Watkiss PowerSquare™ 200

Kodak

Service Training Workbook

Issue 1, August 2008
969-501

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

Trainer’s Version
© Watkiss Automation Limited 2008
All Rights Reserved.

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 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, performance or use of this material.
CONTENTS

REFERENCE

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Conventions in this workbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Paper Enters the System via the Connecting Bridge . . . . . . . . . . 4
3.2 The Gathering Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 The Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 The Stitch Head and Clincher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 The Stitch Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Fold and Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.8 Outfeed and Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 User Interface (GUI) - Operator Menu . . . . . . . . . . . . . . . 8

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Power save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 The Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 GUI buttons and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Advanced Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Paper quality and machine performance. . . . . . . . . . . . . . . . . . . 12
5.2 Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3 Clear paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6 User Interface - Service Overview . . . . . . . . . . . . . . . . . 13

7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8 Machine Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

continued . . .

PSQ200 Kodak Service Training Workbook. Issue 2, September 08. Part No. 969-501

Watkiss PowerSquare™ 200 Service Training Workbook i

 8.1 Intoduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.2 Connecting Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.3 Gathering Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.4 Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.5 Stitcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.6 Fold and Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.7 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.8 Outfeed and Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.9 Machine Cycle control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.1 Operator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.2 Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.3 Care Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

10 Power and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

10.1 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.3 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.4 DFA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

11 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.1 Software System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.2 Software download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

12 Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 31

13 Quality Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

14 PSQ Site Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 34

15 Glossary of booklet making terms . . . . . . . . . . . . . . . . 37

ii Watkiss PowerSquare™ 200 Service Training Workbook

Introduction

1. Introduction

Online PowerSquare

Offline PowerSquare

The Watkiss PowerSquare™200 is an innovative, complete book making sys-

tem for digital print applications. In a single machine it combines the four proc-
esses of stitching, folding, spine forming and trimming to produce
SquareBack™ books up to 200 pages thick. It features fully automatic setting
for different book size and pagination, including variable stitch leg length for var-
ying book thickness.
The maximum book thickness, of 10mm (200 pages 80gsm), is double that of
alternative conventional booklet making machines, so it is ideally suited to
higher paginations or to thicker stocks. This makes the Watkiss Power-
Square™200 a fast and cost effective alternative to perfect binding or tape bind-
ing. Since it will also produce books from only a few sheets, it provides a single
book making solution for documents from 8 through to 200 pages.
Digital print applications frequently use heavier stocks and need the flexibility to
produce a wider range of finished books from a single process, with little or no
operator intervention - the new Watkiss PowerSquare™ is a perfect match.

1.1 Conventions in this workbook

The PowerSquare is referred to by its 3-letter code of PSQ.
! this is an instruction or task that the trainer will do
" this is a task that the student will do

This workbook refers to the following PowerSquare Service Manual:

• Issue 2c, September 2008

Watkiss PowerSquare™ 200 Service Training Workbook 1

Product Overview

2. Product Overview
2.1 Paper Path

 

FIGURE 1. Plan view of PSQ showing paper path

Stage Description Service Manual Reference

The sheets of paper leave the printer and See Section 1.10.1.

enter the infeed of the connecting bridge.
The paper is rotated in the connecting See Section 1.10.1.
 bridge if necessary.
The sheets of paper are gathered into a set See Section 1.10.2.
 in the gathering area. When a set is com- See Section 1.10.3.
plete it is collected by the shuttle.
The set is moved to the stitch head where See Section 1.10.4.

the set is stitched See Section 1.10.5.
The set is moved to the fold position where See Section 1.10.6.

the fold blade pushes the set into the spine
form clamp.

2 Watkiss PowerSquare™ 200 Service Training Workbook

Product Overview

FIGURE 2. End view of PSQ showing paper path

Stage Description Service Manual Reference

The fold blade lifts and the form clamp See Section 1.10.6.

closes. The form roller creates the Square-
Back spine on the book.
The book is moved to the trim stop and See Section 1.10.7.

clamped in position. The fore-edge of the
book is trimmed by the trimmer blade that
moves horizontally.
The book is released and conveyed by the See Section 1.10.8.
 outfeed mechanism to the stacker.
The finished books are stacked neatly, See Section 1.10.8.
 ready for the operator to remove.

Watkiss PowerSquare™ 200 Service Training Workbook 3

Description of Operation

3. Description of Operation

Trainer Note: Use this section to explain how the PSQ works. A detailed
‘hands-on’ study of the PSQ follows later (see Section 8.)

After the PSQ is turned on, the operator configures the paper size and direction,
the set-thickness and the number of stitches. The PSQ is controlled by the
printer and by a system of internal sensors.

The PSQ is made from these modules

• PBR1 - Bridge
• PSHU - Shuttle
• PSTI - Stitcher
• PFLD - Folder
• PFRM - Spine Former
• PSTP - Trim Stop
• PTRM - Trimmer
• POFD - Outfeed
• PSTK - Stacker

Part-number information for these modules is found in the related Illustrated

Parts Calalogues.

3.1 Paper Enters the System via the Connecting Bridge

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
through the connecting bridge by belts into the gathering area. When the page
is in portrait format, the paper can be rotated through 90° by the rotator in the
connecting bridge if necessary.

A3 (17 x 11") and A4 (11 x 8½") Landscape jobs move straight through the
bridge without rotation. The turning ball and sidelay are not in the paper path.
The bridge drive belt is parallel to the sidelay.

A4 (8½ x 11") Portrait jobs are rotated around the turning ball. The paper is
driven against the sidelay by the angled, bridge drive-belt. The sidelay makes
sure the paper aligns to the centre reference line of the bridge.

The drive belts are run from a 230V AC electric motor in the connecting bridge.
The connecting bridge axes are adjusted by two 24V DC electric motors.

Static elimination bars in the bridge and the gathering area neutralise the static-
electric charge on the paper. Sheets of paper with a static-charge stick together
and will not jog into a tidy book.

An optical sensor in the bridge infeed sees that a piece of paper has entered the
system. Another optical sensor at the entry to the gathering area sees that the
paper has left the bridge. If the time between the operation of the sensors is

4 Watkiss PowerSquare™ 200 Service Training Workbook

Description of Operation

more than a calculated period, a paper jam is indicated. The PSQ sends an
error message to the printer. The print job and the PSQ stop.

3.2 The Gathering Area

When the paper is fed into the gathering area, the paper falls between the end-
lays and sidelays. The endlays and sidelays are adjusted by the PSQ according
to the paper size selected. This adjustment is important and necessary to the
quality of the finished book. Adjustments to the sidelays and endlays are made
with two 24V DC electric motors.

The tamper fingers guide smaller sheets of paper to help them drop between
the sidelays and the endlays. A ramp on the connecting bridge gives a range of
height for the tamper fingers in proportion to the paper size. The lowest position
for the tamper fingers is for the smallest size of paper. The highest position for
the tamper 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 set
move to the stitch position.

When a set is printed the printer sends an ‘end of set’ signal to the PSQ, which
starts the PSQ cycle of operation.

The tamper fingers drop and apply pressure to the top of the set, which
removes the air from between the pages. After a standard interval, the tamper
fingers lift and leave the set ready for collection by the shuttle. A rear tamper in
the gathering area prevents sheets from riding-up over the rear pick-up fingers.

3.3 The Shuttle

The set 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.

The set is stitched, then moved by the shuttle to the next stitch position. This
process is repeated as necessary to a maximum of 6 stitches. When set to
AUTO, the PSQ automatically calculates the stitch positions. The user can
change the stitch pitch within certain 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 the folding area, the pick-up fingers loosen on the book.

The shuttle is operated by a 230V AC electric motor through a linear transmis-

sion.

Watkiss PowerSquare™ 200 Service Training Workbook 5

Description of Operation

3.4 The Stitch Head and Clincher

The single stitch head is a custom version of the Deluxe G8 stitch head. The
stitch head is installed vertically and upside down. The stitch-wire 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 the PSQ. This auto-
matic adjustment makes sure the correct size of stitch is formed for every thick-
ness of book. The operator does not need to adjust the stitch head.

The clincher is held in a frame above the stitch head. The PSQ uses a clincher
with 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, shafts and clutches. The stitch head vertical-axis
adjustment is made by a 24V DC electric motor.

3.5 The Stitch Process

The shuttle collects the set between the pick-up fingers and moves to the first
stitch position. When the book is stitched and moved to the next stitch-position,
the previous stitch moves across a stitch sensor. The stitch 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 opti-
cal sensor next to the stitch head, a jam is indicated and the PSQ is stopped.
If the stitch head jams, a stitch head jam sensor stops the machine. The stitch
head jam sensor is fitted next to the clincher cam and is connected to a PCB on
the stitcher PCB bracket.

3.6 Fold and Form

When the shuttle stops in the park position, the folder blade is operated. The
folder blade pushes against the centre line of the book - located by the stitches
- and folds the book in half. The folder blade pushes the book to a calculated
depth between a pair of feed-rollers and into the form clamp. On each face 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
rod. Drive for the spine form clamp is provided by the main motor and trans-
ferred to a drive shaft by a chain and clutch. Adjustment of the fold blade posi-
tion for different set thicknesses is made with a 24V DC motor.

6 Watkiss PowerSquare™ 200 Service Training Workbook

Description of Operation

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 pressure applied is calculated by the PSQ or can be over-
ridden on the touch screen by the operator.

The form roller is transported on a carriage that runs along the carriage guide.
The carriage drive is from the main electric motor by 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 jam is indicated. The form roller is turned by a gear wheel that
engages with a rack.

When the spine is formed, the carriage stops at one end of the carriage guide
and the spine form clamp is released. A solenoid is operated that moves the
eject rollers into contact with the book. The 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 oper-
ator can change the amount of trim from the touch screen if necessary. The trim
clamp and trimmer blade move forwards in one action to hold and trim the book.
The trim clamp and trimmer blade then return to their start position. Offcuts are
pushed into the trim bin by flexible fingers on one of the trimmer infeed con-
veyor shafts.

The trimmer uses a chevron blade to apply balanced cutting pressure across
the width of the book. The chevron blade decreases to the minimum any shear
forces.

Drive for the trimmer blade and the trim clamp is transferred from the main elec-
tric motor by a chain and clutch system. Rotary movement is changed to linear
movement with a crank mechanism.

3.8 Outfeed and Stacker

When 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 the catch tray.
An adjustable collection-table makes sure the finished books stack correctly.

There is an optical sensor in the outfeed to detect jams. This sensor prevents
the books on a full stacker from backing-up into the outfeed.

Watkiss PowerSquare™ 200 Service Training Workbook 7

User Interface (GUI) - Operator Menu

4. User Interface (GUI) - Operator Menu

Trainer Note: Use the GUI demo application to explain the Graphical
User Interface.

The user interface includes a colour touch screen and START/STOP buttons.

START Button
STOP Button

Touch Screen

FIGURE 3. The User Interface

4.1 Introduction
Operate the touch screen with a fingertip. You can touch the screen with a blunt
item, for example a palm-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 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 the machine is in opera-
tion.

Some functions and buttons are only available at certain access levels.

4.2 Power save

The touch 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.

8 Watkiss PowerSquare™ 200 Service Training Workbook

User Interface (GUI) - Operator Menu

The Touch Screen

The HELP button gives you

STATUS more information.
• GREEN = Ready or running. • Touch HELP, then touch
• ORANGE - PLEASE WAIT any button.
• ORANGE - ATTENTION = operator action needed. • Touch HELP, then touch
• RED = Error condition. the message list.

The MESSAGE LIST

shows errors and other
information.

JOB MIMIC
• paper size
• stitch pitch
• set thickness
• form
• trim

Window Buttons Window Tabs:

• Each Window tab LOAD & SAVE
has its own group
of window buttons. BASIC
ADVANCED
CONFIGURE
MENU

Watkiss PowerSquare™ 200 Service Training Workbook 9

User Interface (GUI) - Operator Menu

4.3 GUI buttons and options

Window Buttons
BASIC PAPER SIZE Enter the paper size
PAGE DIRECTION Portrait or Landscape
PRESETS Standard paper sizes
ROTATE On or Off
SET THICKNESS Set thickness
STITCHES Number of stitches
STITCH PITCH Distance between stitches
AUTO Automatic stitch pitch setting
FORM
AUTO Automatic, according to thickness
NUMBER Number of form roller actions
PRESSURE Pressure to make spine -9 to +9
THRESHOLD Minimum thickness for square spine
TRIM Trimmed dimension of the book
AUTO Automatic, according to thickness
LOAD & SAVE SAVE Save the job
REPLACE Overwrite the existing job
CANCEL Cancel the save
SAVE NEW 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 stitch head for maintenance
PURGE SET Clear the set from the machine
MAKE BOOK
CONFIGURE MACHINE OPTIONS
MEASUREMENT Select mm or inches as units
STITCH SENSOR Turn stitch sensor on or off
PRESET PAPER ISO ‘A’ sizes or US sizes
SIZES
NETWORK SETTINGS (service function)
FORM SETUP (service function)
MENU ACCESS LEVEL Operator, Supervisor, Service
(Distributor & Factory)
CURRENT LANGUAGE
AXES Re-reference individual axes
BRIDGE Reference individual axes
COUNTERS Book / Sheet / Stitch
RESET Resets the operator count

10 Watkiss PowerSquare™ 200 Service Training Workbook

User Interface (GUI) - Operator Menu

Perform the following tasks:

" Set the PSQ to make a preset size book:

A3 input size
25 sheets (2.5mm thick)
2 stitches

" Set the PSQ to make a non-standard book:

A4 input size
35 sheets (3.5mm thick)
3 stitches, with custom stitch pitch
4 forms, with +5 pressure
trim to 130mm

" Re-reference all axes. Observe what happens on the message list.

" Open the trim bin, then use HELP to find out about the error message on
the GUI message list.

Watkiss PowerSquare™ 200 Service Training Workbook 11

Advanced Operation

5. Advanced Operation
5.1 Paper quality and machine performance
Careful measurement of the paper size and set thickness is important in order
to produce good quality books.
• To make an accurate book you must enter accurate paper dimensions into
the touch screen.
• Measure the size of the printed paper. The paper dimension changes due to
shrinkage when the paper is printed.
• If the book is made from several different types of paper, make sure the dif-
ferent paper types are all the same size. If the size of the paper is different,
an accurate book cannot be made.
• The paper must be cut accurately. If the sheets are not cut squarely, an accu-
rate book cannot be made.
• Quality tolerance specification is included in this training workbook (see Sec-
tion 13.)

5.2 Paper 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 are 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 clear most paper or book jams. These procedures are
described in the User Manual and include paper jams in the
• connecting bridge
• gathering area
• stitch area
• fold and form area
• trim area

Paper jams that require service intervention are:

• If the former clamp does not open, manual operation with the hand crank is
needed (see Section 4.4.3).
• If the trimmer paper clamp remains closed and the trimmer blade remains in
the forward position, the trimmer needs manual operation (see Section
4.4.4).

12 Watkiss PowerSquare™ 200 Service Training Workbook

User Interface - Service Overview

6. User Interface - Service Overview

Trainer Note: Use the GUI demo application to introduce the functions of
each of the service screens. Then move to the machine, and review them
in use.

Service functions on the User Interface require the service access code.
• Service access code 1973 .

The service functions on the User Interface provide

• counters for gate, stitch, form and trim cycles
• calibration, configuration settings and machine options
• machine status information including error reporting
• machine control functions

Refer to Section 6.17 ‘‘GUI Functions’’ and Section 4.3 Diagnostic Procedures.

Review the following functions:

" [Link] (1st Stitch Offset)

" [Link] (Endlay Axis Calibration)

" [Link] (Bridge Axis Calibration)

Perform the following tasks:

" 4.3.2 (Manual Operation of Machine Axes from Axis Control PCBs)

" [Link] (Operate the Stitch Head from the Touch Screen)

Trainer Note: This point should be reached by the end of Day 1.

In preparation for the next task, make sure you have some paper which is a
non-standard size available.

Watkiss PowerSquare™ 200 Service Training Workbook 13

Installation

Trainer Note: This point should be the beginning of Day 2.

To recap what was learnt yesterday, the students should independently set
up the PSQ to make some books using a non-standard paper size.

7. Installation
Detailed instructions for installing the PSQ are included on the service support
CD.
• WatkissPowerSquare™200 Unpacking and Installation Instructions

" 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 PowerSquare is level

" Check the gas strut setting

" Check the alignment of the Connecting Bridge to the printer

" Review the location and routing of cables

14 Watkiss PowerSquare™ 200 Service Training Workbook

Machine Areas

8. Machine Areas

Trainer Note: Explain the PowerSquare in detail, following the paper path.
Listed in this section are all the key components that you should show the
students: clutches, axes, sensors etc.

8.1 Intoduction
During this section of the training, we review the different areas of the machine,
and the key set up procedures for each area.
If the PSQ needs calibration or adjustment, and it is not possible to identify the
area at fault, there is a complete set-up sequence (see 4.16 “PSQ Set-up Pro-
cedures”).

The Axis Calibration of the PowerSquare is critical to the quality of the books it
will produce. Performing this procedure ensures all of the subassemblies are in
correct alignment to each other.

8.2 Connecting Bridge

(PL 5.4, Fig. 1 - Fig. 20)
The paper transport belts are driven by a 230vac motor and the axis are
adjusted by two 24vdc Axis Motors, one for the Bridge Axis and one for the
Rotator Axis. (PL 5.4, Fig. 18)

The Bridge Drive motor, (PL 5.4, Fig. 10), always runs when the Power Square
is cycled up.

The sheets are transported under 2 Optical Sensor in the connecting bridge.
The first Optical Sensor is located at the Bridge Infeed, (PL 5.4, Fig. 5), and the
second Optical Sensor is located at the entrance to the Gathering Area. (PL 5.4,
Fig. 8).

If the time between the sheets passing under the Bridge Infeed Sensor to the
Gathering Area Input Sensor is more than a pre-calculated time, a jam indica-
tion will be indicated.

There are also 3 Static Elimination Bars, (PL 5.4, Fig. 7, 8 and 12) in the bridge
and gathering area that neutralize the static electric charge in the sheets.
Sheets with a static charge will stick together and not jog properly in the gather-
ing area.

Locate the following in the Connnecting Bridge (Top):

! Bridge Interlock Switch
! Gathering Area Loaded Optical Sensor
! Gathering Area Flow Optical Sensor
! Bridge Interface PCB
! Bridge Motor Interface PCB

Watkiss PowerSquare™ 200 Service Training Workbook 15

Machine Areas

! Rotate Axis Motor Control PCB

! Bridge Axis Motor Control PCB
! Tamper Clutch
! Static Elimination Bar
! Bridge Drive Motor

Locate the following in the Connnecting Bridge (Bottom):

! Bridge Infeed Optical Sensor
! Bridge Axis Home Switch
! Rotate Axis Home Switch
! Hand Feed Operation Switches
! DFA Connect PCB
! Bridge Axis Motor
! Rotate Axis Motor

Perform the following tasks:

" 4.5.1 (Calibrate the Bridge Axis)

" 4.5.2 (Calibrate the Rotate Axis)

8.3 Gathering Area

(PL 5.5, Fig. 6 - 19)
When the paper is fed into the gathering area, the paper falls between the end-
lays and sidelays. The endlays and sidelays are adjusted by the PSQ accord-
ing 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. (PL 5.5, Figs. 9 and 11)

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, (PL 5.5, Fig.14), lifts
away to let the set move to the stitch position.

Locate the following:

! Sidelay Axis Motor Control PCB
! Endlay Axis Motor Control PCB
! Sidelay Axis Motor
! Endlay Axis Motor
! Sidelay Axis Home Switch
! Sidelay Axis Limit Switch
! Endlay Axis Home Switch
! Endlay Axis Limit Switch
! Rear Tamper Solenoid
! Active Tamper-gate Motor
! Active Gate Control PCB
! Tamper Distribution PCB

16 Watkiss PowerSquare™ 200 Service Training Workbook

Machine Areas

Perform the following tasks

" 4.5.3 (Calibrate the Endlays)

" 4.5.11 (Check and Adjust the Sidelays for Square)

" 4.5.4 (Check and Calibrate the Sidelays)

" 4.5.8 (Check the Shuttle Pick-up Fingers for Square and Calibration)

" 4.8.5 (Check the Stitch Head Alignment Central to the Endlays)

" 4.5.6 (Calibrate the Active Tamper-gate Motor Speed)

8.4 Shuttle
The set 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 (PL 5.5, Fig.6) to prevent toner deposition
that could mark the covers of the books.

The set is stitched, then moved by the shuttle to the next stitch position. This
process is repeated as necessary to a maximum of 6 stitches. When set to
AUTO, the PSQ automatically calculates the stitch positions. The user can
change the stitch pitch within certain 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 the folding area, the pick- up fingers loosen on the book. The shuttle is
driven by a 230V AC electric motor, Shuttle Drive Motor (PL 5.5, Fig.3), through
a linear transmission.

Locate the following in the Shuttle Chassis - Bottom (PL 5.5, Figs. 2, 3 and
4):
! Shuttle Axis Motor Control PCB
! Shuttle Interface PCB
! Shuttle Axis Motor
! Shuttle Servo Motor
! Shuttle proximity sensor

Locate the following in the Shuttle Chassis - Top

! Shuttle Axis Home Switch
! Shuttle Axis Limit Switch
! Paper Position Optical Sensor
! Tamper-gate micro-switch
! Shuttle Jog Clutch

Watkiss PowerSquare™ 200 Service Training Workbook 17

Machine Areas

Perform the following:

" 4.5.8 (Check the Shuttle Pick-up Fingers for Square and Calibration)

" 4.5.9 (Check and Adjust the Shuttle Pick-up Position Calibration)

8.5 Stitcher
The shuttle collects the set between the pick- up fingers and moves to the first
stitch position. When the book is stitched and moved to the next stitch- position,
the previous stitch moves across a stitch sensor, (PL 5.6, Fig.2). The Stitch
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 (PL 5.5, Fig.4)
next to the stitch head, a jam is indicated and the PSQ is stopped. If the stitch
head jams, a Stitch Head Jam Sensor (PL 5.6, Fig.3) stops the machine. The
Stitch Head Jam Sensor is fitted next to the clincher cam and is connected to a
Stitch Sensor PCB.

Stitcher and Clincher : (PL 5.6, Figs.1 to 6)

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 the PSQ. This auto-
matic adjustment makes sure the correct size of stitch is formed for every thick-
ness of book. The single stitch head is a custom version of the Deluxe G8 stitch
head, Diagram. The stitch head is installed vertically and upside down. The
stitch head and clincher (PL 5.6, Figs.1 and 6) are aligned to the centre refer-
ence line of the PSQ. The book is moved to each stitch position by the shuttle.

The clincher (PL 5.6, Fig. 6) is held in a frame above the stitch head. The PSQ
uses a clincher with 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, shafts and clutches. The stitch head vertical- axis
adjustment is made by a 24V DC electric motor, (PL 5.6, Fig.5).

Locate the following:

! Stitch Axis Home Switch
! Stitch-wire Feed On or Off Detect Switch
! Stitch Sensor. Ferrous Metal Sensor.
! Stitch Head Jam. Proximity Sensor
! Stitch Clutch
! Stitch-wire Feed Toggle Clutch
! Stitcher Control PCB.
! Stitch Sensor Interface PCB
! Stitch Axis Motor

18 Watkiss PowerSquare™ 200 Service Training Workbook

Machine Areas

Perform the following:

" 4.8.6 (Align the Stitch Head Central to the Endlays)

" 4.5.19 (Check and Adjust the Clincher Alignment. Side-to-side.)

" 4.5.20 (Check and Adjust the Clincher Alignment. Back-to-back.)

" 4.8.9 (Test the Wire-feed Clutch)

" 4.5.22 (Set the Clincher Height)

" 4.5.12 (Check the Stitch Head Axis Calibration)

" 4.5.14 (Adjust the Stitch Head Wire Draw)

" 4.5.23 (Check and Adjust the Height of the Stitch Sensor)

8.6 Fold and Form

(PL 5.7 and PL 5.8)

When the shuttle stops in the park position, the folder blade is operated. The
folder blade (PL 5.7 Fig.3) pushes against the centre line of the book - located
by the stitches - and folds the book in half. The folder blade pushes the book to
a calculated depth between a pair of feed- rollers (PL 5.7 Fig.3) and into the
form clamp.

On each face 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 rod.

Drive for the spine form clamp is provided by the main motor and transferred to
a drive shaft by a chain and clutch. Adjustment of the fold blade position for dif-
ferent set thicknesses is made with a 24V DC motor (PL 5.7 Fig.6). The fold
blade retracts and the clamp closes on the book.

The form roller (PL 5.8 Fig.6) rolls along the spine of the book to create the
SquareBack book. The number of spine forms and the pressure applied is cal-
culated by the PSQ or can be overridden on the touch screen by the operator.

The form roller is transported on a carriage (PL 5.8 Fig.6) that runs along the
carriage guide. The carriage drive is from the main electric motor by a clutch
and chain system (PL 5.8 Fig.6). When the carriage reaches the end of the car-
riage guide, either the LH or RH limit sensor (PL 5.8 Fig.3) is operated. If the
carriage stops before either of the limit sensors is reached, a jam is indicated.
The form roller is turned by a gear wheel that engages with a rack. When the
spine is formed, the carriage stops at one end of the carriage guide and the
spine form clamp is released. A solenoid (PL 5.8 Fig.11) is operated that moves

Watkiss PowerSquare™ 200 Service Training Workbook 19

Machine Areas

the eject rollers into contact with the book. The eject rollers rotate and move the
book towards the trimmer infeed.

Locate the following in the Folder:

! Axis Home Switch
! Folder Area Optical Fold Sensor
! Fold Axis Motor Control PCB
! Folder Interface PCB
! GUI Interface PCB
! GUI SVGA inverter PCB
! Fold Axis Motor
! GUI SVGA Screen
! Folder Clutch

Locate the following in the Former:

! Safety Interlock Switch
! RH End of Carriage Proximity Switch
! LH End of Carriage Proximity Switch
! Transfer Area Optical Sensor
! Former Interface PCB
! Form Clamp Clutch
! Eject Roller Solenoid
! Form Clutch
! Form Clutch Brake

Perform the following:

" 4.5.29 (Check and Adjust the Former Clamp for Square)

" 4.5.26 (Check and Adjust the Folder Blade for Rotation)

" [Link] (Check the Folder Blade is Parallel to the Endlays)

" 4.5.27 (Centralise the Folder Blade)

" 4.5.32 (Check the Quality of the Spine Form - End to End)

8.7 Trim
(PL 5.9 and PL 5.10)
The book passes between two facing sets of conveyors (PL 5.10 Fig.9 and
Fig.10) 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 change the amount of trim from the
touch screen if necessary.

20 Watkiss PowerSquare™ 200 Service Training Workbook

Machine Areas

The trim clamp (PL 5.10 Fig.7) and trimmer blade (PL 5.10 Fig.1) move for-
wards in one action to hold and trim the book. The trim clamp and trimmer blade
then return to their start position. Offcuts are pushed into the trim bin by flexible
fingers (PL 5.10 Fig.9) 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 the minimum any shear
forces.

The Drive for the trimmer blade and the trim clamp is transferred from the main
electric motor by a chain and clutch (PL 5.10 Fig.4) system. Rotary movement
is changed to linear movement with a crank mechanism.

Locate the following in the Trim Stop:

! Trim Stop Axis Home Switch
! Book at Trim Stop Optical Sensor
! Trim Stop Guard Switch
! Trim Stop Axis Motor Control PCB
! Trim Stop Axis Motor
! Trim Stop Solenoids

Locate the following in the Trimmer:

! Tacho - Magnet Ring Encoder
! Hall Effect Switch
! Trim Bin Full Optical Sensor
! Trim Blade Proximity Switch
! Bin Guard Switch - 1
! Bin Guard Switch - 2
! Trimmer Interface PCB
! Stacker Interface PCB
! Trimmer Clutch
! Eject Roller Clutch

Perform the following:

" 4.5.36 (Check the Angle of the Trimmer Infeed Conveyors)

" 4.5.37 (Check and Adjust the Trim Stop for Square)

8.8 Outfeed and Stacker

When 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 con-
veyor moves the books from the PSQ and drops them on the catch tray. An
adjustable collection-table makes sure the finished books stack correctly. There
is an optical sensor (PL 5.11 Fig.3) in the outfeed to detect jams. This sensor
prevents the books on a full stacker from backing-up into the outfeed.

Watkiss PowerSquare™ 200 Service Training Workbook 21

Machine Areas

Locate the Sensor

! Outfeed Flow Optical Sensor
! Stacker Motor

Perform this task:

" 4.14.3 (Remove the Stacker from the PSQ)

8.9 Machine Cycle control

At this stage of the training, you understand how the machine works and how it
is controlled.

" To witness the entire machine cycle, make a test book using the TEST
screen.

Before you begin:

• Use the GUI to adjust the PSQ for 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:

• Pick-up - Shuttle
• Activate Rear Tamper x2
• 1st Stitch - Shuttle
• Stitch Wire On x2
• Incr Move - Shuttle
• Stitch Wire Off
• Park - Shuttle
• Fold x3
• Clamp
• Form (number of times depends on thickness of book)
• Clamp
• Eject x2
• Blade x3
• Trim Stop
• Outfeed
• Trim Stop
• Outfeed
• Stack Feed x2

22 Watkiss PowerSquare™ 200 Service Training Workbook

Maintenance

9. Maintenance
9.1 Operator Maintenance
Operator maintenance is documented in the user manual. The operator must
• Clean the machine
• Clean the Static Elimination Bars
• Clean the Former Roller
• Clean the the Polyurethane Strips in the Form Clamp
• Clean the Trimmings-removal Fingers
• Clean excess grease from the Stitch Head
• Lubricate the Stitch Head

Perform these tasks:

" Lubricate the stitch head (operator lubrication)

9.2 Routine Maintenance

Routine Maintenance is documented in the Service Manual (see 1.8 “Routine
Maintenance”).

The recommended service interval is every 4 months.

In addition, after 1 million stitches or 3 spools of stitch-wire the stitch head must
be taken to pieces and inspected for wear. This procedure was already per-
formed earlier in the training.

There is a kit of replacement parts for this procedure:

• G8 Stitch Head Maintenance Kit, Part No. 914-874

Perform the following tasks:

" 1-million stitch head maintenance procedure

Refer to the G8 Stitch Head Maintenance Instruction Manual on the
service support CD.
This procedure includes removing and refitting the stitch head.

Trainer Note: This point should be reached by the end of Day 2.

Trainer Note: At the beginning of Day 3, recap what has been learnt so
far. To check the students’ understanding:
Ask the students to use the TEST screen to make a book. This procedure
was done previously (see Section 8.9).

" 4.12.1 (Trimmer Blade and Anvil Replacement and Setting)

Watkiss PowerSquare™ 200 Service Training Workbook 23

Maintenance

9.3 Care Pack

Trainer Note: Show the care pack to the students.

The PowerSquare is shipped with a care pack of essential spare parts.

If spare parts are used, the care pack must be replenished. Order forms are
included in the care pack and in the service manual.

24 Watkiss PowerSquare™ 200 Service Training Workbook

Power and Control

10. Power and Control

Trainer Note: Conduct the power and control sections in the classroom,
using a projector. Then move to the machine to identify components in the
electrical cabinet.

10.1 Power
The PSQ uses a single phase power supply. Internally the power supply voltage
is changed to:
• 242V for the low voltage power unit and the main drive motor
• 230V for the Anti static Power unit, 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.

Refer to the following:

• 7.1 (High Voltage Connections) shows the AC Wiring

Watkiss PowerSquare™ 200 Service Training Workbook 25

Power and Control

10.2 Control
The 900-208 Main Control PCB is the interface between the GUI screen, the
CPU and all the input and output functions of the machine.
The PCB has a split 28vdc supply protected by three fuses that reset on power-
off.
Red LEDs indicate output function.
Green LEDs indicuate sensor and input functions.
The main control software is programmed into the IC on this PCB. The version
number is displayed on the GUI screen during power-up.

Refer to the following:

• 7.2 (Block Diagram for the PSQ)
• 7.3 (Block Diagram for the Connecting Bridge)
• 7.7.1 (900-208c Control PCB)

26 Watkiss PowerSquare™ 200 Service Training Workbook

Power and Control

10.3 Component Locations

7.4 (Location of Components) shows the location of electrical components in
each module.

Electrical components are also listed in the Parts Listings - for example PL 5.3,
Figs. 10, 11, 12, 13 and 14.
Locate the following electrical components:
! GUI CPU
! 900-208 Mains Control PCB
! Anti Static Transformer Power Unit
! AntiStatic Power Unit
! Relay & Fuse PCB
! Fuse Holder
! Interlock Relay
! Inverter
! Low Voltage Transformer Assembly
! Mains Power Input Connector
! Mains Power On and Off Switch
! Power Interface PCB
! Shuttle Motor Interface PCB
! Terminal Block
! Torroidal Transformer.

Watkiss PowerSquare™ 200 Service Training Workbook 27

Power and Control

" Identify the components:

900-208 Mains Control PCB

Power Interface PCB

Mains Power On and Off Switch

Fuse Holder

Mains Power Input Connector

Terminal Block

Shuttle Motor Interface PCB

Anti Static Transformer Power Unit

AntiStatic Power Unit Relay & Fuse PCB

Low Voltage Transformer Assembly

Interlock Relay

Inverter

Torroidal Transformer

900-208 Mains Control PCB Interlock Relay Power Interface PCB

Anti Static Transformer Power Unit Inverter Shuttle Motor Interface PCB
AntiStatic Power Unit Low Voltage Transformer Assembly Terminal Block
Relay & Fuse PCB Mains Power Input Connector Torroidal Transformer
Fuse Holder Mains Power On and Off Switch

28 Watkiss PowerSquare™ 200 Service Training Workbook

Power and Control

10.4 DFA
The DFA Finisher Interface PCB is the interface between the printer and the fin-
isher.

The following input and output signals are provided:

Status ouput signals from the PSQ Control input signals from the
printer
LEDs are RED. All should be ON. LEDs are GREEN.
LED 11 ST0 LED off = Offline LED19 C0 Sheet exit
LED12 ST1 LED off = Fault LED20 C1 End of set
LED13 ST2 LED off = Full LED21 C2 Cycle up

Sheet exit

End of set

Cycle up
Printer PowerSquare
Offline

Fault

Full

Watkiss PowerSquare™ 200 Service Training Workbook 29

Software

11. Software
11.1 Software System Description
There are two parts to the software in the CPU:
• The ‘application software’ controls the operation of the PSQ and includes the
language support.
• The ‘boot firmware’ lets you install the application software. The boot
firmware also loads the application software from the flash memory when
you turn on the machine.

Normally, software updates only affect the application software because soft-
ware updates have a direct effect on the operation of the machine.

Touch MENU to display the version of the software and firmware installed on the
PSQ. Software is marked as ‘S/W’, firmware is marked as ‘F/W’.

The boot firmware and application software are stored 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 when you turn off the machine.
• The flash memory does store information when you turn off the machine.

11.2 Software download

Perform Software download procedure

(see 6.13 ‘‘Software update from a Network Connection’’)

" Software download completed

30 Watkiss PowerSquare™ 200 Service Training Workbook

Product Specifications

12. Product Specifications

Watkiss PowerSquare™200 Rel 2.1
09 April 2008
Operating 10-35°C at 35-85% relative humidity
Conditions
Production Cycle time: Printer dependant
Interset gap: 2 seconds
Minimum set time: 7.5 seconds
Maximum set time: 12.5 seconds
Typical set time: depending on job settings
Stock Sizes - Minimum input size: 200 x 200mm
Online Maximum input size: 340 x 500mm

Stitch & fold line

200 x 200mm

340 x 500mm indicates original lead edge

from the printer

Sheet Rotation Integrated rotator ensures maximum printer pro-

(online machines) ductivity.
Maximum rotation sheet size: 320 x 227mm
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.
207mm

Stitch & fold line

200mm
indicates original lead edge
320 x 227mm from the printer

Stock Range 70 - 250gsm dependant on paper type and qual-

ity
Book Thickness Minimum set thickness:
2 sheets (when folded makes an 8 page booklet)
Maximum finished book thickness:
10mm (approx 200 pages 80gsm)
Maximum set thickness:
5mm (approx 50 sheets 80gsm)

Watkiss PowerSquare™ 200 Service Training Workbook 31

Product Specifications

Stitching 1 - 6 stitches, evenly spaced on the spine of the

book
Stitches/spool: up to 291,500
Books*/spool: approx 127,000
Trimming Maximum fore-edge trim: 28mm
Minimum trimmed book size: 80mm

min. 80mm† max. 28mm

† Serial no. 22 onwards

Stacker Capacity 35 books*

Future development: high capacity stacker
Paper Input Input sheets must be of consistent size and cut
Requirements square.
Machine must be set to match paper size at the
input to PowerSquare.
Book quality is dependent upon quality of input
sheets.
Dimensions Footprint (online): 1870 x 1675mm
Height: 1330 mm maximum
Weight Base machine including stitching wire: 542kg
As above, plus bridge and bridge covers: 702kg
Power Supply Adjustable to 200, 208, 220, 230 and 240V
50/60Hz, single phase
Power standby: 92VA (75W)
Consumption in operation: 700VA (500W)
Noise Emission standby: ambient
in operation: 66 dB (A), peak 87 dB (A)
Approvals Complies with CE and UL. Conforms to FCC
rules Part 15 Class A.
Patents GB.2360013, GB.2401820
USA 6692208, 7325799
EU 1138521, others pending
Japan. patents pending
* 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 pol-
icy of continual product improvement, the manufacturer reserves the right
to alter the materials or specification of this product at any time without
notice.

Copyright © 2007-8 Watkiss Automation Limited

32 Watkiss PowerSquare™ 200 Service Training Workbook

Quality Tolerances

13. Quality Tolerances

Sheet Alignment Sheet to sheet: up to 0.5mm

Within set: up to 1.0mm
Accuracy of Stitch position: within 0.5mm of the centreline of the
stitching and folding sheet, measured on an un-trimmed book.
Formed spines: Centreline of stitch within
centre 50% of spine width
Un-formed spines: On spine +/- 1mm 50%

Squareness of From spine to trimmed edge:

folding within 0.28° x°

open edge
spine
Accuracy of Within 1mm (a, b, c) a
trimming illustration
shows a book
c

Stitch form Legs should lie flat so they cannot cause injury
Legs should not re-penetrate the spine
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 spine will vary according to material
and machine set-up.
Spine forming should not cut the paper nor cause exces-
sive wrinkling. A witness from clamp, spine forming and
fold blade is visible. It should not encroach into the book
beyond the clamp line.
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.

Watkiss PowerSquare™ 200 Service Training Workbook 33

PSQ Site Requirements

14. PSQ Site Requirements

(Online Version)

14.1 Environment

Parameter Value
Ambient Temperature 10-35°C (50-95°F)
Relative Humidity 35-85%

14.2 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, cush-
ioned underlays can cause problems when the PSQ is moved.

14.3 Access
• The PSQ is 755 mm wide and fits through a standard-size doorway. A stand-
ard-size doorway is 762 mm (30") wide.
• If the PSQ is installed up or down stairs, give special consideration to how
you lift and move the equipment.

14.4 Space needed to unload the PSQ

• The PSQ is shipped on a bespoke pallet. The pallet includes ramps that are
used to unload the machine.
• An area of 1m x 6m (40" x 237") is needed to unload the PSQ from the pallet.

14.5 Dimensions

PSQ Width Depth Height

Online PSQ with stacker and 1675 mm 1870 mm 1330 mm
connecting bridge 66" 74" 52"

Pallets Length Width Height

PSQ 2090 mm 940 mm 1480 mm
83" 37" 59"
Connecting bridge 1880 mm 750 mm 590 mm
74" 30" 24"
Bridge covers 1120 mm 900 mm 1350 mm
44" 36" 54"

34 Watkiss PowerSquare™ 200 Service Training Workbook

PSQ Site Requirements

14.6 Weight

PowerSquare Weight
Online with connecting bridge and stitch-wire 702 kg, 1548-lb

14.7 Electrical

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
Protection Fuse 2 X F7.0A HRC
Mains PSQ connection : IEC60320 C19
Connection Removable cable and plug supplied.
Europe : IEC83 'Shuko'
UK : BS 1363
North America / Japan : NEMA 6-15
For other areas, contact the supplier for the correct cable.
Power 700VA (500W) maximum
Consumption

14.8 Printer Interface

A DFA interface cable is supplied with the online PSQ.

14.9 Floor Space

The floor space requirement is shown below.

Watkiss PowerSquare™ 200 Service Training Workbook 35

36
NOT TO SCALE

Input for Mains Power Supply

PSQ Site Requirements

Printer Connecting Bridge

PowerSquare
1870 mm; 74"

Stacker

1675 mm; 66"

OPERATING AREA MAINTENANCE AREA
700 mm; 28” to the left of the 500 mm; 20” in front, to the right
machine. and to the rear of the machine.

Total floor space requirement is 2500 x 2870 mm (99 x 113")

The height is 1330 mm (52"). An additional 500 mm (20") is required
above the machine for service access.

Watkiss PowerSquare™ 200 Service Training Workbook

Glossary of booklet making terms

15. Glossary of booklet making terms

The following booklet making terms are in common use. Many are used in Wat-
kiss documentation.

3-knife trim To trim the three open sides of a book(let).

book & A collection of sheets which have been stitched and folded to
booklet make a book(let).
The term ‘booklet’ is usually used for up to 48 or 64 pages.

creep The slight but cumulative offset 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 an item where width is greater than

height. The opposite of 'portrait'.

loop / omega A type of stitch which is shaped like an omega. Used when
book(lets) are to be placed in a ring-binder.

moving clinch The clinch bends the legs of the stitch or staple.
A moving clinch produces a stitch with straight legs which lie
flat.
A static stitch produces a stitch with curved legs (like a desk-
top stapler).

page One side of one leaf (of a book or magazine or newspaper or

letter etc.).
When making booklets, each sheet, when folded, makes 4
pages. A booklet is always a multiple of 4 pages.

perfect bind A binding process using a glue to bind the pages of a catalog
or book to a separate cover like a paperback book. This proc-
ess also produces a visible flat spine.

portrait The format of a page or an item where height is greater than

width. The opposite of 'landscape'.

saddle stitch A method which inserts one signature into another and the
signatures are either sewn or stapled down the centre of the
fold.
Booklet making by the stitch-fold-trim method (as with Watk-
iss equipment) is sometimes called saddle stitching, but this is
not technically correct.

Watkiss PowerSquare™ 200 Service Training Workbook 37

Glossary of booklet making terms

set A collection of sheets of paper which will make a complete

book(let).

set thickness The measured thickeness of a set, before it has been made
into a book(let).
This measurement is required when a job is set up on the
PowerSquare or other booklet maker.

sheet One piece of paper

signature The name given to a printed sheet once it has been folded.
Dependent on the number of folds, the signature may be 4,

spine The binding side of a book(let).

SquareBack Name of a book which has a stitched square spine. Technol-

ogy developed and patented by Watkiss.
Related terms:
Square fold: term used by Kodak to describe the Plockmatic
product, which uses Watkiss technology under licence.
Square edge: term used by Kodak to describe the Bourg prod-
uct, which is manufactured by Watkiss.

staple To bind sheets of paper together using a staple.

A staple is a pre-cut length of wire, which may already 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).

38 Watkiss PowerSquare™ 200 Service Training Workbook

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