Watkiss PowerSquare 224 User manual

Watkiss PowerSquare™224
User Manual
with Side-Trimming option
English, Issue 5, June 2013

© Watkiss Automation Limited 2013
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 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™224 User Manual i
1. Introduction to the Watkiss PowerSquare™224 . . . . . . . 1
Description of the PowerSquare . . . . . . . . . . . . . . . . . . . . . . . 2
2. How to Run the PowerSquare . . . . . . . . . . . . . . . . . . . . . 9
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Turn On the PowerSquare . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Enter the Job Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjust the Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Run the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. The User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The Job Mimic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
The BASIC Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The LOAD & SAVE Window . . . . . . . . . . . . . . . . . . . . . . . . . 23
The ADVANCED Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
The CONFIGURE Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
The MENU Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4. Standard Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Load and Save the Job Settings . . . . . . . . . . . . . . . . . . . . . . 30
Adjust the Stitch Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Adjust the Side-Trim Offset . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Open the Connecting Bridge Cover . . . . . . . . . . . . . . . . . . . . 33
Open and Close the Folder Cover . . . . . . . . . . . . . . . . . . . . . 34
Lift and Lower the Clincher Frame . . . . . . . . . . . . . . . . . . . . . 35
Open the Gathering Area Cover . . . . . . . . . . . . . . . . . . . . . . 36
Lift the PowerSquare Main Deck . . . . . . . . . . . . . . . . . . . . . . 36
Table of Contents
continued . . .
User Manual for Watkiss PowerSquare™224 with side-trimmer
English, Issue 5, June 2013. Watkiss Part No. 960-941
Effective Serial No. WA/PSQ/0800 onwards

ii Watkiss PowerSquare™224 User Manual
Empty the Trim Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Open the Stitch-Wire Cabinet . . . . . . . . . . . . . . . . . . . . . . . . 39
Adjust the Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Adjust the Book Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Unload the Book Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Move the Book Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Empty the Side-Trim Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjust the Side-Trimmer Stacker . . . . . . . . . . . . . . . . . . . . . . 45
Raise and Lower the Side-Trimmer Stacker . . . . . . . . . . . . . 46
Move the Side-Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove and re-fit the Side-Trimmer Book Supports . . . . . . . 48
Operate the PowerSquare offline . . . . . . . . . . . . . . . . . . . . . . 53
5. Error Conditions, Problems and Solutions . . . . . . . . . . 55
Printer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PowerSquare Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
General Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Book Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Message List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Clear a Stitch-wire Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Clear a Stitch Head Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Calibrate the Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Change the Fuses - PowerSquare . . . . . . . . . . . . . . . . . . . . . 97
Change the Fuses - Book Stacker . . . . . . . . . . . . . . . . . . . . . 98
Change the Fuses - Side-Trimmer . . . . . . . . . . . . . . . . . . . . . 98
Manually park the Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Clean the PowerSquare . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Clean the Former Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Clean the Polyurethane Strips in the Form Clamp . . . . . . . . 106
Clean the Trimmings-removal Fingers . . . . . . . . . . . . . . . . . 108
Clean excess grease from the Stitch Head . . . . . . . . . . . . . 110
Lubricate the Stitch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Install New Stitch-wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Clear paper from the trim stop . . . . . . . . . . . . . . . . . . . . . . . 120
7. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8. Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . 125
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Image Creep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Watkiss PowerSquare™224 User Manual 1
CHAPTER 1 Introduction to the Watkiss
PowerSquare™224
Thank you for choosing the Watkiss PowerSquare™224.
Your Manual
The Watkiss PowerSquare™224 User Manual describes how to do these tasks.
• Operate the Watkiss PowerSquare™224
• 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™224 User Manual does not describe the operation
of the printer. If needed, refer to your printer user manual.
In this manual the ‘Watkiss PowerSquare™224’ is referred to as the
‘PowerSquare’.
The ‘P2T Two Knife Trimmer’ is referred to as the ‘Side-Trimmer’.
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 dangerous. To prevent injury, you must follow the instructions.

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
2Watkiss PowerSquare™224 User Manual
CAUTION: A CAUTION message tells you that a procedure or operation
can damage the machine or the product. To prevent damage, you must fol-
low the instructions.
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 cor-
rect 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 connected 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 55). 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. The PowerSquare
can be fitted with a standard Stacker or with a Book Stacker. An optional Side-
Trimmer can be fitted.

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
Watkiss PowerSquare™224 User Manual 3
Operator Side of the PowerSquare
FIGURE 1. Operator Side of the PowerSquare.
Stacker
Connecting Bridge
User Interface
PowerSquare
FIGURE 2. Book Stacker (optional)
Book Stacker
FIGURE 3. Side-Trimmer (optional)
P2T Side-Trimmer

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
4Watkiss PowerSquare™224 User Manual
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. Rotation 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 (See Figure
1).
The book stacker The book stacker is optional. It is a high-capacity
stacker for the finished books (See Figure 2).
The P2T side-trimmer The side-trimmer is optional. It trims the top and bot-
tom edge of the books (See Figure 3).
Stitch Wire Cabinet
Trim Bin
FIGURE 4. Right hand side of the PowerSquare.
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.

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
Watkiss PowerSquare™224 User Manual 5
The Rear Panel of the PowerSquare
Component - Function Table
FIGURE 5. The Rear Panel of the PowerSquare.
Rating and Serial Label
Mains Power ON/OFF Switch
Fuses
Mains Power Input Connector
Voltage Label
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.
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.

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
6Watkiss PowerSquare™224 User Manual
The Input Panel of the Book Stacker
Component - Function Table
FIGURE 6. The Input Panel of the Book Stacker.
1
2
3
4
5
No. Component Function
1 Rating and serial label The rating label displays the type of machine,
serial number, power use and fuse information.
2 Voltage advisory label The voltage advisory label shows that the input
voltage is 230V AC. The 230V power is supplied
by the PowerSquare.
3 Power input connector The power input connector is used to connect the
power supply from the PowerSquare to the Book
Stacker.
4 Mains power ON/OFF
switch
The mains power ON/OFF switch turns ON the
Book Stacker or turns OFF the Book Stacker.
5 Fuses The fuses make sure the operator and the
machine are protected if there is an electrical
problem or short circuit.

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
Watkiss PowerSquare™224 User Manual 7
The Side-Trimmer
Component - Function Table
1
2
3
5
6
7
8
9
4
FIGURE 7. Side-Trimmer Components
No. Component Function
1 The Top Cover The top cover opens to allow error recovery.
2 The Trim Bin The trim bin collects the paper that is trimmed
from the top and bottom of the book.
If the PowerSquare is configured with a Book
Stacker and a P2T Side-Trimmer, the P2T trim bin
is located in the Book Stacker.
3 The Stacker The stacker collects the finished books.
4 Communications cable The communications cable connects the Side-
Trimmer to the PowerSquare.
5 Voltage label The voltage label displays the machine voltage.
6 Mains power input con-
nector
The mains power input connector is used to con-
nect the Side-Trimmer to mains electrical power.
7 Mains power ON/OFF
switch
The mains power ON/OFF switch turns ON the
Side-Trimmer or turns OFF the Side-Trimmer.

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
8Watkiss PowerSquare™224 User Manual
8 Fuses The fuses make sure the operator and the
machine are protected if there is an electrical
problem or short circuit.
9 Rating and serial label The rating label displays the type of machine,
serial number, power use and fuse information.
No. Component Function

Watkiss PowerSquare™224 User Manual 9
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 15.
Information about standard procedures, for example opening covers to clear a
paper jam, is included in “Standard Tasks” on page 29.

2 - How to Run the PowerSquare - Before You Begin
10 Watkiss PowerSquare™224 User Manual
Before You Begin
Paper and Book Quality Instructions
• The size of the paper, and either the set thickness or the sheet thickness,
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.
• To get best accuracy, use millimetres to measure the set. See page 11.
• 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 Problems” on page 57 for further information.
Set Thickness and Sheet Thickness
In order to make a high quality finished book, the machine adjusts the length of
the stitch and the amount of spine-form according to the set thickness. There
are two operating modes:
Sheet thickness and page count
This is the default operating mode.
Measure the thickness of a single sheet. Enter the value into the touch screen.
Use the measuring tool supplied with the machine. The sheets are counted as
they enter the machine and the settings adjust automatically.
Tip: It is easiest to measure 10 sheets of paper and divide the value by 10.
If you use the same type of paper frequently, record the value so that you do
not need to measure it each time.
Set thickness
Measure the thickness of a complete set. Enter the value into the touch screen.
Measure the set thickness as accurately as possible. Use the measuring tool
supplied with the machine.
Turn On the PowerSquare
Procedure
1. Connect the PowerSquare and any accessories to the mains power supply.
2. Use the mains ON/OFF switches to turn ON the PowerSquare and accesso-
ries.
The PowerSquare makes this sequence of beeps:
‘beep__beep beep beep beep______beep __ beep’.

2 - How to Run the PowerSquare - Enter the Job Settings
Watkiss PowerSquare™224 User Manual 11
The touch screen illuminates and the machine calibrates.
When READY is displayed on the screen, 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 15 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
Note: This set can be made into a book. See “Operate the PowerSquare
offline” on page 53.
Step Action Information
1 Print a set to the stacker.
2 Measure the sheet size.
Measure either the sheet
thickness or the set thick-
ness.
To make an accurate book you must enter
accurate paper dimensions into the touch
screen.
To get best accuracy, use millimetres to
measure the set.
If needed, set the PowerSquare to use milli-
metres.
• Touch MENU.
• Select Supervisor access level.
• Touch MENU > CONFIGURE >
MACHINE OPTIONS.
• Touch mm > CLOSE.
3 Use these dimensions for
the job setting.

2 - How to Run the PowerSquare - Enter the Job Settings
12 Watkiss PowerSquare™224 User Manual
Procedure for a New Job
Step Action Information
1Touch BASIC .
2 Enter the paper size. Touch PAPER SIZE. Enter the dimensions of
the paper.
The job setting is easier if you first select a
preset paper size, then adjust the settings as
necessary.
Touch PAPER SIZE > PRESETS > A3 or A4.
(USA: 11x17, 8.5x11 or 8.5x14)
3 Enter the page direction. Touch PAGE DIRECTION > LANDSCAPE or
PORTRAIT.
If the PAGE DIRECTION option is not available,
the PAGE DIRECTION cannot be changed.
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 ROTATE to turn the sheet rotation ON or
OFF. Always select the page direction before
you change the rotate setting.
5 Enter the sheet thickness
or
Touch SET THICKNESS. Set AUTO to ON. Use
‘+’ or ‘ - ’ to enter the SHEET THICKNESS.
Enter the set thickness.
See “Set Thickness and
Sheet Thickness” on
page 10.
Touch SET THICKNESS. Set AUTO to OFF.
Use ‘+’ or ‘ - ’ to enter the SET THICKNESS.
6 Enter the number of
stitches.
Touch STITCHES and enter the number of
stitches. If needed, the stitch pitch can be
changed. See “STITCH PITCH” on page 20.
Xerox Nuvera users: Select the correct profile
on the printer.
7 Enter the spine form set-
ting.
The spine form setting is automatic, accord-
ing to the SET THICKNESS setting. If needed,
the setting can be changed. See “FORM” on
page 21
8 Enter the trim setting. The trim setting is automatic, according to the
PAGE SIZE and SET THICKNESS settings. To
change the setting, touch TRIM. See “TRIM”
on page 21

2 - How to Run the PowerSquare - Adjust the Stacker
Watkiss PowerSquare™224 User Manual 13
Procedure for a Saved Job
1. Touch LOAD & SAVE .
2. Touch the job name or use the Up arrow and the Down arrow to select the
job.
3. Touch LOAD.
4. Wait until the PowerSquare is ready.
Adjust the Stacker
Side-Trimmer Stacker
Adjust the stacker according to the size and thickness of the finished book. See
“Adjust the Side-Trimmer Stacker” on page 45.
Book Stacker
Check the Book Stacker is ready to accept books. See “Adjust the Book
Stacker” on page 41.
Run the Job
Procedure
1. Make sure the adjustments on the PowerSquare are complete before you
release the print job from the print queue.
2. Start the print job. The PowerSquare starts automatically.
3. Check the quality of the first book.
4. If the quality is not acceptable, make adjustments. See “Book Quality Prob-
lems” on page 57 for further information.
9 Enter the side-trim setting. The side trim dimension is calculated auto-
matically according to the PAGE SIZE.
To change the size and trim position, touch
SIDE TRIM. See “SIDE TRIM” on page 22.
If the side-trim size is 190mm or less, remove
the book supports. See “Remove and re-fit
the Side-Trimmer Book Supports” on
page 48.
10 Touch CLOSE.
11 If needed, save the job set-
tings to memory.
If the same job settings are used frequently,
then save the job settings to memory.
See “Save a job” on page 30.
Step Action Information

2 - How to Run the PowerSquare - Run the Job
14 Watkiss PowerSquare™224 User Manual
During the job
• Unload books from the stacker before the stacker is full. The PowerSquare
stops and displays a message if the stacker is full.
• If the optional Book Stacker is fitted, see “Unload the Book Stacker” on
page 42.
• Empty the trim bin from time to time. The PowerSquare displays a message
if the trim bin is full. See “Empty the Trim Bin” on page 38.
• Empty the side-trim bin from time to time. The PowerSquare displays a mes-
sage if the side-trim bin is full. See “Empty the Side-Trim Bin” on page 44.

Watkiss PowerSquare™224 User Manual 15
CHAPTER 3 The User Interface
The user interface includes a colour touch screen and START/STOP buttons.
The Touch Screen
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.
FIGURE 8. The User Interface
START Button
STOP Button
Touch Screen

3 - The User Interface - The Touch Screen
16 Watkiss PowerSquare™224 User Manual
Some functions and buttons are only available at certain access levels. See
“ACCESS LEVEL” on page 27.
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.
Illustration







FIGURE 9. The Touch Screen
