Duplo DPB-500 Instruction Manual

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INSTRUCTION MANUAL

Perfect Binder

DuBinder

Be sure to read this manual prior to use.

Please leave this manual at the site of use for easy reference.

DPB-500

Direttiva sui macchinari 98/37/CE e 2006/42 CE in base a EN 1010-1: 2004, EN 1010-4: 2004, EN 60204-1: 2006 Direttiva relativa alle apparecchiature a bassa tensione 2006/95/CE in base a IEC 60950-1: 2001 incluse deviazioni EN 60950-1: 2001+ A11: 2004 Direttiva di compatibilità elettromagnetica 89/336/CEE e 2004/108/CE in base a EN 61000-3-2: 2006, EN 61000-3-3: 1995+A1: 2001+A2: 2005,

EN 61000-6-2: 2001,

EN 61000-6-4: 2001

Directiva sobre máquinas 98/37/CE y 2006/42/CE, según EN 1010-1: 2004, EN 1010-4: 2004, EN 60204-1: 2006 Directiva sobre baja tensión 2006/95/CE, según IEC 60950-1: 2001, incluyendo las derogaciones EN 60950-1: 2001+ A11: 2004 Directiva sobre compatibilidad electromagnética 89/336/CEE y 2004/108/CE, según EN 61000-3-2: 2006, EN 61000-3-3: 1995+A1: 2001+A2: 2005, EN 61000-6-2: 2001, EN 61000-6-4: 2001

Directive Machines 98/37/CE et 2006/42/CE en application des normes EN 1010-1: 2004, EN 1010-4: 2004 et EN 60204-1: 2006 Directive Basse tension 2006/95/CE en application de IEC 60950-1: 2001, dérogations selon EN 60950-1: 2001 +A11: 2004 incluses Directive sur la compatibilité électromagnétique 89/336/CEE et 2004/108/CE en application des normes EN 61000-3-2: 2006, EN 61000-3-3: 1995+A1: 2001+A2: 2005, EN 61000-6-2: 2001, EN 61000-6-4: 2001

Maschinenrichtlinie 98/37/EG und 2006/42 EG unter EN 1010-1: 2004, EN 1010-4: 2004, EN 60204-1: 2006 Niederspannungsrichtlinie 2006/95/EG unter IEC 60950-1: 2001 einschließlich EN 60950-1: 2001 + A11: 2004 Abweichungen Richtlinie zur elektromagnetischen Verträglichkeit 89/336/EWG und 2004/108/EG unter EN 61000-3-2: 2006, EN 61000-3-3: 1995 + A1: 2001 + A2: 2005, EN 61000-6-2: 2001, EN 61000-6-4: 2001

KONFORMITÄTSERKLÄRUNG

Die DUPLO CORPORATION mit Sitz in 1-6, Oyama 4-chome, Sagamih ara -shi,

Kanagaw a-k en 229 -11 80, Japan , erklärt

hiermit, dass das folgende Produkt,

• Bezeichnung des Produkts : Bindemaschine

• Modell : DPB-500

den nachfolgend aufgelisteten Richtlinien entspricht:

• Richtlinien :

DICHIARAZIONE DI CONFORMITÁ

DU P L O CO RPORATI O N si ta a 1- 6 , Oy ama 4-chome , Sagamihara-shi, Kanagawa-ken 229-1180 Japan, dichiara che il seguente prodotto,

• Nome del prodotto : macchina cucitrice per legatoria

• Modello : DPB-500

è conforme ai requisiti definiti dalle norme sotto elencate:

• Direttiva Bassa Tensione :

DECLARATION OF CONFORMITY

DUPLO CORPORATION, located at 1-6, Oyama 4-chome, Sagamihara-shi, Kanagawa-ken 229-1180, Japan, declares that the following product,

• Name of product : Binder

• Model : DPB-500

complies with the provisions defined by the regulations listed below.

• Regulation : Machinery Directive 98/37/EC and 2006/42/EC under EN 1010-1: 2004, EN 1010-4: 2004, EN 60204-1: 2006 Low Voltage Directive 2006/95/EC under IEC 60950-1: 2001 including EN 60950-1: 2001+A11: 2004 deviations Electromagnetic compatibility Directive 89/336/EEC and 2004/108/EC under EN 61000-3-2: 2006, EN 61000-3-3: 1995+A1: 2001+A2: 2005, EN 61000-6-2: 2001, EN 61000-6-4: 2001

DECLARACIÓN DE CONFORMIDAD

DUPL O CORPORA TION, con domicilio en 1-6, Oyama 4-chome,

Sagamihara-shi, Kanagawa-ken 229-1180 Japan,

declara que el producto siguiente :

• Nombre del producto : Encuadernadora

• Modelos : DPB-500

cu m p le con l o dispues t o por lo s reglamen t o s que s e in d i can a c o n tinuació n .

• Reglamentaciones :

DECLARATION DE CONFORMITE

DUPLO CORPORATION, située à 1-6, Oyama 4-chome, Sagamihara-shi,

Kanagawa-ken 229-1180, Japon, déclare que le

produit suivant ;

• Nom du produit : Relieuse

• Modèle : DPB-500

est conforme aux dispositions définies par les réglementations suivantes :

• Réglementations :

Disposal of Old Electrical & Electronic Equipment

This symbol (the symbol of the crossed out wheeled bin) indicates that in European countries this product should not be disposed of as household waste.

Please recycle where facilities exist by checking with your local authority or supplier for recycling advice.

By ensuring this product is disposed of correctly through proper treatment, recovery and recycling, you will help prevent potential negative e

ffects on the

environment and human health.

Entsorgung von alten elektrischen und elektronischen

Ausrüstungsteilen

Dieses Symbol (das Symbol mit dem durchgekreuzten fahrbaren Müllbehälter) zeigt an, dass dieses Produkt in europäischen Länden nicht als Haushaltsmüll entsorgt werden darf. Bitte informieren Sie sich bei Ihren örtlichen Behörden oder bei Ihrem Händler hinsichtlich einer Empfehlung für die Entsorgung und führen Sie die betre

ffenden Teile dort, wo solche Einrichtungen vorhanden sind, einem RecyclingProzess zu.

Indem sie sicherstellen, dass das betre

ffende Produkt durch richtige Behandlung, Rückführung und Recycling entsorg

t wird, tragen Sie dazu bei, möglichen negativen Auswirkungen auf die Umwelt und die menschliche Gesundheit vorzubeugen.

Elimination du matériel électronique et électrique usagé

Ce symbole (une poubelle marquée d’une croix) indique que dans les pays européens, ce produit ne doit pas être éliminé comme des ordures ménagères.

Recyclez-le dans les sites adaptés qui vous seront indiqués par les autorités locales ou renseignez-vous auprès de votre fournisseu

En veillant à ce que ce produit soit éliminé correctement avec un traitement, une collecte et un recyclage adaptés, vous contribuez à éviter son action nocive potentielle sur l

’ environnement et la santé

humaine.

Smaltimento di attrezzature elettriche ed elettroniche consumate

Questo simbolo (il simbolo della pattumiera con rotelle barrata) indica che nei paesi europei questo prodotto non deve essere buttato nei ri

ﬁuti domestici.

Per favore smaltire in luogo addetto al riciclo, dove esistente, chiedendo informazioni alle autorità locali o a chi fornisce consulenza a proposito.

Garantendo uno smaltimento adeguato di questo prodotto (trattamento, recupero e riciclo corretto), aiuterete a prevenire e

ffetti negativi sull’ambiente e

sulla salute dell’uomo.

Eliminación de residuos de aparatos eléctricos y electrónicos

Este símbolo (un cubo de basura tachado) indica que en los países europeos este producto no deberá eliminarse como si se tratara de un residuo doméstico. Solicite asesoramiento sobre reciclaje a las autoridade

locales o a su distribuido

r, y siga la normativa en materia de gestión medioambiental y reciclaje de este tipo de residuos.

Si toma las medidas pertinentes para que este producto se elimine mediante un tratamiento, recuperación y reciclaje adecuados, contribuirá a evitar posibles efectos negativos en el medio ambiente y la salud humana.

Note: This symbol mark is for EU countries only.

This symbol mark is according to the directive 2006/66/ EC

Article 20 Information for end-users and Annex II.

This symbol means that batteries and accumulators, at their end-of-life, should be disposed of separately from your household waste.

If a chemical symbol is printed beneath the symbol shown above, this chemical symbol means that the battery or accumulator contains a heavy metal at a certain concentration.

This will be indicated as follows:

Hg: mercury (0.0005%), Cd: cadmium (0.002%), Pb: lead (0.004%)

In the European Union there are separate collection systems for used batteries and accumulators.

Please, dispose of batteries and accumulators correctly at your local community waste collection/recycling centre.

Note:

You do not need to replace the battery for

this machine by yourself.

Nota: questo contrassegno interessa soltanto i Paesi UE

Questo contrassegno è conforme alla direttiva 2006/66/CE Articolo 20 Informazioni per gli utenti finali e Appendice II.

Indica che le batterie e gli accumulatori, una volta esauriti, devono esssere gettati separatamente dai rifiuti domestici.

Se sotto il simbolo mostrato qui sotto è stampato un simbolo chimico, quest'ultimo indica che la batteria o l'accumulatore contiene un metallo pesante in una determinata concentrazione. Ciò verrà indicato come segue:

Hg: mercurio (0.0005%), Cd: cadmio (0,0002%), Pb: piombo (0.004%).

Nei Paesi dell'Unione Europea esistono sistemi di raccolta diversi per le batterie e gli accumulatori usati.

Vi preghiamo di smaltire le batterie e gli accumulatori correttamente presso il vostro centro di smaltimento rfiuti/ riciclo locale.

Nota: non dovete sostituire da soli la batteria di questa macchina.

Nota: Este símbolo sólo sirve para países de la UE.

Este símbolo cumple lo dispuesto en el Artículo 20 Información para los usuarios finales y el Anexo II de la Directiva 2006/66/EC.

Este símbolo significa que las pilas y los acumuladores, al finalizar su vida útil, deben eliminarse a parte de los residuos habituales de su hogar.

Si debajo del símbolo que se muestra más arriba aparece un símbolo de producto químico, entonces este símbolo significa que la pila o el acumulador contienen cierta concentración de metal pesado. Ello se indica del siguiente modo:

Hg: mercurio (0,0005%), Cd: cadmio (0,002%), Pb: plomo (0,004%).

En la Unión Europea existen sistemas separados para la recogida de pilas y acumuladores usados.

Le rogamos que elimine las pilas y los acumuladores correctamente en su centro local de recogida/reciclaje de residuos.

Nota: No es necesario que usted mismo cambie la pila de este aparato.

Hinweis: Diese Symbol-Markierung gilt nur für EULänder.

Diese Symbol-Markierung entspricht der Direktive 2000/66/EG Artikel 20 Informationen sowie Anhang II.

Dieses Symbol bedeutet, dass verbrauchte Batterien getrennt vom Haushaltsmüll zu entsorgen sind.

Wenn ein chemisches Symbol unter das oben dargestellte Symbol gedruckt ist, so bedeutet dieses chemische Symbol, dass die Batterie oder der Akku ein Schwermetall in einer bestimmten Konzentration enthält, Dies wird wie folgt angezeigt:

Hg: Quecksilber (0,0005 %), CD: Cadmium (0,002 %), Pb: Blei (0,004 %)

In der Europäische Union gibt es separate Sammelsysteme für verbrauchte Batterien und Akkus.

Bitte entsorgen Sie die Batterien und Akkus vorschriftsmäßig in Ihrem örtlichen Müllsammel-/Müllrecycling-Zentrum.

Hinweis: Sie brauchen die Batterie für diese Maschine nicht selbst auszutauschen.

Remarque : Ce symbole n’est valable que pour les pays de l’UE.

Ce symbole est conforme à la directive 2006/66/CE, Article 20 Informations destinées aux utilisateurs finaux et Annexe II.

Ce symbole signifie que les batteries et accumulateurs, une fois arrivés en fin de vie, ne doivent pas être jetés avec les ordures ménagères.

Si un symbole chimique est imprimé au-dessous du symbole indiqué ci-dessus, ce symbole chimique signifie que la batterie ou l’accumulateur contient un métal lourd atteignant une certaine concentration. Ceci sera alors indiqué de la façon suivante :

Hg : mercure (0,0005 %), Cd : cadmium (0,002 %), Pb : plomb (0,004 %)

Il existe dans l’Union Européenne des systèmes de collecte distincts pour les piles et accumulateurs.

Veuillez déposer vos batteries et accumulateurs dans votre centre local de recyclage ou de collecte des déchets.

Remarque : Vous n’avez pas besoin de remplacer vous-même la batterie de cette machine.

Note:

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

Introduction

Thank you for purchasing a Duplo product.

Be sure to read this manual prior to using the product.

After reading, leave the manual at the site of use for easy reference whenever questions related to the product arise in the future.

Symbols

In this manual, several symbols are used to indicate important warnings. Please make sure to read instructions accompanied by these symbols. These symbols have the following

meanings.

Describes instructions which must be followed in use.

Be sure to read the instructions to avoid problems due to incorrect operations.

Indicates supplementary or useful information.

Describes names of related items and supplementary instructions.

Trademark

The product name and company name used in this manual are trademarks or registered trademarks of the respective companies.

Safety Precautions

In this manual, operations and handling of the unit which are hazardous are described using the following marks to prevent personal injury or property damage to the user and others.

Ignoring this mark could result in the possibility of serious injury or even death.

Ignoring this mark could result in the possibility of injury or physical damage.

This mark indicates a “Warning” or “Caution”.

A graphic may be shown inside the mark to describe the warning or caution more speciﬁcally.

This mark indicates a forbidden action.

A graphic may be shown inside the mark to describe the forbidden action more speciﬁcally.

This mark indicates actions that must be performed.

A graphic may be shown inside the mark to describe the action to be performed more speciﬁcally.

Power Supply

● This unit shall be installed near the socket-outlet where the plug on the power supply cord is easily accessible.

● Make sure the power supply used is always within the following range.

Power supply : Y208V,

240V AC (three-phase), 60 Hz (USA, Canada)

Y380 to Y415 V AC (three-phase), 50/60 Hz (Europe)

● When you power other appliances from the same AC outlet, make sure that the combined power consumption does not exceed the power supply capacity.

Rated current (Rated power) : 3.2 kW AC (three-phase 208 V, 240 V 60Hz) 8 A/single-phase (USA, Canada)

3.2 kW AC (three-phase 380 to 415 V 50/60Hz) 5 A/single phase (Europe)

Use only the power supply voltage speciﬁed on the main nameplate.

Using other voltages could result in a ﬁre or an electrical shock.

Make sure that the combined power consumption of the appliances to be connected does not exceed the capacity rating of the power outlets or plug receptacles.

Exceeding the capacity rating could cause the power outlets, plug receptacles, or power extension cords to overheat and catch a ﬁre.

High touch current

Earth connection essential before connecting supply.

Safety Precautions

Operating Environment

Operate this unit in the following environment.

● where the temperature range is between 5 and 35°C/41 and 95°F (-10 to +50°C/ 14 to 122°F) in storage)

● where the humidity range is between 10 and 85% RH (10 to 90% RH in storage, however no condensation)

● which is not subject to direct sunlight

● which is reasonably free from dust

● which is subject to little or no vibration

● which is free from air-borne salt

● where there are no harmful chemicals

● where the unit is not exposed to water

Keep this unit and the power cord away from heaters and heater vents.

Excessive heat could melt the cover or power cord covering, and result in a ﬁre or an electrical shock.

Do not place metal objects or vessels containing liquids on top of the unit.

The entry of any metal object or liquid could result in a ﬁre or an electrical shock.

Do not insert any metal or easily-combustible object inside this unit.

This could result in a ﬁre or an electrical shock.

Do not use ﬂammable sprays inside or near the unit (e.g. when cleaning the unit).

Such ﬂammable gas may ignite and cause a ﬁre or combustion.

Do not install this unit in a location where there is excessive humidity or where contact with water is possible.

Poor choice of location could result in deterioration of the insulation, a ﬁre or an electrical shock.

Install this unit on a level, stable stand or ﬂoor, with sufﬁcient space around it.

Failure to do so could result in the unit overturning and causing injury.

Disconnect the power plug from the power outlet before attempting to move this unit.

Failure to do so could result in power cord damage, a ﬁre or an electrical shock.

Always disconnect the power plug from the power outlet when the unit is not to be used for an extended period.

Failure to do so could result in a ﬁre due to leakage current if the insulation should deteriorate.

iii

Safety Precautions

Do not damage the power cord or power plug.

Do not scratch, alter, bend, twist, pull or place heavy objects on the power cord or power plug.

This could result in damage, a ﬁre or an electrical shock.

Do not touch the power switch with wet hands.

Otherwise electric hazards may occur.

Do not remove the cover or back panel.

This unit contains high-voltage components that could cause an electrical shock.

Do not disassemble, modify or repair this unit.

There is a danger of ﬁre, electrical shock or injury.

Contact your dealer when repairs are necessary.

If any foreign object such as metal or liquid should enter this unit, immediately turn the unit off at the power switch and disconnect the power plug from the power outlet.

Failure to do so could result in a ﬁre or an electrical shock.

Contact your dealer immediately.

Before cleaning this unit, turn the unit off at the power switch and disconnect the power plug from the power outlet.

Accidental operation of the unit during cleaning could result in injury.

Remove any dust that accumulates on the power plug prongs and the surface of the plug from which the prongs extend.

Accumulated dust could result in a ﬁre.

Always grip the plug when disconnecting the power plug from the power outlet.

Forcibly pulling on the power cord could cause damage, resulting in a ﬁre or an electrical shock.

Do not touch or insert foreign objects into any rotating part during operation.

This could result in injury.

Maintenance / Others

Safety Precautions

Hot Melt Glue

Do not block off the hume exhaust.

This unit exhausts vaporized hot melt glue to the outside of the unit using the fan. If the hume exhaust is blocked off, the fumes that stay inside the unit may cause ﬁre.

Attach a hume exhaust hose to the hume exhaust of this unit so that the fumes can be exhausted outdoors or to a well-ventilated place.

The fumes are generated while the hot melt glue is being melted at high temperatures. The fumes may irritate your eyes, nose and throat. If you do not feel well, go out into the fresh air. If you still feel sick, get prompt medical attention.

Read carefully the precautions for handling the hot melt glue you are going to use.

Because the hot melt glue is combustible, do not put the glue close to ﬁre.

It may cause a burn injury or ﬁre.

When you handle the hot melt glue, make sure that you wear protection gloves, long-sleeved clothes, eye protectors to prevent burn injuries.

In case the liqueﬁed or vaporized hot melt glue gets into your eye or is attach to your skin, cool it with cold water immediately and get prompt medical attention.

Safety Precautions

WARNING / CAUTION Labels

"WARNING" and "CAUTION" labels are pasted on the machine to ensure user safety.

Do not remove or change them.

When the labels become dirty or are lost, be sure to contact your dealer for a new one.

WARNING

Do not put hands inside during operation.

It may injure you.

Safety Precautions

Details on Warning and Caution Label

Label Explanation

Do not touch the milling blade and roughening blade during machine operation. This may cause you severe injury.

High voltage of electricity supplied to the glue tank may cause an electric shock. Be careful.

Because the touch current is high, make sure that a ground connection is provided before connecting the power cord.

The glue tank temperature is very high.

When pressing a book block against the support clamp, be careful not to get your hand caught in it. When opening a main cover, be careful not to get your hand caught in it. Do not touch the nipping section while the machine is in operation. Your ﬁngers may get caught in the nipper. Do not touch the nipping section while the machine is in operation. Your ﬁngers may get caught in the nipper.

Do not put your hand inside the machine while the paper feed tray is moving. It may injure you.

Do not take out booklets during machine operation. This may cause unexpected injuries.

There are high voltage parts inside the machine. Do not remove the cover.

Before discharging glue from the tank, switch the machine to the glue discharge mode.

Leaving the tank without glue inside may cause a malfunction to the machine.

Glue discharged from the tank is very hot. Be careful not to burn yourself.

vii

Safety Precautions

Safety Precautions .....................................i

Power Supply ...................................................... i

Operating Environment .......................................ii

Maintenance / Others .........................................iii

Hot Melt Glue .....................................................iv

WARNING / CAUTION Labels ...........................

Chapter 1

BEFORE OPERATION

1. Features .............................................1-2

2. Workﬂow ............................................

1-3

3. Names and Functions ......................1-4

3-1. External Parts ........................................ 1-4

3-2. Milling Section .......................................

1-5

3-3. Glue

Tank Section ................................. 1-6

3-4. Nipping Section .....................................

1-7

3-5. Scoring Section .....................................

1-8

3-6. Feed Section .........................................

1-9

3-7. Delivery Section .................................. 1-10

4. Screen Descriptions ....................... 1-11

4-1. Settings Screen for Binding ................. 1-11

4-2. Fine-adjustment Screen ......................

1-11

4-3. Motion Check Screen ..........................1-12

4-4. Option Setting Screen ......................... 1-13

5. Accessories ....................................1-14

Precautions on Hot Melt Glue ...............1-16

8. Cautions for Handling ....................1-17

9. Emergency Stop .............................1-18

10. Paper Size .......................................1-19

10-1. Cover and Book Block Size ................. 1-19

10-2. Book Block Thickness and

Cover Weight ......................................1-19

10-3.

Using Single-folded or Double-folded

Paper ....................................................1-20

10-4 Cover Type ..........................................1-20

Chapter 2

PREPAR

ING FOR

OPERATIO

1. Turning On the Power ......................2-2

2. Preparing Hot Melt Glue ...................2-3

3. Preparing Each Section ...................2-6

3-1. Level Plate ............................................2-6

3-2. Glue Tank .............................................. 2-7

3-3. Nipping Section ..................................... 2-8

3-4. Replacing the Receiving Tray with

the Stacker Stopper ..............................2-9

3-5. Replacing the Stacker Stopper with

the Receiving Tray .............................. 2-10

4. Entering Job Information ...............2-12

4-1. Cover (With a cover/Without a

cover) .................................................. 2-12

4-2. Setting Double Feed Detection for

Cover .................................................. 2-14

4-3. Setting Book Block Size ...................... 2-16

4-4. Setting the Cover Size ........................2-18

4-5. Cover Base Spine Position .................2-19

4-6. Checking and Saving Settings ............ 2-21

Chapter 3

STARTING BINDING

OPERATIO

1. Placing a Book Block .......................3-2

2. Test-Feeding a Cover .......................3-6

3. Starting Binding ..............................3-14

4. Removing the Booklet ....................3-17

5. Adding Covers ................................3-20

6. Finishing Binding ...........................3-21

7. Using Supplied Parts .....................3-23

8. Using Wing Scoring ........................3-25

viii

Safety Precautions

Chapter 4

FINE-ADJUSTMENT AND

OPTION SETTING

Fine adjusting Each Part ..................4-2

1-1. Setting the Paper Feed Guide ............... 4-2

1-2. Setting the Scoring Width ...................... 4-4

1-3. Adjusting the Nipper Guide ................... 4-5

1-4. Setting the Nipper .................................4-7

1-5. Setting the Glue Cutting Position .......... 4-8

1-6. Setting the Width of Side Glue .............. 4-9

1-7. Adjusting Spine Glue Amount ............. 4-10

1-8. Adjusting Side Glue Amount ............... 4-11

1-9 Adjusting the Nipping Station .............. 4-12

Using Motion Check .......................4-13

2-1. Ejecting Jammed Paper ...................... 4-13

2-2. Discharging Booklet ............................ 4-13

2-3. Adjusting the Height of Paper Feed

Tray ..................................................... 4-14

2-4. Moving the Clamp ...............................

4-14

Setting the Options .........................4-15

3-1. Setting the Nipping Delay Time ........... 4-15

3-2. Setting the Nipping Time .....................4-15

3-3. Setting the Clamp Speed .................... 4-16

3-4. Setting the Glue Tank Temperature .....4-18

3-5. Setting the Standby Mode ...................4-18

3-6. Setting the Heater Schedule ............... 4-19

3-7. Setting the Auto Start ON/OFF ............4-21

3-8. Setting the Hispeed ON/OFF .............. 4-22

3-9. Setting the Receiving Tray ON/OFF ....4-23

3-10. Setting the Feed Guide and Nipper

Guide Synchronously .......................... 4-24

3-11. Setting the External Equipment

ON/OFF ............................................... 4-25

3-12. Setting the Contrast ............................4-26

3-13. Setting Opening Amount of Clamp

(for Normal Mode) ............................... 4-27

3-14. Setting Opening Amount of Clamp

(for Variable Mode) .............................. 4-28

3-15. Setting a Transparent Cover

ON/OFF ............................................... 4-29

Chapter 5

CLEANING THE UNIT

Cleaning Each Section .....................5-2

1-1. Cleaning the Suction Belt ......................5-2

1-2. Cleaning the Level Plate .......................

5-3

1-3. Cleaning the Paper Path ....................... 5-4

2. Replacing Hot Melt Glue ..................5-6

Adjusting the Date and Time ..............5-10

Chapter 6

TROUBLESHOOTING

GUIDE

Solving Glue Problem ......................6-2

Troubleshooting ................................6-6

2-1. Stacker Problem .................................... 6-6

2-2. Milling Problem ...................................... 6-6

2-3. Glue Problem ........................................ 6-7

2-4. Nipping Problem .................................... 6-8

2-5. Feeding Problem ...................................6-9

2-6. Scoring Problem .................................. 6-10

2-7. Booklet Quality Problem ...................... 6-11

Error Messages ...............................6-12

3-1. Messages about Paper Jam ...............6-12

3-2. Messages about External Cover ......... 6-13

3-3. Messages about Motor and Sensor .... 6-13

3-4. Other Messages ..................................6-16

3-5. Other Error Codes ...............................6-18

Chapter 7 APPENDIX

Speciﬁcation .....................................7-2

Chapter 1

BEFORE OPERATION

1-2

CHAPTER 1 BEFORE OPERATION

1. Features

This machine enables you to make a book with or without a cover.

(1) With a cover

Glue is applied to the side and spine of a book block, then a cover is applied to the pasted area.

Book block

Cover

(2) Without a cover (Pad binding)

Glue is applied only to the spine of a book block. You can make a note pad or scratch pad.

Book block

1-3

CHAPTER 1 BEFORE OPERATION

2. Workﬂow

1 Turn on the power

2 Prepare for hot melt glue

4 Enter job information

6 Start binding

7 Take out a booklet

9 Finish binding

Chapter 2 “1. Turning on the Power” ( p.2-2)

Chapter 2 “3. Preparing Each Section” ( p.2-6)

Chapter 2 “4. Entering Job Information” ( p.2-12)

Chapter 3 “3.Starting Binding” ( p.3-14)

Chapter 3 “6. Finishing Binding” ( p.3-21)

Chapter 3 “5. Adding Covers” ( p.3-20)

Chapter 3 “4. Removing the Booklet” ( p.3-17)

Chapter 3 “1. Placing a Book Block” ( p.3-2)

Chapter 3 “2. Test-Feeding a Cover” ( p.3-6)

10 Fine adjust

Chapter 4 Fine-adjustment and Option Setting ( p.4-2)

8 Add covers

5 Test feed

3 Prepare each section

Chapter 2 “2.Preparing Hot Melt Glue” ( p.2-3)

1-4

CHAPTER 1 BEFORE OPERATION

3. Names and Functions

3-1. External Parts

ouch Panel Angle Adjustment Knob

Adjusts the angle of the touch panel.

Main Cover

Prevents the user from touching inside of the machine during operation.

Fume Exhaust Opening

Exhausts steam from inside the machine.

Safety Sensor

The machine stops if the light between the sensors is interrupted.

Touch Panel

Use this panel to enter information to operate the machine.

Clamp

Holds a book block and moves horizontally during the binding operation.

Support clamp

When placing a book block on the clamp, the support clamp is used as an aid in holding its shape.

Emergency Stop Button

Press this button to stop the machine urgently.

Start Button

Starts the binding operation.

Glue Drain Access

Open this cover to place a container before draining the glue in the glue tank.

Nipper Level Adjustment Access

Open this access to access to the adjustment lever to raise or lower the nipping station.

Spine Meter Roller Adjustment

Adjusts the amount of spine glue applied to the booklet.

No.2 Glue Drum Meter Adjustment

Adjusts the amount of glue provided to the No. 2 drum.

No.1 Glue Drum Meter Adjustment

Adjusts the amount of glue provided to the No. 1 drum.

Main Switch

Turns on or off the machine.

Jam Removing Knob

When a paper jam occurs during the transportation of a cover, rotate this knob to move the feed roller and remove the jammed cover.

1-5

CHAPTER 1 BEFORE OPERATION

3-2. Milling Section

Milling Adjustment Label

Refer to the label when adjusting the height of the level plate using the milling adjustment bar.

Milling Adjustment Bar

Use this bar to adjust the milling depth.

Level Plate

To change the milling depth, move up or down the level plate.

Milling Guide

This guide prevents paper chips from scattering. The guide moves automatically according to the thickness of the book block.

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CHAPTER 1 BEFORE OPERATION

3-3. Glue Tank Section

Side Glue Meter (non-operator’ s side)

Adjusts the side glue amount provided to the side glue roller according to the position of the side glue meter adjustment.

No.2 Meter

Adjusts the glue amount provided to the application No.2 drum.

Application No.1 Drum

Provides glue that penetrates into the spine.

Application No.2 Drum

Applies additional glue to the spine.

Side Glue Meter (operator’ s side)

Adjusts the side glue amount provided to the side glue roller according to the position of the side glue meter adjustment.

Side Glue Roller Adjustment (non-operator’ s side)

Adjusts the position of the side glue roller.

Side Glue Roller (non-operator’ s side)

Applies the glue to the non-operator’ s side of the book block.

Side Glue Roller (operator ‘s side)

Moves automatically according to the thickness of the book block and applies the glue to the operator’ s side.

Side Glue Meter Adjustment (operator’ s side)

Adjusts the position of the side glue meter and side glue amount provided to the side glue roller.

Side Glue Meter Adjustment (non-operator’ s side)

Adjusts the position of the side glue meter and side glue amount provided to the side glue roller.

No.1 Meter

Adjusts the glue amount provided to the application No.1 drum.

Spine Meter Roller

Evens out the glue applied to the spine.

1-7

CHAPTER 1 BEFORE OPERATION

3-4. Nipping Section

Skewing Adjustment

Cover Stopper

Prevents the cover from moving by holding down its leading edge.

Scale Label

Use this label to decide the position of the cover stopper.

Positioning Fingers

Prevents the cover from moving by holding down its tail edge.

Nipper Guide

Moves automatically according to the size of a cover and holds down its both sides.

Skewing Adjustment Label

Adjusts the position of the cover and the book block so that they are parallel to each other.

Positioning Fingers Adjustment

Adjusts the position of the positioning fingers.

Nipping Station

Nips the cover transported from the paper feed tray to form a spine.

Skewing Adjustment

1-8

CHAPTER 1 BEFORE OPERATION

3-5. Scoring Section

Secondary Feed Roller Pressure Adjustment

Adjusts the pressure of the feed roller.

Scoring Depth Adjustment

Adjusts the depth of a score applied to a cover.

Primary Feed Roller Pressure

Adjustment Adjusts the pressure of the feed roller.

1-9

CHAPTER 1 BEFORE OPERATION

3-6. Feed Section

Cover Feeder Skewing Adjustment

Adjust the angle of the feed guide to align them with the cover edge.

Scoring Line Label

Indicates the standard scoring line on the non-operator s side.

Feeder

Feeds covers automatically.

Feed Guide

Moves automatically according to the cover size and holds the both sides of the cover.

Suction Belt

Sucks and transports each cover.

Stack Height Sensor Adjustment

Select 1 or 2 to decide the stop position of the cover according to the thickness of the cover.

Separating Air Adjustment

Adjusts the amount of air sent to between each cover.

Separator Adjustment

Adjusts the gap between the separator and suction belt to separate covers from each other.

Test Feed Button

Press this switch to perform a test feed or size change.

Guide Adjustment Switch A

Fine-adjusts the width of the feed guide and the nipper guide.

Guide Adjustment Switch B

Fine-adjusts the position of the feed guide and the nipper guide.

Feed Tray Down Button

Press this switch to lower the feed tray.

Back stopper

Holds the tail edge of the cover.

Error Release Button

When the paper feed tray has exceeded the upper limit, press this button to clear the error message “E-025.”

Separator

Prevents double-feed of covers.

1-10

CHAPTER 1 BEFORE OPERATION

3-7. Delivery Section

Book Exit Damper Adjustment Lever

Adjusts the angle of the book exit damper.

Book Exit Damper

Serves as a cushion for the booklets delivered from the exit.

Stacker Stopper

Supports the delivered booklets on the stacker to keep them upright.

Knob Screw

Used to secure the stacker stopper to the machine.

Movable Stacker

Aligns the finished booklets.

1-11

CHAPTER 1 BEFORE OPERATION

4. Screen Descriptions

4-1. Settings Screen for Binding

After you turn the power on, the main menu screen appears on the panel. You can set the details of the binding process on this menu.

Press other tabs on the screen to switch to other menus. Press the setting button to set up a binding process. Refer to Chapter 2 "Preparing for Operation" “4.Entering Job Information" ( p.2-12) for details.

Glue Tank Temperature Button

The current glue tank temperature is displayed. When pressed, the temperature setting screen appears.

Main Menu Tab

Pressing this tab opens the main menu screen.

Fine-adjustment Tab

Pressing this tab opens the fine-adjustment screen.

Motion Check Tab

Pressing this tab opens the motion check screen.

Option Tab Pressing this tab opens the option tab screen.

Memory No.

You can save up to 20 job information.

Date and Time Setting Button

The current date and time are displayed. When pressed, the date and time setting screen appears.

Memory No. Switching Button

Use this button to select a desired memory No.

Setting Button

Pressing this button opens a screen to enter job information.

Size Change Button

Pressing this button executes a size change.

Test Feed Button

Pressing this button starts test feeding.

Clear Button

Keep pressing this button returns the counter to zero.

Counter

Displays the number of sets that was already bound.

Setting Value Data

The job information of the memory currently selected is displayed.

2007-04-05 15:29

4-2. Fine-adjustment Screen

Press the ﬁne adjustment tab to switch to the ﬁne-adjustment screen. Select a section you want to ﬁne adjust. Refer to Chapter 4 "Fine-adjustment and Option Setting" “1. Fine adjusting Each Part" ( p.4-2) for details.

Feed Guide Select Button

Scoring Width Select Button

Nipper Select Button

Nipping Guide Select Button

Side Glue Width Select Button

Glue-cutting Position Select Button

1-12

CHAPTER 1 BEFORE OPERATION

4-3. Motion Check Screen

Press the motion check tab to discharge ﬁnished booklets or jammed paper, to change the level of the paper feed tray, or to move the clamp.

Refer to Chapter 4 "Fine-adjustment and Option Setting" "2.Using Motion Check" ( p.4-13) for details.

Paper Ejection Button

Booklet Exit Button

Paper Feed Tray Up/Down Button

Clamp Horizontal Movement Button

1-13

CHAPTER 1 BEFORE OPERATION

4-4. Option Setting Screen

Press the option tab to select optional menus. Press the next or previous button to change the screen. Refer to Chapter 4 "Fine-adjustment and Option Setting" "3.Setting the Options" ( p.4-15) for details.

Nipping Delay Time

Nipping Time

Clamp Speed

Next Button

External Equipment ON/OFF

Contrast Adjustment

Synchronous Adjustment ON/OFF

Auto Start ON/OFF

Receiving Tray ON/OFF

Next Button

Previous Button

Hispeed Mode ON/OFF

Auto Start Time

Next Button

Previous Button

Glue Tank Temperature

Standby Mode Shift Time

Heater Schedule

Next Button

Previous Button

Next Button

Barcode Setting (for an option)

Clamp opening amount (for normal mode)

Clamp opening amount (for variable mode)

Transparent Cover ON/OFF

1-14

CHAPTER 1 BEFORE OPERATION

5. Accessories

Supplied (quantity)

[2]

[5] [6]

[3]

[4]

[1]

[7]

[8]

[9] [10] [11] [12]

[13]

[14] [15] [16]

No. Name Qty. Explanation

[1] Guide 2 Used when a cover does not go to the nipper

guides smoothly because of a curled edge.

[2] Small Cover Guide L 1 Holds the tail edge of a small cover when feeding

it to the machine.

[3] Small Cover Guide R 1 Holds the tail edge of a small cover when feeding

it to the machine.

1-15

CHAPTER 1 BEFORE OPERATION

No. Name Qty. Explanation

[4] Stabilizer Plate Lite Weight

Cover

1 Used when covers ﬂaps fanned by separating air.

[5] Small Cover Guide 1 Attached to the suction part when feeding a small

cover.

[6] Small Cover Feed Belt

Accessory

1 Attached to the suction part when feeding a small

cover.

[7] Book Block Support Guide 1 Attached to the clamp when a book block is thin

and big to prevent it from bending over.

[8] Scale Label 1 Attach the label to the most suitable location

(sticker).

[9] Receiving Tray 1 Attached to the book exit when necessary. This is

attached to the machine at the factory.

[10] Knob Bolt 2 Used to attach the receiving tray to the book exit.

This is attached to the machine at the factory.

[11]

Instruction Manual 1 This manual [12] Stacker Stopper 1 Attached to the book exit when necessary. [13] Knob Screw 4 Used to attach the stacker stopper to the book

exit. [14] Milling Adjustment Bar 1 Adjusts a milling depth. [15] Wrench

(opposite side distance 3 mm)

1 Used to adjust the side glue meters and side glue

roller adjustment. [16] Spanner 1 Used to adjust the side glue meters and side glue

roller adjustment.

1-16

CHAPTER 1 BEFORE OPERATION

6. Wing Scoring (Optional)

[1] Wing Scoring (1) ------Used when applying a wing score to a cover.

[2] Wrench (opposite side distance 2 mm) (1) ------Used to attach the wing scoring to the ma-

chine.

Chapter 3 "Starting Binding Operation" "8.Using Wing Scoring" ( p.3-25)

1-17

CHAPTER 1 BEFORE OPERATION

Precautions on Hot Melt Glue

a. Precautions

Before you use the hot melt glue, read "Hot Melt Glue" in "Safety Precautions" ( p.iv). Also, read carefully the handling precautions supplied with hot melt glue you are going to use.

1) When you handle the hot melt glue, make sure that you wear protection gloves, long-sleeved clothes, eye protectors to prevent burn injuries.

2) In case the hot melt glue gets into your eye, cool it with cold water immediately and get prompt medical attention.

3) The glue attached to your skin may cause a burn injury. Cool the affected area with cold water immediately and get prompt medical attention.

4) Fumes, which comes out of the machine while the glue is being melted, may irritate your eyes, nose and throat. If you do not feel well, go out into the fresh air.

5) Because the hot melt glue is combustible, do not put the glue close to ﬁre.

b. Recommended Hot Melt Glue

Destination: 208 V, 240V 60 Hz (USA)

Manufacturer: US ADHESIVE COMPANY

Model: HM-53-R

Destination: 380 to 415 V 50/60 Hz (Europe)

Manufacturer: NATIONAL STARCH&CHEMICAL

Model: COOL BIND 1450

c. Ventilation

This machine will exhaust fumes to the outside of the machine using the fan while the hot melt glue is being melted at high temperatures. The fumes may irritate your eyes, nose and throat.

Make sure that you let the fumes exhausted from the machine go outside or to a well-ventilated place. If you feel sick, go out into the fresh air.

1-18

CHAPTER 1 BEFORE OPERATION

8. Cautions for Handling

1) Do not put your hand inside the machine during machine operation. This may cause you

severe injury.

2) Do not touch blades (milling blade and roughening blade) during machine operation. This may cause you severe injury.

Milling guide

Roughening blade

Milling blade

Protect cover

3) Do not touch the hot melt glue while it is being melted. This will cause burn injuries.

4) While the clamp is moving, keep your hand and head out of the book block feeding

section.

1-19

CHAPTER 1 BEFORE OPERATION

9. Emergency Stop

This machine is equipped with the emergency stop functions for the safety of an operator.

When you need to stop the machine for emergency, press the emergency stop button. Turning the button to the right will release the emergency stop.

The machine will also stop automatically when the main cover is opened or the light between the safety sensors is interrupted. To start the machine again, close the main cover when it is open or leave your hand from the safety sensor when you have interrupted it.

Main cover

Safety sensor

Emergency stop button Turn the button to the right to release the emergency stop.

2007-04-05 10:30

1-20

CHAPTER 1 BEFORE OPERATION

10. Paper Size

10-1. Cover and Book Block Size

This machine can handle a cover and book block of the following sizes.

Book block length: 120 to 360 mm (4.72 to 14.17 inches)

Book block height: 120 to 320 mm (4.72 to 12.6 inches)

Cover length: 120 to 360 mm (4.72 to 14.17 inches)

Cover width: 250 to 696 mm (9.84 to 27.4 inches)

Feed direction

Book block thickness: 1 to 51 mm (0.04 to 2.01 inches)

10-2. Book Block Thickness and Cover Weight

Depending on the book block thickness, the appropriate cover weight changes. Refer to the table below to select a book block thickness and cover weight.

Book block thickness (Fine A4 81.4 g/m²)

1 mm/

0.04 inch

10 mm/

0.39 inch

20 mm/

0.79 inch

30 mm/

1.18

inches

40 mm/

1.58

inches

50 mm/

1.97

inches Cover weight

Coat

104.7g/m²

O O O O X X

Coat

127.9 g/m²

O O O O O X

Coat

157 g/m²

O O O O O O

Coat

210 g/m²

X O O O O O

Coat

260 g/m²

X O O O O O

Coat

310 g/m²

X O O O O O

O=Binding available

X=The booklet may has a curled edge or twists or creases on its spine.

1-21

CHAPTER 1 BEFORE OPERATION

10-3.

Using Single-folded or Double-folded Paper

You can use single-folded or double folded paper for a book block. The book block thickness of the folded side (spine) should be 50 mm (1.97 inches) or less when you place the book block on a ﬂat surface.

● If the book block thickness is more than 51 mm (2.01 inches), the clamp cannot hold the book block.

● Depending on the condition of the fold, the clamp may not be able to hold the book block.

10-4. Cover Type

You can use transparent paper as a cover.

When using transparent paper, note that the part shown below must be opaque.

5.0 mm (0.20 inch)

25.0 mm (0.98 inch)

Feed direction

Opaque area

Scoring base line

Chapter 4 "Fine-adjustment and Option Setting" ”3-15.15.Setting a Transparent Cover ON/OFF” ( p.4-29)

1-22

CHAPTER 1 BEFORE OPERATION

Memo

Chapter 2

PREPARING FOR

OPERATION

2-2

CHAPTER 2 PREPARING FOR OPERATION

1. Turning On the Power

Turn the power switch to the right to turn on the power of the machine.

OFF

Power switch

OFF

The hot melt glue in the glue tank will be ready for binding in about 30 minutes at earliest after you turn on the power.

The time for the machine to be ready for a binding operation after turning on the power varies depending on the hot melt glue you are using and the environment.

Turn the panel angle adjustment knob to adjust the angle of the touch panel.

Touch panel

Panel angle adjustment knob

Tighten the panel angle adjustment knob to fasten the touch panel.

2-3

CHAPTER 2 PREPARING FOR OPERATION

2. Preparing Hot Melt Glue

Glue Tank Temperature Button

2007-04-05 10:35

Press the glue tank temperature

button.

The temperature graph will be displayed.

● Check the melt temperature of the hot glue.

The temperature of the glue tank is set at 150°C/302°F by default. Check the melt temperature of the hot melt glue you use and change the glue tank temperature if necessary.

Chapter 4 "Fine-adjustment and Option Setting" ”3-4.Setting the Glue Tank Temperature” ( p.4-18)

20.0

Heater Switch

ON/OFF Button

Press the ON/OFF button of the

heater switch.

Either of the two following icons is displayed.

OFF ON

The ON/OFF position of the heater switch will be maintained even after the machine is turned off. If you turn off the machine with the heater switch ON, the heater switch will be ON next time when you turn on the machine.

Main cover

Open the main cover.

When some hot melt glue is left in the glue tank.

Go to step 4.

When the glue tank is empty.

Go to step 5.

2-4

CHAPTER 2 PREPARING FOR OPERATION

Glue Supply Button

Press the glue supply button.

The side glue rollers will open to the maximum. If the hot melt glue temperature has not reached a temperature that is

20°C/68°F lower than the set temperature, the side glue rollers will not move.

Add hot melt glue in the glue tank.

Add the hot melt glue little by little being careful not to exceed the upper limit.

The upper limit of the hot melt glue

Cutout

Glue tank

Hot melt glue

● When you add hot melt glue, be careful not to put it on the application drums or the side glue rollers. Make sure that you put it in the glue tank.

● If you added hot melt glue when the glue tank is empty, you need to add the glue several times until the melted glue reach the upper limit.

2-5

CHAPTER 2 PREPARING FOR OPERATION

Close the main cover.

● Be careful not to get your hand caught when you close the main cover.

● When the main cover is open, the heater will be turned OFF automatically. Make sure that you close the main cover during heating.

Timing for adding glue

● When the message below appears on the touch panel screen, add hot melt glue.

Touching the screen will clear the message.

Even after adding hot melt glue, the

icon to the right will blink on the main menu screen until the glue is melted completely.

● When the adhesivity of the spine glue is weak or when the surface of the glue on the application drums is lumpy, the remaining amount of the glue may be low in the glue tank.

● Be careful not to boil dry the glue tank.

● When you add hot melt glue, be careful not to put it on the application drums or the side glue rollers. Make sure that you put it in the glue tank.

● The temperature around the glue tank is very high. Be careful when you add hot melt glue.

● High voltage of electricity supplied to the glue tank may cause an electric shock. Be careful.

Previous Button

Press the previous button to return

to the main menu.

2-6

CHAPTER 2 PREPARING FOR OPERATION

3. Preparing Each Section

3-1. Level Plate

To change the milling depth, adjust the height of the level plate. The milling operation jags a spine for better penetration of the glue. When milling depth is set to 0, a milling function is disabled and only notches by the roughening blade are applied to the spine, resulting in poor adhesivity.

Milling adjustment bar

Pull out the milling adjustment bar

from the machine.

Hole

Milling adjustment bar

Insert the milling adjustment bar to

the hole located on the back of the touch panel.

After inserting the bar, turn the bar clockwise until the notch on the tip of the bar meets the convex part of the hole.

Make sure that you do not insert anything other than the milling adjustment bar into the hole.

Milling adjustment bar

Turn the milling adjustment bar

referring to the label.

You can choose from the six levels: 0, 0.5,

1.0, 2.0, 3.0 or 4.0 mm (0, 0.02, 0.04, 0.08,

0.12, 0.16 inch).

Select a lower level for non-folded paper and a higher level for folded paper. When using double-folded paper, select a higher level than you select for the single-folded paper.

● When a book block is thick and larger than the A4 size, actual milling depth may be deeper than the depth you have selected. Do not select a higher level at ﬁrst.

● Be sure to turn the milling adjustment bar clockwise.

● Do not insert the milling adjustment bar to the hole while the machine is in operation.

● Once you change the milling depth, check the appropriate clamp speed. (

p.4-17)

● Do not turn the milling adjustment bar when a book block is in the clamp.

2-7

CHAPTER 2 PREPARING FOR OPERATION

Milling adjustment bar

Pull out the milling adjustment bar

from the hole and put it back to its original place.

3-2. Glue Tank

The position of the side glue rollers need to be changed depending on whether binding a book block with a cover or without a cover.

Screw

Wrench

Screw

Loosen the screws (3) using the

supplied wrench (opposite side distance 3 mm).

Side glue roller adjustment

Spanner

Turn the side glue roller adjustment

using the supplied spanner to adjust the position of the side glue rollers.

The iron spanner gets hot. Do not continue to use it for a long time.

2-8

CHAPTER 2 PREPARING FOR OPERATION

Side glue roller

adjustment

A d j u s t a b l e

r a n g e 6 0 °

O p e r a t o r ’ s s i d e

Base position

You can turn the side glue roller adjustment within the range of 60°.

When binding a book block without a cover, turn the adjustment 60° to the nonoperator's side from the base position to move the side glue rollers to the nonoperator's side.

When binding a book block with a cover, move the adjustment to its base position to move the side glue rollers to the operator's side.

If the leading edge of the cover bends, move the adjustment a bit to the nonoperator's side.

If you turn the adjustment too much to the non-operator's side when binding a book block with a cover, side glue may not be applied to the book block.

Tighten the screws (3) using the

supplied wrench (opposite side distance 3 mm).

● Before turning the side glue roller adjustment, make sure that the hot melt glue is completely melted.

● Touching the inside and outside of the glue tank will cause burn injuries.

● Be careful not drop the supplied tools inside the glue tank.

● High voltage of electricity supplied to the glue tank may cause an electric shock. Be careful.

3-3. Nipping Section

Move the cover stopper to the position for the largest cover size.

Cover stopper

Cover stopper adjustment

To a larger size

Loosen the cover stopper

adjustments.

Move the cover stopper to the

position for the largest cover size.

2-9

CHAPTER 2 PREPARING FOR OPERATION

3-4.

Replacing the Receiving Tray with the Stacker Stopper

You can use the stacker stopper for the booklet size of A5, B5, A4 and legal size or for the booklet with a height of 148 to 216 mm (5.83 to 8.50 inches). To replace the receiving tray with the stacker stopper, follow the procedures below.

Knob bolt

Receiving tray

Remove the knob bolts (2) from the

receiving tray.

Raise the receiving tray and pull it

toward you to remove it from the machine.

Put back the knob bolts (2) removed

in step 1 to their original places.

Select OFF on the paper receiving

tray ON/OFF setting screen of the touch panel.

Chapter 4 "Fine-adjustment and Option Setting" "3-9. Setting the Receiving Tray ON/OFF" ( p.4-23)

Movable stacker

Check that the movable stacker has

been pushed forward (operator's side).

Stacker stopper

Stacker stopper base

Place the supplied stacker stopper

on the position as shown in the ﬁgure.

2-10

CHAPTER 2 PREPARING FOR OPERATION

Stacker stopper

Knob screw

Secure the stacker stopper to the

machine using the supplied knob screws (4).

When both a book block and cover is thin, the booklet may hit the movable stacker and be curled up. Use the receiving tray when the booklet is limp.

3-5.

Replacing the Stacker Stopper with the Receiving Tray

If the stacker stopper does not align the discharged booklets, replace the stacker stopper with the receiving tray.

Stacker stopper

Knob screw

Remove the knob screws (4) from the

stacker stopper.

Remove the stacker stopper.

Put back the know screws (4)

removed in step 1 to their original places.

Select ON on the paper receiving tray

ON/OFF setting screen of the touch panel.

The movable stacker will be pushed backward (non-operator's side).

Chapter 4 "Fine-adjustment and Option Setting" "3-9. Setting the Receiving Tray ON/OFF" ( p.4-23)

2-11

CHAPTER 2 PREPARING FOR OPERATION

Movable stacker

Check that the movable stacker

has been pushed backward (nonoperator's side).

Book exit damper adjustment

Check that the book exit damper

adjustment lever is set to "0."

Stacker stopper base

Stacker side guide

Move the stacker side guide to the

left side.

Move the stacker stopper base to the

non-operator's side by hand.

Knob bolt

Receiving tray

Place the supplied receiving tray as

shown in the ﬁgure and secure it to the machine using the supplied knob bolts (2).

2-12

CHAPTER 2 PREPARING FOR OPERATION

4. Entering Job Information

Setting Button

2007-04-05 10:40

You can make the following settings on the main menu screen.

1. Cover (With a cover/Without a cover)

2. Double feed detection (ON/OFF)

3. Book block size

4. Cover size

5. Cover base position

6. Checking and saving settings for the above items (1-5)

Press the setting button on the main menu screen to go to the cover (with a cover/without a cover) setting screen.

4-1. Cover (With a cover/Without a cover)

Select whether binding a book block with a cover or without a cover.

Book block

Cover

Without a Cover

With a Cover

Book block

With a Cover Button

Without a Cover Button

Cover

Select whether to bind a book with or

without a cover.

When you press the button, the color of the button will change as follows.

Select "With a cover" for binding a book block with a cover and proceed to the step 3.

Select "Without a cover" for pad binding and proceed to the step 2.

2-13

CHAPTER 2 PREPARING FOR OPERATION

Nipping ON/OFF button

Next Button

Select whether to apply nipping to

the book block using the nipping ON/ OFF button.

Nipping (ON) Nipping (OFF)

When nipping is ON, the nipping station will go up during operation.

Press the next button to go to "4-3. Setting Book Block Size" ( p.2-16).

Press the cancel button to delete all the settings you made so far and to go back to the main menu.

● Before binding without a cover, wipe the gray-colored part shown in the ﬁgure using a cloth with silicon spray applied. This will prevent hot melt glue from adhering to the nipping surface.

● When nipping is set to ON, short nipping time may cause glue to adhere to the nipping station. Check the open time of the hot melt glue you use and change the time if necessary ( p.3-15, 4-15).

Cancel Button

Next Button

Double Feed Detection Button

Turn ON or OFF the double feed

detection.

When set to ON, the double feed detection button is displayed. Press this button to go to "4-2. Setting Double Feed Detection for Cover" ( p.2-14).

When set to OFF, press the next button to go to "4-3. Setting Book Block Size"

( p.2-16).

Press the cancel button to delete all the settings you made so far and to go back to the main menu.

2-14

CHAPTER 2 PREPARING FOR OPERATION

4-2. Setting Double Feed Detection for Cover

To make the machine detect double feed, decide and input the detection value. Change the double feed detection settings when detection error occurs frequently at the default setting (standard value).

Press or to select the LED luminescence amount.

Example

LED luminescence amount

“0” will be indicated as shown above.

255

128

Setting range: AUTO (0) to 255 (standard value: Auto)

When the cover is thin or the print is light: Decrease the value.

When the cover is thick or the print is dark: Increase the value.

Press or to select the double feed detection level.

Using the sensor for measuring paper thickness, the thickness of a cover fed at test feed is read as the reference data, and is compared with the data of the cover fed at the subsequent feed.

When the difference between those data exceeds the double feed detection level (%) you speciﬁed, the machine determines that a double-feed has occurred.

Setting range: 5 to 100 (standard value: 50)

Example

Double feed detection level

If the double feed is detected when no double feeds are present: Increase the value.

If the double feed is not detected when double feeds are present: Decrease the value.

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CHAPTER 2 PREPARING FOR OPERATION

Press or to select the starting point of the double feed detection.

The starting point is a distance from the leading edge of the cover.

Setting range: 20.0 mm (0.79 inch) to cover length minus 40.0 mm (1.57 inches) (standard value: 40.0 mm (1.57 inches))

Example

Starting point of double feed detection

28.0

24.0

20.0

The double-feed detection sensor is located at 5.0 mm (0.20 inch) down to the operator's side from the scoring base line.

Spine

Scoring base line

Cover

Double-feed detection sensor

5.0 mm (0.2 inch)

Operator’ s side

Feed direction

Detection errors may frequently occur on a solid black area of the cover. Do not

choose the solid black area as the starting point. Detection error hardly occurs on a white area or light-color print area.

Previous Button

Press the previous button.

The screen shown in step 3 of "4-1.Cover (With a cover/Without a cover)" ( p.2-13) will appear.

Next Button

Press the next button.

The screen for "4-3.Setting Book Block Size"

( p.2-16) will appear.

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CHAPTER 2 PREPARING FOR OPERATION

4-3. Setting Book Block Size

Select whether to change a book block thickness for each process.

Normal mode

Variable mode

Book blocks Book blocks

Normal: The thickness of book blocks is same for each process

Variable: The thickness of book blocks varies for each process.

Next Button

Previous Button

Selector Button

. Press the selector button to select

normal or variable.

: Normal

The sensor detects the thickness of the ﬁrst book block. The same thickness is applied to the following book blocks.

: Variable

The sensor detects the thickness of the book block each time you feed it.

When the variable mode is selected, the processing speed will slow down.

Next Button

Previous Button

Booklet Length Button

Press the book block length button.

The numeric keypad screen will appear.

If you do not need to change the book block length, press the next button.

When "With a Cover" is selected

You will go to "4-4. Setting the Cover Size" ( p.2-18).

When "Without a Cover" is selected

You will go to "4-6. Checking and Saving Settings" ( p.2-21).

Press the previous button to return to the previous screen.

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CHAPTER 2 PREPARING FOR OPERATION

Numeric Keypad

Clear Button

Input value

297. 0

Input the book block length using the

numeric keypad.

Setting range: 120 to 360 mm (4.72 to

14.17 inches)

Book block

Book block length

To clear the input value, press the clear button.

Return Button

Cancel Button

297. 0

Press the return button to conﬁrm

the value.

Press the cancel button to return to the previous screen.

Next Button

297. 0

Press the next button.

When "With a Cover" is selected

You will go to "4-4. Setting the Cover Size" ( p.2-18).

When "Without a Cover" is selected

You will go to "4-6. Checking and Saving Settings" ( p.2-21).

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CHAPTER 2 PREPARING FOR OPERATION

4-4. Setting the Cover Size

Next Button

Previous Button

Cover Width Button

Standard Size Select Button

Cover Length Button

Press the cover width button for

specifying a cover width and the cover length button for specifying the cover length.

The screen to input the value will appear.

If you use a standard-sized cover, press the standard size select button and proceed to "Selecting the standard size."

Numeric Keypad

Clear Button

Input value

297. 0

Input the size using the numeric

keypad.

Setting range:

Cover length:

120 to 360 mm (4.72 to 14.17 inch)

Cover width:

250 to 696 mm (9.84 to 27.40 inches)

To clear the input value, press the clear button.

Return Button

Cancel Button

297. 0

Press the return button to conﬁrm

the value.

You will go to "4-5. Cover Base Spine Position" ( p.2-19).

To delete the input data and return to the screen shown in step 1, press the cancel button.

Selecting the standard size

Press the button of a size you use.

When you press the button, its color will change.

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CHAPTER 2 PREPARING FOR OPERATION

Return Button

Cancel Button

Press the return button to conﬁrm

the settings.

You will go to "4-5. Cover Base Spine Position" ( p.2-19).

To cancel the selection and return to the screen shown in step 1, press the cancel button.

4-5. Cover Base Spine Position

There are two types of base spine position: side base and center base.

Book block

Feed guide

Scoring base line

Specified value

Non-operator’ s side

Operator’ s side

Side base (based on a speciﬁed value):

If the distance between the scoring position and cover edge has been decided, use "side base."

After a size change ( p.3-3), the side guides will move to align the scoring base line with the speciﬁed base line.

Feed guide

Cover center line

Feed guide

Book block center line

Non-operator’ s side

Operator’ s side

Center base:

Use "center base" to align the cover center line with the book block center line.

After a size change ( p.3-3), the side guides will move to align the cover center line with the book block center line.

The acceptable cover length for a center base is 342 to 651 mm (13.46 to 25.63 inches).

Base Spine Position Button

Press the base spine position button.

A value that is equal to half the cover width will be displayed.

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CHAPTER 2 PREPARING FOR OPERATION

For side base

Return Button

Cancel Button

Clear Button

190. 0

The range you can input

Input the length between the scoring position and cover edge using the numeric keypad.

The range you can input will be displayed on the lower right of the screen. Press the cancel button or clear button, then input an appropriate value.

Cover width: 250 to 696 mm/9.84 to 27.40 inches

Specified value: 125 to 325.5 mm/4.92 to 12.82 inches

Cover width – specified value: 125 to 376.5 mm/4.92 to 14.82 inches

Spine

Base Spine Position

Next Button

190. 0

The speciﬁed position will align with the scoring base line.

When you press the next button, you will go to "4-6. Checking and Saving Settings"

( p.2-21).

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CHAPTER 2 PREPARING FOR OPERATION

For center base

Return button

Input “0” using the numeric keypad and press the return button.

Base Spine Position Button

Next Button

The base spine position button will be displayed as shown in the ﬁgure.

The icon means that the scoring base line will align with the book block center line when you perform the size change in a later step.

When you press the next button, you will go to "4-6.Checking and Saving Settings"

( p.2-21).

When you input a cover length other than 342 to 651 mm (13.46 to 25.63 inches) in

"4-4.Setting the Cover Size," "0" will not be accepted.

4-6. Checking and Saving Settings

You will conﬁrm the settings you made so far for a book block size, cover size, and double feed detection and save them to a memory.

Check the settings of before and

after changing.

Book block length

Cover (With a cover, Without a cover

Cover width Cover length

Base spine position

LED luminescence amount

Double feed detection level

Starting point of the double feed detection

Book block thickness (variable/normal)

Before Change

After Change

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CHAPTER 2 PREPARING FOR OPERATION

Memory No.

Cancel Button

Previous Button

Press or to select the

destination to save the settings.

The number of memories is 20 and all of them contains the same setting data by default.

Book block length: 297.0 mm (11.69 inches)

Book block thickness: variable

Cover (with or without a cover): With a cover

Book block width: 420.0 mm (16.54 inches)

Cover length: 297.0 mm (11.69 inches)

Base spine position: 210.0 mm (8.27 inches)

LED luminescence amount: 0 (Auto)

Double feed detection level: 50%

Starting point of the double feed detection: 40.0 mm (1.57 inches)

When you press the cancel button, the setting data will be deleted and you will return to the main menu.

To return to previous screen, press the previous button.

Memory Button

Press the memory button for more

than one second.

The message “Do you want to clear the ﬁne adjustment data?” will appear. Press "Yes" if you want to clear the data.

When you press "Yes," the ﬁne-adjustment data you set in the past will be erased.

You will return to the main menu.

Chapter 3

STARTING BINDING

OPERATION

3-2

CHAPTER 3 STARTING BINDING OPERATION

1. Placing a Book Block

When binding with a cover:

Follow the procedures below.

When binding without a cover:

After completing the step 2, go to "3. Starting Binding" ( p.3-14).

Clamp Section

Book block

Place the book block in the clamp.

Be sure to press the book block against the right edge of the clamp.

When the book block is lower than the support clamp and it is difﬁcult to press the book block against the right edge, adjust the opening amount of the clamp referring to Chapter 4 "Fine-adjustment and Option Setting" "3-13.Setting Opening Amount of Clamp (for Normal Mode)" ( p.4-27) and "3-14.Setting Opening Amount of Clamp (for Variable Mode)" ( p.4-28).

Book block

Support clamp

While holding the book block, press

the support clamp against the book block with your other hand.

● Be sure to use the support clamp.

The support clamp will prevent a limp book block from bending over in the clamp.

● When the book block is small, be

careful not to get your hand caught between the support clamp and book block.

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CHAPTER 3 STARTING BINDING OPERATION

Clamp guide

Screw

When the book block is thin and large:

When the book block is thin and large, attach the supplied clamp guide to prevent the book block from bending over. Secure the clamp guide to the clamp using the screws attached to the clamp.

Size Change Button

2007-04-05 10:50

Press the size change button on the

main menu.

When there is a cover on the paper feed tray or nipping station, you cannot perform a size change. From the second size change, however, you can perform a size change with a cover on the paper feed tray if the cover size is the same as the one used for the ﬁrst size change.

If you want to bind a book block without a cover, a size change is unnecessary.

Go to "3. Starting Binding" ( p.3-14).

Test feed button

You can also perform a size change using the test feed button located above the paper feed tray.

Size Change Cancel Button

During execution of the size change, the message shown to the right is displayed on the touch panel screen.

Each unit will start moving. Wait until the message disappears.

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CHAPTER 3 STARTING BINDING OPERATION

To cancel the size change, press the size change cancel button.

The test feed button above the paper feed tray has a test feed function.

Movable clamp button

If you press this button when the movable clamp button icon is displayed on the main menu screen, a test feed will start.

Size change button

Before pressing the test feed button, make sure that the size change button icon is displayed on the main menu.

2007-04-05 10:50

When the size change is complete, the original screen will appear.

When there is no covers on the paper feed tray, the message to the right will appear. You can clear the message by touching the message screen or placing a cover on the paper feed tray.

When the book block thickness is less than 3 mm, the message to the right will appear. You can clear the message by touching the message screen. Move the axes of the scoring depth adjustments in the upright position for a book block with a thickness of less than 3 mm.

Even if the thickness of the book block is 3 mm or more, if you have adjusted the scoring width in the minus direction in Section 4 “1-2. Setting the Scoring Width” ( p.4-4), the width may become less than 3 mm. In that case, the message to the right will appear.

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CHAPTER 3 STARTING BINDING OPERATION

Taking out the book block set in the clamp after size change

Movable Clamp Button

2007-04-05 10:50

After a size change, you cannot take out the book block from the clamp because it is ﬁrmly held in the clamp. To take out the book block, press the movable clamp button on the main menu.

Movable clamp

The movable clamp will move to the position speciﬁed on the option screen.

When set to normal mode:

book block thickness + speciﬁed value

When set to variable mode: speciﬁed value

Chapter 4 "Fine-adjustment and Option Setting" "3-13.Setting Opening Amount of Clamp (for Normal Mode)" ( p.4-27) and "3-14.Setting Opening Amount of Clamp (for Variable Mode)" ( p.4-28)

After taking out the book block, follow the procedures below according to the size and thickness of the book block you are going to place in the clamp.

● When the length and size of the book block is same as the one you took out:

Follow the steps 1 and 2. Skip the step 3.

● When the book block size is same, but the thickness is different:

Press the movable clamp button again to return it to its original position and follow the steps 1 to 3.

● When the book block size and thickness are different:

Go back to "4.Entering Job Information" ( p.2-12).

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CHAPTER 3 STARTING BINDING OPERATION

2. Test-Feeding a Cover

Paper feed tray

Cover

Back stopper

Load covers on the paper feed tray

and press the back stopper against the covers.

Cover feeder skewing adjustment

Axis

Feed guide Feed guide

Cover

Loosen the cover feeder skewing

adjustments and turn the axes until the feed guides align with the covers.

Do not press the feed guides hard against the covers. This may cause misfeed.

Red beam

Cover

Red beam

Cover

Spine width

Guide adjustment switch A

Guide adjustment switch B

Scoring line

(For a side base) Move the covers

until the spine base line aligns with the red beam, using the guide adjustment switches A or B.

Moving the guide adjustment switch A to the left will move the paper feed guides closer to each other. Moving the guide adjustment switch A to the right will move the paper feed guides farther from each other.

Moving the guide adjustment switch B to the left will move the paper feed guides to the operator's side. Moving the guide adjustment switch B to the right will move the paper feed guides to the non-operator's side.

The increment of the guide adjustment switches A and B varies depending on how long you keep pressing the switch.

Press the switch:

0.1 mm (0.004 inch)

Keep pressing the switch:

1.0 mm (0.04 inch)

When you continue to press the switch, the paper feed guides will keep moving by 1.0 mm (0.04 inch).

3-7

CHAPTER 3 STARTING BINDING OPERATION

When selecting a center base, check the position of the cover attached to the book block, then ﬁne adjust each part.

You can also make the adjustments using the ﬁne-adjustment screen. Refer to Chapter 4 "Fine-adjustment and Option Setting" "1-1. Setting the Paper Feed Guide" ( p.4-2) for details.

Cover

Stack height sensor adjustment

Turn the stack height sensor

adjustment.

The base position is “2.” When a thick cover is not sent to the nipping section, set it to “1.”

Separating air adjustment

Cover

Turn the separating air adjustment

to adjust air volume sent to between each cover.

The base position is “4.”

When you feed a small cover, turn the adjustment to the direction of 1.

When you feed a thick cover, turn the adjustment to the direction of 7.

Turn the adjustment little by little checking the feeding conditions.

Cover

Separator Adjustment

Separator adjustment

Separator

Suction belt

Gap between separator and suction belt

Turn the separator adjustment to

adjust the gap between the separator and suction belt.

The base position is “3.”

When a double feed occurs, turn the adjustment to the direction of 1. The gap between the separator and suction belt will be narrower.

When a mis-feed occurs, turn the adjustment to the direction of 5. The gap between the separator and suction belt will be wider.

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CHAPTER 3 STARTING BINDING OPERATION

Turn the adjustment little by little checking the feeding conditions.

Test feed button

Press the test feed button to feed a

cover.

The cover will be sent to the nipping section.

Make sure that you move the cover stopper to the position for the largest paper size before you press the test feed button. ( p.2-8)

Test Feed Button

2007-04-05 11:00

You can also feed the cover by pressing the test feed button on the main menu screen.

● When the cover size is small and is

not smoothly fed into the nipping section, use the supplied parts ( p.3-23).

● You can feed the cover even when the main cover is open.

Check that double-feed has not

occurred.

During test feeding, even though a doublefeed occurs, an error message "E-022 Double feed" will not appear on the LCD monitor.

When a double-feed has occurred, remove the cover from the nipping station and go back to the step 5.

● If you feed the cover when the main cover is open, make sure that there is no one around the feed section and nipping section.

● Do not put your hand inside the machine while the paper feed tray is moving. This may cause unexpected injuries.

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CHAPTER 3 STARTING BINDING OPERATION

Scoring depth adjustment

Primary feed roller pressure adjustment

Secondary feed roller pressure adjustment

Check the scoring condition.

Base position

Scoring becomes deeper

axis

Knob

Scoring depth adjustment

To adjust the scoring depth, loosen the knob on the right and left scoring depth adjustments and turn each axis to the right.

When the axes are in the upright position, no scoring will be applied.

Depending on the condition, you may need to adjust only one axis. Turn the axis little by little by checking the scoring condition.

● If the axis positions on both sides

are very different from each other, a cover may be torn or skewed.

● If the thickness is less than 3 mm, move the axes of the scoring depth adjustments in the upright position because a score cannot be applied to that thickness.

3-10

CHAPTER 3 STARTING BINDING OPERATION

Adjustment

Base position

When the cover is skewed.

Primary feed roller pressure

adjustment

Leave the adjustment in its original position in normal times. However when the cover is skewed, move the position of the adjustment.

The higher the position is, the stronger the pressure is.

The right and left adjustments should be in the same position.

However, there are times when adjusting either pressure can correct the skew.

If you increase the pressure for a thin cover, the cover may get creases. Adjust the pressure checking the feeding conditions.

Base position When the cover is

not smoothly fed.

Secondary feed

Secondary feed roller pressure

adjustment

Leave the adjustment in its original position in normal times. However when the cover is not fed smoothly, lower the secondary feed roller pressure adjustment to increase the pressure.

● Use a cover with the thickness of 157g/m² or more to apply a score to the cover.

● When the cover thickness is less than 157g/m², a score may be skewed. Also, a print near the folding line may have cracks if the nipping is applied without scoring.

● The paper's grain direction comes in two types: the long grain and the short grain. The applied scoring condition will change according to the paper's grain direction.

Grain direction

Feed direction

When using the short grain paper:

Because the scoring direction (feed direction) is same as the grain, a score will be applied to the short grain paper more easily than to the long grain paper. A thin cover may be partly torn.

Grain direction

Feed direction

When using the long grain paper:

Because the scoring direction (feed direction) meets the grain at a right angle, a score will not be applied to the long grain paper as easily as to the short grain paper.

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CHAPTER 3 STARTING BINDING OPERATION

Nipper guide adjustment

Nipper guide

Leading edge of the cover

Positioning finger

Positioning finger adjustment

Cover stopper

Nipper guide

Knob screw

. Press the tail edge of the cover

against the positioning ﬁngers, then move the cover stoppers to the leading edge of the cover.

. Align the cover with the book block

using the nipper guide adjustments.

Before turning the nipper guide adjustment, loosen the knob screw.

Guide line

Nipper guide adjustment

Center line

Knob screw

Turn the nipper guide adjustment so that the guide line aligns with the center line on the label.

Base position

Moved to the left

Positioning fingers adjustment

Adjustable range 4 mm (0.16 inch)

After adjusting the nipper guide, if the positioning ﬁngers are away from the tail edge of the cover, turn the positioning ﬁnger adjustment to move the positioning ﬁngers.

Turning the positioning ﬁngers adjustment to the operator's side (downward) will move the positioning ﬁnger to the left and turning it to the non-operator's side (upward) will move the positioning ﬁnger to the right (base position) within a range of 0 to 4 mm (0.16 inch).

3-12

CHAPTER 3 STARTING BINDING OPERATION

Nipper base line

Scoring base line

Match these lines.

Nipper (operator

’

s side)

Cover

Spine

Nipper (non-operator

’

s side)

. Adjust the position of the nipper

guides on the touch panel screen so that the nipper base line of the nipper (non-operator's side) is parallel to the scoring base line.

Do not touch the nipping section while the machine is in operation. Your ﬁngers may get caught in the nipper.

You can ﬁne adjust the scoring width with the main cover open. After completing the ﬁne-adjustment, make sure that you close the cover.

Fine-adjustment tab

1) Press the ﬁne-adjustment tab on the main menu.

Nipping Guide Select Button

2) Press the nipper guide select button.

The screen for adjusting the nipper guide will appear and the nipping station will go up. If you have not performed a size change, the screen will not appear.

3) Press the move buttons 1 to 4 to adjust the positions of the nipper guide (front) and nipper guide (back).

Fine-adjustment range: ±25.0 mm (0.98 inch)

Move button 1: The nipper guides (front, back) move to the non-operator’s side.

Move button 2: The nipper guides (front, back) move to the operator’s side.

Move button 3: The nipper guides (front, back) move closer to each other.

Move button 4: The nipper guides (front, back) move farther from each other.

Increment change button:

You can select the increment from 0.1 mm/0.5 mm/1.0 mm (0.004 inch/0.02 inch/0.04 inch).

: 0.1 mm (0.004 inch)

: 0.5 mm (0.02 inch)

: 1.0 mm (0.04 inch)

3-13

CHAPTER 3 STARTING BINDING OPERATION

Increment Change Button

Nipping Guide (back) Fine-adjustment

Nipping Guide (front) Fine-adjustment

Previous Button

Move Button 1 Move Button 5

Move Button 6

Move Button 3

Move Button 2

Move Button 4

Positioning Fingers Fine-adjustment

You can ﬁne adjust the paper feed guides using the guide adjustment switches above the paper feed tray when there is a cover on the nipping station.

Chapter 4 "Fine-adjustment and Option Setting" "1-3. Adjusting the Nipper Guide" ( p.4-5)

4) Press the move button 5 or 6 to adjust the position of the positioning ﬁngers.

Fine-adjustment range: 0 to 25.0 mm (0 to 0.10 inch)

Move button 5: The positioning ﬁngers move to the left.

Move button 6: The positioning ﬁngers move to the right.

The increment you selected in step 3) will be automatically applied to the positioning ﬁngers.

To change the increment, press the increment change button and select the increment from

0.1 mm/0.5 mm/1.0 mm (0.004 inch/0.02 inch/0.04 inch).

You can also adjust the positioning ﬁngers by turning the positioning ﬁnger adjustments in the range of 0 to 4 mm (0 to 0.16 inch) ( p.3-11).

5) Press the return button.

The nipping station will go down.

3-14

CHAPTER 3 STARTING BINDING OPERATION

3. Starting Binding

Safety sensor

Lamp

Clamp

Check that the lamp blinks or lights

up and place a book block in the clamp.

When the lamp blinks or lights up, you can place a book block in the clamp. If you interrupt the light between the safety sensors when the lamp is off, the machine stops for safety. In that case, refer to "When Binding Operations are Interrupted" ( p.3-16).

When the book block you placed in "1.Placing a Book Block" ( p.3-2) is still in the clamp, proceed to the step 2.

Book block

Start button

Check that the lamp lights up and

press the start button.

Although you can place the book block in the clamp when the lamp is blinking, binding will not start even if you press the start button. If the lamp blinks because a cover has not been transported to the nipping section from the paper feed tray or the heater is still heating up, the lamp will light up when the machine is ready. If the lamp blinks because of other reasons, follow an error message displayed on the screen.

When binding with a cover

Only for the ﬁrst set of book block, the caution message and the nipping delay time setting screen appear.

Nipping Delay Time

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CHAPTER 3 STARTING BINDING OPERATION

When nipping is set to ON, if the nipping time is short, the booklet may be discharged before the applied glue is dry and the glue may be adhered to the level plate. Check the open time of the hot melt glue you use and change the time if necessary.

Press or to change the nipping delay time.

Default setting: 0.0 sec.

Setting range: 0.0 to 30.0 sec.

When binding without a cover

Only for the ﬁrst set of book block, if the nipping delay time is set to 6.5 sec. or more, the caution message and the nipping delay time setting screen appear.

Check the open time of the hot melt glue you use and change the time if necessary.

Regardless of the nipping delay time settings, the message does not appear from a

second set of book block. Go to step 4.

Press the start button again.

The lamp goes off and the machine starts binding the book block.

Check the quality of the discharged

booklet.

If you need any adjustment, refer to Chapter 4 "Fine-adjustment and Option Setting" “1. Fine adjusting Each Part" ( p.4-2).

When you use the receiving tray, take out the booklet each time it is discharged.

Repeat the steps 1, 2 and 4.

When the cover thickness is set to "normal," the cover for the next book block will

be fed into the nipper automatically and scores will be applied to it. If you place more covers on the paper feed tray than necessary, the covers will be continually fed even after you have ﬁnished binding for the last book block.

You can start binding without pressing the start button by using the auto start

function. Once you place a book block in the clamp, the machine will start binding operations automatically. Refer to Chapter 4 "Fine-adjustment and Option Setting" "3-7. Setting the Auto Start ON/OFF" (

p.4-21) for details on how to set the auto start

function.

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CHAPTER 3 STARTING BINDING OPERATION

When Binding Operations are Interrupted

If you interrupt the light between the safety sensors during binding operations (when the lamp is off), the operations will stop. When you remove your hand from the sensor area, the following messages are displayed alternately.

When the clamp has returned to the level plate, messages are displayed depending on the situation.

When interrupted after a cover is applied to a book block

Paper ejection button

1) Check that the spine glue is not hot and press the paper ejection button on the touch panel screen.

A booklet will be ejected to the stacker.

2) Remove the booklet from the stacker.

3) Check the quality of the booklet.

Spine glue is very hot. Before you remove the booklet, make sure that it is not hot.

When interrupted before a cover is applied to a book block

Movable clamp button

1) Check that the spine glue is not hot and press the movable clamp button on the touch panel screen.

The movable clamp will open.

2) Remove the booklet from the clamp.

3) Place a new book block in the clamp.

● Spine glue is very hot. Before you remove the booklet, make sure that it is not hot.

● Because parts of binding processes have already been applied to the book block in

the clamp, if you try to continue the operation using that book block, the ﬁnished booklet will have poor quality. Replace a book block in the clamp with a new one.

3-17

CHAPTER 3 STARTING BINDING OPERATION

4. Removing the Booklet

When biniding operations are complete, a ﬁnished booklet with a cover will be discharged automatically to the stacker. Remove the booklet from the stacker following the procedures below. For a booklet without a cover, take it out from the clamp yourself.

Do not take out a booklet while the machine is in operation. It may cause unexpected

injuries.

Stacker stopper

Pull the stacker stopper to your side.

Finished booklet

Remove the ﬁnished booklet from

the machine.

Stacker stopper

Push back the stacker stopper all the

way in.

3-18

CHAPTER 3 STARTING BINDING OPERATION

When the booklet is not discharged smoothly

Booklet

If the book block is thin and the cover is thick, the ﬁnished booklet may not be discharged smoothly. In that case, push the booklet downward with your hand.

When the stacker is full of booklets

When the stacker is full of booklets during operation, the caution message to the right is displayed. To take out the booklets, follow the steps 1 through 3 of the previous page.

After pushing back the stacker stopper all the way in in step 3, the message will disappear.

When the booklets do not align in the stacker

Stacker side guide

Booklet

20 mm (0.79 inch)

When a booklet bounces laterally in the stacker section, use the stacker side guide. The appropriate position for the stacker side guide is 20 mm (0.79 inch) away from the left edge of the booklet.

● If you position the stacker side guide too closely to the booklet, a discharged booklet

may hit the stacker side guide, resulting in damage on the booklet.

● Every time you change a book block size, adjust the position of the stacker side guide.

Otherwise a discharged booklet may hit the stacker side guide, resulting in damage on the booklet.

● Keep the stacker side guide to the left when not in use.

3-19

CHAPTER 3 STARTING BINDING OPERATION

Book exit damper adjustment lever

Depending on the types of a booklet, when impact absorption at the book exit damper is low, the booklets may not align.

Adjust the book exit damper adjustment lever according to the weight (thickness) of the booklet.

Base position: 0

"4" has the highest absorption. Move the lever toward "0" when the booklet is light and toward "4" when it is heavy. When the booklet thickness is 2 mm (0.08 inch) or thinner, set it to "1."

3-20

CHAPTER 3 STARTING BINDING OPERATION

5. Adding Covers

Before you add covers to the paper feed tray, make sure that the lamp lights up or blinks. When the lamp is off, the machine is in operation.

Lamp

Feed guide

Cover

Back stopper

Pull the back stopper to your side.

Feed tray down switch

Press the feed tray down switch.

Only while you are pressing the feed tray down switch, the paper feed tray goes down.

When there is no paper on the paper feed tray, it will automatically go down.

Feed guide

Cover

Back stopper

Load covers on the paper feed tray

and press the back stopper against the tail edge of the covers.

3-21

CHAPTER 3 STARTING BINDING OPERATION

6. Finishing Binding

Once a binding operation is complete, check if there is enough hot melt glue left in the glue tank. If the surface of the glue on the application drums is lumpy, you need to add hot melt glue to the glue tank. Be careful not to boil dry the glue tank.

● High voltage of electricity supplied to the glue tank may cause an electric shock. Be

careful.

● The temperature around the glue tank is very high. Be careful when you add hot melt

glue.

Main cover

Open the main cover.

Check the remaining amount of the

hot melt glue.

Hot melt

The groove is the upper limit for hot melt

Groove

Glue tank

Add hot melt glue to the glue tank if

necessary.

Close the main cover.

Be careful not to get your hand caught when you close the main cover.

3-22

CHAPTER 3 STARTING BINDING OPERATION

Power switch

Turn the power switch in the

direction shown in the ﬁgure to turn off the power of the machine.

3-23

CHAPTER 3 STARTING BINDING OPERATION

7. Using Supplied Parts

When a cover on the paper feed tray is small, it may not be smoothly fed into the machine and a feed error may occur. In that case, use the supplied parts.

When feeding small-sized paper (170 mm (6.69 inches) long or less)

● Turn down the separating air volume by turning the separating air adjustment to the

direction of 1 ( p.3-7).

● Increase the separating pressure by turning the separator adjustment to the direction

of 1 ( p.3-7).

Scoring label

Stabilizer plate lite weight cover

Attachment level

Stabilizer plate lite weight cover

When separating air causes the tail edge of the cover to ﬂip, attach the magnet surface of the stabilizer plate lite weight cover on the scoring label.

Align the upper edge of the stabilizer plate lite weight cover with the attachment level shown in the ﬁgure.

Small cover feed belt accessory

Stack height sensor adjustment

Small cover feed belt accessory

(For a cover with the length of 140 mm (5.51 inches) or less)

When covers are fed into the machine in series, screw this to the back of the stack height sensor adjustment.

Do not use the small cover feed belt accessory for paper weighing 157g/m² or more.

Screw head

Lever

Small cover guide

(For a cover with the length of 140 mm (5.51 inches) or less)

The small cover guide prevents a cover from touching the lever of the stack height sensor.

Attach the hole on the magnet surface of the small cover guide to the screw head, which is located next to the scoring line label.

3-24

CHAPTER 3 STARTING BINDING OPERATION

Cover

Stack height sensor adjustment

Set the stack height sensor adjustment to "2."

Do not use the small cover feed belt accessory for paper weighing 157g/m² or more.

Small cover guide (R)

Paper feed guide (back)

Small cover guide (R)

(For a cover with the length of 170 mm (6.69 inches) or less)

The small cover guide holds down the tail edge of a cover. Attach the magnet surface of the small cover guide (R) to the paper guide (back).

Small cover guide (L)

Paper feed guide (front)

Small cover guide (L)

(For a cover with the length of 170 mm (6.69 inches) or less)

The small cover guide holds down the tail edge of a cover. Attach the magnet surface of the small cover guide (L) to the paper guide (front).

Do not load paper as high as 41 mm (1.61 inches) or more.

Press the guide firmly to the machine.

Guide

When a cover does not ﬁt into the nipper guides because of its curled edge, attach the magnet surface of each guide to the either side of the scoring section.

3-25

CHAPTER 3 STARTING BINDING OPERATION

8. Using Wing Scoring

When you want to turn-in a cover, use the wing scoring (optional) to apply a score to a position to be folded. The range you can apply a score is between 120 to 189 mm (4.72 to 7.44 inches) above the scoring base line on the non-operator's side and between 160 to 199 mm (6.30 to 7.83 inches) below the scoring base line on the operator's side.

As the wing scorings are located on the operator's side and non-operator's side, ﬁrst adjust the wing scoring on the operator's side, then that on the non-operator's side.

Operator’s side

Non-operator’s side

Scoring base line

Adjustable range 189 mm (7.44 inches)

Adjustable range 199 mm (7.83 inches)

Book block maximum thickness 51 mm (2.01 inches)

120 mm (4.72 inches)

160 mm (6.3 inches)

Feed direction

Knob screw

Loosen the knob screw (1) of the

upper wing scoring one or two turns by hand.

Shaft

Jam removing knob

Fixing screw

Turn the jam removing knob to make

the ﬁxing screw (1) of the lower wing scoring shaft face upward.

3-26

CHAPTER 3 STARTING BINDING OPERATION

Fixing screw

Wrench

Loosen the ﬁxing screw (1) of the

lower scoring roller by turning it counterclockwise using the supplied wrench (opposite side distance 2 mm).

Lower scoring roller

Move the lower scoring roller to the

desired position for scoring.

Fasten the ﬁxing screw (1) of the

lower scoring roller by turning it clockwise using the supplied wrench (opposite side distance 2 mm).

Scoring depth adjustment

Knob

Loosen the knob of the upper

scoring roller and put the scoring depth adjustment in the upright position.

Lower scoring roller

Upper scoring roller

Move the upper scoring roller to the

same position as the lower scoring roller.

3-27

CHAPTER 3 STARTING BINDING OPERATION

Lower scoring roller

Upper scoring roller

Align the concave part of the upper

scoring roller with the convex part of the lower scoring roller.

Tighten the knob of the upper

scoring roller.

. Tighten the knob screw (1) of the

upper scoring roller by hand.

. Loosen the knob of the upper

scoring roller.

Scoring depth adjustment

Lower scoring roller

Upper scoring roller

Gap

Fixing screw

. Adjust the gap between the upper

scoring roller and the lower scoring roller using the scoring depth adjustment.

. Tighten the knob of the upper

scoring roller.

. Repeat the steps 1 to 13 for the wing

scoring on the non-operator's side.

. Perform a test feed to check the

scoring depth.

3-28

CHAPTER 3 STARTING BINDING OPERATION

Memo

Chapter 4

FINE-ADJUSTMENT

AND OPTION SETTING

4-2

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

Fine adjusting Each Part

Press the ﬁne-adjustment tab to go to the screen for ﬁne-adjustment.

Fine-adjustment tab

An adjustments made on the ﬁne adjustment screen will be saved on the memory you are currently using.

1-1. Setting the Paper Feed Guide

If the scoring position is incorrect, ﬁne adjust the paper feed guide.

Paper Feed Guide Select Button

Press the paper feed guide select

button.

The screen for adjusting the paper feed guide will appear. If you have not performed a size change, the screen will not appear.

Increment Change Button

Paper Feed Guide (back) Fine-adjustment Value

Paper Feed Guide (front) Fine-adjustment Value

Previous Button

Move Button 1

Move Button 3

Move Button 2

Move Button 4

Press the move buttons to adjust

the paper feed guide (front) and the paper feed guide (back).

The maximum ﬁne-adjustment range:

±25.0 mm (0.98 inch)

Move button 1: The paper feed guides (front, back) move to the non-operator’s side.

Move button 2: The paper feed guides (front, back) move to the operator’s side.

Move button 3: The paper feed guides (front, back) move closer to each other.

Move button 4: The paper feed guides (front, back) move farther from each other.

4-3

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

Increment change button:

You can select the increment from 0.1 mm/0.5 mm/1.0 mm (0.004 inch/0.02 inch/0.04 inch).

: 0.1 mm (0.004 inch)

: 0.5 mm (0.02 inch)

: 1.0 mm (0.04 inch)

Guide adjustment switch A

Guide adjustment switch B

You can ﬁne adjust the paper feed guides using the guide adjustment switches above the paper feed tray.

The increment of the guide adjustment switches A and B varies depending on how long you keep pressing the switch.

Press the switch:

0.1 mm (0.004 inch)

Keep pressing the switch:

1.0 mm (0.04 inch)

When you continue to press the switch, the paper feed guides will keep moving by

1.0 mm (0.04 inch).

When there is a cover on the nipping station, the nipper guide will move.

Press the return button to return to

the screen used in step 1.

You can ﬁne adjust the paper feed guide with the main cover open. After completing

the ﬁne-adjustment, make sure that you close the cover.

4-4

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

1-2. Setting the Scoring Width

While a scoring width is automatically set according to the thickness of the book block, you can ﬁne adjust the scoring width by moving the scoring unit.

Scoring Width Select Button

Press the scoring width select

button.

The screen to select the scoring width will appear. If you have not performed a size change, the screen will not appear.

Increment Change Button

Scoring Width Fine-adjustment

Previous Button

Move Button 1

Move Button 2

Press the move button to adjust the

scoring unit position.

Maximum ﬁne-adjustment value: ±5.0 mm (0.20 inch)

Move button 1: The scoring width becomes wider.

Move button 1: The scoring width becomes narrower.

Increment change button:

You can select the increment from 0.1 mm/0.5 mm/1.0 mm (0.004 inch/0.02 inch/0.04 inch).

: 0.1 mm (0.004 inch)

: 0.5 mm (0.02 inch)

: 1.0 mm (0.04 inch)

Press the previous button to return

to the screen used in step 1.

4-5

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

1-3. Adjusting the Nipper Guide

When the folding position of the cover does not align with the scoring position, or the cover is out of position on the book block, ﬁne adjust the nipper guide (front, back) and positioning ﬁngers.

Do not touch the nipping section while the machine is in operation. Your ﬁngers may

get caught in the nipper.

Nipping Guide Select Button

Press the nipper guide select button.

The screen for adjusting the nipper guide will appear and the nipping station will go up. If you have not performed a size change, the screen will not appear.

Press the move buttons 1 to 4 to adjust the positions of the nipper guide (front)

and nipper guide (back).

Fine-adjustment range: ±25.0 mm (0.98 inch)

Move button 1: The nipper guides (front, back) move to the non-operator’s side.

Move button 2: The nipper guides (front, back) move to the operator’s side.

Move button 3: The nipper guides (front, back) move closer to each other.

Move button 4: The nipper guides (front, back) move farther from each other.

Increment change button:

You can select the increment from 0.1 mm/0.5 mm/1.0 mm (0.004 inch/0.02 inch/0.04 inch).

: 0.1 mm (0.004 inch)

: 0.5 mm (0.02 inch)

: 1.0 mm (0.04 inch)

Increment Change Button

Nipping Guide (back) Fine-adjustment

Nipping Guide (front) Fine-adjustment

Previous Button

Move Button 1 Move Button 5

Move Button 6

Move Button 3

Move Button 2

Move Button 4

Positioning Fingers Fine-adjustment

4-6

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

Guide adjustment switch A

Guide adjustment switch B

You can ﬁne adjust the paper feed guides using the guide adjustment switches above the paper feed tray when there is a cover on the nipping station.

When you move the guide adjustment switch A to the left, the nipper guides will move closer to each other. When you move the guide adjustment switch A to the right, the nipper guides will move farther from each other.

When you move the guide adjustment switch B to the left, the nipper guides will move to the operator's side. When you move the guide adjustment switch B to the right, the nipper guides will move to the non-operator's side.

The increment of the guide adjustment switch for the nipping guide is same as for the paper feed guide ( p.4-2).

When there is no cover on the nipping station, the paper feed guide will move.

Press the move button 5 or 6 to adjust the position of the positioning ﬁngers.

Fine-adjustment range: 0 to 25.0 mm (0 to 0.10 inch)

Move button 5: The positioning ﬁngers move to the left.

Move button 6: The positioning ﬁngers move to the right.

The increment you selected in step 2 will be automatically applied to the positioning ﬁngers.

To change the increment, press the increment change button and select the increment from

0.1 mm/0.5 mm/1.0 mm (0.004 inch/0.02 inch/0.04 inch).

You can also adjust the positioning ﬁngers by turning the positioning ﬁnger adjustments in the range of 0 to 4 mm (0 to 0.16 inch) ( p.3-11).

Press the return button to return to the screen used in step 1.

The nipping station will go down.

You can ﬁne adjust the scoring width with the main cover open. After completing the

ﬁne-adjustment, make sure that you close the cover.

4-7

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

1-4. Setting the Nipper

If the spine is too round or too sharp, adjust the width of the nipper.

Nipper Select Button

Select the nipper select button.

The screen for adjusting the nipper will appear. If you have not performed a size change, the screen will not appear.

Increment Change Button

Nipper Fine-adjustment

Previous Button

Move Button 1

Move Button 2

Press the move buttons to adjust the

nipper.

Fine-adjustment range: –2.0 to 5.0 mm (–0.08 to 0.20 inch)

Move button 1: The nipper moves farther from each other.

Move button 2: The nipper moves closer to each other.

Increment change button:

You can select the increment from 0.1 mm/0.5 mm/1.0 mm (0.004 inch/0.02 inch/0.04 inch).

: 0.1 mm (0.004 inch)

: 0.5 mm (0.02 inch)

: 1.0 mm (0.04 inch)

Press the return button to return to

the screen used in step 1.

To know the current width of the nipper, press the nipper guide select button ( p.4-5).

When you press the nipper guide select button, the nipper guides will go up and the

nipper width will be the same as the book block width. Then you will know the current width of the nipper.

4-8

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

1-5. Setting the Glue Cutting Position

A spine glue cutting position is adjusted automatically according to the book block length. However if you want to change the position, you can adjust the starting and ending points of spine glue.

Glue Cutting Position Select Button

Press the glue cutting position select

button.

The screen for adjusting the glue cutting position will appear.

Press or to change the glue

cutting position (starting point).

Each time you press the button, the glue cutting position will change by 0.5 mm (0.02 inch).

Fine-adjustment range: ±50.0 mm (1.97 inches)

Press or to change the glue

cutting position (ending point).

Each time you press the button, the glue cutting position will change by 0.5 mm (0.02 inch).

Fine-adjustment range: ±50.0 mm (1.97 inches)

Previous Button

Glue cutting position (starting point)

Glue cutting position (ending point)

Example

3.0

2.5

2.0

● When the ﬁne-adjustment value is "0.0," glue will run off the edge (starting point) because the wiper does not move and the glue cutting position is not adjusted.

● If you cannot adjust the glue cutting position as desired even after selecting the maximum value, contact your dealer.

Press the return button to return to

the screen used in step 1.

4-9

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

1-6. Setting the Width of Side Glue

The width of the side glue is adjusted automatically according to the book block thickness. However, if you want to change the width, adjust the distance between the side glue rollers.

Side Glue Width Select Button

Press the side glue width select

button.

The screen for adjusting the side glue width appears. If you have not performed a size change, the screen will not appear.

Also, if the glue tank has not reached the certain temperature (the set temperature minus 20°C/68°F), the caution message is displayed and the screen for setting the side glue width does not appear.

Side Glue Roller Width Fine-adjustment

Previous Button

Move Button 1

Move Button 2

Increment Change Button

Side Glue Meter Adjustment Button

Press the move button to adjust the

width of side glue.

Fine-adjustment range:

–2.0 to +5.0 mm (–0.08 to 0.20 inch)

Move button 1:

The distance between the side glue rollers will be longer and the amount of glue attached to the sides will decrease.

Move button 2:

The distance between the side glue rollers will be shorter and the amount of glue attached to the sides will increase.

Increment change button:

You can select the increment from 0.1 mm/0.5 mm/1.0 mm (0.004 inch/0.02 inch/0.04 inch).

: 0.1 mm (0.004 inch)

: 0.5 mm (0.02 inch)

: 1.0 mm (0.04 inch)

Side glue meter adjustment button:

When the side glue rollers are open to the maximum, the side glue roller on the operator's side comes under the external cover and therefore you cannot adjust the side glue meter. If you press the side glue meter adjustment button, the side glue roller moves to the position where you can adjust the side glue meter.

Press the return button to return to the screen used in step 1.

4-10

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

1-7. Adjusting Spine Glue Amount

Check the ﬁnished booklet and adjust the amount of the spine glue and side glue if necessary.

No.1 Glue Drum Meter Adjustment

Adjusts the glue amount to be applied to the application No.1 drum.

Spine meter roller adjustment

Application No.1 dru

No.1 meter

No.2 meter

Side glue meter (operator’s side)

Side glue meter (non-operator’s side)

No.2 glue drum meter adjustment

No.1 glue drum meter adjustment

Side glue meter adjustment (operator’s side)

Application No.2 drum

Side glue meter adjustment (non-operator’s side)

Side glue roller (non-operator’s side)

Spine meter roller

Side glue roller (operator’s side)

Base position:

The indicator on the No.1 glue drum meter adjustment points to the left.

Turning to the left:

The amount of the glue applied to the drum is largest.

Turning to the right:

The amount of the glue applied to the drum is smallest.

No.2 Glue Drum Meter

Adjustment

Adjusts the glue amount to be applied to the

application No.2 drum.

Base position:

The indicator on the No.2 glue drum meter adjustment points to the left.

Turning to the left:

The amount of the glue applied to the drum is largest.

Turning to the right:

The amount of the glue applied to the drum is smallest.

Spine Meter Roller Adjustment

Adjusts the amount of glue applied to the spine.

Base position:

The indicator on the spine meter roller adjustment points to the right.

Turning to the left:

The amount of the glue applied to the drum is smallest.

Turning to the right:

The amount of the glue applied to the drum is largest.

4-11

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

Locking screw

Adjustment

Turn the locking screw to the left to

loosen the adjustment.

Move the adjustment to the desired

position.

Turn the locking screw to the right to

tighten the adjustment.

1-8. Adjusting Side Glue Amount

When the side glue amount is different between the right and left sides of a ﬁnished booklet, move the side glue meter to adjust the side glue amount.

Side Glue Meter

Turning the side glue meter adjustment changes the side glue amount.

If the side glue meter on the operator's side is positioned under the external cover, move it to the nonoperator's side by pressing the side glue meter adjustment button on the touch panel screen (

p.4-9).

Wrench

Screw

Wrench

Side glue meter

Loosen the screws (each 2) using

the supplied wrench (opposite side distance 3 mm).

Spanner

Side glue meter adjustment (operator’s side)

Side glue meter adjustment (non-operator’s side)

Turn the side glue meter adjustment

using the supplied spanner to adjust the amount of glue.

Turn the adjustment little by little checking the glue amount.

The iron spanner gets hot. Do not continue to use it for a long time.

Tighten the screws (each 2) using

the supplied wrench (opposite side distance 3 mm).

4-12

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

● Before adjusting the glue amount, make sure that the hot melt glue is completely melted.

● The temperature around the glue tank is very high. Be careful when you adjust the glue amount.

● Be careful not drop the supplied tools inside the glue tank.

● High voltage of electricity supplied to the glue tank may cause an electric shock. Be careful.

1-9 Adjusting the Nipping Station

When the spine of the ﬁnished booklet is round or when there is some space between the book block and the cover, you may need to adjust the height of the nipping station. Check the ﬁnished booklets and adjust the height of the nipping station if necessary.

Nipper level adjustment access

Open the nipper level adjustment

access.

Move the adjustment lever seeing the

scale.

Adjustment lever

Fine-adjustment range:

–1.5 to +0.5 mm (–0.06 to +0.02 inch)

Base position: -0.5

Turning the lever to the + direction will raise the height of the nipping station.

Turning the lever to the – direction will lower the height of the nipping station.

Close the nipper level adjustment

access.

4-13

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

Using Motion Check

Press the motion check tab to eject jammed cover or a ﬁnished booklet, to change the level of the paper feed tray, or to move the clamp. Press the main menu tab to return to the main menu.

Motion Check Tab

2-1. Ejecting Jammed Paper

Paper ejection button

When a paper jam has occurred on the paper feed tray, the caution message will appear. Press the paper ejection button to remove the jammed paper.

If the message does not appear, press the paper ejection button on the motion check menu. While you are pressing down the button, the conveyance motor will keep turning.

Paper Ejection Button

If you cannot remove the jammed paper by pressing the paper ejection button, remove it by hand.

2-2. Discharging Booklet

When a booklet is left in the clamp, the caution message will appear.

Press the booklet ejection button to discharge the booklet. The level plate will open to drop the booklets on the stacker.

Booklet Ejection Button

4-14

CHAPTER 4 FINE-ADJUSTMENT AND OPTION SETTING

2-3. Adjusting the Height of Paper Feed Tray

When you add paper during binding operation, press the paper feed tray up/down button to raise or lower the paper feed tray. When the paper feed tray is at its highest position or in a middle position, it will descend. When it is at its lowest position, it will rise.

Paper Feed Tray

Up/Down Button

While the paper feed tray is rising or descending, the message will be displayed on the touch panel screen.

You can descend the paper feed tray by pressing the feed tray down button above the

paper feed tray. (

p.1-9)

2-4. Moving the Clamp

Before cleaning the level plate, press the clamp horizontal movement button to move the clamp to the right. The clamp will move to the nipping section ( p.5-3).

Clamp horizontal Movement Button

Before pressing the clamp horizontal movement button, make sure that there is no one around the clamp section and the nipping section.

Duplo DPB-500 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Precautions

Power Supply

Operating Environment

Maintenance / Others

Hot Melt Glue

WARNING / CAUTION Labels

Contents

Chapter 1 BEFORE OPERATION

1. Features

3. Names and Functions

3-1. External Parts

3-2. Milling Section

3-3. Glue Tank Section

3-4. Nipping Section

3-5. Scoring Section

3-6. Feed Section

3-7. Delivery Section

4. Screen Descriptions

4-1. Settings Screen for Binding

4-2. Fine-adjustment Screen

4-3. Motion Check Screen

4-4. Option Setting Screen

5. Accessories

Precautions on Hot Melt Glue

8. Cautions for Handling

9. Emergency Stop

10. Paper Size

10-1. Cover and Book Block Size

10-2. Book Block Thickness and Cover Weight

Using Single-folded or Double-folded Paper

10-4. Cover Type

Chapter 2 PREPARING FOR OPERATION

1. Turning On the Power

2. Preparing Hot Melt Glue

3. Preparing Each Section

3-1. Level Plate

3-2. Glue Tank

3-3. Nipping Section

Replacing the Receiving Tray with the Stacker Stopper

Replacing the Stacker Stopper with the Receiving Tray

4. Entering Job Information

4-1. Cover (With a cover/Without a cover)

4-2. Setting Double Feed Detection for Cover

4-3. Setting Book Block Size

4-4. Setting the Cover Size

4-5. Cover Base Spine Position

4-6. Checking and Saving Settings

Chapter 3 STARTING BINDING OPERATION

1. Placing a Book Block

2. Test-Feeding a Cover

3. Starting Binding

4. Removing the Booklet

5. Adding Covers

6. Finishing Binding

7. Using Supplied Parts

8. Using Wing Scoring

Chapter 4 FINE-ADJUSTMENT AND OPTION SETTING

Fine adjusting Each Part

1-1. Setting the Paper Feed Guide

1-2. Setting the Scoring Width

1-3. Adjusting the Nipper Guide

1-4. Setting the Nipper

1-5. Setting the Glue Cutting Position

1-6. Setting the Width of Side Glue

1-7. Adjusting Spine Glue Amount

1-8. Adjusting Side Glue Amount

1-9 Adjusting the Nipping Station

Using Motion Check

2-1. Ejecting Jammed Paper

2-2. Discharging Booklet

2-3. Adjusting the Height of Paper Feed Tray

2-4. Moving the Clamp

Chapter 1

BEFORE OPERATION

Chapter 2

PREPARING FOR

OPERATION

Chapter 3

STARTING BINDING

OPERATION

Chapter 4

FINE-ADJUSTMENT

AND OPTION SETTING