Watkiss Bookletmaker Operating Manual: Stitch-Fold and Trim Version, For Nexpress Users English, Issue 1A, August 2006
Watkiss Bookletmaker Operating Manual: Stitch-Fold and Trim Version, For Nexpress Users English, Issue 1A, August 2006
Watkiss Bookletmaker Operating Manual: Stitch-Fold and Trim Version, For Nexpress Users English, Issue 1A, August 2006
Operating Manual
Stitch-Fold and Trim version, for NexPress users
English, Issue 1a, August 2006
Table of Contents
CHAPTER 1 Introduction to the Watkiss
BookletMaker . . . . . . . . . . . . . . . . . . 1
CHAPTER 4 Maintenance . . . . . . . . . . . . . . . . . . 53
Operator Maintenance - Tower . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Operator Maintenance - Stitch-Fold and Trimmer . . . . . . . . . . . . 56
CHAPTER 7 Specifications . . . . . . . . . . . . . . . . . 77
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Watkiss BookletMaker with Stitch-Fold & Trim - Operating Manual for NexPress users
Watkiss Part No. 960-761 - Issue 1a - English - Aug 2006
About Your Manual. This manual explains how to operate the Watkiss
BookletMaker, correct and solve most error conditions and perform routine
maintainence. It does not explain the operation of the printer.
Getting Help. We are confident that your Watkiss BookletMaker 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 Watkiss supplier.
Gathering Station
Outfeed Stitch-Fold
Conveyor
Trimmer (optional)
Mains Input. There are two mains inputs: one on the rear of the tower
drive unit and one on the rear of the stitch-fold. Two fuses are fitted next to
each of the mains inputs.
Mains Input
Serial Number
Mains Input
Mains ON/OFF
Switch
Voltage Indicator
Serial Number
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 stitch-fold
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.
Emergency Stop
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 emer-
gency stop button is used, the system will not restart until the button has
been released by turning it clockwise.
This chapter provides details on how to use the Watkiss BookletMaker for
production jobs, both online and offline to the printer.
For details on the individual modules and how to adjust them, please refer to
Chapter 3 on page 15.
Online Operation
This set-up routine should be followed each time a new job is started. It is
easiest to start at the outfeed end, and then to work backwards towards the
printer.
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 Watkiss BookletMaker system.
• Ensure that ONLINE is displayed on the GUI control panel.
Tip: Load the Default Template to return the control panel to its default
factory settings:
Touch END JOB
Touch LOAD & 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 Tem-
plate
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.
Tip: If you do not run a test set, the printer will not start.
Error Handling
In the event of an error occuring within the Watkiss BookletMaker system:
• Remove all sheets in the Watkiss BookletMaker paper path, checking in
the connecting bridge, in the gathering station and in the stitch-fold and
trimmer.
• Check the most recently produced booklet. This may be faulty, in which
case it should be discarded and reprinted at the end of the run.
• Correct any errors on the Watkiss BookletMaker, referring to the GUI
control panel for details.
• Press INCH on the GUI control panel. This will clear any error messages
and reset the interface status indicator to green.
• Follow any instructions on printer control panel and then restart print-
ing.
• Check the next booklet to be produced. If any sheets are missing or out
of sequence, the booklet should be discarded and reprinted at the end of
the run.
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 Watkiss BookletMaker system.
• Touch ONLINE in the BASIC window so that ONLINE OFF is displayed.
Tip: Load the Default Template to return the control panel to its default
factory settings:
Touch END JOB
Touch LOAD & 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 Tem-
plate
Centre Spread
Face Up
Outside Face
Down
• Load the bins and switch on, use bin linking if required.
• 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.
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: If 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: If a cover is being inserted, it is not fed during the test set. The
calibration reading for the cover is automatically taken when the job is
started.
The Watkiss BookletMaker can also be used for the normal collating and
finishing of batch printed sheets. When the Watkiss BookletMaker is used
in this way, PRENUMBER can be switched off if required.
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 Watkiss BookletMaker system.
• Touch ONLINE in the BASIC window so that ONLINE OFF is displayed.
Tip: Load the Default Template to return the control panel to its default
factory settings:
Touch END JOB
Touch LOAD & 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 Tem-
plate
Loading Sequence
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 lower-
most bin with the outside face down.
Centre Spread
Face Up
Outside Face
Down
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 stitch-fold.
This chapter explains in detail about each of the different modules that make
up your Watkiss BookletMaker, and how to make adjustments to them.
Control Panel
There are start and stop buttons mounted on the control panel’s frame, these
buttons are also repeated on the touch-screen.
Touch-screen
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 bright-
ness when it is switched on.
Control Buttons
‘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 dupli-
cated by the start/stop buttons above the touch screen.
Note: When using the Watkiss BookletMaker online, the printer will
start the machine automatically.
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 the 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 set-
tings cannot be changed, to prevent accidental changes. END JOB unlocks
these settings.
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 Watkiss Booklet-
Maker is ready to run a test set. The Watkiss BookletMaker 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 accidental button
pushes.
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 high-
lighted.
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 recalibrate
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.
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.
There are several access levels: some of the settings can only be changed by
users with an appropriate access code.
Mimic Diagram
Counter
Bridge mimic:
• White: The bridge is online and ready.
• Red: The bridge is online but not ready. This may be caused by the
guard being open, or by a paper jam.
• Outline: The Watkiss BookletMaker is operating offline.
SPH ~ SPH shows the actual production speed of the Watkiss Booklet-
Maker, in sets per hour. The production speed is affected by paper size,
online finishing equipment and the job setup.
‘BASIC’ Window.
SETS PER HOUR ~ SETS PER HOUR allows the production rate of the Watk-
iss BookletMaker to be set. This is automatically limited according to the
machine configuration and cannot be altered when the Watkiss Booklet-
Maker is operating online with the printer.
AIR BLOW ~ AIR BLOW alters the amount of air available for sheet separa-
tion in the feed bins and gathering station. As a general rule, the heavier and
larger the sheet, the more air you need. The default factory setting is 40%.
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.
‘ADVANCED’ Window.
If an offset is required, it is usual for the bottom sheet of the set to lead:
select a positive offset.
different part of the sheet. This affects all the bins in the Watkiss Booklet-
Maker.
The Watkiss BookletMaker 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 necessary where there are larger variations in
stock.
FEED CLUTCH ~ FEED CLUTCH adjusts the clutch feed length for all bins
during the test set only. Increasing the value will cause the feed wheels or
belt to 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 pro-
duce 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 AUTO to set the clutch feed length to the default value of
186.2mm (7.35").
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 set-
ting is 300mS.
‘FINISHING’ Window.
PAPER SIZE ~ Touch PAPER SIZE to alter the settings of the stitch-fold and
trimmer to suit the input paper size.
STITCH AND FOLD ~ The position of the stitch and fold can be offset rela-
tive 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.
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
booklets are as neat as possible. The maximum speed of the stitch-fold 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 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
stitch-fold will be reduced if the delay is increased.
The LOAD & 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
up and down arrows.
SAVE ~ Touch SAVE to save the current settings of the Watkiss Booklet-
Maker. 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.
CANCEL: Touch CANCEL if you do not wish to save a job that you have
modified.
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 keyboard 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.
PADLOCK SYMBOL ~ The padlock 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 opera-
tor-saved jobs can be reordered.
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.
‘BATCH’ Window.
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: When feeding to the front of the collator, 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 backing board for 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.
This function will also separate batches on a booklet maker outfeed con-
veyor. The pause time can be altered on the Machine Options page (touch
MENU, MACHINE OPTIONS).
The FEED window contains the Multifeed, Multiset and Mixed Feed
options. With these options the collator can be programmed to feed in selec-
tive or special sequences.
‘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.
For example, a four part set can be loaded three times in a twelve bin colla-
tor. When Multiset is switched on, the counter will count three sets per
cycle instead of one.
Mutiset will also automatically divide an odd 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.
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 collator 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.
The Watkiss BookletMaker can have up to eight feed bins. Additional bins
can be added if required even after the machine has been installed.
Feed bins are numbered from 1 upwards, with the bottom bin being bin 1.
Each bin has its own controls immediately alongside it.
Tray Extenders
For large sheet sizes (over A4, 8½ x 11") or
when running A4 (or 8½ x 11") portrait it will
be necessary to fit tray extenders to support
the sheets.
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 rubber endlay will
B sit on the tray extender, posi-
tion it so that ’A’ is under-
A neath the paper stack.
330-351
When the rubber endlay will
A sit on the bar across the front
edge of the bin, position it so
B that ’B’ is underneath the
paper stack and the step is on
Step the bar.
330-446
When the rubber endlay will
sit within the bin itself, use the
special endlay 330-446. Posi-
tion it so that ’C’ is under-
C neath the paper stack.
Position the rubber endlays on each tray at the end of the paper stack. The
endlay should be underneath and just clear of the edge of the paper (by
about 1mm, 1/16”).
The paper tray raises automatically when the system initially starts and
thereafter 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.
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 neces-
sary).
Adjustments
There are three adjustments to the feed system which allow the feeding of a
wide range of papers.
Suction Feeder
Suction Feed Angle
Adjustment
Sheet Corrugation
Adjustment
Adjustment is via the knob on the right hand side of the suction feeder. The
indicator line on the knob shows the degree of adjustment. The knob is infi-
nitely 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 position 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 start-
ing point if in doubt for initial running.
Note: When lowering the tray height, the change will only take effect
the next time the tray raises (i.e. after reloading or restarting).
Bin 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 automati-
cally 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 highlighted 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 Watkiss BookletMaker 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 (this is not possible when using the Watkiss Booklet-
Maker online).
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.
Difficult Papers
Whenever feed difficulties are encountered we recommend that you follow
two basic guidelines:
• Switch off all the bins except one. This allows you to concentrate fully
on the feed of a single bin
• Ensure that only one 'remedy' is tried at a time. This will make it much
easier to identify the solution
The feeder may suck through one sheet • Increase sheet corrugation
and onto the next, resulting in double • Lower the tray height to increase the distance
feeds. between the feeder and the paper stack
Connecting Bridge
If sheet rotation is NOT required: Set the paper transport sidelay to the
home position.
Glossary: ‘Portrait’ means that the short edge of the sheet is leading.
‘Landscape’ means that the long edge of the sheet is leading.
If the paper transport is set too narrow, paper jams will occur in the con-
necting bridge
Infeed cover
Outfeed cover
Gathering Station
The gathering station holds the sheets, which have been delivered from the
printer and the feed bins, until the set is complete. The set is then released
into the stitch-fold.
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 con- Not Online
nect the stitch-fold) and one smaller socket that is cur- Used Finishing
rently not used.
A3 A4 A5
Sheet Length
Adjustment
push the sidelays inwards to check the tamper position, they should just
touch the paper. Make further adjustment if necessary.
Gathering Station
Sheet Length Adjustment Air Blow Adjustment
Sidelay
Sheet Width Adjustment
Bypass Gate
Interface Sockets
(Hidden)
Note: The manual bypass gate only works when the Watkiss Booklet-
Maker is already running. Start the machine first, and then pull it out.
The stitch-fold and trimmer units stitch, fold and trim the printed sheets to
form a booklet. Finished booklets are delivered onto the outfeed conveyor,
or into the optional SpineMaster.
The stitch-fold can also be started by manually feeding a set into the unit.
The unit will then automatically stop after approximately 10 seconds.
ASF
Interface
Cable
Motor Transport
Switch
pushed. Remember to re-engage the wheel lock by turning the knob fully
clockwise when in position.
For edge stitching. Lift up, slide in and lower. This will also
automatically switch off the fold and trim actions. The maximum
sheet length that can be side stitched is 340mm, 13.3".
For Edge Stitching and then Folding. Select centre stitching, NOT edge
stitching - lift up, slide out and lower. Then set STITCH POSITION to ON
EDGE from the STITCH AND FOLD window. This will automatically switch
off the trimmer action. The only limitation to this is that the distance from
the stitched edge to the fold must be at least half the length of the paper.
Jockey Wheel
Catch
Side Stitch
Drive Wheel
Lever
The side stitch drive wheel is located between the stitch heads. Unhook the
jockey wheel catch and push in the drive mechanism lever (identified by an
orange dot), so that the jockey wheel and drive wheel contact. This
improves feeding for side/corner stitching by providing a more positive
drive.
Ensure the catch is hooked on the screw and the drive mechanism lever is
out for centre stitching.
When edge stitching heavier papers, the optional Edge Stitch Drive kit, Part
No. 914-512, may be required.
Payout Wheels
square, close the gap. If a thick book is either being scuffed, or is jamming
on entry into the trimmer, open the gap.
Closed Open
Conveyor Gap
Adjustment Bar
Warning: Before carrying out any work on the stitch heads you MUST
move the stitch-fold unit away from the collator and disconnect it from
the mains electricity supply.
Infeed Guide
Hand Crank
Solenoid
2. Never operate the stitcher with wire feeding without paper between
the clincher and formers.
Ideally the stitch pitch should be set between 65 and 190mm (2¾ to 7¾") so
that the heads line up with the cutouts in the fold blade.
Drive Lug
Stitch Head
Clamp and Scale Infeed
Guide
Hand Nut
For each stitch head, release the stitch head clamp by turning it anti-clock-
wise. Slide the stitch head along its mounting to the required position (tak-
ing note of the scale for stitch pitch) and re-tighten the clamp. Ensure that
the drive lug is also moved so that it is central on the stitch head.
Note: Do not place the stitch heads over the bottom of the infeed side-
lay. Sensors prevent the stitch-fold from stitching if this happens in order
to prevent damage to both the head and the sidelay. An LED on each
sensor is illuminated when this occurs and the message Cannot start:
sidelay under stitch head appears on the touch-screen.
To place the stitch heads in their widest position, the two infeed guides will
have to be moved. Undo the orange hand nut and refit the guides in between
the stitch heads.
Clincher Fixing
Screws
For each head, release the clincher by loosening the two clincher fixing
screws. Slide the clincher along until it aligns with the stitch head.
Retighten the fixing screws and use the hand crank to complete the stitch
head cycle before closing the stitch-fold unit.
Visually check that there is no staple wire stuck in the clinchers or stitch
heads.
over and up towards the wire guide spring. Replace the large disc and
retaining clip.
Note: Hold the wire taut at all times and do not release it until it has
been threaded through the wire guides and wire straighteners. If neces-
sary, remove any loose or tangled wire before you begin. This is essen-
tial to prevent de-spooling and tangling.
Note: When a spool of wire has run out, there will be a small amount of
wire left in the middle wire tube. This MUST be removed before a new
spool can be threaded. To do this, unclip the middle wire tube from the
stitch head. Remove the wire then replace the middle wire tube, ensuring
that it is correctly located.
Remove the end of the wire from the hole in the outer edge of the spool and
thread it through the wire guide spring and through the two wire guides.
Turn to engage
Small and Large
Feed Gears
Guide Wire
between the Small
and Large Feed
Gears
Tension Pawl
Replace the wire holder and re-engage the wire holder retaining spring.
Manually crank the heads over to cut the excess wire off.
Service Interval
It is recommended that your Watkiss BookletMaker is serviced by an
approved Watkiss engineer every 1,000 operating hours. Please contact your
Watkiss supplier for further details.
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.
As with all machinery, your Watkiss BookletMaker will benefit from peri-
odic cleaning of general accumulations of paper dust, ink etc.
Cleaning Materials
The Watkiss BookletMaker 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 sepa-
rators, feed wheels or conveyor wheels:
✗ Cleaners based on esters and ketones, e.g ethyl or butyl acetate
esters or methyl ketone (MEK).
✗ Aliphatic solvents, e.g. petrol or SBP1.
✗ Aromatic solvents/cleaners, e.g. toluene xylene, napthas.
✗ Chlorinated solvents/cleaners, e.g. trichloroethylene, perchloroeth-
ylene genclenes.
All of these chemicals will damage the separators, feed wheels and con-
veyor wheels to a varying degree resulting in poor performance and pre-
mature failure.
Touch Screen
The touch screen should only be cleaned with a clean, dry cloth. Abrasive
materials and chemicals should never be used to clean the screen.
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.
Cleaning
Build up of set-off powder, ink, toner or general dust will gradually impair
the performance of your stitch-fold and trimmer. Optimum performance
will be obtained by keeping the machine clean.
Caution: Access to the trimmer hand crank and clutch requires the side
cover and the black cover under the blade to be removed. For safety rea-
sons this should only be conducted by authorised personnel.
Fold Roller
Stitch Heads
The stitch heads should be fully serviced every one million cycles. Please
contact your Watkiss supplier or the manufacturer for further details.
Using any standard SAE10 (3 in 1) oil, lubricate using one drop of oil in
each point, shown in the illustration below.
Weekly. Stitch heads that are in constant operation should be removed and
lubricated weekly or once every 250,000 stitches.
Every Third Spool Change. Stitch heads that are operated periodically
should be removed and lubricated every 120,000 stitches or every third
wire spool change, which ever comes first.
Monthly. If the unit has low usage, it should be lubricated once a month.
This chapter explains how to resolve any problems that may occur with your
Watkiss BookletMaker System. If a problem persists, please call your Watk-
iss supplier.
The problems listed in this chart apply to both online and offline operation.
General Problems
Problem Cause Solution
THE MACHINE WILL NOT The machine is not plugged in Plug in and switch on
POWER UP
Faulty fuse Check the fuse at the mains
input and replace if necessary
(see p.67)
THE MACHINE WILL NOT Several possible causes, exact Correct any faults shown on
START cause will be shown on the the display
display
SHEETS NOT IN COR- The unit has not been set to Set the levers on the front of
RECT ORDER/NOT the correct paper size the unit to the correct paper
STACKING WELL size (see p.39)
Sheets are falling forwards in Adjust the air blow (see p.40)
the gathering station
POOR FEEDING INTO The static elimination bar is Clean the static elimination
STITCH-FOLD dirty, reducing effectiveness bars (see p.54)
and causing the back sheet(s)
of the book to cling to the
gathering station as they are
released
Operational Problems
STITCH-FOLD WILL NOT The Stitch-Fold is not Plug into mains connection of
START plugged in the correct type and voltage
Interface between Stitch-Fold Plug in
and tower is not plugged in
Fuse has blown on the main On 220-240V machines there
input are two 7 amp fuses in the
mains input connector, check
and replace as necessary. On
115V machines they are 10
amp fuses.
One of the Stitch-Fold safety Close all safety covers and
covers is open replace the trimmer offcut bin
AUTOMATIC STITCH- A set is partially jammed and Open covers, locate and
FOLD DOES NOT STOP the Stitch-Fold is trying to remove the jam
ON TOUCHING clear it
(Note: There is a 5s delay
Stitch-Fold has lost commu- Check that the interface is
after touching the stop button.
nication with the tower plugged in - it may have
For an immediate stop, use
become disconnected when
the emergency stop button or
moving the Stitch-Fold
open a safety guard.)
ONE OR BOTH STITCH Stitch not selected Make sure STITCH is set to ON
HEADS ARE NOT ACTI- in the STITCH AND FOLD win-
VATED dow (see p.24)
Drive lugs not in position Position lugs centred on each
stitch head (see p.48)
The stitch heads are adjusted Adjust the stitch heads so that
over the bottom of the infeed they do not activate the safety
sidelays. Sensors prevent the sensors
Stitch-Fold from stitching if
this happens in order to pre-
vent damage to both the head
and the sidelay. An LED on
each sensor is illuminated
when this occurs and the mes-
sage Cannot start: sidelay
under stitch head appears on
the touch-screen
A bad paper jam has caused Use the hand crank to cycle
the stitch heads to lock the stitch heads (see p.47)
FOLD IS NOT ACTIVATED Unit is in edge stitch mode Move lever into centre stitch
position ((see p.43))
BOOK IS NOT TRIMMED Trim not selected Make sure TRIM is switched
on (see p.25)
Trim position is set off the Reset trim position
edge of the sheet
Trimmer conveyor gap is too Increase conveyor gap (see
tight p.44)
Edge stitching is selected or Not available in these modes
STITCH POSITION is set to ON
EDGE
EDGE STITCH FUNCTION Edge stitch not selected Select by moving lever to cor-
NOT WORKING rect position (see p.43)
Edge stitched sets do not pass Fit the optional edge stitch
through the stitch fold. drive kit (Part No. 914-512).
STITCH IS NOT ON THE Heavy and/or coated stock is Fine tune the fold position
FOLD dragging against the rollers relative to the fold (see p.45)
Set is bouncing before stitch- Allow the set more time to
ing settle by increasing STITCH
DELAY
Set needs more time to settle Allow more time for the set to
before stitching settle by increasing STITCH
DELAY
STITCH COMES OUT IN Incorrect wire size Replace with the correct size
PIECES (see p.49)
Wire jammed in the stitch Inspect and remove any
head jammed wire
WIRE TANGLES ON THE Spool is incorrectly installed Check and correct (see p.49)
SPOOL
DOUBLE FEEDS The tray is too high Lower the tray height (see
p.34)
MISS FEEDS Not enough air separation Increase the value of AIR
BLOW in the BASIC window
TOP AND/OR BOTTOM Batch insert selected from Check that INSERTS in the
BIN ONLY FEEDS ON batch menu BATCH window are set as
TEST SET required.
FRONT EDGE OF SHEET Too much sheet corrugation Reduce the sheet corruga-
DAMAGED tion (see p.33)
Paper Jams
Open the safety covers of the stitch-fold (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 out-
feed 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. The perspex cover
assembly must be taken off (four M5 screws) to remove any trim offcuts.
Infeed cover
Side guide
Ball frame
Outfeed cover
If paper remains in the bridge when the system stops. Touch INCH on
the control panel. This will transport the sheet(s) to the gathering station,
from where they can be easily removed.
If paper is jammed in the infeed area. Open the lid of the connecting
bridge and then raise the infeed cover. Carefully remove the jammed paper,
ensuring that the complete sheet is removed. Take care not to damage the
paper detector switch and not to dislodge the green paper transport belts.
If paper is jammed under the the top belt drive shaft. Open the lid of
the connecting bridge and then raise the infeed cover. The shaft can be
removed by pushing it to one end against the spring pressure and lifting the
other end clear.
If paper is jammed in the outfeed area. Open the lid of the connecting
bridge and then remove the outfeed cover. Carefully remove the jammed
paper taking care not to damage the paper detector switch.
Replacing Fuses
Your Watkiss BookletMaker is fitted with two fuses at each of the mains
inputs. If either of these fail the machine will not power up.
Error Messages
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
section 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 con-
tinue the job when using the Watkiss BookletMaker
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 # 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 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 # part reset It is necessary to switch the machine off and then on
again after 10 seconds before running another test set. If
this problem persists, contact your Watkiss 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 sin-
gle 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.
Bin programming The bins in the Watkiss BookletMaker have not initial-
error ised properly. Switch the machine off and then on again.
If the problem persists, contact your Watkiss supplier.
Cannot start fold The fold axis (size adjustment) of the booklet maker is in
axis changing the process of adjusting. Wait for the booklet maker to
finish before touching INCH. (Touch to continue the
job when using the Watkiss BookletMaker offline.)
Cannot start sheets The sheets axis (book thickness adjustment) of the book-
axis changing let 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 Watkiss Booklet-
Maker offline.)
Cannot start tray One of the switched-on bins was empty when was
empty touched. Fill the bin with paper and touch again.
Cannot start trim The trim axis (size adjustment) of the trimmer is in the
axis changing process of adjusting. Wait for the trimmer to finish before
touching .
Cannot start width The width axis (size adjustment) of the Watkiss Booklet-
axis changing Maker is in the process of adjusting. Wait for the booklet
maker to finish before touching .
Check fuse A fuse may have blown in the drive unit. Contact your
Watkiss supplier.
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.
Fuse blown A fuse has blown on the Motor Drive PCB in the drive
unit. Contact your Watkiss supplier.
Fuses blown Fuses have blown on the Motor Drive PCB, in the drive
unit. Contact your Watkiss supplier.
Initialising bins The bins in the Watkiss BookletMaker are being checked.
If this message appears regularly, contact your Watkiss
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 conveyor. If the Watkiss BookletMaker does not
restart, a fault may have occurred in the drive unit: con-
tact your Watkiss supplier.
Power fail The mains supply has been interrupted. Switch the Watk-
iss BookletMaker off and on again.
PSU voltage error: There is a voltage error. Contact your Watkiss supplier.
SFT jam 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 con-
tact your Watkiss supplier.
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 book-
let maker off and on again to free the head. If this does
not work contact your Watkiss supplier.
Staple 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.
Stitch guard open The top cover of the booklet maker is open. Close the
cover.
Tray lift error (Friction feed bin only) There is a fault with the tray low-
ering mechanism. Contact your Watkiss 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
Watkiss supplier.
Trim bin full The trimmer offcut bin is full. Empty the offcut bin.
Trim guard open The trimmer cover is open and should be closed.
Your Watkiss BookletMaker has been designed with safety as a key feature
and in accordance with international safety standards.
Safety Rules
• Do not carry out any maintenance procedures other than those docu-
mented in this manual
• Do not remove any screws, fixings or covers, other than when told to do
so in this manual
• If a procedure requires removing covers or changing fuses, always first
disconnect the machine from the mains electricity supply by switching
off and unplugging the machine
• Do not modify the machine in any way. This may affect safe working and
will invalidate your warranty
• Do not do anything to interfere with the safety cut-out switches fitted to
some machine covers
• Do not block air ventilation grilles on the machine
Installation
• The installation of your Watkiss BookletMaker requires specialist
knowledge and should therefore only be carried out by a Watkiss
approved engineer
• The Watkiss BookletMaker must only be plugged into an electrical sup-
ply line of the correct voltage and with a proven earth. Any damage
caused by failure to do so will not be covered by the guarantee. The
required machine voltage is shown on the label on the rear of the Watk-
iss BookletMaker and the rear of the stitch-fold
• Allow sufficient working space around the machine
• Take care when moving machinery and observe safe lifting practices
Trimmer Guillotine
• The trimmer unit contains a motorised guillotine. It is therefore essential
that due care is taken and the operating instructions adhered to when
using the unit. Also pay particular attention to any specific warnings
given
A
action buttons
end job 17
help 18
inch 17
menu 18
start/stop 17
test set 18
advanced window 22
detector position
double detection 23
tolerance 23
drive speed 22
feed clutch 23
auto 23
sheet offset 22
suction hold 23
air blow 21
air blow adjustment 40
auto 20, 23
B
basic window 20
air blow 21
online 21
prenumber 21
preset 21
sets per hour
auto 20
remote 20
single set 21
batch window 27
inserts 28
bottom 28
top 28
number of sets 28
pause / separate 29
restart batch 29
stop 28
bin controls 31
bin linking 34
C
cleaning - see ’maintenance’
cleaning the touch screen 54
conformity, declaration of 79
connecting bridge 37
control panel 16–30
basic operation 16–17
error messages 70–73
cover, inserting 10
D
delete 27
detector position 22
difficult papers
slimvac 34
double detection 23
double jog 25
drive speed 22
E
emergency stop 4
end job 17
endlays, rubber, slimvac bins 31
error handling, online operation 7
error messages 70–73
F
feed clutch 23
feed window 29
mixed feed 30
multifeed 29
multiset 29
feeder angle, slimvac bins 33
finishing window 24
paper size 24
page direction 24
presets 24
re-ref 24
pre fold jogging 25
fold delay 25
side jog hold 25
pre stitch jogging 25
double jog 25
pre jog 25
stitch delay 25
stitch and fold 24
stitch on fold 24
trim 25
fold delay 25
fuses 69
G
gathering station 39–40
H
hand crank 47
help 18
I
inch 17
infeed guides 48
inserts 28
installation 1
interface sockets 39
introduction 1–4
J
job details 26
K
key symbol - see ’padlock symbol’
L
landscape 42
load 26
load and save window 26
delete 27
job details 26
load 26
padlock symbol 27
save
cancel 26
replace 26
save new 26
view of job list 27
a->z 27
by use 27
loading sequence, normal collating 12
loading slimvac bins 32
loading, offline 9
locking jobs 27
M
mains input 3
mains on/off switch 3
maintenance 53
maintenance
cleaning the asf 56
edge stitch deflector 56
fold roller and conveyors 56
manual bypass gate 40
menu 18
mimic diagram 19
mixed feed 30
multifeed 29
multiset 29
N
normal collating 12
loading sequence 12
number of sets 28
O
offline operation 2
collating sequentially printed sets 9
normal collating 12
online 21
online operation 6
operation, offline 9, 12
operation, online 6
operator maintenance 53
P
padlock symbol 27
page direction 24, 42
paper size 24
pause 17
pause / separate 29
portrait 42
power save 16
pre fold jogging 25
pre jog 25
pre stitch jogging 25
prenumber 21
preset 21
presets 24
problem solving 59–73
error messages 70–73
gathering station problems 60
general problems 60
U
unlocking jobs 27
V
view of job list 27
W
window system 16
wiring the stitch heads 49