SAFETY FIRST Your Vario has been designed with safety as a key feature. However, as with all electrical equipment, when removing any covers or changing fuses always first discon- nect the machine from the mains electricity supply by switching off and unplugging the machine.
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Watkiss approved engineer. MAINS INPUT The Mains input for the Vario is on the rear of the drive unit. The collator must be plugged into a mains supply of the correct voltage. Two fuses are fitted next to the Mains input.
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GETTING HELP We are confident that your Vario will give many years of trouble-free production. If you have any queries or prob- lems, in the first instance please refer to the problem solving section in this book.
Operating the touch screen with a sharp object, or with excessive force, will damage the screen. The Vario is controlled by touching buttons on the control panel. Buttons that perform related functions are grouped together in ’windows’. Each window is selected by touch-...
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There are also six ‘control’ buttons along the top of the screen. To display help text about any of the machine’s functions, touch and then touch the required button. HELP 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...
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WITH PAPER to check that there is no paper left in the conveyor INCH from the previous job. Touch to tell the Vario that END JOB 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.
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SlimVAC Bins • Initially set the tray height lever to its mid position • Angle the suction feeder down • Set the corrugation adjustment (on the feeder) to the mid-position Suction Bins • Initially set the edge flick control to the mid position. Stacker Adjust the stacker for paper size.
Control Panel Your Vario 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...
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Start/Stop Test Set Inch/Pause Help Menu End Job Control Buttons Each window contains a group of related buttons Touch the relevant tab to display each window Load & Save Feed Basic Batch Finishing Advanced Main Window Tabs on the Control Panel ‘CONTROL’...
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When the test set icon is highlighted, the collator is ready TEST SET to run a test set. The Vario 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).
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• Flashing green: This bin is selected, but it has run out of paper • Steady red: (Vario is in divert mode). This bin has had a double feed. The machine will continue to run and the error will be displayed for 6 cycles •...
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Errors in other modules are indicated in red. Mimic Diagram Touching resets the set counter to 0. shows the actual production speed of the Vario, in sets per hour. The production speed is affected by paper size, online finishing equipment and the job setup.
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SETS PER HOUR to be set. This is automatically limited according to the machine configuration. Selecting allows the Vario to run at its max- AUTO: AUTO imum production speed according to paper size, online finishing equipment and the job setup.
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If you are running mixed stocks on friction bins, individual air taps on each bin allow the air to be independently controlled. is used if an exact number of sets are required. PRESET PRESET Touch and enter the number of sets required on PRESET the number pad.
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THE ‘ADVANCED’ window allows advanced machine set- ADVANCED WINDOW tings to be altered. These settings may be altered to optimise the quality and productivity of a job. ‘ADVANCED’ Window. alters the drive speed of the conveyor DRIVE SPEED DRIVE SPEED rollers and therefore the speed at which the sheets exit the collator.
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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 Vario and a positive offset when feeding to the front of the Vario.
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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. Touch to set the clutch feed length to the AUTO: AUTO default value of 186.2mm (7.35").
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THE ‘BATCH’ WINDOW window allows sets to be grouped into batch- BATCH es, with an action at the end of each batch (stop, pause, oscillate or insert sheets). ‘BATCH’ Window.
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Touch to enter the number of sets in NUMBER OF SETS NUMBER OF SETS each batch. Entering 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.
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When feeding to the rear 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 bottom of the batch pile, as the backing board for a pad for example. , when selected from the Batch window, off- OSCILLATE OSCILLATE...
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THE ‘FINISHING’ window controls the settings for the book- FINISHING WINDOW let maker and trimmer. ‘FINISHING’ Window. Touch to alter the settings of the booklet PAPER SIZE PAPER SIZE maker and trimmer to suit the input paper size. If you suspect the booklet maker or trimmer RE-REF: adjustment system is not calibrated correctly, touch to re-reference the adjustment axes.
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The position of the stitch and fold can be offset relative STITCH AND FOLD to the centre of the paper. allows this STITCH AND FOLD position to be adjusted up to 20mm in either direction, in increments of 0.2mm. Touching opens a choice of stitch op- STITCH: STITCH...
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Increasing the value will STITCH DELAY: STITCH DELAY 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. window has options to alter the PRE FOLD JOGGING PRE FOLD JOGGING way sets are jogged prior to folding.
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’LOAD & SAVE’ Window. Touch to save the current settings of the Vario and SAVE SAVE its on-line finishing equipment. When the on-screen key- board appears, enter the job name and then touch .
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enter the new job name and then touch CLOSE The original job is unchanged. If the job name is not changed before touching , the job will be saved with the current name, CLOSE suffixed by an asterisk. Touching shows the settings for each saved JOB DETAILS JOB DETAILS job.
Friction Bins Each Vario tower may have any number of Friction feed bins between 1 and 16. Additional bins can be added if required even after the machine has been installed. For operation of Suction and SlimVAC bins please refer to the relevant chapters.
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For on-line booklet making at the rear of a bench top machine, use method 1. When using the Vario rear corner stapler, use method 2, with the corner to be stapled loaded outermost. Tray Extenders For large sheet sizes (over A4, 8 ½ x 11") or when running A4 (A4, 8 ½...
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Loading the Bins Slide the stock into the bin between the sidelays. Push in the sidelays to centralise the paper in the bin and so that they hold the paper securely. Bin Sidelays Switching Bins On & Off Before a test set is produced, individual bins will auto- matically switch on and off as they are loaded and unloaded.
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Moving the lever to its highest position disengages the separator. This position is used for the improved feeding of heavy cardstocks. Tray Pressure Separator Pressure Adjustment Adjustment Tray Pressure Increasing the tray pressure gives the feed wheels greater force on the paper; too much will result in double feeds and increases the possibility of scuffing the paper.
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This will be indicated by the small green light. The Vario outline diagram on the control panel will show a broken line between bins that are linked.
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Particularly heavy or opaque stock such as a straw board backing sheet may cause the bin sensor to go ’over- range’. This means that the sheet is too optically dense for the sensor to ’see’ through it. Double feeds will not be detected but misses, trailing sheets and jams will be detected as normal.
SlimVAC Bins Each Vario tower may have any number of SlimVAC feed bins between 1 and 16. Additional bins can be added if required even after the machine has been installed. For operation of Suction and Friction bins please refer to the individual chapters.
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For on-line booklet making at the rear of a bench top machine, use method 1. When using the Vario rear corner stapler, use method 2, with the corner to be stapled loaded outermost. Tray Extenders For large sheet sizes (over A4, 8 ½ x 11") or when running A4 (A4, 8 ½...
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Incorrect usage may result in either misfeeds or double feeds. 330-351 When the rubber endlay will sit on the tray extender, position it so that ’A’ is underneath the paper stack. 330-351 When the rubber endlay will sit on the bar across the front edge of the bin, position it so that ’B’...
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or when is touched after the machine stops for any reason. Switching Bins On & Off Before a test set is produced, individual bins will auto- matically switch on and off as they are loaded and unloaded. Bins can also be manually selected by pressing the red button alongside the bin.
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types and should be used as a starting point if in doubt for initial running. Feeder Angle The angle between the feeder and the paper can be adjusted to allow the feeding of particularly heavy and/or curled stocks. Adjustment is made using the knob on the left hand side of the suction feeder.
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This will be indicated by the small green light. The Vario outline diagram on the control panel will show a broken line between bins that are linked.
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Paper Condition Recommended Settings Standard Settings • Suction Feeder angled down • Tray height in mid-position • Sheet corrugation in mid-position Heavy or rigid stock Heavy or rigid stock or board may be unable to bend sufficiently to meet the suction feeder in its lower position.
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Paper Condition Recommended Settings Stock curling up The upward curl means the tray height detector will ‘see’ the paper before it is close enough to the feeder. • Raise the tray height to lift the paper stack closer to the feeder. Lightweight porous papers •...
Suction Bins Each Vario tower may have any number of Suction feed bins between 1 and 8. Additional bins can be added if required even after the machine has been installed. For operation of SlimVAC and Friction bins please refer to the individual chapters.
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the front of the machine and run parallel with the manifold. The suckers produce the corrugation in the sheet which ensures effective sheet separation (see x-section below). Whilst doing this, check that all the sucker cups are undamaged and that they are correctly seated (see p.75). Repeat this procedure for all bins.
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For on-line booklet making at the rear of a bench top machine, use method 1. When using the Vario rear corner stapler, use method 2, with the corner to be stapled loaded outermost. Loading the Bins Normally the trays are all in the up position, in order to load the bins they must first be lowered.
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the stack is loaded neatly and square, and then place the magnetic sidelays on all three sides. Make sure that the loaded bins are selected (remember that the bins are automatically selected as you load them, before you run the test set). Set the drive speed to 80%, the air separation to about 30% and the sets per hour to about 2,000.
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loading the Default Template will switch on all loaded bins. Remember that bins cannot be switched on or off when the system is locked (touch if necessary). END JOB SENSOR Sensor overrange is indicated after the test set by a slow OVERRANGE flashing red light on the bin in question.
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will raise the tray height, whilst turning it in the - direction will lower the tray height. Edge Flick Tray Height Switch Blow Nozzles Paper Stack Control Knob (Hidden) Correct Height of Paper Stack in Relation to Blow Nozzles Removing the Outer Edge Flicks Under some circumstances, especially when collating very light weight and flimsy paper, the edges of the sheets may catch on the outer edge flicks and become creased.
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Coated / Carbonless A4 (8½ x 11") Note: Under some conditions plugs may be omitted Porous A4 (8½ x 11") Coated / Carbonless A3 (11 x 17") Porous A3 (11 x 17") Card A3 (11 x 17")
Bench Base Three different bases are available for the Vario, a bench base, an oscillating bench base and a floor base. If your machine is fitted with an oscillating bench base, please refer to Section 7. If your machine is fitted with a floor base, please refer to Section 8.
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Under normal circumstances the sets are delivered to the REAR front of the collator. The sets can also be delivered to the rear into, for example, the Watkiss Vario corner stapler, or into an on-line booklet maker. The stacker tray may...
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also be positioned at the rear, in which case it must be supported by the edge of the work bench. The deflector lever at the front of the stacker base should be pivoted upwards for delivery to the rear, and pivoted downwards for delivery to the front.
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STACKER FULL When the stacker is full the collator will automatically stop SENSOR will be displayed on the control STACKER FULL panel. The sensor only operates when feeding to the front of the collator. PAPER GUIDES There are paper guides at the delivery outfeed both at the front and at the rear of the collator.
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DEFLECTOR STRIP A deflector strip is provided to aid the stacking of large flimsy sheets such as NCR. As flimsy or curly sheets enter the receiving tray they may ride up against the endlay causing an untidy stack. To remedy this, clip the deflector strip to the underside of the grey tube (see above) at the front of the bench base.
Oscillating Bench Base Three different bases are available for the Vario, a bench base, an oscillating bench base and a floor base. If your machine is fitted with a bench base, please refer to Section 6. If your machine is fitted with a floor base, please refer to section 8.
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The sidelays should be positioned so that their outer edge aligns with the inner edge of the guide mark. The dotted lines in the illustration indicate the correct alignment of the sidelay with the guide mark. Sidelay Guide Mark Paper Size Shown here Sidelay and Guide Mark Alignment Important Ensure the sidelay anti-static cables (see p.55) are...
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NON-STANDARD For non-standard paper sizes a different method is re- PAPER SIZES quired. Straight Stacking Take a few sheets of the paper and align them centrally between the guide marks for the next standard size up. Position the sidelays on the base leaving a 5mm (¼”) gap between the inside corner of the sidelay and the paper.
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Paper Guides If the back edge of the paper stack is uneven this may be due to trailing sheets. Identify the bin that is trailing and adjust the feed to remedy the problem. PAPER DELIVERY Paper can be delivered to the front or the rear of the DIRECTION LEVER machine.
Floor Base Three different bases are available for the Vario, a bench base, an oscillating base and a floor base. If your machine is fitted with a bench base, please refer to Section 6. If your machine is fitted with an oscillating bench base, please refer to Section 7.
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Failure to do this will result in damage to the collator. When feeding into a Deep Pile Stacker unit, it is essen- tial that the front feedout conveyor is removed. Please refer to your Watkiss supplier for more information. The divert catch tray should also be removed. Paper Guides...
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Air Blast When stacking large and/or flimsy sheets, such as car- bonless paper, air can be directed into the jogger to aid neat stacking. The volume of air is controlled by an air tap (see p.59). Turning the tap to the right provides more air, and turning to the left reduces the air.
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Front Delivery Rear Delivery Rear Deflector Lever Feeding into a Jogger at the Front Ensure the divert catch tray (B) is fitted correctly. It should hang vertically down between the base back bar and central shaft under the conveyor. Position and set up the jogger in front of the floor base (see photo p.65).
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REAR FEEDOUT The rear feedout conveyor is an option to allow rear CONVEYOR delivery from a floor base into a jogger. (OPTIONAL) Rear Feedout Conveyor Rear Feedout Conveyor and Jogger Feeding to the Rear When delivering to the rear of the floor base, the rear deflector lever should be pushed down so that the fingers (A) deflect the paper to the rear.
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Button Functions : Starts the collator : Stops the collator : Decreases the drive speed : Increases the drive speed : Inches the conveyor The Remote Control handset Note If using the remote control to operate a Stitch Fold unit off-line, the button functions are different.
Joggers There are two types of jogger available for the Vario, the X-Jogger and the Straight Jogger. The X-Jogger straight or offset stacks whilst the Straight Jogger is used when set separation is not required. X-JOGGER Setting Up the Jogger Position the X-Jogger under the collator as shown.
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(Part No. 914-304). Using the Jogger with a Bench Top Vario The X-Jogger cannot be used with a standard bench top base. However, it can be used with an oscillating bench base.
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The Straight Jogger can be interfaced with either a stand- ard or oscillating bench base. In both cases please refer to your Watkiss supplier for more information. The Straight Jogger can be also be used off-line either independently or with any of the Vario bases (see below).
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Jogging Off-line The straight jogger can also be used off-line. Connect the jogger to the mains and switch on both the mains on/off switch and the local control switch.
Rear Corner Stapler The Vario Rear Corner Stapler (RCS) is an optional ac- cessory that may be fitted onto your Vario. This unit fits onto the rear of the collator. Loading the Collator The sheets should be loaded face down and with the top page in the bottom bin.
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For more information about these messages, see p.85. Loading the Staple Cartridge The RCS uses staple cartridges, each holding 5,000 staples. These can be reordered from your Watkiss sup- plier quoting part number 800-020. • Open the access flap and release the red cartridge retaining spring by pushing firmly to the right •...
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• Push the red spring firmly to the left until it clicks into place on the cartridge. It is essential that the cartridge is securely held Red Retaining Clip Each staple cartridge holds 5,000 staples. When it is nearly empty, is displayed on the control Staples Low panel.
Maintenance SERVICE INTERVAL It is recommended that your Vario 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 Vario will benefit from periodic MAINTENANCE cleaning of general accumulations of paper dust, ink etc.
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replacement interval will depend upon the usage level and the type of papers used. Paper Separator • Remove the feed wheel shaft by pushing it to the left against the spring pressure and lifting the right end clear. • Locate the separator and lift it out vertically. •...
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• Replace the shaft. • Select in the win- CLEANING MENU, USER SETTINGS dow and press the red button on the bin controls to turn the feed wheel shaft. Visually check that each wheel runs true. To straighten a wheel, gently hold a flat edge against the wheel whilst it turns.
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• Press and hold the red button on the bin controls to drop the manifold for access. • Whilst continuing to hold the red button, deselect in the window so CLEANING MENU, USER SETTINGS that the manifold remains in the down position. •...
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• Insert the new cable, noose end first, into the hole in the shaft and pull through (note that the entry hole is larger than the exit hole). • Ensure that the cable is wrapped around the shaft to match the cable on the other side of the tray. Fitting the Shear Pin •...
Problem Solving As far as possible the Vario has been designed to be self-explanatory. In most cases problems or errors will be identified on the control panel. The following is a further guideline to help solve any problems. If a problem persists, please call the Watkiss Service Department or your Watkiss Dealer.
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FRICTION FEED PROBLEMS Problem Cause Solution DOUBLE FEEDS Too much tray pressure Reduce by moving handle in by one notch at a time (see p.30) Too little separation pressure Increase by moving the lever down by one notch at a time (see p.29) Insufficient air separation Increase the value of...
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FRICTION FEED PROBLEMS Problem Cause Solution TRAILING FEED Late feeding double sheet Treat as double feed above (On a trailing sheet the machine stops immediately. You need to Slow feeding sheet Treat as miss feed above look carefully to identify which of the following is the cause.
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SLIMVAC FEED PROBLEMS Problem Cause Action MISS FEEDS Not enough air separation Increase the value of AIR BLOW in the window BASIC Too much sheet corrugation Reduce the sheet corrugation (see p.36) The tray is too low Raise the tray height (see p.37) Heavy and/or rigid sheets Raise the angle of the suction feeder (see p.37)
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SUCTION FEED PROBLEMS Problem Cause Action DOUBLE FEEDS Incorrectly positioned sucker Check the positioning of the plugs plugs (see p.41) Porous paper Refer to section on porous paper (see p.44) Too little edge flick Increase the edge flick depth by lowering the control (see p.42) The tray is too high Lower the tray (see p.45)
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The tray is too low Adjust accordingly (see p.45) X-JOGGER PROBLEMS Problem Cause Solution NOT OFFSET STACKING is not available or not Plug X-Jogger into the Vario and OSCILLATE selected in the select in the BASIC BATCH OSCILLATE BASIC...
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REPLACING FUSES Your Vario is fitted with two fuses at the mains input. If either of these fail the machine will not power up. Caution! The Vario system uses double-pole/neutral fusing (ie, two fuses), so when removing any covers or changing...
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Manual. Bin programming error The bins in the collator have not initialised properly. Switch the machine off and then on again. If the problem persists, contact your local Watkiss Service Department. Bin reset An error has occurred in the electronics of the bin detailed. Any number over 16 relates to a module other than a bin.
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The collator's base is not set up correctly for the current job. Change the paper path to feed down. Check fuse A fuse may have blown in the drive unit. Contact your local Watkiss service department. Conveyor Jam A paper jam has occurred in the bottom of the conveyor. Remove the rear guard and clear the jam.
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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.
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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.
Advanced Functions There are several advanced functions that can be selected on the Vario. These functions should only be used if the standard adjustments detailed in the previous chapters fail to give the desired effect. To access the advanced functions, touch...
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INTER TOWER DISTANCE mode. The network settings need to be correct in order to link NETWORK SETTINGS the Vario to a computer via the Ethernet connection. Touch to view the Vario’s IP address NETWORK SETTINGS and subnet mask. See the Watkiss Vario GUI Panel Installation Guide for more information about setting up a network.
Specifications Intended use The Watkiss Vario is intended for the collation of materials as specified below Operating Conditions 10-35°C at 35-85% relative humidity GUI Control Panel Dimensions (W,D,H): 245, 25, 205mm; (3.3 kg), 9.6, 1.0, 8.1"; (7.3 lb) Weights include Control Panel, Cable and CPU...
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Suction Feed Bin Rel. D Configuration: Up to 8 bins per tower Production: Up to 4,000 feeds per hour Capacity: 100mm (4") for stock up to 340mm (13¼") wide 88mm (3½") for stock over 340mm (13¼") wide Sheet Sizes: 130 x 160mm to 364 x 520mm, 5¼ x 6¼" to 14¼ x 20¼" Stock Range: 40 to 300gsm, 11# bond to 110# cover Detection:...
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X-Jogger Production: Straight stacking up to 7,200 sets per hour Offset stacking up to 3,500 sets per hour Capacity: 100mm, 4" Sheet sizes: Straight stacking 130 x 160mm to 364 x 520mm, 5¼ x 6¼" to 14¼ x 20¼" Offset stacking 148 x 210mm to 364 x 520mm, 6 x 8¼" to 14¼...
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 Vario Product Number WA/VAR/2450 onwards (230V versions only) Product Variants Friction Feed Suction Feed...
Index preset 15 access level 91 sets per hour action buttons auto 14 end job 11 single set 14 help 11 batch window inch 10 inserts 20 menu 12 bottom 20 start/stop 10 top 20 test set 11 number of sets 20 advanced functions 91 oscillate 21 access level 91...
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Index difficult papers rear feedout conveyor 63 slimvac 38 remote control 63 suction 44 with deep pile stacker 60 divert 15 with jogger 60, 61, 63 double detection 17 with stitch fold 60, 62 double jog 23 fold delay 24 drive speed 16 friction bins 27–31 adjustments 29–31...
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Index magnetic sidelays 55 language 91 non-standard paper sizes 57 lighter 91 offset stacking 56 load 26 paper guides 57 load and save window problem solving 84 delete 26 scale 55 job details 26 stacking a5 sheets 57 load 26 straight stacking 56 padlock symbol 26 overrange 31, 38, 45...
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67 jogging off-line 68 safety 1 setting up the jogger 66 save 25 using with a bench top vario 67 screen contrast 91 straight stack liner 66 separator pressure, friction bins 80, 81 suckers, suction bins 41, 46, 75, 83 sets per hour 14 suction bins 41–47...
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Index units of measurement 92 unlocking jobs 26 user settings 91 view of job list 26 window system 9 x-jogger 65 jogging adjustment 66 problem solving 84 setting up the jogger 65 straight stack liner 66...
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