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Watkiss PowerSquare 224 R2L User Manual. Issue

1. Are there dirty marks on Marks beside the the cover of the book spine near to the spine WM No Yes Clean the polyurethane form strips See Clean the Polyurethane Strips in the Form Clamp on page 84 Are there curved dirty N fo marks on either the front or rear cover of the In a book Curved marks on the book No Yes Clean the trimmings removal fingers See Clean the Trimmings removal Fingers on page 86 Print a sample to the printer stacker Is the printer the cause of the dirty marks No Yes Printer service is required Call your service engineer Watkiss PowerSquare 224 User Manual 53 5 Error Conditions Problems and Solutions Book Quality Problems Damaged book Normal witness mark left by the form clamp during spine forming Are there damage marks on the cover of the book near to the spine from the form clamp that are worse than the normal witness mark No Yes Run a standard job using 80gsm 20 bond paper Does the problem continue Yes No The problem is caused by the cover material or the finish Change the cover material Call your service engineer Is the spine torn or creased No Yes The spine is over formed See Spine form problems on page 46 Is there damage to the spine at the stitch positions or is the cover falling off No Yes Run a standard job using 80gsm 20 bond paper Does the
2. 36 Watkiss PowerSquare 224 User Manual 4 Standard Tasks Unload the Book Stacker Unload the Book Stacker Guide rail Book divider FIGURE 21 The book divider Procedure 1 If required insert the book divider so that the stack does not slip while you unload the books 2 Remove the books Push the book support completely to the left See Figure 19 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 oo Watkiss PowerSquare 224 User Manual 37 4 Standard Tasks Move the Book Stacker Move the Book Stacker The Book Stacker locks in position onto the PowerSquare The docking latch is released by a foot pedal When to do toaccess the mains ON OFF switch toreplace the mains input fuses Procedure FIGURE 22 The Book Stacker docking latch 1 Use your foot to release the docking latch 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 38 Watkiss PowerSquare 224 User Manual 4 Standard Tasks Operate the PowerSquare offline Operate the PowerSquare offline You can hand feed sets into the PowerSquare if offline operation is needed The machine operates w
3. GATHER MOTOR STALL Check for a paper jam in the Gath ering area Touch STOP 9 to stop the PowerSquare Clear the paper jam Touch STOP to clear the message from the screen Continue the print job GATHER MTR No comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer INVERTER ERROR Check for a paper jam and clear if necessary Touch STOP 9 to clear the mes sage from the screen If the problem continues contact your Watkiss service engineer See Paper Jams on page 64 JAM AT BRIDGE INFEED There is a paper jam at the infeed to the connecting bridge Clear the jam and continue See Jam in the Bridge Infeed on page 64 JAM AT FORM Open the folder cover remove the See Jam in the ROLLER paper close the folder cover Folder or Former Area on page 66 JAM AT STACKER There is a jam in the stacker See Jam at INFEED infeed Remove the books from stacker infeed the stacker infeed Press the reset Book Stacker on button on the stacker page 70 JAM AT STACKER There is a jam in the stacker out See Jam at OUTFEED feed or there are paper trimmings stacker outfeed in the stacker outfeed Remove the books from the stacker out feed Check for paper trimmings and remove them if present Press the reset button on the stacker Book Stacker on page 71 JAM BE
4. Remove the jammed paper Close the bridge infeed cover Close the connecting bridge cover O1 C0 nm Open the connecting bridge cover Jam in the Connecting Bridge 1 2 3 If the message FLOW ERROR BRIDGE is displayed on the screen touch Open the connecting bridge cover Remove the jammed paper Check in the rotator and open the uplift cover When clear of paper close the uplift cover Close the connecting bridge cover STOP to clear the message from the screen Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Paper Jams Jam in the Gathering Area FIGURE 27 Gathering Area Belt Positions 1 Lift the gathering area cover 2 Remove the jammed paper 3 Check the belts are in the correct position Adjust the position of the belts if necessary See Figure 27 4 Close the gathering area cover Watkiss PowerSquare 224 User Manual 65 5 Error Conditions Problems and Solutions Paper Jams Jam in the Stitch Area Step Action Information 1 Open the folder cover See Open and Close the Folder Cover on page 29 2 Lift the clincher frame See Lift and Lower the Clincher Frame on page 30 Remove the jammed paper 4 Check for broken or damaged Press to manually stitches in the clincher area Man operate the ually operate the clincher to clear clincher any stitches that are jamme
5. Some functions and buttons are only available at certain access levels see ACCESS LEVEL on page 24 The CONFIGURE Window Buttons Button Information _ 9 O Hidden Q Active Q Visible 5 25 O o0 MACHINE Touch MACHINE OPTIONS to view the general Ole OPTIONS machine set up Some of the settings can be changed depending on the current access level MEASURE Select mm or inch as the unit of measurement oe MENT as To get best accuracy use millimetres to measure the set STITCH There is a sensor that checks for stitches Touch Ole SENSOR STITCH SENSOR to turn the stitch sensor on or off The default setting is ON PRESET The preset paper sizes can be either ISO Asizesor O e PAPER US paper sizes To select which preset paper sizes SIZES are available touch the relevant button PBS Touch PBS INSTALLED to switch off communication to O amp INSTALLED the Book Stacker Only do this if the Book Stacker is disconnected SHUTTLE Touch SHUTTLE to make adjustment to the tamper oe TAMPER This button is used by the service engineer Ol DELAY TAMPER TAMPER TIME adjusts the time that the tamper Ole TIME touches the set An increase in TAMPER TIME causes a decrease in the production rate for thin books FORM SETUP This button is used by the service engineer Watkiss PowerSquare 224 User Manual 23 3 The User Interface The MENU
6. RE REF to re reference the machine 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 49 5 Error Conditions Problems and Solutions Book Quality Problems Trimming problem the book is not trimmed Is the TRIM option turned off No Yes Turn on the TRIM option Is AUTO turned off in the TRIM window No Yes Set TRIM to AUTO Does the problem continue Yes No Further action is not needed If you need to use a custom trim size enter the trim dimension in the TRIM window Make sure the size is not larger than the book size or the book will not be trimmed Touch ADVANCED gt RE REF gt RE REF to re reference the machine Does the problem continue Yes No Further action is not needed Call your service engineer 50 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Book Quality Problems Trimming problem the book is not trimmed to the correct size Is TRIM turned on Yes No Turn on the TRIM Make sure the size is not larger than the book size or the book will not be trimmed Is the correct trim size entered in the touch screen Yes No Enter the correct size in the touch screen Re reference the machine Touch ADVANCED gt RE REF gt RE REF to re reference the machine Does the problem continue Yes No Further action is not needed Call your
7. 1 Remove the book if present 2 Check for paper trimmings and remove them if present 3 Press the reset button on the stacker If the pusher is in the forward position so that the stacker outfeed is not visible 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 71 5 Error Conditions Problems and Solutions 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 P Metal Spring Clip Feed Gears FIGURE 35 Stitch Head 72 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Clear a Stitch wire Jam Clear the Jammed Wire Step Action Information 1 Cut the stitch wire at position A approximately 50mm 2 inches from where the stitch wire leaves the stitch wire guide Cut the stitch wire at position B between the feed gears and the middle wire tube Pull the stitch wire from the stitch wire guide block Pull stitch wire in direction of arrow Remove the middle wire tube See Figure 35 on page 72 Pull the wire from the stitch head Install
8. 291 500 Books spool approximately 127 000 Fore Edge Maximum fore edge trim 28mm Trimming Minimum trimmed book size 78mm min 78mm max 28mm Stacker Capacity Standard stacker 35 books 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 Dimensions Footprint With standard stacker 1870 x 2755mm With Book Stacker 2420 x 2280 Height 1330mm Weight Online PowerSquare 532kg Book Stacker 150kg 100 Watkiss PowerSquare 224 User Manual 7 Specifications Power Supply Adjustable to 200 208 220 230 and 240V 50 60Hz single phase Power PowerSquare Consumption stand by 92VA 75W in operation 700VA 500W Book Stacker stand by 35VA 16W in operarion 75VA 53W Noise Emission stand by 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 Radio Frequency This equipment has been tested and found to comply with Emissions the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can r
9. Driver Bar Driver Apply grease here Driver bar Watkiss PowerSquare 224 User Manual 91 6 Maintenance Lubricate the Stitch Head Step Action Information Apply a thin line of grease from the tube 20mm long to the visible surface of the driver bar The line of grease must be a maxi mum of 0 5mm thick and as shown in FIGURE 48 Note Apply the grease in an upward direction from the bottom of the driver bar Note Only apply the grease as shown If you apply additional grease the paper gets marked See FIGURE 48 20mm long x 0 5mm thick Fit the wire holder 92 Watkiss PowerSquare 224 User Manual 6 Maintenance Lubricate the Stitch Head Lubricate the Wire feed Cam Nozzle of the tube of grease Wire feed cam Feed lever FIGURE 50 Lubricate the wire feed cam Step Action Information 1 Apply 10mm of grease from the See FIGURE 50 tube between the bearing surface of the wire feed cam and the feed lever 2 Lower the PowerSquare main deck 3 Lower the clincher frame See Lower the Clincher Frame on page 30 4 Close all of the covers 5 Make some test books 6 Clean excess grease from the top See Clean excess grease from of the stitch head the Stitch Head on page 88 Reset the Operator Maintenance Counter 1 Touch MENU 2 Touch and hold RESET A
10. MANUALLY PARK SHUTTLE and SHUTTLE NOT PARKED are displayed Illustrations Pick up fingers FIGURE 39 Pick up fingers Watkiss PowerSquare 224 User Manual 79 5 Error Conditions Problems and Solutions Manually park the Shuttle Procedure Step Action Information 1 Open the folder cover See Open and Close the Folder Cover on page 29 2 Push the shuttle assembly to the Figure 38 on page 79 shows the end correct position for the shuttle assembly The screw A must align with the white gear B If the shuttle assembly does not move to the correct position push the pick up fingers away from each other by 2 3mm and try again Repeat if necessary See Figure 39 3 Wait until the error message SHUT If the message does not clear TLE NOT PARKED is cleared from check that the shuttle assembly is the screen in the correct position Repeat Step 2 if necessary 4 Close the folder cover Result The error message MANUALLY PARK SHUTTLE is cleared from the screen The shuttle axis re references and the message Shuttle axis moving is displayed When the message list is clear you can continue operation 80 Watkiss PowerSquare 224 User Manual cHapterns Maintenance Service Interval 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
11. PowerSquare 8 Start the PowerSquare 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 76 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Calibrate the Touch Screen Calibrate the Touch Screen When to do Calibrate the touch screen if the buttons do not operate or the buttons do not operate correctly N CAUTION Use a pencil the blunt end of a pen or a palm top wand for this procedure Do not use a sharp object Sharp objects damage the screen Procedure 1 Touch the STOP button 9 5 times 2 Follow the instructions on the touch screen You must touch the screen where shown as accurately as possible 3 Touch DONE in the centre of the screen Change the Fuses PowerSquare Introduction The PowerSquare has two fuses at the mains power input See Figure 3 on page 4 If either fuse is broken the PowerSquare will not operate AY WARNING Turn OFF the machine and remove the mains power supply cable before you change the fuses This machine uses two fuses in parallel N WARNING To avoid the risk of fire replace fuses using only the same type and rating Fuse Description 7A HRC Quick acting F Part Number 730 018 Procedure 1 Turn OFF the PowerSquar
12. Watkiss service engineer can service the PowerSquare Contact your supplier for further information Operator Maintenance Correct maintenance by the operator makes sure that The machine operates correctly The machine makes high quality books The machine is safe to use e Small problems can be identified early Watkiss PowerSquare 224 User Manual 81 6 Maintenance Clean the PowerSquare Operator Maintenance Plan Interval Task Reference Every week Clean the machine See page 82 When the message Lubricate the stitch head See page 89 OPERATOR MAINTENANCE is displayed on the screen Clean the former roller See page 83 Clean the polyurethane strips in See page 84 the form clamp Clean the trimmings removal See page 86 fingers Clean excess grease from the See page 88 stitch head Clean the PowerSquare Introduction Clean the PowerSquare every week to remove surface dust AN CAUTION Only clean the machine with materials that are recommended in this manual Do not use other chemicals or abrasive material Outside of the PowerSquare Use a moist cloth to clean the outside of the PowerSquare Touch screen 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 82 Watkiss PowerSquare 224 User Ma
13. ferent 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 Adjustments to the FORM settings can be necessary for some types of paper Machine Adjustments Machine adjustments can be made while the machine is in operation The PAPER SIZE adjustment is limited to a maximum of 1mm when the machine is in operation Watkiss PowerSquare 224 User Manual 43 5 Error Conditions Problems and Solutions Book Quality Problems Untidy book problem The finished book is not tidy The sheets are not aligned The book is not folded squarely Are the covers of the books and the insides of the books made from the same paper weight and paper type Yes No Accurately measure the different papers Are the different types of paper exactly the same size Yes No You must use paper that is the same size Is the paper within specification See Specifications on page 99 Yes No Do not use paper that is outside the specification Have you accurately measured the paper size after printing Yes No Print a sample to the stacker and measure the printed paper Accurate measurement will improve book quality Have you entered the measured PAPER SIZE into the touch screen Yes No Enter the correct measured PAPER SIZE into the touch screen Have you accurately measured e
14. green light See Figure 31 Small pieces of paper trimmings can cover the sensor and cause an error message Watkiss PowerSquare 224 User Manual 69 5 Error Conditions Problems and Solutions Paper Jams Step Action Information 5 Close the trim stop Push the trim stop guard into position guard Hold the locking plates in position and tighten the orange hand screws 6 Attach the trim bin Jam at stacker infeed Book Stacker The error message JAM AT STACKER INFEED is displayed This means a book is covering the sensor at the Book Stacker infeed Stacker infeed Stacker reset button FIGURE 32 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 36 3 Press the reset button on the stacker 70 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Paper Jams Jam at stacker outfeed Book Stacker The error message JAM AT STACKER OUTFEED is displayed This means a book or some paper trimmings are covering the sensor at the Book Stacker outfeed Stacker outfeed Stacker reset button Pusher FIGURE 33 Book Stacker outfeed Stacker outfeed is visible The pusher is in forward position The stacker out feed is not visible FIGURE 34 Stacker outfeed If the stacker outfeed is visible
15. into the stacker by hand Press the reset button on the stacker 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 gt RE REF BRIDGE INFEED COVER OPEN The bridge infeed cover is open The machine will not operate until the cover is closed See Jam in the Bridge Infeed on page 64 Watkiss PowerSquare 224 User Manual 55 5 Error Conditions Problems and Solutions Message List Message Information Reference BRIDGE MOTOR STALL Check for a paper jam in the con necting bridge Touch STOP 9 to stop the PowerSquare Clear the paper jam Touch STOP to clear the message from the screen Continue the print job See Jam in the Connecting Bridge on page 64 BRIDGE No Comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer CENTRE No Comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer Centre axis moving The centre axis in the bridge is moving This message clears when the adjustment is complete If the message does not clear touch ADVANCED gt RE REF CHECK PAPER SIZE Remember to ch
16. job name or use the Up arrow or Down arrow to make the selection The LOAD amp SAVE Window Buttons Button Information SAVE Touch SAVE to save the current settings An on screen keyboard is displayed Enter the job name Touch OK or CLOSE The new job appears in the list of saved jobs You can reload a saved job to decrease set up time in the future REPLACE If you change the settings of a saved job touch REPLACE to save the new settings CANCEL Touch CANCEL if you do not need to save a job that you have changed SAVE NEW _ If you change the settings of a saved job touch SAVE NEW to save the new settings as a new job An on screen keyboard is displayed Enter the new job name Touch OK or CLOSE The original job is not changed If the job name is not changed before OK or CLOSE is touched the job will be saved with the current name followed by an asterisk JOB DETAILS JOB DETAILS shows the settings for each saved job Select the job that you need to view from the job list Touch JOB DETAILS to see a summary of the job settings LOAD Touch the job name or use the Up arrow or the Down arrow to make the selection Touch the LOAD button PADLOCK The padlock symbol shows when a saved job is locked or SYMBOL unlocked There is a small padlock symbol next to each locked job To lock or unlock a job 1 select the job from the job list 2 touch the large key symbol A padlock symbol displayed in lig
17. 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 15 3 The User Interface The Job Mimic The Job Mimic The job mimic shows the current machine status SET THICKNESS FORM Tn E PAPER SIZE FIGURE 7 The Job Mimic 3 1 wv P 4 TRIM m m 5 No Icon Information 1 Paper Size 420 0 The following items are shown the size of paper the format of the paper in the gathering area the broken line shows the fold line the small thick lines show the stitches the arrow shows the original feed edge in the printer 2 Stitch Pitch 148 5 The stitch pitch is shown only when a non standard setting is selected 16 Watkiss PowerSquare 224 User Manual 3 The User Interface The Job Mimic No Icon Information 3 Sheet Thickness The sheet thickness in mm is shown Note that the arrows show a single sheet 0 10 AUTO or Set Thickness The set thickness in mm is shown Note that the arrows show the complete set 3 0 4 Form The number of forms is shown If the pressure is adjusted the setting is shown in brackets Emi A red X shows that the form function is not active 5 Trim The trim se
18. paper from the PowerSquare then Check the Touch START to start the machine Touch ADVANCED gt PURGE SET gt PURGE SET The partial book is delivered to the stacker Discard the book 3 Check the PowerSquare screen If an error message is displayed take the corresponding action See Message List on page 55 PowerSquare Error If a paper jam or other error occurs in the PowerSquare the printer and the PowerSquare stop The type of PowerSquare error is displayed on the touch screen See Message List on page 55 Procedure 1 Clear the PowerSquare error The error message on the touch screen tells you about the error 2 Remove all sheets from the PowerSquare 3 Follow the instructions on the printer Watkiss PowerSquare 224 User Manual 41 5 Error Conditions Problems and Solutions General Problems General Problems The PowerSquare does not start Is the touch screen illuminated No Yes Are error messages displayed on the touch screen No Yes See Message List on page 55 Is there an error message on the printer No Yes Correct the printer error If the printer error message is Check Third Party Finishing Device or check custom then check for an error message on the PowerSquare touch screen If the problem continues then call your service engineer Turn OFF and turn ON the PSQ If the problem continues then call your service engineer Is the touch screen in power save mode
19. when the trim bin is full You can empty the trim bin when you choose For example before you start a print job Trim Bin Side Handle Trim Bin open FIGURE 15 Trim Bin Open Note The PowerSquare operates with the trim bin removed for a short time The printer waits while the trim bin is removed then continues when the trim bin is replaced To prevent lost production you must remove empty and return the trim bin to the PowerSquare as quickly as possible Procedure Use the handle to open the trim bin Use the side handles to lift and remove the trim bin Empty the trim bin Fit the bottom of the trim bin over the mounting rail Push the trim bin closed at the top apoy Watkiss PowerSquare 224 User Manual 33 4 Standard Tasks Open the Stitch Wire Cabinet Open the Stitch Wire Cabinet When to do Toseeifthe stitch wire is jammed or finished An error message is displayed on the touch screen when the stitch wire is jammed or finished Toinstall a new stitch wire spool See Install New Stitch wire on page 94 Stitch wire Cabinet open FIGURE 16 Stitch wire Cabinet Procedure 1 Open the stitch wire cabinet cover The cover is held closed by a magnetic catch 34 Watkiss PowerSquare 224 User Manual 4 Standard Tasks Adjust the Stacker Adjust the Stacker The stacker must be adjusted according to book thickness and book size Wh
20. wire spool Use wire cutters to remove the damaged end of the stitch wire Remove enough stitch wire to 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 96 Watkiss PowerSquare 224 User Manual 95 6 Maintenance Install New Stitch wire Install the Stitch wire into the Stitch Head Step Action Information 1 Pull the stitch wire from the end of the stitch wire guide 2 Make sure the stitch wire runs behind the gas strut 3 Feed the end of the stitch wire between the felt wire cleaning pads Felt Wire Cleaning Pads 4 Push the stitch wire into the stitch wire guide block 5 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 96 Watkiss PowerSquare 224 User Manual 6 Maintenance Install New Stitch wire Close the PowerSquare Step Action Information 1 Close the stitch wire cabinet 2 Lower the PowerSquare main deck Lower the clincher frame See Lower the Clincher Frame on page 30 Close the folder cover Feed the Stitch wire Step Action Information 1 Touch START 2 Set the number of stitches t
21. 6 Fold blade axis moving The fold blade axis book thick ness adjustment is moving This message clears when the adjust ment is complete If the message does not clear touch ADVANCED gt RE REF FOLD BLADE NOT PARKED Open the folder cover remove the paper close the folder cover Touch START then follow the instructions on the screen FOLD No comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer FORM CLAMP CLOSED The form clamp is in the wrong position Touch START to reset the position Follow the instruc tions on the screen FORM ROLLER ERROR Open the folder cover remove the paper close the folder cover See Jam in the Folder or Former Area on page 66 FORM ROLLER NOT PARKED The form roller is in the wrong position Touch START to reset the position Follow the instruc tions on the screen FORM CLAMP ERROR There is an error at the former Open the folder cover and remove the book If necessary open the main deck to remove the book See Jam in the Folder or Former Area on page 66 GATHERING AREA COVER OPEN Close the gathering area cover if you need to operate the machine online 58 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Message List Message Information Reference
22. ART Button STOP Button Touch Screen 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 AN CAUTION Do not operate the touch screen with a sharp object or with too much force These actions can damage the touch screen If you hear a beep when you operate the touch screen the selected function is not available Some functions are not available when the machine is in opera tion Watkiss PowerSquare 224 User Manual 13 3 The User Interface The Touch Screen Some functions and buttons are only available at certain access levels See ACCESS LEVEL on page 24 Power save The touch screen has a power save function After several minutes without use the brightness of the touch screen decreases After several hours the touch screen turns off Touch the screen to restore the normal brightness The touch screen takes two or three minutes to reach full brightness Illustration 5 READY HELP na 00 7 8 JEOOKS T THICKNE Li t SET STITCHES FORM a THICKNESS gt x LOAD amp SAVE ADVANCED CONFIGURE FIGURE 6 The Touch Screen 14 Watkiss PowerSquare 224 User Manual 3 The User Interface The Touch Screen Component Function Table No Component Function 1 Window Tabs The touch scree
23. Band ted Pee Dew amp 18 The LOAD amp SAVE Window eens 20 The ADVANCED Window 54x era RSS ERE ERI 545 22 The CONFIGURE Window xe p RELIER ERE DER x 23 The MENU Window 2 602 220 3 vases de Pre E oCRES AS 24 4 Standard Tasks 2 292 clrRLr ERREUR 42 25 IntrOdUCtlOF x iere ER E ctc donet Er De desc a ee 25 Load and Save the Job Settings 0004 26 Adjust the Stitch Pilehi 2 wade rs e Rn tts 27 Open the Connecting Bridge Cover 0 28 Open and Close the Folder Cover 2 0 29 Lift and Lower the Clincher Frame llslssss 30 Open the Gathering Area Cover sulslu 31 Lift the PowerSquare Main Deck 0 05 31 Empty the Trim BIIa siue EE Me eed ee aa AY 33 continued User Manual for Watkiss PowerSquare 224 Right to Left Model English Issue 1 November 2014 Watkiss Part No 960 961 Effective Serial No WA PSQ 0800 onwards Watkiss PowerSquare 224 User Manual i Open the Stitch Wire Cabinet 20000 34 Aaiustih SIB KO so e REIS epe tiet eek a tee 35 Adjust the Book Stacker 0 0 00 c cee eee eee 36 Unload the Book Stacker 0 0c eee eee eee 37 Move the Book Stacker ccc eee eens 38 Operate the PowerSquare offline 00 39 5 Error Conditions Problems and Solutions 41 Printer Eror 5er ee EE ae oe ROREM Bae ne Pots 41 PowerSquare Error s
24. FORE TRIM MER There is a book jammed before the trimmer Open the main deck to remove the book See Jam before the Trimmer on page 67 JAM IN GATHERING AREA There is a paper jam in the gather ing area Open the gathering area and remove the paper jam See Jam in the Gathering Area on page 65 Watkiss PowerSquare 224 User Manual 59 5 Error Conditions Problems and Solutions Message List Message Information Reference JAM IN STACKER AREA There is a paper jam at the outfeed of the machine Remove the jammed books and continue JAM IN STITCHER AREA There is a paper jam in the stitch area Open the folder cover remove the paper jam and con tinue See Jam in the Stitch Area on page 66 JAM IN STITCH HEAD There is a jam in the stitch head See Clear a Stitch Head Jam on page 74 JAM IN TRIMMER There is a book jammed in the trimmer Clear the jam and con tinue See Jam in the Trim Area on page 69 MAIN CONTROL No comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer MANUALLY PARK The shuttle is not parked correctly See Manually SHUTTLE Open the folder cover and move park the Shuttle the shuttle to the park position on page 79 Close the folder cover The shuttle will reset When the message list is clea
25. Manual Thank you for choosing the Watkiss PowerSquare 224 The Watkiss PowerSquare 224 User Manual describes how to do these tasks e 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 The Watkiss PowerSquare 224 User Manual does not describe the operation of the printer If needed refer to your printer user manual In this manual the Watkiss PowerSquare 224 is referred to as the PowerSquare Safety Information Safety information is included in the separate Safety Information Manual Read the safety information before you use your PowerSquare Warning and Caution Messages A A The warning and caution messages used in this manual are shown below WARNING A WARNING message tells you that a procedure or operation can be dangerous To prevent injury you must follow the instructions CAUTION A CAUTION message tells you that a procedure or operation can damage the machine or the product To prevent damage you must fol low the instructions Watkiss PowerSquare 224 User Manual 1 Introduction to the Watkiss PowerSquare 224 Description of the PowerSquare Installation Your PowerSquare must be installed by a Watkiss approved service engineer Special knowledge is needed to install the machine AN CAUTIO
26. N Only connect the machine to a mains power supply of the cor rect voltage with a good earth connection The correct machine voltage is shown on the label at the mains power supply input on the rear of the machine If the machine is connected to the wrong supply the warranty is cancelled How to Get Help If you have any questions or problems refer to the problem solving section in this manual see Error Conditions Problems and Solutions on page 41 Con tact your PowerSquare supplier for further help Description of the PowerSquare Introduction The PowerSquare operates online with digital printers to process sets of printed pages into stitched books The main parts are shown below The PowerSquare can be fitted with a standard Stacker or with a Book Stacker An optional Side Trimmer can be fitted Operator Side of the PowerSquare PowerSquare User Interface Connecting Bridge eee Book Stacker optional Trim Bin FIGURE 1 Operator side of the PowerSquare Stacker Stitch Wire Cabinet FIGURE 2 Stacker side of the PowerSquare 2 Watkiss PowerSquare 224 User Manual 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
27. OFF the PowerSquare the current settings are stored Fuses The fuses make sure the operator and the machine are protected if there is an electrical problem or short circuit Voltage label The voltage label is fitted to the PowerSquare dur ing the installation procedure The voltage label dis plays the selected voltage Mains power input connec tor The mains power input connector is used to con nect the PowerSquare to mains electrical power Watkiss PowerSquare 224 User Manual 1 Introduction to the Watkiss PowerSquare 224 Description of the PowerSquare The Input Panel of the Book Stacker A OO N FIGURE 4 The Input Panel of the Book Stacker Component Function Table No Component Function 1 Rating and serial label The rating label displays the type of machine serial number power use and fuse information Voltage advisory label The voltage advisory label shows that the input voltage is 230V AC The 230V power is supplied by the PowerSquare Power input connector The power input connector is used to connect the power supply from the PowerSquare to the Book Stacker Mains power ON OFF switch The mains power ON OFF switch turns ON the Book Stacker or turns OFF the Book Stacker Fuses The fuses make sure the operator and the machine are protected if there is an electrical problem or short circuit Watkiss Pow
28. See Power save on page 14 Touch the screen to restore the normal brightness No Yes Go back to the start of this fault finding table Is the mains power ON OFF switch illuminated No Yes Call your service engineer Is the PowerSquare turned ON and connected to the mains power supply of the correct type and voltage No Yes Replace the fuse at the mains input See Change the Fuses PowerSquare on page 77 If the problem continues then call your service engineer Connect the PowerSquare to the mains supply of the correct type and voltage and then turn the machine ON The touch screen does not work Is the touch screen in power save mode See Power save on page 14 Touch the screen to restore the normal brightness No Yes No further action is needed Calibrate the touch screen See Calibrate the Touch Screen on page 77 42 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Book Quality Problems Book Quality Problems Paper Size and Book Quality Instructions Careful measurement of the paper size and the set or sheet thickness is important To make an accurate book you must enter accurate paper dimensions into the touch screen To get best accuracy use millimetres to measure the set See page 9 Measure the size of the printed paper The paper dimension changes when the paper is printed If the book is made from several different types of paper make sure the dif
29. Watkiss PowerSquare 224 User Manual Right to Left Model English Issue 1 November 2014 Watkiss Automation Limited 2014 All Rights Reserved Reproduction adaptation or translation without prior written permission is prohibited except as allowed under the copyright laws Warranty The information contained in this document is subject to change without notice Watkiss Automa tion Limited makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Watkiss Automation Limited shall not be liable for errors contained herein or for incidental or con sequential damage in connection with the furnishing performance or use of this material Table of Contents 1 Introduction to the Watkiss PowerSquare 224 1 Description of the PowerSquare sess 2 2 How to Run the PowerSquare 7 Introduction llle ee 7 Before YOU BEGIN e vete REL EI Ren ques 8 Turn On the PowerSquare 0020 0 cee eee ess 8 Enter the Job Setllnds zoe wey ced ben biGeyate eee es 9 Adjust the Stacker toos Bh dott Mee d dd Eire urea 11 RUM TNE JOD ood saei ne e exte teen ha de ks 11 3 The User Interface sslll e 13 The To h Sereen ocu eon ub EX Se tete e e a ER eee tit 13 The Job Mimic 00 0 cece en 16 The BASIC Window 2 oes wecwee ee
30. Window The MENU Window MENU ZZ shows the settings that are not changed during day to day operation These settings include Change the Access Level Change the display language Advanced machine settings that are accessed by a person who has the cor rect access code The MENU Window Buttons Button Information ACCESS LEVEL The Touch Screen has five different access levels Operator Supervisor Service Distributor Factory Touch ACCESS LEVEL and select the correct level from the list The last three levels are protected by access codes To protect the job settings the supervisor level allows jobs to be locked CURRENT Touch one of the flags to select the language you need LANGUAGE AXES Touch AXES to re reference individual axes Supervisor access level is needed for this function Other functions on this button are used by the service engineer BRIDGE Touch BRIDGE to re reference the bridge axes Supervisor access level is needed for this function Other functions on this button are used by the service engineer SERVICE This button is used by the service engineer OPTIONS TEST This button is used by the service engineer COUNTERS The counters display the number of books that have been made number of sheets that have been processed number of stitches that have been used RESET Touch RESET to zero the book sheet and stitch counter Use RESET after operator maintenance to
31. adiate radio frequency energy and if not installed and used in accord ance with the instruction manual may cause harmful inter ference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense 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 101 7 Specifications 102 Watkiss PowerSquare 224 User Manual charters Declaration of Conformity According to ISO IEC 17050 1 Name of Manufacturer Watkiss Automation Limited Address of Manufacturer Watkiss House Blaydon Road Sandy Bedfordshire SG19 1RZ United Kingdom Declares that the product Name of Product e Watkiss PowerSquare Serial No WA PSQ 0010 onwards Watkiss PowerSquare Book Stacker Serial No WA PBS 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 EN 60950 1 2006 ed 2 A11 2009 A1 2010 A12 2011 EMC 2004 108 EC Counc
32. and can result in loss of image if no adjustment is made Watkiss PowerSquare 224 User Manual 105 Image Creep Calculating Creep Adjustment 1 Measure the thickness of the set before booklet making i e the number of sheets of paper multiplied by the thickness of the paper 2 The spine thickness of the finished booklet is two times the set thickness 3 The pages need to be incrementally adjusted by the spine thickness Depending on the job this can be achieved by Positive creep adjustment gt Move the pages on the outermost sheet away from the spine The innermost sheet is not adjusted This is sometimes called a positive creep or pull out Negative creep adjustment The outermost sheet is not adjusted lt Move the pages on the inner sheets towards the spine This is sometimes called a negative creep or push in Balanced creep adjustment gt The adjustment is balanced between the E inside and outside pages eM Example The book is 40 sheets of 80gsm paper The set thickness is measured at 4mm The spine thickness is therefore 8mm Positive creep Adjust the pages incrementally so that the front page and back page are both moved 8mm away from the spine Negative creep Adjust the pages incrementally so that the inside pages are both moved 8mm towards the spine Balanced adjustment Adjust the pages incrementally so that the inside pages are both moved 4
33. clear the mes sage from the screen See Jam in the Trim Area on page 69 ERROR No Comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer FLOW ERROR There is an error at the connecting See Jam in the BRIDGE bridge Open the connecting Connecting bridge cover and check for a paper Bridge on jam page 64 Touch STOP to clear the mes sage from the screen FLOW ERROR 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 66 main deck to remove the book FLOW ERROR There is a paper jam in the gather See Jam in the GATHER AREA ing area Open the gathering area Gathering Area and remove the paper jam on page 65 FLOW ERROR OUT FEED There is an error at the outfeed Remove the trim bin and open the trim stop guard to remove the book If necessary open the main deck to remove the book See Jam in the Trim Area on page 69 Watkiss PowerSquare 224 User Manual 57 5 Error Conditions Problems and Solutions Message List Message Information Reference FLOW ERROR There is an error at the stitcher See Jam in the STITCHER Open the folder cover and remove Stitch Area on the book If the problem continues then call your service engineer page 6
34. d 5 Lower the clincher frame See Lift and Lower the Clincher Frame on page 30 6 Close the folder cover 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 69 3 Close the folder cover 66 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Paper Jams Jam before the Trimmer The error message JAM BEFORE TRIMMER is displayed This error can be abook jammed before the trimmer apiece of paper trimming has covered the jam sensor Trimmer Infeed Conveyor Former clamp mechanism Reach in here to access the trim infeed conveyor Former clamp look in here for paper trimmings Former clamp mechanism 2 A FIGURE 29 Access to the Trimmer Infeed Conveyor Step Action Information 1 Open the PowerSquare See Lift the PowerSquare Main Deck on main deck page 31 2 Remove the trim bin Watkiss PowerSquare 224 User Manual 67 5 Error Conditions Problems and Solutions Paper Jams Step Action Information Loosen the trimmer infeed conveyor The procedure can be seen from the top of the machine See Figure 28 Access to the parts is through the former clamp mechanism See Figure 29 Hold the shaft and push to the right against spring pressure to disengage the s
35. d screws 5 Attach the trim bin 98 Watkiss PowerSquare 224 User Manual cuaerenz Specifications Operating 10 35 C Conditions 35 85 relative humidity up to 2000m above mean sea level Production Cycle time Printer dependent Interset gap minimum 1 second Minimum set time 4 2 seconds Maximum set time 12 5 seconds Stock Sizes Minimum input size 200 x 200mm Online Maximum input size with PBR5 370 x 520mm tt Stitch amp fold line Minimum Maximum 4 indicates original lead edge from the printer Watkiss PowerSquare 224 User Manual 99 7 Specifications Sheet Rotation Integrated rotator ensures maximum printer productivity Maximum rotation sheet size PBR5 353 x 252mm Minimum rotation sheet size 207 x 200mm The cross track dimension of the sheet before rotation must be at least 7mm greater than the in track dimension t S z x Stitch amp fold line du 4 indicates original lead edge 353 x 252mm from the printer Stock Range 60 250gsm dependent on paper type and quality Book Thickness Maximum finished book thickness up to 10 4mm approximately 208 pages 80gsm 224 pages 70gsm dependent on paper type and quality Maximum set thickness up to 5 2mm approximately 52 sheets 80gsm 56 sheets 70gsm dependent on paper type and quality Stitching 1 6 stitches evenly spaced on the spine of the book Stitches spool up to
36. direction Touch PAGE DIRECTION LANDSCAPE or PORTRAIT If the PAGE DIRECTION option is not available the PAGE DIRECTION cannot be changed 4 Enter the page rotation set For A4 paper size the normal setting for ting ROTATE is ON Rotation lets the printer oper ate at optimum speed Touch ROTATE to turn the sheet rotation ON or OFF Always select the page direction before you change the rotate setting 5 Enter the sheet thickness Touch SET THICKNESS Set AUTO to ON Use Or or to enter the SHEET THICKNESS Enter the set thickness Touch SET THICKNESS Set AUTO to OFF See Set Thickness and Use or to enter the SET THICKNESS Sheet Thickness on page 8 6 Enter the number of Touch STITCHES and enter the number of stitches stitches If needed the stitch pitch can be changed See STITCH PITCH on page 18 7 Enter the spine form set The spine form setting is automatic accord ting ing to the SET THICKNESS setting If needed the setting can be changed See FORM on page 19 8 Enter the trim setting The trim setting is automatic according to the PAGE SIZE and SET THICKNESS settings To change the setting touch TRIM See TRIM on page 19 9 Touch CLOSE 10 If needed save the job set If the same job settings are used frequently tings to memory then save the job settings to memory See Save a job on page 26 10 Watkiss PowerSquare 224 User Manual 2 How to Run t
37. e 2 Disconnect the PowerSquare from the mains power supply 3 Turn one fuse holder to the left and remove the fuse holder from the PowerSquare 4 Check the fuse If the fuse is broken then replace with a fuse of the correct specification 6 Repeat the procedure for the other fuse c1 Result If the fuse breaks again then call your Watkiss service engineer Watkiss PowerSquare 224 User Manual TI 5 Error Conditions Problems and Solutions Change the Fuses Book Stacker Change the Fuses Book Stacker Introduction The Book Stacker has two fuses at the power input connector See Figure 4 on page 5 If either fuse is broken the Book Stacker will not operate AN WARNING Turn OFF the machine and remove the mains power supply cable before you change the fuses This machine uses two fuses in parallel AN WARNING To avoid the risk of fire replace fuses using only the same type and rating Fuse Description 3A HRC Quick acting F Part Number 730 017 Procedure 1 Turn OFF the Book Stacker 2 Disconnect the Book Stacker 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 78 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Manually park the Shuttle Manually park the Shuttle When to do The error messages
38. e problem continue Yes No The problem is caused by the cover material or the finish on the cover Change the cover material Re reference the machine Touch ADVANCED gt RE REF gt RE REF to re reference the machine Does the problem continue Yes No Further action is not needed Call your service engineer Stitching problems the book is not stitched Stitch wire cabinet Stitch wire Accessory bag Middle wire tube Large feed gear Stitch wire jam Small feed gear LZ y FIGURE 24 Stitch wire jam Watkiss PowerSquare 224 User Manual 47 5 Error Conditions Problems and Solutions Book Quality Problems Is the number of STITCHES set between 1 and 6 Yes No Select STITCHES 1 6 See STITCHES on page 18 Check the stitch wire spool Is there stitch wire present Yes No Load a new stitch wire spool See Install New Stitch wire on page 94 Open the PSQ main deck See Lift the PowerSquare Main Deck on page 31 Pull approximately 100 150mm of stitch wire from the stitch wire spool See Fig ure 23 on p 47 Does the wire move freely Yes No Open the stitch wire cabinet Discard any tangled wire and reload the stitch wire spool See Install New Stitch wire on page 94 Check the stitch head for stitch wire jams See Figure 24 on p 47 Is the stitch head clear of stitch wire jams Yes No Clear the stitch wire jam See Clear a Stitch wire Jam on page 72 Lubricate th
39. e stitch head See Lubricate the Stitch Head on page 89 Does the problem continue Yes No Further action is not needed Call your service engineer 48 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Book Quality Problems Stitching problems the book is badly stitched A correctly formed stitch 34 has equal leg length has straight legs the distance between the ends of the stitch legs is approximately 1mm the dis tance can vary by 0 5mm has a flat crown Is the stitch formed correctly Yes No Call your service engineer The stitches should be aligned centrally on the spine Are the stitches positioned correctly Yes No Are the covers of the books and the insides of the books made from the same paper weight and paper type Yes No Accurately measure the different papers Are the different types of paper exactly the same size Yes No You must use paper that is the same size Is the paper within specification See Specifications on page 99 Yes No Do not use paper that is outside the specification Have you accurately measured the paper size after printing Yes No Print a sample to the stacker and measure the printed paper Accurate measurement will improve book quality Have you entered the measured PAPER SIZE into the touch screen Yes No Enter the correct measured PAPER SIZE into the touch screen Touch ADVANCED gt RE REF gt
40. eck the paper size To make an accurate book you must enter accurate paper dimen sions into the touch screen Measure the size of the printed paper The paper dimension changes when the paper is printed CHECK THE TRIM BIN The trim bin is either open or full Check the trim bin Empty the trim bin if necessary See Empty the Trim Bin on page 33 COVER OPEN A safety cover is open The machine will not operate until the cover is closed DFA INTERFACE No comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer 56 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Message List Message Information Reference DRIVE MOTOR STALL There is a paper jam Check the machine and correct the error Touch STOP 9 to clear the mes sage from the screen See Paper Jams on page 64 Endlay axis moving The endlay axis size adjustment is moving This message clears when the adjustment is complete If the message does not clear touch ADVANCED gt RE REF ENDLAY No comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer ERROR IN TRIM AREA There is an error at the trimmer Check the trimmer for a paper or book jam Touch STOP 9 to
41. en to do When you start a new job e If the books do not stack correctly y ni e IW I p a H me j Catch tray adjustment 4 b A A Collection table e Catch tray FIGURE 17 The stacker Book size in window LEE D y Collection table Orange plastic hand screw e Catch tray FIGURE 18 Collection table position Procedure Step Action Information 1 Set the catch tray angle according For books that are 1 5mm thick or to the thickness of the book less use position 1 For books that are more than 1 5mm thick use position 2 See Figure 17 2 Set the collection table position Read the setting through the win according to the size of the book dow See Figure 18 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 35 4 Standard Tasks Adjust the Book Stacker Adjust the Book Stacker Magnetic paper guide FIGURE 20 The magnetic paper guide for thin books Procedure 1 Before you use the Book Stacker make sure the book support is pushed completely to the left There is no need to empty the Book Stacker until the stacker is full 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 20
42. erSquare 224 User Manual 1 Introduction to the Watkiss PowerSquare 224 Description of the PowerSquare 6 Watkiss PowerSquare 224 User Manual charter How to Run the PowerSquare Introduction This chapter gives information on how to run a job on the PowerSquare For information on how to operate the printer refer to the printer documentation Information about the user interface is included in The User Interface on page 13 Information about standard procedures for example opening covers to clear a paper jam is included in Standard Tasks on page 25 Watkiss PowerSquare 224 User Manual 7 2 How to Run the PowerSquare Before You Begin Before You Begin Paper and Book Quality Instructions The size of the paper and either the set thickness or the sheet thickness must be measured These measurements are entered into the touch screen before you begin a print job Measure the size of the printed paper The paper dimension changes when the paper is printed To get best accuracy use millimetres to measure the set See page 9 Enter accurate dimensions into the touch screen fthe book is made from several different types of paper make sure the dif ferent paper types are all the same size See Book Quality Problems on page 43 for further information Set Thickness and Sheet Thickness In order to make a high quality finished book the machine adjusts the length of the st
43. ere is a fault with the START and STOP touch pads If the prob lem continues then call your Wat kiss service engineer Touch START to clear machine There may be some paper in the machine Touch START to clear the machine before you start a new job Trim axis moving The trim axis size adjustment is moving This message clears when the adjustment is complete If the message does not clear touch ADVANCED gt RE REF TRIM BIN OPEN The trim bin is not fitted or is not contacting the safety switch Fit the trim bin See Empty the Trim Bin on page 33 TRIM BLADE NOT PARKED The trim blade is in the wrong position Touch START to reset the position Follow the instructions on the Screen TRIM No comms Use the mains ON OFF switch 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 to restart the machine Watkiss PowerSquare 224 User Manual 63 5 Error Conditions Problems and Solutions Paper Jams Paper Jams Stitch Area Gathering Area Connecting Bridge Fold and Forming Areas Trim Area Uplift cover Rotator Bridge infeed cover u FIGURE 26 Inside the connecting bridge Jam in the Bridge Infeed 1 Open the bridge infeed cover
44. h RE REF to re reference the adjustment axes The adjustment axes return to the current settings At intervals the machine will re reference the axes during the set up procedure STITCHER UP Touch STITCHER UP before you lubricate the stitch head This action moves the stitch head to the correct position for lubrica tion PURGE SET If the print job has been cancelled a set or part of a set can remain in the gathering area Touch START then touch PURGE SET to clear the set from the machine The book is not stitched or trimmed According to the type of error that occurred there can be a pause of 7 seconds before the PURGE SET button will operate For safety reasons this function is disabled when the gather ing area cover is open MAKE BOOK If there is a set in the gathering area you can make it into a book Caution Do not use this option if SET THICKNESS is set to AUTO Touch START then touch MAKE BOOK to clear the set from the machine The book is stitched and trimmed According to the type of error that occurred there can be a pause of 7 seconds before the MAKE BOOK button will oper ate For safety reasons this function is disabled when the gather ing area cover is open 22 Watkiss PowerSquare 224 User Manual 3 The User Interface The CONFIGURE Window The CONFIGURE Window The CONFIGURE cx window lets you make changes to the configuration of the machine
45. haft from the drive pin Lift the left hand end clear 4 Remove the book if one is found 5 Remove any paper offcuts Look down through the former clamp See from the trimmer infeed Figure 29 Balen Small pieces of paper trimmings can cover the jam sensor and cause an error message 6 Fit the trimmer infeed con Look down through the former clamp VEYBS Insert the right hand end of the shaft into the bearing against the spring pressure 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 7 Fit the trim bin 8 Close the PowerSquare main deck and covers 68 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Paper Jams Jam in the Trim Area FIGURE 31 Location of the sensor 3 Orange Plastic Hand Screw Locking Plate Trim Stop Guard Step Action Information 1 Remove the trim bin 2 Open the trim stop guard See Figure 30 Loosen the 2 orange plastic hand screws to release the locking plates The locking plates can rotate to release the trim stop guard Pull the trim stop guard towards you Remove the jammed book Check the trim stop and remove any pieces of trimmed paper In particular check around the sensor The sensor is where you can see a red and a
46. he PAPER SIZE and PAGE DIRECTION settings are entered on the touch screen These dimensions refer to the format of the paper when it enters the PowerSquare AN CAUTION Do not operate the touch screen with a sharp object or with too much force These actions can damage the touch screen Before You Begin Step Action Information 1 Print a set to the stacker 2 Measure the sheet size Measure either the sheet thickness or the set thick ness To make an accurate book you must enter accurate paper dimensions into the touch Screen To get best accuracy use millimetres to measure the set If needed set the PowerSquare to use milli metres Touch MENU Select Supervisor access level Touch MENU gt CONFIGURE Cr gt MACHINE OPTIONS Touch mm gt CLOSE Use these dimensions for the job setting Note This set can be made into a book See Operate the PowerSquare offline on page 39 Watkiss PowerSquare 224 User Manual 2 How to Run the PowerSquare Enter the Job Settings Procedure for a New Job Step Action Information 1 Touch BASIC fJ 2 Enter the paper size Touch PAPER SIZE Enter the dimensions of the paper The job setting is easier if you first select a preset paper size then adjust the settings as necessary Touch PAPER SIZE gt PRESETS gt A3 or A4 USA 11x17 8 5x11 or 8 5x14 3 Enter the page
47. he PowerSquare Adjust the Stacker Procedure for a Saved Job 1 Touch LOAD amp SAVE 7 2 Touch the job name or use the Up arrow and the Down arrow to select the job 3 Touch LOAD 4 Wait until the PowerSquare is ready Adjust the Stacker Book Stacker Check the Book Stacker is ready to accept books See Adjust the Book Stacker on page 36 Run the Job Procedure 1 Make sure the adjustments on the PowerSquare are complete before you release the print job from the print queue 2 Start the print job The PowerSquare starts automatically Check the quality of the first book 4 If the quality is not acceptable make adjustments See Book Quality Prob lems on page 43 for further information oo During the job Unload books from the stacker before the stacker is full The PowerSquare stops and displays a message if the stacker is full Ifthe optional Book Stacker is fitted see Unload the Book Stacker on page 37 Empty the trim bin from time to time The PowerSquare displays a message if the trim bin is full See Empty the Trim Bin on page 33 Watkiss PowerSquare 224 User Manual 11 2 How to Run the PowerSquare Run the Job 12 Watkiss PowerSquare 224 User Manual cuaPreRs T he User Interface The user interface includes a colour touch screen and START STOP buttons dms FIGURE 5 The User Interface The Touch Screen Introduction ST
48. he machine ON If the problem continues then call your service engineer Stitch position adjusting The stitch position is adjusting This message clears when the adjustment is complete If the message does not clear touch ADVANCED gt RE REF STITCH TIMEOUT Press STOP Open the folder cover remove the paper close the folder cover SYSTEM ERROR 00 20 40 21 40 22 42 XX 43 xx Touch STOP to clear the message from the screen If the message does not clear use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer SYSTEM ERROR 39 xx Press the reset button on the stacker If the message does not clear use the stacker mains ON OFF switch Turn the stacker OFF then turn the stacker ON If the problem continues then call your service engineer TAMPER No comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer TOO MANY PAGES The printer has delivered too many sheets into the gathering area Remove the incorrect set Touch STOP to clear the message from the screen Check the settings for SET THICK NESS or SHEET THICKNESS Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Message List Message Information Reference TOUCH PAD ERROR Th
49. hen you push the two buttons When to do Procedure N A af Ww PP To check the settings are correct To make a small number of books offline WARNING Do not put your hands in the gathering area when the machine operates Use two hands to push the buttons For safety reasons this task is for a single operator Do not let another person help you CAUTION Do not use this function when SET THICKNESS is set to AUTO The SET THICKNESS must be the correct setting for the book Enter the correct settings on the touch screen according to the size and thickness of the job Touch START Open the gathering area cover Put the set in the gathering area with the middle pages of the book face up 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 39 4 Standard Tasks Operate the PowerSquare offline 40 Watkiss PowerSquare 224 User Manual caaPrens Error Conditions Problems and 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 Procedure 1 Clear the printer error 2 Follow the instructions on the printer If the printer tells you to remove
50. ht grey shows that a job has been locked by a supervisor to prevent changes to the set tings DELETE To delete a particular job it must be unlocked Touch the job name or use the Up arrow or Down arrow to make the selec tion from the job list Touch and hold DELETE A red line appears The red line fills from left to right Hold DELETE until the red line reaches the right hand side 20 Watkiss PowerSquare 224 User Manual 3 The User Interface The LOAD amp SAVE Window Button Information VIEW OF JOB LIST VIEW OF JOB LIST changes the order that saved jobs are listed There is a line between Factory Template jobs and jobs saved by the operator The Factory Template jobs are at the top of the list A gt Z Touch A gt Z to list the jobs in alphabetical order BY USE Touch BY USE to list jobs in the order they were last used The most recently run job is at the top of the list BY INDEX Touch BY INDEX to list jobs in numerical order the machine gives a number to all jobs that are saved Watkiss PowerSquare 224 User Manual 21 3 The User Interface The ADVANCED Window The ADVANCED Window The ADVANCED Window Buttons The ADVANCED ze window gives you access to special machine functions Button Information RE REF If the machine calibration appears incorrect or if an axis mov ing error message remains on the screen touc
51. il Directive on the approximation of laws of Member States relating to electromagnetic compatibility EN55022 2010 Class A EN55024 2010 EN61000 3 2 2006 A1 2009 A2 2009 EN61000 3 3 2008 Watkiss PowerSquare 224 User Manual 103 8 Declaration of Conformity 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 104 Watkiss PowerSquare 224 User Manual Appendix Image Creep About Image Creep When a stack of paper is folded to make a booklet the thickness of the paper causes a progressive image movement between the inner most and outer most pages This is called creep To keep the image in the same place on each page an adjustment for creep can be made Some print machines can automatically compensate when they print in booklet mode Alternatively adjustment can be made in origination software such as InDe sign or PDF pages can be adjusted before they are printed using imposition software such as Quite Imposing The amount of creep adjustment needed depends on the number of pages and the thickness of the paper A booklet with only a few pages and wide margins may not need adjustment because the difference after the book is trimmed is not noticeable With more pages smaller margins or bulkier paper the creep becomes more noticeable
52. itch and the amount of spine form according to the set thickness There are two operating modes Sheet thickness and page count This is the default operating mode Measure the thickness of a single sheet Enter the value into the touch screen Use the measuring tool supplied with the machine The sheets are counted as they enter the machine and the settings adjust automatically Tip t is easiest to measure 10 sheets of paper and divide the value by 10 If you use the same type of paper frequently record the value so that you do not need to measure it each time Set thickness Measure the thickness of a complete set Enter the value into the touch screen Measure the set thickness as accurately as possible Use the measuring tool supplied with the machine Turn On the PowerSquare Procedure 1 Connect the PowerSquare and any accessories to the mains power supply 2 Use the mains ON OFF switches to turn ON the PowerSquare and accesso ries The PowerSquare makes this sequence of beeps beep beep beep beep beep beep X beep 8 Watkiss PowerSquare 224 User Manual 2 How to Run the PowerSquare Enter the Job Settings The touch screen illuminates and the machine calibrates When READY is displayed on the screen the machine is ready for use Enter the Job Settings Introduction Make the settings for a new job in the BASIC window on the touch screen See The User Interface on page 13 for more information T
53. ither the set thickness or the sheet thickness Yes No rect SET THICKNESS or SHEET THICKNESS into the touch screen Have you entered either the measured set thickness or sheet thickness into the touch screen Yes No Enter the correct SET THICKNESS or SHEET THICKNESS into the touch screen Touch ADVANCED gt RE REF gt RE REF to re reference the machine Does the problem continue Yes No Measure either the set thickness or the sheet thickness and enter the cor Further action is not needed Is the paper thin and or curly Yes No Call your service engineer 44 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Book Quality Problems Increase the TAMPER TIME to give the paper more time to settle Supervisor access level is needed see page 24 On thin books this may reduce the produc tion speed Touch CONFIGURE gt SHUTTLE Increase the TAMPER TIME in incre ments of 200 Does the problem continue Yes No Further action is not needed Call your service engineer Watkiss PowerSquare 224 User Manual 45 5 Error Conditions Problems and Solutions Book Quality Problems Spine form problems Correct spine form Incorrect spine form Incorrect spine form The square spine is part The spine is over formed formed or not formed and the book is damaged A x I x Is the spine form different at each end of the spine Yes N
54. lets the printer operate at optimum print speed Adjustment for the size of the paper and sheet rota tion is automatic according to the settings entered on the touch screen The user interface The user interface has a colour touch screen a start button and a stop button The PowerSquare The PowerSquare stitches folds spine forms and trims the sheets to make a finished book The stacker The stacker collects the finished books See Figure 2 The book stacker The book stacker is optional It is a high capacity stacker for the finished books See Figure 2 The stitch wire cabinet The stitch wire cabinet holds the spool of stitch wire The trim bin The trim bin collects the paper that is trimmed from the edge of the book Watkiss PowerSquare 224 User Manual 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 3 The Rear Panel of the PowerSquare Component Function Table Component Function Rating and serial label The rating label displays the type of machine serial number power use and fuse information Mains power ON OFF The mains power ON OFF switch turns ON or turns switch OFF the PowerSquare When you turn
55. ll dirty marks on the book Ink and toner can collect on the trimmings removal fingers and cause marks on the book N T ye FIGURE 43 Curved marks on the book Materials needed Alcohol wipe Part number 951 710 AN CAUTION Wear protective gloves when you use the alcohol wipe Trimmer infeed conveyor Former clamp mechanism Reach in here to access the trim infeed conveyor Trimmer infeed conveyor Trimmings removal fingers Former clamp mechanism FIGURE 45 Trimmer infeed conveyor viewed from above_2 86 Watkiss PowerSquare 224 User Manual 6 Maintenance Clean the Trimmings removal Fingers Procedure Step Action Information Lift the PowerSquare main deck See Lift the PowerSquare Main Deck on page 31 Remove the trim bin Clean the four visible trimmings removal fingers with an alcohol wipe The procedure can be seen from the top of the machine Access to the parts is through the former clamp mechanism See Figure 44 Wear protective gloves when you use the alcohol wipe Rotate the conveyor shaft by half a turn 1 Hold the shaft and push to the right against spring pressure to disengage the shaft from the drive pin 2 Rotate the shaft by half a turn 3 Align the shaft with the drive pin and release Clean the four visible trimmings removal fingers with an alcohol wipe Wear protective gloves
56. llect on these parts especially when you make thin books FIGURE 41 Dirty marks beside the spine Materials description Alcohol wipe Part number 951 710 oralint free cloth and alcohol isopropanol AN CAUTION Only use alcohol to clean this part of the machine Other chem icals can damage the machine 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 INN FIGURE 42 Polyurethane strips 84 Watkiss PowerSquare 224 User Manual 6 Maintenance Clean the Polyurethane Strips in the Form Clamp Procedure Step Action Information 1 Open the folder cover 2 Use an alcohol wipe or apply a Wear protective gloves when you small amount of alcohol to a lint use the alcohol wipe free cloth 3 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 4 Close the folder cover Watkiss PowerSquare 224 User Manual 85 6 Maintenance Clean the Trimmings removal Fingers Clean the Trimmings removal Fingers When to do When the message OPERATOR MAINTENANCE is displayed on the screen Clean the trimmings removal fingers if there are sma
57. mber 951 095 Air duster Part number 952 436 CAUTION Only use the grease shown in this manual Correct lubrication extends the performance and service life of the stitch head Other types of grease do not protect the stitch head Only apply the grease as shown If you apply additional grease the paper gets marked mm Step Action Information Trim the first 2 5mm from the See Figure 47 on page 89 nozzle Remove the cap from the tube of grease Fit the nozzle to the tube of grease Watkiss PowerSquare 224 User Manual 89 6 Maintenance Lubricate the Stitch Head Step Action Information 4 On the user interface touch The folder cover must be closed ADVANCED gt STITCHER UPS This action moves the stitch head to STITCHER UP i erent the correct position for lubrication 5 Lift the PowerSquare main deck See Lift the PowerSquare Main Deck on page 31 You will see that the stitch head in the STITCHER UP position 6 Use the supplied air duster to remove dust from the stitch head 7 Remove the wire holder from the stitch head Move the wire holder retaining spring A to the right Remove the wire holder B 90 Watkiss PowerSquare 224 User Manual 6 Maintenance Lubricate the Stitch Head Apply the Grease to the Driver Bar FIGURE 49 Apply the Grease to the
58. mm towards the spine and the front and back page are both moved 4mm away from the spine 106 Watkiss PowerSquare 224 User Manual D Watkiss Automation Limited 1 Blaydon Road Middlefield Industrial Estate Sandy Bedfordshire SG191RZ United Kingdom Tel 44 0 1767 685700 Fax 44 0 1767 689900 Email info watkiss com
59. n buttons are divided into groups that have connected functions Each group of buttons has a separate window Touch the correct tab to select the window LOAD amp SAVE fy BASIC gt ADVANCED CONFIGURE M MENU Window Buttons Each window contains a group of buttons Touch the button to select the function Message List Information and error messages are shown in the MESSAGE LIST To display the information about a message touch HELP then touch the message list Use the right arrow and left arrow to see the help text for each message Job Mimic The job mimic shows the current machine settings Status The STATUS line shows the machine status GREEN The PowerSquare is READY or RUNNING ORANGE PLEASE WAIT wait until the PowerSquare is ready ATTENTION the PowerSquare needs an action by the operator RED The PowerSquare is in an ERROR condition Help Help text is available on the touch screen Touch HELP then touch any button or tab on the screen Information about that button or tab is dis played To display the information about a message touch HELP then touch the message list Use the Up arrow and the Down arrow to scroll up and scroll down the screen Some text has more than one screen Use the right arrow and left arrow to see the other screens To leave the help text touch HELP or touch X Sheet Counter The sheet counter shows the
60. nual 6 Maintenance Clean the Former Roller Clean the Former Roller When to do When the message OPERATOR MAINTENANCE is displayed on the screen Clean the former roller if the spines of the books are dirty Ink and toner can collect on the former roller FIGURE 40 Dirty marks on the spine Materials needed Clean plain paper that is not printed A3 size USA 11 x 17 is recommended 4mm thickness is needed for each cycle More than one cycle can be needed Procedure Step Action Information 1 Enter the correct settings on the Set the touch screen to the cor touch screen rect PAPER SIZE Set the SET THICKNESS to 4 0 Set the number of STITCHES to 0 Set the number of FORMS to 4 2 Touch START G Lift the gathering area cover 4 Put 4mm of clean paper in the gathering area 5 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 83 6 Maintenance Clean the Polyurethane Strips in the Form Clamp Clean the Polyurethane Strips in the Form Clamp When to do When the message OPERATOR MAINTENANCE is displayed on the screen Clean the polyurethane strips in the form clamp if there are dirty marks near the spine on the front and back cover of the book Ink and toner can co
61. o The spine is incorrect along the full length Is the folder cover closed fully Yes No Lock the folder cover See Close the Folder Cover on page 29 Is the SET THICKNESS or SHEET THICKNESS correct Yes No Measure the SET THICKNESS or the SHEET THICKNESS and enter the value in the touch screen Does the problem continue Yes No Further action is not needed Check the THRESHOLD setting If the SET THICKNESS is less than the THRESHOLD a square spine is not formed See THRESHOLD on page 19 Adjust THRESHOLD if needed Does the problem con tinue Yes No Further action is not needed Adjust the PRESSURE setting Increase the PRESSURE to give more spine form and decrease the PRESSURE to give less spine form Does the problem continue Yes No Further action is not needed Adjust the NUMBER of forms setting Increase the NUMBER of forms to give more spine form and decrease the NUMBER of forms to give less spine form Does the problem continue Yes No Further action is not needed Load a Default Job This will reset the FORM settings including PRESSURE NUMBER and THRESHOLD See Reset the PowerSquare to default set tings on page 26 Does the problem continue Yes No e 46 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Book Quality Problems Further action is not needed Run a standard job using 80gsm 20 bond paper Does th
62. o 6 Touch BASIC gt STITCHES 3 Hand feed or print an A4 or larger size test job Enter the correct settings on the touch screen according to the size and thickness of the job The stitch wire loads automati cally during the stitch head cycle Check the stitch wire is loaded Check that a stitch is made 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 96 Reset the number of stitches on the touch screen Watkiss PowerSquare 224 User Manual 97 6 Maintenance Clear paper from the trim stop Clear paper from the trim stop When to do Clear paper from the trim stop if the books are not trimmed square If paper trimmings collect on the trim stop the books are not trimmed square Orange Plastic Hand Screw Locking Plate Trim Stop Guard Trim Stop FIGURE 53 Trim Stop Step Action Information 1 Remove the trim bin 2 Open the trim stop guard See Figure 52 Loosen the 2 orange plastic hand screws to release the locking plates The locking plates can rotate to release the trim stop guard Pull the trim stop guard towards you 3 Check the trim stop and See Figure 53 remove any pieces of trimmed paper 4 Close the trim stop guard Push the trim stop guard into position Hold the locking plates in position and tighten the orange han
63. ot apply force to the wire guide bars or the pivot block when you do this procedure Force on these parts will damage the stitch head FIGURE 37 Inspect for stitch wire A Tools and Materials Kl ber 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 75 5 Error Conditions Problems and Solutions Clear a Stitch Head Jam Step Action Information 1 Lift the PowerSquare main deck See Lift the PowerSquare Main Deck on page 31 2 Remove the wire holder from the Move the wire holder retaining stitch head spring to the right See Figure 36 on page 75 Remove the wire holder If the wire holder is held in posi tion use a screw driver to help the removal of the wire holder from the stitch head CAUTION Do not apply force to the wire guide bars or the pivot block See Figure 37 3 Inspect the area behind the wire See Figure 37 on page 75 holder for pieces of stitch wire 4 Remove any stitches or pieces of Use the wire cutters to remove stitch wire and clean the area with any jammed stitches or pieces of the air duster stitch wire 5 Lubricate the stitch head See Lubricate the Stitch Head on page 89 6 Fit the wire holder Remember to put the wire holder retaining spring in position 7 Close the
64. problem continue Yes No 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 No Yes Printer service is required Call your service engineer 54 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Message List Message List Information and error messages are shown in the message list The error messages are shown in order of priority Follow the action needed for the messages starting with the message at the top of the list To display the information about a message Touch HELP then touch the message list Use the right arrow and left arrow to see the help text for each message made To decrease the book cycle time adjust the machine settings decrease the number of FORMS decrease the number of STITCHES decrease the TAMPER TIME touch STOP to clear the message from the screen Message Information Reference AXES MOVING Some of the machine axes are moving This message clears when the adjustment is complete If the message does not clear touch ADVANCED gt RE REF BOOK CYCLE TIME The printer has delivered the sets TOO LONG faster than the books can be BOOK DELIVERY TOO FAST Books are being delivered to the stacker too fast This error can happen when you insert books
65. r continue operation MISSING STITCHES The machine has detected missed See Clear a stitches Check if the stitch wire is jammed or if the stitch wire spool is empty Stitch wire Jam on page 72 or see Install New Stitch wire on page 94 MOTOR CONTROLLER NOT READY The drive motor controller is not ready If the problem continues contact your service engineer OPERATOR MAINTE NANCE The machine needs routine main tenance by the operator See Operator Maintenance on page 81 REBOOT THE MACHINE Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer REMOVE SET FROM FOLD AREA Open the folder cover and remove the set See Jam in the Folder or Former Area on page 66 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Message List Message Information Reference REMOVE SET GATH Open the gathering area and See Jam in the ERING AREA remove the sheets Gathering Area on page 65 REMOVE SET Open the folder cover and remove See Jam in the STITCH AREA the set Stitch Area on page 66 Rotate axis moving The rotate axis is moving This message clears when the adjust ment is complete If the message does not clear touch ADVANCED gt RE REF SHUTTLE MOTOR COMMS FAIL Use the mains ON OFF switch T
66. r the Clincher Frame Lift and Lower the Clincher Frame When to do If a machine error occurs or for maintenance Toclear a paper jam in the stitch area Tounlock the PowerSquare main deck Folder Cover Clincher Frame Clincher Locking Handle Clincher Frame FIGURE 12 Clincher Frame Components Lift the Clincher Frame 1 Open the folder cover 2 Turn the locking handle to the left until the thread is disengaged 3 Lift the clincher frame to the vertical position Lower the Clincher Frame 1 Lower the clincher frame 2 Turn the locking handle to the right until the handle is tight 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 30 Watkiss PowerSquare 224 User Manual 4 Standard Tasks Open the Gathering Area Cover Open the Gathering Area Cover When to do If a machine error occurs or for maintenance To access the gathering area The PowerSquare will stop if you open the gathering area cover Gathering Area Cover Handle FIGURE 13 Gathering Area Cover Open Procedure Use the handle to lift the gathering area cover Lift the PowerSquare Main Deck When to do If a machine error occurs or for maintenance To access the
67. rease in NUMBER increases the time taken to form the spine and can decrease the production rate for thin books Alternatively increase the PRESSURE PRESSURE Touch PRESSURE to increase or decrease the pressure used to form the spine Touch to increase the amount of spine form Touch to decrease the amount of spine form The range is 9 to 9 The default setting is O THRESHOLD Use THRESHOLD to choose if a square spine is formed If the SET THICKNESS value is thinner than the THRESHOLD value a square spine is not formed If the SET THICKNESS value is thicker than the THRESHOLD value a square spine is formed If the SET THICKNESS value is 1 5mm or thicker a square spine is always formed The default value is 0 8mm The allowed range is 0 1mm to 1 5mm TRIM The trim dimension is calculated automatically according to the PAPER SIZE and SET THICKNESS If needed the trim dimension can be changed Touch TRIM to 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 AUTO Touch AUTO to select the default trim position Watkiss PowerSquare 224 User Manual 19 3 The User Interface The LOAD amp SAVE Window The LOAD amp SAVE Window The LOAD amp SAVE window lets you save and reload job settings Each job is given a name The jobs are displayed in a list on the screen Touch the
68. red line appears The red line fills from left to right Hold RESET until the red line reaches the right hand side 3 Touch MENU Watkiss PowerSquare 224 User Manual 93 6 Maintenance Install New Stitch wire Install New Stitch wire Introduction Only use stitch wire that is approved by your supplier Stitch wire that is not approved by your supplier can cause bad performance and cancels the war ranty Stitch wire Description PSQ Stitch Wire PowerBind 0 6mm 15kg Part number 812 038 Before You Begin Lift the PowerSquare main deck See Lift the PowerSquare Main Deck on page 25 Remove the Stitch wire from the Stitch Head Stitch wire Guide Block Stitch wire Felt wire cleaning pads FIGURE 51 Stitch wire Guide Block Step Action Information 1 Cut the stitch wire to the right of the stitch wire guide block Cut here 2 Pull the stitch wire from the stitch wire guide block 3 Fit a new stitch wire spool See Fit a New Stitch wire Spool on page 95 94 Watkiss PowerSquare 224 User Manual 6 Maintenance Install New Stitch wire Fit a New Stitch wire Spool Step Action Information 1 Open the stitch wire cabinet 2 Remove the stitch wire cap and finished stitch wire spool Fit a new stitch wire spool Fit the stitch wire cap Loosen the end of the stitch wire from the edge of the stitch
69. seda See e Haee ERI E RU 41 General Problems o rac Rasa esa x e s 42 Book Quality Problems 222 3 eru d RC a 43 Message List 4 ick figure S48 rx ERR ee eR AR Ede 55 Paper Jams i snioia ac PRI Dx tig RE Ru 64 Clear a Stitch wire Jam 0 00 es 72 Clear a Stitch Head Jam seaweeds betta RR ERE 74 Calibrate the Touch Screen 000 0 eee eees 77 Change the Fuses PowerSquare 0 0000 77 Change the Fuses Book Stacker 0005 78 Manually park the Shuttle n on nananana 79 6 Maintenance vv rcli vex p ee eee o e 81 Service Interval aus ceed Oe Roe ea Er cer 6 D edel ee ed 81 Operator Maintenance 000 e cece eee ees 81 Clean the PowerSquare 0 0000 e eee eee 82 Clean the Former Roller 000 e eae 83 Clean the Polyurethane Strips in the Form Clamp 84 Clean the Trimmings removal Fingers lisse 86 Clean excess grease from the Stitch Head 88 Lubricate the Stitch Head 0 0 cece eee eee 89 Install New Stitch wire llle 94 Clear paper from the trim stop 00000 eee aae 98 T Specifications cence eee eee eae ees 99 8 Declaration of Conformity 103 ADDGNGIX aii eg ene xaO Ps aden Cee CR RC C OR 105 Image resp sss dee doceo ORT E ORC CR aR 105 Watkiss PowerSquare 224 User Manual CHAPTER 1 Introduction to the Watkiss PowerSquare 224 Your
70. service engineer Trimming problem the book is not trimmed square Open the trim stop guard and check for paper trimmings See Clear paper from the trim stop on page 98 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 5 Error Conditions Problems and Solutions Book Quality Problems Trimming problem poor trim quality 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 Are there marks on the trimmed edge other than the blade witness mark No Yes Call your service engineer No further action is needed Blade witness mark in the centre of the book Blade damage mark 52 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Book Quality Problems Dirty marks on book Are there dirty marks on the spine Marks on the spine No Yes Clean the former roller See Clean the Former Roller on page 83 Are there grease or oil spots on the spine of the book yx yx Grease marks near the stitches No Yes Clean grease from the top of the stitch head See Clean excess grease from the Stitch Head on page 88
71. ss of one sheet of the paper SHEET THICKNESS determines the maximum number of sheets that is allowed This number is shown on the screen STITCHES Touch STITCHES to select the number of stitches Available options are 1 6 The machine automatically calculates the position of the stitches according to the size of the paper Select 0 to turn off the stitch function STITCH PITCH 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 to make the adjustment 18 Watkiss PowerSquare 224 User Manual 3 The User Interface The BASIC Window Button Information AUTO Touch AUTO to select the default stitch pitch FORM To make the square spine of the book pressure is applied to the spine This process is called forming Touch FORM to specify the amount of spine form To make a good spine on different paper types the amount of spine form can be changed To change the amount of spine form Touch NUMBER to change how many times the spine is processed Touch PRESSURE to change the pressure AUTO Touch AUTO to select the optimum amount of spine form according to the set thickness NUMBER Touch NUMBER to select how many times the form roller proc esses the spine The available options are 1 2 3 or 4 An inc
72. st the Stitch Pitch Adjust the Stitch Pitch Introduction When to do The stitch pitch is the space between the stitches The machine automatically calculates the stitch pitch according to the size of the paper and the number of stitches The stitches are inserted symmetrically on the spine of the book If a non standard stitch pitch is needed use STITCH PITCH to make the adjust ment A Stitch Pitch FIGURE 8 Stitch Pitch Limitations The minimum stitch pitch A is 25mm The minimum distance from the centre of the stitch to the edge of the sheet B is 15mm If you need the PowerSquare to insert the stitches in a non standard position For example to keep the stitches away from the text on the spine of the book Select a non standard stitch pitch 1 Touch BASIC gt STITCHES 2 Touch AUTO The STITCH PITCH value goes green 3 Change the stitch pitch value Either use the and or touch the green stitch pitch value to open a numeric keypad 4 Touch STITCHES to close the window The stitch pitch value is displayed in the job mimic and on the STITCHES button Select a standard stitch pitch 1 Touch BASIC Y gt STITCHES 2 Touch AUTO to select ON 3 Touch STITCHES to close the window The stitch pitch value is not displayed in the job mimic or on the STITCHES but ton Watkiss PowerSquare 224 User Manual 27 4 Standard Tasks Open the Connecting Bridge Co
73. stitch head To access the former area 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 PARKED is shown on the screen A A Watkiss PowerSquare 224 User Manual 31 4 Standard Tasks Lift the PowerSquare Main Deck FIGURE 14 Lift the PowerSquare Main Deck Before you begin Check the touch screen for the error message FOLD BLADE NOT PARKED Procedure Folder Cover Clincher Frame Lift here Main Deck If the error message is displayed Open the folder cover remove any paper close the folder cover Touch START then follow the instructions on the screen Wait for the message to clear Then continue with the procedure below If the error message is not displayed Continue with the procedure below Step Action Information 1 Open the folder cover 2 Lift the clincher frame See Lift the Clincher Frame on page 30 3 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 32 Watkiss PowerSquare 224 User Manual 4 Standard Tasks Empty the Trim Bin Empty the Trim Bin When to do An error message CHECK THE TRIM BIN is displayed on the touch screen
74. the stitch head Touch and hold RESET A red line appears The red line fills from left to right Hold RESET until the red line reaches the right hand side 24 Watkiss PowerSquare 224 User Manual cHaptens Standard Tasks Introduction This chapter describes the standard tasks that are needed in the day to day operation of your PowerSquare Watkiss PowerSquare 224 User Manual 25 4 Standard Tasks Load and Save the Job Settings Load and Save the Job Settings Introduction Save a job Load a job The current job settings can be saved to the memory and reloaded for use again at a later date Load the Default Job Template to reset the PowerSquare to normal settings 3 4 Touch LOAD amp SAVE 7 gt SAVE If these options appear select one REPLACE to over write the previous job with the current job settings SAVE NEW to save the current job with a new name CANCEL to cancel the job save Enter the name for the job on the keyboard Touch OK or CLOSE Touch LOAD amp SAVE 7 Touch the job name or use the Up arrow and the Down arrow to select the job Touch LOAD Wait until the PowerSquare has made the adjustments Reset the PowerSquare to default settings 1 2 3 4 Touch LOAD amp SAVE 7 Select the Default Job Template from the list of jobs Touch LOAD Touch YES 26 Watkiss PowerSquare 224 User Manual 4 Standard Tasks Adju
75. the stitch wire into the stitch head See Install the Stitch wire into the Stitch Head on page 96 Watkiss PowerSquare 224 User Manual 73 5 Error Conditions Problems and Solutions Clear a Stitch Head Jam Clear a Stitch Head Jam When to do Procedure 1 The error message JAM IN STITCH HEAD is displayed This may be caused by the SET THICKNESS setting is incorrect the stitch head is jammed by broken wire the stitch head needs lubrication Do Procedure 1 If the error message continues do Procedure 2 Step Action Information Open the folder cover See Open and Close the Folder Cover on page 29 2 Lift the clincher frame See Lift and Lower the Clincher Frame on page 30 Remove the jammed paper 4 Check for broken or damaged Press to manually stitches in the clincher area Man operate the ually operate the clincher to clear clincher any stitches that are jammed 5 Lower the clincher frame See Lift and Lower the Clincher Frame on page 30 6 Close the folder cover 7 Press the START button Fol low the on screen instructions 74 Watkiss PowerSquare 224 User Manual 5 Error Conditions Problems and Solutions Clear a Stitch Head Jam Procedure 2 Stitch head Wire holder Inspect this area for pieces of stitch wire Wire guide bars see Caution Pivot block see Caution CAUTION Do n
76. tting is displayed A red X shows that the trim function is not active 205 0 Watkiss PowerSquare 224 User Manual 17 3 The User Interface The BASIC Window The BASIC Window The BASIC Window Buttons The BASIC f window gives you access to frequently changed machine set tings Button Information PAPER SIZE Measure the accurate size of the printed paper before you make a book Touch PAPER SIZE to enter the paper size When the machine is in operation you can adjust the PAPER SIZE by a maximum of 1mm PAGE Touch PAGE DIRECTION to change the direction of the paper to DIRECTION Landscape or Portrait ROTATE Touch ROTATE to set the sheet rotation ON or OFF If you select A4 portrait USA 8 5x11 ROTATE is set to ON automatically PRESETS Touch PRESET to select a standard paper size SET THICKNESS Use the SET THICKNESS window to define the thickness of the Set Either Measure the thickness of the set before you make a book Touch SET THICKNESS and enter the value Or Use AUTO and SHEET THICKNESS to automatically calcu late the SET THICKNESS AUTO Touch SET THICKNESS gt AUTO to select automatic adjustment of SET THICKNESS Then enter the SHEET THICKNESS The sheets are counted when they enter the machine The SET THICKNESS is calculated from the SHEET THICKNESS and the sheet count SHEET THICK NESS Use SHEET THICKNESS to enter the measured thickne
77. urn the machine OFF then turn the machine ON If the problem continues then call your service engineer SHUTTLE MOTOR ERROR Use the mains ON OFF switch Turn the machine OFF then turn the machine 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 gt RE REF SIDELAY No comms Use the mains ON OFF switch Turn the machine OFF then turn the machine ON If the problem continues then call your service engineer STACKER FULL The stacker is full Unload the books from the stacker STACKER No comms Check that the stacker power input is connected Check that the stacker mains ON OFF switch is ON If the problem continues then call your service engineer Stitch axis moving The stitch axis is moving This message clears when the adjust ment is complete If the message does not clear touch ADVANCED gt RE REF Watkiss PowerSquare 224 User Manual 61 5 Error Conditions Problems and Solutions Message List Message Information Reference Stitch length will change soon The stitch length cannot adjust at the moment The stitch leg length will adjust after the next book STITCH No comms Use the mains ON OFF switch Turn the machine OFF then turn t
78. ver Open the Connecting Bridge Cover When to do If a machine error occurs or for maintenance Toclear a paper jam The PowerSquare will not stop if you open the connecting bridge cover Connecting Bridge Cover FIGURE 9 Connecting Bridge Cover AN WARNING Keep your hands clothing and hair away from the belts Procedure Lift the connecting bridge cover 28 Watkiss PowerSquare 224 User Manual 4 Standard Tasks Open and Close the Folder Cover Open and Close the Folder Cover When to do If a machine error occurs or for maintenance To access the stitch area To access the folder area Note The folder cover has an interlock switch The PowerSquare stops if you open the folder cover FIGURE 10 Unlock and Lock the Folder Cover Open the Folder Cover 1 Lift the black locking handle against the spring pressure 2 Turn the handle through 90 to unlock 3 Lift the folder cover carefully to the vertical Close the Folder Cover AN CAUTION Check that the folder cover will not hit the clincher frame locking handle when you close the folder cover If necessary lift and rotate the clincher frame locking handle to a new position See Figure 12 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 29 4 Standard Tasks Lift and Lowe
79. when you use the alcohol wipe Fit the trim bin Close the PowerSquare Watkiss PowerSquare 224 User Manual 87 6 Maintenance Clean excess grease from the Stitch Head Clean excess grease from the Stitch Head When to do When the message OPERATOR MAINTENANCE is displayed on the screen Clean excess grease from the stitch head if there are grease marks around the stitches on the book fi uy FIGURE 46 Grease marks around the stitches Materials needed e Lint free cloth Procedure Step Action Information 1 On the user interface touch The folder cover must be closed eee gt STITCHER UP gt This action moves the stitch head to the correct position for lubrication 2 Open the folder cover See Open and Close the Folder Cover on page 29 3 Lift the clincher frame See Lift and Lower the Clincher Frame on page 30 4 Clean grease from the sides of the stitch head 5 Lower the clincher frame 6 Close the folder cover 88 Watkiss PowerSquare 224 User Manual 6 Maintenance Lubricate the Stitch Head Lubricate the Stitch Head When to do Materials needed A Initial Procedure FIGURE 47 Trim the nozzle of the tube of grease When the message OPERATOR MAINTENANCE is displayed on the screen When a new stitch wire is installed if this interval is shorter Kl ber Isoflex NBU15 Grease 50g Part nu

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