Related Manuals for Watkiss Automation Plockmatic PowerSquare 224
Summary of Contents for Watkiss Automation Plockmatic PowerSquare 224
- Page 1 Plockmatic PowerSquare™ 224 Service Training Workbook Right to Left Version Issue 1, November 2014, edited January 2017 Doc. No.x05082 Name: ................
- Page 2 Limited makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Watkiss Automation Limited shall not be liable for errors contained herein or for incidental or conse- quential damage in connection with the furnishing, performance or use of this material.
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Page 3: Table Of Contents
CONTENTS Introduction ........1 Conventions in this workbook ......1 Adobe Reader and Adobe Acrobat Instructions . - Page 4 Machine Areas ....... . 19 Introduction ......... 19 Connecting Bridge .
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Page 5: Introduction
Introduction Introduction Online PowerSquare Offline PowerSquare The Plockmatic PowerSquare™ 224 is an innovative, complete book making system for digital print applications. In a single machine it combines the four processes of stitching, folding, spine forming and trimming to produce SquareBack™ books up to 224 pages thick. It features fully automatic setting for different book size and pagination, including variable stitch leg length for varying book thickness. -
Page 6: Adobe Reader And Adobe Acrobat Instructions
Introduction Adobe Reader and Adobe Acrobat Instructions If you use Adobe Reader or Adobe Acrobat to read this manual, we recommend you follow these instructions: Make sure all the navigation buttons are visible Adobe Reader and Adobe Acrobat include navigation buttons to help you move around the file. -
Page 7: Illustrated Parts Catalogues
Introduction Illustrated Parts Catalogues The Plockmatic PowerSquare™ 224 is made from these modules: PSQK - Complete M/C PBCK - Connecting Bridge PBR5 - Rotator PRTP - Base Machine PBRG - Gathering Module PRSH - Shuttle PSTI - Stitcher PRFD - Folder PFRM - Spine Former PSTP - Trim Stop PTRM - Trimmer... - Page 8 Introduction Every exploded diagram is followed by the related part number information. The part number information is given for the top level assembly, sub-assemblies and components where available. See FIGURE 3. FIG.16 - TAMPER GATE FRAME PSQ SHUTTLE -PSHU LAST EDIT:18 AUG 09 Item Part No.
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Page 9: Product Overview
FIGURE 4. Plan view of the Plockmatic PowerSquare 224 showing Stage Description Service Manual Reference The sheets of paper leave the printer and See Section 1.7.1. enter the infeed of the connecting bridge. - Page 10 Product Overview Plockmatic PowerSquare 224 showing Figure 2:1. End view of the Stage Description Service Manual Reference The fold blade lifts and the form clamp See Section 1.7.6. closes. The form roller creates the SquareBack spine on the book.
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Page 11: Description Of Operation
Description of Operation Description of Operation After the PSQ is turned on, the operator configures the paper size and direction, the set-thickness and the number of stitches. The PSQ is controlled by the printer and by a system of internal sensors. The PSQ includes these modules •... -
Page 12: The Gathering Area
Description of Operation The PBR5 bridge does not have static elimination bars. Blue, non-conductive belts and additional anti-static brushes remove the static charge on the paper. An optical sensor in the bridge infeed sees that a piece of paper has entered the system. -
Page 13: The Stitch Head And Clincher
Description of Operation The set is moved to the folding area when the set is stitched. When the shuttle moves to the folding area, the pick-up fingers loosen on the book. The shuttle is operated by a 230V AC electric motor through a linear transmission. The Stitch Head and Clincher The single stitch head is a custom version of the Deluxe G8 stitch head. -
Page 14: Fold And Form
Description of Operation Fold and Form When the shuttle stops in the park position, the folder blade is operated. The folder blade pushes against the centre line of the book - located by the stitches - and folds the book in half. The folder blade pushes the book to a calculated depth between a pair of feed-rollers and into the form clamp. -
Page 15: Outfeed And Stacker
Description of Operation main electric motor by a chain and clutch system. Rotary movement is changed to linear movement with a crank mechanism. Outfeed and Stacker When the trim clamp is released, two solenoids move the trim stop from below the book. -
Page 16: User Interface (Gui) - Operator Menu
User Interface (GUI) - Operator Menu User Interface (GUI) - Operator Menu The user interface includes a colour touch screen and START/STOP buttons. START Button STOP Button Touch Screen FIGURE 3. The User Interface Introduction Operate the touch screen with a fingertip. You can touch the screen with a blunt item, for example a palm-top ‘wand’... -
Page 17: The Touch Screen
User Interface (GUI) - Operator Menu The Touch Screen button gives you HELP STATUS more information. • = Ready or running. GREEN • Touch , then touch HELP • ORANGE - PLEASE WAIT any button. • = operator action needed. ORANGE - ATTENTION •... -
Page 18: Gui Buttons And Options
User Interface (GUI) - Operator Menu GUI buttons and options Window Buttons PAPER SIZE Enter the paper size BASIC PAGE DIRECTION Portrait or Landscape PRESETS Standard paper sizes ROTATE On or Off SET THICKNESS Either input the measured set thick- ness or use AUTO AUTO Auto calculates the set thickness... - Page 19 User Interface (GUI) - Operator Menu Window Buttons MACHINE OPTIONS CONFIGURE MEASUREMENT Select mm or inches as units STITCH SENSOR Turn stitch sensor on or off PRESET PAPER ISO ‘A’ sizes or US sizes SIZES SIDE TRIM (P2T) Touch to turn off communication to the Side-Trimmer.
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Page 20: Advanced Operation
Advanced Operation Advanced Operation Paper quality and machine performance Careful measurement of the paper size and set thickness is important in order to produce good quality books. • To make an accurate book you must enter accurate paper dimensions into the touch screen. -
Page 21: Book Quality And Machine Specifications
Advanced Operation Note: A dirty sensor or a sensor covered by paper trimmings will give a jam error. Paper jams that require service intervention are: • If the former clamp does not open, manual operation with the hand crank is needed (see Section 6.20.3 in the PSQ Service Manual). -
Page 22: User Interface - Service Overview
User Interface - Service Overview User Interface - Service Overview Service functions on the User Interface require the service access code. See Section 6.13 - “GUI Access Levels” in the PSQ Service Manual. 1973 • Service access code The service functions on the User Interface provide •... -
Page 23: Machine Areas
Machine Areas Machine Areas Introduction During this section of the training, we review the different areas of the machine, and the key set up procedures for each area. See Section 7.4 in the Service Manual for the location of components. The Axis Calibration of the PSQ is critical to the quality of the books it will produce. -
Page 24: Gathering Area Module
Machine Areas Gathering Area Module The gathering area module accepts the paper from the connecting bridge. When the correct number of sheets has arrived, tampers knock down the paper between the sidelays and the endlays, (see Section 8.4) Locate the following in the Gathering Area (Top) ... -
Page 25: Shuttle - Book Gathering And Pick-Up
Machine Areas Shuttle - Book Gathering and Pick-up When the paper is fed into the gathering area, the paper falls between the end- lays and sidelays. The endlays and sidelays are adjusted by the PSQ according to the paper size selected. This adjustment is important and necessary for the quality of the finished book. -
Page 26: Shuttle - Book Transport
Machine Areas Shuttle - Book Transport The set is collected by the shuttle and moved to the 1st stitch position. A cam mechanism tightens the shuttle pick-up fingers on the set when the shuttle moves towards the 1st stitch position. The increased hold makes sure the pages remain in alignment when the set is stitched. -
Page 27: Stitcher
Machine Areas Stitcher The shuttle collects the set between the pick-up fingers and moves to the first stitch position. When the book is stitched and moved to the next stitch- position, the previous stitch moves across a stitch sensor. The Stitch Detect Sensor detects the steel of the stitch wire. - Page 28 Machine Areas Locate the following: Stitch Axis Home Position Sensor Stitcher Wire-feed Cam Sensor Stitch Sensor. Ferrous Metal Sensor. Stitch Head Jam. Proximity Sensor Stitch Clutch Stitch-wire Feed Toggle Clutch Stitcher Control PCB (900-274) ...
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Page 29: Fold And Form
Machine Areas Fold and Form When the shuttle stops in the park position, the folder blade is operated. The folder blade pushes against the centre line of the book - located by the stitches - and folds the book in half. The folder blade pushes the book to a calculated depth between a pair of feed-rollers and into the form clamp. - Page 30 Machine Areas Locate the following in the Folder: Axis Home Switch Folder Area Optical Fold Sensor Fold Axis Motor Control PCB (900-212) Folder Interface PCB (900-250) GUI Interface PCB (900-210) The serial number label for the GUI ...
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Page 31: Trim
Machine Areas Trim The book passes between two facing sets of conveyors in the trimmer infeed. These conveyors move the book to the trim stop. The distance of the trim stop from the trimmer blade is calculated by the PSQ according to the size of the job. -
Page 32: Outfeed And Stacker
Machine Areas Review the following: ADJ 4.9.1 (Calibrate the Trim Stop) ADJ 4.9.3 (Check and Adjust the Trim Stop for Square) Use the RAPs to diagnose and repair the problem created by the trainer. Outfeed and Stacker When the trim clamp is released, two solenoids move the trim stop from below the book. -
Page 33: Machine Cycle Control
Machine Areas 8.10 Machine Cycle Control At this stage of the training, you understand how the machine works and how it is controlled. To see the full machine cycle, make a test book using the screen. TEST Before you begin: •... -
Page 34: Routine Maintenance
Routine Maintenance Routine Maintenance Operator Maintenance Operator maintenance is documented in Chapter 6 of the user manual and in Section 6.17 of the PSQ Service Manual. Operator Maintenance Plan Interval Task • Every week Clean the machine. • Every month Lubricate the stitch head. -
Page 35: Power And Control
Power and Control Power and Control 10.1 Power The PSQ uses a single phase power supply. Internally the power supply voltage is changed to: • 242V AC for the low voltage power unit and the main drive motor • 230V AC for the shuttle positioner motor and the bridge motor. The main drive motor is a 3 phase motor. -
Page 36: Control
Power and Control 10.2 Control The 900-208 Main Control PCB is the interface between the GUI screen, the CPU and all the input and output functions of the machine. The PCB has a split 28V DC supply protected by three fuses that reset on power-off. -
Page 37: Component Locations
Power and Control 10.3 Component Locations 7.4 (Location of Components) shows the location of electrical components in each module. Electrical components are also listed in the Parts Listings. Locate the following electrical components: GUI CPU 900-208 Main Control PCB ... - Page 38 Power and Control Identify the components: (use the list below) 900-208 Main Control PCB Inverter Power Interface PCB Anti-Static Power Unit Fuse & Low Voltage Transformer Assy Shuttle Motor Interface PCB Relay PCB Fuse Holder Mains Power Input Connector Terminal Block Interlock Relay PCB Mains Power On and Off Switch...
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Page 39: Dfa
Power and Control 10.4 The DFA Finisher Interface PCB is the interface between the printer and the finisher. The following input and output signals are provided: Status ouput signals from the PSQ Control input signals from the printer LEDs are RED. LED 11, 12 & 13 must be ON to LEDs are GREEN. -
Page 40: Software
Software Software 11.1 Software System Description There are two parts to the software in the CPU: • The ‘application software’ controls the operation of the PSQ and includes the language support. • The ‘boot firmware’ lets you install the application software. The boot firmware also loads the application software from the flash memory when you turn on the machine. -
Page 41: Replace Trimmer Blade (Optional - Time Permitting)
Replace Trimmer Blade (optional - time permitting) Replace Trimmer Blade (optional - time permitting) REP 4.18.4 (Trimmer Blade and Anvil Replacement and Setting) PSQ Accessories The following optional accessories for the PowerSquare are documented in separate Computer Based Training courses (CBTs). If time permits, a short introduction to these accessories will be included. -
Page 42: Product Specifications
Product Specifications Product Specifications March 2016 Operating 10-35°C at 35-85% relative humidity, up to 2000m amsl Conditions Production Cycle time: Printer dependent Interset gap: 1 second Minimum set time: 4.2 seconds Maximum set time: 12.5 seconds Typical set time: depending on job settings Stock Sizes Minimum input size: 200 x 200mm Maximum input size with PBR5: 370 x 520mm... - Page 43 Product Specifications Book Thickness Minimum set thickness: 1 sheet (when folded makes a 4 page booklet) Maximum finished book thickness: up to 10.4mm Maximium book thickness is dependent on paper type, quality, grain direction, coating, ink/toner type and coverage. The following figures are given as a guide. Plain papers: 80gsm: approx.
- Page 44 Product Specifications Integrity Factors Average Document Size: 20 sheets, 80gsm, 2 stitches Average volume: 50,000 books per month Peak volume: 150,000 books per month Scheduled service intervention: 2 times per year, or at every 3rd wire spool change if this is sooner. (each 2 hours average) Un-scheduled service intervention: 3 per year (each 2.5 hours average) Operator recoverable errors:...
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Page 45: Quality Tolerances
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. Copyright © 2016 Watkiss Automation Limited Quality Tolerances Sheet Alignment Sheet to sheet: up to 0.5mm... - Page 46 Quality Tolerances Trim blade marking The trim process uses a double-edge blade to cut thick books. This can leave a small mark in the centre of the trimmed edge. The visibility of this mark will depend on the paper quality and characteristics. Stitch form Legs should lie flat so they cannot cause injury Legs should not re-penetrate the spine...
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Page 47: Psq Site Requirements
PSQ Site Requirements PSQ Site Requirements 17.1 Environment Parameter Value Ambient Temperature 10-35°C (50-95°F) Relative Humidity 35-85% Altitude up to 2000m amsl 17.2 Floor surface and cover • Only install the PSQ on a level floor. • The PSQ needs a solid and durable floor. Deep pile carpet and thick, cushioned underlays can cause problems when the PSQ is moved. - Page 48 PSQ Site Requirements 17.6 Weight Weight Online with connecting bridge and stitch-wire 532 kg, 1173-lb 17.7 Electrical Item Specification Supply A single phase, earthed (grounded) power supply is needed Voltage Adjustable to 200, 208, 220, 230 and 240V Frequency 50/60Hz Current 4.0A Note: Startup peak value max 30A.
- Page 49 PSQ Site Requirements 17.9.1 Online PowerSquare NOT TO SCALE Input for Mains Power Supply Connecting Bridge Stacker 2755mm, 109" Maintenance area: 3255 mm, 129" Plockmatic PowerSquare™ 224 - Service Training Workbook...
- Page 50 PSQ Site Requirements 17.9.2 Online PowerSquare with PBS Book Stacker NOT TO SCALE Input for Mains Power Supply Connecting Bridge PBS Book Stacker 2280 mm, 90" Maintenance area: 2800 mm, 111" Plockmatic PowerSquare™ 224 - Service Training Workbook...
- Page 51 PSQ Site Requirements 17.9.3 Online PowerSquare with P2T 2-Knife Trimmer NOT TO SCALE Input for Mains Power Supply Connecting Bridge P2T 2-Knife Trimmer Input for Mains Power Supply 2970 mm, 117" Maintenance area: 3470 mm, 137" Plockmatic PowerSquare™ 224 - Service Training Workbook...
- Page 52 PSQ Site Requirements 17.9.4 Online PowerSquare with P2T 2-Knife Trimmer and PBS Book Stacker NOT TO SCALE Input for Mains Power Supply PowerSquare Connecting Bridge P2T Trimmer Input for Mains Power Supply PBS Book Stacker Maintenance area: 2780 mm, 110" Maintenance area: 3280 mm, 130"...
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Page 53: Glossary Of Booklet Making Terms
Glossary of booklet making terms Glossary of booklet making terms The following booklet making terms are in common use. Many are used in the PSQ documentation. 3-knife trim To trim the three open sides of a book(let). book & A collection of sheets which have been stitched and folded to booklet make a book(let). - Page 54 Glossary of booklet making terms A collection of sheets of paper which will make a complete book(let). set thickness The measured thickness of a set, before it has been made into a book(let). This measurement is required when a job is set up on the or other booklet maker.
- Page 56 Watkiss Automation Limited 1 Blaydon Road Middlefield Industrial Estate Sandy, Bedfordshire SG19 1RZ United Kingdom Tel: +44 (0)1767 685700 Fax: +44 (0)1767 689900 Email: info@watkiss.com...