Horizon SPF-200A, FC-200A, SPF-200L, FC-200L User Manual

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BOOKLETMAKER

SPF-200A

FC-200A

SPF-200L

FC-200L

*UM201102*

BOOKLETMAKER

Important Information

• This manual is designed to help you to install, operate and maintain the SPF-200A/SPF-200L or FC-200A/FC-200L Bookletmaker. Please read and understand this manual, and keep it in a safe and convenient place.

• Do not operate the SPF-200A/SPF-200L or FC-200A/FC-200L until you read and understand the instructions in this manual.

• Horizon International Inc. shall not be liable for incidental consequential damages resulting from: improper or inadequate maintenance by the customer, unauthorized modification or misuse, or operation outside of the environmental specifications for the product.

• Horizon International Inc. pursues a policy of continuing improvement in design and performance of the product. Therefore, the product design and specifications are subject to change without prior notice and without our legal obligation.

• All rights are reserved. No part of this manual may be photocopied, reproduced or translated to another language without the prior written consent of Horizon International Inc.

160218/SPF200A/FC200A/SPF200L/FC200L/20E/HN,TM,AT/F7/ICS5/PXI

This manual explains on the basis of the SPF-200A/FC-200A. The operating instructions for the SPF-200L/FC-200L are added as necessary. In case that the sheet length is longer than 500 mm (19.68”), some functions may not available in the upstream and downstream devices of the SPF-200L.

UM201102-20(000)

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Safety Precautions

Safety precautions are indicated in this manual as follows:

The term WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

The term CAUTION indicates a potentially hazardous situation which, if not avoided, may result in serious injury, or damage to the machine.

This symbol indicates a note which includes important information. Follow the note to operate the machine safely.

This symbol indicates a prohibited action. Do not perform any prohibited action.

This symbol indicates an essential procedure. Follow the procedure to operate the machine safely.

Important

Attention

Note

Additional Information

• This lists the range of acceptable values and operating conditions.

• This information will help you to avoid problems with the machine or help you learn how to operate the machine.

• Refer to this note when you operate the machine.

• This explains a mechanism in the machine.

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Operating Safety Precautions

WARNINGS for Operation

This machine must be operated by just one person at a time.

Work alone when you maintain and lubricate the machine. Letting someone else operate the machine may cause severe personal injury.

Do not remove or bypass any safety features. Moving parts can cause severe personal injury.

Some adjustments must be made with some of the machine covers opened. Keep your hands and fingers outside of the safety cover and away from any moving parts while the machine is running. Otherwise moving parts can cause severe personal injury.

The machine will not stop immediately if the Emergency Stop switch on an upstream device is pressed. After all in-process booklets are delivered, the machine will stop.

Do not allow anyone else near the machine when you are moving the main section of the SPF forwards or backwards.

When replacing the knife, wear gloves and do not touch the edge of the knife directly. The knife is extremely sharp, and may cause severe personal injury.

Press the Emergency Stop button before turning the handwheel. A sudden accidental start of the machine can cause severe personal injury.

Do not operate the fore-edge trim section separately from the SPF main unit.

CAUTIONS for Operation

After turning off the power switch, wait ten seconds before turning it on again. Otherwise, a circuit board may be damaged.

The fold knife and roller may strike each other if the fold knife is lifted too far. Turn the fold knife height adjustment knob in small amounts.

Remove the cable connected to the SPF main unit before moving the fore-edge trim section away.

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WARNINGS for Maintenance

Turn off the power switch before beginning any maintenance operation. If the machine accidentally starts suddenly, this can cause severe personal injury.

Turn off the power switch before clearing a jam. If the machine accidentally starts suddenly, this can cause severe personal injury.

When working inside the machine, be careful to keep your hands away from nearby parts.

Be sure to press the Emergency Stop button before opening the fold section cover. The machine may start suddenly, causing severe personal injury.

Turn off the power switch before resetting a circuit breaker. Otherwise, the machine may start suddenly, causing severe personal injury.

Fuse replacement must be done under the supervision of a maintenance administrator. Turn off the power switch and unplug the power cable before replacing a fuse.

When the booklet thickness detector is installed, evacuate the laser unit. Otherwise the sensor may be damaged.

CAUTIONS for Maintenance

Use the types of lubrication oil and grease which are recommended by HORIZON. Other oil or grease may reduce the life of the machine or cause damage.

WARNINGS for Installation

Turn off the main power or circuit breaker in the factory before connecting the power cord to the machine. High voltage electricity can cause severe personal injury.

CAUTIONS for Installation

Be sure to install the floor mounting plates to keep the machine level. Otherwise, vibration may cause the machine to move. The binding quality may deteriorate, or the machine may be damaged.

The SPF-200A ＋the FC-200A weigh about 720 kg (1590 lb). The SPF-200L ＋the FC-200L weigh about 750 kg (1653 lb). Transport and install the machine safely, and keep the weight of the unit in mind.

Install the machine correctly, referring to the installation manual or installation instructions in the user’s manual before starting the machine. Otherwise, the binding quality cannot be guaranteed.

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CONTENTS

Important Information ............................................................................................................... i

Safety Precautions ...................................................................................................................ii

Operating Safety Precautions .................................................................................................iii

1 Machine Description

1-1 Automatic and Manual Settings ................................................................................. 1

1-2 Machine Descriptions .................................................................................................. 2

1-2-1 Safety Device / Safety Functions ......................................................................... 2

1-2-2 Overall Machine ................................................................................................... 3

1-2-3 Manual Feed / Infeed Conveyor Section ............................................................. 5

1-2-4 Infeed Section ...................................................................................................... 6

1-2-5 Jog Section .......................................................................................................... 7

1-2-6 Stitch Section ....................................................................................................... 8

1-2-7 Fold Section ......................................................................................................... 9

1-2-8 Fore-edge Trim Section ..................................................................................... 10

1-2-9 Delivery Conveyor ............................................................................................. 11

1-2-10 Control Panel ................................................................................................... 12

1-3 Screen Descriptions .................................................................................................. 13

1-3-1 Setting-Binding Pattern Screen ......................................................................... 13

1-3-2 Setting-Sheet Size Screen ................................................................................ 13

1-3-3 Setting-Finishing Size Screen ........................................................................... 14

1-3-4 Setting-Instruction Screen ................................................................................. 15

1-3-5 Setting-Confirmation Screen ............................................................................. 19

1-3-6 Binding-Operation Screen ................................................................................. 20

1-3-7 Binding-Fine Adjust Screen ............................................................................... 22

1-3-8 Binding-Status Setting Screen ........................................................................... 24

1-3-9 Memory Screen ................................................................................................ 28

1-3-10 Information-Main Screen ................................................................................ 29

1-3-11 Information-Monitor/Single Operation Screen ................................................ 30

1-3-12 Information-Administrator Screen .................................................................... 31

1-3-13 Error Screen .................................................................................................... 34

2 Checks before Operating

2-1 Checking the Emergency Stop Function ................................................................. 35

3 Operating Procedures

3-1 Overview of Operating Procedures .......................................................................... 37

3-2 Setting Up a Job Using the Setting Screen ............................................................. 39

3-3 Doing a Changeover .................................................................................................. 44

3-3-1 Removing Parts Before the Changeover ........................................................... 44

3-3-2 Attaching Parts After Changeover ..................................................................... 49

3-3-3 Confirmation After Changeover ......................................................................... 52

3-4 Doing a Test Binding ................................................................................................. 53

3-4-1 Preparing the Upstream Device ........................................................................ 53

3-4-2 Binding a Booklet as a Test ............................................................................... 55

3-4-3 Do a Test Binding and Check the Settings ........................................................ 56

3-4-4 Perform the Test Stitching ................................................................................. 59

3-5 Confirming the Status Settings ............................................................................... 60

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3-6 Start Binding .............................................................................................................. 62

3-7 Manual Feeding .......................................................................................................... 65

3-8 Saving, Loading and Deleting Jobs ......................................................................... 70

3-8-1 Saving a Job ...................................................................................................... 70

3-8-2 Loading a Job .................................................................................................... 71

3-8-3 Deleting a Job .................................................................................................... 73

3-9 Power Saving Mode ................................................................................................... 74

3-10Reversing the Stitcher Heads ................................................................................... 75

4 Adjustments

4-1 Stitch Adjustments ................................................................................................... 77

4-2 Infeed Section Adjustments ...................................................................................... 79

4-3 Jog Section Adjustments .......................................................................................... 81

4-4 Fold Section Adjustments ......................................................................................... 83

4-5 Fore-edge Trim Section Adjustments ...................................................................... 84

5 Troubleshooting

5-1 If an Icon Is Displayed on the Error Screen ............................................................. 87

5-1-1 If An Error Icon Is Displayed .............................................................................. 87

5-1-2 If a System Error Occurs ................................................................................... 90

5-2 Removing Jammed Sheets ....................................................................................... 99

5-3 Stitch-Related Problems ......................................................................................... 101

5-3-1 The Stitches Are Moved Parallel to the Fold Line ........................................... 101

5-3-2 The Distance Is Not Correct ........................................................................... 101

5-3-3 The Stitches Are Angled................................................................................. 101

5-3-4 The Stitch Position Varies............................................................................... 102

5-3-5 The Stitches Are Curved................................................................................. 102

5-3-6 There Are Problems With The Stitch Length.................................................. 102

5-3-7 The Sheets Are Not Stitched.......................................................................... 103

5-3-8 The Wire Jams................................................................................................ 103

5-3-9 The Shape of the Stitch is Incorrect................................................................ 104

5-4 Poor Sheet Arrangement ......................................................................................... 107

5-5 Folding-Related Problems ...................................................................................... 109

5-5-1 Fold Skewing.................................................................................................. 109

5-5-2 The Folding Position Varies............................................................................ 109

5-5-3 Failed to Fold at Correct Position ................................................................... 110

5-5-4 Jog Error Not Detected...................................................................................111

5-5-5 The Sheets Are Bent ...................................................................................... 111

5-6 Fore-edge Trimming-Related Problems ................................................................. 112

5-6-1 The Sheets Are Trimmed Incorrectly.............................................................. 112

5-6-2 Incorrect Trim Position.................................................................................... 112

5-7 Scratched Sheets ..................................................................................................... 113

5-8 Specific Symptom-Related Problems .................................................................... 114

5-8-1 The Buzzer Beeps at an Interval of Two Seconds.......................................... 114

5-8-2 Fine Adjustment from the Touch Panel Does Not Work................................. 114

5-8-3 The Delivery Conveyor Does Not Move ......................................................... 114

5-8-4 The Trim Is Not Collected (The pump does not operate) ................................ 114

5-8-5 The Touch Panel Does Not Light Up.............................................................. 115

5-8-6 A Stitcher Head is Jammed............................................................................115

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5-9 Other Problems ........................................................................................................ 116

5-9-1

The Booklets Overlap Each Other at the Delivery Conveyor though They are Offset.... 116

6 Maintenance

6-1 Loading Stitch Wire ................................................................................................ 117

6-2 Threading the Wire Through the Stitcher Head .................................................... 118

6-3 Attaching the Transport Pusher ............................................................................. 119

6-4 Lubrication ............................................................................................................... 120

6-4-1 Top and Bottom Guide Slide Shaft .................................................................. 120

6-4-2 Stitcher Vertical Slide Shaft ............................................................................. 120

6-4-3 Fold Knife Section ........................................................................................... 120

6-4-4 Stitcher Head ................................................................................................... 121

6-4-5 Clincher Drive Cam ......................................................................................... 121

6-5 Cleaning ....................................................................................................................122

6-5-1 Around the Stitcher Heads .............................................................................. 122

6-5-2 Transport Belts / Transport Rollers .................................................................. 122

6-5-3 Sensors ........................................................................................................... 123

6-6 Replacing the Fore-edge Trim Knife ...................................................................... 125

6-6-1 Upper Knife Replacement ............................................................................... 125

6-6-2 Lower Knife Replacement ............................................................................... 127

6-7 Clincher Point Replacement ................................................................................... 130

6-8 Guide Sheet Replacement ....................................................................................... 131

6-9 Stitcher Head Removal / Attachment ..................................................................... 132

6-9-1 Stitcher Head Removal .................................................................................... 132

6-9-2 Stitcher Head Attachment ................................................................................ 132

6-10Resetting the Circuit Breakers ............................................................................... 136

6-11Replacing the Fuses ................................................................................................ 137

7 Installation

7-1 Installing the Main Unit ............................................................................................ 139

7-2 Installing the Fore-edge Trim Section .................................................................... 141

7-3 Attaching the Accessories ...................................................................................... 143

7-4 Installing the Delivery Conveyor ............................................................................ 145

7-4-1 SC-200 Short Conveyor .................................................................................. 145

7-4-2 LC-200 Long Conveyor ................................................................................... 146

7-5 Connecting to an Upstream Device ....................................................................... 147

7-6 Checking ROM Versions of Connected Devices ................................................... 150

7-7 Connecting the Main Unit Power Cable ................................................................. 152

7-8 Setting the System Configuration .......................................................................... 153

7-9 Setting Up for Optional Devices ............................................................................. 154

7-10Synchronizing Between the Devices ..................................................................... 155

8 Options

8-1 Preset Kicker PK-30 ................................................................................................. 157

8-1-1 Installation of Preset Kicker ............................................................................. 157

8-1-2 Operation ......................................................................................................... 158

8-2 Paper Insertion Kit PN-200 ...................................................................................... 159

8-2-1 Operation ......................................................................................................... 159

8-2-2 Installation of Paper Insertion Kit ..................................................................... 161

8-3 Four Stitching Kit FST-200 ...................................................................................... 166

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8-3-1 Accessories for Four Stitching Kit................................................................... 166

8-3-2 Installation of Clincher ..................................................................................... 168

8-3-3 Installation of Stitcher Head ............................................................................. 169

8-3-4 Wire Attachment .............................................................................................. 171

8-3-5 Option Setup .................................................................................................... 173

8-3-6 Limitation for Use ............................................................................................. 174

8-4 Side/Corner Stitch Kit SSK-200/SSK-200L ............................................................ 175

8-4-1 Installation of Side/Corner Stitch Kit............................................................... 175

8-4-2 Option Setup................................................................................................... 178

8-5 Mis-stitch Detector SDS-200 ................................................................................... 179

8-5-1 Installation of Mis-stitch Detector ..................................................................... 179

8-5-2 Operation........................................................................................................182

8-6 Thickness Detector TD-200 ..................................................................................... 183

8-6-1 Installation of Thickness Detector .................................................................... 183

8-6-2 Calibrating the TD-200.................................................................................... 185

8-6-3 Operation ......................................................................................................... 187

8-7 Chip Extractor TB-200 ............................................................................................. 189

8-7-1 Operation ......................................................................................................... 189

8-7-2 Installation of Chip Extractor ............................................................................ 190

8-8 Loop Stitching .......................................................................................................... 192

8-8-1 Loop Stitcher Head Replacement .................................................................... 192

9 Appendix

9-1 Specifications ........................................................................................................... 195

9-1-1 SPF-200A....................................................................................................... 195

9-1-2 FC-200A ......................................................................................................... 198

9-1-3 SPF-200L........................................................................................................ 199

9-1-4 FC-200L.......................................................................................................... 203

9-2 Accessories .............................................................................................................. 204

9-2-1 SPF-200A/SPF-200L ....................................................................................... 204

9-2-2 FC-200A/FC-200L .......................................................................................... 206

9-2-3 IFU-200 ............................................................................................................ 207

9-3 Consumables ........................................................................................................... 208

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11119 10101A1

Front Transport Belt Gap Adjustment

Transport Belt Height Adjustment

Stopper Position

Fold Roller Gap

Jog Pusher

Fold Section Top and Bottom Guide Width

Fold Section Top and Bottom Guide Stroke

Forward Roller Position

Delivery Roller Position

Saddle Stitch Stopper Replacement

(Large / Small)

Saddle Stitch Stopper Position

Guide Bar Attachment

Transport Pusher Speed

Corner Stitch Guide Replacement

Top and Bottom Guide Width

Top and Bottom Guide Stroke

Jogging Frequency

Manual Feed Guide Width

Fore-edge Trim Section

Alignment for a Small Booklet

Buckle Gap Adjustment

Fold Skew Correction

Fold Knife Height Adjustment

Infeed Section Direction

Stitcher Head Drive Block Attachment

Stitch Angle

Stitch Distance

Stitch Length

1 Machine Description

This chapter explains how to use the automatic and manual settings, and describes the parts of the machine and their functions.

1-1 Automatic and Manual Settings

Automatic: This indicates a setting which is performed automatically to match the sheet size and

binding pattern. The setting can be changed using the touch panel.

Manual: This indicates a setting which is performed manually using a knob or lever.

Machine Description

Automatic and Manual Settings /

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11119 10201A1

Jog Section Cover

Fore-edge Trim Section Cover

Infeed Section Cover

Emergency Stop Button

Press

Release

Fold Section Cover

1-2-1

1-2 Machine Descriptions

Safety Device / Safety Functions

1-2-1 Safety Device / Safety Functions

The whole system stops when a safety cover is opened or the Emergency Stop bottom is pressed during operation.

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21102 10202A1

11119 10202D1

11119 10202B1

Fold Section

Connectors for Upstream Devices

2. The sheet is pushed up by the fold knife, then is caught in the fold roller and folded. Next the press rollers crease the folded sheet.

Power Switch

Control Panel

Refer to 1-2-10.

Horizontal Transport Section

The unfolded sheets are transported through this section.

Stitch Section Control Panel

1. The sheet is squared-up in the top-bottom and fore-edge directions before folding. (This happens if the top and bottom guide jog function is turned on.)

Infeed Section

The sheets are transported from this section to the jog section.

Manual Feed Section

The sheets can be manually fed when the stopper opens in this section.

Press Rollers

Fold Rollers

Fold Knife

Air Line from the Collator

Not Used

Signal Connectors for Collator

Signal Connector for IFU-200 Infeed Conveyor

Stitch Section

The sheets are stapled here.

11119 10202C1

Jog Section

The sheet is squared-up in the top-bottom and fore-edge direction before stitching.

Connectors for Downstream Device

Power Connector for Fore-edge Trim

Connector for Delivery Conveyor

Signal Connector for Fore-edge Trim Section

Arcnet Communication Connector

Optional IFU-200 Infeed Conveyor

The collated sheets are transported from the collator to the infeed section of the SPF-200A/200L.

1-2-2

1-2 Machine Descriptions

Overall Machine

1-2-2 Overall Machine

This explains how to use the system configuration including the optional IFU-200 infeed conveyor, FC200A/200L fore-edge trim section, and the SC-200 delivery conveyor.

11119 10202J1

Machine Description

Machine Descriptions /

11119 10202E1

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1-2 Machine Descriptions

Fore-edge Trim Section

The transport belts compress the booklets, and then the fore-edge of each booklet is trimmed.

Connectors for Downstream Devices

Connector for TB-200 Chip Extractor

Fore-edge Trim Section Control Panel

Transport Belt

Not Used

Hole for MKU54, MKU-54T or PST-40 Communication Cable

Delivery Conveyor (Option)

This illustration shows a short conveyor.

Connector for PK-30 Preset Kicker

Power Connector for Delivery Conveyor

Faulty Set Ejecting Section

A faulty set is ejected to the faulty set ejecting tray.

Good Set

Bad Set

Gate

Faulty Set Ejecting Tray

Trim Chute

The trim is ejected from this chute.

Not Used (for Short Circuit Connector)

1-2-2

Overall Machine

11119 10202H1

11119 10202G1

11119 10202I1

11119 10202F1

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1-2 Machine Descriptions

Manual Feed Stopper

Sheets can be fed manually if the stopper is lowered.

Manual Feed Sheet Sensor

This sensor detects any sheets placed on the manual feed table.

Manual Feed Guide

This guide can be set to match the width of the sheet being fed.

Guide Position Scale

Sheet Sensor

This sensor detects a sheet as it feeds from the collator and triggers the manual feed.

Upper Transport Section Lifting Handle

1-2-3 Manual Feed / Infeed Conveyor Section

1-2-3

Manual Feed / Infeed Conveyor Section

Machine Description

11119 10203A1

Machine Descriptions /

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1-2 Machine Descriptions

Infeed Section Direction Adjusting Knob

There are five possible settings. To make an adjustment, pull the knob and turn it.

Sheet Length

Short Long

Knob Position

Infeed Direction

In the ideal setting, the sheet is directed toward the corner of the stopper.

11119

11119 10204B1

Low

Middle

High (Horizontal)

Weights

The transport roller pressure can be adjusted by changing the positions of these weights. To move a weight, turn the top to loosen it.

Hold-down Guides

These guides help to control sheets which are bent or rolled.

Fore-edge Jog Plate

This squares up the sheet in the foreedge direction.

Jam Sensor

Sheet Holder

If the tail of the sheet remains at the exit of the infeed section and is not transported completely, the sheet can be pushed to the belt using this holder. (If the holder pushes too strongly, the sheet may be scratched.)

1-2-4 Infeed Section

1-2-4

Infeed Section

11119 10204F1

11119 10204G1

11119 10204A1

11119 10204E1

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11119 10204D1

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1-2 Machine Descriptions

21102 10205A1

Transport Pusher for

Paper Insertion (Option)

Transport Pusher

This pusher transports the flat sheet when it is inserted into the center page of a stitched booklet.

The sheet is pushed and transported by this pusher. The pusher may be removed if there are paper jams. (Remember to re-install the pusher for normal setups.)

The waiting position for the transport pusher can be adjusted using the touch panel screen. Refer to page 25 for details.

11119 10205C1

Saddle Stitch Stopper

Install large or small stoppers to match the sheet width. (The instruction screen is displayed on the touch panel.)

Side Stitch Stopper

This stopper is used for side stitching and corner stitching.

Top and Bottom Guides

- These guides jog the sheets from the top and bottom sides before stitching.

- The settings listed below can be done using the touch panel.

- Jogging frequency before stitching

- Stroke (Guide opening when the sheet comes in)

- Delivery Stroke (Guide opening when the sheet

goes out)

- When you are doing corner stitching, these guides are replaced by the corner stitch guide.

- This guide assembly consists of three parts. When you are running small booklets, you may have to remove these guides. (The instruction screen is displayed on the touch panel.)

Side Stitch Sheet Hold-Down Plate

This plate prevents the sheets from floating. Long type and short plates are available.

Guide Bar

This bar prevents the sheets from being bent down. You must remove this bar before doing a changeover. (The instruction screen is displayed on the touch panel.)

Parallel Adjusting Bolt

This bolt is used as a gauge to adjust the top-bottom guide so that it is parallel.

1-2-5 Jog Section

11119 10205B1

1-2-5

Jog Section

Machine Description

Machine Descriptions /

11119 10205D1

11119 10205E1

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1-2 Machine Descriptions

11119 10206D1

Wire Feeding Detection Sensor

As the wire is feeding, the wire guide bends down and immediately returns to its original position. This sensor watches the movement of the wire guide to see that the wire is feeding properly. The sensor is turned on (red LED lights) when the wire guide is bent down.

Clincher Lever

This allows you to remove a stitch which remains in the clincher section.

Stitcher Head Drive Block

When one of these blocks is removed, the machine does not make stitches on that side. The block on the non-stitched side should be removed when you are doing corner stitching. (The instruction screen is displayed on the touch panel.)

Coil Brake

This brake prevents the coil from turning too easily and tangling the wire. If the brake is pressed harder against the coil, it becomes harder to turn the coil.

Stitch Angle Adjusting Knob

The stitch angle can be adjusted using this knob if one stitch is not lined up.

Wire Coil

Standard wire is No.25 (0.5 mm in diameter) Optional wire No.26 (0.45 mm in diameter) is available.

Wire Guide

Red LED This lamp lights when the sensor detects the wire guide.

There are circuit breakers inside this cover. See Section 6-10.

These holes allow for installation of two optional stitcher heads. The positions of these two stitchers are fixed.

Sheet Holder

This holder prevents the sheet from floating. Long, short, and side stitching holders are available. Select the holder to match the binding pattern and sheet size. To change the holder, loosen the locking knob. Set the position of the holder to match the thickness of the booklet.

Locking Knob

1-2-6 Stitch Section

The operation of the stitcher head is explained in Section 4-1.

Stitch Section

11119 10206C1

1-2-6

11119 10206A1

11119 10206B1

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1-2 Machine Descriptions

Fold Knife Height Adjusting Knob

The fold knife lifts when you turn this knob clockwise. (If you lift the fold knife too far, it may hit the fold roller.)

Press Rollers

These rollers compress the booklets.

Fold Rollers

The gap between the rollers is automatically set to match the booklet thickness entered on the touch panel.

Fold Section Top and Bottom Guides

-These guides jog the sheets before folding.

-The settings listed below can be done using the touch panel.

- Distance between guides when jogging sheets

- Stroke (Guide opening when the sheet comes in)

- Delivery stroke (Guide opening when the sheet goes out)

Fold Section Jog Pushers

-These pushers jog the sheets before folding.

-The positions of these pushers when jogging the sheets can be adjusted on the touch panel. (Refer to 1-3-7.)

Sheet Hold-Down Plate

These plates prevent the sheets from floating.

Sheet Guide Locking Knobs

If sheets jam between the fold rollers and press rollers, remove the sheet guide by loosening these knobs.

Fold Skew Correction Knob

As shown in the illustration, any fold skewing can be corrected by turning this knob clockwise.

Buckle Gap Adjusting Knob

The buckle gap can be adjusted in three levels to match the sheet thickness.

The fold section stopper can be reached by opening this cover.

Press the Emergency Stop button before turning the handwheel. A sudden accidental start of the machine can cause severe personal injury.

WARNING

Do not open this cover while the machine is running. Otherwise, moving parts can cause severe personal injury.

WARNING

Forward Rollers

These rollers transport the sheets to the fold section and prevent the sheets from bouncing.

Handwheel

The fold roller and press rollers can be turned by hand for cleaning.

1-2-7 Fold Section

1-2-7

Fold Section

11119 10207B1

11119 10207A1

Machine Description

Machine Descriptions /

11119 10207F1

11119 10207E1

11119 10207D1

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1-2 Machine Descriptions

11119 10208A1

Booklet Stopper

This stopper is automatically set to match the finishing size of the booklet.

Transport Belts

The sheet is transported by these belts. The gap between the upper and lower belts is automatically set up to match the book thickness entered on the touch panel.

Locking Lever

Front Transport Belt Height Adjusting Knob

If the booklets do not move correctly, adjust this knob. To reduce the gap at the front of the transport belts, loosen the locking lever and turn the knob clockwise.

Jam Sensor

Trim Knife (Upper Knife)

Infeed Belts

These belts move the sheet into the foreedge trim section.

Fore-edge Trim Section Locking Lever

If you are trimming small booklets (smaller than B5), the booklet may not move correctly if the pressure is different at the front and rear transport belts.

Transport Belt

Lift the locking lever up and move the fore-edge trim mechanism to the front.

When the fore-edge trim mechanism is moved to the front, the stopper holds the far side of the booklet, and the booklet should stop straight against the stopper. (The instruction screen for this is displayed on the touch panel when binding sheets smaller than B5.)

Position for Small Booklet

Normal Position

Stopper

1-2-8 Fore-edge Trim Section

1-2-8

Fore-edge Trim Section

11119 10208B1

11119 10208C1

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1-2 Machine Descriptions

11119 10209A1

Faulty Set Ejecting Gate

If the machine detects a faulty set, this gate moves and the faulty set is delivered to the faulty set ejecting tray.

Delivery Conveyor

When a booklet is delivered, the belts move for a moment. The running time for the belts can be set on the touch panel.

Delivery Rollers

These rollers hold the delivered booklet. These rollers should be placed about 30 mm (1.2") from the end of the booklet.

Locking Knob

Jog Button

The conveyor belts move when this button is pressed.

Faulty Set Ejecting Tray

When the faulty set eject function is activated on the touch panel, faulty sets are delivered to this tray. The possible causes of faulty sets are:

- Mis-feed / double feed / Jam in upstream device

- Fold section jog error

- Missed stitch detection (option)

- Fore-edge trim section thickness detection (option) If the operation starts with a sheet remaining in the machine,

the sheet is delivered to this tray.

Trim Chute

The trim is ejected through this chute.

Trim Full Sensor

This sensor detects the trim full error.

Mirror

1-2-9 Delivery Conveyor

1-2-9

Delivery Conveyor

Machine Description

Machine Descriptions /

Page 20

1-2 Machine Descriptions

11119 10210C1

Fore-edge Trim Section Power LED

Trim Knife Reverse Jog Button

When this button is pressed and held, the trim knife operates once and then stops at the top position. If the knife is locked, the trim knife can be returned to the top position using this button.

When some screens are displayed on the touch screen, these buttons will not work.

Stop Button

This button stops the binding operation. Feeding from the upstream device stops when this button is pressed. All booklets in-process are delivered, and the transport rollers keep moving. When this button is pressed again, the machine stops completely.

Main Machine Power LED

This LED lights when the power switch is turned On. The LED blinks if the machine is using the power saving mode.

Transport Belt Inching Button

The transport belt at the fore-edge trim section drives only while this button is pressed.

Start Button

This button starts the binding operation. If there are sheets remaining inside the machine, they will be ejected. While this is happening, the button blinks. When the machine is ready, the button lights and feeding from the upstream device (collator) starts.

Machine Jog Button

This jogs the jog section and the fold section. Jogging is stopped when this button is pressed again. This button will work even if a cover is opened.

Stitch Jog Button

Operating the stitcher heads in the normal direction Press and hold this button to make one stitch in the normal direction while the cover is closed and the Emergency Stop button is not pressed.

Reversing the stitcher heads The stitcher heads will return to the original position by reverse movement if you press this button while pressing the Machine Jog button when the cover is closed and the Emergency Stop button is not pressed. See page 75 for details.

Releasing the top and bottom guides The top and bottom guides move outward if this button is pressed while the cover is opened or the Emergency Stop button is pressed. Any sheets remaining at the jog section can be removed easily. (The top and bottom guide returns to its setting position when the jog button is pressed.)

When the power is first turned on, these buttons will not work until the first changeover has been done.

1-2-10 Control Panel

11119 10210B1

1-2-10

Control Panel

11119 10210A1

11119 10210D1

Page 21

1-3 Screen Descriptions

21102 10301A1

- After the power is turned on, the Initial Screen and Binding Pattern Screen are displayed.

- The binding pattern can be selected on this screen. Press one of the icons, and the Sheet Size screen shown below is displayed.

If the SSK-200A or the SSK-200L has been selected on the Administrator Mode-Option Screen, these icons are active.

Binding Pattern Screen

21102 10302A1

21102 10302B1

Sheet Size-Saddle Stitch Screen

Sheet Size-Side Stitch Screen

The dimensions are entered in steps of 0.1 mm (0.005").

Sheet Size

Press one of these buttons for standard size sheets, and the dimensions are entered automatically.

Press this button after entering the sheet size.

The Finishing Size screen (next page) is displayed.

Booklet Thickness

Measure the thickness using a caliper (accessory), and enter the value. The allowable range is 0.1mm (0.005") to 4.0mm (0.155”).

This icon blinks if the HOF-20/30 connected upstream of the SPF-200A/200L has a problem.

= No changeover is performed and the

Binding screen is displayed.

= Each section returns to its home

position and then starts the changeover.

= The machine starts the changeover with

going to the home positions.

The actual positions of the guides and stoppers may be different from the set positions. If there is a problem with the binding quality, send all of the parts to the home positions before doing the changeover.

1-3-1 Setting-Binding Pattern Screen

1-3-1

Setting-Binding Pattern Screen

Machine Description

1-3-2 Setting-Sheet Size Screen

Screen Descriptions /

Page 22

1-3 Screen Descriptions

Stitch Distance

For Saddle Stitching The “stitch distance” is the distance between the centers of the stitches. Set the stitch distance as listed below:

When top and bottom distance is 185mm (7.285") or more

- 79.1 to 92.0 (mm)

- 138.0 to 150.9 (mm)

- 234.0 to 246.0 (mm)

- 3.860” to 5.905”

If the top-to-bottom distance is less than 185mm (7.285")

- 79.1 to 80.9 (mm)

If the stitch distance is adjusted outside this range, skewing may occur because the stitch hits the fold knife, or the crooked trimming may occur because the stitch hits the booklet stopper. If a value outside the normal range is entered, the value is shown in red and the

caution icons( ) are displayed.

On a machine set to measure in inches, you must set the stitch distance carefully so that the stitches do not hit the fold knife or booklet stopper.

Stitch distance so that the stitch does not hit the fold knife

- 3.860” to 5.905”

Stitch distance so that the stitch does not hit the booklet stopper

- 3.115” to 3.185”

21102 10303A1

Finishing Size-Saddle Stitch Screen

Finishing Size

Press one of these buttons for standard size sheets, and the dimensions are entered automatically.

Stitch Type

Select a stitch type from one of the five styles. Depending on the sheet size, some stitch types may not be available.

Press this button to do fore-edge trimming.

This icon blinks if the HOF-20/30 connected upstream of the SPF200A/200L has a problem.

Booklet Thickness

Measure the thickness using a caliper (accessory), and enter the value. The allowable range is 0.1mm (0.005") to 4.0mm (0.155”).

The fold roller gap and the height of the fore-edge transport belts are adjusted automatically to match this value.

Top-to-Bottom Distance

= Flat Stitch = Loop Stitch

= No changeover is performed and the

Binding screen is displayed.

= Each mechanism returns to the home

position and then starts the changeover.

= The machine starts the changeover without

sending the parts to the home positions.

1-3-3 Setting-Finishing Size Screen

Setting-Finishing Size Screen

11119 10303B1

1-3-3

11119 10303C1

Page 23

1-3 Screen Descriptions

Instruction-Remove Screen

11119 10304E1

Instruction-Attachment Screen

11119 10304B1

There is no instruction screen for the guide bar attachment. Attach the guide bars if necessary.

11119 10304C1

1-3-4 Setting-Instruction Screen

1-3-4

Setting-Instruction Screen

If you press , the following instruction screens appear:

11119 10304A1

Remove the upper and lower parts for the top and bottom guides.

The following screens are displayed after the changeover.

Machine Description

Attach the upper and lower parts for the top and bottom guides.

Screen Descriptions /

Remove the guide bars.

Replace the large saddle stitch stopper with the small one.

11119 10304F1

Replace the small saddle stitch stopper with the large one.

Page 24

1-3 Screen Descriptions

11119 10304J1

1-3-4

Setting-Instruction Screen

If you press , the following instruction screens appear:

11119 10304D1

Remove two stitcher head assemblies, including the mounting block and the clincher inside.

(Four stitch Two stitch)

The following screens below are displayed after the changeover.

11119 10304G1

Attach two stitcher head assemblies, including the mounting block and the clincher inside.

(Two stitch Four stitch)

Remove the sheet hold-down plates in the fold section.

11119 10304H1

Move the fore-edge trim section to the front (for small sheets).

11119 10304I1

Move the fore-edge trim section back (for normal or large sheets).

Page 25

1-3 Screen Descriptions

1-3-4

Setting-Instruction Screen

If you press , the following instruction screens appear:

11119 10304K1

The following screens below are displayed after

the changeover.

Remove the stitch detection sensor. Install the stitch detection sensor.

11119 10304L1

Machine Description

Screen Descriptions /

Page 26

11119 10305F1

11119 10305L1

11119 10305M1

1-3-4

1-3 Screen Descriptions

Setting-Instruction Screen

If corner stitching has just been selected, or if you are stopping corner stitching and using another binding pattern, the following instruction screens are displayed. (Corner stitching is an option.)

11119 10305G1

Replace the rear top and bottom guides with the corner stitch guides.

11119 10305H1

Replace the front top and bottom guide with the corner stitch guides.

Remove the front stitcher head drive block.

11119 10305I1

Remove the rear stitcher head drive block.

11119 10305J1

Replace the front corner stitch guide with the top and bottom guides.

Replace the rear corner stitch guide to the top and bottom guide.

11119 10305K1

Attach the rear stitcher head drive block.

Attach the front stitcher head drive block.

Page 27

1-3 Screen Descriptions

11119 10305N1

21102 10305Q1

Stitcher Head Position Confirmation Screen

If the stitch heads are positioned in the hollow area of the corner stitch guide:

Setting Confirmation Screen

Automatically deactivated functions due to the selected sheet size are displayed here.

Hollow Area Under Corner Stitch Guide

If the stitch heads are positioned outside the hollow area of the corner stitch guide:

This screen confirms the stitcher head position. Check the position of the stitcher head in relation to the corner stitch guide.

If the stitcher head is positioned in the hollow area of the corner stitch guide, the stitcher head can interfere with the guide during changeover. This screen appears to prevent the stitcher head from hitting with corner stitch guide.

1-3-5 Setting-Confirmation Screen

1-3-5

Setting-Confirmation Screen

11119 10305R1

Machine Description

Screen Descriptions /

11119 10305O1

11119 10305P1

Page 28

1-3 Screen Descriptions

Operation Screen

Job Information

The job name and the job number are displayed after the job is saved.

Upstream/Downstream Device Information

= The SPF-200A/200L or FC-200A/200L has a problem.

Press to learn about the problem.

= The collator has a problem.

= A downstream device has a problem.

= Trim Full

If the binding operation continues for one more minute, feeding stops.

Total Count

- The total binding count is displayed here. The total count does not clear even when the power is turned Off. To clear the total count, press .

Batch Count

- When delivered booklets are offset, the number of batch is displayed here. To clear the batch count, press .

Production Speed (book per hour.)

- Maximum production speed differs depending on the binding type, sheet size, and the status settings. When the production speed is changed using the or , the feeding speed from the upstream device will adjust automatically.

Delivery Conveyor Offset settings

= The booklets are delivered straight without offsetting.

= The last booklet is offset when the count reaches a preset number.

（This icon is available only if the optional PK-30 Kicker is connected.）

= The booklets are offset by changing the speed of the delivery conveyor.

=The current number of booklets / The preset number of booklets per batch (Available range: 1 to 99)

See Next Page

1-3-6 Binding-Operation Screen

1-3-6

Binding-Operation Screen

21102 10306A1

Page 29

1-3 Screen Descriptions

21102 10305D1

Operation Screen

= Only manual feeding

= Using the HMU (Hand Marry Unit on the collator)

= Feeding starts from the collator after sheets are loaded

into the manual feed section.

= Feeding the sheets manually to match the feed

from the collator.

= When feeding the sheet manually under the sheets fed

from the collator.

This button is available only if the SPF-200A/200L is operated using the pXnet system.

Jog Button Press once to jog the sheets using the guides. Press again to deactivate jogging.

This mode is used to reduce power consumption when the machine will not be operated for a long time.

This button is used to do the test binding step by step. When this button is pressed, the Binding-Fine Adjust screen is displayed and one sheet is transported to the jog section.

Status Indication Screen

After you press the button for the setting to be changed, the BindingStatus Setting screen is displayed.

Return to the Operation screen.

pXnet Screen

The total binding count and the numbers of the remaining sets at starting or restarting are displayed.

Enter the number if you are changing the operator.

Press this button to pause the current job and start another job.

Press this button when the job is complete.

Place a sheet which is the same size as the current setting under the

stitcher head, and press

The sheet will be stitched the preset number of times.

Available Range:3 to 30

Power Saving Mode Confirmation Screen

The touch panel turns off and the machine enters the power saving mode. When you touch the screen, the Setting screen is displayed, and the machine returns from the power saving mode. Do a changeover.

When the machine returns from the power saving mode, changeover is required. Save the job before entering the power saving mode.

Error screen is displayed.

One booklet is produced as a test.

Stitching Test Screen

One booklet is produced without trimming as a test.

Enter the number of faulty sets.

The job name is displayed.

21102 10305A1

Binding-Operation Screen

21102 10305B1

1-3-6

Machine Description

Screen Descriptions /

21102 10305C1

21102 10305E1

Page 30

1-3 Screen Descriptions

11119 10307E1

Fine Adjust-Stitch Section Screen

The sheets are stitched the set number of times.

The sheets are fed to the jog section.

Press once to jog the sheets.

The sheets are transported to the fold section.

These areas can be changed when sheets are being jogged.

Body fore/back position: (-10.0 to +10.0mm) (-0.400 to 0.400")

Press to stitch once.

Distance between jog plate and the stopper: (-10.0 to +10.0mm)(-0.400 to 0.400")

Top and bottom guide width: (-10.0 to +10.0mm) (-0.400” to 0.400")

Stitch position: (-10.0 to +10.0mm)(-0.400 to 0.400"

Stitch distance: (-10.0 to +10.0mm)(-0.400 to 0.400")

Distance between fold knife and the stopper: (-10.0 to +10.0mm) (-0.400 to 0.400")

The parts move together so that the distance between the stopper and the jog pusher does not change.

Distance between fold roller and the jog pusher: (-10.0 to +10.0mm) (-0.400 to

0.400")

Distance between fold knife and the forward roller: (-10.0 to +10.0mm)(-0.400 to 0.400")

Maximum Fine Adjust Value =

4.0mm (0.15")-(booklet thickness)

Booklet Thickness

Fold Position (Knife)

Fine Adjust-Fold Section Screen

These areas can be changed when sheets are being jogged.

The sheets are fed to the fold section.

Press once to jog the sheets.

Transport the sheets to the next process.

The Fine Adjust- Punch Section Screen is described in the user's manual of the HP-200A hole punch unit.

The status setting of "fold section jog direction" has influence on this area.

If the sheets are jogged by the jog pusher and the top and bottom guides:

This area can be changed only when sheets are being jogged.

If the sheets are jogged only by the jog pusher:

This area always cannot be changed.

The status setting of "forward roller movement" has influence on this area.

If the sheets are jogged while being pushed by the forward rollers:

This area can be changed whether the sheets are being jogged or not.

If the forward rollers move away from the sheets when the sheets are being jogged:

This area can be changed only when the sheets are not being jogged.

1-3-7 Binding-Fine Adjust Screen

21102 10307A1

11119 10307D1

1-3-7

Binding-Fine Adjust Screen

21102 10307B1

11119 10307F1

11119 10307G1

Page 31

1-3 Screen Descriptions

21102 10307C1

11119 10307I1

Transport Belt Height Maximum fine adjust value: 7.0mm (0.275")(booklet thickness)

Finishing fore-edge dimension: (-10.0 to +10.0) (-0.400” to 0.400”) The default setting for the trim width is 3mm (0.125").

Feed the sheets to the fore-edge trim section.

Lower the transport belts.

Trim once.

Press this button to deliver the sheets.

Fine Adjust-Fore-edge Trim Section Screen

This area can be changed when the transport belts are raised.

1-3-7

Binding-Fine Adjust Screen

11119 10307H1

Machine Description

Screen Descriptions /

Page 32

1-3 Screen Descriptions

This button is used to match (decrease)

the speed of the trim section with the stitch section and prevent a booklet from being pulled while delivery when using single sheet or performing the job with folding only.

21102 10308A1

Collator/Faulty Set Detect/Manual Feed/Stitch Screen

- Normally use .

- If there is just a small amount of wire left, the sensor may keep deactivating even though the wire is being fed correctly. If this happens, select .

1-3-8 Binding-Status Setting Screen

Items marked like this are default settings.

Transport Speed

This indicates the operating speed of the belt or roller. It can be adjusted in six steps.

VAC Support Guide

(Used for sheets with a width smaller than 148 mm (5.83”).)

= Guide is not used.

= Guide is used. This can be selected when sheet

width is 230 mm (9.05”) or smaller.

Faulty Set Ejection

= Faulty Set Ejection Off

1-3-8

Binding-Status Setting Screen

= Faulty Set Ejection On (When an error

occurs in the upstream device, booklets are delivered to the mis-feed tray without trim.)

Wire Feeding Detection

This function is used to watch that the wire is fed correctly.

= Off

= An error is detected if the sensor is activated for a set time.

= An error is detected if the sensor is active or not active for

longer than the specified time.

Manual Feed Setting

= No manual feeding

= Only manual feeding

= Using the HMU (Hand Marry Unit on the collator). This function cannot be selected from the screen.It must

be selected by using the switch on the HMU.

= Feeding starts from the collator after sheets are loaded in the manual feed section. (Production speed:

Slow)

= Use when feeding the sheet manually to match the feeding from the collator. (Production speed: Fast)

= Use when feeding the sheet manually under the sheets fed from the collator.

Page 33

1-3 Screen Descriptions

21102 10308H1

Collator/Faulty Set Detect/Manual Feed/Stitch Screen

Items marked like this are default settings.

1-3-8

Binding-Status Setting Screen

Stitch Section Jogging Frequency

This indicates the number of jogs done before stitching. Press if the sheets are not squared up.

(This will slow down the production speed.)

Stitch Delay Time

This indicates the delay from the moment the sheets are transported from the jog section until the sheets are stitched.

Transport Pusher Speed

Slow the speed of the transport pusher if the booklets bend between the jog section and the fold section.

Transport Pusher Waiting Position

- The adjustable range is from -50 to +40mm (-1.97" to +1.58".)

- If the transport pusher for paper inserter does not catch the sheet, adjust the waiting position using

Stitch Section Top and Bottom Guide Stroke

- This sets the opening between the top and bottom guides when the sheets enter.

- The default setting is 3.0 mm (0.120").

- This is adjustable within 1.0 to 6.0 mm (0.050" to

0.200").

Machine Description

Screen Descriptions /

Stitch Section Top and Bottom Guide Delivery Stroke

- This indicates the opening between the top and bottom guides while the sheets are being delivered from the jog section.

- The default setting is 0.5 mm (0.025").

- This is adjustable within 0.5 to 2.0 mm (0.025" to 0.080").

=The guides open for the guide delivery stroke when the sheets are delivered. This ensures stable delivery

although the highest production speed is not available.

=The guides open for the normal guide stroke when the sheets are delivered.The delivered sheets may not

move correctly.

Page 34

1-3 Screen Descriptions

Fold/Fore-edge Trim/Conveyor Screen

Fold Section Top and Bottom Guide Delivery Stroke

- This indicates the opening between the top and bottom guides while the sheets are being delivered.

- The default setting is 1 mm (0.040").

- This is adjustable within 0.5 to 3.0mm (0.025" to

0.100").

Fold/Fore-edge Trim/Conveyor Screen

Items marked this way are default settings.

Fold Section Jog Direction

= The

sheets are jogged

top and bottom guides.

= The

sheets are jogged only by the jog pusher.

Using the default setting, the sheets are jogged only by the jog pusher. If you are doing folding only, or using the paper insertion function, you must jog using the top and bottom guides.

Fold Section Jogging Frequency

If you are only doing folding and the sheets are not arranged correctly, press .

Fold Delay Time

delay from the moment the sheets are transported to the fold section until the sheets are jogged and folded.

by the jog pusher and the

1-3-8

Binding-Status Setting Screen

Fold Section Top and Bottom Guide Stroke

- This indicates the opening between the top and bottom guides while the sheets are being fed.

- The default setting is 3.0mm (0.120").

- This is adjustable within 1.0 to 6.0mm (0.050" to 0.200").

When Stitch Section Top and Bottom Guide Delivery Stroke is On

If you set this value smaller than the stitch section top and bottom guide

delivery stroke, its value is also reduced.

When Stitch Section Top and Bottom Guide Delivery Stroke is Off

If you set this value smaller than the stitch section top and bottom guide

stroke, its value is also reduced.

Fold Section Jog Pusher Stroke

- This indicates the opening width of the jog pusher while

the sheets are being fed.

- The default setting is 5.0 mm (0.260").

- This is adjustable within 2.0 to 10.0mm (0.075" to 0.400").

21102 10308C1

Forward Roller Movement

The movement of the forward rollers while the sheets are being jogged can be selected.

= The sheets are jogged while being pushed

by the forward rollers.

= The forward rollers move away from the sheets

when the sheets are being jogged. When using thin sheets, they may be bent by the forward roller and the jog error may not be detected correctly. If this happens, use this button.

Delivery Conveyor Run Distance for Offset Function

- When you use the offset function, this indicates how long

the conveyor runs between the last booklet in one batch and the first one in the next batch.

- If the first booklet in the one batch slips inside the last one in

the previous batch, press to increase the run distance.

21102 10308G1

11119 10308F1

Fore-edge Trim Delay Time

- This indicates the delay from the moment the sheets reach the fore edge trim stopper until the sheets are trimmed.

- Press to increase the pause time.

Delivery Conveyor Run Distance

- This indicates how long the conveyor runs after a booklet is delivered.

- Press to increase the run time.

Page 35

1-3 Screen Descriptions

21102 10308D1

Option Screen

Return to the initial setting.

Items marked this way are default settings.

Stitch Detection

This function detects if the stitching has been done correctly. It can be selected only if the optional SDS-200 is connected.

1-3-8

Binding-Status Setting Screen

Paper Insertion

This selects whether the paper insertion function is used. It can be selected only if the optional PN-200 Paper Inserter is installed.

= Off

= On

= Function not used

= Function used

Machine Description

Screen Descriptions /

21102 10308i1

21102 10308E1

FC Booklet Thickness Detection

Faulty set is detected by measuring the booklet thickness in the fore-edge trim section. These buttons are active only if the optional TD-200 is connected.

= Off

= On

Sensitivity Low High

Chip Extractor

This sets whether the optional TB-200 Chip Extractor is used. These buttons are active only if the TB-200 is connected.

= Not Used

= Used

Page 36

1-3 Screen Descriptions

Job No. Input

Enter the number of the job to be displayed using the numeric keypad screen which appears when this is pressed. (Job no.01 to

200)

Save Confirmation Screen

Keyboard Screen

Save

This saves the current machine settings under the selected job number.

= This uses the stan-

dard typewriter keyboard layout.

= The keys are laid

out in alphabetical order.

Display Window Up to 19 letters can be entered.

= The job is saved and the Memory-

Main screen is displayed.

= The Memory-Main screen is displayed

without saving the settings.

Detailed Information Screen Delete Confirmation Screen

Load Confirmation Screen

1-3-9 Memory Screen

21102 10309A1

1-3-9

Memory Screen

The detailed information for the selected job is displayed.

21102 10309B1

Scroll Buttons

= Screen Scrolling (5 previous jobs)

= Scrolling (up)

= Scrolling (down)

BOOK

Book

21102 10309C1

Screen Scrolling (5 following jobs)

Delete

The selected job is deleted. (* Once deleted, the job cannot be recalled.)

21102 10309F1

= The job is deleted and the Memory-

Main screen is displayed.

= The Memory-Main screen is displayed

without deleting the job.

Load

The selected job is loaded.

21102 10309D1

21102 10309E1

= The Setting-Finishing Size screen is

displayed. Do the changeover.

= The Memory-Main screen is displayed

without loading the job.

Page 37

1-3 Screen Descriptions

21102 10310A1

Information-Main Screen

Password Input Screen

Administrator Mode Screen

A Password is required to display this screen.

Enter the password and then press

See [1-3-12]

This button is used by the service person only.

See next page.

This is the total binding count since the machine was shipped.

This counter can be cleared in the Administrator Mode. Use the counter as a guide for trim knife replacement.

This is the total trim count since the machine was shipped.

21102 10310D1

System Error Code

The last eight errors are shown on the page, and a total of 24 errors are recorded.

This shows the system configuration and any optional devices which are installed with the SPF-200A/200L. These settings can be changed in the Administrator Mode.

1-3-10 Information-Main Screen

1-3-10

Information-Main Screen

11119 10310F1

Machine Description

= Counter

= Error History = System Configuration /Option

21102 10310B1

= Software Version/Serial Number

21102 10310C1

Screen Descriptions /

21102 10310E1

Page 38

1-3 Screen Descriptions

Each section of the machine can be operated separately using these screens.

2110110311H1

Stepper Motor Lock Release

If the is displayed you can move each guide and stopper by hand.

The input condition of each sensor signal can be monitored using these screens.

= Sensor is inactive (Off).

= Sensor is active (on).

2110210311E1

2110210311D1

Stepper Motor Lock Release

If the is displayed you can move each guide and stopper by hand.

Information-Monitor/Single Operation Screen

1-3-11 Information-Monitor/Single Operation Screen

= Single Operation

21102 10311A1

1-3-11

= Monitor

2110210311F1

2110210311G1

2110210311B1

2110210311C1

Page 39

1-3 Screen Descriptions

21102 10312A1

21102 10312D1

21102 10312E1

21102 10312F1

Administrator Mode Screen

= Page 32

= Next page

Power Saving Mode

When is selected, enter the time until the machine goes over to a power saving mode. (The possible delay range is 1 to 120 min.) If the machine is not operated within the delay period, it automatically switches to the power saving mode.

Press to clear the counter.

Administrator-Password Screen

Press after the password is entered.

Trim Count

The same trim count as on the Information-Counter screen is displayed here.

Information-Counter Screen

Wire Feeding Detection

= An error is triggered

if the sensor has been activated even though the stitching has been done for the correct number of times.

= An error is triggered if

the sensor is not activated even though the stitching has been done for the correct number of times.

OFF

The top and bottom guides open and release.

The guides return to the set positions.

Stitch Section Top and Bottom

Guide Adjustment

This screen is used to ensure that the top and bottom guides are parallel.

1-3-12 Information-Administrator Screen

1-3-12

Information-Administrator Screen

11119 10312B1

21102 10312C1

Machine Description

Screen Descriptions /

Page 40

1-3 Screen Descriptions

21102 10312G1

21102 10312I1

Enter the correction or offset value here. To increase the correction, use a larger number

The values entered on the current fine adjustment screen are displayed here.

This corrects the home position value so that the fine adjustment value becomes zero.

This corrects the home position values so that the all fine adjustment values become zero.

= Home Position Calibration

= Input Signal ON/Off

If one of the motors or sensors stops working, the binding operation can be continued by turning off the broken motor or sensor. If you want to turn off one of these motors, contact a service technician for detailed instructions.

= The selected motor or

sensor is included in the control circuit.

= The selected motor or

sensor is taken out of the control circuit and will not operate.

The binding quality may not be reliable if you turn off one of the motors or sensors.

If you find yourself making the same fine adjustment every time, the home position can be calibrated so that no adjustment is required. This is available only when saddle stitch is selected.

Information-Administrator Screen

21102 10312H1

1-3-12

21102 10312M1

21102 10312J1

Page 41

1-3 Screen Descriptions

21102 10312N1

21102 10312S1

System Configuration

Use this to select the upstream/downstream devices connected to the SPF200A/200L.

= Option

Use this to selected the optional devices installed with the SPF-200A/200L.

SSK-200A /SSK-200L

SDS-200

PN-200

FST-200

PK-30

TD-200

TB-200

Horizontal Transport

Mis-stitch Detector

Paper Inserter

Four Stitching Kit

Preset Kicker

FC Booklet Thickness Detector

Chip Extractor

1-3-12

Information-Administrator Screen

21102 10312T1

Machine Description

21102 10312R1

Screen Descriptions /

Page 42

1-3 Screen Descriptions

= A jog error has occurred in the fold section.

= The feed interval between the booklets is too short,

and the booklets are not trimmed correctly.

= The transport belt speed in the FC-200A/200L is

slower than the belt speed in the upstream device.

= The communication network has a problem.

= An error has occurred in a device downstream of

the FC-200A/200L.

= The faulty Set ejecting tray is full.

= A wire feeding error has occurred in the stitch sec-

tion.

= A faulty set cannot be ejected to the faulty set eject-

ing tray.

= Jog section top and bottom guide or transport

pusher overload.

= The trim chute is full.

= The stitcher head is not at the correct position.

Option

= The front wire is not stitched.

= The rear wire is not stitched.

= A booklet thickness error has been detected in the

fore-edge trimmer.

Go to the Binding-Operation screen

This icon is displayed if a system error occurs.

An error code is displayed here if an error occurs during the binding operation and the machine stops.

If a faulty set is ejected to the faulty set ejection tray, an error icon is displayed here.

Error Icon

= A cover is open.

= An Emergency Stop button is pressed.

= A sheet jam has occurred.

= An upstream device has a problem.

= No sheets are arrived in the machine within 10

seconds after the binding operation started.

= The sheets needed for manual feeding are not in

position.

= There is a communication error with an upstream

device.

1-3-13 Error Screen

This section explains the function of the error screen and how to interpret the error icons. See Section 5-1-1 for instructions on recovery after an error.

11119 10313A1

1-3-13

Error Screen

Page 43

Initial Screen

Setting-Binding Pattern Screen

21102 20101E1

21102 20101F1

Setting-Binding Pattern Screen

Setting-Sheet Size Screen

Setting-Finishing Size Screen

Instruction-Removal Screen

Binding-Operation Screen

Error Screen

2 Checks before Operating

This chapter explains the safety checks you must make before beginning the binding

operation.

2-1 Checking the Emergency Stop Function

This machine has many safety functions designed to protect customers from possible risk during operation. Before operating the machine, check that all of the safety functions are working normally.

The Emergency Stop circuit is activated after the power switch is turned On and all sections of the machine have returned to their home positions.

Turn on the power switch.

- Turn the handle to the right to turn on the switch.

The Set-up screen and then the Setting-Binding Pattern screen are displayed on the touch panel.

- If the HOF-400/HOF-30/HOF-20 is connected, turn on the power switch for that also.

- If the icon

is displayed on the Initial

screen, it indicates that there is a problem with the system configuration settings.

Press

to reset the system configuration.

- If the icon

is displayed on the Initial screen,

refer to Section 5-1-1 to correct the problem.

Do the changeover.

1.Press



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11119

20101B1

Checks before Operating

ONONON

2110220101C1

The Setting-Sheet Size screen is displayed.

Press .

The Setting-Finishing Size screen is displayed.

Press .

The Instruction-Removal screen is displayed.

4. Press .

The Binding-Operation screen is displayed when the changeover is complete.

Press .

The Error screen is displayed.

21102 20101D1

Checking the Emergency Stop Function /

21102 20101G1

21102 20101H1

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Page 44

2-1 Checking the Emergency Stop Function

If an error icon is not displayed

1234

If an error icon is not displayed

Press

Release

Check the safety interlocks on the safety covers.

- Check that the correct icon is displayed on the screen when you open each of the following covers:

1. Infeed Section Cover

2. Stitch Section Cover

3. Fold Section Cover

4. Fore-edge Section Cover

- Each error icon will disappear when the cover is closed.

- There is a problem with the safety circuit. Stop using the machine and make a service call.

Check the safety functions of the Emergency Stop buttons.

- Press each Emergency Stop button.

The machine has two Emergency Stop buttons.

5. SPF Main Unit Emergency Stop Button

6. Fore-edge Trim Section Emergency Stop Button

- Check that the correct icon is displayed on the screen.

- Each error icon is cleared by turning the Emergency Stop button clockwise and pulling up.

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11119 20101J1

11119 20101K1

- There is a problem with the safety circuit. Stop using the machine and make a service call.

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Page 45

21102 30101C1

11119 30101E1

3 Operating Procedures

This chapter describes the procedure for doing a regular bookbinding job.

3-1 Overview of Operating Procedures

This section provides an outline of the procedure for the bookbinding job. Refer to Section 3-2 for details.

Turn On Power

Chapter 2, “Check Before

Operating.”

Set Up Job - Setting

Screen

Select the binding type.

Enter the sheet size.

Enter the finishing size.

Do the Changeover

Refer to page 35

Refer to page 39

Refer to page 44

21102 30101A1

21102 30101B1

Operating Procedures

Press .

Remove the required parts before doing the changeover.

Do the changeover.

Attach the required parts after doing the changeover.

Confirm the settings after doing the changeover.

21102 30101D1

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Overview of Operating Procedures /

Page 46

3-1 Overview of Operating Procedures

21102 30101N1

11119 30101O1

Test Binding

Prepare the upstream device.

Produce one booklet, or do a test binding

and check all of the settings.

Do some test stitching, if necessary.

Refer to page 53

123

21102 30101J1

21102 30101H1

11119 30101G1

21102 30101L1

Confirming the Status

Settings

VAC support guide Use/Not Used

Faulty Set Ejecting Function On/Off

Wire Feeding Detection On/Off

Manual Feeding On/Off

Optional Device Settings

Start Binding

Set the offset function.

Press the Start button.

Press the Stop button to complete the operation.

Refer to page 60

Refer to page 62

21102 30101I1

21102 30101M1

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Page 47

3-2 Setting Up a Job Using the Setting Screen

Rear Corner Stitch (Option)

Fold Only

Side Stitch and Fold

Side Stitch (Option)

Front Corner Stitch (Option)

Saddle Stitch

Pass Through (Option)

The following sections include detailed instructions for each part of the machine.

Select the binding pattern.

- Select the icon which indicates the required binding pattern.

The Sheet Size screen is displayed.

21102 30201A1

Operating Procedures

Setting Up a Job Using the Setting Screen /

Page 48

3-2 Setting Up a Job Using the Setting Screen

Top/Side Stitch

Sheet Size A=Length B=Width

Max. mm (inch)

432.0 (17.000")

356.0 (14.000")

Min. mm (inch)

138.0 (5.435")

180.0 (7.090")

Corner Stitch

Sheet Size A=Length B=Width

Max. mm (inch)

364.0 (14.330")

326.0 (12.820")

Min. mm (inch)

210.0 (8.270")

Top Stitch and Fold

Sheet Size A=Length B=Width

Max. mm (inch)

432.0 (17.000")

356.0 (14.000")

Min. mm (inch)

180.0 (7.090")

Saddle Stitch/Fold Only/Pass Through

Sheet Size A=Length B=Width

Max. mm (inch) (For the SPF-200A)

508.0 (20.000")

356.0 (14.000")

Max. mm (inch) (For the SPF-200L)

610.0 (24.015")

356.0 (14.000")

Min. mm (inch)

180.0 (7.090")

120.0 (4.725")

21102 30201B1

Sheet Size Screen

Select one of these if you are using a standard size sheet.

Sheet Size Screen

HOF Error Icon

No changeover is done and the Binding screen is displayed.

All sections return to their home positions before beginning the changeover.

The machine starts the changeover.

The range of sheet sizes available can be limited if the sheets are fed from the machines listed below.

- VAC-100/60H/1000/600H Max. W 350.0 X L 500.0 mm (13.775” X 19.685”) Min. W 120.0 X L 148.0 mm (4.725” X 5.830”)

- HOF-20/30 Max. W 350.0 X L 500.0 mm (13.775” X 19.685”) Min. W 200.0 X L 275.0 mm (7.875” X 10.830”)

- ST-40 (Only when the ST-40 is used as bypass to the stitcher) Max. W 350.0 X L 500.0 mm (13.775” X 19.685”) Min. W 182.0 X L 128.0 mm (7.166” X 5.040”)

- BC-20 Max. W 350.0 X L 500.0 mm (13.775” X 19.685”) Min. W 128.0 X L 148.0 mm (5.040” X 5.827”)

* When the LG-1000 is installed on the VAC-100 or the

VAC-1000, the maximum available length for the SPF-200L is 610 mm (24.015”).

* When the ST-40 is connected with the SPF-200L,

even a long sheet (up to 610 mm or 24.015") can be rejected to the ST-40, if the stopper plate for the ST40 is removed.

Enter each dimension.

- Enter in steps of 0.1 mm (0.005"). A: Sheet Length B: Sheet Width

When doing saddle stitching -

When doing side stitching -

21102 30201C1

C: Stitch Position

- Half of the sheet length is automatically

displayed. D: Stitch Distance E: Booklet Thickness

- Measure the thickness using a caliper

(accessory) and enter the value within 0.1

to 4.0 mm (0.005" to 0.155").

Page 49

3-2 Setting Up a Job Using the Setting Screen

Sheet Size-Other Binding Pattern Screen

Sheet Size-Saddle Stitch Screen

(This example shows the screen for side stitching.)

When doing saddle stitching -

-Press .

The Finishing Size screen is displayed.

When doing binding patterns except saddle stitching -

-Press .

- If the HOF error icon is displayed, there is a problem with the HOF-20/30. Clear the error on the HOF-20/30 before trying to do the changeover.

The Setting-Instruction screen is displayed.

Go to Section 3-3.

AAA

21102 30201G1

Operating Procedures

Setting Up a Job Using the Setting Screen /

Page 50

3-2 Setting Up a Job Using the Setting Screen

Finishing size Top and Bottom

Max. (with foreedge trim) (For the SPF-200A)

254.0mm or

10.000” (250.0mm or

9.840”)

356.0mm or

14.000”

Max. (For the SPF-200L)

305.0 mm or

12.00”

356.0mm or

14.000”

Min.

85.0mm or

3.350”

120.0mm or

4.725”

Top and Bottom

Finishing size

On a machine set to measure in inches, you must set the stitch distance carefully so the stitches do not hit the fold knife or booklet stopper. For details, see Section 1-3-3.

21102 30201E1

Finishing Size Screen

Select one of these if you are using a standard sheet size.

Stitch Type

Select a stitch type from the 5 choices. (When using small size sheets, the four stitch may not be selected.)

Flat

Loop

Press this button to do a fore-edge trim.

HOF Error Icon

= No changeover is done and the Binding screen is

displayed.

= Each section returns to the home position before

starting the changeover.

= The machine starts the changeover without sending

the parts to their home positions.

= Caution Icon for

Fold Skewing

= Caution Icon for

Crooked Trim

Enter all of the dimensions.

- Enter the finishing size for saddle stitch or fold only.

- Enter in steps of 0.1 mm (0.005").

A: Finishing Size

11119 30201D1

B: Stitch Distance

- We recommend you to adjust the stitch distance within the ranges shown below:

If the top and bottom distance is 185 mm (7.285") or more

- 79.0 to 92.0 mm

- 138.0 to 151.0 mm

- 3.860” to 5.905"

If the top and bottom distance is shorter than 185 mm (7.285")

- 79.0 to 80.9 mm

11119 30201F1

- If the stitch distance is adjusted outside of this range, the folding or trimming

may be incorrect.

C: Booklet Thickness Measure value using a caliper (accessory)

and enter the value within 0.1 to 4.0 mm (0.004" to 0.15").

Page 51

3-2 Setting Up a Job Using the Setting Screen

Press .

The Setting-Instruction screen is displayed.

- If the HOF error icon is displayed, there is a problem with the HOF-20/30. Clear the error on the HOF-20/30 before doing the changeover.

- Go to the next page.

Operating Procedures

Setting Up a Job Using the Setting Screen /

Page 52

3-3 Doing a Changeover

Guide Bar

Remove the guide bars in the jog section.

Remove the upper and lower section of the top and bottom guides.

1. Loosen

Upper Part of the Guide

Remove

1. Loosen

Lower Part of the Guide

This section explains how to remove or attach the guides and stoppers before and after the changeover by referring to the Instruction screen.

3-3-1 Removing Parts Before the

Changeover

After removing the specified parts, press .

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3-3-1 Removing Parts Before

the Changeover

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Page 53

3-3 Doing a Changeover

- Replace the large saddle stitch stopper to the small one.

- Loosen the locking screws to remove the stopper.

Lock by pressing the stopper down.

If the stopper is located in a place where it is hard to reach the locking screws, press . The stopper will move to a better location.

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Locking Screws

- Remove the sheet holddown plates in the fold section.

- Once you remove the locking knob, the plate can be removed.

11119 30301H1

Locking knob

Remove two stitcher head assemblies, along with the mounting blocks and clinchers.

Be sure to remove the mounting block and the clincher, not just the stitcher head.

CAUTION

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3-3-1 Removing Parts Before

the Changeover

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- Refer to Section 8-3 for removal instructions.

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Operating Procedures

Doing a Changeover /

Page 54

3-3 Doing a Changeover

If you press , the following instruction screens appear:

11119 10304K1

Remove the stitch detection sensor. Refer to Section 8-4.

3-3-1 Removing Parts Before

the Changeover

Page 55

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11119 30301M1

Rear Corner Stitch Guide

Top and Bottom Guide

Positioning Pin

Locking Screws

Fit here

Top and bottom guide mounting screws

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3-3-1 Removing Parts Before

3-3 Doing a Changeover

- When you stop doing corner stitching and go to another binding pattern, or

- When you select corner stitching for the first time,

The stitch section moves to the left end, the top and bottom guides open, then the machine stops before doing the changeover. (The top and bottom guide guides can be removed easily by hand.)

Replace the rear top and bottom guides with the corner stitch guide.

Replace the front top and bottom guides with the corner stitch guide.

Front corner stitching is optional.

11119 30301R1

Remove the front stitcher head drive block.

Remove the rear stitcher head drive block.

the Changeover

11119 30301T1

Replace the front corner stitching guide with

Attach the rear stitcher

head drive block. the top and bottom guides.

11119 30301N1

Replace the rear corner stitching guide with the

Attach the front stitcher

head drive block.

11119 30301Q1

top and bottom guides.

Parallel Adjustment

Press and hold the top and bottom guides, and tighten the mounting screws.

- Fit the left end of each guide over the bolt head.

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Operating Procedures

Doing a Changeover /

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Page 56

3-3 Doing a Changeover

This screen is displayed in the situations listed below because the machine does not know the current positions of the stitcher heads.

- First changeover since the power was turned on.

- If an Emergency Stop button is pressed during a changeover.

If the stitcher heads are positioned in the cutout of the corner stitch guide, the stitcher heads will interfere with the guide during the changeover. This screen appears to prevent a case where the stitcher heads hit the corner stitch guide.

Stitcher Head Position Confirmation Screen

Corner Stitch Guide

Cutout

- The screen shown to the right may be displayed before you begin the changeover for corner stitching.

- This screen is used to confirm the stitcher head positions.

- Select either icon.

A: The stitcher heads are positioned in the cutout

of the corner stitch guide.

B: The stitcher heads are positioned outside of the

cutout of the corner stitch guide.

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11119 30301W1

3-3-1 Removing Parts Before

the Changeover

- After making the right selection, press

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Page 57

3-3 Doing a Changeover

11119 30302H1

Attach the upper and lower sections of the top and bottom guides.

Upper Part of the Guide

3. Tighten

Lower Part of the Guide

Tighten

If you are using wide sheets, the sheets may sag between the transport belt and the top and bottom guides. If this happens, attach the guide bar.

Top and Bottom Guide

Sag

Transport Belt

Guide Bar

11119 30302M1

- Replace the small saddle stitch stopper with the large one.

- Loosen the locking screws to remove the stopper.

Lock by pressing the stopper down.

If the stopper is located in a place where it is hard to reach the locking screws, press . The stopper will move to a better location.

Locking Screws

3-3-2 Attaching Parts After Changeover

- After required parts are attached, press on

the display.

3-3-2 Attaching Parts After

Changeover

11119 30302I1

- Attach the guide bars if necessary. (There is no instruction on the screen telling you to attach the guide bars.)

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11119 30302K1

Operating Procedures

Doing a Changeover /

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Page 58

3-3 Doing a Changeover

-Attach stitcher head assemblies with the clinchers. Refer to Section 8-3-2 through 83-5 for instructions.

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Lever

11119 30302B1

Move the fore-edge trim section to the front (for small size sheets).

1. Lift the lever.

2. Pull the fore-edge trim section forward.

3. Lower the lever to lock the fore-edge trim section.

Socket driver

If the stitches on the booklet hit the stopper and the trim position varies, adjust the position of the fore-edge trim section. You can make this adjustment also when the fore-edge trim section is at normal position (rear).

1. Lift the lever.

2. Insert the supplied socket driver as shown below and turn the shaft to adjust the fore-edge trim section.

3. Lower the lever to lock the fore-edge trim section.

11119 30302C1

Move the fore-edge trim section to the line (for normal or large size sheets).

1. Lift the lever.

2. Push the fore-edge trim section backward.

3. Lower the lever to lock the fore-edge trim section.

Lever

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3-3-2 Attaching Parts After

Changeover

222

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Page 59

3-3 Doing a Changeover

11119 10304L1

If the sheet width is 200 mm (7.875") or wider and the side of the sheet floats up, use the sheet holddown plates.

11119 30302F1

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Stay using the magnet.

Fit to the shaft.

The following screens below are displayed after the changeover.

3-3-2 Attaching Parts After

Changeover

Install the stitch detection sensor. Refer to Section 8-4.

- Attach the sheet hold-down plates in the fold section if necessary.

(There are no instructions on the screen telling you

to attach the sheet hold-down plates.)

- Mount each plate on the guide and tighten the locking knob.

- For the side stitching or corner stitching, attach the sheet hold plate for side stitching if necessary.

- This plate prevents the sheet from floating and going beyond the stopper.

(There are no instruction screen to attach the sheet

hold plate for side stitching.)

11119 30302G1

Operating Procedures

Doing a Changeover /

- There are two types (long and short) of the sheet hold plates. When length of the sheet is 297 mm (11.700") or longer, use the longer plate.

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Page 60

3-3 Doing a Changeover

Setting Confirmation Screen

Binding-Operation Screen

Operate the machine with the knob pushed in.

Middle

Small

Large

3-3-3 Confirmation After Changeover

After the required parts are attached, the screen shown to the right may be displayed.

- This screen shows function that have been turned off.

- Press if the correct functions have been turned off.

The Binding-Operation screen will be displayed.

21102 30303B1

3-3-3 Confirmation After

Changeover

Checking the buckle gap on the fold section

- Confirm that the guide gap is adjusted to match the booklet thickness.

- Select from the three steps listed below:

When the thickness is

0.5 mm (0.020") or less Small

0.5 to 1.0 mm (0.020" to 0.039")

1.0 to 2.0 mm (0.039" to 0.079")

Middle Large

Adjusting the knob

1. Pull the knob forward.

2. Adjust the gap by turning the knob.

3. Push in the knob.

21102 30303C1

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Page 61

3-4 Doing a Test Binding

Transport Guide

Stitch (Lamp On)

faulty set Ejecting Function (Lamp On)

The Locking knob is located behind the stopper.

Stopper

Test Feed Button

3-4-1 Preparing the Upstream Device

Turn on the power switch on the

upstream device.

- It does not matter which machine is turned on first.

Set up the upstream devices.

- Refer to the user's manual for each device.

ST-40

1.Set up the guides to match the sheet size if you want to use the faulty set ejecting function.

2.Turn on the Stitch function.

3. Attach the transport guide.

3-4-1

Preparing the Upstream Device

1 2 3

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11119 30401A1

BC-20

1. Set the horizontal transport conveyor on the BC-20 to the horizontal position.

2. Set up the faulty set ejecting function.

- When you turn on the faulty set ejecting function, adjust the stopper on the reject tray to match the sheet size.

HOF-400/HOF-30/HOF-20

1. Load the sheets.

2. Do a test feed.

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21102 30401F1

11119 30401E1

234

LED

21102 30401D1

Operating Procedures

Doing a Test Binding /

Page 62

3-4 Doing a Test Binding

21102 30401G1

123

21102 30401H1

Binding-Status Setting-Collator/Faulty Set Detect/Manual Feed/Stitch Screen

VAC-100/1000/60H/600H

1. Set up the support guide.

- If the sheet width is 148 mm (5.830") or less, be sure to install the support guide. (Refer to Section 2-2-2 in the user's manual for the VAC.)

- When the support guide is used, select on the Collator/Faulty Set Detect/Manual Feed/Stitch

screen. (This can be selected when sheet width is 230 mm (9.05”) or smaller.

2. Load the sheets in the bins.

3. Set up each section of the collator referring to Chapter 2 in the user's manual for the VAC.

3-4-1

Preparing the Upstream Device

4. Do the sheet thickness calibration.

- Press on the Set 2 screen, and the sheets for one set will be fed.

Page 63

3-4 Doing a Test Binding

Binding-Operation Screen Locking Knob

About 30mm (1.18")

3-4-2 Binding a Booklet as a Test

* This function is not available when you are using the manual feeding function.

Press .

The sheets for one set are fed from the upstream device, then one booklet is delivered.

- If the bound booklet is not delivered correctly or there is a problem with the binding quality, go to Chapter 5, Troubleshooting.

- If the delivery conveyor is connected, set the delivery roller 30 mm (1.18") away from the end of the booklet.

21102 30402A1

3-4-2 Binding a Booklet as a Test

11119 30402B1

Operating Procedures

Doing a Test Binding /

Page 64

3-4 Doing a Test Binding

21102 30403A1

Binding-Operation Screen

21102 30403B1

Binding-Fine Adjust-Stitch Section Screen

This button is not available if manual feeding has been selected. Place the sheets directly in the jog section and go to step 2.

3-4-3 Do a Test Binding and Check the Settings

In the example used in this section, we will describe a job with saddle stitching with foreedge trimming.

Press .

The sheets for one set are delivered from the upstream device, and the sheets stop at the jog section.

- The Binding-Fine Adjust-Stitch Section screen is displayed.

Adjusting the jog section

3-4-3 Do a Test Binding and Check

the Settings

Press .

The sheets will be jogged.

- Open the cover and check if there is a gap between the sheets and the guides or the stopper.

If there is a gap, correct this:

A: Distance between the jog plate and the

stopper B: Top and bottom guide width (These items can be adjusted only while

sheets are being jogged.)

- To test the stitcher, close the cover and press .

- If is pressed while the sheets are being jogged, the sheets will be released.

Press .

The sheets will be transported to the fold section.

JJJ

21102 30403C1

Page 65

3-4 Doing a Test Binding

C D

Binding-Fine Adjust-Fold Section Screen

Go to the next page.

Adjusting the fold section

Press .

The sheets will be jogged.

- Open the cover and check if there is a gap between the sheets and the guides or the jog pusher.

If there is a gap, correct this:

C: Distance between the fold knife and the

jog pusher

D: Top and bottom guide width at fold sec-

tion

(These items can be adjusted only while the

sheets are being jogged.)

21102 30403D1

3-4-3 Do a Test Binding and Check

the Settings

C D

Press .

The booklets will be transported to the foreedge trim section.

Operating Procedures

Doing a Test Binding /

Page 66

3-4 Doing a Test Binding

E I

Binding-Fine Adjust-Fore-edge Trim Section Screen

If the gap between the booklet and the transport belt is too wide, the booklet is bound and skewed when the booklet hits the stopper. If the gap is too narrow, the booklet may be pressed against the stopper and skewed.

C D

Binding-Fine Adjust-Stitch Section Screen

Binding-Fine Adjust-Fold Section Screen

If the fold line and the stitch line are not aligned when doing saddle stitching, first check if the booklet is being folded in the proper position, then match the stitch position to the fold line.

- Position H can be adjusted only when the sheets are being jogged.

- If you notice skewed folding, go to Chapter 5, Troubleshooting.

- Position G can be adjusted only when the sheets are being jogged.

- If you notice skewed folding, go to Chapter 5, Troubleshooting.

The stitch position for corner stitching and side stitching is set at 6 mm (0.24") from the sheet edge.

Adjusting the fore-edge trim section

The booklet which has been transported to the fore-edge trim section stops. It is held by the transport belt.

Confirm that the booklet is held

correctly by the transport belts and there are no gap between the booklet and the stopper.

- If the booklet is held diagonally,

E: Adjust the gap between the booklet

and the transport belt.

- To do fore-edge trimming, close the cover and press

Press .

The booklet is delivered.

21102 30403E1

3-4-3 Do a Test Binding and Check

the Settings

If there is a problem with the binding quality

- To change the stitch distance,

adjust the value of setting F.

- If the fold line is shifted parallel,

adjust position H.

- If the stitches are shifted parallel to the fold line,

adjust the value of setting G.

- To change the corner stitch position,

adjust the value of setting J.

21102 30403F1

C D

- Adjust the value of setting I to change the fin-

ishing size.

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Page 67

3-4 Doing a Test Binding

Binding-Operation Screen

Input Range: 3 to 30 (times)

Stitching Test Screen

Saddle Stitch : 5 mm (0.2") pitch Side Stitch : 10 mm (0.4") pitch Corner Stitch : 30 mm (1.2") pitch

3-4-4 Perform the Test Stitching

This section explains how to do multiple test stitching.

Place the sheets in the jog section.

- Use the size of sheets the machine is set to run. Place these so they sit between the top and bottom guides, stopper, and the jog plate in the stitch section.

Close the cover after placing the

sheets.

3-4-4

Perform the Test Stitching

11119 30404C1

Press .

The Stitching Test screen is displayed.

Enter the number of times to make

the stitch.

- The available range is 3 to 30 times.

Press .

While the sheets are being moved, they are

stitched for the entered number of times.

- When the stitch reaches within 10 mm (0.4") from the sheet edge, the operation stops.

- Sheets already used for test stitching can be used again if they are reversed.

21102 30404A1

Operating Procedures

Doing a Test Binding /

To adjust the length of the stitch legs, or the balance between the left and right stitches, refer to Section 4-1.

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Page 68

3-5 Confirming the Status Settings

2 3

Caution Screen

Status Setting-Collator/Faulty Set Detect/Manual Feed/Stitch Screen

If the wire has almost run out, the sensor may turn off even though the wire is still feeding correctly. If this happens, press .

This section only describes the status settings you must make before every binding operation. There may also be other status settings which are not mentioned here.

Display the Binding-Status Setting

screen.

Select if the support guide

is used in the VAC.

The Caution screen is displayed.

- Press to start the changeover.

Select when using the

faulty set ejecting function.

Select when using the wire

feeding detect function.

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21102 30501B1

To do manual feeding or feeding

from the HMU (the manual feed unit of the optional VAC), select the proper icon.

= No manual feeding

= Only manual feeding

= When the HMU is used (Hand

Marry Unit of the collator). This function cannot be selected on the screen. This function can only selected using a switch on the HMU.

= Feeding starts from the collator

after sheets are loaded in the manual feed section. (Production speed: Slow)

= The sheets are fed manually to

match the feeding from the collator. (Production speed: Fast)

2 3

21102 30501C1

= The sheets are fed manually under

the sheets fed from the collator.

To do manual feeding, go to Section 3-7.

Page 69

3-5 Confirming the Status Settings

Status Setting-Option Screen

Confirmation Screen

Select the Status Setting-Option

screen.

Select the optional devices to use.

- The default is for all of the optional devices to be turned off.

To restore to the default settings

1. Press .

The Confirmation screen is displayed.

Press .

All the settings are restored to the defaults.

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21102 30501E1

Operating Procedures

Confirming the Status Settings /

Page 70

3-6 Start Binding

21102 30601A1

Operation Screen

The Number of Booklets in the Current Batch

The Preset Number for Each Batch

To do manual feeding, go to Section 3-7 and start binding.

VAC

HOF-20/30

SPF

21102 30601S1

HOF-400

Set up the offset function.

- Non-offset delivery is selected as a default setting.

= Offset the last booklet when it

reaches the preset count number. (This icon is available only if the optional PK-30 Preset Kicker is connected.)

= Offset by changing the speed of the

delivery conveyor.

- Enter the preset number (the number of booklets in each batch). Press the box to display the Numeric Keypad screen.

Press the Start button.

- The binding operation can be started from any of the following Start buttons:

- SPF: Start button next to the touch panel

- VAC: Start button on the remote control

- VAC: Start button on the Main screen

- HOF-20/30: Start button on the control panel

- HOF-400: Start button on the Main screen

11119 30601C1

21102 30601E1

If any sheets remain inside the machine, they will be ejected as the machine prepares for the next sheets. During this operation, the Start button blinks. After the machine is ready, the Start button lights up and sheets are fed from the upstream device.

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21102 30601G1

21102 30601F1

234

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Page 71

3-6 Start Binding

21102 30601H1

Here is a good way to remove the jammed sheets from the jog section: Press the Stitcher Jog Button while the cover is opened. The top and bottom guides will open so the sheets can be removed easily.

11119 30601M1

Operation Screen

Error Screen

Information about Upstream/Downstream Devices

Stitcher Jog Button

Settings which can be changed during the binding operation

- Production speed

- Delivery Conveyor Run Distance This indicates how far the conveyor will move each time a booklet is delivered.

Delivery Conveyor Run Distance for Offset Function When you use the offset function, this indicates how long the conveyor runs between the last booklet in one batch and the first one in the next batch.

Problems during binding

- Icon is displayed on the Operation screen.

= There is a problem with the SPF-

200A/200L or FC-200A/200L. Press

to find out the problem.

= There is a problem with the collator.

= There is a problem with a down-

stream device.

= The trim bin is full. If the binding

operation continue for one more minute, feeding will stop. Remove the trim.

- If the buzzer beeps at intervals of two seconds, the trim bin is full. If the binding operation continue for one more minute, feeding will stop.

- If the Error screen is displayed, correct the problem. Refer to Section 5-1.

21102 30601J1

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21102 30601I1

Operating Procedures

Start Binding /

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Page 72

3-6 Start Binding

VAC

HOF-20/30

SPF

HOF-400

Stopping the binding operation

Press the Stop Button.

- The binding operation can be stopped using any of the following stop buttons:

- SPF: Stop button next to the touch panel

- VAC: Stop button on the remote control

- VAC: Stop button on the Main screen

- HOF-20/30: Stop button on the control panel

- HOF-400: Stop button on the Main screen

Feeding stops and all processing booklets are bound and delivered. (The transport rollers keep rotating.)

- Press the Stop button again to stop the machine completely.

When the Emergency Stop button on an upstream device is pressed

The machine stops after all in-process booklets are bound and delivered.

11119 30601N1

11119 30601C1

21102 30601G1

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⛎

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11119 30601P1

21102 30601R1

234

21102 30601O1

21102 30601T1

Page 73

3-7 Manual Feeding

IFU-200

Manual Feed Guide

Sheet Width

Manual Feed Guide

ST-40

Guide

Manual Feed Table

HOF-20/HOF-30

Manual Feed Table

Front Guide

Set These for Half the Sheet Width

11119 30701C2

HOF-400

Manual Feed Guide

This section explains how to do manual feeding. Complete the changeover beforehand.

Set up the manual feed section.

When the IFU-200 is connected:

- Set the manual feed guide to match the sheet size.

When the ST-40 is connected:

- Set up the manual feed table and the guide.

- Refer to the user's manual for the ST-40 for details.

11119 30701A1

When the HOF-20/HOF-30 is connected:

- Set up the manual feed table and the front guide.

- Refer to the user's manual for the HOF-20/ HOF-30 for details.

When the HOF-400 is connected:

- Set up the manual feed guide.

- Refer to the user's manual for the HOF-400 for details.

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11119 30701B1

Operating Procedures

Manual Feeding /

Page 74

3-7 Manual Feeding

Status Setting-Collator/Faulty Set Detect/Manual Feed/ Stitch Screen

Manual Feed

*1 When the HOF-400 is connected, the three modes that are marked with (*1) are available. See the user’s manual for HOF-400.

Select the manual feed mode.

= When only doing manual feeding

(*1)

= Feeding using the HMU (optional

Hand Marry Unit of the collator). This function cannot be selected on the screen. This function can only selected using a switch on the HMU.

= Feeding starts from the collator

(*1)

after sheets are loaded in the manual feed section. (Production speed: slow) (This icon can be selected only if the IFU-200 is connected.)

= Sheets are fed manually to match

the feeding from the collator. (Production speed: Fast) (This icon can be selected only if the IFU-200 is connected.)

21102 30701D1

= Sheets are fed manually under the

(*1)

sheets fed from the collator. (This icon can be selected only if the IFU200 is connected.)

Page 75

3-7 Manual Feeding

11119 30701E1

Insert sheets after you hear the "beep."

11119 30701G1

Align the sheets on this side.

Sheet which is being fed manually

Hand Marry Unit

Insert Mode Selecting Switch

= A manually fed sheet is

inserted below the collated sheets.

= A manually fed sheet is

inserted above the collated sheets.

= The manual feed unit is

turned off.

Start Binding

If has been selected,

1. Press the Start button.

The machine prepares for manual feeding. When it is ready, the machine will “beep.”

2. Insert the sheets for one set in the manual feed section.

The sheets will be bound and delivered. When the machine is ready for the next sheets, the machine will “beep” again.

3. Press the Stop button after the binding operation is finished.

If has been selected,

1. Select the insertion mode using the Insert Mode Selecting switch.

2. Press the Start button on the collator.

3. Place the sheets on the manual feed table of the HMU.

If has been selected, the sheet will be fed in one second after a sheet is placed on the manual feed table, then the collating will starts.

If has been selected, collating will start one second after the sheet is placed on the manual feed table, then the sheet is fed.

11119 30701F1

Operating Procedures

Manual Feeding /

OFF

Page 76

3-7 Manual Feeding

When the accessory slide is attached on IFU-200, manual feed sheets can be fed smoothly. Use it if necessary.

Slide

Binding-Operation Screen

Start Button

Stop Button

Manual Feed Stopper

If the manual feeding is not done in time, the sheets fed from the upstream device will stop in the jog section. Remove the sheets or press the Start button again to eject the sheets to the faulty set ejecting tray.

If has been selected,

1. Press the Start button.

The machine will prepare for manual feeding. When it is ready, the machine will “beep.”

2. Insert a sheet in the manual feed section.

- Push the sheet toward the manual feed stopper and hold it.

When the sensor detects the sheet, the upstream device starts feeding. The manual feed stopper moves down to match the sheet fed from the collator, and the sheet on the manual feed section is fed.

To continue the binding operation,

3. Insert the next sheet in the manual feed section.

4. Press the Stop button after the binding operation is

If has been selected,

1. Make the production speed slower so that you can

2. Press the Start button.

3. Insert a sheet in the manual feed section.

- Push the sheet toward the manual feed stopper

finished.

do manual feeding.

The machine prepares for manual feeding. When it is ready, the machine will “beep.”

and hold it.

When the sensor detects the sheet, the upstream device starts feeding. The manual feed stopper moves down to match the sheet fed from the collator, and the sheet on the manual feed section is fed.

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11119 30701J1

4. The collated sheets are fed from the upstream device with a uniform timing. Insert the sheets in the manual feed section to match the feeding of the collated sheets.

5. Press the Stop button after the binding operation is

finished.

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Page 77

3-7 Manual Feeding

Start Button

Stop Button

Manual Feed Stopper

If has been selected,

1. Press the Start button.

The machine will prepare for manual feeding. When it is ready, the machine will “beep.”

2. Insert a sheet in the manual feed section.

- Push the sheet toward the manual feed stopper and hold it.

When the sensor detects the sheet, the manual feed stopper moves down, and the sheet on the manual feed section is fed. Then the collated sheets from the upstream device is fed, and performed. When the machine is ready for the next sheets, the machine will “beep” again.

3. Press the Stop button after the binding operation is finished.

the binding operation is

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Operating Procedures

Manual Feeding /

Page 78

3-8 Saving, Loading and Deleting Jobs

21102 30801F1

10 BOOK

Binding-Operation Screen

Memory-Main Screen

Numeric Keypad Screen

Press 5 times or Press once

Memory-Main Screen

Keyboard Screen

Memory-Main Screen

If this icon blinks, there is a problem with the HOF20/30. Clear the problem on HOF20/30 and save the job again.

Confirmation Screen

Up to 19 letters can be entered.

To scroll through the jobs, press the Scroll buttons and on the right.

If is pressed on the Keyboard screen, the display returns to the Memory-Main screen. The entered job name will not be entered.

- If another job is already stored for that job number, the old information will be overwritten.

- If is pressed in the Confirmation screen, the display will return to the Memory-Main screen. The new job will not be saved.

A job which is used frequently should be saved and loaded using the Memory screen. This section explains how to save, load, and delete a job.

3-8-1 Saving a Job

Before saving a job, finish the changeover and fine adjustments so that the machine is necessary to set correctly for the job you want to save.

Press .

Select the job number where you

want to save the job.

There are two ways to select the Job number:

1. Enter the job number using the Numeric

2. Touch the job number directly on the Mem-

The Memory-Main screen is displayed.

Keypad screen or

ory-Main screen.

Press to display the Numeric Key-

pad screen.

3-8-1

Saving a Job

21102 30801A1

11119 30801B1

11119 30801C1

Press .

The Keyboard screen is displayed.

Enter the job name.

- Up to 19 letters can be entered.

Press .

The Memory-Main screen is displayed.

- In this example, the current job is saved in Job No.10 as [job name: BOOK.

21102 30801D1

BOOK

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10 BOOK 06 06 10

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Page 79

3-8 Saving, Loading and Deleting Jobs

Binding-Operation Screen

If this icon blinks, there is a problem with the HOF-20/30. Remove the problem on the HOF-20/30 and load the job again.

Memory-Main Screen

11119 30802B1

Numeric Keypad Screen

21102 30802G1

10 BOOK

Setting-Finishing Size Screen

11119 30802C1

Press 5 times or Press once

Memory-Main Screen

Detailed Information Screen

Confirmation Screen

To scroll through the jobs, press the Scroll buttons and on the right.

If is pressed on the Confirmation screen, the display will return to the Memory-Main screen. The job will not be loaded.

3-8-2 Loading a Job

Press .

3-8-2

Loading a Job

Select the number for the job you

want to load.

- There are two ways to select the job number:

Check the detailed information for

the job you want to load.

1. Press .

The Memory-Main screen is displayed.

1. Enter the job number using the Numeric Keypad screen or

2. Touch the job number directly on the Memory-Main screen.

Press to display the Numeric Keypad screen.

10 BOOK 06 06 10

21102 30802D1

21102 30802A1

Operating Procedures

-1.

The Detailed Information screen is displayed. Check the job information.

2. Press .

Press .

The Memory-Main screen is displayed.

The Confirmation screen is displayed.

Press .

The Memory-Main screen is displayed.

- The job you selected is now loaded, but the changeover has not been done yet.

10 BOOK 06 06 10

21102 30802E1

21102 30802I1

10 BOOK 06 06 10

-2.

21102 30802F1

Saving, Loading and Deleting Jobs /

Page 80

3-8 Saving, Loading and Deleting Jobs

All the job information is loaded - not just the binding pattern and size data, but also the fine adjustment settings and status settings.

Setting-Finishing Size Screen

Do the changeover.

All parts of the machine start to move to the saved positions.

- If this is the first changeover since the power was turned on, press .

21102 30802J1

3-8-2

Loading a Job

Page 81

3-8 Saving, Loading and Deleting Jobs

Binding-Operation Screen

Memory-Main Screen

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Numeric Keypad Screen

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10 BOOK

Confirmation Screen

Memory-Main Screen

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Press 5 times or Press once

Memory-Main Screen

10 BOOK 06 06 10

21102 30802F1

-2.

Detailed Information Screen

To scroll through the job, press the Scroll buttons

and on the right.

If is pressed on the Confirmation screen, the display returns to the Memory-Main screen. The job will not be deleted.

3-8-3 Deleting a Job

Press .

3-8-3

Deleting a Job

Select the number of the job you

want to delete.

- There are two ways to select the job number:

1. Enter the job number using the Numeric

2. Touch the job number directly on the Mem-

Check the detailed information for

the job you want to delete.

1. Press .

The Memory-Main screen is displayed.

Keypad screen or

ory-Main screen.

Press to display the Numeric Keypad screen.

The Detailed Information screen is displayed. Check the job information.

10 BOOK 06 06 10

21102 30802D1

21102 30802A1

Operating Procedures

-1.

2. Press .

The Memory-Main screen is displayed.

Press .

The Confirmation screen is displayed.

Press .

The Memory-Main screen is displayed.

- The selected job is now deleted.

10 BOOK 06 06 10

21102 30802E1

21102 30803H1

Saving, Loading and Deleting Jobs /

Page 82

3-9 Power Saving Mode

When returning from the power saving mode, always save the current settings to the job memory before entering the power saving mode. Refer to Section 3-8-1.

21102 30901A1

Binding-Operation Screen

Power Saving Mode Confirmation Screen

Setting- Finishing Size Screen

If the power saving mode is cancelled,

Perform the changeover.

Power Lamp

Select the power saving mode if the machine will not be operated for a long time. This decreases standby power consumption and saves energy.

Press .

The Power Saving Mode Confirmation screen is displayed.

Press .

The display on the touch panel disappears and the machine goes to power saving mode.

- The power lamp blinks while the machine is in power saving mode.

21102 30902B1

To return from power saving mode

Touch the touch panel.

The Setting-Finishing Size screen is displayed.

Do a changeover.

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Page 83

3-10 Reversing the Stitcher Heads

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Clincher Lever

Stitcher Jog Button

Machine Jog Button

If you are stitching a very thick booklet, or if the stitch jams because of overstitching, the stitcher heads may be locked. If this happens, reverse the stitcher heads.

Press the Stitcher Jog button while

pressing the Machine Jog button.

Stitcher head returns to the original position by reverse movement.

Remove the booklets or stitches.

- If a stitch jams inside the clincher, move the clincher lever up or down and remove the jammed stitch.

11119 31001B1

Operating Procedures

Reversing the Stitcher Heads /

Page 84

This page is intentionally left blank.

Page 85

Shorten Wire Length

Lengthen Wire Length

After you make an adjustment, the first stitch may not be made correctly. Check the second stitch.

11119 40101A1

11119 40101E1

Adjusting wheel

do this,

To correct this,

and get this result.

4 Adjustments

This chapter explains how to adjust each section as needed.

4-1 Stitch Adjustments

This section explains how to change the appearance of the stitch.

Stitch Length Adjustment

Turn the wire length adjusting

knob.

11119 40101B1

Stitch Balance Adjustment

Adjust the stitch balance by turn-

ing the adjusting wheel up or down.

Stitch Angle Adjustment

Turn the stitch angle adjusting

knob.

21102 40101C1

Adjustments

Stitch Adjustments /

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Page 86

4-1 Stitch Adjustments

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11119 40101I1

Leaf Spring

Former

Wire Adjusting Lever

Attach the former to the same stitcher head. Each stitcher head and former have paint of the same color.

Wire Straightening Adjustment

The wire is supplied in a coil, so it is not straight. Adjust the wire so that it comes out straight.

Move the leaf spring to the right

and remove the former.

Insert the wire adjusting lever and

turn it clockwise.

This should feed some wire.

- If the wire does not feed, check that the wire

feed On/Off knob is turned to the On position.

Adjust the wire so that it comes out

straight.

- Adjust the angle of the eccentric shaft which

feeds the wire.

Cut the wire, attach the former and

return the leaf spring to its original position.

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Page 87

4-2 Infeed Section Adjustments

Weight

Infeed Direction

Knob Position

Sheet Length

Short

Long

Stopper

Low Middle High (Horizontal)

Weight Adjustment

- The "drive" provided by the transport rollers can be adjusted by changing the positions of the weights. (Normally the weights are positioned in the middle.)

- Move each weight toward the stitcher when feeding thick papers or multiple sheets.

Slide each weight

Turn each weight counterclock-

wise.

Slide each weight in the correct

direction.

Turn each weight clockwise to lock

it.

11119 40201A1

Infeed Section Direction Adjustment

- In the best setup, the front edge of the sheet is directed toward the corner of the stopper when the sheet is fed from the infeed section.

- Adjust the direction of the infeed section to match the sheet length (five steps).

How to adjust

Pull out the infeed section direc-

tion adjusting knob.

Turn the knob.

Push the knob in.

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Adjustments

Infeed Section Adjustments /

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Page 88

4-2 Infeed Section Adjustments

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Knob

Sheet Holder

Hold-down Guide

Knob

If the holder is set too low, it may scratch the sheets.

Lifter Attachment

- Attach lifter if thin sheets are folded as they move.

- Remove lifter if thick sheets do not move smoothly.

- Attach the lifter to the lower guide in the infeed section.

Hold-down Guide Adjustment

- When feeding from the infeed section, if the sheets float and do not enter the top and bottom guides, adjust the hold-down guides.

- Loosen the knob and adjust the height of each guide.

11119 40201G1

11119 40201H1

Sheet Holder Adjustment

- This guide holds the sheet on the belt if the tail of the sheet remains at the exit of the infeed section and is not transported completely.

- Loosen the knob to adjust the angle of the holder.

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Page 89

4-3 Jog Section Adjustments

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Locking Knob Saddle Stitch Holder (Short)

Saddle Stitch Holder (Long)

Side Stitch Holder

Stroke Adjustment

Jog Frequency

Collator/Faulty Set Detect/Manual Feed/Stitch Screen

Sheet Holder Attachment

- This holder helps to control the sheet if a thin sheet floats and goes beyond the stopper.

- Three types of sheet holders are available. Use the correct type to match the binding pattern and sheet size.

11119 40301A1

- Loosen the locking knob to replace a holder.

- When attaching or removing the side stitch holder, remove the locking knob before moving the part.

- Adjust the locked position to match the booklet thickness.

Top and Bottom Guide Stroke Adjustment

- If the incoming sheet hits the top and bottom guides and jams, increase the opening.

- The default setting is 3.0 mm (0.120

- The opening is adjustable within a range of 1.0 to

6.0 mm (0.050

Top and Bottom Guide Jog Frequency

" to 0.200").

Adjustment

- If the sheets are not squared up, press to increase the jog frequency.

").

11119 40301B1

11119 40301C1

3.0

0.5

21102 40301E1

Adjustments

Jog Section Adjustments /

Page 90

4-3 Jog Section Adjustments

21102 40301G1

Guide Return Screen

Guide Movement Screen

Administrator Mode Screen

Top and Bottom Guide Mounting Screw

Top and Bottom Guide Mounting Screws

Fit over the bolt head.

Top and Bottom Guide Parallel Adjustment

- Check that the top and bottom guides are parallel to the frame of the machine. If the machine is installed with the casters touching on the floor, the frame itself may be distorted. The machine must be installed correctly so that it remains horizontal.

- This adjustment must be done by an administrator.

How to Adjust

The Administrator Mode screen is

displayed.

Press .

21102

40301F1

The Guide Movement screen is displayed.

Press .

The top and bottom guides move out.

- The top and bottom guide becomes free to move manually.

Loosen the mounting screws for the top and bottom guides on the front and rear.

Move the top and bottom guides

out, then tighten the mounting screws.

- Fit the left end of each guide over the bolt head.

11119 40301H1

Press the button in the

Guide Return screen.

The top and bottom guides return to their original setting positions.

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Page 91

4-4 Fold Section Adjustments

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11119 40401B1

To find the standard setting, turn the knob clockwise as far as possible. Next, turn the knob 1 to 1.5 turns counter-clockwise.

11119 40401C1

High

Low

- To find the standard position, turn the knob clockwise as far as possible. Next, turn the knob counter-clockwise three turns.

Do not raise the fold knife too far. If the top-bottom length of sheet is short, the fold rollers and fold knife may hit each other and may be damaged. Adjust the knob in small amounts.

CAUTION

11119

Gate

Small Booklet HoldDown Plate

Fold Skew Adjustment

- Fold skewing can be corrected by changing the angle of the fold section stopper.

- Correct for fold skewing by turning the fold skew correction knob.

Fold Knife Height Adjustment

- Raise the fold knife position if the fold rollers cannot pick up a small number of sheets even if the fold knife holds up the sheets.

Attachment of Small Booklet Hold-Down Plate

11119 40401D1

Adjustments

Fold Section Adjustments /

- If a small size sheet (sheet length less than 200 mm or 7.87 attach the small booklet hold-down plate.

- To attach the plate, hook it over the gate shaft.

- The hold-down plate works by pushing the sheet against the belts.

") stops after passing through the gate,

- Remove the hold-down plate if the sheet length is more than 400 mm or 15.75

Page 92

4-5 Fore-edge Trim Section Adjustments

11119 40501A1

Booklet Stopper Transport Belt

Usually, the transport belt gap is automatically set to mach the book thickness.

Binding-Fine Adjust-Fore-edge Trim Section Screen

11119 40501K1

Front Transport Belt Height Adjusting Knob

Screw of Locking Lever

If the booklet is not transported straight from the upstream device, this cannot be corrected using the belt height adjustment. Adjust the upstream device so that the booklet is delivered correctly.

Transport Belt Gap Adjustment

- If the booklet bounces when it hits the stopper, it may not be trimmed to the set finishing size.

- If this happens, reduce the gap at the transport belts to prevent the booklet from flipping over.

How to Adjust

Display the Fine Adjust-Fore-edge

Trim Section screen.

Reduce the value for the transport

belt height.

Check that the booklet does not

bounce when it hits the stopper.

1. Press .

The booklet is transported to the fore-edge trim section.

2. Check that the booklet does not bounce when it hits the stopper.

3. Press to deliver the booklet.

Front Transport Belt Height Adjustment

- If the booklet expands by different amounts in the front and rear, adjust the height of just the front transport belt to prevent the booklet from feeding crookedly.

- Loosen the locking lever and turn the front transport belt height adjusting knob clockwise. This lowers the front transport belt and reduces the gap.

- Tighten the locking lever firmly after making the adjustment.

- If the locking lever is hard to tighten, apply lubrication oil to the screw of locking lever.

11119 40501D1

11119 40501C1

Page 93

4-5 Fore-edge Trim Section Adjustments

11119 40501E1

Infeed Belts

Belt Pressure Adjusting Bar

Release

Standard

Strong

Pulley

Locking Screw

11119 40501H1

View from Rear

Stop in this area

Infeed Belt Pressure Adjustment

- Adjust the pressure of the infeed belts to match the booklet weight.

- Increase the pressure of the infeed belts if the booklet stops at the entrance of the fore-edge trim section.

11119 40501F1

Infeed Belt Gap Adjustment

- If a small booklet is transported from the upstream device to the fore-edge trim section at a low speed, the booklet may stop at the entrance of the foreedge trim section.

- In this case, narrow the gap of infeed belt.

How to Adjust

Loosen the locking screw as shown in the illustration to the right and lower the pulley.

- Adjust both the front and rear pulleys by the same amounts.

Tighten the locking screw.

11119 40501I1

Adjustments

11119 40501J1

Fore-edge Trim Section Adjustments /

Page 94

This page is intentionally left blank.

Page 95

11119 50101A1

123141214

2 2

10 11 12

18 17

5 6 7

5 Troubleshooting

This chapter explains how to correct some typical problems.

5-1 If an Icon Is Displayed on the Error Screen

5-1-1 If An Error Icon Is Displayed

If a problem occurs, a sensor will detect the problem and stop the machine. Icons which indicate the error status are displayed on the touch panel. This section explains the meaning of the error icons.

No Icon Explanation

There is a problem with the wire feed. Press

and check if the wire is jamming

inside the stitcher head and is strained.

No Icon Explanation

130, 151, 155, 156

A cover is open. Close the cover and press .

Some sheets are jammed. Open the cover, remove the jammed

sheets, and press . If this error occurs even though there is no

jammed sheet, see the error code (page 90) and correct the problem.

There was too much load on the jog section top and bottom guide, or the transport pusher, and one of the parts moved.

Press .

An Emergency Stop button has been pressed. Turn the Emergency Stop button to release

it, then press .

If the problem occurs again even though the wire is OK, change the wire feeding detection setting. (Refer to Section 3-5, step 4.) On the Administrator Mode screen, change the number of stitches until this error is detected. (Refer to page 31.)

A faulty set was not delivered to the faulty set ejecting tray. Icons indicating the problems are displayed here. Remove any booklet which has been delivered to the downstream device (delivery

conveyor) and press .

The faulty set ejecting tray is full. Remove the booklets from the tray and

press .

An error has occurred in a downstream device. Clear the error in the downstream device,

and press .

The trim chute is full.

Remove the trim and press

The belt speed for the fore-edge trim unit is slower than the speed of the upstream device.

Press . Adjust the transport speed for the fore-edge trim section by pressing on the

Administrator-Transport Speed Adjustment screen.

The spacing between the transported booklets was too short, and the booklets cannot be trimmed correctly.

Press . The booklet delivery from the SPF-200A/200L is incor-

rect. The sheets may not be fed into the fold section smoothly. Check if there is a piece of paper remained on the sheet path. If there is no piece of paper remaining, increase the fold section top and bottom guide stroke using the Binding-Status Setting-Fold/Fore-edge Trim/Conveyor screen. If the problem occurs again, slow down the production speed.

Troubleshooting

If an Icon Is Displayed on the Error Screen /

Page 96

5-1 If an Icon Is Displayed on the Error Screen

No Icon Explanation No Icon Explanation

A jog error has occurred in the fold section.

Options

Press . If the sheets are not arranged correctly in

the stitch section, increase the jogging frequency using the Binding Status Setting screen. (Refer to page 25) If the problem recurs, increase the distance between the fold knife and the jog pusher on the Binding-Fine Adjust-Fold Section screen. (Refer to Section 1-3-7.)

A communication error with the upstream device has occurred.

Press . Check if the connector with the upstream

device is connected to the SPF-200A/200L correctly, and that the upstream device is powered on.

No sheets for manual feeding were loaded in time to be fed. Press and load

the sheets for manual feeding in the manual feed section and restart the binding operation.

The sheets are not transported to the SPF200A/200L within the correct time after the binding operation has started.

Press inside the upstream device.

and check for sheet jams

An error has occurred in the upstream device. Clear the error in the upstream device, and

press . This error is also displayed if Test Collating on the collator or Test Feed-

ing on the HOF is not complete.

A communication network error has occurred. Turn off the power switch. Check if the communication cable between the devices is connected correctly, then turn on the power switch again.

A system error has occurred. Refer to Section 5-1-2 and clear the error.

The stitcher head is not at the correct position. Place a sheet under the stitcher head. Press and hold the stitch jog button to return the stitcher head to the correct position.

A booklet thickness error has been detected in the fore-edge trim section.

Press . Check the booklet. If this error is detected

repeatedly although the booklet thickness is OK, decrease the sensitivity using the Binding-Status Setting-Option screen.

Front Side

Rear Side

The machine did not make a stitch. Press

out, or if the wire has jammed inside the stitcher head.

. Check if the wire has run

Page 97

5-1 If an Icon Is Displayed on the Error Screen

If the faulty set ejecting function is turned on and a faulty set is delivered to the faulty set ejecting tray correctly, the icons indicate the cause of the problem. If the same error is displayed repeatedly, follow the procedure listed below to correct the problem.

= A feed error has occurred at the upstream device.

Set up the feed section of the upstream device again.

= Sheets for manual feeding were not loaded in time to

be fed. Load the sheets into the manual feed section to match the feed timing from the upstream device.

= A jog error has occurred in the fold section.

If the sheets are not arranged correctly in the stitch section, increase the jogging frequency using the Binding Status Setting screen. (Refer to

page 25.)

If the problem occurs again, increase the distance between the fold knife and the jog pusher using the Binding-Fine Adjust-Fold Section screen. (Refer to Section 1-3-7.)

= The front wire is not stitched.

= The rear wire is not stitched.

Check if the wire has run out, or if the wire has jammed.

= A booklet thickness error has been detected in the

fore-edge trim section. Check the booklet. If the problem occurs again although the booklet thickness is OK, decrease the sensitivity using the Binding-Status Setting-Option screen.

Last set

10th set to the last

11119 50101B1

Troubleshooting

If an Icon Is Displayed on the Error Screen /

Page 98

5-1 If an Icon Is Displayed on the Error Screen

This icon indicates that the machine has a system error.

Error Code

Press this button to clear the error.

5-1-2 If a System Error Occurs

If a system error icon is displayed on the screen, check the error code next to the icon, and clear the cause of the error. See the tables shown below.

11119 50102A1

Error Code Description Cause and Solution

0 to 99 Whole System

97 Upstream Device Error

98 Sheet Infeed Error

99 Standby Error

100 to 199 SPF Section Jam Cause and Solution

100

101

TBC-200L Transport Belt Deceleration

HOF Error During Changeover

HP-200A/200L Transport Belt Speed Lowering

Fore-edge Trim Section Transport Speed Lowering

Upstream Device Communication Error

SPF Section Emergency Stop

The transport speed of the top and bottom trim section is set slower than that of the SPF. If the problem occurs again, please call your local dealer.

Clear the error displayed on the control panel of the HOF.

The transport speed of the HP-200A is set slower than that of the upstream device. If the problem occurs again, please call your local dealer.

The transport speed of the fore-edge trimming section is set slower than that of the upstream device. If the problem occurs again, please call your local dealer.

Clear the error on the upstream device. This error is also displayed if Test Collating on the collator or Test Feeding on the HOF is not complete.

The sheets are not transported to the SPF-200A/200L within the correct time after the binding operation has started. Check for sheet jams inside the upstream device.

The machine did not go to the Standby mode within the allowable time. If the problem occurs again, please call your local dealer.

Check if the connector with the upstream device is connected to the SPF-200A/200L correctly, and that the upstream device is powered on.

Turn the Emergency Stop button to release it.

102

107

110

111

120 121 Jog Section Cover Open Close the cover.

130 Infeed Section Jam

Upstream Device Signal Error (Segmentation Signal)

Fold Section Cover Open No Manual Feeding

Sheets Manual Feeding Sheets

Transport Error Infeed Section Cover Open

1. When is selected, the manual feed timing did not match the feed timing of the collator.

-Feed the sheets manually to match the feed from the collator.

-If the problem occurs again, use (Sheets are fed manually under the sheets fed from the collator).

2. The SPF-200A/200L does not receive the segmentation Signal from the upstream device, therefore, the SPF-200A/200L does not work normally. Check that the position of the VAC delivery sensor is correct. Connect and disconnect the connection cable between the SPF-200A/200L and the upstream device.

3. If the segmentation signal is invalid temporarily, the feed error occurs and the error icon appears.

Close the cover. No sheets for manual feeding are loaded. Load the sheets for manual feeding in the

manual feed section and restart the binding operation.

Although the manual feeding operation was performed, the sheet was not fed.

Close the cover.

There is a sheet jam in the infeed section. Open the cover and remove the sheets. If a sheet is not jammed, the sensor may be dirty. See Section 6-5-3 and clean the sensor.

Page 99

5-1 If an Icon Is Displayed on the Error Screen

100 to 199 SPF Section Jam Cause and Solution

There were no sheets in the jog section when the stitching operation was done.

132 No Sheet at Jog Section

133

134

135

136

137

138

150 Fold Section Jog Error

151 Fold Section Exit Jam

155 Fold Section Jam

156

Jog Section Top and Bottom Guide Step-out

Stitch Section Front Feeding Error

Stitch Section Rear Feeding Error

Jog Section Transport Belt Step-out

Jog Section Transport Error

Jog Section Delivery Error

Delivery Error from Fold Section

Wire

The sheets enter into the jog section before the stopper rises. Therefore, the sheets may not stop at the correct position. Lower the production speed on the BindingOperation screen.

There was too much load on the top and bottom guide, or transport pusher, and one of the parts moved. Check that only the specified guides and stoppers are attached when you do the changeover.

There is a problem with the wire feed. This error is displayed if the preset number of stitching operations has been completed, or if the wire guide has been detected continuously (wire is tangled), or if the wire guide has not been detected at all (wire has run out). Check if the wire is strained from the wire coil to the wire guide. Check if the wire has run out, or the wire has jammed inside the stitcher head, Check if a booklet with no stitches has been delivered to the downstream device. If the problem occurs again although the wire is OK, change the wire feeding detection setting. (Refer to Section 3-5, step 4.) On the Administrator Mode screen, set the number of times the machine can miss a stitch before this error is detected. (Refer to page 31.)

There is a problem with the wire feed. This error is displayed if the preset number of stitching operations has been completed, or if the wire guide has been detected continuously (wire is tangled), or if the wire guide has not been detected at all (wire has run out.) Check if the wire is strained from the wire coil to the wire guide. Check if the wire has run out, or the wire has jammed inside the stitcher head. Check if a booklet with no stitches has been delivered to the downstream device. If the problem occurs again although the wire is OK, change the wire feeding detection setting. (Refer to Section 3-5, step 4.) On the Administrator Mode screen, set the number of times the machine can miss a stitch before this error is detected. (Refer to page 31.)

There was too much load on the transport pusher, and the position of the transport pusher has changed. If there are jammed sheets, remove the sheets. If the transport pusher is disconnected, attach the transport pusher. Increase the stitch delay time in Binding-Status Setting Screen. ( Refer to Section 1-3-8.)

Some sheets remain in the jog section. Remove the sheets. The possible causes are following.

- This error may be displayed when operating in high production speed, and the transport belt moves to one side.

- The tail edge of the sheets may stay in the exit of the infeed section, and the sheets are not transported completely. Adjust the angle of the sheet holder. (Refer to Section 4-2.)

Sheet jams in the transport way between the jog section and the fold section. Remove the sheets.

This error may be displayed if the distance between the jog pushers is too tight in relation to the sheet size. If the sheets are not jogged in the stitch section, increase the jogging frequency using the Binding-Status Setting screen. (Refer to page 25.) If the problem occurs again, increase the distance between the fold knife position and the jog pusher using the Binding-Fine Adjust-Fold Section screen. (Refer to Section 1-3-7.)

A booklet is jammed in the exit of the fold section. Remove the jammed booklet. If a sheet is not jammed, the sensor may be dirty. See Section 6-5-3 and clean the sensor.

A booklet is jammed in the fold section. Remove the jammed booklet. Check if the buckle gap is too narrow. (Refer to Section 3-3-3.) If a sheet is not jammed, the sensor may be dirty. See Section 6-5-3 and clean the sensor.

A sheet is jammed in the horizontal transport section (if you are not doing folding) or in the fold section (if you are doing folding). Remove the sheets. If it is difficult to remove them, remove the sheet guides first. (Refer to Section 5-2.) When folding thin booklets, raise the fold knife. Also check if the booklet thickness has been entered correctly.

Troubleshooting

If an Icon Is Displayed on the Error Screen /

Page 100

5-1 If an Icon Is Displayed on the Error Screen

200 to 299 HP-200A Jam Cause and Solution

201 Punch Cover Open Close the punch section cover.

211

212 Infeed Section Jam

213 Punch Section Jam

200 to 299 HP-200A Jam Cause and Solution

220

230

250 Punch Section Jog Error

300 to 399

301

302

313

314

315

318

320

330

400 to 499

700 to 799 Downstream Device Error Cause and Solution

700

Infeed Error to Infeed Section

Upstream Device Delivery TIming Error

Sheet Undetected at Punch Section

Fore-edge Trim Section

Fore-edge Trim Section Emergency Stop

Fore-edge Trim Section Cover Open

Infeed Error to Foreedge Trim Section Entrance

Fore-edge Trim Section Entrance Jam

Fore-edge Trim Section Jam

Fore-edge Trim Section Transport Error

Upstream Device Delivery Timing Error

Faulty Set Ejecting Section Jam

Downstream Device Error

Jam

Top and Bottom Trim

Section Jam

The booklet is transported from the upstream device. However, the HP-200A entrance sensor did not detect the booklet.

The booklet is jammed in the infeed section. Remove the booklet. If a booklet is not jammed, the sensor may be dirty. See Section 6-5-3 and clean the sensor.

The booklet is jammed in the punch section. Remove the booklet. If a booklet is not jammed, the sensor may be dirty. See Section 6-5-3 and clean the sensor.

The delivery timing error from the upstream device occurred. If the problem occurs again, slow down the production speed.

Sheet could not be detected at punch section.

The jog error occurred. This error occurs when a booklet with folding only or a fed booklet are not arranged properly. First, set the punch delay time longer. If this error occurs repeatedly, increase the number of jog. If the jog pusher mis-jogs, increase the jog pusher stroke.

Cause and Solution

Turn the Emergency Stop button to release it.

Close the cover.

Although a booklet was delivered from the upstream device, the sensor in the entrance of the fore-edge section did not detect the booklet. If the booklet stopped because the distance between the upper and lower infeed belts is too wide, reduce the distance between the upper and lower infeed belts in the fore-edge trim section. (Refer to Section 4-5.)

A booklet is jammed at the entrance of the fore-edge trim section. Remove the booklet.

If the problem occurs again, Section 4-5.) If a booklet is not jammed, the sensor may be dirty. See Section 6-5-3 and clean the sensor.

A booklet is jammed in the fore-edge trim section. Remove the booklet. If a booklet is not jammed, the sensor may be dirty. See Section 6-5-3 and clean the sensor.

A booklet may be transported diagonally in the fore-edge trim section. Check that when using small booklets, the fore-edge trim unit is positioned toward the front as instructed. If the booklet is crooked when it hits the stopper, adjust the gap between the transport belts. (Refer to Section 4-5.)

The distance between the transported booklets was too short. The booklet delivery operation from the SPF-200A/200L is incorrect. The sheets may not be fed into the fold section smoothly. Check if there are sheet strips remaining on the sheet path. If there are no sheet strips remaining, increase the fold section top and bottom guide stroke using the Binding-Status Setting-Fold/Fore-edge Trim/Conveyor screen. If the problem occurs again, slow down the production speed.

Remove the sheets.

Refer to the user’s manual for TBC-200L.

An error has occurred in a downstream device. Clear the problem in the downstream device.

adjust the pressure of the transport belts. (Refer to

Horizon SPF-200A, FC-200A, SPF-200L, FC-200L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important Information

Safety Precautions

Operating Safety Precautions

1 Machine Description

1-1 Automatic and Manual Settings

1-2 Machine Descriptions

1-2-1 Safety Device / Safety Functions

1-2-2 Overall Machine

1-2-3 Manual Feed / Infeed Conveyor Section

1-2-4 Infeed Section

1-2-5 Jog Section

1-2-6 Stitch Section

1-2-7 Fold Section

1-2-8 Fore-edge Trim Section

1-2-9 Delivery Conveyor

1-2-10 Control Panel

1-3 Screen Descriptions

1-3-1 Setting-Binding Pattern Screen

1-3-2 Setting-Sheet Size Screen

1-3-3 Setting-Finishing Size Screen

1-3-4 Setting-Instruction Screen

1-3-5 Setting-Confirmation Screen

1-3-6 Binding-Operation Screen

1-3-7 Binding-Fine Adjust Screen

1-3-8 Binding-Status Setting Screen

1-3-9 Memory Screen

1-3-10 Information-Main Screen

1-3-11 Information-Monitor/Single Operation Screen

1-3-12 Information-Administrator Screen

1-3-13 Error Screen

2 Checks before Operating

2-1 Checking the Emergency Stop Function

3 Operating Procedures

3-1 Overview of Operating Procedures

3-2 Setting Up a Job Using the Setting Screen

3-3 Doing a Changeover

3-3-2 Attaching Parts After Changeover

3-3-3 Confirmation After Changeover

3-4 Doing a Test Binding

3-4-1 Preparing the Upstream Device

3-4-2 Binding a Booklet as a Test

3-4-3 Do a Test Binding and Check the Settings

3-4-4 Perform the Test Stitching

3-5 Confirming the Status Settings

3-6 Start Binding

3-7 Manual Feeding

3-8 Saving, Loading and Deleting Jobs

3-8-1 Saving a Job

3-8-2 Loading a Job

3-8-3 Deleting a Job

3-9 Power Saving Mode

3-10 Reversing the Stitcher Heads

4 Adjustments

4-1 Stitch Adjustments

4-2 Infeed Section Adjustments

4-3 Jog Section Adjustments

4-4 Fold Section Adjustments

4-5 Fore-edge Trim Section Adjustments

5 Troubleshooting

5-1 If an Icon Is Displayed on the Error Screen

5-1-1 If An Error Icon Is Displayed

5-1-2 If a System Error Occurs