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"

Quality Tolerances
42 Plockmatic PowerSquare™ 224 - Service Training Workbook
Trim blade marking
The trim process uses a double-edge blade to cut thick
books. This can leave a small mark in the centre of the
trimmed edge. The visibility of this mark will depend on
the paper quality and characteristics.
Stitch form Legs should lie flat so they cannot cause injury
Legs should not re-penetrate the spine
If this is not the case, correct job settings or make
service correction.
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
excessive 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.
Description of Operation
Plockmatic PowerSquare™ 224 - Service Training Workbook 7
3. Description of Operation
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 includes these modules
• PSQK - Complete M/C
• PBCK - Bridge Covers
• PRTP - Base Machine
• PBR5 - Rotator
• PBRG - Gathering Area
• PRSH - Shuttle
• PSTI - Stitcher
• PRFD - Folder
• PFRM - Spine Former
• PSTP - Trim Stop
• PTRM - Trimmer
• POFD - Outfeed
• PSTK - Stacker
• PBS - PowerSquare Book Stacker (optional)
• P2T - PowerSquare 2-Knife Trimmer (optional)
Part-number information for these modules is found in the related Illustrated
Parts Catalogues (see Section 1.3).
3.1 Paper Enters the System via the Connecting Bridge
For additional information, see Section 1.7 in the PSQ Service Manual.
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 bridge drive belts are driven by a brushless 3-phase electric motor via a
dedicated controller box in the connecting bridge.
The rotate axis in the connecting bridge is adjusted by a 24V DC electric motor.

Description of Operation
8Plockmatic PowerSquare™ 224 - Service Training Workbook
The PBR5 bridge does not have static elimination bars. Blue, non-conductive
belts and additional anti-static brushes remove the static charge on the paper.
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
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
endlays 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. The tamper fingers are positioned and operated
by a stepper motor. 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.
Quality Tolerances
Plockmatic PowerSquare™ 224 - Service Training Workbook 41
Copyright © 2016 Watkiss Automation Limited
16. Quality Tolerances
Power Supply Adjustable to 200, 208, 220, 230 and 240V
50/60Hz, single phase
Note: startup peak value max 30A. A slow circuit breaker
of minimum 16A is required.
Power
Consumption
standby: 92VA (75W)
in operation: 700VA (500W)
Acoustical 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 and VCCI Class A.
Patents GB.2360013, EP.1138521, US.6692208, JP.5059997
GB.2401820, EP.1479258, US.7325799, JP.4887449
* 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 policy of
continual product improvement, the manufacturer reserves the right to alter the
materials or specification of this product at any time without notice.
Sheet Alignment Sheet to sheet: up to 0.5mm
Within set: up to 1.0mm
Accuracy of
stitching and folding
Stitch position: within 0.5mm of the centreline of the
sheet, measured on an un-trimmed book.
Formed spines: Centreline of stitch within
centre 50% of spine width
Un-formed spines: On spine +/- 1mm
Squareness of
folding
From spine to trimmed edge:
within 0.28°
Accuracy of
trimming
Within 1mm (a, b, c)
50%
x°
spine
open edge
a
b
c
illustration
shows a book

Product Specifications
40 Plockmatic PowerSquare™ 224 - Service Training Workbook
Integrity Factors Average Document Size:
20 sheets, 80gsm, 2 stitches
Average volume:
50,000 books per month
Peak volume:
150,000 books per month
Scheduled service intervention:
2 times per year, or at every 3rd wire spool change
if this is sooner. (each 2 hours average)
Un-scheduled service intervention:
3 per year (each 2.5 hours average)
Operator recoverable errors:
2 per day
Trim blade lifetime:
Blade lifetime is dependent on material and other
factors.
User Interface
Languages
English, French, German, Spanish, Italian, Dutch, US
English, Chinese (PRC).
Operator
Maintenance
Weekly:
At screen prompt (20,000 stitches):
lubricate the stitch head
clean machine as instructed in user manual
Dimensions &
Weight
including standard stacker
Online (L>R)
Width : 1675mm
Depth : 1870mm
Height: 1330mm
Weight: 587kg
Dimensions &
Weight
Online (R>L)
as installed
Width : 2755mm
Depth : 1870mm
Height: 1330mm
Weight: 532kg
Point loading: Weight is not distributed evenly. Weight
distribution front/back is approximately 55:45.
Shipping
Dimensions &
Weight
Length Width Height Weight
PowerSquare
2090mm 940mm 1560mm 535kg
PBR5 Bridge
1180mm 900mm 1350mm 240kg
Floorspace
Requirements
Refer to Site Requirements document for different
machine configurations.
Description of Operation
Plockmatic PowerSquare™ 224 - Service Training Workbook 9
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 transmission.
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
automatic adjustment makes sure the correct size of stitch is formed for every
thickness 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 stepper motor. The set
thickness can also be automatically calculated from the thickness of the paper
and the number of sheets in a set. The stepper motor allows wire-draw and
stitch-head compression to change dynamically to match varying thickness jobs
without operator intervention.
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 ‘missing stitch’
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 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.

Description of Operation
10 Plockmatic PowerSquare™ 224 - Service Training Workbook
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
transferred to a drive shaft by a chain and clutch. Adjustment of the fold blade
position for sets of different thickness is made with a 24V DC motor.
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
overridden 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.
While the book is in the form clamp, a pair of lifters either side of the book, raise
the book clear of the shuttle. The shuttle can then return to the pick-up area to
collect the next book to be stitched.
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
operator 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 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. Drive for the trimmer blade and the trim clamp is transferred from the
Product Specifications
Plockmatic PowerSquare™ 224 - Service Training Workbook 39
Book Thickness Minimum set thickness:
1 sheet (when folded makes a 4 page booklet)
Maximum finished book thickness: up to 10.4mm
Maximium book thickness is dependent on paper type,
quality, grain direction, coating, ink/toner type and
coverage. The following figures are given as a guide.
Plain papers:
80gsm: approx. 208 pages (52 sheets)
70gsm: approx. 224 pages (56 sheets)
Coated papers:
115gsm: approx. 128 pages (32 sheets)
Stitching 1 - 6 stitches, evenly spaced on the spine of the book
Stitching can be turned off
Stitches/spool: up to 291,500
Books*/spool: approx 127,000
Trimming Maximum fore-edge trim: 28mm
Minimum trimmed book size: 78mm
Trimming can be switched off
Recommended minimum trim amount: 1mm
Stacker Capacity Standard stacker: 35 books*
Book Stacker (optional): 930mm; approx 185 standard
books*
Paper Input
Requirements
Input sheets must be of consistent size and cut square.
Machine must be set to match paper size at the input to
the booklet maker.
Book quality is dependent upon quality of input sheets.
Mechanical
Interface
Dependent on connecting bridge:
Communications
Interface
DFA
max. 28mmmin. 78mm
Sheet
Reference
Input Height
(mm)
Input Speed
(mm/sec)
Centre Edge
Rotate
Off
Rotate
On
PBR5 Yes No 710/860, to
suit printer
4 selectable set-
tings:
A
B
C
D
1096
980
1110
1330
1096
1096
1220
1330

Product Specifications
38 Plockmatic PowerSquare™ 224 - Service Training Workbook
15. Product Specifications
March 2016
Operating
Conditions
10-35°C at 35-85% relative humidity, up to 2000m amsl
Production Cycle time: Printer dependent
Interset gap: 1 second
Minimum set time: 4.2 seconds
Maximum set time: 12.5 seconds
Typical set time: depending on job settings
Stock Sizes Minimum input size: 200 x 200mm
Maximum input size with PBR5: 370 x 520mm
Sheet Rotation Integrated rotator ensures maximum printer productivity.
Maximum rotation sheet size: 353 x 252mm
Minimum rotation sheet size: 207 x 200mm
The cross-track (z-direction) dimension of the sheet
before rotation must be at least 7mm greater than the in-
track (x-direction) dimension.
Sheet Feed
Orientation
Cover first, face down
Stock Range 60 - 250gsm dependent on paper type and quality
200 x 200mm
370 x 520mm
Stitch & fold line
indicates original lead edge
from the printer
Stitch & fold line
indicates original lead edge
from the printer
200mm
353 x 252mm
207mm
Description of Operation
Plockmatic PowerSquare™ 224 - Service Training Workbook 11
main electric 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.

User Interface (GUI) - Operator Menu
12 Plockmatic PowerSquare™ 224 - Service Training Workbook
4. User Interface (GUI) - Operator Menu
The user interface includes a colour touch screen and START/STOP buttons.
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
operation.
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.
FIGURE 3. The User Interface
START Button
STOP Button
Touch Screen
Replace Trimmer Blade (optional - time permitting)
Plockmatic PowerSquare™ 224 - Service Training Workbook 37
12. Replace Trimmer Blade (optional - time permitting)
REP 4.18.4 (Trimmer Blade and Anvil Replacement and Setting)
13. PSQ Accessories
The following optional accessories for the PowerSquare are documented in
separate Computer Based Training courses (CBTs).
If time permits, a short introduction to these accessories will be included.
• PBS - PowerSquare Book Stacker
• P2T - PowerSquare 2-knife Trimmer
14. Product Updates and Technical Bulletins
Product updates and technical information are distributed by means of technical
bulletins that are issued when required.

Software
36 Plockmatic PowerSquare™ 224 - Service Training Workbook
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
software updates have a direct affect 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 6.9 “Software Update. Ethernet Connection. Primary Method”)
Software download completed
11.3 Web-browser Based Diagnostics
Internal diagnostic information and procedures are accessed via a web-browser
such as Internet Explorer™ or Firefox™ running on a PC connected to the PSQ.
Review Section 6.14 (Web-browser Based Diagnostics) with emphasis
on the following sections that are used in RAPs and Replacement Pro-
cedures:
•Section 6.14.6 (CPU Data Backup)
•Section 6.14.7 (CPU Data Restore)
•Section 6.14.16 (Clutch Diagnostic/Reset)
•Section 6.14.17 (Clutch Calibration)
•Section 6.14.18 (B3 Motor Settings)
User Interface (GUI) - Operator Menu
Plockmatic PowerSquare™ 224 - Service Training Workbook 13
The Touch Screen
Window Tabs:
LOAD & SAVE
BASIC
ADVANCED
CONFIGURE
MENU
The MESSAGE LIST
shows errors and other
information.
The HELP button gives you
more information.
• Touch HELP, then touch
any button.
• Touch HELP, then touch
the message list.
STATUS
•GREEN = Ready or running.
• ORANGE - PLEASE WAIT
•ORANGE - ATTENTION = operator action needed.
•RED = Error condition.
JOB MIMIC
• paper size
• stitch pitch
• set thickness
•form
•trim
• side trim
Window Buttons
• Each Window tab
has its own group
of window buttons.

User Interface (GUI) - Operator Menu
14 Plockmatic PowerSquare™ 224 - Service Training Workbook
4.3 GUI buttons and options
Window Buttons
BASIC PAPER SIZE
PAGE DIRECTION
PRESETS
ROTATE
Enter the paper size
Portrait or Landscape
Standard paper sizes
On or Off
SET THICKNESS
AUTO
SHEET
THICKNESS
Either input the measured set thick-
ness or use AUTO
Auto calculates the set thickness
from the sheet thickness and sheet
count.
Use SHEET THICKNESS to enter
the measured thickness of one sheet
of paper.
STITCHES
STITCH PITCH
AUTO
Number of stitches
Distance between stitches
Automatic stitch pitch setting
FORM
AUTO
NUMBER
PRESSURE
THRESHOLD
Automatic, according to thickness
Number of form roller actions
Pressure to make spine -9 to +9
Minimum thickness for square spine
TRIM
AUTO
Trimmed dimension of the book
Automatic, according to thickness
SIDE TRIM (where fitted)
AUTO
TRIM SIZE
TRIM OFFSET
Trimmed dimension of the book
Automatic, according to PAGE SIZE
Side-trim dimension can be changed
Trim can be biased to top or bottom
LOAD & SAVE SAVE
REPLACE
CANCEL
SAVE NEW
Save the job
Overwrite the existing job
Cancel the save
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
MAKE BOOK
Clear the set from the machine
Power and Control
Plockmatic PowerSquare™ 224 - Service Training Workbook 35
10.4 DFA
The DFA Finisher Interface PCB is the interface between the printer and the
finisher.
The following input and output signals are provided:
Status ouput signals from the PSQ Control input signals from the
printer
LEDs are RED. LED 11, 12 & 13 must be ON to
let the PSQ run online.
LEDs are GREEN.
LED11 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
LED14 ST3 Pulse = sheet delivered LED22 C3 End of job
LED15 ST4 Pulse = set delivered
Sheet Exit
End of set
Cycle up
End of job
Printer Offline PowerSquare
Fault
Full
Sheet Delivered
Set Delivered

Power and Control
34 Plockmatic PowerSquare™ 224 - Service Training Workbook
Identify the components: (use the list below)
900-208 Main Control PCB
Anti-Static Power Unit Fuse &
Relay PCB Fuse Holder
Interlock Relay PCB
Inverter
Low Voltage Transformer Assy
Mains Power Input Connector
Mains Power On and Off Switch
Power Interface PCB
Shuttle Motor Interface PCB
Terminal Block
Toroidal Transformer
User Interface (GUI) - Operator Menu
Plockmatic PowerSquare™ 224 - Service Training Workbook 15
Perform the following tasks:
Set the PSQ to make a preset size book:
A3 input size
Measure the paper from the ream
Enter the measured size into the touch screen
40 sheets (4mm thick)
2 stitches
Save as “A3 Test”
Set the PSQ to make a non-standard book:
A4 input size
Measure the paper from the ream
Enter the measured size into the touch screen
35 sheets (3.5mm thick)
3 stitches, with custom stitch pitch
4 forms, with +5 pressure
Trim to 130mm
Save as “A4 Test”
Re-reference all axes. Observe what happens on the message list.
Open the gathering area, then use HELP to find out about the error
message on the GUI message list.
CONFIGURE MACHINE OPTIONS
MEASUREMENT
STITCH SENSOR
PRESET PAPER
SIZES
SIDE TRIM (P2T)
PBS INSTALLED
Select mm or inches as units
Turn stitch sensor on or off
ISO ‘A’ sizes or US sizes
Touch to turn off communication to
the Side-Trimmer. Only do this if the
Side-Trimmer is disconnected.
Touch to turn off communication to
the Book Stacker. Only do this if the
Book Stacker is disconnected.
NETWORK SETTINGS (service function)
FORM SETUP (service function)
SHUTTLE (service function)
MENU ACCESS LEVEL Operator, Supervisor, Service
(Distributor & Factory)
CURRENT LANGUAGE
AXES Re-reference individual axes
BRIDGE Reference individual axes
COUNTERS
RESET
Book / Sheet / Stitch
Resets the operator count
Window Buttons

Advanced Operation
16 Plockmatic PowerSquare™ 224 - Service Training Workbook
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 dimensions change due to
shrinkage when the paper is printed.
• If the book is made from several different types of paper, make sure the
different 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
accurate book cannot be made.
Perform the following tasks:
Load the saved “A3 Test” job.
A3 input size
Measure the paper from the stacker
Make the book
Delete the saved job.
Load the saved “A4 Test” job.
A3 input size
Measure the paper from the stacker
Make the book
Delete the saved job.
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 is 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
Power and Control
Plockmatic PowerSquare™ 224 - Service Training Workbook 33
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.
Locate the following electrical components:
GUI CPU
900-208 Main Control PCB
Anti Static Power Unit Fuse & Relay PCB (900-228)
Fuse Holder
Interlock Relay PCB (900-220)
Inverter
Low Voltage Transformer Assembly
Mains Power Input Connector
Mains Power On and Off Switch
Power Interface PCB (900-217)
Shuttle Motor Interface PCB (900-222)
Terminal Block
Toroidal Transformer