MBM Corporation DocuVac User Manual

Air Feed Collator Model 100 Set Stacker Model 101 High Capacity Stacker Model 101
Operator Manual
November 2001
Part No. 14447
1. Introduction
1.1 Operational Safety
2. Getting to know the Model 100, 101, 101 HCS
2.1 Main Components, Model 100
2.2 Main Components, Model 101
2.3 Main Components, Model 101 HCS
3. Operator instructions
3.1 Adjusting the LCD display contrast
3.2 One, two or three collators
3.3 Setting up and loading Model 100
3.4 Docking the Lift
3.5 Using the fan
3.6 Running a job
4. The Menus
4.1 Programs
4.1.1 Alternate bin 1+2
4.1.2 Alternate bin mode
4.1.3 Block mode
4.1.4 Insertion sheet mode
4.1.5 Bin select mode
4.2 Statistics
4.3 Stored jobs
4.4 Preset counter
4.5 Reset
4.6 Added features
4.7 Select calibration mode
4.8 Error screens
1-1
2-1 2-4 2-5
3-1 3-1 3-2 3-4 3-4 3-5
4-1 4-1 4-2 4-2 4-3 4-3 4-4 4-4 4-5 4-6 4-6 4-7 4-8
5. Troubleshooting
5.1 Trouble shooting
6. Specifications
6.1 Specifications
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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5-1
6-1
i
1. Introduction
1.1 Operational safety
Attention to the following notes ensures the continued safe operation of your equipment.
Always connect the equipment to a properly grounded power source recep­tacle. In doubt, have the receptacle checked by a qualified electrician.
WARNING: Improper connection of the equipment grounding conductor can result in electrical shock.
Always follow all warnings marked on, or supplied with, the equipment.
Always locate the equipment on a solid support surface with adequate strength for the weight of the machine.
Always exercise care in moving or relocating the equipment.
Always keep magnets and all devices with strong magnetic field away from the machine.
Never use a ground adapter plug to connect the equipment to a power source receptacle that lacks a ground connection terminal.
Never attempt any maintenance func­tion that is not specifically described in this documentation.
Never remove the covers or guards that are fastened with screws.
Never install the unit near a radiator or any other heat source.
Never override or “cheat” electrical or mechanical interlock devices.
Never operate the equipment if you notice unusual noises or odours. Dis­connect the power cord from the power source receptacle and call your cus­tomer service engineer to correct the problem.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
1-1
2. Getting to know the Model 100, 101
2.1 Main components, Model 100
1
2
3
4
5
6
1 Control panel (not present on second or third collator) 2 Conveyor door 3 Outfeed area 4 Base (optional) 5 Docking latch 6 Height adjustment
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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2-1
2.1 Main components, Model 100, cont.
465 7
1
2
3
left side
rear side
11
8
9
12 13
14 1510
front side
1 Main power switch 2 Fuse 3 Fuse 4 Stop fingers adjustment lever 5 Stop finger assembly 6 Suction belt 7 Bin height switch lever 8 Bin 9 Paper positioning stop 10 Height adjustment 11 Power cord receptacle
right side
12 Secondary unit connector
(i.e. secondary unit collator)
NOTE: If no secondary unit is used, jumper plug
part No. 140226 (female) has to be con­nected.
13 Third party device connector
(i.e. stacker, stapler/folder)
14 Power receptacle for conveyor bridge
(only on B and C collators in double or tripple collator systems)
15 A5 (5.5”) plate
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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2-2
2.1 Main components, Model 100, cont.
4
3
2
1
5
6
7
8
9
1 Set up guide button 2 Third party device error message
indicator
3 Double feed / paper jam symbol
(shown by bin indicator - firm light) 4 Bin indicator 5 Misfeed / empty bin symbol
(shown by bin indicator - flashing)
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
6 Second / third collator error
message indicator 7 LCD display 8 Multi function buttons 9 Start / stop button
2-3
2.2 Main components, Model 101
132 4
7
6
9810
11
12
13
5
14
1 Collator connector 2 Third party device connector
(i.e. stapler/folder)
NOTE: If no third party device unit is used,
jumper plug part No. 140227 (male) has to be connected.
3 Power cord receptacle 4 Fuse 5 Docking latch
6 Bypass paper path 7 Bar 8 Main power switch 9 Idler roller bar 10 Opening handle 11 Paper guide (man. adjust.) 12 Top cover 13 Document table 14 Height adjustment
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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2-4
2.3 Main components, High Capacity Stacker Model 101
7
6
132 4
8
9
10
11
12
13
5
15
16
1 Collator connector 2 Third party device connector
(i.e. stapler/folder)
NOTE: If no third party device unit is used,
jumper plug part No. 140227 (male) has to be connected.
3 Power cord receptacle 4 Fuse 5 Docking latch 6 Bypass paper path 7 Bar 8 Main power switch
17
19
18
9 Idler roller bar 10 Opening handle 11 Top cover 12 Paper guide (man. adjust.) 13 Lift, document table including 14 Height adjustment 15 Maximum load sign 16 Docking instruction sign 17 Lowering Lift button 18 Elevating Lift button 19 Battery indicator
14
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
2-5
3. Operator instructions
Most settings and adjustments are operated from the control panel using the multi function buttons. The actual function of the buttons in each menu will be indicated by an icon above the corresponding button.
Note: The settings for the last job will be erased when switching off the power or changing to a
different job. Store the job in order to easily recover your settings.
3.1 Adjusting the LCD display contrast
Switch on the power with the main power switch. The Main Menu will appear in the LCD display. Increase/decrease the
contrast of the LCD display by pressing the contrast adjust­ment buttons.
contrast adjustment buttons
3.2 One, two or three collators
Several menus, for example the BLOCK MODE menu, shows that there is a possibility to use two or three collators. Until additional collators are installed in the system, these options will be displayed in grey to show that they are not accessible.
The collator closest to the stacker or bookletmaker is called the A tower. All programming, for the two or three collator system, is done from this A tower that is the only collator in the system with a display.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
3-1
3.3 Setting up and loading Model 100
Before loading the bins make sure that the sheets are well fanned, aligned and that the ink has dried out. Load the sheets into the bins so that all the sheets are in contact with the stop finger assembly (left side) and the main frame (rear side). Place the paper positioning stops as shown in the figure.
bi n sheets paper positioning
stop
A5 plate
Stop finger adjustment lever
The suction area should be limited when running A5 (5.5” x 8.5”) by inserting the A5 plate inbetween the suction belt and the suction belt assembly on the bottom side.
132
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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3-2
3.3 Setting up and loading Model 100, cont.
Recommendations in table below are only guide lines to get started. The adjustments can vary a lot depending on paper quality, print quality, air humidity etc.
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If miss or double feeding occurs when a job is set up according to table, adjust according to below:
Air flow
Increase if miss feeding
Decrease if double feeding
Stop finger position
Increase gap by moving the lever to the left if misfeeding
Decrease gap by moving the lever to the right if
doublefeeding
stop fingers in position 3
For mixed jobs papers are loaded
* - move lever to the left in bins where thicker
Bin height switch
Move lever upwards if misfeeding
Move lever downwards if doublefeeding
For mixed jobs papers are loaded
bin height switch in normal position
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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*The difference in paper weight between cover sheets and
bodysheets should not exceed 100 gsm.
* - move lever upwards in bins where heavier
3-3
3.4 Docking the Lift
When pushing the lift into the Model 101 HCS, it is not necessary to open the top cover. The lift will auto­matically lock to the Model 101 HCS while pushed in. However, make sure that the lift is not in the upper­most position to avoid damaging the paper guide in the cover. Also be careful while pushing in the lift in to avoid damaging the electrical connector located on the right leg of the lift. To pull out the lift,first lift the top cover on the Model 101 HCS.
Note: When not using the Model 101 HCS for longer time, leave the Lift docked to the Model 101 HCS. Do not disconnect the power cord, otherwise the com­pensation charge does not work.
3.5 Using the fan
Normally the fan should be switched off. Switch on the fan to facilitate stacking of static sheets. Lift the top cover to access the switch located on the right side (1) of the Model 101 HCS. The fan only operates when the system is running.
1
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual 3-4
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3.6 Running a job
To ensure that any earlier program settings does not interfere with your job, reset according to section 4.5.
Note: Do not reset if you have started programming according to
section 4.1 or loaded a stored job according to section 4.3.
To start a job - just press the yellow set up guide button from the main menu.
Select calibrate mode by using the arrow buttons and press the ”OK” button. For details, see section 4.7.
Note: The calibration set does not affect the insertion sheet
counter, preset counter or set counter.
Select standard format by using the left/right arrow buttons. To use custom format or to change direction between land­scape/portrait, select item with the up/down arrow buttons and adjust with the left/right arrow buttons. Press the ”OK” button. If calibrate mode “STRAIGHT STACKING” or “OFFSET STACKING” is selected calibration will start.
If calibrate mode ”STRAIGHT STACKING” or ”OFFSET STACKING” was selected
The calibrated set will stop on the bypass paper path of the Model 101/101 HCS.
Viewed from above, slide the paper guide so that there will bee a slight gap between the innermost edge of the paper guide and the outermost edge of the set.
Remove the set and check that it is OK .
Note 1 : If the calibrated set does not have the correct number
of sheets, restart the calibration by pressing the yellow setup guide button.
Note 2: When the job is started and the sets are fed into the
stacker, the gap should be minimized, but not to narrow to avoid paper jam.
paper guide
If calibrate mode ”BOOKLET MAKING” was selected
A message on the display will appear asking: ”IS BOOKLETMAKER SETUP PERFORMED?”. Check that the booklet maker is adjusted to correct paper size. If neces­sary, check booklet maker operator manual for details. Press the ”OK” button to start calibration.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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3-5
3.6 Running a job, cont.
If calibrate mode ”BOOKLET MAKING” was selected, cont.
The calibrated set will stop in the bookletmaker before it has been stapled and folded. You have two ways to check the calibrated set.
A Press the purge button on the display of the Model 100. The set will be stapled,
folded and ejected from the booklet maker. Check the calibrated set.
B Open the top cover of the booklet maker to check/remove the calibrated set.
Note: If the calibrated set does not have the correct number of sheets, restart the calibration
by pressing the yellow setup guide button.
Regardless of which calibrate mode was selected
If running a slightly absorbing paper, such as a thick paper, a message “CHECK SET. IS SET OK?” can appear on the display. Check the calibrated set according to above. If the set is OK, press the “YES” button and a second calibration will be performed. Check the second calibrated set according to above. If the set is not OK, press the “NO” button and the calibration will be repeated.
Note: The message “DSD Off”can be displayed if an extremely light absorbing and/or thick paper is used. This means that the optical double sheet detection now is limited. However, the lengthwise double sheet detection is still fully functional.
After a successfully performed calibration the message ”CALIBRATION DONE” will be shown. Press the ”ST” button if you want to store the calibrated job now. You can also store the job later after the job is finished or during* the job, until the “ESC” button is pressed.
To run the job, press the green start/stop button.
*To store the running job, first press the green button to stop
the job.
Frequently used settings can be stored as “jobs”. Up to 100 different jobs can be stored. This menu shows you jobs that are already programmed and positions that still are free. Use the arrow buttons to select “EMPTY” to store or “PRO­GRAMMED” to overwrite an old job. Press the “OK” button to confirm. If you want to see information about a certain job, press the “info” button. Press the “info” button again to return to the previous menu. To delete a stored job, press the “C” button.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
3-6
4. The menus
4.1 Programs
To access the different programming possibilities select PROGRAMS” menu from the MAIN MENU and press the “OK” button.
From the PROGRAMS menu you can select which actions you want to use. Select and press the “OK” button to enter the corre­sponding submenu.
4.1.1 Alternate bin 1+2
Note: After selecting/changing any action the yellow or the
green button can be pressed to calibrate or to start the job.
Enter the ALTERNATE BIN MODE 1+2 menu.
This program doubles the loading capacity of covers by allowing you to load the cover sheets in both bin 1 and bin 2. Use this program when the covers have a higher paper weight than the body sheets. Select alternate bin mode 1+2 with the arrow buttons. Press the “OK” button to confirm. Follow the procedure in “3.6 Running a job” to calibrate and start the job.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
4-1
4.1.2 Alternate bin mode
Enter the ALTERNATE BIN MODE menu.
This program allows you to reload the collator while running by loading the same sheet in two bins. As soon as any bin is empty the collator automatically switches to the alternate bins. With one collator it is possible to load up to 4 sheets per set (with two collators - 8 sheets and with three collators up to 12 sheets). Mark the total No. of bins to be used with the arrow buttons. The marked bins will be shown inverted. Press the “OK” button to confirm. Follow the procedure in “3.6 Running a job” to calibrate and start the job.
Note 1: Load sheet one in bin 1 and bin 2, sheet two in bin 3
Note 2: After reloading, press the up arrow button to activate
and bin 4 and so on.
the reloaded bin/s to achieve continuous running.
4.1.3 Block mode
Enter the BLOCK MODE menu.
This program allows you to reload the collator while running by loading the set twice in two separate blocks. When any of the bins in one block become empty, the collator automati­cally switches to the other block. With one collator it is possi­ble load up to 4 sheets per set (with two collators - 8 sheets and with three collators up to 12 sheets). Mark the number of bins to be used (i.e. the No. of sheets in the set) in the first block with the arrow buttons. The marked bins will be shown inverted. Press the “OK” button to con­firm. When the “OK” button is pressed the collator will suggest the next bins to be used by showing them inverted. You may select other bins than the suggested by moving the block with the arrow buttons. Press the “OK” button to confirm. Follow the procedure in “3.6 Running a job” to calibrate and start the job.
Note 1: The example is shows how to run a set of two sheets.
Load sheet one in bin 1 (first block) and bin 3 (second block). Sheet two should consequently be loaded in bin 2 and bin 4.
Note 2: After reloading, press the up arrow button to activate
the reloaded bin/s and achieve continuous running.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
4-2
4.1.4 Insertion sheet mode
Enter the INSERTION SHEET MODE menu.
This program allows you to separate a stack of sets by using an insertion sheet. Select the digit you want to change with the left/right arrow buttons. The selected digit will be shown inverted. With the up/down arrow buttons you can enter a number between 0 - 9. Press the “OK” button to confirm. Follow the procedure in “3.6 Running a job” to calibrate and start the job. The calibration set does not affect the insertion sheet mode counter. Insertion sheet mode can be combined with any other program.
Note 1: The insertion sheets must be loaded in the next bin
Note 2: If “BLOCK MODE” is selected two bins with insertion
below the loaded set.
sheets must be used. Load the insertion sheets in the next following bins of each block.
4.1.5 Bin select mode
cross button tick button
Enter the BIN SELECT MODE menu.
This program allows you to use empty bins for new jobs without removing already loaded sheets. Use the arrow buttons and press the “tick” button to activate the bins you want to use for the new job. Selected bins will be shown inverted. To deselect a bin, use the arrow buttons and press the “cross” button. Load the sheets into the empty bins. Press the “OK” button to confirm. Follow the procedure in “3.6 Running a job” to calibrate and start the job.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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4-3
4.2 Statistics
Enter the STATISTICS menu.
This menu shows statistics of the last job. Press the “ESC” button to return to the MAIN MENU. Each calibration resets the statistics.
4.3 Stored jobs
Enter the STORED JOBS menu.
Frequently used settings can be stored as “jobs”. Up to 100
different job can be stored. This menu shows you which jobs that are already programmed and which positions that still are free. Select job with the arrow buttons. Press the “OK” button to load a job. Follow the procedure in “3.6
Running a job” to calibrate and start the job.Press the “C” button to delete a stored job.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
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4-4
4.3 Stored jobs, continues
If you want to see information about a certain job, press the “info” button from the STORED JOBS menu.
Press the “info” button again to return to the STORED JOBS MENU or the “C” button to erase the job.
4.4 Preset counter
info button
To erase the job, confirm by pressing the ”OK” button.
Enter the PRESET COUNTER menu.
This program allows you to stop the collator after a certain number of sets. Select the digit you want to change with the left/ right arrow buttons. The digit subject to change will be shown inverted. With the up/ down arrow buttons you can enter a number between 0 - 9.
The calibration set does not affect the preset counter.
Press the “OK” button to confirm.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
4-5
4.5 Reset
4.6 Added features
Enter the “RESET” menu.
From this menu you can choose to reset ”PROGRAMS”, ”PRE­SET COUNTER”, ”SET COUNTER” or all three. Press the ”ESC” button to return to the MAIN MENU or select item to reset and press the ”OK” button. To reset according to selection, confirm by
pressing the ”OK” button.
Note 1: Do not reset if you have started programming accord-
ing to section 4.1 or loaded a stored job according to section 4.3.
Note 2: Resetting “PROGRAMS” will erase the currently loaded
job or programmed settings.
Note 3: Resetting “PROGRAMS or resetting “ALL” does not
affect stored jobs.
Enter the ADDED FEATURES menu.
From this menu you can adjust the speed, the air flow, the overlap, change the user interface language and select double sheet detection ON or OFF. Select the item you want to adjust with the up/down arrow buttons. Change setting with the left/right arrow buttons. Collating
speed can be adjusted from 1000 sph (sets per hour) to 3800 sph. Check the speci­fication for the connected machines before changing the speed. Air flow can be adjusted from 30% to 100%. If “AIR FLOW A” is selected, also tower B and C will be adjusted. Select “AIR FLOW B” and/ or “AIR FLOW C” to set the B and C collators air flow individually.
NOTE: Also see section 3.6 and 5.1 for recommendations and
trouble shooting .
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
4-6
4.6 Added features, continues
Overlap can be adjusted from -2 to 50, where 50 gives the largest length in the set. Default value is 0. If problems are experienced when jogging the sets in the booklet maker or external unit, the overlap value can be changed. For static sheets run into stacker, decrease value to -2 to get a better stacking result. For static sheets run into booklet maker, increase value if sheets are not properly jogged.
small overlap value
large overlap value
If the opacity of the sheets varies so much that the Model 100 indicates false doubles, the detection can be switched OFF. If switched OFF all bin are effected. The length double detection are still functioning though.
NOTE: If a thin line is located exactly at the position of the
4.7 Select calibration mode
This menu appears when the yellow Setup Guide button is pressed
sensor (17mm from inner edge) the Model 100 can also indicate false double. In that case the sheets in the bin can be turned 180 degrees, rather than switing the double detection OFF.
Select “BOOKLETMAKING” to deliver the set to the booklet maker.
Select “STRAIGHT STACKING” or “OFFSET STACKING” to deliver the set to the stacker.
“EXTERNAL UNIT” should be selected to deliver the set to any other, to the system not connected unit.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
4-7
4.8 Error screens
This example error screen shows that at collator No. 1 (the A tower), a number of errors has occurred. Double feed from bin 1, misfeed from bin 3 and jam in bin 5. See section 5.1 for how to correct these problems before the the system is restarted. You can also see that bin 8 is empty and need to be re­loaded.
This error screen tells you that the stacker is full. Open the top cover, empty the stacker before the system is restarted.
This error screen tells you that there is a jam in the stacker. Open the top cover and clear the stacker from jammed sheets.
Check that the stacker is properly set up according to
section 3.6 and restart the system.
If the problem persists, the machines may have been
misaligned (moved) after installation and therefore causes the set to jam. Call service to have the system aligned according to the installation instruction.
This error screen tells you that there is jam at the booklet maker or trimmer. Check the control panels at the booklet maker and trimmer to see what caused the problem. If nec­essary, consult the booklet maker and/or trimmer operator manual for how to correct the problem.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual 4-8
T10127 November 2001
4.8 Error screens cont.
This error message will be displayed if the Model 100 or Model 101 has a malfunction. Note which machine has the malfunction (i.e. PL100) and the malfunction code (i.e. 030).
Malfuntion code 009-014 can be generated by a temporar-
ily low voltage supply. Switch off the machines and try switching them on later on or try using another wall outlet.
Malfunction code 040-047 can be generated by strong
incoming light. Block or redirect light sources such as sun light, spot lights etc.
If above does not correct the problem - call service and report which machine and malfunction code that was displayed.
This error screen tells you that the Lift is not docked into Model 101 HCS. Check that the Lift is correctly docked to the Model 101 HCS.
Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
4-9
5. Trouble shooting
5.1 Trouble shooting
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Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
5-1
6. Specifications
6.1 Specifications
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Air Feed Collator Model 100, Stacker Model 101, Model 101 HCS Operator Manual
T10127 November 2001
6-1
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