The Watkiss Vario Document Finishing System (DFS) automatically gathers sets from a sequentially printed stack of paper. The sheets are held in a gathering station until the set is complete, it is then released for online finishing. The DFS can be used with Watkiss Vario and

Watkiss BookMaster bookletmakers. Separate operating manuals are provided for these units.

The Document Finishing System features integral static elimination equipment that neutralises any charge present in feed stock.

The system may also be used as a standard collator if

required (See “Normal Collating” on page 59).

GUI

Drive Unit

Feed Bins

Gathering

Base

Module

Remote Control

(optional)

Stitch-Fold

(Hidden)

Trimmer

(Optional)

Outfeed

Conveyor

(Optional)

Document Finishing System Showing

BookMaster Pro, TrimMaster Pro and

Outfeed Conveyor

Sample Configuration Showing Stitch-Fold & Trim Units

ABOUT YOUR

MANUAL

The manual has a chapter called ’Running the Job’ 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.

Details of operating the SlimVAC and Friction feed bins are included. Note that High Pile Suction bins can be fitted to the Document Finishing System if required, and additional operating instructions covering this option are available.

SAFETY FIRST Your Document Finishing System 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 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 rear panel.

Emergency Stop

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

Mains ON/OFF Switch

Emergency Stop

INSTALLATION The installation of your Document Finishing System requires specialist knowledge and should therefore only be carried out by a Watkiss approved engineer.

Important

This machine must only be plugged into an electrical supply line of the correct voltage and with a proven earth. Any damage caused by failure to do so will not be covered by the warranty. The required machine voltage is shown on the label on the rear of the Drive

Unit (see photo below).

MAINS INPUT The Mains input for the Document Finishing System is on the rear of the drive unit. Two fuses are fitted next to the

Mains input. If either of the fuses fails the system will not

power up (see p.53 for details about changing fuses).

The online finishing systems have independent mains inputs.

Mains Input and Fuses

Serial Number and Mains

Input Voltage Label

MAINS ON/OFF

SWITCH

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

On/Off switches.

Important

To maintain the efficiency and prolong the service life of the static elimination equipment, it is important to switch off the Document Finishing System when it is not being used for a period of hours e.g. overnight.

GETTING HELP We are confident that your Document Finishing System 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.

Running the Job

Plug the system into a mains supply of the correct voltage and switch on the mains ON/OFF switches (see note on

page 3).

Note: The system may also be used as a standard

collator if required (See “Normal Collating” on page

59).

OPERATING THE

TOUCH SCREEN

In normal use, the touch-screen can be operated by finger-tip. It is not necessary to touch the screen with any other implement. However, the screen can be operated with any blunt instrument, such as a palm top ‘wand’ or the blunt end of a pen.

Do not use excessive force: a light touch is all that is needed.

Caution

Operating the touch screen with a sharp object, or with excessive force, will damage the screen.

The Vario is controlled by touching buttons on the control panel. Buttons that perform related functions are grouped together in ’windows’. Each window is selected by touching the relevant tab at the bottom of the control panel.

There are also six ‘control’ buttons along the top of the screen. To display help text about any of the machine’s functions, touch HELP and then touch the required button.

LOADING SEQUENCE If the job is to be stitched and folded, load the sheets so that the centre spread of the book is face up. Remember to replace any sheets used for setting up the DFS back into the stack in the correct order.

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

Centre Spread

Face Up

Outside Face

Down

Finishing Sequentially Printed Sheets

LOADING THE BINS

WITH PAPER

Remove any unwanted paper from the bins and touch

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

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").

Bin Linking

If the job will not fit into a single bin, load from the top of the stack and then reload the bin each time it runs out.

Alternatively, it is possible to split it between two or more feed bins. Load from the top of the stack into the top bin, progressing downwards using as many bins as are required or available. Then, starting with the top bin, link the bins by pressing the grey button to link it with the bin

below. This will be indicated by the small green light.

Press the red button of the uppermost bin to make this bin feed first.

Note: Bin linking can only be enabled when the bins are unlocked i.e. when TEST SET is highlighted on the display.

Setting the Number of Sheets

Touch NUMBER OF SETS in the BATCH window and input the number of sheets required in each book.

Inserting a Cover

From the BATCH window, touch INSERTS and set BOTTOM to ON (the NUMBER OF SETS in the BATCH window must be set to 1 or greater).

ADJUSTING THE

MACHINE

For a detailed description of individual bin adjustments please refer to the relevant chapters.

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.

•

All Bins

Check that all required bins are switched on. The bins will switch on automatically when they are loaded, or they can be switched on and off manually using the bin controls.

Tip

If necessary, you can reset the machine settings by loading the default template.

Touch LOAD & SAVE , select the default template from the job list and touch LOAD .

Adjust the Gathering Base Module for size (see p.41).

Adjust the online finishing units for size (see relevant operating manual).

In the BASIC window, select

PRENUMBER (see p.15), and

set the SETS PER HOUR to AUTO

(see p.14).

STARTING THE JOB Test Set

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

If a cover is being inserted, it is not fed during the test set. The calibration reading for the cover is automatically taken when the job is started.

Note: If PRENUMBER is not selected, the test set is not counted , and the sheet should be removed from the gathering station and replaced in the feed bin.

Touch to run the job.

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 touching .

Note: To avoid wasting sheets during the test set, the sheets can be diverted out of the front of the gathering

station using the manual bypass gate (see p.42)

Control Panel

Your Document Finishing System will be fitted with a GUI

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

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

Stop Button Start Button

Touch-screen

GUI Control Panel

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

Tip

The touch-screen takes two or three minutes to reach full brightness when it is switched on.

THE WINDOW

SYSTEM

The Document Finishing System is controlled by touching buttons on the control panel. The buttons are divided into groups that perform related functions. Each group of buttons has its own ’window’ which is selected by touching the relevant tab:

• Load & Save

• Basic

• Advanced

• Feed

• Batch

• Finishing

Control Buttons

Start/Stop

Inch/Pause

End Job

Test Set

Help

Each window contains a group of related buttons

Touch the relevant tab to display each window

Load & Save

Basic

Advanced

Feed

Main Window Tabs on the Control Panel

Batch

Finishing

Functions related to modules that are not installed on your

DFS will not be displayed on-screen.

‘CONTROL’ BUTTONS There are six main ’control’ buttons listed across the top of the screen:

START/STOP The button is used to start the machine. When the machine is running, this button changes to which stops the machine. These are duplicated by the start/stop buttons above the touch screen.

INCH Touch and hold INCH to turn the conveyor. The conveyor will stop when INCH is released. This is used for clearing any sets remaining in the conveyor after a jam, etc.

When the machine is running, this button changes to

PAUSE . Touch PAUSE to pause the feed for approximately

5 seconds, the conveyor continues to run. The pause time can be altered on the Machine Options page.

END JOB Touch END JOB when you want to set the machine up for a new job, or alter an existing job. When a job is loaded, some of the machine settings cannot be changed, to prevent accidental changes. END JOB releases these settings.

This only affects settings that change the integrity of the job, e.g. the number of sheets in a set, or the number of sets in a batch.

TEST SET When the test set icon is highlighted , the collator is ready to run a test set. The collator uses the test set to calibrate the system according to the stock in each bin. The test set is not counted by the counter (except when in prenumber mode). Once the test set is completed and is accepted by starting the machine, the bins and certain functions cannot be changed,to prevent errors and accidental button pushes.

To run a test set:

• Load the collator.

• Touch the button.

• The collator will feed a single sheet from each bin that is switched on and loaded.

• If an error occurred during the test set, or the bin loading is changed at this stage, touch to run another test set.

• When the test set icon is grey, the machine is ready to run. Touch .

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

If you are having trouble running a job and false errors are being reported, it may help to run another test set.

This can be done at any time to recalibrate the detector system.

HELP Touch HELP and then touch any area of the screen to display the help text. Use the ’up’ and ’down’ arrows next to the text to scroll up or down the screen.

Some sections of help text have a ’right’ arrow next to them. This indicates that there is more text available, explaining a related function in more detail. Touch the

’right’ arrow to view this text. A ’left’ arrow will then also appear: touch this to return to the previous text.

When you are viewing text, you can find out about any of the other tabs that remain on display by touching them.

To exit the help text, touch HELP or OK .

MENU MENU gives access to settings that do not need to be changed on a day-to-day basis. These settings include:

• Change the display language

• Toggle between metric and imperial measurements

• Adjust the screen contrast

• Adjust the pause duration

• Advanced machine settings which can only be accessed by someone who has an appropriate access code.

MIMIC DIAGRAM The mimic diagram of the system shown on screen is automatically created, based on how many bins are fitted and what finishing equipment is connected. Various areas on the outline will be highlighted in different colours, according to the system's operational status. The feed bin colours mimic the bin indicator lights:

• Steady green: This bin is selected, and is loaded with paper.

• White: This bin is not selected.

• Broken line between bins: These bins are linked.

• Flashing green: This bin is selected, but it has run out of paper.

• Flashing red: This bin has had a double feed, which has caused the collator to stop. The error will be explained in a pop-up box.

• Flashing yellow: This bin has had a miss, which has caused the collator to stop. The error will be explained in a pop-up box.

Errors in other modules are indicated in red.

Mimic Diagram

C Touching C resets the set counter to 0.

SPH SPH shows the actual production speed of the system, in sets per hour. The production speed is affected by paper size, online finishing equipment and the job setup.

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

‘BASIC’ Window.

SETS PER HOUR SETS PER HOUR allows the production rate of the system to be set. This is automatically limited according to the machine configuration.

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

Note: AUTO is the recommended setting for the DFS.

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

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

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

PRESET PRESET is used if an exact number of sets are required.

Touch PRESET and enter the number of sets required on the number pad. The counter in the main area of the screen will turn white. When the machine is started the counter will automatically count down to zero and the collator will then stop.

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

The Preset function is ideal for producing a one-off batch.

If you wish to produce several identical batches, it is easier to use the Batch function.

PRENUMBER PRENUMBER is intended for use when collating prenumbered carbonless sets. Touching PRENUMBER selects Single Set mode, disables the Divert function and causes the test set to be counted by the counter. It also prevents the operator from switching linked bins before one bin has emptied.

It is possible to switch off Single Set mode once Prenumber is selected. This allows the machine to run faster when using stock that feeds easily.

Note: PRENUMBER ON is the recommended setting for the DFS.

THE ‘ADVANCED’

WINDOW

The ADVANCED window allows advanced machine settings to be altered. These settings may be altered to optimise the quality and productivity of a job.

‘ADVANCED’ Window.

DRIVE SPEED DRIVE SPEED alters the drive speed of the conveyor 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. This setting is independent from the SETS PER HOUR setting. The default factory setting is 80%.

SHEET OFFSET (Only applicable when using the DFS for normal collating.)

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

If an offset is required, it is usual for the bottom sheet of the set to lead: Select a negative offset when feeding to the rear of the collator and a positive offset when feeding to the front of the collator.

A small offset can make jogging more effective when using a booklet maker.

DETECTOR POSITION The sheet detector measures 15.2mm (0.6") from the feed edge of the sheet and then takes a reading. If the edge of a particularly dark or solid area of print is in this area it can cause detection problems. The DETECTOR POSITION can be adjusted so that it looks at a different part of the sheet. This affects all the bins in the collator.

TOLERANCE: Changing TOLERANCE to x2 COARSE allows for more variation in the detector readings. This prevents false errors being reported when there are variations in the paper or ink density. The default setting is x1 NORMAL .

The collator allows for some variation in the paper or ink density, and constantly changes the range of values it will accept by working out an average value for previous sheets. Increasing Tolerance to x2 COARSE will only be necessary where there are larger variations in stock.

DOUBLE DETECTION: Under unusual circumstances, e.g. there are large variations in stock, it may be necessary to turn off DOUBLE DETECTION . This affects all the bins in the collator. Miss feed detection is unaffected.

Before switching off double detection, first try setting

TOLERANCE to x2 COARSE .

FEED CLUTCH FEED CLUTCH adjusts the clutch feed length for all bins during the test set only. Increasing the value will cause the feed wheels to drive the paper for longer, which can prevent sheets from slipping. The value can be reduced to prevent excessive pre-feeding of the next sheet in the bin.

Optimising the clutch feed length for non-standard paper lengths will produce a more accurate test set, which in turn should reduce errors during the job. The default value is 186.2mm (7.35") during the test set, thereafter the feed length is automatically set to suit the paper size.

AUTO: Touch AUTO to set the clutch feed length to the default value of 186.2mm (7.35").

SHORT: (not applicable for DFS) SHORT will decrease the clutch feed length during the test set to 121mm (4.8"), which is ideal for A5 or 5.5 x 8.5" landscape or similar.

SUCTION HOLD Increasing the SUCTION HOLD value causes the feeder to allow more time to pick up each sheet. If you are using stock that tends to stick together, increasing the suction hold can improve paper pick-up and in some instances, separation.

It is possible to reduce the suction hold when using paper that is easy to feed: this will increase the operating speed of the machine. The default setting is 300mS.

THE ‘BATCH’ WINDOW The BATCH window allows sets to be grouped into batches, with an action at the end of each batch (stop, pause, oscillate or insert sheets).

‘BATCH’ Window.

NUMBER OF SETS Touch NUMBER OF SETS to enter the number of sets in each batch. Entering 0 on the keypad will turn the batch mode off.

Counts the total number of sets produced

Counts the number of sets per batch

Counts the total number of batches produced

Note: With the DFS, only one bin feeds at a time. Therefore the number of sets in the batch is the same as the number of sheets in the book.

Batch Counter.

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

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

TOP: When feeding to the front of the collator, select TOP to feed a sheet from the top bin with the first set of each batch. The inserted sheet will be at the bottom of the batch pile, as the backing board for a pad for example.

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

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

BOTTOM to feed a sheet from the bottom bin with the last

20 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.

Note: With the DFS, select BOTTOM to insert a separate cover on the booklet.

When feeding to the rear of the collator, select BOTTOM to feed a sheet from the bottom bin with the first set of each batch. The inserted sheet will be at the bottom of the batch pile, as the backing board for a pad for example.

STOP STOP causes the machine to stop after each batch, and the counter display will flash. Touch the start button to run another batch.

If STOP is selected while the machine is part-way through collating a batch, it will stop once it has completed that batch. This allows the operator to interrupt a job at a convenient point.

PAUSE / SEPARATE (This function should not be used on the DFS)

PAUSE / SEPARATE causes the machine to pause for approximately 5 seconds after each batch. The pause icon on the control panel will flash between batches.

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

OPTIONS ).

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

THE ‘FINISHING’

WINDOW

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

‘FINISHING’ Window.

PAPER SIZE Touch PAPER SIZE to alter the settings of the booklet maker and trimmer to suit the input paper size.

RE-REF: If you suspect the booklet maker or trimmer adjustment system is not calibrated correctly, touch RE-

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

Periodically the booklet maker will automatically rereference the axes during the setup procedure.

PAGE DIRECTION: Touching PAGE DIRECTION switches the orientation of the paper between landscape and portrait. This is only possible if the sheet does not exceed the maximum width accepted by the booklet maker.

PRESETS: Select from a choice of standard paper sizes by touching the PRESET window.

STITCH AND FOLD The position of the stitch and fold can be offset relative to the centre of the paper. STITCH AND FOLD allows this position to be adjusted up to 20mm in either direction, in increments of 0.2mm.

STITCH : The STITCH OFF option will produce booklets that are folded, but not stitched.

STITCH POSITION: The ON FOLD option produces booklets which are stitched on the fold line. The ON EDGE option produces sets which are edge-stitched and folded.

The Stitch Selection Lever on the booklet maker must be in the centre-stitch position.

TRIM Touch TRIM to set the finished book size after trimming.

When a preset paper size is selected, this distance is automatically adjusted, but can be fine-tuned. The trim function can also be switched off.

PRE STITCH JOGGING The PRE STITCH JOGGING window has options to alter the way sets are jogged prior to stitching. This ensures the finished booklets are as neat as possible. The maximum speed of the booklet maker will be reduced when any of the Pre Stitch Jogging options are selected.

PRE JOG: This provides additional jogging to the bottom of the set, when using heavy or large sheets. The booklet is stopped by the edge-stitch latch and jogged, before it drops to the stitch latch.

DOUBLE JOG: This provides additional jogging to the sides of the set, when using heavy or large sheets. The sidelays jog the set twice when it reaches the stitch latch.

STITCH DELAY: Increasing the STITCH DELAY value will cause a delay between the set arriving on the stitch latch and it being stitched. This allows more time for the sheets to settle. The default delay is 1mS.

PRE FOLD JOGGING The PRE FOLD JOGGING window has options to alter the way sets are jogged prior to folding. This ensures the finished booklets are as neat as possible.

SIDE JOG HOLD: When SIDE JOG HOLD is selected, the sidelays hold the set during both stapling and folding without releasing. This is useful if the booklet is not being folded square, however it is essential that the sheet width is set accurately.

FOLD DELAY: This can be adjusted to alter the delay between the set arriving on the fold latch and being folded. This is useful if the booklet is not being folded square, and allows more time for the sheets to settle. The default delay is 180mS. The maximum production speed of the booklet maker will be reduced if the delay is increased.

BOOK THICKNESS The BOOK THICKNESS window alters the gap between the feed rollers of the Auto Stitch-Fold. The thickness of the set is entered on a scale of 1 to 25: this scale represents 1 to 25 sheets of 80gsm paper. The value will need to be adjusted to allow for heavier or lighter stock.

THE ‘LOAD & SAVE’

WINDOW

The LOAD & SAVE window allows job settings to be saved and reloaded at the touch of a button. Each job is given a name, and the jobs are listed on the screen. To select a job, highlight it by either touching it or by using the up and down arrows.

’LOAD & SAVE’ Window.

SAVE Touch SAVE to save the current settings of the collator and its on-line finishing equipment. When the on-screen keyboard appears, enter the job name and then touch

OK or CLOSE . The new job will appear in the list of saved jobs. This allows the settings to be recalled in the future, which saves set-up time.

REPLACE: If an existing job has been loaded and modified, touching REPLACE will replace the old job with the modified version.

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

SAVE NEW: If an existing job has been loaded and modified, touching SAVE NEW will save the modified version as a new job. When the on-screen keyboard appears,

enter the new job name and then touch OK or CLOSE .

The original job is unchanged.

If the job name is not changed before touching OK or

CLOSE , the job will be saved with the current name, suffixed by an asterisk.

JOB DETAILS Touching JOB DETAILS shows the settings for each saved job. Select the job that you wish to view from the job list and touch JOB DETAILS to see a summary of the job settings.

LOAD To load a job, select it on the job list using the up and down arrows or by touching it. Touch the LOAD button.

You must touch END JOB before loading a job.

PADLOCK SYMBOL The padlock symbol is used to lock and unlock saved jobs. Each saved job has a small padlock symbol next to it, to show whether it is locked or not. To lock or unlock a job, select it on the job list and touch the large padlock button.

Some padlock symbols may be greyed out. This is because there are several access levels to the system, which can be used to prevent jobs being altered.

DELETE To delete a particular job it must be unlocked. Select the job from the job list using the up and down arrows or by touching it. Touch and hold DELETE . A red bar will appear, filling from left to right. Continue to hold until the red bar reaches the right-hand side.

VIEW OF JOB LIST VIEW OF JOB LIST alters the order in which saved jobs are listed, either alphabetically or most recent first.

There is a line between Factory Template jobs, and other jobs saved by the operator. The Factory Template jobs are always listed first: only the operator-saved jobs can be reordered.

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

BY USE: To list jobs in the order they were last used, touch

BY USE . The job that was run most recently will appear at the top of the list.

THIS PAGE IS

INTENTIONALLY

BLANK

Friction Bins

The Document Finishing System may have any number of Friction feed bins between 2 and 8. Additional bins can be added if required even after the machine has been installed.

For operation of SlimVAC bins please refer to the relevant chapter.

BIN CONTROLS AND

INDICATORS

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

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

’overrange’, see p.30)

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.30)

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

Tray Extenders

Tray Extenders

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

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

One B3 (14¼ x 20¼") tray extender is 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.

Bin Sidelays

Switching Bins On & Off

Before a test set is produced, individual bins will automatically switch on and off as they are loaded and unloaded. Bins can also be manually selected by pressing the red button alongside the bin. In addition, loading the Default Template will switch on all loaded bins.

Remember that bins cannot be switched on or off when the system is locked (touch END JOB if necessary).

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

Separator Pressure

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

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

Separator Pressure

Adjustment

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

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 altering the AIR BLOW value, in the BASIC

window (see p.14). The air level is also

adjustable on each individual bin via a tap on the right hand sidelay.

The tap on the sidelay controls the air level into the side of the paper stack. The tap has three positions. The default position is 90° to the sidelay which provides 100% air.

Moving the lever one notch towards you provides 50%

air. Moving the lever towards you so that it is parallel with the sidelay shuts off the air.

Air Separation

Adjustment

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

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 the

TEST SET icon is highlighted on the control panel. Press the grey button on the upper bin to link it with the one below. This will be indicated by the small green light. The mimic diagram on the control panel will show a broken line between bins that are linked.

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

PRENUMBER in the BASIC window is selected).

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.

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SlimVAC Bins

The Document Finishing System may have any number of SlimVAC feed bins between 2 and 8. Additional bins can be added if required even after the machine has been installed.

For operation of Friction bins please refer to the relevant chapter.

BIN CONTROLS AND

INDICATORS

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

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

’overrange’, see p.37)

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.37)

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

Tray Extenders

Tray Extenders

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

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

One B3 (14¼ x 20¼") tray extender is 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

34 orientation for the paper size in use. Do not push the endlay hard up against the edge of the paper stack.

Incorrect usage may result in either misfeeds or double feeds.

330-351

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

330-351

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.

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.

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 system initially starts and thereafter when the tray is loaded. It is therefore important to load a full stack of paper at a time.

The tray automatically lowers either when the tray is empty or when is pressed after the machine stops for any reason.

Switching Bins On & Off

Remember that bins cannot be switched on or off when the system is locked (touch END JOB if necessary).

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

Tray height adjustment lever types and should be used as a starting point if in doubt for initial running.

Feeder Angle

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

Adjustment is made using the knob on the left hand side of the suction feeder. Turning the 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 Make sure that the loaded bins are selected (remember that the bins are automatically selected as you load them, before you run the test set). 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.

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

TEST SET icon is highlighted on the control panel. Press the grey button on the upper bin to link it with the one below. This will be indicated by the small green light. The

Vario outline diagram on the control panel will show a broken line between bins that are linked.

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

PRENUMBER in the BASIC window is selected).

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

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

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.

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.

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Gathering Base Module

The Gathering Base Module holds the sheets fed from the feed bins until the set is complete. The set is then released to the next finishing process.

INTERFACE SOCKETS The interface sockets are located on the right underside of the Gathering Station.

Not

Used

Online

Finishing

There are three sockets in all (see left). Two identical sockets (either one of which is used to connect the online finishing system) and one smaller socket that is currently not used.

Static Elimination Bar

Sheet Length Adjustment

Gathering

Station

Air Blow

Adjustment

Sidelay

Sheet Width Adjustment

Bypass Gate

Remote Control Socket

Interface

Sockets

(Hidden)

ADJUSTMENTS Sheet Width

Adjust the DFS to the correct sheet width by inserting a few sheets from the job in between the sidelays.

Note: It is easier to insert sheets from the back of the machine (remove the rear guard first)

Turn the thumbwheel until the marker aligns with the correct point on the scale. Firmly push the sidelays inwards to check the tamper position, they should just touch the paper. Make further adjustment if necessary.

Sheet Length Adjusment

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

A3 A4 A5

Sheet Length Adjustment

Air Blow Adjustment

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

Manual Bypass Gate

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

Note

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

REMOTE CONTROL

(OPTIONAL)

The remote control handset (supplied with the Vario

Automatic Stitch-fold & Trim) can be used to control certain functions on the Document Finishing System.

The remote control interface socket is located on the front of the Gathering Base Module on the right hand side.

Button Functions

: Starts the system

: Stops the system

: No function

: Inches the conveyor

The Remote Control handset

Note

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

ERROR CORRECTION Feed Errors

If a feed error occurs part way through feeding sequentially printed sheets, it is essential to keep the sheets in sequence. Remove the error sheet(s) together with the remaining sheets of the book from the active feed bin and from the Gathering Station.

Put the sheets back into the correct sequence and replace in the bin.

Press RESTART BATCH in the BATCH window to reset the batch count.

Press to continue.

Paper Jam

If paper jams in the Gathering Base Module the machine will stop. Remove the paper, ensure the sheets are in sequence as described above and press to continue.

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Maintenance

SERVICE INTERVAL It is recommended that your Document Finishing System 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 Document Finishing System will benefit from periodic cleaning of general accumulations of paper dust, ink etc. Other operator maintenance is detailed below.

CLEANING THE

TOUCH SCREEN

The touch screen should only be cleaned with a clean, dry cloth. Abrasive materials and chemicals should never be used to clean the screen.

Light pressure with a suitable cloth should be sufficient to remove fingerprints. Do not use excessive force.

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.

STATIC ELIMINATION

BAR

The static elimination bar is located in the gathering station.

Caution!

Disconnect the machine from the mains electricity supply before cleaning the static elimination bar.

The pin side of the bar should be cleaned regularly using a small brush such as a toothbrush. This is vital to the effectiveness and life expectancy of the static elimination equipment.

Static Elimination Bar

FRICTION FEED BINS Paper Separators (P/No 909-485)

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

Paper Separator

• Remove the feed wheel shaft by pushing it to the left against the spring pressure and lifting the right end clear.

• Locate the separator and lift it out vertically.

• Clean or replace the separator as required. When cleaning the separator use only soap and water or alcohol (isopropanol). Refit the separator and ensure that it seats firmly in the correct position.

• Refit the feed wheel shaft.

Feed Wheels (P/No. 330-301)

The friction feed bins are fitted with three feed wheels (B) mounted on a shaft. They should be cleaned if dirty and replaced when worn. The replacement interval will depend upon the usage level and the type of papers used.

• 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 in the MENU, USER SETTINGS window and press the red button on the bin controls to turn the feed wheel shaft. Visually check that each wheel runs

48 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 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 conveyor wheels to a varying degree resulting in poor performance and premature failure.

Problem Solving

As far as possible the Document Finishing System has been designed to be selfexplanatory. 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.53)

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

DOUBLE FEEDS ARE NOT

BEING DETECTED

Batch insert selected from batch menu

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

Check that window are set as required.

N/A

INSERTS in the BATCH

Detector Position tolerance is set to x2 Coarse

Set TOLERANCE to x1 NORMAL in the ADVANCED , DETECTOR POSI-

TION window

Double Detection is not selected Set DOUBLE DETECTION to ON in the ADVANCED , DETECTOR POSI-

TION window

GATHERING BASE PROBLEMS

Problem Cause Solution

SHEETS NOT IN CORRECT

ORDER/NOT STACKING WELL

POOR FEEDING INTO ONLINE

FINISHING SYSTEM

The unit has not been set to the correct paper size

Set the levers on the front of the

unit to the correct paper size (see p.42)

Sheets are falling forwards in the gathering station

Adjust the air blow (see p.42)

The static elimination bar is dirty, reducing effectiveness and causing the back sheet(s) of the book to cling to the gathering station as they are released

Clean the static elimination bar

(see p.46)

The static elimination equipment is not enabled causing the back sheet(s) of the book to cling to the gathering station as they are released

Ensure the machine is switched on and the emergency stop button is

not engaged. Look through the air vent at the rear of the drive unit, the red switch on the black transformer should be illuminated. If not, contact the Watkiss Service Department (UK) or your local Watkiss supplier

FRICTION FEED PROBLEMS

Problem

DOUBLE FEEDS

Cause Solution

Too much tray pressure

Too little separation pressure

Insufficient air separation

Worn or missing separators

Reduce by moving handle in by

one notch at a time (see p.29)

Increase by moving the lever

down by one notch at a time (see p.28)

Increase the value of AIR BLOW in the BASIC window

Check separators are present,

and replace if worn (see p.46)

Bad guillotine burr, or blunt drilling

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

Miscalibration during the test set Run another test set by touching

, followed by TEST SET followed by

FRICTION FEED PROBLEMS

Problem

MISS FEEDS

Cause

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 touching and holding INCH

)

PAPER JAM

FRONT EDGE OF SHEET

DAMAGED

Solution

Too little tray pressure

Too much separation pressure

Untidy loading

Worn feed wheels

Increase by pulling the handle out

by one notch at a time (see p.29)

Reduce by moving the lever up

by one notch at a time (see p.28)

Reload the bins tidily, ensuring the paper stack is underneath the feed wheels and under the guides

Check and replace the feed

wheels if necessary (see p.47)

Miscalibration during the test set Run another test set by touching

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

Late feeding double sheet

Slow feeding sheet

Slow feeding during test set causing incorrect calibration

Treat as double feed above

Treat as miss feed above

Run another test set by touching

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

fol-

Sheet is jammed in the paper path

Sheet is only half feeding

Feeding A5 (5½ x 8½") landscape without selecting SHORT in the ADVANCED : FEED CLUTCH window

Too much separation pressure

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

Treat as miss feed above

Select SHORT in the ADVANCED :

FEED CLUTCH window and run another test set by touching , followed by TEST SET followed by

Reduce by moving the lever up

by one notch at a time (see p.28)

SLIMVAC FEED PROBLEMS

Problem Cause

DOUBLE FEEDS

MISS 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

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

Lower the tray height (see p.36)

Increase sheet corrugation (see p.35)

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

Use correct type and positioning

(see p.34)

Increase the value of AIR BLOW in the BASIC window

Reduce the sheet corrugation

(see p.35)

Raise the tray height (see p.36)

Raise the angle of the suction

feeder (see p.36)

Refer to recommended settings

(see p.39)

Position the endlay approx.

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

rect type for the paper size (see p.34)

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 touching and holding INCH

)

PAPER JAM

Trailing double feed

Trailing single feed

FRONT EDGE OF SHEET

DAMAGED

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.35)

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

Caution!

The system uses double-pole/neutral fusing (i.e. 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, 1.25" (32mm) 7.0A HRC (Quick Acting, F)

115V machines:

730-020 Fuse, 1.25" (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 # double

Bin # empty

Bin # jam

Meaning

A double feed error has occurred on the bin detailed. This means that the bin has fed two sheets of paper, instead of one. Check and correct the faulty set and restart the machine. If the error persists see the Problem

Solving section of the Operating Manual.

The paper tray of the bin detailed is empty. Reload the bin and touch to continue the job.

A paper jam has occurred in the bin detailed. Touch INCH to clear any partial sets from the conveyor. If the error persists see the Problem Solving section of the Operating Manual.

Message

Bin # lift error

Bin # miscal

Bin # miss

Bin # overload

Bin # Part Reset

Bin # trailing

Bin programming error

Bin reset

Cannot start fold axis changing

Cannot start sheets axis changing

Cannot start sidelay under stitch head

Cannot start tray down

Meaning

(Suction feed bin only) Too much paper has been loaded into the bin

(note that the grey button will not raise or lower the tray). Remove the stock and reload a smaller quantity.

A feed/sensor error has occurred during the test set. The bin will recalibrate automatically, but check the very first set for errors.

A miss feed error has occurred on the bin detailed. This means that the bin did not feed a sheet in the last set. Check and correct the faulty set and restart the machine. If the error persists see the Problem Solving section of the Operating Manual.

An obstruction in the bin is preventing it from lifting correctly. Check and remove any obstructions. It may be that the stock has not been pushed fully forward into the bin.

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

A trailing feed error has occurred on the bin detailed. This can mean one of two things:

1) The sheet from this bin was delivered late (trailing single feed)

2) An extra sheet was delivered from this bin, slightly behind the first sheet (trailing double feed)

If the problem persists see the Problem Solving section of the Operating

Manual.

The bins in the collator have not initialised properly. Switch the machine off and then on again. If the problem persists, contact your local Watkiss

Service Department.

An error has occurred in the electronics of the bin detailed. Any number over 16 relates to a module other than a bin. Restart the machine. If the problem persists, contact your local Watkiss service department.

The fold axis (size adjustment) of the booklet maker is in the process of adjusting. Wait for the booklet maker to finish before pressing .

The sheets axis (book thickness adjustment) of the booklet maker is in the process of adjusting. Wait for the booklet maker to finish before pressing .

The Stitch-Fold stitch heads are positioned over the bottom of the infeed sidelays. Adjust the stitch heads so that they do not activate the safety sensors.

(Suction feed bin only) One of the trays has been lowered by the operator.

Press the grey button on the bin controls to raise the tray. Press .

Message

Cannot start tray empty

Cannot start trim axis changing

Cannot start width axis changing

Change feed output to front

Change feed output to rear

Change feed path down

Check fuse

Conveyor Jam

Emergency stop

Fuse blown

Fuses blown

INITIALISING BINS

Motor Stalled

No power to stacker

No Response

Output path deflector changed

Meaning

One of the switched-on bins was empty when was touched. Fill the bin with paper and touch again.

The trim axis (size adjustment) of the trimmer is in the process of adjusting.

Wait for the trimmer to finish before pressing .

The width axis (size adjustment) of the booklet maker is in the process of adjusting. Wait for the booklet maker to finish before pressing .

The collator's base is not set up correctly for the current job. Change the paper path to feed to the front of the collator.

The collator's base is not set up correctly for the current job. Change the paper path to feed to the rear of the collator.

The collator's base is not set up correctly for the current job. Change the paper path to feed down.

A fuse may have blown in the drive unit. Contact your local Watkiss service department.

A paper jam has occurred in the bottom of the conveyor. Remove the rear guard and clear the jam. Touch INCH to clear any partial sets from the conveyor.

The emergency stop button has been pressed. Turn the emergency stop button clockwise to release it.

A fuse has blown on the Motor Drive PCB in the drive unit. Contact your local Watkiss service department.

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

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

There may be a bad jam causing the conveyor to lock. Clear the jam.

Touch INCH to clear any partial sets from the conveyor. If the collator does not restart, a fault may have occurred in the drive unit: contact your local

Watkiss service department.

Check that the stacker is plugged into a suitable mains supply, and is switched on.

The bins in the collator have not initialised properly. Switch the machine off and then on again. If the problem persists, contact your local Watkiss

Service Department.

The paper path has been altered on the collator's base. Select the correct paper path before restarting the job.

Message

Power Fail

PSU voltage error:

Rear cover open

Remote stop

Set size wrong

SFT Jam

SFT stalled

(SFT only)

SFT stalled

(BMP/TMP only)

Stacker full

Stacker jam

Stacker not connected

Staple head err

Meaning

The mains supply has been interrupted. Switch the collator off and on again.

There is a voltage error. Contact your local Watkiss service department.

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

The Collator has stopped because there is a problem with ancillary equipment to which it is linked. Clear the problem with this equipment before restarting the job.

The wrong number of bins are switched on for the job specified in Multiset.

The number of bins switched on must be a multiple of the number of sheets in a set.

There is a paper jam in the booklet maker. Open the booklet maker and remove the jam.

There is a bad paper jam in the Stitch-Fold unit, one or more of the stitch heads is jammed, or a fault has occurred.

Open the Stitch-Fold and clear any paper jams. If this does not work, lift the perspex lid on the Stitch-Fold and release the drive to the Stitch Heads, as follows:

• Undo the two star-shaped, orange drive lugs that sit just behind the wire spools

• Slide each drive lug along the guide, until they are clear of the Stitch

Heads

• Hand-crank the machine to release the jammed Stitch head(s)

• Replace the drive lugs before starting the machine again

If this does not work, contact your local Watkiss service department.

There is a paper jam in the booklet maker. Open the booklet maker and remove the jam.

The stacker is full of paper. Unload the stacker and touch to continue the job.

There is a jam in the stacker. Clear the jam before restarting the job.

The stacker is not connected to the collator, and a job has been loaded that requires the stacker to be in place.

A fault has occurred in the BookMaster or Rear Corner Stapler. Turn the mains switch off and then on again. If the problem persists contact your local Watkiss service department.

Message

Staple head error

Staple heads offline

Stapler Guard Open

Stapler Jam

Staples Low

Stitch Guard Open

Touch START to clear machine

Tower comms error

Tray lift error

Trim bin full

Trim Guard Open

Trim Bin Open

2xDivert

Meaning

There has been a staple head error in the BookMaster. The heads should self-clear. If they do not, turn the BookMaster off and on again to free the head. If this does not work contact your local Watkiss service department.

The staple heads are not selected on the BookMaster. To select the staple heads, press the Staple Head Select button on the BookMaster. The staple head indicator lights on the BookMaster show which heads are selected.

The top cover of the rear corner stapler is open. Close the cover.

A paper jam has occurred in the rear corner stapler. Lift the top cover and clear the jam.

A staple cartridge in the BookMaster or Rear Corner Stapler needs replacing. Fit a new staple cartridge.

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

There may still be paper in the conveyor. Touch to clear the machine before starting a new job.

There has been a communications error between the towers. 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.

(Friction feed bin only) There is a fault with the tray lowering mechanism.

Contact your local Watkiss service department.

(SlimVAC bin only) One of the trays has not lifted. Try unloading and reloading the bin. If this does not work, press the emergency stop switch and allow 10 seconds before releasing it. If the problem persists contact your local Watkiss service department.

The Trimmer offcut bin is full. Empty the offcut bin.

The TrimMaster cover is open and should be closed.

The 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) have occurred from the same bin.

Check the bin is feeding correctly.

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Normal Collating

The DFS can also be used for the normal collating and finishing of batch printed sheets. When the DFS is used in this way, PRENUMBER can be switched off if required

(see p.15).

Loading Sequence

Load the centre spread of the book face up in the uppermost bin (see below). The other pages should be loaded progressively downwards using as many bins as are required. The cover should be loaded into the lowermost bin with the outside face down.

Centre Spread

Face Up

Outside Face

Down

Finishing Batch Printed Sheets

From the BATCH window,set the NUMBER OF SETS to 1 .

This will feed one sheet from each active bin, and then open the latch in the gathering station to allow the set to travel into the bookletmaker.

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.

Note: Bin linking can only be enabled when the bins are unlocked i.e. when TEST SET is highlighted on the display.

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.

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

Adjust the Machine

Adjust the machine and start the job as detailed previ-

ously in the manual (See “Running the Job” on page 5).

Advanced Functions

There are several advanced functions that can be selected on the Vario. These functions should only be used if the standard adjustments detailed in the previous chapters fail to give the desired effect.

To access the advanced functions, touch MENU on the control panel.

USER SETTINGS Touch USER SETTINGS to make general changes to the

Vario, such as the display language or screen contrast.

ACCESS LEVEL The control panel has five different access levels:

• Operator

• Supervisor

• Service

• Distributor

• Factory

Touch ACCESS LEVEL and choose the appropriate level from the menu. The last three levels are protected by access codes.

The supervisor level provides additional security for locking saved jobs.

Current Language: Touch one of the flags displayed in order to select the appropriate language.

LIGHTER Touch LIGHTER to increase the screen’s contrast by one step. Repeat until the required contrast is obtained.

The greyscale next to the LIGHTER and DARKER buttons shows the screen’s current setting. The top square is level with the top of the LIGHTER button, and should always be invisible because it is white. When the contrast is correctly set, the square below the white one should be just visible.

DARKER Touch DARKER to decrease the screen’s contrast by one step. Repeat until the required contrast is obtained.

FEEDER INFO FEEDER INFO shows information about the sheet detection system of each bin. You only need to refer to this 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 bee n 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.

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

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

CLEANING CLEANING turns the conveyor on. Press the red button on the bin controls to activate the feed clutch for that bin.

Touch CLEANING again to switch the conveyor off. Refer to your operating manual for information on machine maintenance.

MACHINE OPTIONS Touch MACHINE OPTIONS to view the general machine set-up. Some of the settings can be changed, depending on the current access level.

MEASUREMENT Select MM or INCH as the unit of measurement.

PAUSE TIME Adjusting the PAUSE TIME increases or decreases the pause time at the end of a batch when PAUSE / SEPARATE is selected from the BATCH window, or when PAUSE is selected whilst the machine is running.

NETWORK SETTINGS The network settings need to be correct in order to link the Vario to a computer via the Ethernet connection.

Touch NETWORK SETTINGS to view the Vario’s IP address and subnet mask. See the Watkiss Vario GUI Panel

Installation Guide for more information about setting up a network.

Specifications

Intended use The Watkiss Document Finishing System is intended for the feeding of materials as specified below

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

Document Finishing

System

Configuration: From 2 to 8 bins

Production: Dependant on operating mode and finishing option

Stock Sizes: Min: 140 x 120mm, 5.5 x 8.3"

Max: 320 x 450, 12.6 x 17.75" (BookMaster Pro)

Max: 350 x 450mm, 13.75 x 17.75" (Auto Stitch-Fold)

Maximum Book Thickness: 25 sheets (80gsm)

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

GUI Control Panel

Dimensions (W,D,H): 245, 25, 205mm; (3.3 kg), 9.6, 1.0, 8.1"; (7.3 lb)

Weights include Control Panel, Cable and CPU

Drive Unit

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

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

Friction Feed Bin

Rel. F

Capacity: 40mm,1½"

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

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

Capacity: 45mm, 1¾"

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

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

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

Gathering Base

Module

Dimensions (W,D,H): 700, 750, 1150mm (75kg)

Online Finishing

System

See corresponding operating manual

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.