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1. 34 Document Finishing System User Manual 3 About the Machine Gathering Station The gathering station holds the sheets which have been delivered from the feed bins until the set is complete The set is then released into the BookMaster Pro Interface Sockets The interface sockets are located on the right underside of the gathering station There are three sockets in all Two identical sockets either one of which is used to connect the BookMas ter Pro and one smaller socket that is currently not used Sheet Length Adjustment Not Used Online Finishing Select the correct paper size using the two levers on the front of the DFS see below For non standard paper sizes use the setting for the next largest stand ard paper size A3 A4 A5 Sheet Length Adjustment Document Finishing System User Manual 35 3 About the Machine Sheet Width Adjustment Insert a few sheets from the job in between the sidelays Turn the thumbwheel until the marker aligns with the correct point on the scale Firmly push the side lays inwards to check the tamper position they should just touch the paper Make further adjustment if necessary Sheet Length Adjustment Static Elimination Bar Gathering Station Air Blow Adjustment Sidelay Sheet Width Adjustment Bypass Gate Interface Sockets Hidden Air Blow Adjustment An a
2. The X Jogger with A3 11 x 17 Paper Plug the jogger into the socket on the underside of the floor base via the inter connection cable The cable will only fit in to one of the sockets Take a few sheets of the stock to be collated and place them in the stacker off set by 20 Use the hand wheel to adjust the sidelays to suit the width of the stack Adjust the bottom sidelay so that the middle of the sheet is over the middle of the stacker tray You can check this by folding a sheet in half as dotted line in photo and checking that the fold on the left and right edge is equal distances X above and below the angle in the sidelays Paper Guide Width Adjustment Support Post Bottom Sidelay Adjustment The X Jogger with A4 8 x 11 Paper Adjust the position of the support posts by twisting anti clockwise to release sliding to about 5mm from the edge of the stack and then re tightening 48 Document Finishing System User Manual 3 About the Machine Straight Jogger Adjust the position of the X Jogger itself moving it further in or out so that the paper falls neatly into the receiving area Select OSCILLATE in either the BASIC or BATCH menu if required from the con trol panel menu and run a test set If needed fine adjust the position of the sidelays and support posts to achieve a neat stack Jogging Adjustment If necessary adjust the amount of vibration via the knob on
3. Gap Rear of Outfeed Once in place clip the locating hooks over the tie bar Tie Bar Locating Hooks AN Caution Before letting go of the front outfeed conveyor ensure that the rear end is being supported if not it will swing down 46 Document Finishing System User Manual 3 About the Machine Attach the outfeed earth wire to the connector on the side of the base Paper Guide Earth Wire Connector Paper Guides Clip a paper guide onto the tie bar There are two paper guides provided with the front outfeed short and stand ard The choice of which guide to use is dependent upon paper size and orien tation The guide should be positioned to control the set as it is delivered into the jogger AN Caution When the DFS is to be used with a BookMaster Pro the front out feed conveyor must be removed first Document Finishing System User Manual 47 3 About the Machine Joggers X Jogger Two types of jogger are available as optional modules The X Jogger straight or offset stacks whilst the Straight Jogger is used when set separation is not required If a jogger is to be used the front outfeed conveyor must be fitted see p 46 Setting Up the Jogger Position the X Jogger under the tower so that the back edge of the stack is level with the front outfeed as shown Connect the jogger to the mains supply and switch on A
4. Static Elimination Bar 62 Document Finishing System User Manual 5 Maintenance Friction Feed Bins Paper Separators P No 909 485 There is one paper separator located in the centre of each friction feed bin It slots into the aluminium pick up manifold immediately beneath the central feed wheel They should be cleaned if dirty and replaced when worn The replacement interval will depend upon the usage level and the type of papers used Paper Separator Remove the feed wheel shaft by pushing it to the left against the spring pres sure and lifting the right end clear Locate the separator and lift it out vertically Clean or replace the separator as required When cleaning the separator use only soap and water or alcohol isopropanol Refit the separator and ensure that it seats firmly in the correct position Refit the feed wheel shaft Feed Wheels P No 330 301 The friction feed bins are fitted with three feed wheels B mounted on a shaft They should be cleaned if dirty and replaced when worn The replacement interval will depend upon the usage level and the type of papers used Remove the feed wheel shaft by pushing it to the left against the spring pres sure and lifting the right end clear Clean the wheels using only soap and water or alcohol isopropanol If the wheels need to be replaced grasp the shaft firmly and slide off each wheel this will be eased by wetting the shaft
5. Cannot start fold axis changing The fold axis size adjustment of the booklet maker is in the process of adjusting Wait for the booklet maker to finish before touching INCH Touch to continue the job when using the DFS offline Cannot start sheets axis changing The sheets axis book thickness adjustment of the booklet maker is in the process of adjusting Wait for the booklet maker to finish before touching INCH Touch to continue the job when using the DFS offline Cannot start tray down Suction feed bin only One of the trays has been lowered by the operator Press the grey button on the bin controls to raise the tray Press Cannot start tray empty One of the switched on bins was empty when was touched Fill the bin with paper and touch again Cannot start trim axis changing The trim axis size adjustment of the trimmer is in the proc ess of adjusting Wait for the trimmer to finish before touching Cannot start The width axis size adjustment of the DFS is in the process width axis of adjusting Wait for the booklet maker to finish before changing touching Change feed The tower s base is not set up correctly for the current job output to front Change the paper path to feed to the front of the tower Change feed output to rear The tower s base is not set up correctly for the current job Change the paper path to feed to the rear of the tower
6. Change feed The tower s base is not set up correctly for the current job path down Change the paper path to feed down Check fuse A fuse may have blown in the drive unit Contact your sup plier Conveyor jam A paper jam has occurred in the bottom of the conveyor Clear the jam Touch INCH to clear any partial sets from the conveyor Emergency stop The emergency stop button has been pressed Turn the emergency stop button clockwise to release it 88 Document Finishing System User Manual 6 Problem Solving Error Message Meaning Fuse blown A fuse has blown on the Motor Drive PCB in the drive unit Contact your supplier Fuses blown Fuses have blown on the Motor Drive PCB in the drive unit Contact your supplier Initialising bins The bins in the DFS are being checked If this message appears regularly contact your supplier Motor stalled There may be a bad jam causing the conveyor to lock Clear the jam Touch INCH to clear any partial sets from the con veyor If the DFSDFS does not restart a fault may have occurred in the drive unit Contact your supplier No power to stacker Check that the stacker is plugged into a suitable mains sup ply and is switched on No response The bins in the DFS have not initialised properly Switch the machine off and then on again If the problem persists Con tact your supplier Output path deflector changed The pap
7. V M S 65 85 V Ft S Table Speed 20 26 V M Min 65 85 V Ft Min Feed Per Pass 0 01 0 02mm 0 0004 0 0008 Important A 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 dd a Correct Incorrect 74 Document Finishing System User Manual cHapterns Problem Solving This chapter explains how to resolve any problems that may occur with your DFS If a problem persists please contact your supplier Trouble Shooting Chart As far as possible the DFS has been designed to be self explanatory In most cases problems or errors will be identified on the control panel This trouble shooting chart provides a further guideline to help solve any problems General Problems Problem Cause Solution THE MACHINE WILL The machine is not Plug in and switch on NOT POWER UP plugged in Faulty fuse Check the fuse at the mains input and replace if necessary see p 86 THE MACHINE WILL Several possible causes Correct any faults shown NOT START exact cause will be shown on the display on the display Document Finishing System User Manual 75 6 Problem Solving Gathering Station Problems Problem Cause Solution SHEETS NOT IN COR The unit has not been set Set the levers on the front RECT ORDER NOT to the correct paper size of the unit to the correct STACKING WELL
8. air separation 27 bin controls 25 bin linking 28 loading the bins 26 maintenance 63 sensor overrange 28 separator pressure 26 sidelay taps 27 switching bins on amp off 26 tray extenders 25 tray pressure 27 front outfeed attaching the front outfeed 46 front outfeed conveyor 46 46 47 fuses 86 G gathering station 35 36 H help 13 honing trimmer blade 74 l inch 13 39 indicator lights 39 bin 39 booklet maker status 39 staple head 39 inserts 22 installation 1 interface sockets 35 introduction 1 5 J job details 20 joggers 48 49 joggers straight jogger 49 x jogger 48 K key symbol see padlock symbol L landscape 39 load 20 load and save window 20 delete 21 job details 20 load 20 padlock symbol 21 save cancel 20 replace 20 save new 20 view of job list 21 a gt z 21 by use 21 loading friction bins 26 loading sequence normal collating 9 loading slimvac bins 30 loading offline 8 locking jobs 21 M mains input 4 mains on off switch 4 maintenance 61 61 74 manual bypass gate 36 manual cranking point booklet maker 68 manual cranking point trimmer 69 menu 14 mimic diagram 14 mixed feed 24 multifeed 23 multiset 23 N normal collating loading sequence 9 number of sets 21 0 operator maintenance 61 61 74 outfeed conveyor adjustment 44 P padlock symbol 21 page direction 18 39 paper guides 47 paper jam 81 paper separators friction bins 26 63 paper size 1
9. set causing incorrect cali bration Treat as double feed above Treat as miss feed above Run another test set by touching followed by TEST SET followed by Q It may be necessary to increase the tray pres sure to obtain a better feed PAPER JAM Sheet is jammed in the Locate the sheet and paper path either pull it out or INCH it through Sheet is only half feeding Treat as miss feed above Feeding A5 57 x 87 Select SHORT in the landscape without select ADVANCED FEED ing SHORT in the CLUTCH window and run ADVANCED FEED another test set by touch CLUTCH window ing followed by TEST SET followed by FRONT EDGE OF Too much separation Reduce by moving the SHEET DAMAGED pressure lever up by one notch ata time see p 26 Document Finishing System User Manual 83 6 Problem Solving SlimVAC Feed Problems Problem Cause Action DOUBLE FEEDS The tray is too high Not enough corrugation on suction feeder Mechanical paper prob lem guillotine burr sticky ink poor perforations high static charge etc Rubber endlay is incor rect type or position Lower the tray height see p 32 Increase sheet corruga tion see p 31 Fan stock by hand before loading and ensure these problems are avoided in future Use correct type and positioning see p 30 MISS FEEDS Not enough air separation Too much sheet corruga tion The tray is too low Heavy and or rigid shee
10. 17Kg Auto SpineMaster option 132Kg 291lb Electrical 105 127V 60Hz or 208 254V 50Hz single phase Radio Frequency This equipment has been tested and found to comply Emissions 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 instruc tion 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 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 E amp OE 94 Document Finishing System User Manual cuaptera Declaration of Conformity Name of Manufacturer Watkiss Automation Limited Address of Manufacturer Watkiss House Blaydon Road Sandy Bedfordshire G19 1RZ United Kingdom Declares that the product Name of Product Document Finishing System with Bookmaster Pro and TrimMaster Pro Conforms to the following Directives Safety 2006 95 EC Council Dir
11. 48 4 Bar Code Reader 00 cece ence teenies 51 INtrOCUCTION 25 0 ARMac ee seh 8 aso Rosen Ay nod Res ot 51 Running the Job ss eisad eae ihe ee Ree eke be ee 52 About the Barcode Reader 000000 ees 53 Defining and Printing the Barcode 55 Problemi SOWING s ceua ceed seaweed Gwe beta death als we 59 5 Maintenance 2 ass aad ae ete wae ee Sie 61 Service Interval 0 000000 eee eee eee 61 Operator Maintenance 20200000000 0s 61 BookMaster Pro and Trimmer 05 64 continued Watkiss Document Finishing System User Manual BookMaster Pro Version English Issue 1 November 2011 Watkiss Part No 960 881 Effective Serial No WA VAR 2450 onward Document Finishing System User Manual 6 Problem Solving 00 cece eee eee eens 75 Trouble Shooting Chart 200 cece 75 Pap rJamS as denent teres BA Dein hk hse Sean Pinkie 85 Replacing Fuses aise sca uce ea rte Meee etd de 86 Error Messages i03 ocawsu Nea san Pew ae own 86 7 User Safety Information 000e ee eeee 91 Instructions for safe use 2 eee eee eee eee 91 8 Specifications 220 bss st vases et eed ie Sees OAs 93 9 Declaration of Conformity 0 00 eee eee 95 INDEX 25 tcesee Seba A ote teers year er ateteene 97 Document Finishing System User Manual cHapter1 Introduction to the Document Finishing System Thank you for c
12. A miss feed error has occurred on the bin detailed This means that the bin did not feed a sheet in the last set Check and correct the faulty set and restart the machine If the error persists see the Problem Solving section of this manual Bin overload An obstruction in the bin is preventing it from lifting correctly Check and remove any obstructions It may be that the stock has not been pushed fully forward into the bin Bin part reset It is necessary to switch the machine off and then on again after 10 seconds before running another test set If this prob lem persists contact your supplier Bin trailing A trailing feed error has occurred on the bin detailed This can mean one of two things 1 The sheet from this bin was delivered late trailing single feed 2 An extra sheet was delivered from this bin slightly behind the first sheet trailing double feed If the problem persists see the Problem Solving section of this manual Document Finishing System User Manual 87 6 Problem Solving Error Message Meaning Bin programming error The bins in the DFS have not initialised properly Switch the machine off and then on again If the problem persists con tact your supplier Bin reset An error has occurred in the electronics of the bin detailed Any number over 16 relates to a module other than a bin Restart the machine If the problem persists contact your supplier
13. Document Finishing System Switching the Document Finishing System On and Off Mains Input There are two mains inputs one on the rear of the tower drive unit and one on the rear of the BookMaster Pro Two fuses are fitted next to each of the mains inputs Mains Input Serial Number LY Document Finishing System Mains Input Lie 3 SA Ea i re i ee 4 ead a he awit se ea Pn Pee BookMaster Pro Mains Input Mains On Off Switch Mains On Off switches are located on the side of the tower next to the emergency stop button and alongside the BookMaster Pro mains input The mains On Off switches should be used to turn the system on and off when required When the system is switched off it retains the control panel settings in memory Mains ON OFF Switch Emergency Stop 4 Document Finishing System User Manual 1 Introduction to the Document Finishing System Important To maintain the efficiency and prolong the service life of the static elimination equipment it is important to switch off the tower when it is not being used for a period of hours e g overnight Emergency Stop The emergency stop button should only be used when an immediate stop of the machine is required Under normal circumstances the machine should be stopped by touching the stop button on the control panel If the emergency stop button is used the system will not restart until the button h
14. JOG This provides additional jogging to the sides of the set when using heavy or large sheets The sidelays jog the set twice when it reaches the stitch latch STITCH DELAY Increasing the STITCH DELAY value will cause a delay between the set arriving on the stitch latch and it being stitched This allows more time for the sheets to settle The default delay is 1mS PRE FOLD JOGGING The PRE FOLD JOGGING window has options to alter the way sets are jogged prior to folding This ensures the finished booklets are as neat as possible SIDE JOG HOLD When SIDE JOG HOLD is selected the sidelays hold the set during both stapling and folding without releasing This is useful if the booklet is not being folded square however it is essential that the sheet width is set accurately FOLD DELAY This can be adjusted to alter the delay between the set arriving on the fold latch and being folded This is useful if the booklet is not being folded square and allows more time for the sheets to settle The default delay is 180mS The maximum production speed of the BookMaster Pro will be reduced if the delay is increased Document Finishing System User Manual 19 3 About the Machine The LOAD amp SAVE Window The LOAD amp SAVE window allows job settings to be saved and reloaded at the touch of a button Each job is given a name and the jobs are listed on the screen To select a job highlight it by either touching it or by using the
15. Linking If required two or more feed bins may be linked to operate as a single bin When one runs out of stock the next bin in the linked group will automatically take over This allows reloading without stopping the machine Bin linking can only be enabled when the bins are unlocked i e when the TEST SET icon is high lighted on the control panel Press the grey button on the upper bin to link it with the one below This will be indicated by the small green light The mimic dia gram on the control panel will show a broken line between bins that are linked By pressing the red bin on off button it is possible to select which bin in the linked group is active If the system is locked pressing the grey button on any bin will indicate which bins are in the same linked group Sensor Overrange Sensor overrange is indicated after the test set by a slow flashing red light on the bin in question Particularly heavy or opaque stock may cause the bin sensor to go overrange This means that the sheet is too optically dense for the sensor to see through it Double feeds will not be detected but misses trailing sheets and jams will be detected as normal 28 Document Finishing System User Manual 3 About the Machine SlimVAC Suction Feed Bins For operation of Friction bins please refer to Friction Feed Bins on page 25 Bin Controls and Indicators Feed bins are numbered from 1 upwards with the bottom bin being
16. a convenient point PAUSE SEPARATE PAUSE SEPARATE causes the machine to pause for approximately 5 seconds after each batch The pause icon on the control panel will flash between batches This function will also separate batches on a booklet maker outfeed conveyor The pause time can be altered on the Machine Options page touch MENU MACHINE OPTIONS 22 Document Finishing System User Manual 3 About the Machine RESTART BATCH Touching RESTART BATCH zeros the batch counter so that you can restart a batch Note that if the tower is running this button will interrupt a batch that is partly completed and a new batch will be started The FEED Window The FEED window contains the Multifeed Multiset and Mixed Feed options With these options the tower can be programmed to feed in selective or special sequences MULTIFEED MULTISET MIXED FEED a a a FEED Window MULTIFEED MULTIFEED allows multiple feeds from each bin per set For example a Multifeed size of 4 will feed 4 sheets from each bin in turn Touch MULTIFEED and enter the number required using or Touch O to switch on Switch off after use MULTISET MULTISET allows multiple sets to be loaded and counted For example a four part set can be loaded three times in a twelve bin tower When Multiset is switched on the counter will count three sets per cycle instead of one Multiset will also automatically divide an o
17. 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 Document Finishing System User Manual 71 5 Maintenance or below it at point B Lightly tighten the centre screw sufficient to hold the blade in this position BLADE 2 0 2 20 Remove the left hand trimmer side cover two x M5 button screws and wash ers Release the clutch by depressing the lever see below through the access hole in the side plate Manual a Crank Drive x E Access Hole Use a 19mm spanner to manually crank the unit until the blade is at top dead centre At point C 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 72 Document Finishing System User Manual 5 Maintenance from the centre and working out Lightly tension the anvil adjuster screws against the anvil Final Adjustment Release the clutch and manually crank slowly several rota tions Check that
18. handle to the left and lift ing The lid is supported by a strut on the right side Support Strut To close the BookMaster Pro lid lift it slightly push the support strut inwards and close the lid Turn the handle to the right to lock in place The trimmer lid can be opened by lifting the orange hand screw Orange Hand Screw for Opening the Trimmer Lid Connecting the BookMaster Pro amp Trimmer The BookMaster Pro and trimmer will be connected together when the Docu ment Finishing System is installed However it may be necessary to separate them when moving the units or when clearing paper jams Document Finishing System User Manual 37 3 About the Machine Disconnecting the BookMaster Pro and Trimmer Open the BookMaster Pro lid Disconnect the communications and power cables and wheel the BookMas ter Pro and trimmer units apart Connecting the BookMaster Pro and Trimmer Line up the trimmer docking plates with the BookMaster Pro Re connect the power and communications cables to the sockets on the BookMaster Pro Communications Cable Power Cable Docking Plate Push the two units together so that the hooks on the trimmer docking plates align with the holes in the BookMaster Pro side plates Close the BookMaster Pro lid and turn the handle to the right to lock the trimmer in place Starting and Stopping the BookMaster Pro The BookMaster Pro and
19. of the unit e d Trimmer Lid E N Conveyor Assembly Separate the trimmer from the booklet maker Open the trimmer lid Remove the two M5 button screws and washers that secure the conveyor assembly to the trimmer unit M5 Button Screws 70 Document Finishing System User Manual 5 Maintenance Lift away the conveyor assembly to reveal the blade assembly Anvil Mark Along Here Blade Important Note the angled position of the trimmer blade and with a marker pen or similar mark along the bottom edge of the blade This will act as a guide when refitting Removing the Trimmer Blade Slightly loosen all five blade fixing screws Remove the outer two screws and screw them into the locator holes These will now act as handles Remove the remaining screws and carefully lift the blade away Immediately put the blade away safely y Po tt ANVIL FIXING BOLTS ANVIL ADJUSTER SCREWS ANVIL m L CLAMP BLADE Qo 20 ica BLADE FIXING SCREWS LOCATOR HOLES FOR HANDLING Check the Anvil Carefully check the anvil for any damage If it requires re grinding remove the five fixing screws and lift away Refitting the Blade and Anvil Slacken the anvil adjuster screws back two rev olutions Position the anvil fully back towards the conveyor and lightly tighten the anvil fixing screws Affix the
20. paper size see p 35 Sheets are falling forwards Adjust the air blow see in the gathering station p 36 POOR FEEDING INTO The static elimination baris Clean the static elimina BOOKMASTER PRO dirty reducing effective tion bars see p 62 ness and causing the back sheet s of the book to cling to the gathering sta tion as they are released 76 Document Finishing System User Manual 6 Problem Solving BookMaster Pro and Trimmer Problems Problem Cause Solution If you suspect the booklet maker adjustment system is not calibrated correctly touch RE REF in the PAPER SIZE window to manually recalibrate the BookMas ter Pro adjustment axes After recalibration the BookMaster Pro adjustment axes will return to the current settings If the DFS s software detects a possible axis positional fault the unit will automatically recalibrate the axes Operational Problems BOOKLET MAKER WILL NOT START The booklet maker is not plugged in Interface between book let maker and tower is not plugged in Fuse has blown on the main input Booklet maker or trimmer lid is open Blanking plug or ASM data cable is not plugged into the socket on the rear panel of the trimmer Plug into mains connec tion of the correct type and voltage Plug in On 220 240V machines there are two 5 amp fuses in the mains input connec tor check and replace as necessary On 115V machines they are 10 amp fuses Clos
21. settle before stapling Tower delivering an untidy set The booklet maker adjustment system is not calibrated correctly p 18 Allow more time for the set to settle by increasing STITCH DELAY Improve tower delivery Touch RE REF in the PAPER SIZE window to manually recalibrate the BookMaster Pro adjust ment axes FINISHED BOOKLET Fold roller gap is too wide Adjust the fold roller gap IS TOO LOOSE see p 43 TOP JOG DAMAGE The sheet length has Adjust PAPER SIZE see ON THE SET been set too short p 18 Fold roller gap is too nar row when edge stitch ing Tower delivering an untidy set Adjust the fold roller gap see p 43 Improve tower delivery BMP WILL NOT FIT BACK UNDERNEATH THE TOWER Front feed out conveyor is in down position It is ESSENTIAL to raise the feed out conveyor and clip up the feed out paper guides before placing the BMP back underneath the tower Document Finishing System User Manual 79 6 Problem Solving Problem BOOKLETS WILL NOT STACK ON THE CONVEYOR Cause Large payout wheels incorrectly positioned Electrical connection is unplugged Solution Reposition see p 44 Plug in electrical connec tion between the booklet maker trimmer and the outfeed conveyor BOOKLET COVER IS MARKED Dirty fold rollers Fold roller gap is too nar row Clean them with a cloth dampened with soapy water or alcohol isopro panol Do NOT us
22. slightly Ensure the shaft is clean and slide on each new wheel ensuring that the wheels align with the correct marks on the shaft The standard position for the wheels is shown below Document Finishing System User Manual 63 5 Maintenance e Replace the shaft e Select CLEANING in the MENU USER SETTINGS window and press the red button on the bin controls to turn the feed wheel shaft Visually check that each wheel runs true To straighten a wheel gently hold a flat edge against the wheel whilst it turns BookMaster Pro and Trimmer Changing the Staple Cartridge When a staple cartridge runs out the corresponding red indicator light will blink once per second The message STAPLES LOW will also be shown on the Docu ment Finishing System control panel New cartridges are available from your Watkiss supplier Watkiss P N 810 022 To change a cartridge first open the BookMaster Pro lid by turning the handle to the left and lifting The lid is supported by a strut on the right side Indicator Light 64 Document Finishing System User Manual 5 Maintenance Grasp the cartridge at the top and pull directly away from the staple head as shown by the arrow in the photo Staple Cartridge Staple Head Fit the new cartridge and check machine operation by making a few test book lets Staple Position Adjustment If both staples are consistently off the spine of the b
23. specified feeder e g If R 3 the next feed will be from Bin 3 and the Barcode on that sheet will be used to control the subsequent actions NB If R 0 then subsequent feed and control will pass back to the master test set bin Examples Basic Set Control Size of set 12 Sheet counter counting down 12 11 10 etc ZZ SS 12 12 12 11 12 10 12 09 etc Basic Set Control with sheet insertion Size of set 3 Sheet counter counting down 3 2 1 Insert from specified bin Insert from specified bin w oo col N pol ol wm oO oj O A O O Insert from bins 3 and 4 58 Document Finishing System User Manual 4 Bar Code Reader Document Security DDDD F SS Document ID changes for each set First sheet marker Sheet counter counting down Document Security JJJ DDDD F SS Job ID the same for all sets in the job Document ID changes for each set First sheet marker Sheet counter counting down Stop marker Problem Solving Error Causes Errors may occur Error Reporting if the barcode is printed incorrectly if the barcode is defined incorrectly during set up if the job is loaded incorrectly if the wrong master bin is selected if the feed bin s have a feed error If an error occurs an error message is displayed on the GUI screen and t
24. 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 AN 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 Document Finishing System User Manual 73 5 Maintenance Trimmer Blade Grinding Specification BLADE Note 2 faces must be flat to within 0 03mm 8mm ANVIL Note 2 faces must be flat to within 0 01mm 12 7mm x This edge must be straight to within 0 04mm Note TrimMaster blade 253 835 is fitted with a guide leg This must be removed when the blade is reground and refitted afterwards Blade Material High Carbon High Chrome Aisi D2 D3 Grinding Angle See drawing alongside Grinding Wheel Cup or Cylinder Grinding Material Grit 46 60 Hardness G H Bond Vitrified Peripheral Speed of the Grinding Wheel 20 26
25. the top of the motor housing just above the mains On Off switch Use the minimum amount of vibration that will successfully jog the stack Setting up the Jogger Place the Straight Jogger in a central position under the tower Ensure the local control switch is in the off position green strip not visible Connect the jogger to the mains supply and turn on the red mains on off switch Jogger full Sensor Mains ON OFF Switch Local Control Switch Jogging Adjustment Mains Input Height Adjustment Release Lever Plug the jogger into the socket on the underside of the floor base via the inter connection cable The cable will only fit in one of the sockets Run a test set and if necessary adjust the position of the jogger Move it further in or out so that the paper falls neatly into the receiving area A sideways posi tional adjustment may also be necessary depending on the size of the paper and type of stock The height of the jogger can be adjusted by releasing the height adjustment release lever Jogging Adjustment If necessary adjust the amount of vibration via the knob on the side of the jogger as shown above Use the minimum amount of vibra tion that will successfully jog the stack Document Finishing System User Manual 49 3 About the Machine 50 Document Finishing System User Manual cHapterns4 Bar Code Reader Introduction The optional barcode reader module fully integrates into the cont
26. up and down arrows Ale s ey 3 DELETE VIEW OF DETAILS a JOBUST a LOAD AND SAVE LOAD amp SAVE Window SAVE Touch SAVE to save the current settings of the DFS When the on screen keyboard appears enter the job name and then touch OK or CLOSE The new job will appear in the list of saved jobs This allows the settings to be recalled in the future which saves set up time REPLACE If an existing job has been loaded and modified touching REPLACE will replace the old job with the modified version CANCEL Touch CANCEL if you do not wish to save a job that you have modi fied SAVE NEW If an existing job has been loaded and modified touching SAVE NEW will save the modified version as a new job When the on screen key board appears enter the new job name and then touch OK or CLOSE The original job is unchanged If the job name is not changed before touching OK or CLOSE the job will be saved with the current name suffixed by an asterisk JOB DETAILS Touching JOB DETAILS shows the settings for each saved job Select the job that you wish to view from the job list and touch JOB DETAILS to see a summary of the job settings LOAD To load a job select it on the job list using the up and down arrows or by touching it Touch the LOAD button You must touch END JOB before loading a job 20 Document Finishing System User Manual 3 About the Machine PADLOCK SYMBOL The padloc
27. 8 paper size adjusting 39 pause 13 pause separate 22 payout wheels 44 portrait 39 power save 11 pre fold jogging 19 pre jog 19 pre stitch jogging 19 prenumber 16 preset 15 presets 18 problem solving 75 90 booklet maker and trimmer problems 77 error messages 86 90 friction feed problems 82 gathering station problems 76 general problems 75 paper jam 81 slimvac feed problems 84 staple head problems 80 trouble shooting 75 R re ref 18 77 restart batch 23 rubber endlays slimvac bins 30 Document Finishing System User Manual 98 S safety 1 save 20 sensor overrange 28 32 service interval 61 sets per hour 15 setting up the booklet maker 37 45 connecting 37 opening 37 starting 38 setting up the bookletmaker outfeed conveyor adjustment 44 trim offcut box 45 sharpening trimmer blade 70 74 sheet corrugation slimvac bins 31 sheet length adjusment 35 sheet offset 16 sheet width adjustment 36 side jog hold 19 single set 15 slimvac bins 29 34 adjustments 31 33 bin controls 29 bin linking 32 difficult papers 33 feeder angle 32 loading the bins 30 rubber endlays 30 sensor overrange 32 sheet corrugation 31 switching bins on amp off 31 tray extenders 29 tray height 32 specifications 93 sph 15 staple cartridges changing 64 staple head clincher 43 position 42 selecting 42 staple cartridges changing 64 staple head indicator lights 39 staple position adjustment 65 staples low 64 start stop 12
28. Bins On amp Off Before a test set is produced individual bins will automatically switch on and off as they are loaded and unloaded Bins can also be manually selected by pressing the red button alongside the bin In addition loading the Default Template will switch on all loaded bins Remember that bins cannot be switched on or off when the system is locked touch END JOB if nec essary Adjustments for paper type and or size include control over the amount of tray pressure and the amount of separator pressure Separator Pressure Increasing the separator pressure acts like a brake mak ing it more difficult for a second sheet of paper to pass the separator pad Too little separator pressure will result in double feeds too much will result in miss feeds or damage to the feed edge of the paper The ideal separator pressure will depend upon the stock in use Initially set the lever to its mid position To increase separation move the lever downwards one notch at a time and to decrease separation move the lever upwards one notch at a time Moving the lever to its highest position disengages the separator This position is used for the improved feeding of heavy cardstocks 26 Document Finishing System User Manual 3 About the Machine Tray Pressure Increasing the tray pressure gives the feed wheels greater force on the paper too much will result in double feeds and increases the possi bility of scuffing the paper fa
29. Document Finishing System Operating Manual BookMaster Pro Version Issue 1 November 2011 Watkiss Automation Limited 2011 All Rights Reserved Reproduction adaptation or translation without prior written permission is prohibited except as allowed under the copyright laws Warranty The information contained in this document is subject to change without notice Watkiss Automa tion Limited makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Watkiss Automation Limited shall not be liable for errors contained herein or for incidental or con sequential damage in connection with the furnishing performance or use of this material Table of Contents 1 Introduction to the Document Finishing System 1 2 Using the Document Finishing System 7 Collating Sequentially Printed Sets 7 Normal Collating 23 cc 9 oiice sew bee eae eee gta eet 9 3 About the Machine 00 cece eee eee 11 Control Panel 0 0020s 11 Friction Feed Bins 0 0000 c eee eee eee 25 SlimVAC Suction Feed Bins 2 005 29 Gathering Station tc0 3 nae tieed oe ba eee ad eaten Bates 35 BookMaster Pro amp Trimmer 020200005 37 Front Outfeed Conveyor 0 000 eee eee eee 46 JOGOSIS gt ot cals Rak ome aed dete as tian ba heh roa
30. MBER and set the SETS PER HOUR to AUTO Test Set A test set must be run at the start of each job Touch to run a test set If PRENUMBER is selected the test set is counted and the sheet should be left in the gathering station Tip To avoid wasting sheets during the test set the sheets can be diverted out of the front of the gathering station using the manual bypass gate Note f PRENUMBER is not selected the test set is not counted and the sheet should be removed from the gathering station and replaced in the feed bin Note f a cover is being inserted it is not fed during the test set The cali bration reading for the cover is automatically taken when the job is started Touch to run the job Once the machine is running adjustments may be necessary depending upon the stock in use The machine can be stopped at any time by touching Alternatively to stop the machine when the current batch set is complete touch STOP in the BATCH window Normal Collating Preparation e Press END JOB to end the previous job e Press INCH to check that there are no sheets remaining in the conveyor e Clear any remaining sheets from the DFS system Tip Load the Default Template to return the control panel to its default fac tory settings Touch END JOB Touch LOAD amp SAVE Select the Default Template from the list of jobs Touch LOAD If asked select YES to confirm that you wish to load the Default Template Loading S
31. O to set the clutch feed length to the default value of 186 2mm 7 35 Document Finishing System User Manual 17 3 About the Machine SUCTION HOLD Increasing the SUCTION HOLD value causes the feeder to allow more time to pick up each sheet If you are using stock that tends to stick together increasing the suction hold can improve paper pick up and in some instances separation It is possible to reduce the suction hold when using paper that is easy to feed this will increase the operating speed of the machine The default setting is 300mS The FINISHING Window The FINISHING window controls the settings for the BookMaster Pro and trim mer PAPER STITCH TRIM PRE STITCH PRE FOLD 5101014 SI aj AND FOLD a aj JOGGING a JOGGING aj THICKNESSa FINISHING FINISHING Window PAPER SIZE Touch PAPER SIZE to alter the settings of the BookMaster Pro and trimmer to suit the input paper size RE REF If you suspect the BookMaster Pro or trimmer adjustment system is not calibrated correctly touch RE REF to re reference the adjustment axes The adjustment axes will return to the current settings once this is complete Periodically the DFS will automatically re reference the axes during the setup procedure PAGE DIRECTION Touching PAGE DIRECTION switches the orientation of the paper between landscape and portrait This is only possible if the sheet does not exceed the maximum width accepted by t
32. The DFS is controlled by touching buttons on the control panel The buttons are divided into groups that perform related functions Each group of buttons has its own window which is selected by touching the relevant tab Load amp Save e Basic e Advanced e Feed e Batch e Finishing Start Stop Test Set Inch Pause Help End Job Menu _ Control Buttons Watkiss GUI Panel Feb 132001 SETS 000000 BATCH a SPH 0000 Each window contains a group SETS PER AIR BLOW PRESET PRENUMBER OSCILLATE HOUR of related buttons Touch the relevant 7 tab to display each Load amp Save Feed window Basic Batch Advanced Finishing Main Window Tabs on the Control Panel Control Buttons There are six main control buttons listed across the top of the screen START STOP The button starts the machine When the machine is run ning this button changes to which stops the machine These are duplicated by the start stop buttons above the touch screen 12 Document Finishing System User Manual 3 About the Machine INCH Touch and hold INCH to turn the conveyor The conveyor will stop when INCH is released This is used for clearing any sets remaining in the conveyor after a jam etc When the machine is running this button changes to PAUSE Touch PAUSE to pause the feed for approximately 5 seconds the conveyor continues to run The pause time can be altered on th
33. Wheels Tip Common sizes are highlighted on the scale For example for an A5 5 X 8 book use the A5 marker 44 Document Finishing System User Manual 3 About the Machine Trimmer Offcut Box The trimmer offcuts are delivered into the trimmer offcut box This box hooks onto the trimmer Offcut Box Remember to empty the trimmer offcut box periodically There is a sensor on the trimmer to detect when the offcut box is full Once this sensor is activated the booklet maker will beep after every second booklet pro duced Trim Margin If you are inserting sheets from a Friction bin which have been printed offset litho 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 In this way any marking that could possibly occur due to wet ink or ink rub will always be in the trim margin Document Finishing System User Manual 45 3 About the Machine Front Outfeed Conveyor The front outfeed conveyor is an optional module It facilitates the delivery of sets from the gathering station into either a straight jogger or an X jogger Tie Bar Front Outfeed Paper Guide X Jogger Attaching the Front Outfeed Conveyor When attaching the front outfeed conveyor ensure that you slide it into the small gap between the tower base and the gathering area This is to support the rear of the outfeed
34. a sequential sheet identification number running through whole job This may count up or down it is initialised at the start of the job D Document ID This is a document set identification code All sheets of the document set must have the same ID This is initialised on the first sheet of a set Z siZe of set This is the number of sheets in the set It is used in conjunction with the Sheet counter S Sheet counter This is the sheet number within the set If used together with siZe no First or Last mark is needed It may count up or down If siZe is not used either a First or Last mark must be used If a First marker is used the counter must count down If a Last marker is used the counter must count up F First sheet of the set This marks the first sheet of a set and must be used in conjunction with the Sheet counter counting downwards L Last sheet of the set This marks the last sheet of a set It is not necessary to use a Last marker if both S and Z are used T sTop Terminates operation of the machine after this sheet Document Finishing System User Manual 4 Bar Code Reader Barcode Elements Insert Inserts a sheet from the relevant feeder e g If 3 a sheet will be inserted from bin 3 This character can be used as many times as required within the bar code to give multiple inserts R Read Feed a sheet and Read the Barcode from a
35. ails on changing the staple cartridge Adjustment for Paper Size Adjustment for paper size is made on the GUI Graphical User Interface e Touch FINISHING to display and adjust the booklet maker settings e Touch PAPER SIZE PRESETS and select a standard sheet size A3 A4 or A5 11x17 8 5x11 or 5 5x8 5 e Choose PORTRAIT or LANDSCAPE in the PAPER SIZE PAGE DIRECTION win dow e For non standard paper sizes touch PAPER SIZE and then use the and keys to set the size Note PORTRAIT is the normal setting for booklet making Document Finishing System User Manual 39 3 About the Machine Tip Remember that you can recall the settings from previously stored jobs in the LOAD amp SAVE window Select Edge or Centre Stapling Use the Edge Centre Staple Selection Lever to select centre staple operation lift up or side corner staple operation push down Staple Head Selection Edge Centre Staple Selection Lever Staple Head Indicator Light Staple Head Select When edge or corner stapling the staples will be inserted into the feed edge of the sheet Note The maximum sheet length that can be edge or corner sta pled is 250mm 9 8 If the sheet length exceeds this the top jog is automatically switched off and may not give satisfactory results Third Staple Head Kit The booklet maker has two staple heads as standard A third head can be spec ified as an
36. air blow 15 prenumber 16 preset 15 sets per hour auto 15 single set 15 batch window 21 inserts 22 bottom 22 top 22 number of sets 21 pause separate 22 restart batch 23 stop 22 bin controls 25 29 bin linking 28 32 blade sharpening 70 booklet making setting up the booklet maker 37 45 Cc calibration see re ref centre stapling 40 clamp roller shafts 67 68 cleaning see maintenance cleaning the touch screen 62 conformity declaration of 95 control panel 11 24 basic operation 11 12 error messages 86 90 conveyor clamp adjustment 66 corner stapling 40 cover inserting 8 D delete 21 detector position 17 difficult papers slimvac 33 docking plates trimmer 38 double detection 17 double jog 19 drive speed 16 E edge stapling 40 edge stapling amp folding 42 edge stitch assistor 40 edge stitch drive engage the 41 emergency stop 5 end job 13 endlays rubber slimvac bins 30 error messages 86 90 F feed clutch 17 feed wheels friction bins 63 feed window 23 mixed feed 24 multifeed 23 multiset 23 feeder angle slimvac bins 32 finishing window 18 paper size 18 page direction 18 presets 18 re ref 18 pre fold jogging 19 fold delay 19 side jog hold 19 pre stitch jogging 19 double jog 19 pre jog 19 stitch delay 19 stitch and fold 19 stitch on fold 19 trim 19 fold delay 19 fold rollers adjustable 43 Document Finishing System User Manual 97 friction bins 25 28 adjustments 26
37. aple heads offline The staple heads are not selected on the booklet maker To select the staple heads press the Staple Head Select button on the booklet maker The staple head indicator lights on the booklet maker show which heads are selected Stapler Guard The top cover of the rear corner stapler is open Close the Open cover Stapler Jam A paper jam has occurred in the rear corner stapler Lift the top cover and clear the jam Staples low A staple cartridge in the booklet maker needs replacing Fit a new staple cartridge Stitch guard open The top cover of the booklet maker is open Close the cover Touch START to clear machine There may still be paper in the conveyor Touch to clear the machine before starting a new job Tray lift error Friction feed bin only There is a fault with the tray lowering mechanism Contact your supplier Tray lift error SlimVAC bin only One of the trays has not lifted Try unloading and reloading the bin If this does not work press the emergency stop switch and allow 10 seconds before releasing it If the problem persists contact your supplier Trim bin full The trimmer offcut bin is full Empty the offcut bin Trim Bin Open The Trimmer offcut bin is not fitted or is not contacting the safety switch Fit the offcut bin correctly Trim guard open The trimmer cover is open and should be closed 2xDivert Two successive diverts i
38. as been released by turning it clockwise Document Finishing System User Manual 5 1 Introduction to the Document Finishing System 6 Document Finishing System User Manual charter Using the Document Finishing System This chapter provides details on how to use the Document Finishing System For details on the individual modules and how to adjust them please refer to Chapter 3 on page 11 Collating Sequentially Printed Sets The DFS system can be used to automatically gather sets from a sequentially printed stack of paper The sheets are held in the gathering station until the set is complete and it is then released into the BookMaster Pro and trimmer Preparation e Press END JOB to end the previous job e Press INCH to check that there are no sheets remaining in the conveyor e Clear any remaining sheets from the DFS system Tip Load the Default Template to return the control panel to its default fac tory settings Touch END JOB Touch LOAD amp SAVE Select the Default Template from the list of jobs Touch LOAD If asked select YES to confirm that you wish to load the Default Template Document Finishing System User Manual 7 2 Using the Document Finishing System Loading the Bins with Paper Load the sheets so that the centre spread of the book is face up Centre Spread Face Up VSN RA l Ss Outside Face Down onsen Finishing Sequentially Printed Sheets e Load the
39. ates that in EU member states the machine must be correctly discarded At the end of service life the machine must be collected separately and recycled correctly according to local regulations 92 Document Finishing System User Manual CHAPTER 8 Specifications Intended Use The Document Finishing System is intended for feed ing stapling folding and trimming materials as speci fied below Operating Conditions 10 35 C at 35 85 relative humidity Up to 2000m above mean sea level Configuration From 2 to 8 feed stations with online BookMaster Pro amp trimmer Production Dependent on operating mode and finishing option Stock Sizes Min 140 x 210mm 5 5 x 8 3 Max 320 x 482mm 12 6 x 19 Stock Range 60 240gsm SlimVAC feed 60 300gsm Friction feed Coated paper 90gsm minimum Max Book Thickness 22 sheets 80gsm Detection Electronic detection for miss double jam and empty bin Dimensions Width Length Height 693mm 27 3 707mm 27 9 with ASM option 1960mm 78 with BookMaster Pro trimmer and out feed Friction feed 1415 plus 77mm per feeder SlimVAC feed 1588 62 5 plus 77mm 3 per feeder Document Finishing System User Manual 93 8 Specifications Weight 118Kg 260lb plus per Friction Feeder 6 9Kg 15 2Ib per SlimVAC Feeder 7 6Kg 171b BookMaster Pro 70Kg 154lb Trimmer 85Kg 187Ib Outfeed Conveyor
40. b During the job the GUI displays the barcode definition the result of the code last read and the next required code where applicable ID Ow P INCH END JOB TEST SET HELP MENU BARCODE JOB SETS 000001 Ze 4 Master bin number BATCH BATCHES wee ee a Barcode definition Results display amp 0 Required next result SPH 1500 MULTIFEED BARCODE Defining and Printing the Barcode The barcode can be generated and printed using barcode generation software of your choice provided it complies with the parameters on the following pages Instructions for Finishing The following information is needed by the DFS operator in order to finish the job e The Barcode elements to be programmed into the GUI For example ZZSS or DDDDFSS e The bin loading sequence This information is needed if the barcode ele ments include R read and feed from a specified bin or insert Document Finishing System User Manual 55 4 Bar Code Reader Barcode Specification Minimum 3 5mm preferred 2mm possible Height Length 2 22 characters Type Code 128 is the preferred format Code 39 may be used Resolution The print should have a minimum resolution of 0 3mm This applies to the line width and line separation Colour Black barcode on a white background is recommended Other colour combinations should be tested for reliable performance prior to proceeding Position The barco
41. bin 1 Each bin has its own controls immediately alongside it 4 5 oo Key Item Description Function 1 Red light Indicates a double feed slow flash indicates the bin sensor is overrange see p 32 2 Yellow light Indicates a miss feed 1 amp 2 Red and yellow lights Indicate a feed jam or trailing sheet 3 Red button Bin on off switch 4 Green light Indicates the bin is switched on Green flashing light Indicates the bin is switched on but needs loading Grey button Bin linking switch see p 32 6 Small lower green light Indicates the bin is linked to the one below Tray Extenders For large sheet sizes over A4 8 x 11 or when running A4 or 8 x 11 portrait it will be necessary to fit tray extenders to support the sheets One B3 14 x 20 tray extender is supplied as standard with each SlimVAC bin An optional tray extender is available for running A4 portrait 8 x 11 Watkiss P No 251 303 Document Finishing System User Manual 29 3 About the Machine Rubber Endlays Rubber endlays are used to control the paper stack in the tray Two different types are supplied with the machine It is important that the correct endlay is used in the correct orientation for the paper size in use Do not push the endlay hard up against the edge of the paper stack Incorrect usage may result in either misfeeds or double feeds 330 351 When the r
42. bins and switch on use bin linking if required e Adjust the feed bin settings to suit the paper type Inserting a Cover If you wish to insert a separate cover it should be loaded into the lowermost bin with the outside face down The other sheets are then loaded in the bin s directly above Adjust the BookMaster Pro and Trimmer Adjust the BookMaster Pro and trimmer for the paper size using the GUI con trol panel Note The Bookmaster Pro and TrimMaster Pro contain several axes that are automatically adjusted to suit the job settings The machine will beep twice when the axes have finished adjusting e Adjust the outfeed conveyor wheel e Select edge or centre stapling e Select which staple heads should be used and adjust their position if neces sary e Adjust the fold roller gap Adjust the Gathering Station e Adjust the gathering station for sheet width e Adjust for sheet length e Adjust the air blow if necessary Bar Code Reader where fitted e Adjust the Bar Code Reader as needed See Bar Code Reader on page 51 Starting the Job e Touch NUMBER OF SETS in the BATCH window and input the number of sheets required in each book 8 Document Finishing System User Manual 2 Using the Document Finishing System To insert a cover in the BATCH window touch INSERTS and set BOTTOM to ON the NUMBER OF SETS in the BATCH window must be set to 1 or greater In the BASIC window select PRENU
43. ccumulations of paper dust ink etc 61 Document Finishing System User Manual 5 Maintenance Cleaning Materials The DFS should only be cleaned with a cloth moistened with soap and water or with alcohol isopropanol Important Do not use any of the following chemicals to clean the separators feed wheels or conveyor wheels x Cleaners based on esters and ketones e g ethyl or butyl acetate esters or methyl ketone MEK x Aliphatic solvents e g petrol or SBP 1 x Aromatic solvents cleaners e g toluene xylene napthas x Chlorinated solvents cleaners e g trichloroethylene perchloroeth ylene genclenes All of these chemicals will damage the separators feed wheels and conveyor wheels to a varying degree resulting in poor performance and premature failure Touch Screen The touch screen should only be cleaned with a clean dry cloth Abrasive mate rials and chemicals should never be used to clean the screen Light pressure with a suitable cloth should be sufficient to remove fingerprints Do not use excessive force Static Elimination Bar The static elimination bar is located in the gathering station AN Caution Disconnect the machine from the mains electricity supply before cleaning the static elimination bar The pin side of the bar should be cleaned regularly using a small brush such as a toothbrush This is vital to the effectiveness and life expectancy of the static elimination equipment
44. clear If not turn the unit off and on again to free the head If this does not work contact your author ised distributor FOLD IS NOT ACTI VATED Unit is in edge staple mode Move lever into centre sta ple position see p 40 BOOK IS NOT TRIMMED Trim not selected Trim position is set off the edge of the sheet Edge stapling is selected or STITCH POSITION is set to ON EDGE Make sure TRIM is switched on see p 19 Reset trim position Not available in these modes EDGE STAPLE FUNC TION NOT WORKING Edge staple not selected Move lever to correct posi tion and select staple head see p 40 STAPLE IS NOT ON THE FOLD Set is bouncing before stapling Allow the set more time to settle by increasing STITCH DELAY 78 Document Finishing System User Manual 6 Problem Solving Problem Cause Solution Set is bouncing before Allow the set more time to folding settle by increasing FOLD DELAY Loose paper or staples in Locate and remove see the fold plate area p 81 SIDE JOG HOLD is Adjust PAPER SIZE so selected whilst the infeed that both the infeed side sidelays are set too tight lays barely touch the paper see p 18 STITCH POSITION isset Set STITCH POSITION to to ON EDGE ON FOLD Staple position is not Fine tune the position of adjusted correctly the staples see p 65 UNTIDY BOOKLET Infeed sidelays are not Adjust PAPER SIZE see adjusted correctly Set needs more time to
45. cted TION to on in the ADVANCED DETEC TOR POSITION window PAPER JAM Sheet is pre feeding Treat as a double feed Sheet is miss feeding Treat as a miss feed Paper Jams FRONT EDGE OF Too much sheet corruga SHEET DAMAGED tion Paper Jams in the BookMaster Pro and Trimmer Paper jams are most commonly caused by incorrect settings of PAPER SIZE by paper jammed in the trimmer infeed an over full trimmer offcut box the use of curly paper using PRE JOG with large sheet sizes Reduce the sheet corru gation see p 31 Open the safety covers of the BookMaster Pro this will disconnect the power for safety and remove any jammed sets Sets jammed in the trimmer can be removed from either the infeed or outfeed of the unit or by removing the trimmer offcut box Check carefully and correct any faulty adjustments that caused the jam to occur Paper Offcuts Obscuring the Sensor Paper jams can also be caused by offcuts obscuring the sensor in the trimmer conveyor AN Warning Disconnect the machine from the mains electricity supply before removing the trimmer cover assembly Document Finishing System User Manual 85 6 Problem Solving Replacing Fuses Your DFS is fitted with two fuses at each of the mains inputs If either of these fails the machine will not power up AN Caution The system uses double pole neutral fusing i e two fuses When removing any covers or changing fuses always first disconnect th
46. cument Finishing System User Manual 6 Problem Solving Error Message Meaning Barcode Setup Error The Barcode reader has not responded as expected This usually means that the barcode reader is not communicating with the control system Touch END JOB open the BARCODE window and turn the barcode off and then on again If the error persists switch the entire finishing system off and on again at the Mains On Off switch before retrying Bin double A double feed error has occurred on the bin detailed This means that the bin has fed two sheets of paper instead of one Check and correct the faulty set and restart the machine If the error persists see the Problem Solving sec tion of this manual Bin empty The paper tray of the bin detailed is empty Reload the bin and touch INCH to continue the job Touch to continue the job when using the DFS offline Bin jam A paper jam has occurred in the bin detailed Touch INCH to clear any partial sets from the conveyor If the error persists see the Problem Solving section of this manual Bin lift error Suction feed bin only Too much paper has been loaded into the bin note that the grey button will not raise or lower the tray Remove the stock and reload a smaller quantity Bin miscal A feed sensor error has occurred during the test set The bin will recalibrate automatically but check the very first set for errors Bin miss
47. dd number of sets into a batch Using the previous example if the desired batch size was fifty the number of sets fed at each cycle three would not divide exactly into the total required In this case Multiset would feed forty eight sets normally and then just two sets on the final cycle to complete the required batch Load the job and switch on the bins Set a batch quantity and action from the BATCH window if required In the MULTISET window use or to choose how the sets should be split Touch O to switch on Switch off after use Document Finishing System User Manual 23 3 About the Machine MIXED FEED By using MIXED FEED special feed sequences can be pro grammed Each column represents a stage in the collating cycle Up to twelve stages can be programmed The tower will complete each stage in turn and then repeat the cycle Use the left right arrow keys to navigate to the required stage Use the up down arrow keys to navigate to the required feed bin Touch the enter arrow to switch on Use the and keys to enter the number of feeds in each stage Touch O to switch on Switch off after use BAR CODE When the bar code reader is fitted this button is visible in the Feed window See Bar Code Reader on page 51 MULTIFEED Barcode option in the FEED window 24 Document Finishing System User Manual 3 About the Machine Friction Feed Bins For operation of Sli
48. de reads across the width of the sheet i e a picket fence barcode The barcode can be positioned anywhere across the width of the feed edge of the sheet Minimum distance from feed edge of sheet 2mm Minimum distance from trailing edge of sheet 130mm When booklet making this means that the barcode can be positioned in the trim margin so that it is trimmed off the finished booklet Alternatively it can be positioned in the centre of the sheet so that it is in the gutter spine of the finished booklet The barcode cannot be printed in the grey portions of the sheet FEED 3 DIRECTION 130mm 2mm Orientation When the printed sheets are loaded into the DFS feed bin the barcode will be on the underside of the sheet When booklet making the barcode should therefore be printed on the outside face of each sheet i e facing the cover of the booklet and on the outside of the cover 56 Document Finishing System User Manual 4 Bar Code Reader Barcode Elements Barcode elements can be used in any sequence and an element can be as many numeric characters as required It is not necessary for the barcode to include all the elements listed below Barcode Elements Undefined This character of the barcode is not used J Job ID This ID is a static job identification code and is fixed at the start of a Job All sheets of the Job must have the same ID Q seQuential This is
49. e two errors have occurred from the same bin Check the bin is feeding correctly 90 Document Finishing System User Manual 7 User Safety Information charter User Safety Information Instructions for safe use This product is designed with safety as an important feature and according to international safety standards Read and follow these safety rules Warning and Caution Messages The warning and caution messages used in this manual are shown below A WARNING A WARNING message tells you that a procedure or operation can be dangerous To prevent injury you must follow the instructions AN CAUTION A CAUTION message tells you that a procedure or operation can damage the machine or the product To prevent damage you must fol low the instructions Safety Rules e Do only maintenance procedures that are included in the User Manual Do not remove screws hardware or covers unless you are told to in the User Manual e Do not remove covers before the machine is disconnected from the main power supply Refer to the User Manual for the correct procedure e Do not change fuses before the machine is disconnected from the main power supply Refer to the User Manual for the correct procedure e Do not modify the machine A modified machine is not safe to operate The product warranty is cancelled if you modify the machine e Do not change or adjust the safety interlock switches fitted to the machine e Do not bl
50. e Machine Options page END JOB Touch END JOB when you want to set the machine up for a new job or alter an existing job When a job is loaded some of the machine settings can not be changed to prevent accidental changes END JOB unlocks these set tings This only affects settings that change the integrity of the job e g the number of sheets in a set or the number of sets in a batch TEST SET When the test set icon is highlighted the DFS is ready to run a test set The DFS uses the test set to calibrate the system according to the stock in each bin The test set is not counted by the counter except when in prenumber mode Once the test set is completed and is accepted by starting the machine the bins and certain functions cannot be changed to prevent errors and acci dental button pushes To run a test set e Load the DFS e Touch the button e The tower will feed a single sheet from each bin that is switched on and loaded e Ifan error occurred during the test set or the bin loading is changed at this stage touch to run another test set e When the test set icon is grey the machine is ready to run If either the TEST SET or END JOB button is touched another test set will need to be run before the job can be restarted the test set icon will be highlighted If you are having trouble running a job and false errors are being reported it may help to run another test set This can be done at any time to recalib
51. e blan ket wash see p 68 Adjust the fold roller gap see p 43 CANNOT CLOSE Support strut is in place Lift the booklet maker lid BOOKLET MAKER slightly push the support LID strut see p 37 and close the lid BOOKLET IS Trimmer conveyor clamp See p 66 TRIMMED OUT OF requires adjustment SQUARE BOOKLETS ARE Trimmer conveyor clamp See p 66 TRIMMED TOO requires adjustment SHORT COVER IS DAM Trimmer conveyor clamp See p 66 AGED AROUND STA PLES requires adjustment Fold roller gap is too nar row Adjust the fold roller gap see p 43 Staple Head Problems ONE OR BOTH LEGS TURN OUT Incorrect clincher align ment Re align see p 42 STAPLE COMES OUT IN PIECES Staple jammed in the car tridge A staple head error has occurred Inspect cartridge see p 64 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 author ised distributor 80 Document Finishing System User Manual 6 Problem Solving Problem STAPLE HEAD INDI CATOR LIGHT BLINKS ONCE PER SECOND Cause Staple cartridge empty Solution Replace cartridge see p 64 STAPLE HEAD INDI CATOR 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 author ised d
52. e finishing equipment and the job setup SINGLE SET Normally there will be more than one set in the conveyor at any one time Touch SINGLE SET to allow only one set in the conveyor at a time This minimises the correction required should an error occur The sets per hour will automatically adjust to achieve this AIR BLOW AIR BLOW alters the amount of air available for sheet separation in the feed bins As a general rule the heavier and larger the sheet the more air you need Document Finishing System User Manual 15 3 About the Machine PRESET PRESET is used if an exact number of sets are required Touch PRE SET and enter the number of sets required on the number pad The counter in the main area of the screen will turn white When the machine is started the counter will automatically count down to zero and the DFS will then stop Touch to restart the machine The counter will revert to black and will count up to show how many overs are produced The Preset function is ideal for producing a one off batch If you wish to produce several identical batches it is easier to use the Batch function PRENUMBER PRENUMBER is intended for use when collating pre numbered carbonless sets Touching PRENUMBER selects Single Set mode and causes the test set to be counted by the counter It also prevents the operator from switch ing linked bins before one bin has emptied It is possible to switch off Single Set mode once Pren
53. e machine from the mains electricity supply by switching off and unplugging the machine e Unplug the mains input lead and open the flap on the fuse holder e Pull out each fuse casing in turn and check the fuse e Replace if necessary with a fuse of the correct specification as detailed below Machine Part No Description DFS Drive Unit 240V 730 018 Fuse 1 25 32mm 7 0A HRC Quick Acting F DFS Drive Unit 115V 730 020 Fuse 1 25 32mm 10 0A HRC Quick Acting F BookMaster Pro 240V 730 016 Fuse 1 25 32mm 5 0A HRC Quick Acting F BookMaster Pro 115V 730 103 Fuse 1 25 32mm 10 0A HRC Anti Surge T TABLE 1 Error Messages Under certain error conditions a message will be displayed on the control panel Some of the error messages will refer to an individual bin or module address In this case the relevant module number will appear where is shown below Error Message Meaning Barcode Error The barcode reader failed to read the barcode e Check that the barcode is valid e Check the reader alignment See Positioning the Bar code Reader on page 53 e Check the barcode setup length and format e Check the drive speed v barcode height See DOUBLE SCAN on page 54 e Retry the last sheet The Barcode Error message may be combined with other information for example Barcode Error Bin miss indicating that bin has missed a feed 86 Do
54. e the lid Fit the blanking plug or ASM data cable BOOKMASTER PRO STATUS INDICATOR LIGHT IS BLINKING RAPIDLY There is a jam or other error in the unit Clear the jam see p 81 BOOKMASTER PRO STATUS INDICATOR Booklet maker or trimmer lid is open or unit is not Close the lid switch on the unit LIGHT IS NOT ILLU switched on MINATED BOOKMASTER PRO The Offcut Box is full Empty the Offcut Box BEEPS CONTINU OUSLY Document Finishing System User Manual 77 6 Problem Solving Problem BOOKMASTER PRO DOES NOT STOP ON TOUCHING 0 Note There is a 10s delay after touching For an immediate stop use the DFS emer gency stop button or open the booklet Cause Booklet maker has lost communication with the tower Solution Check that the interface is plugged in it may have become disconnected when moving the Book Master Pro in and out maker lid ONE OR BOTH STA Staple heads are not Make sure STITCH is set PLE HEADS ARE NOT selected to ON in the STITCH AND ACTIVATED FOLD window see p 18 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 author ised distributor STAPLES LOW MES SAGE ON DISPLAY Staple cartridge empty Replace cartridge see p 64 STAPLE HEAD ERROR MESSAGE ON DISPLAY A staple head error has occurred The heads should self
55. each batch Entering 0 on the keypad will turn the batch mode off Document Finishing System User Manual 21 3 About the Machine Note A set is a feed cycle When making booklets from sequentially printed i e electronically collated sheets a set will be a single sheet In this case enter the number of sheets in the document Counts the total number of batches produced Counts the number of sets per batch Counts the total number of sets produced Batch Counter INSERTS INSERTS allows sheets from the top bin and or bottom bin to be inserted at the beginning or end of each batch If the inserted sheet is not part of the job i e it is being used purely as a batch separator it can be fed from either the top or bottom bin TOP Select TOP to feed a sheet from the top bin with the first set of each batch The inserted sheet will be at the bottom of the batch pile as the back ing board for a pad for example BOTTOM Select BOTTOM to feed a sheet from the bottom bin with the last set of each batch The inserted sheet will be at the top of each batch pile the cover sheet of a pad for example STOP STOP causes the machine to stop after each batch and the counter display will flash Touch the start button to run another batch If STOP is selected while the machine is part way through collating a batch it will stop once it has completed that batch This allows the operator to interrupt a job at
56. ective on the approximation of laws of Member States relating to electrical equipment designed for use within certain voltage limits EN 60950 1 2006 ed 2 A11 2009 EMC 2004 108 EC Council Directive on the approximation of laws of Member States relating to electromagnetic compatibility EN55022 2006 A1 2007 Class A EN55024 1998 A1 2001 A2 2003 EN61000 3 2 2006 EN61000 3 3 1995 A1 2001 A2 2005 RoHS 2002 95 EC Council Directive Document Finishing System User Manual 95 9 Declaration of Conformity WEEE 2002 96 EC Council Directive amended by 2008 34 EC and 2008 35 EC Reach REGULATION EC No 1907 2006 M C Watkiss Technical Director Watkiss Automation Ltd 25 November 2010 96 Document Finishing System User Manual INDEX A action buttons end job 13 help 13 inch 13 menu 14 start stop 12 test set 13 adjustable fold rollers 43 adjusting the paper size 39 adjustment axes re referencing 77 advanced window 16 detector position double detection 17 tolerance 17 drive speed 16 feed clutch 17 auto 17 sheet offset 16 suction hold 18 air blow 15 air blow adjustment 36 air separation adjustment 27 anvil sharpening 70 auto 15 17 axes calibration 77 B barcode reader about the barcode reader 53 barcode specification 56 defining and printing the barcode 55 error recovery 60 introduction 51 positioning the barcode reader 53 problem solving 59 running the job 52 basic window 15
57. ent part of the sheet This affects all the bins in the DFS TOLERANCE Changing TOLERANCE to x2 COARSE allows for more variation in the detector readings This prevents false errors being reported when there are variations in the paper or ink density The default setting is x1 NOR MAL The DFS allows for some variation in the paper or ink density and constantly changes the range of values it will accept by working out an average value for previous sheets Increasing Tolerance to x2 COARSE will only be neces sary where there are larger variations in stock DOUBLE DETECTION Under unusual circumstances e g there are large vari ations in stock it may be necessary to turn off DOUBLE DETECTION This affects all the bins in the DFS Miss feed detection is unaffected Before switching off double detection first try setting TOLERANCE to x2 COARSE FEED CLUTCH FEED CLUTCH adjusts the clutch feed length for all bins during the test set only Increasing the value will cause the feed wheelsto drive the paper for longer which can prevent sheets from slipping The value can be reduced to prevent excessive pre feeding of the next sheet in the bin Optimising the clutch feed length for non standard paper lengths will produce a more accurate test set which in turn should reduce errors during the job The default value is 186 2mm 7 35 during the test set thereafter the feed length is automatically set to suit the paper size AUTO Touch AUT
58. equence Load the centre spread of the book face up in the uppermost bin see below The other pages should be loaded progressively downwards using as many bins as are required The cover should be loaded into the lowermost bin with the outside face down Document Finishing System User Manual 9 2 Using the Document Finishing System Centre Spread Face Up 1 2 3 COVER Outside Face Down Finishing Batch Printed Sheets From the BATCH window set the NUMBER OF SETS to 1 This will feed one sheet from each active bin and then open the latch in the gathering station to allow the set to travel into the BookMaster Pro Adjust the BookMaster Pro and Trimmer Adjust the BookMaster Pro and trimmer for the paper size using the GUI con trol panel Note The Bookmaster Pro and TrimMaster Pro contain several axes that are automatically adjusted to suit the job settings The machine will beep twice when the axes have finished adjusting Adjust the outfeed conveyor wheel Select edge or centre stapling Select which staple heads should be used and adjust their position if neces sary Adjust the fold roller gap Adjust the gathering station Starting The Job Adjust the gathering station for sheet width Adjust for sheet length Adjust the air blow if necessary Touch to run a test set A test set must be run at the start of each job Remove the resulting booklet from the outfeed conveyor and check that
59. er path has been altered on the tower s base Select the correct paper path before restarting the job Power fail The mains supply has been interrupted Switch the DFS off and on again PSU voltage error There is a voltage error Contact your supplier Rear cover open Check the rear cover guard is fitted and is actuating the safety switch correctly Remote stop The DFS has stopped because there is a problem with ancil lary equipment to which it is linked Clear the problem with this equipment before restarting the job Set size wrong The wrong number of bins are switched on for the job speci fied in Multiset The number of bins switched on must be a multiple of the number of sheets in a set SFT jam There is a paper jam in the booklet maker Open the booklet maker and remove the jam SFT stalled BMP TMP only There is a paper jam in the booklet maker Open the booklet maker and remove the jam Staple head err A fault has occurred in the booklet maker Turn the mains switch off and then on again If the problem persists contact your supplier Document Finishing System User Manual 89 6 Problem Solving Error Message Meaning Staple head error There has been a staple head error in the booklet maker The heads should self clear If they do not turn the booklet maker off and on again to free the head If this does not work con tact your supplier St
60. est set is produced individual bins will automatically switch on and off as they are loaded and unloaded Bins can also be manually selected by pressing the red button alongside the bin In addition loading the Default Tem plate will switch on all loaded bins Remember that bins cannot be switched on or off when the system is locked touch END JOB if necessary There are three adjustments to the feed system which allow the feeding of a wide range of papers Suction Feed Angle Adjustment Sheet Corrugation Adjustment Suction Feeder Sheet Corrugation The profile of the suction feeder can be adjusted to provide varying amounts of corrugation in the sheet Greater corrugation aa 6 a gives greater separation less corrugation gives less separation Adjustment is via the knob on the right hand side of the suction feeder The indi cator line on the knob shows the degree of adjustment The knob is infinitely adjustable between the limits of its travel When the indicator line on the knob is in the fully up position there is no added sheet separation The fully down posi tion produces maximum separation In general the heavier the sheet the less added separation is required The mid position is suitable for most paper types and should be used as a starting point if in doubt for initial running Document Finishing System User Manual 31 3 About the Machine Bin Linking Feeder Angle The angle b
61. etween the feeder and the paper can be adjusted to allow the feeding of particularly heavy and or curled stocks Adjustment is made using the knob on the left hand side of the suction feeder Turning the knob one stop in either direction has the effect of raising or lowering the outer edge of the feeder Continuing to turn the knob will alternate between the two positions The default position is down Tray Height The tray height is adjusted via the lever on the SlimVac bin controls Moving the lever 3 downwards progressively lowers the paper tray This increases the distance between the top of the paper stack and suction feeder and also simultaneously E adjusts the flow angle of the air separation Tray my Height The default position for the lever is the mid position Adjust which should be suitable for the majority of stock D ment Lever ranges Note When lowering the tray height the change will only take effect the next time the tray raises i e after reloading or restarting If required two or more feed bins may be linked to operate as a single bin When one runs out of stock the next bin in the linked group will automatically take over This allows reloading without stopping the machine Bin linking can only be enabled when the bins are unlocked i e when the TEST SET icon is high lighted on the control panel Press the grey button on the upper bin to
62. feed bin s and touch to restart the machine If a missfeed has occurred Touch to restart the machine The sheet should feed and the set will be correct If this error recurs refer to Miss Feeds in the Problem Solving section of your finishing system operating manual If a double feed has occurred Remove the double sheets from the gathering station and replace them in the feed bin in the correct sequence Touch to restart the machine If this error recurs refer to Double feeds in the Problem Solving section of your finishing system operating manual To restart the set Remove all error sheets from the gathering station and or feed bin s Ensure that the sheets in the feed bins are in the correct sequence Touch END JOB and open the BARCODE window Turn the barcode off and then on again close the BARCODE window Touch to restart the machine 60 Document Finishing System User Manual chapters Maintenance Service Interval It is recommended that your DFS is serviced by an approved Watkiss engineer every 1 000 operating hours Please contact your supplier This chapter covers all routine adjustment and maintenance procedures that can be carried out by an operator Some of these procedures require a degree of technical competence and you may prefer for these to be undertaken by your Watkiss engineer Operator Maintenance As with all machinery your DFS will benefit from periodic cleaning of general a
63. gs e Suction Feeder angled down e Tray height in mid position Sheet corrugation in mid posi tion ag a Heavy or Rigid Stock Heavy or rigid stock or board may I So be unable to bend sufficiently to Ceder meet the suction feeder in its 0n e O at lower position e Raising the angle of the suction feeder reduces the feed angle e Raise the tray height Document Finishing System User Manual 33 3 About the Machine Paper Condition Recommended Settings Stock Curling Down The stock is too close to the feeder for air to get in between the sheets E O Lowering the tray height will increase the space between the feeder and the sheets If necessary increase the feeder angle also Stock Curling Up The upward curl means the tray height detector will see the paper before it is close enough to the feeder Jj ee Suctio lt n Feeder 3 SSS ft Raise the tray height to lift the paper stack closer to the feeder Lightweight Porous Papers The feeder may suck through one sheet and onto the next resulting in double feeds Oo O j N Increase sheet corrugation Lower the tray height to increase the dis tance between the feeder and the paper stack
64. he faulty character in the definition and result lines are highlighted in red showing the error us Barcode error indication vw ol Document Finishing System User Manual 59 4 Bar Code Reader Error Recovery Barcode Error The barcode reader failed to read the barcode e Check that the barcode is valid e Check the reader alignment See Positioning the Barcode Reader on page 53 e Check the barcode setup length and format e Check the drive speed v barcode height See DOUBLE SCAN on page 54 e Retry the last sheet The Barcode Error message may be combined with other information for exam ple Barcode Error Bin miss indicating that bin has missed a feed Barcode Setup Error The Barcode reader has not responded as expected This usually means that the barcode reader is not communicating with the con trol system Touch END JOB open the BARCODE window and turn the barcode off and then on again If the error persists switch the entire finishing system off and on again at the Mains On Off switch before retrying If the wrong master bin is selected Touch END JOB and turn off the barcode in the BARCODE window Switch off all bins except the master bin using the bin on off switches beside the bins Switch the Barcode back on again in the BAR CODE window The correct master bin should now be selected This is indicated on the GUI see p 55 Replace any error sheets in the
65. he BookMaster Pro PRESETS Select from a choice of standard paper sizes by touching the PRE SET window 18 Document Finishing System User Manual 3 About the Machine STITCH AND FOLD The position of the stitch and fold can be offset relative to the centre of the paper STITCH AND FOLD allows this position to be adjusted up to 20mm in either direction in increments of 0 2mm STITCH The STITCH OFF option will produce booklets that are folded but not stitched STITCH POSITION The ON FOLD option produces booklets which are stitched on the fold line The ON EDGE option produces sets which are edge stitched and folded The Edge Centre Staple Selection Lever on the BookMaster Pro must be in the centre staple position see p 40 TRIM Touch TRIM to set the finished book size after trimming When a preset paper size is selected this distance is automatically adjusted but can be fine tuned The trim function can also be switched off PRE STITCH JOGGING The PRE STITCH JOGGING window has options to alter the way sets are jogged prior to stitching This ensures the finished book lets are as neat as possible The maximum speed of the BookMaster Pro will be reduced when any of the Pre Stitch Jogging options are selected PRE JOG This provides additional jogging to the bottom of the set when using heavy or large sheets The booklet is stopped by the edge stitch latch and jogged before it drops to the stitch latch DOUBLE
66. hoosing the Document Finishing System About Your Manual This manual explains how to operate the Document Finishing System correct and solve most error conditions and perform routine maintenance Operator training will be provided when the machine is installed however it is recommended that you also take time to read this manual In this manual the Document Finishing System is referred to as the DFS Safety Information Safety information is included in User Safety Information on page 91 You are advised to read this information before you start to use the Document Finishing System Installation The installation of your DFS requires specialist knowledge and should therefore only be carried out by a supplier approved engineer AN Caution The DFS 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 Document Finishing System and the rear of the BookMaster Pro Getting Help We are confident that your DFS will give many years of trouble free production If you have any queries or problems in the first instance please refer to the problem solving section in this book Should you require further assistance please contact your supplier Document Finishing System User Manual l 1 Introduction to the Document Finishing System Abo
67. indicator lights e Steady green This bin is selected and is loaded with paper e White This bin is not selected Broken line between bins These bins are linked e Flashing green This bin is selected but it has run out of paper e Flashing red This bin has had a double feed which has caused the Docu ment Finishing System to stop The error will be explained in a pop up box e Flashing yellow This bin has had a miss which has caused the Document Finishing System to stop The error will be explained in a pop up box BookMaster Pro and Trimmer e White The BookMaster Pro and trimmer are ready for use e Red The BookMaster Pro and trimmer are not ready This may be caused by an open guard or full trim bin 14 Document Finishing System User Manual 3 About the Machine Errors in other modules are indicated in red C Touching C resets the set counter to 0 SPH SPH shows the actual production speed of the DFS in sets per hour The production speed is affected by paper size online finishing equipment and the job setup The BASIC Window The BASIC window contains settings that regularly need to be altered when set ting up a new job SETS PER AIR BLOW PRESET PRENUMBER HOUR a a a BASIC Window SETS PER HOUR SETS PER HOUR allows the production rate of the DFS to be set AUTO Selecting AUTO allows the DFS to run at its maximum production speed according to paper size onlin
68. ing the job reset the paper size as neces sary Note t is important to return both clamp roller shafts to the factory default height of 17mm before booklets of a more typical thickness are produced Fold Roller and Conveyors A Build up of dust or dirt on the fold rollers and conveyor belts will eventually cause slippage or ink transfer They should therefore be cleaned periodically Warning Access to the manual cranking points on the BookMaster Pro and trimmer requires the side covers to be removed For safety reasons this pro cedure should therefore only be conducted by authorised personnel Discon nect the power before removing the side covers At all times keep your hands away from the blade area of the trimmer BookMaster Pro To clean the rollers and belts on the BookMaster Pro first remove the right hand side cover two x M5 button screws to give access to the manual cranking point M5 Button Screw Right Hand Side Cover 68 Document Finishing System User Manual 5 Maintenance Open the BookMaster Pro lid to access the fold rollers Using a 10mm A F spanner wrench manually crank the BookMaster Pro by turning the nut clock wise and clean the rollers and belts with a cloth dampened with soap and water or alcohol isopropanol Do NOT use blanket wash or other chemicals Manual Cranking Point Trimmer To clean the belts on the trimmer first remove the left hand side cover
69. ir jet is used to prevent sheets in the gathering station from curling forwards This can be adjusted using the air blow adjustment tap on the side of the gathering station Manual Bypass Gate When the gathering station releases the sheets they are delivered into the BookMaster Pro To bypass the BookMaster Pro pull out the manual bypass gate and the sheets will be delivered out of the front of the gathering station above the BookMaster Pro This is useful to avoid wasting sheets during the test set Note The manual bypass gate only works when the DFS is already run ning Start the machine first and then pull it out 36 Document Finishing System User Manual 3 About the Machine BookMaster Pro amp Trimmer The BookMaster Pro and trimmer staple fold and trim the printed sheets to form a booklet Finished booklets are delivered onto the outfeed conveyor The BookMaster Pro fits underneath the Document Finishing System tower It is wheel mounted and can be pulled in and out when required Opening the BookMaster Pro amp Trimmer Access to the inside of the BookMaster Pro is necessary for changing the staple cartridge adjusting the staple heads and clearing paper jams Access to the inside of the trimmer may be necessary for clearing paper jams The BookMaster Pro and trimmer lids incorporate safety switches which auto matically cut the power when the lid is opened The BookMaster Pro lid can be opened by turning the
70. istributor Paper Jam Problems PAPER IS JAMMED IN THE BOOKLET MAKER Open the booklet maker lid this will dis connect the power for safety and remove any jammed sets Check carefully and correct any faulty adjustments that caused the jam to occur Paper is badly curled Staples are stuck in the clinchers Edge stitch drive is engaged when booklet making Infeed sidelays are not adjusted correctly Fold roller gap is too wide Paper curl can normally be avoided by observing correct paper handling and storage procedures If there are staples stuck in the clinchers remove with a pair of pliers Disengage the edge stitch drive see p 41 Adjust PAPER SIZE so that both the infeed sidelays barely touch the paper see p 18 Adjust the fold roller gap a small gap gives more drive to pull the booklet through see p 43 PAPER IS JAMMED IN THE TRIMMER Paper offcuts are obscur ing the sensor in the con veyor Open the metal conveyor cover and remove any trim offcuts Taian Discon nect the machine from the mains electricity supply before working near the blade area Document Finishing System User Manual 81 6 Problem Solving Friction Feed Problems Problem Cause Solution DOUBLE FEEDS Too much tray pressure Too little separation pres sure Insufficient air separation Worn or missing separa tors Bad guillotine burr or blunt drilling Miscalib
71. k symbol is used to lock and unlock saved jobs Each saved job has a small padlock symbol next to it to show whether it is locked or not To lock or unlock a job select it on the job list and touch the large padlock button Some padlock symbols may be greyed out This is because there are several access levels to the system which can be used to prevent jobs being altered DELETE To delete a particular job it must be unlocked Select the job from the job list using the up and down arrows or by touching it Touch and hold DELETE A red bar will appear filling from left to right Continue to hold until the red bar reaches the right hand side VIEW OF JOB LIST VIEW OF JOB LIST alters the order in which saved jobs are listed either alphabetically or most recent first There is a line between Factory Template jobs and other jobs saved by the operator The Factory Template jobs are always listed first only the operator saved jobs can be reordered A gt Z To list jobs alphabetically touch A gt Z BY USE To list jobs in the order they were last used touch BY USE The job that was run most recently will appear at the top of the list The BATCH Window The BATCH window allows sets to be grouped into batches with an action at the end of each batch stop pause oscillate or insert sheets NUMBER OF SETS BATCH Window NUMBER OF SETS Touch NUMBER OF SETS to enter the number of sets in
72. l Tray Pressure Adjustment Separator Pressure Adjustment The ideal pressure will depend upon the stock in use Always use the least pressure possible The lever has five positions and is adjusted by gently push ing downwards whilst sliding the lever in or out The innermost position gives minimum pressure Initially set the pressure to minimum for small stock For large sheets i e if tray extenders are used initially position the lever one notch out Air Separation Air directed from the right hand sidelay is used to separate the top sheets of paper in the stack The overall air level is adjusted if required by altering the AIR BLOW value in the BASIC window see p 15 The air level is also adjustable on each individual bin via a tap on the right hand sidelay The tap on the sidelay controls the air level into the side of the paper stack The tap has three positions The default position is 90 to the sidelay which provides 100 air Moving the lever one notch towards you provides 50 air Moving the lever towards you so that it is parallel with the sidelay shuts off the air Air Separation Adjustment Too much air into the side of the stack can cause the paper to skew as it feeds Any bins that are not being used should have the air tap shut off on the sidelay to preserve overall system air Remember to open the tap when the bin is next used Document Finishing System User Manual 27 3 About the Machine Bin
73. late from the list of jobs Touch LOAD If asked select YES to confirm that you wish to load the Default Template Your print supplier will provide information regarding the barcode definition and the bin loading sequence if applicable Ensure you have this information before starting the job Loading the Bins with Paper Starting the Job Load the sheets so that the barcode is on the underside of the sheets When booklet making the centre spread of the book is face up If all sheets are to be fed from one stack the lower most bins of the tower should be used Bin linking may be used if required in which case load the bins so that the uppermost bin of the group feeds first If the job includes several different sheets for example a cover or variable inserts your print supplier will provide instructions for the bin loading sequence together with the barcode definition Identify which is the master bin This is the feed bin which contains the first sheet of the set and is used for the test set Switch off all bins except the master bin Adjust the feed bins gathering station and booklet maker to suit the paper size and type Touch BARCODE in the FEED window Input the number of barcode characters and the barcode definition Switch on the barcode by touching the Barcode On Off selection icon Close the FEED window and check that the barcode definition is displayed on the screen Check that the correct master bin number disp
74. layed Touch to run a test set Check that only a single sheet has fed and that it has fed from the correct bin Note Only the master bin will feed during the test set The calibration read ing for other bins is automatically taken when they first feed a sheet 52 Document Finishing System User Manual 4 Bar Code Reader e Leave the test set sheet in the gathering station and touch to continue run ning The machine can be stopped by touching The current set will be completed and then the machine will stop If an immediate stop is required press the Emergency Stop button Barcode definitions and other job parameters can be saved and recalled in the LOAD amp SAVE window in the normal way About the Barcode Reader The barcode reader scans the barcode as the sheet enters the gathering area Barcode Reader Adjustment thumbscrew Indicator lights The barcode reader has 4 indicator lights e Device Ready always on e Result flashes when a barcode is read satisfactorily e Laser On illuminated when the barcode is reading e Data unused Positioning the Barcode Reader The reader will scan across the full width of the sheet This can be observed by watching the red light projected onto the sheets when the reader is scanning The position of the barcode reader can be adjusted along the width of the mounting bar For optimum performance it should be positioned approximately inline wi
75. lincher fully across in the required direction Tighten the hand screw Orange Hand Screw Clincher Note You may need to increase the infeed sidelay gap in order to access the hand screws Do this by touching FINISHING PAPER SIZE and then increasing the sheet width A Caution Before placing your hands inside the booklet maker you should disconnect the unit from the mains electricity supply Fold Roller Gap Adjustment The fold rollers should be set sufficiently close together to produce a neat book let If the fold rollers are set too close together the booklet covers may be pulled resulting in damage around the staples or the spine of the booklets may be scuffed Document Finishing System User Manual 43 3 About the Machine The gap between the fold rollers is adjusted using a lever to the left of the front face of the booklet maker Fold Roller Adjustment Lever The lever has 11 positions To move the fold rollers further apart i e for larger sets or heavier stock move the lever upwards Move the lever down to bring the fold rollers closer together When edge stapling the fold rollers should be fully open i e the lever should be fully upwards Outfeed Conveyor Adjustment 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 Use the scale on the outfeed as a guide H E Scale E Payout
76. link it with the one below This will be indicated by the small green light The DFS mimic diagram on the control panel will show a broken line between bins that are linked By pressing the red bin on off button it is possible to select which bin in the linked group is active If the system is locked pressing the grey button on any bin will indicate which bins are in the same linked group Sensor Overrange Sensor overrange is indicated after the test set by a slow flashing red light on the bin in question Particularly heavy or opaque stock such as a straw board backing sheet may cause the bin sensor to go overrange This means that the sheet is too opti cally dense for the sensor to see through it Double feeds will not be detected but misses trailing sheets and jams will be detected as normal 32 Document Finishing System User Manual 3 About the Machine Difficult Papers Whenever feed difficulties are encountered we recommend that you follow two basic guidelines e Switch off all the bins except one This allows you to concentrate fully on the feed of a single bin e Ensure that only one remedy is tried at a time This will make it much easier to identify the solution The following suggested settings are a recommendation only Paper character istics vary and therefore any particular stock may require settings different to those shown Paper Condition Recommended Settings Standard Settin
77. mVAC bins please refer to SlimVAC Suction Feed Bins on page 29 Bin Controls and Indicators Feed bins are numbered from 1 upwards with the bottom bin being bin 1 Each bin has its own controls immediately alongside it mn 1 4 5 Key Item Description Function 1 Red light Indicates a double feed slow flash indicates the bin sensor is overrange see p 28 2 Yellow light Indicates a miss feed 1 amp 2 Red and yellow lights Indicate a feed jam or trailing sheet 3 Red button Bin on off switch 4 Green light Indicates the bin is switched on Green flashing light Indicates the bin is switched on but needs loading Grey button Bin linking switch see p 28 6 Small lower green light Indicates the bin is linked to the one below Tray Extenders For large sheet sizes over A4 8 x 11 or when running A4 or 8 x 11 portrait it will be necessary to fit tray extenders to support the sheets One B3 14 x 20 tray extender is supplied as standard with each Friction bin Document Finishing System User Manual 25 3 About the Machine Adjustments An optional tray extender is available for running A4 portrait 8 x 11 Watkiss P No 251 303 Loading the Bins Slide the stock into the bin between the sidelays Push in the sidelays to centralise the paper in the bin and so that they hold the paper securely Bin Sidelays Switching
78. ock the air ventilation grilles on the machine Document Finishing System User Manual 91 7 User Safety Information Installation Trimmer Blade The Touch Screen Clean the touch screen with a clean dry cloth Never use abrasive materials or chemicals to clean the touch screen Gentle pressure with a clean dry cloth is enough to remove fingerprints Do not use excessive force General End of service life This machine is marked with the crossed out wheeled bin symbol Do not use the machine if the machine makes unusual noises Turn off the machine Disconnect the machine from the main power supply Call your Watkiss service engineer Only an approved Watkiss service engineer must install the machine Only connect the machine to a mains power supply of the correct voltage with a good earth connection The correct machine voltage is shown on the label at the mains power supply input on the rear of the machine If the machine is connected to the wrong supply the warranty is cancelled Make sure there is enough work area around the machine Refer to the Site Requirements document for the machine Install the machine on a level floor Use caution when you move the machine The machine is heavy This machine contains a power driven trimmer blade When the machine is operated you must follow the safety rules in this document Only use the machine to make books Refer to the machine specification This symbol indic
79. ook first ensure that the BookMaster Pro is adjusted correctly and that delivery into the unit is good If the problem persists fine tuning of the staple position may be necessary Tools Required Flat Blade Screwdriver Adjustment is via the central screw on the fold plate mechanism located behind the perspex cover y j Fold Position Fine Tuning Document Finishing System User Manual 65 5 Maintenance In the FINISHING window set PRESETS to A3 or 11x17 regardless of booklet size The screws will now align with the holes in the perspex cover Using a flat blade screwdriver loosen the two locking screws Turn clockwise to lower the staples B t Locking Screw Fine Adjustment Screw Locking Screw Turn anticlockwise to raise the staples Turn the fine adjustment screw 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 Conveyor Clamp Adjustment The trimmer 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 This will be necessary if the follo
80. option to enable corner stapling Watkiss part number 914 414 Optional Third Staple Head for Corner Stapling Edge Stitch Assistor When edge or corner stapling only a few sheets it is possible for the thin sets to jam in the booklet maker In this case the Edge Stitch Assistor should be fitted 40 Document Finishing System User Manual 3 About the Machine This is supplied as part of the optional third staple head kit or can be ordered as an accessory Watkiss part number 907 442 Tabs Ca Locating Pins Fitting the edge stitch assistor To fit the edge stitch assistor open the book let maker lid Hold the assistor with the locating pins facing downwards and slide the tabs under the staple clinchers Make sure the assistor is positioned squarely and then press down until it clicks into place see below Clincher Edge Stitch Assistor in place Engage the Edge Stitch Drive Open the staple panel Unhook the orange edge stitch tyres from their retaining position and place into the grooves on the top jog pulley control discs on either side of the belt Orange Edge Stitch Tyres in their retaining position Document Finishing System User Manual 41 3 About the Machine l Orange Edge Stitch Tyres in pP their grooves ac Close the staple panel and place the edge stitch selector lever to the edge sta pling position Note When returning to booklet making the
81. orange edge stitching tyres MUST be removed from the belt control discs and returned to their retaining position Leaving the tyres on the belt control discs during booklet making will result in jams in the booklet maker Edge Stapling amp Folding If required it is possible to edge staple the set and then fold it The only limita tion to this is that the distance from the stapled edge to the fold must be at least half the width of the paper e Set STITCH POSITION to ON EDGE from the STITCH AND FOLD window Lift the Edge Centre Staple Selection Lever up to select centre stapling NOT edge stapling Select the Staple Heads Use the Staple Head Selection Button to select which staple heads are active For bookletmaking the two centre staple heads should be used Corner stapling is only possible if the optional third staple head is fitted The staple head indica tor lights show which heads are selected Staple Head Position 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 42 Document Finishing System User Manual 3 About the Machine To adjust move the staple head adjustment lever to the right to select the inner position Staple Head Adjustment Lever Clincher Adjust the clinchers to suit by loosening the orange hand screw and sliding the c
82. rate the detector system HELP Touch HELP and then touch any area of the screen to display the help text Use the up and down arrows next to the text to scroll up or down the screen Some sections of help text have a right arrow next to them This indicates that there is more text available explaining a related function in more detail Touch the right arrow to view this text A left arrow will then also appear touch this to return to the previous text Document Finishing System User Manual 13 3 About the Machine When you are viewing text you can find out about any of the other tabs that remain on display by touching them To exit the help text touch HELP or OK MENU MENU gives access to settings that do not need to be changed ona day to day basis These settings include e Change the display language Toggle between metric and imperial measurements e Adjust the screen contrast e Adjust the pause duration There are several access levels some of the settings can only be changed by users with an appropriate access code MIMIC DIAGRAM The mimic diagram of the DFS shown on screen is auto matically created based on how many bins are fitted and what finishing equip ment is connected Various areas on the outline will be highlighted in different colours according to the operational status of the DFS Mimic Diagram Ne Counter The feed bin colours mimic the bin
83. ration during the test set Reduce by moving han dle in by one notch ata time see p 27 Increase by moving the lever down by one notch at a time see p 27 Increase the value of AIR BLOW in the BASIC win dow Check separators are present and replace if worn see p 63 Fan the stock by hand before loading ensure paper is cut well next time Run another test set by touching followed by TEST SET followed by MISS FEEDS Too little tray pressure Too much separation pressure Untidy loading Worn feed wheels Miscalibration during the test set Increase by pulling the handle out by one notch at a time see p 27 Reduce by moving the lever up by one notch ata time see p 27 Reload the bins tidily ensuring the paper stack is underneath the feed wheels and under the guides Check and replace the feed wheels if necessary see p 63 Run another test set by touching followed by TEST SET followed by It may be necessary to increase the tray pres sure to obtain a better feed 82 Document Finishing System User Manual 6 Problem Solving Problem Cause Solution TRAILING FEED On a trailing sheet the machine stops imme diately You need to look carefully to iden tify which of the follow ing is the cause The faulty set can be inched through by touching and holding INCH Late feeding double sheet Slow feeding sheet Slow feeding during test
84. rol system of the DFS It is configured through the GUI colour touch screen user interface Where verifiable integrity is needed the barcode reader provides multi level security verification at sheet set and job level It can also control the insertion of covers and multiple additional sheets for customized sets You can configure the system to interpret the barcode characters as required and save the config urations in easy recall job memories This means that every sheet can be guaranteed accurate and every set or doc ument can be customized It extends variable data beyond the printer to the fin isher with the potential for each set or document to include a different combination of additional inserted sheets For security verification elements include job document and sheet identifiers a sheet counter and sequence check Controls for sheet feeding and insertion include insert and specified feed and read commands Document Finishing System User Manual 51 4 Bar Code Reader Running the Job Complete setting up procedures for your DFS are included in the Operating Manual provided with the machine Preparation Press END JOB to end the previous job Press INCH to check that there are no sheets remaining in the conveyor Clear any remaining sheets from the DFS Tip Load the Default Template to return the control panel to its default fac tory settings Touch END JOB Touch LOAD amp SAVE Select the Default Temp
85. static elimination bar 62 status indicator light 39 stitch and fold 19 stitch delay 19 stitch on fold 19 straight jogger 49 jogging adjustment 49 setting up the jogger 49 suction hold 18 T test set 13 third staple head 40 tolerance 17 tray extenders 25 29 tray height slimvac bins 32 tray pressure friction bins 27 trim 19 trim offcut box 45 trimmer blade sharpening 70 74 honing 74 U unlocking jobs 21 V view of job list 21 Ww window system 12 X x jogger 48 jogging adjustment 49 setting up the jogger 48 Document Finishing System User Manual 99 Document Finishing System User Manual 100 D Watkiss Automation Limited 1 Blaydon Road Middlefield Industrial Estate Sandy Bedfordshire SG19 1RZ United Kingdom Tel 44 0 1767 685700 Fax 44 0 1767 689900 Email info watkiss com
86. th the position of the barcode on the sheet Loosen the thumbscrew on the underneath of the barcode reader and slide it into the required position then retighten the thumbscrew Document Finishing System User Manual 53 4 Bar Code Reader Barcode Window on the Control Panel The barcode definition is set up via the BARCODE option in the FEED window I O 3 B i F MULTIFEED Barcode option in the FEED window Configuring the barcode e Select the number of characters contained in the barcode e Define each character in the barcode using the up down arrows to select the barcode element and the left right arrows to move from one character to the next Number of barcode ID gt I fe characters INCH END JOB TESTAET 00 1 BATCH 0000 DOUBLE SCAN Barcode definition Barcode ON OFF selection Definition navigation and selection DOUBLE SCAN By default the barcode reader requires two identical scans to recognise the barcode With small barcodes at high speed there may not be time to complete two scans In this case either lower the drive speed or touch DOUBLE SCAN so that OFF is displayed In this mode only a single scan is required to recognise the barcode Double scan should be ON unless it is not possible to obtain satisfactory results in which case it can be switched OFF 54 Document Finishing System User Manual 4 Bar Code Reader During the jo
87. the sheet sequence is correct Touch to run the job Once the machine is running adjustments may be necessary depending upon the stock in use The machine can be stopped at any time by touching 10 Document Finishing System User Manual cHapter3s About the Machine This chapter explains in detail about each of the different modules that make up your Document Finishing System and how to make adjustments to them For instructions on using the Document Finishing System for production jobs please refer to Chapter 2 on page 7 Control Panel Your DFS is fitted with a GUI Graphical User Interface control panel The con trol panel has an 8 2 colour touch screen which offers a user friendly interface for operators There are start and stop buttons mounted on the control panel s frame these buttons are also repeated on the touch screen Start Button O _ Stop Button SS a somsa de H casso G I __ s Touch screen Tah lee eal eaea alll eed d GUI Control Panel The touch screen has a power save function if it is not used for a period of time it automatically dims After an extended period it switches off In either case touch the screen to return it to normal Tip The touch screen takes two or three minutes to reach full brightness when it is switched on Document Finishing System User Manual 11 3 About the Machine The Window System
88. trimmer automatically start and stop when required After the tower stops there is a delay of approximately 10 seconds before the BookMaster Pro stops For an immediate stop either press the Emergency Stop button or open the lid on either the BookMaster Pro or trimmer 38 Document Finishing System User Manual 3 About the Machine Tip f you need to start the BookMaster Pro and trimmer without starting the tower touch INCH It will automatically shut down 10 seconds after its last action Status Indicator Light The yellow indicator light on the top left surface of the BookMaster Pro shows the status of the unit Indicator Light Mode BookMaster Pro Status Blinking once per second The unit is ready to run Constantly illuminated The unit is running Blinking rapidly There is a jam or other error Not illuminated BookMaster Pro or trimmer 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 BookMaster Pro lid show the status of the corre sponding staple head Indicator Light Mode Staple Head Status Blinking once per second The staple cartridge is about to or has run out Constantly illuminated The staple head is selected and ready to run Blinking rapidly There is a staple head jam or other error Not illuminated The staple head is not selected Refer to Changing the Staple Cartridge on page 64 for det
89. ts Paper has curly edge Rubber endlay is too tight against the paper stack or is incorrect type Increase the value of AIR BLOW in the BASIC win dow Reduce the sheet corru gation see p 31 Raise the tray height see p 32 Raise the angle of the suction feeder see p 32 Refer to recommended settings see p 33 Position the endlay approx 1mm 1 16 clear of the edge of the stack Ensure it is the correct type for the paper size see p 30 TRAILING FEED On a trailing sheet the machine stops immedi ately You need to look carefully to identify which of the following is the cause The faulty set can be inched through by touching and holding INCH Trailing double feed Trailing single feed Treat as a double feed Treat as a miss feed TOP AND OR BOT TOM BIN ONLY FEEDS ON TEST SET Batch insert selected from batch menu Check that INSERTS in the BATCH window are set as required 84 Document Finishing System User Manual 6 Problem Solving Problem Cause Action DOUBLE FEEDS ARE _ The bin sensor is over NOT BEING range due to the feeding DETECTED of particularly heavy or opaque stock The red light on the bin controls will flash slowly when the sensor is overrange Detector Position toler ance is set to x2 Coarse Double Detection is not N A Set TOLERANCE to x1 NORMAL in the ADVANCED DETEC TOR POSITION window Set DOUBLE DETEC sele
90. two x M5 button screws to give access to the manual cranking point Trimmer Lid Orange Hand Screw M5 Button Screw ii Left Hand Side Cover Open the trimmer lid and using a 19mm A F spanner wrench manually crank the trimmer by turning the nut clockwise whilst cleaning the belts with a cloth dampened with soap and water or alcohol isopropanol Do NOT use blanket wash or any other chemicals Manual Cranking Point Document Finishing System User Manual 69 5 Maintenance Sharpening the Trimmer blade Periodically all trimmer 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 74 which should accompany the blade and anvil when they are sent for re grinding Your Watkiss engineer will arrange regrinding for you if required Whenever the trimmer blade is re ground 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 con ducted 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 Tools Required 3mm Allen Key 4mm Allen Key 6mm Allen Key 10mm Allen Key 19mm Spanner The trimmer blade and anvil are located behind the conveyor assembly at the docking end
91. ubber endlay will sit on the tray extender position it so A that A is underneath the paper stack 330 351 When the rubber endlay A will sit on the bar across the front edge of the bin B position it so that B is underneath the paper stack and the step is on the bar Step Wr 330 446 When the rubber endlay will sit within the bin itself use the special endlay 330 446 Posi C tion it so that C is underneath the paper stack Loading the Bins Place a full stack of paper between the two sidelays in the base of the tray Max imum capacity is achieved when the paper is slightly below the top of the side lays Slide the sidelays inwards to centralise the paper Position the rubber endlays on each tray at the end of the paper stack The end lay should be underneath and just clear of the edge of the paper by about 1mm 1 16 Note When using the DFS to collate small sheet sizes make sure the tray loaded sensor is not covered by the rubber endlay 30 Document Finishing System User Manual 3 About the Machine The paper tray raises automatically when the system initially starts and thereaf ter when the tray is loaded It is therefore important to load a full stack of paper at a time The tray automatically lowers either when the tray is empty or when is pressed after the machine stops for any reason Switching Bins On amp Off Adjustments Before a t
92. umber is selected This allows the machine to run faster when using stock that feeds easily The ADVANCED Window The ADVANCED window allows advanced machine settings to be altered These settings may be altered to optimise the quality and productivity of a job SHEET DETECTOR FEED SUCTION OFFSET a POSITION CLUTCH a HOLD a HC ADVANCED ADVANCED Window DRIVE SPEED DRIVE SPEED alters the drive speed of the conveyor rollers and therefore the speed at which the sheets exit the DFS This setting is inde pendent from the SETS PER HOUR setting 16 Document Finishing System User Manual 3 About the Machine SHEET OFFSET SHEET OFFSET shales the sheets as they exit the feed bins This can assist the neat stacking of thick sheets or large sets The range of off set is 20mm between each sheet and affects all bins The default sheet off set is 0 this causes the sheets in a set to enter the gathering base module with their leading edges level If an offset is required it is usual for the bottom sheet of the set to lead select a positive offset A small offset can make jogging more effective DETECTOR POSITION The sheet detector measures 15 2mm 0 6 from the feed edge of the sheet and then takes a reading If the edge of a particularly dark or solid area of print is in this area it can cause detection problems The DETECTOR POSITION can be adjusted so that it looks at a differ
93. ut the Document Finishing System The DFS typically consists of the following components A GUI Graphical User Interface colour touch screen that controls the oper ation of the DFS Feed bins that are used to add covers or inserts to booklets where required A gathering station that gathers complete sets of pages A BookMaster Pro that staples and folds the sheets into booklets A trimmer that trims the fore edge of the booklet This is optional and can be added to the DFS at any time An outfeed conveyor that connects to the BookMaster Pro or trimmer where fitted An optional bar code reader An Automatic Spine Master that post processes booklets to give them the appearance of perfect binding with the security of a stapled spine This is an optional module and is documented in a separate operating manual GUI graphical user interface Feed bins Optional bar code reader Gathering station Automatic Spine Master Trimmer BookMaster Pro Document Finishing System and Automatic Spine Master Document Finishing System User Manual 1 Introduction to the Document Finishing System GUI graphical user interface Feed bins Optional bar code reader Gathering station Document Finishing System and outfeed conveyor Trimmer BookMaster Pro Document Finishing System User Manual 1 Introduction to the
94. wing problems arise e Booklets are trimmed out of square e Booklets are trimmed too short e The covers of the booklets are pulled resulting in damage around the sta ples Tools Required 4mm Allen Key 2 off 150mm 6 Rule Select A4 or 8 5x11 in the FINISHING PAPER SIZE window regardless of the booklet size Once the BookMaster Pro beeps to confirm it is ready disconnect it from the mains electricity supply 66 Document Finishing System User Manual 5 Maintenance Open the trimmer lid by lifting the orange hand screw Adjustment Screws Clamp Roller Shafts Adjusting the Conveyor Clamps e Turn the adjustment screws clockwise to increase the gap reducing clamp pressure e Turn the adjustment screws anti clockwise to reduce the gap increasing clamp pressure 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 Using the second rule measure the height from the top of the shaft to the bot tom of the first rule Document Finishing System User Manual 67 5 Maintenance Adjust the shafts as necessary and re measure to ensure they are both set to the same height Second Rule Wire Frame First Rule Clamp Roller Shaft Restarting the Job Before restart

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