Page 1 Watkiss PowerSquare™224 User Manual with Side-Trimming option English, Issue 5, June 2013...
Page 2 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.
Page 3: Table Of Contents
Table of Contents 1. Introduction to the Watkiss PowerSquare™224 ..1 Description of the PowerSquare ..... . . 2 2.
Page 4 Image Creep ........127 Watkiss PowerSquare™224 User Manual...
Page 5: Introduction To The Watkiss Powersquare™224
CHAPTER 1 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.
Page 6: Description Of The Powersquare
1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare CAUTION: A CAUTION message tells you that a procedure or operation can damage the machine or the product. To prevent damage, you must fol- low the instructions. Installation Your PowerSquare must be installed by a Watkiss service engineer.
Page 7 1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare Operator Side of the PowerSquare Connecting Bridge User Interface PowerSquare Stacker FIGURE 1. Operator Side of the PowerSquare. Book Stacker FIGURE 2. Book Stacker (optional) P2T Side-Trimmer FIGURE 3. Side-Trimmer (optional)
Page 8 1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare Component - Function Table Component Function The connecting bridge The connecting bridge moves the printed sheets from the printer to the PowerSquare. If needed, the sheets are rotated into the correct direction. Rotation lets the printer operate at optimum print speed.
Page 9 1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare The Rear Panel of the PowerSquare Mains Power ON/OFF Switch Rating and Serial Label Fuses Voltage Label Mains Power Input Connector FIGURE 5. The Rear Panel of the PowerSquare.
Page 10 1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare The Input Panel of the Book Stacker FIGURE 6. The Input Panel of the Book Stacker. Component - Function Table No. Component Function Rating and serial label The rating label displays the type of machine, serial number, power use and fuse information.
Page 11 1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare The Side-Trimmer FIGURE 7. Side-Trimmer Components Component - Function Table No. Component Function The Top Cover The top cover opens to allow error recovery. The Trim Bin The trim bin collects the paper that is trimmed from the top and bottom of the book.
Page 12 1 - Introduction to the Watkiss PowerSquare™224 - Description of the PowerSquare No. Component Function Fuses The fuses make sure the operator and the machine are protected if there is an electrical problem or short circuit. Rating and serial label The rating label displays the type of machine, serial number, power use and fuse information.
Page 13: How To Run The Powersquare
Information about the user interface is included in “The User Interface” on page 15. Information about standard procedures, for example opening covers to clear a paper jam, is included in “Standard Tasks” on page 29. Watkiss PowerSquare™224 User Manual...
Page 14: Before You Begin
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’. Watkiss PowerSquare™224 User Manual...
Page 15: Enter The Job Settings
Touch MENU > CONFIGURE > MACHINE OPTIONS • Touch mm > CLOSE Use these dimensions for the job setting. Note: This set can be made into a book. See “Operate the PowerSquare offline” on page 53. Watkiss PowerSquare™224 User Manual...
Page 16 See “FORM” on page 21 Enter the trim setting. The trim setting is automatic, according to the settings. To PAGE SIZE SET THICKNESS change the setting, touch . See “TRIM” TRIM on page 21 Watkiss PowerSquare™224 User Manual...
Page 17: Adjust The Stacker
2. Start the print job. The PowerSquare starts automatically. 3. Check the quality of the first book. 4. If the quality is not acceptable, make adjustments. See “Book Quality Prob- lems” on page 57 for further information. Watkiss PowerSquare™224 User Manual...
Page 18 See “Empty the Trim Bin” on page 38. • Empty the side-trim bin from time to time. The PowerSquare displays a mes- sage if the side-trim bin is full. See “Empty the Side-Trim Bin” on page 44. Watkiss PowerSquare™224 User Manual...
Page 19: The User Interface
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. Watkiss PowerSquare™224 User Manual...
Page 20 Touch the screen to restore the normal brightness. The touch screen takes two or three minutes to reach full brightness. Illustration         FIGURE 9. The Touch Screen Watkiss PowerSquare™224 User Manual...
Page 21 The sheet counter shows the number of sheets in the gathering area. The counter starts again with each book. Book Counter The book counter shows the number of books made. The counter is reset to zero when the PowerSquare is turned off. Watkiss PowerSquare™224 User Manual...
Page 22: The Job Mimic
• the small thick lines show the stitches • the arrow shows the original feed edge in the printer Stitch Pitch The stitch pitch is shown only when a non-standard setting is selected. Watkiss PowerSquare™224 User Manual...
Page 23 The side-trim setting is displayed. The number at the top shows the trim size. The number at the bottom shows if the trim is offset from the centre-line. A red X shows that the side-trim function is not active. Watkiss PowerSquare™224 User Manual...
Page 24: The Basic Window
The stitch pitch is the space between the stitches. The machine automatically calculates the stitch pitch according to the size of the paper. If a non-standard stitch pitch is needed, use STITCH PITCH make the adjustment. Watkiss PowerSquare™224 User Manual...
Page 25 TRIM adjust the size of the finished book after the fore-edge is trimmed. The maximum trim is 28 mm. The trim function can be turned off. Touch to select the default trim position. - AUTO AUTO Watkiss PowerSquare™224 User Manual...
Page 26 By default, the book is trimmed equally on both sides. Touch TRIM OFFSET ' or ' ' to move the trim position away from the centre line. The range is -40mm to +40mm, dependent on how much is to be trimmed. The default setting is 0mm. Watkiss PowerSquare™224 User Manual...
Page 27: The Load & Save Window
Up arrow or Down arrow to make the selec- tion from the job list. Touch and hold . A red line appears. The red line fills DELETE from left to right. Hold until the red line reaches the DELETE right-hand side. Watkiss PowerSquare™224 User Manual...
Page 28 The BY USE most recently-run job is at the top of the list. - BY INDEX Touch to list jobs in numerical order. the machine BY INDEX gives a number to all jobs that are saved. Watkiss PowerSquare™224 User Manual...
Page 29: The Advanced Window
According to the type of error that occurred, there can be a pause of 7 seconds before the button will oper- MAKE BOOK ate. For safety reasons, this function is disabled when the gather- ing area cover is open. Watkiss PowerSquare™224 User Manual...
Page 30: The Configure Window
TAMPER TIME TIME touches the set. An increase in causes a decrease in TAMPER TIME the production rate for thin books. FORM SETUP This button is used by the service engineer. Watkiss PowerSquare™224 User Manual...
Page 31: The Menu Window
RESET after operator maintenance to the stitch head. RESET Touch and hold . A red line appears. The red line fills from RESET left to right. Hold until the red line reaches the right-hand RESET side. Watkiss PowerSquare™224 User Manual...
Page 32 3 - The User Interface - The MENU Window Watkiss PowerSquare™224 User Manual...
Page 33: Standard Tasks
Standard Tasks CHAPTER 4 Introduction This chapter describes the standard tasks that are needed in the day-to-day operation of your PowerSquare. Watkiss PowerSquare™224 User Manual...
Page 34: Load And Save The Job Settings
4. Wait until the PowerSquare has made the adjustments. Reset the PowerSquare to default settings 1. Touch LOAD & SAVE 2. Select the from the list of jobs. Default Job Template 3. Touch LOAD 4. Touch Watkiss PowerSquare™224 User Manual...
Page 35: Adjust The Stitch Pitch
Select a standard stitch pitch 1. Touch > BASIC STITCHES 2. Touch to select AUTO 3. Touch to close the window. STITCHES The stitch pitch value is not displayed in the job mimic or on the but- STITCHES ton. Watkiss PowerSquare™224 User Manual...
Page 36: Adjust The Side-Trim Offset
‘+’ or ‘ - ’ to adjust the BASIC > SIDE TRIM TRIM OFFSET 2. Touch to close the window. CLOSE Select the default side-trim offset 1. Touch and then touch BASIC > SIDE TRIM AUTO 2. Touch to close the window. CLOSE Watkiss PowerSquare™224 User Manual...
Page 37: Open The Connecting Bridge Cover
The PowerSquare will not stop if you open the connecting bridge cover. Connecting Bridge Cover FIGURE 12. Connecting Bridge Cover in the open position. WARNING: Keep your hands, clothing and hair away from the belts. Procedure • Lift the connecting bridge cover. Watkiss PowerSquare™224 User Manual...
Page 38: Open And Close The Folder Cover
If necessary, lift and rotate the clincher frame locking-handle to a new position (See Figure 15). 1. Lower the folder cover. 2. Turn the handle through 90° to lock. 3. Close the locking handle to lock the folder cover. Watkiss PowerSquare™224 User Manual...
Page 39: Lift And Lower The Clincher Frame
3. Check that the locking handle will not be hit by the folder cover when you close the folder cover. The locking handle should point towards the middle of the machine. If necessary, lift and rotate the locking-handle to a new posi- tion. 4. Close the folder cover. Watkiss PowerSquare™224 User Manual...
Page 40: Open The Gathering Area Cover
• To access the trim area WARNING: Keep your hands and fingers clear when you lift the main deck. CAUTION: Do not lift the main deck if the error message FOLD BLADE NOT is shown on the screen. PARKED Watkiss PowerSquare™224 User Manual...
Page 41 Cover” on page 36. Lift the PowerSquare main deck. The main deck lifts to approximately 60°. The weight of the main deck is supported by a gas strut. Let the gas strut control the movement of the main deck. Watkiss PowerSquare™224 User Manual...
Page 42: Empty The Trim Bin
2. Use the side handles to lift and remove the trim bin. 3. Empty the trim bin 4. Fit the bottom of the trim bin over the mounting rail. 5. Push the trim bin closed at the top. Watkiss PowerSquare™224 User Manual...
Page 43: Open The Stitch-Wire Cabinet
• To install a new stitch-wire spool. See “Install New Stitch-wire” on page 116. Stitch-wire Cabinet open FIGURE 19. Stitch-wire Cabinet Procedure 1. Open the stitch-wire cabinet cover. The cover is held closed by a magnetic catch. Watkiss PowerSquare™224 User Manual...
Page 44: Adjust The Stacker
Read the setting through the win- according to the size of the book. dow. (See Figure 21) These settings are recommendations. The settings can change with the size, thickness and material of book. Make further adjustment if necessary. Watkiss PowerSquare™224 User Manual...
Page 45: Adjust The Book Stacker
2. If you are making thin books, attach the magnetic paper guide above the book outfeed on the PowerSquare. Insert the loose end of the magnetic paper guide into the slot opposite (See Figure 23). Watkiss PowerSquare™224 User Manual...
Page 46: Unload The Book Stacker
3. Push the book support completely to the left (See Figure 22). 4. Remove the book divider until it is needed. Store the book divider on the right-hand end of the guide rail of the stacker. Watkiss PowerSquare™224 User Manual...
Page 47: Move The Book Stacker
2. Rotate the Book Stacker away from the PowerSquare as far as the safety chain allows. Note: The safety chain prevents damage to the power and communication cables. 3. When needed, rotate the Book Stacker back to the docked position, the latch will click closed. Watkiss PowerSquare™224 User Manual...
Page 48: Empty The Side-Trim Bin
1. Use the handles to move the side-trim bin away from the machine. 2. Empty the side-trim bin. 3. Return the side-trim bin under the chute. Check the bin is positioned close to the machine. Magnets hold the bin in position. Watkiss PowerSquare™224 User Manual...
Page 49: Adjust The Side-Trimmer Stacker
Book size in window Collection table Orange plastic hand-screw Catch tray FIGURE 29. Collection table position Procedure Set the collection table position according to the size of the book. Read the set- ting through the window. Watkiss PowerSquare™224 User Manual...
Page 50: Raise And Lower The Side-Trimmer Stacker
3. Release pressure from the top of the stacker, the stacker will raise to a folded position. Procedure - Lower the stacker 1. Push down on the top of the stacker until it clicks into position. Watkiss PowerSquare™224 User Manual...
Page 51: Move The Side-Trimmer
The safety chain prevents damage from the PowerSquare as far as to the power and communication the safety chain allows. cables. When needed, rotate the Side-Trimmer back to the docked position, the latch will click closed. Watkiss PowerSquare™224 User Manual...
Page 52: Remove And Re-Fit The Side-Trimmer Book Supports
2. Inner book support, left (marked LH IN) 3. Centre book support 4. Inner book support, right (marked RH IN) 5. Outer book support, right (marked RH OUT)      FIGURE 35. Side-Trimmer book supports Watkiss PowerSquare™224 User Manual...
Page 53 See “PAPER SIZE” on page 20. PAPER SIZE to 365mm. Then use to set the side-trim See “SIDE TRIM” on page 22. SIDE TRIM dimension to 365mm. Open the top cover of the Side-Trimmer. See Figure 36 on page 49. Watkiss PowerSquare™224 User Manual...
Page 54 Remove one at a time. Hold each end of the inner book support and lift upwards. Remove the inner book support through the top of the machine. Repeat with the other inner book sup- port. Inner book support (right) Watkiss PowerSquare™224 User Manual...
Page 55 On each book support, there are semi- circular cut outs at each end. Position the cut-outs over the fixing points. Press down on the book support so that Fixing it fits onto the fixing points. Repeat with the other book supports. Cut-out Watkiss PowerSquare™224 User Manual...
Page 56 Keep the book support central. See Figure 36 on page 49 The centre book support is secured with spring clips. Hold the the centre book support with two hands. Lift and slide forwards until it clips onto the fixings. Watkiss PowerSquare™224 User Manual...
Page 57: Operate The Powersquare Offline
5. Put the set in the gathering area with the middle pages of the book face up. 6. Press the two orange buttons and hold for 9 seconds, or until you hear the folder operate. The time interval changes according to the number of stitches. Watkiss PowerSquare™224 User Manual...
Page 58 4 - Standard Tasks - Operate the PowerSquare offline Watkiss PowerSquare™224 User Manual...
Page 59: Error Conditions, Problems And Solutions
Solutions This chapter describes how to correct problems that can occur on your PowerSquare. If a problem continues, contact your Watkiss service engineer. Printer Error If a paper jam or other error occurs in the printer, the printer and the PowerSquare stop.
Page 60: General Problems
Is the touch screen in power-save mode? See “Power save” on page 16. Touch the screen to restore the normal brightness. No further action is needed. Calibrate the touch screen. See “Calibrate the Touch Screen” on page 97. Watkiss PowerSquare™224 User Manual...
Page 61: Book Quality Problems
FORM Machine Adjustments Machine adjustments can be made while the machine is in operation. adjustment is limited to a maximum of +/- 1mm when the PAPER SIZE machine is in operation. Watkiss PowerSquare™224 User Manual...
Page 62 SET THICKNESS SHEET THICKNESS screen. Touch to re-reference the machine. ADVANCED > RE-REF > RE-REF Does the problem continue? Further action is not needed. Is the paper thin and/or curly? Call your service engineer Watkiss PowerSquare™224 User Manual...
Page 63 (see page 27). On thin books, this may reduce the produc- tion speed. Touch . Increase the in incre- CONFIGURE > SHUTTLE TAMPER TIME ments of 200. Does the problem continue? Further action is not needed. Call your service engineer Watkiss PowerSquare™224 User Manual...
Page 64 Does the problem continue? Further action is not needed. Load a Default Job. This will reset the settings, including FORM PRESSURE . See “Reset the PowerSquare to default set- NUMBER THRESHOLD tings” on page 30. Does the problem continue? Watkiss PowerSquare™224 User Manual...
Page 65 Further action is not needed. Call your service engineer. Stitching problems - the book is not stitched Stitch-wire cabinet Stitch-wire Accessory bag FIGURE 37. Pulling stitch-wire Middle wire-tube Large feed gear Stitch-wire jam Small feed gear FIGURE 38. Stitch-wire jam Watkiss PowerSquare™224 User Manual...
Page 66 Clear the stitch-wire jam. See “Clear a Stitch-wire Jam” on page 92. Lubricate the stitch head. See “Lubricate the Stitch Head” on page 111. Does the problem continue? Yes No Further action is not needed. Call your service engineer Watkiss PowerSquare™224 User Manual...
Page 67 PAPER SIZE Touch to re-reference the machine. ADVANCED > RE-REF > RE-REF Does the problem continue? Yes No Further action is not needed. Call your service engineer Further action is not needed. Watkiss PowerSquare™224 User Manual...
Page 68 Make sure the size is not larger than the book size, or TRIM the book will not be trimmed. Touch to re-reference the machine. ADVANCED > RE-REF > RE-REF Does the problem continue? Yes No Further action is not needed. Call your service engineer. Watkiss PowerSquare™224 User Manual...
Page 69 120. Is the trim stop clear of paper trimmings? Yes No Clear paper from the trim stop. Does the problem continue? Yes No No further action is needed. Call your service engineer Watkiss PowerSquare™224 User Manual...
Page 70 Further action is not needed. Turn off the Side-Trimmer at the mains ON/OFF switch. Wait for 5 seconds and then turn on the Side-Trimmer. Does the problem continue? Yes No Further action is not needed. Call your service engineer. Watkiss PowerSquare™224 User Manual...
Page 71 Further action is not needed. Turn off the Side-Trimmer at the mains ON/OFF switch. Wait for 5 seconds and then turn on the Side-Trimmer. Does the problem continue? Yes No Further action is not needed. Call your service engineer. Watkiss PowerSquare™224 User Manual...
Page 72 No further action is needed. Turn off the Side-Trimmer at the mains ON/OFF switch. Wait for 5 seconds and then turn on the Side-Trimmer. Does the problem continue? Yes No Further action is not needed. Call your service engineer. Watkiss PowerSquare™224 User Manual...
Page 73 PITCH • The side-trim setting is larger than the book size. • The side-trim offset is too big relative to the book size and/or the amount of trim. Watkiss PowerSquare™224 User Manual...
Page 74 Clean the trimmings removal fingers. See “Clean the Trimmings-removal Fingers” on page 108. Print a sample to the printer stacker. Is the printer the cause of the dirty marks? Printer service is required. Call your service engineer. Watkiss PowerSquare™224 User Manual...
Page 75 The problem is caused by the cover material or the finish. Change the cover material. Call your service engineer. Print a sample to the printer stacker and inspect the pages. Is the printer the cause of the damage? Printer service is required. Call your service engineer. Watkiss PowerSquare™224 User Manual...
Page 76: Message List
If the problem continues, then call your service engineer. Bridge axis moving The bridge axis is moving. This message clears when the adjust- ment is complete. If the message does not clear, touch > ADVANCED RE-REF Watkiss PowerSquare™224 User Manual...
Page 77 Empty the side-trim bin if neces- page 44. sary. CHECK THE TRIM BIN The trim bin is either open or full. See “Empty the Check the trim bin. Empty the trim Trim Bin” on bin if necessary. page 38. Watkiss PowerSquare™224 User Manual...
Page 78 There is an error at the former. See “Jam in the FORMER Open the folder cover and remove Folder or Former the book. If necessary, open the Area” on page 86. main deck to remove the book. Watkiss PowerSquare™224 User Manual...
Page 79 Folder or Former Area” on page 86. FORM ROLLER NOT The form roller is in the wrong PARKED position. Touch START to reset the position. Follow the instruc- tions on the screen. Watkiss PowerSquare™224 User Manual...
Page 80 84 Touch STOP to clear the mes- sage from the screen. If the problem continues, contact your Watkiss service engineer. JAM AT BRIDGE There is a paper jam at the infeed See “Jam in the INFEED to the connecting bridge. Clear the Bridge Infeed”...
Page 81 JAM IN GATHERING There is a paper jam in the gather- See “Jam in the AREA ing area. Open the connecting Gathering Area” bridge cover, lift the connecting on page 85. bridge and remove the paper jam. Watkiss PowerSquare™224 User Manual...
Page 82 The machine has detected missed See “Clear a stitches. Stitch-wire Jam” on page 92 or see Check if the stitch-wire is jammed “Install New Stitch- or if the stitch-wire spool is empty. wire” on page 116. Watkiss PowerSquare™224 User Manual...
Page 83 ON. If the problem continues, then call your service engineer. Sidelay axis moving The sidelay axis (size adjustment) is adjusting. This message clears when the adjustment is complete. If the message does not clear, touch > ADVANCED RE-REF Watkiss PowerSquare™224 User Manual...
Page 84 If the message still does not clear, use the side-trimmer mains ON/ OFF switch. Turn the side-trimmer OFF, wait at least 5 seconds and then turn the side-trimmer ON. If the problem continues, then call your service engineer. Watkiss PowerSquare™224 User Manual...
Page 85 The stitch position is adjusting. This message clears when the adjustment is complete. If the message does not clear, touch > ADVANCED RE-REF STITCH TIMEOUT Press STOP . Open the folder cover, remove the paper, close the folder cover. Watkiss PowerSquare™224 User Manual...
Page 86 Check the settings for SET THICK- NESS SHEET THICKNESS TOUCH PAD ERROR There is a fault with the START and STOP touch pads. If the prob- lem continues, then call your Wat- kiss service engineer. Watkiss PowerSquare™224 User Manual...
Page 87 Turn the machine OFF, then turn the machine ON. If the problem continues, then call your service engineer. USER STOP The user has touched the STOP button while the machine is in operation. Touch START restart the machine. Watkiss PowerSquare™224 User Manual...
Page 88: Paper Jams
1. Open the connecting bridge cover. 2. Remove the jammed paper. 3. Close the connecting bridge cover. 4. If the message is displayed on the screen, touch FLOW ERROR - BRIDGE STOP to clear the message from the screen. Watkiss PowerSquare™224 User Manual...
Page 89 3. Remove the jammed paper. 4. Check the belts are in the correct position. Adjust the position of the belts if necessary. See Figure 43. 5. Close the gathering area cover. 6. Close the connecting bridge cover. Watkiss PowerSquare™224 User Manual...
Page 90 Jam in the Folder or Former Area 1. Open the folder cover. 2. Remove the jammed paper. If you cannot see the paper in the former area, see “Jam in the Trim Area” on page 89. 3. Close the folder cover. Watkiss PowerSquare™224 User Manual...
Page 91 Former clamp - look in here for paper trimmings Former clamp mechanism. FIGURE 45. Access to the Trimmer Infeed Conveyor Step Action Information Open the PowerSquare See “Lift the PowerSquare Main Deck” on main deck. page 36 Remove the trim bin. Watkiss PowerSquare™224 User Manual...
Page 92 Rotate the trimmer infeed conveyor, so that the green belts are vertical. • Insert the left hand end, so that the shaft engages with the drive pin. Fit the trim bin. Close the PowerSquare main deck and covers. Watkiss PowerSquare™224 User Manual...
Page 93 In particular, check around the sensor. The remove any pieces of sensor is where you can see a red and a trimmed paper. green light. See Figure 47. Small pieces of paper trimmings can cover the sensor and cause an error message. Watkiss PowerSquare™224 User Manual...
Page 94 FIGURE 48. Book Stacker infeed 1. Remove the book. 2. If you are making thin books, attach the magnetic paper guide. See “Adjust the Book Stacker” on page 41. 3. Press the reset button on the stacker. Watkiss PowerSquare™224 User Manual...
Page 95 1. Use your hand to move the pusher to the left, against the spring pressure. 2. Remove the book, if present. 3. Check for paper-trimmings and remove them, if present. 4. Press the reset button on the stacker. Watkiss PowerSquare™224 User Manual...
Page 96: Clear A Stitch-Wire Jam
Clear a Stitch-wire Jam Before You Begin Lift the PowerSquare main deck. See “Lift the PowerSquare Main Deck” on page 25. Top location of Middle Wire Tube Middle Wire Tube Metal Spring Clip Feed Gears FIGURE 51. Stitch Head Watkiss PowerSquare™224 User Manual...
Page 97 Remove the middle wire tube. See Figure 51 on page 92. Pull the wire from the stitch head. Install the stitch-wire into the stitch See “Install the Stitch-wire into the head. Stitch Head” on page 118. Watkiss PowerSquare™224 User Manual...
Page 98: Clear A Stitch Head Jam
Lower the clincher frame. See “Lift and Lower the Clincher Frame” on page 35. Close the folder cover. Press the START button . Fol- low the on-screen instructions. Watkiss PowerSquare™224 User Manual...
Page 99 FIGURE 53. Inspect for stitch-wire Tools and Materials: • Klüber Isoflex NBU15 Grease, 50g. Part number 951-095 • Air duster. Supplied with the machine. • Wire cutters. Supplied with the machine. • Flat blade screwdriver Watkiss PowerSquare™224 User Manual...
Page 100 If the head operates normally and returns to the parked position, then further action is not needed. If the stitch head remains jammed, then repeat the procedure one time. If the problem continues, then con- tact your Watkiss service engineer. Watkiss PowerSquare™224 User Manual...
Page 101: Calibrate The Touch Screen
4. Check the fuse. 5. If the fuse is broken then replace with a fuse of the correct specification. 6. Repeat the procedure for the other fuse. Result If the fuse breaks again, then call your Watkiss service engineer. Watkiss PowerSquare™224 User Manual...
Page 102: Change The Fuses - Book Stacker
3. Check each fuse. 4. If the fuse is broken then replace with a fuse of the correct specification. Result If the fuse breaks again, then call your Watkiss service engineer. Change the Fuses - Side-Trimmer Introduction The Side-Trimmer has two fuses at the power input connector. See Figure 7 on page 7.
Page 103 2. Disconnect the Side-Trimmer from the power supply. 3. Check each fuse. 4. If the fuse is broken then replace with a fuse of the correct specification. Result If the fuse breaks again, then call your Watkiss service engineer. Watkiss PowerSquare™224 User Manual...
Page 104: Manually Park The Shuttle
5 - Error Conditions, Problems and Solutions - Manually park the Shuttle Manually park the Shuttle When to do The error messages MANUALLY PARK SHUTTLE SHUTTLE NOT PARKED displayed. Illustrations FIGURE 55. Shuttle Assembly Position - CORRECT Pick-up fingers FIGURE 56. Pick-up fingers Watkiss PowerSquare™224 User Manual...
Page 105 Close the folder cover. Result The error message is cleared from the screen. The MANUALLY PARK SHUTTLE shuttle axis re-references and the message is displayed. Shuttle axis moving When the message list is clear, you can continue operation. Watkiss PowerSquare™224 User Manual...
Page 106 5 - Error Conditions, Problems and Solutions - Manually park the Shuttle Watkiss PowerSquare™224 User Manual...
Page 107: Maintenance
• The PowerSquare needs service every six months. • After every one-million stitches, the stitch head needs service. This interval is every 3rd spool of stitch-wire. Only a Watkiss service engineer can service the PowerSquare. Contact your supplier for further information. Operator Maintenance Correct maintenance by the operator makes sure that •...
Page 108: Clean The Powersquare
Clean the touch screen with a clean, dry cloth. Never use an abrasive material or chemical to clean the touch screen. Light pressure with a clean, dry cloth is enough to remove fingerprints. Do not use too much force. Watkiss PowerSquare™224 User Manual...
Page 109: Clean The Former Roller
Press the two orange buttons and hold for 9 seconds, or until you hear the folder operate. Check The book is delivered to the stacker. Check the book. Repeat the procedure until the book spine is clean. Watkiss PowerSquare™224 User Manual...
Page 110: Clean The Polyurethane Strips In The Form Clamp
CAUTION: Wear protective gloves when you use the alcohol wipe. Note If you push the eject rollers, the rollers can move together against your hand. This movement can alarm you, but is not dangerous. Illustration Polyurethane Strip FIGURE 58. Polyurethane strips Watkiss PowerSquare™224 User Manual...
Page 111 Reach into the form clamp and There is a polyurethane strip on clean each of the polyurethane the face of each side of the clamp. strips. Repeat this step until the poly- urethane strips are clean. Close the folder cover Watkiss PowerSquare™224 User Manual...
Page 112: Clean The Trimmings-Removal Fingers
Trimmer infeed conveyor Former-clamp mechanism Reach in here to access the trim- infeed conveyor FIGURE 60. Trimmer infeed conveyor viewed from above_1 Trimmer infeed conveyor Trimmings-removal fingers Former-clamp mechanism FIGURE 61. Trimmer infeed conveyor viewed from above_2 Watkiss PowerSquare™224 User Manual...
Page 113 3. Align the shaft with the drive pin and release. Clean the four visible trimmings- Wear protective gloves when you removal fingers with an alcohol use the alcohol wipe. wipe. Fit the trim bin. Close the PowerSquare. Watkiss PowerSquare™224 User Manual...
Page 114: Clean Excess Grease From The Stitch Head
See “Open and Close the Folder Cover” on page 34. Lift the clincher frame. See “Lift and Lower the Clincher Frame” on page 35. Clean grease from the sides of the stitch head. Lower the clincher frame. Close the folder cover. Watkiss PowerSquare™224 User Manual...
Page 115: Lubricate The Stitch Head
FIGURE 63. Trim the nozzle of the tube of grease Step Action Information Trim the first 2.5mm from the See Figure 63 on page 111 nozzle. Remove the cap from the tube of grease. Fit the nozzle to the tube of grease. Watkiss PowerSquare™224 User Manual...
Page 116 ‘STITCHER UP’ position. Use the supplied air duster to remove dust from the stitch head. Remove the wire holder from the stitch head: Move the wire holder retaining spring ‘A’ to the right. Remove the wire holder ‘B’. Watkiss PowerSquare™224 User Manual...
Page 117 6 - Maintenance - Lubricate the Stitch Head Apply the Grease to the Driver Bar Driver Apply grease here Driver bar FIGURE 64. Driver bar Stop Start FIGURE 65. Apply the Grease to the Driver Bar Watkiss PowerSquare™224 User Manual...
Page 118 Note: Apply the grease in an 20mm long upward direction, from the bottom x 0.5mm thick of the driver bar. Note: Only apply the grease as shown. If you apply additional grease, the paper gets marked. Fit the wire holder. Watkiss PowerSquare™224 User Manual...
Page 119 Reset the Operator Maintenance Counter 1. Touch MENU 2. Touch and hold . A red line appears. The red line fills from left to right. RESET Hold until the red line reaches the right-hand side. RESET 3. Touch MENU Watkiss PowerSquare™224 User Manual...
Page 120: Install New Stitch-Wire
Cut the stitch-wire to the right of the stitch-wire guide block. Cut here Pull the stitch-wire from the stitch- wire guide block. Fit a new stitch-wire spool. See “Fit a New Stitch-wire Spool” on page 117. Watkiss PowerSquare™224 User Manual...
Page 121 Remove enough stitch-wire to damaged end of the stitch-wire. leave the end of the stitch-wire clean and straight. Feed the stitch-wire through the stitch-wire guide. Install the stitch-wire. See “Install the Stitch-wire into the Stitch Head” on page 118. Watkiss PowerSquare™224 User Manual...
Page 122 Push the stitch-wire into the stitch- wire guide block. Push stitch-wire in direction of arrow Push the stitch-wire as far as pos- sible. Make sure the stitch-wire runs between the wire feed rollers and into the middle wire tube. Watkiss PowerSquare™224 User Manual...
Page 123 If needed, repeat the previous step. If a stitch is still not made, repeat the procedure “Install the Stitch- wire into the Stitch Head” on page 118. Reset the number of stitches on the touch screen. Watkiss PowerSquare™224 User Manual...
Page 124: Clear Paper From The Trim Stop
See Figure 69 remove any pieces of trimmed paper. Close the trim stop guard. Push the trim stop guard into position. Hold the locking plates in position and tighten the orange hand screws. Attach the trim bin. Watkiss PowerSquare™224 User Manual...
Page 125: Specifications
Maximum set time: 12.5 seconds Stock Sizes - Minimum input size: 200 x 200mm Online Maximum input size: 365 x 500mm Stitch & fold line 200 x 200mm indicates original lead edge 365 x 500mm from the printer Watkiss PowerSquare™224 User Manual...
Page 126 Book Stacker (optional): 930mm Paper Input Input sheets must be of consistent size and cut square. Requirements Machine setting must match paper size at the input to the PowerSquare. Book quality is dependent upon quality of input sheets. Watkiss PowerSquare™224 User Manual...
Page 127 * Standard book is made from 20 sheets of 80gsm 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. Watkiss PowerSquare™224 User Manual...
Page 128 7 - Specifications - Watkiss PowerSquare™224 User Manual...
Page 129: Declaration Of Conformity
• Watkiss PowerSquare Serial No. WA/PSQ/---/0010 onwards • Watkiss PowerSquare Book Stacker Serial No. WA/PBS/0001 onwards • Watkiss P2T Two Knife Trimmer Serial No. WA/P2T/0001 onwards Conforms to the following Directives: Safety: 2006/95/EC Council Directive 'on the approximation of laws of Member States relating to electrical equipment designed for use within certain voltage limits'.
Page 130 EN55022:2010 Class A EN55024:2010 EN61000-3-2:2006 +A1:2009 + A2:2009 EN61000-3-3:2008 RoHS: 2011/65/EC Council Directive WEEE: 2002/96/EC Council Directive amended by 2008/34/EC and 2008/35/EC Reach: REGULATION (EC) No. 1907/2006 M C Watkiss Technical Director, Watkiss Automation Ltd. 21 May 2013 Watkiss PowerSquare™224 User Manual...
Page 131: Appendix
With more pages, smaller margins, or bulkier paper, the creep becomes more noticeable and can result in loss of image if no adjustment is made. Watkiss PowerSquare™224 User Manual...
Page 132 8mm towards the spine. Balanced adjustment. Adjust the pages so that the inside pages incrementally are both moved 4mm towards the spine and the front and back page are both moved 4mm away from the spine. Watkiss PowerSquare™224 User Manual...
Page 134 Watkiss Automation Limited 1 Blaydon Road Middlefield Industrial Estate Sandy, Bedfordshire SG19 1RZ United Kingdom Tel: +44 (0)1767 685700 Fax: +44 (0)1767 689900 Email: info@watkiss.com...

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