Watkiss Automation PowerSquare 200 Manuel utilisateur

Watkiss PowerSquare™200

User Manual

English, Issue 1f, November 2007

Reproduction, adaptation, or translation without prior written permission is prohibited, except as

allowed under the copyright laws.

Warranty

The information contained in this document 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 merchantability and fitness for a particular purpose.

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.

Watkiss PowerSquare™200 User Manual i

1. Introduction to the Watkiss PowerSquare™200 . . . . . . . 1

Description of the PowerSquare . . . . . . . . . . . . . . . . . . . . . . . 2

2. How to Run the PowerSquare . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Turn On the PowerSquare . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Enter the Job Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Adjust the Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Adjust the Position of the Gate in the Gathering Area . . . . . . . 8

Run the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3. The User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

The Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

The Job Mimic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Connecting Bridge Cover . . . . . . . . . . . . . . . . . . . . 22

Open the Folder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Lift and Lower the Clincher Frame . . . . . . . . . . . . . . . . . . . . . 23

Open the Gathering Area Cover . . . . . . . . . . . . . . . . . . . . . . 24

Lift the PowerSquare Main Deck . . . . . . . . . . . . . . . . . . . . . . 25

Empty the Trim Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Open the Stitch-Wire Cabinet . . . . . . . . . . . . . . . . . . . . . . . . 26

Table of Contents

continued . . .

Watkiss PowerSquare™200 User Manual

English, Issue 1f, November 2007. Watkiss Part No. 960-801

Effective Serial No. WA/PSQ/0050 onwards, software 2.2

ii Watkiss PowerSquare™200 User Manual

Adjust the Stacker Collection Table . . . . . . . . . . . . . . . . . . . . 27

Adjust the Gate in the Gathering Area . . . . . . . . . . . . . . . . . . 28

Operate the PowerSquare offline . . . . . . . . . . . . . . . . . . . . . . 29

5. Error Conditions, Problems and Solutions . . . . . . . . . . 31

Printer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

PowerSquare Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

General Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Message List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Book Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Clean the PowerSquare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Clean the Static Elimination Bars . . . . . . . . . . . . . . . . . . . . . . 56

Clean the Former Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Clean the the Polyurethane Strips in the Form Clamp . . . . . . 59

Lubricate the Stitch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Install New Stitch-wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

7. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

8. Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . 73

Watkiss PowerSquare™200 User Manual 1

CHAPTER 1 Introduction to the Watkiss

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. To make sure you

use your PowerSquare correctly, read your manual.

The Watkiss PowerSquare™200 User Manual does not 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 included in the separate “Safety Information Manual”.

Read the safety information before you use your PowerSquare.

Warning and Caution Messages

The warning and caution messages used in this manual are shown below.

WARNING A WARNING message tells you that a procedure or operation can be danger-

ous. To prevent injury, you must follow the instructions.

CAUTION A CAUTION message tells you that a procedure or operation can damage the

machine or the product. To prevent damage, you must follow the instructions.

1 - Introduction to the Watkiss PowerSquare™200 - Description of the PowerSquare

2Watkiss PowerSquare™200 User Manual

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. The correct machine-voltage is shown on the label at

the mains power supply input 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

this manual (see “Error Conditions, Problems and Solutions” on page 31). Con-

tact your PowerSquare supplier for further help.

Description of the PowerSquare

Introduction

The PowerSquare operates online with digital printers to process sets of printed

pages into stitched books. The main parts are shown below.

Operator Side of the PowerSquare

FIGURE 1. Operator Side of the PowerSquare.

Stacker

Connecting Bridge

User Interface

PowerSquare

1 - Introduction to the Watkiss PowerSquare™200 - Description of the PowerSquare

Watkiss PowerSquare™200 User Manual 3

Component - Function Table

Right Hand Side 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.

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

button and a stop button .

The PowerSquare The PowerSquare stitches, folds, spine-forms and

trims the sheets to make a finished book.

The stacker The stacker collects the finished books.

Component Function

The stitch wire cabinet The stitch-wire cabinet holds the spool of stitch-wire.

The trim bin The trim bin collects the paper that is trimmed from

the edge of the book.

Stitch Wire Cabinet

Trim Bin

FIGURE 2. Right hand side of the PowerSquare.

1 - Introduction to the Watkiss PowerSquare™200 - Description of the PowerSquare

4Watkiss PowerSquare™200 User Manual

The Rear Panel of the PowerSquare

Component - Function Table

Component Function

Rating and serial label The rating label displays the type of machine, serial

number, power use and fuse information.

Mains power ON/OFF

switch

The mains power ON/OFF switch turns ON or turns

OFF the PowerSquare. When you turn OFF the

PowerSquare, the current settings are stored.

Voltage advisory label The voltage advisory label tells the installer 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 sure the operator and the machine

are protected if there is an electrical problem or

short circuit.

Voltage label The voltage label is fitted to the PowerSquare dur-

ing the installation procedure. The voltage label dis-

plays the selected voltage.

Mains power input connec-

tor

The mains power input connector is used to con-

nect the PowerSquare to mains electrical power.

FIGURE 3. The Rear Panel of the PowerSquare.

Rating and Serial Label

Mains Power ON/OFF Switch

Fuses

Mains Power Input Connector

Voltage Advisory Label

Voltage Label

Watkiss PowerSquare™200 User Manual 5

CHAPTER 2 How to Run the PowerSquare

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.

Information about standard procedures, for example opening covers to clear a

paper jam, is included in “Standard Tasks” on page 21.

2 - How to Run the PowerSquare - Before You Begin

6Watkiss PowerSquare™200 User Manual

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.

• Measure the size of the printed paper. The paper dimension changes when

the paper is printed.

• Measure the set thickness as accurately as possible. Use the measuring tool

supplied with the machine.

• Enter accurate dimensions into the touch screen.

• If the book is made from several different types of paper, make sure the dif-

ferent paper types are all the same size.

See “Book Quality” on page 37 for further 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:

‘beep__beep beep beep beep______beep beep’.

The touch screen illuminates and the machine is ready for use.

Enter the Job Settings

Introduction

Make the settings for a new job in the BASIC window on the touch screen.

See “The User Interface” on page 11 for more information.

The PAPER SIZE and PAGE DIRECTION settings are entered on the touch screen.

These dimensions refer to the format of the paper when it enters the

PowerSquare.

CAUTION: Do not operate the touch screen with a sharp object or with too much force.

These actions can damage the touch screen.

Before You Begin

1. Print a set to the stacker.

2. Measure the sheet size and the set thickness.

3. Use these dimensions for the job setting.

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