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BookMaster
Watkiss Automation BookMaster User Manual
128 pages
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Watk
iss BookM
aste
r Servi
ce Manua
l - I
ssue
1 -
14/1
2/00
Watkiss BookMaster
Service Manual
Includi
ng BookMaster
and Tri
mMaster Sta
ndard an
d Pro Versi
ons
Issue Dat
e :
14 December 200
0
Issue Numbe
r :
1
Part Number :
969-240
1 Blaydon
Road
Middlefi
eld Indus
tria
l Estate
Sandy, Bedf
ordshire
SG1
9 1
RZ
U.
K.
Tel: +4
4 (0)17
67 682177
Fax: +44
(0)176
7 691769
Emai
l: in
fo@w
at
kiss
.c
om
Watk
iss
Automation
Limited
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 System Description
7
Introduction
7
Compatibility & Configurations
7
BMS Bookmaster Standard 115V
8
BMP Bookmaster Pro 115V
8
Tms
8
Tmp
8
Boc
8
Bookmaster Overview
9
Normal Operating Cycle (When Booklet-Making)
9
Status Indication
11
Trimmaster Overview
13
Bookmaster Outfeed Conveyor (BOC)
14
Bookmaster Motorised Infeed (BMI)
14
Bookmaster Outfeed Conveyor
14
Bookmaster Infeed Guide (BIG)
15
Bookmaster Receiving Tray (BRT)
15
Bookmaster Infeed Guide
15
Bookmaster Receiving Tray
15
Bookmaster Offline Control Panel (BCP)
16
Fuses
16
Bookmaster Standard
16
Bookmaster Offline Control Panel
16
Bookmaster Pro
17
2 Tools and Materials
19
Recommended Tools
19
Consumables
20
3 Service Procedures
21
Introduction
21
Safety
21
Operation
21
Orientation
21
Test Paper
21
Metric and Imperial Measurements
21
Machine Covers
21
Bookmaster Standard
22
Cycling the Bookmaster by Hand
22
Fitting a Third Staple Head
23
Staple Sensor Calibration
25
Staple to Fold Calibration
25
Edge Staple Latch Solenoid Adjustment
26
Replacing the Staple Latch Solenoid
27
Removal and Fitting of Fold Rollers
28
Fold Roller / Blade Alignment
29
Fold Blade Replacement
31
Fold Blade Clutch Replacement
31
Squaring up Procedure
34
Drive Motor Replacement
36
PCB Removal and Fitting - General Comments
37
Guard Switch Adjustment
37
Fold Roller Spacer Rings
37
Bookmaster Pro
38
Axis Home Position Calibration - Sidelays
39
Axis Home Position Calibration - Fold
39
Top Jog Belt Calibration
40
Top Jog Belt Clutch Replacement
41
Trimmaster Standard
42
Cycling the Trimmaster by Hand
42
Conveyor Clamp Adjustment
42
Squaring the Trim Stop
43
Infeed Conveyor Pivot Point and Removal
44
Replacing Infeed Conveyor Belts
44
Replacing Main Conveyor Belt
45
Replacing Waste Conveyor Belt
46
Centralising Waste Conveyor Belt
47
Removing and Regrinding the Trimmer Blade
48
Blade and Anvil Grinding Instructions
52
Trimmaster Pro
52
Trim Axis Home Position Calibration
52
4 Electronics & Software
55
Connection Diagrams
55
Pcbs
68
900-141C, Eco-Vario Interface Board
68
900-152B, Position Motor Control Board (PIC)
69
900-155B, Auto VTR Control Board
70
Staple Head Control Board
71
Bookmaster Pro Main Control Board
72
Bookmaster Interface Board
73
900-165A, Bookmaster Clinch Drive
73
Bookmaster Standard Main Control Board
74
Bookmaster Pro Software
74
Loading Software
75
Terminal Emulator Mode
75
5 Machine Inspections
77
6 Routine Maintenance
97
7 Installation
103
General Considerations
103
Connecting the Bookmaster and Trimmaster
103
Outfeed Conveyor (BOC)
104
Bookmaster Receiving Tray (BRT)
105
Motorised Infeed (MIF)
106
Using the BMI as a Collecting Station
107
Bookmaster Infeed Guide (BIG)
107
Bookmaster Offline Control Panel (BCP)
107
Installing the Bookmaster with a Watkiss Vario Collator
108
Accessories
110
Connecting to the Watkiss Vario Oscillating Floor Base
111
Nagle Panel and Settings
111
8 Trouble Shooting
113
Trouble Shooting Chart
113
Error Indicators
117
Status Indicator Light
117
Staple Head Indicator Lights
118
Startup and Error Bleeps
118
Error Diagnostics
118
Position Motor Control Board
118
Terminal Emulator Mode
120
Staple Head Control Board (900-156)
123
Manually Firing the Staple Head
123
9 Appendix
125
Conversions
125
Technical Documentation Feedback Form
126
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Watkiss Automation BookMaster Specifications
General
Brand
Watkiss Automation
Model
BookMaster
Category
Booklet makers
Language
English
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