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Watkiss Vario Operating Instructions Manual

Document finishing system
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  • Page 3: Table Of Contents

    CONTENTS Welcome ..........1 Running the Job ........5 Control Panel ........9 Friction Bins ........27 SlimVAC Bins ........33 Gathering Base Module ....41 Maintenance ........45 Problem Solving ......49 Appendices Normal Collating ........59 Advanced Functions ......61 Specifications ........63 Declaration of Conformity ..... 65 Index ..........67 Issue 3 - Nov 2002 - Part No.

  • Page 5: Welcome

    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.
  • Page 6 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 addi- tional operating instructions covering this option are available. SAFETY FIRST Your Document Finishing System has been designed with safety as a key feature.
  • Page 7 INSTALLATION The installation of your Document Finishing System re- quires 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.
  • Page 8 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 Depart- ment (UK) or your local Watkiss supplier will be happy to help.

  • Page 9: Running The Job

    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 touch- ing the relevant tab at the bottom of the control panel.
  • Page 10 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 Remove any unwanted paper from the bins and touch WITH PAPER...
  • Page 11 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 is highlighted on the display. TEST SET Setting the Number of Sheets Touch...
  • Page 12 Adjust the online finishing units for size (see relevant operating manual). In the window, select (see p.15), and BASIC PRENUMBER set the (see p.14). SETS PER HOUR AUTO STARTING THE JOB Test Set A test set must be run at the start of each job. Touch to run a test set.

  • Page 13: Control Panel

    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.
  • Page 14 Start/Stop Test Set Inch/Pause Help Menu End Job Control Buttons Each window contains a group of related buttons Touch the relevant tab to display each window Load & Save Feed Basic Batch Advanced Finishing Main Window Tabs on the Control Panel Functions related to modules that are not installed on your DFS will not be displayed on-screen.
  • Page 15 When the machine is running, this button changes to . Touch to pause the feed for approximately PAUSE PAUSE 5 seconds, the conveyor continues to run. The pause time can be altered on the Machine Options page. Touch when you want to set the machine up for END JOB END JOB a new job, or alter an existing job.
  • Page 16 Touch and then touch any area of the screen to HELP HELP 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.
  • Page 17 Mimic Diagram Touching resets the set counter to 0. 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.
  • Page 18 THE ‘BASIC’ WINDOW window contains settings that regularly need BASIC to be altered when setting up a new job. ‘BASIC’ Window. allows the production rate of the system SETS PER HOUR SETS PER HOUR to be set. This is automatically limited according to the machine configuration.
  • Page 19 If you are running mixed stocks on friction bins, individual air taps on each bin allow the air to be independently controlled. is used if an exact number of sets are required. PRESET PRESET Touch and enter the number of sets required on PRESET the number pad.
  • Page 20 THE ‘ADVANCED’ window allows advanced machine set- ADVANCED WINDOW tings to be altered. These settings may be altered to optimise the quality and productivity of a job. ‘ADVANCED’ Window. alters the drive speed of the conveyor DRIVE SPEED DRIVE SPEED rollers and therefore the speed at which the sheets exit the collator.
  • Page 21 A small offset can make jogging more effective when using a booklet maker. The sheet detector measures 15.2mm (0.6") from the feed DETECTOR POSITION 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.
  • Page 22 Touch to set the clutch feed length to the AUTO: AUTO default value of 186.2mm (7.35"). (not applicable for DFS) will decrease the SHORT: SHORT 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. Increasing the value causes the feeder SUCTION HOLD...
  • Page 23 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. Counts the total number of sets produced Counts the number of sets per batch Counts the total number of batches produced...
  • Page 24 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 to insert a separate BOTTOM 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.
  • Page 25 THE ‘FINISHING’ window controls the settings for the book- FINISHING WINDOW let maker and trimmer. ‘FINISHING’ Window. Touch to alter the settings of the booklet PAPER SIZE PAPER SIZE maker and trimmer to suit the input paper size. If you suspect the booklet maker or trimmer RE-REF: adjustment system is not calibrated correctly, touch to re-reference the adjustment axes.
  • Page 26 The position of the stitch and fold can be offset relative STITCH AND FOLD to the centre of the paper. allows this STITCH AND FOLD position to be adjusted up to 20mm in either direction, in increments of 0.2mm. : The option will produce booklets that STITCH STITCH OFF...
  • Page 27 When is selected, the SIDE JOG HOLD: SIDE JOG HOLD 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.
  • Page 28 THE ‘LOAD & SAVE’ window allows job settings to be saved LOAD & SAVE WINDOW 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.
  • Page 29 enter the new job name and then touch CLOSE The original job is unchanged. If the job name is not changed before touching , the job will be saved with the current name, CLOSE suffixed by an asterisk. Touching shows the settings for each saved JOB DETAILS JOB DETAILS job.
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  • Page 31: Friction Bins

    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.
  • Page 32 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 auto- matically switch on and off as they are loaded and unloaded.
  • Page 33 Moving the lever to its highest position disengages the separator. This position is used for the improved feeding of heavy cardstocks. Tray Pressure Separator Pressure Adjustment 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.
  • Page 34 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.
  • Page 35 Particularly heavy or opaque stock such as a 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, trailing sheets and jams will be detected as normal.
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  • Page 37: Slimvac Bins

    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.
  • Page 38 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’...
  • Page 39 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 Before a test set is produced, individual bins will auto- matically switch on and off as they are loaded and unloaded.
  • Page 40 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.
  • Page 41 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.
  • Page 42 Paper Condition Recommended Settings Standard Settings • Suction Feeder angled down • Tray height in mid-position • Sheet corrugation in mid-position 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.
  • Page 43 Paper Condition Recommended Settings Stock curling up The upward curl means the tray height detector will ‘see’ the paper before it is close enough to the feeder. • Raise the tray height to lift the paper stack closer to the feeder. Lightweight porous papers •...
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  • Page 45: Gathering Base Module

    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.
  • Page 46 The manual bypass gate only works when the DFS is already running. Start the machine first, and then pull it out. REMOTE CONTROL The remote control handset (supplied with the Vario (OPTIONAL) Automatic Stitch-fold & Trim) can be used to control certain functions on the Document Finishing System.
  • Page 47 Button Functions : Starts the system : Stops the system : No function : 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...
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  • Page 49: Maintenance

    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 As with all machinery, your Document Finishing System...
  • Page 50 STATIC ELIMINATION 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.
  • Page 51 • 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).
  • Page 52 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).

  • Page 53: Problem Solving

    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...
  • Page 54 If not, con- tact the Watkiss Service Depart- ment (UK) or your local Watkiss supplier FRICTION FEED PROBLEMS Problem Cause Solution...
  • Page 55 FRICTION FEED PROBLEMS Problem Cause Solution MISS FEEDS Too little tray pressure Increase by pulling the handle out by one notch at a time (see p.29) Too much separation pressure Reduce by moving the lever up by one notch at a time (see p.28) Untidy loading Reload the bins tidily, ensuring the paper stack is underneath the...
  • Page 56 SLIMVAC FEED PROBLEMS Problem Cause Action DOUBLE FEEDS The tray is too high Lower the tray height (see p.36) Not enough corrugation on suc- Increase sheet corrugation (see tion feeder p.35) Mechanical paper problem - Fan stock by hand before load- guillotine burr, sticky ink, poor ing, and ensure these problems perforations, high static charge...
  • Page 57 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 unplug- ging the machine...
  • Page 58 Manual. Bin programming error 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. Bin reset An error has occurred in the electronics of the bin detailed. Any number over 16 relates to a module other than a bin.
  • Page 59 The collator's base is not set up correctly for the current job. Change the paper path to feed down. Check fuse A fuse may have blown in the drive unit. Contact your local Watkiss service department. Conveyor Jam A paper jam has occurred in the bottom of the conveyor. Remove the rear guard and clear the jam.
  • Page 60 The mains supply has been interrupted. Switch the collator off and on again. PSU voltage error: There is a voltage error. Contact your local Watkiss service department. Rear cover open Check the rear cover/guard is fitted and is actuating the safety switch correctly.
  • Page 61 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. Staple heads offline The staple heads are not selected on the BookMaster.
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  • Page 63: Normal Collating

    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, can be switched off if required PRENUMBER (see p.15). Loading Sequence Load the centre spread of the book face up in the uppermost bin (see below).
  • Page 64 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”...

  • Page 65: Advanced Functions

    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...
  • Page 66 PAUSE selected whilst the machine is running. The network settings need to be correct in order to link NETWORK SETTINGS the Vario to a computer via the Ethernet connection. Touch to view the Vario’s IP address NETWORK SETTINGS and subnet mask. See the Watkiss Vario GUI Panel Installation Guide for more information about setting up a network.

  • Page 67: Specifications

    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"...
  • Page 68 Online Finishing See corresponding operating manual System 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.

  • Page 69: Declaration Of Conformity

    Manufacturer’s Watkiss House Address Blaydon Road Sandy, Bedfordshire, UK. SG19 1RZ Declares that the product Product Name Watkiss Vario Document Finishing System Product Number WA/VAR/2450 onwards (230V versions only) Product Variants Friction Feed Suction Feed SlimVAC Feed Gathering Base Module...
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  • Page 71: Index

    Index sets per hour access level 61 auto 14 action buttons single set 14 end job 11 batch window help 12 inserts 19 inch 10 bottom 19 menu 12 top 19 start/stop 10 number of sets 18 test set 11 pause / separate 20 adjusting the machine 7 restart batch 20...
  • Page 72 Index feed errors, gathering base module 43 interface sockets 41 feed wheels, friction bins 47 sheet length adjustment 42 feeder angle, slimvac bins 36, 52 sheet width adjustment 41 feeder info 61 getting help 4 finishing window book thickness 23 help 12 paper size 21 page direction 21...
  • Page 73 Index machine options 62 radio frequency emissions 64 mains input 3 rear guard 2 mains on/off switch 3 remote control 42 maintenance 45–?? re-ref 21 conveyor wheels 45 restart batch 20 feed wheels 47 rubber endlays, slimvac bins 33 paper separators 46 running a job 5–8 manual bypass gate 42 measurement 62...
  • Page 74 Index static elimination bar 46 stitch and fold 22 stitch delay 22 stitch on fold 22 suction hold 18 test set 8, 11 tolerance 17 tray extenders 27, 33 tray height slimvac bins 36, 52 tray pressure, friction bins 29, 50, 51 trim 22 troubleshooting 49–53 units of measurement 62...
  • Page 76 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: info@watkiss.com Web: http://www.watkiss.com Document Finishing System Operating Instructions, English. Issue 3, November 2002, Part No. 960-561...

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