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Duplo DB-250
Perfect Binder
Service Manual
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PERFECT BINDER
DB-250
SERVICE MANUALSERVICE MANUAL
Duplo USA Corp.
May 2000, Rev. 2.6
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Table of Contents
Instruction
1. Warning ………………………………………………………….……. 1
2. Installing the machine………………………………………………..... 1
2-1 Notes on installation……………………………………………... 1
2-2 Installation……………………………………………………….. 2
3. Part names…………………………………………………………..…. 3
4. Names and functions of the control panel……………………………... 3
5. Specification………………………………………………………….... 4
6. Using the DB-250………………………………………………….….. 5
6-1 STARTUP……………………………………………………..… 5
6-2 GLUE ADJUSTMENT………………………………………..… 6
6-3 NIPPING PRESSURE CONTROL……………………….…….. 7
6-4 REPLENISHING THE GLUE TANK……………………….…. 7
6-5 MANUAL MODE…………………………………………….… 8
6-6 AUTO MODE………………………………………………….... 10
6-7 PADDING MODE…………………………………………….… 12
6-8 STANDBY MODE……………………………………………… 13
Machinery
Mechanism, Function and Adjustment…………………………….…… 14
1. Notching station…………………………………………………….…. 14
1-1 Mechanism…………………………………………………….… 14
1-2 Function…………………………………………………………. 14
1-3 Adjustment………………………………………………………. 15
2. Glue Tank……………………………………………………………… 16
2-1 Mechanism………………………………………………………. 16
2-2 Function…………………………………………………………. 16
2-3 Adjustment………………………………………………………. 16
3. Nipping station………………………………………………………… 18
3-1 Mechanism………………………………………………………. 18
3-2 Function………………………………………………………….. 18
3-3 Adjustment……………………………………………………….. 18
4. Clamp station…………………………………………………………... 21
4-1 Mechanism……………………………………………………….. 21
4-2 Function………………………………………………………….. 21
4-3 Adjustment……………………………………………………….. 21
5. Driving Section………………………………………………………… 23
5-1 Mechanism……………………………………………………….. 23
5-2 Function………………………………………………………….. 23
5-3 Adjustment……………………………………………………….. 23
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Electricity
1. Construction Block layout………………………………………….…. 24
2. Layout of Each Block……………………………………………….… 25
3. Checking the Motions – Test Modes…………………………………. 27
4. Circuit Diagrams………………………………………………………. 28
4-1 Main Schematic Diagrams….………………………………….... 28
CPU ( TG200A1 )……………………………………………….. 28
Control Panel ( TG200B1 )……………………………………… 29
SSR ( TG200C1 )………………………………………………... 30
Fuse Board ( TG200D2 )………………………………………… 31
4-2 Wiring Diagram………….….…………………………………... 32
4-3 Pin Assignments…………………………………………………. 33
Parts Catalog
1. Frame / Exterior Section…………………………………………..…... 34
2. Notching Station Section………………………………………….…... 36
3. Glue Tank Section……………………………………..………….…... 37
4. Nipping Station Section……………………………………….……... 38
5. Clamp Station Section………………………………………….……... 40
6. Driving Section………………………………………………………... 42
7. Electricity Section……………………………………………………... 43
8. Assemble Parts List…………………………………………………... 44
Maintenance
1. Daily Cleaning Procedures ….………………………………..………. 45
2. General Maintenance Procedures ….………………………………..... 45
3. Maintenance Parts List………………………………………………... 46
Appendix
A - Troubleshooting Guide for Spine Adjustment……………………… 49
A1 Clamp Spine Adjustment…………………………………...……. 50
(A) Round / hollow middle through the spine………………...… 50
(B) Nail head through the spine……………………………...…. 51
(C) Left-end round / hollow middle………………………..….... 52
(D) Right-end round / hollow middle…………..…………..…… 52
(E) Left-end nail head…………….…………………….….…… 53
(F) Right-end nail head…………….……………………….…... 54
(G) Left-end nail head and right-end round…..……………….... 55
(H) Right-end nail head and left-end round…..……………..….. 55
A2 Nipping Plates spine Adjustment…………………………….….. 56
B - Troubleshooting Guide for Error Messages…………………….…..… 57
B1 Error Messages………...…………………………………...….... 57
B2 Troubleshooting and Correction…………………………...….... 58
C - Setup for Timers ….…………………………………………………. 61
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INSTRUCTION
1. Warning
Be careful of the following items that may cause injury or damage.
• Do not place tiny items on top of the machine to avoid dropping them into the
machine.
• Pay close attention to the warning signs on the machine that indicates a dangerous or
“no-touch” area of the machine.
• Keep hands and fingers away from glue tank and notching station.
• Use only the suggested hot melt glues with the following characteristics:
Application temperature: 293 °F (145 °C) to 320°F (160 °C)
Working Glue Viscosity: 1,500 to 2,600 CPS
• Duplo USA is not responsible for the quality of the binding that is produced by
the non-suggested glues.
In case of thermostat failure :
DB-250 has implemented the secondary thermostat to protect the glue tank temperature
over 392 °F (200 °C). When it occurs, the power of DB-250 will be automatically turned
off. You have to wait for the glue tank to cool down before you can restart the machine.
If this problem occurs again, call your authorized dealer for service.
2. Installing the machine
2-1 Notes on Installation
Power Supply
(A) Connect the machine to a dedicated power outlet. Never connect the machine to
a power outlet servicing other appliances or electrical devices.
(B) Place the machine close to the power outlet. Do not use extension cords. Use the
machine only where voltage is relatively constant.
(C) The range of power supplies for proper operation of the machine.
Tolerance of power supply: LOCAL VOLTAGE 110V or 220V ± 10%
Frequency fluctuation : 110 V @ 60Hz ± 10% or 220V @ 50Hz ± 10%
(D) Check periodically to ensure the following:
• The plug is not excessively hot.
• The power cord is not damaged.
• The plug is firmly plugged into the outlet.
Installation Environment
(A) Install the machine on a level safe, firm and solid table which will hold the
weight of the machine.
(B) Keep the machine away from the direct sunlight and heat sources such as stoves,
heaters and radiators.
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2-2 Installation
1) Remove the red shipping bracket located on the
left side of the clamp station as shown. Then
reinstall the screws in clamp station.
2) Remove two red shipping brackets that are
located around the nipping station as shown.
3) Lift up your DB-250, then slide in the bottom
cover and glue draining tray underneath the glue tank
as shown.
4) Place your DB-250 on a safe, firm and solid
table. Then mount the cover-sheet holder to the
right side of the machine as shown.
Optional :
The following steps are only for your selected
hot melt glue with working temperatures other
than 320 °F (160 °C).
(1) Open the cover of control panel by
removing three screws along bottom.
(2) Turn the arrow of dial to the working
temperature of your selected glue.
(3) Replace the cover of the control panel.
Note :
Glue heating-time may vary by the type of hot
melt glue and room temperature.
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3. Part names
(1) Nipping Station
(2) Glue Tank
(3) Notching Station
(4) Clamp Station
(5) Control Panel
(6) Nipping Pressure Control
4. Names and functions of the control panel
No. Name Function LED Display /
Example
1 EMERGENCY Stop all the actions of the machine.
Except when “HOT” shows on the
LED display.
2 STAND BY /
LED
3 CLOSE Close clamp.
4 LED DISPLAY 1) The amount of books bound. ____100
2) Operating status. BIND
3) Perform self-test and stir
4) Error messages. ERR = L1
Temporarily lowers the temperature
of glue tank so it won’t burn the glue
when the machine is not operated.
the hot melt glue.
“STOP” (flashing)
WARM__
S-TEST
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No. Name Function LED Display /
Example
5 CLEAR Clear the display counter for books
____0
bound.
6 COVER Reserved
7 START / LED Indicates the “START” button is
ready for proceeding to the next
operation.
8 OPEN Open clamp.
9 FUNCTION /
LED
Select one of the function modes MANUAL, AUTO, or PAD.
One of the mode
indicators will be lit.
10 NOTCH / LED Select the notching function during
the bookbinding operation.
5. Specification
Model DB-250 Perfect Binder
Maximum Book Size 12.6” x 15.75” ( 320mm x 400mm )
Minimum Book Size 3.15” x 1.97” ( 80mm x 50mm )
Maximum Binding Thickness 1.6” ( 40mm )
Glue Warm Up 25 minutes ( varies depending upon glue type )
Glue Warm Up in Stand-by Mode 5 minutes
Cycle Speed 360 cycles per hour
Production Speed Up to 200 books per hour
Power Source 110V, 60 Hz ( Option: 220V, 50 Hz )
Power Consumption 10 Amps.
Machine Weight 255 LBS ( 116 Kg )
Machine Dimension 46”(L) x 22”(W) x 15”(H) (1150x560x370mm)
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6. Using the DB-250
6-1 STARTUP :
1. Turn ON the power switch of DB-250 as shown.
( where “I” for ON; “O” for OFF )
The heater of DB-250 will automatically heat
the glue to the preset working temperature and
display the status of the heating processes.
• The 4 leftmost spaces of LED: the status of
heating process ( COLD, WARM, or HOT ).
• The 2 rightmost spaces of LED: The elapsed
time of heating.
2. Start melting the glue.
The status is COLD and the elapsed time is one
minute for this example as shown.
3. Melting glue is processing.
The status is WARM and the elapsed time is 10
minutes for this example as shown.
4. After heating for a while, the glue temperature
has reached HOT status. The elapsed time is 20
minutes for this example as shown.
5. When the glue temperature has reached the
working temperature, DB-250 performs the selftest and stirs the melting glue.
6. DB-250 is ready for bookbinding and set to
MANUAL mode for your desired operation.
At this moment, the control panel will display
and flash "LOAD BOOK" for your attention.
For binding operations, please refer to the
MANUAL, AUTO and PAD operations.
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6-2 GLUE ADJUSTMENT :
The glue level may require adjustment when the thickness of the book or pad varies.
Use the following book spine illustrations for guidelines.
• Increasing the holt-melt glue when
Hollow middle OR Round
• Decreasing hot-melt glue when
Too much glue on both sides OR Nail head
• Adjusting the glue level :
1.) Turn the glue adjustment lock knob counter clockwise to loosen.
2.) Increase the amount of glue by sliding the knob to the right at the
appropriate position.
MIN MAX
Decrease the amount of glue by sliding the knob to the left at the
appropriate position.
MIN MAX
3.) Turn the knob clockwise to lock the setting
• Note that the thickness of the cover sheet is an important factor for you to
make a good spine. Use only the suitable thickness of the cover sheet associated
with the appropriate glue-meter position to make a good book.
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6-3 NIPPING PRESSURE CONTROL :
The nipping pressure control knob is
located on the left-side of the machine
(next to the power switch). It allows
you to adjust the nipping pressure
based on the thickness of the books
and the quality of the book spine.
Normally the thinner the books, the
more the nipping pressure. The factory
setting is set to the mark on the scale.
• Turn the knob clockwise to increase the nipping pressure when
round spine occurs or making thinner books.
• Turn the knob counter clockwise to decrease the nipping pressure when
nail head spine occurs or making thicker books.
6-4 REPLENISHING THE GLUE TANK :
CAUTION: Great care must be taken when handling hot molten glue.
Be sure not to place an excessive amount of glue in the tank at one time. Keep it at
such a level that the glue will not go over the redline in the tank while the application
drum is rotating. This will prevent glue from spilling out of the tank.
Glue Replacement
1. Warm up the DB-250 as described in the STARTUP section on page 5.
2. Make sure the draining tray is warped by Aluminum foil and positioned
underneath the glue tank so that the tank drains into it.
3. Use the 6 mm Allen wrench to loosen (Counter Clockwise) the glue drain Allen
screw, which is located on top of the glue tank.
Do not attempt to remove the draining tray until the glue cools down.
4. Close (Clockwise) the glue drain Allen screw when the glue stops flowing.
5. Add new glue to the glue tank Be sure to keep the glue level not going over the red
line.
6. Remove the glue drain tray and discard the cold drained glue.
Note that it’s not necessary to drain the glue frequently if the machine is used
constantly under normal working conditions. However, in case the glue has been left
unused for a long period of time with the unit in the “ON” position, and the quality is
found to be unacceptable, use the glue replacement procedures or call your authorized
dealer.
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6-5 MANUAL MODE :
After the “STARTUP” procedures, the DB-250 will automatically set itself
MANUAL operation and flashing "LOAD BOOK" display. Note that the
“NOTCH” LED is ON.
1. (1) Press the “OPEN” button and place the book
block inside the clamps. Be sure to follow
the label instructions on the clamp to load
the book block to the RIGHT of the red line,
then slide the book block to the far LEFT of
the clamps and you will see the flashing
"PUSH CLOSE" display.
Step 1:
Load book to the
RIGHT of the red line.
Step 2:
Slide the book to
The far LEFT.
(2) Then press the “CLOSE” button to clamp
down the book block and you will see the
flashing "PUSH START" display.
Note:
In case you need to adjust the book block after
you have closed the clamps, you can press the
"OPEN" button twice to release it. The LED
display will show "PUSH CLOSE". After you
have adjusted the book block, you have to press
"CLOSE" button until the clamps close. Then
you will see the flashing "PUSH START"
display again.
(3) Press the “START” button. The LED
display of control panel will show a “ß”
sign and the clamp station will move over
the notching station for notching.
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2. After the first notching process, the clamp
station will remain to the left side of DB-250
and the LED display of the control panel will
display and flash "LOAD COVER".
3. Center the cover sheet and adjust the side guide:
Measure the width of the book plus half the
thickness of the spine. Then set side guide
accordingly.
4. Place the cover on the nipping station, the
“START” LED will be lit and flashing "PUSH
START". Then press the “START” button to
move the clamp station over the nipping station
starting the binding process for the book block
and cover sheet.
Note:
If you accidentally remove or drop the cover
sheet during the clamping station returning to
the nipping station, the control panel will show
“COVER?”. At this moment, you have to place
the cover on the nipping station and press
"START" button to resume the process.
5. When the display indicates “PUSH OPEN”,
press the “OPEN” button to open the clamps.
Then, remove the finished book from the right
end of the clamp station.
Having completed one bound book, the LED
display of control panel will count once for the
total binding amount as shown.
Then the control panel will display and flash
"LOAD BOOK" for binding next book.
6. Repeat step 1 to 5 for more books in
“MANUAL” operation.
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follow the label instructions on the clamp
6-6 AUTO MODE :
Note: All books done in this mode must be same thickness.
1. In the MANUAL mode, make one book.
Centering the cover to the centered point and
adjust the side guide.
2. Press “FUNCTION” button to switch to
“AUTO” operation. The “AUTO” LED will
be lit and display flashing "LOAD BOOK" as
shown.
Note:
The “NOTCH” LED is ON.
Step 1:
Load book to the
RIGHT of the red line.
Step 2:
Slide the book to
The far LEFT.
3. (1) Press the “OPEN” button. Be sure to
to load the book block to the RIGHT of
the red line, then slide the book block to
the far LEFT of the clamps and you will
see the flashing "PUSH CLOSE" display.
(2) Then press the “CLOSE” button to clamp
down the book block and you will see the
flashing "PUSH START" display.
Note:
In case you need to adjust the book block
after you have closed the clamps, you can
press the "OPEN" button twice to release it.
The LED display will show "PUSH CLOSE".
After you have adjusted the book block, you
have to press "CLOSE" button until the
clamps close. Then you will see the flashing
"PUSH START" display again.
(3) Press the “START” button. The LED
DISPLAY of control panel will show the
“ß” sign. The clamp station will move to
the left side of DB-250 and will remain
there.
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4. Place the cover sheet onto the nipping station
when the display flashing "LOAD COVER".
The clamp station will automatically move
back to the position above the nipping station
and start the binding process for the book
block and cover sheet.
Note:
If you accidentally remove or drop the cover
sheet during the clamping station return to
the nipping station, the control panel will
show “COVER?”. At this moment, you have
to place the cover on the nipping station and
press "START" button to recover the process.
Having completed one bound book, the
clamp will automatically open and display
"UNLOAD" so that you can remove the
finished book from the right end. Meanwhile,
the LED display of control panel will count
once for the total binding amount as shown.
The DB-250 will flash "LOAD BOOK"
display.
5. Place the same thickness of book block onto
the clamp as the label instructions on the
clamp. The clamp station will automatically
clamp down the book block and move to the
left. Repeat step 5 to 4 for more books in
“AUTO” operation.
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Press the “OPEN” button. Be sure to
follow the label instructions on the clamp
6-7 PADDING MODE:
“PAD” is one of the DB-250 operations that apply to special binding
applications such as binding without cover sheet.
1.
Press “FUNCTION” button to switch to
“PAD” operation. The “PAD” LED will be lit
and display flashing "LOAD PAD" as shown.
Note:
The “NOTCH” LED is normally OFF. But
you can press “NOTCH” button to actuate it,
if desired.
2. (1)
To load the pad block to the RIGHT of
the red line, then slide the pad block to
the far LEFT of the clamps and you will
see the flashing "PUSH CLOSE" display.
Step 1:
Load book to the
RIGHT of the red line.
Step 2:
Slide the book to
The far LEFT.
(2) Then press the “CLOSE” button to clamp
down the pad block and you will see the
flashing "PUSH START" display.
Note:
In case you need to adjust the pad block after
you have closed the clamps, you can press the
"OPEN" button twice to release it. The LED
display will show "PUSH CLOSE". After you
have adjusted the pad block, you have to press
"CLOSE" button until the clamps close. Then
you will see the flashing "PUSH START"
display again.
3. (1) Press the “START” button. The LED
display of control panel will show a “ß”
sign and the clamp station will move over
the notching station and return to clamp
station.
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(2) Having moved to the left position of DB-
, adjust
2 Glue
250, the clamp station will automatically
move back to the right position and display
"BIND".
(2) Wait for a few seconds until the LED
display of control panel displays “PUSH
OPEN” as shown.
4.
Then press the “OPEN” button to open the
cl amp so that you can withdraw the bound pad
block. Meanwhile, the LED display of control
panel will count once for the total binding
amount.
Then the control panel will display and flash
"LOAD PAD" for padding next pad.
Note:
If glue is too thick on spine
thickness in accordance with Sec. 6Adjustment.
5. Repeat step 2 to 4 for more books in “PAD”
operation.
6-8 STANDBY MODE:
Press “STANDBY” button, the DB-250 will temporarily lower the temperature of glue
tan k so it won’t burn the glue when the machine is not operated. The LED displays
"STBY00" as shown below. Where "00" is the timer display for the duration of the
standby period.
Press “STANDBY” button again when the “STANDBY” LED is on, the DB-250 will
reh eat the glue tank to the working temperature, then the “READY” LED will be lit and
waiting for your desired operation.
Note that you have to wait a few minutes when LED displays "WARM00" status. The
glue tank of DB-250 will be reheated, then the control panel will display and flash
"LOAD BOOK" after "HOT" status.
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MACHINERY
Mechanism, Function and Adjustment
1. Notching Station
1-1 Mechanism
The mechanism of notching station is shown below.
1-2 Function
The purpose of notching is to enhance the solidification of the bookbinding. The
notching blade makes numerous cuts on the spine of the book so that the melted glue
can penetrate the binding area.
Inner Pages
Cuts
Hot-Melt Glue
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1-3 Adjustment
In order to get appropriate depth of the cuts and the precision of the center path for
clamp station, the notching station can be adjusted to the up, down, right, and left
positions as shown. Note that notching surface should be adjusted evenly on both sides
to prevent tilting the notching surface. Otherwise, the cuts of the book will have one
side deeper than the other. The standard depths of the cuts are 1 mm evenly on the
spine of the book.
You also can lift up the notching station to gain the depth of the cuts when the blade
has been worn out a little bit. Or you have to change the blade.
Left
Up Center Line
Down
Right
Changing the blade:
1) Open one side of the notching station.
2) Loosen the blade screw and remove the old blade.
3) Install the new blade as shown, then set the height of the blade about 3mm above
the surface of notching wheel.
4) Tighten the blade screw.
7 mm Blade Direction
3 mm on Notching Wheel
( CCW )
Notching Wheel
Screw
Blade
Side View Top View
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2. Glue Tank
2-1 Mechanism
The mechanism of glue tank is shown below.
2-2 Function
Providing a layer of melted glue on the spine of the book so that cover and inner pages
can be bound together. The glue scraper of glue tank controls the quantity of the
melted glue on the glue drum while the glue meter controls the thickness of melted
glue that is applied to the spine.
Glue Meter
Glue Drum
Glue-adjusting Knob
Glue Scraper
2-3 Adjustment
• Adjusting the gap for the glue meter:
1) Set the glue-adjusting knob to the left ( MIN ) position.
2) Use a ruler from the surface of the nipping station across the glue tank as shown on
the following page. The ruler should touch the glue meter. Then measure the
distance between the ruler and the peak of glue drum. Note that the standard gap
between the ruler and the peak of glue drum is 2 to 3 mm.
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3) To adjust the standard gap for the glue meter, you can use the screws on the glue
tank bracket to adjust the position of the glue tank. Then measure the distance
between the ruler and the highest point of glue drum. To adjust the height of the
glue meter, loosen the two sets of screws located on each end.
2 – 3 mm Ruler
The level of clamping position
Glue Scraper
Glue Meter
Glue Drum
2 mm
• Adjusting the gap for the glue scraper:
1) Loosen the two screws on the glue scraper.
2) Measure the distance between glue scraper and the glue drum as shown. Note that the
standard gap between glue scraper and the glue drum is 2 mm.
3) Tighten the screws.
• Setting the glue-adjusting knob to the appropriate positions: Normally, the indicator is
set at 1/3 to 1/2 of the arrow mark.
1/3 1/2
MIN MAX
1/3 1/2
MIN MAX
• Controlling the quality of a book by means of the glue meter:
Note that the thickness of the cover sheet is an important factor for you to make a
good spine. Use only the appropriate thickness of cover sheet to make a good book.
1) Decrease the melted glue when
Too much glue on both sides OR Nail Head
2) Increase the melted glue when
Hollow Middle OR Round
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3. Nipping Station
3-1 Mechanism
The mechanism of nipping station is shown below.
3-2 Function
Provided a flat surface for the book block, when there are being placed into the clamp
station. It also provides the nipping force to form the cover around the spine of the
book.
3-3 Adjustment
1) During the nipping process, the nipping plates must exert an even pressure on the
cover in order to form a good spine.
2) The nipping swing arms provide this pressure.
Center line
A B
Open the nipping station, then turn the swing
arms counter-clockwise to the position
shown. The swing arms must touch together
at the centerline as shown.
If not, they need to be adjusted.
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• Position change on the position disc of nipping station:
There are three positions of the nipping station for executing the clamping, the cover,
and the nipping processes. The LED of the sensor ( LS3 or LS4 ) goes on when the
notch of position disc travels through the trench of the sensor as shown below:
( Clamping Position )
Bearing 1) Highest Point Range
2) Lowest Point
( Cover Position )
Position Disc
3)Sub-high Point Range
( Binding Position )
LS4 Sensor
LS3 sensor
1) Clamping: when the bearing is at the highest point.
LS3 OFF LS4 ON
2) Cover: when the bearing is at the lowest point.
LS3 ON LS4 OFF
3) Nipping: when the bearing is at the sub-high point.
LS3 OFF LS4 OFF
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If the spine is not being nipped evenly, adjust the nipping plates as follows:
• Adjusting on the Nipping Plates:
Push each side of nipping plates to
find out which side is too tight.
Then use the nipping plate screws to
do the fine adjustment until both sides
have the same tension.
Note that you can use the
“MOTOR2” of “TEST2” to verify the
nipping plate position before
tightening them.
Nipping plate adjustment screws
• Position Adjustments on Nipping Station:
(A) The level of nipping station should be adjusted evenly on the corresponding ends to
preven t tilting the nipping station surface, by level adjusting screws. (B) The centerline
of the nipping station must match the projected centerline of the clamp station by the
front/rear adjusting screws. (C) The position of cover can be adjusted by the cover
position adjusting screws, along with the position of LS1.
(C) Cover Position Adjusting Screws
(A) Level Adjusting Screws
( 2 of them on each side )
(B) Front / Rear Adjusting Screws
( 2 of them on each side )
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4. Clamp Station
4-1 Mechanism
The mechanism of clamp station is shown below.
4-2 Function
Holding the book block for the notching, gluing, and nipping processes of
bookbinding.
4-3 Adjustment
The acceptable spine of a book and the shape of book block after being clamped are
shown below. If you find different shapes such as “round”, “hollow” and “nail head”
for one end or both ends, remove the clamp covers, then use the screws on both
clamps to adjust them. Normally there is no gap between the spine and the nipping
plate surface.
Standard Spine of Book Standard Shape of Book Block
Nipping Plate Surface 0
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• Adjusting for round or hollow middle :
If you see the spine of the book has a round or hollow middle, most of the cases
you may 1) increase the certain quantity of hot-melt glue by the glue meter or 2)
turn VR knob clockwise to increase the nipping force to correct it. Otherwise you
have to slightly loosen the bottom lock nuts and tighten the bottom screws of the
clamps. Then check to ensure there is no gap between the nipping plate surface and
inner pages as shown below. Please refer to the spine adjustment in Appendix A for
details.
Nipping Plate Surface
• Adjusting for nail head :
If you see the spine of the book has a nail head, most of the cases you may 1)
decrease the certain quantity of hot-melt glue by the glue meter or 2) turn VR
knob counter clockwise to decrease the nipping force to correct it. Otherwise you
have to slightly loosen the upper lock nuts and tighten the upper screws of the clamps.
Then check to ensure there is no flare between the nipping plate surface and inner
pages as shown below. Please refer to the spine adjustment in Appendix A for details.
Nipping Plate Surface
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5. Driving Section
5-1 Mechanism
The mechanism for driving section is shown below.
5-2 Function
Provides driving power to move and locate the clamp station over the glue drum and
notching station, then return it back to the nipping station for covering and binding.
5-3 Adjustment
Adjust tensioner to eliminate any slack in chain.
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Electricity
1. Construction block layout
1. SWITCHING
POWER
2. CONTROL PANEL
(TG200B1) POWER
3. CLAMP STATION 11. EMERGENCY
RIGHT SENSOR (LS1) SWITCH
9. 10.
CPU SSR
(TG200A1) (TG200C2)
4. CLAMP STATION 12. THERMOSTAT
LEFT SENSOR (LS2)
5. NIPPING STATION 13. FUSE BOARD
SENSOR (LS3/LS4) (TG200D2)
6. CLAMP INNER PAGE 14. MAIN MOTOR (M1)
SENSOR (SN1)
7. NIPPING COVER 15. NIPPING MOTOR (M2)
SENSOR (SN2)
8. HALF TEMPERATURE 16. NOTCHING MOTOR (M4)
SENSOR (TEMP2)
17. CLAMP MOTOR (M6)
20. SAFETY TEMPERATURE SENSOR (TEMP3)
18. HEATER
19. CAPACITORS
24
Page 29
2. Outline of each block
1. Switching Power
Converts AC110V / 220V into DC 5V and DC 12 V.
2. Control Panel ( TG200B1 )
Displays the current status of the machine.
3. Clamp Station Right Sensor ( LS1 )
Detects and locates the clamp station at its home position.
4. Clamp Station Left Sensor ( LS2 )
Detects and stops the clamp station to the left of the machine.
5. Nipping Station Sensor ( LS3 / LS4 )
LS3: detects the lowest point of the nipping station surface.
LS4: detects the highest point of the nipping station surface.
6. Clamp Inner Page Sensor ( SN1 )
Detects when pages are placed in the clamp station.
7. Nipping Cover Sensor ( SN2 )
Detects when cover page is placed on the nipping station.
8. Half Temperature Sensor ( TEMP2 )
Sets the lowest temperature of the glue tank when the machine has been switched to
“STANDBY” mode.
9. CPU ( TG200A1 )
Controls the operating procedures, the input/output and the error message handling
of the machine.
10. SSR ( TG200C2 )
Controls the driving components for the motors and thermostat.
11. Emergency Switch
Used for stopping the machine when machine has encountered a malfunction or
abnormal operation.
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12. THERMOSTAT
Sets the working temperature of the glue.
13. Fuse Board ( TG200D2 )
Protects the motors and heater from overloading.
14. Main Motor ( M1 )
Drives the clamp station to the left and right positions. It also drives the glue drum
when the clamp station is moving to the right position of the machine.
15. Nipping Motor ( M2 )
Drives the nipping plates to make the spine of the book. It also controls the highest
and lowest points of the nipping station surface.
16. Notching Motor ( M4 )
Drives the notching blade to make the cuts on the spine of the book.
17. Clamp Motor ( M6 )
Drives the clamps to hold or release the inner pages of the book.
18. Heater
Heats the glue tank to melt the glue reaching to its working temperature.
19. Capacitors
Triggers M1, M2, M3, and M4 motors.
20. Safety Temperature Sensor (TEMP3)
Sets the safety temperature to protect the glue tank from overheats. TEMP3 will shut
off the power of the machine as soon as the glue tank temperature reaches to this
pre-set temperature.
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3. Checking the motions - Test modes
• TEST1 – Operation Test:
Press and hold down the “FUNCTION” and “START” buttons, then turn the power on.
You should see the “TEST1” in the LED display. After performing the “WARM”,
“HOT”, and “S-TEST” processes, the DB-250 will execute the entire operation test
procedures as the following order:
Open the clamps à Close the clamps à Move clamp station to pass the notching station
/ Run the notching wheel à Back to nipping station à Up/Down the nipping station /
Close/Open the nipping plates
Note: Test1 is an infinite loop. To return to MANUAL operation, you can stop Test1 by
pressing the FUNCTION button when the LED display shows "READY".
• TEST2 – Module Test:
Press and hold down the “FUNCTION” and “STANDBY” buttons, then turn the power
on. You should see the “TEST2” in the LED display. After performing the “WARM”,
“HOT”, and “S-TEST” processes, the DB-250 will display “MOTOR 1” in the LED
display. Then you can select the following module tests by pressing “OPEN” or
“CLOSE” button to toggle “MOTOR 1”, “MOTOR 2”, “MOTOR 4”, and “MOTOR 6”
followed by pressing “START” button to execute.
MOTOR 1 (Main motor motion):
Moves clamp station to notching station, then back to nipping station.
MOTOR 2 (Nipping motor motion):
Moves the nipping station surface to the highest point, the sub-high point, and the lowest
point and provides the nipping force for nipping plates.
MOTOR 4 (Notching motor motion):
Runs the notching wheel for a few seconds.
MOTOR 6 ( Clamp motor motion)
Opens the clamps, then close the clamps.
Note: To return to MANUAL operation, press FUNCTION button when LED display
shows "MOTOR1/2/4/6".
• Displays the total amount of bookbinding:
Press and hold down the “FUNCTION” and “CLEAR” buttons, then turn the power on.
You should see the total amount of bookbinding in the LED display.
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4. Circuit Diagrams
4-1 Main Schematic Diagrams
• CPU ( TG200A1 )
28
Page 33
• CONTROL PANEL ( TG200B1 )
29
Page 34
• SSR ( TG200C2 )
30
Page 35
• FUSE BOARD ( TG200D2 )
31
Page 36
4-2 Wiring diagram
LEGEND
C1: Motor Capacitor 1
C2: Motor Capacitor 2
C4: Motor Capacitor 4
C6: Motor Capacitor 6
CCW: Counter Clockwise
CW: Clockwise
EMG: Emergency Switch
LS1: Limit Sensor 1
LS2: Limit Sensor 2
LS3: Limit Sensor 3
LS4: Limit Sensor 4
M1: Main Motor
M2: Nipping Motor
M4: Notching Motor
M6: Clamp Motor
PSR: Pressure Sensor
SN1: Clamp Photo Switch
SN2: Cover Photo Switch
TEMP2: Half Temperature Sensor
TEMP3: Safety Temperature Sensor
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Page 37
4-3 Pin Assignments
Power LED Display
S-Power Capacitors Heater
Emergency
CPU Motors
Relay Fuse
33
Page 38
Parts Catalog
1. Frame / Exterior Section
INDEX PARTS NO. DESCRIPTION QTY AREA
1 E4005 Compartment Pillar 1
2 E6001 Main Frame 1
3 E6019 Front Guide 1
4 E6020 Rear Guide 1
5 E6004 PCB Box Bracket 1
6 E6005 Control Panel Bracket 1
7 E6021 Front Cover 1
8 E6007 Rear Cover 1
9 E6025 Control Panel Cover 1
10 E6023 Front Guide Cover 1
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INDEX PARTS NO. DESCRIPTION QTY AREA
11 E6022 Rear Guide Cover 1
12 E6013 Glue Tank Bottom Cover 1
13 E6017 Cover Sheet Holder 1
14 E6018 Control Panel Hanger 2
15 E6201 Glue Tank Top Cover 1
16 E6401 Notching Station Cover 1
17 E6403 Glue Tank Bracket 1
18 E6405 Shipping Bracket 1 1
19 E6406 Shipping Bracket 2 1
20 E6408 Shipping Bracket 3 1
21 E8302 Glue Tank Tag 1
22 E8401 Machine Leg 4
23 E8406 Fuse PCB Cover 1
24 E6024 Notching Bottom Cover 1
25 E8309 Nipping Warning Label 1
26 E8311 Clamp Motion Warning Label 1
27 E8310 Fuse Board Warning Label 1
28 E8313 Ground Label 1
29 E8312 Electric Warning Label 1
30 E8315 PE Label 1
31 E8306 Machine Name Plate 1
32 E8314 CE Label 1
33 E6209 Glue Draining Tray 1
35
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2. Notching Station Section
INDEX PARTS NO. DESCRIPTION QTY AREA
1 E3008 Notching Roller Shaft 4
2 E3003 Notching Wheel 1
3 E3004 Notching Roller 4
4 E3005 Notching Position Spacer 2
5 E3006 Notching Position Arm 4 G3001
6 E3007 Notching Station Body 1
7 E6304A Notching Cover 1
8 E6304B Notching Cover 1
9 E6303 Notching Position Connector 2 G3001
10 E6402 Notching Station Bracket 2
11 E7103 Notching Motor ( M4 ) 1
12 E7401W Notching Motor Power Connector – female 1
13 E8203 Position Connector Spring 2
14 E8205 Notching Blade Spring 1
15 E8303 Notching Warning Label 1
16 E8403 Notching Blade 1
17 U3004 Connecting Rivet 4 G3001
18 U3006 Position Arm Screw 4 G3001
19 U3007A Connecting Collar 8 G3001
20 U3009B Notching Base Adjustment Screw 3
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3. Glue Tank Section
INDEX PARTS NO. DESCRIPTION QTY AREA
1 E2001 Glue Tank Body 1
2 E2002 Glue Meter Shaft 1
3 E2003 Glue Wheel Shaft 1
4 E2004 Glue Scraper Shaft 1
5 E2005 Glue Wheel Bearing 1
6 E2006 Glue Tank Shaft Unit 1
7 E6202 Glue Scraper Plate 1
8 E6203 Glue Heater Cover 1
9 E7305 Glue Tank Heater 1
10 E7306 Glue Tank Temperature Probe 1
11 E7307 Glue Tank Half Temperature Sensor 1
12 E8104 Bearing for Glue Tank Shaft 4
13 E8204 Glue Meter Spring 1
14 E8305 Glue Level Indicator 1
15 E8404 Glue Adjustment Knob 1
16 U2006 Glue Meter 1
17 U2010 Glue Wheel 1 G2001
18 U2011 Glue Wheel Cover 1 G2001
19 U2012 Glue Accumulator Seat 1 G2002
20 U2013 Glue Accumulator 1 G2002
21 U2018 Glue Adjustment Block 1 G2003
22 U2019 Glue Adjustment Guide 1 G2003
23 U6202 Glue Meter Connector 1
24 U6207 Glue Adjustment Bracket 1
25 E7317 Glue Tank Temperature Safety Sensor 1
26 E2007 Glue Draining Plug 1
37
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4. Nipping Station Section
38
Page 43
INDEX PARTS NO. DESCRIPTION QTY AREA
1 E1001 Nipping Station Base 1
2 E1002 Nipping Station Body Part 1 G1001
3 E1003 Nipping Station Swing Shaft 2
4 E1004 Lifting Cam for Nipping Station 1
5 E1006 Nipping Plate 2
6 E1007 Lifting Bracket 1
7 E1008 Bearing Shaft for Lifting Bracket 1
8 E1024 Nipping Slide Block 4 G1002
9 E1010 Nipping Station Timing Shaft 1
10 E1011 Hinge Seat for Nipping Station 2 G1003
11 E1012 Hinge Shaft for Nipping Station 2
12 E1013 Nipping Slide Block Guide 2
13 E1014 Nipping Inner Slide Block 4
14 E1015 Fixed End for Nipping Slide Block Guide 4
15 E1026 Bearing Shaft for Nipping Slide Block 4
16 E1017 Nipping Station Swing Arm 4
17 E1018 Bearing Shaft for Nipping Stop 2
18 E6101 Nipping Table 1
19 E6102 Cover Center Mark 1
20 E6103 Cover Ruler Seat 1
21 E6104 Nipping Sensor Seat 1
22 E6105 Nipping Table Front Cover 1
23 E6106 Nipping Spring Bracket 1 2
24 E6107 Nipping Spr ing Bracket 2 2
25 E6108 Nipping Table Rear Cover 1
26 E6110 Cover Ruler Holder 1 G1004
27 E7102 Nipping Station Motor ( M2 ) 1 G1005
28 E7102G Nipping Motor Reduced Gear Box 1
29 E7205 Photo Switch ( LS3, LS4 ) 2
30 E7207 Cover Photo Switch 1
31 E7401-W Nipping Motor Power Connector - female 1 G1005
32 E8101 Nipping Slide Bearing ( 6000ZZ ) 5
33 E8102 Bearing for Nipping Station Shaft ( 12-16*8L ) 8 G1001
34 E8103 Bearing for Nipping Hinge Shaft ( 10-14*8L ) 2 G1003
35 E8107 Nipping Stop Bearing ( 608ZZ ) 2
36 E8201 Nipping Plate Spring 2
37 E8202 Cover Ruler Seat Spring 1
38 E8402 Cover Ruler 1 G1004
39 E9002 Nipping Gear 1 1
40 E1027 Cover Position Adjustment 2
41 U4026 Nipping Position Ring 2
42 U6415 Nipping Position Disc 2
43 U9010 Nipping Gear 2 3
44 E8108 Nipping Slide Block Bearing 4 G1002
39
Page 44
5. Clamp Station Section
40
Page 45
INDEX PARTS NO. DESCRIPTION QTY AREA
1 E5003 Clamp Wheel Seat 2 G5001
2 E5004 Clamp Driving Connector 1
3 E5008 Clamp Worm Support 1
4 E5009 Clamp Left-Right Worm 1 G5002
5 E5010 Clamp Worm Seat 2 G5003
6 E5012 Clamp Wheel Support 2
7 E6502 Clamp Station Cover 1
8 E6512 Clamp Station Body 1
9 E6513A Clamp Adjustment 1
10 E6513B Clamp Adjustment 1
11 E6514A Clamp Cover 1
12 E6514B Clamp Cover 1
13 E6515A Clamp 1
14 E6515B Clamp 1
15 E6516A Clamp Beam Block Plate 1
16 E6516B Clamp Beam Block Plate 1
17 E6517 Block Plate for Clamp Wire Hose 1
18 E6519 Clamp Station Wire Connector Seat 1
19 E7104 Clamp Motor ( M6 ) 1
20 E7104-G Clamp Motor Gear Box 1
21 E7206 Clamp Photo Switch 1
22 E7401-M Clamp Motor Power Connector - male 2
23 E8101 Clamp Worm Bearing ( 6000ZZ ) 6 G5001,
G5003,G5004
24 E8304 Clamp Station Ruler for Binding Width 1
25 U9003 Clamp Transmission Gear 1 1
26 U5001 Clamp Transmission Bearing Seat 4 G5004
27 E5006 Clamp Left Worm 1 G5005
28 E5007 Clamp Right Worm 1 G5006
29 U5006 Clamp Right Worm Seat 1 G5006
30 U5007 Clamp Left Worm Seat 1 G5005
31 U5009 Clamp Front Right Worm Seat 1 G5002
32 U5010 Clamp Front Left Worm Seat 1 G5002
33 U9004 Clamp Chain Wheel 4
34 U9012 Clamp Transmission Chain 2
35 U9013 Clamp Transmission Gear 2 1
36 E8308 Clamping Warning Label 1
37 E8311 Clamp Station Warning Label 1
38 E8317 Book/Pad Loading Instruction Label 1
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6. Driving Section
INDEX PARTS NO. DESCRIPTION QTY AREA
1 E4001 Driving Shaft Screw 6
2 E4002 Driving Shaft Slide Seat 2 G4001
3 E4003 Driving Shaft 1
4 E4004 Sprocket Shaf t 1 1
5 E4006 Chain Adjustment 1
6 E7101 Main Motor ( M1 ) 1 G4002
7 E7101-G Main Motor Reduced Gear Box 1
8 E7402-W Main Motor Power Connector - female 1 G4002
9 E8101 Chain Shaft Bearing 10 G4003
10 E8105 Glue Drum Bearing 1 G4004
11 E8106 Driving Shaft Slide Bearing 2 G4001
12 E9001 Sprocket Gear 1 1
13 U4007 Sprocket Shaft 2 3
14 U9006 Sprocket Gear 2 1 G4004
15 U9007 Sprocket Gear 3 5 G4003
16 U9011 Chain 1
17 E4008-1 Bumper Mounting Block 1 G4005
18 E4008-2 Bumper Rough Adjust 1 G4005
19 E4008-3 Bumper Shaft 1 G4005
20 E4008-4 Bumper Fine Adjust 1 G4005
21 E8206 Bumper Spring 1 G4005
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7. Electricity Section
INDEX PARTS NO. DESCRIPTION QTY AREA
1 E6011 PCB Box Base 2
2 E6012 Temperature Switch Brack et 1
3 E6014 Capacitance Base 1
4 E6015 PCB SSR Cover 1
5 E6016 PCB CPU Cover 1
6 E6404 Photo Switch Bracket 2
7 E7201 TG -200 CPU 1
8 E7203 TG -200 SSR 1
9 E7202 TG -200 Panel 1
10 E7204 TG -200D2 Fuse PCB 1
11 E7205 Photo Switch (LS1) 1
12 E7205 Photo Switch (LS2) 1
13 E7301 Switch Power 1
14 E7302 Emergency Switch 1
15 E7303 Main Power Switch 1
16 E7304 Main Power Chord 1
17 E7306 Temperature Switch 1
18 E7308 PCB Cable ( 26 pin ) 1
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INDEX PARTS NO. DESCRIPTION QTY AREA
19 E7309 Control Panel Cable ( 16 pin ) 1
20 E7401-M Nip / Notch Motor Power Connector - male 2
21 E7401-W Clamp Motor Power Connector - female 2 G6001
22 E7402-M Main Motor Power Connector - male 1
23 E8301 Control Panel Tag 1
24 E8405 Wiring Hose with Wires 1 G6001
25 E7311 Terminator 1
26 E7310 Safety Switch 1
27 E7314 Emission Suppressor 1 (PCB cable/sn2/ls3/ls4) 2
28 E7313 Emission Suppressor 2 (control panel cable) 4
29 E7315 Power Chord Fastener 1
30 E7316 VR Nipping Pressure Control Knob 1
8. Assemble Parts List
The following parts have to order in assemble:
PARTS NO. DESCRIPTION ASSEMBLED
PARTS
G1001 Nipping Station Body Assemble E1002, E8102 6
G1002 Nipping Slide Block Assemble E1024, E8108 6
G1003 Nipping Hinge Shaft Assemble E1011, E8103 6
G1004 Cover Ruler Assemble E6110, E8402 6
G1005 Nipping Motor Assemble E7102, E7401-W 6
G2001 Glue Wheel Assemble U2010, U2011 4
G2002 Glue Accumulator Assemble U2012, U2013 4
G2003 Glue Adjustment Assemble U2018, U2019 4
G3001 Notching Cover Linkage Assemble E3006, E6303,
U3004, U3006,
U3007A
G4001 Driving Shaft Slide Assemble E4002, E8106 9
G4002 Main Motor Assemble E7101, E7101-G 9
G4003 Chain Shaft Assemble E8101, U9007 9
G4004 Glue Drum Assemble E8105, U9006 9
G4005 Bumper Assemble E4008-1, E4008-2,
E4008-3, E4008-4,
E8206
G5001 Clamp Wheel Assemble E5003, E8101 8
G5002 Clamp Front Worm Assemble E5009, U5009,
U5010
G5003 Clamp Right Worm Seat Assemble E5010, E8101 8
G5004 Clamp Left Worm Seat Assemble E8101, U5001 8
G5005 Clamp Left Worm Assemble E5006, U5007 8
G5006 Clamp Right Worm Assemble E5007, U5009 8
G6001 Wiring Hose Assemble E7401-W, E8405 10
PAGE
3
9
8
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Maintenance
1. Daily Cleaning Procedures
After you have finished using the binder for the day, follow the following steps:
1. Close the clamps while the LED display flashing "LOAD BOOK" or "LOAD PAD".
2. Press "START" and "CLEAR" keys simultaneously. The clamp station will
automatically move to the left of the machine and LED display "NP SVC".
3. Clean the residual glue that might be on the nipping plates and plate surfaces.
4. Press the "START" and "CLEAR" keys again, the clamp station will return to its
home position. Open the clamps to the maximum position. Clean their surfaces and
wax them.
5. Turn the DB-250 off.
2. General Maintenance Procedures
Depends on how frequency you use the machine, we recommend that you should do the
following maintenance at least once during three-month period.
(1) Clamp Station
1. Open the clamps to the maximum position then turn off the power of the machine.
2. Take apart the clamps from the clamp station.
3. Clean the residual glue that might be on the clamps.
4. Install the clamps to the clamp station.
5. Turn on the power of the machine.
6. Clamp some inner pages to see if the clamps have been installed properly. If clamp
adjustment need, please refer to A1 section of Appendix for details.
(2) Notching Station
This is a monthly maintenance. However, we recommend that you should use vacuum
to clean the paper dust on the notching station when the machine has made 2,000 books.
Warning: You must power off the machine in order to perform the notching blade
maintenance.
1. Power off the machine.
2. Remove the notching covers.
3. Use the vacuum to clean up the paper dust.
4. Clean up the residual glue around the notching wheel, rollers and blade.
5. Clean the notching covers, notching blade, and rollers.
6. Check to see if the notching blade has been worn out or broken. If so, replace a new one.
7. Install the notching covers.
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Page 50
(3) Checking the Motions – TEST2
Please refer to the “Checking the motions” section of the electricity on page 27 for
details.
(4) Making Sample Books
Run the following modes and make some sample books to see if every mode is
functioning properly and doesn’t form the nail head or round angle on the spine of
books.
Pad:
Set the glue meter to minimum position and the operating mode to “PAD” with
“NOTCH”. Then make a 40mm (1.57”) book to see if the glue thickness and notching
depth are evenly distributed on the spine. Note that the standard glue thickness is 0.4 to
0.5 mm or (0.015” to 0.020”) while the standard notching depth is 0.7mm or (0.028”.)
Manual:
Set the operating mode to “MANUAL”. Then make three 6.35 mm (¼”), 12.7 mm (½”),
25.4 mm (1”), and 40mm (1.57”) books in MANUAL mode.
Auto:
Set the operating mode to “AUTO”. Then make five 6.35 mm (¼”), 12.7 mm (½”), 25.4
mm (1”), and 40mm (1.57”) books in AUTO mode.
3. Maintenance Parts List
PARTS
NO.
E1004 Lifting Cam for Nipping Station (4) Nipping Station 1
E1008 Bearing Shaft for Lifting Bracket (4) Nipping Station 1
E1011 Hinge Seat for Nipping Station (4) Nipping Station 2
E1012 Hinge Shaft for Nipping Station (4) Nipping Station 2
E1017 Nipping Station Swing Arm (4) Nipping Station 4
E1026 Bearing Shaft for Nipping Slide Block (4) Nipping Station 4
E2005 Glue Wheel Bearing Shaft (3) Glue Tank 1
E3003 Notching Wheel (2) Notching Station 1
E3004 Notching Roller (2) Notching Station 4
E3005 Notching Position Spacer (2) Notching Station 2
E4002 Driving Shaft Slide Seat (6) Driving 2
E4004 Sprocket Shaft 1 (6) Driving 1
E4006 Chain Adjustment (6) Driving 1
E5003 Clamp Wheel Seat (5) Clamp Station 2
E5008 Clamp Worm Support (5) Clamp Station 1
E5009 Clamp Left-Right Worm (5) Clamp Station 1
E5010 Clamp Worm Seat (5) Clamp Station 2
E6018 Control Panel Hanger (1) Frame / Exterior Section 2
E6516A Clamp Beam Block Plate (5) Clamp Station 1
E6516B Clamp Beam Block Plate (5) Clamp Station 1
E6517 Block Plate for Clamp Wire Hose (5) Clamp Station 1
E7101 Main Motor ( M1 ) (6) Driving 1
DESCRIPTION SECTION QTY
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PARTS
DESCRIPTION SECTION QTY
NO.
E7101-G Main Motor Reduced Gear Box (6) Driving 1
E7102 Nipping Station Motor ( M2 ) (4) Nipping Station 1
E7102G Nipping Motor Reduced Gear Box (4) Nipping Station 1
E7103 Notching Motor ( M4 ) (2) Notching Station 1
E7104 Clamp Motor ( M6 ) (5) Clamp Station 1
E7104-G Clamp Motor Gear Box (5) Clamp Station 1
E7201 TG-200 CPU (7) Electricity 1
E7202 TG-200 Panel (7) Electricity 1
E7203 TG-200 SSR (7) Electricity 1
E7204 TG-200D2 Fuse PCB (7) Electricity 1
E7205 Photo Switch ( LS3, LS4 ) (4) Nipping Station 2
E7205 Photo Switch (LS1) (7) Electricity 1
E7205 Photo Switch(LS2) (7) Electricity 1
E7206 Clamp Photo Switch (5) Clamp Station 1
E7207 Nipping Photo Switch (4) Nipping Station 1
E7301 Switch Power (7) Electricity 1
E7302 Emergency Switch (7) Electricity 1
E7303 Main Power Switch (7) Electricity 1
E7304 Main Power Chord (7) Electricity 1
E7305 Glue Tank Heater (3) Glue Tank 1
E7306 Temperature Probe ( Temp 1 ) (3) Glue Tank 1
E7306 Temperature Switch (7) Electricity 1
E7307 Temperature Switch ( Temp 2 ) (3) Glue Tank 1
E7308 Ribbon Cable ( 26 pin ) (7) Electricity 1
E7309 Ribbon Cable ( 16 pin ) (7) Electricity 1
E7401-M Clamp Motor Power Connector - male (5) Clamp Station 2
E7401-M Nip / Notch Motor Power Connector - male (7) Electricity 2
E7401W Notching Motor Power Connector – female (2) Notching Station 1
E7401-W Nipping Motor Power Connector - female (4) Nipping Station 1
E7401-W Clamp Motor Power Connector - female (7) Electricity 2
E7402-M Main Motor Power Connector - male (7) Electricity 1
E7402-W Main Motor Power Connector - female (6) Driving 1
E8101 Nipping Slide Bearing ( 6000ZZ ) (4) Nipping Station 5
E8101 Clamp Worm Bearing ( 6000ZZ ) (5) Clamp Station 6
E8101 Chain Shaft Bearing ( 6000ZZ ) (6) Driving 10
E8102 Bearing for Nipping Station Shaft ( 12-16*8L ) (4) Nipping Station 16
E8103 Bearing for Nipping Hinge Shaft ( 10-14*8L ) (4) Nipping Station 2
E8104 Bearing for Glue Tank Shaft (3) Glue Tank 4
E8105 Glue Drum Bearing (6) Driving 1
E8106 Driving Shaft Slide Bearing (6) Driving 2
E8107 Nipping Stop Bearing ( 608ZZ ) (4) Nipping Station 2
E8108 Nipping Slide Block Bearing (4) Nipping Station 4
E8201 Nipping Plate Spring (4) Nipping Station 2
E8202 Cover Ruler Seat Spring (4) Nipping Station 1
E8203 Position Connector Spring (2) Notching Station 2
E8204 Glue Meter Spring (3) Glue Tank 1
E8205 Notching Blade Spring (2) Notching Station 1
E8301 Control Panel Tag (7) Electricity 1
47
Page 52
PARTS
DESCRIPTION SECTION QTY
NO.
E8302 Glue Tank Tag (1) Frame / Exterior Section 1
E8303 Notching Station Tag (2) Notching Station 1
E8304 Clamp Station Ruler for Binding Width (5) Clamp Station 1
E8305 Glue Level Indicator (3) Glue Tank 1
E8401 Machine Leg (1) Frame / Exterior Section 4
E8402 Cover Ruler (4) Nipping Station 1
E8403 Notching Blade (2) Notching Station 1
E8404 Glue Adjustment Knob (3) Glue Tank 1
E8405 Wiring Hose with Wires (7) Electricity 1
E9001 Sprocket Gear 1 (6) Driving 1
E9002 Nipping Gear 1 (4) Nipping Station 1
E9003 Clamp Transmission Gear 1 (5) Clamp Station 1
U1003 Cover Position Adjustment (4) Nipping Station 2
U2006 Glue Meter (3) Glue Tank 1
U2013 Glue Accumulator (3) Glue Tank 1
U3007A Connecting Collar (2) Notching Station 8
U3009B Notching Base Adjustment Screw (2) Notching Station 3
U4007 Sprocket Shaft 2 (6) Driving 3
U4026 Nipping Position Ring (4) Nipping Station 2
U5001 Clamp Transmission Bearing Seat (5) Clamp Station 4
U5004 Clamp Left Worm (5) Clamp Station 1
U5005 Clamp Right Worm (5) Clamp Station 1
U5006 Clamp Right Worm Seat (5) Clamp Station 1
U5007 Clamp Left Worm Seat (5) Clamp Station 1
U5009 Clamp Right Worm Seat (5) Clamp Station 1
U5010 Clamp Left Worm Seat (5) Clamp Station 1
U6415 Nipping Position Disc (4) Nipping Station 2
U9004 Clamp Chain Wheel (5) Clamp Station 4
U9006 Sprocket Gear 2 (6) Driving 1
U9007 Sprocket Gear 3 (6) Driving 5
U9010 Nipping Gear 2 (4) Nipping Station 3
U9011 Chain (6) Driving 1
U9012 Clamp Transmission Chain (5) Clamp Station 2
U9013 Clamp Transmission Gear 2 (5) Clamp Station 1
Note: The unlisted parts are all durable.
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APPENDIX
A - Troubleshooting Guide for Spine Adjustment
Note: Before you perform the spine adjustment, try to use the following methods
to correct it.
(A) Round / hollow middle through the spine
(1) Increase the certain quantity of hot-melt glue by the glue meter.
(2) Turn VR knob clockwise to increase the nipping pressure.
(B) Nail head through the spine:
(1) Decrease the certain quantity of hot-melt glue by the glue meter.
(2) Turn VR knob counter clockwise to decrease the nipping pressure.
There are two types of the spine adjustment: A1- Clamp Spine Adjustment and A2 Nipping Plates Adjustment. In order to make good spine of books, we suggest that
you can use the clamps / the nipping plates to hold three different amount of inner
pages. For example: 25, 150 , and 300 pages or 1/8” (3 mm), ¾” (18 mm), and 1 1/2”
(40 mm) in thickness of book block and do the adjustment accordingly.
• Clamp Spine Adjustment:
Use the “CLOSE” button to hold one amount of inner pages on the clamps. Then
check if there is no gap between the nipping plate surface and inner pages as shown
below. Otherwise you need to do the adjustment for the clamps. Repeat the same
procedures for different amount of inner pages.
• Nipping Plates Spine Adjustment:
Use the “MOTOR 2” of the “TEST2” to hold one amount of inner pages on the
nipping plates. Then check if both nipping plates can evenly hold the inner pages
without off the centerline as shown below. Otherwise you need to do the adjustment
for the nipping plates. Repeat the same procedures for different amount of inner pages.
Centerline
Nipping plates
LL: Left corner of left-end spine
RL: Right corner of left-end spine
LR: Left corner of right-end spine
RR: Right corner of right-end spine
Good spine should be: LL = RL = RR = LR Four corners of the spine
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A1 - Clamp Spine Adjustment
(A) Round / hollow middle through the spine
LL = RL, RR = LR
OR OR
(1) Increasing certain quantity of the hot-melt glue by glue meter, then make
some books to see if the spine has been improved on both sides.
(2) Slightly turn the VR knob clockwise to increase the nipping pressure, then
make some books to see if the spine has been improved on both sides.
(3) If (1) or (2) can not improve the book spine, you have to do the adjustment
for the clamps. Slightly loosen the bottom lock nuts, then gradually tighten
the bottom screws of the clamps until there is no gap between the spine and
the nipping plate surface when you close the clamps. Make some books to
see if the spine has been improved on both sides.
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(B) Nail head through the spine
LL = RL, RR = LR
(1) Decreasing certain quantity of the hot-melt glue by glue meter, then make
some books to see if the spine has been improved on both sides.
(2) Slightly turn the VR knob counter clockwise to decrease the nipping
pressure, then make some books to see if the spine has been improved on
both sides.
(3) If (1) or (2) can not improve the book spine, you have to do the adjustment
for the clamps. Slightly loosen the upper lock nuts, then gradually tighten the
upper screws of the clamps until there is no gap between the spine and the
nipping plate surface when you close the clamps. Make some books to see if
the spine has been improved on both sides.
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(C) Left-end round / hollow middle
LL = RL, RR = LR
OR
You have to do the adjustment for the clamps. Slightly loosen the left-side
bottom lock nuts, then gradually tighten the left bottom screws of the clamps
until there is no gap between the spine and the nipping plate surface when you
close the clamps. Make some books to see if the spine has been improved on left
side.
(D) Right-end round / hollow middle
LL = RL, RR = LR
OR
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You have to do the adjustment for the clamps. Slightly loosen the right-side
bottom lock nuts, then gradually tighten the right bottom screws of the clamps
until there is no gap between the spine and the nipping plate surface when you
close the clamps. Make some books to see if the spine has been improved on
right side.
(E) Left-end nail head
LL = RL, RR = LR
You have to do the adjustment for the clamps. Slightly loosen the left-side upper
lock nuts, then gradually tighten the left upper screws of the clamps until there is
no gap between the spine and the nipping plate surface when you close the
clamps. Make some books to see if the spine has been improved on left side.
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(F) Right-end nail head
LL = RL, RR = LR
You have to do the adjustment for the clamps. Slightly loosen the right-side
upper lock nuts, then gradually tighten the right upper screws of the clamps until
there is no gap between the spine and the nipping plate surface when you close
the clamps. Make some books to see if the spine has been improved on right
side.
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(G) Left-end nail head and right-end round
LL = RL, RR = LR
You have to reset the clamps. Loosen all the lock nuts, then gradually tighten all
the screws of the clamps until there is no gap between the spine and the nipping
plate surface when you close the clamps. Make some books to see if the spine
has been improved on both sides.
(H) Right-end nail head and left-end round
LL = RL, RR = LR
You have to reset the clamps. Loosen all the lock nuts, then gradually tighten all
the screws of the clamps until there is no gap between the spine and the nipping
plate surface when you close the clamps. Make some books to see if the spine
has been improved on both sides.
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A2 - Nipping Plates Spine Adjustment
One side round and one side square
LL ≠ RL RR ≠ LR
OR OR
You have to adjust the nipping plates.
Push each side of nipping plate to find which side is loosing or too tight. Then
slightly loosen all the nipping plate adjustment screws on each plate. Then use the
nipping plate screws to do the fine adjustment until both sides have the same tension
that can be pushing smoothly. Then use the “MOTOR 2” of “TEST2” to hold the
inner pages to check if both nipping plates can evenly hold the inner pages without
off the centerline as shown below. Having verified the nipping plate position, you
can tighten the nipping plates. Make some books to see if the spine has been
improved on both sides.
Centerline
Nipping plate adjustment screws
Nipping plate adjustment screws
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B - Troubleshooting and Error Message
B1 - Error Message
LED Display Description Cause of Error
ERR = L1 Clamp station is 1. MT1 - fuse blown.
not in the home position. 2. LS1 - sensor is bad.
3. MT1 - motor problem.
ERR = L2 Clamp station is 1. MT1 - fuse blown.
not in the left holding 2. LS2 - sensor bad.
position. 3. MT1 - motor problem.
ERR = L3 Nipping station is unable 1. MT2 - fuse blown.
to reach the lowest 2. LS3 - sensor bad.
position. 3. MT2 - motor problem.
ERR = L4 Nipping station is unable 1. MT2 - fuse blown.
to reach the highest 2. LS4 - sensor bad.
position. 3. MT2 - motor problem.
ERR = T1 After warm up more than 1. Heater fuse blown.
one hour, binder is not 2. Temperature switch
ready to bind. bad.
3. Heater bad.
TEMP ERROR Temperature too low. 1. Heater fuse blown.
2. Temperature switch
bad.
3. Heater bad.
HALF00 Skip from Cold to Hot. 1. Stand by sensor bad.
2. Thermostat bad.
Note: Check all electrical connectors of appropriate items when
troubleshooting errors.
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B2 - Troubleshooting and Correction
Check if clamp station Yes Check if LS1 No LS1 has been
ERR=L1 has returned to the is functioning damaged.
right position ? OK ? Change LS1
Yes
No Check the LS1
connector and the
related circuits
Check if the M1 fuse No M1 fuse has
is functioning OK ? been damaged.
Change M1 fuse.
Yes Check
capacitor and related
circuits.
Check if clamp station Yes Check if LS2 No LS2 has been
ERR=L2 has returned to the is functioning damaged.
left position ? OK ? Change LS2
Yes
No Check the LS2
connector and the
related circuits
Check if the M1 fuse No M1 fuse has
is functioning OK ? been damaged.
Change M1 fuse.
Yes Check
capacitor and related
circuits.
the M1 connector,
the M1 connector,
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Check if nipping Yes Check if LS3 No LS3 has been
ERR=L3 station has returned to is functioning damaged.
the lowest position ? OK ? Change LS3
Yes
No Check the LS3
connector and the
related circuits
Check if the M2 fuse No M2 fuse has
is functioning OK ? been damaged.
Change M2 fuse.
Yes Check
the M2 connector,
capacitor and related
circuits.
Check if nipping Yes Check if LS4 No LS4 has been
ERR=L4 has returned to the is functioning damaged.
the highest position ? OK ? Change LS4
Yes
No Check the LS4
connector and the
related circuits
Check if the M2 fuse No M1 fuse has
is functioning OK ? been damaged.
Change M2 fuse.
Yes Check
the M2 connector,
capacitor and related
circuits.
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Check if the hot-melt Yes Thermostat has
ERR=T1 glue has been melted been damaged.
completely ? Change thermostat.
No
Check if the heater No Heater fuse has been
fuse is functioning OK ? damaged.
Change heater fuse.
Yes Heater has been
damaged.
Change heater.
Check if the heater No Heater fuse has
TEMP fuse is functioning OK ? been damaged.
ERROR Change heater fuse.
Yes
Check if the heater No Heater has been
is functioning OK ? damaged.
Change heater.
Yes
Check if thermostat No Thermostat has been
is functioning OK ? damaged.
Change thermostat.
Yes Check the heater
and related circuits.
Check if thermostat No TEMP2 sensor has
HALF00 is functioning OK ? been damaged.
Change TEMP2.
Yes Heater has been
damaged.
Change heater.
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C - Setup for Timers
To enter the timer setup menu, you will need to press and hold down both the “OPEN” and
“CLOSE” buttons, then turn the power on. You should see “SET TR” in the LED display.
Press the “FUNCTION” button to sequentially display TR1, TR2, TR3, TR4, TR5, TR6,
“SAVE”, “CANCEL”, and “RESET”. Once you have selected the setting to change, you
need to press the “OPEN” to increase the time and the “CLOSE” to decrease the time within
their ranges. Press “FUNCTION” button until you see “SAVE” in the LED display. Then
press the “START” button to change it. Or select “CANCEL” and press “START” button
to exit. To return all settings to default, please use “RESET” followed by “START” button
to recover the factory settings.
WARNING: We only recommend you to change TR1.
Below are the default times for each TRx and it’s description:
Name Default Time Range Description
TR1 4 sec. 2.0 - 10 sec. Nipping time.
TR2 1 sec. 0.5 - 5 sec. Auto mode: After loading the
cover, the delay time before clamp
station returns.
TR3 2 sec. 1.0 - 5 sec. Auto mode: Clamp closing time
for the book.
TR4 1 sec. 0.5 - 5 sec. Auto mode: Clamp opening
time for the book.
TR5 .5 sec. 0.5 - 5 sec. Auto mode: The clamp detecting
time right after closing.
TR6 5 sec. 3.0 - 10 sec. Padding mode: The closing
time of clamp before opening it.
The fastest speed of settings that AUTO mode can perform is:
TR1 = 2 sec., TR2 = 0.5 sec., TR3 = 1 sec., TR4 = 0.5 sec., TR5 = 0.5 sec.
• Note that the book making speed depends on thickness of the book and the loading
technique for the paper and cover.
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