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Watkiss Automation Automatic SpineMaster Service Manual

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Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04
Watkiss
Automatic SpineMaster
Service Manual
Issue Date :
17 June 2004
Issue Number : 1a
Part Number : 969-235
Watkiss Automation Ltd
1 Blaydon Road,
Middlefield Industrial Estate,
Sandy, Beds SG19 1RZ
United Kingdom
tel: +44 (0)1767 682177
fax: +44 (0)1767 691769
email: info@watkiss.com

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Summary of Contents for Watkiss Automation Automatic SpineMaster

  • Page 1 Issue Number : 1a Part Number : 969-235 Watkiss Automation Ltd 1 Blaydon Road, Middlefield Industrial Estate, Sandy, Beds SG19 1RZ United Kingdom tel: +44 (0)1767 682177 fax: +44 (0)1767 691769 email: info@watkiss.com Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 2 The information contained in this document is subject to change without notice. Watkiss Automation Limited makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.

  • Page 3: Table Of Contents

    1 Introduction 2 Status Indicator RAPs 3 Quality RAPS 4 Service Procedures 5 Illustrated Parts Catalogue 6 General Procedures 7 Wiring Diagrams & Electrics 8 Installation Procedures 9 Operator Manuals 10 Appendix Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 4 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 5 Routine Maintenance ........8 1 - 1 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 6: Introduction

    The function of the unit is unchanged. Only the infeed assembly and base assembly are different. 1.1.2 Terminology In this manual the Watkiss Automatic SpineMaster is referred to by its product code ‘ASM’. Where instructions refer to particular product variants, they are referred to by the product code, suffixed with ‘B’...

  • Page 7: Safety

    Caution messages appear before procedures which, if not observed, could re- Caution sult in damage to equipment. 1.4 Warning Labels The following warning labels are used in the Watkiss Automatic SpineMaster. Indicates high voltages are present. Label is sometimes accompanied with voltage indication. Black figure on Yellow background.

  • Page 8: Orientation

    RH side Delivery (outfeed) end Figure 1:1 Top view (ASM version shown) 1.6 Product Overview 1.6.1 Paper Path Upper Infeed Lower Infeed Figure 1:2 Paper Path - SquareBack Mode 1 - 4 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 9: Basic Operating Principles

    Stop (see Figure 1:5) Anvil Carriage Motor Transverse Chain Stop Carriage Clutch Bolster Drive Motor LH Cam Link RH Cam Link Infeed Figure 1:4 Automatic SpineMaster Component Diagram (top View) 1 - 5 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 10 If for any reason the Carriage is stopped before it reaches one of the Limit WARNING Sensors, it will move towards either the RH or LH Limit Sensor once power is 1 - 6 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 11: Book Thickness Adjustment

    In this mode, the Carriage passes along the booklet’s spine twice (once in either direction) SquareBack Mode: The booklets will be processed and receive a squared spine (SquareBack). 1 - 7 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 12: Error Indicator / Reset Button

    The normal service interval for the ASM is 12 months. This interval should be reduced if the ASM is subject to heavy use. 1 - 8 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 13 Ensure all connectors are seated correctly 15. Check condition of the interface cable between ASM and trimmer. Checks completed by : Date : Table 1:2 ASM Routine Maintenance Schedule 1 - 9 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 14 Introduction • Routine Maintenance 1 - 10 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 15: Status Indicator Raps

    Carriage Motor and Transverse Chain RAP ..... . . 6 2 - 1 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 16: Entry Rap

    Support. when a start signal on PCB 900-141. is present? Does the Main Motor Check Wiring/ rotate when a start Motor. signal is present? Check Drive Chains (see 4.8.7). 2 - 2 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 17: Ac Mains Rap

    Replace the fuse*. power to the Mains plug OK? Lead end? Check mains supply. Is the fuse* in the Replace fuse*. Input Socket OK? Replace complete Input Socket. *Fuses (see 7.1). 2 - 3 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 18: Error Indicator Rap

    Sensor (see 4.7.4). Jammed Booklet Clamp Stop? RAP (see 2.4).. Check/Replace PCB 900-197. *on PCB 900-197 † LED10 for ASM & ASMN LED11 for ASMB & ASMD 2 - 4 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 19: Jammed Booklet Rap

    Clean the conveyor belts, ensure the booklet feeds in square and it is not folded too tightly. 2 - 5 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 20: Carriage Motor And Transverse Chain Rap

    (see 4.8.4). correct (68 Ohms +/-5%)? Is the Roller Assembly jammed? Is the Drive Motor Replace PCB faulty? 900-197. Free Roller Assem- bly (see 4.5). Replace Drive Motor (see 4.8.16). 2 - 6 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 21: Quality Raps

    Poor Stacking RAP ......... 5 3 - 1 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 22: Spine Forming Rap

    Some stocks may require Double Pass Mode to achieve an even result. If booklet spines are being formed unevenly, check that the Stop is parallel with the Clamp, and that the minimum depth is correctly set (see 4.7.7). 3 - 2 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 23: Thin Booklet Rap

    If the Stop oscillates excessively, there is a risk that the following booklet may fall down between the edge of the Stop and the Anvil. To prevent this adjust the Stop damping (see 4.7.8). 3 - 3 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 24: Damaged Booklet Rap

    • Bolster/anvil damaged (see 4.7.9). Torn Spine: • Check the damage is not caused by poor trimming. • Booklet is over-formed (see 3.1). Creasing on spine: • Booklet is over-formed (see 3.1). 3 - 4 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 25: Poor Stacking Rap

    Stack flat (as Bypass Mode) and do not allow the Stacker to become too full. 4. Thick Booklets Check the Control Springs are not in use (see Small Booklets). 3 - 5 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 26 Quality RAPS • Poor Stacking RAP 3 - 6 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 27: Service Procedures

    Replacing the Lower Infeed Sensor (ASM & ASMN) ... . 34 Replacing the Clamp Optical Sensor ......36 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 28: Introduction

    The LH and RH Side Covers are removed by undoing the two captive M5 screws near the top of each panel. Top Delivery Assembly Figure 4:2 Machine Covers - Front view (Stacker removed) 4 - 2 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 29: Cycling The Asm By Hand

    Figure 4:4 Locating the Hand Crank Tool 6. Manually crank the ASM by turning the Hand Crank Tool in a clockwise direction. Note that the Clutch will not allow the shaft to be cranked in an anti-clockwise direction. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 30: Cleaning The Carriage Roller And Stop

    4. If the booklet is difficult to remove, cycle the machine by hand until the Clamp is open (see 4.2). Find and rectify the cause of the jam (see 2.4) before restarting the ASM. 4 - 4 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 31: Freeing A Carriage Roller Jam

    Figure 4:5 Pull the Carriage Roller Assembly towards you. 5. If the Clamp is open, proceed to Step 6. If the Clamp is still holding the booklet, reconnect the ASM and switch on the mains power. The machine Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 32: Removing Components

    1. Open the Top Delivery Assembly. 2. Lift the Stacker Assembly to give internal access to the ASM (see Figure 4:7). Stacker Assembly Top Delivery Assembly Figure 4:7 ASM access 4 - 6 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 33: Removal Of The Top Delivery Assembly

    TOOLS REQUIRED None 3mm Allen Key 4mm Allen Key 1. Switch off the power and disconnect the mains input lead. 2. Remove the Side Covers. 3. Remove the Top Delivery Assembly Cover. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 34: Machine Adjustments

    3. Remove the LH Side Cover. 4. Check the tension in the Transverse Chain. To do this, push the top section of the Chain down mid-way between the Sprockets. If the tension is 4 - 8 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 35: Adjusting Lh & Rh Limit Sensors

    Anvil. Move the Mount as required, and re-tighten the screw. The Sensor Mount is accessed from the top of the unit (see Figure 4:14). Sensor Mount Bracket Figure 4:14 Sensor Mount Bracket Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 36 9. If the Carriage does not stop in the right place, adjust the Sensor again. Check the end position of the Carriage at both ends of the Carriage Guide. 4 - 10 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 37: Adjusting The Clamp Open Sensor

    (moving the Sensor back can prevent false triggers or reaction to background reflections). If adjusting the Sensor makes no difference then it should be replaced (see 4.8.21). PARTS REQUIRED TOOLS REQUIRED None 3mm Allen Key 4mm Allen Key 8mm Spanner Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 38: Adjusting The Clutch Control Collar

    Small Electrical Screwdriver 955-014 Hand Crank Tool Procedure 1. Switch off the power and disconnect the mains input lead. 2. Remove the Side Covers. 3. Remove the Infeed Assembly (see 4.6.1). 4 - 12 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 39 BDC. 12. If the Clamp does not park at BDC, reset the Control Collar as necessary and re-test. 13. Once the Clutch is correctly set, replace the Retaining Ring in its groove. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 40: Setting The Solenoid

    3. Rotate the Adjuster Shaft (265-835) anti-clockwise, to bring the Stop to its minimum depth. Use a 13mm spanner to loosen the Trantorque Bush on the end of the Adjuster Shaft. 4 - 14 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 41: Adjusting The Stop Damping

    Two oscilations is the most desirable. PARTS REQUIRED TOOLS REQUIRED None 3mm Allen Key 8mm Spanner Procedure 1. Switch off the power and disconnect the mains input. 2. Remove the RH Side Cover. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 42: Burring The Bolster

    Clamping Ridge. Do not file the corners of the Bolster or Anvil into a radius. 5. Replace the Covers and test. 6. Advise the operator that processing thin or badly formed booklets can cause damage. 4 - 16 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 43: Replacing Components

    2. Remove the RH Side Cover 3. Remove all the cables from the PCB assembly (see Figure 4:27). Note their position for refitting. The cables will only fit into the correct connec- tor in the correct orientation. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 44: Replacing The Transformer

    PARTS REQUIRED TOOLS REQUIRED 905-377 Carriage Motor Ballast Resistor Assy 2.5mm Allen Key 3mm Allen Key 4 - 18 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 45: Replacing The Cam Links

    Circlips Figure 4:28 Cam Link - LH (Side Control Assembly removed) 4. When fitting a new Cam Link, make sure it is square to the Drive Shaft ends. Always use new circlips. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 46: Replacing The Transverse Drive Chain

    7. Unbolt both Idler Sprockets. The Chain can now be removed from the ma- chine. 8. Remove the Chain Link Shaft from the old Chain, and replace it in the new Chain. 4 - 20 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 47: Replacing The Main Drive Chain And The Drive Transfer Chain

    4. Unclip the Locking Plate and the Link Plate. Withdraw the Split Link from the Chain. 5. Unhook the Chain from the Sprockets and remove. 6. Check the Sprockets for wear or damage. Replace if necessary (see 4.8.9 and 4.8.10). Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 48: Replacing The Final Drive Chain

    4. Unclip the Locking Plate and the Link Plate. Withdraw the Split Link from the Chain. 5. Unhook the Chain from the Sprockets and remove. 6. Check the Sprockets for wear or damage. Replace if necessary (see 4.8.11). 4 - 22 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 49: Replacing The Clutch Sprockets And/Or Intermediate Drive Sprocket

    2. Place the Clutch Assembly onto a flat work surface and remove the Sprocket fixing bolts, taking care to note the spacer and washer positions. 3. Remove the worn Sprockets and re-assemble using new ones. 4. Replace the Clutch Assembly in the reverse order. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 50: Replacing The Main Drive Motor Sprocket

    Small Electrical Screwdriver Circlip Pliers (external) Hammer 4mm Pin Punch Procedure 1. Remove the Cam Links from the ASM (see 4.8.5). 2. Remove the Final Drive Chain (see 4.8.7). 4 - 24 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 51: Replacing The 24V Motor

    3. Undo the Connector Block that links the 24V Motor to the rest of the wir- ing loom. 4. Undo the Trantorque Bush from the 24V Motor Drive (see Figure 4:36). This will be easier if the Carriage is pulled against the stops at one end of Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 52: Replacing The Cooling Fan

    1. Switch off the power and disconnect the mains input lead. 2. Remove the Infeed Assembly (see 4.6.1). 3. Cut the cable ties. Remove the Fan Assembly. Cut the cable ties Figure 4:37 Removing the Cooling Fan 4 - 26 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 53: Replacing The Clutch

    Allen Key, undo the grub screw that holds the Clutch to the Drive Shaft. This grub screw is located in the RH side of the Clutch Body (see Figure 4:39). Clutch Body Grub screw M8 screw Figure 4:39 Clutch Assembly Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 54: Replacing The Clutch Solenoid

    4mm Allen Key 5mm Allen Key 10mm Spanner Pliers - Side Cutters, small 1. Switch off the power and disconnect the mains input lead. 2. Remove the Infeed Assembly (see 4.6.1). 4 - 28 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 55: Replacing The Bolster And/Or Anvil Clamp Bar

    Hammer 1. Switch off the power and disconnect the mains input lead. 2. Remove the Side Covers. 3. Remove the Top Delivery Assembly (see 4.6.2). 4. Remove the Infeed Assembly (see 4.6.1). Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 56 M6 screws in the LH and RH Adjustment Supports (see Figure 4:44), and remove the screws securing the LH and RH Stop Springs. M6 screws Figure 4:44 Stop Assembly RH Mounting screws 4 - 30 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 57 1. Use Loctite 242 on the screws that hold the Anvil Clamp Bar to the Mount- ing Blocks. 2. Hold the Anvil Clamp Bar firmly in place when tightening the screws that hold the Mounting Blocks to the Bolster Side Plates. Use Loctite 242 on these screws. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 58 12. When refitting the Stop Assembly, check that it is still parallel with the face of the Bolster and Anvil Clamp Bar. Refer to Procedure 4.7.7 if the Stop needs adjusting. 4 - 32 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 59: Replacing The Stop Assembly

    If the LED is lit when no book is present, ensure that the Sensor is not reacting to reflections within the ASM. A piece of black, light absorbent tape is nor- mally adhered to the underside of the Stacker Motor. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 60: Replacing The Lower Infeed Sensor (Asm & Asmn)

    Lower Infeed, the Infeed Sensor may be faulty. Place a book- let over the Sensor and watch the status of LED11 on PCB 900-197. If the Sen- 4 - 34 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 61 12. Adjust the Sensor Housing plastic locking nuts so that the Sensor pro- trudes above the upper nut by approximately 5mm. Tighten the nuts to se- cure the Sensor. 13. Replace the Infeed Assembly (see 4.6.1) and test. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 62: Replacing The Clamp Optical Sensor

    11. Remove the front locking nut from the new Sensor and set the back nut to approximately the same position as the old Sensor. 12. Thread new cable ties but do not tighten. 4 - 36 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 63 15. Secure the Mounting Bracket to the Motor Mounting Plate and check the Sensor Position (see 4.7.4). 16. Replace the Book Deflector Plate and secure. 17. Replace the Side Covers and close the Top Delivery Assembly. 18. Reconnect mains power and test. Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 64 Service Procedures • Replacing Components 4 - 38 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 65: Illustrated Parts Catalogue

    Illustrated Parts Catalogue • Chapter 5 Illustrated Parts Catalogue The Illustrated Parts Catalogue for the Automatic SpineMaster is a separate document available in electronic form. PART NO DESCRIPTION ISSUE / DATE SERIAL NO FILE NAME 964-680 Automatic SpineMaster IPC Issue 1, 06/2003 WA/ASM/0010-0044 asm1ipc.pdf...
  • Page 66 Illustrated Parts Catalogue • 5 - 2 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 67: General Procedures

    Recommended Spare Parts ........6 6 - 1 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 68: Product Specifications

    Operation of this equipment in a residential area is likely to cause harmful interfer- ence in which case the user will be required to correct the interference at his own expense. 6 - 2 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 69: Safety Data Sheet

    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 information 6 - 3 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 70: Space Requirements

    ‘C’ HEIGHT 707mm; 28” 745mm; 29½” 1161mm; 45¾” ASMB 707mm; 28” 751mm; 29¾” 1138mm; 45” ASMD 707mm; 28” 690mm; 27¼” 1138mm; 45” ASMN 707mm; 28” 762mm; 30” 1178mm; 46½” 6 - 4 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 71: Recommended Tools & Consumables

    Fine File or Oil Stone 740-294 Bypass Cable 955-014 Special Tool: ASM Hand Crank Tool 951-007 Loctite 242 (Thread Locking Compound) 951-155 Chain Lubricant Table 6:1 Recommended Tools & Consumables 6 - 5 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 72: Recommended Spare Parts

    • Full Recommended Spares List - Automatic SpineMaster 115V • Full Recommended Spares List - Automatic SpineMaster 230V • First Line Support Spares Kit - Automatic SpineMaster (ASMB) 115V 6 - 6 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 73: Wiring Diagrams & Electrics

    Power Interface PCB 900-141 Layout ......13 7 - 1 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 74  SpineMaster Drive Moter 115V 905-351 ELECTRO- MECHANICAL SpineMaster Drive Motor 203V 905-345  Hold Magnet 905-251  Clutch 907-977  Diverter Solenoid 760-339  Stacker Drive Motor 907-954 7 - 2 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 75: Fuses

    The Infeed Optical Sensor detects the booklet as it enters the ASM. 7.4.2 Clamp Optical Sensor (booklet presence) This sensor detects the presence of a booklet when it reaches the Clamp. 7 - 3 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 76: Clamp Open Proximity Sensor

    PCB itself Figure 7:1. All the Taps must be set in the same posi- tion. Details of the Tap settings are shown in the table below. TAP SETTING INPUT 93-110V 105-127V 187-220V 210-254V 7 - 4 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 77 Wiring Diagrams & Electrics • Transformer Taps (Blue) Figure 7:1 Transformer Tap Settings (115V Selected) 7 - 5 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 78: Block Diagram

    Wiring Diagrams & Electrics • Block Diagram 7.6 Block Diagram 7 - 6 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 79: Spinemaster Control Pcb (900-197)

    Wiring Diagrams & Electrics • SpineMaster Control PCB (900-197) 7.7 SpineMaster Control PCB (900-197) 7.7.1 900-197 Schematic - sheet 1/2 7 - 7 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 80: Schematic - Sheet 2/2

    Wiring Diagrams & Electrics • SpineMaster Control PCB (900-197) 7.7.2 900-197 Schematic - sheet 2/2 7 - 8 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 81: Indicators

    Wiring Diagrams & Electrics • SpineMaster Control PCB (900-197) 7.7.3 900-197 Indicators 7 - 9 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 82: Asm Machine Interface Pcb (900-198)

    Wiring Diagrams & Electrics • ASM Machine Interface PCB (900-198) 7.8 ASM Machine Interface PCB (900-198) 7 - 10 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 83: Asm Payout Interface Pcb (900-201)

    Wiring Diagrams & Electrics • ASM Payout Interface PCB (900-201) 7.9 ASM Payout Interface PCB (900-201) 7 - 11 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 84: Power Interface Pcb

    Wiring Diagrams & Electrics • Power Interface PCB (900-141 7.10 Power Interface PCB (900-141 7.10.1 Power Interface PCB 900-141 Schematic 7 - 12 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 85: Power Interface Pcb 900-141 Layout

    Wiring Diagrams & Electrics • Power Interface PCB (900-141 7.10.2 Power Interface PCB 900-141 Layout 7 - 13 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 86 Wiring Diagrams & Electrics • Power Interface PCB (900-141 7 - 14 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 87: Installation Procedures

    Installing the ASM onto a Nagel Trimmer ......18 8 - 1 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 88: General Considerations

    2. Check that the Transformer is set to suit the input voltage (see 7.4 ‘‘Trans- former’’). 3. Check that the environmental conditions are suitable for the ASM. This machine is designed for the following environment: • 10-35°C at 35-85% relative humidity 8 - 2 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 89: Installing The Asm Onto A Watkiss Automatic Trimmer

    • If no jump switch is fitted, check that a link wire con- nects the two pin positions. L1 link position (jumper switch fitted) Note: If PCB 900-155 Rel.D is fitted, please refer to separate instructions. 8 - 3 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 90 8. Connect the interface cable to the 2 connectors PL1 and PL6 on the Trimmer Control PCB and reconnect the two previously disconnected cables to the connectors on the interface cable. 8 - 4 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 91 12. Align the ASM to the rear of the ATR and connect the ASM interface lead to the ATR interface socket. 13. Connect the ASM to a suitable power supply of the cor- rect voltage and test the system. 8 - 5 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 92: Installing The Asm Onto A Watkiss Manual Trimmer

    Connector on the Interface Cable. Fit the new Rear Inspection Plate to the machine. 6. Fit the Green earthwire under a suitable M5 screw. 8 - 6 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 93 VTR and connect the ASM Interface Lead to the VTR Interface Socket. 10. Connect the ASM to a suitable power supply of the cor- rect voltage and test the system. 8 - 7 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 94: Installing The Asm Onto A Watkiss Trimmaster

    Note: For machines PRIOR to serial no. TMP/1189 and TMS/ 0059, a drill jig and drill kit (914-838) should be ordered. For machines TMP/1190 and TMS/0059 onwards, go to step 9. 8 - 8 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 95 8. De-burr the holes and clean away the swarf. 9. Fit the interface socket and cable assembly. Use one of the fixing screws to secure the TrimMaster bypass plug. 8 - 9 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 96 15. Reconnect the TrimMaster to the mains power supply and check that the BookMaster/TrimMaster functions correctly. This will prove that the interface installation is correct. Check trim guard open function. 8 - 10 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 97 16. Align the ASM to the rear of the TrimMaster and connect the ASM interface lead to the TrimMaster interface socket. 17. Connect the ASM to a suitable power supply of the cor- rect voltage and test the system. 8 - 11 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 98: Installing The Asm Onto A Bourg Bdf

    4. Connect the ASM Interface Cable into the interface socket on the BDF. 5. Connect the ASM to a suitable power supply of the cor- rect voltage and test the system. 8 - 12 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 99: Installing The Asm Onto A Duplo 400T Trimmer

    9. Feed the loose wires through the hole in the LH Side Frame. Replace the Rear Cover. 10. Fit the bypass plug into the interface socket. 8 - 13 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 100 Interface Cable. Black Green 13. Clip the interface wiring into the existing cable clips. 14. Refit the Side Cover. 15. Engage the docking plate into the Trimmer mounting holes. 8 - 14 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 101 22. The ASM will start when the Trimmer starts, and will ’Time-Out’ stop when the Trimmer stops. 23. If there is an error on the ASM, the Trimmer will display an error message. 8 - 15 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 102: Installing The Asm Onto A Duplo 48T Trimmer

    Black wire and the connector to the relay. Connect the Green wire from the Interface Cable to the existing Brown wire and the Connector to the Relay. 8 - 16 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 103 18. The ASM will now start when the Trimmer starts and will ’Time Out’ stop when the Trimmer stops. 19. If there is an error on the ASM, the Duplo Trimmer will display an error message. 8 - 17 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 104: Installing The Asm Onto A Nagel Trimmer

    Installation Procedures • Installing the ASM onto a Nagel Trimmer 8.8 Installing the ASM onto a Nagel Trimmer The Watkiss Automatic SpineMaster (ASM) can be installed online to a Nagel Trimmer. • The ASM is factory-modified to suit the Nagel Trimmer. This should be specified when the ASM is ordered.
  • Page 105 4. Enlarge the centre hole to 17mm using a hole saw and arbor. De-burr the holes and clean away the swarf. 5. Remove the cover from the Trimmer electrical compart- ment 6. Fit the socket onto the Trimmer. 8 - 19 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 106 7. Fit the shorting plug wire onto the bottom left screw. 8. Connect the red and purple wires onto the blue outfeed motor control relay. Purple Observe the routing for the wires, as shown in the photo- graph 8 - 20 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 107 14. Adjust the height of the ASM to ensure that a good paper path is achieved between the two units. To set the height, adjust the 4 jacking screws attached to the base wheels using a 14mm spanner. 8 - 21 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 108 18. If the ASM is not used, the bypass plug MUST be fitted to the Trimmer, or the Trimmer will not function. 19. The ASM will start when the Trimmer starts, and will ’Time-Out’ stop when the Trimmer stops. 8 - 22 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 109: Operator Manuals

    Operator Manuals • Chapter 9 Operator Manuals Operating Manuals for the Automatic SpineMaster are separate documents available in printed and electronic form. PART # DESCRIPTION LANGUAGE ISSUE / DATE FILE NAME 960-661 Watkiss Automatic SpineMaster Operator Guide English 1 - 01/2003 asm1_uk.pdf...
  • Page 110 Operator Manuals • 9 - 2 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 111: Appendix

    SECTION PAGE Recommended Spares List - Automatic SpineMaster 115V ..2 Recommended Spares List - Automatic SpineMaster 230V ..4 First Line Support Spares Kit - Automatic SpineMaster (ASMB) 115V . . 6 Conversion Chart .

  • Page 112: Recommended Spares List - Automatic Spinemaster 115V

    Appendix • Recommended Spares List - Automatic SpineMaster 115V 10.1 Recommended Spares List - Automatic SpineMaster 115V Effective 1 Jan 2004 - Complete Spares Kit including all of below P/N 990-043 PART NO. DESCRIPTION PK SIZE 110-207 SCREW, SKT HD SHLDER, M8 x 16mm (MOD)
  • Page 113 Appendix • Recommended Spares List - Automatic SpineMaster 115V 10.1 Recommended Spares List - Automatic SpineMaster 115V Effective 1 Jan 2004 - Complete Spares Kit including all of below P/N 990-043 PART NO. DESCRIPTION PK SIZE 914-494 BELT, (ASM) MAT 02H x 25 x 1925 LONG...

  • Page 114: Recommended Spares List - Automatic Spinemaster 230V

    Appendix • Recommended Spares List - Automatic SpineMaster 230V 10.2 Recommended Spares List - Automatic SpineMaster 230V Effective 1 Jan 2004 - Complete Spares Kit including all of below P/N 990-044 PART NO. DESCRIPTION PK SIZE 165-205 S/PROOF WASHER, M8 STAINLESS CRINKLE 180-099 SPRING, CIRCLIP 12.7mm SHAFT 1mm WIDE...
  • Page 115 Appendix • Recommended Spares List - Automatic SpineMaster 230V 10.2 Recommended Spares List - Automatic SpineMaster 230V Effective 1 Jan 2004 - Complete Spares Kit including all of below P/N 990-044 PART NO. DESCRIPTION PK SIZE 914-495 BELT, MAT-02H x 25 x 965 LONG...

  • Page 116: First Line Support Spares Kit - Automatic Spinemaster (Asmb) 115V

    Appendix • First Line Support Spares Kit - Automatic SpineMaster (ASMB) 115V 10.3 First Line Support Spares Kit - Automatic SpineMaster (ASMB) 115V Effective 1 Jan 2004 - Complete Spares Kit including all of below P/N 990-045 PART NO. DESCRIPTION...

  • Page 117: Conversion Chart

    PAPER WEIGHT GSM (G/M EQUIVALENT IN # (USA) 8 # bond 11 # bond 20 # bond 74 # cover 93 # cover 110 # cover Table 10-1 : Conversion Chart 10 - 7 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...

  • Page 118: Operator/Service Publication Feedback Form

    Please give specific page references and fax the completed form to us on (+44 (0)1767 691769). NAME TELEPHONE JOB TITLE DATE COMPANY PUBLICATION REVISION DATE PAGE NUMBER COMMENT Please make photocopies of this form if further copies are required 10 - 8 Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04...
  • Page 120 Watkiss Automation Ltd 1 Blaydon Road, Middlefield Industrial Estate, Sandy, Beds SG19 1RZ United Kingdom tel: +44 (0)1767 682177 fax: +44 (0)1767 691769 email: info@watkiss.com Watkiss Automatic SpineMaster Service Manual - Edited 17/06/04 Part Number 969-235...

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