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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: [email protected]

Plockmatic PowerSquare™ 224

Service Training Workbook

Right to Left Version

Issue 1, November 2014, edited January 2017

Doc. No.x05082

Name:    ............................................................................

Summary of Contents for Plockmatic PowerSquare 224

Page 1: ...ustrial Estate Sandy Bedfordshire SG19 1RZ United Kingdom Tel 44 0 1767 685700 Fax 44 0 1767 689900 Email info watkiss com Plockmatic PowerSquare 224 Service Training Workbook Right to Left Version Issue 1 November 2014 edited January 2017 Doc No x05082 Name ...

Page 2: ...document 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 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 performan...

Page 3: ...ady be formed into a staple shape stitch To bind sheets of paper together using a wire stitch The stitch is cut from a spool of wire as part of the stitching process tape bind To bind sheets of paper together using a glued tape usually at either the left or the top of the sheets i Plockmatic PowerSquare 224 Service Training Workbook CONTENTS 1 Introduction 1 1 1 Conventions in this workbook 1 1 2 ...

Page 4: ...ffset of the edges of the sheets after they have been folded fore edge trim To trim a single edge off the book let The trimmed edge is opposite the spine Fore edge trimming is necessary to remove the creep on the centre sheets Also called face trimming single knife trimming gutter The central part of a sheet that is on and adjacent to the fold line of the book let landscape The format of a page or...

Page 5: ...arying book thickness The maximum book thickness of 10 4mm 208 pages 80gsm 224 pages 70gsm is double that of alternative conventional booklet making machines so it is ideally suited to higher 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 provides a s...

Page 6: ...ion tools 3 From the list select the buttons you want to display Button Function Click to go to first page in the document Click to go to the previous page in the document Click to go to the next page in the document Click to go to last page in the document Shows the current page number To move to a certain page type the page number and press Enter Click to go to the previous view or the next view...

Page 7: ...hese modules is found in the related Illustrated Parts Catalogues IPC The modules are split into assemblies Each assembly is shown as an exploded 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 POFD Outfeed PSTK Stacker PBS PowerSquare Book Stacker...

Page 8: ...IVOT DRIVE SIDE 1 2a 100 334 SCREW SKT HD CAP M2 5x10mm STAINLESS 1 2b 160 202 WASHER M2 5 FORM A BZP 1 2c 257 833 ST ST PSQ PIVOT LOCATION PLATE 1 2d 266 088 SHAFT PSQ ACTIVE GATE PIVOT PIN 1 3 315 775 PLASTIC PSQ ACTIVE GATE PIVOT BLOCK 1 4 891 645 P ASSY PSQ TAMPER GATE BRACKET 1 5 891 646 P ASSY PSQ TAMPER PIVOT PLATE 1 5a 266 088 SHAFT PSQ ACTIVE GATE PIVOT PIN 1 5b 257 833 ST ST PSQ PIVOT LO...

Page 9: ...1363 North America Japan NEMA 6 15 For other areas contact the supplier for the correct cable Power Consumption 700VA 500W maximum Product Overview Plockmatic PowerSquare 224 Service Training Workbook 5 2 Product Overview 2 1 Paper Path Stage Description Service Manual Reference The sheets of paper leave the printer and enter the infeed of the connecting bridge See Section 1 7 1 The paper is rotat...

Page 10: ...7 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 17 3 Access The PSQ is 755 mm wide and fits through a standard size doorway A standard size doorway is 762 mm 30 wide If the PSQ is installed up or down stairs give special consideration to how you lift and...

Page 11: ...he PSQ is controlled by the printer and by a system of internal sensors The PSQ includes these modules PSQK Complete M C PBCK Bridge Covers PRTP Base Machine PBR5 Rotator PBRG Gathering Area PRSH Shuttle PSTI Stitcher PRFD Folder PFRM Spine Former PSTP Trim Stop PTRM Trimmer POFD Outfeed PSTK Stacker PBS PowerSquare Book Stacker optional P2T PowerSquare 2 Knife Trimmer optional Part number informa...

Page 12: ... 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 The rear or large shuttle pick up fingers incorporate rollers to prevent toner deposition that could mark the covers of the books ...

Page 13: ... is fed from a 15kg 33 lb spool in the stitch wire cabinet The stitch wire spool can supply a maximum of 291 500 stitches The stitch head and clincher are aligned to the centre reference line of the PSQ The book is moved to each stitch position by the shuttle The size of stitch or wire draw setting is calculated from the set thickness input by the operator Adjustment is made to the wire draw by th...

Page 14: ...he eject rollers rotate and move the book towards the trimmer infeed 3 7 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 The PSQ applies an amount of trim according to the size of the paper The operator can cha...

Page 15: ...t Feed Orientation Cover first face down Stock Range 60 250gsm dependent on paper type and quality 200 x 200mm 370 x 520mm Stitch fold line indicates original lead edge from the printer Stitch fold line indicates original lead edge from the printer 200mm 353 x 252mm 207mm Description of Operation Plockmatic PowerSquare 224 Service Training Workbook 11 main electric motor by a chain and clutch syst...

Page 16: ...h screen has a power save function After several minutes without use the brightness of the touch screen decreases After several hours the touch screen turns off Touch the screen to restore the normal brightness The touch screen takes two or three minutes to reach full brightness FIGURE 3 The User Interface START Button STOP Button Touch Screen Replace Trimmer Blade optional time permitting Plockma...

Page 17: ... the machine 11 2 Software download Perform Software download procedure see 6 9 Software Update Ethernet Connection Primary Method Software download completed 11 3 Web browser Based Diagnostics Internal diagnostic information and procedures are accessed via a web browser such as Internet Explorer or Firefox running on a PC connected to the PSQ Review Section 6 14 Web browser Based Diagnostics with...

Page 18: ...anged Trim can be biased to top or bottom LOAD SAVE SAVE REPLACE CANCEL SAVE NEW Save the job Overwrite the existing job Cancel the save Save as a new job JOB DETAILS List of the job settings LOAD Load a job from memory PADLOCK SYMBOL Supervisor use to lock unlock a job DELETE Delete a job VIEW OF JOB LIST View A Z by use by index ADVANCED RE REF Re calibrate the machine axes STITCHER UP Lift the ...

Page 19: ...size into the touch screen 35 sheets 3 5mm thick 3 stitches with custom stitch pitch 4 forms with 5 pressure Trim to 130mm Save as A4 Test Re reference all axes Observe what happens on the message 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 INSTALLED S...

Page 20: ...aper Path It is important that the alignment of the PSQ and the printer is correct This can change if either the PSQ or the printer is moved accidentally Curly paper can sometimes cause the set to remain in the stitch area causing a jam Paper curl problems must be resolved at the printer by changing or turning the paper or making adjustment to the printer 5 3 Clear paper jams The operator can clea...

Page 21: ...r 7 3 1 PSQ Main Control PCB Wiring Diagram 7 3 2 Rotator Wiring Diagram 7 3 4 Gathering Area Wiring Diagram 7 7 1 900 208 Control PCB 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 ...

Page 22: ... support CD Watkiss PowerSquare 224 Unpacking and Installation Instructions Right to Left Versions Locate the Unpacking and Installation Instructions The PSQs used in the service training are already installed With the training instructor review the following Check that the PSQ is level Check the alignment of the Connecting Bridge to the printer Check the alignment of the PSQ to the Connecting Bri...

Page 23: ... Workbook 19 8 Machine Areas 8 1 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 Performing these procedures ensures all of the sub assemblies are in cor...

Page 24: ...r Tamper stepper motor Tamper proximity sensor Perform the following tasks ADJ 4 4 3 Calibrate the Bridge Axis Machine Areas Plockmatic PowerSquare 224 Service Training Workbook 29 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 TEST screen Before you begin Use the GUI to...

Page 25: ...ys 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 Adjustments to the sidelays and endlays are made with two 24V DC electric motors 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 s...

Page 26: ...DJ 4 5 14 Check and Calibrate the Shuttle Pick up Fingers ADJ 4 5 16 Check and Adjust the Shuttle Pick up Position Calibration Use the RAPs to diagnose and repair the problem created by the trainer Machine Areas Plockmatic PowerSquare 224 Service Training Workbook 27 8 8 Trim The book passes between two facing sets of conveyors in the trimmer infeed These conveyors move the book to the trim stop T...

Page 27: ...itch Detect Sensor detects the steel of the stitch wire If this sensor does not detect a stitch a stitch head fault is indicated and production is stopped When the book is stitched correctly the book is moved by the shuttle to the fold position If a book remains over the optical Stitch Jam Sensor next to the stitch head a jam is indicated and the PSQ is stopped If the stitch head jams a Stitch Hea...

Page 28: ...ce of the form clamp there is a horizontal polyurethane strip that gives a cushioned grip The polyurethane strip is important for thin books because the soft surface prevents the stitch cutting through the front and back covers of the book Drive for the fold blade is transferred from the main motor by chain and clutch The drive is changed from rotary to linear movement by a crank and connecting ro...

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