Watkiss Vario User manual

Operating Manual Issue 2

CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

Appendix

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

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

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

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

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

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

Welcome

Congratulations, you have just purchased the very finest

of collators, the Watkiss Vario. Your Vario has been de-

signed to make collating efficient, productive and above

all, easy.

ABOUT YOUR

MANUAL

This operating manual (Issue 2) covers machines fitted

with Release C Floor Bases (see below) installed with

Vario application software V7.0 onwards. For machines

fitted with earlier bases please refer to Issue 1.

The manual has a 'Quick Start' section to get you up and

running quickly. It is then followed by more detail on each

of the modules that make up your machine, and by

problem solving charts and additional notes.

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

However, as with all electrical equipment, when removing

any covers or changing fuses always first discon-

nect the machine from the mains electricity

supply by switching off and unplugging the machine.

Rear Guard

The rear guard of the collator must be fitted for the

machine to run. A safety switch prevents machine oper-

ation when the guard is removed. When fitting the guard,

ensure that the bar on the top bracket locates correctly

on the hooks under the drive unit. Also ensure the guard’s

bottom bracket locates on the lower conveyor shaft.

Release C Floor Base Release A & B Floor Base

Emergency Stop

The emergency stop button should only be used when

an immediate stop of the machine is required. Under

normal circumstances the machine should be stopped

by pressing on the control panel. If the emergency

stop button is used, the collator will not restart until the

button has been released by turning clockwise.

INSTALLATION The installation of your Vario 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 be plugged into a mains supply of

the correct voltage. Two fuses are fitted next to the Mains

input. If either of the fuses fails the collator will not power

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

Mains ON/OFF Switch

Emergency Stop

Mains Input and Fuses

MAINS ON/OFF

SWITCH

The mains On/Off switch should be used to turn the

collator on and off when required. When the collator is

switched off it retains the control panel settings in mem-

ory.

GETTING HELP We are confident that your 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

assistance, the Watkiss Service Department (UK) or your

local Watkiss supplier will be happy to help.

THIS PAGE IS

INTENTIONALLY

BLANK

1Quick Start

This section is intended only as a brief operating guide.

Detailed operating procedures are included in subse-

quent chapters.

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

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

on the control panel.

CONTROL PANEL On the bottom of the display you will see there are two

rows of control options. These are used by pressing on

the two rows of arrow keys below them. For instance, the

left hand message on the bottom row is . To use this,

press the bottom left arrow key .

Note that when an option or action is selected it is

highlighted (e.g. becomes ).

During normal use the display shows the main menu. By

pressing the second menu is displayed. This con-

tains options for counting, batching etc.. In turn these also

have sub-menus.

For now, simply remember that changes from one

menu to another, and that the two rows of arrow keys allow

you to use the two rows of options shown on the display.

LOADING THE BINS

WITH PAPER

Remove any unwanted paper from the bins and press

to check that there is no paper left in the conveyor

from the previous job.

The job should be organised either with the sheets face

uppermost, and the first page in the top bin or face down

with the first page in the bottom bin.

INCH

Tip

Pressing and holding (on menu 2) until it changes to will automatically

return the control panel to its default factory settings.

SETUP SETUP

INCH

Friction Bins

Take a stack of paper and slide it into the bin between

the sliding sidelays. Push in the sidelays to centralise the

paper in the bin, they should hold the paper securely.

SlimVAC Bins

Take a stack of paper and slide it into the bin between

the sliding sidelays. Push in the sidelays to centralise the

paper in the bin, they should hold the paper securely.

Position the rubber endlay on the tray at the end of the

paper stack. The endlay should be underneath and just

clear of the edge of the paper (by about 1mm, 1/16").

Suction Bins

Switch off any suckers that would be off the edge of the

paper by turning the tap to the left.

Normally the trays are all in the up position, in order to

load the bins they must first be lowered. Starting with the

bottom bin (bin 1), press the grey bin lowering button and

then load the bin, lower bin 2 and load it, lower bin 3 and

load it etc.

Slide the stock into the bin, centralising it between the

two locating pins. Ensure the stack is loaded neatly and

square, and then place the magnetic sidelays on all three

sides.

ADJUSTING THE

MACHINE

Friction Bins

• Initially set the separation pressure lever (left) to its mid-

position.

• Set the tray pressure to minimum by pushing down on

thelever(right)andreleasingittoitsinnermostposition.

If loading large sheets it should be one notch out.

SlimVAC Bins

• Initially set the tray height lever to its mid position

• Angle the suction feeder down

• Set the corrugation adjustment (on the feeder) to the

mid-position

Suction Bins

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

All Bins

Press to switch on all loaded bins.

If required, you can press and hold until it changes

to to set the machine to standard settings.

Adjust the stacker for paper size.

STARTING THE JOB Press to run the test set.

When the test set is complete, press again to run

the job.

Once the machine is running, adjustments may be nec-

essary depending upon the stock in use. Full details for

eachtype of feed bin arefound in the appropriate chapter.

The machine can be stopped at any time by pressing

SETUP

THIS PAGE IS

INTENTIONALLY

BLANK

2Control Panel

Your Vario will be fitted with either a top or side mounted

control panel. The only difference in operation between

the two types is that the side mounted panel has an

additional quick stop button on the top.

The quick stop button immediately stops the collator.

Under normal circumstances use the stop button

on the control panel and allow the system to sequence

down.

Stop Button

Start Button

LCD Display

Menu Button Arrow Key

Side Mounted Control Panel

Keypad

Quick Stop Button

Top Mounted Control Panel

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

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

The top line shows machine information including the

number of bins fitted, the collator production rate (in sets

per hour) and the current job area number.

The central area is the set counter and message display.

The lower area is used to access the menu system. The

menu consists of two rows of control options. These are

used by pressing on the two rows of arrow keys below

them. For instance, the left hand message on the bottom

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

During normal use the display shows the main menu. By

pressing the second menu is displayed. This con-

tains options for counting, batching etc. In turn these also

have sub-menus.

Machine Information

Counter and Message

display

12 Bins 1234 SPH Job : 1

000264

TEST SET SPH+ DRIVE+ AIR+

INCH SPH- DRIVE- AIR-

Note: When an option or action is selected it is

highlighted (e.g. becomes ).

Note: The menu will only show available options,

these will depend on machine configuration.

INCH

STARTING THE JOB Press , a single set will be collated. Check this and,

if needed, another test set may be obtained by pressing

and . If the set is correct, press again

to commence the job.

COUNTER Press to clear the counter. When the machine is started

the counter will count upwards.

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

to clear the counter and then enter the number of sets

required using the number keys. When the machine is

started the counter will automatically count down to zero

and the collator will then stop.

DURING THE JOB During the job the control panel will tell you the status of

the machine and the number of sets collated. In addition

it will identify any errors that may occur. The lights beside

Basic Menu Navigation

MENU 1

ADVANCED

MENU 2

BATCH

SFT

JOB

TEST SET

each bin will also indicate errors. The machine can be

stopped at any time by pressing .

When the job is completed, press to unlock the

bins. If necessary, the control panel may instruct you to

press to clear the machine ready for the next job.

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

, the bins are 'security locked' to prevent errors and

accidental button presses. This means that pressing the

buttons on the bin controls will have no effect. To unlock

the bins press and then .

MENU 1 Menu 1 is used to adjust the basic operating parameters

of the Vario.

: When displayed, the collator is ready to run a

test set. A test set consists of a single feed from each bin

that is switched on and loaded. The Vario uses the test

set to calibrate the detection system. The test set is not

counted by the counter (except when in prenumber

mode). Press to run a test set.

: The test set is complete. Pressing now

will accept the test set and lock the bin settings. If an error

occurs during the test set it will have to be run again.

Correct the problem and press , again.

: Displayed once the test set is accepted. Press

to unlock the bins prior to running a new job.

END JOB

Menu 1 Adjustments

12 Bins 1234 SPH Job : 1

000264

END JOB

TEST SET SPH+ DRIVE+ AIR+

INCH SPH- DRIVE- AIR-

TEST SET

END JOB

: Press and hold to turn the conveyor. Used for

delivering any sets remaining in the conveyor after a jam

etc.

and : Sets per hour adjustment. The produc-

tion rate can be varied to suit your application. The initial

setting is 3,000 sets per hour. If other Vario ancillary

equipment,suchas the X-Jogger is on line,theproduction

rate will automatically be limited to suit that piece of

equipment. (Note: If you have selected via

Menu 2, the SPH adjustment no longer appears on the

menu. In mode the SPH and drive speed

adjustments are combined. In this case use and

to control the production rate)

and : The conveyor drive speed may be

adjusted for different paper types. This alters the drive

speed of the rollers and therefore the speed at which the

sheets exit the collator. Certain stocks will stack better if

the drive speed is adjusted to suit. The default factory

setting is 60%.

and : This alters the amount of air available for

air separation. As a general rule, the heavier and larger

the sheet, the more air you need. If you are running mixed

stocks, individual air taps on each bin allow the air to be

independently controlled. The default factory setting is

25%. If any SlimVAC bins are fitted and the installed

software is version 6.1h or later the default air setting is

40%.

MENU 2 Press to enter Menu 2

: Twin Tower only. When selected, the collated

set from tower B delivers ahead and separately from that

of tower A. This allows better knock up for sets with a lot

of sheets .

: Enters the batch menu (see below).

: Enables oscillation when an oscillating bench

base, X-Jogger or Deep Pile Stacker is fitted.

INCH

SPH + SPH -

PRENUMBER

DRIVE +

DRIVE -

DRIVE +

DRIVE -

AIR + AIR -

STAGGER

BATCH

OSCILL

: Normally there will be more than one set in

the conveyor at any one time. For pre-numbered work you

may want only one set in the conveyor at a time, meaning

that each set is delivered to the stacker before the next

set is collated. This minimises the correction required

should an error occur. However, because the sets are

spread further apart, the overall production rate is re-

duced. Also note that in prenumber mode linked bins (see

p.31) cannot be changed over manually.

: Any faulty sets are diverted to the reject tray

without stopping the collator (floor standing models only).

Faulty sets are not counted by the counter. The

command is not available when in mode.

: This is only displayed if a Stitch Fold is online. Press

to enter the SFT menu which is explained in the Stitch

Fold operating manual.

or : By default, sets are delivered forwards

and is displayed. Press to select delivery straight

PRENUMBER

Menu 2 Navigation

12 Bins 1234 SPH Job : 1

000264

TEST SET SPH+ DRIVE+ AIR+

INCH SPH- DRIVE- AIR-

STAGGER OSCILL DIVERT JOB

BATCH PRENUMBER SFT / SETS ↓SETUP

MENU 1

MENU 2

BATCH MENU SFT MENU JOB MENU

(only if SFT online)

DIVERT

PRENUMBER

SFT

SETS ↓SETS ↓

SETS ↓

downwards and will be displayed. (Delivery to the

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

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

: Press once to switch on all loaded bins. Note that

the green light comes on next to each loaded bin, this

means the bin is switched on. (Note. You can manually

switch bins on and off by pushing the red button on each

bin).

Press and hold until it changes to to return

the Vario to default factory settings.

BATCH MENU To enter the batch menu press from Menu 2.

The batch mode allows you to preset the number of sets

required, insert at a chosen interval, or offset the stacker

at a chosen interval.

When in batch mode the main counter display changes

to show from left to right: cumulative set total, the number

of batches completed and the number of sets needed to

complete the batch.

The set counter will count downwards until the batch is

complete. The batch counter will then increase by one.

The cumulative set counter counts upwards showing the

total number of delivered sets. The example above there-

fore shows ten sets left to complete the batch, three

completed batches and seventy total sets.

SETS ↓

JOB

SETUP

SETUP SETUP

BATCH

12 Bins 1234 SPH Job : 1

000070 0003:00010

END JOB SPH+ DRIVE+ AIR+

INCH SPH- DRIVE- AIR-

Menu 1 Batch Mode

Cumulative Set Total

Number of Complete Batches

Number of Sets to Complete

the Batch

If you want to use the batch counter press , ,

, enter the number of sets required in each batch

followed by . After the number of sets per batch is

chosen one or more of the following actions must be

selected to enable batch mode.

: The machine will stop after each batch and the

counter display will flash. To run another batch press

: Offsets the stack after each batch if an X-Jogger

or Oscillating Bench Base is fitted.

: When feeding to the front of the collator, a sheet

will be fed from the top bin with the first set of each batch.

MENU BATCH

SIZE #

Batch Menu Navigation

12 Bins 1234 SPH Job : 1

000264

TEST SET SPH+ DRIVE+ AIR+

INCH SPH- DRIVE- AIR-

STAGGER OSCILL DIVERT JOB

BATCH PRENUMBER SFT / SETS ↓SETUP

MENU 1

MENU 2

BATCH MENU

MULTIFEED

STOP INSERT ↑MULTISET SIZE

OSCILL INSERT ↓PAUSE

STOP

OSCILL

INSERT ↑

The inserted sheet will be at the bottom of the batch pile,

as the backing board for a pad for example.

When feeding to the rear of the collator, a sheet will be

fed from the top bin with the last set of each batch. The

inserted sheet will be at the top of the batch pile, as the

cover sheet of a pad for example.

: When feeding to the front of the collator, a sheet

will be fed from the bottom bin with the last set of each

batch. The inserted sheet will be at the top of each batch

pile, as the cover sheet of a pad for example.

When feeding to the rear of the collator, a sheet will be

fed with the first set of each batch. The inserted sheet will

be at the bottom of the batch pile, as the backing board

of a pad for example.

If the inserted sheet is not part of the job, i.e. it is being

used purely as a batch separator, it can be fed from either

the top or bottom bin.

: the machine will pause for approximately 5 sec-

onds after each batch. The counter display will flash and

an audible beep will be heard. The pause time can be

adjusted by a Watkiss approved engineer.

: Enters the Multiset mode. Multiset allows mul-

tiple sets to be loaded

and counted

For example, a two part set can be loaded three times in

a six bin collator. Normally only one set would be counted

per cycle even though three are being fed at a time. In

this case selecting Multiset will count three sets per cycle

instead of one.

Mutiset will also automatically divide an odd number of

sets into a batch. Using the previous example, if the

desired batch size was fifty, the number of sets fed at

each cycle (three) would not divide exactly into the total

required. In this case Multiset would feed forty eight sets

normally and then just two sets on the final cycle to

complete the required batch.

INSERT ↓

PAUSE

MULTISET

For this example you would press , and to

enter the number of sheets per set. Next enter the size of

the batch by pressing , followed by and and

finally .

Multiset can also be used as a sheet counter when the

number of sheets in the set is entered as . All the bins

are loaded and the required number of sheets is entered

by pressing .

: To enter Multifeed mode, press ,

then press and hold until it changes to .

Finally press . Multifeed allows multiple feeds

from each bin per set. For example, a Multifeed size of 4

will feed 4 sheets from each bin in turn per set. To change

the Multifeed size, press , followed by the number of

required feeds and .

Press and hold until it changes to to

return to Multiset mode.

: Alters the number of sets per batch

To exit batch mode press from Menu 2 to enter the

batch menu and deselect the options previously high-

lighted. Press twice to return to Menu 1.

JOB MEMORY MENU To enter the job memory menu press from Menu 2.

To exit the job memory menu without making any changes

press .

Up to 9 job areas with different collator settings are saved

in the memory. These are retained when the collator is

switched off. The collator always operates in one of the

job areas to determine its settings.

Any changes you make to the collator settings are auto-

matically stored in the current job area. When the collator

is switched on it automatically enters the most recently

used job area.

MULTISET 2#

SIZE 5 0

SIZE

MULTIFEED MULTISET #

MULTISET MULTIFEED

MULTIFEED

SIZE

MULTIFEED MULTISET

SIZE

BATCH

JOB

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