Watkiss Plockmatic PowerSquare 224 Installation guide

Watkiss Automation Limited
1 Blaydon Road
Middlefield Industrial Estate
Sandy, Bedfordshire
SG19 1RZ United Kingdom
Tel: [phone]
Fax: [phone]
Email: [email protected]
Plockmatic PowerSquare™ 224
Service Training Workbook
Right to Left Version
Issue 1, November 2014, edited January 2017
Doc. No.x05082
Name: ............................................................................

© Watkiss Automation Limited 2019
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.

Glossary of booklet making terms
50 Plockmatic PowerSquare™ 224 - Service Training Workbook
set A collection of sheets of paper which will make a complete
book(let).
set thickness The measured thickness of a set, before it has been made into
a book(let).
This measurement is required when a job is set up on the
PSQ or other booklet maker.
sheet One piece of paper
signature The name given to a printed sheet once it has been folded.
The signature will always be a multiple of 4. Dependent on the
number of folds, the signature can be 4, 8, 12, 16, etc.
spine The binding side of a book(let).
SquareBack Name of a book which has a stitched square spine.
Technology developed and patented by Watkiss.
Related terms:
Square fold: term used by Xerox to describe the Plockmatic
product, which uses Watkiss technology under licence.
Square edge: term used by Xerox to describe the Plockmatic
product, 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).
iPlockmatic PowerSquare™ 224 - Service Training Workbook
CONTENTS
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Conventions in this workbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Adobe Reader and Adobe Acrobat Instructions . . . . . . . . . . . . . . 2
1.3 Illustrated Parts Catalogues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Paper Enters the System via the Connecting Bridge . . . . . . . . . . 7
3.2 The Gathering Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 The Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 The Stitch Head and Clincher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 The Stitch Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Fold and Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.8 Outfeed and Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 User Interface (GUI) - Operator Menu . . . . . . . . . . . . . . 12
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Power save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 The Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 GUI buttons and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Advanced Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Paper quality and machine performance. . . . . . . . . . . . . . . . . . . 16
5.2 Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Clear paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Book Quality and Machine Specifications . . . . . . . . . . . . . . . . . . 17
6 User Interface - Service Overview . . . . . . . . . . . . . . . . . 18
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
continued . . .
Plockmatic PowerSquare™ 224, Service Training Workbook.
R2L. Issue 1, Nov 2014 edited Jan 2017.

ii Plockmatic PowerSquare™ 224 - Service Training Workbook
8 Machine Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.2 Connecting Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.3 Gathering Area Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.4 Shuttle - Book Gathering and Pick-up . . . . . . . . . . . . . . . . . . . . . 21
8.5 Shuttle - Book Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.6 Stitcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.7 Fold and Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.8 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.9 Outfeed and Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.10 Machine Cycle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.1 Operator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.2 Technical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.3 Care Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10 Power and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.1 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.3 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.4 DFA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.1 Software System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2 Software download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.3 Web-browser Based Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 36
12 Replace Trimmer Blade (optional - time permitting) . . 37
13 PSQ Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
14 Product Updates and Technical Bulletins . . . . . . . . . . 37
15 Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 38
16 Quality Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
17 PSQ Site Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 43
18 Glossary of booklet making terms . . . . . . . . . . . . . . . . 49
Glossary of booklet making terms
Plockmatic PowerSquare™ 224 - Service Training Workbook 49
18. Glossary of booklet making terms
The following booklet making terms are in common use. Many are used in the
PSQ documentation.
3-knife trim To trim the three open sides of a book(let).
book &
booklet
A collection of sheets which have been stitched and folded to
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 that is shaped like the Greek letter omega - Ω .
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
desktop 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
process 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 Watkiss
equipment) is sometimes called saddle stitching, but this is not
technically correct.

PSQ Site Requirements
48 Plockmatic PowerSquare™ 224 - Service Training Workbook
17.9.4 Online PowerSquare with P2T 2-Knife Trimmer and PBS Book Stacker
PowerSquare Connecting
Bridge
P2T Trimmer
Input for Mains
Power Supply
PBS Book Stacker
Input for Mains Power Supply
Maintenance area: 3280 mm, 130"
Maintenance area: 2780 mm, 110"
2430 mm, 96"
Maintenance area: 3900 mm, 154"
NOT TO SCALE
Introduction
Plockmatic PowerSquare™ 224 - Service Training Workbook 1
1. Introduction
The Plockmatic PowerSquare™ 224 is an innovative, complete book making
system for digital print applications. In a single machine it combines the four
processes of stitching, folding, spine forming and trimming to produce
SquareBack™ books up to 224 pages thick. It features fully automatic setting
for different book size and pagination, including variable stitch leg length for
varying book thickness.
The maximum book thickness, of 10.4mm (208 pages/80gsm, 224 pages/
70gsm), is double that of alternative conventional booklet-making machines, so
it is ideally suited to higher paginations or to thicker stocks. This makes the
PowerSquare 224 a fast and cost effective alternative to perfect binding or tape
binding. Since it will also produce books from only a few sheets, it provides a
single book-making solution for documents from 8 through to 224 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 PowerSquare 224 is a perfect match.
1.1 Conventions in this workbook
The PowerSquare 224 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 224 Service Manual:
• Issue 1b, October 2016, Part No. 969-292
Offline PowerSquare
Online PowerSquare

Introduction
2Plockmatic PowerSquare™ 224 - Service Training Workbook
1.2 Adobe Reader and Adobe Acrobat Instructions
If you use Adobe Reader or Adobe Acrobat to read this manual, we recommend
you follow these instructions:
Make sure all the navigation buttons are visible
Adobe Reader and Adobe Acrobat include navigation buttons to help you move
around the file. When certain versions of Adobe Reader and Adobe Acrobat are
first installed, some of the navigation buttons are hidden.
Make sure all buttons are visible, as shown below:
Procedure:
1. Right-click on one of the arrows on the Navigation Toolbar.
2. Click on ‘Show page navigation tools’.
3. From the list, select the buttons you want to display.
Button Function
Click to go to first page in the document
Click to go to the previous page in the document
Click to go to the next page in the document
Click to go to last page in the document
Shows the current page number. To move to a certain
page, type the page number and press Enter.
Click to go to the previous view or the next view.
You can use these buttons to re-trace your steps.
FIGURE 1. The Navigation Toolbar, Adobe Acrobat Reader DC
PSQ Site Requirements
Plockmatic PowerSquare™ 224 - Service Training Workbook 47
17.9.3 Online PowerSquare with P2T 2-Knife Trimmer
PSQ
Connecting
Bridge
P2T 2-Knife
Trimmer
Input for
Mains Power
Supply
Input for Mains Power Supply
Maintenance area: 3470 mm, 137"
2970 mm, 117"
1870 mm, 74"
Maintenance area: 3520 mm, 139"
NOT TO SCALE

PSQ Site Requirements
46 Plockmatic PowerSquare™ 224 - Service Training Workbook
17.9.2 Online PowerSquare with PBS Book Stacker
PSQ
Connecting
Bridge
PBS Book Stacker
Input for Mains Power Supply
Maintenance area: 2800 mm, 111"
2280 mm, 90"
2420 mm, 96"
Maintenance area: 3580 mm, 141"
NOT TO SCALE
Introduction
Plockmatic PowerSquare™ 224 - Service Training Workbook 3
1.3 Illustrated Parts Catalogues
The Plockmatic PowerSquare™ 224 is made from these modules:
The Illustrated Parts Catalogues for the PSQ are separate documents available
in electronic form.
Part-number information for these modules is found in the related Illustrated
Parts Catalogues (IPC). The modules are split into assemblies. Each assembly
is shown as an exploded diagram. See FIGURE 2.
PSQK - Complete M/C
- PBCK - Connecting Bridge
- - PBR5 - Rotator
- PRTP - Base Machine
- - PBRG - Gathering Module
- - PRSH - Shuttle
- - PSTI - Stitcher
- - PRFD - Folder
- - PFRM - Spine Former
--PSTP - Trim Stop
- - PTRM - Trimmer
- - POFD - Outfeed
- - PSTK - Stacker
PBS - PowerSquare Book Stacker (optional)
P2TK - PowerSquare 2-Knife Trimmer (optional)
Oct 2009 PSHU - FIG 16 - TAMPER GATE FRAME
10
2b
∗
2a
∗
REL 2.3 PSQ/0300 ONWARDS (Mod 39c)
1a 1b 1c 1d 1e 1f 1d
5d
5c
5b
6
7
2d 31g
4
9
13
8
11
12
order kit 940-127.
2c
5a
Prior to PSQ/0300, when
replacing these parts,
∗
∗
891-460
891-461
FIGURE 2. Extract from PSHU, Issue 3. Fig.16 - tamper gate frame
Additional information
Exploded diagram

Introduction
4Plockmatic PowerSquare™ 224 - Service Training Workbook
Every exploded diagram is followed by the related part number information. The
part number information is given for the top level assembly, sub-assemblies and
components where available. See FIGURE 3.
Part No.Item Description Qty. Fig.
FIG.16 - TAMPER GATE FRAME PSQ SHUTTLE -PSHU LAST EDIT:18 AUG 09
Fig16 891-648 P.ASSY, (PSQ) TAMPER-GATE FRAME 1
1 891-688 • P.ASSY, (PSQ) TAMPER-GATE TIE BAR 1
1a 180-418 • • SPRING, E-CLIP FOR 4mm GROOVE 6
1b 190-575 • • OILITE, 5ID x 8OD x12LG + MOS2 2
1c 180-078 • • SPRING, 18mm x 9mm Ext., Extra strong 2
1d 266-086 • • SHAFT,(PSQ) ACTIVE-GATE TOP HAT SPACER 2
1e 190-370 • • BEARING, ROLLER 12mmODx8mmIDx3.5mm LG 2
1f 266-087 • • SPACER, (PSQ) GATE 10.50ODX8IDX3LG 1
1g 266-095 • • SHAFT, (PSQ) ACTIVE-GATE TIE BAR 1
•
2 891-647 • P.ASSY, (PSQ) TAMPER PIVOT DRIVE SIDE 1
2a 100-334 • • SCREW, SKT HD CAP, M2.5x10mm STAINLESS 1
2b 160-202 • • WASHER, M2.5 FORM A BZP 1
2c 257-833 • • ST ST, (PSQ) PIVOT LOCATION PLATE 1
2d 266-088 • • SHAFT,(PSQ) ACTIVE-GATE PIVOT PIN 1
•
3 315-775 • PLASTIC,(PSQ) ACTIVE-GATE PIVOT BLOCK 1
4 891-645 • P.ASSY, (PSQ) TAMPER GATE BRACKET 1
5 891-646 • P.ASSY, (PSQ) TAMPER PIVOT PLATE 1
5a 266-088 • • SHAFT,(PSQ) ACTIVE-GATE PIVOT PIN 1
5b 257-833 • • ST ST, (PSQ) PIVOT LOCATION PLATE 1
5c 160-202 • • WASHER, M2.5 FORM A BZP 1
5d 100-334 • • SCREW, SKT HD CAP, M2.5x10mm STAINLESS 1
•
6 160-002 • WASHER, M3 FORM A BZP 2
7 100-326 • SCREW, SKT HD CAP, M3 x 10mm STAINLESS 2
8 165-001 • SHAKEPROOF WASHER, M4 INTERNAL BZP 2
FIGURE 3. Extract from PSHU, Issue 3. Fig.16. Part number information.
Top-level assembly
Sub assembly
Component level
PSQ Site Requirements
Plockmatic PowerSquare™ 224 - Service Training Workbook 45
17.9.1 Online PowerSquare
PSQ
Connecting
Bridge
Input for Mains Power Supply
Maintenance area: 3255 mm, 129"
2755mm, 109"
1870 mm, 74"
Maintenance area: 2870 mm, 113"
NOT TO SCALE
Stacker

PSQ Site Requirements
44 Plockmatic PowerSquare™ 224 - Service Training Workbook
17.6 Weight
17.7 Electrical
17.8 Printer Interface
A DFA interface cable is supplied with the online PSQ.
17.9 Floor Space
The floor space requirement is shown below.
PSQ Weight
Online with connecting bridge and stitch-wire 532 kg, 1173-lb
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
Note: Startup peak value max 30A. A slow circuit breaker
of minimum 16A is required.
Protection Fuse 2 X F7.0A HRC
Mains
Connection
PSQ connection : IEC60320 C19
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
Consumption
700VA (500W) maximum
Product Overview
Plockmatic PowerSquare™ 224 - Service Training Workbook 5
2. Product Overview
2.1 Paper Path
Stage Description Service Manual Reference
The sheets of paper leave the printer and
enter the infeed of the connecting bridge.
See Section 1.7.1.
The paper is rotated in the connecting
bridge if necessary.
See Section 1.7.1.
The sheets of paper are gathered into a set
in the gathering area. When a set is
complete it is collected by the shuttle.
See Section 1.7.2.
See Section 1.7.3.
The set is moved to the stitch head where
the set is stitched
See Section 1.7.4.
See Section 1.7.5.
The set is moved to the fold position where
the fold blade pushes the set into the spine
form clamp.
See Section 1.7.6.






FIGURE 4. Plan view of the Plockmatic PowerSquare 224 showing

Product Overview
6Plockmatic PowerSquare™ 224 - Service Training Workbook
Stage Description Service Manual Reference
The fold blade lifts and the form clamp
closes. The form roller creates the
SquareBack spine on the book.
See Section 1.7.6.
The book is moved to the trim stop and
clamped in position. The fore-edge of the
book is trimmed by the trimmer blade that
moves horizontally.
See Section 1.7.7.
The book is released and conveyed by the
outfeed mechanism to the stacker.
See Section 1.7.8.
The finished books are stacked neatly,
ready for the operator to remove.
See Section 1.7.8.




Figure 2:1. End view of the Plockmatic PowerSquare 224 showing
PSQ Site Requirements
Plockmatic PowerSquare™ 224 - Service Training Workbook 43
17. PSQ Site Requirements
17.1 Environment
17.2 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,
cushioned underlays can cause problems when the PSQ is moved.
17.3 Access
• The PSQ is 755 mm wide and fits through a standard-size doorway. A
standard-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.
17.4 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.
17.5 Dimensions
Parameter Value
Ambient Temperature 10-35°C (50-95°F)
Relative Humidity 35-85%
Altitude up to 2000m amsl
PSQ Width Depth Height
Online PSQ with stacker and
connecting bridge
1675 mm
66"
1870 mm
74"
1330 mm
52"
Pallets Length Width Height
PSQ 2090 mm
83"
940 mm
37"
1480 mm
59"
Connecting bridge 1180 mm
47"
900 mm
36"
1350 mm
54"