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Watkiss Automation Plockmatic PowerSquare 224, Workbook

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Advanced Operation

Plockmatic PowerSquare™ 224 - Service Training Workbook 

17

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).

• If the trimmer paper clamp remains closed and the trimmer blade remains in 

the forward position, the trimmer needs manual operation (see Section 
6.20.4 in the PSQ Service Manual).

5.4

Book Quality and Machine Specifications

• Quality tolerance specification is included in this training workbook 

(see 

Section 16.)

• Product specification is included in this training workbook 

(see Section 15.)

Summary of Contents for 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: ...ocument is subject to change without notice Watkiss Automation Limited makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability...

Page 3: ...8 3 4 The Stitch Head and Clincher 9 3 5 The Stitch Process 9 3 6 Fold and Form 10 3 7 Trim 10 3 8 Outfeed and Stacker 11 4 User Interface GUI Operator Menu 12 4 1 Introduction 12 4 2 Power save 12 4...

Page 4: ...aintenance 30 9 1 Operator Maintenance 30 9 2 Technical Maintenance 30 9 3 Care Pack 30 10 Power and Control 31 10 1 Power 31 10 2 Control 32 10 3 Component Locations 33 10 4 DFA 35 11 Software 36 11...

Page 5: ...r paginations or to thicker stocks This makes the PowerSquare 224 a fast and cost effective alternative to perfect binding or tape binding Since it will also produce books from only a few sheets it pr...

Page 6: ...are hidden Make sure all buttons are visible as shown below Procedure 1 Right click on one of the arrows on the Navigation Toolbar 2 Click on Show page navigation tools 3 From the list select the but...

Page 7: ...diagram See FIGURE 2 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: ...5mm LG 2 1f 266 087 SPACER PSQ GATE 10 50ODX8IDX3LG 1 1g 266 095 SHAFT PSQ ACTIVE GATE TIE BAR 1 2 891 647 P ASSY PSQ TAMPER PIVOT DRIVE SIDE 1 2a 100 334 SCREW SKT HD CAP M2 5x10mm STAINLESS 1 2b 16...

Page 9: ...onnecting bridge if necessary See Section 1 7 1 The sheets of paper are gathered into a set in the gathering area When a set is complete it is collected by the shuttle See Section 1 7 2 See Section 1...

Page 10: ...See Section 1 7 6 The book is moved to the trim stop and clamped in position The fore edge of the book is trimmed by the trimmer blade that moves horizontally See Section 1 7 7 The book is released an...

Page 11: ...on see Section 1 7 in the PSQ Service Manual When the print job starts the printer sends a start signal to the PSQ Paper leaves the printer and enters the connecting bridge infeed The paper is moved t...

Page 12: ...fingers is for A3 size 11 x 17 paper An active gate in the sidelay closest to the stitch head jogs the incoming sheets into a tidy set When the set is complete the active gate lifts away to let the se...

Page 13: ...ith moving points The clincher forms a high quality stitch that lies flat against the book Drive for the stitch head and clincher operation is transferred from the main motor by a system of chains sha...

Page 14: ...a clutch and chain system When the carriage reaches the end of the carriage guide either the LH or RH limit sensor is operated If the carriage stops before either of the limit sensors is reached a ja...

Page 15: ...the trim clamp is released two solenoids move the trim stop from below the book The book is moved out of the trimmer by the book eject belt A conveyor moves the books from the PSQ and drops them on th...

Page 16: ...bject or with too much force These actions can damage the touch screen If you hear a beep when you operate the touch screen the selected function is not available Some functions are not available when...

Page 17: ...ors and other information The HELP button gives you more information Touch HELP then touch any button Touch HELP then touch the message list STATUS GREEN Ready or running ORANGE PLEASE WAIT ORANGE ATT...

Page 18: ...OLD Automatic according to thickness Number of form roller actions Pressure to make spine 9 to 9 Minimum thickness for square spine TRIM AUTO Trimmed dimension of the book Automatic according to thick...

Page 19: ...list Open the gathering area then use HELP to find out about the error message on the GUI message list CONFIGURE MACHINE OPTIONS MEASUREMENT STITCH SENSOR PRESET PAPER SIZES SIDE TRIM P2T PBS INSTALLE...

Page 20: ...t cut squarely an accurate book cannot be made Perform the following tasks Load the saved A3 Test job A3 input size Measure the paper from the stacker Make the book Delete the saved job Load the saved...

Page 21: ...with the hand crank is needed see Section 6 20 3 in the PSQ Service Manual If the trimmer paper clamp remains closed and the trimmer blade remains in the forward position the trimmer needs manual ope...

Page 22: ...1 GUI Functions and Section 6 20 Diagnostic Procedures in the PSQ Service Manual Review the following functions 6 11 3 2 1st Stitch Offset 6 11 7 3 Endlay Axis Calibration 6 11 8 2 Bridge Axis Calibra...

Page 23: ...roller The rotate axis is adjusted by a 24V DC Axis Motor The Bridge Drive motor runs when the PSQ starts The sheets are transported under 2 Optical Sensors The first Optical Sensor is located at the...

Page 24: ...in the Gathering Area Top Bridge Interface PCB 900 278 Tamper Stepper Motor PCB 900 277 Main Drive Stepper Motor PCB 900 279 Bridge Axis Motor Control PCB 900 212 Gathering Area Loaded Optical Sensor...

Page 25: ...titch position Locate the following Sidelay Axis Motor Control PCB 900 212 Endlay Axis Motor Control PCB 900 212 Sidelay Axis Motor Endlay Axis Motor Sidelay Axis Home Switch Sidelay Axis Limit Switch...

Page 26: ...limits This function can be used to give a clearance between the stitches and the print on the spine of the book The set is moved to the folding area when the set is stitched When the shuttle moves to...

Page 27: ...and is connected to the Stitch Sensor PCB The size of stitch or wire draw setting is calculated from the thickness of the paper and the number of sheets in the set or from the set thickness input by t...

Page 28: ...4 14 1 2 Fit the Existing Stitch Head ADJ 4 6 8 Check the Stitch Head Alignment Central to the Endlays ADJ 4 6 10 Check and Adjust the Clincher Alignment Side to side ADJ 4 6 11 Check and Adjust the...

Page 29: ...made with a 24V DC motor The fold blade retracts and the clamp closes on the book The form roller rolls along the spine of the book to create the SquareBack book The number of spine forms and the pre...

Page 30: ...cate the following in the Former Safety Interlock Switch RH End of Carriage Proximity Sensor LH End of Carriage Proximity Sensor Transfer Area Optical Sensor Former Interface PCB 900 213 Form Clamp Cl...

Page 31: ...rs on one of the trimmer infeed conveyor shafts The trimmer uses a chevron blade to apply balanced cutting pressure across the width of the book The chevron blade decreases to a minimum the shear forc...

Page 32: ...ds move the trim stop from below the book The book is moved out of the trimmer by the book eject belt A conveyor moves the books from the PSQ and drops them on the catch tray An adjustable collection...

Page 33: ...or the correct paper size book thickness etc Select 2 stitches Place the paper in the gathering area Use the TEST screen to make a book Motor Slow Pick up Shuttle x2 Activate Rear Tamper x2 1st Stitch...

Page 34: ...6 months In addition after 1 million stitches or 3 spools of stitch wire the stitch head must be disassembled and inspected for wear There is a kit of replacement parts for this procedure G8 Stitch H...

Page 35: ...r 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 A frequency inverter is used to change the single phase to 3 phase...

Page 36: ...n power off Red LEDs indicate output function Green LEDs indicate sensor and input functions The main control software is programmed into the IC on this PCB The version number is displayed on the GUI...

Page 37: ...nts are also listed in the Parts Listings Locate the following electrical components GUI CPU 900 208 Main Control PCB Anti Static Power Unit Fuse Relay PCB 900 228 Fuse Holder Interlock Relay PCB 900...

Page 38: ...s use the list below 900 208 Main Control PCB Anti Static Power Unit Fuse Relay PCB Fuse Holder Interlock Relay PCB Inverter Low Voltage Transformer Assy Mains Power Input Connector Mains Power On and...

Page 39: ...he PSQ Control input signals from the printer LEDs are RED LED 11 12 13 must be ON to let the PSQ run online LEDs are GREEN LED11 ST0 LED off Offline LED19 C0 Sheet exit LED12 ST1 LED off Fault LED20...

Page 40: ...ored in the flash memory When you turn on the machine the boot firmware loads the application software into the run memory so that the machine can operate The run memory does not store information whe...

Page 41: ...sories 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: ...mum input size with PBR5 370 x 520mm Sheet Rotation Integrated rotator ensures maximum printer productivity Maximum rotation sheet size 353 x 252mm Minimum rotation sheet size 207 x 200mm The cross tr...

Page 43: ...ches spool up to 291 500 Books spool approx 127 000 Trimming Maximum fore edge trim 28mm Minimum trimmed book size 78mm Trimming can be switched off Recommended minimum trim amount 1mm Stacker Capacit...

Page 44: ...Languages English French German Spanish Italian Dutch US English Chinese PRC Operator Maintenance Weekly At screen prompt 20 000 stitches lubricate the stitch head clean machine as instructed in user...

Page 45: ...820 EP 1479258 US 7325799 JP 4887449 Standard book is made from 20 sheets of 80gsm bond paper with 2 stitches Production may vary according to operating conditions In line with a policy of continual p...

Page 46: ...Spine forming The quality of the SquareBack spine is subjective and is operator adjustable Its purpose is to produce a book with a superior appearance to a non formed spine The appearance of the spin...

Page 47: ...Q is installed up or down stairs give special consideration to how you lift and move the equipment 17 4 Space needed to unload the PSQ The PSQ is shipped on a bespoke pallet The pallet includes ramps...

Page 48: ...3 lb 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 A sl...

Page 49: ...atic PowerSquare 224 Service Training Workbook 45 17 9 1 Online PowerSquare PSQ Connecting Bridge Input for Mains Power Supply Maintenance area 3255 mm 129 2755mm 109 1870 mm 74 Maintenance area 2870...

Page 50: ...uare 224 Service Training Workbook 17 9 2 Online PowerSquare with PBS Book Stacker PSQ Connecting Bridge PBS Book Stacker Input for Mains Power Supply Maintenance area 2800 mm 111 2280 mm 90 2420 mm 9...

Page 51: ...ning Workbook 47 17 9 3 Online PowerSquare with P2T 2 Knife Trimmer PSQ Connecting Bridge P2T 2 Knife Trimmer Input for Mains Power Supply Input for Mains Power Supply Maintenance area 3470 mm 137 297...

Page 52: ...ne PowerSquare with P2T 2 Knife Trimmer and PBS Book Stacker PowerSquare Connecting Bridge P2T Trimmer Input for Mains Power Supply PBS Book Stacker Input for Mains Power Supply Maintenance area 3280...

Page 53: ...ight The opposite of portrait loop omega A type of stitch that is shaped like the Greek letter omega Used when book lets are to be placed in a ring binder moving clinch The clinch bends the legs of th...

Page 54: ...he binding side of a book let SquareBack Name of a book which has a stitched square spine Technology developed and patented by Watkiss Related terms Square fold term used by Xerox to describe the Ploc...

Page 55: ......

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...

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