Horizon Fitness Perfect Binder BQ-260 User manual

I
BOOK BINDER
BOOK BINDER
060404/BQ260/06E/DV UM202001-06
Important Information
- This manual is designed to help you to install, operate and maintain Perfect Binder BQ-
260/260L. Read, understand and keep this manual in a safe and convenient place.
- Do not operate BQ-260/260L until you read and understand 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.
BQ-260/260L

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 safety instructions with signal word such as WARNING and
CAUTION. If safety instructions are ignored, personal injury will result.
- Horizon International Inc. cannot anticipate every possible situation that might involve
a potential hazard. The instruction 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 where it is locked or tagged out.
- Do not operate the machines with any covers being removed.
- Some of the drawings in this manual shows the machine uncovered for explaining the
detail or inside of machine.

III
CONTENTS
Important Information ............................................................................................I
Safety Precautions....................................................................................................II
1. Machine Parts Descriptions
1-1 General View of BQ-260 ...................................................................................2
1-2 Control Panel .....................................................................................................3
1-3 Operation Panel .................................................................................................5
1-4 Accessories and Tools ........................................................................................6
1-5 Accessory Tools..................................................................................................7
2. Installation Instructions
2-1 Installation Instructions ....................................................................................10
2-1-1 Installing Place ...............................................................................................10
2-1-2 Installing BQ-260 ...........................................................................................10
2-1-3 Releasing Transport Lock Nut .......................................................................11
2-1-4 Connecting Power Cord .................................................................................12
3. Before Starting Operation
3-1 Safety Device Function Check ..........................................................................13
3-1-1 Stop Button .....................................................................................................13
3-1-2 Safety Cover ...................................................................................................16
3-2 Every Day Check Up .........................................................................................18
3-2-1 Glue Level Check ...........................................................................................18
3-2-2 Level Plate Cleaning Check ...........................................................................18
3-2-3 Nipper Unit Check..........................................................................................19
3-2-4 Dust Bag Check ..............................................................................................19
4. Set Up BQ-260
4-1 Nipper Unit Set Up ............................................................................................21
4-1-1 Nipper Unit Set Up for Stock Thickness ........................................................21
4-1-2 Cover Positioning Set Up ...............................................................................24

IV
4-2 Clamper Unit Set Up .........................................................................................26
4-3 Milling Unit Set Up............................................................................................27
4-3-1 Milling Guide Set Up .....................................................................................27
4-3-2 Milling Depth Set Up .....................................................................................28
4-4 Vertical Stacker Unit Set Up ............................................................................29
4-5 Melt Tank Unit Set Up ......................................................................................30
4-6 Operation Switches Set Up ...............................................................................32
4-7 Test Binding .......................................................................................................33
4-7-1 Test Binding for With Milling Binding..........................................................33
4-7-2 Pad Binding ....................................................................................................35
5. Operation Procedure
5-1 With Cover Binding Operation ........................................................................37
5-2 Pad Binding ........................................................................................................39
6. Special Binding Method
6-1 Small Size Binding .............................................................................................43
6-1-1 Register Shaft Position Adjustment ...............................................................43
6-1-2 Cover Position Register Block Installation ....................................................45
6-1-3 Small Cover Stopper Installation ...................................................................46
6-1-4 Shooter Attachment ........................................................................................47
6-2 To Increase Glue Film Thickness.....................................................................48
6-2-1 Spacer Plate Attachment ................................................................................48
6-2-2 Melt Tank Height Adjustment........................................................................51
6-3 To Adjust Condition of Spine ...........................................................................52
7. After Binding Finish
7-1 Glue Supply ........................................................................................................53
7-2 Clean Up While Power On................................................................................55
7-2-1 Nipping Plate and Nipper Jaw Clean Up........................................................55
7-2-2 Level Plate Clean Up......................................................................................56
7-3 Clean Up after Power Off .................................................................................58
7-3-1 Dust Bag Clean Up .........................................................................................58
7-3-2 Vertical Stacker Unit Clean Up ......................................................................58
7-4 Clean Up after Power Off .................................................................................59
7-4-1 Milling Unit Clean Up....................................................................................59
7-4-2 Gluing Length Sensor Clean Up ....................................................................60
7-4-3 Cover Sensor Clean Up ..................................................................................60

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8. Maintenance
8-1 Once A Month ....................................................................................................61
8-1-1 Lubrication on Melt Tank Unit ......................................................................62
8-1-2 Greasing on Clamper Rail ..............................................................................62
8-1-3 Oiling on Nipper Unit.....................................................................................62
8-2 As Required........................................................................................................63
8-2-1 Milling Cutter Replacement ...........................................................................63
8-2-2 Roughening Cuter Replacement.....................................................................64
8-2-3 Glue Draining .................................................................................................66
9. Installation of Suction Cover Feeder CF-260(Optional Equipment)
9-1 Before You Begin ...............................................................................................67
9-1-1 Specifications .................................................................................................68
9-1-2 Machine Descriptions and Functions .............................................................68
9-1-3 Descriptions and Functions of Operation Panel .............................................69
9-1-4 Tools and Accessories ....................................................................................70
9-2 Set Up and Operation........................................................................................71
9-2-1 Cover Piling....................................................................................................71
9-2-2 Open/Close of Sucker Valve ..........................................................................72
9-2-3 Cover Feeder Position Set Up ........................................................................72
9-2-4 Support Plate Set Up ......................................................................................72
9-2-5 Attachment of Accessories .............................................................................73
9-2-6 Feeding Test ...................................................................................................74
9-2-7 Cover Piling....................................................................................................74
9-2-8 Binding Finish ................................................................................................75
9-3 Trouble Shooting ...............................................................................................76
9-3-1 When Misfeed Occurs. ...................................................................................76
9-3-2 When Two Covers are fed at the same time...................................................77
9-4 CF-220 Accessories ............................................................................................78
10. Installation of Friction Cover Feeder CF-220(Optional Equipment)
10-1 CF-220 Accessories ..........................................................................................79
10-2 Set Up................................................................................................................81
10-3 Installation of CF-220......................................................................................88

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1
1. Machine Parts Descriptions
1. Machine Parts Descriptions
1-1 General View of BQ-260 ......................................................................... 2
1-2 Control Panel ........................................................................................... 3
1-3 Operation Panel ....................................................................................... 5
1-4 Accessories and Tools.............................................................................. 6
1-5 Accessory Tools........................................................................................ 7

2
1. Machine Parts Descriptions
1-1 General View of BQ-260
Nipping Unit
Control Panel
Milling Unit
Melt Tank Unit
Vertical Stacking Section Cover Feeding Unit
(Option)
Level Plate
Safety Cover
Clamper Unit

3
1. Machine Parts Descriptions
Trouble Monitor
1 234 56
1-2 Control Panel
7 8 9 10111213
1.Gluing Length Adjusting Knobs
Used to adjust spine glue length.
2.Milling Start Button
Used to start to rotate milling cutter.
3.Cover Single Feed Button
Used to feed one cover sheet from cover
feeder with automatic cover feeding
mode.
4.Nipper Up/Down Button
Used to raise or lower nipper unit for
setting up nipping unit.
5.Nipping Time Control Knob
Used to control nipping time.
6.Nipping Mode Select Switch
Used to select nipping mode. Three
different modes, With milling binding
mode, Signature binding mode and Pad
binding mode can be selected.
7.Trouble Monitor
(Please refer to next page.)
8.Milling Mode Select Switch
Used to select milling mode, with milling
or without milling.
9.Level Plate Mode Select Switch
Used to select reset mode of Level Plate
after one complete cycle of binding
automatic or manual.
10. Cover Feed Mode Select Switch
Used to select cover feed mode, auto-
matic or manual
11.Clamper Pin On/OFF Switch
Used to turn on/off clamper pin which
holds stock in clamper when without
milling mode is selected..
12.Nipping Delay Time Control Knob
Used to control nipping delay time
length.
13.Pad Binding Lamp
This lamp turns on when pad binding
mode is selected.

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1. Machine Parts Descriptions
Trouble Monitor
Trouble Monitor
Indicates incorrect point on BQ-260.
When one of them turns on except power
lamp, BQ-260 can not be started.
Each LED turns on when :
(1) safety cover opens.
- Close safety cover.
(2) milling cutter does not rotate although
with milling binding mode is selected.
- Depress milling cutter start button to
rotate milling cutter.
(3) level plate opens.
- Depress start button to reset level plate.
(4) emergency stop switch is depressed.
- Pull up emergency stop switch to re-
lease it.
1-2 Control Panel
With Milling Binding Mode Signature Binding Mode
NOTE : Difference of Nipper Movement
Nipping unit has two different movements, with milling binding mode and signature bind-
ing mode. In with milling binding mode, nipper plate raises at first and then front and back
nipper jaws nip stock. So, this binding mode is suitable for binding milled stock or cut sheet
stock. In signature binding mode, nipper plate and two nipper jaws raise and nip stock at
same time. So this binding mode is suitable for binding signature which spine is shaped
thicker because of folded edge. Book spine will be formed too sharp or destroyed when
spine is pressed at first as in with milling binding mode. Binding quality or book spine
shape bound with signature binding mode is not affected so much by folding.
(4)
(3) (6)
(1)
(7) (5)
(2)
(5) glue is not ready for biding.
- Wait until glue will be melted.
(6) cover is not fed to stopper.
- Feed cover completely until it gets
stopped against stopper.
(7) main power is on.
1
2 2
1
1 1

5
1. Machine Parts Descriptions
1-3 Operation Panel
1.Counter (with reset button)
Used to count amount of binding. When
reset button is set at far side, number in
counter can not be reset.
2.Level Plate Button
Used to open and reset level plate manually
when level plate switch is set at manual
operation mode.
3.Start Lamp and Start Button
Lamp indicates that BQ-260 is ready to
bind.
4.Stop Button
4
3
2
1

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1. Machine Parts Descriptions
1-4 Accessories and Tools
Check all accessories are supplied with your BQ-260 when you open package.
10. Chain Oil (1 pc)
11. Hot Melt HM-110 (5 kg)
12. Mount Base with Leveling Bolt (3 sets)
13. Chute for small book (1 pc)
6. Drain for Glue Replacement (1 pc)
7. Dust Bag (1 pc)
8. Milling Cutter (1 pc)
9. Grease (1 pc)
Large :1 pc
Normal : 1pc
4. Clamper Support Guide
5. Space Plate (1 pc)
2. Small Cover Stopper (1 pc)
3. Small Cover Position Register (2 sets)
Large :1 pc
Small :1 pc
1. Support Plates for Cover Feeder Unit
HM-110
5kg

7
1. Machine Parts Descriptions
1-5 Accessory Tools
3. Spanner (13/17 mm) (1 pc)
4. Box Wrench ( 30 mm) (1 pc)
5. Special Wrench (1 pc)
1. Screw Driver (1 pc)
2. Spanner (30 mm) (1 pc)
6. Allen Wrench (2.5, 3, 4, 5, 6 mm)
(1 pc of each)
7. Roughening Cutter Height Gauge (1 pc)
Check all tools supplied with your BQ-260 when you open package.
0.8
0.5

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1. Machine Parts Descriptions
This page is intentionally left blank.

9
2. Installation Instructions
2. Installation Instructions
2-1 Installation Instructions.......................................................................... 10

10
2. Installation Instructions
2-1 Installation Instructions
2-1-1 Installing Place
Necessary Tools : Spanner (19 mm)
1. Place BQ-260 on installation place.
2. Place 3 mount base under levelling bolts.
3. Turn leveling bolts with spanner clock-
wise until bottom of BQ-260 is 120 mm in
height.
4. Fasten 3 lock nuts on 3 leveling bolts.
Mount
Leveling Bolt
120 mm
This section shows condition of installing
place for BQ-260.
WARNING
Weights of BQ-260 is about 500 kg.
Pay attention enough to transportation.
BQ-260 could fall down or catch a
person with something like wall.
1. Select a flat, rigid floor free from vibra-
tion.
2. Select a place free from direct exposure
to sun light.
3. Select a place free from extremely high
temperature and humidity.
This section shows how to install BQ-260.
2-1-2 Installing BQ-260

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2. Installation Instructions
2-1 Installation Instructions
2-1-3 Releasing Transport Lock Nut
Lock
WARNING
- Be sure to depress stop button to
prevent sudden work of BQ-260.
- Confirm voltage and frequency to be
used on your BQ-260 are correct.
1. Depress stop button.
2. Make sure that power switch is off.
3. Turn off main power or breaker in your
shop.
4. Attach power cord to 3-phase power
source.
Main Switch
Blue
Brown 3-Phase
Black
Height Adjust Bolt
Melt Tank lock nut is installed to prevent
melt tank moving up and down during trans-
portation.
1. Loosen melt tank lock nut.
NOTE
- It is not necessary to remove transport lock
nut. Remain it loosen.
- Remain height adjust bolt loosen unless
melt tank height adjustment is required.
2-1-4 Connecting Power Cord
This section shows how to connect power
cord on BQ-260.
Green/Yellow Ground

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2. Installation Instructions
5. Turn on main power or breaker in your
shop.
6. Turn on power switch on BQ-260.
7. Remove the spring and open the shutter
plate.
8. Pull up stop button.
9. Depress milling mode select switch to
far side to select with milling mode.
10. Depress milling start button.
- Blower will start at the same time.
11. Depress milling mode select switch to
near side to stop the milling cutter, watch-
ing the rotating milling cutter from above.
- Check the rotating direction of the milling
cutter.
- The milling cutter should rotate counter-
clockwise.
12. If the milling cutter rotates clockwise,
stop immediately and perform as follows:
- Turn off power on BQ-260 and main
power or breaker in your shop.
- Change wiring on 3-phase terminal and
perform step 5 through 12.
13. Depress stop button after connecting
power cord correctly.
2-1 Installation Instructions
Dust Bag
Stop button
Milling Start Button
Milling Mode
Select Switch
With Milling Mode
Shutter Plate
Spring
Normal Rotating Direction
wat

13
3. Before Starting Operation
3. Before Starting Operation
3-1 Safety Device Function Check................................................................ 14
3-2 Every Day Check Up............................................................................... 18

14
3. Before Starting Operation
This section shows how to check safety device
function. Check all safety device function
before starting operation on BQ-260.
3-1 Safety Device Function Check
Stop Button
Nipping Mode Select Switch
Milling Mode
Select Switch
Pad Binding
Lamp
Start Button
WARNING
Do not touch clamper while clamper is
moving. Moving clamper can cause
severe personal injury.
1. Pull up stop button. LED on monitor for
stop button turns off.
2. Set nipping mode select switch to center
position to select pad binding mode.
- Pad binding lamp on control panel turns
on to indicate that pad binding is selected.
3. Select without milling mode with milling
mode select switch.
- Confirm lamp on start button is ON.
NOTE
Depress level plate control button when start
lamp is not on.
Near Side
LED for Stop But-
ton
3-1-1 Stop Button
Center