Horizon Fitness Bookletmaker SPF-200A User manual

i
• This manual is designed to help you to install, operate and maintain the
SPF-200A/SPF-200L or FC-200A/FC-200L Bookletmaker. Please read and
understand this manual, and keep it in a safe and convenient place.
• Do not operate the SPF-200A/SPF-200L or FC-200A/FC-200L 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.
This manual explains on the basis of the SPF-200A/FC-200A.
The operating instructions for the SPF-200L/FC-200L are added
as necessary.
In case that the sheet length is longer than 500 mm (19.68”),
some functions may not available in the upstream and down-
stream devices of the SPF-200L.
Important Information
BOOKLETMAKER
BOOKLETMAKER
SPF-200A / FC-200A
SPF-200L
/ FC-200L
160218/SPF200A/FC200A/SPF200L/FC200L/20E/HN,TM,AT/F7/ICS5/PXI UM201102-20(000)
*UM201102*

ii
Safety Precautions
Safety precautions are indicated in this manual as follows:
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 • This lists the range of acceptable values and operating
conditions.
Attention • This information will help you to avoid problems with the
machine or help you learn how to operate the machine.
Note • Refer to this note when you operate the machine.
Additional
Information
• This explains a mechanism in the machine.

iii
Operating Safety Precautions
WARNINGS for Operation
This machine must be operated by just one person at a time.
Work alone when you maintain and lubricate the machine. Letting someone else operate the
machine may cause severe personal injury.
Do not remove or bypass any safety features. Moving parts can cause severe personal
injury.
Some adjustments must be made with some of the machine covers opened.
Keep your hands and fingers outside of the safety cover and away from any moving parts
while the machine is running. Otherwise moving parts can cause severe personal injury.
The machine will not stop immediately if the Emergency Stop switch on an upstream device
is pressed. After all in-process booklets are delivered, the machine will stop.
Do not allow anyone else near the machine when you are moving the main section of the
SPF forwards or backwards.
When replacing the knife, wear gloves and do not touch the edge of the knife directly. The
knife is extremely sharp, and may cause severe personal injury.
Press the Emergency Stop button before turning the handwheel. A sudden accidental start
of the machine can cause severe personal injury.
Do not operate the fore-edge trim section separately from the SPF main unit.
CAUTIONS for Operation
After turning off the power switch, wait ten seconds before turning it on again. Otherwise, a
circuit board may be damaged.
The fold knife and roller may strike each other if the fold knife is lifted too far. Turn the fold
knife height adjustment knob in small amounts.
Remove the cable connected to the SPF main unit before moving the fore-edge trim section
away.

iv
WARNINGS for Maintenance
Turn off the power switch before beginning any maintenance operation. If the machine acci-
dentally starts suddenly, this can cause severe personal injury.
Turn off the power switch before clearing a jam. If the machine accidentally starts suddenly,
this can cause severe personal injury.
When working inside the machine, be careful to keep your hands away from nearby parts.
Be sure to press the Emergency Stop button before opening the fold section cover. The
machine may start suddenly, causing severe personal injury.
Turn off the power switch before resetting a circuit breaker. Otherwise, the machine may
start suddenly, causing severe personal injury.
Fuse replacement must be done under the supervision of a maintenance administrator.
Turn off the power switch and unplug the power cable before replacing a fuse.
When the booklet thickness detector is installed, evacuate the laser unit.
Otherwise the sensor may be damaged.
CAUTIONS for Maintenance
Use the types of lubrication oil and grease which are recommended by HORIZON. Other oil
or grease may reduce the life of the machine or cause damage.
WARNINGS for Installation
Turn off the main power or circuit breaker in the factory before connecting the power cord to
the machine. High voltage electricity can cause severe personal injury.
CAUTIONS for Installation
Be sure to install the floor mounting plates to keep the machine level. Otherwise, vibration
may cause the machine to move. The binding quality may deteriorate, or the machine may
be damaged.
The SPF-200A ＋the FC-200A weigh about 720 kg (1590 lb). The SPF-200L ＋the FC-200L
weigh about 750 kg (1653 lb). Transport and install the machine safely, and keep the weight
of the unit in mind.
Install the machine correctly, referring to the installation manual or installation instructions in
the user’s manual before starting the machine. Otherwise, the binding quality cannot be
guaranteed.

v
CONTENTS
Important Information ............................................................................................................... i
Safety Precautions ...................................................................................................................ii
Operating Safety Precautions .................................................................................................iii
1 Machine Description
1-1 Automatic and Manual Settings ................................................................................. 1
1-2 Machine Descriptions .................................................................................................. 2
1-2-1 Safety Device / Safety Functions ......................................................................... 2
1-2-2 Overall Machine ................................................................................................... 3
1-2-3 Manual Feed / Infeed Conveyor Section ............................................................. 5
1-2-4 Infeed Section ...................................................................................................... 6
1-2-5 Jog Section .......................................................................................................... 7
1-2-6 Stitch Section ....................................................................................................... 8
1-2-7 Fold Section ......................................................................................................... 9
1-2-8 Fore-edge Trim Section ..................................................................................... 10
1-2-9 Delivery Conveyor ............................................................................................. 11
1-2-10 Control Panel ................................................................................................... 12
1-3 Screen Descriptions .................................................................................................. 13
1-3-1 Setting-Binding Pattern Screen ......................................................................... 13
1-3-2 Setting-Sheet Size Screen ................................................................................ 13
1-3-3 Setting-Finishing Size Screen ........................................................................... 14
1-3-4 Setting-Instruction Screen ................................................................................. 15
1-3-5 Setting-Confirmation Screen ............................................................................. 19
1-3-6 Binding-Operation Screen ................................................................................. 20
1-3-7 Binding-Fine Adjust Screen ............................................................................... 22
1-3-8 Binding-Status Setting Screen ........................................................................... 24
1-3-9 Memory Screen................................................................................................ 28
1-3-10 Information-Main Screen................................................................................ 29
1-3-11 Information-Monitor/Single Operation Screen................................................ 30
1-3-12 Information-Administrator Screen .................................................................... 31
1-3-13 Error Screen .................................................................................................... 34
2 Checks before Operating
2-1 Checking the Emergency Stop Function ................................................................. 35
3 Operating Procedures
3-1 Overview of Operating Procedures .......................................................................... 37
3-2 Setting Up a Job Using the Setting Screen ............................................................. 39
3-3 Doing a Changeover .................................................................................................. 44
3-3-1 Removing Parts Before the Changeover ........................................................... 44
3-3-2 Attaching Parts After Changeover ..................................................................... 49
3-3-3 Confirmation After Changeover ......................................................................... 52
3-4 Doing a Test Binding ................................................................................................. 53
3-4-1 Preparing the Upstream Device ........................................................................ 53
3-4-2 Binding a Booklet as a Test ............................................................................... 55
3-4-3 Do a Test Binding and Check the Settings ........................................................ 56
3-4-4 Perform the Test Stitching ................................................................................. 59
3-5 Confirming the Status Settings............................................................................... 60

vi
3-6 Start Binding .............................................................................................................. 62
3-7 Manual Feeding .......................................................................................................... 65
3-8 Saving, Loading and Deleting Jobs ......................................................................... 70
3-8-1 Saving a Job ...................................................................................................... 70
3-8-2 Loading a Job .................................................................................................... 71
3-8-3 Deleting a Job .................................................................................................... 73
3-9 Power Saving Mode ................................................................................................... 74
3-10Reversing the Stitcher Heads ................................................................................... 75
4 Adjustments
4-1 Stitch Adjustments................................................................................................... 77
4-2 Infeed Section Adjustments ...................................................................................... 79
4-3 Jog Section Adjustments .......................................................................................... 81
4-4 Fold Section Adjustments ......................................................................................... 83
4-5 Fore-edge Trim Section Adjustments ...................................................................... 84
5 Troubleshooting
5-1 If an Icon Is Displayed on the Error Screen ............................................................. 87
5-1-1 If An Error Icon Is Displayed .............................................................................. 87
5-1-2 If a System Error Occurs ................................................................................... 90
5-2 Removing Jammed Sheets ....................................................................................... 99
5-3 Stitch-Related Problems ......................................................................................... 101
5-3-1 The Stitches Are Moved Parallel to the Fold Line ........................................... 101
5-3-2 The Distance Is Not Correct........................................................................... 101
5-3-3 The Stitches Are Angled................................................................................. 101
5-3-4 The Stitch Position Varies............................................................................... 102
5-3-5 The Stitches Are Curved................................................................................. 102
5-3-6 There Are Problems With The Stitch Length.................................................. 102
5-3-7 The Sheets Are Not Stitched.......................................................................... 103
5-3-8 The Wire Jams................................................................................................ 103
5-3-9 The Shape of the Stitch is Incorrect................................................................ 104
5-4 Poor Sheet Arrangement ......................................................................................... 107
5-5 Folding-Related Problems ...................................................................................... 109
5-5-1 Fold Skewing.................................................................................................. 109
5-5-2 The Folding Position Varies............................................................................ 109
5-5-3 Failed to Fold at Correct Position................................................................... 110
5-5-4 Jog Error Not Detected................................................................................... 111
5-5-5 The Sheets Are Bent...................................................................................... 111
5-6 Fore-edge Trimming-Related Problems ................................................................. 112
5-6-1 The Sheets Are Trimmed Incorrectly.............................................................. 112
5-6-2 Incorrect Trim Position.................................................................................... 112
5-7 Scratched Sheets ..................................................................................................... 113
5-8 Specific Symptom-Related Problems .................................................................... 114
5-8-1 The Buzzer Beeps at an Interval of Two Seconds.......................................... 114
5-8-2 Fine Adjustment from the Touch Panel Does Not Work................................. 114
5-8-3 The Delivery Conveyor Does Not Move......................................................... 114
5-8-4 The Trim Is Not Collected (The pump does not operate) ................................ 114
5-8-5 The Touch Panel Does Not Light Up.............................................................. 115
5-8-6 A Stitcher Head is Jammed............................................................................ 115

vii
5-9 Other Problems ........................................................................................................ 116
5-9-1
The Booklets Overlap Each Other at the Delivery Conveyor though They are Offset  .... 116
6 Maintenance
6-1 Loading Stitch Wire................................................................................................ 117
6-2 Threading the Wire Through the Stitcher Head .................................................... 118
6-3 Attaching the Transport Pusher ............................................................................. 119
6-4 Lubrication ............................................................................................................... 120
6-4-1 Top and Bottom Guide Slide Shaft .................................................................. 120
6-4-2 Stitcher Vertical Slide Shaft ............................................................................. 120
6-4-3 Fold Knife Section ........................................................................................... 120
6-4-4 Stitcher Head ................................................................................................... 121
6-4-5 Clincher Drive Cam ......................................................................................... 121
6-5 Cleaning ....................................................................................................................122
6-5-1 Around the Stitcher Heads .............................................................................. 122
6-5-2 Transport Belts / Transport Rollers .................................................................. 122
6-5-3 Sensors ........................................................................................................... 123
6-6 Replacing the Fore-edge Trim Knife ...................................................................... 125
6-6-1 Upper Knife Replacement ............................................................................... 125
6-6-2 Lower Knife Replacement ............................................................................... 127
6-7 Clincher Point Replacement ................................................................................... 130
6-8 Guide Sheet Replacement ....................................................................................... 131
6-9 Stitcher Head Removal / Attachment ..................................................................... 132
6-9-1 Stitcher Head Removal .................................................................................... 132
6-9-2 Stitcher Head Attachment ................................................................................ 132
6-10Resetting the Circuit Breakers ............................................................................... 136
6-11Replacing the Fuses ................................................................................................ 137
7 Installation
7-1 Installing the Main Unit ............................................................................................ 139
7-2 Installing the Fore-edge Trim Section .................................................................... 141
7-3 Attaching the Accessories ...................................................................................... 143
7-4 Installing the Delivery Conveyor ............................................................................ 145
7-4-1 SC-200 Short Conveyor .................................................................................. 145
7-4-2 LC-200 Long Conveyor ................................................................................... 146
7-5 Connecting to an Upstream Device ....................................................................... 147
7-6 Checking ROM Versions of Connected Devices ................................................... 150
7-7 Connecting the Main Unit Power Cable ................................................................. 152
7-8 Setting the System Configuration .......................................................................... 153
7-9 Setting Up for Optional Devices ............................................................................. 154
7-10Synchronizing Between the Devices ..................................................................... 155
8 Options
8-1 Preset Kicker PK-30 ................................................................................................. 157
8-1-1 Installation of Preset Kicker ............................................................................. 157
8-1-2 Operation ......................................................................................................... 158
8-2 Paper Insertion Kit PN-200 ...................................................................................... 159
8-2-1 Operation ......................................................................................................... 159
8-2-2 Installation of Paper Insertion Kit ..................................................................... 161
8-3 Four Stitching Kit FST-200 ...................................................................................... 166

viii
8-3-1 Accessories for Four Stitching Kit................................................................... 166
8-3-2 Installation of Clincher ..................................................................................... 168
8-3-3 Installation of Stitcher Head ............................................................................. 169
8-3-4 Wire Attachment .............................................................................................. 171
8-3-5 Option Setup .................................................................................................... 173
8-3-6 Limitation for Use ............................................................................................. 174
8-4 Side/Corner Stitch Kit SSK-200/SSK-200L ............................................................ 175
8-4-1 Installation of Side/Corner Stitch Kit............................................................... 175
8-4-2 Option Setup................................................................................................... 178
8-5 Mis-stitch Detector SDS-200 ................................................................................... 179
8-5-1 Installation of Mis-stitch Detector ..................................................................... 179
8-5-2 Operation........................................................................................................ 182
8-6 Thickness Detector TD-200 ..................................................................................... 183
8-6-1 Installation of Thickness Detector .................................................................... 183
8-6-2 Calibrating the TD-200.................................................................................... 185
8-6-3 Operation ......................................................................................................... 187
8-7 Chip Extractor TB-200 ............................................................................................. 189
8-7-1 Operation ......................................................................................................... 189
8-7-2 Installation of Chip Extractor ............................................................................ 190
8-8 Loop Stitching .......................................................................................................... 192
8-8-1 Loop Stitcher Head Replacement .................................................................... 192
9 Appendix
9-1 Specifications ........................................................................................................... 195
9-1-1 SPF-200A....................................................................................................... 195
9-1-2 FC-200A......................................................................................................... 198
9-1-3 SPF-200L........................................................................................................ 199
9-1-4 FC-200L.......................................................................................................... 203
9-2 Accessories .............................................................................................................. 204
9-2-1 SPF-200A/SPF-200L ....................................................................................... 204
9-2-2 FC-200A/FC-200L.......................................................................................... 206
9-2-3 IFU-200 ............................................................................................................ 207
9-3 Consumables ........................................................................................................... 208

Automatic and Manual Settings / Machine Description
1
1
s1 Machine Description
This chapter explains how to use the automatic and manual settings, and describes the
parts of the machine and their functions.
1-1 Automatic and Manual Settings
Automatic: This indicates a setting which is performed automatically to match the sheet size and
binding pattern. The setting can be changed using the touch panel.
Manual: This indicates a setting which is performed manually using a knob or lever.
11119
10101A1
Front Transport Belt Gap Adjustment
Transport Belt Height Adjustment
Stopper Position
Fold Roller Gap
Jog Pusher
Fold Section Top and Bottom Guide Width
Fold Section Top and Bottom Guide Stroke
Forward Roller Position
Delivery Roller Position
Saddle Stitch Stopper Replacement
(Large / Small)
Saddle Stitch Stopper Position
Guide Bar Attachment
Transport Pusher Speed
Corner Stitch Guide Replacement
Top and Bottom Guide Width
Top and Bottom Guide Stroke
Jogging Frequency
Manual Feed Guide Width
Fore-edge Trim Section
Alignment for a Small Booklet
Buckle Gap Adjustment
Fold Skew Correction
Fold Knife Height Adjustment
Infeed Section Direction
Stitcher Head Drive Block Attachment
Stitch Angle
Stitch Distance
Stitch Length

2
1-2 Machine Descriptions
1-2-1 Safety Device / Safety Functions
The whole system stops when a safety cover is opened or the Emergency Stop bottom is pressed dur-
ing operation.
11119
10201A1
Jog Section
Cover
Fore-edge Trim Section
Cover
Infeed Section
Cover
Emergency Stop Button
Press
Release
Fold Section
Cover
1-2-1
Safety Device / Safety Functions