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Horizon Fitness BOOK BINDER BQ-470 User Manual

Horizon Fitness BOOK BINDER BQ-470
246 pages
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I
• This manual is designed to help you to install, operate and maintain the BQ-470/
BQ-470D Book Binder. Please read and understand this manual, and keep it in a
safe and convenient place.
• Do not operate the BQ-470/BQ-470D 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.
Important Information
BOOK BINDER
BOOK BINDER
BQ-470/BQ-470D
151210/BQ470/30E/HN,TM,HK/F7/IXI/PXI
UM202064-30(000)
*UM202064*

Table of Contents

Questions and Answers:

Horizon Fitness BOOK BINDER BQ-470 Specifications

General IconGeneral
BrandHorizon Fitness
ModelBOOK BINDER BQ-470
CategoryCommercial Food Equipment
LanguageEnglish

Summary

Important Information

Safety Precautions

Operating Safety Precautions

WARNINGS for Operation

Details critical operational hazards and warnings for safe use of the machine.

CAUTIONS for Operation

Outlines operational risks and precautions to prevent damage or injury.

Operating Safety Precautions

WARNINGS for Maintenance

Highlights critical hazards and warnings during maintenance procedures.

CAUTIONS for Maintenance

Details risks and precautions relevant to machine maintenance.

WARNINGS for Installation

Emphasizes critical hazards and warnings during machine installation.

CAUTIONS for Installation

Outlines risks and precautions for safe machine installation.

Warning Label Locations and Meanings

1. Machine Description

1-1 Automatic and Manual Settings

Explains machine settings that can be automatic or manual.

1. Machine Description

1-2 Machine Parts and Functions

Details the various parts of the machine and their functions.

1. Machine Description

1-2-2 Book Block Feed Section

Describes the section for feeding book blocks into the carriage clamp.

1. Machine Description

1-2-3 Milling Section

Details the milling section for preparing book block spines.

1. Machine Description

1-2-4 Side Gluing Section

Describes the section responsible for applying side glue to spines.

1. Machine Description

1-2-5 Spine Gluing Section

Details the section for applying spine glue to book block spines.

1. Machine Description

1-2-5 Spine Gluing Section - continued

Continues the description of the spine gluing section components.

1. Machine Description

1-2-6 Nipping Section

Details the nipping section for attaching covers to spines.

1. Machine Description

1-2-7 Cover Feed Section

Describes the section responsible for feeding covers to the machine.

1. Machine Description

1-2-8 Delivery Section

Details the section where finished books are delivered.

1. Machine Description

1-2-9 Stacker

Describes the stacker where bound books are collected.

1. Machine Description

1-3 Screen Functions

Explains the various screens and interface functions of the machine.

1-3-1 Setup Screen

Details the primary screen for setting up bookbinding jobs.

1. Machine Description

1-3-1 Setup Screen - continued

Continues the description of the setup screen functionalities.

1. Machine Description

1-3-2 Bookbinding Screens

Explains the interface screens used during the bookbinding process.

1. Machine Description

1-3-3 Memory Screens

Details how to save, load, and delete job settings.

1. Machine Description

1-3-4 Information Screens

Describes screens displaying machine status and diagnostic information.

1. Machine Description

1-3-5 Error Screen

Explains how to interpret and respond to error codes displayed on the screen.

2. Checks Before Operating

2-1 Turning On the Power Switch

Provides steps for correctly powering on the machine.

2. Checks Before Operating

2-2 Checking the Emergency Stop Function

Verifies the functionality of the emergency stop buttons for safety.

2. Checks Before Operating

2-2 Checking the Emergency Stop Function

Continues verification of emergency stop functions and other safety checks.

2-3 Checking the Glue Collection Tray

Procedure to check and dispose of glue from the collection tray.

3. Operating Procedures

3-1 Overview of Operating Procedures

Provides a general outline of the steps for a normal bookbinding job.

3. Operating Procedures

3-2 Doing the Changeover

Details procedures for changing machine configurations or parts.

3-2-1 Replacing the tank unit

Step-by-step guide for replacing the glue tank unit.

3. Operating Procedures

3-2 Doing the Changeover

Continues procedures for changing machine settings.

3-2-2 Changing the EVA glue after using the PUR glue

Procedure for switching between EVA and PUR glue types.

3. Operating Procedures

3-2 Doing the Changeover

Continues changeover procedures for machine settings.

3-2-3 Job setup using the screens

Instructions for setting up bookbinding jobs via the machine interface.

3. Operating Procedures

3-3 Manual Setup Procedures

Details manual adjustments for specific machine functions.

3-3-1 With cover scoring

Manual setup procedure for scoring covers.

3. Operating Procedures

3-3 Manual Setup Procedures

Continues manual setup procedures.

3-3-2 Without cover scoring

Manual setup procedure when covers are not scored.

3. Operating Procedures

3-3 Manual Setup Procedures

Continues manual setup procedures.

3-3-3 Setting the stacker

Manual procedure for setting the stacker position and belt speed.

3. Operating Procedures

3-4 Setting the Covers

Procedures for correctly positioning and loading covers.

3. Operating Procedures

3-5 Test Binding

Steps for performing a test binding to check quality.

3. Operating Procedures

3-6 Starting Bookbinding

Instructions for starting the main bookbinding process.

3. Operating Procedures

3-7 Saving, Loading and Deleting Jobs

Manages saved job settings for efficient reuse.

3-7-1 Saving jobs

Procedure for saving current machine settings as a job.

3. Operating Procedures

3-7 Saving, Loading and Deleting Jobs

Continues procedures for managing saved job settings.

3-7-2 Loading jobs

Procedure for loading previously saved job configurations.

3. Operating Procedures

3-7 Saving, Loading and Deleting Jobs

Continues procedures for managing saved job settings.

3-7-3 Deleting jobs

Procedure for removing saved job configurations.

3. Operating Procedures

3-8 Adjusting the Milling Depth

Fine-tuning the depth of the milling operation.

3. Operating Procedures

3-9 Adjusting the Scoring Position

Fine-tuning the alignment of scoring lines on covers.

3. Operating Procedures

3-10 Adjusting the Scoring Depth and Angle

Adjusting scoring pressure and angle for optimal results.

3. Operating Procedures

3-11 Adjusting the Glue Amount for the Side Glue Rollers

Adjusting the quantity of side glue applied by the rollers.

3. Operating Procedures

3-12 Adjusting the Nipper Height

Adjusting the nipper height to shape the book spine.

3. Operating Procedures

3-13 Adjusting the Nipper Angle

Adjusting the nipper angle for spine shape consistency.

3. Operating Procedures

3-14 Adjusting the Cover Angle

Adjusting the angle of the cover tail edge positioner.

3. Operating Procedures

3-15 Adjusting the Blower Air

Adjusting air flow from the blower for cover feeding.

3. Operating Procedures

3-16 Adjusting the Double Feed Stop Pad Height

Adjusting the double feed stop pad to prevent misfeeds.

3. Operating Procedures

3-17 Adjusting the Cover Table Height

Adjusting the cover table height for proper cover feeding.

3. Operating Procedures

3-18 Setting for the PUR glue

Procedures for setting up the machine to use PUR glue.

3-18-1 Changing the PUR glue after using the EVA glue

Steps to switch from EVA glue to PUR glue.

3. Operating Procedures

3-18 Setting for the PUR glue

Continues procedures for setting up PUR glue.

3-18-2 Setting for the PUR glue

Specific steps for setting up the PUR glue system.

3. Operating Procedures

3-18 Setting for the PUR glue

Continues PUR glue setup procedures.

3-18-2 Setting for the PUR glue

Continues specific steps for PUR glue setup.

3. Operating Procedures

3-19 Adding the Glue

Procedures for adding glue to the tanks.

3. Operating Procedures

3-20 Setting the Glue Tank Temperatures

Setting the correct operating temperatures for the glue tanks.

3. Operating Procedures

3-21 Adjusting the Scraper Roller Height

Adjusting the scraper roller for optimal spine glue thickness.

3. Operating Procedures

3-22 Rotating the Carriage Clamp Using the Handwheel

Manually moving carriage clamps with a handwheel.

3. Operating Procedures

3-23 Installing the Cover Lifting Guide

Procedure for installing the cover lifting guide accessory.

3. Operating Procedures

3-24 Opening the Carriage Clamp using the Handwheel

Manually opening the carriage clamp for jams.

3. Operating Procedures

3-25 Attaching the Cover Edge Lifting Guide

Procedure for attaching the cover edge lifting guide accessory.

3. Operating Procedures

3-26 Removing the jammed cover sheets using the Handwheel

Using a handwheel to clear jammed cover sheets.

4. Troubleshooting

4-1 If an Icon Appears on the Error Screen

General guidance for interpreting and resolving error screen icons.

4-1-1 If an error icon is displayed

Explains the meaning of specific error icons on the machine's screen.

4. Troubleshooting

4-1 If an Icon Appears on the Error Screen

Continues explanation of error icons and alarm indicators.

4-1-2 If an alarm icon appears

Explains the meaning of alarm icons displayed during operation.

4. Troubleshooting

4-1 If an Icon Appears on the Error Screen

Details system errors and their corresponding error codes and solutions.

4-1-3 If a system error occurs

Provides solutions for various system-level errors.

4. Troubleshooting

4-2 Glue-Related Problems

Common issues encountered with glue application and quality.

4-2-1 If stringy glue sticks to the nipper

Troubleshooting for stringy glue adhering to the nipper.

4-2-2 If lumps of glue stick to the nipper

Troubleshooting for glue lumps adhering to the nipper.

4. Troubleshooting

4-2 Glue-Related Problems

Continues troubleshooting for common glue-related issues.

4-2-4 Spine glue is not applied

Troubleshooting steps when spine glue is not applied correctly.

4. Troubleshooting

4-2 Glue-Related Problems

Continues troubleshooting for common glue-related issues.

4-2-5 Too much side glue is applied

Troubleshooting for excessive side glue application.

4-2-6 Too much spine glue is applied

Troubleshooting for excessive spine glue application.

4. Troubleshooting

4-2 Glue-Related Problems

Continues troubleshooting for common glue-related issues.

4-2-7 Spine glue is protruding at the sides

Troubleshooting for spine glue protruding from the sides.

4-2-8 Spine glue is not applied to the book block edges

Troubleshooting for spine glue not adhering to book block edges.

4. Troubleshooting

4-2 Glue-Related Problems

Continues troubleshooting for common glue-related issues.

4-2-9 Spine glue is only partially applied to the book blocks

Troubleshooting for partial spine glue application.

4-2-10 The glue does not heat up

Troubleshooting for issues where the glue is not heating properly.

4. Troubleshooting

4-2 Glue-Related Problems

Continues troubleshooting for common glue-related issues.

4. Troubleshooting

4-3 Spine-Related Problems

Common issues related to the formation and appearance of book spines.

4-3-1 The spines on the covers are dented

Troubleshooting for dented spines on book covers.

4-3-2 One side of the spine is dented

Troubleshooting for spines dented on only one side.

4. Troubleshooting

4-3 Spine-Related Problems

Continues troubleshooting for spine formation issues.

4-3-4 The corners of the spines are too sharp

Troubleshooting for spines with excessively sharp corners.

4. Troubleshooting

4-3 Spine-Related Problems

Continues troubleshooting for spine formation issues.

4-3-5 The corners of the spines are too round

Troubleshooting for spines with excessively round corners.

4. Troubleshooting

4-4 Cover-Related Problems

Common issues encountered with cover placement and adhesion.

4-4-1 The covers are skewed diagonally from the book blocks

Troubleshooting for covers skewed diagonally relative to book blocks.

4. Troubleshooting

4-4 Cover-Related Problems

Continues troubleshooting for cover-related issues.

4-4-2 The covers move in the fore-edge direction on the book blocks

Troubleshooting for covers shifting in the fore-edge direction.

4. Troubleshooting

4-4 Cover-Related Problems

Continues troubleshooting for cover-related issues.

4-4-3 The covers move in the top/bottom direction on the book blocks

Troubleshooting for covers shifting in the top/bottom direction.

4-4-4 There are variations in the cover adhesion position

Troubleshooting for inconsistent cover adhesion positioning.

4. Troubleshooting

4-4 Cover-Related Problems

Continues troubleshooting for cover-related issues.

4-4-5 The covers do Not stick to the spines

Troubleshooting for covers not adhering to book spines.

4. Troubleshooting

4-5 Wrinkle-Related Problems

Common issues that cause wrinkles in book spines or covers.

4-5-1 The spines are wrinkled

Troubleshooting steps for wrinkled book spines.

4. Troubleshooting

4-5 Wrinkle-Related Problems

Continues troubleshooting for wrinkle-related issues.

4-5-2 The spines are scratched or marked

Troubleshooting for spines that are scratched or marked.

4. Troubleshooting

4-6 Scoring-Related Problems

Common issues related to the scoring function.

4-6-1 The covers are cut during scoring

Troubleshooting for covers being cut during the scoring process.

4-6-2 No scoring

Troubleshooting when the scoring function is not working.

4. Troubleshooting

4-6 Scoring-Related Problems

Continues troubleshooting for scoring-related issues.

4-6-4 The covers are scored diagonally

Troubleshooting for covers being scored diagonally.

4. Troubleshooting

4-7 Problems with the Main Part of the Machine

Troubleshooting for general operational issues with the main machine.

4-7-1 Covers misfeeding

Troubleshooting steps when covers are misfeeding.

4. Troubleshooting

4-7 Problems with the Main Part of the Machine

Continues troubleshooting for main machine operational issues.

4-7-3 Covers double-feeding

Troubleshooting steps for double-feeding of covers.

4. Troubleshooting

4-7 Problems with the Main Part of the Machine

Continues troubleshooting for main machine operational issues.

4-7-5 Thick books are not delivered smoothly

Troubleshooting for issues with thick books not being delivered smoothly.

4-7-6 Thin books are not delivered smoothly

Troubleshooting for issues with thin books not being delivered smoothly.

4. Troubleshooting

4-7 Problems with the Main Part of the Machine

Continues troubleshooting for main machine operational issues.

4-7-7 The tank temperature does not rise

Troubleshooting for the tank temperature not reaching the set point.

4. Troubleshooting

4-7 Problems with the Main Part of the Machine

Continues troubleshooting for main machine operational issues.

4-7-10 The carriage clamp slows or stops during milling

Troubleshooting for carriage clamp slowing or stopping during milling.

4. Troubleshooting

4-7 Problems with the Main Part of the Machine

Continues troubleshooting for main machine operational issues.

4-7-12 Some parts do not move

Troubleshooting for specific machine parts not moving.

4-7-13 No power

Troubleshooting steps when the machine has no power.

4. Troubleshooting

4-8 If a Cover Sheet or Book Block Jams

Procedures for clearing jams involving cover sheets or book blocks.

4-8-1 If a cover sheet has jammed

Specific steps for removing a jammed cover sheet.

4. Troubleshooting

4-8 If a Cover Sheet or Book Block Jams

Continues procedures for clearing jams.

4-8-2 If the book block has jammed in milling mechanism

Steps for removing a book block jammed in the milling mechanism.

4. Troubleshooting

4-8 If a Cover Sheet or Book Block Jams

Continues procedures for clearing jams.

4-8-3 If the book block has jammed in the level plate section

Steps for removing a book block jammed in the level plate section.

4. Troubleshooting

4-8 If a Cover Sheet or Book Block Jams

Continues procedures for clearing jams.

4-8-4 If the book block has jammed in the delivery section

Steps for removing a book block jammed in the delivery section.

5. Maintenance

5-1 Regular Maintenance

General guidelines for routine machine maintenance.

5. Maintenance

5-2 Cleaning the Nipper Section

Procedure for cleaning the nipper section of the machine.

5. Maintenance

5-3 Cleaning the Milling Section

Procedure for cleaning the milling section of the machine.

5. Maintenance

5-4 Cleaning the Delivery Section Conveyor

Procedure for cleaning the delivery section conveyor.

5. Maintenance

5-5 Cleaning and Replacing the Filter Bag

Instructions for cleaning or replacing the filter bag.

5. Maintenance

5-6 Cleaning the Cover Sheet Waiting Position Sensor

Procedure for cleaning the cover sheet waiting position sensor.

5. Maintenance

5-7 Cleaning the Book Block Sensor

Procedure for cleaning the book block sensor and mirror.

5. Maintenance

5-8 Cleaning the Book Deliver Confirmation Sensor

Procedure for cleaning book delivery confirmation sensors and mirrors.

5. Maintenance

5-9 Cleaning the PUR Tank

Detailed steps for cleaning the PUR glue tank.

5. Maintenance

5-10 Replacing the Support Plate

Procedure for replacing a deformed support plate.

5. Maintenance

5-11 Replacing the Milling Cutter

Instructions for replacing a dull or worn milling cutter.

5. Maintenance

5-12 Replacing the PUR Chip Cutter

Procedure for replacing the PUR chip cutter.

5. Maintenance

5-13 Replacing the EVA Notching Cutters

Procedure for replacing EVA notching cutters.

5. Maintenance

5-14 Replacing the Glue

Procedures for replacing the machine's glue.

5-14-1 Replacing the EVA spine glue

Steps for replacing the EVA spine glue.

5. Maintenance

5-14 Replacing the Glue

Continues procedures for replacing the machine's glue.

5-14-2 Replacing the side glue

Steps for replacing the side glue.

5. Maintenance

5-15 What to Do If the Glue Has Overflowed

Instructions for handling situations where glue has overflowed.

5. Maintenance

5-16 Replacing the Double Feed Stop Pads

Procedure for replacing worn double feed stop pads.

5. Maintenance

5-17 Resetting the Circuit Breakers

Steps for resetting tripped circuit breakers.

5. Maintenance

5-18 Lubrication

General procedures for lubricating machine parts.

5-18-1 Melt tank chains

Specific lubrication procedure for melt tank chains.

5. Maintenance

5-18 Lubrication

Continues lubrication procedures for machine parts.

5-18-2 Carriage clamp rails

Specific lubrication procedure for carriage clamp rails.

5. Maintenance

5-18 Lubrication

Continues lubrication procedures for machine parts.

5-18-3 Level plate slide rails

Specific lubrication procedure for level plate slide rails.

5. Maintenance

5-19 Replacing the Thermal Fuses

Procedure for replacing thermal fuses for safety.

5. Maintenance

6. Optional Devices

Information on installing and operating optional devices.

6-1 T-470 Weekly Timer

Details about the T-470 Weekly Timer optional device.

6-1-1 Operation Procedure

Steps for operating the T-470 Weekly Timer.

6. Optional Devices

6-1 T-470 Weekly Timer

Continues details on the T-470 Weekly Timer.

6-1-2 Installation Procedure

Instructions for installing the T-470 Weekly Timer.

6. Optional Devices

6-1 T-470 Weekly Timer

Continues details on the T-470 Weekly Timer.

6-1-2 Installation Procedure

Continues installation instructions for the T-470 Weekly Timer.

6-3 Extra Table ET-470

Details about the ET-470 Extra Table optional device.

6-3-1 Bundled Items

Lists the components included with the ET-470 Extra Table.

6. Optional Devices

6-1 T-470 Weekly Timer

Continues details on the T-470 Weekly Timer.

6-1-3 Installation Procedure

Installation instructions for T-470 Weekly Timer for specific S/N.

6. Optional Devices

6-2 Flap Cover Sheet FLP-470

Details about the FLP-470 Flap Cover Sheet optional device.

6. Optional Devices

6-2 Flap Cover Sheet FLP-470

Continues details on the FLP-470 Flap Cover Sheet.

7. Installation

7-1 Moving the Main Part of the Machine

Steps for safely moving the main machine unit.

7. Installation

7-1 Installing the Main Part of the Machine

Provides machine dimensions and weight for installation planning.

7. Installation

7-2 Installing the Main Part of the Machine

Step-by-step instructions for installing the main machine components.

7. Installation

7-3 Attaching the Stacker

Procedure for attaching the stacker component.

7. Installation

7-4 Wiring Connections

Instructions for making correct electrical wiring connections.

7. Installation

7-5 Installing the Smoke Extractor

Procedure for installing the smoke extractor option.

7. Installation

7-6 Setting Up For Optional Devices

Configuring the machine for connected optional devices.

8. Appendix

8-1 Specifications

Lists the technical specifications of the machine.

8. Appendix

8-2 Accessories

Lists the accessories included with the machine.

8-2-1 Accessories for BQ-470

Specific accessories provided for the BQ-470 model.

8. Appendix

8-2 Accessories

Continues the list of machine accessories.

8-2-2 Accessories for MU-470EVA

Specific accessories for the MU-470EVA unit.

8. Appendix

8-2 Accessories

Continues the list of machine accessories.

8-2-3 Accessories for MU-470PUR

Specific accessories for the MU-470PUR unit.

8. Appendix

8-2 Accessories

Continues the list of machine accessories.

8-6 De-commissioning and Dismantling

Information on safe de-commissioning and dismantling procedures.

8. Appendix

8-3 Consumables

Lists items that are consumed during machine operation.

8. Appendix

8-4 Options

Details optional devices and their functionalities.

8. Appendix

8-5 Periodic Replacing Parts for PUR

Lists parts for PUR system that require periodic replacement.