Watkiss PowerSquare 224 User manual

Watkiss PowerSquare™224
User Manual
Offline Model
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 . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Turn On the PowerSquare . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Enter the Job Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjust the Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Run the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. The User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The Job Mimic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
The BASIC Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
The LOAD & SAVE Window . . . . . . . . . . . . . . . . . . . . . . . . . 20
The ADVANCED Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
The CONFIGURE Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The MENU Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4. Standard Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Load and Save the Job Settings . . . . . . . . . . . . . . . . . . . . . . 26
Adjust the Stitch Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Open and Close the Folder Cover . . . . . . . . . . . . . . . . . . . . . 28
Lift and Lower the Clincher Frame . . . . . . . . . . . . . . . . . . . . . 29
Lift the PowerSquare Main Deck . . . . . . . . . . . . . . . . . . . . . . 30
Empty the Trim Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Open the Stitch-Wire Cabinet . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjust the Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table of Contents
continued . . .
User Manual for Watkiss PowerSquare™224
English, Issue 5, June 2013. Watkiss Part No. 960-931
Effective Serial No. WA/PSQ/0800 onwards

ii Watkiss PowerSquare™224 User Manual
Adjust the Book Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Unload the Book Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Move the Book Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5. Error Conditions, Problems and Solutions . . . . . . . . . . 39
PowerSquare Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Light Guard Interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
General Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Book Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Message List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Clear a Stitch-wire Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Clear a Stitch Head Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Calibrate the Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Change the Fuses - PowerSquare . . . . . . . . . . . . . . . . . . . . . 70
Change the Fuses - Book Stacker . . . . . . . . . . . . . . . . . . . . . 71
Manually park the Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Clean the PowerSquare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Clean the Former Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Clean the Polyurethane Strips in the Form Clamp . . . . . . . . . 78
Clean the Trimmings-removal Fingers . . . . . . . . . . . . . . . . . . 80
Clean excess grease from the Stitch Head . . . . . . . . . . . . . . 82
Lubricate the Stitch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Install New Stitch-wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Clear paper from the trim stop . . . . . . . . . . . . . . . . . . . . . . . . 92
7. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8. Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . 95
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Image Creep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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.
In this manual the ‘Watkiss PowerSquare™224’ 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 dangerous. 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 fol-
low the instructions.

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
2Watkiss PowerSquare™224 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 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 39). Con-
tact your PowerSquare supplier for further help.
Description of the PowerSquare
Introduction
The PowerSquare processes 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
Component - Function Table
FIGURE 1. Operator Side of the PowerSquare.
Stacker
Gathering Area
User Interface
PowerSquare
FIGURE 2. Book Stacker (optional)
Book Stacker
Component Function
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 light guard A light guard protects the gathering area while the
shuttle moves. If you put your hands, or the next
book, into the gathering area while the shuttle moves,
the light guard stops the machine.
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).

1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare
4Watkiss PowerSquare™224 User Manual
Right Hand Side of the PowerSquare
Component - Function Table
Stitch Wire Cabinet
Trim Bin
FIGURE 3. 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 4. 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 5. 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.

Watkiss PowerSquare™224 User Manual 7
CHAPTER 2 How to Run the PowerSquare
Introduction
This chapter gives information on how to run a job on the PowerSquare.
Information about the user interface is included in “The User Interface” on
page 13.
Information about standard procedures, for example opening covers to clear a
paper jam, is included in “Standard Tasks” on page 25.

2 - How to Run the PowerSquare - Before You Begin
8Watkiss PowerSquare™224 User Manual
Before You Begin
Paper and Book Quality Instructions
• The size of paper and the thickness of the set must be measured.
• 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.
• To get best accuracy, use millimetres to measure the set. See page 9.
• 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 41 for further information.
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’.
The touch screen illuminates and the machine calibrates.
When 036READY 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 13 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 you put it in the gather-
ing area.
CAUTION: Do not operate the touch screen with a sharp object or with too
much force. These actions can damage the touch screen.

2 - How to Run the PowerSquare - Enter the Job Settings
Watkiss PowerSquare™224 User Manual 9
Before You Begin
Procedure for a New Job
Step Action Information
1 Take a complete set, that is
to be made into a book.
2 Measure the sheet size and
the set thickness.
Measure the set accurately. 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.
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 set thickness. Touch SET THICKNESS. Enter the measured
value.
5 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 18.

2 - How to Run the PowerSquare - Adjust the Stacker
10 Watkiss PowerSquare™224 User Manual
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
Stacker
Adjust the stacker according to the size and thickness of the finished book. See
“Adjust the Stacker” on page 34.
Book Stacker
Check the Book Stacker is ready to accept books. See “Adjust the Book
Stacker” on page 35.
Run the Job
Note
A light guard protects the gathering area while the shuttle moves. If you put your
hands, or the next book, into the gathering area while the shuttle moves, the
light guard stops the machine. The error message ‘SHUTTLE MOTOR ERROR’ is
displayed in the message list. See “Light Guard Interruption” on page 39.
Procedure
1. Touch START .
6 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 18
7 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 19
8Touch CLOSE.
9 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 26.
Step Action Information

2 - How to Run the PowerSquare - Run the Job
Watkiss PowerSquare™224 User Manual 11
2. Put the set in the gathering area, with the middle pages of the book face up.
3. Remove your hands from the gathering area.
The shuttle moves the set to the stitching area and the book is made.
Do not put your hands, or the next set, into the gathering area while the shut-
tle moves. The green button illuminates when the machine is ready for the
next set.
4. Check the quality of the first book.
5. If the quality is not acceptable, make adjustments. See “Book Quality Prob-
lems” on page 41 for further information.
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 36.
• 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 32.

2 - How to Run the PowerSquare - Run the Job
12 Watkiss PowerSquare™224 User Manual

Watkiss PowerSquare™224 User Manual 13
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 6. The User Interface
START Button
STOP Button
Touch Screen

3 - The User Interface - The Touch Screen
14 Watkiss PowerSquare™224 User Manual
Some functions and buttons are only available at certain access levels. See
“ACCESS LEVEL” on page 24.
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 7. The Touch Screen


3 - The User Interface - The Touch Screen
Watkiss PowerSquare™224 User Manual 15
Component - Function Table
No. Component Function
1 Window Tabs The touch screen buttons are divided into groups that
have connected functions. Each group of buttons has
a separate window. Touch the correct tab to select the
window.
LOAD & SAVE
BASIC
ADVANCED
CONFIGURE
MENU
2 Window Buttons Each window contains a group of buttons. Touch the
button to select the function.
3 Message List Information and error messages are shown in the
MESSAGE LIST.
To display the information about a message, touch
HELP then touch the message list. Use the right-arrow
and left-arrow to see the help text for each message.
4 Job Mimic The job mimic shows the current machine settings.
5 Status The
STATUS line shows the machine status.
- GREEN The PowerSquare is READY or RUNNING.
- ORANGE PLEASE WAIT - wait until the PowerSquare is ready.
ATTENTION - the PowerSquare needs an action by the
operator.
- RED The PowerSquare is in an ERROR condition.
6 Help Help text is available on the touch screen.
•Touch
HELP then touch any button or tab on the
screen. Information about that button or tab is dis-
played.
• To display the information about a message, touch
HELP then touch the message list.
• Use the Up arrow and the Down arrow to scroll-up
and scroll-down the screen.
• Some text has more than one screen. Use the
right-arrow and left-arrow to see the other screens.
To leave the help-text, touch HELP or touch X.
7 &
8
Book Counter The book counter shows the number of books made.
The counter is reset to zero when the PowerSquare is
turned off. Touch ‘C’ to reset the book counter to zero.

3 - The User Interface - The Job Mimic
16 Watkiss PowerSquare™224 User Manual
The Job Mimic
The job mimic shows the current machine status.
FIGURE 8. The Job Mimic





No. Icon Information
1 Paper Size The following items are shown
• the size of paper
• the format of the paper in the gathering area
• the broken line shows the fold line
• the small thick lines show the stitches
2 Stitch Pitch The stitch pitch is shown only when a non-standard
setting is selected.
3 Set Thickness The set thickness, in mm, is shown.