Watkiss Vario BookMaker

Operating Manual
English, Issue 3, June 2005
Table of Contents
CHAPTER 1 Introduction to the Watkiss Vario
BookMaker . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 2 Using the Vario BookMaker . . . . . . . 5

Online Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Offline Operation (collating sequentially printed sets) . . . . . . . . . . 9
Offline Operation (normal collating) . . . . . . . . . . . . . . . . . . . . . . 12

CHAPTER 3 About the Machine . . . . . . . . . . . . . 15

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Friction Feed Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SlimVAC Suction Feed Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connecting Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Gathering Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Booklet Maker & Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Front Outfeed Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Joggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

CHAPTER 4 Maintenance . . . . . . . . . . . . . . . . . . 59

CHAPTER 5 Problem Solving . . . . . . . . . . . . . . 73

Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

CHAPTER 6 Safety Information . . . . . . . . . . . . . 89

CHAPTER 6 Product Safety Data Sheet . . . . . . . 91

CHAPTER 7 Specifications . . . . . . . . . . . . . . . . 93

CHAPTER 8 Declaration of Conformity . . . . . . . 95

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Watkiss Vario BookMaker Operating Manual, Watkiss Part No. 960-741

Issue 3 - English - June 2005

© Watkiss Automation Limited

Watkiss Vario BookMaker Operator Manual

Watkiss Vario BookMaker Operator Manual
CHAPTER 1 Introduction to the
Watkiss Vario
BookMaker

Thank you for choosing the Watkiss Vario BookMaker.

About Your Manual. This manual explains how to operate the Vario Book-
Maker, correct and solve most error conditions and perform routine main-
tainence. It does not explain the operation of the printer.

Operator training will be provided when the machine is installed, however it

is recommended that you also take time to read this manual.

Safety Information. Safety information is included in “Safety Information”

on page 89. You are advised to read this information before you start to use
the Vario BookMaker.

Installation. The installation of your BookMaker requires specialist knowl-

edge and should therefore only be carried out by a Watkiss approved engi-
neer.

Caution: The BookMaker 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 warranty. The
required machine voltage is shown on the label on the rear of the Vario
BookMaker and the rear of the booklet maker.

Getting Help. We are confident that your BookMaker 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 authorised distributor.

Watkiss Vario BookMaker Operator Manual 1

 1 - Introduction to the Watkiss Vario BookMaker -

About the Vario BookMaker

The Watkiss Vario BookMaker works online with digital printers and con-
verts sets of printed pages into staple-folded booklets. It will also add a sep-
arate pre-printed cover if required.

The BookMaker can be configured in several different ways, but typically

consists of the following components:
• A connecting bridge, that transfers printed sheets from the printer to the
BookMaker
• A GUI (Graphical User Interface) colour touch-screen that controls the
operation of the BookMaker
• Feed bins, that are used to add covers or inserts to booklets where
required
• A gathering station, that gathers complete sets of pages from the printer
• A booklet maker that staples and folds the sheets into booklets
• A trimmer that trims the fore edge of the booklet. This is optional, and
can be added to the BookMaker at any time
• An outfeed conveyor that connects to the booklet maker (or trimmer
where fitted)
• An Automatic Online SpineMaster which post-processes booklets to
give them the appearance of perfect binding with the security of a
stitched spine. This is an optional module and is documented in a sepa-
rate operating manual.

GUI (Graphical User Interface)

Connecting Bridge
Feed Bins

Gathering Station

Outfeed
Conveyor
Booklet Maker

Trimmer (optional)

Offline Operation. The Vario BookMaker may also be used offline as a

normal collator and booklet maker, see “Offline Operation (normal collat-
ing)” on page 12.

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1 - Introduction to the Watkiss Vario BookMaker -

Switching the Vario BookMaker On and Off

Mains Input. There are two mains inputs: one on the rear of the Book-
Maker drive unit and one on the rear of the booklet maker. Two fuses are
fitted next to each of the mains inputs.

Vario BookMaker Mains Input

Booklet Maker Mains Input

Mains On/Off Switch. Mains On/Off switches are located on the side of
the BookMaker next to the Emergency Stop button (see p.4), and alongside
the booklet maker 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.

Important: To maintain the efficiency and prolong the service life of

the static elimination equipment, it is important to switch off the Vario
BookMaker when it is not being used for a period of hours e.g. over-
night.

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 1 - Introduction to the Watkiss Vario BookMaker -

Emergency Stop

The emergency stop button should only be used when an immediate stop
of the machine is required. Under normal circumstances the machine
should be stopped by touching the stop button on the control panel. If
the emergency stop button is used, the system will not restart until the
button has been released by turning it clockwise.

Emergency Stop

4 Watkiss Vario BookMaker Operator Manual

CHAPTER 2 Using the Vario
BookMaker

This chapter provides details on how to use the Vario BookMaker for pro-
duction 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.

Watkiss Vario BookMaker Operator Manual 5

 2 - Using the Vario BookMaker - Online Operation

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.

For details on how to make adjustments, see Chapter 3 on page 15.

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 BookMaker system
• Ensure that the connecting bridge is horizontal, and that ONLINE is dis-
played 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

Adjust the Booklet Maker and Trimmer

• Adjust the booklet maker and trimmer for the paper size using the GUI
control panel. Use saved job settings if appropriate.
• Adjust the outfeed conveyor wheel
• Select edge or centre stitching
• Select which staple heads should be used and adjust their position if nec-
essary
• Adjust the fold roller gap

Adjust the Gathering Station

• Adjust the gathering station for sheet width
• Adjust for sheet length
• Adjust the air blow if necessary

Adjust the Feed Bins

• If insert sheets are to be used, load the bins and switch on

6 Watkiss Vario BookMaker Operator Manual

2 - Using the Vario BookMaker - Online Operation

• Adjust the feed bin settings to suit the paper type

• If no insert sheets are required, switch the bins off

Adjust the Connecting Bridge

• Adjust the paper transport sidelay to suit the paper size

Run a Test Set

A test set must be run at the start of each job, even if no inserts are being
added to the booklet.
• Touch TEST SET and press
• One sheet will be fed from each feed bin which is loaded and switched
on. Remove the resulting booklet from the outfeed conveyor and check
that the sheet sequence is correct. Discard the booklet

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.

Start the Printer

Make any changes or setup that are necessary on the printer, and then start
the print job. The BookMaker will automatically start up under control of
the printer.

Tip: If you do not run a test set, the printer will not start. The message
‘Solve the off-line finisher problem” will be displayed on the printer
control panel.

Error Handling
In the event of an error occuring within the BookMaker system, the printer
will divert its output to the printer purge tray and stop at the end of the set
or document.
• Remove all sheets in the BookMaker paper path, checking in the con-
necting bridge, in the gathering station and in the booklet maker 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 BookMaker, referring to the GUI control panel
for details
• Press INCH on the GUI control panel to clear any error messages
• Follow any instructions on printer control panel and then restart printing

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 2 - Using the Vario BookMaker - Online Operation

• 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

Chapter 5 on page 73 includes details of trouble shooting and problem solv-

ing.

8 Watkiss Vario BookMaker Operator Manual

2 - Using the Vario BookMaker - Offline Operation (collating sequentially printed sets)

Offline Operation (collating

sequentially printed sets)

The BookMaker system can be used to automatically gather sets from a

sequentially printed stack of paper. The sheets are held in the gathering sta-
tion until the set is complete, and it is then released into the booklet maker
and trimmer.

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 BookMaker system
• Move the connecting bridge to the offline position and 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 the Bins with Paper

Load the sheets so that the centre spread of the book is face up.

Centre Spread
Face Up

Outside Face
Down

Finishing Sequentially Printed Sheets

• Load the bins and switch on, use bin linking if required
• Adjust the feed bin settings to suit the paper type

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 2 - Using the Vario BookMaker - Offline Operation (collating sequentially printed sets)

Inserting a Cover
If you wish to insert a separate cover it should be loaded into the lowermost
bin with the outside face down. The other sheets are then loaded in the
bin(s) directly above.

Adjust the Booklet Maker and Trimmer

• Adjust the booklet maker and trimmer for the paper size using the GUI
control panel
• Adjust the outfeed conveyor wheel
• Select edge or centre stitching
• Select which staple heads should be used and adjust their position if nec-
essary
• Adjust the fold roller gap

Adjust the Gathering Station

• Adjust the gathering station for sheet width
• Adjust for sheet length
• Adjust the air blow if necessary

Starting the Job

• Touch NUMBER OF SETS in the BATCH window and input the number of
sheets required in each book.
• To insert a cover, in the BATCH window, touch INSERTS and set BOT-
TOM to ON (the NUMBER OF SETS in the BATCH window must be set to 1
or greater)
• In the BASIC window, select PRENUMBER, and set the SETS PER HOUR
to AUTO.

Test Set. A test set must be run at the start of each job. Touch to run a
test set. If PRENUMBER is selected, the test set is counted and the sheet
should be left in the gathering station.

Tip: To avoid wasting sheets during the test set, the sheets can be
diverted out of the front of the gathering station using the manual bypass
gate.

Note: 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.

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2 - Using the Vario BookMaker - Offline Operation (collating sequentially printed sets)

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.
Touch to run the job.
Once the machine is running, adjustments may be necessary depending
upon the stock in use.
The machine can be stopped at any time by touching . Alternatively, to
stop the machine when the current batch/set is complete, touch STOP in the
BATCH window.

Watkiss Vario BookMaker Operator Manual 11

 2 - Using the Vario BookMaker - Offline Operation (normal collating)

Offline Operation (normal collating)

The Vario BookMaker can also be used for the normal collating and finish-
ing of batch printed sheets. When the BookMaker 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 BookMaker system.
• Move the connecting bridge to the offline position and 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

Finishing Batch Printed Sheets

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2 - Using the Vario BookMaker - Offline Operation (normal collating)

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 booklet maker.

Adjust the Booklet Maker and Trimmer

• Adjust the booklet maker and trimmer for the paper size using the GUI
control panel
• Adjust the outfeed conveyor wheel
• Select edge or centre stitching
• Select which staple heads should be used and adjust their position if nec-
essary.
• Adjust the fold roller gap

Adjust the gathering station

• Adjust the gathering station for sheet width
• Adjust for sheet length
• Adjust the air blow if necessary

Starting The Job

Touch to run a test set. A test set must be run at the start of each job.
Remove the resulting booklet from the outfeed conveyor and check that the
sheet sequence is correct.
Touch to run the job.
Once the machine is running, adjustments may be necessary depending
upon the stock in use.
The machine can be stopped at any time by touching .

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 2 - Using the Vario BookMaker - Offline Operation (normal collating)

14 Watkiss Vario BookMaker Operator Manual

CHAPTER 3 About the Machine

This chapter explains in detail about each of the different modules that make
up your Vario BookMaker, and how to make adjustments to them.

For instructions on using the Vario BookMaker for production jobs, please
refer to Chapter 2 on page 5.

Watkiss Vario BookMaker Operator Manual 15

 3 - About the Machine - Control Panel

Control Panel

Your BookMaker is fitted with a GUI (Graphical User Interface) control

panel. The control panel has an 8.2" colour touch-screen, which offers a
user-friendly interface for operators.

There are start and stop buttons mounted on the control panel’s frame, these
buttons are also repeated on the touch-screen.

Start Button Stop Button

Touch-screen

GUI Control Panel

The touch-screen has a ’power save’ function: if it is not used for a period
of time, it automatically dims. After an extended period, it switches off. In
either case, touch the screen to return it to normal.

Tip: The touch-screen takes two or three minutes to reach full bright-
ness when it is switched on.

The Window System

The BookMaker is controlled by touching buttons on the control panel. The
buttons are divided into groups that perform related functions. Each group
of buttons has its own ’window’ which is selected by touching the relevant
tab:
• Load & Save
• Basic
• Advanced
• Feed (offline use only)
• Batch (offline use only)
• Finishing

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 3 - About the Machine - Control Panel

Start/Stop Test Set

Inch/Pause Help
End Job Menu

Control Buttons

Each window contains a

group of related buttons

Touch the relevant tab to

display each window
Load & Save Feed
Basic Batch
Advanced Finishing

Main Window Tabs on the Control Panel

‘Control’ Buttons
There are six main ’control’ buttons listed across the top of the screen:

START/STOP ~ The button starts the machine. When the machine is run-
ning, this button changes to which stops the machine. These are dupli-
cated by the start/stop buttons above the touch screen.

Note: When using the BookMaker 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.

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 3 - About the Machine - Control Panel

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 BookMaker is ready
to run a test set. The BookMaker 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.

To run a test set:

• Load the BookMaker
• Touch the button
• The collator will feed a single sheet from each bin that is switched on
and loaded
• If an error occurred during the test set, or the bin loading is changed at
this stage, touch to run another test set
• When the test set icon is grey, the machine is ready to run

If either the TEST SET or END JOB button is touched, another test set will
need to be run before the job can be restarted: the test set icon will be 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.

MENU ~ MENU gives access to settings that do not need to be changed on a

day-to-day basis. These settings include:
• Change the display language
• Toggle between metric and imperial measurements
• Adjust the screen contrast
• Adjust the pause duration

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3 - About the Machine - Control Panel

There are several access levels: some of the settings can only be changed by
users with an appropriate access code.

MIMIC DIAGRAM ~ The mimic diagram of the BookMaker shown on screen

is automatically created, based on how many bins are fitted and what finish-
ing equipment is connected. Various areas on the outline will be highlighted
in different colours, according to the BookMaker’s operational status. The
feed bin colours mimic the bin indicator lights:
• Steady green: This bin is selected, and is loaded with paper
• White: This bin is not selected
• Broken line between bins: These bins are linked
• Flashing green: This bin is selected, but it has run out of paper
• Flashing red: This bin has had a double feed, which has caused the Vario
to stop. The error will be explained in a pop-up box
• Flashing yellow: This bin has had a miss, which has caused the Vario to
stop. The error will be explained in a pop-up box

Errors in other modules are indicated in red. The mimic diagram also shows
if the connecting bridge is up or down.

Mimic Diagram

Counter

C ~ Touching C resets the set counter to 0.

SPH ~ SPH shows the actual production speed of the BookMaker, in sets per
hour. The production speed is affected by paper size, online finishing equip-
ment and the job setup.

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 3 - About the Machine - Control Panel

The ‘BASIC’ Window

The BASIC window contains settings that regularly need to be altered when
setting up a new job.

‘BASIC’ Window.

SETS PER HOUR ~ SETS PER HOUR allows the production rate of the Book-
Maker to be set. This is automatically limited according to the machine
configuration and cannot be altered when the BookMaker is operating
online with the printer.

REMOTE: This indicates that the BookMaker is running under control of

the printer. This is the normal operating mode when running online to
the printer.

AUTO: (Only available when the BookMaker is operating offline to the

printer) Selecting AUTO allows the BookMaker to run at its maximum
production speed according to paper size, online finishing equipment
and the job setup.

SINGLE SET: (Only available when the BookMaker is operating offline

to the printer) Normally there will be more than one set in the conveyor
at any one time. Touch SINGLE SET to allow only one set in the con-
veyor at a time. This minimises the correction required should an error
occur. The sets per hour will automatically adjust to achieve this.

AIR BLOW ~ AIR BLOW alters the amount of air available for sheet separa-
tion in the feed bins. As a general rule, the heavier and larger the sheet, the
more air you need. The default factory setting depends on the type of feed
bins (25% for friction, 40% for SlimVAC).

If you are running mixed stocks on friction bins, individual air taps on each
bin allow the air to be independently controlled.

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3 - About the Machine - Control Panel

PRESET ~ (Only available when the BookMaker is operating offline to the

printer) PRESET is used if an exact number of sets are required. Touch PRE-
SET and enter the number of sets required on the number pad. The counter
in the main area of the screen will turn white. When the machine is started
the counter will automatically count down to zero and the BookMaker will
then stop.

Touch to restart the machine. The counter will revert to black and will
count up to show how many ‘overs’ are produced.

The Preset function is ideal for producing a one-off batch. If you wish to
produce several identical batches, it is easier to use the Batch function.

PRENUMBER ~ (Only available when the BookMaker is operating offline to

the printer) PRENUMBER is intended for use when collating pre-numbered
carbonless sets. Touching PRENUMBER selects Single Set mode and causes
the test set to be counted by the counter. It also prevents the operator from
switching linked bins before one bin has emptied.

It is possible to switch off Single Set mode once Prenumber is selected.

This allows the machine to run faster when using stock that feeds easily.

ONLINE ~ Selects Online or Offline operation. When the connecting bridge

is in the online position (horizontal), ONLINE ON is automatically enabled.

For offline operation, ensure END JOB is highlighted, move the connecting
bridge to the offline position and then set ONLINE to OFF.

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 3 - About the Machine - Control Panel

The ‘ADVANCED’ Window

The ADVANCED window allows advanced machine settings to be altered.

These settings may be altered to optimise the quality and productivity of a
job.

‘ADVANCED’ Window.

DRIVE SPEED ~ (Only available when the BookMaker is operating offline to

the printer) DRIVE SPEED alters the drive speed of the conveyor rollers and
therefore the speed at which the sheets exit the BookMaker. This setting is
independent from the SETS PER HOUR setting.

SHEET OFFSET ~ (Only available when the BookMaker is operating offline

to the printer) SHEET OFFSET shales the sheets as they exit the feed bins.
This can assist the neat stacking of thick sheets or large sets. The range of
offset is +/- 20mm between each sheet and affects all bins. The default
sheet offset is 0: this causes the sheets in a set to enter the gathering base
module with their leading edges level.

If an offset is required, it is usual for the bottom sheet of the set to lead:
select a positive offset.

A small offset can make jogging more effective.

DETECTOR POSITION ~ The sheet detector measures 15.2mm (0.6") from

the feed edge of the sheet and then takes a reading. If the edge of a particu-
larly dark or solid area of print is in this area it can cause detection prob-
lems. The DETECTOR POSITION can be adjusted so that it looks at a
different part of the sheet. This affects all the bins in the BookMaker.

TOLERANCE: Changing TOLERANCE to x2 COARSE allows for more

variation in the detector readings. This prevents false errors being

22 Watkiss Vario BookMaker Operator Manual

3 - About the Machine - Control Panel

reported when there are variations in the paper or ink density. The
default setting is x1 NORMAL.

The BookMaker 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.

DOUBLE DETECTION: Under unusual circumstances, e.g. there are large

variations in stock, it may be necessary to turn off DOUBLE DETECTION.
This affects all the bins in the BookMaker. Miss feed detection is unaf-
fected.

Before switching off double detection, first try setting TOLERANCE to x2

COARSE.

FEED CLUTCH ~ FEED CLUTCH adjusts the clutch feed length for all bins
during the test set only. Increasing the value will cause the feed wheels 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.

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 3 - About the Machine - Control Panel

The ‘FINISHING’ Window

The FINISHING window controls the settings for the booklet maker and
trimmer.

‘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 RE-REF to re-reference the adjustment
axes. The adjustment axes will return to the current settings once this is
complete.

Periodically the BookMaker 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.

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 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.

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3 - About the Machine - Control Panel

STITCH POSITION: The ON FOLD option produces booklets which are

stitched on the fold line. The ON EDGE option produces sets which are
edge-stitched and folded.

The Stitch Selection Lever on the booklet maker must be in the centre-
stitch position (see p.49).

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: 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
booklet maker will be reduced if the delay is increased.

Watkiss Vario BookMaker Operator Manual 25

 3 - About the Machine - Control Panel

The ‘LOAD & SAVE’ Window

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.

’LOAD & SAVE’ Window.

SAVE ~ Touch SAVE to save the current settings of the BookMaker. When
the on-screen keyboard appears, enter the job name and then touch OK or
CLOSE. The new job will appear in the list of saved jobs. This allows the
settings to be recalled in the future, which saves set-up time.

REPLACE: If an existing job has been loaded and modified, touching

REPLACE will replace the old job with the modified version.

CANCEL: Touch CANCEL if you do not wish to save a job that you have
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.

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3 - About the Machine - Control Panel

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.

A->Z: To list jobs alphabetically, touch A->Z.

BY USE: To list jobs in the order they were last used, touch BY USE. The
job that was run most recently will appear at the top of the list.

The ‘BATCH’ Window

The BATCH window is only available when the BookMaker is operating
offline to the printer.
The BATCH window allows sets to be grouped into batches, with an action
at the end of each batch (stop, pause, oscillate or insert sheets).

‘BATCH’ Window.

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 3 - About the Machine - Control Panel

NUMBER OF SETS ~ Touch NUMBER OF SETS to enter the number of sets in

each batch. Entering 0 on the keypad will turn the batch mode off

Note: A 'set' is a feed cycle. When making booklets from sequentially

printed (i.e. electronically collated) sheets, a 'set' will be a single sheet. In
this case, enter the number of sheets in the document (a gathering station is
required for this application)..

Counts the total number of

sets produced

Counts the number of sets

per batch

Counts the total number of

batches produced

Batch Counter.

INSERTS ~ INSERTS allows sheets from the top bin and/or bottom bin to be
inserted at the beginning or end of each batch.

If the inserted sheet is not part of the job, i.e. it is being used purely as a
batch separator, it can be fed from either the top or bottom bin.

TOP: 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.

When feeding to the rear of the collator, select TOP to feed a sheet from
the top bin with the last set of each batch. The inserted sheet will be at
the top of the batch pile, as the cover sheet for a pad for example.

BOTTOM: When feeding to the front of the collator, select BOTTOM to

feed a sheet from the bottom bin with the last set of each batch. The
inserted sheet will be at the top of each batch pile, as the cover sheet of a
pad for example.

When feeding to the rear of the collator, select BOTTOM to feed a sheet
from the bottom bin with the first set of each batch. The inserted sheet

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3 - About the Machine - Control Panel

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.

If STOP is selected while the machine is part-way through collating a batch,

it will stop once it has completed that batch. This allows the operator to
interrupt a job at a convenient point.

PAUSE / SEPARATE ~ PAUSE / SEPARATE causes the machine to pause for

approximately 5 seconds after each batch. The pause icon on the control
panel will flash between batches.

This function will also separate batches on a booklet maker outfeed con-
veyor. The pause time can be altered on the Machine Options page (touch
MENU, MACHINE OPTIONS).

RESTART BATCH ~ Touching RESTART BATCH zeros the batch counter, so

that you can restart a batch. Note that if the collator is running, this button
will interrupt a batch that is partly completed, and a new batch will be
started.

The ‘FEED’ Window

The FEED window is only available when the BookMaker is operating

offline to the printer.

Watkiss Vario BookMaker Operator Manual 29

 3 - About the Machine - Control Panel

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.

MULTISET ~ MULTISET allows multiple sets to be loaded and counted.

For example, a four part set can be loaded three times in a twelve bin 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.

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3 - About the Machine - Control Panel

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.

Watkiss Vario BookMaker Operator Manual 31

 3 - About the Machine - Friction Feed Bins

Friction Feed Bins

The BookMaker has three bins as standard, which may be Friction or Slim-
VAC suction feed bins. Additional bins can be added if required even after
the machine has been installed.

For operation of SlimVAC bins please refer to “SlimVAC Suction Feed

Bins” on page 36.

Bin Controls and Indicators

Feed bins are numbered from 1 upwards, with the bottom bin being bin 1.
Each bin has its own controls immediately alongside it.

Red light . . . . . . . . . . . . .Indicates a double feed (slow flash indicates the

2 bin sensor is ‘overrange’, see p.35)

Yellow light. . . . . . . . . . .Indicates a miss feed

Red & yellow lights . . . .Indicate a feed jam or trailing sheet

Red button . . . . . . . . . . . .Bin on/off switch

Green light. . . . . . . . . . . .Indicates the bin is switched on
Green flashing light. . . . .Indicates the bin is switched on, but needs loading

Grey button . . . . . . . . . . .Bin linking switch (see p.35)

Small lower green light . .Indicates the bin is linked to the one below.

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.

One B3 (14¼ x 20¼") tray extender is sup-

plied as standard with each Friction bin.

An optional tray extender is available for running A4 portrait (8½ x 11")

Watkiss P/No. 251-303.

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3 - About the Machine - Friction Feed Bins

Loading the Bins. Slide the stock into the bin between the sidelays. Push
in the sidelays to centralise the paper in the bin and so that they hold the
paper securely.

Bin Sidelays

Switching Bins On & Off. Before a test set is produced, individual bins
will automatically switch on and off as they are loaded and unloaded. Bins
can also be manually selected by pressing the red button alongside the bin.
In addition, loading the Default Template will switch on all loaded bins.
Remember that bins cannot be switched on or off when the system is locked
(touch END JOB if necessary).

Adjustments
Adjustments for paper type and/or size include control over the amount of
tray pressure and the amount of separator pressure.

Separator Pressure. Increasing the separator pressure acts like a brake,

making it more difficult for a second sheet of paper to pass the separator
pad. Too little separator pressure will result in double feeds, too much will
result in miss feeds or damage to the feed edge of the paper.

The ideal separator pressure will depend upon the stock in use. Initially set
the lever to its mid-position. To increase separation, move the lever down-
wards one notch at a time, and to decrease separation move the lever
upwards one notch at a time.

Moving the lever to its highest position disengages the separator. This posi-
tion is used for the improved feeding of heavy cardstocks.

Watkiss Vario BookMaker Operator Manual 33

 3 - About the Machine - Friction Feed Bins

Tray Pressure. Increasing the tray pressure gives the feed wheels greater
force on the paper; too much will result in double feeds and increases the
possibility of scuffing the paper.

Tray Pressure
Separator Pressure
Adjustment Adjustment

The ideal pressure will depend upon the stock in use. Always use the least
pressure possible. The lever has five positions and is adjusted by gently
pushing downwards whilst sliding the lever in or out. The innermost posi-
tion gives minimum pressure. Initially set the pressure to minimum for
small stock. For large sheets (i.e. if tray extenders are used) initially posi-
tion the lever one notch out.

Air Separation. Air directed from the right hand sidelay is used to separate
the top sheets of paper in the stack. The overall air level is adjusted if
required by altering the AIR BLOW value, in the BASIC window (see p.20).
The air level is also adjustable on each individual bin via a tap on the right
hand sidelay.

The tap on the sidelay controls the air level into the side of the paper stack.
The tap has three positions. The default position is 90° to the sidelay which
provides 100% air. Moving the lever one notch towards you provides 50%
air. Moving the lever towards you so that it is parallel with the sidelay shuts
off the air.

Air Separation
Adjustment

Too much air into the side of the stack can cause the paper to skew as it
feeds. Any bins that are not being used should have the air tap shut off on
the sidelay to preserve overall system air. Remember to open the tap when
the bin is next used.

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3 - About the Machine - Friction Feed Bins

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 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 BookMaker
online).

If the system is locked, pressing the grey button on any bin will indicated
which bins are in the same linked group.

Sensor Overrange
Sensor overrange is indicated after the test set by a slow flashing red light
on the bin in question.

Particularly heavy or opaque stock may cause the bin sensor to go ‘over-
range’. This means that the sheet is too optically dense for the sensor to
‘see’ through it. Double feeds will not be detected but misses, trailing
sheets and jams will be detected as normal.

Watkiss Vario BookMaker Operator Manual 35

 3 - About the Machine - SlimVAC Suction Feed Bins

SlimVAC Suction Feed Bins

The BookMaker has three bins as standard, which can be a combination of

Friction and SlimVAC bins. Additional bins can be added if required even
after the machine has been installed.

For operation of Friction bins please refer to “Friction Feed Bins” on

page 32.

Bin Controls and Indicators

Feed bins are numbered from 1 upwards, with the bottom bin being bin 1.
Each bin has its own controls immediately alongside it.

Red light . . . . . . . . . . . . .Indicates a double feed (slow flash indicates the

2 bin sensor is ‘overrange’, see p.39)

Yellow light. . . . . . . . . . .Indicates a miss feed

Red & yellow lights . . . .Indicate a feed jam or trailing sheet

Red button . . . . . . . . . . . .Bin on/off switch

Green light. . . . . . . . . . . .Indicates the bin is switched on
Green flashing light. . . . .Indicates the bin is switched on, but needs loading

Grey button . . . . . . . . . . .Bin linking switch (see p.39)

Small lower green light . .Indicates the bin is linked to the one below.

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.

One B3 (14¼ x 20¼") tray extender is sup-

plied as standard with each SlimVAC bin.

An optional tray extender is available for running A4 portrait (8½ x 11")

Watkiss P/No. 251-303.

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

36 Watkiss Vario BookMaker Operator Manual

3 - About the Machine - SlimVAC Suction Feed Bins

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.

Loading the Bins

Place a full stack of paper between the two sidelays in the base of the tray.
Maximum capacity is achieved when the paper is slightly below the top of
the sidelays. Slide the sidelays inwards to centralise the paper.

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”).

Note: When using the BookMaker to collate small sheet sizes, make
sure the tray loaded sensor is not covered by the rubber endlay.

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.

Watkiss Vario BookMaker Operator Manual 37

 3 - About the Machine - SlimVAC Suction Feed Bins

Switching Bins On & Off

Before a test set is produced, individual bins will automatically switch on
and off as they are loaded and unloaded. Bins can also be manually selected
by pressing the red button alongside the bin. In addition, loading the
Default Template will switch on all loaded bins. Remember that bins cannot
be switched on or off when the system is locked (touch END JOB if 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

Sheet Corrugation. The profile of the suction

feeder can be adjusted to provide varying
amounts of corrugation in the sheet. Greater
corrugation gives greater separation; less cor-
rugation gives less separation.

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.

Feeder Angle. The angle between the feeder

and the paper can be adjusted to allow the
feeding of particularly heavy and/or curled
stocks.

Adjustment is made using the knob on the left

hand side of the suction feeder. Turning the

38 Watkiss Vario BookMaker Operator Manual

3 - About the Machine - SlimVAC Suction Feed Bins

knob one stop in either direction has the effect of raising or lowering the
outer edge of the feeder. Continuing to turn the knob will alternate between
the two positions. The default position is down.

Tray Height. The tray height is adjusted via

the lever on the SlimVac bin controls. Moving
the lever downwards progressively lowers the
paper tray. This increases the distance between
the top of the paper stack and suction feeder,
and also simultaneously adjusts the flow angle Tray Height
Adjustment
of the air separation.
Lever

The default position for the lever is the mid

position which should be suitable for the
majority of stock ranges.

Note: When lowering the tray height, the change will only take effect
the next time the tray raises (i.e. after reloading or restarting).

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 BookMaker 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 BookMaker
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.

Watkiss Vario BookMaker Operator Manual 39

 3 - About the Machine - SlimVAC Suction Feed Bins

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 following suggested settings are a recommendation only. Paper charac-

teristics vary and therefore any particular stock may require settings differ-
ent to those shown.

Paper Condition Recommended Settings

Standard Settings

• Suction Feeder angled down

• Tray height in mid-position
• Sheet corrugation in mid-position

Heavy or Rigid Stock

Heavy or rigid stock or board may be
unable to bend sufficiently to meet the
suction feeder in its lower position.

• Raising the angle of the suction feeder reduces

the feed angle
• Raise the tray height
Stock Curling Down

The stock is too close to the feeder for air

to get in between the sheets. • Lowering the tray height will increase the space
between the feeder and the sheets
• If necessary, increase the feeder angle also

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 3 - About the Machine - SlimVAC Suction Feed Bins

Paper Condition Recommended Settings

Stock Curling Up

The upward curl means the tray height

detector will ‘see’ the paper before it is
close enough to the feeder.

• Raise the tray height to lift the paper stack

closer to the feeder
Lightweight Porous Papers

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

Watkiss Vario BookMaker Operator Manual 41

 3 - About the Machine - Connecting Bridge

Connecting Bridge

The Connecting Bridge links the printer to the Vario BookMaker. As each
sheet is printed, the connecting bridge transports it from the printer to the
BookMaker.

Raising and Lowering the Bridge

The bridge can be raised or lowered (depending on printer type) to allow
greater access to the printer, or when using the Vario BookMaker offline. It
must always be in its operating position (i.e. horizontal) when using the
Vario BookMaker online to the printer.

Connecting Bridge Lid

Outfeed Safety Cover

Paper Width Adjustment Scale

Paper Transport Area

Paper Width Adjustment

Wheel
Bridge Raising/Lowering
Handle

Paper Width Adjustment

The width of the paper transport must be adjusted to suit the paper size. A
hand wheel on the underside of the bridge adjusts the position of the paper
transport sidelay. The sidelay should be adjusted so that it corresponds with
the correct point on the scale.
A3 and A5 sheets are printed and transported in portrait orientation.

A4 sheets, which are printed in landscape orientation, are rotated in the

Bridge so that they enter the Gathering Station in portrait orientation. This
is the normal orientation for booklet making.

Glossary: ‘Portrait’ means that the short edge of the sheet is leading.
‘Landscape’ means that the long edge of the sheet is leading.

Note: If you want A4 sheets to be delivered into the Gathering Station

in landscape orientation, set the Bridge width adjustment to A3. This
will prevent the sheets from being rotated.

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3 - About the Machine - Connecting Bridge

• If the paper transport is set too narrow, paper jams will occur in the con-
necting bridge
• If the paper transport is set too wide, the sheets will be untidy in the
gathering station, resulting in untidy booklets

Opening the Connecting Bridge

The lid of the connecting bridge can be raised to gain access inside. This
may be necessary for better visibility when adjusting the paper transport
sidelay, or for clearing paper jams.

Caution: Ensure the lid of the Connecting Bridge is closed before the
Bridge is raised or lowered. Failure to do so may result in damage to the
Vario BookMaker.

The Outfeed Safety Cover can also be removed. This operates a safety
switch and must be in place for the Vario BookMaker to run.

Watkiss Vario BookMaker Operator Manual 43

 3 - About the Machine - Gathering Station

Gathering Station

The Gathering Station holds the sheets fed from the printer and the feed
bins until the set is complete. The set is then released into the booklet
maker.

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 booklet maker) and one smaller socket that is Used Finishing
currently not used.

Sheet Length Adjustment

Select the correct paper size using the two levers on the front of the Book-
Maker (see below). For non-standard paper sizes, use the setting for the
next largest standard paper size.

A3 A4 A5

Sheet Length
Adjustment

Sheet Width Adjustment

Insert a few sheets from the job in between the sidelays.Turn the thumb-
wheel until the marker aligns with the correct point on the scale. Firmly

44 Watkiss Vario BookMaker Operator Manual

 3 - About the Machine - Gathering Station

push the sidelays inwards to check the tamper position, they should just
touch the paper. Make further adjustment if necessary.

Static Elimination Bar

Gathering Station
Sheet Length Adjustment Air Blow Adjustment

Sidelay
Sheet Width Adjustment

Bypass Gate

Interface Sockets
(Hidden)

Air Blow Adjustment

An air jet is used to prevent sheets in the gathering sta-
tion from curling forwards. This can be adjusted using
the air blow adjustment tap on the side of the gathering
station.

Manual Bypass Gate

When the gathering station releases the sheets, they are delivered into the
booklet maker. To bypass the booklet maker, pull out the manual bypass
gate and the sheets will be delivered out of the front of the gathering station,
above the booklet maker. This is useful to avoid wasting sheets during the
test set.

Note: The manual bypass gate only works when the BookMaker is
already running. Start the machine first, and then pull it out.

Watkiss Vario BookMaker Operator Manual 45

 3 - About the Machine - Booklet Maker & Trimmer

Booklet Maker & Trimmer

The booklet maker and trimmer staple, fold and trim the printed sheets to
form a booklet. Finished booklets are delivered onto the outfeed conveyor.

The booklet maker fits underneath the Vario BookMaker tower. It is wheel-
mounted and can be pulled in and out when required.

Opening the Booklet Maker & Trimmer

Access to the inside of the booklet maker is necessary for changing the sta-
ple cartridge, adjusting the staple heads, and clearing paper jams. Access to
the inside of the trimmer may be necessary for clearing paper jams.

The booklet maker and trimmer lids incorporate safety switches which
automatically cut the power when the lid is opened.

The booklet maker lid can be opened by turning the handle to the left and
lifting. The lid is supported by a strut on the right side.

Support Strut

To close the booklet maker lid, lift it slightly, push the support strut inwards
and close the lid. Turn the handle to the right to lock in place.

The trimmer lid can be opened by lifting the orange hand screw.

Orange Hand Screw for Opening

the Trimmer Lid

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3 - About the Machine - Booklet Maker & Trimmer

Connecting the Booklet Maker & Trimmer

The booklet maker and trimmer will be connected together when the Book-
Maker is installed. However, it may be necessary to separate them when
moving the units or when clearing paper jams.

Disconnecting the Booklet Maker and Trimmer. Open the booklet

maker lid. Disconnect the communications and power cables and wheel the
booklet maker and trimmer units apart.

Connecting the Booklet Maker and Trimmer. Line up the trimmer dock-
ing plates with the booklet maker. Re-connect the power and communica-
tions cables to the sockets on the booklet maker.

Communications
Cable
Power Cable

Docking
Plate

Push the two units together so that the hooks on the trimmer docking plates
align with the holes in the booklet maker side plates.

Close the booklet maker lid and turn the handle to the right to lock the trim-
mer in place.

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 3 - About the Machine - Booklet Maker & Trimmer

Starting and Stopping the Booklet Maker

The booklet maker and trimmer automatically start and stop when required.
After the BookMaker stops, there is a delay of approximately 10 seconds
before the booklet maker stops.

For an immediate stop, either press the Emergency Stop button, or open the
lid on either the booklet maker or trimmer.

Tip: If you need to start the booklet maker and trimmer without starting
the BookMaker, touch INCH. It will automatically shut down 10 seconds
after its last action.

Status Indicator Light

The yellow indicator light on the top left surface of the booklet maker
shows the status of the unit.

Indicator Light Mode Booklet Maker Status

Blinking once per second The unit is ready to run

Constantly illuminated The unit is running
Blinking rapidly There is a jam or other error
Not illuminated Booklet maker or trimmer lid is open,
paper is stuck in the paper path or the
unit is not switched on

Staple Head Indicator Lights

The red indicator lights on the booklet maker lid show the status of the cor-
responding staple head.

Indicator Light Mode Staple Head Status

Blinking once per second The staple cartridge is about to or has run out
Constantly illuminated The staple head is selected and ready to run
Blinking rapidly There is a staple head jam or other error
Not illuminated The staple head is not selected

Refer to “Changing the Staple Cartridge” on page 63 for details on chang-

ing the staple cartridge.

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 3 - About the Machine - Booklet Maker & Trimmer

Adjustment for Paper Size

Adjustment for paper size is made on the GUI (Graphical User Interface).
• Touch FINISHING to display and adjust the booklet maker settings
• Touch PAPER SIZE, PRESETS and select a standard sheet size - A3, A4
or A5 (11x17", 8.5x11" or 5.5x8.5")
• Choose PORTRAIT or LANDSCAPE in the PAPER SIZE, PAGE DIRECTION
window
• For non-standard paper sizes, touch PAPER SIZE and then use the ‘+’
and ‘-’ keys to set the size

Note: PORTRAIT is the normal setting for booklet making.

Tip: Remember that you can recall the settings from previously stored
jobs in the LOAD & SAVE window.

Select Edge or Centre Stapling

Use the Edge/Centre Staple Selection Lever to select centre staple operation
(lift up) or side/corner staple operation (push down).

Edge/Centre Staple Selection Lever

Staple Head Selection

Staple Head
Indicator Light
Staple
Head Centre
Select Staple

Edge
Staple

When edge or corner stapling, the staples will be inserted into the feed edge
of the sheet.

Note: The maximum sheet width that can be edge or corner

stapled is 250mm, 9.8". If the sheet width exceeds this, the top
jog is automatically switched off and may not give satisfac-
tory results.

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 3 - About the Machine - Booklet Maker & Trimmer

Third Staple Head Kit

The booklet maker has two staple heads as standard. A third head can be
specified as an option, to enable corner stapling (Watkiss part number 914-
414).

Optional Third Staple Head

for Corner Stapling

Edge Stitch Assistor

When edge or corner stapling only a few sheets, it is possible for the thin
sets to jam in the booklet maker. In this case, the Edge Stitch Assistor
should be fitted. This is supplied as part of the optional third staple head kit,
or can be ordered as an accessory (Watkiss part number 907-442).

Tabs

Locating Pins

Fitting the edge stitch assistor. To fit the edge stitch assistor, open the
booklet maker lid. Hold the assistor with the locating pins facing down-
wards, and slide the tabs under the staple clinchers. Make sure the assistor
is positioned squarely and then press down until it clicks into place (see
below).

Clincher
Edge Stitch Assistor
in place

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3 - About the Machine - Booklet Maker & Trimmer

Engage the Edge Stitch Drive

Open the staple panel. Unhook the orange edge stitch tyres from their
retaining position, and place into the grooves on the top jog pulley control
discs, on either side of the belt.

Orange Edge Stitch Tyres

in their retaining position.

Orange Edge Stitch

Tyres in their grooves.

Close the staple panel and place the edge stitch selector lever to the edge
stapling position.

Note. When returning to booklet making, the orange edge stitching tyres
MUST be removed from the belt control discs and returned to their
retaining position. Leaving the tyres on the belt control discs during
booklet making will result in jams in the booklet maker.

Edge Stapling & Folding

If required, it is possible to edge staple the set and then fold it. The only
limitation to this is that the distance from the stapled edge to the fold must
be at least half the width of the paper.
• Set STITCH POSITION to ON EDGE from the STITCH AND FOLD window
• Lift the Edge/Centre Staple Selection Lever up to select centre stapling
(NOT edge stapling)

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 3 - About the Machine - Booklet Maker & Trimmer

Select the Staple Heads

Use the Staple Head Selection Button to select which staple heads are
active. For bookletmaking, the two centre staple heads should be used. Cor-
ner stapling is only possible if the optional third staple head is fitted. The
staple head indicator lights show which heads are selected.

Staple Head Position

The staple heads have two positions. Normally the heads should be in the
outer position (138mm, 5.4" between staple centres). For small booklets the
inner position can be used (115mm, 4.5" between staple centres).

To adjust, move the staple head adjustment lever to the right to select the
inner position.

Staple Head Adjustment Lever

Clincher

Adjust the clinchers to suit by loosening the orange hand screw and sliding
the clincher fully across in the required direction. Tighten the hand screw.

Orange Hand Screw

Clincher

Note: You may need to increase the infeed sidelay gap in order to
access the hand screws. Do this by touching FINISHING, PAPER SIZE and
then increasing the sheet width.

Caution: Before placing your hands inside the booklet maker, you
should disconnect the unit from the mains electricity supply.

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3 - About the Machine - Booklet Maker & Trimmer

Fold Roller Gap Adjustment

The fold rollers should be set sufficiently close together to produce a neat
booklet. If the fold rollers are set too close together, the booklet covers may
be pulled (resulting in damage around the staples) or the spine of the book-
lets may be scuffed.

The gap between the fold rollers is adjusted using a lever to the left of the
front face of the booklet maker.

Fold Roller Adjustment Lever

The lever has 11 positions. To move the fold rollers further apart (i.e. for
larger sets or heavier stock) move the lever upwards. Move the lever down
to bring the fold rollers closer together.

When edge stapling, the fold rollers should be fully open, i.e. the lever
should be fully upwards.

Outfeed Conveyor Adjustment

Slide the large payout wheels up or down their mounting rail so that they
are just nipping the spine of the book when it is released from the rollers.
Use the scale on the outfeed as a guide.

Scale

Payout
Wheels

Tip: Common sizes are highlighted on the scale. For example for an A5
(5½ x 8½") book, use the A5 marker.

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 3 - About the Machine - Booklet Maker & Trimmer

Trimmer Offcut Box

The trimmer offcuts are delivered into the trimmer offcut box. This box
hooks onto the trimmer.

Offcut Box

Remember to empty the trimmer offcut box periodically.

There is a sensor on the trimmer to detect when the offcut box is full. Once
this sensor is activated, the booklet maker will beep after every second
booklet produced.

Trim Margin
If you are inserting sheets from a Friction bin, which have been printed off-
set litho, we recommend that the job be printed with a 12mm trim margin
on the feed edge and a smaller (perhaps 3-5mm) trim margin on the trailing
edge. In this way any marking that could possibly occur due to wet ink or
ink rub will always be in the trim margin.

54 Watkiss Vario BookMaker Operator Manual

3 - About the Machine - Front Outfeed Conveyor

Front Outfeed Conveyor

The front outfeed conveyor is an optional module. It facilitates the delivery

of sets from the gathering station into either a straight jogger or an X-jog-
ger.

Tie Bar

Front Outfeed

Paper Guide

X-Jogger

Attaching the Front Outfeed Conveyor. When attaching the front out-
feed conveyor, ensure that you slide it into the small gap between the colla-
tor base and the gathering area. This is to support the rear of the outfeed.

Gap

Rear of Outfeed

Once in place, clip the locating hooks over the tie bar.

Tie Bar

Locating Hooks

Caution. Before letting go of the front outfeed conveyor, ensure that the
rear end is being supported, if not it will swing down.

Watkiss Vario BookMaker Operator Manual 55

 3 - About the Machine - Front Outfeed Conveyor

Attach the outfeed earth wire to the connector on the side of the base.

Paper Guide

Earth Wire Connector

Paper Guides. Clip a paper guide onto the tie bar.

There are two paper guides provided with the front outfeed (short and
standard). The choice of which guide to use is dependent upon paper size
and orientation. The guide should be positioned to control the set as it is
delivered into the jogger.

Caution. When the BookMaker is to be used with a booklet maker, the

front outfeed conveyor must be removed first.

56 Watkiss Vario BookMaker Operator Manual

3 - About the Machine - Joggers

Joggers

Two types of jogger are available as optional modules. The X-Jogger

straight or offset stacks whilst the Straight Jogger is used when set separa-
tion is not required.

If a jogger is to be used, the front outfeed conveyor must be fitted (see p.55)

X-Jogger
Setting Up the Jogger. Position the X-Jogger under the collator, so that the
back edge of the stack is level with the front outfeed, as shown. Connect the
jogger to the mains supply and switch on.

The X-Jogger with A3 (11 x 17”) Paper

Plug the jogger into the socket on the underside of the floor base via the
interconnection cable. The cable will only fit in to one of the sockets.

Take a few sheets of the stock to be collated and place them in the stacker
offset by 20°. Use the hand wheel to adjust the sidelays to suit the width of
the stack.

Adjust the bottom sidelay so that the middle of the sheet is over the middle
of the stacker tray. You can check this by folding a sheet in half (as dotted
line in photo) and checking that the fold on the left and right edge is equal
distances (’X’) above and below the angle in the sidelays.

Paper Guide

X Width Adjustment
X Support Post

Bottom Sidelay Adjustment

The X-Jogger with A4 (8½ x 11") Paper

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 3 - About the Machine - Joggers

Adjust the position of the support posts by twisting anti-clockwise to

release, sliding to about 5mm (¼") from the edge of the stack and then re-
tightening.

Adjust the position of the X-Jogger itself, moving it further in or out so that
the paper falls neatly into the receiving area.

Select OSCILLATE in either the BASIC or BATCH menu (if required) from the
control panel menu and run a test set.

If needed, fine-adjust the position of the sidelays and support posts to

achieve a neat stack.

Jogging Adjustment. If necessary, adjust the amount of vibration via the

knob on the top of the motor housing (just above the mains On/Off switch).
Use the minimum amount of vibration that will successfully jog the stack.

Straight Jogger

Setting up the Jogger. Place the Straight Jogger in a central position under
the collator. Ensure the local control switch is in the off position (green strip
not visible). Connect the jogger to the mains supply and turn on the red
mains on/off switch.
Jogger ‘full’ Sensor

Jogging Adjustment

Mains Input
Local Control Switch
Height Adjustment
Release Lever Mains ON/OFF Switch

Plug the jogger into the socket on the underside of the floor base via the
interconnection cable. The cable will only fit in one of the sockets.

Run a test set and if necessary, adjust the position of the jogger. Move it fur-
ther in or out so that the paper falls neatly into the receiving area. A side-
ways positional adjustment may also be necessary depending on the size of
the paper and type of stock. The height of the jogger can be adjusted by
releasing the height adjustment release lever.

Jogging Adjustment. If necessary, adjust the amount of vibration via the

knob on the side of the jogger (as shown above). Use the minimum amount
of vibration that will successfully jog the stack.

58 Watkiss Vario BookMaker Operator Manual

CHAPTER 4 Maintenance

Service Interval
It is recommended that your BookMaker is serviced by an approved Watkiss
engineer at six month intervals. Please contact your Watkiss supplier or the
manufacturer for further details.

Operator Maintenance
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 BookMaker will benefit from periodic cleaning
of general accumulations of paper dust, ink etc.

Watkiss Vario BookMaker Operator Manual 59

 4 - Maintenance -

Cleaning Materials
The BookMaker 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, perchloroethyl-
ene 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.

Light pressure with a suitable cloth should be sufficient to remove finger-

prints. Do not use excessive force.

Static Elimination Bar

The static elimination bar is located in the gathering station.

Caution: Disconnect the machine from the mains electricity supply

before cleaning the static elimination bar.

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 4 - Maintenance -

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.

Static Elimination Bar

Friction Feed Bins

Paper Separators (P/No 909-485). There is one paper separator located in

the centre of each friction feed bin. It slots into the aluminium pick-up
manifold immediately beneath the central feed wheel. They should be
cleaned if dirty and replaced when worn. The replacement interval will
depend upon the usage level and the type of papers used.

Paper Separator

• Remove the feed wheel shaft by pushing it to the left against the spring
pressure and lifting the right end clear
• Locate the separator and lift it out vertically
• Clean or replace the separator as required. When cleaning the separator
use only soap and water or alcohol (isopropanol). Refit the separator and
ensure that it seats firmly in the correct position
• Refit the feed wheel shaft

Feed Wheels (P/No. 330-301). The friction feed bins are fitted with three
feed wheels (B) mounted on a shaft. They should be cleaned if dirty and
replaced when worn. The replacement interval will depend upon the usage
level and the type of papers used.

B • Remove the feed wheel shaft by pushing it to the left against the spring
pressure and lifting the right end clear. Clean the wheels using only soap
and water or alcohol (isopropanol)

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 4 - Maintenance -

• If the wheels need to be replaced, grasp the shaft firmly and slide off
each wheel (this will be eased by wetting the shaft slightly)
• Ensure the shaft is clean, and slide on each new wheel, ensuring that the
wheels align with the correct marks on the shaft. The standard position
for the wheels is shown below

• Replace the shaft

• Select CLEANING in the MENU, USER SETTINGS window and press the
red button on the bin controls to turn the feed wheel shaft. Visually
check that each wheel runs true. To straighten a wheel, gently hold a flat
edge against the wheel whilst it turns

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4 - Maintenance -

Booklet Maker and Trimmer

Changing the Staple Cartridge

When a staple cartridge runs out, the corresponding red indicator light will
blink once per second. The message STAPLES LOW will also be shown on
the BookMaker control panel.

New cartridges are available from your Watkiss supplier (Watkiss P/N 810-
022).

To change a cartridge, first open the booklet maker lid by turning the handle
to the left and lifting. The lid is supported by a strut on the right side.

Indicator Light

Grasp the cartridge at the top and pull directly away from the staple head, as
shown by the arrow in the photo.

Staple Cartridge

Staple Head

Fit the new cartridge and check machine operation by making a few test
booklets.

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 4 - Maintenance -

Staple Position Adjustment

If both staples are consistently off the spine of the book, first ensure that the
booklet maker is adjusted correctly and that delivery into the unit is good. If
the problem persists, fine tuning of the staple position may be necessary.

Tools Required. Flat Blade Screwdriver.

Adjustment is via the central screw on the fold plate mechanism, located
behind the perspex cover.

Fold Position
Fine Tuning

In the FINISHING window, set PRESETS to A3 or 11x17" (regardless of

booklet size). The screws will now align with the holes in the perspex
cover. Using a flat blade screwdriver, loosen the two locking screws .

Turn clockwise to lower

the staples

Locking Screw

Fine Adjustment
Screw

Locking Screw
Turn anticlockwise to
raise the staples

Turn the fine adjustment screw clockwise to lower the position of the sta-
ples (as viewed when the book exits the unit) and anticlockwise to raise the
staples. One quarter turn of the screw equates to approximately 2mm of
travel.

Tighten the locking screws and produce a test booklet. Repeat the proce-
dure if necessary.

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4 - Maintenance -

Conveyor Clamp Adjustment

The trimmer conveyor clamps are set to a default position at the factory,
which gives a good trim over a wide variety of booklet thicknesses.

However, when trimming unusually thick or thin booklets, the conveyor

clamps may need to be adjusted. This will be necessary if the following
problems arise:
• Booklets are trimmed out of square
• Booklets are trimmed too short
• The cover of the booklets are pulled, resulting in damage around the sta-
ples

Tools Required. 4mm Allen Key, 2 off 150mm/6" Rule.

Select A4 or 8.5x11" in the FINISHING, PAPER SIZE window (regardless of

the booklet size). Once the bookmaker beeps to confirm it is ready, discon-
nect it from the mains electricity supply.

Open the trimmer lid by lifting the orange hand screw.

Trimmer Lid

There are two clamp roller shafts, which are adjusted using a 4mm allen
key.

Adjustment Adjustment
Screw Screw

Clamp Roller Clamp Roller

Shaft Shaft

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 4 - Maintenance -

Adjusting the Conveyor Clamps.

• Turn the adjustment screws clockwise to increase the gap (reducing
clamp pressure)
• Turn the adjustment screws anti-clockwise to reduce the gap (increasing
clamp pressure)

Checking the Adjustments. It is important that both clamp roller shafts

are adjusted to the same height. The factory default is 17mm between the
top of each shaft and the top of the wire frame.

Lay the first rule across the wire frame, so that it is above the clamp roller
shaft.

Using the second rule, measure the height from the top of the shaft to the
bottom of the first rule.

Adjust the shafts as necessary and re-measure to ensure they are both set to
the same height.

Wire Frame

Second Rule

First Rule
Clamp Roller Shaft

Restarting the Job. Before restarting the job, reset the paper size as neces-
sary.

Note: It is important to return both clamp roller shafts to the factory

default height of 17mm before booklets of a more typical thickness are
produced.

Fold Roller and Conveyors

Build up of dust or dirt on the fold rollers and conveyor belts will eventu-
ally cause slippage or ink transfer. They should therefore be cleaned period-
ically.

Warning: Access to the manual cranking points on the booklet maker

and trimmer requires the side covers to be removed. For safety reasons
this procedure should therefore only be conducted by authorised person-

66 Watkiss Vario BookMaker Operator Manual

4 - Maintenance -

nel. Disconnect the power before removing the side covers. At all times
keep your hands away from the blade area of the trimmer.

Booklet Maker. To clean the rollers and belts on the booklet maker, first
remove the right hand side cover (two x M5 button screws) to give access
to the manual cranking point.

M5 Button Screw Right Hand Side Cover

Open the booklet maker lid to access the fold rollers. Using a 10mm A/F
spanner (wrench), manually crank the booklet maker by turning the nut
clockwise, and clean the rollers and belts with a cloth dampened with soap
and water or alcohol (isopropanol). Do NOT use blanket wash or other
chemicals.

Manual Cranking Point

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 4 - Maintenance -

Trimmer. To clean the belts on the trimmer, first remove the left hand side
cover (two x M5 button screws) to give access to the manual cranking
point.

Orange Hand Screw

Trimmer Lid

Left Hand Side Cover

M5 Button Screw

Open the trimmer lid, and using a 19mm A/F spanner (wrench), manually
crank the trimmer by turning the nut clockwise, whilst cleaning the belts
with a cloth dampened with soap and water or alcohol (isopropanol). Do
NOT use blanket wash. or any other chemicals.

Manual Cranking
Point

Sharpening the Trimmer blade

Periodically all trimmer blades will require re-grinding. Poor grinding will
result in poor life, cracks and nicks in the blade. We therefore offer the
guidelines on p.72 which should accompany the blade and anvil when they
are sent for re-grinding. Your Watkiss engineer will arrange regrinding for
you if required.

Whenever the trimmer blade is re-ground, check the condition of the anvil
also. This will only require re-grinding if it has become damaged.

Warning: This procedure is potentially hazardous and should only be

conducted by suitably skilled personnel. Disconnect the power before
removing the conveyor assembly. Handle the blade with extreme caution
and keep hands clear of cutting edges at all times.

Tools Required. 3mm Allen Key, 4mm Allen Key, 6mm Allen Key, 10mm
Allen Key, 19mm Spanner.

68 Watkiss Vario BookMaker Operator Manual

4 - Maintenance -

The trimmer blade and anvil are located behind the conveyor assembly at
the docking end of the unit.

Trimmer
Lid

Conveyor Assembly

Separate the trimmer from the booklet maker. Open the trimmer lid.
Remove the two M5 button screws and washers that secure the conveyor
assembly to the trimmer unit.

M5 Button
Screws

Lift away the conveyor assembly to reveal the blade assembly.

Anvil

Blade Mark Along Here

Important: Note the angled position of the trimmer blade and with a
marker pen or similar, mark along the bottom edge of the blade. This
will act as a guide when refitting

Removing the Trimmer Blade. Slightly loosen all five blade fixing
screws. Remove the outer two screws and screw them into the locator

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 4 - Maintenance -

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. Carefully check the anvil for any damage. If it requires
re-grinding, remove the five fixing screws and lift away.

Refitting the Blade and Anvil. Slacken the anvil adjuster screws back two
revolutions. Position the anvil fully back towards the conveyor and lightly
tighten the anvil fixing screws. Affix the blade using the five blade fixing
screws but do not tighten. Using the mark made when the blade was
removed, adjust the angle of the blade. Ensure that it does not protrude
above the clamp at point ‘A’ or below it at point ‘B’. Lightly tighten the
centre screw, sufficient to hold the blade in this position.

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4 - Maintenance -

Remove the left hand trimmer side cover (two x M5 button screws and
washers). Release the clutch by depressing the lever (see below) through
the access hole in the side plate.

Manual
Crank Drive

Access Hole

Use a 19mm spanner to manually crank the unit until the blade is at top
dead centre. At point ‘C’ the blade must pass the anvil by 1mm (1/25").
Make fine adjustments to the position if necessary. Tighten all the blade fix-
ing 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. Release the clutch and manually crank slowly several
rotations. Check that the blade passes the anvil smoothly without obstruc-
tion.

Place a single sheet of paper (large sheet size) between the blade and the
anvil and manually crank to produce a test cut.

Warning: Ensure that hands are kept clear at all times

Check that a clean cut is obtained across the full width of the blade. If nec-
essary loosen the anvil fixing screws at the point where adjustment is
needed, apply additional pressure to the anvil adjusting screws (1/6th turn
at a time) and re-tighten the anvil fixing screws.

Perform another test cut and make further adjustments if necessary.

Hook the conveyor assembly onto the support posts and push into position.
Secure with two M5 button screws and washers. Fit the side cover and
secure.

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 4 - Maintenance -

Trimmer Blade Grinding Specification

Blade Material High Carbon High

BLADE ANVIL Chrome (Aisi D2/
Note: 2 faces Note: 2 faces D3)
must be flat to must be flat to
within 0.03mm. within 0.01mm. Grinding Angle See drawing along-
side
Grinding Wheel Cup or Cylinder
Grinding Material Grit : 46-60
Hardness : G-H
Bond : Vitrified
Peripheral Speed of 20-26 (V M/S)
the Grinding Wheel 65-85 (V Ft/S)
Table Speed 20-26 (V M/Min)
65-85 (V Ft/Min)
This edge must Feed Per Pass 0.01 - 0.02mm
be straight to
within 0.04mm. 0.0004 - 0.0008"

Important:
Grind In This
Direction Only

Honing
After re-grinding, the burr should be carefully removed by honing. The
quality of honing affects the useful life of the cutting edge.

Correct Incorrect

72 Watkiss Vario BookMaker Operator Manual

CHAPTER 5 Problem Solving

This chapter explains how to resolve any problems that may occur with your
BookMaker System. If a problem persists, please call the Watkiss Service
Department or your Watkiss Dealer.

If the BookMaker System is switched off:

(Océ 31x5 and 84x5 only)
The BookMaker and printer are electronically linked. In some circum-
stances, if the BookMaker is non-operational or it is switched off, the printer
cannot run and the control panel will display “Solve the off-line finisher
problem”.

To use the printer under these conditions, a bypass plug must be fitted to the
9-way D-type socket on the printer. This plug is supplied with the Book-
Maker.

Reference. Watkiss Part Number 905-367, Océ 31x5 Offline Plug

Watkiss Vario BookMaker Operator Manual 73

 5 - Problem Solving - Trouble Shooting Chart

Trouble Shooting Chart

As far as possible the BookMaker has been designed to be self-explanatory.

In most cases problems or errors will be identified on the control panel.
This trouble shooting chart provides a further guideline to help solve any
problems.

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.84)
THE MACHINE WILL NOT Several possible causes, exact Correct any faults shown on
START cause will be shown on the the display
display
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.
DOUBLE FEEDS ARE NOT The bin sensor is ‘overrange’ N/A
BEING DETECTED due to the feeding of particu-
larly heavy or opaque stock.
The red light on the bin con-
trols will flash slowly when
the sensor is overrange
Detector Position tolerance is Set TOLERANCE to x1 NOR-
set to x2 Coarse MAL in the ADVANCED,
DETECTOR POSITION window

Double Detection is not Set DOUBLE DETECTION to ON

selected in the ADVANCED, DETECTOR
POSITION window

74 Watkiss Vario BookMaker Operator Manual

 5 - Problem Solving - Trouble Shooting Chart

Gathering Station Problems

Problem Cause Solution

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.44)
Sheets are falling forwards in Adjust the air blow (see p.45)
the gathering station
POOR FEEDING INTO The static elimination bar is Clean the static elimination
BOOKLET MAKER dirty, reducing effectiveness bars (see p.60)
and causing the back sheet(s)
of the book to cling to the
gathering station as they are
released
The static elimination equip- Ensure the machine is
ment is not enabled causing switched on and the emer-
the back sheet(s) of the book gency stop button is not
to cling to the gathering sta- engaged. Look through the air
tion as they are released vent at the rear of the drive
unit, the red switch on the
black transformer should be
illuminated. If not, contact
your authorised distributor.

Watkiss Vario BookMaker Operator Manual 75

 5 - Problem Solving - Trouble Shooting Chart

Booklet Maker and Trimmer Problems

Problem Cause Solution

If you suspect the booklet maker adjustment system is not calibrated correctly, touch RE-
REF in the PAPER SIZE window to manually recalibrate the booklet maker adjustment axes.
After recalibration, the booklet maker adjustment axes will return to the current settings. If
the BookMaker’s software detects a possible axis positional fault, the unit will automati-
cally recalibrate the axes.

Operational Problems

BOOKLET MAKER WILL The booklet maker is not Plug into mains connection
NOT START plugged in of the correct type and volt-
age

Interface between booklet Plug in

maker and collator is not
plugged in

Fuse has blown on the main On 220-240V machines

input there are two 5 amp fuses in
the mains input connector,
check and replace as neces-
sary. On 115V machines
they are 10 amp fuses.

Booklet maker/trimmer lid Close the lid

is open

BOOKLET MAKER STA- There is a jam or other error Clear the jam (see p.80)
TUS INDICATOR LIGHT in the unit
IS BLINKING RAPIDLY

BOOKLET MAKER STA- Booklet maker/trimmer lid Close the lid/switch on the
TUS INDICATOR LIGHT is open or unit is not unit
IS NOT ILLUMINATED switched on

BOOKLET MAKER DOES Booklet maker has lost com- Check that the interface is
NOT STOP ON TOUCH- munication with the collator plugged in - it may have
ING become disconnected when
(Note: There is a 10s delay moving the booklet maker
after touching . For an in and out
immediate stop, use the
BookMaker emergency stop
button or open the BOOK-
LET MAKER lid)

ONE OR BOTH STAPLE Staple heads are not selected Make sure STITCH is set to
HEADS ARE NOT ACTI- ON in the STITCH AND FOLD
VATED window (see p.24)

76 Watkiss Vario BookMaker Operator Manual

 5 - Problem Solving - Trouble Shooting Chart

Booklet Maker and Trimmer Problems

Problem Cause Solution

A staple head error has The heads should self clear.

occurred If not, turn the unit off and
on again to free the head. If
this does not work contact
your authorised distributor.

STAPLES LOW MESSAGE Staple cartridge empty Replace cartridge (see p.63)
ON DISPLAY

STAPLE HEAD ERROR A staple head error has The heads should self clear.
MESSAGE ON DISPLAY occurred If not, turn the unit off and
on again to free the head. If
this does not work contact
your authorised distributor.

FOLD IS NOT ACTI- Unit is in edge staple mode Move lever into centre sta-
VATED ple position (see p.49)

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

Edge stapling is selected or Not available in these

STITCH POSITION is set to modes
ON EDGE

EDGE STAPLE FUNC- Edge staple not selected Move lever to correct posi-
TION NOT WORKING tion and select staple head
(see p.49)

STAPLE IS NOT ON THE Set is bouncing before sta- Allow the set more time to
FOLD pling settle by increasing STITCH
DELAY

Set is bouncing before fold- Allow the set more time to

ing settle by increasing FOLD
DELAY

Loose paper or staples in the Locate and remove (see

fold plate area p.80)

SIDE JOG HOLD is selected Adjust PAPER SIZE so that

whilst the infeed sidelays both the infeed sidelays
are set too tight barely touch the paper (see
p.24)

STITCH POSITION is set to Set STITCH POSITION to ON

ON EDGE FOLD

Watkiss Vario BookMaker Operator Manual 77

 5 - Problem Solving - Trouble Shooting Chart

Booklet Maker and Trimmer Problems

Problem Cause Solution

Staple position is not Fine tune the position of the

adjusted correctly staples (see p.64)

UNTIDY BOOKLET Infeed sidelays are not Adjust PAPER SIZE (see
adjusted correctly p.24)

Set needs more time to settle Allow more time for the set
before stapling to settle by increasing
STITCH DELAY

Collator delivering an Improve collator delivery

untidy set

The booklet maker adjust- Touch RE-REF in the PAPER

ment system is not cali- SIZE window to manually
brated correctly recalibrate the booklet
maker adjustment axes

FINISHED BOOKLET IS Fold roller gap is too wide Adjust the fold roller gap
TOO LOOSE (see p.53)

TOP JOG DAMAGE ON The sheet length has been Adjust PAPER SIZE (see
THE SET set too short p.24)

Fold roller gap is too narrow Adjust the fold roller gap
(when edge stitching) (see p.53)

Collator delivering an Improve collator delivery

untidy set

BOOKLETS WILL NOT Large payout wheels incor- Reposition (see p.53)
STACK ON THE CON- rectly positioned
VEYOR

Electrical connection is Plug in electrical connection

unplugged between the booklet maker/
trimmer and the outfeed
conveyor

BOOKLET COVER IS Dirty fold rollers Clean them with a cloth

MARKED dampened with soapy water
or alcohol (isopropanol). Do
NOT use blanket wash (see
p.66)

Fold roller gap is too narrow Adjust the fold roller gap
(see p.53)

78 Watkiss Vario BookMaker Operator Manual

 5 - Problem Solving - Trouble Shooting Chart

Booklet Maker and Trimmer Problems

Problem Cause Solution

CANNOT CLOSE BOOK- Support strut is in place Lift the booklet maker lid
LET MAKER LID slightly, push the support
strut (see p.46) and close the
lid

BOOKLET IS TRIMMED Trimmer conveyor clamp See p.65

OUT OF SQUARE requires adjustment

BOOKLETS ARE Trimmer conveyor clamp See p.65

TRIMMED TOO SHORT requires adjustment

COVER IS DAMAGED Trimmer conveyor clamp See p.65

AROUND STAPLES requires adjustment

Fold roller gap is too narrow Adjust the fold roller gap
(see p.53)

Staple Head Problems

ONE OR BOTH LEGS Incorrect clincher alignment Re-align (see p.52)

TURN OUT

STAPLE COMES OUT IN Staple jammed in the car- Inspect cartridge (see p.63)
PIECES tridge and remove any jammed
staple wire

A staple head error has The heads should self clear.

occurred If not, turn the unit off and
on again to free the head. If
this does not work contact
your authorised distributor.

STAPLE HEAD INDICA- Staple cartridge empty Replace cartridge (see p.63)
TOR LIGHT BLINKS
ONCE PER SECOND

STAPLE HEAD INDICA- A staple head error has The heads should self clear.
TOR LIGHT BLINKS occurred If not, turn the unit off and
RAPIDLY on again to free the head. If
this does not work contact
your authorised distributor.

Watkiss Vario BookMaker Operator Manual 79

 5 - Problem Solving - Trouble Shooting Chart

Booklet Maker and Trimmer Problems

Problem Cause Solution

Paper Jam Problems

PAPER IS JAMMED IN Paper is badly curled Paper curl can normally be

THE BOOKLET MAKER avoided by observing cor-
Open the booklet maker lid rect paper handling and stor-
(this will disconnect the age procedures
power for safety) and Staples are stuck in the If there are staples stuck in
remove any jammed sets. clinchers the clinchers, remove with a
Check carefully and correct pair of pliers
any faulty adjustments that
caused the jam to occur. Edge stitch drive is engaged Disengage the edge stitch
when booklet making drive (see p.51)

Infeed sidelays are not Adjust PAPER SIZE so that

adjusted correctly both the infeed sidelays
barely touch the paper (see
p.24)

Fold roller gap is too wide Adjust the fold roller gap - a
small gap gives more drive
to pull the booklet through
(see p.53)

PAPER IS JAMMED IN Paper offcuts are obscuring Open the metal conveyor
THE TRIMMER the sensor in the conveyor cover and remove any trim
offcuts

Warning: Disconnect
the machine from the mains
electricity supply before
working near the blade
area.

80 Watkiss Vario BookMaker Operator Manual

 5 - Problem Solving - Trouble Shooting Chart

Friction Feed Problems

Problem Cause Solution

DOUBLE FEEDS Too much tray pressure Reduce by moving handle in

by one notch at a time (see
p.34)

Too little separation pres- Increase by moving the

sure lever down by one notch at a
time (see p.34)

Insufficient air separation Increase the value of AIR

BLOW in the BASIC window

Worn or missing separators Check separators are

present, and replace if worn
(see p.61)

Bad guillotine burr, or blunt Fan the stock by hand

drilling before loading, ensure paper
is cut well next time

Miscalibration during the Run another test set by

test set touching , followed by
TEST SET followed by

MISS FEEDS Too little tray pressure Increase by pulling the han-
dle out by one notch at a
time (see p.34)

Too much separation pres- Reduce by moving the lever

sure up by one notch at a time
(see p.34)

Untidy loading Reload the bins tidily,

ensuring the paper stack is
underneath the feed wheels
and under the guides

Worn feed wheels Check and replace the feed

wheels if necessary (see
p.61)

Miscalibration during the Run another test set by

test set touching , followed by
TEST SET followed by . It
may be necessary to
increase the tray pressure to
obtain a better feed

Watkiss Vario BookMaker Operator Manual 81

 5 - Problem Solving - Trouble Shooting Chart

Friction Feed Problems

Problem Cause Solution

TRAILING FEED Late feeding double sheet Treat as double feed above
(On a trailing sheet the Slow feeding sheet Treat as miss feed above
machine stops immediately.
You need to look carefully Slow feeding during test set Run another test set by
to identify which of the fol- causing incorrect calibration touching , followed by
lowing is the cause. The TEST SET followed by . It
faulty set can be inched may be necessary to
through by touching and increase the tray pressure to
holding INCH) obtain a better feed

PAPER JAM Sheet is jammed in the Locate the sheet and either
paper path pull it out or INCH it through

Sheet is only half feeding Treat as miss feed above

Feeding A5 (5½ x 8½") Select SHORT in the

landscape without selecting ADVANCED: FEED CLUTCH
SHORT in the ADVANCED: window and run another test
FEED CLUTCH window set by touching , followed
by TEST SET followed by
.

FRONT EDGE OF SHEET Too much separation pres- Reduce by moving the lever
DAMAGED sure up by one notch at a time
(see p.33)

82 Watkiss Vario BookMaker Operator Manual

 5 - Problem Solving - Trouble Shooting Chart

SlimVAC Feed Problems

Problem Cause Action

DOUBLE FEEDS The tray is too high Lower the tray height (see
p.39)

Not enough corrugation on Increase sheet corrugation

suction feeder (see p.38)

Mechanical paper problem - Fan stock by hand before

guillotine burr, sticky ink, loading, and ensure these
poor perforations, high problems are avoided in
static charge etc. future

Rubber endlay is incorrect Use correct type and posi-

type or position tioning (see p.36)

MISS FEEDS Not enough air separation Increase the value of AIR
BLOW in the BASIC window

Too much sheet corrugation Reduce the sheet corruga-

tion (see p.38)

The tray is too low Raise the tray height (see

p.39)

Heavy and/or rigid sheets Raise the angle of the suc-

tion feeder (see p.38)

Paper has curly edge Refer to recommended set-

tings (see p.40)

Rubber endlay is too tight Position the endlay approx.

against the paper stack, or is 1mm (1/16”) clear of the
incorrect type edge of the stack. Ensure it
is the correct type for the
paper size (see p.36)

TRAILING FEED Trailing double feed Treat as a double feed

(On a trailing sheet the Trailing single feed Treat as a miss feed
machine stops immediately.
You need to look carefully
to identify which of the fol-
lowing is the cause. The
faulty set can be inched
through by touching and
holding INCH)

PAPER JAM Sheet is pre-feeding Treat as a double feed

Sheet is miss feeding Treat as a miss feed

FRONT EDGE OF SHEET Too much sheet corrugation Reduce the sheet corruga-
DAMAGED tion (see p.38)

Watkiss Vario BookMaker Operator Manual 83

 5 - Problem Solving - Replacing Fuses

Replacing Fuses

Your BookMaker is fitted with two fuses at each of the mains inputs. If
either of these fail the machine will not power up.

Caution: The system uses double-pole/neutral fusing (i.e. two fuses).

When removing any covers or changing fuses - always first disconnect
the machine from the mains electricity supply by switching off and
unplugging the machine
• Unplug the mains input lead and open the flap on the fuse holder
• Pull out each fuse casing in turn and check the fuse
• Replace if necessary with a fuse of the correct specification, as detailed
below.

Machine Watkiss Description

Part No.
BookMaker Drive Unit, 730-018 Fuse, 1.25" (32mm) 7.0A HRC
240V (Quick Acting, F)
BookMaker Drive Unit, 730-020 Fuse, 1.25" (32mm) 10.0A HRC
115V (Quick Acting, F)
Booklet maker, 240V 730-016 Fuse, 1.25" (32mm) 5.0A HRC
(Quick Acting, F)
Booklet maker, 115V 730-103 Fuse, 1.25" (32mm) 10.0A HRC
(Anti Surge, T)

84 Watkiss Vario BookMaker Operator Manual

5 - Problem Solving - Error Messages

Error Messages

Under certain error conditions a message will be displayed on the control

panel. Some of the error messages will refer to an individual bin or module
address. In this case the relevant module number will appear where # is
shown below.

Error Message Meaning

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 BookMaker 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 # overload An obstruction in the bin is preventing it from lifting cor-

rectly. Check and remove any obstructions. It may be that
the stock has not been pushed fully forward into the bin.

Bin # part reset It is necessary to switch the machine off and then on
again after 10 seconds before running another test set. If
this problem persists, contact your local Watkiss service
department.

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.

Watkiss Vario BookMaker Operator Manual 85

 5 - Problem Solving - Error Messages

Error Message Meaning

Bin programming The bins in the BookMaker have not initialised properly.
error Switch the machine off and then on again. If the problem
persists, contact your local Watkiss Service Department.

Bin reset An error has occurred in the electronics of the bin

detailed. Any number over 16 relates to a module other
than a bin. Restart the machine. If the problem persists,
contact your local Watkiss service department.

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 BookMaker 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 BookMaker 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 BookMaker is in
axis changing 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
local Watkiss service department.

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 local Watkiss service department.

Fuses blown Fuses have blown on the Motor Drive PCB, in the drive
unit. Contact your local Watkiss service department.

Initialising bins The bins in the BookMaker are being checked. If this
message appears regularly, contact your local Watkiss
service department.

86 Watkiss Vario BookMaker Operator Manual

5 - Problem Solving - Error Messages

Error Message Meaning

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 BookMaker does not restart, a fault
may have occurred in the drive unit: contact your local
Watkiss service department.

No response The bins in the BookMaker have not initialised properly.

Switch the machine off and then on again. If the problem
persists, contact your local Watkiss Service Department.

Power fail The mains supply has been interrupted. Switch the Book-
Maker off and on again.

PSU voltage error: There is a voltage error. Contact your local Watkiss serv-
ice department.

Remote stop The BookMaker has stopped because there is a problem

with ancillary equipment to which it is linked. Clear the
problem with this equipment before restarting the job.

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 local Watkiss service department.

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 local Watkiss service department.

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.

Staples low A staple cartridge in the booklet maker needs replacing.

Fit a new staple cartridge.

Stitch guard open The top cover of the booklet maker is open. Close the
cover.

Touch START to There may still be paper in the conveyor. Touch to

clear machine clear the machine before starting a new job.

Tray lift error (Friction feed bin only) There is a fault with the tray low-
ering mechanism. Contact your local Watkiss service
department.

Watkiss Vario BookMaker Operator Manual 87

 5 - Problem Solving - Error Messages

Error Message Meaning

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
local Watkiss service department.

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.

88 Watkiss Vario BookMaker Operator Manual

CHAPTER 6 Safety Information

Your BookMaker has been designed with safety as a key feature and in
accordance with international safety standards.

Please read and observe the following safety rules.

Warnings and Cautions

Where warnings and cautions are given in the body of this manual, they are
identified by a warning triangle.

Warning: Warning messages alert you to a specific procedure or prac-

tice which, if not followed correctly, could cause serious personal injury.

Caution: Caution messages appear before procedures which, if not

observed, could result in damage to the equipment.

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

Watkiss Vario BookMaker Operator Manual 89

 6 - Safety Information -

• Do not use the machine if it is making unusual noises. Disconnect the

machine from the mains electricity supply and call your Watkiss engi-
neer

Installation
• The installation of your BookMaker requires specialist knowledge and
should therefore only be carried out by a Watkiss approved engineer
• The BookMaker must only be plugged into an electrical supply line of
the correct voltage and with a proven earth. Any damage caused by fail-
ure to do so will not be covered by the guarantee. The required machine
voltage is shown on the label on the rear of the Vario BookMaker and
the rear of the booklet maker
• 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

90 Watkiss Vario BookMaker Operator Manual

PRODUCT SAFETY DATA SHEET

Watkiss Automation Limited

Watkiss House
Blaydon Road
Middlefield Ind. Est. tel: +44 (0)1767 682177
Sandy, Bedfordshire SG19 1RZ fax: +44 (0)1767 689900
United Kingdom email: [email protected] Date: March 2005, Rev.3

Model(s) Watkiss Vario BookMaker (online system)

Watkiss Document Finishing System (offline system)
Description Booklet making system for digital printers. Including Vario tower with rotary suction sheet
feeders and gathering station; booklet maker; trimmer*; spine-former* and connecting
bridge*. (* options)
Operating Conditions 10-35°C at 35-85% relative humidity
Definitions BMP: BookMaster Pro booklet maker; TMP TrimMaster Pro trimmer
ASF: Automatic Stitch-Fold; ATR: Automatic Trimmer
ASM: Automatic SpineMaster
Dimensions (installed system) BMP & TMP BMP & TMP & ASM ASF & ATR ASF & ATR & ASM
Width 693mm 693mm 693mm 693mm
Length 2080mm 1810mm 2110mm 1995mm
Online: add 560 mm - 1,270 mm (depending upon printer) for the connecting bridge
Height 1588mm plus 77mm per feeder
Weight (Vario tower) 118Kg plus 7.6Kg per feeder. Online: add 64Kg
Weight (finishing) 172Kg 287Kg 275Kg 392Kg
Vario tower BMP & TMP ASF & ATR ASM
Voltage 230V (210-254V) 230V (210-254V) 230V (210-254V) 230V (210-254V)
Frequency 50/60Hz 50Hz 50Hz 50Hz
Current 6.8A 3.5A 5.2A 3.0A
Protection Fuse 10.0A 5.0A 7.0A 5.0A
Power consumption: operation 1400VA 700VA 1190VA 700VA
standby 50VA 30VA 30VA 30VA
Mains connection removable cable & plug
Safety class I I I I
Protection class IP 20 IP 20 IP 20 IP 20
Sound pressure level
(at operator/bystander position) Standby: 0 dB (A); In use: 74 dB (A) typical, 80 dB (A) impulse peak
Radio interference Complies with Directive 89/336/EEC
Radiation Not applicable
Ozone emission Negligible (predicted peak ozone concentration 0.004ppm)
Room volume No special requirements
Room ventilation
Consumables None

CE Compliance
Safety: 73/23/EEC and 98/37/EC
EMC: 89/336/EEC

This safety data sheet has been compiled to the best of our knowledge as a compact guide to safe handling of this product. We reserve the right
to revise safety data sheets as new information becomes available. It is the user’s responsibility to determine the suitability of this information for
the adoption of safety precautions as may be necessary and to contact the company to make sure that this sheet is the latest one issued. If and
in sofar as limitation of liability is permitted under the applicable laws, we do not accept liability for any inaccuracy that may occur in this infor-
mation.
Copyright © 2005 Watkiss Automation Limited
 6 - Product Safety Data Sheet -

92 Watkiss Vario BookMaker Operator Manual

CHAPTER 7 Specifications

Intended Use The Watkiss BookMaker is intended for feeding, sta-

pling, folding and trimming materials as specified
below.
Operating Conditions 10-35°C at 35-85% relative humidity
Configuration From 3 to 8 feed stations, with online booklet maker &
trimmer
Production Dependant on operating mode and finishing option
Stock Sizes Min: 140 x 210mm, 5.5 x 8.3"
Max: 320 x 482, 12.6 x 19"
Max. Book Thickness 22 sheets (80gsm)
Detection Electronic detection for miss, double, jam and empty bin
Dimensions
Width 693mm
Length 1990-2700mm with booklet maker (depending on
printer
2640-3350mm with booklet maker and trimmer
(depending on printer)
Height Friction feed: 1415 plus 77mm per feeder
SlimVAC feed: 1588 plus 77mm per feeder
Weight 118Kg plus:
per Friction Feeder: 6.9Kg
per SlimVAC Feeder: 7.6Kg
Booklet maker: 70Kg
Trimmer: 85Kg
Outfeed Conveyor: 17Kg
Connecting Bridge: up to 64Kg (depending on
printer)

Watkiss Vario BookMaker Operator Manual 93

 Specifications -

Electrical 105-127V or 210-254V; 50/60Hz; single phase

Radio Frequency This equipment has been tested and found to comply
Emissions with the limits for a Class A digital device, pursuant to
part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interfer-
ence when the equipment is operated in a commercial
environment. This equipment generates, uses and can
radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may
cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely
to cause harmful interference in which case the user will
be required to correct the interference at his own
expense.

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.

94 Watkiss Vario BookMaker Operator Manual

CHAPTER 8 Declaration of
Conformity

Manufacturer’s Name. Watkiss Automation Limited

Manufacturer’s Address. Watkiss House, Blaydon Road, Sandy,
Bedfordshire, SG19 1RZ, UK.
Declares that the product
Product Name. Watkiss Vario BookMaker
Product Number. WA/VAR/2450 onwards (230V versions only)
Product Variants. Friction Feed
SlimVAC Feed
Gathering Base Module
BookMaster Pro
TrimMaster Pro
Conforms to the following Product Specifications:
Safety. 73/23/EEC and 89/392/EEC Council Direc-
tive 'on the approximation of laws of Member
States relating to machinery’, amended by 91/
368/EEC
BS EN 60950: 1992
EMC. 89/336/EEC Council Directive 'on the approxi-
mation of laws of Member States relating to
electromagnetic compatibility'
EN55022: 1995 Class A
EN50082-1: 1992
IEC 801-2 (1991) 8kV AD
IEC 801-3 (1984) 3V/m
IEC 801-4 (1988) 0.5kV SL, 1kV PL

M C Watkiss, Technical Director, Watkiss Automation Ltd.

Watkiss Vario BookMaker Operator Manual 95

 Declaration of Conformity -

96 Watkiss Vario BookMaker Operator Manual

INDEX

A error messages 85–88

action buttons conveyor clamp adjustment 65
end job 17 corner stapling 50
help 18 cover, inserting 10
inch 17
menu 18 D
start/stop 17 delete 27
test set 18 detector position 22
adjustable fold rollers 53 difficult papers
adjusting the paper size 49 slimvac 40
adjustment axes, re-referencing 76 docking plates, trimmaster 47
advanced window 22 double detection 23
detector position double jog 25
double detection 23 drive speed 22
tolerance 22
E
drive speed 22
feed clutch 23 edge stapling 49
auto 23 edge stapling & folding 51
sheet offset 22 edge stitch assistor 50
edge stitch drive, engage the 51
suction hold 23
emergency stop 4
air blow 20
end job 17
air blow adjustment 45
endlays, rubber, slimvac bins 36
air separation, adjustment 34
error handling, online operation 7
anvil, sharpening 68
error messages 85–88
auto 20, 23
axes calibration 76 F
B feed clutch 23
feed wheels, friction bins 61
basic window 20
feed window 29
air blow 20
mixed feed 30
online 21
multifeed 30
prenumber 21
multiset 30
preset 21
feeder angle, slimvac bins 38
sets per hour
auto 20 finishing window 24
paper size 24
remote 20 page direction 24
single set 20 presets 24
batch window 27 re-ref 24
inserts 28
pre fold jogging 25
bottom 28 fold delay 25
top 28 side jog hold 25
number of sets 28 pre stitch jogging 25
pause / separate 29
restart batch 29 double jog 25
stop 29 pre jog 25
bin controls 32, 36 stitch delay 25
bin linking 35, 39 stitch and fold 24
blade, sharpening 68 stitch on fold 25
booklet making trim 25
setting up the booklet maker 46–54 fold delay 25
fold rollers, adjustable 53
C friction bins 32–35
calibration - see ’re-ref’ adjustments 33
centre stapling 49 air separation 34
clamp roller shafts 65, 66 bin controls 32
cleaning - see ’maintenance’ bin linking 35
cleaning the touch screen 60 loading the bins 33
conformity, declaration of 95 maintenance 61
connecting bridge 42–43 sensor overrange 35
control panel 16–31 separator pressure 33
basic operation 16–17 sidelay taps 34

Watkiss Vario BookMaker Operator Manual 97

 INDEX

switching bins on & off 33 maintenance 59–72

tray extenders 32 manual bypass gate 45
tray pressure 34 manual cranking point, booklet
front outfeed maker 67
attaching the front outfeed 55 manual cranking point, trimmer 68
front outfeed conveyor 55–56 menu 18
fuses 84 mimic diagram 19
mixed feed 30
G multifeed 30
gathering station 44–45 multiset 30

H N
help 18 normal collating 12
honing, trimmaster blade 72 loading sequence 12
number of sets 28
I
inch 17, 48 O
indicator lights 48 offline operation 2
bin 48 collating sequentially printed sets 9
booklet maker status 48 normal collating 12
staple head 48 online 21
inserts 28 online operation 6
installation 1 operation, offline 9, 12
interface sockets 44 operation, online 6
introduction 1–4 operator maintenance 59–72
outfeed conveyor adjustment 53
J
job details 26 P
joggers 57–58 padlock symbol 27
joggers page direction 24, 49
straight jogger 58 paper guides 56
x-jogger 57 paper jam 80
paper separators, friction bins 33, 61
K paper size 24
key symbol - see ’padlock symbol’ paper size, adjusting 49
pause 17
L pause / separate 29
landscape 49 payout wheels 53
load 26 portrait 49
load and save window 26 power save 16
delete 27 pre fold jogging 25
job details 26 pre jog 25
load 26 pre stitch jogging 25
padlock symbol 27 prenumber 21
save preset 21
cancel 26 presets 24
problem solving 73–88
replace 26
bookmaster and trimmaster
save new 26 problems 76
view of job list 27 error messages 85–88
a->z 27 friction feed problems 81
by use 27 gathering station problems 75
loading friction bins 33 general problems 74
loading sequence, normal paper jam 80
collating 12 slimvac feed problems 83
loading slimvac bins 37 staple head problems 79
loading, offline 9 trouble shooting 74
locking jobs 27
R
M re-ref 24, 76
mains input 3 restart batch 29
mains on/off switch 3 rubber endlays, slimvac bins 36

98 Watkiss Vario BookMaker Operator Manual

INDEX

S trim 25
safety 1, 89 trim offcut box 54
save 26 trimmaster blade sharpening 68–72
sensor overrange 35, 39 honing 72
service interval 59
sets per hour 20 U
setting up the booklet maker 46–54 unlocking jobs 27
connecting 47
opening 46 V
starting 48 view of job list 27
setting up the bookletmaker
outfeed conveyor adjustment 53 W
trim offcut box 54 window system 16
sharpening, trimmaster blade 68–72
sheet corrugation, slimvac bins 38 X
sheet length adjusment 44 x-jogger 57
sheet offset 22 jogging adjustment 58
sheet width adjustment 44 setting up the jogger 57
side jog hold 25
single set 20
slimvac bins 36–41
adjustments 38–40
bin controls 36
bin linking 39
difficult papers 40
feeder angle 38
loading the bins 37
rubber endlays 36
sensor overrange 39
sheet corrugation 38
switching bins on & off 38
tray extenders 36
tray height 39
specifications 93
sph 19
staple cartridges, changing 63
staple head
clincher 52
position 52
selecting 52
staple cartridges, changing 63
staple head indicator lights 48
staple position adjustment 64
staples low 63
start/stop 17
static elimination bar 60
status indicator light 48
stitch and fold 24
stitch delay 25
stitch on fold 25
straight jogger 58
jogging adjustment 58
setting up the jogger 58
suction hold 23
T
test set 18
third staple head 50
tolerance 22
tray extenders 32, 36
tray height
slimvac bins 39
tray pressure, friction bins 34

Watkiss Vario BookMaker Operator Manual 99

 INDEX

100 Watkiss Vario BookMaker Operator Manual

Watkiss Automation Limited
1 Blaydon Road
Middlefield Industrial Estate
Sandy, Bedfordshire
SG19 1RZ U.K.
Tel: +44 (0)1767 685700
Fax: +44 (0)1767 689900
Email: [email protected]