Operating Manual Issue 2

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 CONTENTS
Welcome..............................................1
Quick Start ..........................................5
Control Panel ......................................9
Friction Bins .....................................21
SlimVAC Bins ...................................27
Suction Bins .....................................35
Bench Base.......................................43
Oscillating Bench Base ...................49
Floor Base.........................................53
Joggers .............................................59
Rear Corner Stapler .........................63
Maintenance......................................67
Problem Solving ...............................73
Appendix
Advanced Menu .................................... 85
Specifications ....................................... 91
Declaration of Conformity ..................... 95
Index .................................................97

Issue 2 - Dec 1997 - Part No. 960-321

Issue 1 - Apr 1996 - Part No. 960-301

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 Welcome

Congratulations, you have just purchased the very finest

of collators, the Watkiss Vario. Your Vario has been de-
signed to make collating efficient, productive and above
all, easy.

ABOUT YOUR This operating manual (Issue 2) covers machines fitted

MANUAL with Release C Floor Bases (see below) installed with
Vario application software V7.0 onwards. For machines
fitted with earlier bases please refer to Issue 1.

Release C Floor Base Release A & B Floor Base

The manual has a 'Quick Start' section to get you up and

running quickly. It is then followed by more detail on each
of the modules that make up your machine, and by
problem solving charts and additional notes.

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.

Rear Guard
The rear guard of the collator must be fitted for the
machine to run. A safety switch prevents machine oper-
ation when the guard is removed. When fitting the guard,
ensure that the bar on the top bracket locates correctly
on the hooks under the drive unit. Also ensure the guard’s
bottom bracket locates on the lower conveyor shaft.

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 Emergency Stop
The emergency stop button should only be used when
an immediate stop of the machine is required. Under
normal circumstances the machine should be stopped
by pressing on the control panel. If the emergency
stop button is used, the collator will not restart until the
button has been released by turning clockwise.

Mains ON/OFF Switch

Emergency Stop

INSTALLATION The installation of your Vario requires specialist knowl-

edge and should therefore only be carried out by a
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. If either of the fuses fails the collator will not power
up (see p.79 for details about changing fuses).

Mains Input and Fuses

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

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. Should you require further
assistance, the Watkiss Service Department (UK) or your
local Watkiss supplier will be happy to help.

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 1 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.

CONTROL PANEL On the bottom of the display you will see there are two
rows of control options. These are used by pressing on
the two rows of arrow keys below them. For instance, the
left hand message on the bottom row is INCH . To use this,
press the bottom left arrow key .

Note that when an option or action is selected it is

highlighted (e.g. INCH becomes INCH ).

During normal use the display shows the main menu. By

pressing MENU the second menu is displayed. This con-
tains options for counting, batching etc.. In turn these also
have sub-menus.

For now, simply remember that MENU changes from one

menu to another, and that the two rows of arrow keys allow
you to use the two rows of options shown on the display.

Tip
Pressing and holding SETUP (on menu 2) until it changes to SETUP will automatically
return the control panel to its default factory settings.

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.

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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 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. Push in the sidelays to centralise the
paper in the bin, they should hold the paper securely.
Position the rubber endlay on the tray at the end of the
paper stack. The endlay should be underneath and just
clear of the edge of the paper (by about 1mm, 1/16").

Suction Bins
Switch off any suckers that would be off the edge of the
paper by turning the tap to the left.

Normally the trays are all in the up position, in order to

load the bins they must first be lowered. Starting with the
bottom bin (bin 1), press the grey bin lowering button and
then load the bin, lower bin 2 and load it, lower bin 3 and
load it etc.

Slide the stock into the bin, centralising it between the

two locating pins. Ensure the stack is loaded neatly and
square, and then place the magnetic sidelays on all three
sides.

ADJUSTING THE Friction Bins

MACHINE • Initially set the separation pressure lever (left) to its mid-
position.
• Set the tray pressure to minimum by pushing down on
the lever (right) and releasing it to its innermost position.
If loading large sheets it should be one notch out.

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.

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 All Bins
Press SETUP to switch on all loaded bins.

If required, you can press and hold SETUP until it changes

to SETUP to set the machine to standard settings.

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.

Once the machine is running, adjustments may be nec-

essary depending upon the stock in use. Full details for
each type of feed bin are found in the appropriate chapter.

The machine can be stopped at any time by pressing

.

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 2 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.

The quick stop button immediately stops the collator.

Under normal circumstances use the stop button
on the control panel and allow the system to sequence
down.

Quick Stop Button

LCD Display

Arrow Key
Menu Button

Start Button Keypad

Stop Button

Side Mounted Control Panel

Top Mounted Control Panel

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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

display
000264
Menu TEST SET SPH+ DRIVE+ AIR+
INCH SPH- DRIVE- AIR-

The top line shows machine information including the

number of bins fitted, the collator production rate (in sets
per hour) and the current job area number.

The central area is the set counter and message display.

The lower area is used to access the menu system. The

menu consists of two rows of control options. These are
used by pressing on the two rows of arrow keys below
them. For instance, the left hand message on the bottom
row is INCH . To use this, press the bottom left arrow key .

Note: When an option or action is selected it is

highlighted (e.g. INCH becomes INCH ).

During normal use the display shows the main menu. By

pressing MENU the second menu is displayed. This con-
tains options for counting, batching etc. In turn these also
have sub-menus.

Note: The menu will only show available options,

these will depend on machine configuration.

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 MENU 1 MENU 2

BATCH
MENU

JOB
MENU

SFT
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
TEST SET and . If the set is correct, press again
to commence the job.

COUNTER Press C to clear the counter. When the machine is started

the counter will count upwards.

PRESET COUNTER Alternatively, to collate a preset number of sets, press C

to clear the counter and then enter the number of sets
required using the number keys. When the machine is
started the counter will automatically count down to zero
and the collator will then stop.

DURING THE JOB During the job the control panel will tell you the status of
the machine and the number of sets collated. In addition
it will identify any errors that may occur. The lights beside

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 each bin will also indicate errors. The machine can be
stopped at any time by pressing .

When the job is completed, press END JOB to unlock the

bins. If necessary, the control panel may instruct you to
press to clear the machine ready for the next job.

SYSTEM LOCK Once the test set is completed and accepted by pressing
, the bins are 'security locked' to prevent errors and
accidental button presses. This means that pressing the
buttons on the bin controls will have no effect. To unlock
the bins press and then END JOB .

MENU 1 Menu 1 is used to adjust the basic operating parameters

of the Vario.

12 Bins 1234 SPH Job : 1

000264
END JOB
TEST SET SPH+ DRIVE+ AIR+
INCH SPH- DRIVE- AIR-
Menu 1 Adjustments

TEST SET : When displayed, the collator is ready to run a

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). Press to run a test set.

TEST SET : The test set is complete. Pressing now

will accept the test set and lock the bin settings. If an error
occurs during the test set it will have to be run again.
Correct the problem and press TEST SET , again.

END JOB : Displayed once the test set is accepted. Press

to unlock the bins prior to running a new job.

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 INCH : Press and hold to turn the conveyor. Used for
delivering any sets remaining in the conveyor after a jam
etc.

SPH + and SPH - : Sets per hour adjustment. The produc-

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. (Note: If you have selected PRENUMBER via
Menu 2, the SPH adjustment no longer appears on the
menu. In PRENUMBER mode the SPH and drive speed
adjustments are combined. In this case use DRIVE + and
DRIVE - to control the production rate)

DRIVE + and DRIVE - : The conveyor drive speed may be

adjusted for different paper types. This alters the drive
speed of the rollers and therefore the speed at which the
sheets exit the collator. Certain stocks will stack better if
the drive speed is adjusted to suit. The default factory
setting is 60%.

AIR + and AIR - : This alters the amount of air available for
air separation. As a general rule, the heavier and larger
the sheet, the more air you need. If you are running mixed
stocks, individual air taps on each bin allow the air to be
independently controlled. The default factory setting is
25%. If any SlimVAC bins are fitted and the installed
software is version 6.1h or later the default air setting is
40%.

MENU 2 Press MENU to enter Menu 2

STAGGER : Twin Tower only. When selected, the collated

set from tower B delivers ahead and separately from that
of tower A. This allows better knock up for sets with a lot
of sheets .

BATCH : Enters the batch menu (see below).

OSCILL : Enables oscillation when an oscillating bench

base, X-Jogger or Deep Pile Stacker is fitted.

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 PRENUMBER : Normally there will be more than one set in
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. This minimises the correction required
should an error occur. However, because the sets are
spread further apart, the overall production rate is re-
duced. Also note that in prenumber mode linked bins (see
p.31) cannot be changed over manually.

12 Bins 1234 SPH Job : 1

000264

MENU 1
TEST SET SPH+ DRIVE+ AIR+
INCH SPH- DRIVE- AIR-

MENU

MENU 2
STAGGER OSCILL DIVERT JOB
BATCH PRENUMBER SFT / SETS ↓ SETUP

BATCH MENU SFT MENU JOB MENU

(only if SFT online)

Menu 2 Navigation

DIVERT : Any faulty sets are diverted to the reject tray

without stopping the collator (floor standing models only).
Faulty sets are not counted by the counter. The DIVERT
command is not available when in PRENUMBER mode.

SFT : This is only displayed if a Stitch Fold is online. Press

to enter the SFT menu which is explained in the Stitch
Fold operating manual.

SETS ↓ or SETS ↓ : By default, sets are delivered forwards

and SETS ↓ is displayed. Press to select delivery straight

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 downwards and SETS ↓ will be displayed. (Delivery to the
rear is controlled by the rear deflector lever, see p.55)

JOB : Enters the job memory menu (see p.18).

SETUP : Press once to switch on all loaded bins. Note that

the green light comes on next to each loaded bin, this
means the bin is switched on. (Note. You can manually
switch bins on and off by pushing the red button on each
bin).

Press and hold SETUP until it changes to SETUP to return

the Vario to default factory settings.

BATCH MENU To enter the batch menu press BATCH from Menu 2.

Cumulative Set Total 12 Bins 1234 SPH Job : 1

Number of Complete Batches

000070 0003:00010
END JOB SPH+ DRIVE+ AIR+
Number of Sets to Complete
the Batch INCH SPH- DRIVE- AIR-
Menu 1 Batch Mode

The batch mode allows you to preset the number of sets

required, insert at a chosen interval, or offset the stacker
at a chosen interval.

When in batch mode the main counter display changes

to show from left to right: cumulative set total, the number
of batches completed and the number of sets needed to
complete the batch.

The set counter will count downwards until the batch is

complete. The batch counter will then increase by one.
The cumulative set counter counts upwards showing the
total number of delivered sets. The example above there-
fore shows ten sets left to complete the batch, three
completed batches and seventy total sets.

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 If you want to use the batch counter press MENU , BATCH ,
SIZE , enter the number of sets required in each batch
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.

12 Bins 1234 SPH Job : 1

000264

MENU 1
TEST SET SPH+ DRIVE+ AIR+
INCH SPH- DRIVE- AIR-

MENU

MENU 2
STAGGER OSCILL DIVERT JOB
BATCH PRENUMBER SFT / SETS ↓ SETUP
BATCH MENU

MULTIFEED
STOP INSERT ↑ MULTISET SIZE
OSCILL INSERT ↓ PAUSE
Batch Menu Navigation

STOP : The machine will stop after each batch and the
counter display will flash. To run another batch press
.

OSCILL : Offsets the stack after each batch if an X-Jogger

or Oscillating Bench Base is fitted.

INSERT ↑ : When feeding to the front of the collator, a sheet

will be fed from the top bin with the first set of each batch.

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 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, a sheet will be

fed 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 of a pad for example.

INSERT ↓ : When feeding to the front of the collator, a sheet

will be fed 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.

When feeding to the rear of the collator, a sheet will be

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

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.

PAUSE : the machine will pause for approximately 5 sec-

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.

MULTISET : Enters the Multiset mode. Multiset allows mul-

tiple sets to be loaded and counted.

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

a six bin collator. Normally only one set would be counted
per cycle even though three are being fed at a time. In
this case selecting Multiset 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.

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 For this example you would press MULTISET , 2 and # to
enter the number of sheets per set. Next enter the size of
the batch by pressing SIZE , followed by 5 and 0 and
finally # .

Multiset can also be used as a sheet counter when the

number of sheets in the set is entered as 1 . All the bins
are loaded and the required number of sheets is entered
by pressing SIZE .

MULTIFEED : To enter Multifeed mode, press MULTISET , #

then press and hold MULTISET until it changes to MULTIFEED .
Finally press 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 per set. To change
the Multifeed size, press SIZE , followed by the number of
required feeds and # .

Press and hold MULTIFEED until it changes to MULTISET to

return to Multiset mode.

SIZE : Alters the number of sets per batch

To exit batch mode press BATCH from Menu 2 to enter the

batch menu and deselect the options previously high-
lighted. Press MENU twice to return to Menu 1.

JOB MEMORY MENU To enter the job memory menu press JOB from Menu 2.
To exit the job memory menu without making any changes
press C .

Up to 9 job areas with different collator settings are saved

in the memory. These are retained when the collator is
switched off. The collator always operates in one of the
job areas to determine its settings.

Any changes you make to the collator settings are auto-

matically stored in the current job area. When the collator
is switched on it automatically enters the most recently
used job area.

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 MENU

12 Bins 1234 SPH Job : 1

000264

MENU 2
STAGGER OSCILL DIVERT JOB
BATCH PRENUMBER SFT / SETS ↓ SETUP

SELECT

SPH 3000 PRENUMBER BATCH PAUSE

DRV 60 DIVERT MULTISET
AIR 37 INSERT ↑
STAGGER

JOBS MENU
SHORT
Job: 2 JOB +
OFFSET 0mm SELECT JOB -

JOB +/- : Used to browse the job areas saved in memory.

Sets per hour, drive speed, air blast and any selected
options, such as prenumber etc., for the job are shown
on the left of the display. Any selected batch options, such
as pause etc., for the job are shown on the right of the
display.

SELECT : Press to select the current job shown on the

display and return to the SFT menu.

ADVANCED MENU The Advanced Menu offers additional control over the
collator. Under normal circumstances its functions will not
be needed. Details of the Advanced Menu are included
in Appendix 1.

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 3 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.

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

Red light. . . . . . . . . . . . Indicates a double feed (slow

2 flash indicates the bin sensor is

’overrange’, see p.25)
Yellow light . . . . . . . . . . Indicates a miss feed
Red & yellow lights. . . . Indicate a feed jam or trailing
sheet
Red button . . . . . . . . . . Bin on/off switch
Green light . . . . . . . . . . Indicates the bin is switched on
Green flashing light . . . Indicates the bin is switched
on, but requires loading
Grey button . . . . . . . . . Bin linking switch (see p.25)
Small lower green light. Indicates the bin is linked to the
one below.

LOADING Loading Sequence

There are two loading methods. Which one you use will
depend upon the job in question and whether the sets
are delivered to the front or rear of the machine.

1. Load the sheets face up

and with the first page in
the uppermost bin to
#1
give face up delivery to #2
the rear or face down de- #3
livery to the front.
Load sheets
face up

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 2. Load the sheets face
down and with the first
page in the bottom bin to
#3
give face down delivery #2
to the rear or face up de- #1
livery to the front.
Load sheets
face down

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, 8½ x 11") or when running
A4 (A4, 8½ x 11") portrait it will be necessary to fit tray
extenders to support the sheets.

One B3 (14¼ x 20¼") tray extender is supplied as stand-

ard with each Friction bin.
Tray Extenders
An optional tray extender is available for running A4
portrait (8½ x 11") P/No. 251-303.

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. l

Bin Sidelays

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 Switching Bins On & Off
When in TEST SET mode, individual bins can be manually
switched on and off by pressing the red button alongside
the bin. Alternatively press SETUP to switch on all loaded
bins. Remember that bins cannot be switched on or off
when the system is locked.

ADJUSTMENTS Adjustments for paper type and/or size include control

over the amount of tray pressure and the amount of
separator pressure.

Separator Pressure
Increasing the separator pressure acts like a brake,
making it more difficult for a second sheet of paper to
pass the separator pad. Too little separator pressure will
result in double feeds, too much will result in miss feeds
or damage to the feed edge of the paper.

The ideal separator pressure will depend upon the stock

in use. Initially set the lever to its mid-position. To increase
separation, move the lever downwards one notch at a
time, and to decrease separation move the lever upwards
one notch at a time.

Moving the lever to its highest position disengages the

separator. This position is used for the improved feeding
of heavy cardstocks.

Note
On Friction bins prior to Release F (identified by air taps
on the rear of the bins), this feature is not available. The
separators must be removed to achieve this effect.

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 Separator Pressure Tray 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. The lever has five
positions and is adjusted by gently pushing downwards
whilst sliding the lever in or out. The innermost position
gives minimum pressure. Initially set the pressure to
minimum for small stock. For large sheets (i.e. if tray
extenders are used) initially position the lever one notch
out.

Air Separation
Air directed from the right hand sidelay is used to separate
the top sheets of paper in the stack. The overall air level
is adjusted if required by AIR + and AIR - (see p.13). The
air level is also adjustable on each individual bin via a tap
on the right hand sidelay.

Note
Friction bins prior to Release F also have air separation
on the feed edge of each bin controlled by a tap at the
rear.

The tap on the sidelay controls the air level into the side
of the paper stack. The tap has three positions. The default
position is 90° to the sidelay which provides 100% air.
Moving the lever one notch towards you provides 50%

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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. Remember to open the tap
when the bin is next used.

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
TEST SET is shown on the menu. Press the grey button on
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).

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

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

SENSOR OVERRANGE Sensor overrange is indicated after the test set by a slow
flashing red light on the bin in question.

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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.

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 4 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.

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

Red light. . . . . . . . . . . . Indicates a double feed (slow

2 flash indicates the bin sensor is

’overrange’, see p.32)
Yellow light . . . . . . . . . . Indicates a miss feed
Red & yellow lights. . . . Indicate a feed jam or trailing
sheet
Red button . . . . . . . . . . Bin on/off switch
Green light . . . . . . . . . . Indicates the bin is switched on
Green flashing light . . . Indicates the bin is switched
on, but requires loading
Grey button . . . . . . . . . Bin linking switch (see p.31)
Small lower green light. Indicates the bin is linked to the
one below.

LOADING Loading Sequence

There are two loading methods. Which one you use will
depend upon the job in question and whether the sets
are delivered to the front or rear of the machine.

1. Load the sheets face

up and with the first
page in the uppermost
#1
bin to give face up de- #2
livery to the rear or face #3
down delivery to the
front.
Load sheets
face up

Downloaded from www.dlmanuals.com 27

 2. Load the sheets face
down and with the first
page in the bottom bin
#3
to give face down deliv- #2
ery to the rear or face up #1
delivery to the front.
Load sheets
face down

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, 8½ x 11") or when running
A4 (A4, 8½ x 11") portrait it will be necessary to fit tray
extenders to support the sheets.

One B3 (14¼ x 20¼") tray extender is supplied as stand-

ard with each SlimVAC bin.

Tray Extenders An optional tray extender is available for running A4

portrait (8½ x 11") P/No. 251-303.

Rubber Endlays
Rubber endlays are used to control the paper stack in the
tray. Two different types are supplied with the machine.
It is important that the correct endlay is used in the correct
orientation for the paper size in use. Do not push the
endlay hard up against the edge of the paper stack.
Incorrect usage may result in either misfeeds or double
feeds.

Note
SlimVAC bins prior to serial number 1450 may have been
supplied with only one type of endlay. Your local Watkiss
supplier will be able to supply endlays if required.

P/No. 330-351 Rubber Endlay (VSLM)

P/No. 330-446 Rubber Endlay (VSLM) (small work)

28
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 330-351
When the rubber endlay will sit
B on the tray extender, position it
so that ’A’ is underneath the
paper stack.
A
330-351
When the rubber endlay will sit
on the bar across the front edge
A of the bin, position it so that ’B’ is
underneath the paper stack and
the step is on the bar.
B
Step
330-446
When the rubber endlay will sit
within the bin itself, use the spe-
cial endlay 330-446. Position it
so that ’C’ is underneath the
paper stack.
C

Loading the Bins

Place a full stack of paper between the two sidelays in
the base of the tray. Maximum capacity is achieved when
the paper is slightly below the top of the sidelays. Slide
the sidelays inwards to centralise the paper.

Position the rubber endlays on each tray at the end of the

paper stack. The endlay should be underneath and just
clear of the edge of the paper (by about 1mm, 1/16”).

Note
When collating small sheet sizes, make sure the tray
loaded sensor is not covered by the rubber endlay.

The paper tray raises automatically when the collator

initially starts and thereafter when the tray is loaded. It is
therefore important to load a full stack of paper at a time.
The tray automatically lowers either when the tray is empty
or when is pressed after the machine stops for any
reason.

Downloaded from www.dlmanuals.com 29

 Switching Bins On & Off
When in TEST SET mode, individual bins can be manually
switched on and off by pressing the red button alongside
the bin. Alternatively press SETUP to switch on all loaded
bins. Remember that bins cannot be switched on or off
when the system is locked.

ADJUSTMENTS There are three adjustments to the feed system which

allow the collation of a wide range of papers.

Suction Feeder

Suction Feed Angle

Adjustment

Sheet Corrugation
Adjustment

Sheet Corrugation
The profile of the suction feeder can be adjusted to
provide varying amounts of corrugation in the sheet.
Greater corrugation gives greater separation; less corru-
gation gives less separation.

Adjustment is via the knob on the right hand side of the

suction feeder. The indicator line on the knob shows the
degree of adjustment. The knob is infinitely adjustable
between the limits of its travel. When the indicator line on
the knob is in the fully up position there is no added sheet
separation. The fully down position produces maximum
separation.

In general the heavier the sheet the less added separation

is required. The mid position is suitable for most paper
types and should be used as a starting point if in doubt
for initial running.

30
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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. Continuing to turn the knob will
alternate between the two positions. The default position
is down.

Tray height
The tray height is adjusted via the lever on the SlimVac
bin controls. Moving the lever downwards progressively
lowers the paper tray. This increases the distance be-
tween the top of the paper stack and suction feeder, and
also simultaneously adjusts the flow angle of the air
separation.
Tray height
adjustment
lever The default position for the lever is the mid position which
should be suitable for the majority of stock ranges.

Note
When lowering the tray height, the change will only take
effect the next time the tray raises (i.e. after reloading
or restarting).

RUNNING THE JOB Press SETUP to switch on all loaded bins. Set the drive
speed to 80%, the air separation to about 40% and the
sets per hour to about 2,000. These settings can be
adjusted to suit the job if required. The air should just
separate the top three or four sheets from the stack.

Press to feed a single test set. If the test set is

satisfactory, press again to run the job. When the
job is running satisfactorily, increase the sets per hour if
required.

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

Downloaded from www.dlmanuals.com 31

 only be enabled when the bins are unlocked i.e. when
TEST SET is shown on the menu. Press the grey button on
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).

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

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

SENSOR OVERRANGE Sensor overrange is indicated after the test set by a slow
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’. 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 Whenever feed difficulties are encountered we recom-

mend that you follow two basic guidelines:

• Switch off all the bins except one. This allows you to
concentrate fully on the feed of a single bin.

• Ensure that only one 'remedy' is tried at a time. This

will make it much easier to identify the solution.

The following suggested settings are a recommendation

only. Paper characteristics vary and therefore any partic-
ular stock may require settings different to those shown.

32
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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.

• Raising the angle of the suction feeder re-

duces the feed angle.
• Raise the tray height
Stock curling down

The stock is too close to the feeder for • Lowering the tray height will increase the
air to get in between the sheets. space between the feeder and the sheets.
• If necessary, increase the feeder angle also.

Downloaded from www.dlmanuals.com 33

 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

The feeder may suck through one • Increase sheet corrugation.

sheet and onto the next, resulting in • Lower the tray height to increase the distance
double feeds. between the feeder and the paper stack.

34
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 5 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.

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

Red light. . . . . . . . . . . . Indicates a double feed (slow

2 flash indicates the bin sensor is

’overrange’, see p.39)
Yellow light . . . . . . . . . . Indicates a miss feed
Red & yellow lights. . . . Indicate a feed jam or trailing
sheet
Red button . . . . . . . . . . Bin on/off switch
Green light . . . . . . . . . . Indicates the bin is switched on
Green flashing light . . . Indicates the bin is switched
on, but requires loading
Grey button . . . . . . . . . Tray lowering/raising switch
Small lower green light. Flashes when the tray is in
transit and stays on when the
tray is at the top of its travel.

ADJUSTMENTS Unlike Friction and SlimVAC bins, Suction bin feed ad-
justments should be made before loading the trays with
paper.

Sheet Width
Take a sheet of the stock to be collated and place it in
Closed Open the bin between the two locating pins in the base of the
(off) (on) tray (which should be slid inwards to centralise the paper).
Switch off any suckers that would be off the edge of the
paper by turning the tap to the left. Switch on the remain-
der by turning the tap to the right (so the orange spot is
to the front).

Insert plugs into alternate pairs of suckers, starting from

the centre. The flat edge of the plugs should face towards

Downloaded from www.dlmanuals.com 35

 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.

TOP
Taps

Stock to be Collated

BOTTOM
Plugs

X-Section

PN 310-537, Plastic Mould (VSCN) Manifold Plug Open

PN 310-589, Rubber (VSCN) Manifold Plug Closed

Edge Flick Control

This controls the depth of the edge flick. For most mate-
rials it should be in the mid-position. If more separation
is required (e.g. when the feed edge of the stock is curled
up), increase the depth of the edge flick by moving the
control downwards. If less separation is required (e.g.
heavy card stock), decrease the depth of the edge flick
by moving the control upwards.

Edge Flick
Control

36
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 LOADING Loading Sequence
There are two loading methods. Which one you use will
depend upon the job in question and whether the sets
are delivered to the front or rear of the machine.

1. Load the sheets face

up and with the first
page in the uppermost
bin to give face up de- #1
#2
livery to the rear or face #3
down delivery to the
front.
Load sheets
face up

2. Load the sheets face

down and with the first
page in the bottom bin #3
to give face down deliv- #2
ery to the rear or face #1
up delivery to the front.
Load sheets
face down

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. Starting with the
bottom bin (bin 1), press the grey bin lowering button and
then load the bin, lower bin 2 and load it, lower bin 3 and
load it etc.. In this way the gap between the bins is
maximised and access into the bin is improved.

Unused bins may be lowered for loading during a run by

pressing the grey button.

Slide the stock into the bin, centralising it between the

two locating pins in the base of the bin which should be
slid inwards to meet the edge of the paper stack. Ensure

Downloaded from www.dlmanuals.com 37

 the stack is loaded neatly and square, and then place the
magnetic sidelays on all three sides.

Press SETUP to switch on all loaded bins. Set the drive

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. The air should just
separate the top two or three sheets from the stack whilst
the machine is idling. If necessary the air can be individ-
ually controlled for each bin by using the taps on the rear
of the bins.

Press to feed a single test set. If the test set is

satisfactory press again to run the job. When the
job is running satisfactorily, increase the sets per hour if
required.

Whenever feed difficulties are encountered we always

recommend that you follow two golden rules:

• Switch off all the bins except one and look at only one
bin at a time.
• Ensure that only one 'remedy' is tried at a time. This
will make it much easier to identify the solution.

Porous papers
Porous papers are more inclined to feed doubles as the
suction sucks through one sheet and onto the next. This
can be overcome by checking that the plugs are correctly
inserted (see p.40). Close the tap on any sucker where
an open plug is fitted.

Deformed sheets
Where the sheets are deformed such that the stack has
high and low points, not all suckers will be able to make
contact with the stack. Therefore the taps should be
switched off at either all the 'high spots', or alternatively
at all the ’low spots’.

Switching Bins On & Off

When in TEST SET mode, individual bins can be manually
switched on and off by pressing the red button alongside
the bin. Alternatively press SETUP to switch on all loaded
bins. Remember that bins cannot be switched on or off
when the system is locked.

38
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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’. 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.

ADVANCED Tray Height

ADJUSTMENTS The tray height is factory
set and should be as
shown in the illustration
below. With the tray raised
and the air switched off,
the top of the paper stack
should come up to the bot-
tom edge of the centre
blow nozzle. Note that the
top blow nozzle is plugged
closed but is still visible.

If for any reason the tray

height is out of adjustment,
reliable feeding will not be
achieved and so adjust-
ment will be necessary via
the orange control knob,
as shown alongside. Turning the knob in the + direction
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

Downloaded from www.dlmanuals.com 39

 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
Edge Flick the right and pull out. The control lever should then be
returned to its operating position to allow the inner edge
flicks to function normally. Be sure to replace the edge
flicks on completion of the job.

Spring Steel Edge Flicks

When collating stiff board it may be necessary to remove
the outer edge flicks and to replace the inner ones with
the optional spring steel edge flicks (P/No. 909-985).

Additional Sucker Configurations

Certain stocks may require different sucker/plug config-
Spring Steel Edge Flick urations to those previously detailed.

The following suggested settings are a recommendation

only. Paper characteristics vary and therefore any partic-
ular stock may require settings different to those shown
below.

Coated / Carbonless
A4 (8½ x 11")

Note: Under some conditions plugs may be omitted

Porous A4 (8½ x 11")

40
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 Coated / Carbonless
A3 (11 x 17")

Porous A3 (11 x 17")

Card A3 (11 x 17")

.

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INTENTIONALLY
BLANK

42
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 6 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.

SETTING UP THE Take a few sheets of the stock to be collated and place
STACKER them in the stacker. Move the sliding sidelays in to fit the
width of the sheet.

Using INCH ’park’ the stacker tamper in its forward posi-

tion. Hold the sheets so that the top edge is barely
touching the stacker tamper and then slide the end lay
up to meet the bottom edge of the sheet. Note that the
endlay is reversible to accommodate different paper
sizes.

Stacker Tamper

Sliding Sidelays

Magnetic Lay

End Lay

The Bench Base with A4 (8.5 x 11") Paper

The Bench Base with A3

(11 x 17") Paper.

For small sheet sizes, position the magnetic lays so that

they support the bottom corners of the stack. For large
sheet sizes they should be positioned at an angle along
the sides of the stack so that they guide the sheets and
ensure a neat stack.

Downloaded from www.dlmanuals.com 43

 OFFSET STACKING There are a number of ways in which the collated sets
can be separated in the bench base stacker. The choice
of which method is used will depend upon the collating
task in question.

Sheet Offset Separation

By offsetting a single sheet in the set, the sets can be
efficiently separated without any reduction in speed. Two
offset sidelays are supplied with the straight stacker.
1 2
The bin offset sidelay should be clipped on to the left hand
sidelay of the top bin. This will offset the single sheet. The
1. Stacker Offset Sidelay stacker offset sidelay should be fitted to the left hand
2. Bin Offset Sidelay sliding sidelay in the stacker, by sliding on from the top,
to compensate for the offset sheet.

Use of a Slip Sheet

If the number of sheets in the set means that there is an
unused feed bin, use the bottom bin to feed a slip sheet
as part of the set. A slip sheet is usually a different colour,
or a slightly larger size than the rest of the set to allow
easy separation. Where the job is A4 (or 8½ x 11") in size,
the slip sheet can be fed portrait whilst the remainder of
the job is fed landscape (see below).

Set Offset
If the job is A4 (or 8½ x 11")
size and has only half the
number of sheets as the ma-
chine has feed bins; load
the job twice up, one half
portrait and one half land-
scape. Position the stacker
sidelays as indicated along-
side. This will separate the
sets and double the produc-
tion rate at the same time.
(Note: the portrait set should
be loaded in the lower bins
to ensure good stacking.)

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,

44
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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.

Delivery Direction Lever

Rear Delivery

Front Delivery

On earlier machines there is no lever so the deflector

fingers must be moved from the rear (see below). The
fingers should be pivoted forwards for delivery to the rear,
and pivoted backwards for delivery to the front.

Deflector Fingers

Positioning the Stacker Tray at the Rear

Disconnect the earth connection at the back left of the
tray. Lift the inner edge of the tray firmly upwards to
release it from the mounting bar. Position the tray at the
rear, locating the clips over the mounting bar, and push
down firmly. Connect the earth connection at the back
left of the tray (viewed from the rear of the machine).

Downloaded from www.dlmanuals.com 45

 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.

Their purpose is to cup the set so that the sheets travel

smoothly into the stacker. They can be flipped up or down,
and under normal circumstances should all be down
except EITHER the middle one OR the outermost ones
relative to the sheet size in use. The optimal positioning
will vary with sheet size, direction of grain, paper weight
etc.

Tube

Paper Guides
at the Front

46
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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. The strip should be positioned between one of the
sidelays and the endlay; and should rest on the edge of
the stack, level with the endlay.

Deflector Strip

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 THIS PAGE IS
INTENTIONALLY
BLANK

48
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 7 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.

SETTING UP THE The Scale

STACKER The “L” shaped guide marks on the stacker scale repre-
sent the sidelay positions for various standard paper
sizes. The dark grey coloured scale is for European 'A'
sizes, the red for Imperial sizes and the green for Japa-
nese 'B' sizes. Smaller sizes have two sets of marks
corresponding to either landscape or portrait orientation.

Magnetic Sidelay

Anti-static Cable

Paper Tray

Scale

The Oscillating Bench Base With A4 (8½ x 11) Paper

Align the Sidelays

Position the two magnetic sidelays on the scale using the
appropriate guide marks for the chosen paper. Take into
account the orientation (i.e. portrait or landscape) and
size of the paper.

The sidelays should be positioned so that their outer edge

aligns with the inner edge of the guide mark. The dotted

Downloaded from www.dlmanuals.com 49

 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.

OFFSET STACKING For offset stacking the position of the left sidelay is the
same as for straight stacking. The right sidelay must be
aligned with the corresponding unfilled guide mark on the
right side of the stacker tray.

Press MENU and then OSCILL on the control panel to enable

the oscillating function. Batch offsetting is also available
from the control panel by pressing MENU , BATCH and then
OSCILL .

The sidelays' position can be adjusted during initial col-

lating if necessary to ensure neat stacking.

NON-STANDARD For non-standard paper sizes a different method is re-

PAPER SIZES quired.

50
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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
aligned with the bottom edge of the paper.

As before, the sidelays' position can be adjusted after

initial collating to ensure neat stacking.

25mm (1")

Offset Stacking Sidelay Positioning

STACKING A5 It is recommended that A5 (6 x 8½") sheets are stacked

SHEETS in landscape orientation whenever possible as this will
give better results.

PAPER GUIDES The purpose of the paper guides is to make the paper
rigid in order for the sheets to travel smoothly into the
stacker. They can be flipped up or down, and under
normal circumstances should all be down except EITHER
the middle one OR the outermost ones relative to the sheet
size (the optimal positioning will vary with sheet size,
direction of grain, paper weight etc.).

Downloaded from www.dlmanuals.com 51

 Paper
Guides

Tip
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. The direction is selected using the paper deliv-
ery direction lever. This has three positions, the top
position delivers paper to the oscillating tray. The bottom
position delivers paper to the rear of the collator, into a
jogger for example. The middle position is currently not
used but would deliver the set vertically downwards.

Delivery Direction Lever

Front Delivery

Downwards Delivery
(currently not used)

Rear Delivery

52
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 8 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.

The floor base is required to operate the Stitch-Fold and

Deep Pile Stacker modules. The floor base must be used
with a jogger or one of the above modules as it does not
have an integral stacker.

Front Feedout Remote

Conveyor Release Control
Lever Socket
Air Tap
Front Feedout
Conveyor
Air Blast
Supply
Paper Guides
Divert Catch
Tray

The Floor Base

Interface Sockets
The interface sockets are located on the right underside
of the floor base, below the front air control (see diagram
below). There are four sockets in all. One each for the
Deep Pile Stacker, Stitch-Fold, Twin Tower Link/Inline
Tower Link and jogger. Each type of socket will only
accept the correct interface cable.

Downloaded from www.dlmanuals.com 53

 Deep Pile
Stacker

Stitch-Fold
Twin/In-line
Tower Link

Jogger

SETTING UP THE Front Feedout Conveyor

FLOOR BASE The front feedout conveyor has two positions, raised or
lowered. It is secured in its raised position by a lever at
the front of the base (see photo p.53). To lower, simply
turn the lever clockwise. To raise, lift the conveyor up and
turn the lever anti-clockwise.

When feeding into a jogger the front feed out conveyor

should be in its lower position (see photo p.53).

When feeding into a Stitch Fold unit it is essential that

the conveyor is in its upper (horizontal) position. All the
paper guides, located between the two shafts on the front
underside of the conveyor, should also be pushed up.
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
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.53).

Turning the tap to the right provides more air, and turning
to the left reduces the air. When not using the jogger,
ensure that the tap is turned off (fully left) to preserve
system air.

54
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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

PAPER PATH The rear deflector fingers allow you to determine if sets
are delivered to the front or the rear of the machine. They
are located at the rear of the floor base and can be pivoted
forwards or backwards via a lever to alter the paper path.

When feeding to the front of the machine, paper exits the

floor base either forwards or straight down. The paper
path is adjusted automatically depending on whether you
are feeding into a Jogger, Deep Pile Stacker or Stitch-
Fold. If required this can be over-ridden using SETS ↓ (see
p.14).

Front Delivery

Rear Delivery

Rear Deflector Lever

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 Feeding into a Jogger at the Front
Ensure the divert catch tray (B) is fitted correctly. It should
A
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).
B

Push the rear deflector lever up to move the rear deflector

fingers (A) out of the paper path which is shown by the
dotted line.
Feeding into a Jogger at the Front
Selecting DIVERT from Menu 2 on the control panel will
divert any faulty sets into the catch tray (B).

Feeding into a Stitch Fold

Push the rear deflector lever up to move the rear deflector
fingers (A) out of the paper path which is shown by the
A dotted line.
B
Selecting DIVERT from Menu 2 on the control panel will
now divert any faulty sets onto the top of the Stitch-Fold
unit (B).

Feeding into a Stitch Fold

56
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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
A deflector lever should be pushed down so that the fingers
(A) deflect the paper to the rear.

When delivering to the rear the DIVERT function is not

available. If the collator stops because of a miss or double
feed the set with the error(s) will be on the top of the stack.
Feeding to the Rear

PAPER JAMS If a paper jam occurs in the base, the drive mechanism
is automatically disengaged. If required, remove the rear
guard and/or Stitch-Fold etc. and remove any jammed
sheets. Replace the rear guard and press to con-
tinue the job.

REMOTE CONTROL The remote control handset (supplied with the Stitch-Fold
(OPTIONAL) unit and also available separately P/N 42-260) can be
used to control certain functions on floor standing Varios.

The remote control interface socket is located on the front

of the base on the right hand side.

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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. See the Stitch
Fold operating manual for details

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 9 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. Con-
nect the jogger to the mains supply and switch on.

Plug the jogger into the socket on the underside of the

floor base via the interconnection cable. The cable will
only fit in to one of the sockets (see p.53).

Take a few sheets of the stock 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.
The X-Jogger with A3 (11 x 17")
Paper 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.

Stacker Air Blast

Width Adjustment
X

X
Support Post

Bottom Sidelay
Adjustment

The X-Jogger with A4 (8½ x 11") Paper

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 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.

Adjust the position of the X-Jogger itself. Slide it further

in or out so that the back edge of the stack is level with
the outfeed of the collator.

Adjust the direction of the air blast towards the bottom

edge of the stack, using a combination of air pipes and
connectors to suit the paper size.

Select OSCILL (if required) from the control panel menu

and run a test set.

If needed, fine adjust the position of the sidelays, support

posts and air blast to achieve a neat stack.

Jogging Adjustment
If necessary, adjust the amount of vibration via the knob
on the top of the motor housing (just above the mains On/
Off switch). Use the minimum amount of vibration that will
successfully jog the stack.

Straight Stack Liner

A Straight Stack Liner is available for the X-Jogger to
increase straight stacking performance, especially when
collating carbonless paper (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. Please refer to your Watkiss supplier for more
information.

STRAIGHT JOGGER Setting up the Jogger

Wheel the Straight Jogger into a central position under
the collator (as shown in the diagram for the X-Jogger
p.59). Ensure the local control switch is in the off position
(green strip not visible). Connect the jogger to the mains
supply and turn on the red mains on/off switch.

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 Plug the jogger into the socket on the underside of the
floor base via the interconnection cable. The cable will
only fit in one of the sockets (see p.53).

Adjust the direction of the air blast towards the bottom

edge of the stack. For large sheet sizes it will be necessary
to use the extension tubes.

Mains On/Off Local Control

Switch Switch

Jogging
Mains Input
Adjustment

Straight Jogger Fed From the Rear

of a Floor Base

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

jogger. Wheel 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.

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

Using the Jogger with a Bench Top Vario

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.

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 10 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. The corner to be stapled should
be loaded outermost.

Adjusting the RCS

• Take a sheet of paper the same size as that to be
stapled.
• With the top hinged cover closed, adjust the infeed
sidelays for the sheet width by turning the hand-wheel
so that the sidelays correspond to the appropriate point
on the scale.

Top knock

Infeed Sidelay Scale

Infeed Sidelays

Infeed Sidelay
Adjustment

RCS Bypass Lever

• Open the top hinged cover of the corner stapler, this

will cause the sidelays to move to their inner position.
Insert the sheet between the sidelays and make any
fine adjustments required. The sidelays must tidy the
set, yet still allow the sheets to fall freely between them.
• In the orientation in which it is to be stapled, stand the
sheet inside the RCS so that it is resting on the small
rollers. Adjust the top knock by sliding it up or down
so that it is approximately 5mm clear of the edge of the
sheet.

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 • Ensure that the RCS bypass lever is in the down
position (In the up position sets will still be delivered to
the rear of the collator, but will feed out below the RCS).

Adjusting the Collator

Move the set divert lever to the upper position (for delivery
to the rear).

Error Messages
Error messages will be shown on the display (see p.79)
for any of the following reasons :

• There is a paper jam in the stapler.

• There is a problem with the staple head.
• The staple cartridge is nearly finished.
• 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.
• Pull out the used cartridge.
• Prepare the new cartridge by pulling out a small amount
of staple strip, and tearing off along the tear line.
• Insert the new cartridge pushing it firmly into place.
• 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.

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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).

Resetting the Staple Counter

Remove the side cover from the machine by releasing the
securing screw, located in the centre, bottom inside edge
of the cover, and then lifting the cover up and away. Press
and hold the manual feed button whilst the stapler triggers
and continue to hold until the red light goes out.

Manual Feed Button

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 11 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.
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 upon the usage level and stock character-
istics.

Conveyor
Wheel

• Remove the rear guard by lifting up and out.

• Turn the black conveyor wheels by hand whilst clean-
ing with a cloth dampened with soapy water.

FRICTION FEED BINS Paper Separators (P/No 909-485)

There is one paper separator located in the centre of each
friction feed bin. It slots into the aluminium pick-up man-
ifold immediately beneath the central feed wheel. They
should be cleaned if dirty and replaced when worn. The
replacement interval will depend upon the usage level
and the type of papers used.

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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). Refit the separator and ensure
that it seats firmly in the correct position.
• Refit the feed wheel shaft.

Feed Wheels (P/No. 330-301)

The friction feed bins are fitted with three feed wheels (B)
mounted on a shaft. They should be cleaned if dirty and
replaced when worn. The replacement interval will de-
pend upon the usage level and the type of papers used.
B
• Remove the feed wheel shaft by pushing it to the left
against the spring pressure and lifting the right end
clear. Clean the wheels using only soap and water or
alcohol (isopropanol).
• If the wheels need to be replaced, grasp the shaft firmly
and slide off each wheel (this will be eased by wetting
the shaft slightly).
• Ensure the shaft is clean, and slide on each new wheel,
ensuring that the wheels align with the correct marks
on the shaft. The standard position for the wheels is
shown below.

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 • Replace the shaft.
• Select CLEANING from the advanced menu (See p.86)
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.

Important
Do not use any of the following chemicals to clean the
separators, 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. trichloroethyl-
ene, perchloroethylene genclenes.

All of these chemicals will damage the separators, feed

wheels and conveyor wheels to a varying degree
resulting in poor performance and premature failure.

SUCTION FEED BINS Suckers (P/No. 330-035)

In the event that unexplained misfeeds are occurring it is
possible that the sucker cups have become worn or
damaged and should be replaced. The frequency will
depend upon the usage of the machine and the type of
material being collated.

• Select CLEANING from the advanced menu (see p.86).

• Press and hold the red button on the bin controls to
drop the manifold for access.
• Whilst continuing to hold the red button, press CLEANING
again so that the manifold remains in the down position.
Suction Manifold Showing Correct • Remove the sucker cups, inspect, and replace any that
Sucker Fitment appear worn, either evenly or on one side, or are
damaged. When replacing, ensure the suckers are
correctly seated on the manifold.
• Select CLEANING again and press the red button to return
the manifold to its original position.

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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. This is intentional and is designed to prevent
injury to the operator or damage to the machine. Refitting
either of these parts is simple and is explained below.

Shaft

Tray Lift Cable

Tray

Shear Pin

Noose

Fitting the Cable

• Ensure that the tray is fully down.
• Remove the existing cable by unthreading it from the
hole in the shaft.
• 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

• Open the noose in the end of the cable and then, lifting
the tray with one hand, pass the cable through the hole
in the tray.

70
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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.

Part NoDescription
370-203 Tray Lifting Cable (VSCN)
310-444 PL Mould (VSCN) Lift Wire Shear Pin

Note
Two spare shear pins are supplied with each new
suction bin and two spare tray lifting cables are sup-
plied with each new machine

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72
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 12 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.

GENERAL PROBLEMS
Problem Cause Solution
THE MACHINE WILL NOT The machine is not plugged in Plug in and switch on
POWER UP
Faulty fuse Check the fuse at the mains input
and replace if necessary (see p.79)

THE MACHINE WILL NOT START Several possible causes, exact Correct any faults shown on the
cause will be shown on the display display

TOP AND/OR BOTTOM BIN Batch insert selected from batch Press MENU and then BATCH .
ONLY FEEDS ON TEST SET menu Check to see if INSERT ↑ or
INSERT ↓ is selected. If so, deselect

DOUBLE FEEDS ARE NOT The bin sensor is ’overrange’ due N/A
BEING DETECTED to the feeding of particularly heavy
or opaque stock. The red light on
the bin controls will flash slowly
when the sensor is overrange

DOUBLE/MISS FEEDS ARE NOT The diverter fingers in the floor Realign the fingers so that they can
BEING DIVERTED base are jammed on the paper move freely
guides

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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

control panel AIR +

Worn or missing separators Check separators are present,

and replace if worn (see p.67)

Bad guillotine burr, or blunt drill- Fan the stock by hand before
ing loading, ensure paper is cut well
next time

Miscalibration during the test set Run another test set by pressing
END JOB , TEST SET ,

MISS FEEDS Too little tray pressure Increase by pulling the handle out
by one notch at a time (see p.24)

Too much separation pressure Reduce by moving the lever up

by one notch at a time (see p.23)

Untidy loading Reload the bins tidily, ensuring

the paper stack is underneath the
feed wheels and under the
guides

Worn feed wheels Check and replace the feed

wheels if necessary (see p.68)

Miscalibration during the test set Run another test set by pressing
END JOB , TEST SET , . It
may be necessary to increase the
tray pressure to obtain a better
feed

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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. The Slow feeding during test set Run another test set by pressing
faulty set can be inched through causing incorrect calibration END JOB , TEST SET , . It
by pressing and holding INCH ) may be necessary to increase the
tray pressure to obtain a better
feed

PAPER JAM Sheet is jammed in the paper Locate the sheet and either pull
path it out or INCH it through

Sheet is only half feeding Treat as miss feed above

Feeding A5 (5½ x 8½") land- Select SHORT (see p.86) from

scape without selecting SHORT the advanced menu and run
from the advanced menu another test set by pressing
END JOB , TEST SET , .

FRONT EDGE OF SHEET Too much separation pressure Reduce by moving the lever up
DAMAGED by one notch at a time (see p.23)

SLIMVAC FEED PROBLEMS

Problem Cause Action

DOUBLE FEEDS The tray is too high Lower the tray height (see p.31)

Not enough corrugation on suc- Increase sheet corrugation (see

tion feeder p.30)

Mechanical paper problem - Fan stock by hand before load-

guillotine burr, sticky ink, poor ing, and ensure these problems
perforations, high static charge are avoided in future
etc.

Rubber endlay is incorrect type Use correct type and positioning

or position (see p.29)

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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)

Paper has curly edge Refer to recommended settings

(see p.34)

Rubber endlay is too tight Position the endlay approx.

against the paper stack, or is 1mm (1/16”) clear of the edge of
incorrect type the stack. Ensure it is the correct
type for the paper size (see
p.29)

TRAILING FEED Trailing double feed Treat as a double feed

(On a trailing sheet the machine
stops immediately. You need to Trailing single feed Treat as a miss feed
look carefully to identify which of
the following is the cause. The
faulty set can be inched through
by pressing and holding INCH )

PAPER JAM Sheet is pre-feeding Treat as a double feed

Sheet is miss feeding Treat as a miss feed

FRONT EDGE OF SHEET Too much sheet corrugation Reduce the sheet corrugation
DAMAGED (see p.30)

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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)

MISS FEEDS The edge flick is set too deep Reduce the edge flick depth by
raising the control (see p.36)

Sucker cups are damaged or Check and replace/refit any

are incorrectly seated faulty sucker cups (see p.69)

Insufficient suction for heavy/ Remove the plugs from all suck-
thick stock ers

Tray is too low Adjust the tray height accord-

ingly (see p.39)

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. The Slow feeding during test set Run another test set by pressing
faulty set can be inched through causing incorrect calibration END JOB , TEST SET , .
by pressing and holding INCH )

PAPER JAM Sheet is jammed in the paper Locate the sheet and either pull
path it out or INCH it through

Sheet is only half feeding Treat as miss feed above

CREASED CORNERS Soft paper is being 'sucked up' Fit open plugs to the outer most
into the sucker suckers on the sheet (PN 310-
537, Plastic Mould (VSCN) Man-
ifold plug open)

The corners of the sheet are Remove the outer edge flicks
catching on the outer edge flicks (see p.40)

’BIN OVERLOAD' MESSAGE An obstruction in the bin is pre- Check and remove any obstruc-
AND SMALL GREEN LIGHT IS venting it from lifting correctly tions. It may be that the stock has
BLIPPING (• • • •) not been pushed fully forward
into the bin

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 SUCTION FEED PROBLEMS
Problem Cause Action
’BIN # LIFT ERROR' Too much paper has been loaded Remove the stock and reload a
MESSAGE AND SMALL into the bin (note that the grey smaller quantity:
GREEN LIGHT IS FLASHING button will not raise or lower the
QUICKLY (• • • •) tray) Sheet Size to: Max Load
340x520mm 100mm
13¼"x20¼" 4"
364x520mm 88mm
14¼"x20¼" 3¾"

An obstruction in the bin has pre- Remove any obstructions and

vented the tray from lowering cor- then press the grey button, the
rectly. This has caused the tray tray lift cable will automatically
lift cable to reverse-wrap and correct itself
raise the tray again

The tray is too low Adjust accordingly (see p.39)

X-JOGGER PROBLEMS

Problem Cause Solution

NOT OFFSET STACKING OSCILL is not available or not Plug X-Jogger into the Vario and
selected on the control panel select OSCILL on the control
panel

Stacker is not set up correctly Follow set up instructions (see

p.59)

Poor set delivery Adjust drive speed to suit the

stock and if necessary adjust the
paper guides

OSCILLATING BASE PROBLEMS

Problem Cause Solution
NOT OFFSET STACKING OSCILL is not selected on the Select OSCILL on the control
control panel panel

An obstruction is stopping the Remove obstruction

tray from moving

The sidelays are too tight Readjust the sidelays

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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
fuses always first disconnect the machine from the
mains electricity supply by switching off and unplug-
ging the machine

• Unplug the mains input lead and open the flap on the
fuse holder.
• Pull out each fuse casing in turn and check the fuse.
• Replace if necessary with a fuse of the correct speci-
fication, as detailed below.

Reference
240V machines:
730-018 Fuse, 1½" (32mm) 7.0A HRC (Quick Acting, F)

115V machines:
730-020 Fuse, 1½" (32mm) 10.0A HRC (Quick Acting, F)

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 Cause Action

BIN # RESET An error has occurred in the Press any key to restart the
electronics of the bin detailed. machine. If the problem persists,
Any number over 16 relates to a contact your local Watkiss serv-
module other than a bin ice department

BIN # DOUBLE A double feed error has occurred If the error persists, refer to the
on the bin detailed troubleshooting chart to remedy
the problem

BIN # MISS A miss feed error has occurred If the error persists, refer to the
on the bin detailed troubleshooting chart to remedy
the problem

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 Message Cause Action
BIN # JAM A paper jam has occurred in the Clear the jam. Use INCH to clear
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
on the bin detailed troubleshooting chart to remedy
the problem

BIN # EMPTY The paper tray of the bin detailed Reload the bin and press
is empty to continue the job

BIN # LIFT ERROR Too much paper has been loaded Remove the stock and reload a
(Suction only) into the bin (note that the grey smaller quantity:
button will not raise or lower the
tray) Sheet Size to: Max Load
340x520mm 100mm
13¼"x20¼" 4"
364x520mm 88mm
14¼"x20¼" 3¾"

BIN # MISCAL A feed/sensor error has occurred Recalibration is automatic but

during the test set check the very first set for errors

BIN # OVERLOAD An obstruction in the bin is pre- Check and remove any obstruc-
(Suction only) venting it from lifting correctly tions. It may be that the stock has
not been pushed fully forward
into the bin

BIN # PART RESET An error has occurred in the elec- Press END JOB and switch on
tronics of the bin detailed. the affected bin via the red button
on the bin controls. Press
TEST SET and then to
continue the job

CANNOT START SFT CHANG- Automatic Stitch-Fold is in the Wait for the ASF to finish adjust-
ING AXIS process of adjusting axes ing before pressing

CANNOT START SIDELAY Automatic Stitch-Fold stitch Adjust the stitch heads so that
OVER STITCH heads are adjusted over the bot- they do not activate the safety
tom of the infeed sidelays. Sen- sensors
sors prevent the ASF from
stitching if this happens in order
to prevent damage to both the
head and the sidelay

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 Message Cause Action
CANNOT START TRAY DOWN SlimVAC: During the start up Check that the tray is not
sequence one of the trays has not obstructed and press
raised to the running position again. 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 controls to raise the tray and
the tray to its down position press again

CANNOT START TRAY EMPTY One of the switched on bins was Fill the bin with paper and press
empty when was pressed again

CHECK FUSE F# Possible blown fuse in the drive Contact your local Watkiss serv-
unit ice department

CONVEYOR JAM A paper jam has occurred in the Remove the rear guard. Clear the
bottom of the conveyor jam. Use INCH to clear any partial
sets from the conveyor

EMERGENCY STOP The emergency stop button has Turn the emergency stop button
been pressed clockwise to disengage

ERROR ON 9V RAIL The mains voltage is either too Check the mains voltage and
high or low and has caused an connections
error.

An error has occurred in the drive Contact your local Watkiss serv-
unit ice department

FUSE(S) BLOWN Blown fuse(s) on the Motor Drive Contact your local Watkiss serv-
PCB in the drive unit ice department

MOTOR STALLED Bad paper jam causing the con- Clear the jam. Use INCH to clear
veyor to lock any partial sets from the con-
veyor and then restart the collator

A fault has occurred in the drive Contact your local Watkiss serv-
unit ice department

NO POWER TO STACKER The jogger is not connected to Connect the jogger to the mains
the mains or is not switched on supply and/or switch on

NO ZEROX or SLOW ZEROX A fault has occurred in the drive Contact your local Watkiss serv-
unit ice department

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 Message Cause Action
NOISY ZEROX Interference from the mains sup- Connect the collator directly to
ply or other nearby equipment is the mains outlet i.e. not via a
causing a problem multiway adapter

The mains supply connection is Check the connection

faulty

POWER FAIL The mains supply has been inter- Switch the collator off and on
rupted again

REAR COVER OPEN The rear cover/guard is not fitted Check the rear cover/guard is fit-
or is not fitted correctly ted and is actuating the safety
switch correctly

REAR DEFLECTOR CHANGED Either the delivery direction lever Move the delivery direction lever/
or the rear divert fingers have divert fingers back to their original
been moved whilst the machine position. Only change the posi-
is locked tion of the lever once END JOB
has been pressed

SFT JAM Paper jam in the Stitch Fold unit Open the stitch fold and clear the
jam

SFT STALLED Bad paper jam in the Stitch Fold Open the stitch fold and clear the
unit jam

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
is jammed Fold and release the drive to the
Stitch Heads

STACKER FULL The stacker is full of paper Unload the stacker and press
to continue the job

STACKER NOT CONNECTED The jogger is not connected to Check the connection
the collator

Oscillate or batch oscillate func- Deselect oscillate function from

tion is selected from the control the control panel
panel menu and the jogger has
been disconnected

STAPLE HEAD ERR A fault has occurred in the Rear Contact your local Watkiss serv-
Corner Stapler ice department

STAPLER GUARD OPEN The top cover of the Rear Corner Close the cover
Stapler is open

82
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 Message Cause Action
STAPLER JAM Paper jam in the Rear Corner Lift the top cover and clear the
Stapler jam

STAPLES LOW The Rear Corner Stapler staple Refer to the Rear Corner Stapler
cartridge needs replacing operating instructions and fit a
new staple cartridge

STITCH GUARD OPEN The top cover of the Stitch Fold Close the cover
is open

TOWER COMMS ERROR Communications error between Check the interconnection cable
the towers in a twin tower system between the two towers is fitted
correctly

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 Empty the bin

TRIM GUARD OPEN Trimmer offcut bin is not fitted or Fit the offcut bin correctly
is not contacting the safety switch

2XDIVERT Two successive diverts (i.e. two Check the feed of the bin
errors) from the same bin

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84
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 A1 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 MENU when in Menu 1.

HOLD
MENU

MENU

OFFSET+ SHORT TRAY FRICTION

OFFSET- CLEANING LENGTH SUCTION

MENU MENU

SLIP+ FDET+ CLUTCH+ SLIP+ SDET+ HOLD+

SLIP- FDET- CLUTCH- SLIP- SDET- HOLD-

Advanced Menu Navigation

OFFSET + and OFFSET - : Normally the sheets in a set exit

the collator with their edges level. Sheet offset shales the
sheets as they exit. This can assist the neat stacking of
thick sheets or large sets into a jogger. A small offset can
also assist Stitch/Fold Trim knock up. The range of offset
is +/- 29.45mm and effects all bins. If an offset is required,
it is usual for the bottom sheet of the set to enter the stacker
first.

Set Delivery to the Front Set Delivery to the rear

Positive Offset The bottom sheet of the set (i.e The top sheet of the set (i.e from
i.e. OFFSET + from the uppermost bin) will enter the uppermost bin) will enter the
the stacker first. stacker first.

Negative Offset The top sheet of the set (i.e from The bottom sheet of the set (i.e
i.e. OFFSET - the lowermost bin) will enter the from the lowermost bin) will enter
stacker first. the stacker first.

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 SHORT : The standard clutch feed length during the test
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 SHORT gives a clutch length of 126.25mm (4.98")
during the test set. You may also use the CLUTCH feature
from the FRICTION menu to manually adjust the test set
clutch length.

CLEANING : Turns the conveyor on. Pressing the red button

on the bin controls will then activate the feed clutch for
that bin. Press CLEANING again to switch off.

TRAY : Raises or lowers the trays on Friction bins for

access or transport. As the trays raise the X-Jogger (if
fitted) will turn.

LENGTH : Enters the LENGTH display (See below).

FRICTION : Enters the FRICTION menu (see p.88).

SUCTION : Enters the SUCTION menu (see p.89).

LENGTH DISPLAY The length display shows information about the sheet
detection system of each bin. You only need to refer to
the length display if you are having feed problems.

Bin : The bin number to which the information relates.

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.

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

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

86
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 HOLD
MENU

MENU

ADVANCED MENU
OFFSET+ SHORT TRAY FRICTION
OFFSET- CLEANING LENGTH SUCTION

MENU

Bin Length Ref Pwr Lim Scn

6 291 122 - 31 .

LENGTH DISPLAY
5 290 128 - 30 .
4 290 135 - 28 .
3 292 167 - 23 .
2 290 132 - 28 .
1 290 91 - 38 .

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

ADVANCED MENU
MENU

OFFSET+ SHORT TRAY FRICTION

OFFSET- CLEANING LENGTH SUCTION

MENU

FRICTION MENU
SLIP+ FDET+ CLUTCH+
SLIP- FDET- CLUTCH-

Friction Menu Navigation

SLIP + and SLIP - : Displays and adjusts the allowance for

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. The slip allowance may need
changing for especially difficult papers (the default set-
ting is 14.25mm / 0.56"). Before changing the slip value:

• Ensure that the feed is optimised using the normal

adjustments
• Establish that sheet slip is definitely the cause of the
problem

88
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 FDET + and FDET - : Friction Detection. The sheet detector
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. In this case the detection position can be
moved relative to the feed edge of the sheet.

CLUTCH + and CLUTCH - : Displays and 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. Decreasing the value has the opposite effect.
The default value is 186.2mm (7.35") during the test set,
thereafter the feed length is automatically set to suit the
paper size.

SUCTION MENU The SUCTION menu is used to adjust certain variables in

the feed system of Suction and SlimVAC bins. Any ad-
justments shown in brackets may not appear on your
machine.

HOLD
MENU

ADVANCED MENU
MENU

OFFSET+ SHORT TRAY FRICTION

OFFSET- CLEANING LENGTH SUCTION

MENU
SUCTION MENU

SLIP+ SDET+ HOLD+

SLIP- SDET- HOLD-

Suction Menu Navigation

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 SLIP + and SLIP - : Displays and adjusts the allowance for
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. The slip allowance may need
changing for different weight papers (the default setting
is 14.25mm / 0.56"). However, always obtain a good feed
with standard adjustments before changing the slip value.

SDET + and SDET - : Suction / SlimVAC Detection. The sheet

detector operates 15.2mm (0.6") in from the feed edge of
the sheet. The edge of particularly dark or solid areas of
print in this area can cause detection problems. In this
case adjust the detection position to avoid any such
areas.

HOLD + and HOLD - : Displays and adjusts the time the

suction manifold (Suction bins) or feeder (SlimVAC bins)
holds the paper for before it releases it into the conveyor.
The default setting is 300ms.

90
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 A2 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)

Drive Unit
Dimensions (W,D,H): 610, 423, 233mm; (25kg), 24, 17, 9"; (55lb)
Electrical: 110 - 120V or 230V, 50/60Hz; single phase

Friction Feed Bin

Rel. F
Configuration: Up to 16 bins per tower
Production: Up to 7,200 feeds per hour
Capacity: 40mm,1½"
Stock Sizes: 120 x 160mm to 364x 520mm, 5 x 6¼" to 14¼ x 20¼"
Stock Range: 40 to 300 gsm, 11# bond to 110# cover
Detection: Electronic detection for miss, double, jam and empty bin
Dimensions (W,D,H): 610, 590, 77mm; (6.9kg), 24, 23, 3"; (15.2lb)
Sound Emission: Typical 70dB (A) for machine in use

SlimVAC Feed Bin

Rel. B
Configuration: Up to 16 bins per tower
Production: Up to 5,000 feeds per hour
Capacity: 45mm, 1¾"
Stock Sizes: 120 x 160mm to 364 x 520mm, 5 x 6¼" to 14¼ x 20¼"
Stock Range: 40 to 240 gsm, 11# bond to 90# cover
Detection: Electronic detection for miss, double, jam and empty bin
Dimensions (W,D,H): 610, 667, 77mm; (7.6kg), 24, 26, 3"; (16.7lb)
Sound Emission: Typical 74dB (A) for machine in use

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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: Electronic detection for miss, double, jam and empty bin
Dimensions (W,D,H): 610, 667, 154mm; (14.5kg), 24, 26, 6"; (32lb)
Sound Emission: Typical 74dB (A) for machine in use
(Note: When intermixing SlimVAC, Suction and Friction
feed bins, a suction-friction spacer may be required.)

Benchtop Base
Production: Up to 7,200 sets may be stacked per hour
Stacker Capacity: 70mm, 2¾"
Stock sizes: 130 x 160mm to 364 x 520mm, 5¼ x 6¼" to 14¼ x 20¼"
Sensing: Optical tray full sensor
Dimensions (W,D,H): 610, 603, 218mm; (13kg), 24, 24, 9"; (29lb)

Oscillating Bench
Base
Production: Straight stacking up to 7,200 sets per hour
Offset stacking up to 4,500 sets per hour
Stacker capacity: 70mm, 2¾"
Stock sizes: Straight stacking up to 364 x 520mm, 14½ x 20¼"
Offset stacking up to 320 x 450mm, 12½ x 17¼"
Sensing: Optical stacker full sensing
Dimensions (W,D,H): 615, 745, 207mm; (19.5kg), 24, 29, 8"; (43lb)

Floorstanding Base
Rel. C
Dimensions (W,D,H): 692, 827, 720mm; (67kg), 27, 33, 28"; (147lb)

92
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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 x 20¼"
Sensing: Optical stacker full sensing
Dimensions (W,D,H): 509, 600, 530mm; (21kg), 20, 24, 21"; (46lb)
Electrical: 110 - 120V or 230V, 50/60Hz; single phase

Straight Jogger
Capacity: 75mm, 3"
Sensing: Optical stacker full sensor
Dimensions (W,D,H): 375, 560, 521mm; (22kg), 15, 22, 21"; (49lb)
Electrical: 110 - 120V or 230V, 50/60Hz; single phase

Production may vary according to operating conditions. In line with a

policy of continual product improvement, the manufacturer reserves the
right to alter the materials or specification of this product at any time
without notice.

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.

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94
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 A3 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
SlimVAC Feed
Floor Base
Bench Top Base
Oscillating Bench Base

Conforms to the following Product Specifica-

tions:
Safety 89/392/EEC Council Directive 'on the approximation of
laws of Member States relating to machinery’, amended
by 91/368/EEC

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

laws of Member States relating to electromagnetic com-
patibility'
EN55022 Class A
EN50082-1
IEC 801-2 (1991) 8kV AD
IEC 801-3 (1984) 3V/m
IEC 801-4 (1988) 0.5kV SL, 1kV PL

M C Watkiss
Technical Director
Watkiss Automation Ltd.

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96
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 Index
Index
A conveyor jam 81
advanced menu 19, 85–90 counting sets 11
cleaning 86
D
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
suction 38
air separation, adjustment 13, 24
display 10
B divert, menu command 14
batch menu 15 drive speed, adjustment 13
insert 16
E
multifeed 18
edge flick, suction bins 36, 40, 77
multiset 17
emergency stop button 2, 81
oscill 16
end job, menu command 12
pause 17
size 18 F
stop 16 feed wheels, friction bins 68
batch mode 15–18 feeder angle, slimvac bins 31, 76
bench base 43–47 floor base 53–58
deflector fingers 45 air blast 54
delivering to the rear 44 delivery direction lever 55
offset stacking 44 front feedout conveyor 54
paper guides 46 interface sockets 53
setting up the stacker 43 rear deflector fingers 55
stacker full sensor 46 rear feedout conveyor 57
bin controls 21, 27, 35 remote control 57
bin linking 25, 31 with deep pile stacker 54, 56
with jogger 54, 56, 57
C
with stitch fold 54, 56
cleaning - see ’maintenance’
friction bins 21–25
cleaning, advanced menu 86
adjustments 23–25
control panel 9–19
advanced adjustments 88
advanced menu 19, 85–90
air separation 24
basic operation 9–12
sidelay taps 24
batch menu 15
bin controls 21
error messages 79–83
bin linking 25
menu1 12
loading the bins 21
menu2 13
maintenance 67
conveyor 67, 81
problem solving 74–75

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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 inch 13
slip 88 sets per hour 13
fuses 2, 79 sph 13
test set 12
I
menu2 13
inch, menu command 13
divert 14
insert, batch menu command 16
job 14
installation 2
oscill 13
J prenumber 14
jam 75, 76, 77, 80, 81 setup 15
job areas 14 sft 14
job memory menu 18 stagger 13
joggers 59–62 multifeed, batch menu command 18
straight jogger 60 multiset, batch menu command 17
x-jogger 59
O
jogging off-line 62
offset, advanced menu 85
L oscill, menu command 13, 16
lcd display 10 oscillating bench base 49–53
length display 86 delivery direction lever 52
bin 86 magnetic sidelays 49
length 86 non-standard paper sizes 50
lim 87 offset stacking 50
pwr 86 paper guides 51
ref 86 problem solving 78
scn 87 scale 49
loading the bins 21, 27, 37 stacking A5 sheets 51
straight stacking 50
M
overrange 25, 32, 39
mains input 2
mains on/off switch 3 P
maintenance 67–70 paper guides 46, 51, 54, 78
conveyor wheels 67 paper jam 75, 76, 77, 80, 81
feed wheels 68 paper separators, friction bins 23, 67, 74
paper separators 67 pause, batch menu command 17

98
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 Index

prenumber, menu command 14 rubber endlays 28

preset counter 11 running the Job 31
problem solving 73–83 sensor overrange 32
error messages 79–83 sheet corrugation 30
friction feed problems 74–75 switching bins on & off 30
general problems 73 tray extenders 28
oscillating bench base problems 78 tray height 31
slimvac feed problems 75–76 specifications 91–93
suction feed problems 77–78 sph, adjustment 13
x-jogger problems 78 stagger, menu function 13
staple cartridge 64
Q
staple counter 65
quick start 5–7
staple counter, resetting 65
quick stop button 9
starting the job 11
R stitch fold 54, 56
rear corner stapler 63 stop, batch menu command 16
staple cartridge 64 straight jogger 60
staple counter 65 jogging adjustment 61
rear feedout conveyor 57 jogging off-line 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
S
adjustments 35–41
safety 1
advanced adjustments 39–41, 89
separator pressure, friction bins 74, 75
bin controls 35
sets per hour, adjustment 13
deformed sheets 38
setup, menu command 15
edge flick 36, 40
sft, menu2 command 14
loading the bins 37
sheet corrugation, slimvac bins 30, 75, 76
maintenance 69
short, advanced menu 86
porous papers 38
size, batch menu command 18
problem solving 77–78
slimvac bins 27–34
sensor overrange 39
adjustments 30–32
sucker configuration 35, 40
advanced adjustments 89
switching bins on & off 38
bin controls 27
tray height 39
bin linking 31
suction menu 89
difficult papers 32
hold 90
feeder angle 31
sdet 90
loading the bins 27
slip 90
problem solving 75–76

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 Index

system lock 12
T
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
x-jogger 59
jogging adjustment 60
problem solving 78
setting up the jogger 59
straight stack liner 60

100
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 WATKISS AUTOMATION LIMITED
Watkiss House, Blaydon Road, Middlefield Ind. Est.,
Sandy, Bedfordshire. SG19 1RZ ENGLAND.
Tel: +44 (0)1767 682177 Fax: +44 (0)1767 691769
Email: info@watkiss.com Web: http://www.watkiss.com
Operator Manual, Vario, English
Issue 2, Dec. 1997. Part No. 960-321

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