Watkiss Vario Operating Manual

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Watkiss Vario Operating Manual | Manualzz

CONTENTS

Welcome..............................................1

Quick Start ..........................................5

Control Panel ......................................9

Friction Bins .....................................21

SlimVAC Bins ...................................27

Suction Bins .....................................35

Bench Base.......................................43

Oscillating Bench Base ...................49

Floor Base.........................................53

Joggers .............................................59

Rear Corner Stapler .........................63

Maintenance......................................67

Problem Solving ...............................73

Appendix

Advanced Menu .................................... 85

Specifications ....................................... 91

Declaration of Conformity ..................... 95

Index .................................................97

Issue 2 - Dec 1997 - Part No. 960-321

Issue 1 - Apr 1996 - Part No. 960-301

Welcome

Congratulations, you have just purchased the very finest of collators, the Watkiss Vario. Your Vario has been designed to make collating efficient, productive and above all, easy.

ABOUT YOUR

MANUAL

This operating manual (Issue 2) covers machines fitted with Release C Floor Bases (see below) installed with

Vario application software V7.0 onwards. For machines fitted with earlier bases please refer to Issue 1.

Release C Floor Base Release A & B Floor Base

The manual has a 'Quick Start' section to get you up and running quickly. It is then followed by more detail on each of the modules that make up your machine, and by problem solving charts and additional notes.

SAFETY FIRST Your Vario has been designed with safety as a key feature.

However, as with all electrical equipment, when removing any covers or changing fuses always first disconnect the machine from the mains electricity supply by switching off and unplugging the machine.

Rear Guard

The rear guard of the collator must be fitted for the machine to run. A safety switch prevents machine operation when the guard is removed. When fitting the guard, ensure that the bar on the top bracket locates correctly on the hooks under the drive unit. Also ensure the guard’s bottom bracket locates on the lower conveyor shaft.

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2

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 pressing on the control panel. If the emergency stop button is used, the collator will not restart until the button has been released by turning clockwise.

Mains ON/OFF Switch

Emergency Stop

INSTALLATION The installation of your Vario requires specialist knowledge and should therefore only be carried out by a

Watkiss approved engineer.

MAINS INPUT The Mains input for the Vario is on the rear of the drive unit. The collator must be plugged into a mains supply of the correct voltage. Two fuses are fitted next to the Mains input. If either of the fuses fails the collator will not power

up (see p.79 for details about changing fuses).

Mains Input and Fuses

MAINS ON/OFF

SWITCH

The mains On/Off switch should be used to turn the collator on and off when required. When the collator is switched off it retains the control panel settings in memory.

GETTING HELP We are confident that your Vario 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, the Watkiss Service Department (UK) or your local Watkiss supplier will be happy to help.

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1

Quick Start

This section is intended only as a brief operating guide.

Detailed operating procedures are included in subsequent chapters.

Plug the collator into a mains supply of the correct voltage.

Switch on the mains ON/OFF switch and press any key on the control panel.

CONTROL PANEL On the bottom of the display you will see there are two rows of control options. These are used by pressing on the two rows of arrow keys below them. For instance, the left hand message on the bottom row is

INCH

. To use this, press the bottom left arrow key .

Note that when an option or action is selected it is highlighted (e.g. INCH becomes INCH ).

During normal use the display shows the main menu. By pressing

MENU

the second menu is displayed. This contains options for counting, batching etc.. In turn these also have sub-menus.

For now, simply remember that

MENU

changes from one menu to another, and that the two rows of arrow keys allow you to use the two rows of options shown on the display.

Tip

Pressing and holding

SETUP

(on menu 2) until it changes to

SETUP

will automatically return the control panel to its default factory settings.

LOADING THE BINS

WITH PAPER

Remove any unwanted paper from the bins and press

INCH

to check that there is no paper left in the conveyor from the previous job.

The job should be organised either with the sheets face uppermost, and the first page in the top bin or face down with the first page in the bottom bin.

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6

Friction Bins

Take a stack of paper and slide it into the bin between the sliding sidelays. Push in the sidelays to centralise the paper in the bin, they should hold the paper securely.

SlimVAC Bins

Take a stack of paper and slide it into the bin between the sliding sidelays. Push in the sidelays to centralise the paper in the bin, they should hold the paper securely.

Position the rubber endlay on the 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").

Suction Bins

Switch off any suckers that would be off the edge of the paper by turning the tap to the left.

Normally the trays are all in the up position, in order to load the bins they must first be lowered. Starting with the bottom bin (bin 1), press the grey bin lowering button and then load the bin, lower bin 2 and load it, lower bin 3 and load it etc.

Slide the stock into the bin, centralising it between the two locating pins. Ensure the stack is loaded neatly and square, and then place the magnetic sidelays on all three sides.

ADJUSTING THE

MACHINE

Friction Bins

• Initially set the separation pressure lever (left) to its midposition.

• Set the tray pressure to minimum by pushing down on the lever (right) and releasing it to its innermost position.

If loading large sheets it should be one notch out.

SlimVAC Bins

• Initially set the tray height lever to its mid position

• Angle the suction feeder down

• Set the corrugation adjustment (on the feeder) to the mid-position

Suction Bins

• Initially set the edge flick control to the mid position.

All Bins

Press

SETUP

to switch on all loaded bins.

If required, you can press and hold

SETUP

until it changes to

SETUP

to set the machine to standard settings.

Adjust the stacker for paper size.

STARTING THE JOB Press to run the test set.

When the test set is complete, press the job.

again to run

Once the machine is running, adjustments may be necessary depending upon the stock in use. Full details for each type of feed bin are found in the appropriate chapter.

The machine can be stopped at any time by pressing

.

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Control Panel

Your Vario will be fitted with either a top or side mounted control panel. The only difference in operation between the two types is that the side mounted panel has an additional quick stop button on the top.

The quick stop button immediately stops the collator.

Under normal circumstances use the stop button on the control panel and allow the system to sequence down.

Quick Stop Button

Menu Button

Start Button

Stop Button

LCD Display

Arrow Key

Keypad

Side Mounted Control Panel

Top Mounted Control Panel

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THE MENU SYSTEM The Vario is controlled via a menu system shown on an

LCD display. The display is divided into three main areas.

Machine Information

Counter and Message

display

Menu

12 Bins 1234 SPH Job : 1

000264

TEST SET

INCH

SPH+

SPH-

DRIVE+

DRIVE-

AIR+

AIR-

The top line shows machine information including the number of bins fitted, the collator production rate (in sets per hour) and the current job area number.

The central area is the set counter and message display.

The lower area is used to access the menu system. The menu consists of two rows of control options. These are used by pressing on the two rows of arrow keys below them. For instance, the left hand message on the bottom row is

INCH

. To use this, press the bottom left arrow key .

Note: When an option or action is selected it is highlighted (e.g.

INCH

becomes

INCH

).

During normal use the display shows the main menu. By pressing

MENU

the second menu is displayed. This contains options for counting, batching etc. In turn these also have sub-menus.

Note: The menu will only show available options, these will depend on machine configuration.

MENU 1 MENU 2

BATCH

MENU

JOB

MENU

SFT

MENU

ADVANCED

MENU

Basic Menu Navigation

STARTING THE JOB Press , a single set will be collated. Check this and, if needed, another test set may be obtained by pressing

TEST SET

and . If the set is correct, press to commence the job.

again

COUNTER Press to clear the counter. When the machine is started the counter will count upwards.

PRESET COUNTER Alternatively, to collate a preset number of sets, press

C to clear the counter and then enter the number of sets required using the number keys. When the machine is started the counter will automatically count down to zero and the collator will then stop.

DURING THE JOB During the job the control panel will tell you the status of the machine and the number of sets collated. In addition it will identify any errors that may occur. The lights beside

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12 each bin will also indicate errors. The machine can be stopped at any time by pressing .

When the job is completed, press

END JOB

to unlock the bins. If necessary, the control panel may instruct you to press to clear the machine ready for the next job.

SYSTEM LOCK Once the test set is completed and accepted by pressing

, the bins are 'security locked' to prevent errors and accidental button presses. This means that pressing the buttons on the bin controls will have no effect. To unlock the bins press and then

END JOB

.

MENU 1 Menu 1 is used to adjust the basic operating parameters of the Vario.

12 Bins 1234 SPH Job : 1

000264

END JOB

TEST SET

INCH

Menu 1 Adjustments

SPH+

SPH-

DRIVE+

DRIVE-

AIR+

AIR-

TEST SET : When displayed, the collator is ready to run a test set. A test set consists of a single feed from each bin that is switched on and loaded. The Vario uses the test set to calibrate the detection system. The test set is not counted by the counter (except when in prenumber mode). Press to run a test set.

TEST SET : The test set is complete. Pressing now will accept the test set and lock the bin settings. If an error occurs during the test set it will have to be run again.

Correct the problem and press TEST SET , again.

END JOB

: Displayed once the test set is accepted. Press to unlock the bins prior to running a new job.

INCH

: Press and hold to turn the conveyor. Used for delivering any sets remaining in the conveyor after a jam etc.

SPH +

and

SPH -

: Sets per hour adjustment. The production rate can be varied to suit your application. The initial setting is 3,000 sets per hour. If other Vario ancillary equipment, such as the X-Jogger is on line, the production rate will automatically be limited to suit that piece of equipment. (Note: If you have selected

PRENUMBER

via

Menu 2, the SPH adjustment no longer appears on the menu. In

PRENUMBER

mode the SPH and drive speed adjustments are combined. In this case use

DRIVE +

and

DRIVE -

to control the production rate)

DRIVE +

and

DRIVE -

: The conveyor drive speed may be adjusted for different paper types. This alters the drive speed of the rollers and therefore the speed at which the sheets exit the collator. Certain stocks will stack better if the drive speed is adjusted to suit. The default factory setting is 60%.

AIR +

and

AIR -

: This alters the amount of air available for air separation. As a general rule, the heavier and larger the sheet, the more air you need. If you are running mixed stocks, individual air taps on each bin allow the air to be independently controlled. The default factory setting is

25%. If any SlimVAC bins are fitted and the installed software is version 6.1h or later the default air setting is

40%.

MENU 2 Press

MENU

to enter Menu 2

STAGGER

: Twin Tower only. When selected, the collated set from tower B delivers ahead and separately from that of tower A. This allows better knock up for sets with a lot of sheets .

BATCH

: Enters the batch menu (see below).

OSCILL

: Enables oscillation when an oscillating bench base, X-Jogger or Deep Pile Stacker is fitted.

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PRENUMBER

: Normally there will be more than one set in the conveyor at any one time. For pre-numbered work you may want only one set in the conveyor at a time, meaning that each set is delivered to the stacker before the next set is collated. This minimises the correction required should an error occur. However, because the sets are spread further apart, the overall production rate is re-

duced. Also note that in prenumber mode linked bins (see p.31) cannot be changed over manually.

12 Bins 1234 SPH Job : 1

000264

TEST SET

INCH

SPH+

SPH-

DRIVE+

DRIVE-

AIR+

AIR-

MENU

STAGGER

BATCH

OSCILL DIVERT

PRENUMBER SFT / SETS ↓

JOB

SETUP

BATCH MENU SFT MENU

(only if SFT online)

Menu 2 Navigation

JOB MENU

DIVERT

: Any faulty sets are diverted to the reject tray without stopping the collator (floor standing models only).

Faulty sets are not counted by the counter. The

DIVERT command is not available when in

PRENUMBER

mode.

SFT

: This is only displayed if a Stitch Fold is online. Press to enter the SFT menu which is explained in the Stitch

Fold operating manual.

SETS ↓ or and

SETS ↓

SETS ↓

: By default, sets are delivered forwards

is displayed. Press to select delivery straight

downwards and

SETS ↓ will be displayed. (Delivery to the

rear is controlled by the rear deflector lever, see p.55)

JOB

: Enters the job memory menu (see p.18).

SETUP : Press once to switch on all loaded bins. Note that the green light comes on next to each loaded bin, this means the bin is switched on. (Note. You can manually switch bins on and off by pushing the red button on each bin).

Press and hold

SETUP

until it changes to the Vario to default factory settings.

SETUP to return

BATCH MENU To enter the batch menu press

BATCH

from Menu 2.

Cumulative Set Total

12 Bins 1234 SPH Job : 1

000070 0003:00010

Number of Complete Batches

Number of Sets to Complete

the Batch

END JOB

INCH

Menu 1 Batch Mode

SPH+

SPH-

DRIVE+

DRIVE-

AIR+

AIR-

The batch mode allows you to preset the number of sets required, insert at a chosen interval, or offset the stacker at a chosen interval.

When in batch mode the main counter display changes to show from left to right: cumulative set total, the number of batches completed and the number of sets needed to complete the batch.

The set counter will count downwards until the batch is complete. The batch counter will then increase by one.

The cumulative set counter counts upwards showing the total number of delivered sets. The example above therefore shows ten sets left to complete the batch, three completed batches and seventy total sets.

15

If you want to use the batch counter press

SIZE

MENU

,

BATCH

, enter the number of sets required in each batch

, chosen one or more of the following actions must be selected to enable batch mode.

12 Bins 1234 SPH Job : 1

000264

TEST SET

INCH

SPH+

SPH-

DRIVE+

DRIVE-

AIR+

AIR-

MENU

STAGGER

BATCH

OSCILL DIVERT

PRENUMBER SFT / SETS ↓

JOB

SETUP

16

STOP

OSCILL

INSERT ↑

INSERT ↓

Batch Menu Navigation

MULTIFEED

MULTISET

PAUSE

SIZE

STOP

: The machine will stop after each batch and the counter display will flash. To run another batch press

.

OSCILL : Offsets the stack after each batch if an X-Jogger or Oscillating Bench Base is fitted.

INSERT ↑ : When feeding to the front of the collator, a sheet will be fed 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, a sheet will be fed 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 of a pad for example.

INSERT ↓ : When feeding to the front of the collator, a sheet will be fed 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, a sheet will be fed with the first set of each batch. The inserted sheet will be at the bottom of the batch pile, as the backing board of a pad for example.

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.

PAUSE

: the machine will pause for approximately 5 seconds after each batch. The counter display will flash and an audible beep will be heard. The pause time can be adjusted by a Watkiss approved engineer.

MULTISET : Enters the Multiset mode. Multiset allows multiple sets to be loaded and counted.

For example, a two part set can be loaded three times in a six bin collator. Normally only one set would be counted per cycle even though three are being fed at a time. In this case selecting Multiset 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.

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For this example you would press

MULTISET enter the number of sheets per set. Next enter the size of the batch by pressing SIZE , followed by and and

Multiset can also be used as a sheet counter when the are loaded and the required number of sheets is entered by pressing SIZE .

MULTIFEED

: To enter Multifeed mode, press

MULTISET

, # then press and hold

Finally press

MULTISET

MULTIFEED

until it changes to

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 per set. To change the Multifeed size, press

SIZE

, followed by the number of

Press and hold

MULTIFEED

until it changes to

MULTISET

to return to Multiset mode.

SIZE : Alters the number of sets per batch

To exit batch mode press

BATCH

from Menu 2 to enter the batch menu and deselect the options previously highlighted. Press

MENU

twice to return to Menu 1.

JOB MEMORY MENU To enter the job memory menu press

JOB

from Menu 2.

To exit the job memory menu without making any changes

Up to 9 job areas with different collator settings are saved in the memory. These are retained when the collator is switched off. The collator always operates in one of the job areas to determine its settings.

Any changes you make to the collator settings are automatically stored in the current job area. When the collator is switched on it automatically enters the most recently used job area.

MENU

12 Bins 1234 SPH Job : 1

000264

STAGGER

BATCH

OSCILL DIVERT

PRENUMBER SFT / SETS ↓

JOB

SETUP

SELECT

SPH 3000 PRENUMBER

DRV 60 DIVERT

AIR 37

STAGGER

SHORT

OFFSET 0mm

BATCH

MULTISET

INSERT ↑

PAUSE

Job: 2

SELECT

JOB +

JOB -

JOB +/-

: Used to browse the job areas saved in memory.

Sets per hour, drive speed, air blast and any selected options, such as prenumber etc., for the job are shown on the left of the display. Any selected batch options, such as pause etc., for the job are shown on the right of the display.

SELECT

: Press to select the current job shown on the display and return to the SFT menu.

ADVANCED MENU The Advanced Menu offers additional control over the collator. Under normal circumstances its functions will not be needed. Details of the Advanced Menu are included in Appendix 1.

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Friction Bins

Each Vario tower may have any number of Friction feed bins between 1 and 16. Additional bins can be added if required even after the machine has been installed.

For operation of Suction and SlimVAC bins please refer to the relevant chapters.

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.

2

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

’overrange’, see p.25)

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 requires loading

Grey button . . . . . . . . . Bin linking switch (see p.25)

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

LOADING Loading Sequence

There are two loading methods. Which one you use will depend upon the job in question and whether the sets are delivered to the front or rear of the machine.

1. Load the sheets face up and with the first page in the uppermost bin to give face up delivery to the rear or face down delivery to the front.

#1

#2

#3

Load sheets face up

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Tray Extenders

2. Load the sheets face down and with the first page in the bottom bin to give face down delivery to the rear or face up delivery to the front.

#3

#2

#1

Load sheets face down

For on-line booklet making at the rear of a bench top machine, use method 1.

When using the Vario rear corner stapler, use method 2, with the corner to be stapled loaded outermost.

Tray Extenders

For large sheet sizes (over A4, 8½ x 11") or when running

A4 (A4, 8½ x 11") portrait it will be necessary to fit tray extenders to support the sheets.

One B3 (14¼ x 20¼") tray extender is supplied as standard with each Friction bin.

An optional tray extender is available for running A4 portrait (8½ x 11") P/No. 251-303.

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. l

Bin Sidelays

Switching Bins On & Off

When in

TEST SET

mode, individual bins can be manually switched on and off by pressing the red button alongside the bin. Alternatively press

SETUP

to switch on all loaded bins. Remember that bins cannot be switched on or off when the system is locked.

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 downwards 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 position is used for the improved feeding of heavy cardstocks.

Note

On Friction bins prior to Release F (identified by air taps on the rear of the bins), this feature is not available. The separators must be removed to achieve this effect.

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24

Separator Pressure

Adjustment

Tray Pressure

Adjustment

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.

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 position gives minimum pressure. Initially set the pressure to minimum for small stock. For large sheets (i.e. if tray extenders are used) initially position 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

AIR +

and

AIR -

(see p.13). The

air level is also adjustable on each individual bin via a tap on the right hand sidelay.

Note

Friction bins prior to Release F also have air separation on the feed edge of each bin controlled by a tap at the rear.

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.

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 automatically take over. This allows reloading without stopping the machine. Bin linking can only be enabled when the bins are unlocked i.e. when

TEST SET

is shown on the menu. Press the grey button on the upper bin to link it with the one below. This will be indicated by the small green light.

By pressing the red bin on/off button it is possible to select which bin in the linked group is active (unless in prenumber mode).

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.

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26

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 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.

4

SlimVAC Bins

Each Vario tower may have any number of SlimVAC feed bins between 1 and 16. Additional bins can be added if required even after the machine has been installed.

For operation of Suction and Friction bins please refer to the individual chapters.

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.

2

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

’overrange’, see p.32)

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 requires loading

Grey button . . . . . . . . . Bin linking switch (see p.31)

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

LOADING Loading Sequence

There are two loading methods. Which one you use will depend upon the job in question and whether the sets are delivered to the front or rear of the machine.

1. Load the sheets face up and with the first page in the uppermost bin to give face up delivery to the rear or face down delivery to the front.

#1

#2

#3

Load sheets face up

27

28

Tray Extenders

2. Load the sheets face down and with the first page in the bottom bin to give face down delivery to the rear or face up delivery to the front.

#3

#2

#1

Load sheets face down

For on-line booklet making at the rear of a bench top machine, use method 1.

When using the Vario rear corner stapler, use method 2, with the corner to be stapled loaded outermost.

Tray Extenders

For large sheet sizes (over A4, 8½ x 11") or when running

A4 (A4, 8½ x 11") portrait it will be necessary to fit tray extenders to support the sheets.

One B3 (14¼ x 20¼") tray extender is supplied as standard with each SlimVAC bin.

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

Note

SlimVAC bins prior to serial number 1450 may have been supplied with only one type of endlay. Your local Watkiss supplier will be able to supply endlays if required.

P/No. 330-351 Rubber Endlay (VSLM)

P/No. 330-446 Rubber Endlay (VSLM) (small work)

330-351

B

When the rubber endlay will sit on the tray extender, position it so that ’A’ is underneath the paper stack.

A

330-351

A

When the rubber endlay will sit on the bar across the front edge of the bin, position it so that ’B’ is underneath the paper stack and the step is on the bar.

B

330-446

Step

When the rubber endlay will sit within the bin itself, use the special endlay 330-446. Position it so that ’C’ is underneath the paper stack.

C

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 collating small sheet sizes, make sure the tray loaded sensor is not covered by the rubber endlay.

The paper tray raises automatically when the collator 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 reason.

is pressed after the machine stops for any

29

30

Switching Bins On & Off

When in

TEST SET

mode, individual bins can be manually switched on and off by pressing the red button alongside the bin. Alternatively press

SETUP

to switch on all loaded bins. Remember that bins cannot be switched on or off when the system is locked.

ADJUSTMENTS There are three adjustments to the feed system which allow the collation 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 corrugation 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 infinitely 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 starting point if in doubt for initial running.

Tray height adjustment lever

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 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 of the air separation.

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).

RUNNING THE JOB Press

SETUP

to switch on all loaded bins. Set the drive speed to 80%, the air separation to about 40% and the sets per hour to about 2,000. These settings can be adjusted to suit the job if required. The air should just separate the top three or four sheets from the stack.

Press to feed a single test set. If the test set is satisfactory, press again to run the job. When the job is running satisfactorily, increase the sets per hour if required.

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 automatically take over. This allows reloading without stopping the machine. Bin linking can

31

32 only be enabled when the bins are unlocked i.e. when

TEST SET

is shown on the menu. Press the grey button on the upper bin to link it with the one below. This will be indicated by the small green light.

By pressing the red bin on/off button it is possible to select which bin in the linked group is active (unless in prenumber mode).

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 such as a straw board backing sheet may cause the bin sensor to go ’overrange’. 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.

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 characteristics vary and therefore any particular stock may require settings different to those shown.

Paper Condition

Standard Settings

• Suction Feeder angled down

• Tray height in mid-position

• Sheet corrugation in mid-position

Recommended Settings

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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34

Paper Condition

Stock curling up

The upward curl means the tray height detector will ‘see’ the paper before it is close enough to the feeder.

Recommended Settings

Lightweight porous papers

• Raise the tray height to lift the paper stack closer to the feeder.

The feeder may suck through one sheet and onto the next, resulting in double feeds.

• Increase sheet corrugation.

• Lower the tray height to increase the distance between the feeder and the paper stack.

5

Suction Bins

Each Vario tower may have any number of Suction feed bins between 1 and 8. Additional bins can be added if required even after the machine has been installed.

For operation of SlimVAC and Friction bins please refer to the individual chapters.

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.

2

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

Grey button . . . . . . . . . Tray lowering/raising switch

Small lower green light. Flashes when the tray is in transit and stays on when the tray is at the top of its travel.

ADJUSTMENTS Unlike Friction and SlimVAC bins, Suction bin feed adjustments should be made before loading the trays with paper.

Closed

(off)

Open

(on)

Sheet Width

Take a sheet of the stock to be collated and place it in the bin between the two locating pins in the base of the tray (which should be slid inwards to centralise the paper).

Switch off any suckers that would be off the edge of the paper by turning the tap to the left. Switch on the remainder by turning the tap to the right (so the orange spot is to the front).

Insert plugs into alternate pairs of suckers, starting from the centre. The flat edge of the plugs should face towards

35

36

TOP

Taps

BOTTOM

Plugs

X-Section the front of the machine and run parallel with the manifold.

The suckers produce the corrugation in the sheet which ensures effective sheet separation (see x-section below).

Whilst doing this, check that all the sucker cups are

undamaged and that they are correctly seated (see p.69).

Repeat this procedure for all bins.

Stock to be Collated

PN 310-537, Plastic Mould (VSCN) Manifold Plug Open

PN 310-589, Rubber (VSCN) Manifold Plug Closed

Edge Flick Control

This controls the depth of the edge flick. For most materials it should be in the mid-position. If more separation is required (e.g. when the feed edge of the stock is curled up), increase the depth of the edge flick by moving the control downwards. If less separation is required (e.g.

heavy card stock), decrease the depth of the edge flick by moving the control upwards.

Edge Flick

Control

LOADING Loading Sequence

There are two loading methods. Which one you use will depend upon the job in question and whether the sets are delivered to the front or rear of the machine.

1. Load the sheets face up and with the first page in the uppermost bin to give face up delivery to the rear or face down delivery to the front.

#1

#2

#3

Load sheets face up

2. Load the sheets face down and with the first page in the bottom bin to give face down delivery to the rear or face up delivery to the front.

#3

#2

#1

Load sheets face down

For on-line booklet making at the rear of a bench top machine, use method 1.

When using the Vario rear corner stapler, use method 2, with the corner to be stapled loaded outermost.

Loading the Bins

Normally the trays are all in the up position, in order to load the bins they must first be lowered. Starting with the bottom bin (bin 1), press the grey bin lowering button and then load the bin, lower bin 2 and load it, lower bin 3 and load it etc.. In this way the gap between the bins is maximised and access into the bin is improved.

Unused bins may be lowered for loading during a run by pressing the grey button.

Slide the stock into the bin, centralising it between the two locating pins in the base of the bin which should be slid inwards to meet the edge of the paper stack. Ensure

37

38 the stack is loaded neatly and square, and then place the magnetic sidelays on all three sides.

Press

SETUP

to switch on all loaded bins. Set the drive speed to 80%, the air separation to about 30% and the sets per hour to about 2,000. These settings can be adjusted to suit the job if required. The air should just separate the top two or three sheets from the stack whilst the machine is idling. If necessary the air can be individually controlled for each bin by using the taps on the rear of the bins.

Press to feed a single test set. If the test set is satisfactory press again to run the job. When the job is running satisfactorily, increase the sets per hour if required.

Whenever feed difficulties are encountered we always recommend that you follow two golden rules:

• Switch off all the bins except one and look at only one bin at a time.

• Ensure that only one 'remedy' is tried at a time. This will make it much easier to identify the solution.

Porous papers

Porous papers are more inclined to feed doubles as the suction sucks through one sheet and onto the next. This can be overcome by checking that the plugs are correctly

inserted (see p.40). Close the tap on any sucker where

an open plug is fitted.

Deformed sheets

Where the sheets are deformed such that the stack has high and low points, not all suckers will be able to make contact with the stack. Therefore the taps should be switched off at either all the 'high spots', or alternatively at all the ’low spots’.

Switching Bins On & Off

When in

TEST SET

mode, individual bins can be manually switched on and off by pressing the red button alongside the bin. Alternatively press

SETUP

to switch on all loaded bins. Remember that bins cannot be switched on or off when the system is locked.

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 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.

ADVANCED

ADJUSTMENTS

Tray Height

The tray height is factory set and should be as shown in the illustration below. With the tray raised and the air switched off, the top of the paper stack should come up to the bottom edge of the centre blow nozzle. Note that the top blow nozzle is plugged closed but is still visible.

If for any reason the tray height is out of adjustment, reliable feeding will not be achieved and so adjustment will be necessary via the orange control knob, as shown alongside. Turning the knob in the + direction will raise the tray height, whilst turning it in the - direction will lower the tray height.

Edge Flick Tray Height Switch Blow Nozzles

Paper Stack

Control Knob (Hidden)

Correct Height of Paper Stack in Relation to Blow Nozzles

39

40

Edge Flick

Spring Steel Edge Flick

Removing the Outer Edge Flicks

Under some circumstances, especially when collating very light weight and flimsy paper, the edges of the sheets may catch on the outer edge flicks and become creased.

These can therefore be removed by first pushing the edge flick control lever fully downwards (so the edge flicks are in their outermost position), then slide the edge flick to the right and pull out. The control lever should then be returned to its operating position to allow the inner edge flicks to function normally. Be sure to replace the edge flicks on completion of the job.

Spring Steel Edge Flicks

When collating stiff board it may be necessary to remove the outer edge flicks and to replace the inner ones with the optional spring steel edge flicks (P/No. 909-985).

Additional Sucker Configurations

Certain stocks may require different sucker/plug configurations to those previously detailed.

The following suggested settings are a recommendation only. Paper characteristics vary and therefore any particular stock may require settings different to those shown below.

Coated / Carbonless

A4 (8½ x 11")

Note: Under some conditions plugs may be omitted

Porous A4 (8½ x 11")

Coated / Carbonless

A3 (11 x 17")

Porous A3 (11 x 17")

Card A3 (11 x 17")

.

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42

THIS PAGE IS

INTENTIONALLY

BLANK

6

Bench Base

Three different bases are available for the Vario, a bench base, an oscillating bench base and a floor base. If your machine is fitted with an oscillating bench base, please refer to Section 7. If your machine is fitted with a floor base, please refer to Section 8.

SETTING UP THE

STACKER

Take a few sheets of the stock to be collated and place them in the stacker. Move the sliding sidelays in to fit the width of the sheet.

Using

INCH

’park’ the stacker tamper in its forward position. Hold the sheets so that the top edge is barely touching the stacker tamper and then slide the end lay up to meet the bottom edge of the sheet. Note that the endlay is reversible to accommodate different paper sizes.

Stacker Tamper

Sliding Sidelays

Magnetic Lay

End Lay

The Bench Base with A4 (8.5 x 11") Paper

The Bench Base with A3

(11 x 17") Paper.

For small sheet sizes, position the magnetic lays so that they support the bottom corners of the stack. For large sheet sizes they should be positioned at an angle along the sides of the stack so that they guide the sheets and ensure a neat stack.

43

44

OFFSET STACKING There are a number of ways in which the collated sets can be separated in the bench base stacker. The choice of which method is used will depend upon the collating task in question.

1 2

1.

Stacker Offset Sidelay

2.

Bin Offset Sidelay

Sheet Offset Separation

By offsetting a single sheet in the set, the sets can be efficiently separated without any reduction in speed. Two offset sidelays are supplied with the straight stacker.

The bin offset sidelay should be clipped on to the left hand sidelay of the top bin. This will offset the single sheet. The stacker offset sidelay should be fitted to the left hand sliding sidelay in the stacker, by sliding on from the top, to compensate for the offset sheet.

Use of a Slip Sheet

If the number of sheets in the set means that there is an unused feed bin, use the bottom bin to feed a slip sheet as part of the set. A slip sheet is usually a different colour, or a slightly larger size than the rest of the set to allow easy separation. Where the job is A4 (or 8½ x 11") in size, the slip sheet can be fed portrait whilst the remainder of the job is fed landscape (see below).

Set Offset

If the job is A4 (or 8½ x 11") size and has only half the number of sheets as the machine has feed bins; load the job twice up, one half portrait and one half landscape. Position the stacker sidelays as indicated alongside. This will separate the sets and double the production rate at the same time.

(Note: the portrait set should be loaded in the lower bins to ensure good stacking.)

DELIVERING TO THE

REAR

Under normal circumstances the sets are delivered to the front of the collator. The sets can also be delivered to the rear into, for example, the Watkiss Vario corner stapler,

or into an on-line booklet maker. The stacker tray may also be positioned at the rear, in which case it must be supported by the edge of the work bench.

The deflector lever at the front of the stacker base should be pivoted upwards for delivery to the rear, and pivoted downwards for delivery to the front.

Delivery Direction Lever

Rear Delivery

Front Delivery

On earlier machines there is no lever so the deflector fingers must be moved from the rear (see below). The fingers should be pivoted forwards for delivery to the rear, and pivoted backwards for delivery to the front.

Deflector Fingers

Positioning the Stacker Tray at the Rear

Disconnect the earth connection at the back left of the tray. Lift the inner edge of the tray firmly upwards to release it from the mounting bar. Position the tray at the rear, locating the clips over the mounting bar, and push down firmly. Connect the earth connection at the back left of the tray (viewed from the rear of the machine).

45

46

Rear Delivery Front Delivery

STACKER FULL

SENSOR

When the stacker is full the collator will automatically stop and the display will show ’Stacker full’. The sensor only operates when feeding to the front of the collator.

PAPER GUIDES There are paper guides at the delivery outfeed both at the front and at the rear of the collator.

Their purpose is to cup the set so that the sheets travel smoothly into the stacker. They can be flipped up or down, and under normal circumstances should all be down except EITHER the middle one OR the outermost ones relative to the sheet size in use. The optimal positioning will vary with sheet size, direction of grain, paper weight etc.

Tube

Paper Guides

at the Front

DEFLECTOR STRIP A deflector strip is provided to aid the stacking of large flimsy sheets such as NCR. As flimsy or curly sheets enter the receiving tray they may ride up against the endlay causing an untidy stack.

To remedy this, clip the deflector strip to the underside of the grey tube (see above) at the front of the bench base. The strip should be positioned between one of the sidelays and the endlay; and should rest on the edge of the stack, level with the endlay.

Deflector Strip

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INTENTIONALLY

BLANK

7

Oscillating Bench Base

Three different bases are available for the Vario, a bench base, an oscillating bench base and a floor base. If your machine is fitted with a bench base, please refer to

Section 6. If your machine is fitted with a floor base, please refer to section 8.

SETTING UP THE

STACKER

The Scale

The “L” shaped guide marks on the stacker scale represent the sidelay positions for various standard paper sizes. The dark grey coloured scale is for European 'A' sizes, the red for Imperial sizes and the green for Japanese 'B' sizes. Smaller sizes have two sets of marks corresponding to either landscape or portrait orientation.

Magnetic Sidelay

Anti-static Cable

Paper Tray

Scale

The Oscillating Bench Base With A4 (8½ x 11) Paper

Align the Sidelays

Position the two magnetic sidelays on the scale using the appropriate guide marks for the chosen paper. Take into account the orientation (i.e. portrait or landscape) and size of the paper.

The sidelays should be positioned so that their outer edge aligns with the inner edge of the guide mark. The dotted

49

lines in the illustration indicate the correct alignment of the sidelay with the guide mark.

Sidelay

50

Guide Mark

Paper Size Shown here

Sidelay and Guide Mark Alignment

Important

Ensure the sidelay anti-static cables (see p.49) are

connected to the paper tray.

STRAIGHT STACKING For straight stacking the appropriate solid guide marks are used for both sidelays.

OFFSET STACKING For offset stacking the position of the left sidelay is the same as for straight stacking. The right sidelay must be aligned with the corresponding unfilled guide mark on the right side of the stacker tray.

Press

OSCILL

MENU

and then

OSCILL

on the control panel to enable the oscillating function. Batch offsetting is also available from the control panel by pressing

MENU

,

BATCH

and then

.

The sidelays' position can be adjusted during initial collating if necessary to ensure neat stacking.

NON-STANDARD

PAPER SIZES

For non-standard paper sizes a different method is required.

Straight Stacking

Take a few sheets of the paper and align them centrally between the guide marks for the next standard size up.

Position the sidelays on the base leaving a 5mm (¼”) gap between the inside corner of the sidelay and the paper.

Offset Stacking

For offset stacking, setup as above and then move the right sidelay 25mm (1") to the right whilst keeping it aligned with the bottom edge of the paper.

As before, the sidelays' position can be adjusted after initial collating to ensure neat stacking.

25mm (1")

Offset Stacking Sidelay Positioning

STACKING A5

SHEETS

It is recommended that A5 (6 x 8½") sheets are stacked in landscape orientation whenever possible as this will give better results.

PAPER GUIDES The purpose of the paper guides is to make the paper rigid in order for the sheets to travel smoothly into the stacker. They can be flipped up or down, and under normal circumstances should all be down except EITHER the middle one OR the outermost ones relative to the sheet size (the optimal positioning will vary with sheet size, direction of grain, paper weight etc.).

51

52

Paper

Guides

Tip

If the back edge of the paper stack is uneven this may be due to trailing sheets. Identify the bin that is trailing and adjust the feed to remedy the problem.

PAPER DELIVERY

DIRECTION LEVER

Paper can be delivered to the front or the rear of the machine. The direction is selected using the paper delivery direction lever. This has three positions, the top position delivers paper to the oscillating tray. The bottom position delivers paper to the rear of the collator, into a jogger for example. The middle position is currently not used but would deliver the set vertically downwards.

Delivery Direction Lever

Front Delivery

Downwards Delivery

(currently not used)

Rear Delivery

Front Feedout

Conveyor Release

Lever

Front Feedout

Conveyor

Paper Guides

8

Floor Base

Three different bases are available for the Vario, a bench base, an oscillating base and a floor base. If your machine is fitted with a bench base, please refer to Section 6. If your machine is fitted with an oscillating bench base, please refer to Section 7.

The floor base is required to operate the Stitch-Fold and

Deep Pile Stacker modules. The floor base must be used with a jogger or one of the above modules as it does not have an integral stacker.

Remote

Control

Socket

Air Tap

Air Blast

Supply

Divert Catch

Tray

The Floor Base

Interface Sockets

The interface sockets are located on the right underside of the floor base, below the front air control (see diagram below). There are four sockets in all. One each for the

Deep Pile Stacker, Stitch-Fold, Twin Tower Link/Inline

Tower Link and jogger. Each type of socket will only accept the correct interface cable.

53

54

Deep Pile

Stacker

Stitch-Fold

Twin/In-line

Tower Link

Jogger

SETTING UP THE

FLOOR BASE

Front Feedout Conveyor

The front feedout conveyor has two positions, raised or lowered. It is secured in its raised position by a lever at

the front of the base (see photo p.53). To lower, simply

turn the lever clockwise. To raise, lift the conveyor up and turn the lever anti-clockwise.

When feeding into a jogger the front feed out conveyor

should be in its lower position (see photo p.53).

When feeding into a Stitch Fold unit it is essential that the conveyor is in its upper (horizontal) position. All the paper guides, located between the two shafts on the front underside of the conveyor, should also be pushed up.

Failure to do this will result in damage to the collator.

When feeding into a Deep Pile Stacker unit it is essential that the front feedout conveyor is removed. Please refer to your Watkiss supplier for more information. The divert catch tray should also be removed.

Air Blast

When stacking large and/or flimsy sheets, such as carbonless paper, air can be directed into the jogger to aid neat stacking.

The volume of air is controlled by an air tap (see p.53).

Turning the tap to the right provides more air, and turning to the left reduces the air. When not using the jogger, ensure that the tap is turned off (fully left) to preserve system air.

Air should usually be directed at the bottom corner of the stack, but different positioning may be necessary to suit the paper characteristics, curl etc.. A combination of air pipes and connectors are provided to allow optimum positioning.

Air Tap

Air Pipes and Connectors

SETTING THE

PAPER PATH

Rear Deflector Fingers

The rear deflector fingers allow you to determine if sets are delivered to the front or the rear of the machine. They are located at the rear of the floor base and can be pivoted forwards or backwards via a lever to alter the paper path.

When feeding to the front of the machine, paper exits the floor base either forwards or straight down. The paper path is adjusted automatically depending on whether you are feeding into a Jogger, Deep Pile Stacker or Stitch-

Fold. If required this can be over-ridden using

SETS ↓

(see p.14).

Front Delivery

Rear Delivery

Rear Deflector Lever

55

56

A

Feeding into a Jogger at the Front

Ensure the divert catch tray (B) is fitted correctly. It should hang vertically down between the base back bar and central shaft under the conveyor.

Position and set up the jogger in front of the floor base

(see photo p.59).

B

Push the rear deflector lever up to move the rear deflector fingers (A) out of the paper path which is shown by the dotted line.

Feeding into a Jogger at the Front

Selecting

DIVERT

from Menu 2 on the control panel will divert any faulty sets into the catch tray (B).

B

A

Feeding into a Stitch Fold

Push the rear deflector lever up to move the rear deflector fingers (A) out of the paper path which is shown by the dotted line.

Selecting DIVERT from Menu 2 on the control panel will now divert any faulty sets onto the top of the Stitch-Fold unit (B).

Feeding into a Stitch Fold

REAR FEEDOUT

CONVEYOR

(OPTIONAL)

The rear feedout conveyor is an option to allow rear delivery from a floor base into a jogger.

Rear Feedout Conveyor

Rear Feedout Conveyor and Jogger

A

Feeding to the Rear

When delivering to the rear of the floor base, the rear deflector lever should be pushed down so that the fingers

(A) deflect the paper to the rear.

When delivering to the rear the DIVERT function is not available. If the collator stops because of a miss or double feed the set with the error(s) will be on the top of the stack.

Feeding to the Rear

PAPER JAMS If a paper jam occurs in the base, the drive mechanism is automatically disengaged. If required, remove the rear guard and/or Stitch-Fold etc. and remove any jammed sheets. Replace the rear guard and press tinue the job.

to con-

REMOTE CONTROL

(OPTIONAL)

The remote control handset (supplied with the Stitch-Fold unit and also available separately P/N 42-260) can be used to control certain functions on floor standing Varios.

The remote control interface socket is located on the front of the base on the right hand side.

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58

The Remote Control handset

Button Functions

: Starts the collator

: Stops the collator

: Decreases the drive speed

: Increases the drive speed

: Inches the conveyor

Note

If using the remote control to operate a Stitch Fold unit off-line, the button functions are different. See the Stitch

Fold operating manual for details

9

Joggers

There are two types of jogger available for the Vario, the

X-Jogger and the Straight Jogger. The X-Jogger straight or offset stacks whilst the Straight Jogger is used when set separation is not required.

X-JOGGER Setting Up the Jogger

Position the X-Jogger under the collator as shown. Connect the jogger to the mains supply and switch on.

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 (see p.53).

The X-Jogger with A3 (11 x 17")

Paper

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.

X

X

Stacker Air Blast

Width Adjustment

Support Post

Bottom Sidelay

Adjustment

The X-Jogger with A4 (8½ x 11") Paper

59

60

Adjust the position of the support posts by twisting anticlockwise 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. Slide it further in or out so that the back edge of the stack is level with the outfeed of the collator.

Adjust the direction of the air blast towards the bottom edge of the stack, using a combination of air pipes and connectors to suit the paper size.

Select

OSCILL

(if required) from the control panel menu and run a test set.

If needed, fine adjust the position of the sidelays, support posts and air blast 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 Stack Liner

A Straight Stack Liner is available for the X-Jogger to increase straight stacking performance, especially when collating carbonless paper (Part No. 914-304).

Using the Jogger with a Bench Top Vario

The X-Jogger cannot be used with a standard bench top base. However, it can be used with an oscillating bench base. Please refer to your Watkiss supplier for more information.

STRAIGHT JOGGER Setting up the Jogger

Wheel the Straight Jogger into a central position under the collator (as shown in the diagram for the X-Jogger

p.59). 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.

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 (see p.53).

Adjust the direction of the air blast towards the bottom edge of the stack. For large sheet sizes it will be necessary to use the extension tubes.

Mains On/Off

Switch

Mains Input

Local Control

Switch

Jogging

Adjustment

Straight Jogger Fed From the Rear of a Floor Base

Run a test set and If necessary, adjust the position of the jogger. Wheel it further in or out so that the paper falls neatly into the receiving area. A sideways positional adjustment may also be necessary depending on the size of the paper and type of stock.

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.

Using the Jogger with a Bench Top Vario

The Straight Jogger can be interfaced with either a standard or oscillating bench base. In both cases please refer to your Watkiss supplier for more information. The Straight

Jogger can be also be used off-line either independently or with any of the Vario bases (see below).

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Jogging Off-line

The straight jogger can also be used off-line. Connect the jogger to the mains and switch on both the mains on/off switch and the local control switch.

10

Rear Corner Stapler

The Vario Rear Corner Stapler (RCS) is an optional accessory that may be fitted onto your Vario. This unit fits onto the rear of the collator.

Loading the Collator

The sheets should be loaded face down and with the top page in the bottom bin. The corner to be stapled should be loaded outermost.

Adjusting the RCS

• Take a sheet of paper the same size as that to be stapled.

• With the top hinged cover closed, adjust the infeed sidelays for the sheet width by turning the hand-wheel so that the sidelays correspond to the appropriate point on the scale.

Top knock

Infeed Sidelay Scale

Infeed Sidelays

Infeed Sidelay

Adjustment

RCS Bypass Lever

• Open the top hinged cover of the corner stapler, this will cause the sidelays to move to their inner position.

Insert the sheet between the sidelays and make any fine adjustments required. The sidelays must tidy the set, yet still allow the sheets to fall freely between them.

• In the orientation in which it is to be stapled, stand the sheet inside the RCS so that it is resting on the small rollers. Adjust the top knock by sliding it up or down so that it is approximately 5mm clear of the edge of the sheet.

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64

• Ensure that the RCS bypass lever is in the down position (In the up position sets will still be delivered to the rear of the collator, but will feed out below the RCS).

Adjusting the Collator

Move the set divert lever to the upper position (for delivery to the rear).

Error Messages

Error messages will be shown on the display (see p.79)

for any of the following reasons :

• There is a paper jam in the stapler.

• There is a problem with the staple head.

• The staple cartridge is nearly finished.

• The lid of the stapler unit is open.

Loading the Staple Cartridge

The RCS uses staple cartridges, each holding 5,000 staples. These can be reordered from your Watkiss supplier quoting part number 800-020.

• Open the access flap and release the red cartridge retaining spring by pushing firmly to the right.

• Pull out the used cartridge.

• Prepare the new cartridge by pulling out a small amount of staple strip, and tearing off along the tear line.

• Insert the new cartridge pushing it firmly into place.

• Push the red spring firmly to the left until it clicks into place on the cartridge. It is essential that the cartridge is securely held.

Red Retaining Clip

Each staple cartridge holds 5,000 staples. When it is nearly empty, ’STAPLES LOW’ is displayed on the control panel. This operates from an inbuilt counter, therefore if a staple cartridge is changed when it is only part used, the staple counter will need resetting (see below).

Resetting the Staple Counter

Remove the side cover from the machine by releasing the securing screw, located in the centre, bottom inside edge of the cover, and then lifting the cover up and away. Press and hold the manual feed button whilst the stapler triggers and continue to hold until the red light goes out.

Manual Feed Button

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11

Maintenance

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

OPERATOR

MAINTENANCE

As with all machinery, your Vario will benefit from periodic cleaning of general accumulations of paper dust, ink etc.

Other operator maintenance is detailed below.

CONVEYOR WHEELS The conveyor wheels should be cleaned periodically to remove any accumulations of ink etc. The cleaning interval depends upon the usage level and stock characteristics.

Conveyor

Wheel

• Remove the rear guard by lifting up and out.

• Turn the black conveyor wheels by hand whilst cleaning with a cloth dampened with soapy water.

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.

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Paper Separator

B

• 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.

• 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).

• 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

from the advanced menu (See p.86)

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.

Important

Do not use any of the following chemicals to clean the separators, 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, perchloroethylene genclenes.

All of these chemicals will damage the separators, feed wheels and conveyor wheels to a varying degree resulting in poor performance and premature failure.

SUCTION FEED BINS Suckers (P/No. 330-035)

In the event that unexplained misfeeds are occurring it is possible that the sucker cups have become worn or damaged and should be replaced. The frequency will depend upon the usage of the machine and the type of material being collated.

Suction Manifold Showing Correct

Sucker Fitment

• Select

CLEANING

from the advanced menu (see p.86).

• Press and hold the red button on the bin controls to drop the manifold for access.

• Whilst continuing to hold the red button, press

CLEANING again so that the manifold remains in the down position.

• Remove the sucker cups, inspect, and replace any that appear worn, either evenly or on one side, or are damaged. When replacing, ensure the suckers are correctly seated on the manifold.

• Select

CLEANING

again and press the red button to return the manifold to its original position.

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Shaft

Tray Lift Cable

Repairing Overloaded Trays

In the event of one of the Suction bin trays becoming severely obstructed or overloaded, there is a safety mechanism which causes the tray lift cable support shear pins to break. Under certain conditions the cable itself may also break. This is intentional and is designed to prevent injury to the operator or damage to the machine. Refitting either of these parts is simple and is explained below.

Tray

Shear Pin

Noose

Fitting the Cable

• Ensure that the tray is fully down.

• Remove the existing cable by unthreading it from the hole in the shaft.

• Insert the new cable, noose end first, into the hole in the shaft and pull through (note that the entry hole is larger than the exit hole).

• Ensure that the cable is wrapped around the shaft to match the cable on the other side of the tray.

Fitting the Shear Pin

• Open the noose in the end of the cable and then, lifting the tray with one hand, pass the cable through the hole in the tray.

• Insert the shear pin through the noose and gently lower the tray ensuring that the flat side of the pin lies against the bottom of the tray.

• Raise the tray and ensure that the cable wraps smoothly around the shaft. The cable should wind progressively inwards.

Part NoDescription

370-203 Tray Lifting Cable (VSCN)

310-444 PL Mould (VSCN) Lift Wire Shear Pin

Note

Two spare shear pins are supplied with each new suction bin and two spare tray lifting cables are supplied with each new machine

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12

Problem Solving

As far as possible the Vario has been designed to be self-explanatory. In most cases problems or errors will be identified on the control panel. The following is a further guideline to help solve any problems. If a problem persists, please call the Watkiss

Service Department or your Watkiss Dealer.

GENERAL PROBLEMS

Problem Cause Solution

THE MACHINE WILL NOT

POWER UP

The machine is not plugged in

Faulty fuse

Plug in and switch on

Check the fuse at the mains input

and replace if necessary (see p.79)

THE MACHINE WILL NOT START Several possible causes, exact cause will be shown on the display

Correct any faults shown on the display

TOP AND/OR BOTTOM BIN

ONLY FEEDS ON TEST SET

Batch insert selected from batch menu

Press MENU and then BATCH .

Check to see if

INSERT ↓

INSERT ↑ or

is selected. If so, deselect

DOUBLE FEEDS ARE NOT

BEING DETECTED

The bin sensor is ’overrange’ due to the feeding of particularly heavy or opaque stock. The red light on the bin controls will flash slowly when the sensor is overrange

N/A

DOUBLE/MISS FEEDS ARE NOT

BEING DIVERTED

The diverter fingers in the floor base are jammed on the paper guides

Realign the fingers so that they can move freely

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FRICTION FEED PROBLEMS

Problem

DOUBLE FEEDS

MISS FEEDS

Cause

Too much tray pressure

Too little separation pressure

Insufficient air separation

Worn or missing separators

Bad guillotine burr, or blunt drilling

Solution

Reduce by moving handle in by

one notch at a time (see p.24)

Increase by moving the lever

down by one notch at a time (see p.23)

Increase air separation via the control panel AIR +

Check separators are present,

and replace if worn (see p.67)

Fan the stock by hand before loading, ensure paper is cut well next time

Miscalibration during the test set Run another test set by pressing

END JOB

, ,

Too little tray pressure Increase by pulling the handle out

by one notch at a time (see p.24)

Too much separation pressure

Untidy loading

Reduce by moving the lever up

by one notch at a time (see p.23)

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.68)

Miscalibration during the test set Run another test set by pressing

END JOB

,

TEST SET , . It may be necessary to increase the tray pressure to obtain a better feed

FRICTION FEED PROBLEMS

Problem

TRAILING FEED

(On a trailing sheet the machine stops immediately. You need to look carefully to identify which of the following is the cause. The faulty set can be inched through by pressing and holding INCH

)

PAPER JAM

FRONT EDGE OF SHEET

DAMAGED

Cause

Late feeding double sheet

Slow feeding sheet

Slow feeding during test set causing incorrect calibration

Sheet is jammed in the paper path

Sheet is only half feeding

Feeding A5 (5½ x 8½") landscape without selecting from the advanced menu

SHORT

Too much separation pressure

Solution

Treat as double feed above

Treat as miss feed above

Run another test set by pressing

END JOB

,

TEST SET , . It may be necessary to increase the tray pressure to obtain a better feed

Locate the sheet and either pull it out or INCH it through

Treat as miss feed above

Select SHORT

(see p.86) from

the advanced menu and run another test set by pressing

END JOB

, ,

Reduce by moving the lever up

by one notch at a time (see p.23)

SLIMVAC FEED PROBLEMS

Problem Cause

DOUBLE FEEDS The tray is too high

Not enough corrugation on suction feeder

Mechanical paper problem - guillotine burr, sticky ink, poor perforations, high static charge etc.

Rubber endlay is incorrect type or position

Action

Lower the tray height (see p.31)

Increase sheet corrugation (see p.30)

Fan stock by hand before loading, and ensure these problems are avoided in future

Use correct type and positioning

(see p.29)

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SLIMVAC FEED PROBLEMS

Problem

MISS FEEDS

Cause

Not enough air separation

Too much sheet corrugation

The tray is too low

Heavy and/or rigid sheets

Paper has curly edge

Rubber endlay is too tight against the paper stack, or is incorrect type

Action

Increase air separation via the control panel AIR +

Reduce the sheet corrugation

(see p.30)

Raise the tray height (see p.31)

Raise the angle of the suction

feeder (see p.31)

Refer to recommended settings

(see p.34)

Position the endlay approx.

1mm (1/16”) clear of the edge of the stack. Ensure it is the correct

type for the paper size (see p.29)

Treat as a double feed

Treat as a miss feed

TRAILING FEED

(On a trailing sheet the machine stops immediately. You need to look carefully to identify which of the following is the cause. The faulty set can be inched through by pressing and holding INCH

)

PAPER JAM

FRONT EDGE OF SHEET

DAMAGED

Trailing double feed

Trailing single feed

Sheet is pre-feeding

Sheet is miss feeding

Too much sheet corrugation

Treat as a double feed

Treat as a miss feed

Reduce the sheet corrugation

(see p.30)

SUCTION FEED PROBLEMS

Problem

DOUBLE FEEDS

MISS FEEDS

Cause

Incorrectly positioned sucker plugs

Porous paper

Too little edge flick

The tray is too high

The edge flick is set too deep

Sucker cups are damaged or are incorrectly seated

Insufficient suction for heavy/ thick stock

Tray is too low

Action

Check the positioning of the

plugs (see p.35)

Refer to section on porous

paper (see p.38)

Increase the edge flick depth by

lowering the control (see p.36)

Lower the tray (see p.39)

Reduce the edge flick depth by

raising the control (see p.36)

Check and replace/refit any

faulty sucker cups (see p.69)

Remove the plugs from all suckers

Adjust the tray height accord-

ingly (see p.39)

Treat as double feed above

Treat as miss feed above

Run another test set by pressing

END JOB

, ,

TRAILING FEED

(On a trailing sheet the machine stops immediately. You need to look carefully to identify which of the following is the cause. The faulty set can be inched through by pressing and holding INCH

)

PAPER JAM

Late feeding double sheet

Slow feeding sheet

Slow feeding during test set causing incorrect calibration

CREASED CORNERS

’BIN OVERLOAD' MESSAGE

AND SMALL GREEN LIGHT IS

BLIPPING (• • • •)

Sheet is jammed in the paper path

Sheet is only half feeding

Soft paper is being 'sucked up' into the sucker

The corners of the sheet are catching on the outer edge flicks

An obstruction in the bin is preventing it from lifting correctly

Locate the sheet and either pull it out or INCH it through

Treat as miss feed above

Fit open plugs to the outer most suckers on the sheet (PN 310-

537, Plastic Mould (VSCN) Manifold plug open)

Remove the outer edge flicks

(see p.40)

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

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SUCTION FEED PROBLEMS

Problem

’BIN # LIFT ERROR'

MESSAGE AND SMALL

GREEN LIGHT IS FLASHING

QUICKLY (• • • •)

Cause

Too much paper has been loaded into the bin (note that the grey button will not raise or lower the tray)

Action

Remove the stock and reload a smaller quantity:

An obstruction in the bin has prevented the tray from lowering correctly. This has caused the tray lift cable to reverse-wrap and raise the tray again

The tray is too low

340x520mm

13¼"x20¼"

364x520mm

14¼"x20¼"

100mm

4"

88mm

3¾"

Remove any obstructions and then press the grey button, the tray lift cable will automatically correct itself

Adjust accordingly (see p.39)

X-JOGGER PROBLEMS

Problem Cause

NOT OFFSET STACKING OSCILL is not available or not selected on the control panel

Stacker is not set up correctly

Poor set delivery

Solution

Plug X-Jogger into the Vario and select panel

OSCILL on the control

Follow set up instructions (see p.59)

Adjust drive speed to suit the stock and if necessary adjust the paper guides

OSCILLATING BASE PROBLEMS

Problem Cause

NOT OFFSET STACKING OSCILL is not selected on the control panel

An obstruction is stopping the tray from moving

The sidelays are too tight

Solution

Select panel

OSCILL on the control

Remove obstruction

Readjust the sidelays

REPLACING FUSES Your Vario is fitted with two fuses at the mains input. If either of these fail the machine will not power up.

Caution!

The Vario system uses double-pole/neutral fusing (ie, two fuses), so 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.

Reference

240V machines:

730-018 Fuse, 1½" (32mm) 7.0A HRC (Quick Acting, F)

115V machines:

730-020 Fuse, 1½" (32mm) 10.0A HRC (Quick Acting, F)

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.

Message

BIN # RESET

BIN # DOUBLE

BIN # MISS

Cause

An error has occurred in the electronics of the bin detailed.

Any number over 16 relates to a module other than a bin

A double feed error has occurred on the bin detailed

A miss feed error has occurred on the bin detailed

Action

Press any key to restart the machine. If the problem persists, contact your local Watkiss service department

If the error persists, refer to the troubleshooting chart to remedy the problem

If the error persists, refer to the troubleshooting chart to remedy the problem

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Message

BIN # JAM

BIN # TRAILING

BIN # EMPTY

BIN # LIFT ERROR

(Suction only)

BIN # MISCAL

BIN # OVERLOAD

(Suction only)

BIN # PART RESET

CANNOT START SFT CHANG-

ING AXIS

Cause Action

A paper jam has occurred in the bin detailed

A trailing feed error has occurred on the bin detailed

The paper tray of the bin detailed is empty

Too much paper has been loaded into the bin (note that the grey button will not raise or lower the tray)

Clear the jam. Use INCH to clear any partial sets from the conveyor. If the error persists, refer to the troubleshooting chart to remedy the problem

If the error persists, refer to the troubleshooting chart to remedy the problem

Reload the bin and press to continue the job

Remove the stock and reload a smaller quantity:

A feed/sensor error has occurred during the test set

An obstruction in the bin is preventing it from lifting correctly

An error has occurred in the electronics of the bin detailed.

Automatic Stitch-Fold is in the process of adjusting axes

340x520mm

13¼"x20¼"

364x520mm

14¼"x20¼"

100mm

4"

88mm

3¾"

Recalibration is automatic but check the very first set for errors

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

Press END JOB and switch on the affected bin via the red button on the bin controls. Press

TEST SET and then continue the job

to

Wait for the ASF to finish adjusting before pressing

CANNOT START SIDELAY

OVER STITCH

Automatic Stitch-Fold stitch heads are adjusted over the bottom of the infeed sidelays. Sensors prevent the ASF from stitching if this happens in order to prevent damage to both the head and the sidelay

Adjust the stitch heads so that they do not activate the safety sensors

Message Cause Action

CANNOT START TRAY DOWN

CANNOT START TRAY EMPTY

CHECK FUSE F#

CONVEYOR JAM

EMERGENCY STOP

ERROR ON 9V RAIL

FUSE(S) BLOWN

MOTOR STALLED

NO POWER TO STACKER

NO ZEROX or SLOW ZEROX

SlimVAC: During the start up sequence one of the trays has not raised to the running position

Suction: The grey up/down button has been pressed , sending the tray to its down position

One of the switched on bins was

Possible blown fuse in the drive unit

A paper jam has occurred in the bottom of the conveyor

Check that the tray is not obstructed and press again. If the problem persists contact your local Watkiss service department

Press the grey button on the bin controls to raise the tray and press again

Fill the bin with paper and press

again

Contact your local Watkiss service department

Remove the rear guard. Clear the jam. Use INCH to clear any partial sets from the conveyor

Turn the emergency stop button clockwise to disengage

Check the mains voltage and connections

The emergency stop button has been pressed

The mains voltage is either too high or low and has caused an error.

An error has occurred in the drive unit

Blown fuse(s) on the Motor Drive

PCB in the drive unit

Bad paper jam causing the conveyor to lock

A fault has occurred in the drive unit

The jogger is not connected to the mains or is not switched on

A fault has occurred in the drive unit

Contact your local Watkiss service department

Contact your local Watkiss service department

Clear the jam. Use INCH to clear any partial sets from the conveyor and then restart the collator

Contact your local Watkiss service department

Connect the jogger to the mains supply and/or switch on

Contact your local Watkiss service department

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Message

NOISY ZEROX

POWER FAIL

REAR COVER OPEN

SFT JAM

SFT STALLED

STACKER FULL

STACKER NOT CONNECTED

STAPLE HEAD ERR

STAPLER GUARD OPEN

Cause

Interference from the mains supply or other nearby equipment is causing a problem

The mains supply connection is faulty

The mains supply has been interrupted

The rear cover/guard is not fitted or is not fitted correctly

REAR DEFLECTOR CHANGED Either the delivery direction lever or the rear divert fingers have been moved whilst the machine is locked

Action

Connect the collator directly to the mains outlet i.e. not via a multiway adapter

Check the connection

Switch the collator off and on again

Check the rear cover/guard is fitted and is actuating the safety switch correctly

Move the delivery direction lever/ divert fingers back to their original position. Only change the position of the lever once END JOB has been pressed

Paper jam in the Stitch Fold unit Open the stitch fold and clear the jam

Bad paper jam in the Stitch Fold unit

Open the stitch fold and clear the jam

A fault has occurred in the Stitch

Fold unit

One or more of the Stitch Heads is jammed

The stacker is full of paper

Contact your local Watkiss service department

Lift the perspex lid on the Stitch

Fold and release the drive to the

Stitch Heads

Unload the stacker and press

to continue the job

Check the connection The jogger is not connected to the collator

Oscillate or batch oscillate function is selected from the control panel menu and the jogger has been disconnected

A fault has occurred in the Rear

Corner Stapler

The top cover of the Rear Corner

Stapler is open

Deselect oscillate function from the control panel

Contact your local Watkiss service department

Close the cover

Message

STAPLER JAM

STAPLES LOW

STITCH GUARD OPEN

TOWER COMMS ERROR

TRAY LIFT ERROR

TRIM BIN FULL

TRIM GUARD OPEN

2XDIVERT

Cause Action

Paper jam in the Rear Corner

Stapler

The Rear Corner Stapler staple cartridge needs replacing

Lift the top cover and clear the jam

Refer to the Rear Corner Stapler operating instructions and fit a new staple cartridge

Close the cover The top cover of the Stitch Fold is open

Communications error between the towers in a twin tower system

Blown fuse in drive unit or fault with tray lifting mechanism

Trimmer offcut bin is full

Check the interconnection cable between the two towers is fitted correctly

If the error persists, turn off both machines, wait ten seconds and turn them on again

Contact the Watkiss service department

Empty the bin

Trimmer offcut bin is not fitted or is not contacting the safety switch

Fit the offcut bin correctly

Two successive diverts (i.e. two errors) from the same bin

Check the feed of the bin

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HOLD

MENU

A1

Advanced Menu

The Advanced Menu offers additional adjustments to the collator. It’s functions should only be used if the standard adjustments detailed in the previous chapters fail to give the desired effect. To enter the Advanced Menu press and hold

MENU

when in Menu 1.

MENU

OFFSET+

OFFSET-

SHORT

CLEANING

TRAY

LENGTH

FRICTION

SUCTION

MENU MENU

SLIP+

SLIP-

FDET+

FDET-

CLUTCH+

CLUTCH-

Advanced Menu Navigation

SLIP+

SLIP-

SDET+

SDET-

HOLD+

HOLD-

OFFSET + and OFFSET : Normally the sheets in a set exit the collator with their edges level. Sheet offset shales the sheets as they exit. This can assist the neat stacking of thick sheets or large sets into a jogger. A small offset can also assist Stitch/Fold Trim knock up. The range of offset is +/- 29.45mm and effects all bins. If an offset is required, it is usual for the bottom sheet of the set to enter the stacker first.

Positive Offset i.e. OFFSET +

Negative Offset

i.e. OFFSET -

Set Delivery to the Front Set Delivery to the rear

The bottom sheet of the set (i.e from the uppermost bin) will enter the stacker first.

The top sheet of the set (i.e from the uppermost bin) will enter the stacker first.

The top sheet of the set (i.e from the lowermost bin) will enter the stacker first.

The bottom sheet of the set (i.e from the lowermost bin) will enter the stacker first.

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SHORT

: The standard clutch feed length during the test set is 186.2mm (7.35"). After the test set the clutch feed length is automatically set to suit the paper size. When feeding small sizes such as A5 (5½ x 8½") landscape selecting

SHORT

gives a clutch length of 126.25mm (4.98") during the test set. You may also use the CLUTCH feature from the FRICTION menu to manually adjust the test set clutch length.

CLEANING

: Turns the conveyor on. Pressing the red button on the bin controls will then activate the feed clutch for that bin. Press

CLEANING

again to switch off.

TRAY

: Raises or lowers the trays on Friction bins for access or transport. As the trays raise the X-Jogger (if fitted) will turn.

LENGTH

: Enters the LENGTH display (See below).

FRICTION

: Enters the FRICTION menu (see p.88).

SUCTION

: Enters the SUCTION menu (see p.89).

LENGTH DISPLAY The length display shows information about the sheet detection system of each bin. You only need to refer to the length display if you are having feed problems.

Bin : The bin number to which the information relates.

Length : Sheet length as measured by the emitter/sensor during the test set. Normally zero before the test set has been completed. A small variation from bin to bin in the reported sheet size is normal.

Ref : The amount of light passed through the sheet by the emitter/sensor on the test set. The higher the value, the less light is passing through the sheet and hence the thicker (optically) the sheet. This value is updated with a moving average on every subsequent good feed. The value range is between 0 and 255.

Pwr : This will read either "+" or "-" depending on whether the emitter/sensor is using the high or low power setting respectively.

HOLD

MENU

MENU

OFFSET+

OFFSET-

SHORT

CLEANING

TRAY

LENGTH

FRICTION

SUCTION

MENU

Bin

6

5

4

3

2

1

Length

291

290

290

292

290

290

Length Display Navigation

Ref

122

128

135

167

132

91

-

-

-

-

-

Pwr

-

Lim

31

30

28

23

28

38

.

.

.

.

.

Scn

.

Lim : The allowed tolerance on either side of the reference value for sheet opacity variation.

Scn : (Suction bins only) This indicates the adjustment that has been made to the timing of each individual bin during the electronic bin synchronisation procedure.

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88

FRICTION MENU The FRICTION menu is used to adjust certain variables in the feed system of friction bins. Any adjustments shown in brackets may not appear on your machine.

HOLD

MENU

MENU

OFFSET+

OFFSET-

SHORT

CLEANING

TRAY

LENGTH

FRICTION

SUCTION

MENU

SLIP+

SLIP-

FDET+

FDET-

Friction Menu Navigation

CLUTCH+

CLUTCH-

SLIP +

and

SLIP -

: Displays and adjusts the allowance for paper slip when detecting feed errors. The detection system allows for a certain amount of sheet slippage at the start of the feed. If too much slip occurs it will be interpreted as a miss. The slip allowance may need changing for especially difficult papers (the default setting is 14.25mm / 0.56"). Before changing the slip value:

• Ensure that the feed is optimised using the normal adjustments

• Establish that sheet slip is definitely the cause of the problem

FDET +

and

FDET -

: Friction Detection. The sheet detector measures 15.2mm (0.6") in from the feed edge of the sheet and then takes a reading. The edge of particularly dark or solid areas of print in this area can cause detection problems. In this case the detection position can be moved relative to the feed edge of the sheet.

CLUTCH +

and

CLUTCH -

: Displays and 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. Decreasing the value has the opposite effect.

The default value is 186.2mm (7.35") during the test set, thereafter the feed length is automatically set to suit the paper size.

SUCTION MENU The SUCTION menu is used to adjust certain variables in the feed system of Suction and SlimVAC bins. Any adjustments shown in brackets may not appear on your machine.

HOLD

MENU

MENU

OFFSET+

OFFSET-

SHORT

CLEANING

TRAY

LENGTH

FRICTION

SUCTION

MENU

SLIP+

SLIP-

SDET+

SDET-

Suction Menu Navigation

HOLD+

HOLD-

89

90

SLIP +

and

SLIP -

: Displays and adjusts the allowance for paper slip when detecting feed errors. The detection system allows for a certain amount of sheet slippage at the start of the feed. If too much slip occurs it will be interpreted as a miss. The slip allowance may need changing for different weight papers (the default setting is 14.25mm / 0.56"). However, always obtain a good feed with standard adjustments before changing the slip value.

SDET +

and

SDET -

: Suction / SlimVAC Detection. The sheet detector operates 15.2mm (0.6") in from the feed edge of the sheet. The edge of particularly dark or solid areas of print in this area can cause detection problems. In this case adjust the detection position to avoid any such areas.

HOLD +

and

HOLD -

: Displays and adjusts the time the suction manifold (Suction bins) or feeder (SlimVAC bins) holds the paper for before it releases it into the conveyor.

The default setting is 300ms.

A2

Specifications

Intended use The Watkiss Vario is intended for the collation of materials as specified below

Operating Conditions 10-35°C at 35-85% relative humidity

Control Panel

Dimensions (W,D,H): Top Mount

515, 80, 184mm; (2kg), 20, 3, 7"; (5lb)

Side Mount

265, 48, 245mm; (2kg), 10, 2, 10"; (5lb)

Drive Unit

Dimensions (W,D,H): 610, 423, 233mm; (25kg), 24, 17, 9"; (55lb)

Electrical: 110 - 120V or 230V, 50/60Hz; single phase

Friction Feed Bin

Rel. F

Configuration: Up to 16 bins per tower

Production: Up to 7,200 feeds per hour

Capacity: 40mm,1½"

Stock Sizes: 120 x 160mm to 364x 520mm, 5 x 6¼" to 14¼ x 20¼"

Stock Range: 40 to 300 gsm, 11# bond to 110# cover

Detection: Electronic detection for miss, double, jam and empty bin

Dimensions (W,D,H): 610, 590, 77mm; (6.9kg), 24, 23, 3"; (15.2lb)

Sound Emission: Typical 70dB (A) for machine in use

SlimVAC Feed Bin

Rel. B

Configuration: Up to 16 bins per tower

Production: Up to 5,000 feeds per hour

Capacity: 45mm, 1¾"

Stock Sizes: 120 x 160mm to 364 x 520mm, 5 x 6¼" to 14¼ x 20¼"

Stock Range: 40 to 240 gsm, 11# bond to 90# cover

Detection: Electronic detection for miss, double, jam and empty bin

Dimensions (W,D,H): 610, 667, 77mm; (7.6kg), 24, 26, 3"; (16.7lb)

Sound Emission: Typical 74dB (A) for machine in use

91

92

Suction Feed Bin

Rel. D

Configuration: Up to 8 bins per tower

Production: Up to 4,000 feeds per hour

Capacity: 100mm (4") for stock up to 340mm (13¼") wide

88mm (3½") for stock over 340mm (13¼") wide

Sheet Sizes: 130 x 160mm to 364 x 520mm, 5¼ x 6¼" to 14¼ x 20¼"

Stock Range: 40 to 300gsm, 11# bond to 110# cover

Detection: Electronic detection for miss, double, jam and empty bin

Dimensions (W,D,H): 610, 667, 154mm; (14.5kg), 24, 26, 6"; (32lb)

Sound Emission: Typical 74dB (A) for machine in use

(Note: When intermixing SlimVAC, Suction and Friction feed bins, a suction-friction spacer may be required.)

Benchtop Base

Production: Up to 7,200 sets may be stacked per hour

Stacker Capacity: 70mm, 2¾"

Stock sizes: 130 x 160mm to 364 x 520mm, 5¼ x 6¼" to 14¼ x 20¼"

Sensing: Optical tray full sensor

Dimensions (W,D,H): 610, 603, 218mm; (13kg), 24, 24, 9"; (29lb)

Oscillating Bench

Base

Production: Straight stacking up to 7,200 sets per hour

Offset stacking up to 4,500 sets per hour

Stacker capacity: 70mm, 2¾"

Stock sizes: Straight stacking up to 364 x 520mm, 14½ x 20¼"

Offset stacking up to 320 x 450mm, 12½ x 17¼"

Sensing: Optical stacker full sensing

Dimensions (W,D,H): 615, 745, 207mm; (19.5kg), 24, 29, 8"; (43lb)

Floorstanding Base

Rel. C

Dimensions (W,D,H): 692, 827, 720mm; (67kg), 27, 33, 28"; (147lb)

X-Jogger

Production: Straight stacking up to 7,200 sets per hour

Offset stacking up to 3,500 sets per hour

Capacity: 100mm, 4"

Sheet sizes: Straight stacking 130 x 160mm to 364 x 520mm, 5¼ x

6¼" to 14¼ x 20¼"

Offset stacking 148 x 210mm to 364 x 520mm, 6 x 8¼" to

14¼ x 20¼"

Sensing: Optical stacker full sensing

Dimensions (W,D,H): 509, 600, 530mm; (21kg), 20, 24, 21"; (46lb)

Electrical: 110 - 120V or 230V, 50/60Hz; single phase

Straight Jogger

Capacity: 75mm, 3"

Sensing: Optical stacker full sensor

Dimensions (W,D,H): 375, 560, 521mm; (22kg), 15, 22, 21"; (49lb)

Electrical: 110 - 120V or 230V, 50/60Hz; single phase

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.

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 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.

93

94

THIS PAGE IS

INTENTIONALLY

BLANK

A3

Declaration of Conformity

Manufacturer’s name Watkiss Automation Limited

Manufacturer’s

Address

Watkiss House

Blaydon Road

Sandy, Bedfordshire, UK.

SG19 1RZ

Declares that the product

Product Name Watkiss Vario

Product Number WA/VAR/2450 onwards (230V versions only)

Product Variants Friction Feed

Suction Feed

SlimVAC Feed

Floor Base

Bench Top Base

Oscillating Bench Base

Conforms to the following Product Specifications:

Safety 89/392/EEC Council Directive 'on the approximation of laws of Member States relating to machinery’, amended by 91/368/EEC

EMC 89/336/EEC Council Directive 'on the approximation of laws of Member States relating to electromagnetic compatibility'

EN55022 Class A

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.

95

96

THIS PAGE IS

INTENTIONALLY

BLANK

A

advanced menu 19, 85–90

cleaning 86

friction menu 88

length display 86

offset 85

short 86

suction menu 89

tray 86

air separation, adjustment 13, 24

B

batch menu 15

insert 16

multifeed 18

multiset 17

oscill 16

pause 17

size 18

stop 16

batch mode 15–18

bench base 43–47

deflector fingers 45

delivering to the rear 44 offset stacking 44

paper guides 46

setting up the stacker 43

stacker full sensor 46

bin controls 21, 27, 35

bin linking 25, 31

C

cleaning - see ’maintenance’

cleaning, advanced menu 86

control panel 9–19

advanced menu 19, 85–90

basic operation 9–12

batch menu 15

error messages 79–83

menu1 12

menu2 13

conveyor 67, 81

Index

Index

conveyor jam 81

counting sets 11

D

declaration of conformity 95

deep pile stacker 54, 56

delivery direction 44, 52, 55, 82

difficult papers

slimvac 32

suction 38

display 10

divert, menu command 14

drive speed, adjustment 13

E

edge flick, suction bins 36, 40, 77

emergency stop button 2, 81

end job, menu command 12

F

feed wheels, friction bins 68

feeder angle, slimvac bins 31, 76

floor base 53–58

air blast 54

delivery direction lever 55

front feedout conveyor 54

interface sockets 53

rear deflector fingers 55

rear feedout conveyor 57 remote control 57

with deep pile stacker 54, 56 with jogger 54, 56, 57 with stitch fold 54, 56

friction bins 21–25

adjustments 23–25

advanced adjustments 88

air separation 24 sidelay taps 24

bin controls 21

bin linking 25

loading the bins 21

maintenance 67

problem solving 74–75

97

98

Index

sensor overrange 25

separator pressure 23 switching bins on & off 23

tray extenders 22

tray pressure 24

friction menu 88

clutch 89 fdet 89

slip 88

fuses 2, 79

I

inch, menu command 13

insert, batch menu command 16

installation 2

J

jam 75, 76, 77, 80, 81

job areas 14

job memory menu 18

joggers 59–62

straight jogger 60

x-jogger 59

jogging off-line 62

L

lcd display 10

length display 86 bin 86 length 86

lim 87

pwr 86 ref 86

scn 87

loading the bins 21, 27, 37

M

mains input 2

mains on/off switch 3

maintenance 67–70 conveyor wheels 67

feed wheels 68

paper separators 67

repairing overloaded trays 70

suckers 69

memory - see ’job memory menu’

menu1 12

air separation 13 drive speed 13

end job 12

inch 13 sets per hour 13 sph 13

test set 12

menu2 13

divert 14

job 14

oscill 13

prenumber 14

setup 15

sft 14

stagger 13

multifeed, batch menu command 18

multiset, batch menu command 17

O

offset, advanced menu 85

oscill, menu command 13, 16

oscillating bench base 49–53

delivery direction lever 52

magnetic sidelays 49

non-standard paper sizes 50 offset stacking 50

paper guides 51

problem solving 78

scale 49

stacking A5 sheets 51

straight stacking 50

overrange 25, 32, 39

P

paper guides 46, 51, 54, 78

paper jam 75, 76, 77, 80, 81

paper separators, friction bins 23, 67, 74

pause, batch menu command 17

Index

prenumber, menu command 14

preset counter 11

problem solving 73–83

error messages 79–83

friction feed problems 74–75

general problems 73

oscillating bench base problems 78

slimvac feed problems 75–76

suction feed problems 77–78

x-jogger problems 78

Q

quick start 5–7

quick stop button 9

R

rear corner stapler 63

staple cartridge 64

staple counter 65

rear feedout conveyor 57

rear guard 1

remote control 57

repairing overloaded suction trays 70

rubber endlays, slimvac bins 28

S

safety 1

separator pressure, friction bins 74, 75

sets per hour, adjustment 13

setup, menu command 15

sft, menu2 command 14

sheet corrugation, slimvac bins 30, 75, 76

short, advanced menu 86

size, batch menu command 18

slimvac bins 27–34

adjustments 30–32

advanced adjustments 89

bin controls 27

bin linking 31

difficult papers 32

feeder angle 31

loading the bins 27

problem solving 75–76

rubber endlays 28

running the Job 31

sensor overrange 32

sheet corrugation 30 switching bins on & off 30

tray extenders 28

tray height 31

specifications 91–93

sph, adjustment 13 stagger, menu function 13

staple cartridge 64

staple counter 65 staple counter, resetting 65

starting the job 11

stitch fold 54, 56

stop, batch menu command 16

straight jogger 60

jogging adjustment 61

jogging off-line 62

setting up the jogger 60

using with a bench top vario 61

straight stack liner 60

suckers, suction bins 35, 40, 69, 77 suction bins 35–41 adjustments 35–41

advanced adjustments 39–41, 89

bin controls 35

deformed sheets 38

edge flick 36, 40

loading the bins 37

maintenance 69

porous papers 38

problem solving 77–78

sensor overrange 39

sucker configuration 35, 40

switching bins on & off 38

tray height 39

suction menu 89

hold 90 sdet 90

slip 90

99

100

Index

system lock 12

T

test set 12

tray extenders 22, 28

tray height

slimvac bins 31, 75, 76

suction bins 39, 77

tray pressure, friction bins 24, 74

tray, advanced menu 86

troubleshooting 73–83

X

x-jogger 59

jogging adjustment 60

problem solving 78

setting up the jogger 59

straight stack liner 60

WATKISS AUTOMATION LIMITED

Watkiss House, Blaydon Road, Middlefield Ind. Est.,

Sandy, Bedfordshire. SG19 1RZ ENGLAND.

Tel: +44 (0)1767 682177 Fax: +44 (0)1767 691769

Email: [email protected] Web: http://www.watkiss.com

Operator Manual, Vario, English

Issue 2, Dec. 1997. Part No. 960-321

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