Professional Documents
Culture Documents
BQ-270
Important Information
This manual is designed to help you to install, operate and maintain the BQ-270 Perfect Binder.
Please read and understand this manual, and keep it in a safe and convenient place.
Do not operate the BQ-270 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.
UM202048-11
Safety Precautions
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.
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.
Note
This explains a mechanism in the machine.
Additional
Information
Turn off the power switch before adjusting the machine. If the start button is pressed, it may
cause severe personal injury.
Do not touch the milling cutter and roughening cutter. Otherwise it may cause severe personal
injury.
Be careful not to pinch your hands when inserting the book block into the clamp.
Disconnect the power cable from the socket when recovering the breaker.
BQ-270 weighs 900 kg (1,980 lb). Transport and install the machine safely, and keep the weight
of the unit in mind.
CAUTION
When turning off the power switch and on again, wait a dozen of seconds. Otherwise, the board
may be damaged.
When the milling guide and the nipper are set narrower than the clamp width, do not move the
clamp. Otherwise, the lower part of the clamp may hit the guide and be damaged.
Do not insert book block into clamp and drive the machine while chanover. Otherwise, tha
machine may be damaged.
Make sure to tighten the lock screw of milling cover brush. Otherwise the brush may fall out
when the clamp passes over.
Do not drive the application drum when the glue is not melted completely. Othewise, the
machine may be damaged.
When using optional weekly timer, the melt tank is heated up in the set up day, at the set up time.
Check the machine when the melt tank is heated up for safe.
Use the lubrication grease recommended by Horizon. If the ingredient of the grease changes, the
life of the machine may be shortened or the machine may be damaged.
CONTENTS
Important Information
Safety Precautions
Safety Operation Precautions
1. Machine Description .................................................................................... 1
1-1 Machine Description............................................................................................... 1
1-2 Safety Functions .................................................................................................... 1
1-3 Parts Descriptions .................................................................................................. 2
1-3-1 Carriage Clamp Section ...........................................................................................
1-3-2 Level Plate Section...................................................................................................
1-3-3 Milling Section ..........................................................................................................
1-3-4 Melt Tank Section.....................................................................................................
1-3-5 Nipping Section ........................................................................................................
1-3-6 Cover Feed Section..................................................................................................
1-3-7 Delivery Section .......................................................................................................
1-3-8 Touch Screen ...........................................................................................................
2
2
3
4
5
6
7
7
21
22
22
23
24
25
26
27
27
28
28
30
31
31
32
32
55
55
56
57
58
58
59
61
62
64
65
66
67
67
68
68
5. Maintenance ............................................................................................... 69
5-1 Cleaning the Book Block Path..............................................................................
5-2 Cleaning the Sensors...........................................................................................
5-3 Lubrication............................................................................................................
5-4 Book Support Plate Replacement ........................................................................
5-5 Milling Cutter Replacement ..................................................................................
5-6 Roughening Cutter Replacement.........................................................................
5-7 Glue Replacement ...............................................................................................
5-8 Double Feed Stop Pad Replacement...................................................................
5-9 Transport Belt Replacement ................................................................................
69
71
72
73
75
78
81
83
84
6. Troubleshooting ......................................................................................... 85
6-1 Problems with Booklet Quality .............................................................................
6-2 Error Codes..........................................................................................................
6-3 If a Circuit Breaker Trips ......................................................................................
6-4 If a Message Screen Appears ..............................................................................
85
90
94
95
9. Appendix................................................................................................... 109
9-1 Specifications ..................................................................................................... 109
9-2 Accessories........................................................................................................ 110
9-3 Consumable Parts.............................................................................................. 113
9-4 Option................................................................................................................. 114
9-5 Index ................................................................................................................... 115
1. Machine Description
Milling Section
Carriage Clamp
Nipping Section
Level Plate
PERFECT BINDER
BQ-270
Trimmings Bag
Collects the trimmings.
Delivery Section
).
Area Sensors
PERFECT BINDER
BQ-270
Lubricate with
grease here.
BQ-270
Start Buttons
When using the manual starting mode, press
both buttons to start the binding operation.
Delivery Section
Each booklet is delivered here.
PERFECT BINDER
BQ-270
NG
NI
WAR
Upper Knife
This guide holds the book
spine while the milling
operation is done.
Guide Block
BQ-270
CAUTION
Wiper 2
Do not touch the melt tank after the power is turned on.
The melt tank is heated to 200 degrees Celsius (400
Fahrenheit) and may cause severe skin burn.
Lubrication Point
Application Drum 2
This drum is used to put the
glue on the book spine.
Scrape Roller
This roller scrapes the extra
glue off of the spine.
Wiper 1
The distance of glue penetration
into the spine depends on the wiper
opening.
Application Drum 1
This drum is used to provide the
glue that penetrates into the spine.
Transport Belts
Registration Stopper
Rear Nipper
This forms the book
spine with the front
nipper.
Front Nipper
DE
IN
TB
EC
RF
PE
0
7
-2
Q
B
Registration Stopper
Angle Adjusting Lever
This lever is used to adjust
the cover sheet angle.
Refer to [4-12] for details.
End Guide
Feed Table
Feed Rotor
This feeds the cover sheets
using suction and friction.
Double Feed
Detect Sensor
This detects double
feeding by measuring
the light that penetrates
the sheet.
Push Plate
This plate pushes the
delivered booklets forward.
Stopper
Set this stopper next to the push
plate. The stopper will be pushed
forward as the booklets are stacked.
BQ-270
Setting Screens
These screens are used to input the
necessary job information. Refer to [2-1].
Binding Screens
These screens are used to display the current
job information during the binding operation.
The can also be used to make fine
adjustments. Refer to [2-2].
Service Screen
Memory Screen
This screen is used to save or recall the
job settings. Refer to [2-5].
Information Screen
This screen is used to show the ROM version
and the total binding number. Refer to [2-7].
Function Screen
P. 1
P. 2
P. 3
P. 4
3
1
OK button. Each of the Setting Screens has an OK button. Press this button to input
the setting and go to the next screen.
10
1
2
3
: Each part of the machine goes back to the home position before moving to
a new set position.
: Each part of the machine moves to the set position directly.
11
Input the book block thickness. Measure the actual book block thickness using the
attached caliper and input the value. The input range is 0.3 to 50 mm (0.010 to
2.000).
Input the book block length. Measure the actual book block length and input the
value. The input range is 135.0 to 320.0 mm (5.315 to 12.600).
12
1
2
Input the cover sheet length in increments of 0.1 mm (0.005). The input range is
230.0 to 660.0 mm (9.055 to 25.985).
Input this setting first on this screen.
Input the length between the cover sheet rear edge and the spine (using either
edge, or the center of the spine). The input range is shown in illustration below.
or
: Either edge of the spine Fixed Side Downstream Movable Side
Scoring
(Front Side)
135 to 320
Scoring
(Rear Side)
110 to 310
(5.32" to 12.60")
120 to 350
25.98")
mm(inch)
Input the cover sheet width in increments of 0.1 mm (0.005). The input range is
135.0 to 320.0 mm (5.315 to 12.600).
When measuring the distance to the center of the spine, use the accessory
alignment plate.
1
9 10
.
tion
ma
uto
ka
thin
tomati
think au
1
9 20
on.
Alignment Plate
13
Function Screen
14
2-2
2-1
2-2
2-3
2-3
: Milling OFF
- If the milling set lever is set incorrectly, an error message screen will
appear.
- When Milling OFF is selected, the Insert Shim message appears.
Insert the shims, referring to the message screen and [4-7] on page 59.
2 : 2-1
2 : 2-2
Select this when doing milling. The nipper raises, then closes.
Select this when nipping without milling. The nipper closes as it raises to prevent the spine from swelling.
If this mode is selected when the milling operation is done, the spine
will become round.
2 : 2-3
Select this when binding without cover sheets. The nipper will not operate. The
machine will wait until the glue on the spine hardens, then the booklet will be
delivered.
15
P. 1
: The glue amount, wiper opening, nipping time and the nipping delay time is
set automatically depending on the book block thickness.
: The spine glue amount is set on the Gluing Part 2 and Gluing Part 4 screens.
P. 2
1
2
3
Adjust the spine glue thickness in increments of 0.1mm (0.005). The adjustment
range is 0 to +4.0 mm (0.155).
Adjust the starting point to apply the spine glue. The adjustment range is -20.0 mm to
+20.0 mm (-0.785 to +0.785).
Adjust the end point for the spine glue. The adjustment range is -20.0 mm to +20.0
mm (-0.785 to +0.785).
16
P. 3
CAUTION
10
Adjust the side gluing roller distance in increments of 0.1 mm (0.005). The input
range is -1.0 mm to +5.0 mm (-0.040 to +0.195).
P. 4
1
2
1
CAUTION
The wiper opening adjustment should not
be used to adjust the spine glue thickness.
But when the opening is set 0.5 mm (0.02)
or less, glue may not be applied to the book
spine at all.
17
P. 1
P. 2
P. 3
P. 1
P. 2
P. 3
P. 4
P. 5
18
The current job information and the production conditions are displayed here.
30
1
2
10
Binding Counter
00000
Pre-set Counter
0000 0030
0
5
Binding Counter/Pre-set Counter. Press C to clear the counter. To change to the pre-set counter,
press the counter box and input the new pre-set number using the Numeric Keypad Screen. Press the
right part of the pre-set counter (
2
3
This adjusts the production speed (carriage clamp moving speed) in five steps.
: Slow down
: Speed up
This indicates the book block thickness already entered on the Setting Screen.
This indicates the distance between the cover sheet edge and the spine already entered on the Setting
Screen.
When using a saved job, the job number appears here. When not using a saved job or the read memory
has been changed, 0 is indicated here.
6
7
Press this button to feed one cover sheet. The machine memorizes the cover sheet thickness in order to
detect the double feeding.
This button is used to stop the motor on each unit after the binding operation. (Before the motor drives,
start icon is indicated.) Press this button before switching the power off.
10
Status Monitor
: This symbol will appear when the cover sheet is fed to the nipping section, and the book block is
put in the carriage clamp.
:This symbol will appear if a cover sheet is not fed automatically to the nipping section. Feed a cover
sheet by pressing both start buttons.
Booklet is not delivered within 2 seconds after the carriage clamp has opened.
Double feeding
Misfeeding
In operation
OK
19
The test milling and test gluing operations can be performed using this screen.
4
2
Test Milling Button. Press this button, and only the milling operation is performed and
the booklet is delivered from the delivery section. Use this function to check milling
depth.
Test Gluing Button. Press this button to perform milling and gluing operation. The
booklet stops above the nipping section with no cover sheet and stays there until the
start button is pressed. Wait until the glue hardens, and check the applied glue
amount. Press start buttons to deliver the booklet. Use this function to check the glue
amount on the booklet.
Test Binding Button. Press this button to perform a single binding with a cover sheet.
The machine does not feed the next cover sheet.
This button is used to stop the motor on each unit after the binding operation. (Before
the motor drives, start icon is indicated.) Press this button before switching the power
off.
Press this button to feed one cover sheet. The machine memorizes the cover sheet
thickness in order to detect the double feeding.
20
You can use this screen to make fine adjustments to the carriage clamp width and the
milling guide width.
1
2
Adjust the carriage clamp opening amount so that the book block is inserted
smoothly. Unless you make this adjustment, the carriage clamp opens just the same
amount as the book block thickness. Increase the opening to match the type of the
book block. The input range is 0 to +15.0 mm (+0.590).
: Makes the carriage clamp width wider. (Use this when using signatures.)
: Makes the carriage clamp width narrower. (Use this when using sheets which
crease or tear easily.)
Adjust the opening so that the book block can move into the carriage clamp easily
without being disturbed. After the adjustment, check that there is enough carriage
clamp pressure by pressing the Carriage Clamp Close button on the Single Operation
Screen.
Adjust the milling guide width. The input range is 0 to +10. 0 mm (+0.395).
This adjustment may be necessary when using signatures. (Signatures can cause the
spine of the book block to swell and hit the milling guide.)
: Make the milling guide wider.
: Make the milling guide narrower.
When using signatures, make the milling guide wider to give the spine a good finish.
However, if the guide is set too wide, the spine will be allowed to expand too much.
21
P. 1
1
2
3
This adjusts the spine glue thickness in increments of 0.1mm (0.005). The adjustment range is 0 to +4.0 mm (0.155).
This adjusts the starting point for the spine glue. The adjustment range is -20.0 mm to
+20.0 mm (-0.785 to +0.785).
This adjusts the end point for the spine glue. The adjustment range is -20.0 mm to
+20.0 mm (-0.785 to +0.785).
P. 2
This adjusts the side gluing roller distance in increments of 0.1 mm (0.005). The
adjustment range is -1.0 mm to +5.0 mm (-0.040 to +0.195).
CAUTION
The side gluing roller distance should not
be used for adjustment of the side glue
amount. This adjust the side gluing roller to
correct position depending on the booklet
thickness.
22
P. 3
1
2
CAUTION
The wiper opening adjustment should not
be used to adjust the spine glue thickness.
But when the opening is set 0.5 mm (0.02)
or less, glue may not be applied to the book
spine at all.
23
This allows for adjustment of the nipping delay time, nipping time and nipper width.
1
2
3
24
1
2
The fixed rollers actually do not move. If the fixed scoring roller position is
adjusted on the screen, the stack of cover sheets actually moves to compensate.
25
P. 1
This allows for fine adjustment of the nipper against the cover sheet.
Registration Position
Cover Sheet
2
3
Original Position
3mm (0.12")
4
Cover Sheet
3mm (0.12")
Press this button to move the nipper against the cover sheets.
Normally, step 2 through 4 cannot be performed because the jog guides are
not pressed against the cover sheet. Before doing the other adjustments
(step 2 through 4), press button 1 to bring the jog guides up against the
cover sheet. After the adjustments, press the button again to return the jog
guides to their original positions.
3
4
Press the
button to move the stack of sheets position to the right (cover feeder
side) by 0.2 mm (0.008). The input range is -3.0 mm to +3.0 mm (-0.110 to +0.110).
This changes the jog guide spacing by 0.1 mm (0.005). The input range is -10.0 mm
to + 10.0 mm (-0.395 to +0.395).
Press the
button to move the cover sheet position to the rear by 0.1 mm
(0.005). The input range is -10.0 mm to +10.0 mm (-0.395 to +0.395)
If you make this adjustment, make sure to adjust the position of the stack of
cover sheets by the same amount.
26
P. 2
This allows for fine adjustment of the cover sheet stack position.
11
P. 3
Registration Stopper
This sets the pressure produced by the transport belts. After the cover sheets are fed
by the feed rotor, the transport belts feed the covers back to the registration stopper.
The pressure of the transport belt is adjustable in five steps. Normally, use a loose
setting when using thin sheets and use a tight setting when using thick sheets. The
standard setting is
.
This adjusts the vacuum to the feed rotor when feeding the stacked sheets. If doublefeeding occurs often, make the vacuum weaker. If mis-feeding occurs often, make the
vacuum stronger. The standard setting is
.
27
12
P. 4
1
2
for normal use. If using thick or dark cover sheet, or if fault detection of
and
This sets the sensitivity of the double feeding detect sensor using
(middle), and
(high),
(low).
P. 5
58mm
This sets the number of the window (hole) on the cover sheets.
The sensor which detects the window on the cover is located 58 mm rear side from
the rear registration position.
When not entering the number of the window, reposition the cover sheet and the book
block so that the window does not pass over the sensor.
Input range is 0 to 9.
28
2
6
Milling Operation ON
This area indicates the job settings saved for the selected job number. (In this example, the screen shows that job number 10 includes
: milling operation ON and
nipping with milling.)
This is the save button. Press this button to save the present settings to memory.
Select the job number, then press the save button. Press OK on the Write OK Screen,
and the present setting will be stored to the selected job number.
5
6
This is the read out or recall button. Press the job number you want to read out, the
press this button. Press OK on the Read Out OK Screen and go back to the Binding
Screen. Press OK on the Changeover OK Screen, and all parts of the machine will
move to the set (read out) positions.
This is the Delete button. Select the job number to delete and press this button. The
selected memory will be deleted.
This is the Current Settings button. Press this button to indicate the current settings.
29
P. 1
P. 2
P. 3
P. 1
6
7
Press
3
4
5
6
7
Jammed Booklet Delivery Button. Press this button to open the clamp to release the
jammed booklet.
Carriage Clamp Close
Carriage Clamp Open
This triggers the booklet delivering motion: the level plate moves back and the carriage clamp opens.
This is the Carriage Clamp Move button. Press this button and then press the Start
buttons. The carriage clamp rail rises and the carriage clamp moves above the nipper. This button is used when setting the milling depth, or when replacing the carriage
clamp support plate.
Instruction for the next step to move the carriage clamp.
riage clamp is moving.
30
P. 2
CAUTION
The upper adjustable scoring roller will not
move if it presses too tightly against the
lower adjustable scoring roller.
3
5
The nipper moves down and opens completely. This button is used when cleaning the
nipping section.
The lower adjustable scoring roller moves next to the fixed scoring rollers.
This button is used to bring the upper and lower adjustable scoring rollers together.
4
5
This moves the lower adjustable scoring roller to the set position.
: Opens the milling guide to the limit.
: Moves the milling guide to the set position.
P. 3
1
2
: Press this button once, and the carriage clamp opens by 10 mm (0.395).
Use this button when the book block is caught on the carriage clamp.
:Press this button to reposition the delivery section after cleaning.
:The delivery section moves back. This button is used when cleaning the
delivery section.
31
Press the
button for the section which you want to send to the home position.
(There are conditions which could cause part of the machine to lose its home position.)
This is the brake release button for the milling motor. The milling motor can not be
released by pressing the brake release button on the machine until this button is
pressed. Use this button when replacing the milling cutter or the roughening cutter.
32
1
2
3
4
5
6
1
2
3
4
: When changing the binding mode, the milling operation is set automatically
depending on the selected binding mode.
: When changing the binding mode, the milling operation is set manually
by operator.
6
7
: The jog guides are opened when the cover sheet is moved back to the registration stopper.
: The jog guides are closed when the cover sheet is moved back to the registration stopper.
33
1
2
3
4
5
This screen is used to enter or input values. Input the value, then press ent (enter).
If you enter an improper value, the value will not be accepted, and an E will appear
on the screen.
Press
34
WARNING
The glue inside the tank melts 40 to 50 minutes
PERFECT BINDER
Warm-Up Screen
CAUTION
Power Switch
When the warm up has completed, the glue temperature does not necessarily rise to the set
temperature, therefore it can be warm enough
for the application drum to rotate.
Area Sensor
Emergency
Stop Button
35
36
Without Milling
37
With Milling
PERFECT
- Press
, and the changeover is canceled
and the previous screen appears.
- While the changeover, Changeover Screen
appears.
38
OK. If
is pressed, the changeover is canceled and the previous screen appears.
rectly, press
to move the clamp and set the
level plate height correctly referring to page 59, then
press OK. If
is pressed, the changeover is
canceled and the previous screen appears.
39
Binding counter
This area can display both the
binding counter and the pre-set counter.
sensor
Window
58mm
Cover Sheet
40
Press the
(standard) button
for the scoring roller on the Single
Operation Screen Part 2.
CAUTION
If the safety cover is opened while the scoring roller is moving, the scoring roller will
stop at the wrong position. Check that the
scoring roller has finished moving before
opening the cover.
Adjustable Scoring
Roller
Scoring Roller
Pressure Knob
Upper Adjustable
Scoring Roller
Fixed
Roller
Lower Adjustable
Scoring Roller
41
Press the
(Setting Position)
button on the Single Operation
Screen.
CAUTION
If the scoring pressure is so strong so
that the scoring roller does not rotate,
the machine may be damaged when
performing a changeover. Before each
changeover, check with your finger to
ensure that the scoring rollers rotate
smoothly.
42
[How to adjust]
- Loosen the lock screw using the wrench, and
move the scraper holding the lever.
CAUTION
screen. Select
(Manual) on the
Gluing Screen Part 1, and raise the
scraper gradually checking the glue
scraping condition. Do not raise the
scraper too much, otherwise the
scraper hits the booklet and be damaged.
- Scraper is very hot. Wear thick gloves
when setting the scraper.
Press
on the Gluing Screen
Part 2 and set the glue thickness to
1.0 mm.
Open the safety cover (right).
CAUTION
- When performing the binding with
cover sheets, make sure to reposition
the scraper at lowest position. Otherwise, the scraper hits the booklet and
be damaged.
- If the glue is burned, the scraper can
not be smoothly adjusted. Make sure to
wipe off the extra glue on the scraper
after the operation, so that it can be
adjusted in anytime.
Scraper
Lever
Lock Screw
Stopper
43
The screen will tell you to dislocate the side glue roller
on the far side.
CAUTION
CAUTION
Wear thick gloves during this operation. The melt tank may be heated to
200 degrees Celsius (400 Fahrenheit)
and may cause severe skin burns.
Wear thick gloves during this operation. The melt tank may be heated to
200 degrees Celsius (400 Fahrenheit)
and may cause severe skin burns.
Allen Wrench
Allen Wrench
0
0
Locking Screw
Positioning Plate
Locking Screw
Positioning Plate
44
1 to check that the glue is heated to the setting temperature and melted completely.
WARNING
- Do not put your hand inside the machine
when the carriage clamp is operating. This
part can cause severe personal injury.
- When feeding a book block, remove your
hand from the carriage clamp before it
moves. This part can cause severe personal injury.
45
46
Feed Table
47
WARNING
Press the Emergency Stop button before
removing the booklets. If you do not do
this, the machine may start suddenly and
cause severe personal injury.
Stopper
Stopper
Delivery Guide
Delivery Chute
48
Press the
button.
- White ( 1 ): Empty
- Gray ( 5 ): Saved job
- Black ( 10 ): Now selected
Press
OK
49
Press OK.
50
Press
(delete).
Press OK.
- Selected memory will be deleted.
51
WARNING
CAUTION
52
Press the
(Stop) button on
the Binding Screen.
PERFECT BINDER
Power Switch
53
54
4. Adjustments
4-1 Changing the Spine Glue Amount and Position
If too much or too little spine glue is applied, you can
adjust the amount of spine glue and the starting and
ending position.
55
Adjust the nipping delay time, nipping time and the nipper width
using the Nipping Screen. Refer to
page 24.
Nipping Delay Time
Nipper Width
Nipping Time
56
Registration Stopper
Registration Button
Adjust the cover sheet stack position to match the settings made in
step 1.
Feed Rotor
Vacuum
Cover Sheet
Guide Width
1
2
57
Fixed Side
Adjustable Side
4-6 Changing the Carriage Clamp Opening and Milling Guide Width
If the book block escapes when the machine is performing a milling or nipping operation, decrease the
opening of the carriage clamp.
If the book block moves when it hits the milling guide,
increase the milling guide width.
58
59
Level Plate
Shim
3 mm (0.12)
2 mm (0.08)
1.5
1.5 mm (0.06)
1 mm (0.04)
1 and 1.5
0.5 mm (0.02)
1 and 2
60
Thermometer
Application Drums
CAUTION
PERFECT BINDER
BQ-270
120 140 C
160
180
61
CAUTION
Wear thick gloves during this operation.
The melt tank may be heated to 200
degrees Celsius (400 Fahrenheit) and may
cause severe skin burns.
Allen Wrench
Locking Screw
Positioning Plate
62
WARNING
Wear thick gloves during this operation.
The glue amount adjusting plate is very
hot, and may cause severe skin burns.
63
- If the spine is round, turn the ring counterclockwise. If the spine is too sharp, turn
the ring clockwise.
- Usually the ring is set between 3 and 6.
- The ring is set to 4.5 at the factory.
Higher (Spine
becomes
sharp)
(Spine
becomes
round) Lower
Adjusting Pin
64
Nipper
Locking Screw
65
Adjust Knob
Registration
Stopper Angle
Adjusting Lever
Cover
Locking Knob
Registration Stopper
Angle Adjusting Lever
66
Strong
Weak
Pad Height
Adjusting Lever
67
Feed Table
- Turn the scoring roller pressure knob counterclockwise to make the scoring line more shallow. Turn it clockwise to make the scoring line
deeper.
- To get the standard settings, turn the knob
one rotation counterclockwise from the stop.
CAUTION
If the scoring pressure is so strong that the
scoring rollers do not turn, the machine
may be damaged during the changeover.
Before each changeover, check that the
scoring rollers rotate smoothly by turning
them by hand.
68
5. Maintenance
5-1 Cleaning the Book Block Path
Press the
button (Carriage
Clamp Move) on the Single Operation Screen Part 1.
WARNING
Do not touch the melt tank. The melt tank is
heated to 200 degrees Celsius (400 Fahrenheit), and may cause severe skin burns.
Do not touch the milling and the roughening cutters. These can cause severe personal injury.
Vacuum Cleaner
Press the
button (Carriage
Clamp Move) on the Single Operation Screen Part 1.
- Press both Start buttons twice. The carriage
clamp will move back to the left side by first
press. Then the clamp rail lowers by second
press and carriage clamp opens.
Cover Links
Cutter Cover
69
Press the
button (Nipper
Cleaning) on the Single Operation
Screen Part 2 while the safety
cover is closed.
WARNING
Turn off the power switch before cleaning
this area. The machine may start suddenly,
causing severe personal injury.
Stopper
Press the
button (Nipper
Cleaning) again.
- The nipper will return the previous position.
70
= Cotton Swab
multiple number.
1d = Every Day
1w = Once every week Example:
2w = Once every 2 weeks
1m = Once every month
= Once every 6 months
6m
1y = Once every year
= Brush
= Air
(Horizon Air Duster)
1m
Cover Sheet
Detect Sensor
on Feed Table
1m
Compressed
Air
1m
Double Feed
Detect Sensor
PERFECT BINDER
BQ-270
71
5-3 Lubrication
Frequency Symbol
Lubrication Symbols
= Lubricate using a lubrication brush
= Lubricate using an oil applicator
= Lubricate using a grease gun
1d
1w = Once every week Example:
2w = Once every 2 weeks
1m = Once every month
= Once every 6 months
6m
1y = Once every year
= Every Day
1m
20 drops
Grease Nipples
3m
1m
CAUTION
After applying grease, run the
application drums for at least 10
minutes before binding.
PERFECT BINDER
1m
BQ-270
Level Plate
72
Side Cover
.
Carriage Clamp
Carriage Clamp
73
74
CAUTION
- When loosening the mounting screws of the
milling cutter, turn off the power switch. Otherwise, the machine may start suddenly and
cause severe personal injury.
- Wear thick gloves during this operation, and
do not touch the edges of the milling or
roughening cutters. Otherwise, the sharp cutters can cause severe personal injury.
- The melt tank is very hot for a while after the
power is turned off. Do not touch the tank.
75
Milling Cutter
Mounting Screw
Pulley
CAUTION
Clockwise
- Wipe off the grease on the surface of the cutter before attaching it.
- Mount the new milling cutter and temporarily
tighten the four mounting screws.
Place the front milling guide in a position where the rear milling guide can be
attached.
Upper Knife
76
CAUTION
In general, do not sharpen the top surface
of the milling cutter. This will reduce the
height of the milling cutter. If the milling
cutter is sharpened, insert a spacer
between the milling cutter and the milling
holder. This will raise the milling cutter as
shown in the illustration below. The roughening cutter should also be lowered. Make
a stack of sheets which has a thickness
equal to the amount removed from the milling cutter during sharpening. Insert this
stack between the roughening cutter and
the roughening cutter setting gauge.
Roughening Cutter
Setting Gauge
Spacer
Milling Cutter
Milling Holder
Upper Knife
0.1 mm (0.04")
0.1 mm
(0.04")
Milling Cutter
77
Press the
button (Brake
Release) on the Milling Brake
Release Screen.
WARNING
Turn off the power switch before performing this operation. A sudden start of the
machine can cause severe personal injury.
Wear thick gloves and do not touch the
edge of the milling or roughening cutter.
Otherwise, a sharp cutter can cause severe
personal injury.
Safety Cover
Cover
Gummed
Tape
Gummed
Tape
Cover
Safety Cover
78
(5) Loosen the mounting screw of the roughening cutter using a 2.5 mm (0.098) Allen
wrench.
Brake
Release
Button
Rotating Direction
Roughening Cutter
Roughening Cutter
(2) There are cutters on both sides of each
roughening cutter. One roughening cutter can
be used twice.
Clockwise
(3) Push down the edge of the roughening cutter using the roughening cutter setting gauge
and tighten the set screw.
Roughening Cutter
Milling Cutter
Roughening
Cutter Setting
Gauge
Spring
Roughening Cutter
Allen Wrench
Set Screw
Cloth
(4) Remove the roughening cutter setting
gauge.
Spring
Set
Screw
Allen
Wrench
79
80
Hook the drain guide on the attaching screws on the melt tank.
WARNING
The melt tank may be heated to 200
degrees Celsius (400 Fahrenheit), and may
cause severe skin burns. Wear tightlywoven cotton gloves when draining the
glue.
Attaching
Screws
Press the
button on the Single
Operation Screen Part 2 to lower
the melt tank.
WARNING
For the box to catch the glue, use a
durable one against the heat. It is
dangerous when the box is broken
or cracks.
81
Mounting
Screws
82
Mounting Screws
83
Transport Belt
Transport Belt
Nylon Tie
84
6. Troubleshooting
6-1 Problems with Booklet Quality
Gluing Problems
Problem
Cause
Remedy
See page
Page 22
Page 22
Page 22
Page 16
Page 22
Page 55
Page 16
Page 22
Page 23
Page 22
Page 64
Page 55
Page 22
Page 23
Page 94
Page 24
85
Cause
Remedy
See page
Page 70
Page 70
Page 21
Page 24
Page 15
Page 64
Page 24
Page 15
Page 15
Page 64
Page 24
Page 24
Page 22
Page 65
Page 103
86
Cause
Remedy
See page
Page 27
Page 66
Service
Page 33
Page 26
Page 25
Page 71
Page 26
Page 27
Page 5
Page 5
The jog guide width on the nipper is too wide, or too narrow.
Page 26
Page 27
Page 84
Page 19
Page 61
Page 24
Page 94
The cover sheet is shifted parallel to the book block toward the
fore-edge.
The cover sheet is shifted parallel to the book block in the topbottom direction.
87
Cause
Remedy
See page
Page 68
Page 68
Page 41
Page 6
Page 27
Page 25
Cause
Remedy
See page
Page 111
88
Cause
Remedy
See page
Page 10
The jog guides and the positioning guides are not aligned
with each other.
Page 26
Page 27
Page 5
Page 5
Page 75
Page 59
Page 10
Page 22
Page 69
Page 94
Page 71
Page 27
Page 27
Page 94
Page 94
89
Page 32
Error Codes
Cause
Remedy
See page
0001
0002
0003
0004
0501
0601
1001
Service call
Service call
1101
Service call
1111
Service call
1112
Service call
1113
Service call
1121
Page 94
Service call
Page 94
Service call
1122
90
Cause
Remedy
See page
1123
Page 94
Service call
Page 94
Service Call
Page 94
Service Call
1131
1132
1201
Service Call
1301
Service Call
1302
Service Call
1303
Service Call
1304
Service Call
91
Cause
Remedy
See page
1401
Page 12
Service Call
Page 94
Service Call
Page 94
Service Call
1411
1412
1501
Service Call
1502
Service Call
1503
Service Call
1601
Service Call
1611
Check the feed table upper position sensor B63 and the motor
rotation.
Service Call
1612
Check the feed table lower position sensor B64 and the motor
rotation.
Service Call
92
Cause
Remedy
See page
0801
Delivery error
Page 94
Service Call
Page 48
Page 94
1801
Thermo-Fuse error
93
WARNING
Turn off the power switch before turning
ON the breaker. Otherwise, it can cause an
electrical shock.
DER
T BIN
10
70
BQ-2
A50
FEC
PER
A40
A30
A20
Error No.
Location
Code No.
Trouble
1121,1122,1123
Q50
1131,1132
Q40
1411,1412
Q30
1123
Q20
0801
Q70
1801
Q80
No Error No.
Q60
No Error No.
Q12
No Error No.
Q11
No Error No.
Q01
94
When
95
96
7. Optional Device
7-1 Weekly Timer
Two power switch operation
ON
PERFECT BINDER
BQ-270
97
OFF
7-1
Weekly Timer
- If the starting time for the melt tank heating is set beforehand, the binding operation can be started without waiting for the
glue to be melted.
- When using the weekly timer, leave the
main power switch turned ON.
- If the power switch for the main body of
BQ-270 is not turned on for over 300 hours,
the Sunday (S) lamp may blink when the
power switch is turned on. In this case, set
the current time and day. (Refer to the next
page)
Reset Lamp
When this timer does not work correctly
according to setting, reset lamp illuminates.
Setting Scale
This scale is used to set the time to
turn the BQ-270 ON or OFF. One
rotation takes a day and the indexes
can be set every 15 minutes. Set the
tabs inside to turn on the setting.
NORMAL
CONTINUOUS
RESET
OUTPUT
OFF
AUTO
S
1 24 23
22
21
18
20 19
T
W
T
40
Minutes Scale
45
Day Lamps
Output Lamp
13 12 11 10
Hours Scale
DAY
SETTING
PRESENT
TIME
OFF
AUTO
ON
OFF
AUTO
98
ON
7-1
Weekly Timer
1 24 23
22
21
18
20 19
40
45
NORMAL
CONTINUOUS
RESET
OUTPUT
13 12 11 10
AUTO
OFF
S
M
T
W
T
F
S
Scale
Hour
Normal/Continuous Switch
Minute
CAUTION
Day Select
Switch
DAY
SETTING
OFF
ON/Auto/OFF Switch
ON
AUTO
MondayFriday
ON
CONTINUOUS
RESET
OUTPUT
12:00
(B) 17:00
19:00
Saturday,
Sunday
12
DAY
SETTING
AUTO
S
M
T
W
T
F
S
OFF
(A) 8:00
19 17
OFF
OFF
Current Day
Lamp
Output
Current Day
Setting Button
SUN
ON
Time Switch
MON
AUTO
99
TUE
WED
THU
FRI
SAT
7-1
Weekly Timer
- When controlling the machine auto-startup over a break between days, the program continues from the previous day.
Therefore, the machine is powered up until
it reaches the off setup time, even though
the day select switch for the day is turned
off.
MondayFriday
ON
(A) 8:00
16:00
(B) 20:00
6:00
Saturday,
Sunday
OFF
Satu
rday, Sunday
NORMAL
CONTINUOUS
RESET
OUTPUT
NORMAL
CONTINUOUS
RESET
OUTPUT
S
M
T
W
T
F
S
S
M
T
W
T
F
S
Day Select
Switches
Normal/Continuous
Switch
AUTO
OFF
Normal/Continuous
Switch
AUTO
OFF
Day Select
Switches
DAY
SETTING
OFF
DAY
SETTING
OFF
ON
AUTO
ON
AUTO
Time Switch
6
17
20
16
Time Switch
Output
Output
SUN
SUN
MON
TUE
WED
THU
FRI
MON
WED
THU
FRI
SAT
8:00
TUE
100
17:00
SAT
8. Installation
8-1 Installation
This section includes procedures that can be performed
only by our service engineer.
CAUTION
The BQ-270 weighs about 900Kg (409 lb).
Be careful when moving the machine.
Top View
PERFECT BINDER
Chain
BQ-270
Carriage Clamp
- Place a water level on the nipper in two directions (shown in the illustration below) to check
for level.
ER
EC
F
ER
P
101
D
BIN
0
7
2
Q
B
8-1 Installation
Place a foot under the fourth leveling bolt shown in the illustration
below.
Top View
Lock Nut
Leveling Bolt
Ground
Foot
CON3
CON4
Spacer
Mouth
102
8-1 Installation
Wire the machine.
Cover
Gummed
Tape
Gummed
Tape
Cover
Safety Cover
4) Press
Sheet Guide
WARNING
Clockwise
Tape
5) If the milling cutter rotates counterclockwise, exchange the two black cables (out of
three) each other at the power box, which
supply the power to the machine.
Black
Ground
103
Hose Band
Duct
Small Cover
K82 A22
Flange
1 3 6 13 A1
K82
2 4 6 14 A2
BLK
RED
WHT
104
GRN
K82 A22
Q80
10
9
9A
6
10A
Check that the fan rotates to the direction shown in the illustration above. If
the fan rotates backward, switch the
position of two wires out of three.
105
99
RED
WHT
BLK
Not
used for
BQ-270
100
61
95
BLK
WHT
WHT
BLK
WHT
WHT
BLK
73
98
106
8-3
Wires
Lock Screw
Fixing Plate
PERFECT BINDE
BQ-270
Front Cover
Plate
Switch
Bracket
Handle
Screw
107
99
100
Bracket
Handle
8-3
(1) Reconnect the heater wire which is connected on the terminal No.4, to the terminal
No.9.
Terminal Board
K01
K02
WHT
26
BLK
1
2
3
4
5
6
7
8
9
RED
WHT
26
BLK
RED
BLK
(1) Remove three wires No.18 which is connected between Q01 and Q80.
BLK
Q01
BLK
18
BLK
18
18
RED
Q80
BLK
BLK
BLK
K11
K20
K60
K10
K83
BLK
WHT
BLK
RED
RED
WHT
BLK
RED
99
100
73
WHT
98
To Power
Switch for
main body
of BQ-270
To Relay
1
2
3
4
5
6
7
8
9
KO1
KO2
WHT
Q01
Q80
108
9. Appendix
9-1 Specifications
Binding Type
Number of Clamper
Binding Thickness
1 to 50 mm (0.04 to 2.00)
Max. 70 mm (2.7)
Warm up Time
40 min.
135 to 320
Movable Side
Scoring
(Front Side)
110 to 310
(5.32" to 12.60")
120 to 350
mm(inch)
Glue Temperature
3 mm (0.12)
Production Speed
Voltage/Frequency
AC220V/230V/240V/400V 50Hz/60Hz
(3 phases 3 wires plus PE)
Rated Current
Power Consumption
Machine Dimensions
Noise Level
L A peak: 83.3 dB
L A eq: 74.0 dB
Machine Weight
109
9-2 Accessories
Tool Box (4-003344)
1pc
Shim
2 pcs each
1.0mm (0.04")(M011601)
1.5mm (0.06")(M049499)
2.0mm (0.08")(M011602)
1.0 mm thim is attached on the machine.
1 pc
1 pc each
1 pc
1 pc
6 mm (0.24")(4001744)
5 mm (0.2") (4000968)
4 mm (0.16")(4001439)
3 mm (0.12")(4001438)
2.5 mm (0.1") (4001437)
2 mm (0.08")(4001320)
1 pc
30 mm (1.18")
7 x 8 mm (0.28"x 0.31")
1 pc
110
1 pc
9-2 Accessories
Installation Bolts
4 pcs
1 pc
Screwdriver (4000967)
1 pc
1 pc
1 pc
Foot (M005374)
1 pc
1 pc
Adapter (M127356-01)
1 pc
4 pcs
Spacer (M127359-00)
1 pc
111
9-2 Accessories
Fuse (E319737)
Grease (4017229)
2 pcs
1 pc
Glue (HM-220)
1 pack
1 pc
10
70
80
90
10
0
1 pc
1 pc
1 pc
1 pc
1 pc
Thermometer (4017505)
1 pc
Concave
100
80
60
40
20
0
120
140
160
200
180
112
1 box
1 pc
1 pc
1 pc
Grease (4017229)
1 pc
1 pc
1 pc
HM
-22
2 pcs
(Violet)
113
9-4 Option
Extractor (VS-270)
1 pc
Weekly Timer
114
1 pc
9-5 Index
B
Binding Counter ......................................................................................................................... 19
Binding Mode Screen ................................................................................................................. 10
Binding Screens ......................................................................................................................... 18
Blower Air Adjustment ............................................................................................................... 67
Book Block Length Setting......................................................................................................... 12
Book Block Size Screen ............................................................................................................. 12
Book Block Thickness Setting .................................................................................................... 12
Book Support Plate Replacement .............................................................................................. 73
C
Carriage Clamp Section ............................................................................................................... 2
Clamp and Milling Fine-Adjustment Screen................................................................................ 21
Clamp Opening Amount Adjustment .......................................................................................... 21
Cover Feed Section ..................................................................................................................... 6
Cover Feeding Settings ............................................................................................................. 57
Cover Sheet Angle Adjustment .................................................................................................. 66
Cover Sheet Fine-Adjust Screen Part 1 ..................................................................................... 26
Cover Sheet Fine-Adjust Screen Part 2 ..................................................................................... 27
Cover Sheet Fine-Adjust Screen Part 3 ..................................................................................... 27
Cover Sheet Fine-Adjust Screen Part 4 ..................................................................................... 28
Cover Sheet Fine-Adjust Screen Part 5 ..................................................................................... 28
Cover Sheet Length Seting......................................................................................................... 13
Cover Sheet Size Screen ........................................................................................................... 13
Cover Sheet Width Setting ......................................................................................................... 13
D
Delete Button ............................................................................................................................. 29
Delivery Section ........................................................................................................................... 7
Double Feed Detecting Function ............................................................................................... 14
Double Feed Stop Pad Adjustment ............................................................................................ 67
Double Feed Stop Pad Replacement ......................................................................................... 83
E
Error Screen................................................................................................................................ 34
Extractor ................................................................................................................................... 104
F
Feed Rotor Vacuum Adjustment ................................................................................................ 27
Feed Table Height Adjustment .................................................................................................. 68
Function Screen......................................................................................................................... 14
G
Glue Amount Adjusting Plate ..................................................................................................... 63
Glue Fine-Adjust Screen Part 1 ................................................................................................. 22
Glue Fine-Adjust Screen Part 2 ................................................................................................. 22
Glue Fine-Adjust Screen Part 3 ................................................................................................. 23
Glue Replacement ..................................................................................................................... 81
Gluing Screens .......................................................................................................................... 16
H
Home Positioning Screen .......................................................................................................... 32
I
Information Screen ..................................................................................................................... 33
115
L
Level Plate Section ...................................................................................................................... 2
M
Main Binding Screen ............................................................................................................ 19, 40
Melt Tank Section ........................................................................................................................ 4
Memory Function ....................................................................................................................... 49
Memory Screen.......................................................................................................................... 29
Milling and Nipping Screen ........................................................................................................ 15
Milling Brake Release Screen.............................................................................................. 32, 75
Milling Cutter Replacement ........................................................................................................ 75
Milling Depth Adjustment ........................................................................................................... 59
Milling Guide Width Adjustment ................................................................................................. 21
Milling Section .............................................................................................................................. 3
N
Nipper Angle .............................................................................................................................. 65
Nipper Height ............................................................................................................................. 64
Nipping Delay Time .................................................................................................................... 24
Nipping Fine-Adjust Screen ....................................................................................................... 24
Nipping Section ............................................................................................................................ 5
Numeric Keypad Screen ............................................................................................................ 34
P
Pre-set Counter .......................................................................................................................... 19
R
Read Out Button ........................................................................................................................ 29
Registration Stopper Angle Adjustment ..................................................................................... 66
Roughening Cutter Replacement ............................................................................................... 78
S
Safety Function Check............................................................................................................... 35
Scoring Fine-Adjust Screen ....................................................................................................... 25
Scoring Position Change ........................................................................................................... 58
Scoring Roller Pressure Adjustment ........................................................................................... 68
Scoring Roller Setting ................................................................................................................ 41
Setting Screens ...................................................................................................................... 9, 36
Shim Installation.......................................................................................................................... 60
Side Glue Amount Adjustment ............................................................................................. 55, 62
Side Gluing Roller (Far Side) Positioning Plate ......................................................................... 62
Side Gluing Roller Settings .................................................................................................. 22, 44
Single Operation Screens .......................................................................................................... 30
Single Operation Screen Part 1 ................................................................................................. 30
Single Operation Screen Part 2 ................................................................................................. 31
Single Operation Screen Part 3 ................................................................................................. 31
Spine Glue Amount Adjustments ............................................................................................... 55
Start Mode Screen ..................................................................................................................... 11
T
Touch Screen ............................................................................................................................... 7
Transport Belt Pressure Adjustment .......................................................................................... 27
W
Weekly Timer ..................................................................................................................... 97, 106
Wiper Opening Adjustment ......................................................................................................... 23
Write Button ............................................................................................................................... 29
116