Deep Pile Stacker Operating Instructions

1
Deep Pile Stacker
Operating Instructions
CONTENTS
Specifications
1
Introduction
3
Operating the Stacker
7
Trouble Shooting
17
Maintenance
19
Issue 1 - Feb 1996
1
Specifications
Intended Use
Production
Specifications
Maximum Input Size
Minimum Input Size
Maximum Stack Height
Maximum Set Size
Paper Range
Electrical
Dimensions
Width
Height
Depth
Weight
Sound Emissions
Conveyor only
In use
As part of a Vario system,
the Deep Pile Stacker unit is
intended for stacking collated sets of materials within
the specified ranges.
Up to 6,000 sets per hour
364 x 520mm, 14.3 x 20.5"
(Portrait)
148 x 210mm, 5.9 x 8.3"
(Landscape)
420mm, 16.5"
32 sheets
Over 60gsm, 16# bond
100V, 50Hz or 60Hz or
115V, 60 Hz or
230V, 50 Hz
Single Phase
(earthed supply required)
605mm, 23.8"
680mm, 26.8"
1330mm, 52.4" (total)
747mm, 29.4" (in use)
105kg, 231.5lb
71dB(A)
81dB (A)
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.
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Introduction
The Watkiss Vario Deep Pile Stacker unit has been
purpose designed to use with your Watkiss Vario Collator.
Together they provide a fully integrated collating and
stacking system.
The instructions that follow include the setup and operating procedure for the Deep Pile Stacker unit.
It is recommended that your Deep Pile Stacker is sited on
a level floor.
Note : In these instructions the Deep Pile Stacker Unit is
referred to as the DPS.
SAFETY FIRST
Your Deep Pile Stacker unit has been designed with
safety as a key feature and incorporates a lid which, when
opened, will automatically cut the power to moving parts.
For your safety, when changing fuses or carrying out
operations other than those detailed in this book:
Always first disconnect the machine from the
mains electricity supply
Ensure that the paper pallet is unloaded and
at the bottom of it's travel
Warning
The paper stack on the pallet can be extremely heavy
and due caution must be taken when unloading the
stacker. Ensure that all body parts are clear of the
mechanism when lowering the pallet to floor level.
INSTALLATION
1. It is essential that the supply to both the DPS and the
collator is earthed.
2. The front payout conveyor assembly must be removed
from the collator before installation of the DPS unit.
3
MOVING THE
STACKER UNIT
To carry out adjustment the DPS must be withdrawn from
the collator. Lift the stacker, by means of the side arms,
and wheel out. When replacing the stacker make sure the
locating brackets butt up to the collator base.
Important:
When replacing the DPS under the collator ensure
that the mains cable is not run over by the unit's
wheels.
SWITCHING ON
DPS
Before use, plug the collator and the DPS unit into single
phase power supplies of the correct voltage as indicated
by the label next to the mains input. Fit the interconnection
cable between the units. The cable will only fit into one of
the the sockets on the underside of the Floor Base (see
figure 1) The collator and the DPS unit have independent
mains ON/OFF switches.
SFT/TTL
JOGGER
Interconnection
Cable
Mains Input Socket
and Fuse
Mains On/Off
Switch
FIGURE 1
USING THE CONTROL
BUTTONS
4
Operating the Pallet lift
The DPS unit has three control buttons (figure 2). The
yellow button operates the pallet lift. Pressing once
activates the lift. Pressing the button once again stops the
lift. Pressing the button a third time operates the lift in the
opposite direction. When the yellow button light flashes
slowly this indicates that the pallet is in transition between
its lower and upper positions.
FIGURE 2
Y
Pallet
Lift
B
Offset Immediate
Stacking
Stop
When the yellow button flashes quickly this indicates that
the lift is in its lowest position and the pallet is ready to be
wheeled away.
When the yellow button is constantly illuminated this
indicates that the lift is in its highest position and the pallet
is ready to accept paper.
Offset stacking
The blue button enables offset stacking. It is either on
(illuminated) or off. When off, the DPS will stack to the right
hand side. This function is also available from the collator
control panel menu.
Immediate stop
This button immediately stops both the DPS unit and
collator. Under normal circumstances use the stop button
on the collator control panel and allow the system to
sequence down.
5
MOVING THE
PALLET
The paper pallet is fitted with wheels for easy movement.
The pallet should only be moved when the lift is in its
lowest position.
When replacing the pallet make sure the lift arms slide
through the appropriate slots in the pallet. Also make sure
the pallet docks fully with the DPS unit before continuing
use.
Warning
The paper stack on the pallet can be extremely heavy
and due caution must be taken when unloading the
stacker. Ensure that all body parts are clear of the
mechanism when lowering the pallet to floor level.
6
Operating the Stacker
SETTING UP THE
STACKER
STEP 1
In order to achieve trouble free stacking it is important that
the following instructions are followed carefully.
Adjust the infeed sidelays
1.
Adjust the infeed sidelays to the approximate required
width using the adjustment belt on the top of the lid and
the scale as a guide (figure 3).
2.
Insert a small quantity of the chosen paper through
the infeed between the two sidelays.
3.
Push one sidelay inward whilst supporting the paper.
4.
Adjust the toothed belt with the other hand. You
should leave enough play for the paper to slide freely
between the sidelays.
Adjustment Belt
Infeed Sidelay
Paper Scale
FIGURE 3
7
STEP 2
Adjust the Endstop
1.
Remove the paper and lift the stacker lid into its upright
position.
2.
Loosen the endstop (figure 6) and slide it up to the infeed.
3.
Close the lid and lift the pivoting infeed guide (figure 4).
Carefully insert the paper through the infeed until the back
edge of the paper is level with the lower conveyor drive
shaft (see dotted line in figure 5).
Pivoting Infeed
Guide
FIGURE 4
Endstop
Back Push
FIGURE 6
8
FIGURE 5
4.
Remove the paper, raise
the lid and carefully tighten
the endstop without moving it out of adjustment.
5.
Close the lid and, if need
be, move the paper pallet
to its highest point using
the yellow control button.
This will cause the conveyor
to start. Push the Immediate Stop button to stop the
conveyor motor.
STEP 3
1.
Align the Stacker and Infeed Sidelays
Lift the stacker sidelay bar (figure 7) into its forward
position.
2.
Loosen the endlay clamp screw by turning anticlockwise
and slide the endlay in until the stacker sidelays come into
Endlay
Stacker Sidelay Bar
(in forward position)
Endlay Clamp Screw
FIGURE 7
3.
contact with the finger guide bar.
Look into the outfeed and adjust the stacker sidelays so
that they align with the infeed sidelays.
4.
The inside faces of both should line up as in figure 8. The
dotted line shows the correct alignment of the sidelay
faces. It is important that the stacker sidelays are not set
too tight to avoid paper jamming.
Lift the sidelay bar back into its original position.
Infeed Sidelay
Stacker Sidelay
FIGURE 8
9
STEP 4
Adjust the Endlay Gap
1.
Slide the endlay fully back.
2.
Place a quantity of paper onto the pallet in the correct
orientation and between the stacker sidelays.
3.
Ensure the conveyor belt is not running. With one hand
pull the back push towards the paper and hold in position.
4.
With the other hand slide the paper against the back
push.
(See figure 9)
5.
6.
Without moving the paper, slide the endlay up to the edge
of the paper until it is nearly touching.
Re-tighten the endlay clamp whilst holding the endlay in
this position.
FIGURE 9
10
STEP 5
Align the Finger Guides
1.
Slide the paper up against the left stacker sidelay.
2.
Line up the left outer finger guide against the left edge
of the paper.
3.
Line up the right inner finger guide with the right edge
of the paper (figure 10).
Align These Finger
Guides First
Paper
Left Stacker
Sidelay
FIGURE 10
4.
Slide the paper against the right stacker sidelay.
5.
Line up the left inner finger guide against the left
edge of the paper.
6.
Line up the right outer finger guide with the right edge of
the paper (figure 11).
Align These Finger
Guides Second
Right Stacker Sidelay
FIGURE 11
11
STEP 6
Align the Endlay Finger Guides
1.
Line up the two outer endlay
finger guides with the two
inner finger guides (Figure
12).
2.
Push the stacker back into
position under the collator.
Outer Endlay Finger Guides
FIGURE 12
STARTING THE
JOB
Set the drive speed of the collator to 80% and the sets per
hour to 2,000. Ensure that the delivery direction lever on
the collator is in the down position.
Press
and
to run a single set. After
inspection, press
again to run the job.
During initial running the finger guides can be fine adjusted to ensure a neat stack. Once you are satisfied with
the running of the DPS, the production rate of the collator
can be increased to a comfortable maximum rate.
HANDLING DIFFICULT PAPERS
Paper Control Wires
The paper control wires are
provided for occasions
when materials are more
difficult to control, especially
if the paper is curly.
Pull the wire out. Pass it
under the endlay finger
guide bar and the stacker
sidelay bar. Secure it
around the outfeed finger
guide bar by hooking it back
onto itself (see figure 13).
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FIGURE 13
SMALL PAPER SIZES
Setting up the stacker for small paper sizes, such as A5
(5½ x 8½"), requires a slightly different method when
adjusting the endlay gap and aligning the finger guides.
Adjust the Endlay Gap
1.
Slide the endlay fully back.
2.
The outer endlay finger guides are not used and are
folded back via the special cutouts as shown in figure 14.
3.
Position the two inner finger guides between the stacker
sidelays.
4.
Position the two outer finger guides on the outside of the
stacker sidelays (these are not used).
5.
Hold the paper and back push in position and move the
endlay up to the edge of the paper until nearly touching.
6.
Re-tighten the endlay clamp whilst holding the endlay in
position.
Only the Inner Finger
Guides are Used
Cut Out in Endlay
The Outer Endlay Finger
Guides are folded back
FIGURE 14
Align the Inner Finger Guides
1.
Slide the paper up against the left stacker sidelay.
2.
Line up the right inner finger guide with the right edge of
the paper.
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3.
Slide the paper against the right stacker sidelay.
4.
Line up the left finger guide against the left edge of the
paper.
Tip
When collating small paper sizes it is not recommended that sets of less than 4 sheets are stacked
with the DPS.
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A4 LANDSCAPE
It is recommended that if possible A4 (or 8½ x 11") sheets
are stacked in portrait orientation as this will give better
results.
1.
When setting up for A4 landscape the stacker sidelays are
not used. Position them out of the way on the outside of
the bar. The outer finger guides are used in place of the
stacker sidelays (see figure 15).
2.
Line up the outer finger guides with the infeed sidelays.
3.
Adjust the endlay gap as normal.
4.
Slide the paper up against the left outer finger guide.
5.
Line up the right inner finger guide with the right edge of
the paper.
6.
Slide the paper up against the right outer finger guide.
7.
Line up the left inner finger guide with the left edge of the
paper.
8.
Line up the two outer endlay finger guides with the two
outer finger guides. The endlay finger guides should rest
on top.
The Outer Finger Guides are used in
place of the Stacker Sidelays
The Stacker Sidelays are
positioned out of the way
The Outer Endlay Finger
Guides Rest on Top of the
Other Finger Guides
FIGURE 15
CLEARING PAPER
JAMS
Care is needed when removing any paper jams from the
DPS unit. Firstly remove any jammed paper from the
on the
collator conveyor or DPS unit. Next use
collator control panel menu to clear any partial sets.
Depending on the nature of the jam you may have to press
more than once. Finally check the top of the stack
and any delivered sets for missing sheets. See 'Trouble
Shooting' in section 4 for possible causes of paper jams.
Important
Before restarting the machine after a paper jam
ensure that the paper stack is still upright and parallel
with the DPS. If the stack is leaning forward then the
stacker sensor will have difficulty in detecting the top
of the stack. Restarting the machine under these
conditions may cause the pallet to raise past the
normal parking point resulting in possible mechanical
damage to the unit.
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Trouble Shooting
The following table is a guide to help solve any problems with your DPS unit. If a problem
persists, please call the Watkiss Service Department or your Watkiss Dealer.
As with any stacker, good set delivery from the collator is vital for a good result. Make
sure that the collator is set up correctly before running the job.
PROBLEM
CAUSE
SOLUTION
PAPER JAMS
The clearance between the paper
and endlay is too tight.
Increase the clearance by adjusting the endlay until the paper stops
bunching.
The finger guides are too close to
paper.
Readjust the finger guides.
The stacker sidelays are set too
tight.
Readjust the sidelays.
Poor set delivery i.e. a trailing sheet
causing the following set to jam.
Remedy the problem at the collator.
Curly Paper
Use the paper control wires
The clearance between the paper
and the endstop is too tight.
Readjust the endstop.
The collator drive speed and/or sets
per hour rate is set too high.
Decrease the drive speed to 80%
and the sets per hour to 2,000.
Once the job runs satisfactorily
the production rate of the collator
can be increased to a comfortable
maximum rate.
Poor set delivery
Remedy the problem at the
collator.
The clearance between the paper
and the endlay is too loose.
Decrease the clearance by adjusting the endlay until the paper stacks
neatly.
The finger guides are too loose.
Readjust the finger guides.
The stacker sidelays are set too
loose.
Readjust the sidelays.
UNTIDY STACK
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Maintenance
SERVICE INTERVAL
It is recommended that your DPS unit is serviced by an
approved Watkiss engineer at six month intervals. Please
contact your Watkiss supplier or the manufacturer for
further details.
OPERATOR
MAINTENANCE
As with all machinery, your DPS unit will benefit from
periodic cleaning of general accumulations of paper
dust, ink etc..
The build up of powder or ink on the
conveyor belts will eventually cause slippage or ink
transfer. Clean with a cloth dampened with soap and
water or alcohol (isopropanol). Do NOT use blanket wash.
Also pay particular attention to the pallet and infeed
emitter/sensors (see figure 15 and 16). Clean using only
a soft, dry cloth.
Infeed
Sensor
Pallet
Sensor
FIGURE 15
FIGURE 16
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WATKISS AUTOMATION LIMITED
Watkiss House, Blaydon Road, Middlefield Ind. Est.,
Sandy, Bedfordshire. SG19 1RZ ENGLAND.
Tel : +44 (0)1767 682177 Fax : +44 (0)1767 691769
Operating Instructions, Vario Deep Pile Stacker, English
Issue 1, Jan 1996. Part No. 959-301
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