Watkiss BookMaster & TrimMaster

Transcription

1 Operating Instructions Watkiss BookMaster & TrimMaster Issue 2b, June 2003

2 THIS PAGE IS INTENTIONALLY BLANK

3 CONTENTS Specifications... 1 Introduction... 3 Quick Start... 9 Adjusting the Units Using the Units Off-line Using the Units with a Bench Top Collator Using the Units with a Floor Standing Watkiss Vario Collator Using the Units with a Watkiss DigiVAC Collator The Staple Heads Troubleshooting Chart Maintenance Appendix Connecting the TrimMaster Staple Position Adjustment Sharpening the TrimMaster Blade Conveyor Clamp Adjustment Index Issue 2b - June Part No

4

5 1 Specifications Intended Use This product is intended to be used for the stapling, folding and trimming of materials as specified. Operating Conditions C at 35-85% relative humidity Production up to 1,800 per hour Specifications Maximum Input Size Minimum Input Size Max Staple Pitch Min Staple Pitch Maximum Book Thickness Maximum Trim Electrical Voltage Power (115V) Power (230V) Current Dimensions BookMaster (W,D,H) TrimMaster (W,D,H) 482 x 320mm, 18.9 x 13.78" 210 x 140mm, 8.27 x 5.5" 138mm, 5.4" 115mm, 4.5" 22 Sheets (80gsm) 25mm, 1" 115V, 60 Hz or 230V, 50 Hz Single Phase (earthed supply required) 150VA exc. TRIM 500VA inc. TRIM 20VA Stand-by 200VA exc. TRIM 700VA inc. TRIM 30VA Stand-by 4.4A (115V) or 3.0A (230V) 546, 495, 595mm, 70kg 21.5, 19.5, 23.4", 154.3lb 546, 650, 595mm, 85kg 21.5, 25.6, 23.4", 187.4lb Outfeed Conveyor (W,D,H) 404, 1050, 720mm*, 17kg 15.9, 41.3, 28.4", 37.5lb *915mm (36") with TMS Noise 74dB (A) 1

6 Production may vary according to operating conditions. In line with a policy of continual product improvement, the manufacturer reserves the right to alter the materials or specification of this product at any time without notice. Radio Frequency Emissions This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. WARNING! The TrimMaster unit contains a motorised guillotine. It is therefore essential that due care is taken and the operating instructions adhered to when using the unit. Also pay particular attention to any specific warnings given. 2

7 2 Introduction The Watkiss BookMaster and TrimMaster units have been purpose designed to use with Watkiss Collators as well as other manufacturers bench-top and table top collators. The units can also be used offline for hand feeding. Various configurations are available. FIGURE 1 BookMaster with Outfeed Conveyor FIGURE 2 BookMaster with Motorised Infeed and Outfeed Conveyor FIGURE 3 BookMaster, TrimMaster and Outfeed Conveyor (Motorised Infeed can be fitted also) 3

8 FIGURE 4 BookMaster Pro and Outfeed Conveyor online with Vario Oscillating Floor Base FIGURE 5 BookMaster and Outfeed Conveyor with Motorised Interface, online with Watkiss Vario Bench-top machine feeding to the rear FIGURE 6 BookMaster, TrimMaster and Outfeed Conveyor, online with DigiVAC+ collator 4

9 The instructions that follow include the set-up and operating procedure for both the BookMaster and the Trim- Master units. Please ignore those parts of the instructions that do not apply to your configuration. In these instructions the BookMaster is referred to as the BMS and the TrimMaster is referred to as the TMS. INSTALLATION It is recommended that your BookMaster and TrimMaster are sited on a level floor. Important This machine must only be plugged into an electrical supply line of the correct voltage and with a proven earth. Any damage caused by failure to do so will not be covered by the warranty. The required machine voltage is shown on the label on the rear of the unit (see Figure 7). SAFETY FIRST Your BookMaster and TrimMaster units have been designed with safety as a key feature and incorporate safety covers which, when opened, will automatically cut the power to moving parts. However, as with all electrical equipment, when changing fuses or carrying out operations other than those detailed in this book: Always first disconnect the machine from the mains electricity supply. CAUTION Before placing the BMS unit back underneath a floorstanding Watkiss Vario, ensure that the collator front feed out conveyor and paper guides are positioned correctly see p.31. 5

10 SWITCHING ON Plug the BMS into a single phase power supply of the correct voltage, as indicated by the mains input (see Figure 7). Mains ON/OFF Switch Voltage Indicator Label Mains Input FIGURE 7 Also ensure the outfeed conveyor cable is connected to the socket on the BMS (see Figure 8). If the TMS is installed, ensure that this too is connected see p.49. The BMS mains ON/OFF switch is located on the rear of the unit (see Figure 7). When the unit is first switched on it will emit a single short beep. The status indicator light will then start to blink, indicating the unit is ready to run. Status Indicator Light (Yellow) Staple Head Indicator Light (Red) Conveyor Socket FIGURE 8 6

11 The BMS will automatically start when a set is fed into the unit and then automatically stop after approximately 10 seconds. Status Indicator Light The yellow indicator light on the BMS (see Figure 8) shows the status of the unit. Indicator Light Mode Blinking once per second Constantly illuminated Blinking rapidly Not illuminated BMS Status The unit is ready to run The unit is running There is a jam or other error BMS/TMS lid is open, paper is stuck in the paper path or the unit is not switched on Staple Head Indicator Lights The red indicator lights on the BMS lid (see Figure 8) show the status of the corresponding staple head. Indicator Light Mode Blinking once per second Constantly illuminated Blinking rapidly Not illuminated Staple Head Status The staple cartridge is about to or has run out The staple head is selected and ready to run There is a staple head jam or other error The Staple head is not selected 7

12 THIS PAGE IS INTENTIONALLY BLANK 8

13 3 Quick Start This section is intended only as a brief operating guide. More complete instructions are included in later chapters. Plug the BookMaster into a mains supply of the correct voltage and switch on the mains ON/OFF switch. Adjust the Infeed Sidelays Use the hand wheel on the rear of the BMS to adjust the infeed sidelays to the correct sheet input size see p.11. Use the scale as a guide. Adjust the Fold and Staple Position Use the hand wheel on the front of the unit to adjust the fold and staple position see p.12. Use the scale as a guide. Select the Mode of Operation Using the lever on the BMS, select the mode of operation you require, either staple-fold or edge staple. Ensure the required staple heads are selected see p.13. Adjust the Staple Heads If required, adjust the position of the staple heads and clinchers see p.14. Adjust the Trim Position Use the hand wheel on the TMS to adjust the trim position see p.16. Use the scale as a guide. Check the Adjustments To check that all the adjustments are correct, manually feed a set into the unit. The unit will automatically stop after approximately 10 seconds. If required, make any fine adjustments. Adjust the Outfeed Conveyor Slide the large payout wheels up or down their mounting rail so that they are just nipping the spine of the book when it is released from the rollers. Note When feeding into the BookMaster, do not exceed the maximum production rate of the unit i.e. 1,800 per hour. This may cause unreliable feeding or paper jams 9

14 THIS PAGE IS INTENTIONALLY BLANK 10

15 4 SETTING UP THE BOOKMASTER & TMS Adjusting the Units Adjust the Infeed Sidelays Use the hand wheel on the rear of the unit (see Figure 9) to adjust the infeed sidelays to the correct sheet input width. Use the scale on the infeed as a guide (see Figure 10). Infeed Sidelay Adjustment Wheel FIGURE 9 Align the inside face of the sidelay with the required size on the scale, as shown by the dotted line in the photo (see Figure 10). Infeed Sidelay Infeed Sidelay Scale FIGURE 10 11

16 Open the BookMaster lid to energise the sidelays. To open, turn the handle to the left and lift (see Figure 11). The lid is supported by a strut on the right side. FIGURE 11 Insert a few sheets in between the sidelays. The sidelays should just touch the sheets but not hold them. FIGURE 12 Adjust the Fold and Staple Position The staple and fold position are set with one simple adjustment, meaning the staple is always on the fold. Measure the length of the sheets from the required fold line to the feed edge (see Figure 12). If edge or corner stapling, this adjustment is not necessary. Fold Position Scale FIGURE 13 Fold Position Adjustment Wheel Turn the fold position hand wheel (see Figure 13) until the top edge of fold plate aligns with the required dimension 12

17 on the adjustment scale, as shown by the dotted line in the photo below (see Figure 14). Fold Plate FIGURE 14 Tip: Common sizes are highlighted on the adjustment scales. For example for an A5 (5½ x 8½") book, use the A5 marker on the infeed and fold position scales Select Stapling Mode Use the lever on the BMS (see Figure 15), to select centre or edge stapling. Edge or Centre Staple Selection Staple Head Select Staple Head Selection Centre Staple Staple Head Selection Indicator Light Edge Staple FIGURE 15 13

18 Select the Staple Heads Use the button next to the lever (see Figure 15) to select the heads to be used. Select the two centre heads for booklets or edge stapling, or a single head for corner stapling. The staple head indicator lights show which heads are selected. Note: Corner stapling is only possible if an optional third staple head is fitted (see Figure 16). Optional Third Staple Head for Corner Stapling FIGURE 16 Note: The maximum input sheet length that can be edge stapled is 250mm, 9.84". Note: When edge stapling is selected the TMS action is automatically switched off. Note: With certain stocks, it is possible that edge-stitched booklets may occasionally jam in the BMS. An edge stitch assistor plate (Watkiss P/N ) will prevent these booklets from jamming. The plate is supplied with the optional 3rd stapler head kit (Watkiss P/N ) and can also be ordered separately. Adjust the Staple Heads It is possible to adjust the staple pitch i.e. the distance between the staple centres. There are two positions - the standard position and one for small books. To adjust, first 14

19 open the BookMaster lid by turning the handle to the left and lifting. The position of the staple heads is adjusted via the lever (see Figure 17). Staple Head Adjustment Lever Clincher FIGURE 17 Normally the heads should be in the outer position. For small booklets the inner position can be used. Move the lever to the right to select the inner position. When adjusting the staple heads, Ensure the staple clinchers are moved to suit. To adjust, loosen the orange hand screw (see Figure 18) and slide the clincher fully across in the required direction. Tighten the hand screw. Orange Hand Screw Clincher FIGURE 18 15

20 Note: You may have to increase the infeed sidelay gap to access the hand screws. Before placing hands inside the BMS, you should disconnect the unit from the mains electricity supply. To close the BMS lid, lift it slightly, push the support strut (see Figure 19) and close the lid. Turn the handle to the right to lock in place. Support Strut FIGURE 19 Adjust the Trim Position Loosen the orange hand nut and open the TMS lid (see Figure 20) to reveal the conveyor and the trim adjustment scale. Orange Hand Screw TMS Lid FIGURE 20 16

21 Use the hand wheel (see Figure 21) located below the outfeed conveyor to adjust the trim position. Use the scale on the TMS conveyor as a guide. Trim Position Hand Wheel FIGURE 21 Turn the hand wheel until the leading edge of the trim stop aligns with the required dimension on the scale, as shown by the dotted line in the photo (see Figure 22). Trim Stop Scale FIGURE 22 Check the Adjustments To check that all the adjustments are correct, manually feed a set into the unit. If required, make any fine adjustments. 17

22 Adjust the Outfeed Conveyor Slide the large payout wheels (see Figure 23) up or down their mounting rail so that they are just nipping the spine of the book when it is released from the rollers. Use the scale on the outfeed as a guide Scale Payout Wheels FIGURE 23 The contact point of the wheels should be aligned with the required dimension on the scale, as shown by the dotted line in the photo (see Figure 23). If required, make any fine adjustments once the job is running. Tip: Common sizes are highlighted on the scale. For example for an A5 (5½ x 8½") book, use the A5 marker. 18

23 Hook the trim offcut box (see Figure 24) onto the Trim- Master. Payout Wheels Offcut Box FIGURE 24 Tip: Remember to empty the TMS offcut box periodically (see Figure 24). 19

24 THIS PAGE IS INTENTIONALLY BLANK 20

25 5 Using the Units Off-line The BookMaster and TrimMaster can be used off-line for hand-fed sets. Adjust the BMS for sheet input size and stapling mode (see Chapter 4 on p.11). The BMS will automatically start when a set is hand fed into the unit, and will automatically stop approximately 10 seconds after the last feed. Note: Wait until the book exits the unit before feeding another set. MOTORISED INFEED An optional Motorised Infeed (P/N ) which fits on to the BMS infeed makes offline use easier. A paper tray (see Figure 25) is supplied with the Motorised Infeed. Sidelay Paper Tray Motorised Infeed P/N FIGURE 25 Fitting the Motorised Infeed Loosen the two hand screws (see Figure 26) on either side of the Motorised Infeed. Fixing Clip Hand Screw FIGURE 26 21

26 Connect the Motorised Infeed interface cable to the socket on the top of the BMS (see Figure 27). Motorised Infeed Socket FIGURE 27 Position the Motorised Infeed on the BMS, so that the fixing clips (see Figure 26) locate inside the BMS infeed. Fit the rear hand screw (see Figure 28) and then tighten the two side hand screws. Length Adjustment Hand Screw Rear Hand Screw FIGURE 28 Fit the paper tray (see Figure 25) if required. Using the Motorised Infeed Adjust the Motorised Infeed sidelays (see Figure 25) to the correct sheet width. The sidelays should just touch the sheets but not hold them. 22

27 Adjust the BMS for sheet input size and stapling mode (see Chapter 4 on p.11). Place the sheets into the Motorised Infeed. The BMS will automatically start, and will stop approximately 10 seconds after the last feed. The Motorised Infeed will only feed the next set when the BMS is ready. 23

28 THIS PAGE IS INTENTIONALLY BLANK 24

29 6 Using the Units with a Bench Top Collator The optional powered Motorised Infeed (P/N ) allows the Watkiss BookMaster and TrimMaster units to be used when feeding to the rear of Watkiss Vario benchtop collators or other manufacturers bench-top and table top collators. Side Panel P/N Motorised Infeed P/N Hand Screw FIGURE 29 The Motorised Infeed provides bi-directional communications between a BMS and a Watkiss Vario bench-top machine via a special side panel P/N on the collator (see Figure 29). For details of connecting to other manufacturers machines contact your nearest Watkiss dealer. Fit the Motorised Infeed to the BMS Loosen the two hand screws (see Figure 29) on either side of the Motorised Interface. 25

30 Connect the cable on the Motorised Interface to the socket on the top of the BMS (see Figure 30). Infeed Socket FIGURE 30 Position the Motorised Infeed on the BMS, so that the fixing clips (see Figure 31) locate inside the BMS infeed. Fixing Clip FIGURE 31 Fit the rear hand screw (see Figure 32) and then tighten the two side hand screws. Communications Socket Length Adjustment Hand Screw Rear Hand Screw FIGURE 32 26

31 Position the BMS Position the BMS at the rear of the bench-top collator as shown in the photo (see Figure 33). Side Panel Socket Communications Cable P/N FIGURE 33 Connect the communications cable P/N between the socket on the Motorised Infeed (see Figure 32) and the socket on the collator side panel (see Figure 33). Attach the Motorised Infeed hooks onto the lower tie bar on the collator (see Figure 34). Ensure the BMS is positioned square to the collator. Motorised Infeed Hook Tie Bar FIGURE 34 27

32 If required, adjust the length of the Motorised Infeed guide (see Figure 35) to suit the length of the sheets. Loosen the orange hand screw under the Motorised Interface (see Figure 32), adjust the guide length and retighten the screw. The sheets should exit the collator conveyor before actuating the infeed trigger switch (see Figure 35). Infeed Trigger Switch Motorised Infeed Sidelay Motorised Infeed Guide FIGURE 35 Adjust the Motorised Infeed sidelays (see Figure 35) to slightly wider than the sheet width. Running the job Set the collator to feed to the rear and adjust the BMS for input sheet size and stapling mode (see Chapter 4 on p.11). The BMS will automatically start when a set is fed from the collator into the Motorised Infeed. Note When feeding into the BookMaster, do not exceed the maximum production rate of the unit i.e. 1,800 per hour. This may cause unreliable feeding or paper jams Correcting Errors Both machines will stop if there is an error on either the BMS or the collator. If the BMS has an error, the message Remote stop (Watkiss Vario) or Anc (Watkiss Eco-Vario) will be shown on the collator control panel. Refer to the BMS indicator lights see p.7 to identify the problem. 28

33 If the Watkiss Vario/Eco-Vario has an error, a message indicating the problem will be shown on the control panel (see Watkiss Vario/Eco-Vario operating manual). If a double or miss feed occurs, the error set will be held in the Motorised Infeed. Check the set and add or remove any sheets as required. Press on the collator control panel to feed the set into the BMS and continue running the job. Alternatively, press INCH to feed the set into the BMS without starting the job. Loading Orientation The cover should be loaded into the uppermost bin with the outside face up. The other sheets are then loaded in sequence in the bin(s) below, finishing with the centre spread face down in the lowermost bin (see Figure 36). Outside Face Up Centre Spread Face Down FIGURE 36 29

34 THIS PAGE IS INTENTIONALLY BLANK 30

35 7 Using the Units with a Floor Standing Watkiss Vario Collator Note: The BookMaster is not compatible with Watkiss Vario floorstanding collators fitted with a Graphical User Interface. It can be used with earlier Watkiss Vario floorstanding collators fitted with a key-pad control panel. However, there will be no communications between the two machines. Please contact your local Watkiss dealer for details of different options. CAUTION Before placing the BMS unit underneath a floorstanding Watkiss Vario, IT IS ESSENTIAL to check that the front feed out conveyor on the collator is in its upper (horizontal) position and that all the feed out paper guides are clipped up. The divert catch tray must also be removed (see Figure 37). Failure to do this will result in damage to the collator. Refer to your Watkiss Vario operating manual for details of raising and lowering the front feed out conveyor. Front Feedout Conveyor (in upper position) Paper Guides Divert Catch Tray FIGURE 37 - Floorstanding Watkiss Vario ORGANISING THE JOB Trim Margin If you have the TrimMaster installed and are using a friction fed Watkiss Vario, we recommend that the job be printed with a 12mm trim margin on the feed edge and a smaller (perhaps 3-5mm) trim margin on the trailing edge. 31

36 In this way any marking that could possibly occur due to wet ink or ink rub will always be in the trim margin. Loading the Bins The sheets should be loaded face down and with the cover in the bottom bin(s). Depending upon the number of sheets in the set, remember that using Bin Grouping can help to ensure continuous running. If the cover is thicker than the inner pages, use the bin grouping to allocate more bins for the cover stock. Set the Collator Paper Path If using a Rel.C Floor Base select SETS from Menu 2 on the Watkiss Vario control panel (see Watkiss Vario Operating Manual) so that the sets are delivered straight down into the BMS unit. Release C. Floor Base Release B. Floor Base FIGURE 38 For the Release B. Floor Base, position the set direction lever into the up position (see Watkiss Vario Operating Manual) so that the sets are delivered straight down into the BMS unit. 32

37 For the Oscillating Floor Base, set the delivery direction lever (see Figure 39) to the mid position, so that the sets are delivered straight down into the BMS unit. Delivery Direction Lever FIGURE 39 Vario OSC Floor Base Adjust the BMS for sheet input size and stapling mode and adjust the TMS trim position (see Chapter 4 on p.11). To check that all the adjustments are correct, manually feed a set into the BMS. If required, make any fine adjustments. Replace the BMS/TMS under the collator. From Menu1, set the collator drive speed to 80-90% by pressing DRIVE + or DRIVE -. Do not exceed the maximum production rate of the BMS i.e. 1,800 per hour. This may cause unreliable feeding or paper jams. The production speed will be affected by the booklet size and settings, but can also be reduced by pressing SPH - if required. Starting the Job Press TEST SET and to run a single book. After inspection, press again to run the job. Tip: Remember to empty the TMS offcut box periodically (see Figure 24). 33

38 Tip: Use batch pause (see Watkiss Vario operating manual) to separate the books into batches on the outfeed conveyor. 34

39 8 Using the Units with a Watkiss DigiVAC Collator The BookMaster can be used with Watkiss DigiVAC collators. Position the BookMaster under the collator s rear outfeed as shown below. Delivery Direction Lever DigiVAC Rear Outfeed BookMaster FIGURE 40 Set the delivery direction lever to its upper position, to deliver sets to the rear. Ensure the BookMaster is plugged into a mains supply of the correct voltage. Connect the interface cable between the BookMaster and the DigiVAC. Adjust the BMS for sheet input size and stapling mode and adjust the TMS trim position (see Chapter 4 on p.11). Do not exceed the maximum production rate of the BMS i.e. 1,800 per hour. Run a few sets. The bookletmaker will start automatically when the set enters the infeed slot. If needed, adjust the settings on the bookletmaker to produce a tidy booklet. Tip: Remember to empty the TMS offcut box periodically (see Figure 24). 35

40 THIS PAGE IS INTENTIONALLY BLANK 36

41 9 The Staple Heads Before carrying out any work on the staple heads it is first necessary to remove the BMS unit from underneath the collator. CHANGING THE STAPLE CARTRIDGES When a staple cartridge runs out, the corresponding red indicator light (see Figure 41) will blink once per second. New cartridges are available in packs of three from your Watkiss supplier (Watkiss P/N ). To change a cartridge, first open the BookMaster lid by turning the handle to the left and lifting (see Figure 41). The lid is supported by a strut on the right side. Indicator Light FIGURE 41 37

42 Grasp the cartridge at the top and pull directly away from the staple head, as shown by the arrow in the photo (see Figure 42). Staple Cartridge Staple Head FIGURE 42 Fit the new cartridge and check machine operation by making a few test booklets. ADJUSTING THE POSITION OF THE STAPLE HEADS The staple heads have two positions. Normally the heads should be in the outer position (138mm, 5.4" between staple centres). For small booklets the inner position can be used (115mm, 4.5" between staple centres). Move the lever (see Figure 43) to the right to select the inner position. Staple Head Adjustment Lever Clincher FIGURE 43 38

43 When adjusting the staple heads, Ensure the staple clinchers are moved to suit. To adjust, loosen the orange hand screw (see Figure 18) and slide the clincher fully across in the required direction.tighten the hand screw. Orange Hand Screw FIGURE 44 Note: You may have to increase the infeed sidelay gap to access the hand screws. Before placing hands inside the BMS, you should disconnect the unit from the mains electricity supply. To close the BMS lid, lift it slightly, push the support strut (see Figure 45) and close the lid. Turn the handle to the right to lock in place. Support Strut FIGURE 45 39

44 THIS PAGE IS INTENTIONALLY BLANK 40

45 10 Troubleshooting Chart Please use this chart as a guide to solving problems with your BookMaster and TrimMaster. If problems persist please call the Watkiss Service Department or your Watkiss Dealer. PROBLEM CAUSE SOLUTION Operational Problems BMS WILL NOT START The BMS is not plugged in Plug into mains connection of the correct type and voltage BMS STATUS INDICATOR LIGHT IS BLINKING RAPIDLY BMS STATUS INDICATOR LIGHT IS NOT ILLUMINATED ONE OR BOTH STAPLE HEADS ARE NOT ACTIVATED Fuse has blown on the main input BMS/TMS lid is open There is a jam or other error in the unit BMS/TMS lid is open Paper is stuck in the paper path BMS not switched on Staple heads are not selected A staple head error has occurred On V machines there are two 5 amp fuses in the mains input connector, check and replace as necessary. On 115V machines they are 7 amp fuses. Close the lid Clear the jam see p.43 Close the lid Open BMS/TMS lid and remove paper Switch on unit Select required staple heads see p.14 The heads should self clear. If not, turn the unit off and on again to free the head. If this does not work contact your local Watkiss service department FOLD IS NOT ACTIVATED Unit is in edge staple mode Move lever into centre staple position (see Figure 38 on p.32) BOOK IS NOT TRIMMED EDGE STAPLE FUNCTION NOT WORKING Trim position is set off the edge of the sheet Edge staple is selected Edge staple not selected Readjust trim position Trim not available in this mode Move lever to correct position and select staple head see p.13 41

46 PROBLEM CAUSE SOLUTION EDGE STAPLED BOOKLETS ARE JAMMING IN THE BMS STAPLE IS NOT ON THE FOLD UNTIDY BOOKLET BOOKLETS WILL NOT STACK ON THE CONVEYOR Leading edge of booklet is catching the edge stitch deflector shaft Loose paper or staples in the fold plate area BMS is not adjusted correctly and/ or delivery into the unit is poor Staple position is not adjusted correctly Infeed sidelays are not adjusted correctly Collator delivering an untidy set Large payout wheels incorrectly positioned Electrical connection is unplugged Fit edge stitch assistor plate (see p.14) Locate and remove see p.43 Adjust BMS correctly see p.11 and improve delivery Fine tune the position of the staples see p.51 Adjust see p.11 Improve collator delivery Reposition see p.18 Plug in electrical connection between the BMS/TMS and the outfeed conveyor BOOKLET COVER IS MARKED Dirty fold rollers Clean them with a cloth dampened with soapy water or alcohol (isopropanol). Do NOT use blanket wash see p.45 CANNOT CLOSE BMS LID Support strut is in place Lift the BMS lid slightly, push the support strut and close the lid Staple Head Problems ONE OR BOTH LEGS TURN OUT Incorrect clincher alignment Re-align see p.38 STAPLE COMES OUT IN PIECES Staple jammed in the cartridge A staple head error has occurred Inspect cartridge see p.37 and remove any jammed staple wire The heads should self clear. If not, turn the unit off and on again to free the head. If this does not work contact your local Watkiss service department STAPLE HEAD INDICATOR LIGHT BLINKS ONCE PER SECOND Staple cartridge empty Replace cartridge see p.37 42

47 PROBLEM CAUSE SOLUTION STAPLE HEAD INDICATOR LIGHT BLINKS RAPIDLY A staple head error has occurred The heads should self clear. If not, turn the unit off and on again to free the head. If this does not work contact your local Watkiss service department Collator Problems BMS WILL NOT FIT BACK UNDERNEATH A WATKISS VARIO FLOOR STANDING COLLATOR MORE THAN ONE SET IS BEING FED INTO THE BMS WHEN FEEDING FROM A BENCH TOP COLLATOR Front feed out conveyor is in down position Collator production speed is too high. It is ESSENTIAL to raise the feed out conveyor and clip up the feed out paper guides before placing the BMS back underneath the collator see p.5 Reduce the collator production speed to 1,800 sets per hour or lower Paper Jams Paper Jams are most commonly caused by: incorrect infeed sidelay settings, paper jammed in the TMS infeed/conveyor, exceeding the unit s maximum production rate, staples stuck in the clinchers or by feeding curly paper. Open the BMS lid (this will disconnect the power for safety) and remove any jammed sets. Check carefully and correct any faulty adjustments that caused the jam to occur (as detailed). If there are staples stuck in the clinchers, remove with a pair of pliers. Paper jams in the TMS can be caused by offcuts obscuring the sensor in the conveyor. The TMS lid (see Figure 48 on p.46) can be opened to remove any jammed sets and trim offcuts. WARNING: DISCONNECT THE MACHINE FROM THE MAINS ELECTRICITY SUP- PLY BEFORE WORKING NEAR THE BLADE AREA 43

48 THIS PAGE IS INTENTIONALLY BLANK 44

49 11 Maintenance The BMS and TMS units require only a small amount of routine maintenance. CLEANING Build up of set-off powder, ink or general dust will gradually impair the performance of your BMS and TMS. Optimum performance will be obtained by keeping the machine clean. Fold Roller and Conveyors Build up of set-off powder or ink on the fold rollers and conveyor belts will eventually cause slippage or ink transfer. Warning! Access to the manual cranking points on the BMS and TMS requires the side covers to be removed. For safety reasons this procedure should therefore only be conducted by authorised personnel. Disconnect the power before removing the side covers. BookMaster To clean the rollers and belts on the BMS, first remove the right hand side cover (two x M5 button screws) to give access to the manual cranking point (see Figure 46). M5 Button Screw Right Hand Side Cover FIGURE 46 Open the BMS lid to access the fold rollers. Using a 10mm A/F spanner (wrench), manually crank the BMS by turning the nut (see Figure 47) clockwise, and clean the rollers 45

50 and belts with a cloth dampened with soap and water or alcohol (isopropanol). Do NOT use blanket wash. Manual Cranking Point FIGURE 47 TrimMaster To clean the belts on the TMS, first remove the left hand side cover (two x M5 button screws) to give access to the manual cranking point (see Figure 48). Orange Hand Screw TMS Lid Left Hand Side Cover M5 Button Screw FIGURE 48 46

51 Loosen the orange hand screw and open the TMS conveyor cover (see Figure 48). Manual Cranking Point FIGURE 49 Using a 19mm A/F spanner (wrench), manually crank the TMS by turning the nut (see Figure 49) clockwise, and clean the belts with a cloth dampened with soap and water or alcohol (isopropanol). Do NOT use blanket wash. Warning! Ensure that hands are kept clear of the TMS blade area at all times TMS BLADE SHARPENING The TMS blade (and anvil) should be sharpened when required (see Appendix 3). 47

52 THIS PAGE IS INTENTIONALLY BLANK 48

53 A1 Connecting the TrimMaster Procedure Open the BookMaster lid by turning the handle to the left and lifting (see Figure 50). The lid is supported by a strut on the right side. FIGURE 50 Line up the TrimMaster docking plates (see Figure 51) with the BookMaster. Connect the power and communications cables to the sockets on the BMS. Communications Cable Power Cable Docking Plate FIGURE 51 49

54 Push the two units together so that the hooks on the TMS docking plates align with the holes in the BMS side plates (see Figure 52). FIGURE 52 Lift the BMS lid slightly, push the support strut and close the lid. Turn the handle to the right to lock the TrimMaster in place. Hook the Outfeed Conveyor onto the support posts on the TrimMaster and connect the interface cable. 50

55 A2 Tools required Flat Blade Screwdriver Staple Position Adjustment If both staples are consistently off the spine of the book first ensure that the BMS is adjusted correctly and that delivery into the unit is good. Also ensure there are no loose staples on the fold plate. If the problem persists, fine tuning of the staple position may be necessary. Adjustment is via the central screw on the fold plate mechanism, located behind the perspex cover (see Figure 53). Fold Position fine tuning FIGURE 53 If necessary, turn the hand wheel until the screws align with the holes in the perspex cover. Using a flat blade screwdriver, loosen the two locking screws (see Figure 54). Turn clockwise to lower the staples Locking Screw Fine Adjustment Screw Turn anticlockwise to raise the staples FIGURE 54 Locking Screw 51

56 Turn the fine adjustment screw (see Figure 54) clockwise to lower the position of the staples (as viewed when the book exits the unit) and anticlockwise to raise the staples. One quarter turn of the screw equates to approximately 2mm of travel. Tighten the locking screws and produce a test booklet. Repeat the procedure if necessary. 52

57 A3 Sharpening the TrimMaster Blade The TrimMaster blade and anvil are located behind the conveyor assembly (see Figure 55) at the docking end of the unit. Conveyor Cover Conveyor Assembly FIGURE 55 Periodically all TrimMaster blades will require re-grinding. Poor grinding will result in poor life, cracks and nicks in the blade. We therefore offer the guidelines on p.58 which should accompany the blade and anvil when they are sent for re-grinding. Whenever the TMS blade is reground, check the condition of the anvil also. This will only require re-grinding if it has become damaged. Warning! This procedure is potentially hazardous and should only be conducted by suitably skilled personnel. Disconnect the power before removing the conveyor assembly. Handle the blade with extreme caution and keep hands clear of cutting edges at all times. Parts Required (if necessary) TMS/1189 onwards: TrimMaster blade & guide TMS/1188 and earlier: TrimMaster blade Tools Required 3mm allen key 4mm allen key 6mm allen key 10mm allen key 19mm spanner 53

58 Procedure Separate the TMS from the BookMaster. Open the TMS conveyor cover (loosen the orange hand nut). Remove the two M5 button screws and washers that secure the conveyor assembly to the TMS unit (see Figure 56). M5 Button Screws FIGURE 56 Lift away the conveyor assembly to reveal the blade assembly (see Figure 57). Anvil Blade Mark Along Here FIGURE 57 Important Note the angled position of the TMS blade and with a marker pen or similar, mark along the bottom edge of the blade (see Figure 57). This will act as a guide when refitting Removing the TMS Blade Slightly loosen all five blade fixing screws (see Figure 58). Remove the outer two screws and screw them into the 54

59 locator holes. These will now act as handles. Remove the remaining screws and carefully lift the blade away. Immediately put the blade away safely. FIGURE 58 Check the anvil Carefully check the anvil for any damage. If it requires regrinding, remove the five fixing screws and lift away. Refitting the TMS blade and anvil Slacken the anvil adjuster screws back two revolutions. Position the anvil fully back towards the conveyor and lightly tighten the anvil fixing screws. Affix the blade using the five blade fixing screws but do not tighten. Using the mark made when the blade was removed, adjust the angle of the blade. Ensure that it does not protrude above the clamp at point 'A' or below it at point 'B' (see Figure 55

60 60). Lightly tighten the centre screw, sufficient to hold the blade in this position. Manual Crank Drive Access Hole FIGURE 59 FIGURE 60 Remove the left hand TMS side cover (two x M5 button screws and washers). Release the clutch by depressing the lever (see arrow) through the access hole in the side plate (see Figure 59). Use a 19mm spanner to manually crank the unit until the blade is at top dead centre. At point 'C' (see Figure 60) the blade must pass the anvil by 1mm (1/25"). Make fine adjustments to the position if necessary. Tighten all the blade fixing screws starting from the centre and working out. Push the anvil firmly forwards against the blade (pushing from behind with your fingers at each end). Maintain a light pressure on the back of the anvil whilst tightening the anvil fixing bolts starting from the centre and working out. Lightly tension the anvil adjuster screws against the anvil. 56

61 Final adjustment Release the clutch and manually crank slowly several rotations to check that the blade passes the anvil smoothly without obstruction. Place a single sheet of paper (large sheet size) between the blade and the anvil and manually crank to produce a test cut. Warning! Ensure that hands are kept clear at all times Check that a clean cut is obtained across the full width of the blade. If necessary loosen the anvil fixing screws at the point where adjustment is needed, apply additional pressure to the anvil adjusting screws (1/6th turn at a time) and re-tighten the anvil fixing screws. Perform another test cut and make further adjustments if necessary. Hook the conveyor assembly onto the support posts and push into position. Secure with two M5 button screws and washers. Fit the side cover and secure. 57

62 BLADE Note: 2 faces must be flat to within 0.03mm. ANVIL Note. 2 faces must be flat to within 0.01mm. Note: TrimMaster blade is fitted with a guide leg. This must be removed when the blade is reground and refitted afterwards. Blade Material Grinding Angle High Carbon High Chrome (Aisi D2/D3) See drawing alongside Grinding Wheel Cup or Cylinder Grinding Material Grit : Hardness : G-H Bond : Vitrified Peripheral speed of the grinding wheel (V M/S) (V Ft/S) This edge must be straight to within 0.04mm. Table Speed Feed per pass (V M/Min) (V Ft/Min) mm " Important: Grind In This Direction Only Honing After re-grinding, the burr should be carefully removed by honing. The quality of honing affects the useful life of the cutting edge. Correct Incorrect 58

63 A4 Conveyor Clamp Adjustment The TMS conveyor clamps are set to a default position at the factory, which gives a good trim over a wide variety of booklet thicknesses. However, when trimming unusually thick or thin booklets, the conveyor clamps may need to be adjusted. If the conveyor clamps are set too loose, the booklet may not be delivered correctly to the trim stop, or it may bounce against the trim stop. This will result in the following problems: Booklets are trimmed out of square (this may also indicate that the left and right conveyor clamps are set unevenly). Booklets are trimmed too short. If the conveyor clamps are set too tight, the following problem may occur: The cover of the booklets are pulled, resulting in damage around the staples. Tools Required 4mm Allen Key 2 off 150mm/6" Rule Procedure Adjust the trim position to A4>A5 or 5.8", regardless of the actual booklet size (see p.16). Disconnect the unit from the mains electricity supply. 59

64 Open the TMS conveyor cover, by lifting the orange hand screw (see Figure 61). Conveyor Cover FIGURE 61 There are two clamp roller shafts, which are adjusted using a 4mm Allen key (see Figure 62). Adjustment screw Adjustment screw Clamp Roller Shaft Clamp Roller Shaft FIGURE 62 Adjusting the Conveyor Clamps To adjust the conveyor clamp: Turn the adjustment screws clockwise to increase the gap (reducing clamp pressure) Turn the adjustment screws anti-clockwise to reduce the gap (increasing clamp pressure) 60

65 Checking the Adjustments It is important that both clamp roller shafts are adjusted to the same height. The factory default is 17mm between the top of each shaft and the top of the wire frame. Lay the first rule across the wire frame, so that it is above the clamp roller shaft (see Figure 63). Using the second rule, measure the height from the top of the shaft to the bottom of the first rule. Adjust the shafts as necessary and re-measure to ensure they are both set to the same height. Wire Frame Second Rule Clamp Roller Shaft First Rule FIGURE 63 Restarting the Job Before restarting the job, don t forget to reset the paper size as necessary. Note: It is important to return both clamp roller shafts to the factory default height of 17mm before booklets of a more typical thickness are produced. 61

66 THIS PAGE IS INTENTIONALLY BLANK 62

67 Index A adjustments clincher 15 fold position 12 infeed sidelays 11 outfeed conveyor 18 staple head position 14 staple head selection 14 staple mode selection 13 trim position 16 C centre stapling 13 clamp roller shafts 60, 61 clincher adjustment 15 collators, connecting to bench top 25 digivac 35 vario (floor standing) 31 conveyor clamp adjustment E edge stapling 13 F fold position, adjusting 12 H hand feeding 21 I indicator light, staple head 7 indicator light, status 7 infeed sidelays, adjusting 11 installation 5 introduction 3 M mains input 6 maintenance blade sharpening 47 cleaning 45 motorised infeed 21, 25 O offline use 21 outfeed conveyor, adjustment 18 P paper jams 43 Q quick start 9 R radio frequency emissions 2 S saddle stitching 13 safety 5 setting up the bms side stapling 13 specifications 1 staple cartridges 37 staple heads adjust the staple heads 14 adjusting the staple head position 38 changing the staple cartridges 37 select stapling mode 13 select the staple heads 14 staple position, adjusting 12 staple position, fine tuning switching on 6 T trim position, adjustment 16 trimmaster blade sharpening final adjustment 57 honing 58 refitting the blade 55 removing blade 55 trimmaster, connecting troubleshooting collator problems 43 operational problems 41 paper jams 43 staple head problems 42 63

68 Index U using the units off-line motorised infeed 21 fitting the motorised infeed 21 using the motorised infeed 22 V voltage 6 64

69 THIS PAGE IS INTENTIONALLY BLANK

70 WATKISS AUTOMATION LIMITED Watkiss House, Blaydon Road, Middlefield Ind. Est., Sandy, Bedfordshire. SG19 1RZ ENGLAND. Tel: +44 (0) Fax: +44 (0) Web: BookMaster & TrimMaster Operating Instructions, English. Issue 2b, June 2003, Part No