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.