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Watkiss P2T Unpacking And Installation Instructions

2-knife trimmer
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P2T 2-Knife Trimmer
Unpacking and Installation Instructions
Issue 1b, June 2018
969-359

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  • Page 1 P2T 2-Knife Trimmer Unpacking and Installation Instructions Issue 1b, June 2018 969-359...
  • Page 2 Watkiss Automation Limited shall not be liable for errors contained herein or for inciden- tal or consequential damage in connection with the furnishing, performance or use of...

  • Page 3: Table Of Contents

    Fit the P2T to the BLM........
  • Page 4 P2T 2-Knife Trimmer Page 1-2 Issue 1b, June 2018...

  • Page 5: Before Installation

    1.5.2 Space to Install the P2T ....... . 1-6 Tools Needed for Installation ....... 1-8 1.6.1...

  • Page 6: Introduction

    This manual describes how to install a P2T 2-Knife Trimmerto a PowerSquare. • In this manual the PowerSquare is referred to as the BLM. • In this manual the P2T 2-Knife Trimmer is referred to as the P2T. 1.1.2 Warnings The warnings that follow are used in this manual Warning: A WARNING message tells you that a procedure or operation can be dangerous.

  • Page 7: Warning Labels

    Warning Labels The warning labels that follow are used in the P2T: Warning Label Description Location Part No. Indicates the danger of crush or cut injuries if fingers or other Trimmer blades. 500-248 body parts are inserted into this part of the machine. Black figure on yellow background.
  • Page 8 On the serial number label. Outside of the machine near to the mains power 仅适用于非热带气候条件下安全使用 inlet. Black figure on a silver background. TABLE 1:1. Warning Labels P2T 2-Knife Trimmer Page 1-4 CHAPTER 1 - Before Installation Warning Labels Issue 1b, June 2018...

  • Page 9: Using A Fork-Lift Truck To Lift The P2T

    The shipping weight of the P2T is 360 kg (792 lb). Figure 1:1. Machine orientation You can lift the P2T directly with a fork-lift or pallet truck, but where possible, lift the Note: The trim bin can be installed on the RHS for left-to-right booklet makers or pallet and P2T together.

  • Page 10: Space Needed To Install The P2T

    CAUTION: Always unload the P2T from the pallet in the direction shown Figure 1:3. NOT TO SCALE Put the pallet in enough space to fit the ramps and unload the P2T. Input for Mains Power Supply • You need a minimum length of 3735 mm (147 inches) and a minimum for BLM width of 1100 mm (43 inches).
  • Page 11 1.5.2.2 PowerSquare and P2T 2-Knife Trimmer. Right-to-Left. NOT TO SCALE Input for Mains Power Supply Connecting Bridge BLM600 P2T Trimmer Input for Mains Power Supply 2970 mm, 117" Maintenance area: 3470 mm, 137" P2T 2-Knife Trimmer Page 1-7 CHAPTER 1 - Before Installation...

  • Page 12: Tools Needed For Installation

    Orange handscrew that holds the blade lift bracket Blade lift bracket Figure 1:6. Tool kit fixing The tool kit for the P2T is in a bag behind the LH side cover. Section 2.1 for LH side cover removal procedure. P2T 2-Knife Trimmer...

  • Page 13: P2T Installation Hardware

    1.7.1.1 Mains power connection 8. Docking latch assem- P2T connection: IEC60320 C19 - cable and plug supplied with the machine. bly and 2 x M5x12 cap- • 740-016 UK : BS 1363 2.5M head screws with •...

  • Page 14: Pbs/P2T Pivot Bracket. Information

    Pivot post PBS/P2T pivot bracket Figure 1:9. PBS/P2T pivot bracket When the P2T is used with a PBS, the PBS/P2T pivot bracket is used instead of the docking pivot pin supplied with the PBS. See Figure 1:9. The PBS/P2T pivot bracket is supplied in: •...

  • Page 15: Blm Installation Requirements

    BLM Installation Requirements IMPORTANT: In addition to the installation hardware for the P2T, the BLM, dependent on serial number, can need modification. Fit the modifications as shown below. BLM Serial No. WA/PSQ/0800 onward: • Modification is not needed. BLM Serial No. WA/PSQ/0500 - 0799: •...

  • Page 16: Machine Covers

     Outfeed stacker  Trim bin. Fitted to the RHS for Left-to-Right machines. Fitted to the LHS for Right-to-Left machines. TABLE 1:2. Machine covers_1 P2T 2-Knife Trimmer Page 1-12 CHAPTER 1 - Before Installation Machine Covers Issue 1b, June 2018...

  • Page 17: Unpack The P2T

    Unload the P2T ........

  • Page 18: Remove The Covers From The P2T

    P2T when shipped, you must use the correct packaging material. Figure 2:1. Machine covers Caution: When you remove the covers from the P2T, make sure you do not damage the paintwork. Make sure you put the covers on smooth Top cover (open) clean surfaces to decrease the risk of damage.
  • Page 19 Figure 2:3. Castor Remove the outer packaging Keep all of the packaging materials. material from the P2T. To prevent damage to the P2T when Wheel gauge tool (43mm) shipped, you must use the correct packaging materials. Remove the plastic-wrap from around the P2T.
  • Page 20 Adjust the castors to the correct • Figure 2:4. height to unload the P2T from the To unload the P2T from the pallet. pallet, you must use the supplied wheel gauge tool to set the height of the 4 adjustable- castors.

  • Page 21: Unload The P2T

    Ramp brace. Needs 8mm Allen key. Cut-out to locate the upper ramp Retaining bolt Figure 2:6. Ramps and ramp brace stored on the pallet. P2T not shown. M6x90 bolt Upper ramp Figure 2:8. Bracket assemblies rotated. P2T not shown. Lower ramp Tools: •...
  • Page 22 Fit the lower ramps to the ramp Figure 2:6. Figure 2:7. brace. • Lock the ramps to the pallet with the M6x90 bolts (B). P2T 2-Knife Trimmer Page 2-6 CHAPTER 2 - Unpack the P2T Unload the P2T Issue 1b, June 2018...
  • Page 23 Information Unlock the brakes of the adjust- Unload the P2T from the pallet. • Push the P2T down the ramps. The able castors on the P2T. P2T is heavy. Make sure you control the movement of the P2T. Return the ramps and bolts to Figure 2:6.
  • Page 24 P2T 2-Knife Trimmer Page 2-8 CHAPTER 2 - Unpack the P2T Unload the P2T Issue 1b, June 2018...

  • Page 25: Prepare The Blm

    Fit the Mounting Brackets and Outfeed Covers ....3-5 • Make sure you have the correct installation hardware for the P2T and that you have fitted the required modifications to the BLM.

  • Page 26: Remove Covers From The Blm

    Figure 3:5. 900-227 stacker interface PCB RH top short cover Fixing screw Figure 3:3. Remove the RH top short cover P2T 2-Knife Trimmer Page 3-2 CHAPTER 3 - Prepare the BLM Remove Covers from the BLM Issue 1b, June 2018...
  • Page 27 • Store this cable in the blue acces- position by 1 x button-head screw. When you remove the outfeed RH connect to the P2T. sory bag in the BLM. cover, you can access the 900-227 • If an outfeed stacker is fitted Figure 3:5.

  • Page 28: Remove The Outfeed Stacker From The Blm

    Go to Section 3.3. Lift the outfeed stacker to disengage completely from the bottom chassis rail. P2T 2-Knife Trimmer Page 3-4 CHAPTER 3 - Prepare the BLM Remove the Outfeed Stacker from the BLM Issue 1b, June 2018...

  • Page 29: Fit The Installation Hardware To The Blm

    Figure 3:7. Figure 3:8.  Tools: Figure 3:7. 914-569 P2T pivot kit - included with the P2T • Allen keys: 3, 4mm • Spanner: 8mm • Wire cutters - supplied with the BLM. See Section 1.6.1.
  • Page 30 Pivot location bracket Leave approximately  300 mm free cable for connection to the mains input of the P2T. Front, left castor Figure 3:10. Fit the mains power cable to the lower chassis rail. Left-to-Right machine shown. Figure 3:12. Fit item to the bottom chassis rail of the BLM ...
  • Page 31 BLM Mains power input  Pivot bracket Figure 3:14. Pivot bracket, item  fitted to the P2T The docking latch assembly is held in position by 2 x M5x12 cap-head screws with shakeproof washers. P2T 2-Knife Trimmer Page 3-7...
  • Page 32 Make sure you leave approximately 300 transformer, then use the mm of cable to the front of the BLM to transformer connection connect to the mains input of the P2T. cable supplied with the • Fit a cable tie either side of the outfeed...
  • Page 33 Figure 3:7. P2T. Figure 3:14. • Use the screws supplied to fasten the pivot bracket to the underside of the P2T. P2T 2-Knife Trimmer Page 3-9 CHAPTER 3 - Prepare the BLM Fit the Installation Hardware to the BLM Issue 1b, June 2018...
  • Page 34 P2T 2-Knife Trimmer Page 3-10 CHAPTER 3 - Prepare the BLM Fit the Installation Hardware to the BLM Issue 1b, June 2018...

  • Page 35: P2T Installation

    Fit the P2T to the BLM ........

  • Page 36: Fit The P2T To The Blm

    Figure 4:2. The P2T 2-Knife Trimmer Spirit level Adjustable castor Figure 4:1. Castor thread on the BLM Pivot bracket Figure 4:3. P2T level adjustment - front to back P2T 2-Knife Trimmer Page 4-2 CHAPTER 4 - P2T Installation Fit the P2T to the BLM...
  • Page 37 Infeed conveyor support Spirit level Figure 4:7. P2T top cover The distance Figure 4:4. P2T level adjustment - side to side between the bottom of the infeed conveyor support and the floor. Outfeed cover Figure 4:6. P2T infeed height The distance...
  • Page 38 6. 3 x short cable ties Infeed conveyor   support  Figure 4:8. 914-569 P2T pivot kit 4 mm Allen key 3rd adjustment hole from the left Outfeed cover Pivot location bracket Figure 4:11. Infeed conveyor support to outfeed cover clearance Figure 4:9.
  • Page 39 Mains power cable Figure 4:12. P2T mains power inlet • To prevent twist on the frame of the P2T, Small cable ties adjust each adjustable-castor a maximum of 6 mm (0.25 inch) in turn. •...
  • Page 40 Figure 4:9. Figure 4:10. When the height of the BLM at the pivot. • Align the hole in the pivot bracket of the P2T P2T is correct, then with the adjustment hole from the left in undock the P2T from the pivot location bracket on the BLM.

  • Page 41: Alignment Of The P2T To The Blm

    C.1. Turn on the P2T. Important: For the BLM to auto-detect the P2T, Mains power cable you must turn on the P2T before you turn on the BLM. Figure 4:14. P2T mains power inlet • Make sure that the BLM is turned off.
  • Page 42 Section 4.4 - Fit the PBS/P2T Pivot Bracket P2T pivot bracket. to the BLM. Fit the covers. Section 4.3 - Fit the Covers to the P2T and to the BLM. P2T 2-Knife Trimmer Page 4-8 CHAPTER 4 - P2T Installation...

  • Page 43: Fit The Covers To The P2T And To The Blm

    Fit the Covers to the P2T and to the BLM Folder cover Tools: • Allen keys: 3, 4 mm • Spanner: 8 mm LH side cover Drive cover Top cover Outfeed cover top RH side cover Outfeed cover RH Outfeed cover LH Trim bin.
  • Page 44 2 x button-head screws. • Fit the drive cover to the BLM. • Close the folder cover. P2T 2-Knife Trimmer Page 4-10 CHAPTER 4 - P2T Installation Fit the Covers to the P2T and to the BLM Issue 1b, June 2018...
  • Page 45 • Pull the top of the outfeed stacker to open. The outfeed stacker locks in position. P2T 2-Knife Trimmer Page 4-11 CHAPTER 4 - P2T Installation Fit the Covers to the P2T and to the BLM Issue 1b, June 2018...

  • Page 46: Check And Adjust Stacker Mounting Height. Canon I300

    Make some test books to confirm correct operation of Stacker conveyor the system. Figure 4:23. Outfeed stacker - high position P2T 2-Knife Trimmer Page 4-12 CHAPTER 4 - P2T Installation Fit the Covers to the P2T and to the BLM Issue 1b, June 2018...
  • Page 47 Press the catch (A) and pull the plug. Do not pull the cable. • Pull and lift the outfeed stacker to remove. P2T 2-Knife Trimmer Page 4-13 CHAPTER 4 - P2T Installation Fit the Covers to the P2T and to the BLM Issue 1b, June 2018...
  • Page 48 Lower the stacker to engage with the fixing studs. Connect the power cable. P2T 2-Knife Trimmer Page 4-14 CHAPTER 4 - P2T Installation Fit the Covers to the P2T and to the BLM Issue 1b, June 2018...

  • Page 49: Fit The Pbs/P2T Pivot Bracket To The Blm

    BLM. LH front. M8x35 cap-head screw Pivot post PBS/P2T pivot bracket PBS/P2T pivot bracket Figure 4:27. Fit the PBS/P2T pivot bracket. From above. Figure 4:25. PBS/P2T pivot bracket Wheel mount plate on the BLM. LH front. PBS/P2T pivot bracket Figure 4:28.
  • Page 50 Move the Book Stacker toward the BLM. See which adjustment hole you Figure 4:29. The adjustment used to align the P2T with the BLM. holes in the PBS/P2T pivot bracket are on the same pitch as those in the pivot location bracket of the P2T.
  • Page 51 Use the cap-head screw, washers and nut to fasten the pivot post to the PBS/P2T pivot bracket. Below Below Above P2T 2-Knife Trimmer Page 4-17 CHAPTER 4 - P2T Installation Fit the PBS/P2T Pivot Bracket to the BLM Issue 1b, June 2018...
  • Page 52 P2T 2-Knife Trimmer Page 4-18 CHAPTER 4 - P2T Installation Fit the PBS/P2T Pivot Bracket to the BLM Issue 1b, June 2018...
  • Page 53 APPENDIX A Check and Adjust the P2T for Level ......A-2 Remove the LH, Bottom, Large Cover......A-4...

  • Page 54: Check And Adjust The P2T For Level

    Check and Adjust the P2T for Level Tools: • Spirit level - see Accuracy of the Spirit Level • Ratchet handle - supplied with the BLM. See Section 1.6.1. Spirit level • Socket: 14mm - supplied with the BLM. See Section 1.6.1.
  • Page 55 P2T by 2mm. Caution: Do not adjust the adjustable- castors further than the top of their threads. See Figure A:3. P2T 2-Knife Trimmer Page A-3 APPENDIX A - Miscellaneous Check and Adjust the P2T for Level Issue 1b, June 2018...

  • Page 56: Remove The Lh, Bottom, Large Cover

    LH bottom large cover tom large cover outward and disengage the brackets at the top. Figure A:6. Figure A:5. Cover lifted P2T 2-Knife Trimmer Page A-4 APPENDIX A - Miscellaneous Remove the LH, Bottom, Large Cover Issue 1b, June 2018...
  • Page 57 Prepare the Pallet ........B-6 Load the P2T onto the Pallet ....... B-9 Remove the Installation Hardware from the BLM .

  • Page 58: Disconnect The P2T From The Blm

    Disconnect the P2T from the BLM Tools: Small cable ties • Allen keys: 3, 4, 5, 8mm • Spanners: 8, 10, 17mm • Steel rule or tape measure • Wire cutters - supplied with the BLM. See Section 1.6.1. •...
  • Page 59 See B, Figure B:2. • Release the downward pres- sure and the outfeed stacker will automatically fold. Rotate the P2T away from the BLM. Disconnect the mains power cable Figure B:1. from the P2T. • Disconnect the mains power cable from the mains power socket on the P2T.

  • Page 60: Prepare The P2T

    Top cover (open) Mains power input M5 cap-head screw Pivot bracket Side cover Figure B:8. Remove a side cover from the P2T Figure B:6. Pivot bracket P2T 2-Knife Trimmer Page B-4 APPENDIX B - Uninstall the P2T Prepare the P2T...
  • Page 61 Remove the LH side cover and Figure B:7. Figure B:8. the RH side cover. • Open the top cover of the P2T. The top cover is supported by gas struts in the open position. • Remove the screw from the mid- Figure B:9.

  • Page 62: Prepare The Pallet

    Lower ramp Ramp brace. Needs 8mm Allen key. Cut-out to locate the upper ramp Retaining bolt Figure B:10. Ramps and ramp brace stored on the pallet. P2T not shown. M6x90 bolt Upper ramp Figure B:12. Bracket assemblies rotated. Tools: Lower ramp •...
  • Page 63 Lock the ramps to the pallet with the M6x90 bolts (B). Fit the upper ramps to the Figure B:10. Figure B:11. lower ramp assembly. P2T 2-Knife Trimmer Page B-7 APPENDIX B - Uninstall the P2T Prepare the Pallet Issue 1b, June 2018...
  • Page 64 See ‘A’ in Figure B:12. • Rotate the bracket assemblies out- ward. See ‘B’ in Figure B:12. P2T 2-Knife Trimmer Page B-8 APPENDIX B - Uninstall the P2T Prepare the Pallet Issue 1b, June 2018...

  • Page 65: Load The P2T Onto The Pallet

    INFEED Retaining bolt INFEED Figure B:14. Bracket assemblies rotated. P2T not shown. Figure B:13. Load the P2T in this direction only. Infeed to the left. Base of the P2T Shipping bolt Transit bracket Figure B:15. Shipping bolt fitted to the...
  • Page 66 Step Action Information Transit bracket Important: Figure B:13. When you push the P2T up the Brake ramps, make sure the infeed faces to the left. Push the P2T up the ramps and Figure B:13. onto the pallet. When the P2T is far enough onto...
  • Page 67 Adjust the height of the castors as needed. Use cable ties to lock the castors in position. Fit the side covers to the P2T. Fit the trim bin on the pallet against Figure B:16. the LH side cover. •...

  • Page 68: Remove The Installation Hardware From The Blm

    Figure B:19. Remove the outfeed top cover disconnect from the mains power. Open the folder cover. Figure B:18. P2T 2-Knife Trimmer Page B-12 APPENDIX B - Uninstall the P2T Remove the Installation Hardware from the BLM Issue 1b, June 2018...
  • Page 69 Lift the drive cover approximately 15mm. • Disengage the drive cover from the support brackets. • Pull the cover toward you. P2T 2-Knife Trimmer Page B-13 APPENDIX B - Uninstall the P2T Remove the Installation Hardware from the BLM Issue 1b, June 2018...

  • Page 70: Remove The Installation Hardware

    Mains power cable. Figure B:23. Mains power cable fitted to the lower chassis rail. L to R machine. P2T 2-Knife Trimmer Page B-14 APPENDIX B - Uninstall the P2T Remove the Installation Hardware from the BLM Issue 1b, June 2018...
  • Page 71 PL4 of the 900-227 stacker interface PCB. When installed, this cable is stored in the accessory bag. P2T 2-Knife Trimmer Page B-15 APPENDIX B - Uninstall the P2T Remove the Installation Hardware from the BLM Issue 1b, June 2018...
  • Page 72 The docking latch assembly is held in position by 2 x M5x12 cap-head screws with shakeproof washers. P2T 2-Knife Trimmer Page B-16 APPENDIX B - Uninstall the P2T Remove the Installation Hardware from the BLM Issue 1b, June 2018...

  • Page 73: Fit The Covers To The Blm

    Fit the drive cover to the BLM. Close the folder cover. Fit the stacker. See the BLM Service Manual. Turn on the BLM. Drive cover Uninstall the P2T from the touch • Touch MENU screen on the BLM. • Select Supervisor Mode •...
  • Page 74 P2T 2-Knife Trimmer Page B-18 APPENDIX B - Uninstall the P2T Remove the Installation Hardware from the BLM Issue 1b, June 2018...
  • Page 75 Connection ......... . C-4 P2T 2-Knife Trimmer...

  • Page 76: Adjust The Operating Voltage

    The fixed end of the brown wire is at the ‘L’ position on the terminal block Figure C:3. The terminal block P2T 2-Knife Trimmer Page C-2 APPENDIX C - Adjust the Transformer Adjust the Operating Voltage Issue 1b, June 2018...

  • Page 77: Preparation

    Measure the local mains-power supply voltage with a multimeter. Figure C:4. Transformer tappings P2T 2-Knife Trimmer Page C-3 APPENDIX C - Adjust the Transformer Adjust the Operating Voltage Issue 1b, June 2018...

  • Page 78: Adjust The Voltage

     Connect the mains-power cable Figure C:5. label from the supplied sheet of supplied with the P2T to the voltage labels. mains-power input connector of Fit the cover to the P2TT auxiliary the P2TT auxiliary transformer.
  • Page 79 Step Action Information Connect the mains-power cable supplied with the P2T to the wall outlet. Use the mains-power on and off  Figure C:5. switch to turn on the auxiliary transformer. P2T 2-Knife Trimmer Page C-5 APPENDIX C - Adjust the Transformer...
  • Page 80 P2T 2-Knife Trimmer Page C-6 APPENDIX C - Adjust the Transformer Adjust the Operating Voltage Issue 1b, June 2018...
  • Page 81 Voltage. • Amended Section 4.2 - Alignment of the P2T to the BLM. • Amended Section 4.3 - Fit the Covers to the P2T and to the BLM. Appendix D: • New Chapter. P2T 2-Knife Trimmer Page D-1 APPENDIX D - List of Changes...
  • Page 82 P2T 2-Knife Trimmer Page D-2 APPENDIX D - List of Changes Issue 1b, June 2018...
  • Page 84 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...

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