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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 3, March 2001. Part No. 960-341

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Summary of Contents for Vario

Page 1: ...Operating Manual Issue 3...

Page 2: ......

Page 3: ...Base 49 Oscillating Bench Base 55 Floor Base 59 Joggers 65 Rear Corner Stapler 69 Maintenance 73 Appendices Problem Solving 79 Advanced Functions 91 Specifications 93 Declaration of Conformity 97 Inde...

Page 4: ......

Page 5: ...the modules that make up your machine and by problem solving charts and additional notes SAFETY FIRST Your Vario has been designedwith safety as a key feature However as with all electrical equipment...

Page 6: ...io requires specialist knowl edge 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 b...

Page 7: ...our Vario will give many years of trouble free production If you have any queries or prob lems in the first instance please refer to the problem solving section in this book Should you require further...

Page 8: ...4 THIS PAGE IS INTENTIONALLY BLANK...

Page 9: ...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...

Page 10: ...tory settings Touch End Job Touch Load Save Select the Default Template from the list of jobs Touch Load In the window that appears touch Yes to confirm that you wish to load the Default Template Load...

Page 11: ...hey 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 Suctio...

Page 12: ...he edge flick control to the mid position Stacker Adjust the stacker for paper size STARTING THE JOB Press to run the test set When the test set is complete press again to run the job Once the machine...

Page 13: ...ically dims After an extended period it switches off In either case touch the screen to return it to normal THE WINDOW SYSTEM The Vario is controlled by touching buttons on the control panel The butto...

Page 14: ...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 change...

Page 15: ...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 collato...

Page 16: ...of the Vario shown on screen is automatically created based on how many bins are fitted andwhatfinishingequipmentis connected Various areas on the outline will be highlighted in different colours acc...

Page 17: ...dicated in red C Touching C resets the set counter to 0 SPH SPH shows the actual production speed of the Vario in sets per hour The production speed is affected by paper size online finishing equipmen...

Page 18: ...ishing equipment and the job setup 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 t...

Page 19: ...identical batches it is easier to use the Batch function PRENUMBER PRENUMBER is intended for use when collating pre numbered carbonless sets Touching PRENUMBER se lects Single Set mode disables the D...

Page 20: ...TS PER HOUR setting The default factory setting is 80 STAGGER Two Tower only When STAGGER is selected the col lated set from Tower B delivers ahead and separately from that of Tower A This allows for...

Page 21: ...nsity The default setting is x1 NORMAL The Vario 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 pre...

Page 22: ...dur ing 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...

Page 23: ...19 THE BATCH WINDOW The BATCH window allows sets to be grouped into batch es with an action at the end of each batch stop pause oscillate or insert sheets BATCH Window...

Page 24: ...t set of each batch The insertedsheet 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 to...

Page 25: ...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...

Page 26: ...F to re reference the adjustment axes The adjustment axes will return to the current settings once this is com plete Periodically the booklet maker will automatically re reference the axes during the...

Page 27: ...OFF The STITCH OFF option will produce book lets that are folded but not stitched TRIM Touch TRIM to set the finished book size after trimming When a preset paper size is selected this distance is aut...

Page 28: ...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 bein...

Page 29: ...creen key board 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 RE...

Page 30: ...the job list and touch the large padlock button Some padlock symbols may be greyed out This is be cause there are several access levels to the system which can be used to prevent jobs being altered D...

Page 31: ...n sensor is overrange see p 31 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 Gree...

Page 32: ...the sheets One B3 14 x 20 tray extender is supplied as stand ard with each Friction bin An optional tray extender is available for running A4 portrait 8 x 11 P No 251 303 Load sheets face up 1 2 3 3 2...

Page 33: ...s 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 Increasi...

Page 34: ...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 Airdirectedfromtherigh...

Page 35: ...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 T...

Page 36: ...straw board backing sheet may cause the bin sensor to go over range This means that the sheet is too optically dense for the sensor to see through it Double feeds will not be detected but misses trai...

Page 37: ...n sensor is overrange see p 38 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 Gree...

Page 38: ...xtenders For large sheet sizes over A4 8 x 11 or when running A4 A4 8 x 11 portrait it will be necessary to fit tray extenders to support the sheets One B3 14 x 20 tray extender is supplied as stand a...

Page 39: ...ly 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 330 351 When the rubber e...

Page 40: ...ers 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 corru gation gives less...

Page 41: ...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 range...

Page 42: ...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 Particular...

Page 43: ...ard may be unable to bend sufficiently to meet the suction feeder in its lower position Raising the angle of the suction feeder re duces the feed angle Raise the tray height Stock curling down The sto...

Page 44: ...der Raise the tray height to lift the paper stack closer to the feeder Lightweight porous papers The feeder may suck through one sheet and onto the next resulting in double feeds Increase sheet corrug...

Page 45: ...d 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 t...

Page 46: ...ol This controls the depth of the edge flick For most mate rials 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...

Page 47: ...en 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 fi...

Page 48: ...ies 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...

Page 49: ...sor 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...

Page 50: ...he 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 f...

Page 51: ...47 Coated Carbonless A4 8 x 11 Porous A4 8 x 11 Coated Carbonless A3 11 x 17 Porous A3 11 x 17 Card A3 11 x 17 Note Under some conditions plugs may be omitted...

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Page 53: ...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 s...

Page 54: ...ally a different colour or a slightly larger size than the rest of the set to allow easy separation Where the job is A4 or 8 x 11 in size the slip sheet can be fed portrait whilst the remainder of the...

Page 55: ...ositioning 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 tra...

Page 56: ...es 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 beflippedup ordown and under n...

Page 57: ...eceiving 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 s...

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Page 59: ...ide marks on the stacker scale repre sent 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 Japa...

Page 60: ...idelay 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 Select OSCILLATE in the BASIC window to e...

Page 61: ...of the paper As before the sidelays position can be adjusted after initial collating to ensure neat stacking STACKING A5 SHEETS It is recommended that A5 6 x 8 sheets are stacked in landscape orientat...

Page 62: ...bottom position delivers paper to the rear of the collator into a jogger for example The middle position delivers the set vertically downwards and is used when the Oscillating Base floorstand is fitt...

Page 63: ...used with a jogger or one of the above modules as it does not have an integral stacker Interface Sockets The interface sockets are located on the right underside of the floor base below the front air...

Page 64: ...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 essen tial that the front feedout conveyor is removed Please refer to your...

Page 65: ...ssary to suit the paper characteristics curl etc A combination of air pipes and connectors are provided to allow optimum positioning SETTING THE PAPER PATH Rear Deflector Fingers The rear deflector fi...

Page 66: ...A out of the paper path which is shown by the dotted line Selecting DIVERT in the BASIC menu will divert any faulty sets into the catch tray B Feeding into a Booklet Maker Push the rear deflector lev...

Page 67: ...r s will be on the top of the stack PAPER JAMS If a paper jam occurs in the base the drive mechanism is automatically disengaged If required remove the rear guard and or booklet maker etc and remove a...

Page 68: ...ator 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 thebuttonfunctionsaredifferent SeetheStitch Fold op...

Page 69: ...e cable will only fit in to one of the sockets see p 59 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 w...

Page 70: ...sary 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 St...

Page 71: ...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 amou...

Page 72: ...68 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...

Page 73: ...ing the hand wheel so thatthe sidelays correspond to the appropriate point on the scale Open the top hinged cover of the corner stapler this will cause the sidelays to move to their inner position Ins...

Page 74: ...is a problem with the staple head The staple cartridge is nearly finished The lid of the stapler unit is open For more information about these messages see p 85 Loading the Staple Cartridge The RCS us...

Page 75: ...ilt 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...

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Page 77: ...o 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 rem...

Page 78: ...eed 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 de pend upon the usage level and the type of papers...

Page 79: ...age of the machine and the type of material being collated Select CLEANING in the MENU USER SETTINGS win dow Important Do not use any of the following chemicals to clean the separators feed wheels or...

Page 80: ...red button to return the manifold to its original position REPAIRING OVERLOADED TRAYS In the event of one of the Suction bin trays becoming severelyobstructedoroverloaded thereisasafetymech anism whi...

Page 81: ...nd 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 tra...

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Page 83: ...own on the control panel Correct any faults shown on the control panel TOP AND OR BOTTOM BIN ONLY FEEDS ON TEST SET Batch insert selected from batch menu Check that INSERTS in the BATCH window is set...

Page 84: ...ensure paper is cut well next time Miscalibration during the test set Run another test set by touching followed by TEST SET fol lowed by MISS FEEDS Too little tray pressure Increasebypullingthehandle...

Page 85: ...at as miss feed above Feeding A5 5 x 8 land scapewithoutselectingSHORT in the ADVANCED FEED CLUTCH window Select SHORT in the ADVANCED FEED CLUTCH window and run another test set by touching followed...

Page 86: ...y approx 1mm 1 16 clear of the edge of the stack Ensure it is the correct type for the paper size see p 35 TRAILING FEED On a trailing sheet the machine stops immediately You need to look carefully to...

Page 87: ...y which of the following is the cause The faulty set can be inched through by touching and holding INCH Late feeding double sheet Treat as double feed above Slow feeding sheet Treat as miss feed above...

Page 88: ...s too low Adjust accordingly see p 45 X JOGGER PROBLEMS Problem Cause Solution NOT OFFSET STACKING OSCILLATE is not available or not selected in the BASIC or BATCH window Plug X Jogger into the Vario...

Page 89: ...relevant module number will appear where is shown below Caution The Vario system uses double pole neutral fusing ie two fuses so when removing any covers or changing fuses always first disconnect the...

Page 90: ...ling 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 Bin p...

Page 91: ...nd clear the jam Touch INCH to clear any partial sets from the conveyor Emergency stop The emergency stop button has been pressed Turn the emergency stop button clockwise to release it Fuse blown A fu...

Page 92: ...paper jams If this does not work lift the perspex lidon the Stitch Fold and releasethe drivetothe Stitch Heads as follows Undo the two star shaped orange drive lugs that sit just behind the wire spool...

Page 93: ...be paper in the conveyor Touch to clear the machine before starting a new job Tower comms error There has been a communications error between the towers Check the interconnection cable between the tw...

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Page 95: ...ovides additional security for lock ing 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...

Page 96: ...d 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 OPTI...

Page 97: ...feeds per hour Capacity 40mm 1 Stock Sizes 120 x 160mm to 364x 520mm 5 x 6 to 14 x 20 Stock Range 40 to 300 gsm 11 bond to 110 cover Detection Electronic detection for miss double jam and empty bin D...

Page 98: ...riction 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 2 Stock sizes 130 x 160mm to 364 x 520mm 5 x 6 to 14...

Page 99: ...icy 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...

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Page 101: ...se Bench Top Base Oscillating Bench Base Conforms to the following Product Specifica tions Safety 73 23 EEC and 89 392 EEC Council Directive on the approximation of laws of Member States relating to m...

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Page 103: ...window air blow 14 divert 15 oscillate 15 prenumber 15 preset 15 sets per hour auto 14 single set 14 batch window inserts 20 bottom 20 top 20 number of sets 20 oscillate 21 pause separate 21 restart b...

Page 104: ...dge 23 stitch on fold 23 trim 23 floor base 59 64 air blast 61 front feedout conveyor 60 interface sockets 59 rear deflector fingers 61 rear feedout conveyor 63 remote control 63 with deep pile stacke...

Page 105: ...59 delivery direction lever 58 magnetic sidelays 55 non standard paper sizes 57 offset stacking 56 paper guides 57 problem solving 84 scale 55 stacking a5 sheets 57 straight stacking 56 overrange 31...

Page 106: ...ications 93 95 sph 13 stagger 16 staple cartridge 70 staple counter 71 staple counter resetting 71 start stop 10 stitch 23 stitch and fold 23 stitch delay 24 stitch fold 60 62 stitch off 23 stitch on...

Page 107: ...03 U units of measurement 92 unlocking jobs 26 user settings 91 V view of job list 26 W window system 9 X x jogger 65 jogging adjustment 66 problem solving 84 setting up the jogger 65 straight stack l...

Page 108: ...Index 104 THIS PAGE IS INTENTIONALLY BLANK...

Page 109: ......

Page 110: ...ss House Blaydon Road Middlefield Ind Est Sandy Bedfordshire SG19 1RZ ENGLAND Tel 44 0 1767 682177 Fax 44 0 1767 691769 Email info watkiss com Web http www watkiss com Operator Manual Vario English Is...

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