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SUCTION FEED PROBLEMS

Problem

Cause

Action

DOUBLE FEEDS

Incorrectly positioned sucker
plugs

Check the positioning of the
plugs (see p.41)

Porous paper

Refer to section on porous
paper (see p.44)

Too little edge flick

Increase the edge flick depth by
lowering the control (see p.42)

The tray is too high

Lower the tray (see p.45)

MISS FEEDS

The edge flick is set too deep

Reduce the edge flick depth by
raising the control (see p.42)

Sucker cups are damaged or
are incorrectly seated

Check and replace/refit any
faulty sucker cups (see p.75)

Insufficient suction for heavy/
thick stock

Remove the plugs from all suck-
ers

Tray is too low

Adjust the tray height accord-
ingly (see p.45)

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

)

Late feeding double sheet

Treat as double feed above

Slow feeding sheet

Treat as miss feed above

Slow feeding during test set
causing incorrect calibration

Run another test set by touching

followed by

TEST SET

followed

PAPER JAM

Sheet is jammed in the paper
path

Locate the sheet and either pull
it out or

INCH

it through

Sheet is only half feeding

Treat as miss feed above

CREASED CORNERS

Soft paper is being 'sucked up'
into the sucker

Fit open plugs to the outer most
suckers on the sheet (PN 310-
537, Plastic Mould (VSCN) Man-
ifold plug open)

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

Remove the outer edge flicks
(see p.46)

’BIN OVERLOAD' MESSAGE
AND SMALL GREEN LIGHT IS
BLIPPING (• • • •)

An obstruction in the bin is pre-
venting it from lifting correctly

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

Содержание Vario

Страница 1: ...Operating Manual Issue 3...

Страница 2: ......

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 109: ......

Страница 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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