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.
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 and press any key on the control panel.
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Friction Bins Take a stack of paper and slide it into the bin between the sliding sidelays. Push in the sidelays to centralise the paper in the bin, they should hold the paper securely. SlimVAC Bins Take a stack of paper and slide it into the bin between the sliding sidelays.
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All Bins Press to switch on all loaded bins. SETUP If required, you can press and hold until it changes SETUP to set the machine to standard settings. SETUP Adjust the stacker for paper size. STARTING THE JOB Press to run the test set. When the test set is complete, press again to run the job.
Control Panel Your Vario will be fitted with either a top or side mounted control panel. The only difference in operation between the two types is that the side mounted panel has an additional quick stop button on the top.
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THE MENU SYSTEM The Vario is controlled via a menu system shown on an LCD display. The display is divided into three main areas. Machine Information 12 Bins 1234 SPH Job : 1 Counter and Message 000264 display TEST SET...
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MENU 2 MENU 1 BATCH MENU MENU MENU ADVANCED MENU Basic Menu Navigation STARTING THE JOB Press , a single set will be collated. Check this and, if needed, another test set may be obtained by pressing . If the set is correct, press again TEST SET to commence the job.
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TEST SET test set. A test set consists of a single feed from each bin that is switched on and loaded. The Vario uses the test set to calibrate the detection system. The test set is not counted by the counter (except when in prenumber mode).
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SPH - tion rate can be varied to suit your application. The initial setting is 3,000 sets per hour. If other Vario ancillary equipment, such as the X-Jogger is on line, the production rate will automatically be limited to suit that piece of equipment.
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: Normally there will be more than one set in PRENUMBER the conveyor at any one time. For pre-numbered work you may want only one set in the conveyor at a time, meaning that each set is delivered to the stacker before the next set is collated.
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Press and hold until it changes to to return SETUP SETUP the Vario to default factory settings. BATCH MENU To enter the batch menu press from Menu 2. BATCH 12 Bins 1234 SPH...
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If you want to use the batch counter press MENU BATCH , enter the number of sets required in each batch SIZE followed by . After the number of sets per batch is chosen one or more of the following actions must be selected to enable batch mode.
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PAUSE onds after each batch. The counter display will flash and an audible beep will be heard. The pause time can be adjusted by a Watkiss approved engineer. : Enters the Multiset mode. Multiset allows mul- MULTISET tiple sets to be loaded and counted .
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For this example you would press MULTISET enter the number of sheets per set. Next enter the size of the batch by pressing , followed by SIZE finally Multiset can also be used as a sheet counter when the number of sheets in the set is entered as .
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MENU 12 Bins 1234 SPH Job : 1 000264 STAGGER OSCILL DIVERT ↓ BATCH PRENUMBER SFT / SETS SETUP SELECT 3000 PRENUMBER BATCH PAUSE DIVERT MULTISET ↑ INSERT STAGGER SHORT Job: 2 JOB + OFFSET 0mm SELECT JOB - : Used to browse the job areas saved in memory. JOB +/- Sets per hour, drive speed, air blast and any selected options, such as prenumber etc., for the job are shown...
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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Switching Bins On & Off When in mode, individual bins can be manually TEST SET switched on and off by pressing the red button alongside the bin. Alternatively press to switch on all loaded SETUP bins. Remember that bins cannot be switched on or off when the system is locked.
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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. The ideal pressure will depend upon the stock in use. Always use the least pressure possible.
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air. Moving the lever towards you so that it is parallel with the sidelay shuts off the air. Air Separation Adjustment Too much air into the side of the stack can cause the paper to skew as it feeds. Any bins that are not being used should have the air tap shut off on the sidelay to preserve overall system air.
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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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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’ is underneath the paper stack and the step is on the bar.
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Switching Bins On & Off When in mode, individual bins can be manually TEST SET switched on and off by pressing the red button alongside the bin. Alternatively press to switch on all loaded SETUP bins. Remember that bins cannot be switched on or off when the system is locked.
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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. Turning the knob one stop in either direction has the effect of raising or lowering the outer edge of the feeder.
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only be enabled when the bins are unlocked i.e. when is shown on the menu. Press the grey button on TEST SET the upper bin to link it with the one below. This will be indicated by the small green light. By pressing the red bin on/off button it is possible to select which bin in the linked group is active (unless in prenum- ber mode).
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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.69). 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. Press to switch on all loaded bins. Set the drive SETUP speed to 80%, the air separation to about 30% and the sets per hour to about 2,000. These settings can be adjusted to suit the job if required.
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SENSOR Sensor overrange is indicated after the test set by a slow OVERRANGE flashing red light on the bin in question. Particularly heavy or opaque stock such as a straw board backing sheet may cause the bin sensor to go ’over- range’.
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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. These can therefore be removed by first pushing the edge flick control lever fully downwards (so the edge flicks are in their outermost position), then slide the edge flick to the right and pull out.
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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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DELIVERING TO THE 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,...
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or into an on-line booklet maker. The stacker tray may 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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Rear Delivery Front Delivery STACKER FULL When the stacker is full the collator will automatically stop SENSOR and the display will show ’Stacker full’. 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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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.49) are connected to the paper tray. STRAIGHT STACKING For straight stacking the appropriate solid guide marks are used for both sidelays.
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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. Offset Stacking For offset stacking, setup as above and then move the right sidelay 25mm (1") to the right whilst keeping it...
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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 essential that the front feedout conveyor is removed. Please refer to your Watkiss supplier for more information. The divert catch tray should also be removed. Air Blast...
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Air should usually be directed at the bottom corner of the stack, but different positioning may be necessary to suit the paper characteristics, curl etc.. A combination of air pipes and connectors are provided to allow optimum positioning. Air Tap Air Pipes and Connectors SETTING THE Rear Deflector Fingers...
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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.59).
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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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• The lid of the stapler unit is open. 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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Red Retaining Clip Each staple cartridge holds 5,000 staples. When it is nearly empty, ’STAPLES LOW’ is displayed on the control panel. This operates from an inbuilt counter, therefore if a staple cartridge is changed when it is only part used, the staple counter will need resetting (see below).
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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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. • Clean or replace the separator as required. When cleaning the separator use only soap and water or alcohol (isopropanol).
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• Replace the shaft. • Select from the advanced menu (See p.86) CLEANING 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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Repairing Overloaded Trays In the event of one of the Suction bin trays becoming severely obstructed or overloaded, there is a safety mech- anism which causes the tray lift cable support shear pins to break. Under certain conditions the cable itself may also break.
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• Insert the shear pin through the noose and gently lower the tray ensuring that the flat side of the pin lies against the bottom of the tray. • Raise the tray and ensure that the cable wraps smooth- ly around the shaft. The cable should wind progres- sively inwards.
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.24) Too little separation pressure Increase by moving the lever down by one notch at a time (see p.23) Insufficient air separation Increase air separation via the...
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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 air separation via the control panel AIR + Too much sheet corrugation Reduce the sheet corrugation (see p.30) The tray is too low Raise the tray height (see p.31) Heavy and/or rigid sheets Raise the angle of the suction feeder (see p.31)
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SUCTION FEED PROBLEMS Problem Cause Action DOUBLE FEEDS Incorrectly positioned sucker Check the positioning of the plugs plugs (see p.35) Porous paper Refer to section on porous paper (see p.38) Too little edge flick Increase the edge flick depth by lowering the control (see p.36) The tray is too high Lower the tray (see p.39)
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Adjust accordingly (see p.39) X-JOGGER PROBLEMS Problem Cause Solution NOT OFFSET STACKING is not available or not Plug X-Jogger into the Vario and OSCILL selected on the control panel select on the control OSCILL panel Stacker is not set up correctly Follow set up instructions (see p.59)
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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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Message Cause Action BIN # JAM A paper jam has occurred in the Clear the jam. Use to clear INCH bin detailed any partial sets from the con- veyor. If the error persists, refer to the troubleshooting chart to remedy the problem BIN # TRAILING A trailing feed error has occurred If the error persists, refer to the...
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If the problem persists contact your local Watkiss serv- ice department Suction: The grey up/down but- Press the grey button on the bin ton has been pressed , sending...
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Bad paper jam in the Stitch Fold Open the stitch fold and clear the unit A fault has occurred in the Stitch Contact your local Watkiss serv- Fold unit ice department One or more of the Stitch Heads Lift the perspex lid on the Stitch...
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If the error persists, turn off both machines, wait ten seconds and turn them on again TRAY LIFT ERROR Blown fuse in drive unit or fault Contact the Watkiss service with tray lifting mechanism department TRIM BIN FULL Trimmer offcut bin is full...
Advanced Menu The Advanced Menu offers additional adjustments to the collator. It’s functions should only be used if the standard adjustments detailed in the previous chapters fail to give the desired effect. To enter the Advanced Menu press and hold when in Menu 1.
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: The standard clutch feed length during the test SHORT set is 186.2mm (7.35"). After the test set the clutch feed length is automatically set to suit the paper size. When feeding small sizes such as A5 (5½ x 8½") landscape selecting gives a clutch length of 126.25mm (4.98") SHORT...
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HOLD MENU MENU OFFSET+ SHORT TRAY FRICTION OFFSET- CLEANING LENGTH SUCTION MENU Length Length Display Navigation Lim : The allowed tolerance on either side of the reference value for sheet opacity variation. Scn : (Suction bins only) This indicates the adjustment that has been made to the timing of each individual bin during the electronic bin synchronisation procedure.
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FRICTION MENU The FRICTION menu is used to adjust certain variables in the feed system of friction bins. Any adjustments shown in brackets may not appear on your machine. HOLD MENU MENU OFFSET+ SHORT TRAY FRICTION OFFSET- CLEANING LENGTH SUCTION MENU SLIP+ FDET+...
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: Friction Detection. The sheet detector FDET + FDET - measures 15.2mm (0.6") in from the feed edge of the sheet and then takes a reading. The edge of particularly dark or solid areas of print in this area can cause detection problems.
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: Displays and adjusts the allowance for SLIP + SLIP - paper slip when detecting feed errors. The detection system allows for a certain amount of sheet slippage at the start of the feed. If too much slip occurs it will be interpreted as a miss.
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 Control Panel Dimensions (W,D,H): Top Mount 515, 80, 184mm; (2kg), 20, 3, 7"; (5lb) Side Mount 265, 48, 245mm; (2kg), 10, 2, 10"; (5lb)
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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 Index conveyor jam 81 advanced menu 19, 85–90 counting sets 11 cleaning 86 friction menu 88 declaration of conformity 95 length display 86 deep pile stacker 54, 56 offset 85 delivery direction 44, 52, 55, 82 short 86 difficult papers suction menu 89 slimvac 32 tray 86...
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Index sensor overrange 25 repairing overloaded trays 70 separator pressure 23 suckers 69 switching bins on & off 23 memory - see ’job memory menu’ tray extenders 22 menu1 12 tray pressure 24 air separation 13 friction menu 88 drive speed 13 clutch 89 end job 12 fdet 89...
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62 rear guard 1 setting up the jogger 60 remote control 57 using with a bench top vario 61 repairing overloaded suction trays 70 straight stack liner 60 rubber endlays, slimvac bins 28 suckers, suction bins 35, 40, 69, 77 suction bins 35–41...
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Index system lock 12 test set 12 tray extenders 22, 28 tray height slimvac bins 31, 75, 76 suction bins 39, 77 tray pressure, friction bins 24, 74 tray, advanced menu 86 troubleshooting 73–83 x-jogger 59 jogging adjustment 60 problem solving 78 setting up the jogger 59 straight stack liner 60...
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