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5 - Error Conditions, Problems and Solutions - Book Quality

Watkiss PowerSquare™200 User Manual

Spine Form Problems

Spine Form

Condition

Solution

Correct

The spine is square at each
end and the paper is not
damaged.

The PowerSquare setting
is correct. Adjustment is
not needed.

Incorrect

The spine needs more form.

If the spine needs more
form at one end

Change

NUMBER

to 2 or 4.

See “FORM” on page 15.

If the spine needs more
form at each end

Increase

NUMBER

increase

PRESSURE

. See

“FORM” on page 15.

Incorrect

The spine is damaged or
there are creases near the
spine.

Decrease

NUMBER

decrease

PRESSURE

See “FORM” on page 15.

Summary of Contents for PowerSquare 200

Page 1: ...Watkiss PowerSquare 200 User Manual English Issue 1f November 2007...

Page 2: ...ocument is subject to change without notice Watkiss Automa tion Limited makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantabilit...

Page 3: ...imic 14 The BASIC Window 15 The LOAD SAVE Window 17 The ADVANCED Window 18 The CONFIGURE Window 19 The MENU Window 20 4 Standard Tasks 21 Introduction 21 Load and Save the Job Settings 21 Open the Con...

Page 4: ...37 Paper Jams 41 Stitch Head Problems 46 Clear a Stitch wire Jam 46 Clear a Stitch Head Jam 49 Calibrate the Touch Screen 51 Change the Fuses 51 Manually park the Shuttle 52 6 Maintenance 55 Service I...

Page 5: ...describe the operation of the printer If needed refer to your printer user manual In this manual the Watkiss PowerSquare 200 is referred to as the PowerSquare Safety Information Safety information is...

Page 6: ...nput on the rear of the machine If the machine is con nected to the wrong supply the warranty is cancelled How to Get Help If you have any questions or problems refer to the problem solving section in...

Page 7: ...eed Adjustment for the size of the paper and sheet rota tion is automatic according to the settings entered on the touch screen The user interface The user interface has a colour touch screen a start...

Page 8: ...nstaller to refer to the installation instructions before the PowerSquare is connected to mains power The PowerSquare can be adjusted for one of several different input voltages Fuses The fuses make s...

Page 9: ...w 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 Inf...

Page 10: ...information Turn On the PowerSquare Procedure 1 Connect the PowerSquare to the mains power supply 2 Use the mains ON OFF switch to turn ON the PowerSquare The machine makes this sequence of beeps bee...

Page 11: ...a Non Standard Paper Size on page 7 a saved job Job Setting for a Saved Job on page 8 Step Action Information 1 Touch BASIC 2 Enter the paper size and page direction Touch PAPER SIZE PRESETS A3 or A4...

Page 12: ...Adjust the Gate in the Gathering Area on page 28 4 Enter the page rotation set ting For A4 paper size the normal setting for ROTATE is ON Rotation lets the printer oper ate at optimum speed Touch ROTA...

Page 13: ...werSquare starts automatically 3 Check the quality of the first book 4 If the quality is not acceptable make adjustments See Book Quality on page 37 for further information During the job Unload books...

Page 14: ...2 How to Run the PowerSquare Run the Job 10 Watkiss PowerSquare 200 User Manual...

Page 15: ...alm top wand or the blunt end of a pen Do not use too much force A light touch is all that is needed CAUTION Do not operate the touch screen with a sharp object or with too much force These actions ca...

Page 16: ...ace The Touch Screen 12 Watkiss PowerSquare 200 User Manual Touch the screen to restore the normal brightness The touch screen takes two or three minutes to reach full brightness Illustration FIGURE 5...

Page 17: ...tus The STATUS line shows the machine status GREEN The PowerSquare is READY or RUNNING ORANGE PLEASE WAIT wait until the PowerSquare is ready ATTENTION the PowerSquare needs an action by the operator...

Page 18: ...of the paper in the gathering area the broken line shows the fold line the small thick lines show the stitches the arrow shows the original feed edge in the printer 2 Set Thickness The set thickness i...

Page 19: ...nter the value STITCHES Touch STITCHES to select the number of stitches Available options are 1 6 The machine automatically calculates the position of the stitches according to the size of the paper S...

Page 20: ...setting is 0 THRESHOLD The square spine is formed only on sets thicker than 0 8mm To change this value touch THRESHOLD and enter the value you need The maximum value is 1 5mm TRIM The trim dimension i...

Page 21: ...job name Touch OK or CLOSE The original job is not changed If the job name is not changed before OK or CLOSE is touched the job will be saved with the current name followed by an asterisk JOB DETAILS...

Page 22: ...ves a number to all jobs that are saved Button Information Button Information RE REF If the machine calibration appears incorrect touch RE REF to re reference the adjustment axes The adjustment axes r...

Page 23: ...r on or off The default setting is ON PRESET PAPER SIZES The preset paper sizes can be either ISO A sizes or US paper sizes To select which preset paper sizes are available touch the relevant button N...

Page 24: ...SS LEVEL The Touch Screen has five different access levels Operator Supervisor Service Distributor Factory Touch ACCESS LEVEL and select the correct level from the list The last three levels are prote...

Page 25: ...the Default Job Template to reset the PowerSquare to normal settings Save a job 1 Touch LOAD SAVE SAVE 2 If these options appear select one REPLACE to over write the previous job with the current job...

Page 26: ...machine error occurs or for maintenance To clear a paper jam To clean the static elimination bar The PowerSquare will not stop if you open the connecting bridge cover WARNING Keep your hands clothing...

Page 27: ...ack locking handle against the spring pressure 2 Turn the handle through 90 to unlock 3 Lift the folder cover carefully to the vertical Lift and Lower the Clincher Frame When to do If a machine error...

Page 28: ...e clincher frame fall on your hand 1 Lower the clincher frame 2 Turn the locking handle to the right until the handle is tight Open the Gathering Area Cover When to do If a machine error occurs or for...

Page 29: ...er area To access the trim area Procedure FIGURE 12 Lift the PowerSquare Main Deck Folder Cover open Clincher Frame lifted Connecting Bridge Cover open Step Action Information 1 Open the connecting br...

Page 30: ...nt lost production you must remove empty and return the trim bin to the PowerSquare as quickly as possible Procedure 1 Use the handle to open the trim bin 2 Use the side handles to lift and remove the...

Page 31: ...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 When to do When you start...

Page 32: ...can be damaged or jam in the machine When to do When you start a new job Lift the Gate in the Gathering Area 1 Open the gathering area cover See Open the Gathering Area Cover on page 24 2 Lift the gat...

Page 33: ...o check the settings are correct To make a small number of books offline WARNING Do not put your hands in the gathering area when the machine operates Use two hands to push the buttons For safety reas...

Page 34: ...4 Standard Tasks Operate the PowerSquare offline 30 Watkiss PowerSquare 200 User Manual...

Page 35: ...e instructions on the printer If the printer tells you to remove paper from the PowerSquare then touch ADVANCED PURGE SET PURGE SET The partial book is delivered to the stacker Discard the book PowerS...

Page 36: ...Close all safety covers The trim bin is not fitted or the trim bin is not fit ted correctly Fit the trim bin The PowerSquare is not connected to the printer interface Check the interface cables Conne...

Page 37: ...e infeed cover is open The machine will not operate until the cover is closed See page 41 BRIDGE MOTOR STALL Check for a paper jam in the con necting bridge Clear the jam and continue See page 41 CHEC...

Page 38: ...reset the position FORM CLAMP CLOSED The form clamp is in the wrong position Touch START to reset the position FORM ROLLER ERROR The form roller is jammed Clear the jam and continue See page 45 FORM R...

Page 39: ...and move the shuttle to the park position Close the folder cover The shuttle will reset When the message list is clear continue operation See page 52 MISSING STITCHES The machine has detected missed s...

Page 40: ...from the stacker Stitch axis moving The stitch axis is moving This message clears when the adjust ment is complete Stitch position adjusting The stitch position is adjusting This message clears when t...

Page 41: ...types are all the same size If the size of the paper is different an accurate book cannot be made Adjustments to the FORM settings can be necessary for some types of paper Machine Adjustments Machine...

Page 42: ...r Watkiss service engi neer The spine is not formed correctly The SET THICKNESS is incorrect Measure the set thickness and enter the correct dimension See Enter the Job Settings on page 6 The settings...

Page 43: ...calibrated correctly Touch RE REF in the PAPER SIZE window to calibrate the PowerSquare adjustment axes See RE REF on page 18 The books do not stack on the stacker The collection table is in the wron...

Page 44: ...maged The PowerSquare setting is correct Adjustment is not needed Incorrect The spine needs more form If the spine needs more form at one end Change NUMBER to 2 or 4 See FORM on page 15 If the spine n...

Page 45: ...m in the Connecting Bridge 1 Open the connecting bridge cover 2 Remove the jammed paper Do not damage or move the belts 3 Close the connecting bridge cover 4 If there is paper in the gathering area to...

Page 46: ...User Manual 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 Close the connecting...

Page 47: ...5 Continue the print job Step Action Information 1 Open the folder cover See Open the Folder Cover on page 22 2 Lift the clincher frame See Lift and Lower the Clincher Frame on page 23 3 Remove the j...

Page 48: ...re Lift the left hand end clear 4 Remove the book 5 Remove any paper offcuts from the trimmer infeed conveyor A small piece of paper can cover the jam sensor and generate an error message 6 Fit the tr...

Page 49: ...ase the trim stop guard 3 Pull the trim stop guard towards you 4 Remove the jammed book Check the trim stop and remove any pieces of trimmed paper 5 Push the trim stop guard into posi tion 6 Hold the...

Page 50: ...ITCH is set to 1 or more See STITCHES on page 15 The stitch wire is fin ished Load a new spool of stitch wire See Install New Stitch wire on page 63 The stitch wire is jammed Clear the jammed stitch w...

Page 51: ...rror Conditions Problems and Solutions Clear a Stitch wire Jam Watkiss PowerSquare 200 User Manual 47 Top location of Middle Wire Tube Middle Wire Tube Metal Spring Clip FIGURE 22 Stitch Head Feed Gea...

Page 52: ...n B between the feed gears and the middle wire tube 3 Pull the stitch wire from the stitch wire guide block 4 Pull the stitch wire from the middle wire tube See Figure 22 on page 47 If there is not en...

Page 53: ...top button The banging noise does not indicate dam age has occurred but can cause alarm Follow the procedure below Tools and Materials Kl ber Isoflex NBU15 Grease 50g Part number 951 095 Air duster Su...

Page 54: ...the area behind the wire holder for pieces of stitch wire See Figure 24 on page 49 4 Remove any stitches or pieces of stitch wire and clean the area with the air duster Use the wire cutters to remove...

Page 55: ...the Fuses Introduction The PowerSquare has two fuses at the mains power input If either fuse is bro ken the PowerSquare will not operate WARNING Turn OFF the machine and remove the mains power supply...

Page 56: ...quare 200 User Manual Manually park the Shuttle When to do The error messages MANUALLY PARK SHUTTLE and SHUTTLE NOT PARKED are displayed Illustrations FIGURE 25 Shuttle Assembly Position CORRECT FIGUR...

Page 57: ...tion 1 Open the folder cover See Open the Folder Cover on page 22 2 Push the shuttle assembly to the right Figure 25 on page 52 shows the correct position for the shuttle assembly If the shuttle assem...

Page 58: ...5 Error Conditions Problems and Solutions Manually park the Shuttle 54 Watkiss PowerSquare 200 User Manual...

Page 59: ...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 Operator Maintenance Correct mai...

Page 60: ...an the touch screen Light pressure with a clean dry cloth is enough to remove fingerprints Do not use too much force Clean the Static Elimination Bars Introduction Clean the static elimination bars ev...

Page 61: ...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 FIGURE 28 The Static Elimination Bar in the Conne...

Page 62: ...4mm thickness is needed for each cycle More than one cycle can be needed Step Action Information 1 Clean the static elimination bar in the connecting bridge Open the connecting bridge cover Clean the...

Page 63: ...951 710 or a lint free cloth and alcohol isopropanol CAUTION Only use alcohol to clean this part of the machine Other chemicals can dam age the machine Note If you push the eject rollers the rollers c...

Page 64: ...extends the performance and service life of the stitch head Other types of grease do not protect the stitch head Only apply the grease as shown If you apply additional grease the paper gets marked Ste...

Page 65: ...tkiss PowerSquare 200 User Manual 61 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 Bar FIG...

Page 66: ...TITCHER UP The folder cover must be closed This action moves the stitch head to the correct position for lubrica tion 5 Lift the PowerSquare main deck See Lift the PowerSquare Main Deck on page 25 Ste...

Page 67: ...he war ranty Stitch wire Description PSQ Stitch Wire PowerBind 0 6mm 15kg Part number 812 038 FIGURE 34 Lubricate the wire feed cam Nozzle of the tube of grease Wire feed cam Feed lever Step Action In...

Page 68: ...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 1 Cut the stitch wire to the right...

Page 69: ...ch wire cap 5 Loosen the end of the stitch wire from the edge of the stitch wire spool 6 Use wire cutters to remove the damaged end of the stitch wire Remove enough stitch wire to leave the end of the...

Page 70: ...etween the felt wire cleaning pads 4 Push the stitch wire into the stitch wire guide block 5 Push the stitch wire as far as pos sible Step Action Information Felt Wire Cleaning Pads Push stitch wire i...

Page 71: ...me on page 24 4 Close the folder cover 5 Close the connecting bridge cover Step Action Information 1 Touch START 2 Set the number of stitches to 6 See Job Setting for a Standard Paper Size on page 7 3...

Page 72: ...6 Maintenance Install New Stitch wire 68 Watkiss PowerSquare 200 User Manual...

Page 73: ...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 Online Minimum input size 200 x 200m...

Page 74: ...oks spool approximately 127 000 Trimming Maximum fore edge trim 28mm Minimum trimmed book size 80mm Stacker Capacity 35 books Paper Input Requirements Input sheets must be of consistent size and cut s...

Page 75: ...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 man...

Page 76: ...7 Specifications 72 Watkiss PowerSquare 200 User Manual...

Page 77: ...Serial Number WA PSQ 0010 onwards Conforms to the following Product Specifications Safety 2006 95 EC 98 37 EC Council Directive on the approxi mation of laws of Member States relating to machinery BS...

Page 78: ...8 Declaration of Conformity 74 Watkiss PowerSquare 200 User Manual...

Page 79: ......

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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