Operating Manual

Issue 3, June 2004

CONTENTS
Welcome .............................................1
About your DigiVAC+ ........................3
Quick Start .........................................7
Control Panel ...................................11
Operating the Bins ..........................31
Hand-Merging Sets ..........................39
Booklet Making ................................41
Joggers ............................................43
Two-Tower DigiVAC+ ......................49
Maintenance .....................................53
Problem Solving ..............................57
Appendices
Advanced Functions ............................. 63
Paper Settings ...................................... 65
Specifications ....................................... 69
Declaration of Conformity ..................... 71

Index ..................................................65

Issue 3 - June 2004 - Part No. 960-721

 THIS PAGE IS
INTENTIONALLY
BLANK
 Welcome

Congratulations on your purchase of the highly produc-

tive Watkiss DigiVAC+ collator. As well as being designed
for high productivity, your DigiVAC+ is also efficient and
easy to use.

About your Manual

This operating manual explains how to use your DigiVAC+
collator. If you have booklet making equipment attached,
please refer to the separate operating manual.

Safety First
Your DigiVAC+ has been designed with safety as a key
feature. However, as with all electrical equipment, when
removing any covers or changing fuses always first
disconnect the machine from the mains electricity
supply by switching off and unplugging the machine.

Installation
The installation of your DigiVAC+ requires specialist
knowledge and should therefore only be carried out by a
Watkiss approved engineer.

Getting Help
We are confident that your DigiVAC+ will give many years
of trouble-free production. 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 Department (UK) or your
local Watkiss supplier will be happy to help.

1
 THIS PAGE IS
INTENTIONALLY
BLANK

2
 1 About your DigiVAC+

The DigiVAC+ is a modular collator, and may include all

or some of the modules shown below.

Feed Bins

Control Panel
Outfeed Conveyor
(optional)

Trimmer
(optional)
Mains ON/OFF
Bookletmaker
Jogger (optional)
(optional)
Base Unit

MAINS INPUT The mains input for the DigiVAC+ is at the rear of the base
unit. The collator must be plug ged into a mains supply
of the correct voltage. Two fuses are fitted next to the
mains input.

Interface Socket (BookMaster Pro

and Automatic Stitch Fold)
Interface Socket (BookMaster
Standard)

Serial Number Label

Voltage Indicator

Fuse Holders

Mains Input

3
 MAINS ON/OFF The mains on/off switch should be used to turn the collator
SWITCH on and off when required. When the collator is switched
off it retains the control panel settings in memory.

CONTROL PANEL The functions and operation of the DigiVAC+ control

panel are explained in full in Chapter 3 (page 11).

FEED BINS The DigiVAC+ may have 8 or 12 bins per tower. A 4-bin
module is available to upgrade an 8-bin machine to 12
bins. Additional towers may be added if required.

The functions and operation of the feed bins are explained

in full in Chapter 4 (page 31).

JOGGER The DigiVAC+ may have a 20° offset jogging stacker fitted
to the front of the machine. Alternatively, a straight stack
jogger may be used at the front or back of the machine.
These are optional modules which may be added to an
existing machine if required.

The function and operation of the jogger is explained in

full in Chapter 7 (page 43).

DELIVERY Collated sets may be delivered to the rear of the DigiVAC+

DIRECTION LEVER into a bookletmaker. If a jogger is fitted, they may also
be delivered to the front of the DigiVAC+ into the jogger.

Delivery Direction Lever

Hand Merge Tray

Rear Outfeed

Roller Uplift Knob

(lift up if using PRE-JOG with
large sheets)
Bookletmaker

The delivery direction is controlled by the delivery direc-

tion lever.

4
 • Push the lever up to deliver sets to the rear.
• Push the lever down to deliver sets to the front.

REAR OUTFEED The rear outfeed of the DigiVAC+ delivers collated sets
from the DigiVAC+ into the bookletmaker.

It can also be used for hand-merging large sets prior to

bookletmaking. See Chapter 5 (page 39).

If a feed error occurs whilst sets are being delivered to

the rear, the faulty set is held in the rear outfeed for removal
by the operator.

ROLLER UPLIFT The roller uplift knob disengages the outfeed drive rollers.
This is necessary when the PRE-JOG option is used when
booklet making with sheets over 300mm long.

• Raise the knob to disengage the rollers

• Lower the knob to engage the rollers

Except when PRE-JOG is used, the rollers should always

be engaged.

Note: The hand merge function (see p.39) can only be

used when the rollers are engaged.

5
 THIS PAGE IS
INTENTIONALLY
BLANK

6
 2 Quick Start

This section is intended only as a brief operating guide.

Detailed operating procedures are included in subse-
quent chapters.

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

Switch on the mains ON/OFF switch.

OPERATING THE In normal use, the touch-screen can be operated by

TOUCH SCREEN finger-tip. It is not necessary to touch the screen with any
other implement. However, the screen can be operated
with any blunt instrument, such as a palm top ‘wand’ or
the blunt end of a pen.

Do not use excessive force: a light touch is all that is

needed.

Caution
Operating the touch screen with a sharp object, or with
excessive force, will damage the screen.

The DigiVAC+ is controlled by touching buttons on the

control panel. Buttons that perform related functions are
grouped together in ’windows’. Each window is selected
by touching the relevant tab at the bottom of the control
panel.

7
 There are also six ‘control’ buttons along the top of the
screen. To display help text about any of the machine’s
functions, touch HELP and then touch the required button.

Start/Stop Test Set

Inch/Pause Help
End Job Menu

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

Tip
Load the Default Template to return the control panel to
its default factory settings:
• Touch END JOB
• Touch LOAD & SAVE
• Select the Default Template from the list of jobs
• Touch LOAD
• In the window that appears, touch YES to confirm that
you wish to load the Default Template

8
LOADING THE BINS Remove any unwanted paper from the bins and press
WITH PAPER INCH to check that there is no paper left in the conveyor
from the previous job. Touch END JOB to tell the DigiVAC+
that the previous job has finished.

The job should be organised either with the sheets face

uppermost, and the first page in the top bin or face down
with the first page in the bottom bin. The bins will auto-
matically switch on when they are loaded with paper.

Slide the paper into the bin between the sidelays. Push
in the sidelays to centralise the paper and to hold it
securely in the bin. Ensure the air blow control is switched
on (pushed in) in each bin.

ADJUSTING THE • Load the default job template from the LOAD & SAVE
MACHINE window to return the control panel to its default factory
settings (or select another job setting if required).
• Initially set the separation lever on each bin to its mid-
position.
• Adjust the stacker or bookletmaker for size.
• Push the delivery direction lever up to deliver sets to
the rear, or down to deliver sets to the front.
• Make sure the paper control springs are in position 2
(on-light).

STARTING THE JOB Press to run the test set.

When the test set is complete, press again to run the

job.

The machine can be stopped at any time by pressing .

9
 THIS PAGE IS
INTENTIONALLY
BLANK

10
 3 Control Panel

Your DigiVAC+ 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.

Start Button Stop Button

Touch-screen

GUI Control Panel

The touch-screen has a ’power save’ function: if it is not

used for a period of time, it automatically dims. After an
extended period, it switches off. In either case, touch the
screen to return it to normal.

Tip
The touch-screen takes two or three minutes to reach full brightness when it is
switched on.

THE WINDOW The DigiVAC+ is controlled by touching buttons on the

SYSTEM control panel. The buttons are divided into groups that
perform related functions. Each group of buttons has its
own ’window’ which is selected by touching the relevant
tab:

• Load & Save

• Basic
• Advanced
• Feed
• Batch
• Finishing (this is only displayed if a booklet maker is
fitted to the DigiVAC+)

11
 Start/Stop Test Set
Inch/Pause Help
End Job Menu

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

The GUI will only display options and functions that are
relevant to your DigiVAC+, dependant on the machine
configuration.

‘CONTROL’ BUTTONS There are six main ’control’ buttons listed across the top
of the screen:

START/STOP The button is used to start the machine. When the

machine is running, this button changes to a button
which stops the machine. These are duplicated by the
start/stop buttons above the touch screen.

12
 INCH Touch and hold INCH to turn the conveyor. The conveyor
will stop when INCH is released. This is used for clearing
any sets remaining in the conveyor after a jam, etc.

When the machine is running, this button changes to

PAUSE. Touch PAUSE to pause the feed for approximately
5 seconds, the conveyor continues to run. The pause time
can be altered on the Machine Options page.

END JOB Touch END JOB when you want to set the machine up for
a new job, or alter an existing job. When a job is loaded,
some of the machine settings cannot be changed, to
prevent accidental changes. END JOB releases these
settings.

This only affects settings that change the integrity of the

job, e.g. the number of sheets in a set, or the number of
sets in a batch.

TEST SET When the test set icon is highlighted , the collator is ready
to run a test set. The collator uses the test set to calibrate
the system according to the stock in each bin. The test
set is not counted by the counter (except when in pre-
number mode). Once the test set is completed and is
accepted by starting the machine, the bins and certain
functions cannot be changed,to prevent errors and acci-
dental button pushes.
To run a test set:
• Load the collator.
• Touch the button.
• The collator will feed a single sheet from each bin that
is switched on and loaded.
• If an error occurred during the test set, or the bin
loading is changed at this stage, touch to run another
test set.
• When the test set icon is grey , the machine is ready
to run. Touch .

If either the TEST SET or END JOB button is touched,

another test set will need to be run before the job can be
restarted: the test set icon will be highlighted .

13
 If you are having trouble running a job and false errors
are being reported, it may help to run another test set.
This can be done at any time to recalibrate the detector
system.

HELP Touch HELP and then touch any area of the screen to
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. This indicates that there is more text available,
explaining a related function in more detail. Touch the
’right’ arrow to view this text. A ’left’ arrow will then also
appear: touch this to return to the previous text.

When you are viewing text, you can find out about any of
the other tabs that remain on display by touching them.
To exit the help text, touch HELP or OK.

MENU MENU gives access to settings that do not need to be

changed on a day-to-day basis. These settings include:
• Change the display language
• Toggle between metric and imperial measurements
• Adjust the screen contrast
• Adjust the pause duration

There are several access levels: some of the settings can

only be changed by someone who has an appropriate
access code.

MIMIC DIAGRAM The mimic diagram of the system shown on screen is

automatically created, based on how many bins are fitted
and what finishing equipment is connected. Various areas
on the outline will be highlighted in different colours,
according to the system’s operational status. The feed
bin colours mimic the bin indicator lights:
• Steady green: This bin is selected, and is loaded with
paper
• White: This bin is not selected
• Broken line between bins: These bins are linked
• Flashing green: This bin is selected, but it has run out
of paper
• Flashing red: This bin has had a double feed, which
has caused the collator to stop. The error will be
explained in a pop-up box

14
 • Flashing yellow: This bin has had a miss, which has
caused the collator to stop. The error will be explained
in a pop-up box

Errors in other modules are indicated in red.

Mimic Diagram

C Touching C resets the set counter to 0.

SPH SPH 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.

15
 THE ‘BASIC’ WINDOW The BASIC window contains settings that regularly need
to be altered when setting up a new job.

‘BASIC’ Window.

SETS PER HOUR SETS PER HOUR allows the production rate of the system
to be set. This is automatically limited according to the
machine configuration.

AUTO: Selecting AUTO allows the system to run at its

maximum production speed according to paper size,
online finishing equipment and the job setup.

SINGLE SET: Normally there will be more than one set in

the conveyor at any one time. Touch SINGLE SET to allow
only one set in the conveyor at a time. This minimises the
correction required should an error occur. The sets per
hour will automatically adjust to achieve this.

AIR BLOW AIR BLOW alters the amount of air available for sheet
separation in the feed bins. As a general rule, the heavier
and larger the sheet, the more air you need. The default
factory setting is (DigiVAC) 65mB.

16
 When the machine is idle, AIR BLOW shows the selected
pressure. When the machine is running, AIR BLOW indi-
cates the actual pressure. Depending on various factors,
the selected pressure may not be possible.

PRESET PRESET is used if an exact number of sets are required.

Touch PRESET and enter the number of sets required on
the number pad. The counter in the main area of the
screen will turn white. When the machine is started the
counter will automatically count down to zero and the
collator will then stop.

Touch to restart the machine. The counter will revert

to black and will count up to show how many ’overs’ are
produced.

The Preset function is ideal for producing a one-off batch.

If you wish to produce several identical batches, it is
easier to use the Batch function.

PRENUMBER PRENUMBER is intended for use when collating pre-

numbered carbonless sets. Touching PRENUMBER se-
lects Single Set mode, disables the Divert function and
causes the test set to be counted by the counter. It also
prevents the operator from switching linked bins before
one bin has emptied.

It is possible to switch off Single Set mode once Prenum-

ber is selected. This allows the machine to run faster when
using stock that feeds easily.

OSCILLATE OSCILLATE offsets the collated sets if a suitable stacker

is fitted.

17
 THE ‘ADVANCED’ The ADVANCED window allows advanced machine set-
WINDOW tings to be altered. These settings may be altered to
optimise the quality and productivity of a job.

‘ADVANCED’ Window.

STAGGER (Two Tower only). When STAGGER is selected, the col-

lated set from Tower B delivers ahead and separately
from that of Tower A. This allows for better jogging of sets
with a lot of sheets. Stagger is only available when feeding
into a jogger.

SHEET OFFSET SHEET OFFSET shales the sheets as they exit. This can
assist the neat stacking of thick sheets or large sets. The
range of offset is +/- 20mm between each sheet and
affects all bins. The default sheet offset is 0: this causes
the sheets in a set to exit the collator with their leading
edges level.

If an offset is required, it is usual for the bottom sheet of

the set to lead: Select a negative offset when feeding to
the rear of the collator and a positive offset when feeding
to the front of the collator.

A small offset can make jogging more effective when

using a booklet maker.

18
DETECTOR POSITION The sheet detector measures 15.2mm (0.6") from the feed
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. The DETECTOR POSITION
can be adjusted so that it looks at a different part of the
sheet. This affects all the bins in the collator.

TOLERANCE: Changing TOLERANCE to x2 COARSE al-

lows for more variation in the detector readings. This
prevents false errors being reported when there are
variations in the paper or ink density. The default setting
is x1 NORMAL.

The collator allows for some variation in the paper or ink

density, and constantly changes the range of values it will
accept by working out an average value for previous
sheets. Increasing Tolerance to x2 COARSE will only be
necessary where there are larger variations in stock.

DOUBLE DETECTION: Under unusual circumstances,

e.g. there are large variations in stock, it may be neces-
sary to turn off DOUBLE DETECTION. This affects all the
bins in the collator. Miss feed detection is unaffected.

Before switching off double detection, first try setting

TOLERANCE to x2 COARSE.

FEED CLUTCH FEED CLUTCH adjusts the clutch feed length for all bins
during the test set only. Increasing the value will cause
the feed wheels to drive the paper for longer, which can
prevent sheets from slipping. The value can be reduced
to prevent excessive pre-feeding of the next sheet in the
bin.

Optimising the clutch feed length for non-standard paper

lengths will produce a more accurate test set, which in
turn should reduce errors during the job. The default value
is 186.2mm (7.35") during the test set, thereafter the feed
length is automatically set to suit the paper size.

AUTO: Touch AUTO to set the clutch feed length to the

default value of 186.2mm (7.35").

19
 SHORT: SHORT will decrease the clutch feed length dur-
ing the test set to 121mm (4.8"), which is ideal for A5 or
5.5 x 8.5" landscape or similar.

SUCTION HOLD Increasing the SUCTION HOLD value causes the feeder
to allow more time to pick up each sheet. If you are using
stock that tends to stick together, increasing the suction
hold can improve paper pick-up and in some instances,
separation.

It is possible to reduce the suction hold when using paper

that is easy to feed: this will increase the operating speed
of the machine. The default setting is 150mS.

20
THE ’FEED’ WINDOW The FEED window contains the Multifeed, Multiset, Mixed
Feed and Hand Merge options. With these options the
collator can be programmed to feed in selective or special
sequences, or to allow hand merging of two partial sets.

‘FEED’ Window.

MULTIFEED MULTIFEED allows multiple feeds from each bin per set.
For example, a Multifeed size of 4 will feed 4 sheets from
each bin in turn. Touch MULTIFEED and enter the number
required using + or -. Touch O to switch on. Switch off
after use.

MULTISET MULTISET allows multiple sets to be loaded and counted.

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

a twelve bin collator. When Multiset is switched on, the
counter will count three sets per cycle instead of one.

Mutiset will also automatically divide an odd number of

sets into a batch. Using the previous example, if the
desired batch size was fifty, the number of sets fed at
each cycle (three) would not divide exactly into the total
required. In this case Multiset would feed forty eight sets
normally and then just two sets on the final cycle to
complete the required batch.

21
 Load the job and switch on the bins. Set a batch quantity
and action from the BATCH window if required. In the
MULTISET window, use + or - to choose how the sets
should be split. Touch O to switch on. Switch off after use.

MIXED FEED By using MIXED FEED, special feed sequences can be

programmed. Each column represents a stage in the
collating cycle. Up to twelve stages can be programmed.
The collator will complete each stage in turn and then
repeat the cycle.

Use the left/right arrow keys to navigate to the required

stage. Use the up/down arrow keys to navigate to the
required feed bin. Touch the 'enter arrow' to switch on.
Use the + and - keys to enter the number of feeds in each
stage. Touch O to switch on. Switch off after use.

HAND MERGE Touch HAND MERGE to switch on the hand merging

facility. This allows two partial sets to be combined. In
this way booklets, which have more sheets than the
collator has bins, can be produced.

Collate the first half of the set into the jogger. Place the
partial set in the hand merge tray, the collator will feed
the remaining sheets and then release the completed set
into the bookletmaker. As soon as the set has been
released, place the next partial set in the tray. For further
details of Hand Merging Sets, refer to Chapter 5 (page
39).

22
THE ‘BATCH’ WINDOW The BATCH window allows sets to be grouped into batch-
es, with an action at the end of each batch (stop, pause,
oscillate or insert sheets).

‘BATCH’ Window.

23
 NUMBER OF SETS Touch NUMBER OF SETS to enter the number of sets in
each batch. Entering 0 on the keypad will turn the batch
mode off.

Counts the total number of

sets produced

Counts the number of sets

per batch

Counts the total number of

batches produced

Batch Counter.

INSERTS INSERTS allows sheets from the top bin and/or bottom bin
to be inserted at the beginning or end of each batch.

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

used purely as a batch separator, it can be fed from either
the top or bottom bin.

TOP: When feeding to the front of the collator, select TOP

to feed a sheet from the top bin with the first set of each
batch. The inserted sheet will be at the bottom of the batch
pile, as the backing board for a pad for example.

When feeding to the rear of the collator, select TOP to

feed a sheet from the top bin with the last set of each
batch. The inserted sheet will be at the top of the batch
pile, as the cover sheet for a pad for example.

BOTTOM: When feeding to the front of the collator, select

BOTTOM to feed a sheet from the bottom bin with the last
set of each batch. The inserted sheet will be at the top of
each batch pile, as the cover sheet of a pad for example.

24
 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. The inserted sheet will be at the bottom of
the batch pile, as the backing board for a pad for example.

OSCILLATE OSCILLATE, when selected from the Batch window, off-

sets the stack after each batch if a suitable stacker is
fitted. This is used to separate each batch.

STOP STOP causes the machine to stop after each batch, and
the counter display will flash. Touch the start button to run
another batch.

If STOP is selected while the machine is part-way through

collating a batch, it will stop once it has completed that
batch. This allows the operator to interrupt a job at a
convenient point.

PAUSE / SEPARATE PAUSE / SEPARATE causes the machine to pause for

approximately 5 seconds after each batch. The pause
icon on the control panel will flash between batches.

This function will also separate batches on a booklet

maker outfeed conveyor. The pause time can be altered
on the Machine Options page (touch MENU, MACHINE
OPTIONS).

RESTART BATCH Touching RESTART BATCH zeros the batch counter, so

that you can restart a batch. Note that if the collator is
running, this button will interrupt a batch that is partly
completed, and a new batch will be started.

25
 THE ‘FINISHING’ The FINISHING window controls the settings for the book-
WINDOW let maker and trimmer.

‘FINISHING’ Window.

PAPER SIZE Touch PAPER SIZE to alter the settings of the booklet
maker and trimmer to suit the input paper size.

RE-REF: If you suspect the booklet maker or trimmer

adjustment system is not calibrated correctly, touch RE-
REF to re-reference the adjustment axes. The adjustment
axes will return to the current settings once this is com-
plete.

Periodically the booklet maker will automatically re-

reference the axes during the setup procedure.

PAGE DIRECTION: Touching PAGE DIRECTION switches

the orientation of the paper between landscape and
portrait. This is only possible if the sheet does not exceed
the maximum width accepted by the booklet maker.

PRESETS: Select from a choice of standard paper sizes

by touching the PRESET window.

26
 STITCH AND FOLD The position of the stitch and fold can be offset relative
to the centre of the paper. STITCH AND FOLD allows this
position to be adjusted up to 20mm in either direction, in
increments of 0.2mm.

STITCH: The STITCH OFF option will produce booklets that

are folded, but not stitched.

STITCH POSITION: The ON FOLD option produces book-

lets which are stitched on the fold line. The ON EDGE
option produces sets which are edge-stitched and fold-
ed.

The Stitch Selection Lever on the booklet maker must be

in the centre-stitch position.

TRIM Touch TRIM to set the finished book size after trimming.
When a preset paper size is selected, this distance is
automatically adjusted, but can be fine-tuned. The trim
function can also be switched off.

PRE STITCH JOGGING The PRE STITCH JOGGING window has options to alter
the way sets are jogged prior to stitching. This ensures
the finished booklets are as neat as possible. The maxi-
mum speed of the booklet maker will be reduced when
any of the Pre Stitch Jogging options are selected.

PRE JOG: This provides additional jogging to the bottom

of the set, when using heavy or large sheets. The booklet
is stopped by the edge-stitch latch and jogged, before it
drops to the stitch latch.

Note: If PRE-JOG is used with sheets over 300mm long,

the roller uplift knob must be raised.

DOUBLE JOG: This provides additional jogging to the

sides of the set, when using heavy or large sheets. The
sidelays jog the set twice when it reaches the stitch latch.

STITCH DELAY: Increasing the STITCH DELAY value will

cause a delay between the set arriving on the stitch latch
and it being stitched. This allows more time for the sheets
to settle. The default delay is 1mS.

27
 PRE FOLD JOGGING The PRE FOLD JOGGING window has options to alter the
way sets are jogged prior to folding. This ensures the
finished booklets are as neat as possible.

SIDE JOG HOLD: When SIDE JOG HOLD is selected, the

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.

FOLD DELAY: This can be adjusted to alter the delay

between the set arriving on the fold latch and being
folded. This is useful if the booklet is not being folded
square, and allows more time for the sheets to settle. The
default delay is 180mS. The maximum production speed
of the booklet maker will be reduced if the delay is
increased.

BOOK THICKNESS The BOOK THICKNESS window alters the gap between
the feed rollers of the Auto Stitch-Fold. The thickness of
the set is entered on a scale of 1 to 25: this scale
represents 1 to 25 sheets of 80gsm paper. The value will
need to be adjusted to allow for heavier or lighter stock.

28
THE ‘LOAD & SAVE’ The LOAD & SAVE window allows job settings to be saved
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.

’LOAD & SAVE’ Window.

SAVE Touch SAVE to save the current settings of the collator

and its on-line finishing equipment. When the on-screen
keyboard appears, enter the job name and then touch
OK or CLOSE. The new job will appear in the list of saved
jobs. This allows the settings to be recalled in the future,
which saves set-up time.

REPLACE: If an existing job has been loaded and modi-

fied, touching REPLACE will replace the old job with the
modified version.

CANCEL: Touch CANCEL if you do not wish to save a job

that you have modified.

SAVE NEW: If an existing job has been loaded and mod-

ified, touching SAVE NEW will save the modified version
as a new job. When the on-screen keyboard appears,
enter the new job name and then touch OK or CLOSE.
The original job is unchanged.

29
 If the job name is not changed before touching OK or
CLOSE, the job will be saved with the current name,
suffixed by an asterisk.

JOB DETAILS Touching JOB DETAILS shows the settings for each saved
job. Select the job that you wish to view from the job list
and touch JOB DETAILS to see a summary of the job
settings.

LOAD To load a job, select it on the job list using the up and
down arrows or by touching it. Touch the LOAD button.
You must touch END JOB before loading a job.

PADLOCK SYMBOL The padlock symbol is used to lock and unlock saved
jobs. Each saved job has a small padlock symbol next to
it, to show whether it is locked or not. To lock or unlock a
job, select it on the job list and touch the large padlock
button.

Some padlock symbols may be greyed out. This is be-

cause there are several access levels to the system,
which can be used to prevent jobs being altered.

DELETE To delete a particular job it must be unlocked. Select the

job from the job list using the up and down arrows or by
touching it. Touch and hold DELETE. A red bar will
appear, filling from left to right. Continue to hold until the
red bar reaches the right-hand side.

VIEW OF JOB LIST VIEW OF JOB LIST alters the order in which saved jobs
are listed, either alphabetically or most recent first.

There is a line between Factory Template jobs, and other

jobs saved by the operator. The Factory Template jobs
are always listed first: only the operator-saved jobs can
be reordered.

A->Z: To list jobs alphabetically, touch A->Z.

BY USE: To list jobs in the order they were last used, touch
BY USE. The job that was run most recently will appear
at the top of the list.

30
 4 Operating the Bins

Your DigiVAC+ may have 8 or 12 feed bins per tower. A

further 4-bin module can be added to 8-bin machines,
even after the machine is installed.

BIN CONTROLS AND Feed stations are numbered from 1 upwards, with the
INDICATORS bottom bin being bin 1. Each bin has its own controls
immediately alongside it.

Red light . . . . . . . . . . .Indicates a double feed

Yellow light . . . . . . . . . .
Indicates a miss feed
Red & yellow lights . . . . Indicates a feed jam
Green button . . . . . . . . Bin on/off switch
Green light. . . . . . . . . . .
Indicates bin is switched on
Green flashing light . . . Indicates the bin is switched on,
but requires loading
Grey button. . . . . . . . . . Bin linking switch
Small lower green light . Indicates the bin is linked to the
one below

Switching Bins On & Off

Bins can be manually switched on and off by pressing
the green button alongside the bin.

If the system is unlocked, bins will automatically switch

on when they are loaded. Remember that bins cannot be
switched on or off when the system is locked.

BIN ADJUSTMENTS The feed bins should be adjusted according to paper

size, type and other conditions. This section explains how
to make adjustments. Recommended settings for differ-
ent, paper types can be found in Appendix 2 (See p.65).

31
 Paper Control Springs
Paper Control Arm Small Sheet
Air Tap

Pack Lift
Air Blow Control
Endlay

Paper Separation
Adjustment

Air Blow Control

Air is blown into the bin to lift the paper stack and to
separate the bottom sheets. Turn off the air blow in un-
used bins to preserve system air and prevent unneces-
sary noise.

The air blow is turned on and off with the air blow control
located on each side of the bin.

• Push in to turn the air blow on.

• Pull out to turn the air blow off.

Note:
If the bin air blow is turned off, the bin will not feed.

Small Sheet Air Tap

When collating small sheets (less than 210mm long), the
air blow should be restricted to the inner part of the bin

32
by closing the air taps on the sidelays. This will preserve
system air and prevent unnecessary noise.

Small Sheet Air Tap : OFF Small Sheet Air Tap : ON

Tray Extenders
The tray of each bin extends by simply pulling it outwards
to the desired length. The trays are spring-loaded and
will lock into position when they reach their maximum
extension.

To shorten the tray extenders, push them back towards

the machine. If the tray extenders are locked (i.e at their
maximum extension), press down on the tray extender
panel and push inwards.

Tray Extender

Tray Extender Panel

Pack Lifts
The pack lift should be positioned beneath the centre of
the paper stack. The black rubber endlay should then be
slid down the pack lift until it butts up to the edge of the

33
 paper stack. The pack lift position will vary, depending
upon paper size.

Sheet length up to 335mm: the pack lift is clipped under the edge of the
inner tray. The endlay is pushed forward to touch the paper stack.

Sheet length over 335mm: the tray is extended and the pack lift is clipped
under the edge of the tray extender. Slide the endlay to the rear of the
packlift, push the tray extender in until the endlay touches the paper
stack.

More
Paper Separation
Separation Different papers may require different amounts of sepa-
ration in order to feed reliably.

• Move the lever upwards to increase separation

• Move the lever downwards to decrease separation
Most papers run with the lever approximately mid-posi-
tion.

If the bin regularly misses a feed (the yellow bin indicator

Less
Separation
light will flash), lower the lever slightly to reduce the
separation.

If the bin regularly feeds a double sheet (the red bin

indicator light will flash), raise the lever slightly to increase
the separation.

If the bin regularly indicates a feed jam (both red and

yellow bin indicator lights will flash), the cause may be:

34
• a late feeding double sheet - treat as a double feed
and raise the lever slightly to increase the separation
• a slow feeding sheet - treat as a misfeed and lower the
lever slightly to reduce the separation
The separator adjustment lever can be altered at any time
during the job to obtain reliable feeding.

Paper Control Springs

The paper control springs give extra control to the feed
edge of the sheet. They are used for light and/or curly
papers. There are three settings, selected by moving the
lever.

1: OFF

2: ON (light) - This is the default setting.

This adds light pressure to the feed edge of the sheets.

3: ON (firm)
This adds firm pressure to the feed edge of the sheets.

35
 BIN LOADING Loading Sequence
There are two loading methods. Which one you use will
depend upon the job in question.

Tip: If not all bins are required for the job, use the
uppermost bins to maximise production speed.

Method 1:

#1 Load the sheets face up and with the first page in the
#2 uppermost bin.
#3
#4 This loading method will deliver sets:

• face down to the front into the cross-jogger (if fitted)

• face up to the rear

Use this method for bookletmaking. Load the cover into

the top bin.

Method 2

Load the sheets face down, with the first page in the
#4
#3
lowermost bin.
#2
#1 This loading method will deliver sets:

• face up to the front into the cross-jogger (if fitted)

• face down to the rear

Loading the Bins

The DigiVAC+ bins feed from the bottom of the paper
stack, which allows the bin to be continuously reloaded
without pausing the job.

36
 Each bin can hold up to 60mm, depending on the paper.
Overloading the bins when using certain papers can
cause misfeeds. Do not load the bins to full capacity until
the collator is running.

Slide the paper into the bin between the sidelays. Push
in the sidelays to centralise the paper and to hold it
securely in the bin.

The paper control arm and paper control springs will

swing out of the way when you push the stack of paper
against them, and then drop back down onto the stack.
The arm controls the last few sheets in the stack when the
bin is almost empty.

Bin Reloading
When adding paper to a bin, push it as far into the bin as
possible before lowering it onto the existing stack of
paper. This will prevent the top sheet of the stack from
being disturbed, which could later cause a misfeed.

Make sure the stack of paper is tidy. The additional paper

should sit squarely on the existing stack, and should not
overlap the sidelays.

BIN LINKING If required, two or more feed bins may be linked to operate
as a single bin. When one runs out of stock, the next bin
in the linked group will automatically take over. This allows
reloading without stopping the machine. Bin linking can
only be enabled when the bins are unlocked i.e. when the
TEST SET icon is highlighted on the control panel. Press
the grey button on the upper bin to link it with the one
below. This will be indicated by the small green light. The
mimic diagram on the control panel will show a broken
line between bins that are linked.

By pressing the red bin on/off button it is possible to select

which bin in the linked group is active (unless
PRENUMBER in the BASIC window is selected).

If the system is locked, pressing the grey button on any

bin will indicate which bins are in the same linked group.

SENSOR OVERRANGE Sensor overrange is indicated by a slow flashing red light

on the bin in question.

37
 Particularly heavy or opaque paper 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.

DIFFICULT PAPERS If the paper is badly curled so that the edges of the stack
do not lie flat on the tray, miss-feeds may occur.

Paper curl can normally be avoided by observing correct

paper handling and storage procedures.

Recommended settings for different paper conditions

can be found in Appendix 2 (See p.65).

If the paper is too curled to run in the DigiVAC+, the curl

can usually be removed by hand. Remove the paper from
the bin and bend the stack in the opposite plane to the
curl. For example, if the sides of the stack are curling
upwards, roll the feed edge downwards.

If the cover sheet for a booklet is badly curled, for example

by poor lamination, hand feed the cover using the hand
merge tray (see “Hand-Merging Sets” on page 39).

38
 5 Hand-Merging Sets

Your DigiVAC+ has either 8 or 12 bins. Booklets com-

prising more than 8 or 12 sheets can be produced in two
stages by hand merging two partial sets in the rear
outfeed unit.

Stage 1: Collate the cover and outmost sheets into the

jogger. The jogger should be set to offset stack the sets.

Stage 2: Load the remaining sheets into the DigiVAC+.

Place the pre-collated partial sets in the hand-merge tray
one at a time and the DigiVAC+ will automatically feed
the remaining sheets to deliver a complete set into the
bookletmaker.

USING THE HAND • Set the delivery direction lever to its upper position, to
MERGE MODE deliver sets to the rear.
• Lower the roller uplift knob to engage the outfeed drive
roller.
• Switch on the hand merge mode by touching HAND
MERGE in the FEED window. ON will be displayed on
the HAND MERGE button.
• Start the collator by pressing , and complete a test
set.
• Restart the collator and place the partial set in the hand
merge tray. The DigiVAC+ will feed the remaining
sheets and then release the completed set into the
bookletmaker. As soon as the set has been released,
place the next partial set in the tray.

Tip: If not all bins are required for the job, use the
uppermost bins to maximise production speed.

Switching off the Hand Merge Mode

Switch off the hand merge mode by touching HAND
MERGE in the FEED window. OFF will be displayed on the
HAND MERGE button.

If the hand merge mode is not switched off, it will remain

active whenever the delivery direction lever is set to its
upper position for delivery to the rear.

39
 ERROR RECOVERY If a feed error occurs, the DigiVAC+ will stop and error
information is displayed on the control panel.

• Remove both parts of the set from the rear outfeed.

• Correct the error and replace the complete set in the
the hand merge tray.
• Start the collator and the set will be released into the
bookletmaker.
• Continue hand merging sets as previously explained.

40
 6 Booklet Making

The DigiVAC+ can be used in conjunction with all Watkiss

bookletmakers to produce booklets. Three versions are
available:

• BookMaster and TrimMaster (staple-fold, manual ad-

justment)
• BookMaster Pro and TrimMaster Pro (staple-fold, au-
tomatic adjustment).
• Stitch Fold and Trim (stitch-fold, automatic adjustment)

USING THE Full operating instructions for your bookletmaker are pro-
BOOKLETMAKER vided in the seperate operating manual supplied with the
unit. Position the bookletmaker under the collator’s rear
outfeed as shown below.

Delivery Direction Lever

DigiVAC+ Rear Outfeed

Roller Uplift Knob

Bookletmaker

Set the delivery direction lever to its upper position, to

deliver sets to the rear.

Ensure the bookletmaker is plugged into a mains supply

of the correct voltage. Connect the interface cable be-
tween the bookletmaker and the DigiVAC+.

Adjust the bookletmaker settings to suit the booklet size.

Note: If PRE-JOG is used with sheets over 300mm long,

raise the roller uplift knob to disengage the outfeed drive
rollers.

41
 Run a few sets. The bookletmaker will start automatically
when the set enters the infeed slot. If needed, adjust the
settings on the bookletmaker to produce a tidy booklet.

ERROR HANDLING In the unlikely event of an error occuring in the booklet-

maker, the collator will stop and the error will be displayed
on the control panel.

If the collator feeds an error, the faulty set will be held in

the rear outfeed.

Remove the faulty set, correct the error, and then place
the corrected set in the hand merge tray. When the
collator is restarted, the set will be released into the
bookletmaker.

USING OTHER The DigiVAC+ may be used with some other manufactur-
BOOKLETMAKERS er’s bookletmakers. Please refer to your Watkiss supplier
for further information.

42
 7 Joggers

Two joggers are available for the DigiVAC+:

• X-Jogger - this is a programmable 20° offset stack

jogger which fits at the front of the tower.
• Straight Jogger - this is a straight stack jogger which
can be positioned at the front or back of the tower.

Note: To deliver sets to the front of the tower, the

DigiVAC+ must be fitted with a front outfeed conveyor.
This is supplied as standard with the X-Jogger, but must
be specified separately for the Straight Jogger.

X-JOGGER Ensure that the mains and interconnection cables on the

jogger are plugged into the sockets on the DigiVAC+.

Set the delivery direction lever to its lower position, to

deliver sets to the front. This will automatically switch on
power to the jogger.

Interconnection Cable Width

Adjustment

Mains Cable Support Post

Vibration Control Knob Bottom Sidelay

Adjustment

Setting Up the Jogger

Take a few sheets of the paper to be collated and place
them in the stacker offset by 20°. Use the hand wheel to
adjust the sidelays to suit the width of the stack.

Adjust the bottom sidelay so that the middle of the sheet

is over the middle of the stacker tray. You can check this
by folding a sheet in half (as dotted line in photo) and
checking that the fold on the left and right edge is equal
distances (’X’) above and below the angle in the sidelays.

43
 x
x

Adjust the position of the support posts by twisting anti-

clockwise to release, sliding to about 5mm (¼") from the
edge of the stack and then re-tightening.

Select OSCILLATE in either the BASIC or BATCH menu (if

required) from the control panel menu and run a test set.

If needed, fine-adjust the position of the sidelays and

support posts to achieve a neat stack.

ADJUSTMENTS Vibration
If necessary, use the vibration adjustment knob to adjust
the amount of vibration. Use the minimum amount of
vibration that will successfully jog the stack.

Paper Control Tape

Some papers, especially light weight papers, may not fall
tidily into the jogger. The paper control tape can be pulled

44
 out to the required length in order to provide additional
control of difficult papers.

Paper Control Guide Rods

Paper Control Tape

Paper Control Wheel

The paper control wheel is used to cup the set as it leaves
the outfeed conveyor. This gives rigidity to the set as it
drops into the jogger.

The paper control wheel shaft can be adjusted to suit the

thickness of the set being collated. On single towers this
will rarely need to be altered, but on twin tower systems
where sets are likely to be thicker, the shaft can be raised
to accommodate this.

Loosen the fixing screw either side of the shaft, position

shaft (see below) and tighten screw

Thicker Set (Max.)

Paper Control Wheel
Default (Centre)

Thinner Set (Min.)

45
 Paper Control Guide Rods
The paper control guide rods can be used to support the
edges of the set for extra control. They are secured in
place with a thumbscrew and may be pushed in or out to
the required length, or pushed fully inwards for storage.

STRAIGHT JOGGER Setting up the Jogger

Position the Straight Jogger in a central position under
the front or rear outfeed of the collator.

Jogger ’full’ sensor Jogging Adjustment

Mains Input Local Control Switch

Height Adjustment Mains ON/OFF switch

Release Lever

Switch off the local control switch (green strip not visible).

Plug the interconnection cable into the socket on the front

of the DigiVAC+ (see p.43).

Connect the jogger to the mains supply and turn on the

mains on/off switch.

Run a test set and if necessary, adjust the position of the

jogger. Position it further in or out so that the paper falls
neatly into the receiving area. A sideways positional
adjustment may also be necessary depending on the size
of the paper and type of stock. The height of the jogger
can be adjusted by releasing the height adjustment re-
lease lever.

Jogging Adjustment
If necessary, adjust the amount of vibration using the knob
on the side of the jogger (as shown above). Use the
minimum amount of vibration that will successfully jog the
stack.

46
 Jogging Off-line
The straight jogger can also be used off-line. Connect the
jogger to the mains supply and switch on both the mains
on/off switch and the local control switch.

ERROR HANDLING If a feed error occurs, the DigiVAC+ will stop and the error
is displayed on the control panel. The faulty set will be
on the top of the stack in the jogger. Remove the set,
correct the error, and replace the set in the jogger.

When offset stacking, it is important to replace the set in

the correct orientation to ensure that the sets are properly
offset.

47
 THIS PAGE IS
INTENTIONALLY
BLANK

48
 8 Two-Tower DigiVAC+

Your DigiVAC+ can be configured with two towers. The

basic operation of the machine is unchanged, so the
information provided in this chapter is in addition to that
in early chapters. The two towers are denoted ’A’ and ’B’
as shown in the photograph below.

In two-tower DigiVAC+ systems, the sets from Tower B

are transported over the connecting bridge and merged
with the sets in Tower A. Completed sets can be delivered
to the jogger or to the booklet-maker.

Caution:
Do not place paper or other objects on the connecting
bridge - it should not be used as a shelf.

Connecting
Bridge

Tower A
Tower B

Automatic SpineMaster
(optional)

Booklet Maker and

Trimmer (optional)

49
 USING THE GUI The GUI control panel on Tower A controls both towers.
CONTROL PANEL

Multi Tower Status

Mimic Diagram

Multi Tower Status

At the top of the screen MULTI TOWER A is displayed.
This indicates that both towers are switched on and are
communicating. A line through the text (MULTI TOWER A)
means that Tower B is switched off, or there is a fault with
the connection between the two towers.

Limitations
Some functions on the GUI are not available when running
two towers. They are still available for single tower use.

• INSERTS > TOP (p.24) is only available in single tower

mode. INSERTS > BOTTOM is available at all times.
• MULTISET, MULTIFEED, MIXED FEED (p.21-22) are not
available in two tower mode.

Job Memories
Job settings for both towers can be saved and loaded
from the LOAD & SAVE window.

Before loading a saved job which uses both towers, both

towers must be switched on. If Tower B is switched off,

50
 the error message Tower comms error is displayed.
Switch on Tower B and reload the job from memory.

USING BOTH TOWERS Each tower has an independent mains ON/OFF switch
(See p.4), both must be switched on.

Loading Sequence
There are two loading methods. Which one you use will
depend upon the job in question.

Tip: If not all bins are required for the job, use all bins
in Tower A and then the uppermost bins in Tower B to
maximise production speed.

A B

Booklet Making
• Load the cover in the top bin of Tower B, with the outside facing upwards.
• Load the centre sheet in the bottom bin of Tower A, with the inside facing
downwards.

51
 A B

Stacking
There are two methods for loading the sheets:
• Load the sheets face up and with the first page in the top bin of Tower B. This
will deliver the set face down into the jogger.
• Load the sheets face down and with the first page in the bottom bin of Tower A.
This will deliver the set face up into the jogger.

USING ONLY ONE Tower A can be used alone if required. Switch on the
TOWER mains ON/OFF switch on both towers and then ensure all
bins in Tower B are switched off.

Tip: Switch on both towers, even if only Tower A is being

used.

Tower B can only be used if Tower A is switched on.

Collated sets are delivered via Tower A into either the
jogger or booklet maker.

ERROR HANDLING Error handling in two towers is the same as in a single

tower. If a feed error occurs, the DigiVAC+ will stop and
the error is displayed on the control panel. The faulty set
will be either on the top of the stack in the jogger or it will
be held in the rear outfeed. Remove the set, correct the
error, and continue as normal (see p.40 and p.42).

52
 9 Maintenance

SERVICE INTERVAL It is recommended that your DigiVAC+ 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 DigiVAC+ will benefit from

MAINTENANCE periodic cleaning of general accumulations of paper dust,
ink etc. Other operator maintenance is detailed below.

Conveyor Wheels
The conveyor wheels should be cleaned periodically to
remove any accumulations of ink etc. The cleaning inter-
val depends on the usage level and paper characteristics.

• Switch OFF the mains ON/OFF switch and disconnect

the mains supply.
• Open the rear cover, by pulling each of the fastening
handles outwards and turning them anti-clockwise.

Rear Cover
Fastening Handle

• Turn the conveyor belts and wheels by hand, and clean

them with a cloth dampened with soapy water or
alcohol (isopropanol).

53
 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).

✗ Aliphatic solvents, e.g. petrol or SBP1.

✗ Aromatic solvents/cleaners, e.g. toluene xylene,

napthas.

✗ Chlorinated solvents/cleaners, e.g. trichloroeth-

ylene, perchloroethylene genclenes.

All of these chemicals will damage the conveyor

wheels to a varying degree resulting in poor perform-
ance and premature failure.

The rear conveyor can be removed quite easily to aid

cleaning. This may also be useful when clearing paper
jams. Remove the rear conveyor assembly by pushing it
to the left against the spring pressure and lifting the right
end clear. Lift the complete assembly clear of the Digi-
VAC+.

To remove the rear conveyor:

A: Push conveyor to the left

against the spring pressure A

B: Pull the right edge of the

conveyor outwards B
C: Ease the conveyor assem-
bly downwards and lift it clear
of the collator C

After refitting the rear conveyor, make sure all the con-
veyor belts are correctly aligned.

54
Main Air Filter
The main air filter should be checked, cleaned or replaced
at regular intervals. The frequency will depend upon the
usage of the machine and the condition of it’s working
environment. Air Filters are available from your Watkiss
supplier (Watkiss P/N 370-230).

• Switch OFF the mains ON/OFF switch and disconnect

the mains supply.
• Using a 3mm allen key, loosen the retaining screws
and remove the air filter access panel from the rear of
the DigiVAC+ base module.
• Reach in through the filter access opening, and remove
the air filter element from it's housing.

Air Filter Access

Panel

Note:
If a new filter element is not available, the existing
element can be cleaned. Shake it (preferably outside)
to remove the dust, wash in soapy water, rinse thor-
oughly and allow to dry. Do NOT refit the filter while it
is still wet.

• Refit the new or cleaned air filter element, ensuring that

the blue coloured side is outwards. Ensure that the filter
element is securely held in place by pushing it beneath

55
 the retaining bracket on the left hand side of the
housing.
• Replace the air filter access panel.

56
 10 Problem Solving

As far as possible the DigiVAC+ has been designed to be self-explanatory. In most

cases problems or errors will be identified on the bin controls and/or 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.

PROBLEM CAUSE SOLUTION

THE MACHINE WILL NOT The machine is not plugged in Plug in and switch on
POWER-UP
Faulty fuse Check the fuses at the mains input
and replace if necessary. (See p.58)

THE MACHINE WILL NOT Several possible causes, exact Correct any faults shown on the con-
START cause will be shown on the control trol panel
panel

BIN(S) DO NOT FEED PAPER Bin is switched off Switch on bin

Hand merge mode is switched on Switch off hand merge mode (See
p.39)

The bin air blow is switched off Switch on the bin air blow by pushing
the air controls in (See p.32)

TOP AND/OR BOTTOM BIN Batch insert selected from batch Check that INSERTS in the BATCH
ONLY FEEDS ON TEST SET menu window is set to NONE.

POOR FEEDING Main air filter needs cleaning or Clean or replace main air filter (See
replacing p.55)

DOUBLE FEEDS Too little separation Increase by moving the separator

(red indicator light) adjustment lever up by a small
amount (See p.34)

MISS FEEDS Too much separation Decrease by moving the separator

(yellow indicator light) adjustment lever down by a small
amount (See p.34)

Incorrect bin settings Use recommended settings (See

p.65)

Untidy loading Reload the bins tidily. Make sure

paper added to the bin sits squarely
on the existing stack

Miscalibration during the first set Unlock the machine and then restart
so that the machine recalibrates

Paper is badly curled Eliminate the curl from the paper.

(See p.38)

57
 PROBLEM
PAPER JAMS (red and yellow
indicator lights) Paper jams can
be caused by a variety of prob- Slow feeding sheet
lems. You will need to look care-
fully to identify which of the
following is at fault.
DOUBLE FEEDS ARE NOT
BEING DETECTED
NOT OFFSET STACKING
SECOND TOWER DOES NOT
SHOW ON GUI, OR Tower
comms error IS DISPLAYED
(Two tower DigiVAC+ only)
HAND MERGE DOES NOT
WORK
REPLACING FUSES
58
CAUSE SOLUTION
Late feeding double sheet Treat as a double feed above
Treat as a miss feed above
Miscalibration during the first set Unlock the machine and then restart
so that the machine recalibrates
The bin sensor is ’overrange’ due to N/A
the feeding of particularly heavy or
opaque stock. The red light on the
bin controls will flash slowly when
the sensor is overrange
Detector Position tolerance is set to Set TOLERANCE to x1 NORMAL in
x2 Coarse the ADVANCED, DETECTOR POSI-
TION window
Double Detection is not selected Set DOUBLE DETECTION to ON in
the ADVANCED, DETECTOR POSI-
TION window
OSCILLATE is not available or not Plug X-Jogger into the collator and
selected in the BASIC or BATCH win- select OSCILLATE in the BASIC or
dow BATCH window
Stacker is not set up correctly Follow set up instructions (See p.43)
Tower B is not switched on Switch on Tower B at the mains ON/
OFF switch
Interconnection cable is unplugged Plug the interconnection cable in.
The cable connects the bridge to
Tower A.
Roller uplift knob is raised Lower the roller uplift knob (see p.5)
to engage the outfeed drive rollers
Your DigiVAC+ is fitted with two fuses at the mains input
(See p.3). If either of these fail the machine will not power
up.
Caution!
The DigiVAC+ system uses double-pole/neutral fusing
(ie, two fuses), so when removing any covers or chang-
ing fuses always first disconnect the machine from the
mains electricity supply by switching off and unplug-
ging the machine
 • Unplug the mains input lead.
• Open each fuse casing in turn and check the fuse.
• Replace if necessary with a fuse of the correct speci-
fication, as detailed below.

Reference
730-103 Fuse, 1.25" (32mm) 10.0A HRC (Anti Surge, T)

ERROR MESSAGES Under certain error conditions a message will be dis-

played on the control panel. Some of the error messages
will refer to an individual bin or module address. In this
case the relevant module number will appear where # is
shown below.

Message Meaning
Bin # double A double feed error has occurred on the bin detailed. This means that the
bin has fed two sheets of paper, instead of one. Check and correct the
faulty set and restart the machine. If the error persists see the Problem
Solving section of the Operating Manual.

Bin # empty The paper tray of the bin detailed is empty. Reload the bin and touch
to continue the job.

Bin # jam A paper jam has occurred in the bin detailed. Touch INCH to clear any
partial sets from the conveyor. If the error persists see the Problem Solving
section of the Operating Manual.

Bin # miscal A feed/sensor error has occurred during the test set. The bin will recali-
brate automatically, but check the very first set for errors.

Bin # miss A miss feed error has occurred on the bin detailed. This means that the
bin did not feed a sheet in the last set. Check and correct the faulty set
and restart the machine. If the error persists see the Problem Solving
section of the Operating Manual.

Bin # Part Reset It is necessary to switch the machine off and then on again after 10
seconds before running another test set. If this problem persists, contact
your local Watkiss service department.

Bin # trailing A trailing feed error has occurred on the bin detailed. This can mean one
of two things:
1) The sheet from this bin was delivered late (trailing single feed)
2) An extra sheet was delivered from this bin, slightly behind the first
sheet (trailing double feed)

If the problem persists see the Problem Solving section of the Operating
Manual.

59
 Message Meaning
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. Restart the machine. If the
problem persists, contact your local Watkiss service department.

Cannot start fold axis chang- The fold axis (size adjustment) of the booklet maker is in the process of
ing adjusting. Wait for the booklet maker to finish before pressing .

Cannot start sheets axis The sheets axis (book thickness adjustment) of the booklet maker is in
changing the process of adjusting. Wait for the booklet maker to finish before
pressing .

Cannot start sidelay under The Stitch-Fold stitch heads are positioned over the bottom of the infeed
stitch head sidelays. Adjust the stitch heads so that they do not activate the safety
sensors.

Cannot start tray empty One of the switched-on bins was empty when was touched. Fill the
bin with paper and touch again.

Cannot start trim axis The trim axis (size adjustment) of the trimmer is in the process of adjusting.
changing Wait for the trimmer to finish before pressing .

Cannot start width axis The width axis (size adjustment) of the booklet maker is in the process
changing of adjusting. Wait for the booklet maker to finish before pressing .

Change feed output to front The collator's base is not set up correctly for the current job. Change the
paper path to feed to the front of the collator.

Change feed output to rear The collator's base is not set up correctly for the current job. Change the
paper path to feed to the rear of the collator.

Check fuse A fuse may have blown in the drive unit. Contact your local Watkiss service
department.

Fuse blown A fuse has blown on the Motor Drive PCB in the drive unit. Contact your
local Watkiss service department.

Fuses blown Fuses have blown on the Motor Drive PCB, in the drive unit. Contact your
local Watkiss service department.

INITIALISING BINS The bins in the collator are being checked. If this message appears
regularly, contact your local Watkiss service department.

Motor Stalled There may be a bad jam causing the conveyor to lock. Clear the jam.
Touch INCH to clear any partial sets from the conveyor. If the collator does
not restart, a fault may have occurred in the drive unit: contact your local
Watkiss service department.

60
Message Meaning
No power to stacker Check that the stacker is plugged into the DigiVAC+

No Response 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.

Output path deflector The paper path has been altered on the collator's base. Select the correct
changed paper path before restarting the job.

Power Fail 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.

Remote stop The Collator has stopped because there is a problem with ancillary
equipment to which it is linked. Clear the problem with this equipment
before restarting the job.

Set size wrong The wrong number of bins are switched on for the job specified in Multiset.
The number of bins switched on must be a multiple of the number of
sheets in a set.

SFT Jam There is a paper jam in the booklet maker. Open the booklet maker and
remove the jam.

SFT stalled There is a bad paper jam in the Stitch-Fold unit, one or more of the stitch
(SFT only) heads is jammed, or a fault has occurred.

Open the Stitch-Fold and clear any paper jams. If this does not work, lift
the perspex lid on the Stitch-Fold and release the drive to the Stitch Heads,
as follows:
• Undo the two star-shaped, orange drive lugs that sit just behind the
wire spools
• Slide each drive lug along the guide, until they are clear of the Stitch
Heads
• Hand-crank the machine to release the jammed Stitch head(s)
• Replace the drive lugs before starting the machine again

If this does not work, contact your local Watkiss service department.

SFT stalled There is a paper jam in the booklet maker. Open the booklet maker and
(BMP/TMP only) remove the jam.

Stacker full The stacker is full of paper. Unload the stacker and touch to continue
the job.

Stacker jam There is a jam in the stacker. Clear the jam before restarting the job.

61
 Message Meaning
Stacker not connected The stacker is not connected to the collator, and a job has been loaded
that requires the stacker to be in place.

Staple head err A fault has occurred in the BookMaster or Rear Corner Stapler. Turn the
mains switch off and then on again. If the problem persists contact your
local Watkiss service department.

Staple head error 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. To select the staple
heads, press the Staple Head Select button on the BookMaster. The
staple head indicator lights on the BookMaster show which heads are
selected.

Staples Low A staple cartridge in the BookMaster or Rear Corner Stapler needs
replacing. Fit a new staple cartridge.

Stitch Guard Open The top cover of the booklet maker is open. Close the cover.

Touch START to clear There may still be paper in the conveyor. Touch to clear the machine
machine before starting a new job.

Tower comms error There has been a communications error between the towers. Check the
interconnection cable between the two towers is fitted correctly. If the
error persists, turn off both machines, wait ten seconds and turn them on
again.

Trim bin full The Trimmer offcut bin is full. Empty the offcut bin.

Trim Guard Open The TrimMaster cover is open and should be closed.

Trim Bin Open The Trimmer offcut bin is not fitted or is not contacting the safety switch.
Fit the offcut bin correctly.

62
 A1 Advanced Functions

There are several advanced functions that can be

selected on the DigiVAC+. These functions should only
be used if the standard adjustments detailed in the pre-
vious chapters fail to give the desired effect.

To access the advanced functions, touch MENU on the

control panel.

USER SETTINGS Touch USER SETTINGS to make general changes to the

collator, such as the display language or screen contrast.

ACCESS LEVEL The control panel has five different access levels:
• Operator
• Supervisor
• Service
• Distributor
• Factory

Touch ACCESS LEVEL and choose the appropriate level

from the menu. The last three levels are protected by
access codes.

The supervisor level provides additional security for lock-

ing saved jobs.

Current Language: Touch one of the flags displayed in order to select the
appropriate language.

LIGHTER Touch LIGHTER to increase the screen’s contrast by one

step. Repeat until the required contrast is obtained.

The greyscale next to the LIGHTER and DARKER buttons

shows the screen’s current setting. The top square is level
with the top of the LIGHTER button, and should always be
invisible because it is white. When the contrast is correctly
set, the square below the white one should be just visible.

DARKER Touch DARKER to decrease the screen’s contrast by one

step. Repeat until the required contrast is obtained.

FEEDER INFO FEEDER INFO shows information about the sheet detec-
tion system of each bin. You only need to refer to this if
you are having feed problems.

Bin: The bin number to which the information relates.

63
 Length: Sheet length as measured by the emitter/sensor
during the test set. Normally zero before the test set has
been completed. A small variation from bin to bin in the
reported sheet size is normal.

Ref: The amount of light passed through the sheet by the

emitter/sensor on the test set. The higher the value, the
less light is passing through the sheet and hence the
thicker (optically) the sheet. This value is updated with a
moving average on every subsequent good feed. The
value range is between 0 and 255.

Power: This will read either "+" or "-" depending on whether

the emitter/sensor is using the high or low power setting
respectively.

Limit: The allowed tolerance on either side of the refer-

ence value for sheet opacity variation.

MACHINE OPTIONS Touch MACHINE OPTIONS to view the general machine

set-up. Some of the settings can be changed, depending
on the current access level.

MEASUREMENT Select MM or INCH as the unit of measurement.

PAUSE TIME Adjusting the PAUSE TIME increases or decreases the

pause time at the end of a batch when PAUSE / SEPARATE
is selected from the BATCH window, or when PAUSE is
selected whilst the machine is running.

INTER TOWER DISTANCE This is an engineer setting for configuring the multi-tower
mode.

NETWORK SETTINGS The network settings need to be correct in order to link

the collator to a computer via the Ethernet connection.
Touch NETWORK SETTINGS to view the collators IP ad-
dress and subnet mask. See the Watkiss GUI Panel
Installation Guide for more information about setting up
a network.

64
 A2 Paper Settings

There are many factors which can affect the paper condi-
tion and feeding performance. Care should be taken to
ensure that paper is correctly stored, printed and cut to
avoid excessive curl. These are the recommended set-
tings for the more common paper conditions.

Bond Paper
Paper Condition Settings Available A5 A4 A3
Side Curl Up Paper Separation Low/Medium/ High Medium Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 2 or 3 2 or 3 2 or 3
Side Curl Down Paper Separation Low/Medium/ High High High High
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 1 2 2
Front Curl Down Paper Separation Low/Medium/ High Medium Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 1 2 2
Front Curl Up Paper Separation Low/Medium/ High Low/ Low/ Low/
Medium Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 2 or 3 2 or 3 2 or 3
Flat Paper Separation Low/Medium/ High Medium Medium Medium/
High
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 1 2 2

*Paper Control Springs 1=Off, 2=On-Light, 3=On-Firm

65
 Art (Glossy) Paper
Paper Condition Settings Available A5 A4 A3
Side Curl Up Paper Separation Low/Medium/ High Low/ Low/ Low
Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 2 or 3 2 or 3 2 or 3
Side Curl Down Paper Separation Low/Medium/ High Medium Medium Low/
Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 1 or 2 2 2
Front Curl Down Paper Separation Low/Medium/ High Medium Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 1 or 2 2 2
Front Curl Up Paper Separation Low/Medium/ High Low Low Low
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 2 or 3 2 or 3 2 or 3

Flat Paper Separation Low/Medium/ High Low/ Low/ Low/

Medium Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 1 or 2 2 2

*Paper Control Springs 1=Off, 2=On-Light, 3=On-Firm

66
Carbonless Paper
Paper Condition Settings Available A5 A4 A3
Side Curl Up Paper Separation Low/Medium/ High Medium/ Medium/ Medium/
High High High
Air Blow Control One on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 2 or 3 2 or 3 2 or 3
Side Curl Down Paper Separation Low/Medium/ High High High Medium/
High
Air Blow Control One on One on Both on
Small Sheet Air Tap Both off One on Both on
Paper Control Springs* 1 2 2
Front Curl Down Paper Separation Low/Medium/ High Medium/ Medium/ Medium/
High High High
Air Blow Control One on One on Both on
Small Sheet Air Tap Both off One on Both on
Paper Control Springs* 1 2 2
Front Curl Up Paper Separation Low/Medium/ High Medium Medium Medium
Air Blow Control One on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 2 or 3 2 or 3 2 or 3

Flat Paper Separation Low/Medium/ High Medium/ Medium/ Medium/

High High High
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 1 2 2

*Paper Control Springs 1=Off, 2=On-Light, 3=On-Firm

67
 Card
Paper Condition Settings Available A5 A4 A3
Side Curl Up Paper Separation Low/Medium/ High Low Low Low
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 3 3 3
Side Curl Down Paper Separation Low/Medium/ High Low/ Low/ Low/
Medium Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 2 2 2
Front Curl Down Paper Separation Low/Medium/ High Low/ Low/ Low/
Medium Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 2 2 2
Front Curl Up Paper Separation Low/Medium/ High Low Low Low
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both off Both on
Paper Control Springs* 3 3 3

Flat Paper Separation Low/Medium/ High Low/ Low/ Low/

Medium Medium Medium
Air Blow Control Both on Both on Both on
Small Sheet Air Tap Both off Both on Both on
Paper Control Springs* 2 2 2

*Paper Control Springs 1=Off, 2=On-Light, 3=On-Firm

68
 A3 Specifications

Intended Use This product is intended for the collation of materials as

specified below

Production Up to 7,200 sets per hour, continuous production

Number of Bins 8 or 12 per tower. 1 or 2 towers.

Bin Capacity Up to 60mm - although bin capacity is irrelevant due to

continuous loading on the run, making the bin capacity
logically unlimited

Sheet Sizes 120 x 200 to 350 x 500mm

Stock Range 50 to 300gsm plus

Detection Electronic detection for miss,double, jam, empty bin and

stacker full

Dimensions
Width: 660mm
Length: 880mm (1220mm with jogger)
Height: 1620mm (8 bins); 1960mm (12 bins)
Weight: 216kg (8 bins) 240kg (8 bins with jogger)
266kg (12 bins) 290kg (12 bins with jogger)

Electrical Adjustable for 190-240V, 50 or 60Hz; single phase, 10

Amp

Noise 75 dB (A)

Operating Conditions 10-35°C at 35-85% relative humidity

Options • Modular 8 or 12 bins - 8 bin machine can be upgraded

to 12 bins
• Multitower configurations
• Programmable 20° offset jogging stacker
• Watkiss BookMaster range of bookletmakers and trim-
mers
• Watkiss Automatic Stitch-Fold and Trim

Production and specifications are subject to operating

conditions. The specified paper thickness figures are
given for guidance only. The actual performance of the

69
 machine will depend on the nature of the paper and
covers used.

In line with a policy of continual improvement, the manu-

facturer reserves the right to alter the materials or speci-
fications of this product at any time without notice.

Radio Frequency This equipment has been tested and found to comply with
Emissions the limits for a Class A digital device, pursuant to part 15
of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when
the equipment is operated in a commercial environment.
This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accord-
ance with the instruction manual, may cause harmful
interference to radio communications. 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.

70
 A4 Declaration of Conformity

Manufacturer’s name Watkiss Automation Limited

Manufacturer’s Watkiss House

Address Blaydon Road
Sandy, Bedfordshire, UK.
SG19 1RZ

Declares that the product

Product Name Watkiss DigiVAC+

Product Number WA/DIG/0020 onwards

Conforms to the following Product Specifica-

tions:
Safety 73/23/EEC and 98/37/EC Council Directive 'on the ap-
proximation of laws of Member States relating to machin-
ery’.
BS EN 60950:1992, A4:1997

EMC 89/336/EEC Council Directive 'on the approximation of

laws of Member States relating to electromagnetic com-
patibility'
EN55022: 1998 Class A
EN55024:1998
EN50082-1: 1992
EN61000-3-2: 2000
EN61000-3-3: 1995 + A1: 2001

M C Watkiss
Technical Director
Watkiss Automation Ltd.

71
 THIS PAGE IS
INTENTIONALLY
BLANK
 Index

A single set 16
access level 63 batch window
adjustments inserts 24
bin 31 bottom 24
adjustments, straight jogger 46 top 24
adjustments, x-jogger 44 number of sets 24
advanced functions 63 oscillate 25
access level 63 pause / separate 25
current language 63 restart batch 25
darker 63 stop 25
feeder info 63 bin adjustments 31
inter tower distance 64 bin controls 31
lighter 63 bin linking 37
machine options 64 bin reloading 37
measurement 64 bins 31–38
network settings 64 bins,switching on 31
pause time 64 bond paper 65
advanced window book thickness 28
detector position booklet making 41
double detection 19
C
tolerance 19
carbonless paper 67
feed clutch 19
card 68
auto 19
clearing paper jams 54
short 20
contrast, screen 63
sheet offset 18
control buttons
stagger 18
end job 13
suction hold 20
help 14
air blow 32
inch 13
air blow (gui) 16
menu 14
air blow control 32
start/stop 12
air tap 32
test set 13
art (glossy) paper 66
control panel 11–30
auto 16, 19
basic operation 11–12
B controls,bin 31
basic window conveyor wheels 53
air blow 16 curled paper 38, 65
oscillate 17
D
prenumber 17
darker 63
preset 17
default template 8
sets per hour
delete 30
auto 16

73
 Index

delivery direction 4 double jog 27

bookletmaking 41 pre jog 27
hand merge 39 stitch delay 27
jogger 43 stitch and fold 27
detector position 19 stitch on fold 27
difficult papers 38 trim 27
double detection 19 fold delay 28
double feed 34 fuse holders 3
double jog 27 fuses 58
E H
end job 13 hand merge 22, 39
endlay 32, 33 help 1, 14
error
I
booklet making 42
inch 13
feed 34, 39
inch->mm 64
hand merge 39
indicators,bin 31
joggers 47
inserts 24
two-tower 52
installation 1
error messages 59
inter tower distance 64
F
J
feed bins 31–38
jams 34
feed clutch 19
jams,clearing 54
feed jams 34
jams,paper 58
feed window
job details 30
hand merge 22
joggers 43–47
mixed feed 22
straight jogger 46
multifeed 21
x-jogger 43
multiset 21
feeder info 63 K
feeders 31–38 key symbol 30
finishing window
L
book thickness 28
language 63
paper size 26
lighter 63
page direction 26
linking bins 37
presets 26
load 30
re-ref 26
load and save window
pre fold jogging 28
delete 30
fold delay 28
job details 30
side jog hold 28
load 30
pre stitch jogging 27
padlock symbol 30

74
 Index

save page direction 26

cancel 29 paper control arm 32
replace 29 paper control guide rods, x-jogger 46
save new 29 paper control springs 32, 35
view of job list 30 paper control tape, x-jogger 44
a->z 30 paper control wheel 45
by use 30 paper jams 58
loading 36 paper separation 32, 34
loading sequence 36 paper settings 65
loading sequence, two-tower 51 paper size 26
loading,bins 36 pause 13
locking jobs 30 pause / separate 25
pause time 64
M
power save 11
machine options 64
pre fold jogging 28
main air filter 55
pre jog 27
mains input 3
pre stitch jogging 27
mains on/off 3, 4
prenumber 17
maintenance 53
preset 17
measurement 64
presets 26
menu 14
problem solving 57
mimic diagram 14
missfeed 34 Q
missfeed,curled paper 38 quick start 7–9
mixed feed 22
R
mm->inch 64
rear outfeed 5
modules 3
reloading 37
multifeed 21
re-ref 26
multiset 21
restart batch 25
N roller uplift 5
network settings 64
S
number of sets 24
safety 1
O save 29
operating the gui screen 7 screen contrast 63
operator maintenance 53 sensor overrange 37
oscillate 17, 25 separation 32, 34
overrange,sensor 37 serial number 3
service 53
P
service interval 53
pack lift 32, 33
sets per hour 16
padlock symbol 30
sheet offset 18

75
 Index

short 20 X
side jog hold 28 x-jogger 43
single set 16 adjustments 44
small sheet 32
small sheet air tap 32
specifications 69
sph 15
springs, paper control 32, 35
stagger 18
start/stop 12
stations 31–38
stitch and fold 27
stitch delay 27
stitch on fold 27
straight jogger 46
adjustments 46
off-line 47
suction hold 20
T
test set 13
tolerance 19
tray extenders 33
trim 27
trouble shooting 57
two-tower digivac+ 49–52
operating the gui screen 50
using both towers 51
using one tower 52
U
units of measurement 64
unlocking jobs 30
user settings 63
V
vibration, x-jogger 44
view of job list 30
voltage 3
W
window system 11

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
Watkiss DigiVAC+ Operating Manual.
Issue 3, June 2004. Part No. 960-721