User / Service Manual Power Stacker Manual Power Stacker 10/06 Rev. 1.
User / Service Manual Power Stacker Contents Contents ............................................................................................................................... 2 General................................................................................................................................. 3 Copyright ..........................................................................................................................................3 What is a "power stacker" ? ..........
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.
User / Service Manual Power Stacker Initiation Unpacking • remove packing parts - take care of documentation and parts • remove option from packaging • the option consists out of - 10/06 the power stacker the platform (disassembled) a cover to protect the sensor from light a magnetic label stopper Rev. 1.
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).
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).
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.
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.
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.
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.
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.
User / Service Manual Power Stacker Information printout / parameter Parameter Menu TDI OFFLINE INFO PRTP IFAC SYSP JCLR SCLR OTHR STA0 PSPD PORT EMUL DOWN STA1 MTYP SPOL NACH LCLR STA2 MLEN BMOD SENS CCLR STA3 MWID BAUD PUNS ICLR DOT1 PUNO PARI FMOD ADJS DOT2 BCHI DBIT OMOD MCHK UPCA SBIT SMOD SCHK XPOS HAND MMOD PCHK YPOS PRID LPOS FACT SSPD SECF SERV GAP EXTR NULL CODE HADJ HRES ACSC CLCK USMD LREP CSET MEND SCAN SERR Standard / standard nur m
User / Service Manual Power Stacker Status printout Are available – please use the media necessary for the printout ! 10/06 Rev. 1.
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: 10/06 Remove label partly or complete Rev. 1.
User / Service Manual Power Stacker Overview - Status reports ST 00 ST 15 head sensor not found (system will be locked) ST 01 NOVRAM error (factory set) ST 16 applicator home position not found ST 02 NOVRAM write error ST 17 dispenser pressure roller not closed ST 03 no material in SNGL sensor ST 18 dispenser backing paper rewinder full ST 04 stacker full ST 19 applicator – touch down not found ST 05 material end ST 20 EASY PLUG wrong command (imedeate) ST 06 printhead overheated S
User / Service Manual Power Stacker ST 30 EASY PLUG logo buffer to small ST 45 ST 31 EASY PLUG logo number error ST 46 ST 32 EASY PLUG postbarcode not OK ST 47 ST 33 EASY PLUG range command #PA to #IM wrong ST 48 ST 34 COLOR PANEL color code not found ST 49 ST 35 COLOR PANEL logo does not fit to the card ST 50 no read of scanner ST 36 COLOR PANEL color card not found or programmable ST 51 scanner not programmable (system will be locked) ST 37 ST 52 stacker full (standard) ST 38 ST
User / Service Manual Power Stacker ST 60 memory allocation error (system will be locked) ST 75 ST 61 font allocation error (system will be locked) ST 76 ST 62 update or numberfield overflow ST 77 ST 63 ST 78 ST 64 ST 79 ST 65 ST 80 EASY CARD wrong name of file in #FO command ST 66 ST 81 EASY CARD field number not found ST 67 ST 82 EASY CARD syntax of #YT or #YB command wrong ST 68 wrong board installed for selected peripherie option ST 83 EASY CARD number of data field to big ST 6
User / Service Manual Power Stacker ST 90 database contains identical records ST 91 barcode not readable POFF Power OFF – printer is switched OFF FAIL Image card could not be formatted SCAN Scanner was unable to decode the information OPEN cover open – switch is open LOCK the printer is locked DATA data receive mode STOP printer in STOP mode SNGL printer in single start mode WAIT printer in wait condition HOST printer stopped by host ST 92 ST 93 ST 94 ST 95 ST 96 EASY CARD undef
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.
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.
User / Service Manual Power Stacker 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 glue with Loctite 648 • open lower plate • remove nut from thread axle • remove platform block • open motor screw (2) and remove motor together with axle min.
User / Service Manual Power Stacker Diagrams 10/06 Rev. 1.
User / Service Manual Power Stacker Cable drawings 10/06 Rev. 1.
User / Service Manual Power Stacker 10/06 Rev. 1.
User / Service Manual Power Stacker 10/06 Rev. 1.
User / Service Manual Power Stacker 10/06 Rev. 1.
User / Service Manual Power Stacker Circuit diagram CPU board VCC 0R51 Q7 1K5 R24 R37 680R 1K5 R20 CN5 1 2 C9 1,2uF R11 VMM1 VBB1 VMM2 VBB2 1 2 3 4 12 MB1 8 MA2 R7 1K C7 680p C6 3n3 JP1 15 MA1 PBL3772 CON4 11 MB2 D5 D6 BYV27 RC GND GND GND GND C1 E1 C2 E2 3 16 14 7 9 22 VCC C 13 IN OUT C Q4 1K R9 C8 680p VCC IC4 1 F1 5 3 1 2 4 R3 390R VCC CN6 4 Phase2 3 VR2 VCC IC3B CD4066B VCC Phase1 VR1 BYV27 R2 33K D1 1N4148 R43 4K7 19 20 VCC Vin Feedback 4 GND IC3C
User / Service Manual Power Stacker Component diagram CPU board 10/06 Rev. 1.
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.
User / Service Manual Power Stacker Part Number : 99723-xx-0 C0829 (TDI 1050) Bezeichnung : ZSB Plattform Identification : platform assy. Part Number : 99678-xx-0 Bezeichnung : ZSB Abdeckung Identification : cover assy. Part Number : 99296-xx-0 Bezeichnung : Anschlag Identification : stopper Part Number : 99722-xx-0 C0831 (TDI 1050) Bezeichnung : Abstreifer 2 Identification : seperator 2 10/06 Rev. 1.
User / Service Manual Power Stacker Part Number : 99299-xx-0 C0070 (Jumbo Stacker) Bezeichnung : Rückhaube Identification : rear cover 10/06 Rev. 1.
User / Service Manual Power Stacker Part Number : 98211-xx-0 Bezeichnung : Reflex Sensor Identification : reflex sensor Part Number : 99303-xx-0 Bezeichnung : Anschluß Identification : connecting part Part Number :99291 -xx-0 Bezeichnung : Achse Identification : axle Part Number : A2128 Bezeichnung : Rundkabel Identification : Round cable Part Number : 99302-xx-0 C0081 (Jumbo Stacker) Bezeichnung : ZSB Boden- und Frontplatte Identification : front- and bottemplate assy.
User / Service Manual Power Stacker Part Number : 99295 Designation: Steel plate Part Number : 99297 Designation : CPU board Part Number : A2299 Designation : Upgrade-Kit Power Stacker (A2299 = A2273 + 99297) Part Number : A2273 Designation : Round cable (Adapter cable for connecting the new board to an old Power Stacker) 10/06 Rev. 1.
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.
User / Service Manual Power Stacker Part Number : 98296-xx-0 Bezeichnung : Platte oben Identification : upper plate Part Number : M 3 x 3,5 Bezeichnung : Innensechskant Schraube Identification : hexagonal screw Part Number : 98280-xx-0 Bezeichnung : Säule Identification : guding axle Part Number : A1701-xx Bezeichnung : Motor mit Spindel für PowerStacker ZSB Identification : Motor with spindle for power stacker ass.
User / Service Manual Power Stacker Part Number : 99293-xx-0 C0827 (Power Stacker TDI 1050) Bezeichnung : Achse 2 Identification : axle 2 Part Number : 98579-xx-0 Bezeichnung : Schnellbefestiger Identification : security part Part Number : 98240-xx-0 Bezeichnung : Gehäuse Identification : cover Part Number : 98247-xx-0 Bezeichnung : ZSB Nabe Identification : hub assy. 10/06 Rev. 1.
User / Service Manual Power Stacker Part Number : 99292-xx-0 Bezeichnung : ZSB Nabe Identification : lever assy. Part Number : 99307-xx-0 Bezeichnung : Führung Identification : guiding Part Number : 98846-xx-0 Bezeichnung : Griff Identification : handle Part Number : 99388-xx-0 Bezeichnung : ZSB Distanzblech Identification : distanz part assy. Part Number : 99294-xx-0 Bezeichnung : Schalter mit Kabel Identification : switch with wire 10/06 Rev. 1.
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.
User / Service Manual Power Stacker Index Mount the option to the TDI ...................6 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................
