Horizon BQ-260, BQ-260L User Manual
BOOK BINDER
BOOK BINDER
BQ-260/260L
Important Information
- This manual is designed to help you to install, operate and maintain Perfect Binder BQ-
260/260L. Read, understand and keep this manual in a safe and convenient place.
- Do not operate BQ-260/260L until you read and understand the instructions in this
manual.
- Horizon International Inc. shall not be liable for incidental consequential damages resulting from : improper or inadequate maintenance by customer; unauthorized modification or
misuse; operation outside of the environmental specifications for the product.
- Horizon International Inc. pursues a policy of continuing improvement in design and
performance of the product. Therefore, the product design and specifications are subject to
change without prior notice and without our legal obligation.
- All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without the prior written consent of Horizon International Inc.
060404/BQ260/06E/DV UM202001-06
I
Safety Precautions
- The signal word WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
- The signal word CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in damage on machines. It may also be used to alert against unsafe
practices.
- Read and understand all safety instructions with signal word such as WARNING and
CAUTION. If safety instructions are ignored, personal injury will result.
- Horizon International Inc. cannot anticipate every possible situation that might involve
a potential hazard. The instruction in this manual and warning labels on the machine are
therefore not all inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation could cause injury to personnel. Do not attempt to
operate any switch, valve, or other energy isolating device where it is locked or tagged out.
- Do not operate the machines with any covers being removed.
- Some of the drawings in this manual shows the machine uncovered for explaining the
detail or inside of machine.
II
CONTENTS
Important Information ............................................................................................I
Safety Precautions....................................................................................................II
1. Machine Parts Descriptions
1-1 General View of BQ-260 ...................................................................................2
1-2 Control Panel .....................................................................................................3
1-3 Operation Panel .................................................................................................5
1-4 Accessories and Tools ........................................................................................6
1-5 Accessory Tools..................................................................................................7
2. Installation Instructions
2-1 Installation Instructions ....................................................................................10
2-1-1 Installing Place ...............................................................................................10
2-1-2 Installing BQ-260 ...........................................................................................10
2-1-3 Releasing Transport Lock Nut .......................................................................11
2-1-4 Connecting Power Cord ................................................................................. 12
3. Before Starting Operation
3-1 Safety Device Function Check ..........................................................................13
3-1-1 Stop Button ..................................................................................................... 13
3-1-2 Safety Cover ...................................................................................................16
3-2 Every Day Check Up .........................................................................................18
3-2-1 Glue Level Check ...........................................................................................18
3-2-2 Level Plate Cleaning Check ...........................................................................18
3-2-3 Nipper Unit Check..........................................................................................19
3-2-4 Dust Bag Check .............................................................................................. 19
4. Set Up BQ-260
4-1 Nipper Unit Set Up ............................................................................................21
4-1-1 Nipper Unit Set Up for Stock Thickness ........................................................ 21
4-1-2 Cover Positioning Set Up ...............................................................................24
III
4-2 Clamper Unit Set Up .........................................................................................26
4-3 Milling Unit Set Up............................................................................................27
4-3-1 Milling Guide Set Up .....................................................................................27
4-3-2 Milling Depth Set Up .....................................................................................28
4-4 Vertical Stacker Unit Set Up ............................................................................29
4-5 Melt Tank Unit Set Up ......................................................................................30
4-6 Operation Switches Set Up ...............................................................................32
4-7 Test Binding .......................................................................................................33
4-7-1 Test Binding for With Milling Binding..........................................................33
4-7-2 Pad Binding ....................................................................................................35
5. Operation Procedure
5-1 With Cover Binding Operation ........................................................................37
5-2 Pad Binding ........................................................................................................39
6. Special Binding Method
6-1 Small Size Binding .............................................................................................43
6-1-1 Register Shaft Position Adjustment ...............................................................43
6-1-2 Cover Position Register Block Installation ....................................................45
6-1-3 Small Cover Stopper Installation ...................................................................46
6-1-4 Shooter Attachment ........................................................................................47
6-2 To Increase Glue Film Thickness.....................................................................48
6-2-1 Spacer Plate Attachment ................................................................................48
6-2-2 Melt Tank Height Adjustment........................................................................51
6-3 To Adjust Condition of Spine ...........................................................................52
7. After Binding Finish
7-1 Glue Supply ........................................................................................................53
7-2 Clean Up While Power On................................................................................55
7-2-1 Nipping Plate and Nipper Jaw Clean Up........................................................55
7-2-2 Level Plate Clean Up......................................................................................56
7-3 Clean Up after Power Off .................................................................................58
7-3-1 Dust Bag Clean Up ......................................................................................... 58
7-3-2 Vertical Stacker Unit Clean Up ...................................................................... 58
7-4 Clean Up after Power Off .................................................................................59
7-4-1 Milling Unit Clean Up....................................................................................59
7-4-2 Gluing Length Sensor Clean Up ....................................................................60
7-4-3 Cover Sensor Clean Up ..................................................................................60
IV
8. Maintenance
8-1 Once A Month ....................................................................................................61
8-1-1 Lubrication on Melt Tank Unit ......................................................................62
8-1-2 Greasing on Clamper Rail ..............................................................................62
8-1-3 Oiling on Nipper Unit.....................................................................................62
8-2 As Required........................................................................................................63
8-2-1 Milling Cutter Replacement ...........................................................................63
8-2-2 Roughening Cuter Replacement.....................................................................64
8-2-3 Glue Draining .................................................................................................66
9.
Installation of Suction Cover Feeder CF-260(Optional Equipment)
9-1 Before You Begin ...............................................................................................67
9-1-1 Specifications ................................................................................................. 68
9-1-2 Machine Descriptions and Functions .............................................................68
9-1-3 Descriptions and Functions of Operation Panel .............................................69
9-1-4 Tools and Accessories ....................................................................................70
9-2 Set Up and Operation........................................................................................71
9-2-1 Cover Piling....................................................................................................71
9-2-2 Open/Close of Sucker Valve ..........................................................................72
9-2-3 Cover Feeder Position Set Up ........................................................................72
9-2-4 Support Plate Set Up ...................................................................................... 72
9-2-5 Attachment of Accessories .............................................................................73
9-2-6 Feeding Test ...................................................................................................74
9-2-7 Cover Piling....................................................................................................74
9-2-8 Binding Finish ................................................................................................75
9-3 Trouble Shooting ...............................................................................................76
9-3-1 When Misfeed Occurs. ...................................................................................76
9-3-2 When Two Covers are fed at the same time...................................................77
9-4 CF-220 Accessories ............................................................................................78
10.
Installation of Friction Cover Feeder CF-220(Optional Equipment)
10-1 CF-220 Accessories ..........................................................................................79
10-2 Set Up................................................................................................................81
10-3 Installation of CF-220......................................................................................88
V
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VI
1. Machine Parts Descriptions
1. Machine Parts Descriptions
1-1 General View of BQ-260 ......................................................................... 2
1-2 Control Panel ........................................................................................... 3
1-3 Operation Panel ....................................................................................... 5
1-4 Accessories and Tools.............................................................................. 6
1-5 Accessory Tools........................................................................................ 7
1
1. Machine Parts Descriptions
1-1 General View of BQ-260
Milling Unit
Safety Cover
Clamper Unit
Melt Tank Unit
Nipping Unit
Level Plate
Vertical Stacking Section
Control Panel
Cover Feeding Unit
(Option)
2
1-2 Control Panel
1 234 56
Trouble Monitor
1. Machine Parts Descriptions
7 8 9 10111213
1.Gluing Length Adjusting Knobs
Used to adjust spine glue length.
2.Milling Start Button
Used to start to rotate milling cutter.
3.Cover Single Feed Button
Used to feed one cover sheet from cover
feeder with automatic cover feeding
mode.
4.Nipper Up/Down Button
Used to raise or lower nipper unit for
setting up nipping unit.
5.Nipping Time Control Knob
Used to control nipping time.
6.Nipping Mode Select Switch
Used to select nipping mode. Three
different modes, With milling binding
mode, Signature binding mode and Pad
binding mode can be selected.
7.Trouble Monitor
(Please refer to next page.)
8.Milling Mode Select Switch
Used to select milling mode, with milling
or without milling.
9.Level Plate Mode Select Switch
Used to select reset mode of Level Plate
after one complete cycle of binding
automatic or manual.
10. Cover Feed Mode Select Switch
Used to select cover feed mode, automatic or manual
11.Clamper Pin On/OFF Switch
Used to turn on/off clamper pin which
holds stock in clamper when without
milling mode is selected..
12.Nipping Delay Time Control Knob
Used to control nipping delay time
length.
13.Pad Binding Lamp
This lamp turns on when pad binding
mode is selected.
3
1. Machine Parts Descriptions
1-2 Control Panel
(1)
Trouble Monitor
(3)
(6)
Trouble Monitor
Indicates incorrect point on BQ-260.
When one of them turns on except power
lamp, BQ-260 can not be started.
Each LED turns on when :
(1) safety cover opens.
- Close safety cover.
(2) milling cutter does not rotate although
with milling binding mode is selected.
- Depress milling cutter start button to
rotate milling cutter.
(3) level plate opens.
- Depress start button to reset level plate.
(4) emergency stop switch is depressed.
- Pull up emergency stop switch to release it.
(7)
(2)
(5)
(4)
(5) glue is not ready for biding.
- Wait until glue will be melted.
(6) cover is not fed to stopper.
- Feed cover completely until it gets
stopped against stopper.
(7) main power is on.
NOTE : Difference of Nipper Movement
Nipping unit has two different movements, with milling binding mode and signature bind-
ing mode. In with milling binding mode, nipper plate raises at first and then front and back
nipper jaws nip stock. So, this binding mode is suitable for binding milled stock or cut sheet
stock. In signature binding mode, nipper plate and two nipper jaws raise and nip stock at
same time. So this binding mode is suitable for binding signature which spine is shaped
thicker because of folded edge. Book spine will be formed too sharp or destroyed when
spine is pressed at first as in with milling binding mode. Binding quality or book spine
shape bound with signature binding mode is not affected so much by folding.
2 211 1
1
With Milling Binding Mode Signature Binding Mode
4
1-3 Operation Panel
4
3
2
1
1. Machine Parts Descriptions
1.Counter (with reset button)
Used to count amount of binding. When
reset button is set at far side, number in
counter can not be reset.
2.Level Plate Button
Used to open and reset level plate manually
when level plate switch is set at manual
operation mode.
3.Start Lamp and Start Button
Lamp indicates that BQ-260 is ready to
bind.
4.Stop Button
5
1. Machine Parts Descriptions
1-4 Accessories and Tools
Check all accessories are supplied with your BQ-260 when you open package.
1. Support Plates for Cover Feeder Unit
Large :1 pc
Small :1 pc
2. Small Cover Stopper (1 pc)
3. Small Cover Position Register (2 sets)
4. Clamper Support Guide
Large :1 pc
Normal : 1pc
8. Milling Cutter (1 pc)
9. Grease (1 pc)
10. Chain Oil (1 pc)
11. Hot Melt HM-110 (5 kg)
5. Space Plate (1 pc)
6. Drain for Glue Replacement (1 pc)
7. Dust Bag (1 pc)
H
M
-1
1
0
5
k
g
12. Mount Base with Leveling Bolt (3 sets)
13. Chute for small book (1 pc)
6
1-5 Accessory Tools
Check all tools supplied with your BQ-260 when you open package.
1. Machine Parts Descriptions
1. Screw Driver (1 pc)
2. Spanner (30 mm) (1 pc)
3. Spanner (13/17 mm) (1 pc)
4. Box Wrench ( 30 mm) (1 pc)
5. Special Wrench (1 pc)
6. Allen Wrench (2.5, 3, 4, 5, 6 mm)
(1 pc of each)
7. Roughening Cutter Height Gauge (1 pc)
.8
0
.5
0
7
1. Machine Parts Descriptions
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8
2. Installation Instructions
2. Installation Instructions
2-1 Installation Instructions.......................................................................... 10
9
2. Installation Instructions
2-1 Installation Instructions
2-1-1 Installing Place
This section shows condition of installing
place for BQ-260.
WARNING
Weights of BQ-260 is about 500 kg.
Pay attention enough to transportation.
BQ-260 could fall down or catch a
person with something like wall.
1. Select a flat, rigid floor free from vibra-
tion.
2. Select a place free from direct exposure
to sun light.
3. Select a place free from extremely high
temperature and humidity.
2-1-2 Installing BQ-260
This section shows how to install BQ-260.
Necessary Tools : Spanner (19 mm)
1. Place BQ-260 on installation place.
2. Place 3 mount base under levelling bolts.
3. Turn leveling bolts with spanner clock-
wise until bottom of BQ-260 is 120 mm in
height.
4. Fasten 3 lock nuts on 3 leveling bolts.
120 mm
Leveling Bolt
Mount
10
2-1 Installation Instructions
2-1-3 Releasing Transport Lock Nut
2. Installation Instructions
Melt Tank lock nut is installed to prevent
melt tank moving up and down during transportation.
1. Loosen melt tank lock nut.
NOTE
- It is not necessary to remove transport lock
nut. Remain it loosen.
- Remain height adjust bolt loosen unless
melt tank height adjustment is required.
2-1-4 Connecting Power Cord
Height Adjust Bolt
Lock
This section shows how to connect power
cord on BQ-260.
WARNING
- Be sure to depress stop button to
prevent sudden work of BQ-260.
- Confirm voltage and frequency to be
used on your BQ-260 are correct.
1. Depress stop button.
2. Make sure that power switch is off.
3. Turn off main power or breaker in your
shop.
4. Attach power cord to 3-phase power
source.
Main Switch
Blue
Brown 3-Phase
Black
11
Green/Yellow Ground
2. Installation Instructions
2-1 Installation Instructions
5. Turn on main power or breaker in your
shop.
6. Turn on power switch on BQ-260.
7. Remove the spring and open the shutter
plate.
8. Pull up stop button.
9. Depress milling mode select switch to
far side to select with milling mode.
10. Depress milling start button.
- Blower will start at the same time.
11. Depress milling mode select switch to
near side to stop the milling cutter, watching the rotating milling cutter from above.
- Check the rotating direction of the milling
cutter.
- The milling cutter should rotate counterclockwise.
Shutter Plate
Spring
Milling Start Button
Milling Mode
Select Switch
With Milling Mode
Normal Rotating Direction
12. If the milling cutter rotates clockwise,
stop immediately and perform as follows:
- Turn off power on BQ-260 and main
power or breaker in your shop.
- Change wiring on 3-phase terminal and
perform step 5 through 12.
13. Depress stop button after connecting
power cord correctly.
wat
Stop button
Dust Bag
12
3. Before Starting Operation
3. Before Starting Operation
3-1 Safety Device Function Check................................................................ 14
3-2 Every Day Check Up............................................................................... 18
13
3. Before Starting Operation
3-1 Safety Device Function Check
This section shows how to check safety device
function. Check all safety device function
before starting operation on BQ-260.
3-1-1 Stop Button
WARNING
Do not touch clamper while clamper is
moving. Moving clamper can cause
severe personal injury.
1. Pull up stop button. LED on monitor for
stop button turns off.
Stop Button
Start Button
2. Set nipping mode select switch to center
position to select pad binding mode.
- Pad binding lamp on control panel turns
on to indicate that pad binding is selected.
3. Select without milling mode with milling
mode select switch.
- Confirm lamp on start button is ON.
NOTE
Depress level plate control button when start
lamp is not on.
LED for Stop Button
Nipping Mode Select Switch
Pad Binding
Lamp
Near Side
Milling Mode
Select Switch
Center
14
3-1 Safety Device Function Check
4. Check emergency stop function.
- Stand in front of operation panel.
- Hold top of stop button with your right
hand to prepare to depress stop button
immediately.
- Depress start button and depress stop
button 1 second after start button was
depressed.
- Clamper will stop in a moment to show
that emergency stop function works
correctly.
NOTE
When clamper does not stop in a moment
even if stop button is depressed, turn off main
power and call your local dealer.
3. Before Starting Operation
Stop Button
Stop Button
5. Move clamper to home position.
- Pull up stop button.
- Depress start button to move clamper to
its original position. Clamper will stop
over nipping unit for 10 seconds.
6. Reset level plate.
- When clamper returns to home position,
depress level plate button once to reset
level plate.
- Start button will turn on to indicate
level plate is reset.
7. Depress stop button to prevent BQ-260
works suddenly by mistake.
Start Button
Level Plate Button
15
3. Before Starting Operation
3-1 Safety Device Function Check
This section shows how to check safety device
function. Check all safety device function
before starting operation on BQ-260.
3-1-2 Safety Cover
WARNING
Do not touch clamper while clamper is
moving. Moving clamper can cause
severe personal injury.
1. Pull up stop button. LED on monitor for
stop button turns off.
Stop Button
Start Button
2. Set nipping mode select switch to center
position to select pad binding mode.
- Pad binding lamp on control panel turns
on to indicate that pad binding is selected.
3. Select without milling mode with milling
mode select switch.
- Confirm lamp on start button is ON.
NOTE
Depress level plate control button when start
lamp is not on.
LED for Stop Button
Nipping Mode Select Switch
Pad Binding
Lamp
Near Side
Milling Mode
Select Switch
Center
16
3-1 Safety Device Function Check
3. Before Starting Operation
4. Check safety cover function.
- Stand in front of operation panel.
- Hold handle on safety cover with your
both hand to prepare to open safety cover
immediately
- Depress start button and open safety cover
1 second after start button was depressed.
- Clamper will stop in a moment to show
that safety cover function works correctly.
NOTE
When clamper does not stop in a moment
even if safety cover is opened, turn off main
power and call your local dealer.
5. Move clamper to home position.
- Close safety cover.
- Depress start button to move clamper to
its original position. Clamper will stop
over nipping unit for 10 seconds.
Safety Cover
Start Button
Handles
6. Reset level plate.
- When clamper returns to home position,
depress level plate button once to reset
level plate.
- Start button will turn on to indicate
level plate is reset.
7. Depress stop button to prevent BQ-260
works suddenly by mistake.
Level Plate
Button
Stop Button
LED for Stop Button
Clamper
Cover Feeder
Unit
17
3. Before Starting Operation
3-2 Every Day Check Up
3-2-1 Glue Level Check
Before start binding, glue level in melt tank
must be checked.
WARNING
Keep off your hands or fingers from
melt tank. Melt tank is heated up to
around 200˚C. High temperature can
cause severe skin burn.
CAUTION
Do not supply glue more than Red Line
on melt tank glue level scale.
NOTE
Check glue level when glue is melted.
1. When glue lower limit mark in melt tank
appears, glue level is not enough for binding.
NOTE
See "7-1 Glue Supply" (Page 54) when you
supply glue.
3-2-2 Level Plate Cleaning Check
Melt Tank Glue Level Scale
Glue Lower Limit Mark
Red Line
CAUTION
Keep glue level
below red line.
Before start binding, surface of level plate
must be cleaned.
1. Check level plate with your eyes
whether paper dust or glue stick on level
plate.
NOTE
See "7-2-2 Level Plate Clean Up" (Page 56)
when cleaning of level plate is necessary.
Level Plate
18
3-2 Every Day Check Up
3-2-3 Nipper Unit Check
Before start binding, surface of nipper plate
and nipper jaw must be cleaned.
1. Check nipper plate and nipper jaws with
your eyes whether paper dust or glue stick
to nipper plate and nipper jaws.
NOTE
See "7-2-1 Nipping Plate and Nipper Jaw
Clean Up" (Page 55 ) when you clean nipper
unit.
3. Before Starting Operation
Nipper Plate
Nipper Plate
3-2-4 Dust Bag Check
Before start binding, dust bag must be empty.
1. Check dust bag with your hands whether
it is empty or not.
NOTE
See "7-3-1 Dust Bag Clean Up" (Page 58 )
when you clean dust bag.
Dust Bag
19
3. Before Starting Operation
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20
4. Set Up BQ-260
4. Set Up BQ-260
4-1 Nipper Unit Set Up .................................................................................. 21
4-2 Clamper Unit Set Up............................................................................... 26
4-3 Milling Unit Set Up ................................................................................. 27
4-4 Vertical Stacker Unit Set Up .................................................................. 29
4-5 Melt Tank Unit Set Up............................................................................ 30
4-6 Operation Switches Set Up ..................................................................... 32
4-7 Test Binding ............................................................................................. 33
21
4. Set Up BQ-260
4-1 Nipper Unit Set Up
NOTE
When your binding job is pad binding
(without cover), nipper unit set up is not
necessary to perform. Select pad binding
mode with nipping mode select switch. Then
proceed to "4-2 Clamper Unit Set Up" in
Page 26.
4-1-1 Nipper Unit Set Up for Stock Thickness
This section shows how to adjust nipping
width against stock thickness.
Nipper Up/Down Button
WARNING
Do not touch melt tank unit when
adjusting nipper unit. Melt tank is
heated up around 200˚C. High temperature can cause severe skin burn.
1. Select either with milling or without
milling binding mode by nipping mode
select switch.
Near Side : for signature binding
Far Side : for with milling binding
Center : for pad binding
2. Depress nipper up/down button to raise
nipper plate. Nipper plate stop at upper
position.
NOTE
- Nipper jaw's width must be adjusted when
nipper unit is at upper position.
- When nipper up/down button is depressed
with nipper being up position, nipper unit will
be down.
- Nipper is at lower position when 5 screws
on nipper plate appear.
Nipping Mode
Select Switch
Screws
3. Depress stop button.
22
4-1 Nipper Unit Set Up
4. Set Up BQ-260
4. Hold 2 handles on safety cover with your
both hands and open safety cover.
5. Turn fix knob counterclockwise to
unlock nipping width adjusting knob.
6. Turn nipping compression adjusting
knob counterclockwise to open nipper jaws
until stock can be placed on nipper plate.
7. Place stock on nipper plate.
8. Turn nipping width adjusting knob
clockwise to nip stock.
9. Read scale on nipping unit. This mea-
surement will be used for setting up
clamper.
Nipping Plate Nipper Jaws
Lock Knob
Nipping Width
Adjusting Knob
Lock Knob
Stock
10. Slightly turn nipping width adjusting
knob counterclockwise to release the stock.
- Nipping width adjusting knob must be
turned back clockwise to secure the
adjusted width of nipper jaws.
11. Turn fix knob Clockwise to lock nipping
width adjusting knob.
12. Close safety cover.
13. Pull up stop button.
14. Depress nipper up/down button to lower
nipper unit.
15. Depress stop button to prevent BQ-260
works suddenly by misoperation.
Scale
Stop Button
Nipping Width
Adjusting Knob
Cover Single Feed Button
23
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