practices.
- Read and understand all the safety instructions with signal word such as WARNING
and CAUTION. If safety instructions are ignored, personal injury may result.
- Horizon International Inc. cannot anticipate every possible situation that might involve
a potential hazard. The instructions in this manual and warning labels on the machine are
therefore not all inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inad-
vertent operation when such operation could cause injury to personnel. Do not attempt to
operate any switch, valve, or other energy isolating device when it is locked or tagged out.
- Do not operate the machines when any covers are removed.
- Some of the drawings in this manual show the machine uncovered to help explain the
detail or inside of machine.
Stirring in the glue tank

III
Contents
Important Information .....................................................................I
Safety Precautions ...........................................................................II
1. Before You Begin ..................................................... 1
1-1 BQ-150 Specifications .............................................................2
1-2 Machine Descriptions ..............................................................3
1-2-1 Overview .........................................................................4
1-2-2 Operation Panel ..............................................................5
1-3 Accessories and Tools..............................................................6
2. Operation Procedure ............................................... 7
2-1 Binding Operation Procedure ...................................................8
2-1-1 Binding with a Cover ......................................................8
2-1-2 Binding without a Cover (Padding).................................11
2-1-3 Binding with Tape ...........................................................13
2-1-4 Standby Mode ................................................................. 17
2-2 Achieving Good Quality Binding .............................................18
(1) Requirements for Binding with Good Quality ....................18
(2) Correct and Incorrect Clamping of the Book Block............18
(3) Position Adjustment for Cover Setting ..............................19
(4) Glue Adjustment..................................................................21
(5) Stirring Glue in the Tank .....................................................21
3. Maintenance ............................................................. 23
3-1 Adding Glue ..............................................................................24
3-2 Emptying the Trimmings Bag ...................................................25
3-3 Brush Replacement ...................................................................26
3-4 Roughening Cutter Replacement ..............................................27
3-5 Draining the Glue ......................................................................29
3-6 Resetting the Circuit Breaker ....................................................30
3-7 Fuse Replacement .....................................................................31

IV
4. Troubleshooting ....................................................... 33
4-1 Troubleshooting .......................................................................34
5. Installation................................................................ 37
5-1 Installation.................................................................................38

1
1. Before You Begin
1. Before You Begin
1-1 BQ-150 Specifications .......................................................................... 2
1-2 Machine Descriptions ........................................................................... 3
1-3 Accessories and Tools ........................................................................... 6

2
1. Before You Begin
1-1 BQ-150 Specifications
Book Size(Max.) Width 400 mm (15.7")
Book Size(Min.) Width 70 mm x Height 128 mm (2.7" x 5.0")
Cover Size(Max.) Width 400 x Length 620 mm (15.7" x 24.4")
Cover Size(Min.) Width 100 x Length 200 mm (3.9" x 7.8")
Cover Sheet Weight Range 70 — 260 kg (80 gsm —300 gsm)
Book Thickness 1 — 30 mm (0.04" —1.1")
Adhesive Hot melt glue
Glue Temperature 160 — 200 degrees Celsius
Warm Up Time 20 min.
Production Speed Padding 110 books/hour
Perfect binding 180 books/hour
Power Requirements 220V 50Hz 6.3A / 240V 50Hz 6.3A / 120V 60Hz 11.4A
Power Consumption * 1.2 kW
Motors 150 w x 2, 90 w x 1, 40 w x 1,
25 w x 1, 6 w x 1
Heater 700 w x 1
Machine Dimensions 1380(W) x 525(D) x 1025(H) mm
(54.3" x 20.6" x 40.3")
Machine Weight 200 kg (441 lb)
* The power consumption described here is the average figure per hour.
The machine design and specifications are subject to change without any notice.

3
1. Before You Begin
Roughening Cutter Guide
The book spine is roughened
during its passage between these
guides.
The roughening cutter rotates
under these guides. The clamper
will not move when these
guides are open.
Glue Adjusting Knob
This knob is loosened and locked in de-
sired position. The number on the scale
shows the amount of glue applied to the
book spine in “mm”.
Brush
This brush prevents scatter-
ing of trimmings.
Glue Supply Port
Glue must be supplied in this port
when the fins project about 1 cm
above the surface of melted glue.
Do not fill above the limit (RED)
line.
Glue Temperature Control Knob
This knob is used to adjust the glue tempera-
ture. A high temperature increases the pen-
etration of the glue into the book spine, but
shortens the service life of glue.
The normal glue temperature is 180 degrees
Celsius.
Melt Tank Unit
The melted glue is applied to the
book spine by this unit.
Application Drum
This drum rotation is synchronized
with the motion of the clamper and
applies glue to the book spine.
1-2 Machine Descriptions
1-2-1 Overview
Guard
This guard protects fingers.
When the guard is tilted by the
finished book, it resets the
nipper.
Nipper
The nipper holds the book block and
cover together and forms the square
spine of the book. The nipper de-
scends with the clamper movement.
Clamper
A set of sheets are clamped with
the clamper and transported to the
gluing station, before being re-
turned to the nipping section.
Tape Alignment Guide Adjusting Knob
This knob is used to adjust the width of the
tape guides. Refer to page 15 for details.
Clamper Open/Close Buttons
The clamper is opened and closed with these
buttons. Refer to page 4 for details.

4
1. Before You Begin
Spine Cooling Blower Pipe
Air blown from this pipe cools
the spine of the perfect bound
book.
Cover Stopper
The cover is aligned with this
stopper which is adjustable to suit
cover size.
Breaker
Refer to “3-6 Resetting the breaker”(p.30)
for operating details.
Trimmings Bag
Trimmings are collected in this bag,
which should be emptied sufficiently
often to maintain adequate suction.
Operation Panel
The machine is operated from this panel.
Refer to page 4 for details.
1-2 Machine Descriptions
Nipper Pressure Adjustment Knob
The knob is used to adjust the nipper
pressure. The nipper pressure in-
creases when the knob is turned
clockwise. When the nipper pressure
is too weak, the binding quality may
deteriorate.

5
1. Before You Begin
Stop Button
Pressing this button will bring the
clamper and roughening cutter to a halt.
1-2 Machine Descriptions
1-2-2 Operation Panel
Roughening Cutter Monitor Lamp
This lamp lights when the roughening cutter
stopped between the two roughening cutter
guides. Binding without roughening cannot
be performed when lamp is on. If this lamp
lights, operate the roughening cutter ON/
OFF switch several times to change the
roughening cutter position until this lamp
goes out.
Power Switch
The power lamp lights when the
power switch is turned on.
Standby Lamp
This lamp lights when the machine is at standby.
Standby Switch
The state of the machine (standby or in
operation) is selected with this switch. When
the machine is not going to be operated for
two hours or more, select the standby mode.
Start Lamp
This lamp lights when the
machine starts operating.
Nipping Time Control Knob
The length of nipping time is adjustable with
this knob.This knob is normally turned
clockwise for binding a thick book or with a
hard cover.
Binding Mode Select Switch
The binding mode can be selected with this
switch.
Left side : Binding without a cover
(Padding)
Right side : Binding with a cover or tape
02BQ51A03
Clamper Close Button
Pressing this button closes the
clamper.
Binding Start Button
When the start lamp is lit and
this button is pressed, the
clamper starts traveling.
Clamper Open Button
Pressing this button opens the clamper.
Roughening Cutter ON/
OFF Switch
Binding with/without rough-
ening can be selected with
this switch.
Left side: Binding without
roughening
Right side: Binding with
roughening
Reset Lamp
Reset Button
If the stop button has been pressed and
the clamper stopped at an intermediate
position of its travel, pressing this button
returns the clamper to the home position.

6
1. Before You Begin
1-3 Accessories and Tools
Hot-melt Glue : HM-110(5 kg) 1
Reversible Screwdriver (4005382-00) 1
Hex Wrenches 2
Cloth Tape
Sensor Cover (M013723-00) 1
Trimmings Bag (M005285-01) 1 Ground Wire 1
2 mm (4001320-00)
3 mm (4001437-00)
HM-110
5kg
Thermo-fuse (A930519-01) 1
Cover for Laser Printer (Ivory, White) 5 each
A4-40 (1.57"), A4-30 (1.18") Black 10 each
A4-40 (0.57") (Navy, Red, Yellow, White, Blue) 2 each

7
2. Operation Procedure
2. Operation Procedure
2-1 Binding Operation Procedure ............................................................. 8
2-2 Achieving Good Quality Binding ....................................................... 18

8
2. Operation Procedure
02BQ51A03
2-1 Binding Operation Procedure
2-1-1 Binding with a Cover
WARNINGS
- Turning on the power switch starts to
heat the glue tank which will finally
reach a temperature of around 180
degrees Celsius. Keep your hands and
fingers away from the glue tank, other-
wise severe personal injury can result.
- Keep your hands and fingers away
from the clamper and nipper when they
are in operation .Otherwise severe
personal injury can result.
- The machine should only be operated
by one person at a time.
1. Turn on the power switch and wait for the
of reset lamp to light which shows that the
hot-melt glue is ready for binding.
NOTE
It takes about 20 minutes to heat the hot-
melt from cold, and about 7 minutes from the
standby mode.
Hot-melt glue may not be applied well when
the glue is just melted, because the tempera-
ture of glue is uneven. In such case, stir the
hot-malt glue in a tank with a few idle opera-
tion. Refer to 2-2 (5)
2. Press the reset button.
- The clamper close button blinks.
3. Select “binding with cover” with the
binding mode selector switch.
4. Adjust the nipping time with the control
knob.
NOTE
When binding a book of more than 2 cm
(0.79") in thickness or binding with a hard
cover of more than 230 gsm in weight, posi-
tion the nipping time control knob to around
12 o'clock. Normal binding can be done with
less nipping time.
Nipping Time Control Knob
Power Switch
Binding Mode Selector Switch
Roughening Cutter ON/OFF Switch
Reset Lamp
Reset Button
Clamper Close Button
Nipping Time Control Knob
Binding Mode Selector Switch
Perfect Binding
(Binding with cover)
Padding

9
2. Operation Procedure
2-1 Binding Operation Procedure
5. Select the binding mode, with or without
roughening, with the roughening cutter
ON/OFF switch.
NOTES
- In general, select roughening cutter ON
when binding with a cover or tape, or rough-
ening cutter OFF when binding without a
cover.
- If the roughening cutter monitor lamp is lit
when the roughening cutter switch is set to
OFF, operate the roughening cutter ON/OFF
switch several times until the roughening
cutter monitor lamp goes out.
6. Adjust the nipper pressure with the nipper
pressure adjustment knob.
NOTES
- The machine is normally operated with the
knob positioned at around 2 o'clock.
- The nipper pressure increases when the
knob is turned clockwise.
7. Adjust the clamper opening with the
clamper open button so that the opening is
about 5 mm wider than the thickness of
the book block.
8. Place the book block into the clamper and
align it with the left side of the
clamper.The clamper close lamp will
light.
9. Close the clamper by pressing the clamper
close button.
NOTE
When the clamper is completely closed, the
light in the clamper close button goes out and
the start lamp lights.
10.Press the start button.
- The clamper moves to the left and stops at
the left end. The start lamp goes out.
Roughening Cutter
Monitor Lamp
ON
Roughening Cutter ON/OFF Switch
OFF
Nipper Pressure Adjustment Knob
Clamper Close Button
Reset Lamp
Start Lamp
Start Button
Clamper Open
Button

10
2. Operation Procedure
2-1 Binding Operation Procedure
11. Place the cover on the nipper unit.
NOTE
- Align the center of the cover with the nipper
center mark.
- Align the cover stopper with the operation
side edge of the cover.
- Start lamp lights again.
- When binding with a cover, the start lamp
will not light and the machine cannot be
started until the cover has been loaded on the
nipper.
12. Press the start button.
- The clamper moves to the right, applying
glue to the spine of the book block, and
then stops at the home position (above the
nipper).
The nipper forms the square spine of the
book.
The nipper moves down, and the clamper
open button lights after the set nipping
time has elapsed.
13. Press the clamper open button.
- The clamper opens, the clamper open
button goes out, and the reset lamp lights.
14. Remove the bound book by drawing it out
to the right.
NOTE
- The nipper is reset automatically by tilting
the guard plate.
When identical binding is to be done,
repeat steps 7 to 14 of the foregoing
procedures.
Nipper Center Mark
Guide
Register
Cover
Cover Stopper
Bound Book
Guard Plate

11
2. Operation Procedure
2-1 Binding Operation Procedure
2-1-2 Binding without a Cover (Padding)
WARNINGS
- Turning on the power switch starts to
heat the glue tank which will finally
reach a temperature of around 180
degrees Celsius. Keep your hands and
fingers away from the glue tank, other-
wise severe personal injury can result.
- Keep your hands and fingers away
from clamper and nipper when they are
in operation.Otherwise severe per-
sonal injury can result.
- The machine should only be operated
by one person at a time.
1. Turn on the power switch and wait for the
reset lamp to light which shows that the
hot-melt glue is ready for binding.
NOTE
It takes about 20 minutes to heat the hot-melt
from cold, and about 7 minutes from the
standby mode.
Hot-melt glue may not be applied well when
the glue is just melted, because the tempera-
ture of glue is uneven. In such case, stir the
hot-malt glue in a tank with a few idle opera-
tion. Refer to 2-2 (5)
2. Press the reset buttom.
- The clamper close button blinks.
3. Select “binding without cover” with the
binding mode selector switch.
4. Select the binding mode, with or without
roughening, with the roughening cutter
ON/OFF switch.
NOTE
- In general, select roughening cutter ON
when binding with a cover or a tape, or
roughening cutter OFF when binding with-
out a cover.
- If the roughening cutter monitor lamp is lit
when the roughening cutter switch is set to
OFF, operate the roughening cutter ON/OFF
switch several times until the roughening
cutter monitor lamp goes out.
02BQ51A03
Nipping Time Control Knob
Power Switch
Binding Mode Selector Switch
Roughening Cutter ON/OFF Switch
Reset Lamp
Reset Button
Clamper Close Button
Binding Mode Selector Switch
Perfect Binding
(Binding with cover or tape)
Padding

12
2. Operation Procedure
2-1 Binding Operation Procedure
5. Adjust the clamper opening with the
clamper open button so that the opening is
about 5 mm wider than the thickness of
the book block.
6. Place the book block into the clamper and
align it with the left side of the clamper.
The clamper close lamp will light.
7. Close the clamper by pressing the clamper
close button.
NOTE
When the clamper is completely closed, the
light in the clamper close button goes out and
the start lamp lights.
8. Press the start button.
- The clamper moves to the left. After it has
reached the left end of its travel, it returns
to the home position (above the nipper)
while applying glue to the spine of the
book block. Air is blown onto the spine of
the book for 15 sec., and then the lamp in
the clamper open button lights.
9. Press clamper open button.
- The clamper opens, the light in the
clamper open button goes out, and the
reset lamp lights.
10. Remove the book by lifting upward.
NOTE
- The nipper is reset automatically by remov-
ing the book.
When identical binding is to be done,
repeat steps 5 to 10 of the foregoing
procedures.
Roughening Cutter
Monitor Lamp
ON
Roughening Cutter ON/OFF Switch
OFF
Clamper Close Button
Reset Lamp
Start Lamp
Start Button
Clamper Open
Button

13
2. Operation Procedure
2-1 Binding Operation Procedure
2-1-3 Binding with Tape
WARNINGS
- Turning on the power switch starts to heat
the glue tank which will finally reach a
temperature of around 180 degrees Celsius.
Keep your hands and fingers away from the
glue tank, otherwise severe personal injury
can result.
- Keep your hands and fingers away from
clamper and nipper when they are in opera-
tion. Otherwise severe personal injury can
result.
- The machine should only be operated by
one person at a time.
- The distance between the nippers must be
adjusted when the sensor cover is removed.
If this is not done, severe personal injury
can result from misoperation.
1. Turn on the power switch and wait for the
reset lamp to light which shows that the
hot-melt glue is ready for binding.
NOTE
It takes about 20 minutes to heat the hot-melt,and
about 7 minutes from the standby mode.
Hot-melt glue may not be applied well when
the glue is just melted, because the tempera-
ture of glue is uneven. In such case, stir the
hot-malt glue in a tank with a few idle opera-
tion. Refer to 2-2 (5)
2. Press the reset button.
- The clamper close button blinks.
3. Select "binding with cover" side with the
binding mode selector switch.
4. Adjust the nipping time with the control
knob.
NOTE
When binding a book of more than 2 cm
(0.79") in thickness, position the nipping time
control knob to around 12 o'clock. Normal
binding can be done with less nipping time.
02BQ51A03
Nipping Time Control Knob
Power Switch
Binding Mode Selector Switch
Roughening Cutter ON/OFF Switch
Reset Lamp
Reset Button
Clamper Close Button
Nipping Time Control Knob
Binding Mode Selector Switch
Perfect Binding
(Binding with tape)
padding

14
2. Operation Procedure
2-1 Binding Operation Procedure
6. Adjust the nipper pressure with the nipper
pressure adjustment knob.
NOTE
- The machine is normally operated with the
knob positioned at around 2 o'clock.
- The nipper pressure increases when the
knob is turned clockwise.
7. Adjust the clamper opening with the
clamper open button so that the opening is
about 5 mm wider than the thickness of
the book block.
8. Place the book block into the clamper and
align it with the left side of the clamper.
The clamper close lamp will light.
9. Close the clamper by pressing the clamper
close button.
NOTE
When the clamper is completely closed, the
light in the clamper close button goes out and
the start lamp lights.
10.Press the start button.
- The clamper moves to the left and stops at
the left end. The start lamp goes out.
11. Peel off the central strip of the released
paper of tape.
NOTE
- Use a tape with the central strip of the
released paper wider than the thickness of the
book block.
Nipper Pressure Adjustment Knob
Clamper Close Button
Clamper Open
Button
Start Lamp
Start Button
Reset Lamp
Released Paper (Central Strip)
Tape
Roughening Cutter
Monitor Lamp
Roughening Cutter ON/OFF Switch
OFF ON
5. Select the binding mode, with or without
roughening, with the roughening cutter
ON/OFF switch.
NOTE
- In general, select roughening cutter ON when
binding with a cover or a tape, or roughening
cutter OFF when binding without a cover.
- If the roughening cutter monitor lamp is lit
when the roughening cutter switch is set to
OFF, operate the roughening cutter ON/OFF
switch several times until the roughening
cutter monitor lamp goes out.

15
2. Operation Procedure
2-1 Binding Operation Procedure
13. Adjust the nipper opening to the same as
the tape width by turning the tape guide
adjusting knob.
14. Position the tape between the tape align-
ment guides. Place the sensor cover over
the sensor. The start lamp will light.
15. Press the start button.
- The clamper moves to the right, applying
glue to the spine of the book block, then
stops at the home position (above the
nipper).
- The nipper forms the square spine of the
book.
- The nipper moves down and the clamper
open button lights after the set nipping
time has elapsed.
16. Press the clamper open button.
- The clamper opens, the light in the
clamper open button goes out, and the
reset lamp lights.
17. Remove the bound book by drawing it out
to the right.
NOTE
- The nipper is reset automatically by tilting
the guard plate.
Sensor Cover
Tape Guide
Sensor
Tape Guide Adjusting Knob
Start Lamp
Reset Lamp
Start Button
Bound Book
Guard Plate
12. Check that sensor cover is open.