HB was kind enough to get me in contact with the designer of the Vario (Kyle from Baratza) regarding my too fine grind. Kyle filled us in on the calibration procedure (zeroing the burrs) and I have recalibrated mine (it took only a few minutes to get it where I like). I took pictures along the way, so here we go:

Tools needed:
1) A thumb nail (right or left)
2) A 2.5mm Allen wrench:


To reset the calibration to a coarser setting do the following:
Locate the rubber grommet (1/4 in wide X 1 inch long) on the roof of the grounds bin cavity, just to the rear of the discharge chute.


Remove the grommet using your thumb nail to grab it.


Just inside the opening locate the black Allen head screw (2.5mm size).


Using a 2.5 mm Allen wrench loosen the screw by turning the Allen wrench to the left as you face the grinder.


With the Allen wrench still in the head of the screw, slide the screw toward the front of the grinder (about 1/8 in to 1/4 in), and tighten the Allen screw.


Replace the grommet.

Pulling the screw forward moves the grind range towards coarse and pushing it in moves the grind range toward fine. Test with coffee to see if espresso is very fine with both levers all the way up. then test for press pot with both levers all the way down. The calibration only sets the zero point. The design is such that if your press pot is too coarse, your espresso will be too coarse, and if the your press pot is too fine your espresso will be too fine also.

Kyle said also:
I hope this will assist you in setting your Vario up just the way you like it. We do calibrate every grinder before it leaves our factory, but we goofed in choosing a set point that was too fine.

UPDATE from Getting started with the Baratza Vario:

Baratza wrote:Calibrating the Vario with the new calibration screw.

Baratza's first shipment of Vario's (March 2009, serial # 001 to 270) were calibrated at the factory to grind too fine. We then changed the factory setting for the Vario so it could be adjusted fine enough for espresso and coarse enough for Press Pot. Since we made this adjustment at the factory we have had much fewer calibration issues. Beginning with serial #271, Baratza added a secondary calibration screw (2mm Allen head set screw) in a round hole between the discharge chute and the calibration grommet. This calibration screw allows the user to easily adjust the calibration in the finer direction with the grinder running. To make the adjustment, empty all beans from the grinder, lower the Macro and Micro levers all the way to the bottom and run it briefly to expel any partially ground coffee. Press the Manual button and then the Start button. While the grinder is running, raise the Macro arm all the way to the top (Espresso). You should not hear any change in motor speed. Now raise the Micro arm up the midpoint. You should begin to hear the motor slow (or labor a little). If not, use a 2mm Allen wrench to slowly turn the 2mm set screw clockwise (when looking up at the screw) until you begin to hear the motor slow or labor. You are done!

Thanks Dan for posting the photos and instructions! I'll add a link from the review. And thanks to Kyle for the quick response!

Great writeup!!! I wonder if there is a set for finer espresso and coarser press pot?

Mark

Yeah, now I'm really happy, adjusted to make a finer espresso so I've now some extra notches (OK, so I went a bit too far but that's OK). Now I've got the headroom in the basket that I want with my Elektra and a thick syrup of goodness dripping out.

Mark

Excellent, Dan.
Now, how does the espresso TASTE?
Did going coarser overall lessen the static?

No static at all, FM

I think it tastes great, but I am not a real good judge. A couple of days and someone who can properly discuss these things will try it out with me.

I also have no static, mind you it's not the driest time of the year in northern CA. Now that I'm in the right range I can click up or down one to fine tune very nicely (or up and down by 1/10 to add/lessen the amount). Taste to me is superb no sign of bitterness. Even with lower dosing, there was no sign of channeling. Yep, grinders make a difference (I think I've heard this mantra before).

My wife is also very pleased with the low rumble while grinding, the size (extra counter space) and the overall aesthetics.
=-=-
Mark

ddr wrote:No static at all, FM

I think it tastes great, but I am not a real good judge. A couple of days and someone who can properly discuss these things will try it out with me.

Dan, you ARE a good judge. If it tastes great it IS great. Compare it to shots you get at a good cafe pulled by a competent barista.
These grinders were built for home use, mainly for folks just like us.
Many here are wondering how it will do with French press, which to ME really needs a grinder that produces little or NO dust.
That's your next assignment!

Hello,

I just received the Vario and the calibrations is way too fine.
The blades seem to be rubbing and putting in coffee procduces no grinds. I've removed the top burrs and the coffee that is in there is talcum. Both sliders are as coarse as they can go (press and coarse).

I checked the adjusting screw near the chute thinking it maybe was all the way back. It was all the way forward, which is supposed to be it's coarsest setting.

I've emailed Baratza and will take it to the dealer I got it at but would really love to avoid the one hour drive if I can.

Does anyone know if the cam mechanism can move on its own once the screw is loosened or is it only the movement of the screw that moves the burrs?

Thanks for your help all.

Wayne

Wayne, I feel somewhat qualified to attempt some help, as I've spent lots of time adjusting that little bugger.
If the allen screw is not FULLY tightened in position it can move, and usually to the back.
Not sure why you're getting talc, but I think you might want to remove the hopper, upper burr, CAREFULLY remove the screws that hold the lower burr in place, remove the lower burr, and thoroughly clean the grinder, blowing some compressed air around, and making sure to blow a bit into the crevices where the Macro/Micro levers reside. Make sure you've totally purged the grinder before disassembly.

Before you replace all, that is the time to re-adjust your allen screw calibration thingy. loosen it so that you can slide it forward. A pretty good position is when you have the grinder upside down, the screw is barely visible. That is, it is about 2/3 forward. Carefully lock it in, making sure the guides on either side are straight and lined up, so they tighten down a bit as well. Tighten the allen screw down securely, but don't strip it or over tighten.

Now...
Replace the lower burr, then the upper, making SURE to rotate it FULLY counter clockwise until it is full in position...you'll see it slide into position.
This is important...
Make sure when you replace the hopper, you hear it CLICK into place.
For grins, set your Macro lever 1 notch below the upper most position, and the Micro lever about 1/4 up from the bottom.
Fill the hopper 1/4 full. Grind about 10 seconds, and feel between your fingers. If it's "sugar", but a wee bit finer, you're pretty much there.
If you're still getting talc, then Kyle @ Baratza would be the person to speak with, not your vendor.
Baratza has excellent customer service and will make it right, or send you another grinder.
Please let us know how it goes.

Just wanted to pass on a note regarding my experience with a Vario.

I ordered one to use in my shop as a decaf grinder.

Due to a quirk on how the grinder was shipped (lever position and having the box upside down at some point) when I tried to grind coffee nothing came out. When I took off the top burrs, the chute was plugged with talcum powder consistency grinds.

Checked the calibration and it was already as coarse as it could go, with both levers as coarse as they could go.

Contacted supplier and at same time sent an email to Baratza with problem.

In less that 24 hours I got a reply from the man who designed the grinder himself, Kyle Anderson, who asked for my number and then called me within a hour of me sending it via email (He was on holidays too!!)

He had it fixed in about two minutes and I now have the grind set and will start using it in my shop tomorrow.

If this is standard customer service from Baratza, they now have a loyal customer!

Wayne Bertrand

Hi guys,

just out of curiosity, how does shipping it upside down screw up the setting? or was it wrongly calibrated straight from the factory? I've heard about those grinders being incorrectly set when taken out from the box a few times now and I'm simply wondering how is this happening?

Second question, has anyone took their grinder apart? I'm still curious how the mechanism looks like.

Regards,
dsc.

laughingbean wrote:
In less that 24 hours I got a reply from the man who designed the grinder himself, Kyle Anderson, who asked for my number and then called me within a hour of me sending it via email (He was on holidays too!!)

He had it fixed in about two minutes and I now have the grind set and will start using it in my shop tomorrow.

If this is standard customer service from Baratza, they now have a loyal customer!

Wayne Bertrand

The answer is Yes, Wayne. Their customer service has always been excellent, as is their service department, headed up by a fellow named Joe, who has the inside scoop on the ins and outs of all Baratza grinders, and is extremely patient. (This I know from personal experience)

Hi everyone. I ordered the Vario grinder from Chris Coffee and received it last week. I'd been playing around with it for a couple of days and even on the finest setting, I was getting very coarse grinds that gave me a very quick (under 15 seconds) extraction. Using my Super Jolly on my Isomac tea at 9 bar of pressure with the same 4 day old home roasted coffee, at the same temperature (using an erics thermometer) and an espro tamper, I am easily able to choke my machine. I read a bit here about recalibrating the grinder and I thought that that might solve the problem. I tried adjusting the allen screw, but now I cannot push the cam to espresso, it pops right back between filter and press. I tried a to move it a couple of times, and one time the little plastic slider popped out and it appears one of the little nubs that clicks into the inside of the slider is broken off.

When I contacted Chris about this issue, he told me that I shouldn't have been changing anything on the grinder. I'm concerned that I may have voided the warranty by adjusting the allen screw and that I'll be stuck with a grinder that doesn't work for me. I've tried adjusting the allen screw back to where it was, but the cam still does not appear to work and will not stay on the espresso setting. It's also now very difficult to adjust the allen screw forward or back as it seems to stick even when loosened and I cannot move it . Does anyone know how to fix this???


...merged with thread on same subject by moderator...

Jacob, call Kyle at Baratza. They will get you going. You did nothing wrong in trying to calibrate, and this will not void any warranty, I am sure.

sweaner wrote:Jacob, call Kyle at Baratza. They will get you going. You did nothing wrong in trying to calibrate, and this will not void any warranty, I am sure.

This is true.
Chris can get you a slider, but Kyle will be faster.
I explained on a Vario thread that a friend's Vario had that same problem of the Macro slider getting stuck 2/3rds of the way up.

Question...is yours a current Vario, with the extra little 2mm (not 2.5mm) screw hole)?
If so, THAT is the only thing you want to mess with right now.
My solution would be..for now, to set your MICRO slider 1/2 way, remove the slider carefully, and attach it to the Macro area.
BUT FIRST
Empty the hopper of beans, grind the remnants, remove the hopper and upper burr...unplug.
If you see copious amounts of grind inside, tip over the grinder and empty, then at a distance use compressed air to get the rest out, including under the lower burr.
Then slide that Macro arm up and down...it should NOW slide freely. If it doesn't, blow a bit of air through there as well.

Reassemble the grinder..but before you place the hopper on, make sure the Macro slider is still moving freely.
Replace the upper burr, making sure it snaps solidly, and rotate counter clockwise into position. Then replace the hopper, turn it clockwise making sure it clicks.

Now, hit manual, turn on the grinder, and SLOWLY raise the Macro lever....when you're past drip, a few above you should hear either the motor start to lower in pitch as it works harder, or at a notch below espresso, you might hear a few ticks of burrs. If at 1 notch below espresso you hear nothing lower the Macro back to the bottom, then adjust the little scree (2mm hex) but slowly rotating it clockwise, while the grinder is running, and at the same time raise the Macro lever. When you hear motor load, THAT is close to your 0 point for espresso.

Leave the Macro where it is, REGARDLESS of it's position. This will change as the burrs break in.
Now, 1/2 fill the hopper, and grind some espresso, tamping lightly as to not choke your machine.
Before loading the PF, feel the grind. Is it sort like sugar, maybe a wee bit finer?
If so, you're very close. BETTER STILL, COMPARE THE SAME COFFEE GROUND IN YOUR OTHER GRINDER. ARE THEY CLOSE?

If you have a 58mm basket, I'd recommend a 12 second grind to start with.. If your basket is way overflowing, you're probably too coarse. If 1/2 empty, you're too fine. As I'm working with a 49mm basket, my figures may be off a bit, but start there. FEEL THE GRIND.

Sorry for the extended post.

Rob,

Thanks very much for your extended reply! I was able to get the cams working again and by adjusting the 2mm hex screw I was able to calibrate it perfectly. I think Baratza should consider hiring you... it was your reviews that convinced me to get the grinder, and now it's your tech support on a Sunday evening that convince me to keep the grinder ! Now all I have to do is get that little plastic nub, I'll try to contact Baratza for that. Thanks again for your help!

You are most welcome.
Most here are WAY more DIY oriented, that is, technically more adept than I.
So when I find a piece of gear (musician talk ) that enables me to actually make a contribution I feel I should.
I have no pony in this race, though I freely admit my preference for CUSTOMER SERVICE that companies like Baratza provide.
There are always niggling little things you'd like to see adjusted/improved, but that is true about most equipment.
I think this grinder provides a viable alternative for folks that are space challenged, have need for an easily adjustable multi purpose grinder, yet desire excellent espresso grind. Is it a Robur or K10?
No, as it is not a conical burr grinder, nor near as fast. But, so far I have not been able to fault the grind quality nor its repeatability.
I do think the manual should delve deeper into the adjustment procedures. perhaps an online line "primer" would be in order. (pdf style)
Also, the PF fork, though much better for us with small PF's (no jokes, please ) could be made to hold our PF's a bit more rigid. Geesh, should have chosen a better word.

Re small size pfs ; I have tried to let the fork and rear tab to hold the small pf but it spilled more than filled when I removed the pf. To fill a small pf basket I use a 2oz plastic portion cup which I got at a drive in. It is the low type and the bottom diameter is just the right size to fit into a 49mm basket. I just cut the bottom out, leaving no curl, and there is enough clearance at the top to hold under the chute and get enough fluffy grind into the basket to fill and tamp to the height I prefer. That also reduces spillage. I had trouble with static when I tried to hold the basket against the chute and off the fork to prevent spillage. I almost never have static now.
I haven't figured a method of no-hands grinding with a small pf and basket.
Cheers!
-Richard
PS. Someone else posted and they used a cut-off metal measuring cup of the proper proportions.

Richard, I've been using my yogurt cup from the get go. I just wanted to (for others sake) give the PF holder a go.
No biggie.