Watkiss spinemaster User manual

Watkiss SpineMaster
Operating Guide
Issue 1, June 2000

CONTENTS
Introduction . . . . . . . . . . . . . . . . .1
Installation
Safety Information
About your SpineMaster . . . . . . .3
How the SpineMaster works
Adjustments and Settings
Using your SpineMaster . . . . . . .7
Error Conditions. . . . . . . . . . . . . .9
Carriage Jam
Latch Jam
Unevenly formed Spine
Replacing Fuses
Seeking Assistance
Maintenance . . . . . . . . . . . . . . .11
Service Interval
Operator Maintenance
Specifications . . . . . . . . . . . . . .13
Declaration of Conformity . . . . .15
Watkiss SpineMaster Operator Guide, P/No. 960-501
Issue 1 - June 2000 - S/No. WA/SPM/010 onwards

CONVENTIONS The following conventions are used in this manual:
Warning Warning messages alert you to a specific procedure or
practice which, if not followed correctly, could cause
serious personal injury.
Caution Caution messages alert you to a specific procedure or
practice which, if not followed correctly, could result in
damage to equipment.
© Watkiss Automation Limited 2000
All Rights Reserved.
Reproduction, adaptation, or translation without prior writ-
ten permission is prohibited, except as allowed under the
copyright laws.
Warranty
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.
WatkissAutomationLimitedshallnotbeliableforerrorscontainedherein
or for incidental or consequential damage in connection with the furnish-
ing, performance or use of this material.

Watkiss SpineMaster Operator Guide - Issue 1 - June 2000 1
1 Introduction
Thank you for purchasing the Watkiss SpineMasterTM.
The Watkiss SpineMasterTM post-processes stitched or
stapled booklets to give them the professional flat ap-
pearance of a perfect bound book, but with the security
of a stitched spine. The resulting SquareBackTM booklets
are flat, making them easy to stack, handle and pack.
If you use your SpineMaster to supply SquareBack book-
lets to your customers, remember to tell them to specify
‘SquareBack booklets’.
INSTALLATION It is recommended that your SpineMaster should be
located on a level floor.
Caution This machine must only be plugged into an electrical
supply line of the correct voltage and with a proven earth.
Anydamage causedby failureto doso willnot becovered
by the guarantee. The required machine voltage is shown
on the label on the rear of the unit.
The SpineMaster is castor-mounted so that it is easy to
position where required. Please note that the castors can
be locked if required.
SAFETY
INFORMATION
Your Watkiss SpineMaster has been designed with safety
as a key feature. However, to ensure it is used safely
please observe the following cautions and warnings:
Warnings • Do not allow hair or clothing to fall inside the Spine-
Master during operation.
• Do not attempt to put your hands or objects, other
than booklets, inside the SpineMaster during opera-
tion.
• As with all electrical equipment, disconnect the unit
from the mains electricity supply when replacing
fuses or when instructed to do so in this manual.
Cautions • Do not stand or sit on the top of the m/c. The quick
release top could be flipped off by your weight.

2 Watkiss SpineMaster Operator Guide - Issue 1 - June 2000
• Do not attempt to lift the machine by the top. If it
requires lifting, lift off the top and then use the hand-
holds provided. This requires two people, and
should be carried out using safe lifting techniques.
• Always ensure that the 4 x M10 securing bolts are
firmly in place between the stand and the machine.
• Do not remove machine covers. Only competent and
trained service engineers should service this equip-
ment.
• Do not allow loose objects to fall inside the Spine-
Master.

Watkiss SpineMaster Operator Guide - Issue 1 - June 2000 3
2 About your SpineMaster
HOW THE
SPINEMASTER
WORKS
• The booklet is put into the Book Loading Slot, until it
rests on a Latch. Sensors detect the presence of the
booklet.
Fig 1. Top view of the Book Loading Slot
• The Clamp holds the booklet, the Latch swings away
and the Carriage passes along the spine of the
booklet to reform it.
• When Pass Through Mode is selected, the Clamp
releases and the booklet drops into the Stacker.
• When Manual Unload Mode is selected, the Latch
swings back into position and the Clamp releases
the booklet, which may then be removed by hand.
ADJUSTMENTS AND
SETTINGS
The following notes refer to the main external components
of the machine, as shown in Fig 2.
Back Stops : Booklets can be stacked on the top of the
SpineMaster before and after processing. The Back
Stops prevent booklets falling off the back of the machine.
Mains ON/OFF : TheMains ON/OFFswitch ison thefront
of the machine. 1 = ON, 0 = OFF.
Mains Input : The Mains Input (not illustrated) is on the
back of the machine. Alongside the Mains Input is a label
indicating the machine voltage requirements.
Book Loading Slot : Books to be processed are placed
spine first into the Book Loading Slot.
Latch
Sensors Carriage (not normally
visible)
Book Loading Slot

4 Watkiss SpineMaster Operator Guide - Issue 1 - June 2000
Book Thickness Adjustment : The Book Thickness Ad-
justment can be used to obtain optimum results with
different booklet thicknesses. Turn the knob clockwise to
increase the effect, and anti-clockwise to decrease the
effect. The type of material will also influence the required
setting.
Operating Mode Selection : The Operating Mode Se-
lection includes the choice of single or double pass, and
the choice of whether to unload manually or to use the
stacker.
Single Pass : The SpineMaster will process the book-
let a single time. This is the default setting, and is suitable
for the vast majority of booklets.
Double Pass : The SpineMaster will process the
booklet twice. This can be useful for thick, inflexible
covers which are more resistant to re-forming.
Manual Unload Mode : After processing, the book-
lets can be removed from the Book Loading Slot.
Back Stops
Mains ON/OFF
Switch
Stacker
Book Thickness
Adjustment
Operating Mode
Selection
Book Loading
Slot
Fig 2. Watkiss SpineMaster
Fig 3. Book Thickness
Adjustment
Max.
Min.

Watkiss SpineMaster Operator Guide - Issue 1 - June 2000 5
Pass-Through Mode : Afterprocessing,thebooklets
pass through the machine and into the stacker. This
option must be selected for booklets smaller than 140mm
high.
Fig 4. Operating Mode Selection
Double Pass
Single Pass
Manual Unload Mode
Pass-Through Mode

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6 Watkiss SpineMaster Operator Guide - Issue 1 - June 2000

Watkiss SpineMaster Operator Guide - Issue 1 - June 2000 7
3 Using your SpineMaster
To use the SpineMaster, first select the required Operat-
ing Mode as explained above.
Set the Book Thickness Adjustment to minimum.
Place the booklet, spine downwards, into the Book Load-
ing Slot until it is resting squarely on the chrome latch.
Note : A thin booklet will drop under its own weight onto
the latch. A thicker booklet may need to be pushed into
the latch. Briskly press down in the middle of the booklet
and then release. This is important to avoid deforming
the shape of the booklet whilst it is being processed,
otherwise uneven forming will result.
Caution • Do not exceed the specified book thickness.
Minimum : 1mm (0.04”)
Maximum : 6.5mm (0.25”) This is approximately 30
sheets of 80gsm (20# bond) folded into a 120 page
booklet.
• Only process one booklet at a time, DO NOT try to
process several booklets at once.
Inspect the formed booklet, and adjust the Book Thick-
ness Adjustment or the Operating Mode as required.
✔Correct: This is how a well formed
spine should look.
✖Incorrect: The spine has not been
formed sufficiently.
Increase the Book Thickness
Adjustment and/or use Double
Pass Mode

8 Watkiss SpineMaster Operator Guide - Issue 1 - June 2000
Wet Ink
Avoid using the SpineMaster on booklets where the ink
has not dried. This may result in ink transfer, and will
increase the amount of cleaning required (see “Operator
Maintenance” on page 11).
Incorrect: The spine has been
over-formed resulting in damage
or creasing on the cover.
Decrease the Book Thickness
Adjustment and/or use Single
Pass Mode.
✖

Watkiss SpineMaster Operator Guide - Issue 1 - June 2000 9
4 Error Conditions
CARRIAGE JAM If for any reason the Carriage jams part-way through
forming the spine, the Clamp will open, but it may not be
possible to remove the booklet. Switch the unit OFF at the
Mains ON/OFF Switch and unplug from the mains elec-
trical supply.
Look into the Book Loading Slot (See Fig 1. on page 3),
and you will be able to see the Carriage. Using a suitable
implement (such as a wooden 30cm ruler), firmly push
the Carriage back towards the end of the Book Loading
Slot, away from the booklet. Remove the booklet.
Caution Take great care not to damage the black plastic sensors.
Avoid using a metal implement, as this may damage the
mechanism.
Switch the unit ON again and the carriage will return to
its park position.
LATCH JAM Whilst the booklet is being processed, the latch swings
out of the way of the carriage. If for any reason a booklet
lodges behind the latch, the unit will jam. This is most
likely to occur by feeding booklets into the unit too quickly
whilst in Pass Through mode.
Switch the unit OFF at the mains ON/OFF switch and
unplug from the mains electrical supply. Using a suitable
implement (such as a wooden 30cm ruler), gently push
the latch towards the end of the Book Loading Slot, and
remove the booklet.
Note : The latch will move easily in one direction only. Do
not force it if it does not move freely as this will cause
damage.
The Carriage push
push
The Latch
push push

10 Watkiss SpineMaster Operator Guide - Issue 1 - June 2000
Caution Take great care not to damage the black plastic sensors.
Avoid using a metal implement, as this may damage the
mechanism.
Switch the unit ON again and it will be ready for operation.
UNEVENLY FORMED
SPINE
If the spine is well formed at only one end, check that the
booklet is being placed squarely onto the latch. If the
booklet is at an angle, uneven forming will result.
Some stocks may require Double Pass Mode to achieve
an even result.
REPLACING FUSES Your SpineMaster is fitted with two fuses at the mains
input. If either of these fail, the SpineMaster will not
operate.
Warning The SpineMaster uses double-pole/neutral fusing (i.e.,
two fuses), so when changing fuses always first discon-
nect the machine from the mains electricity supply by
switching OFF and unplugging the machine.
• Switch the SpineMaster OFF and unplug the mains
input lead. 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 spec-
ification, as detailed below.
Reference
230V machines:
730-016 Fuse, 1.25" (32mm) 5.0A HRC-Quick Acting F
115V machines:
730-020 Fuse, 1.25” (32mm) 10.0A HRC (Quick Acting, F)
SEEKING
ASSISTANCE
If you require assistance with your Watkiss SpineMaster,
please contact your local Watkiss supplier or the Watkiss
Service Department.

Watkiss SpineMaster Operator Guide - Issue 1 - June 2000 11
5 Maintenance
SERVICE INTERVAL It is recommended that your SpineMaster is serviced by
an approved Watkiss engineer at six to twelve month
intervals (depending on usage). Please contact your
Watkiss supplier or the manufacturer for further details.
OPERATOR
MAINTENANCE
As with all machinery, your SpineMaster will benefit from
regular cleaning to prevent build up of dust and general
dirt.
• Check that the air vents are not obstructed or
blocked. Obstructed air vents will cause the motor to
overheat.
• Once a week, or as required, clean the carriage
roller as explained below.
• Do not use the SpineMaster on booklets where the
ink is still wet. This may result in ink transfer, and
increase the need for cleaning.
Cleaning the Carriage Roller
1. Set the operating mode to Double Pass, and the
Book Thickness Adjustment to maximum.
2. Take a maximum thickness (6.5mm) A4 size booklet,
and wrap a sheet of paper around the outside. Alter-
natively, take about 30 sheets of A3 80gsm paper
and fold into an A4 size booklet.
3. Apply a thin coating of a suitable cleaning product
(see below) to the spine of the booklet.
4. Insert the booklet into the SpineMaster in the normal
way and process about 6 times.
5. Remove the outer sheet, to give a fresh clean sur-
face, and repeat step 4.
Suitablecleaningproducts includealcohol(isopropanol),
offset litho blanket wash or RS Solvent Cleaner Aerosol
(Watkiss Part No. 951-097). Always observe any health
and safety information supplied with cleaning products.
Warning Cleaning solvents are flammable. DO NOT spray them
directly into the SpineMaster.
USA Users:
6.5mm is ¼”
For A4, use 8½ x 11”
For A3, use 11 x 17”
80gsm is 20# bond

12 Watkiss SpineMaster Operator Guide - Issue 1 - June 2000
Caution Do not attempt to use a cloth to clean the carriage roller.
This may leave loose fibres or debris inside the machine.

Watkiss SpineMaster Operator Guide - Issue 1 - June 2000 13
6 Specifications
Intended Use This product is intended for the re-forming of booklet
spines, to flatten the booklet and give a square appear-
ance to the spine, within the specifications below.
Production up to 1320 per hour single pass
up to 1000 per hour double pass
Booklet Size
Pass Through Mode
Width up to 350mm, 13.7”
Height 105 to 216mm; 4.2 to 8.5”
Manual Unload Mode
Width up to 350mm, 13.7”
Height minimum of 140mm, 5.5”
Booklet Thickness minimum of 1mm, 0.04”
maximum of 6.5mm, 0.25”. This is approximately 30
sheets of 80gsm (20# bond) folded into a 120 page
booklet.
Dimensions
Width 710mm, 28”
Depth 700mm, 27.6”
Height 1060mm, 41.7”; working height 910mm, 35.8”
Weight 98kg, 216lb
Electrical 230V, 50Hz, 3A or 115V, 60Hz, 5A
Single Phase, Earthed supply required
Noise 72 dB(A)
Operating Conditions 10-35°C at 35-85% relative humidity
Production and specifications are subject to operating
conditions. The specified paper thickness figures are
given for guidance only. The actual performance of the
machine will depend on the nature of the paper and
covers used. In line with a policy of continual
improvement, the manufacturer reserves the right to

14 Watkiss SpineMaster Operator Guide - Issue 1 - June 2000
alter the materials or specifications of this product at
any time without notice.
Radio Frequency
Emissions This equipment has been tested and found to comply with
the limits for a Class A digital device, pursuant to part 15
of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when
the equipment is operated in a commercial environment.
This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accord-
ance 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.

Watkiss SpineMaster Operator Guide - Issue 1 - June 2000 15
7 Declaration of Conformity
Manufacturer's Name: Watkiss Automation Limited
Manufacturer's Address: Watkiss House
Blaydon Road
Sandy, Bedfordshire, UK.
SG19 1RZ
United Kingdom
Declares that the product
Product Name: Watkiss SpineMaster
Product Number: WA/SPM/0010 onwards
Conforms to the following Product Specifica-
tions:
Safety: 73/23/EEC & 89/392/EEC Council Directive 'on the ap-
proximation of laws of Member States relating to machin-
ery', amended by 91/368/EEC BS EN 60950 : 1992
EMC: 89/336/EEC Council Directive 'on the approximation of
laws of Member States relating to electromagnetic com-
patibility' EN55022 Class B
EN50082-1
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

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16 Watkiss SpineMaster Operator Guide - Issue 1 - June 2000