User / Service Manual Power Stacker
Manual
Power Stacker
10/06 Rev. 1.09 1
User / Service Manual Power Stacker
Contents
Contents...............................................................................................................................2
General.................................................................................................................................3
Copyright..........................................................................................................................................3
What is a "power stacker" ? .............................................................................................................3
Initiation................................................................................................................................4
Unpacking ........................................................................................................................................4
Assembling the Power Stacker ........................................................................................................5
Mounting the option to the TDI.........................................................................................................6
Assemble light cover........................................................................................................................7
Set up mode.........................................................................................................................8
Modes of operation - operation.............................................................................................9
Activating the sensor........................................................................................................................9
Adjusting the label width.................................................................................................................10
Adjusting the label length...............................................................................................................10
Magazine full..................................................................................................................................11
Information printout / parameter .........................................................................................12
Parameter Menu TDI......................................................................................................................12
Status printout ....................................................................................................................13
Status reports.....................................................................................................................14
ST04 Power stacker full .................................................................................................................14
Overview - Status reports...............................................................................................................15
Maintenance, cleaning and service....................................................................................19
Maintenance and cleaning.............................................................................................................19
Service............................................................................................................................................19
CPU board...............................................................................................................................19
Micro switch ............................................................................................................................ 20
Reflex Sensor.......................................................................................................................... 20
Stepper motor ......................................................................................................................... 21
Diagrams............................................................................................................................22
Cable drawings...............................................................................................................................23
Circuit diagram CPU board............................................................................................................27
Component diagram CPU board....................................................................................................28
Spare parts list....................................................................................................................29
Index...................................................................................................................................39
10/06 Rev. 1.09 2
User / Service Manual Power Stacker
General
Copyright
This Manual and its contents are subject to copyright. The publisher’s prior written consent
must be obtained for reproduction of the manual as a whole or part thereof.
Names are generally given without any reference to existing patents, registered patterns or
designs, or trademarks. The omission of a corresponding note does not imply that the names
can be used freely. All trademarks are acknowledged.
The manufacturer reserves the right to technical and other alterations without prior notice.
The publisher cannot warrant the accuracy of the content of this manual.
Note: Please follow the notes shown in this text - it will help to cover all situations and
keep your engine working.
If in the manual is used the name TDI - it is as well meant the
Xxtreme !
What is a "power stacker" ?
The power stacker is used as an option for the TDI. It is replacing the magazine witch is OK
for lower quantities – using higher quantities or smaller label, special short label request the
power stacker.
Similar to the TDI – the power stacker is equipped with a stepper motor driven platform to
store the label on. As more label are printed as lower is the position of the platform.
10/06 Rev. 1.09 3
Initiation
Unpacking
• remove packing parts - take care of documentation and parts
• remove option from packaging
• the option consists out of
User / Service Manual Power Stacker
- the power stacker
- the platform (disassembled)
- a cover to protect the sensor from light
- a magnetic label stopper
10/06 Rev. 1.09 4
User / Service Manual Power Stacker
Assembling the Power Stacker
The power stacker is disassembled in the box when you receive it . Before you can use it you
have to assemble the platform !
Move the platform – the plastic part in front has to show to the printer side – on the two axles
coming out of the cover of the power stacker. Move it against the front plate. The axles will
show around 1 mm out of the platform.
Then clip the lock washer to the two axles (as shown on the pictures). The power stacker is
now ready for use with the TDI.
Attention: Please check if the security cover is mounted to the guiding axle (see picture)
of the media guiding.
axles
10/06 Rev. 1.09 5
User / Service Manual Power Stacker
Mounting the option to the TDI
Attention: The power stacker can be mounted to the TDI mechanically from SN
01859xxxx.xxx on – but the TDI has to be equipped with the necessary wiring.
You can easily see if your TDI is equipped with the wires (there has to be a
diode connector on the rear side of the TDI).
Move the guiding axle into the guiding holes of the TDI (see picture) – as well move the front
plate part of the power stacker into the slot of the TDI ! Both units have to stay together
without any distance (see picture).
After you have mounted the power stacker to the TDI – the electrical connection has to be
done.
Attention: Never connect the power stacker to the TDI – if the TDI is powered on !
Always switch OFF POWER before you connect the power stacker – as
well wait after power off around 2 minutes before connecting.
If you do not – both units can be damaged !
10/06 Rev. 1.09 6
User / Service Manual Power Stacker
Move the diode connector into the plug on the rear side of the TDI !
Attention: If your TDI is not equipped with a connector like that – the unit can be
retrofitted easily. Please call your service technician, this work can not be
done by yourself.
diode connector
Assemble light cover
To protect the sensor (infra red) in the power stacker against normal light – a light cover is
delivered together with the power stacker.
If you recognise that light is influencing your power stacker, maybe the platform is moving up
and down without reason, you should mount the light cover ! We recommend to mount the
cover in every case.
Remove the film from the glue parts – remove the film from the complete cover and stick it to
the cover of the TDI (as shown on the picture)
light cover
10/06 Rev. 1.09 7
User / Service Manual Power Stacker
Set up mode
The power stacker is working separately – only the power is used from the TDI.
10/06 Rev. 1.09 8
User / Service Manual Power Stacker
Modes of operation - operation
Activating the sensor
Depending to the used label size (special the label length is important) the power stacker is
working in two different modes !
To understand that you should understand the principal – how the power stacker is working.
The unit is using reflex infra red sensor to check the height of the label stack – or if there is a
label !
Switching on the power stacker (via the TDI) with an empty platform and the platform is
down, the power stacker is moving up the platform until the first sensor is covered by the
platform -–the power stacker is ready for work. If now the second sensor is covered by
printed labels -the platform is moving down automatically.... the sensor is becoming free
again ... the next label is covering it ... and so on.
Depending to the label length a different stack mode is necessary. Short label need less
height to fall down properly then longer label. To compensate this different mode a second
pair of sensor is attached to the unit. The sensor pair can be selected with the attached
switch.
As a rule – label with less then 100 mm should use the upper sensor pair – longer label
should use the lower pair.
Attention: Switch in upper position means pair 1 – lower position pair 2 !
label
sensor 2
sensor 1
platform
sensor pair 1
sensor pair 2
10/06 Rev. 1.09 9
User / Service Manual Power Stacker
Adjusting the label width
To be sure that the stacker is working properly – the width of the expected label has to be
adjusted on the power stacker.
Attention: Never use the exact label width – adjust always 1 –2 mm more to the guiding.
The label should never be squeezed – but secure guided.
The media width is adjusted with a guiding witch is movable in both directions (see picture) it
can be moved on a axle to the different width of the label.
The moving parts of the guiding are used to adjust the guiding to the different sensor 8short
label – long label).
Adjusting the label length
As the label width – the label length has to be adjusted. The reason for is the speed of the
label after leaving the printer. The label is not falling down – it is moving with the same speed
the printer has used. So we have to stop the label in the right position to form a stack looking
properly.
Therefore the label stopper is used. Two different units are used with the poser stacker – one
for short label (not longer then the cover) one for longer label – sticks to the platform itself.
Both are delivered with the power stacker. Please take care that you do not squeeze the
label.
Stopper
10/06 Rev. 1.09 10
User / Service Manual Power Stacker
Magazine full
After the stack of label has reached the maximum – the platform is down in the lowest
position. This position is sensed via a micro switch (see picture) – the power stacker stops
and as well the printer is stopped witch a message on the display.
Removing a part of the stack (or the complete stack) the power stacker is moving up
automatically into the upper end position – the print job can be started again.
end switch
Attention: Start by accepting the message in the display again the print job.
10/06 Rev. 1.09 11
User / Service Manual Power Stacker
Information printout / parameter
Parameter Menu TDI
OFFLINE
INFO PRTP IFAC SYSP JCLR SCLR OTHR
STA0
STA1
STA2
STA3
DOT1
DOT2
PSPD
MTYP
MLEN
MWID
PUNO
BCHI
UPCA
XPOS
YPOS
SSPD
GAP
PORT
SPOL
BMOD
BAUD
PARI
DBIT
SBIT
HAND
PRID
EMUL
NACH
SENS
PUNS
FMOD
OMOD
SMOD
MMOD
LPOS
SECF
EXTR
CODE
HRES
CLCK
DOWN
LCLR
CCLR
ICLR
ADJS
MCHK
SCHK
PCHK
FACT
SERV
NULL
HADJ
ACSC
USMD
LREP
CSET
MEND
SCAN
SERR
Standard / standard
nur mit Image Card Software / with image card software only
nur mit Scanner / with scanner only
Nur mit Color Option / with color option only
Nur für Service / for service only
10/06 Rev. 1.09 12
User / Service Manual Power Stacker
Status printout
Are available – please use the media necessary for the printout !
10/06 Rev. 1.09 13
User / Service Manual Power Stacker
Status reports
Following status messages are the most important for the power stacker – all other are
shown below.
ST04 Power stacker full
Action: Remove label partly or complete
10/06 Rev. 1.09 14
Overview - Status reports
ST 00
ST 01
ST 02
ST 03
ST 04
ST 05
ST 06
ST 07
ST 08
ST 09
ST 10
ST 11
ST 12
ST 13
ST 14
NOVRAM error (factory set)
NOVRAM write error
no material in SNGL sensor
stacker full
material end
printhead overheated
ribbon end
gap not found
ramcard error
ramcard error
barcode reading error or media broken for rewinder
cut sensor not found, dispenser second feeder, nothing
User / Service Manual Power Stacker
ST 15
ST 16
ST 17
ST 18
ST 19
ST 20
ST 21
ST 22
ST 23
ST 24
ST 25
ST 26
ST 27
ST 28
ST 29
head sensor not found (system will be locked)
applicator home position not found
dispenser pressure roller not closed
dispenser backing paper rewinder full
applicator – touch down not found
EASY PLUG wrong command (imedeate)
EASY PLUG wrong command between #ER and #Q
EASY PLUG command without #ER
EASY PLUG not known command
receive error RS 232
spooler overflow
EASY PLUG wrong size or print adjustment
EASY PLUG counter overflow
EASY PLUG field outside print area
EASY PLUG logo number doesn’t exist
10/06 Rev. 1.09 15
User / Service Manual Power Stacker
ST 30
ST 31
ST 32
ST 33
ST 34
ST 35
ST 36
ST 37
ST 38
ST 39
ST 40
ST 41
ST 42
ST 43
ST 44
EASY PLUG logo buffer to small
EASY PLUG logo number error
EASY PLUG postbarcode not OK
EASY PLUG range command #PA to #IM wrong
COLOR PANEL color code not found
COLOR PANEL logo does not fit to the card
COLOR PANEL color card not found or programmable
EASY PLUG speedo error
receive error RS 232
receive error RS 232
ID matrix barcode error
ST 45
ST 46
ST 47
ST 48
ST 49
ST 50
ST 51
ST 52
ST 53
ST 54
ST 55
ST 56
ST 57
ST 58
ST 59
no read of scanner
scanner not programmable (system will be locked)
stacker full (standard)
acess denied for setting printer to zero
10/06 Rev. 1.09 16
ST 60
ST 61
ST 62
ST 63
ST 64
ST 65
ST 66
ST 67
ST 68
ST 69
ST 70
ST 71
ST 72
ST 73
ST 74
User / Service Manual Power Stacker
memory allocation error (system will be locked)
font allocation error (system will be locked)
update or numberfield overflow
wrong board installed for selected peripherie option
interrupt error (system stands)
TDI stepper does not respond
headstrobe checksum wrong (system will be locked)
speedo system error
speedo scaling wrong
ST 75
ST 76
ST 77
ST 78
ST 79
ST 80
ST 81
ST 82
ST 83
ST 84
ST 85
ST 86
ST 87
ST 88
ST 89
EASY CARD wrong name of file in #FO command
EASY CARD field number not found
EASY CARD syntax of #YT or #YB command wrong
EASY CARD number of data field to big
EASY CARD quantity of variable characters = 0
EASY CARD no card found
DATA BASE not enough space for index file
DATA BASE no possibility to build index file
DATA BASE no possibility to sort index file
DATA BASE barcode onformation nor found in
10/06 Rev. 1.09 17
K
A
–
p
p
p
p
p
p
p
p
p
p
p
ST 90
ST 91
ST 92
ST 93
ST 94
ST 95
ST 96
ST 97
ST 98
ST 99
database contains identical records
barcode not readable
EASY CARD undefined error
EASY PLUG undefined error
INTERFACE undefined error
SYSTEM undefined derror
just warning – self confirming
must be confirmed by the user
User / Service Manual Power Stacker
POFF
FAIL
SCAN
OPEN
LOC
DAT
STOP
SNGL
WAIT
HOST
INIT
DOWN
UP
.LDR
.EMU
.SYS
SORT
----
Power OFF
Image card could not be formatted
Scanner was unable to decode the information
cover open –switch is open
the printer is locked
data receive mode
rinter in STOP mode
rinter in single start mode
rinter in wait condition
rinter stopped by host
rinter is initialised
TDI table goes u
TDI table goes down
rinter in loader mode
rinter in emulation mode
rinter in system mode
data base information is sorted
rinter was switched on to early after power down
rinter is switched OFF
LOAD
barcodes loaded from card
10/06 Rev. 1.09 18
User / Service Manual Power Stacker
Maintenance, cleaning and service
Maintenance and cleaning
Clean as a standard printer – sometimes the sensor should be cleaned from paper dust.
Service
Service parts of the power stacker are – CPU board, micro switch, reflex sensor and maybe
the stepper motor.
CPU board
The used board in the power stacker is an intelligent board – holding a CPU with the
necessary program. The power stacker is working on it’s on.
Below you will find a picture of the CPU board showing the connector placing.
Connection TDI J1
Stepper motor
JP1
X3
Fuse F1
2 AT
Group switch
CN 7
Sensor 3 CN 2
Sensor 2
CN 1
Sensor 1
CN 3
Sensor 4
CN 4
Limit switch
(stacker full)
CN 6
10/06 Rev. 1.09 19
User / Service Manual Power Stacker
The sensor pairs placed in the front plate are numbered as following
sensor 1
sensor 2
sensor 3
sensor 4
Micro switch
The micro switch (lower end position) can be removed after the cover of the power stacker is
removed and the wire is removed from the CPU board.
Reflex Sensor
The sensor pairs are glued into the front plate ( with Loctite ....) and a special part. If one of
the sensor is defect it has to be removed carefully, the hole has the be cleaned and the new
sensor glued in.
Attention: The sensor has to stay 1 mm behind the front plate.
10/06 Rev. 1.09 20
sensor 1mm
behind the plate
User / Service Manual Power Stacker
octite 648
do
Stepper motor
The stepper motor – if mounted to the power stacker – is an assembly and can not be
removed separately (motor and threading axle).
Assembly is like described in the TDI manual (platform).
• remove rear cover
• remove board and carrier
• disassemble platform mechanic
• open lower plate
• remove nut from thread axle
• remove platform block
• open motor screw (2) and remove
motor together with axle
• clean new motor and axle with
Aceton
• glue motor and axle together with
Loctite 648 – and assemble immediate
• position hexagonal nut around 20 mm
from the end of the axle
• move mechanic in vertical position and
press the threading axle down
• the glue is ready after 30 minutes – but
the mechanic can be assembled immediate
glue with
L
min. 20 mm
press
wn
10/06 Rev. 1.09 21
Diagrams
User / Service Manual Power Stacker
10/06 Rev. 1.09 22
Cable drawings
User / Service Manual Power Stacker
10/06 Rev. 1.09 23
User / Service Manual Power Stacker
10/06 Rev. 1.09 24
User / Service Manual Power Stacker
10/06 Rev. 1.09 25
User / Service Manual Power Stacker
10/06 Rev. 1.09 26
Circuit diagram CPU board
VCC
Q8
R13
CN1
CN2
CN3
CN4
CN5
CN6
CN7
3R3
100R
R27
1
2
3
4
100R
R30
1
2
3
4
100R
R29
1
2
3
4
100R
R28
1
2
3
4
1
2
1
2
1
2
3R3
3R3
3R3
R14
R15
R16
R25
R26
R4
2K
R5
2K
R38
15K
680R
R31
680R
R32
680R
R33
680R
R34
680R
R35
680R
R36
680R
R37
680R
R21
1K5
R17
1K5
R22
1K5
R18
1K5
R23
1K5
R19
1K5
1K5
R24
R20
BD676
Q1
BC557
Q5
BD676
Q2
BC557
Q6
BD676
2K
Q3
BC557
Q7
BD676
2K
Q4
BC557
VCC
VCC
VCC
VCC
R39
R40
R41
R42
6K8
6K8
VCC
6K8
6K8
C3 1u
C1 22p
C2 22p
VCCVCC
D1
1N4148
20MHz
R43
4K7
User / Service Manual Power Stacker
R2
33K
330R
R1
X1
IC1
1
MCLR
2
RA0
3
RA1
4
RA2
5
RA3
6
RA4
7
RA5
8
VSS
9
OSC1
10
OSC2
11
RC0
12
RC1
13
RC2
14
RC3
PIC16C62B/72A
RB7
RB6
RB5
RB4
RB3
RB2
RB1
RB0
VDD
VSS
RC7
RC6
RC5
RC4
28
27
26
25
24
23
22
21
20
VCC
19
18
17
16
15
R3
390R
IC4
1
Vin
Feedback
5
F1
ON/OF
2AT
3
GND
Output
LM2576T5.0
4
2
D7
BYW29-200
L1
IC3A CD4066B
IN1OUT
C
13
IC3B CD4066B
IN4OUT
C
5
C9
1,2uF
C4
220u/25V
9
10
C8
R12
0R51
MA1
VBB2
MB1
MA2
MB2
E2
1K
R9
R10
C5
10u
15
12
8
11
D5
1R0/0.5W
D3
BYV27
BYV27D6BYV27
D4
BYV27
JP1
1
2
3
4
CON4
IC5
2
3
VCC
15K
19
Phase1
20
VR1
4
Phase2
3
VR2
RC
GND5GND
1
6
R6
C6
680p
3n3
22
VCC
18
C7
16
VMM1
PBL3772
GND17GND
C1
21
R7
1K
7
14
VBB1
VMM2
C2
E1
2
13
R8
680p
1R0/0.5W
R11 0R51
VCC
VCC
IC3C
CD4066B
IN8OUT
C
6
9
IC3D
CD4066B
IN11OUT
12
VCC
CB1
100nF
VCC
CB2
100nF
10
C
J1
1
2
3
4
5
6
7
8
D2
BAT49
Title
A4
Date: 19-Oct-2000 Sheet of
File: Drawn By:
TDI-Stapler 99297-02-0
Number RevisionSize
1/1
Aschenneller Fr.
Z99297-02-0SE.cdr
10/06 Rev. 1.09 27
Component diagram CPU board
User / Service Manual Power Stacker
10/06 Rev. 1.09 28
User / Service Manual Power Stacker
Spare parts list
Part Number : 99300-xx-0
C0066 (Jumbo Stacker)
C0826 (Power Stacker TDI 1050)
Bezeichnung : Power Stacker komplett
Identification : power stacker
10/06 Rev. 1.09 29
User / Service Manual Power Stacker
Part Number : 99678-xx-0
Bezeichnung : ZSB Abdeckung
Identification : cover assy.
Part Number : 99296-xx-0
Bezeichnung : Anschlag
Identification : stopper
Part Number : 99723-xx-0
C0829 (TDI 1050)
Bezeichnung : ZSB Plattform
Identification : platform assy.
Part Number : 99722-xx-0
C0831 (TDI 1050)
Bezeichnung : Abstreifer 2
Identification : seperator 2
10/06 Rev. 1.09 30
User / Service Manual Power Stacker
Part Number : 99299-xx-0
C0070 (Jumbo Stacker)
Bezeichnung : Rückhaube
Identification : rear cover
10/06 Rev. 1.09 31
Part Number : 98211-xx-0
Bezeichnung : Reflex Sensor
Identification : reflex sensor
User / Service Manual Power Stacker
Part Number :99291 -xx-0
Bezeichnung : Achse
Identification : axle
Part Number : 99302-xx-0
C0081 (Jumbo Stacker)
Bezeichnung : ZSB Boden- und
Frontplatte
Identification : front- and
bottemplate assy.
Part Number : 99303-xx-0
Bezeichnung : Anschluß
Identification : connecting part
Part Number : A2128
Bezeichnung : Rundkabel
Identification : Round cable
Part Number : 92395-00-3
Bezeichnung : Gehäusefuß
Identification : rubber feet
10/06 Rev. 1.09 32
User / Service Manual Power Stacker
Part Number : 99295
Designation: Steel plate
Part Number : 99297
Designation : CPU board
Part Number : A2273
Designation : Round cable
(Adapter cable for connecting the new
board to an old Power Stacker)
Part Number : A2299
Designation : Upgrade-Kit Power Stacker
(A2299 = A2273 + 99297)
10/06 Rev. 1.09 33
User / Service Manual Power Stacker
Part Number :98280
C0072 (Jumbo Stacker)
Bezeichnung : Säule TDI
Identification : Column TDI
Part Number :99176
C0073 (Jumbo Stacker)
Bezeichnung : Säule 2
Identification : Column 2
10/06 Rev. 1.09 34
gear
Part Number : 98296-xx-0
Bezeichnung : Platte oben
Identification : upper plate
Part Number : 98280-xx-0
Bezeichnung : Säule
Identification : guding axle
User / Service Manual Power Stacker
Part Number : M 3 x 3,5
Bezeichnung : Innensechskant Schraube
Identification : hexagonal screw
Part Number : A1701-xx
Bezeichnung : Motor mit Spindel für PowerStacker ZSB
Identification : Motor with spindle for power
stacker ass.
Part Number : 98279-xx-0
Bezeichnung : Mutter
Identification : nut
Part Number : 98725-xx-0
Bezeichnung : Kugellager
Identification :
Part Number : 98954-xx-0
Bezeichnung : Platte unten
Identification : lower plate
Part Number : 94763-00-3
Bezeichnung : Microschalter
Identification : micro switch
Part Number : 98293-xx-0
Bezeichnung : Schalterblech
Identification : switch mounting
part
10/06 Rev. 1.09 35
User / Service Manual Power Stacker
Part Number : 99293-xx-0
C0827 (Power Stacker TDI 1050)
Bezeichnung : Achse 2
Identification : axle 2
Part Number : 98247-xx-0
Bezeichnung : ZSB Nabe
Identification : hub assy.
Part Number : 98579-xx-0
Bezeichnung : Schnellbefestiger
Identification : security part
Part Number : 98240-xx-0
Bezeichnung : Gehäuse
Identification : cover
10/06 Rev. 1.09 36
User / Service Manual Power Stacker
Part Number : 99307-xx-0
Bezeichnung : Führung
Identification : guiding
Part Number : 99388-xx-0
Bezeichnung : ZSB Distanzblech
Identification : distanz part assy.
Part Number : 99292-xx-0
Bezeichnung : ZSB Nabe
Identification : lever assy.
Part Number : 98846-xx-0
Bezeichnung : Griff
Identification : handle
Part Number : 99294-xx-0
Bezeichnung : Schalter mit Kabel
Identification : switch with wire
10/06 Rev. 1.09 37
User / Service Manual Power Stacker
Part Number : 98361-xx-0
C0484 (Power Stacker TDI 1050)
Bezeichnung : ZSB Schlitten
Identification : moving part assy.
10/06 Rev. 1.09 38
User / Service Manual Power Stacker
Index
A
Activate sensor...................................... 9
Adjust label length...............................10
Assemble light cover .............................7
C
Cable drawings....................................23
Copyright...............................................3
CPU board.....................................19, 20
Circuit diagram............................27
Component diagram.................... 28
I
Index....................................................39
M
Magazine full ....................................... 11
Maintenance and cleaning................... 19
Micro switch.........................................20
Mount the option to the TDI ...................6
P
Parameter menu TDI ...........................12
Power Stackdr, Assemble the................5
Power stacker full.................................14
R
Reflex sensor.......................................20
S
Service.................................................19
Spare Parts Listd .................................29
ST 04 ...................................................14
Status printout......................................13
Status reports.......................................14
Stepper motor......................................21
U
Unpacking..............................................4
10/06 Rev. 1.09 39
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