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Watkiss Automation PowerSquare 200 User Manual

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Watkiss PowerSquare™200

User Manual

English, Issue 1f, November 2007

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Summary of Contents for Watkiss Automation PowerSquare 200

  • Page 1: User Manual

    Watkiss PowerSquare™200 User Manual English, Issue 1f, November 2007...
  • Page 2 Watkiss Automation Limited shall not be liable for errors contained herein or for incidental or con- sequential damage in connection with the furnishing, performance or use of this material.

  • Page 3: Table Of Contents

    Table of Contents 1. Introduction to the Watkiss PowerSquare™200 ..1 Description of the PowerSquare ..... . . 2 2.
  • Page 4 Adjust the Stacker Collection Table ....27 Adjust the Gate in the Gathering Area ....28 Operate the PowerSquare offline .

  • Page 5: Introduction To The Watkiss Powersquare™200

    Introduction to the Watkiss CHAPTER 1 PowerSquare™200 Thank you for choosing the Watkiss PowerSquare™200. Your Manual The Watkiss PowerSquare™200 User Manual describes how to do these tasks. • Operate the Watkiss PowerSquare™200 • Find and correct error conditions • Do normal maintenance tasks Operator training is given when the PowerSquare is installed.

  • Page 6: Description Of The Powersquare

    1 - Introduction to the Watkiss PowerSquare™200 - Description of the PowerSquare Installation Your PowerSquare must be installed by a Watkiss service engineer. Special knowledge is needed to install the machine. CAUTION Only connect the machine to a mains power supply of the correct voltage with a good earth-connection.
  • Page 7 1 - Introduction to the Watkiss PowerSquare™200 - Description of the PowerSquare Component - Function Table Component Function The connecting bridge The connecting bridge moves the printed sheets from the printer to the PowerSquare. If needed, the sheets are rotated into the correct direction. Rota- tion lets the printer operate at optimum print speed.
  • Page 8 1 - Introduction to the Watkiss PowerSquare™200 - Description of the PowerSquare The Rear Panel of the PowerSquare Rating and Serial Label Mains Power ON/OFF Switch Voltage Advisory Label Fuses Voltage Label Mains Power Input Connector FIGURE 3. The Rear Panel of the PowerSquare. Component - Function Table Component Function...

  • Page 9: How To Run The Powersquare

    How to Run the PowerSquare CHAPTER 2 Introduction This chapter gives information on how to run a job on the PowerSquare. For information on how to operate the printer, refer to the printer documentation. Information about the user interface is included in “The User Interface” on page 11.

  • Page 10: Before You Begin

    2 - How to Run the PowerSquare - Before You Begin Before You Begin Paper and Book Quality Instructions • The size of paper and the thickness of the set must be measured. These measurements are entered into the touch screen before you begin a print job.
  • Page 11 2 - How to Run the PowerSquare - Enter the Job Settings This set can be made into a book. See “Operate the PowerSquare offline” on page 29. Procedure If the Print Job is then follow this procedure a standard paper size “Job Setting for a Standard Paper Size”...

  • Page 12: Adjust The Stacker

    2 - How to Run the PowerSquare - Adjust the Stacker Step Action Information Enter the page rotation set- For A4 paper size, the normal setting for ting. . Rotation lets the printer oper- ROTATE ate at optimum speed. Touch to turn the sheet rotation ROTATE .

  • Page 13: Run The Job

    2 - How to Run the PowerSquare - Run the Job Run the Job Procedure 1. Make sure the adjustments on the PowerSquare are complete before you release the print job from the print queue. 2. Start the print job. The PowerSquare starts automatically. 3.
  • Page 14 2 - How to Run the PowerSquare - Run the Job Watkiss PowerSquare™200 User Manual...

  • Page 15: The User Interface

    The User Interface CHAPTER 3 The user interface includes a colour touch screen and START/STOP buttons. START Button STOP Button Touch Screen FIGURE 4. The User Interface The Touch Screen Introduction Operate the touch screen with a fingertip. You can touch the screen with a blunt item, for example a palm-top ‘wand’...
  • Page 16 3 - The User Interface - The Touch Screen Touch the screen to restore the normal brightness. The touch screen takes two or three minutes to reach full brightness. Illustration         FIGURE 5. The Touch Screen Watkiss PowerSquare™200 User Manual...
  • Page 17 3 - The User Interface - The Touch Screen Component - Function Table Component Function Window Tabs The touch screen buttons are divided into groups that have connected functions. Each group of buttons has a separate window. Touch the correct tab to select the window.

  • Page 18: The Job Mimic

    3 - The User Interface - The Job Mimic The Job Mimic The job mimic shows the current machine status.     FIGURE 6. The Job Mimic Icon Information Paper Size The following items are shown • the size of paper •...

  • Page 19: The Basic Window

    3 - The User Interface - The BASIC Window The BASIC Window window gives you access to frequently-changed machine set- BASIC tings. The BASIC Window Buttons Button Information Touch to enter the paper size. PAPER SIZE PAPER SIZE When the machine is in operation, you can adjust the PAPER by a maximum of +/- 1mm.
  • Page 20 3 - The User Interface - The BASIC Window Button Information - PRESSURE Touch to increase or decrease the pressure used PRESSURE to form the spine. Touch to increase the amount of spine form. Touch decrease the amount of spine form. The range is -9 to +9. The default setting is 0.

  • Page 21: The Load & Save Window

    3 - The User Interface - The LOAD & SAVE Window The LOAD & SAVE Window window lets you save and reload job settings. Each job is LOAD & SAVE given a name. The jobs are displayed in a list on the screen. Touch the job name or use the Up arrow or Down arrow to make the selection.

  • Page 22: The Advanced Window

    3 - The User Interface - The ADVANCED Window Button Information VIEW OF JOB changes the order that saved jobs are VIEW OF JOB LIST LIST listed. There is a line between Factory Template jobs and jobs saved by the operator. The Factory Template jobs are at the top of the list - A->Z Touch...

  • Page 23: The Configure Window

    3 - The User Interface - The CONFIGURE Window The CONFIGURE Window window lets you make changes to the configuration of the CONFIGURE machine. Some of the settings can be changed, depending on the current access level. The CONFIGURE Window Buttons Button Information MACHINE...

  • Page 24: The Menu Window

    3 - The User Interface - The MENU Window The MENU Window shows the settings that are not changed during day-to-day operation. MENU These settings include • Change the Access Level • Change the display language • Advanced machine settings that are accessed by a person who has the cor- rect access-code.

  • Page 25: Standard Tasks

    Standard Tasks CHAPTER 4 Introduction This chapter describes the standard tasks that are needed in the day-to-day operation of your PowerSquare. Load and Save the Job Settings Introduction The current job settings can be saved to the memory and reloaded for use again at a later date.

  • Page 26: Open The Connecting Bridge Cover

    4 - Standard Tasks - Open the Connecting Bridge Cover Reset the PowerSquare to default settings 1. Touch LOAD & SAVE 2. Select the from the list of jobs. Default Job Template 3. Touch LOAD 4. Touch Open the Connecting Bridge Cover When to do If a machine error occurs, or for maintenance.

  • Page 27: Lift And Lower The Clincher Frame

    4 - Standard Tasks - Lift and Lower the Clincher Frame Note The folder cover has an interlock switch. The PowerSquare stops if you open the folder cover. FIGURE 8. Unlock the Folder Cover Procedure 1. Lift the black locking handle against the spring pressure. 2.

  • Page 28: Open The Gathering Area Cover

    4 - Standard Tasks - Open the Gathering Area Cover Clincher Locking Handle Clincher Frame FIGURE 10. Clincher Frame Components Lift the Clincher Frame 1. Open the folder cover. 2. Turn the locking handle to the left , until the thread is disengaged. 3.

  • Page 29: Lift The Powersquare Main Deck

    4 - Standard Tasks - Lift the PowerSquare Main Deck Procedure 1. Open the connecting bridge cover. 2. Use the gathering area cover handle to lift the gathering area cover. Lift the PowerSquare Main Deck When to do If a machine error occurs, or for maintenance. •...

  • Page 30: Empty The Trim Bin

    4 - Standard Tasks - Empty the Trim Bin Empty the Trim Bin When to do • An error message is displayed on the touch screen when the trim bin is full. • You can empty the trim bin when you choose. For example, before you start a print job.

  • Page 31: Adjust The Stacker Collection Table

    4 - Standard Tasks - Adjust the Stacker Collection Table Stitch-wire Cabinet open FIGURE 14. Stitch-wire Cabinet Procedure 1. Open the stitch-wire cabinet cover. The cover is held closed by a magnetic catch. Adjust the Stacker Collection Table The collection table must be in the correct position for the stacker to operate. The position of the collection table depends on the finished size of the job.

  • Page 32: Adjust The Gate In The Gathering Area

    4 - Standard Tasks - Adjust the Gate in the Gathering Area Procedure 1. Insert the collection table into one of the three pairs of slots. Finished Book Metric Finished Book Slot Metric Paper Size Dimensions US Paper Size  105 x 148 mm 4¼...

  • Page 33: Operate The Powersquare Offline

    4 - Standard Tasks - Operate the PowerSquare offline Lower the Gate in the Gathering Area 1. Open the gathering area cover. See “Open the Gathering Area Cover” on page 24. 2. Press on the gate to disengage the gate from the metal spring-clip. See Figure 16 on page 28.
  • Page 34 4 - Standard Tasks - Operate the PowerSquare offline Watkiss PowerSquare™200 User Manual...

  • Page 35: Error Conditions, Problems And Solutions

    Error Conditions, Problems CHAPTER 5 and Solutions This chapter describes how to correct problems that can occur on your PowerSquare. If a problem continues, contact your Watkiss service engineer. Printer Error If a paper jam or other error occurs in the printer, the printer and the PowerSquare stop.

  • Page 36: General Problems

    5 - Error Conditions, Problems and Solutions - General Problems General Problems Problem Cause Solution The PowerSquare The PowerSquare is not Turn ON the PowerSquare. does not start turned on. See “Turn On the PowerSquare” on page 6. The printer has not sent Correct the problem at the a job to the printer.

  • Page 37: Message List

    5 - Error Conditions, Problems and Solutions - Message List Message List Message Information Reference AXES MOVING Some of the machine axes are moving. This message clears when the adjustment is complete. BOOK CYCLE TIME TOO The printer has delivered the sets LONG faster than the books can be made.
  • Page 38 5 - Error Conditions, Problems and Solutions - Message List Message Information Reference FLOW ERROR - FORMER There is an error at the former. See page 43. Open the folder cover and remove the book or books. If necessary, open the main deck to remove the book or books.
  • Page 39 5 - Error Conditions, Problems and Solutions - Message List Message Information Reference JAM IN GATHERING AREA There is a paper jam in the gather- See page 41. ing area. Open the connecting bridge cover, lift the connecting bridge and remove the paper jam. JAM IN STACKER AREA There is a paper jam at the outfeed of the machine.
  • Page 40 5 - Error Conditions, Problems and Solutions - Message List Message Information Reference SHUTTLE MOTOR COMMS Use the mains ON/OFF switch. FAIL Turn the machine OFF, then turn the machine ON. If the problem continues, then call your Watkiss service engineer. SHUTTLE MOTOR ERROR Use the mains ON/OFF switch.

  • Page 41: Book Quality

    5 - Error Conditions, Problems and Solutions - Book Quality Message Information Reference TRIM BIN OPEN The trim bin is not fitted or is not contacting the safety switch. Fit the trim bin. TRIM BLADE NOT PARKED The trim blade is in the wrong position.
  • Page 42 5 - Error Conditions, Problems and Solutions - Book Quality Book Quality Problems Book Quality Cause Solution Problem The finished book is The wrong paper size Measure the paper and enter the not tidy was entered on the correct dimensions. See “Enter touch screen.
  • Page 43 5 - Error Conditions, Problems and Solutions - Book Quality Book Quality Cause Solution Problem The trimmed edge is The trimmer blade is Call your Watkiss service engi- of bad quality blunt or damaged. neer. The stitch is not on The wrong paper size Measure the paper and enter the the centre-line of the...
  • Page 44 5 - Error Conditions, Problems and Solutions - Book Quality Spine Form Problems Spine Form Condition Solution Correct The spine is square at each The PowerSquare setting end and the paper is not is correct. Adjustment is damaged. not needed. Incorrect The spine needs more form.

  • Page 45: Paper Jams

    5 - Error Conditions, Problems and Solutions - Paper Jams Paper Jams Connecting Bridge Gathering Area Stitch Area Fold and Forming Areas Trim Area FIGURE 17. Paper Jam Locations Bridge Infeed Cover FIGURE 18. Paper Jam Location - Bridge Infeed Jam in the Bridge Infeed 1.
  • Page 46 5 - Error Conditions, Problems and Solutions - Paper Jams 3. Remove the jammed paper. 4. Check the belts are in the correct position. Adjust the position of the belts if necessary. See Figure 19. 5. Close the gathering area cover. 6.
  • Page 47 5 - Error Conditions, Problems and Solutions - Paper Jams Jam in the Stitch Area Step Action Information Open the folder cover. See “Open the Folder Cover” on page 22. Lift the clincher frame. See “Lift and Lower the Clincher Frame”...
  • Page 48 5 - Error Conditions, Problems and Solutions - Paper Jams Jam before the Trimmer Trimmer Infeed Conveyor FIGURE 20. Trimmer Infeed Conveyor viewed from above. Step Action Information Open the PowerSquare main deck. Remove the trim bin. Remove the trimmer infeed con- The procedure can be seen from veyor.
  • Page 49 5 - Error Conditions, Problems and Solutions - Paper Jams Jam in the Trim Area Orange Plastic Hand Screw Locking Plate Trim Stop Guard FIGURE 21. Trim Stop Assembly Step Action Information Remove the trim bin. Loosen the 2 orange plastic hand The locking plates can rotate to screws to release the locking release the trim stop guard.

  • Page 50: Stitch Head Problems

    5 - Error Conditions, Problems and Solutions - Stitch Head Problems Stitch Head Problems Problem Cause Solution The stitch head does function is Make sure is set to STITCH STITCH not operate not selected. or more. See “STITCHES” on page 15. The stitch-wire is fin- Load a new spool of stitch- ished.
  • Page 51 5 - Error Conditions, Problems and Solutions - Clear a Stitch-wire Jam Top location of Middle Wire Tube Middle Wire Tube Metal Spring Clip Feed Gears FIGURE 22. Stitch Head Watkiss PowerSquare™200 User Manual...
  • Page 52 5 - Error Conditions, Problems and Solutions - Clear a Stitch-wire Jam Clear the Jammed Wire Step Action Information Cut the stitch-wire at position ‘A’, approximately 50mm (2-inches) from where the stitch-wire leaves the stitch-wire guide. ‘A’. Cut stitch-wire here. Cut the stitch-wire at position ‘B’, between the feed gears and the middle wire tube.

  • Page 53: Clear A Stitch Head Jam

    5 - Error Conditions, Problems and Solutions - Clear a Stitch Head Jam Clear a Stitch Head Jam Problem: A loud and repeated banging noise from the fold area of the PowerSquare or the PowerSquare will not start. Action: Press the stop button .
  • Page 54 5 - Error Conditions, Problems and Solutions - Clear a Stitch Head Jam Step Action Information Lift the PowerSquare main deck. See “Lift the PowerSquare Main Deck” on page 25. Remove the wire-holder from the • Move the wire-holder retaining stitch head.

  • Page 55: Calibrate The Touch Screen

    5 - Error Conditions, Problems and Solutions - Calibrate the Touch Screen Calibrate the Touch Screen When to do Calibrate the touch screen if the buttons do not operate or the buttons do not operate correctly CAUTION Use a pencil, the blunt end of a pen or a palm top wand for this procedure. Do not use a sharp object.

  • Page 56: Manually Park The Shuttle

    5 - Error Conditions, Problems and Solutions - Manually park the Shuttle Manually park the Shuttle When to do The error messages ‘ ’ and ‘ ’ are MANUALLY PARK SHUTTLE SHUTTLE NOT PARKED displayed. Illustrations FIGURE 25. Shuttle Assembly Position - CORRECT "...
  • Page 57 5 - Error Conditions, Problems and Solutions - Manually park the Shuttle Procedure Step Action Information Open the folder cover. See “Open the Folder Cover” on page 22. Push the shuttle-assembly to the Figure 25 on page 52 shows the right.
  • Page 58 5 - Error Conditions, Problems and Solutions - Manually park the Shuttle Watkiss PowerSquare™200 User Manual...

  • Page 59: Maintenance

    Maintenance CHAPTER 6 Service Interval • The PowerSquare needs service every four months. • After every one-million stitches, the stitch head needs service. This interval is every 3rd spool of stitch-wire. Only a Watkiss service engineer can service the PowerSquare. Contact your supplier for further information.

  • Page 60: Clean The Powersquare

    6 - Maintenance - Clean the PowerSquare Operator Maintenance Plan Interval Task Reference • Every week Clean the machine. See page 56 Clean the static elimination See page 56 bars. • Every month, or Lubricate the stitch head. See page 60 •...
  • Page 61 6 - Maintenance - Clean the Static Elimination Bars Illustration Static Elimination Bar FIGURE 28. The Static Elimination Bar in the Connecting Bridge Static Elimination Bars FIGURE 29. The Static Elimination Bars in the Gathering Area Note On the bottom of the static elimination bar there is a row of sharp pins. The pins are not dangerous, but if you touch the pins accidentally, this action can alarm you.

  • Page 62: Clean The Former Roller

    6 - Maintenance - Clean the Former Roller Procedure Step Action Information Clean the static elimination bar in • Open the connecting bridge the connecting bridge. cover. • Clean the pins on the bottom of the static elimination bar with a small brush.

  • Page 63: Clean The The Polyurethane Strips In The Form Clamp

    6 - Maintenance - Clean the the Polyurethane Strips in the Form Clamp Procedure Step Action Information Enter the correct settings on the • Set the touch screen to the cor- touch screen. rect PAPER SIZE. • Set the SET THICKNESS •...

  • Page 64: Lubricate The Stitch Head

    6 - Maintenance - Lubricate the Stitch Head Illustration Polyurethane Strip FIGURE 30. Polyurethane strips Procedure Step Action Information Open the folder cover Use an alcohol wipe, or apply a small amount of alcohol to a lint free cloth. Reach into the form clamp and There is a polyurethane strip on clean each of the polyurethane the face of each side of the clamp.
  • Page 65 6 - Maintenance - Lubricate the Stitch Head Illustrations FIGURE 31. Trim the nozzle of the tube of grease Stitch Head Wire Holder Wire Holder Retaining Spring FIGURE 32. Stitch Head Wire Holder Driver, in upper position Driver Bar FIGURE 33. Driver Bar Watkiss PowerSquare™200 User Manual...
  • Page 66 6 - Maintenance - Lubricate the Stitch Head Before You Begin Step Action Information Trim the first part from the nozzle. See Figure 31 on page 61 Remove the cap from the tube of grease. Fit the nozzle to the tube of grease.

  • Page 67: Install New Stitch-Wire

    6 - Maintenance - Install New Stitch-wire Lubricate the Wire-feed Cam Nozzle of the tube of grease Wire-feed cam Feed lever FIGURE 34. Lubricate the wire-feed cam Step Action Information Lift the PSQ main deck. Apply 10mm of grease from the See FIGURE 34.
  • Page 68 6 - Maintenance - Install New Stitch-wire Before You Begin Lift the PowerSquare main deck. See “Lift the PowerSquare Main Deck” on page 25. Remove the Stitch-wire from the Stitch Head Stitch-wire Guide Block Stitch-wire Felt wire-cleaning pads FIGURE 35. Stitch-wire Guide Block Step Action Information...
  • Page 69 6 - Maintenance - Install New Stitch-wire Fit a New Stitch-wire Spool Step Action Information Open the stitch-wire cabinet. Remove the stitch-wire cap and finished stitch-wire spool. Fit a new stitch-wire spool. Fit the stitch-wire cap. Loosen the end of the stitch-wire from the edge of the stitch-wire spool.
  • Page 70 6 - Maintenance - Install New Stitch-wire Step Action Information Feed the end of the stitch-wire between the felt wire-cleaning pads. Felt Wire-Cleaning Pads Push the stitch-wire into the stitch- wire guide block. Push stitch-wire in direction of arrow Push the stitch-wire as far as pos- sible.
  • Page 71 6 - Maintenance - Install New Stitch-wire Close the PowerSquare Step Action Information Close the stitch wire cabinet. Lower the PowerSquare main deck. Lower the clincher frame. See “Lower the Clincher Frame” on page 24. Close the folder cover. Close the connecting bridge cover. Feed the Stitch-wire Step Action...
  • Page 72 6 - Maintenance - Install New Stitch-wire Watkiss PowerSquare™200 User Manual...

  • Page 73: Specifications

    Specifications CHAPTER 7 Operating 10-35°C at 35-85% relative humidity Conditions Production Cycle time: Printer dependent. Interset gap: 2 seconds Minimum set time: 4.5 seconds Maximum set time: 12.5 seconds Typical set time: 7.5 seconds Stock Sizes - Minimum input size: 200 x 200mm Online Maximum input size: 340 x 500mm Stitch &...
  • Page 74 7 - Specifications - Sheet Rotation Integrated rotator ensures maximum printer productivity. Maximum rotation sheet size: 320 x 220mm Minimum rotation sheet size: 207 x 200mm The cross-track dimension of the sheet (before rotation) must be at least 7mm greater than the in-track dimension. Stitch &...
  • Page 75 7 - Specifications - Approvals Complies with CE and UL. Conforms to FCC rules Part 15 Class A. * Standard book is made from 20 sheets of 80gsm paper, with 2 stitches. 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.
  • Page 76 7 - Specifications - Watkiss PowerSquare™200 User Manual...

  • Page 77: Declaration Of Conformity

    BS EN 60950 : 2002 EMC: 89/336/EEC Council Directive 'on the approximation of laws of Member States relating to electromagnetic compatibility'. EN55022:1998 Class A EN55024:1998 EN61000-3-2:2000 EN61000-3-3:1995 + A1:2001 M C Watkiss Technical Director, Watkiss Automation Ltd. 2nd January 2007 Watkiss PowerSquare™200 User Manual...
  • Page 78 8 - Declaration of Conformity - Watkiss PowerSquare™200 User Manual...
  • Page 80 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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