Watkiss Automatic Stitch-Fold and Trim, English, Issue 4

Watkiss Automatic Stitch-Fold and Trim, English, Issue 4
Operating Instructions
Watkiss Automatic
Stitch-Fold & Trim
Issue 4, November 2006
CONTENTS
Specifications ....................................1
Introduction .......................................3
Quick Start .........................................9
Using the Control Panel ..................11
Booklet Making ................................15
Side & Corner Stitching ..................21
Side Stitching & Folding .................23
The Stitch Heads .............................25
Troubleshooting Chart ....................37
Maintenance .....................................43
Appendices
Using the Units Off-line.......................... 49
Producing Small Booklets...................... 53
Sharpening Trimmer Blades.................. 55
Using the Offline Control Panel ............. 59
Connecting to other Watkiss equipment 65
Declaration of Conformity ...................... 69
Index ..................................................71
Issue 4 - November 2006 - Part No. 960-191
Effective for serial numbers:
WA/ASF/1250 and WA/ATR/1250 onwards.
1
Specifications
Intended Use
This product is intended
to be used for the stitching, folding and trimming
of materials as specified.
Operating Conditions
10-35°C at 35-85% relative humidity
Production
Specifications
Maximum Input Size
Minimum Input Size
Maximum Book Thickness
Maximum Stitch Pitch
Minimum Stitch Pitch
Stitching Wire
Maximum Trim
Electrical
up to 3,300 per hour
488 x 350mm, 18.9 x 13.78"
120 x 160mm, 4.72 x 6.25"
25 Sheets (80gsm)
278mm, 10.94"
86mm, 3.39"
0.53mm (25 gauge)
round electro-galvanised
steel wire
35mm, 1.38"
115V, 60 Hz or
230V, 50 Hz
Single Phase
(earthed supply required)
Dimensions
Automatic Stitch-Fold
(W,D,H)
555, 888, 600mm, 150kg
21.9, 35.0, 23.6", 330lb
Automatic Trimmer
(W,D,H)
560, 585, 598mm, 110kg
22.0, 23.0, 23.5", 242lb
Outfeed Conveyor
(W,D,H)
404, 1050, 730*mm, 17kg
15.9, 41.3, 28.7", 37.5lb
*750mm; 29.6" angled
Noise
72dB (A)
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.
1
Radio Frequency
Emissions
2
This equipment has been tested and found to comply with
the limits for a Class A digital device, pursuant to part 15
of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when
the equipment is operated in a commercial environment.
This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful
interference in which case the user will be required to
correct the interference at their own expense.
2
Introduction
The Watkiss Automatic Stitch-Fold and Trimmer units
have been purpose designed to use with your Watkiss
collator. Together they give a fully integrated finishing
system.
Several different configurations are available:
FIGURE 1
Automatic Stitch-Fold with Outfeed Conveyor (CNV)
FIGURE 2
Automatic Stitch-Fold and Trim with Outfeed Conveyor (BAO)
FIGURE 3
Automatic Stitch-Fold and Trim with Automatic SpineMaster (ASM)
3
The instructions that follow include the set-up and operating procedure for both the Automatic Stitch-Fold unit
and the Automatic Trimmer unit. Please ignore those parts
of the instructions that do not apply to your configuration.
Operating instructions for the Automatic SpineMaster are
supplied with that piece of equipment.
In these instructions the Automatic Stitch-Fold unit is
referred to as the ASF, the Automatic Trimmer unit is
referred to as the ATR and the Automatic SpineMaster is
referred to as the ASM.
INSTALLATION
The installation of your Watkiss collator requires specialist
knowledge and should therefore only be carried out by a
Watkiss approved engineer. It is recommended that your
Automatic Stitch-Fold and Trimmer are sited on a level
floor.
Important
This machine must only be plugged into an electrical
supply line of the correct voltage and with a proven
earth. Any damage caused by failure to do so will not
be covered by the warranty. The required machine
voltage is shown on the label on the rear of the unit
(see Figure 5).
SAFETY FIRST
Your Automatic Stitch-Fold and Trimmer units have been
designed with safety as a key feature and incorporate
safety covers which, when opened, will automatically cut
the power to moving parts. However, as with all electrical
equipment, when changing fuses or carrying out operations other than those detailed in this book:
Always first disconnect the machine from the mains
electricity supply.
4
CAUTION 1
It is essential that the supply to both the ASF and the
collator is earthed.
CAUTION 2
It is possible to damage the fold area of the ASF unit by
dragging it over door thresholds etc. Care should therefore be taken.
CAUTION 3
Vario: Before placing the ASF unit back underneath a
floorstanding Watkiss Vario collator, IT IS ESSENTIAL to
check that the front outfeed conveyor on the collator is in
its upper (horizontal) position and that all the outfeed
paper guides are clipped up. The divert catch tray must
also be removed (see Figure 4). Failure to do this will
result in damage to the collator. Refer to your collator
operating manual for details of raising and lowering the
front outfeed conveyor.
Paper Guides
Interface Sockets (hidden)
Front OutFeed
Conveyor (in
upper position)
Divert Catch
Tray
FIGURE 4 - Floorstanding Vario
SWITCHING ON
Before use, plug in the collator and the ASF unit to single
phase power supplies of the correct voltage as indicated
by the mains input (see Figure 5). Check that the interface
cable (see Figure 6) is connected between the ASF and
the socket on the floor base (see Figure 4). If the ATR and
outfeed conveyor or Automatic SpineMaster are installed,
ensure that these too are connected
Note: if the blanking plug or the ASM cable is not plugged
into the socket on the rear panel of the ATR, it will not
function (see Figure 47 on p.67).
The collator and the ASF unit have independent mains
ON/OFF switches.
5
Mains Input
Mains ON/OFF Switch
Voltage Indicator
FIGURE 5
The ASF and ATR units will automatically start and stop
when the collator does. Note: after stopping the collator,
there is a delay of approximately 5 seconds before the
ASF stops. For an immediate stop, either press the emergency stop button on the collator or open one of the safety
guards.
The ASF can also be started by manually feeding a set
into the unit. The unit will then automatically stop after
approximately 10 seconds.
MOVING THE ASF
UNIT
The ASF and ATR units are castor mounted so that they
can be wheeled underneath the collating tower. Press the
motor transport switch (see Figure 6) to move the units in
and out. An automatic cut-off switch acts when the units
are fully docked under the collator.
ASF
Interface
Cable
Motor Transport Switch
FIGURE 6
6
Disengaging the Motorised Transport System
Under normal circumstances the wheels on the ASF are
locked to prevent unwanted movement, and the unit can
only be moved using the motorised system. To release
this lock in order to move the unit manually, it is necessary
to unscrew the wheel lock knob which is located inside
the unit, underneath the motor transport switch (see
Figure 7). Turn the wheel lock knob anti-clockwise until
the lock disengages. The ASF unit will then move freely
when pushed. Remember to re-engage the wheel lock
by turning the knob fully clockwise when in position.
Wheel Lock Knob
FIGURE 7
7
THIS PAGE IS
INTENTIONALLY
BLANK
8
3
Quick Start
This section is intended only as a brief operating guide.
More complete instructions are included in later chapters.
Plug the collator and Automatic Stitch-Fold (ASF) into a
mains supply of the correct voltage. Switch on the mains
ON/OFF switch on the collator and ASF.
Set Up the Collator
Load the bins with paper and make any necessary machine adjustments (see your collator operating manual).
Select a Job
To retrieve a previous job touch LOAD & SAVE.
Highlight the job you require by touching it (you can also
use the up and down arrows). Touch LOAD to load the
highlighted job.
For a new job, touch FINISHING followed by PAPER SIZE
and either select a preset size, or input a custom size.
Touch FINISHING followed by BOOK THICKNESS and
select a value to suit the book (see p.13). If side stitching,
adjust the ASF for the maximum thickness i.e. 25.
Touch STITCH AND FOLD followed by STITCH POSITION,
and select either ON FOLD or ON EDGE. Touch STITCH to
toggle the stitch function on and off. Make sure the lever
on the ASF is in the correct position (see p.18).
Adjust the Stitch Heads
If required, adjust the position of the stitch heads. This is
not normally necessary because the unit is centre referenced.
Adjust the Outfeed Conveyor
Slide the large payout wheels up or down their mounting
rail so that they are just nipping the spine of the book
when it is released from the rollers.
Set the Collator Speed
Vario Only: Touch ADVANCED followed by DRIVE SPEED
and set the collator drive speed to 80-90%.
9
Start the Job
Touch TEST SET followed by to run a single book. After
again to run the job.
inspection, touch
10
4
Using the Control Panel
The settings for the ASF and ATR are controlled from the
collator control panel using the FINISHING window (see
Figure 8).
FIGURE 8
THE ‘FINISHING’
WINDOW
Touch FINISHING to display the Finishing window. The
main area of the screen will show the current settings for
the booklet maker. The following functions are contained
within the Finishing window:
PAPER SIZE
Touch PAPER SIZE to alter the settings of the booklet
maker and trimmer to suit the input paper size.
RE-REF: If you suspect the booklet maker or trimmer
adjustment system is not calibrated correctly, touch REREF to re-reference the adjustment axes. The adjustment
axes will return to the current settings once this is complete.
Periodically the booklet maker 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 the booklet maker.
11
PRESETS: Select from a choice of standard paper sizes
by touching the PRESET window.
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 book-
lets which are stitched on the fold line.
The ON EDGE option produces sets which are edgestitched and folded.
The Stitch Selection Lever on the booklet maker must be
in the centre-stitch position.
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 booklet maker will be reduced when
any of the Pre Stitch Jogging options are selected.
PRE JOG: PRE JOG 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: DOUBLE JOG 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.
12
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: FOLD DELAY 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 booklet maker will be reduced if the delay is
increased.
BOOK THICKNESS
The BOOK THICKNESS window alters the gap between
the fold rollers of the Auto Stitch-Fold. The thickness of
the set is entered on a scale of 1 to 25: this scale
represents 1 to 25 sheets of 80gsm paper. The value will
need to be adjusted to allow for heavier or lighter stock.
Note: The ASF and ATR contain several axes that are
automatically adjusted to suit the job settings. The
machine will ‘beep’ twice when the axes have finished
adjusting.
Your collator can be set for either imperial or metric
measurements. With the control panel set to Supervisor
access level, touch MENU. Under the heading MEASUREMENT, select either the MM or INCH button.
13
THIS PAGE IS
INTENTIONALLY
BLANK
14
5
ORGANISING THE
JOB
Booklet Making
Trim Margin
If you have the ATR installed and are using a friction fed
Vario, we recommend that the job be printed with a 12mm
trim margin on the feed edge and a smaller (perhaps 35mm) 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.
Loading the Bins
Vario: The sheets should be loaded face down and with
the cover in the bottom bin(s). Depending upon the
number of sheets in the set, remember that using the bin
grouping can help to ensure continuous running. If the
cover is thicker than the inner pages, use the bin grouping
to allocate more bins for the cover stock.
DigiVAC: The sheets should be loaded face up and with
the cover in the top bin.
Set the Collator Paper Path
Floor standing Varios: Set the rear deflector lever to its
upper position (see Figure 9).
Rear Deflector Lever
Front Delivery
FIGURE 9
Rear Delivery
15
DigiVAC+: Set the delivery lever to its upper position, to
deliver sets to the rear.
Delivery Direction Lever
Roller Uplift Knob
(lift up if using PRE-JOG with
large sheets)
FIGURE 10
SETTING UP THE
AUTOMATIC STITCH
FOLD AND TRIM
Control Panel
Touch FINISHING to display and adjust the SFT settings.
Touch PAPER SIZE and adjust the sheet size to suit the
job. Use PRESETS for standard sheet sizes (A3, A4 or A5
or 8x11", 5.5x8.5" or 5.5x4.2").
Select LANDSCAPE or PORTRAIT in the PAPER SIZE,
PAGE DIRECTION window (see Figure 11).
16
FIGURE 11
Touch BOOK THICKNESS and select a value to suit the
book (see p.13).
Tip
Remember that you can recall the settings from previously stored jobs in the LOAD & SAVE window.
17
Select Centre Stitching
Using the lever on the ASF (see Figure 12), select centre
stitch operation (lift up, slide out and lower).
Fine
Tuning
for Fold
Position
Side or Centre Stitch Selection
FIGURE 12
Adjust the Stitch Heads
If required, adjust the position of the stitch heads (see
p.27). This is not normally necessary because the ASF is
centre referenced.
Check the Adjustments
To check that all the adjustments are correct, either
manually feed a set into the unit or run a test set by
touching .
Note:
If you suspect the ASF adjustment system is not calibrated correctly, touch RE-REF in the PAPER SIZE window
to manually recalibrate the ASF adjustment axes. After
recalibration, The ASF adjustment axes will return to the
current settings.
Periodically the ASF will automatically recalibrate the
axes during the setup procedure.
18
Adjust the Outfeed Conveyor
Slide the large payout wheels up or down their mounting
rail so that they are just nipping the spine of the book
when it is released from the rollers.
Payout
Wheels
FIGURE 13
Vario only: Touch the ADVANCED window tab and check
that DRIVE SPEED is set to 80-90%.
The production speed will be a factor of the booklet size
and settings, but you can reduce it if required. Touch the
BASIC window tab and reduce the number of SETS PER
HOUR.
Set the Trimmer Conveyor Gap
The trimmer conveyor gap has two positions, open or
closed, and is set using the conveyor gap adjustment bar
(see Figure 14). The normal setting is open. If a thin book
is bouncing against the trimmer stop and is therefore
trimmed out of square, close the gap. If a thick book is
either being scuffed, or is jamming on entry into the
trimmer, open the gap.
For very thick, narrow booklets (eg. folding A4 paper
landscape), the conveyor gap can be opened further
using an optional aid.
• Part No. 914-541, ATR Thick Book Setting Gauge
19
Open
Closed
Conveyor Gap
Adjustment Bar
FIGURE 14
Starting the Job
Touch to run a test set. After inspection, touch
to run the job.
again
Tip:
If you need to start the ASF and ATR without starting
the collator, touch INCH. It will automatically shut
down 5 seconds after its last action. The ASF can
also be started by manually feeding a set into the
unit.
Tip:
Remember to empty the trimmer offcut box periodically.
Tip:
The ASF can be returned to its default settings by
loading the default template: touch LOAD & SAVE,
select DEFAULT TEMPLATE from the job list and
touch LOAD.
Fine Tuning the Fold Position
Occasionally paper characteristics may cause the stitch
to be marginally off the fold. The ASF can be fine tuned
to compensate for this using the fine tuning control (see
Figure 12 on p.18).
Tip:
20
To separate the books into batches on the outfeed
conveyor, select PAUSE / SEPARATE from the
BATCH window (see your collator operating manual).
6
ORGANISING THE
JOB
Side & Corner Stitching
Loading the Bins
The stitches will be inserted into the feed edge of the
sheet.
Vario: Load the sheets face down, with the first page in
the lowermost bin.
DigiVAC: Load the sheets face up, with the firstpage in
the uppermost bin.
Note: The maximum sheet width that can be
side stitched is 340mm, 13.3". If the
sheet width exceeds this, the top jog is
automatically switched off and may not give satisfactory results.
Set the Collator Paper Path
See page 15.
ADJUSTING THE ASF
FOR SIDE STITCHING
Set Booklet Size
Touch FINISHING to display and adjust the ASF settings.
Touch PAPER SIZE and adjust the sheet size to suit the
job. Use PRESETS for standard sheet sizes (A3, A4 or A5
or 8x11", 5.5x8.5" or 5.5x4.2").
Select LANDSCAPE or PORTRAIT in the PAPER SIZE,
PAGE DIRECTION window.
Touch BOOK THICKNESS and adjust the ASF to the
maximum width (i.e. 25).
Tip
Remember that you can recall the settings from previously stored jobs in the LOAD & SAVE window.
Select Side Stitching
Using the lever on the ASF (see Figure 12), select side
stitch operation (lift up, push in and lower). This will also
automatically switch off the fold and trim actions.
21
Adjust the Side Stitch Drive Wheel
The side stitch drive wheel is located between the stitch
heads (see Figure 15). Unhook the jockey wheel catch
and push the drive mechanism lever (identified by an
orange dot) in 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 normal operation.
When edge stitching heavier papers, the optional Edge
Stitch Drive kit, Part No. 914-512, may be required.
Jockey
Wheel
Catch
Side Stitch
Drive Wheel
Lever
FIGURE 15
Adjust the Position of the Stitch Heads
For side stitching no adjustment should be necessary.
For corner stitching, adjust the position of one head and
disconnect the second head by undoing the drive lug and
sliding it across to one side (see p.27).
Starting the Job
Touch to run a test set. After inspection touch again
to run the job. If necessary another test set may be
obtained by touching TEST SET followed by .
Note: When side stitching is selected the trimmer action
is automatically switched off.
22
7
Side Stitching & Folding
If required, it is also possible to side stitch the set and
then fold it. The only limitation to this is that the distance
from the stitched edge to the fold must be at least half the
width of the paper.
Select Edge Stitching and Folding
Set STITCH POSITION to ON EDGE from the STITCH AND
FOLD window (see Figure 16).
FIGURE 16
Using the lever on the ASF (see Figure 12), select centre
stitching - not edge stitching (lift up, pull out and lower).
Adjustments
Adjust the ASF/ATR for size (see p.21).
Note: When STITCH POSITION is set to ON EDGE, the
trimmer action is automatically switched off.
Note: The maximum sheet width that can be
stitched in this mode is 340mm, 13.3". If
the sheet width exceeds this, the top jog
is automatically switched off and may not give
satisfactory results.)
23
THIS PAGE IS
INTENTIONALLY
BLANK
24
8
The Stitch Heads
Note
Before carrying out any work on the stitch heads you
MUST move the ASF unit away from the collator and
disconnect it from the mains electricity supply.
Your ASF will be fitted with one of three types of stitch
head:
• Magnatek/M2000
• Deluxe G5
• Hohner 43/6
Please use the appropriate instructions.
Magnatek/M2000
Deluxe G5
Hohner 43/6
• M2000 is engraved on
the front
• Deluxe G5 is marked on
the front
• Hohner 43/6 is marked
on the front
25
USING THE HAND
CRANK TO CYCLE
THE STITCH HEADS
When making adjustments to the stitch heads it is sometimes necessary, for safety and convenience, to cycle the
heads by hand. First release the solenoid (see Figure 17)
by sliding your finger behind it and depressing the lever
on the back (you will hear it click when it is released).
Insert the hand crank (stored inside the ASF unit) into the
hand crank access hole (see Figure 18) and turn it anticlockwise to complete one cycle of the heads. It is
necessary to release the solenoid at the beginning of each
cycle.
Infeed Guide
Hand Crank
Solenoid
FIGURE 17
CAUTION !
Avoid damaging your stitch heads by following
these rules:
1. Never drive one stitch on top of another.
2. Never operate the stitcher with wire feeding without
paper between the clincher and formers.
26
Hand Crank Access Hole
FIGURE 18
ADJUSTING THE
POSITION OF THE
STITCH HEADS
Because the system is centre referenced, the stitch head
position will rarely need adjusting. In the majority of cases
a stitch pitch of 130mm (5") will be suitable for both A4
and A5 (or US 8½ x 11" and 5½ x 8½") booklets.
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.
Position the Stitch Heads
Open the perspex safety guard on top of the ASF unit and
then open the ASF unit itself.
Drive Lug
Stitch Head Clamp
and Scale
Infeed
Guide
Hand Nut
FIGURE 19
27
For each stitch head, release the stitch head clamp by
turning it anti-clockwise (see Figure 19). Slide the stitch
head along its mounting to the required position (note 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 sidelay. Sensors prevent the ASF 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 (see Figure 17) will have to be moved.
Undo the orange hand nut (see Figure 19) and refit the
guides in between the stitch heads.
Align the Clinchers
When aligning the clinchers,
it sometimes helps to lower
the staple driver to make
alignment easier and more
accurate. Remove the cut
staple wire from the stitch
head. Use the hand crank to
lower the staple driver. For
each head, release the
clincher by loosening the
two fixing screws (see left).
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 ASF
unit.
Bender Bar lowered
Clincher
Clincher Fixing Screws
FIGURE 20
28
Visually check that there is
no staple wire stuck in the
clinchers or stitch heads.
WIRING THE STITCH
HEADS
Your ASF will be fitted with one of three types of stitch
head. Please follow the appropriate instructions.
All the stitch heads use 0.53mm (25 gauge) round electrogalvanised steel wire on 2.5kg (5lb) spools. These are
available from Watkiss (P/N 812-001) or from your local
supplier.
Install the Wire Spool
Open the perspex safety guard on the top of the ASF unit.
The wire spools are mounted on a split bar, half of which
swings upwards to allow access. For each spool, remove
the retaining clip and large disc, and then remove the
empty spool. Ensure that the remaining spring, bushes
and disc do not fall off. Slide the new wire spool onto the
stud with the wire feeding over and up towards the wire
guide spring. Replace the large disc and retaining clip.
A B C D C E F E B
A
B
C
D
E
F
Spool Mounting Bar
Split Pin
Bush
Spring Coil Retainer
Spool Retainer
Spool
FIGURE 21
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 necessary, remove any loose or tangled wire before you begin. This is essential to prevent
de-spooling and tangling.
29
THREADING
MAGNATEK/M2000
STITCH HEADS
Remove the end of the wire from the hole in the outer edge
of the spool and thread it through the slot at the end of
the wire guide spring, through the two wire guides and
through the upper wire straightener. Ensure that the wire
is underneath the straightener discs (see Figure 22).
G
Straightener Discs
H
FIGURE 22
Now thread the wire through the lower wire straightener.
I
J
K
L
N
M
Unhook the swivel holder spring and swing it away to the
left, then remove the swivel. Feed the wire into the wire
cutter lead-in hole and pull through until it is straight. Push
the grip spring to the left to open the grip, insert the wire
and release. Pull the tension pawl down, insert the wire
between the tension pawl and roller and then release.
Cycle the heads to cut the wire to the correct length.
Replace the swivel and swivel holder spring and cycle
the heads again to load wire into the swivel.
Note: If the grip spring is too tight to open, simply lay the
wire in front of it. The wire will self-load when the
heads are cycled.
FIGURE 23 Magnetek/M2000
G
H
I
J
K
L
M
N
30
Wire Guides
Upper Wire Straightener
Lower Wire Straightener
Tension Pawl
Grip Spring
Grip Spring Lever
Swivel
Swivel Holder Spring
It is important to ensure the stitch wire is straight, particularly if using wire not supplied by Watkiss.
To check the straightness of the wire, hold the wire against
the bottom face plate with your thumb and using pliers
pull the wire straight down (it is important to pull straight
down so as not to induce additional curve to the wire).
Cut the wire just above the point where you were holding
with your thumb. The wire should curve to the right of, and
slightly away from, the face plate.
If necessary, the left/right straightness of the wire is
adjusted by using a screwdriver to turn the pointer on the
lower wire straightener, and the in/out straightness by
turning the pointer on the upper wire straightener (see
Figure 23).
THREADING DELUXE
G5 STITCH HEADS
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 (see Figure 26).
Pass wire between
Oiler Felts
Insert wire into Anti
Back-up Unit
Loosen to allow
thread to pass
Turn to disengage Small
and Large Feed Gears
Tension Pawl (anti
back-up unit)
Upper Wire Tube
FIGURE 24 Threading the Head - Stage 1
31
Turn to engage
Small and Large
Feed Gears
Guide Wire between
the Small and Large
Feed Gears
FIGURE 25 Threading the Head - Stage 2
Cycle the heads to cut the wire to the correct length.
It is important to ensure the stitch wire is straight, particularly if using wire not supplied by Watkiss.
Wire straightness is preset at the factory. To check the
straightness of the wire, slide the wire holder retaining
spring over to the side and remove the wire holder
assembly from the stitcher head. Manually crank the stitch
head and observe the wire exiting the cutter box assembly. The wire should have a slight upward curve.
32
Wire Guide Spring
Wire Oiler Felts
Tension Pawl
Upper Wire Tube
Feed Release Handle
Small Feed Gear
Large Feed Gear
Middle Wire Tube
Wire Holder Retaining Spring
Wire Holder Assembly
Cutter Box Assembly
FIGURE 26 G5 Deluxe Stitcher
Replace the wire holder and re-engage the wire holder
retaining spring. Manually crank the heads over to cut the
excess wire off.
33
THREADING HOHNER
STITCH HEADS
Note:
When a spool of wire has run out, there will a small
amount of wire left over in the guiding funnel. This
MUST be removed before a new spool of wire can be
threaded. To do this, loosen the pan head screw to
enable access to the guiding funnel. Remove the
excess wire from the guiding funnel and re-assemble
it in position. Re-tighten the pan head screw.
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 five wire guides (see Figure 28).
Thread the wire between the two felt discs and into the
brake buffer, using pliers to push the wire, this will hold
the wire secure. Turn the eccentric stop through 90° to
open the transport gears. Thread the wire down until you
feel a resistance, turn the eccentric stop through 90° to
close the transport gears. Fit the adjuster handle to the
bearing bolt and turn it clockwise until the wire is visible
at the bottom of the head. Manually crank the heads over
to cut the excess wire off.
FIGURE 27 Adjusting Handle
34
Wire Guide
Wire Guide
Spring
Felt Discs
Brake Buffer
Eccentric Stop
Bearing Bolt
Transport Gears
Pan Head Screw
Guiding Funnel
FIGURE 28 Hohner 43/6
TESTING THE STITCH
HEADS
After re-wiring the stitch heads, they should be tested.
Slide a few sheets of paper between the heads and the
clinchers and then use the hand crank to cycle the heads.
Check for a correctly formed stitch and if necessary make
adjustments as detailed in the trouble shooting chart.
35
THIS PAGE IS
INTENTIONALLY
BLANK
36
9
Troubleshooting Chart
As far as possible the system has been designed to be self-explanatory. In many
cases problems or errors will be identified on the control panel. The following is a
further guideline to help solve any problems, if they persist please call the Watkiss
Service Department or your Watkiss Dealer.
PROBLEM
CAUSE
SOLUTION
The ASF is not plugged in.
Plug into mains connection of the
correct type and voltage.
Operational Problems
AUTOMATIC STITCH-FOLD
WILL NOT START
Interface between ASF and collator Plug in. (see p.6)
is not plugged in.
Fuse has blown on the main input.
On 220-240V machines there 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 ASF or ATR safety covers Close all safety covers and ensure
is open.
the trimmer offcut bin is in place.
ATR interlock is in ‘safe’ position.
Slide interlock bar to ‘live’ position
and secure (see p.66).
Blanking plug or ASM data cable not Refit blanking plug or ASM cable
plugged into socket on rear panel of (see p.67) .
ATR.
AUTOMATIC STITCH-FOLD
DOES NOT STOP ON
TOUCHING
(Note: There is a 5s delay after
touching the stop button. For an
immediate stop, use the emergency stop button or open a
safety guard.)
A set is partially jammed and the
ASF is trying to clear it.
Open covers, locate and remove the
jam.
ASF has lost communication with
the collator.
Check that the interface is plugged
in - it may have become disconnected when moving the ASF.
ONE OR BOTH STITCH HEADS Stitch not selected.
ARE NOT ACTIVATED
Drive lugs not in position.
Make sure STITCH is set to ON in the
STITCH AND FOLD window (see
p.12).
Position lugs centred on each stitch
head (see p.28).
37
PROBLEM
CAUSE
SOLUTION
The stitch heads are adjusted over
the bottom of the infeed sidelays.
Sensors prevent the ASF 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
Adjust the stitch heads so that they
do not activate the safety sensors
start: sidelay under stitch head
appears on the touch-screen
A bad paper jam has caused the
stitch heads to lock
Use the hand crank to cycle the
stitch heads (see p.26)
FOLD IS NOT ACTIVATED
Unit is in edge stitch mode
Move lever into centre stitch position
(see FIGURE 9 on p.15)
BOOK IS NOT TRIMMED
Trim not selected
Make sure TRIM is switched on (see
p.12)
Trim position is set off the edge of
the sheet
Reset trim position
Trimmer conveyor gap is too tight
Increase conveyor gap (see p.19)
Edge stitching is selected or STITCH Not available in these modes
POSITION is set to ON EDGE
EDGE STITCH FUNCTION NOT Edge stitch not selected
WORKING
Select by moving lever to correct
position (see p.18)
Edge stitch latch solenoid missing
Check that the solenoid has not
been removed to facilitate a below
specification stitch pitch, in which
case, refit
Edge stitched sets do not pass
through the stitch fold.
Fit the optional edge stitch drive kit
(Part No. 914-512).
STITCH IS NOT ON THE FOLD Heavy and/or coated stock is drag- Fine tune the fold position relative to
ging against the rollers
the fold (see p.20)
38
Set is bouncing before stitching
Allow the set more time to settle by
increasing STITCH DELAY
Set is bouncing before folding
Allow the set more time to settle by
increasing FOLD DELAY
Loose paper or stitches in the fold
plate area
Locate and remove (see p.41)
PROBLEM
CAUSE
SOLUTION
SIDE JOG HOLD is selected whilst the Adjust PAPER SIZE so that both the
infeed sidelays are set too tight
infeed sidelays barely touch the
paper (see p.11)
UNTIDY BOOKLET
STITCH POSITION is set to ON EDGE
Set STITCH POSITION to ON FOLD
Head and clinch are not located in
the cut-out of the fold blade
If possible locate the heads so that
they line up with the cut-outs in the
fold knife (see p.27)
Side stitch drive wheel is engaged
Disengage (see p.22)
Infeed sidelays are not adjusted cor- Adjust PAPER SIZE (see p.11)
rectly
Set needs more time to settle before Allow more time for the set to settle
stitching
by increasing STITCH DELAY
Collator delivering an untidy set
Improve collator delivery
The ASF adjustment system is not
calibrated correctly
Touch RE-REF in the PAPER SIZE
window to manually recalibrate the
ASF adjustment axes
FINISHED BOOK IS TOO
LOOSE
Fold roller gap is too wide
Reduce the BOOK THICKNESS value
(see p.13)
TOP JOG DAMAGE ON THE
SET
Collator delivering an untidy set
Improve collator delivery
PAPER SIZE incorrectly set
Check the sheet length value in
PAPER SIZE (see p.11)
ASF MOTOR TRANSPORT IS
NOT WORKING
Fold roller gap is too narrow
Increase the BOOK THICKNESS
value (see p.13)
When side stitching - side stitch
drive wheel not engaged
Engage the side stitch drive wheel
(see p.22)
When side stitching - side stitch
deflector is dirty
Clean deflector (see p.47)
When side stitching, heavy sets do
not pass through the fold roller.
Fit the optional edge stitch drive kit
(Part No. 914-512).
Drive is disengaged
Re-engage by turning the knob
clockwise (see p.7)
39
PROBLEM
CAUSE
SOLUTION
AUTOMATIC STITCH-FOLD
WILL NOT FIT BACK UNDERNEATH THE VARIO COLLATOR
Front outfeed conveyor is in down
position
It is ESSENTIAL to raise the outfeed
conveyor and clip up the outfeed
paper guides before placing the ASF
back underneath the collator (see
p.5)
BOOKLETS WILL NOT STACK
ON THE CONVEYOR
Large payout wheels incorrectly
positioned
Reposition (see p.19)
Electrical connection is unplugged
Plug in electrical connection
between the trimmer and the outfeed conveyor
BOOKLET COVER IS MARKED Dirty fold rollers
Clean them with a cloth dampened
with soapy water or alcohol (isopropanol). Do NOT use blanket wash
(see p.46)
Fold roller or trimmer conveyor gap Reduce the BOOK THICKNESS value
is set too tight
(see p.13) or trimmer gap (see p.19)
SMALL BOOKLETS FALL
The docking bracket is fitted in the
BETWEEN THE ASF AND ATR standard position
Move the docking bracket to its rear
position (see p.53)
Stitch Head Problems
ONE OR BOTH LEGS BUCKLED
Clincher worn or improperly aligned Re-align if necessary (see p.28),
replace if worn
LENGTH OF ONE LEG VARIES Incorrect wire size
CORNER OR CROWN IS DISTORTED OR FRACTURED
Replace with the correct size (see
p.29)
Gripper is worn or dirty
(Magnatek head only)
Clean (see p.30)
Excessive tension on the coil
Release the tension slightly (see
p.29)
Broken wire guide (see Figure 23)
spring
Replace
Clincher improperly aligned or worn Re-align if necessary, replace if
worn (see p.28)
ONE OR BOTH LEGS TURN
OUT
40
Incorrect wire size
Replace with the correct size (see
p.29)
Incorrect clincher alignment
Re-align (see p.28)
PROBLEM
CAUSE
SOLUTION
FLAT PIECE OF WIRE
INSTEAD OF A FORMED
STITCH (MAGNATEK HEAD
ONLY)
Swivel (see Figure 23) is dirty
Clean
Swivel not lubricated
Lubricate swivel with light grease
STITCH COMES OUT IN
PIECES
Incorrect wire size
Replace with the correct size (see
p.29)
Wire jammed in the stitch head
Inspect and remove any jammed
wire
Spool is incorrectly installed
Check and correct (see p.29)
WIRE TANGLES ON THE
SPOOL
Paper Jams
Paper jams are most commonly caused by: incorrect settings of PAPER SIZE; by
paper jammed in the ATR infeed or the conveyor. Other causes include an over-full
trimmer offcut box, the use of curly paper and using PRE-JOG with large sheet sizes.
Open the safety covers of the ASF (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 offcut box. Check carefully and
correct any faulty adjustments that caused the jam to occur (as detailed).
Paper jams can also be caused by offcuts obscuring the sensor in the trimmer
conveyor.
41
THIS PAGE IS
INTENTIONALLY
BLANK
42
10
Maintenance
SERVICE INTERVAL
It is recommended that your ASF and ATR are serviced
by an approved Watkiss engineer at six months intervals.
The stitch heads should be serviced every one million
cycles. Please contact your Watkiss supplier or the manufacturer for further details.
OPERATOR
MAINTENANCE
The ASF and ATR units require only a small amount of
routine maintenance.
STITCH HEAD
LUBRICATION
Important!
Failure to lubricate the stitch heads according to these
schedules may result in damage to the stitch heads and
invalidate your warranty.
MAGNATEK/M2000 STITCH HEADS
Petroleum jelly is the recommended lubricant (e.g. Vaseline™). It is most easily applied from a syringe and can
be obtained in this form from Watkiss by quoting part
number 951-089.
Daily
Remove the swivel, wipe clean and lubricate with petroleum jelly.
At Each Spool Change
The stitch heads should be removed and lubricated at
every spool change (55,000 stitches with 0.53mm wire).
Figure 30 on p.44 shows the areas where the stitch heads
should be lubricated using petroleum jelly or similar.
M2000 Stitch Head: Rotate the lubrication pad on the
wire guide so that the wire is in contact with a clean part
of the pad, apply 30-40 drops of SAE20 oil to the pad.
Replacement pads can be ordered by quoting part no.s
201-227 and 801-228 (one of each per head).
Lubrication
Pad
Magnatek Stitch Head: It may also be advantageous to
lightly oil the new spool with SAE20 oil. Run a single ’bead’
of oil across the width of the wire spool.
FIGURE 29 M2000 Stitch
Head - Wire Guide
43
Monthly
If the unit has low usage, once a month it should be
lubricated as detailed in the section above ‘at each spool
change’.
Inject lubricant into hole
or remove cam and lubricate shaft
Remove rotator operating
spring and lubricate shaft
Wipe area clean and inject a
small amount of lubricant on
the cam
Inject a small amount
of lubricant on the
cam surface of the
driver bar (above
and below the
housing)
Inject a small amount of
lubricant into the cutter
operating slide
Wipe area clean and apply a
light coat of lubricant
Ramp
Lubricate lower surface of
triangular shaped cam
Body
Remove rotator, wipe clean
and lubricate the body and
ramp. Clean rotator holder
before replacing rotator
FIGURE 30
Magnetek/M2000 Stitch Head Lubrication
44
DELUXE G5 STITCH HEADS
Using any standard SAE10 (3 in 1) oil, lubricate using one
drop of oil in each point (see Figure 31).
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.
Wire oiler felts
Top of the bonnet on either
side of the feed slide
In the oil cup of the small
feed gear shaft assembly
securing the small feed gear
to the feed lever
FIGURE 31 G5 Deluxe Stitch
Head Lubrication
45
HOHNER 43/6 STITCH HEADS
Lubrication of the Hohner stitch heads is only necessary
when the stitch head is serviced at one million cycle
intervals.
However, if they do require lubricating before they are
serviced, use a light duty oil, such as 3 in 1. Using a drop
of oil, lubricate all sliding parts.
CLEANING
Build up of set-off powder, ink or general dust will gradually impair the performance of your ASF and ATR. Optimum performance will be obtained by keeping the
machine clean.
Fold Roller and Conveyors
Build up of set-off powder or ink on the fold rollers (see
Figure 32) and conveyor belts will eventually cause slippage or ink transfer. Use the hand crank to turn them and
clean with a cloth dampened with soap and water or
alcohol (isopropanol). Do NOT use blanket wash.
(Note: Access to the trimmer hand crank and clutch
requires the side cover and the black cover under the
blade to be removed (see p.55). For safety reasons this
should only be conducted by authorised personnel).
46
Edge Stitch Deflector
The surface of the deflector should be cleaned periodically using anti-static polish.
Edge Stitch Deflector
Fold Roller
FIGURE 32
TRIMMER BLADE
SHARPENING
The trimmer blade (and anvil) should be sharpened when
required (see Appendix 3).
47
THIS PAGE IS
INTENTIONALLY
BLANK
48
A1
Using the Units Off-line
The ASF and ATR can be used off-line for hand-fed sets.
Note: An offline control panel is available, as an
option, to enable setup and operation of all functions.
The Offline Control Panel allows the ASF and ATR to
be operated completely offline, without the need for a
collator (see ’Using the Offline Control Panel’ on p.59).
• Part No. 041-525, ASF Offline Control Panel
Set up the job whilst the ASF and ATR are still on-line with
the collator (see ’Setting up the Automatic Stitch Fold and
Trim’ on p.16). This will set the ASF axes to suit the job.
The ASF will automatically start when a set is hand fed
into the unit and will automatically stop approximately 20
seconds after the last feed. Note: Wait until the book exits
the unit before feeding another set.
VARIO ONLY:
A hand-feed guide which bolts on to the ASF infeed, is
supplied with Vario versions of the ASF.
Hand Feed Guide
FIGURE 33
Vario versions of the ASF are also supplied with a remote
control handset. To fit the remote control, remove the units
from underneath the Vario, switch off the mains ON/OFF
switch and open up the ASF unit (see Figure 34). Plug the
remote control into the socket inside the ASF next to the
interface socket and then unplug the interface socket (see
Figure 35). Close the ASF taking care to thread the remote
control lead through the hole used by the interface cable.
Switch on the mains ON/OFF switch.
49
Interface/Remote Control
Sockets
FIGURE 34
Remote Control Socket
Interface Socket
FIGURE 35
The units can now be controlled by the remote control
handset:
and
:
:
:
:
:
Starts the ASF and ATR.
Stops the ASF and ATR.
Used to manually adjust the sheet length (this is normally
set automatically on the collator before it is taken off-line).
Press and hold to reset the ASF and ATR parameters to
the factory defaults. A long beep will be heard.
Press once to switch setup on/off. In the setup mode, the
top jog and trim are disabled. This can be helpful when
fine-tuning the adjustments etc.
The following signals are used in units with ASF software
version V1.0a onwards.
‘beep' = Setup switched on
‘beep beep' = Setup switched off
‘long beep' = ASF parameters reset to factory
defaults
50
PRE-JOG is always switched on to obtain best results
when hand feeding sets into the ASF.
51
THIS PAGE IS
INTENTIONALLY
BLANK
52
A2
Producing Small Booklets
From S/Ns ASF/1131 and ATR 1127 onwards, the ATR
can be docked with the ASF in two different positions.
The standard position is designed to prevent trimmings
from being transported through the conveyor system.
Docking Bracket
Trimmer Interlock
Hand Screw,
fitted through
rear fixing
hole
Front Fixing Hole
FIGURE 36 Docking Bracket (shown mounted in the
standard position)
The docking bracket only needs to be adjusted when
producing small booklets (typically A5->A6 or smaller).
Procedure
To alter the position of the docking bracket, first separate
the ASF and ATR (see ’Connecting the Automatic Trimmer’ on p.65). Undo both the orange hand screws that fix
the docking bracket to the ASF’s conveyor. Slide the
docking bracket rearward, and refit the orange hand
screws through the front fixing holes.
This will reduce the gap between the ASF and ATR when
they are connected together. If the docking bracket is not
moved in this way, there is a chance that small booklets
could drop between the two machines.
53
54
A3
Sharpening Trimmer Blades
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 following guidelines
which should accompany the blade when it is sent for regrinding. 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 conducted by suitably skilled personnel. Disconnect
the power before starting. Handle the blade with extreme
caution and keep hands clear of cutting edges at all
times.
Tools Required
3mm Allen Key
6mm Allen Key
10mm Allen Key
Before You Start
Separate the Trimmer from the Automatic Stitch-Fold (see
’Connecting the Automatic Trimmer’ on p.65). In order to
access the hand crank and clutch, take off the right side
cover (viewed from blade) from the Trimmer unit by
removing the two fixing screws. Remove the black cover
beneath the blade by releasing the two screws at left and
right, and lower to the floor. Note the position of the
solenoid clutch behind the two electrical connectors.
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.
55
Anvil Fixing Screws
Anvil Adjuster Screws
Anvil
Push
Anvil
Back
Clamp
Blade
Blade Fixing Screws
Locator Holes For Handling
FIGURE 37 ATR Blade Removal
Removing the Trimmer Blade
Slightly loosen all five blade fixing screws (see above).
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.
Check the Anvil
Remove the guard that covers the anvil and then carefully
check the anvil for any damage. If it requires re-grinding,
remove the five fixing screws and lift away.
Refitting the Trimmer Blade and Anvil
Slacken the anvil adjuster screws (see Figure 37) back
two revolutions. Position the anvil fully back towards the
conveyor (see Figure 37) and lightly tighten the anvil fixing
screws. Affix the blade using the five blade fixing screws
but do not tighten. Using the mark made when the blade
was removed, adjust the angle of the blade. Ensure that
it does not protrude above the clamp at point 'A' or below
it at point 'B' (see Figure 38). Lightly tighten the centre
screw, sufficient to hold the blade in this position.
56
ANVIL
CLAMP
BLADE
FIGURE 38
Manually release the
clutch by pulling the lever towards you and use
the hand crank until the
blade is at top dead centre. At point 'C' (see Figure 38) the blade must
pass the anvil by 1mm (1/
25"). Make fine adjustments to the position if
necessary. Tighten all
the blade fixing screws
starting from the centre
and working out. Push
the anvil firmly forwards
against the blade (pushing from behind with your
fingers at each end).
Maintain a light pressure
on the back of the anvil
whilst tightening the anvil
fixing bolts starting from
the centre and working
out. Lightly tension the
anvil adjuster screws
against the anvil.
Final Adjustment
Manually release the clutch and hand crank slowly several
rotations to check that the blade passes the anvil smoothly
without obstruction.
Warning!
Ensure that hands are kept
clear at all times
Place a single sheet of paper (large sheet size) between
the blade and the anvil and hand crank to produce a test
cut.
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.
57
Replace the anvil guard, black cover and side cover.
BLADE
Note:
2 faces must
be flat to within
0.03mm.
ANVIL
Note.
2 faces must
be flat to within
0.01mm.
Blade Material High speed steel
(18%W)
Grinding Angle See drawing alongside
Grinding Wheel Cup or Cylinder
Grinding Material Grit : 46-60
Hardness : G-H
Bond : Bakerlite
Peripheral speed 20-26 (V M/S)
of the grinding wheel 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"
This edge must
be straight to
within 0.04mm.
Important:
Grind In This
Direction Only
Honing
After re-grinding, the burr should be carefully removed by honing. The quality of honing
affects the useful life of the cutting edge.
Correct
58
Incorrect
A4
Using the Offline Control
Panel
The Offline Control Panel allows the ASF and ATR to be
operated completely offline, without the need for a collator.
• Part No. 041-525, ASF Offline Control Panel
One touch size change for A3/A4 or for 11x17" / 8½x11"
Display screen
Sheet length
Sheet width
Return or Home button
A4>A5 297 210.0
---- +0.0 148.5
Select/Accept button
Option status indicator
Trim position
Stitch/Fold offset from centre
One touch size change A4/A5 or for 8½x11" / 5½x8½"
FIGURE 39 Offline Control Panel (metric measurements shown)
NAVIGATION
There are 5 different menu screens. Use
and
to
move between different options on the screen. When an
option is selected, it is highlighted by arrows on either
side.
e.g. r297l
Press
to select the option - this either takes you to
another menu screen, or allows alterations to be made.
After selecting an option, press
or
to make alterations, followed by
to accept the changes.
At any time press
to return to the main menu.
59
Main Menu
A4>A5
----
297
+00.0
Size Menu
JOB :
A3>A4
Option Menu
RE-REF
A4>A5
PREKNK:0
EDGE+FD:0
LONGSK:1 DEF MORE
08
A5>A6
Job Menu
LOAD
JOB :
210.0
148
Advanced Menu
ð
ð
SAVE
JOB :
SK: 1
TRIM:1
STTL:200 MM
STAP:1
GB
FIGURE 40 Offline Control Panel Menus
PERSONALISING THE
CONTROL PANEL
Language
To change the language of the control panel display:
• press
/
to highlight r----l*, press
• press
/
to highlight rMOREl, press
• press
/
to highlight rGBl, press
• press
press
/
until your chosen language is displayed,
Metric/Imperial
To change between metric and imperial measurements:
• press
/
to highlight r----l*, press
• press
/
to highlight rMOREl, press
• press
/
to highlight rMMl, press
• press
/
then press
to toggle between rMMl and rINl, and
When imperial measurement is selected, US standard
paper sizes are available.
*The option status indicator, r----l, will contain the
letters P, L or E when ‘pre-knock’, ‘long side knock’ or
‘edge and fold’ are selected respectively (see p.63).
60
CHANGING PAPER
SIZES
One-touch size change
One-touch size change is available for the two most
common sizes, simply press the appropriate button. The
ASF will give a double beep when it is ready to run.
Large Book
A3 to A4 (or 11x17" to 8½x11")
Small Book
A4 to A5 (or 8½x11" to 5½x8½")
FIGURE 41 One-touch size changes
Standard sizes
Three standard sizes are available through the control
panel. Press
/
to highlight the top left position on
the screen and press . Press
/
to highlight the
standard size needed and press .
Standard Sizes Input Sheet Size Booklet size
Trim setting
Metric
A3>A4
A5>A6
A4>A5
420x297mm
297x210mm
210x148.5mm
210x297mm
105x148.5mm
148.5x210mm
207mm
145mm
102mm
11"x17"
8.5"x11"
5.5"x8.5"
8.5"x11"
5.5"x8.5"
4.2"x5.5"
8.4"
5.4"
4.1"
Imperial
8.5"x11"
5.5"x8.5"
5.5"x4.2"
Custom sizes
Custom sizes can be entered from the main menu. Press
/
to highlight the required setting and press . Use
/
to increase or decrease the measurement, then
press .
61
}
}
Sheet Length
Staple/Fold Offset
297
+0.0
210
207
}
}
Sheet Width
Trim Length
FIGURE 42 Size Adjustment
By default, the stitch/fold position will be exactly in the
centre of the sheet. This can be altered using the stitch/
fold offset setting (default is +0.0).
r+0.0l
A positive (+) setting moves the stitch/fold position away from the feed edge
A negative (-) setting moves the stitch/fold
position towards the feed edge
FIGURE 43 Staple/Fold Offset
Book Thickness
Book thickness (the fold roller gap) is adjusted from the
size menu. Press
/
to highlight the required setting
and press . Use
/
to increase or decrease the
value, then press .
USING JOB
MEMORIES
If required, up to five custom job settings can be loaded
into memory, to be retrieved at a later date.
Loading a job
• press
/
to highlight the top left position of the
screen, press
62
• press
/
to highlight rJOBl, press
• press
/
to highlight rLOADl, press
• press
press
/
to select the memory required,
Note: When highlighting an option on the screen, the
top left position is always highlighted first, therefore, to
access the Job Menu, you can just press , .
Saving a job to memory
• press
/
to highlight the top left position of the
screen, press
CONTROL PANEL
OPTIONS
• press
/
to highlight rJOBl, press
• press
/
to highlight rSAVEl, press
• press
press
/
to select the memory required,
In addition to the functions explained earlier, the following
options are also available. When selected, some of these
are shown on the ‘option status indicator’ position on the
main menu screen:
PREKNK Selects pre-knock which provides additional
jogging prior to stitching. This is useful for heavy or large
sheets. When selected, this shows as P on the main menu
screen.
EDGE+FD When selected, the set will be edge-stitched
and then folded. When selected, this shows as E on the
main menu screen.
LONGSK Selects long side-knock which causes the infeed sidelays to hold the set during both stitching 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. When selected, this shows
as L on the main menu screen.
DEF Returns the ASF/ATR to default factory settings. This
does not alter job memories or current size settings.
MORE Enters the ‘advanced menu’ where additional parameters can be adjusted.
63
RE-REF If you suspect the adjustment system is not
calibrated correctly, you can select this option. After
recalibration, the adjustment axes will return to the current
settings. If the software detects a possible axis positional
fault, the unit will automatically recalibrate the axes.
It is important that you do not re-reference whilst there is
paper in the machine, if for example there is a paper jam.
SK Press to adjust the delay between the side-knock and
stitching; this is sometimes useful in ensuring a tidy set.
The default value is 1. Increase in increments of about
100, up to a maximum of 1000. Note that increasing the
side-knock will reduce the production speed.
STTL Press to adjust the time delay before folding (the
default is 200mS). Reducing the value will increase
speed.
TRIM Switches the trim operation on and off.
STAP Switches the stitch operation on and off.
64
A5
Connecting to other Watkiss
equipment
The ASF can be connected as follows:
• Automatic Stitch-Fold to Automatic Trimmer
• Automatic Stitch-Fold and Trim to Outfeed Conveyor
The following guidelines regarding connection or disconnection should be observed.
Connecting the Automatic Trimmer
If the ASF is connected to a collator, use the motorised
transport switch and drive the ASF clear of the collator
base unit.
Switch off and disconnect the power to the ASF.
Push the ATR towards the ASF and ensure the docking
bracket on the ASF conveyor outfeed engages squarely
and fully with the locating bar in the ATR infeed and the
cables are not trapped (see Figure 44).
Docking
Bracket on
ASF Conveyor
Outfeed
Locating bar in
ATR in Infeed
See also Figure 36
on p.53
FIGURE 44
Raise the lid on the ASF and connect the power and data
cables from the ATR.
65
Raise the lid on the Automatic Trimmer, unscrew the
orange hand screw on the safety interlock and slide the
interlock bar towards the side of the machine so it engages with the switch unit. If it is difficult to engage the
interlock bar it is probably because the two machines are
incorrectly docked.
Tighten the orange hand screw to secure the interlock in
the ‘live’ position (see Figure 45).
Close the lids on the ASF and ATR.
.
FIGURE 45
Reconnect the power, switch on and drive the combined
ASF/ATR unit back under the collator floor base where
necessary.
Connecting the Outfeed Conveyor to the ATR
Offer up the outfeed conveyor to the ATR. Align the two
orange hand screws on the conveyor to the threaded
mounting holes on the ATR and tighten.
ATR
Outfeed
Orange
hand
screws
Conveyor
FIGURE 46
66
Plug in the conveyor cable to the socket on the rear panel
of the ATR.
Note: to release this cable it is necessary to press in the
metal tab marked ‘PUSH’ while pulling on the plug (see
Figure 47).
‘PUSH’ tab to
release cable
Conveyor cable
Blanking plug in
ASM interface
socket
FIGURE 47
67
THIS PAGE IS
INTENTIONALLY
BLANK
68
A6
Manufacturer's Name:
Manufacturer's
Address:
Product Name:
Safety:
EMC:
Declaration of Conformity
Watkiss Automation Limited
Watkiss House
Blaydon Road
Sandy, Bedfordshire, UK.
SG19 1RZ
United Kingdom
Declares that the product
Watkiss Automatic Stitch-Fold and Trim
Conforms to the following Product
Specifications:
73/23/EEC & 98/37/EC Council Directive 'on the approximation
of laws of Member States relating to machinery'.
BS EN 60950 : 2002
89/336/EEC Council Directive 'on the approximation of
laws of Member States relating to electromagnetic compatibility'.
EN55022:1998 Class A
EN55024:1998
EN61000-3-2:2000
EN61000-3-3:1995 + A1:2001
M C Watkiss
Technical Director
Watkiss Automation Ltd
69
THIS PAGE IS
INTENTIONALLY
BLANK
70
Index
A
adjustment axes, re-referencing 18
asm cable 5
automatic spinemaster 3, 4
B
blanking plug 5, 67
book thickness 13
booklet 15
booklet making 15–20
loading the bins 15
setting the paper path 15, 21
setting up the asf 16–20
trim margin 15
C
centre stitch selection 18
connecting to other watkiss equipment
automatic trimmer 65
outfeed conveyor 66
control panel 11–13
corner & side stitching 21–22
D
docking bracket 53, 65
double jog 12
F
finishing window 11
fold delay 13
fold position fine tuning 20
H
hand crank 26
hand crank access hole 27
hand-feed guide 49
I
in->mm 13
infeed guides 28
installation 4
interface & remote control socket 50
interlock 66
L
loading the bins 15
M
maintenance 43–47
cleaning the asf 46–47
edge stitch deflector 47
fold roller and conveyors 46
stitch head lubrication 43
measurement 13
mm->in 13
motorised transport system 7
moving the unit 6
O
offline control panel 59
offline control panel
menu navigation 59
operator maintenance 43
outfeed conveyor adjustment 19
P
page direction 11
paper jams 41
paper path, setting on the collator 15, 21
paper size 11
page direction 11
presets 12
re-ref 11
pre fold jogging 13
fold delay 13
side jog hold 13
pre jog 12
pre stitch jogging 12
double jog 12
pre jog 12
stitch delay 12
presets 12
producing small booklets 53
Q
quick start 9–10
71
Index
R
radio frequency emissions 2
remote control & interface sockets 50
re-ref 11
S
safety 4
safety interlock 66
service interval 43
setting up the asf 16–20
centre stitch selection 18
control panel 16
fold position fine tuning 20
outfeed conveyor adjustment 19
starting the job 20
stitch head adjustment 18
trimmer conveyor gap 19
side & corner stitching 21–22
side jog hold 13
side stitch drive wheel 22
side stitching & folding 23
small booklets 53
specifications 1
stitch and fold 12
stitch position 12
stitch delay 12
stitch head lubrication 43
deluxe g5 stitch heads 45
hohner 43/6 stitch heads 46
magnatek/m2000 stitch heads 43
stitch heads 25–35
clincher alignment 28
infeed guides 28
lubrication 43
manual cycling 26
positioning 27
sensors 28
testing 35
threading deluxe g5 stitch heads 31
threading hohner stitch heads 34
72
threading magnatek/m2000 stitch
heads 30
wiring 29–35
stitch position 12
switching on 5
T
trim 12
trim margin 15
trimmer blade sharpening 55–58
final adjustment 57
honing 58
refitting the trimmer blade 56
removing the trimmer blade 56
trimmer conveyor gap adjustment 19
troubleshooting 37–42
operational problems 37
paper jams 41
stitch head problems 40
U
units of measurement 13
using the units off-line 49–51
W
wheel lock 7
wiring the stitch heads 29–35
WATKISS AUTOMATION LIMITED
Watkiss House, Blaydon Road, Middlefield Ind. Est.,
Sandy, Bedfordshire. SG19 1RZ United Kingdom.
Tel: +44 (0)1767 685700 Fax: +44 (0)1767 689900
Email: [email protected] Web: http://www.watkiss.com
Watkiss Automatic Stitch Fold & Trim Operating Manual.
Issue 4, November 2006. Part No. 960-191
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement