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Watkiss DigiVAC Service Manual

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Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04
Watkiss DigiVAC
Service Manual
Issue Date:
29 November 2004
Issue Number: 2
Part Number: 969-251
Watkiss Automation Ltd
1 Blaydon Road
Middlefield Industrial Estate
Sandy, Bedfordshire
SG19 1RZ U.K.
Tel: +44 (0)1767 682177
Fax: +44 (0)1767 691769
Email: info@watkiss.com

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  • Page 1 29 November 2004 Issue Number: 2 Part Number: 969-251 Watkiss Automation Ltd 1 Blaydon Road Middlefield Industrial Estate Sandy, Bedfordshire SG19 1RZ U.K. Tel: +44 (0)1767 682177 Fax: +44 (0)1767 691769 Email: info@watkiss.com Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 2 The information contained in this document is subject to change without notice. Watkiss Automation Limited makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.

  • Page 3: Table Of Contents

    General Comments ............16 3.2 Top Module ............16 3.2.1 Replacing the Top Drum & Conveyor Belts.......16 3.3 Control Panel (DigiVAC Standard) ........17 3.3.1 Removing the Control Panel (DigiVAC Standard)....17 3.3.2 Engineering Mode.............18 3.4 GUI Control Panel (DigiVAC+) ........19 3.4.1 Introduction ..............19 3.4.2 Operation ................19...
  • Page 4 3.6.8 Replacing the SMD 8200 Inverter ........42 3.6.9 Removing and Replacing Main Drive Belt ......43 3.6.10 Tensioning Main Drive Belt ..........43 3.6.11 Converting the DigiVAC from 50Hz to 60hz Supply Frequency ............44 3.7 Rear Door ............46 3.7.1 Removal of Rear Door Conveyor Belts 433 Long...
  • Page 5 3.10 Straight Jogger / Adjustable Height Straight Jogger ..56 3.10.1 Description ..............56 3.10.2 Jogging Power Adjustment..........57 3.11 Tower B Top Module & Two-Tower DigiVAC Systems ..57 3.11.1 Adjusting Inter Tower Distance........57 3.11.2 Removing the Tower Link Assembly.......58 3.11.3 Removing the Top Module and Tower Link Assembly ..59 3.11.4 Replacing the Tower B Top Module Conveyor Belts..60...
  • Page 6 7 Installation 7.1 Prior to Installation ..........115 7.2 Unpacking and Installing a DigiVAC ......115 7.3 Upgrade an 8 DigiVAC to a 12 DigiVAC ......117 7.4 Upgrade a DigiVAC Standard to a DigiVAC+ ....118 7.5 Installing the Front Outfeed Conveyor ......120 7.6 Installing a Second Tower ........122...

  • Page 7: Overview

    The following service aids are available and must be used where indicated: 950-042 DigiVAC Rear Door Gear Cover If a service procedure requires the DigiVAC to be operated with the rear door open, exposed gears are a hazard to the engineer. This gear cover MUST be fitted.

  • Page 8: Orientation

    1.1.5 Metric and Imperial measurements In most cases metric measurements and specifications are used in this manual. A conversion chart is included in this manual (see Section 9.1). The DigiVAC control panels can be set to use either metric or imperial measurements, refer to the relevant operating manual.

  • Page 9: Modules & Configuration

    Two different versions are availa- ble, the DigiVAC Standard and the DigiVAC+. 1.2.1 DigiVAC Standard The DigiVAC Standard is available with 8 or 12 bins. It has a 5-digit counter with total count and preset count. Compatible accessories: X-Jogger, Straight Jogger, BookMaster range of bookletmakers and trimmers.
  • Page 10 Figure 1:3 The table below lists the modules available for the DigiVAC Collator, some of these are modules that may be used independently of the Watkiss DigiVAC (e.g. BookMaster). The table gives the product abbreviation, the name, the fac- tory part number and the module software address for each complete module assembly.
  • Page 11 DigiVAC Rear Door extension to suit 12 bins 032-161 DNRD DigiVAC Rear Door, for connection to Nagel 032-163 BookletMaker DigiVAC+, Tower B Rear Door to suit 8 bins 032-164 DigiVAC+, Tower B Rear Door extension to suit 032-165 12 bins DBAS...

  • Page 12: System Overview

    240V machines - see Section 4.1.2 on 65 for details of transformer tappings. The DigiVAC Base Module Rel.B was introduced at Serial No. 150 (Techni- cal Bulletin 150 refers). The Rel.B base includes a 3-phase motor and SMD8200 Inverter.
  • Page 13 DigiVAC Standard Control Panel: The DigiVAC Standard is fitted with a touch membrane control panel which includes the display, control panel keys, and speed control. In order to change the software of the DigiVAC Standard, the Eprom must be changed.

  • Page 14: Fuses

    Multi Tower Systems: Multi-tower systems are only possible with the Digi- VAC+. Two DigiVAC+ towers can be linked to give up to 24 bins. The top module of Tower B includes connecting bridge which transports paper and carries the communication between the two towers.
  • Page 15 Control Panel Dead Transformer LED on Transformer LED on Machine Dead Machine Dead DigiVAC Base PCB F2 Machine will start, but no ‘PSU VOLTAGE ERROR: 28v’ feed occurs showing up on message is displayed the bin as a Jam No Jog or Oscillate Function...
  • Page 16 Overview • Fuses Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 17: Tools & Materials

    Watkiss part numbers are included where relevant, although many of the recommendations are standard tools which are readily available. Some of the tools listed are not required directly for servicing the DigiVAC, but are be required for DigiVAC accessories such as the Automatic Stitch- Fold &...

  • Page 18: Consumables

    PART NO. Digital Multi Meter 370-052 Bin Sensor Calibration Stock 950-041 Tray Gauge - 2 off 950-042 Rear Door Gear Cover 950-043 Safety Switch Bypass 950-044 Blow Gauge 950-045 Vacuum Gauge Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 19: Service Procedures

    The following service aids are available and must be used where indicated: 950-042 DigiVAC Rear Door Gear Cover If a service procedure requires the DigiVAC to be operated with the rear door open, exposed gears are a hazard to the engineer. This gear cover MUST be fitted.

  • Page 20: Removing The Rear Conveyor Assembly

    • Remove the M5 button head screw on the R/H side of the machine (this is the left hand screw when viewed from the rear of the machine). Then loosen the L/H screw and the plate can be eased out. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 21: Removing L/H Side Plates

    2. Remove the side covers from the top module and bin modules on the L/H side of the machine. DigiVAC+ only: carefully disconnect the 50-way cable and earth lead from behind the screen mounting panel. DigiVAC standard only: Remove the control panel (see Section 3.3.1).

  • Page 22: Pcb Removal, Fitting And Adjustments - General Comments

    Service Procedures • Top Module DigiVAC Standard: Put the DigiVAC Standard control panel into Engineering Mode (see Section 3.3.2). Press # - The # LED will flash to indicate that the bins are being prepared for addressing (unlocking the EPROM etc.) and then will remain steady to in- dicate addressing mode.

  • Page 23: Control Panel (Digivac Standard)

    To gain access for certain service procedures, or replace a main control PCB, it is necessary to remove the control panel assembly. This procedure applies only to the DigiVAC standard. The GUI control panel for the DigiVAC+ is mounted directly on the side cover, and only requires unplugging. PARTS REQUIRED...

  • Page 24: Engineering Mode

    Service Procedures • Control Panel (DigiVAC Standard) 3.3.2 Engineering Mode The DigiVAC standard has an Engineering Mode whereby different functions are assigned to the Control Panel keys. Enter Engineering Mode by pressing the grey button (SW4) located on the rear of the Control Panel PCB (see Section 4.1.8).

  • Page 25: Gui Control Panel (Digivac+)

    EPROM of each bin before the machine re- verts to engineering mode again. Test Mode. The DigiVAC has a test mode in which the machine will not stop on miss or double feed errors. Feed errors are indicated by an audible ‘beep’.

  • Page 26: Adjusting The Gui Screen Display

    This allows the display to be easily adjusted to the operator’s preference. To alter the actual screen contrast, carry out the following steps: Procedure 1. Switch the DigiVAC on, and wait for the screen to light up. 2. Touch in the top right of the screen. MENU 3.

  • Page 27: Feeder Modules

    PARTS REQUIRED TOOLS REQUIRED 3mm Allen Key 1.5mm Allen Key, ball ended Electrical Screwdriver Pliers, Long Nose, small Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 28 This will disconnect the clutch drive coupling and pull the separator actuation shaft through the side frame. Lift the feeder head clear of the bin. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 29: Feed Band Removal

    • a faulty feeder clutch • a dry or dirty feeder clutch pulley bearing (see Section 3.5.4). Note: Feeder creep may also be caused by incorrect feeder belt tension (see Section 3.5.12). Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 30: Checking And Lubricating The Feeder Clutch Pulley Bearing

    4mm Allen Key Light oil Procedure 1. Disconnect the DigiVAC from the mains power supply. 2. Remove the joint plates, top conveyor coupling plate, feeder belt clamp plates and feeder clutch plates from the L/H side of the machine (See p.15).

  • Page 31: Replacing Bin Emitter/Sensor

    Light Oil 4mm Allen Key Procedure 1. Remove the feeder clutch shaft assembly from the DigiVAC and then re- move the feeder clutch (see Section 3.5.3). 2. Remove the pulley and then clean and examine the shaft for wear. 3. Lightly oil the pulley bearing with a light oil.

  • Page 32: Bin Emitter/Sensor Calibration

    3. Open the rear door and remove the rear conveyor assembly. 4. Put the DigiVAC into calibration mode: Press any one of the bin on/off buttons on the appropriate bin module, whilst switching on the mains power. All the bins in that module will now be in calibration mode. This will be indicated by the yellow bin indicator light being illuminated.

  • Page 33: Replacing Tray Sensor

    3mm Allen Key Electrical Screwdriver, small Procedure 1. Disconnect the DigiVAC from the mains power supply. 2. Remove the L/H side cover from the bin module with the faulty sensor. 3. Disconnect the faulty tray sensor cable from the 900-174 feeder control PCB.

  • Page 34: Set The Separator Stop Plate

    11. Re-fit the side cover. 3.5.8 Set the Separator Stop Plate If a DigiVAC bin feeds doubles or tears the leading edge of the paper exces- sively the paper separator plate may need to be adjusted. To check the setting: 1.

  • Page 35: Replace Vacuum Air Filters

    To prevent the suction valves becoming clogged with offset powder and paper dust, a small filter is placed between the feeder head and the suction valve. These filters must be checked and replaced regularly as part of the DigiVAC's routine maintenance.

  • Page 36: Replacing Bin Feeder Drive Belts

    Service Procedures • Feeder Modules Procedure - Removal 1. Disconnect the DigiVAC from the mains power supply. 2. Remove the R/H side cover(s) from the bin module(s) requiring service. 3. Disconnect the valve from the 900-175 BSF4 Connection PCB. 4. Grip the valve with one hand whilst turning the elbow pipe, downwards.

  • Page 37: Setting Bin Feeder Drive Belt Tension

    3mm Allen Key 4mm Allen Key x 2 Procedure 1. Disconnect the DigiVAC from the mains power supply. 2. Remove all the bin module side covers from the L/H side of the machine. 3. Open the rear conveyor door. Bin Module Drive Belt...
  • Page 38 9. Close the rear conveyor door 10. Put the relevant bin module(s) into Bin Test Mode (see Section 3.1.1). 11. Start the DigiVAC so that the belts are running. 12. Starting with the lowermost bin of the bin module, push the separator lever to the top position and operate the feed clutch by pressing the bin on/off button.

  • Page 39: Replacing Bin Module Drive Belts

    3mm Allen Key 4mm Allen Key Procedure 1. Disconnect the DigiVAC from the mains power supply. 2. Remove the joint plates, top conveyor coupling plate, feeder belt clamp plates and feeder clutch plates from the L/H side of the machine (see Sec- tion 3.1.4).

  • Page 40: Replacing Worn Conveyor Wheels

    Service Procedures • Feeder Modules Procedure - 8 Bin DigiVAC 1. Disconnect the DigiVAC from the mains power supply. 2. Open the rear conveyor door, and remove the rear conveyor (see Section 3.1.2). 3. Remove the conveyor belts by sliding them over the conveyor shafts and off the rear conveyor assembly.

  • Page 41: Removing The Pinch Wheel Idlers

    10. Bypass the rear door safety switch using the safety switch bypass tool. 11. Switch on the mains power to the DigiVAC and start the machine with the bins switched off. 12. Check that the conveyor wheels are correctly positioned and running straight and true.

  • Page 42: Base Module

    10mm AF Spanner 13mm AF Spanner Procedure 1. Disconnect the DigiVAC from the mains power supply. 2. Remove the rear cover assembly: Undo and remove 4 x M5 button head screws, disconnect the cooling fan electrical connector, lift the cover away from machine.
  • Page 43 9. Remove the tacho sensor and bracket (2 x M5 button screws). 10. Remove the temperature sensor and bracket (2 x M6 hex screws). 11. Remove the motor drive pulley (1 x M6 socket cap screw). Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 44: Checking The Vacuum Pressure

    • For Serial Nos. DIG/0000150 onwards this should be -150 mBar. 3.6.3 Replacing the Vacuum Pump Motor The vacuum pump for the DigiVAC is in the base module. If the pump becomes worn or faulty, it will require replacing to resume machine operation.

  • Page 45: Replacing Motor Tacho Sensor

    LED12 on the 900-176 interface PCB. The Flashes should be on and off evenly. 8. If necessary, adjust the sensor in or out a small amount until it operates correctly. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 46: Replacing Or Cleaning The Main Air Filter

    Service Procedures • Base Module 3.6.5 Replacing or Cleaning the Main Air Filter The main air filter is situated inside the base of the DigiVAC behind the filter access panel. It is important that the main air filter is checked, cleaned or replaced at regular intervals.

  • Page 47: Replacing Blower Motor

    4. Close all bin air taps on both sides of the each bin. 5. On the 900-187c DigiVAC Air/Blow Control PCB, check that LK1 is in the ‘ON’ position, for closed loop operation. This is the normal position. 6. Use switch LK3 to switch on the motors (without starting the machine).

  • Page 48: Replacing The Smd 8200 Inverter

    4mm Allen Key Electrical Screwdriver, small Procedure 1. Switch off the DigiVAC and disconnect the mains power supply. 2. Loosen the two fixing screws and remove the LH side cover from the Base Module. 3. Disconnect the Mains Input cable from the top of the Inverter.

  • Page 49: Removing And Replacing Main Drive Belt

    13mm Spanner or Socket Procedure 1. Disconnect the DigiVAC from the mains power supply. 2. Remove the joint plates, top conveyor coupling plate, feeder belt clamp plates and feeder clutch plates from the L/H side of the machine (see Sec- tion 3.1.4).

  • Page 50: Converting The Digivac From 50Hz To 60Hz Supply Frequency

    Readjust if necessary. 7. Tighten the remaining retaining nuts, replace all covers and test. 3.6.11 Converting the DigiVAC from 50Hz to 60hz Supply Frequency This procedure only applies to DigiVAC Base Modules prior to Serial No. S0000150. PARTS REQUIRED TOOLS REQUIRED...
  • Page 51 13. Replace the control panel surround plate. 14. Replace the base module side panel. Procedure for DigiVAC+ 12. Connect the Zerox PCB to PL8 socket on the DigiVAC Base PCB. Zerox PCB Figure 3:32 Inserting Zerox PCB 13. Replace the base module side panel.

  • Page 52: Rear Door

    3.7 Rear Door 3.7.1 Removal of Rear Door Conveyor Belts 433 Long (Lower) 1. Disconnect the DigiVAC from the mains power supply and open the rear door. 2. Remove the two nyloc nuts, two shake proof washers and two button head...

  • Page 53: Front Outfeed Conveyor

    3.8 Front Outfeed Conveyor For booklet making, the DigiVAC is supplied with an integral outfeed con- veyor in the rear conveyor door. If offset stacking is required, an additional front outfeed conveyor can be fitted to the machine to allow set delivery to the front of the machine.

  • Page 54: Removing The Front Outfeed Conveyor

    3.8.1 Removing the Front Outfeed Conveyor PARTS REQUIRED TOOLS REQUIRED 917-439 Front Outfeed Conveyor 3mm Allen Key Procedure 1. Disconnect the DigiVAC from the mains power supply. Paper Guide Assembly Paper Guide Support Shaft Front Outfeed Conveyor Retailing Screws Conveyor Cap...

  • Page 55: X-Jogger

    The X-Jogger stacks and jogs sets either straight or with a 20° offset. The jog- ging power is variable. It fits onto mounting pegs on the front of the DigiVAC. Power to the X-Jogger is taken from the DigiVAC and fused at DigiVAC Base Power PCB (900-192).

  • Page 56: X-Jogger General Inspection

    Service Procedures • X-Jogger Selecting the Jogger Function: DigiVAC standard: Press @ to offset stack each set. Press ( to offset each batch of sets. DigiVAC+: Touch followed by to offset stack each set. BASIC OSCILLATE Touch followed by to offset each batch of sets.

  • Page 57: X-Jogger Control Pcb/Fuse Replacement

    Service Procedures • X-Jogger Procedure - Endlay 1. Disconnect the D-XJG power and data cables from the DigiVAC. 2. The two endlay M8 grub screws ‘B’ are located in the endlay nut under the endlay plate (see Figure 3:40). 3. Fully open the sidelays to access the outer grub screw.

  • Page 58: X-Jogger Pivot Shaft Cleaning/Lubrication

    10mm Spanner SA 30/40 Oil Procedure 1. Disconnect the D-XJG power and data cables from the DigiVAC. 2. Place the D-XJG upside down on a suitable surface so as not to damage the unit. 3. Remove the M6 hex head screw (see Figure 3:41), shake-proof washer and flat washer from the pivot shaft.

  • Page 59: X-Jogger Vibrator Coil Replacement

    Screwdriver, Pozi Drive, large Small Pliers Procedure 1. Disconnect the D-XJG power and data cables from the DigiVAC. 2. Disconnect the stacker full sensor cable from the electrical box. 3. Open the sidelays fully. 4. Remove the eight M6 nuts (see Figure 3:43) and four washers that secure the vibrator box to the receiving area assembly.

  • Page 60: X-Jogger - Park Position Adjustment

    3mm Allen Key 10mm Spanner Procedure 1. Ensure the DigiVAC has been stopped normally, so that the D-XJG is parked either fully left or fully right. 2. Disconnect the D-XJG power and data cables from the DigiVAC. 3. Place the D-XJG upside down on a suitable surface so as not to damage the unit.

  • Page 61: X-Jogger Diagnostic Procedure

    1. Take the power supply cable from the vibrator box and plug it directly into the D-XJG power supply on the DigiVAC base. If the box vibrates follow the next part of the procedure. If it does not vibrate there is a connection problem or the vibrator coil is faulty.

  • Page 62: Straight Jogger / Adjustable Height Straight Jogger

    When the collator is not running the reading should be nearly 0V. 9. If there is no reading there is either a connection problem between the col- lator and jogger or the output of the DigiVAC Base Control PCB 900-176 is faulty.

  • Page 63: Jogging Power Adjustment

    Service Procedures • Tower B Top Module & Two-Tower DigiVAC Systems unit is controlled from the Straight Jogger Control PCB. The Straight Jogger has variable jogging power. Tray Full Sensor: A tray full sensor controls the collator when the tray is full.

  • Page 64: Removing The Tower Link Assembly

    Remember that the tower link assembly will need supporting until it is clear of Caution Tower A. Always move the DigiVAC not the tower link assembly. Applying lateral forces on the tower link assembly to move the collator can result in damage.

  • Page 65: Removing The Top Module And Tower Link Assembly

    Remember that the tower link assembly will need supporting until it is clear of Caution Tower A. Always move the DigiVAC not the tower link assembly. Applying lateral forces on the tower link assembly to move the collator can result in damage.

  • Page 66: Replacing The Tower B Top Module Conveyor Belts

    Service Procedures • Tower B Top Module & Two-Tower DigiVAC Systems 3.11.4 Replacing the Tower B Top Module Conveyor Belts Should the Top Module conveyor belts become worn or damaged, they will need to be replaced. PARTS REQUIRED TOOLS REQUIRED...

  • Page 67: Replacing The Tower Link Assembly Conveyor Belts

    Service Procedures • Tower B Top Module & Two-Tower DigiVAC Systems 3.11.5 Replacing the Tower Link Assembly Conveyor Belts If the tower link assembly conveyor belts should become worn or damaged, they will require replacing to resume good machine function.
  • Page 68 Service Procedures • Tower B Top Module & Two-Tower DigiVAC Systems Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 69: Electronics & Software

    4.1.10 : DigiVAC+ Low Voltage Connections (S/Nos. DIG/0000150 onwards) 4.1.11 : 900-190a DigiVAC Output Interface PCB Circuit diagrams are available as PDF files on the DigiVAC Product Support CD (981-156). For PCB layouts, with diagnostic information, see section 4.2 ’PCBs’ on page...

  • Page 70: Digivac Block Diagram

    Electronics & Software • Connection Diagrams 4.1.1 DigiVAC Block Diagram Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 71: Transformer Tappings

    Electronics & Software • Connection Diagrams 4.1.2 Transformer Tappings Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 72: Digivac High Voltage Connections (S/Nos. Up To Dig/0000149)

    Electronics & Software • Connection Diagrams 4.1.3 DigiVAC High Voltage Connections (S/Nos. up to DIG/0000149) (sheet 1 of 2) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 73: Digivac High Voltage Connections (S/Nos. Up To Dig/0000149)

    Electronics & Software • Connection Diagrams 4.1.4 DigiVAC High Voltage Connections (S/Nos. up to DIG/0000149) (sheet 2 of 2) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 74: Digivac High Voltage Connections (S/Nos. Dig/0000150 Onwards)

    Electronics & Software • Connection Diagrams 4.1.5 DigiVAC High Voltage Connections (S/Nos. DIG/0000150 onwards) (sheet 1 of 2)) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 75: Digivac High Voltage Connections (S/Nos. Dig/0000150 Onwards)

    Electronics & Software • Connection Diagrams 4.1.6 DigiVAC High Voltage Connections (S/Nos. DIG/0000150 onwards) (sheet 2 of 2) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 76: Digivac Standard Low Voltage Connections (S/Nos. Up To Dig/0000149)

    Electronics & Software • Connection Diagrams 4.1.7 DigiVAC Standard Low Voltage Connections (S/Nos. up to DIG/0000149) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 77: Digivac Standard Low Voltage (S/Nos. Dig/0000150 Onwards)

    Electronics & Software • Connection Diagrams 4.1.8 DigiVAC Standard Low Voltage (S/Nos. DIG/0000150 onwards) Connections Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 78: Digivac+ Low Voltage Connections (S/Nos. Up To Dig/0000149)

    Electronics & Software • Connection Diagrams 4.1.9 DigiVAC+ Low Voltage Connections (S/Nos. up to DIG/0000149) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 79: Digivac+ Low Voltage Connections (S/Nos. Dig/0000150 Onwards)

    Electronics & Software • Connection Diagrams 4.1.10 DigiVAC+ Low Voltage Connections (S/Nos. DIG/0000150 onwards) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 80: 900-190A Digivac Output Interface Pcb

    Electronics & Software • Connection Diagrams 4.1.11 900-190a DigiVAC Output Interface PCB Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 81: Pcbs

    730-032 FUSE, 20mm, 3.15A, HRC- ANTI SURGE,T 4.2.2 900-104e X-Jogger Control PCB The X-Jogger Control PCB is also used for the Vario X-Jogger. For the DigiVAC X-Jogger, the PCB must be Release D onwards. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 82: Straight Jogger Control Pcb

    Straight Jogger Control PCB. The table that follows provides a key for the diagram. DESCRIPTION LED FUNCTION (LED ON) Not Used Connection to Power Control Connection to Vario Collator Main Supply Input Input from ‘Jogger Full’ Sensor Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 83: 900-140B Digivac Standard (Eco-Vario) Control Panel Pcb

    Switch Dual In Line (DIL) Switches: The table below shows the functions of the DIL switches on the DigiVAC Standard Control PCB. The switches have two positions, ON (towards the PCB) and OFF (away from the PCB). The default position for the DIL switches is all OFF.

  • Page 84: 900-174F Digivac Feed Control Pcb

    On when machine is running or in Test Mode SK2,4,6,8 Bin Empty Sensors, one per Rapid blink when machine is running. On in Test Mode VR1,2,3,4 Potentiometer to adjust paper sensor sensitivity; one per bin Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 85: 900-176H Digivac Base Pcb

    LED11 Blinks when command sent Eco-Vario Control Intercon- nection (DigiVAC Standard only) GUI Control Interconnection (DigiVAC+ only) not used LED2 Rear Door Guard Switch Input LED5 Rear Door / Guard Switch closed LED6 always ON Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 86 LED10 Power to jogger LED19 Jogger plugged in Fuse1 730-032 Low voltage system, 3.15A, Glass, Anti-surge, T Fuse2 28V System, 6.3A, Glass, Anti-surge, T Fuse3 Low voltage supply to D-XJG. Self resetting. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 87: 900-187E Digivac Air/Blow Control Pcb

    DESCRIPTION Control from Base PCB Hire voltage wiring harness LED1 On when motor is running Fuse4 730-029 X-Jogger - 2A, HRC-ANTI SURGE, T Fuse5 730-032 Motor - 3.15A, HRC- ANTI SURGE,T Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 88: 900-205A Digivac Release B Base Power Pcb

    730-032 Motor - 3.15A, HRC- ANTI SURGE,T 4.3 SMD 8200 Inverter The SMD 8200 Inverter is fitted to DigiVAC Base Module Rel.B (Serial No. 150 onwards). The inverter takes a single-phase 50/60Hz 180-264V AC elec- trical supply and inverts it to 230V AC 50Hz three-phase output for the 3- phase Drive Motor.

  • Page 89: Installing New Software

    SFM card, via a parallel port programmer (see Section 4.4.2.1). The screen will appear even if there is no parallel port programmer connected to the computer. This does not stop the DigiVAC software from being stored in the C:\GUI folder.
  • Page 90 The computer is used as a terminal and the boot firmware gives the operator various options to choose from when updating the application software (see Section 4.4.7). Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 91 • The information stored on an SFM Card can be overwritten, and it can be used many times Refer to Section 4.4.2 for a detailed description of how to update software using this method. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 92 Electronics & Software • Software - GUI Control Panel 4.4.1.4 Updating Software Via an RS232 Connection As with previous versions of the DigiVAC, software can be updated using an RS232 connection. This plugs directly into the GUI CPU, and allows a service engineer to install software from a computer’s serial port.

  • Page 93: Updating Software With A Memory Card

    Electronics & Software • Software - GUI Control Panel You can communicate with the DigiVAC via any computer on the network us- Glossary ing a Telnet program. Software can be downloaded from any computer on the network, as long as that computer has a ‘TFTP server’ installed. You can...
  • Page 94 Electronics & Software • Software - GUI Control Panel 3. Locate the self-extracting zip file on your computer, which contains the latest version of the DigiVAC software (see Figure 4:9). Double-click the file to run it. The file will extract the software (and other related files) to the folder C:\GUI.

  • Page 95: Installing Software Via An Rs232 Connection

    7. Remove the SFM Card from the CPU and secure the Front Blanking Panel. 4.4.2.3 Updating the DigiVAC Software from an SFM Card (Manual Mode) Updates can be carried out from an SFM Card in Manual Mode. In this mode, the SFM Card is still plugged directly into the GUI CPU, but the transfer of software is controlled by a computer.
  • Page 96 Figure 4:13, this port is ‘Com 1’. Once you have selected a serial port, the other menus will be greyed out. Click on the OK button. Figure 4:13 Hyperterminal Connection Type. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 97 Figure 4:14 Connection Properties. 7. Switch on the DigiVAC Mains On/Off Switch and during the startup beeps, open the rear door or press the space bar on the computer’s key- board (this puts the DigiVAC into ‘boot mode’). When the beeps have stopped, close the rear door.
  • Page 98 1. Type S in the Hyperterminal window, press return and then press ‘Y’. The DigiVAC is now ready to accept the software update. 2. To send the software update to the DigiVAC, select the Transfer drop- down menu and select send file.

  • Page 99: Installing Software Via An Ethernet Connection

    [WALBOOT] Figure 4:18 Checking which Version of Software is Installed on the SFM Card. 3. To see what version of software is stored in the DigiVAC’s flash memory, type f and press return. 4. In order to download the software from the SFM Card to the DigiVAC’s download cache, type l and press return.
  • Page 100 The following procedure explains how to update software via the ethernet Glossary connection. A TFTP Server is required: make sure that the computer that has the TFTP Server installed is correctly connected to the DigiVAC before start- : This is a software TFTP server ing this procedure.
  • Page 101 Electronics & Software • Software - GUI Control Panel 3. Click on the ‘TFTP Root Directory’ tag in the TFTP Server Configuration menu. Set the path to the folder where the DigiVAC Software is stored (see Figure 4:21). Click on the ‘OK’ button.
  • Page 102 1. Switch off the Mains On/Off Switch on the DigiVAC. 2. Switch the Mains On/Off Switch back on and open the rear door during the startup beeps (this puts the DigiVAC in ‘boot mode’). When the beeps have stopped, close the rear door.
  • Page 103 3. At the prompt: Enter filename to load [varioapp.lzw]?> press return to confirm that the file name for the DigiVAC software that you wish to install is varioapp.lzw. If the name for the software update is different to varioapp.lzw, type the new name in and press return.
  • Page 104 Telnet window and press return. The software version will be displayed in a table. 3. To see what version of software is stored in the DigiVAC’s flash memory, type f and press return. 4. In order to download the software from the SFM Card to the DigiVAC’s download cache, type l and press return.

  • Page 105: Networking Digivacs

    These cables allow information to be passed back and forth between any of the computers on the network. If a DigiVAC is connected to such a network, then any computer on that net- work can be used to communicate with it, for example to send the DigiVAC the latest version of the application software.
  • Page 106 DigiVAC will be assigned an IP address automatically: you will not need to alter it. If a new network is being created, then the computers and DigiVAC can be al- located any IP addresses (as long as they have the same Subnet address) (see Figure 4:28).
  • Page 107 MENU 255.255.255.0, proceed to step 3. of this procedure. 3. Access the DigiVAC’s boot firmware, using a computer linked to it via an RS232 cable (for further details, refer to Section 4.4.3). 4. In the Hyperterminal window, type n to access the Ethernet network set- tings menu.

  • Page 108: Troubleshooting Network Connections

    If the network is operating correctly, the window will list all the Digi- VACs that are connected to the network. NOTE: In future versions of the DigiVAC Application Software , you will be able alter the network settings by touching...

  • Page 109: Gui Boot Firmware Commands

    4.4.7 GUI Boot Firmware Commands This section lists the commands available in the GUI boot firmware. Remem- ber, to access these commands, put the DigiVAC in Boot Mode, and connect it to a computer via an RS 232 or Ethernet connection (see Section 4.4.1).

  • Page 110: Error Bleeps

    There is a problem with the machine settings files (which store information about network settings, etc.) or the device that stores them • • • There is a problem with the job memory files or the device that stores them Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 111: Machine Inspections

    Machine Inspections • Chapter 5 Machine Inspections Before leaving the factory, each module of the Watkiss DigiVAC is systemat- ically checked and tested. The inspection schedules listed in this section should be used as indicated before a machine is installed at a customer’s premises.

  • Page 112: Digivac - After-Build Inspection

    5. Stacker-full Sensor 6. Miss and Double Detection 7. BATCH STOP/INSERT/OFFSET 8. Test Hand Merge Function 9. Bin-Empty Sensor 10. Cross Check Machine Voltage with Serial Label Checks completed by: Date: Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 113 1. Address Bins • Go through bin addressing procedure. • DigiVAC Standard: Check correct bin count appears on the top left hand side of the LCD screen during power up. • DigiVAC+: Check correct bin count appears on the GUI Mimic dia- gram.
  • Page 114 • If fitted, check operation of Oscillating Stacker (Refer to the Digi- VAC+ operating manual). 5. Stacker Full Sensor • DigiVAC Standard: Check when Stacker is full that the Collator auto- matically stops and display shows [FULL]. • DigiVAC+: Check when Stacker is full that the Collator automatically...
  • Page 115 • Check that the bin empty sensor works correctly in all bins, green flashing LED on bin switch will appear. 10. Check Machine Voltage • Cross check machine voltage with Serial Label Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 116: Digivac - Pre-Delivery Inspection

    5. Bin Empty Sensor 6. Cross Stack All Bins (if DXJG installed) 7. Stacker Full Sensor 8. Secure for Transit 9. Record Drive Unit Serial No. Checks completed by : Date : Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 117 Check the bin LED and display. 3. Rear Deflector Change Warning • DigiVAC+ only: During running, stop machine, alter deflector direc- tion using lever and restart - control panel should show ‘ CANNOT START ’.
  • Page 118 • Switch off machine. • Cover machine to prevent damage to paint work. 9. Record Drive Unit Serial No. • If all the above have passed, record all the relevant serial nos. and data. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 119: Routine Maintenance

    Isopropanol or soapy water. Replace if worn or damaged (see Section 3.5.16) 15. Lubricate the Main Pivot Shaft on the Jogger using Oil Checks completed by : Date : Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 120: Digivac X-Jogger Routine Maintenance Schedule

    6. Check overall jogging power and adjust if neces- sary (see Section 3.9.5) 7. Check Sidelays on the jogger for operation and adjust tension of hand adjustments if they are too loose Checks completed by : Date : Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 121: Installation

    Never use extension cables to supply more than one module in the system from the same supply socket. The DigiVAC and accessory equipment must only be plugged into an electri- Caution cal 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 guarantee.
  • Page 122 Wooden Clamps Figure 7:2 7. Carefully remove the DigiVAC from the pallet. The DigiVAC is heavy, use extreme care to avoid personal injury. Warning 8. Transport wheels are supplied to assist moving the DigiVAC around. • To fit the wheels, slide the shafts through the holes in the machine base.

  • Page 123: Upgrade An 8 Digivac To A 12 Digivac

    Installation • Upgrade an 8 DigiVAC to a 12 DigiVAC shaft. Remove the shafts from the machine and fill the holes in the base with the grommets provided. 9. When the machine is in position, adjust the jacking screw to ensure that the machine is stable and does not roll on it's wheels.

  • Page 124: Upgrade A Digivac Standard To A Digivac

    26. Replace all covers and test the machine for function. 7.4 Upgrade a DigiVAC Standard to a DigiVAC+ A DigiVAC Standard can easily be upgraded to a DigiVAC+. The standard control panel is removed and the Graphical User Interface (GUI) and CPU are installed instead.
  • Page 125 Figure 7:5 Stand-off Posts (circled) 7. Take the DigiVAC CPU 20-way cable and plug it into the DigiVAC Base PCB. Thread the cable behind the PCB and downwards so that it comes out at the bottom of the PCB. (You may need to ease the PCB off its stand- off posts in order to do this).

  • Page 126: Installing The Front Outfeed Conveyor

    22. Run the machine and check that it operates correctly. 7.5 Installing the Front Outfeed Conveyor The front outfeed conveyor must be fitted if the DigiVAC is to be used with a jogger positioned at the front of the machine. It can be specified and pre- installed at the factory.
  • Page 127 9. Fit the paper guide rods using the brackets, washers and hand screws. 10. Push the paper guide assembly down onto the paper guide support shaft. 11. Replace the R/H and L/H conveyor caps. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 128: Installing A Second Tower

    TOOLS REQUIRED None 3mm Allen Key 6mm Allen Key 12mm AF Spanner In two tower DigiVAC systems, the towers are referred to as ‘A’ and ‘B’. Tower A Tower B Note Two tower configurations require the Rel.B DigiVAC Base Module.
  • Page 129 6. Switch on Tower B and then Tower A. Load the latest software (V2.1a or later) into both towers. Note Two tower DigiVAC support was introduced in GUI S/W version V2.1a. This is the minimum required. Both towers MUST have the same version of software installed.
  • Page 130 This is normal and should not be considered a problem. 13. Run some more sets and check that they are passing through the conveyor cleanly and exiting the system to a good and consistent quality. 14. Thoroughly test the system. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 131: Trouble Shooting

    VAC after a Test Set feed 3.5.5) Red and yellow error indication LED’s Emitter/sensor is damaged or faulty Replace bin emitter/sensor (see Section lighting up after a Test Set feed 3.5.5) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 132 Switch the machine off and then on ble feeds (DigiVAC Standard only) by a flashing point at the right hand end again. Be sure that no keys are pressed of the display whilst switching on Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 133 Front conveyor belts are worn or broken Replace front conveyor belts (see Sec- tion 3.8.2) Not offset stacking X-Jogger is not plugged into the collator Connect power and data cables Oscillate is not selected on control panel Select on the control OSCILLATE panel Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 134: Fuse Failure

    Control Panel Dead Transformer LED on Transformer LED on Machine Dead Machine Dead DigiVAC Base PCB F2 Machine will start, but no ‘PSU VOLTAGE ERROR: 28v’ feed occurs showing up on message is displayed the bin as a Jam No Jog or Oscillate Function...
  • Page 135 Controller too hot inside Ensure sufficient cooling to ature inverter DC bus over voltage Mains voltage too high Check supply voltage Earth leakage on motor side Check motor/motor cable (sepa- rate motor from controller) Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 136 Trouble Shooting • Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 137: Appendix

    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. Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 138: Conversions

    11 x 17” 279.4 x 431.8mm PAPER WEIGHT GSM (G/M EQUIVALENT IN # (USA) 8 # bond 11 # bond 20 # bond 74 # cover 93 # cover 110 # cover Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...

  • Page 139: Technical Documentation Feedback Form

    Please give specific page references and fax the completed form to us on (+44 (0)1767 691769). Please make photocopies of this form if further copies are required NAME TELEPHONE JOB TITLE DATE COMPANY PUBLICATION REVISION DATE PAGE NUMBER COMMENT Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 140 Appendix • Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04...
  • Page 142 Watkiss Automation Ltd 1 Blaydon Road, Middlefield Industrial Estate, Sandy, Beds SG19 1RZ United Kingdom Tel: +44 (0)1767 682177 Fax: +44 (0)1767 691769 Email: info@watkiss.com Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04 Part Number 969-251...

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