50x stacker operations manual

QUIPP Series SJ50X Newspaper Stackers

Operations and Maintenance Manual

QUIPP SYSTEMS, INC.

4800 NW 157 St.

Miami, FL 33014-6434 USA

QPN: 3421-39789-

Web Site: www.quipp.com

email: [email protected]

Telephone: (305) 623-8700

Fax: (305)623-0980

QUIPP Series SJ50X Newspaper Stackers

Operations and Maintenance Manual

QPN:3421-39789-1

Effective Date:January 23, 2005

QUIPP SYSTEMS, INC.

4800 NW 157 St.Miami, FL 33014-6434 USA

Copyright 2002 QUIPP SYSTEMS INC.

Telephone (305)623-8700 - - FAX (305)623-0980Web Site: www.quipp.com email: [email protected]

QPN 3421-39789- QUIPP SYSTEMS INC. MasterTOC Page 1 of 6

Table of Contents

Warranty

Warranty; Materials & Workmanship ...................................................................................Warranty.1Defects and Workmanship ...................................................................................................... Warranty.1

Liability .................................................................................................................................... Warranty.1

Warranty Application ............................................................................................................... Warranty.1

Warranty Limits ....................................................................................................................... Warranty.1

OEM Warranties -- .................................................................................................................. Warranty.1

Faulty Maintenance Exception ................................................................................................ Warranty.2

No Other Warranties ............................................................................................................... Warranty.2

Chapter 1 Introduction and Installation

1.1 General.................................................................................................................................. 1.11.1.1. The Lockout/Security System ................................................................................................1.1

1.2 Basic QUIPP 50X Series Stacker Description....................................................................... 1.11.2.1. Stacker Design.......................................................................................................................1.2

1.2.2. The Main Components...........................................................................................................1.2

1.3 Special Information................................................................................................................ 1.31.3.1. Danger ...................................................................................................................................1.3

1.3.2. Warning..................................................................................................................................1.3

1.3.3. Caution...................................................................................................................................1.3

1.3.4. Note........................................................................................................................................1.3

1.4 Safety Considerations ........................................................................................................... 1.31.4.1. Personal Safety......................................................................................................................1.4

1.4.2. Housekeeping ........................................................................................................................1.4

1.4.3. Operation and Maintenance...................................................................................................1.4

1.5 Specifications ........................................................................................................................ 1.51.5.1. Mechanical .............................................................................................................................1.5

1.5.2. Utilities....................................................................................................................................1.5

1.5.3. Capacities and Capabilities....................................................................................................1.5

1.5.4. Controls..................................................................................................................................1.6

1.5.5. Ethernet Capability (If Installed) .............................................................................................1.7

1.6 Stacker Performance Chart - - - - PRESS and NO PRESS .................................................. 1.7

1.7 Pre-Installation Considerations .......................................................................................... 1.10

1.8 Unpacking ........................................................................................................................... 1.101.8.1. Lifting Stacker from the Skid ................................................................................................1.10

1.8.2. Reporting Shipping Related Damages.................................................................................1.10

1.9 Mechanical Installation ........................................................................................................ 1.111.9.1. Stacker Placement ...............................................................................................................1.11

1.9.2. Ongoing Conveyor ...............................................................................................................1.11

1.10 Utilities and Control Signals ................................................................................................ 1.111.10.1. The Product Stream Encoder...............................................................................................1.11

1.10.2. Power Supply .......................................................................................................................1.11

1.10.3. Auxiliary Signals...................................................................................................................1.12

1.10.4. Air Supply.............................................................................................................................1.12

Table of Contents Series 50X Stacker

MasterTOC Page 2 of 6 QUIPP SYSTEMS INC. QPN 3421-39789-

1.11 Final Pre-Setup Checks ...................................................................................................... 1.141.11.1. Mechanical Inspection ......................................................................................................... 1.14

1.11.2. Touch Screen and Pushbuttons .......................................................................................... 1.14

1.11.3. Electrical/Electronic Inspection............................................................................................ 1.14

1.11.4. General Inspection .............................................................................................................. 1.15

Chapter 2 Controls, Set-Up, and Stacker Start-Up

2.1 General.................................................................................................................................. 2.1

2.2 Stacker Power Switch ........................................................................................................... 2.1

2.3 Operator Controls - Pushbuttons........................................................................................... 2.12.3.1. START/CLEAR (Green) ........................................................................................................ 2.2

2.3.2. BYPASS (White when gate is open - down).......................................................................... 2.3

2.3.3. STOP (Red with yellow outline) ............................................................................................. 2.3

2.3.4. LEFT, ALTERNATE and RIGHT (Orange) ............................................................................ 2.3

2.4 The Touch Screen/Display .................................................................................................... 2.3

2.5 Using the Touch Screen........................................................................................................ 2.42.5.1. The Lock-out Code ................................................................................................................ 2.4

2.6 General Set-Up ..................................................................................................................... 2.5

2.7 Mechanical Adjustments ....................................................................................................... 2.62.7.1. Cut Edge Guide ..................................................................................................................... 2.6

2.7.2. Batch Side Guides................................................................................................................. 2.7

2.7.3. Turntable Walls...................................................................................................................... 2.7

2.7.4. Turntable Eject Pushers ........................................................................................................ 2.8

2.8 Pneumatic Settings ............................................................................................................... 2.9

2.9 Control Clock & Screen Saver............................................................................................... 2.9

2.10 To Set-up for Production ..................................................................................................... 2.10

2.11 New Bundle Data Entry ....................................................................................................... 2.10

2.12 Speed-Set Recording.......................................................................................................... 2.142.12.1. Using Recorded PROFILE Data.......................................................................................... 2.14

2.13 User Help Information ......................................................................................................... 2.152.13.1. MAIN Page Help Examples ................................................................................................. 2.15

2.14 Set-up and Event MESSAGES ........................................................................................... 2.162.14.1. The MESSAGES ................................................................................................................. 2.16

Chapter 3 50XC Series Stacker Pressor Adjustments

3.1 General.................................................................................................................................. 3.1


3.3 Using the Touch Screen........................................................................................................ 3.23.3.1. The Lock-out Code ................................................................................................................ 3.2

3.4 General Set-Up ..................................................................................................................... 3.3

3.5 Mechanical Adjustments ....................................................................................................... 3.33.5.1. Cut Edge Guide ..................................................................................................................... 3.4

3.5.2. Batch Side Guides................................................................................................................. 3.5

3.5.3. Turntable Walls...................................................................................................................... 3.5

Series 50X Stacker Table of Contents


3.5.4. Turntable Eject Pushers.........................................................................................................3.6



3.8 To Set-up for Production ....................................................................................................... 3.8

3.9 New Bundle Data Entry ......................................................................................................... 3.8

3.10 Set-up and Event MESSAGES ........................................................................................... 3.133.10.1. The MESSAGES..................................................................................................................3.13

Chapter 4 Start-Up and Preventive Maintenance

4.1 Introduction............................................................................................................................ 4.1

4.2 Fine Tuning the Stacker During Production .......................................................................... 4.14.2.1. User Help Information ............................................................................................................4.1

4.2.2. The Parameter Page..............................................................................................................4.2

4.2.3. Stacking from an Inserter .......................................................................................................4.4

4.3 General Maintenance ............................................................................................................ 4.6

4.4 Scheduled and Preventive Maintenance............................................................................... 4.64.4.1. Initial Inspection .....................................................................................................................4.6

4.4.2. Daily Attention ........................................................................................................................4.6

4.4.3. Monthly and Extended Attention ............................................................................................4.7

4.4.4. Lubrication - as needed..........................................................................................................4.7

Chapter 5 Troubleshooting

5.1 General.................................................................................................................................. 5.15.1.1. How to set up SIMULATION ..................................................................................................5.1

5.2 MESSAGES .......................................................................................................................... 5.2

5.3 Recorded Messages, Possible Causes, Recommend Corrections...................................... 5.5

5.4 Status Page........................................................................................................................... 5.65.4.1. Status Page Help ...................................................................................................................5.7

5.4.2. Status Page Help Examples ..................................................................................................5.7

5.5 Indicating LIGHTS and LED's................................................................................................ 5.85.5.1. Proximity Switch Indicators ....................................................................................................5.8

5.5.2. Power Supply Indicators ........................................................................................................5.8

5.5.3. CPU in the Card Cage Indicators...........................................................................................5.9

5.5.4. Main Relay Indicators.............................................................................................................5.9

5.5.5. Infeed Motor AC Drive...........................................................................................................5.9

5.5.6. Proximity Switches Troubleshooting Procedures...................................................................5.9

5.6 A Normal Start-up Test........................................................................................................ 5.125.6.1. Initial Start-up Sequence......................................................................................................5.12

5.6.2. Operator Inputs and Checks ................................................................................................5.12

5.6.3. Sequence Completion..........................................................................................................5.13

5.7 The IO Update Page ........................................................................................................... 5.14



Chapter 6 Detailed Maintenance

6.1 Detailed Maintenance............................................................................................................ 6.1

6.2 Infeed Section ....................................................................................................................... 6.26.2.1. Product Carrier Belt Replacement ......................................................................................... 6.2

6.2.2. Infeed Drive Belt Replacement .............................................................................................. 6.4

6.2.3. Infeed Drive Motor Service .................................................................................................... 6.5

6.2.4. Infeed Speed-Distance Sensor.............................................................................................. 6.5

6.2.5. The Product Sensors............................................................................................................. 6.6

6.2.6. Top-of-Batch Sensor Assembly............................................................................................. 6.7

6.3 Stacking Section.................................................................................................................... 6.86.3.1. Stacking Section Prox Sensors ........................................................................................... 6.10

6.3.2. Stacking Section Chain Tension.......................................................................................... 6.12

6.3.3. Stacking Section Stepper Motors ........................................................................................ 6.12

6.4 Pneumatic Elements ........................................................................................................... 6.12

6.5 The Turntable/Pusher Assembly ......................................................................................... 6.126.5.1. Turntable Rotation Functions .............................................................................................. 6.13

6.5.2. Turntable Lift and Press Action ........................................................................................... 6.14

6.5.3. Turntable Wall/Pusher Action .............................................................................................. 6.15

6.5.4. Servicing the Turntable Assembly ....................................................................................... 6.15

6.5.5. Servicing Walls/Pusher Assembly ....................................................................................... 6.16

6.6 The Control.......................................................................................................................... 6.186.6.1. The Touch Screen ............................................................................................................... 6.18

6.6.2. To Check Screen Touch Accuracy ...................................................................................... 6.18

6.6.3. Screen Characteristics Adjust ............................................................................................. 6.19

6.6.4. Electrical/Electronic Enclosure ............................................................................................ 6.19

6.6.5. Discussion of Specific Components .................................................................................... 6.21

6.7 Electrical Service................................................................................................................. 6.236.7.1. Main Supply Power.............................................................................................................. 6.23

6.7.2. +12, -12, +5VDC Checks..................................................................................................... 6.24

6.7.3. 24VDC Check...................................................................................................................... 6.24

6.7.4. Stepper Drive Output ........................................................................................................... 6.24

6.7.5. The Memory Backup Battery ............................................................................................... 6.25

6.8 Factory Default Settings Review ......................................................................................... 6.256.8.1. BUNDLE Screen Default Settings ....................................................................................... 6.25

6.8.2. PARAMETER Default Settings............................................................................................ 6.26

6.9 Options and Configurations................................................................................................. 6.26

Series 50X Stacker Table of Contents


Chapter 7 Diagrams, Schematics, and Parts List

7.1 Diagrams and Schematics .................................................................................................... 7.1

7.2 Parts Drawings and Lists....................................................................................................... 7.1

7.3 Parts, Drawings, and Parts Lists ........................................................................................... 7.67.3.1. Main Assembly.......................................................................................................................7.6

7.3.2. Basic Infeed Assembly.........................................................................................................7.10

7.3.3. Stacking Section ..................................................................................................................7.20

7.3.4. Turntable Assembly .............................................................................................................7.22

7.3.5. Turntable Bottom Assembly .................................................................................................7.25

7.3.6. Turntable Bottom Motors......................................................................................................7.27

7.3.7. Electrical Enclosure Assembly .............................................................................................7.29

7.3.8. Powered Outfeed w/o Idler Rollers ......................................................................................7.31

7.3.9. Pneumatic Assembly............................................................................................................7.33



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QPN 3421-39789- QUIPP SYSTEMS INC. Warranty 1

Warranty

Warranty; Materials & Workmanship

In the following, the referenced Seller is:

QUIPP SYSTEMS INC.

the referenced Buyer is:

Purchaser/end user of the equipment.

Defects and Workmanship

Seller warrants parts, assemblies and pieces of equipment of its own manufacture to be free from

defects in material and workmanship and normal and proper use for a period of twelve (12) months

from the date of shipment.

Liability

Seller's sole liability is, at its option, to repair or replace defective parts, assemblies or pieces of

equipment, FOB factory, in accordance with the terms of this warranty within the stated warranty

period provided that inspection by Seller satisfactorily discloses that:

1. the reported defect is disclosed within the previously stated warranty period;

2. the defective part, assembly or piece of equipment has not been altered or repaired other

than according to procedures described in Seller-furnished maintenance instructions or

manuals;

3. the defective part, assembly or piece of equipment has not been tampered with,

4. the defective part, assembly, or piece of equipment has not been damaged due to misuse,

abuse, negligence, accident or improper maintenance.

Warranty Application

The warranty applies to all Seller-manufactured equipment unless covered by a separate

warranty.

Warranty Limits

Seller liability is limited to the repair, replacement or modification of defective parts, assemblies

or pieces of equipment as outlined above and Seller will not be responsible for any other

expenses, injury, loss or damage, whether direct or consequential, including but not restricted to

loss of profits, production, increased cost of operation or spoilage of material arising in

connection with the sale or use of or the inability to use parts, assemblies or pieces of equipment

supplied under this contract.

OEM Warranties --

QUIPP-installed Components

50X Series Stacker Warranty

Warranty 2 QUIPP SYSTEMS INC. QPN 3421-39789-

This warranty shall not apply to parts, assemblies or pieces of equipment purchased by Seller

which were not manufactured pursuant to Seller's detailed design except that Seller warrants

that installation of such in the equipment furnished herein shall conform to the installation

instructions of the manufacturer. The workmanship involved in the incorporation thereof in the

equipment shall be free from defects. However, Seller shall use its best efforts to obtain from the

manufacturers of such parts assemblies or pieces of equipment, reasonable and adequate

warranties enforceable by Buyer. When requested by Buyer, Seller will furnish copies of the

warranties obtained from such manufacturers.

USER-installed Components

This warranty shall not apply to any parts, assemblies or pieces of equipment which have been

installed, altered or replaced by other than Seller, except as provided in Seller-furnished

maintenance instructions or manuals, nor which have been subject to misuse, neglect or

accident, incorrect wiring by others or improper installation, maintenance or use not in

accordance with instructions furnished by Seller.

Faulty Maintenance Exception

If failure of a part, assembly or piece of equipment is determined by Seller to be caused either

directly or consequently by negligent, inefficient or non-existent maintenance program on the

part of Buyer, then this warranty shall be null and void and shall relieve Seller of all responsibility

and liability relating thererto.

No Other Warranties

No other warranties, statutory, expressed or implied (except as to title), other than those expressly

set forth herein, shall apply to parts, assemblies or pieces of equipment sold by the terms of this

contract and no waiver, alteration or modification of the foregoing warranties shall be valid unless

made in writing and signed by an officer of seller.

QPN 3421-39789- QUIPP SYSTEMS INC. TOC Page 1 of 2

Table of Contents


1.1 General.................................................................................................................................. 1.11.1.1. The Lockout/Security System ................................................................................................1.1

1.2 Basic QUIPP 50X Series Stacker Description....................................................................... 1.11.2.1. Stacker Design.......................................................................................................................1.2

1.2.2. The Main Components...........................................................................................................1.2

1.3 Special Information................................................................................................................ 1.31.3.1. Danger ...................................................................................................................................1.3

1.3.2. Warning..................................................................................................................................1.3

1.3.3. Caution...................................................................................................................................1.3

1.3.4. Note........................................................................................................................................1.3

1.4 Safety Considerations ........................................................................................................... 1.31.4.1. Personal Safety......................................................................................................................1.4

1.4.2. Housekeeping ........................................................................................................................1.4

1.4.3. Operation and Maintenance...................................................................................................1.4

1.5 Specifications ........................................................................................................................ 1.51.5.1. Mechanical .............................................................................................................................1.5

1.5.2. Utilities....................................................................................................................................1.5

1.5.3. Capacities and Capabilities....................................................................................................1.5

1.5.4. Controls..................................................................................................................................1.6

1.5.5. Ethernet Capability (If Installed) .............................................................................................1.7

1.6 Stacker Performance Chart - - - - PRESS and NO PRESS .................................................. 1.7

1.7 Pre-Installation Considerations .......................................................................................... 1.10

1.8 Unpacking ........................................................................................................................... 1.101.8.1. Lifting Stacker from the Skid ................................................................................................1.10

1.8.2. Reporting Shipping Related Damages.................................................................................1.10

1.9 Mechanical Installation ........................................................................................................ 1.111.9.1. Stacker Placement ...............................................................................................................1.11

1.9.2. Ongoing Conveyor ...............................................................................................................1.11

1.10 Utilities and Control Signals ................................................................................................ 1.111.10.1. The Product Stream Encoder...............................................................................................1.11

1.10.2. Power Supply .......................................................................................................................1.11

1.10.3. Auxiliary Signals...................................................................................................................1.12

1.10.4. Air Supply.............................................................................................................................1.12

1.11 Final Pre-Setup Checks ...................................................................................................... 1.141.11.1. Mechanical Inspection..........................................................................................................1.14

1.11.2. Touch Screen and Pushbuttons...........................................................................................1.14

1.11.3. Electrical/Electronic Inspection ............................................................................................1.14

1.11.4. General Inspection ...............................................................................................................1.15

Table of Contents Series 50X Stacker Chapter 1 Introduction and Installation

TOC Page 2 of 2 QUIPP SYSTEMS INC. QPN 3421-39789-


QPN 3421-39789- QUIPP SYSTEMS INC. Page 1.1


1.1 General

This manual includes the information you need to:

• Install

• Maintain, and

• Replace parts for the QUIPP Series 50X Stackers.

Except for certain parts drawings, the information contained in this manual applies to all 50X model

stackers.

1.1.1. The Lockout/Security System

A factory assigned password (Code Number) is used to prevent unauthorized changes to certain

control settings.

When the word - LOCKED - is displayed on any screen, the lockout/security system is on. To

change the locked values, the operator must enter the correct password.

Note: The password is listed on the last page of this manual. Remove the password page from

the manual and provide the number to authorized personnel as needed. For manuals

delivered on CD-ROM, the password can be found on an insert included with the CD

jacket. Remove the insert from the CD jacket and provide the number to authorized

personnel as needed.

To unlock the system, ensure stacker power is on and:

1. Touch LOCKED.

2. Enter the CODE number.

3. Press ENT.

All control settings can now be changed.

To lock the system, ensure stacker power is on and:

1. Touch UNLOCKED.

2. Enter the CODE number.

3. Press ENT.

Locked control values cannot be changed.

1.2 Basic QUIPP 50X Series Stacker Description

The QUIPP 50X Series Stackers can stack the varied products of a typical newspaper facility. The

compression capability of the 500C Models is especially designed to improve the quality of stacks of

smaller products.

Basic QUIPP 50X Series Stacker Description Series 50X Stacker Introduction and Installation

Page 1.2 QUIPP SYSTEMS INC. QPN 3421-39789-

1.2.1. Stacker Design

Stackers incorporate a welded tubular and sheet steel frame to support elements of the stacker

including:

Infeed section, Stack forming section, Turntable, Bundle Eject Section and the Operator

Interface and controls.

1.2.2. The Main Components

Infeed Section - controls the flow of product from supply conveyor into the stacking section. The

speed of its belts is controlled to the speed of the supply conveyor but remains constant above a

certain minimum. A discharge (or bypass) section of the lower belts can swing down to dispose

of "problem" products that might cause a jam. The bypass gate can also be manually switched

down when needed.

A selection of two product sensors in the infeed provide a selection of product count input for the

control system.

Figure 1.1: The 500 Series Stacker

Stacking Section - includes two independent stepper motor-driven sets of two chains each.

Two stacking blade assemblies are carried on each chain set. A set of blades is rotated into the

stream to intercept product as a preset count and formed batch are dropped into the turntable

from the preceding set of blades. The next batch begins to form on the blades.

Introduction and Installation Series 50X Stacker Special Information


Turntable and Stack Eject - The batch of products on the stacking blades is lowered to a point

just above the turntable walls. With quick chain acceleration, the blades are withdrawn and the

batch drops into the turntable. When the 50X stacker is in Pressor mode, the floor of the

turntable raises product up against pressure plates on top of each gate which are momentarily

turned out as stops against which the batch of products is pressed. After product is pressed, the

turntable floor lowers to await the next batch as the stops rotate back to clear the batch.

To form multiple batch stacks, the turntable rotates 180° between batches until the stack is

complete. The ejector then pushes the formed stack out of the turntable.

Operator Interface and Control - Operator interface includes a touch screen display and a set

of operator pushbuttons duplicated on either side.

1.3 Special Information

Throughout this manual, items of special importance are identified as follow:

1.3.1. Danger

DANGER!

A DANGER DESIGNATION INDICATES AN

IMMINENTLY HAZARDOUS SITUATION WHICH,

IF NOT AVOIDED, WILL RESULT IN DEATH OR

SERIOUS INJURY.

1.3.2. Warning

WARNING

A WARNING indicates a potentially hazardous

situation which, if not avoided could result in death or

serious injury.

1.3.3. Caution

CAUTIONA CAUTION indicates a potentially hazardous

situation which, may result in minor or moderate

personal injury or damage to the equipment. It alerts

against unsafe practices.

1.3.4. Note

Note: Information or a reference to an operating procedure or technique that requires special

emphasis.

1.4 Safety Considerations

When using industrial equipment, always follow the documented equipment operating instructions,

observe safe work procedures and observe warning labels placed on the equipment.

Safety Considerations Series 50X Stacker Introduction and Installation


1.4.1. Personal Safety

•. NEVER reach into, over or under an operating stacker for any reason.

WARNING

Keep fingers and hands completely clear of the

turntable area while the stacker is operating.

•. Do not wear loose clothing when operating or working near a machine.

•. Never attempt to service or operate the stacker while overtired or under the influence of

drugs or alcohol.

1.4.2. Housekeeping

•. Good housekeeping habits contribute to a safe and healthful working area.

•. Paper dust, paper shreds and oil should always be cleaned off of and from around the

stacker. It is slippery and a fire hazard.

1.4.3. Operation and Maintenance

•. Only qualified personnel (as determined by the customer) should operate and maintain

industrial machinery.

•. Allow time for preventative maintenance. Never clean, oil, or perform maintenance on an

operating stacker except as required for validating a corrective effort.

•. When major work is required on the stacker, turn power off and lock or tag the power switch

(Figure 1.5).

•. Immediately report any malfunction of a stacker. Discontinue its use until the problem has

been corrected.

Introduction and Installation Series 50X Stacker Specifications


1.5 Specifications

Dimensions within brackets are metric [MM.] unless noted.

1.5.1. Mechanical

See Dimension Drawings (see Figure 1.2)

1.5.2. Utilities

Electrical Power As ordered - 3.0 kVA, 1 Ph

(3 Ph supply for existing stacker position is compatible.)

Voltage and Frequency as ordered

Compressed Air 90-100 psi [6.2-6.9 BAR]; clean, dry

Non-Pressor Models - at max rate 3 scfm [86 L/min]

Pressor Models - at max rate 5.5 scfm [160 L/min]

1.5.3. Capacities and Capabilities

Product Delivery

Product Parameters

Stacker Batch Capacities

Note: Minimum count per batch changes with press rate when stacker is in:

Non-Pressor mode - from 2 at 7800 pph to 21 at 85,000 pph

Pressor Mode on except for last batch - from 2 at 2880 pph to 59 at 8500 pph

Full Pressor mode - all batches pressed - from 2 at 1800 pph to 94 at 85,000 pph

Rate to over 85,000 pph

Orientation folded edge leading and on top of stream

Alignment folded edge perpendicular to stream centerline with 5° max.

deviation

Offcenter Deviation max ± ½" [13 mm]

Minimum Lap 2-½" [63 mm]

Page Count 6 to over 400 pg broadsheet Minimum and Maximum Product

Size (W by L)

50X Models 10-½" to 12" by 12" x 14-½" [267-305 by 305-368 mm]

500W Models 10-½" to 12" by 12" x 16-3/4" [267-305 to 305-420 mm]

Maximum Height 12-½" [317 mm]

Maximum Count; Pages 2000 broadsheet *

* Loose folds and/or unusual inserts can result in lower maximum page counts per

batch and stack.

Minimum Count; Products two (2)

Specifications Series 50X Stacker Introduction and Installation


Stacker Stack (Bundle) Capacities

Stacker Dynamics

Note: If the last batch of a multi-batch stack is pressed, each batch will cycle a minimum 4

seconds. For lowest total stack production time (highest pressed stack rate), turn last

batch press OFF.

QUIPP Product Count Sensors - Pages Broadsheet

Note: Either sensor may be assigned through the Touch Screen MAIN Page.

1.5.4. Controls

Pre-run set-up and control during production plus maintenance procedures are carried out

through:

The Touch Screen - a computerized interface between the operator and the stacker displaying

operating results and conditions that may require attention. The Pushbutton Stations located on

each side of the stacker are

Maximum Height 16" [415 mm]

Maximum Count; Pages 3250 *

* Loose folds and/or unusual inserts can result in lower max page

counts per batch and stack.

Maximum Count; Products 999

Batches per Stack 1 to 9

Cycle Time - Pressor

mode - OFF

0.92 Seconds

Cycle Time - Pressor mode - ON

Batch Press 2.5 seconds

Last batch press 4.0 seconds

Stack Discharge Directions L, R, Alt, Ratioed

Push Velocity adjustable 100-180 fpm [0.5-0.92 M/sec]

Count-Pro II Laser sensor 6 to 400

Mechanical sensors 8 to 144

Emergency STOP mushroom pulls out for START

Bypass Gate latched (closed) or open

Lighted Pushbuttons

START clears/readies for production

LEFT stacks delivered to left

ALTERNATE stacks delivered alternating

RIGHT stacks delivered to right

Introduction and Installation Series 50X StackerStacker Performance Chart - - - - PRESS and NO


1.5.5. Ethernet Capability (If Installed)

The 50X Series stackers may incorporate an internal Ethernet (networking) capability that

permits access to certain stacker information and control values either through local work

stations or even remotely through the Internet. Supplied with each stacker are:

1. Factory-installed COM/Serial PC Card with the necessary connector and cable

2. A second cable assembly, a Serial to Ethernet Converter, CD, power supply and

Software for on-site installation

3. The necessary installation documentation

For additional information, contact QUIPP Customer Service at:

(305) 623-8700, Ext. 356 or 409.

1.6 Stacker Performance Chart - - - - PRESS and NO PRESS

PPH (Products per Hour x 1000)

INSTRUCTIONS

For - Maximum Stack Size (product count in final bundle)

for a specific page count product:

1. Find Pages per Product - Broadsheet - for:

1 batch final stack - - - - - - - Line B

2 to 9 batches final stack - - - Line C - Then:

2. Read to Line A for Max Stack (bundle) size permitted.

Stacker Performance Chart - - - - PRESS and NO PRESSSeries 50X Stacker Introduction and Installation


For - Maximum Press Rate for a specific stack (bundle)

form - use diagonal lines U to Z - Examples:

1. For three batches - Not-Pressed:

a. Find Stack (bundle) Size on line A (60 in example).

b. Read up to Diagonal W (3 batches not pressed).

c. Read left to Press Rate (75,700 PPH - in example)

2. For two batches - Both Pressed:

a. Find Stack (bundle) Size on line A (90 in example).

b. Read up to Diagonal Z (2 batches, both pressed).

c. Read left to Press Rate (40,500 PPH - in example)

3. For 3 to 9 batches refer to the table.

Definitions:

• A Batch - group of products formed on a stacking blade.

• A Stack - delivered group products, 1 to 9 batches.

Formula for Max Press Rate (PPH) for specific Batch counts in 3 to 9 Batch stacks when - - -

N = Products per Batch*

Example:

6 Batch Stack of 60 Products per Batch - All Pressed

Max press rate = 3600 X 60 / 4 = 54,000 PPH

Table 1.1: Example: Max Press Rates for 3 to 9 Batch Stacks

Sample Press

PPH

Minimum Quantity Products in Each Batch*

* Up to 3,250 Pg broadsheet, maximum in final stack.

None Pressed All but Last Pressed All Pressed

85,000 22 59 94

70,000 18 48 77

50,000 13 34 55

30,000 7 20 33

20,000 5 13 22

None Pressed All but Last All Pressed

3600 x N

0.95

3600 x N

2.5

3600 x N

4.0

Introduction and Installation Series 50X StackerStacker Performance Chart - - - - PRESS and NO


Figure 1.2: Dimension Drawings

Stacker Dimensions are as identified on the drawings.Note the identical dimensions among the stackers.

Pre-Installation Considerations Series 50X Stacker Introduction and Installation


1.7 Pre-Installation Considerations

To ensure trouble-free operation of the stacker, carefully observe all unpacking, installation, set-up,

operation and maintenance instructions which follow.

1.8 Unpacking

Inspect the shipment before unpacking to ensure there is no obvious shipping damage. Uncrate and

unpack the shipment. Inspect the unit for shipping damage. If any is discovered or if any

discrepancies are noted, refer to section “1.8.2. Reporting Shipping Related Damages”.

1.8.1. Lifting Stacker from the Skid

Series 50X Stackers are usually shipped mounted vertically or tilted forward on a skid. In either

case, the machine must be lifted free of the skid with an overhead crane, fork lift truck or the like.

Remove shipping protection material.

If the stacker was shipped vertically, lift it with a fork truck. Fork openings are located on the

sides of the stacker.

If desired, the stacker can be raised from overhead by placing lifting straps around the "lifting

bar" at the top of the infeed (Item 5 in Dwg. D3421-A-33875-2 and D3421-A-26871-2, Chapter

7). Place a strap at each end of the bar.

If using a fork truck, move it to the side of the stacker. Loop two straps around the lifting bar as

above. Thread the other ends of the straps around one fork of the fork truck. Fasten the straps to

the fork to prevent slippage as the stacker is raised.

To lift a stacker received in the forward tilted position, use a crane or fork truck with lifting straps

as just described.

CAUTION As the stacker is righted on the floor, it can tilt

upright abruptly. Reduce this effect by slowly

lowering the machine to the floor.

1.8.2. Reporting Shipping Related Damages

If damage to QUIPP equipment occurs during transit, it is the responsibility of the Customer to

file a written claim against the carrier. QUIPP will not honor a claim from a Customer for

immediately visible and/or concealed shipping damage.

Shipping Related Damage Claim Procedure - To file a valid claim, the Customer must request

an inspection by the shipping company or its representative within the time specified on the

carrier’s Bill of Lading (generally within 15 days after receipt of the shipment). All containers and

packing materials must be retained for this inspection.

Claims for Errors and Shortages - It is the Customer’s responsibility to inform QUIPP of any and

all shortages noted in the shipment, in writing, within five (5) days of receipt of the equipment.

The equipment delivered may be verified against the packing list. If these records indicate a

shortage, the Customer must file a claim with the carrier. Also, advise the QUIPP Customer

Service Department of the claim.

Introduction and Installation Series 50X Stacker Mechanical Installation


1.9 Mechanical Installation

Stacker sides are identified as left and right while looking at the infeed, the product source to the

back.

1.9.1. Stacker Placement

All 50X Series Stackers have two locating "bullets" on the front of the infeed. They fit into the

ends of conveyor-mounted fittings supplied for the purpose. When the stacker is rolled into

position with the bullets nested in these fittings, the stacker will be exactly placed for production.

Step on the lockdowns below the back of the stacker.

The carrying surface height of the supply conveyor must match that of the stacker. If necessary,

this conveyor may be declined or inclined as needed but at no greater angle than ten degrees

(10°).

1.9.2. Ongoing Conveyor

The ongoing floor conveyor accepting stacks from the stacker should be level and about ¼"

[6mm] below stacker discharge elevation.

1.10 Utilities and Control Signals

Air and power are fed to the stacker through a fitting and a cable located at the front right side of the

stacker infeed. Three added connectors at this point provide interface to certain additional signals,

when applicable.

A Junction Box (Figure 1.3) supplied with the stacker has matching connectors for power and any

interface signals. Mount the "J" Box close to the stacker on the right side of the supply conveyor.

Internal configuration and terminal numbering are shown in Figure 1.3.

1.10.1. The Product Stream Encoder

To stack press product, the stacker infeed is driven at a speed proportional to the supply

conveyor. An encoder (supplied) provides the supply conveyor speed reference to the stacker

control. The control maintains the stacker infeed speed proportional to the supply conveyor

speed. Mount the encoder on the right side of the supply conveyor within ten feet [3M] of the

stacker. It must be driven by a driven roller of the supply conveyor. Wire its output to terminals

A, B, & C of the J-Box (Figure 1.3). The encoder signal is supplied to the stacker through

connector J6 (Figure 1.3 and Drawing D3421-S-34147 on page 7.3).

Note: When the stacker is to receive product from a constant rate source such as an inserter,

the encoder is generally not required. Stacker infeed speed is adjusted through the

stacker "Minimum Infeed Speed" control (Section 3.2.2-a) while the inserter delivery

conveyor speed is potentiometer-adjusted through the independent inserter conveyor

control.

1.10.2. Power Supply

The stacker will have been prepared for the power supply specified on the stacker order. The

internal transformer will be wired per details in Drawing D3421-S-34147 (see page 7.4) and

wiring table in Drawing D3421-S-34147 (sheet 2 on page 7.4)

Utilities and Control Signals Series 50X Stacker Introduction and Installation


WARNING

Only qualified electrical technicians should service

this portion of the stacker and bring power to the

junction box per local codes

Bring power to the J-Box (Figure 1.3), terminals X, Z and G. Power continues to the stacker via a

cable terminated with a twist-lock plug from the J-Box. A matching socket terminates the power

cable from the stacker. Some models have a matching connector in the connector housing.

IMPORTANT - 50X Series Stackers only need single phase power. However, the stacker

electrical service accommodates a 3-phase supply to permit exchange with stackers requiring

3-phase power.

WARNING

Do not apply power to the stacker at this time.

1.10.3. Auxiliary Signals

Auxiliary signals feed through connectors:

J1 carries the incoming signals,

J2 carries the outgoing signals

as described in Schematic 3421-S-34147A-3A in Chapter 7.

1.10.4. Air Supply

Supply air to the stacker through a flexible hose terminated with a quick disconnect fitting

(supplied with the stacker) attached to the matching fitting on the stacker infeed. Plant air supply

should be clean and dry, 80 to 100 psi with 1.5 cfm free air capacity [43 L/min at 5.5 to 6.9 BAR].

Do not connect another high use device(s) to the air stacker supply line.

CAUTIONBefore connecting the air supply to the stacker, blow

out the supply line to clear it of foreign particles and

excessive moisture.

Introduction and Installation Series 50X Stacker Utilities and Control Signals


Figure 1.3: The J-Box and the Stacker Connector Housing

J2

J1

Locating HornArea

J6

PneumaticQuick Disconnect

Power Input Cable terminatedwith Connector J3

The J-Box

J-Box Cabling

J1 - Stacker OutputSignals

J2 - Stacker InputSignals

J3 - Main Power

J6 - Product SupplyEncoder Signal

These cables, with appropriatelengths, lead to the Stacker ConnectorHousing and power supply cable.

J3

J1

J2

J6

TB1

Final Pre-Setup Checks Series 50X Stacker Introduction and Installation


1.11 Final Pre-Setup Checks

Before power and air are supplied to the stacker, a final check of the machine should be made.

1.11.1. Mechanical Inspection

Inspect and manually operate the stacker mechanical components to ensure no parts were

dislodged or damaged in shipment.

Rotate the turntable; move the stacking section blades. Each device should move freely

between its mechanical limits. All hardware should be tight and no cables or air lines should

interfere with component movement.

1.11.2. Touch Screen and Pushbuttons

The touch screen, with its display panel and the two operator control pushbutton panels, should

be inspected to ensure there is no hidden damage.

1.11.3. Electrical/Electronic Inspection

WARNING

Hazardous voltages are present in the Stacker

electrical box. Only qualified electrical technicians

should perform the following inspection.

Inspect the electrical/electronic enclosure components. Open the enclosure as follows:

Open the electrical/electronic enclosure:

1. Rotate the main power switch (Figure 1.4) on the stacker back to its OFF position.

2. Move the release lever on the top right of the switch down to the right.

3. Holding the lever to the right, pull the door open.

Figure 1.4: Opening the Electrical Enclosure with the Disconnect Switch

Introduction and Installation Series 50X Stacker Final Pre-Setup Checks


To Lockout power to the stacker for maintenance purposes:

1. Hold the small lever as in Figure 1.4 and turn the disconnect handle to the horizontal.

2. Place a lock through the handle per Figure 1.5. The shackle must be between 3/16" and

5/16" [5 to 8mm] in diameter.

3. Attach a warning tag to the switch.

Figure 1.5: Lockout and Door Open-Power on Procedure

To permit power-on access to the control, push the small lever down with the thumb as shown in

Figure 1.4 and open the door. Be sure to tag the disconnect if work is to be done in the enclosure

with power on.

WARNING

Only qualified electrical technicians should service

this portion of the stacker.

Check internal components and wiring for damage. Ensure all fuses and other components in

position. Remove all packing materials.

Press the white ejector tab on each circuit board to ensure the boards are firmly seated. If circuit

board damage is suspected, unsnap the cable restrainer mounted at the end of the card.

Remove each board by pulling up on its tab. Inspect and replace firmly. Replace cabling and

restrainer.

Close the door for automatic latching.

1.11.4. General Inspection

Inspect the remainder of the stacker for potential problems or loose components or hardware.

Final Pre-Setup Checks Series 50X Stacker Introduction and Installation


Note: If no oil is present in the stacker air set, its oil reservoir must be filled before any power-

on testing. Use synthetic, 10-weight, non-detergent oil. Fill through the hole in the upper

surface of the air set or (quicker method) remove the reservoir glass and fill it directly.

Once operation begins, check to ensure the oil mister provides one drop of oil for about

every 20 turntable reversals.


Table of Contents


2.1 General.................................................................................................................................. 2.1

2.2 Stacker Power Switch ........................................................................................................... 2.1

2.3 Operator Controls - Pushbuttons........................................................................................... 2.12.3.1. START/CLEAR (Green) .........................................................................................................2.2

2.3.2. BYPASS (White when gate is open - down) ..........................................................................2.3

2.3.3. STOP (Red with yellow outline) .............................................................................................2.3

2.3.4. LEFT, ALTERNATE and RIGHT (Orange).............................................................................2.3


2.5 Using the Touch Screen........................................................................................................ 2.42.5.1. The Lock-out Code.................................................................................................................2.4

2.6 General Set-Up ..................................................................................................................... 2.5

2.7 Mechanical Adjustments ....................................................................................................... 2.62.7.1. Cut Edge Guide......................................................................................................................2.6

2.7.2. Batch Side Guides .................................................................................................................2.7

2.7.3. Turntable Walls ......................................................................................................................2.7




2.10 To Set-up for Production ..................................................................................................... 2.10

2.11 New Bundle Data Entry ....................................................................................................... 2.10

2.12 Speed-Set Recording .......................................................................................................... 2.142.12.1. Using Recorded PROFILE Data ..........................................................................................2.14

2.13 User Help Information ......................................................................................................... 2.152.13.1. MAIN Page Help Examples..................................................................................................2.15


Table of Contents Series 50X Stacker Chapter 2 Controls, Set-Up, and Stacker Start-Up





2.1 General

To control the stacker, Operators use the following:

• The main power switch

• The two pushbutton panels

• The main touch screen/display

2.2 Stacker Power Switch

Stacker power is controlled by the disconnect switch on the back door. The door must be closed

before power can be turned on except for internal check purposes as noted in section “1.11.3.

Electrical/Electronic Inspection” on page 1.14.

DANGER!

WHEN POWER IS APPLIED TO THE STACKER,

HAZARDOUS VOLTAGES EXIST IN THE

ELECTRICAL CONTROL SECTION. ONLY

QUALIFIED TECHNICIANS SHOULD BYPASS THE

POWER SWITCH INTERLOCK TO SERVICE THE

CONTROL.

2.3 Operator Controls - Pushbuttons

Pushbuttons on either side of the stacker control:

• START/CLEAR and Emergency STOP

• BYPASS Gate Position

• LEFT, ALTERNATE, RIGHT Delivery Directions

Operator Controls - Pushbuttons Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


Figure 2.1: The Operators' Pushbutton Panel.

The buttons shown from top to bottom are:

START/CLEAR (green), STOP (Red),

BYPASS (White), LEFT (Orange),

ALTERNATE (Orange), RIGHT (Orange)

2.3.1. START/CLEAR (Green)

WARNING

Pressing START/CLEAR operates all stacker

sections. Keep hands away from the stacker during

the action.

With stacker air and main power on, press the START/CLEAR pushbutton one time. The

following takes place:

1. The pneumatic system receives its air supply

2. The stacker control receives power

3. The stacker is ready to be cleared

Press START/CLEAR again. Any product on a stacking blade will drop into the turntable. All

products are then pushed out of the stacker.

Controls, Set-Up, and Stacker Start-Up Series 50X Stacker The Touch Screen/Display


2.3.2. BYPASS (White when gate is open - down)

The Bypass gate deposits poorly delivered product that might cause a stacker jam. The gate

drops automatically and resets to normal automatically. Manual actuation is possible as follows:

Press BYPASS to open the bypass gate if it is closed (up position) and the stacker has power.

Press BYPASS to close the gate (raise the gate - lights off)

2.3.3. STOP (Red with yellow outline)

Press STOP for immediate stacker shut down. To permit the next stacker start, press STOP

again. Then press START/CLEAR to restart the stacker.

2.3.4. LEFT, ALTERNATE and RIGHT (Orange)

These pushbuttons control stack delivery:

LEFT or RIGHT deliver all stacks in one or to the other direction.

ALTERNATE delivers stacks first left and then right. From 1 to 9 stacks can be delivered in

one direction before reversing. This pattern is then adjusted using the Parameters Page as

detailed in Section 4.2.2-b and 4.2.2-c.

Note: The directions RIGHT and LEFT are as viewed into the stacker infeed with the product

source to the back.

2.4 The Touch Screen/Display

The touch screen/display is located on the back of the 50X Series Stackers. It permits and provides:

• Set-up for production

• Fine-tuning of operation

• Display of operating information

• Stacker troubleshooting suggestions

Note: The Main Page (below) and the remaining basic displays are all identified as Pages.

Using the Touch Screen Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


Figure 2.2: Main Page Bundle Display Set-up Screen

2.5 Using the Touch Screen

Once stacker power is on, the Main Page appears. Back-lighted data on this (and the other Pages)

can be changed. Touch the word Pages (Upper Right) on any screen to display the pull down menu

(Figure 2.3). The menu accesses the following nine (9) Main Pages:

1. Main

2. Profiles

3. Parameter

4. Status

5. IO Updates

6. Service

7. Messages

8. Set Clock

9. Pressor (applicable to 50XC Series Stackers only, refer to Chapter 3)

Display any of these Pages by:

1. Touching Page of any display - - the Pull-down Menu appears.

2. Touching the desired Page title - - the new Page will be displayed.

2.5.1. The Lock-out Code

Refer to Section 1.1.1. if LOCKED is displayed in the lower LH corner of the screen.

Controls, Set-Up, and Stacker Start-Up Series 50X Stacker General Set-Up


Figure 2.3: The Main Page Pull-Down Menu - upper right

The purpose of the nine (9) Main Pages is explained below. A detailed explanation of the

functions can be found in the referenced sections in this manual.

Main - to set-up the stacker for a specific product run (2.10 & 2.11)

Profiles - the Speed-Set method of bringing up recorded past run parameters (2.12).

Parameter - permits stacker fine-tuning (4.2).

Status - displays conditions, counts and other stacker operating data (5.4).

IO Update - displays status of stacker I/O signals (5.7).

Service - offers service and maintenance instructions for stacker upkeep (4.3).

Message - displays most stacker occurrences, time stamped and recorded (5.2).

Set Clock - permits setting of date and time displayed on the screen (2.9).

Help information on many stacker settings can be called up and displayed as explained in

Section 2.13.

Explanation and use of the various Touch Screen Pages are referenced in Section 2.6.

2.6 General Set-Up

Set-up for production involves one-time, infrequent and daily activities:

• Mechanical Adjustments - Section 2.7

• Pneumatic Adjustments - Section 2.8

• Entering control settings - Section 2.9-12

Mechanical Adjustments Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


2.7 Mechanical Adjustments

Before first-time production, adjust the stacker for the products to be handled and for other local

conditions. These adjustments are:

Figure 2.4: Batch Forming Guide Adjustment Devices

2.7.1. Cut Edge Guide

Place a 3-4" [75-100mm] high stack of products on the center of a set of stacking blades. Their

cut edges should clear the cut edge guide by about 1/4 inch. When correctly set, the upper ends

of the guides will lightly push each product dropped onto the blades back against the rear of the

stack forming area. Ensure that the stack cut edge is undisturbed by the guides as the batch

drops into the turntable. Adjustment knobs are identified in Figure 2.4. Make changes in guide

position only when the stacker is idle.

CAUTIONA jam can result from setting the guide too tight and

the bypass gate could drop unexpectedly.

Side GuideLockdownKnobs

Batch Side GuideAngle Brace

Cut EdgeGuide andLockdownKnobs

Controls, Set-Up, and Stacker Start-Up Series 50X Stacker Mechanical Adjustments


2.7.2. Batch Side Guides

With the 3-4" (75-100mm) stack of products centered on the stacking blades, move the vertical

clear plastic side guides to within about 1/4 inch of the stack ends. Two knobs at each side of the

stacker permit this adjustment (see Figure 2.5). Maintain the guides perpendicular to the floor.

Adjust the incoming angle of the side guides so that their vertical front edges are about 1/2 inch

farther apart than their back edges using the third knob at both stacker sides (Figure 2.5).

2.7.3. Turntable Walls

Turntable walls may require position adjustment to prevent excessive slippage of the product

while in the turntable.

To check settings: Place a copy of the product to be stacked inside the turntable. About 1/4"

[6mm] clearance should remain between walls and product edges.

Figure 2.5: A-Side Table Wall and Belt Take-up Lock Handles

If readjustment is required, refer to Figures 2.5 and 2.6:

1. Each wall has two locking handles and each wall drive motor has a take-up locking

handle. Loosen the six handles involved with the two walls.

A-WallProx Sensor

A-DriveTake-upLock Handles

A-Side WallLock Handle

Table MIDProx Sensors

Lift Guide Bars B-Side Wall DriveComponents

A-WallDrive Motor

Mechanical Adjustments Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


Figure 2.6: View through Turntable (left) and from above (right)

2. Adjust the walls for 1/4" [6mm] clearance either side of the product. Keep them parallel to

and equidistant from the turntable centerline. Retighten the wall locking handles.

3. To tighten their drive belts, rotate the drive motors. Use a wooden lever if needed. Lock

with the two handles. The belts should be tight enough to permit only about 1/4" [6mm]

belt deflection on one side when firmly pushed in.

2.7.4. Turntable Eject Pushers

A 1/4" [6mm] clearance should remain between product ends and the two pusher sets between

which the products drop in the turntable. If clearance is incorrect, contact QUIPP Customer

Service for an optional set of pusher blade spacers. Or manufacture spacers locally; 12

required.

Turntable MIDSensor Targets

Pusher ProximitySwitches (2)

Wall DriveMotor (below) Lift Table Guide Rod Ends

Wall TensioningCylinder

Pressor PlatesCylinder

TurntableHOME Target

Pusher Bars

Exit Directions

Drive Belts (2)

Controls, Set-Up, and Stacker Start-Up Series 50X Stacker Pneumatic Settings


2.8 Pneumatic Settings

With plant supply air from 90 to 100 psi [6.2-6.9 BAR], adjust air pressures as follows (see Figure

2.7.):

1. Main stacker to a 90 psi (left gauge).

2. Bypass Gate from 40 to 80 psi. Adjust to 40 psi for the first run. Test and observe results.

3. Turntable from 25 to 35 psi; adjust for best operation.

4. Table Up/Down; 40psi for first run, then adjust.

5. Squeeze Roller; 40psi for first run, then adjust.

The oil mister should add one drop of oil for every 10 to 20 turntable reversals. Close the Oil Drip

Adjust Knob and then open about 1/8th turn. Observe and adjust. Both the water trap and the oil

reservoir are removed by pushing down the slide latch on the side and turning the reservoir left or

right. It is quicker to fill the oil reservoir directly than through its fill port. Use 10-weight non-detergent

synthetic oil.

Figure 2.7: The Pneumatic Panel Area, Pressor Model Stackers

2.9 Control Clock & Screen Saver

Since all of the MESSAGES (discussed in Section 2.14 and 5.2) are recorded with time and date, the

internal date and time clock must be correctly set.

Note: The clock used is a 24-hour clock for example, 2:22 PM is 14:22. Since the clock is set to

Eastern Standard Time (EDT) at the QUIPP plant, you may need to reset the clock to your

time zone.

Reset as follows:

1. Power up the stacker.

2. Touch Page.

3. Touch Set Clock on Pull-down Menu: Figure 2.3.

To Set-up for Production Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


4. Touch the Hours number displayed; key in the hour required; key ENT.

5. Touch the Minutes number displayed; key in the minutes required; key ENT.

6. In similar way, set Seconds, Month, Day & Year.

The Screen Saver displays the time. The time delay before the screen appears is controllable or can

be eliminated.

Control the Screen Saver by turning it ON and OFF with the first line of the display. The second line

adjusts the delay before it cuts in when the computer is idle in the same way as time and date.

2.10 To Set-up for Production

Production set-up details follow.

Note: After any production run, part or all of that run set-up can be used for the new set-up. If an

existing setting on the touch screen is acceptable, simply move to the next setup step. See

also Section 2.12 for the Speed-Set alternate.

Before the first production run, review the following:

1. Ensure the stacker is in position (Sec. 1.9).

2. Ensure cabling is in place (Sec. 1.10).

3. Ensure the stacker ready for product (Sec. 2.7).

4. Ensure correct air supply (Sec. 2.8).

Refer to Sec. 2.13 for Help Information procedure.

Continue SET-UP:

1. Turn the disconnect switch to ON. The Main Page display (Figure 2.8) appears.

2. If Entry is LOCKED is displayed at the lower left, the control must be accessed using the CODE

PASSWORD. See Section 1.1.1.

The keypad permits change of numbered quantities. Data in smaller type involve modification of

stacker operation and provide further information. Values in parentheses are default values.

Production requirements are entered through the touch screen.

2.11 New Bundle Data Entry

Note: The information contained in 2.11 New Bundle Data Entry is applicable to the C Stacker only

Production set-up procedures follow. However, after any production run, the data for that run can be

recorded. Such stored run data can be called up later to be used totally or partially as needed. See

Section 2.12 for the Speed-Set procedure.

If an error is made in the set-up procedure, an explanation is displayed in the lower left of the Main

Page.

a. If the error is noticed before ENT is touched, touch CLR and enter the correct value.

b. If the error is already displayed, key in the required value and touch ENT.

Bring up the Main Page screen.

Controls, Set-Up, and Stacker Start-Up Series 50X Stacker New Bundle Data Entry


Figure 2.8: The Main Page Display

Entering Set-up Data

In the following procedure, assume the following;

a. Product delivered from a press - broadsheet

b. 220 Products in each final Stack (Bundle)

c. 2 Batches per Stack - reversed

d. 8 Pages per Product

e. The Pressor is to be used on first batch

f. The Pressor is not used on second batch

g. The Squeeze Roller to be ON

1. Touch the lighted numbers following (25/1)>.

2. Key the required total products required (220) in each stack (bundle) (from 2 to 999 possible).

Touch ENT.

3. Key the number of batches required (2) in each stack (1 to 9 possible). Touch ENT. The keyed-in

stack and batch count now appear to the right of the default values (25/1)> --- 220/2.

4. When TABLOID and BRDSHEET are alternating, the control is set for stacking a broadsheet

product. To stack an inserted product, touch the alternating words until TABLOID is displayed.

New Bundle Data Entry Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


5. Touch the number following Pages(50)>. Key in the number of pages (not sheets) in one product

(8) (4 to 500 possible). The number must be in either BRDSHEET or TABLOID pages as entered

during Step 4. Touch ENT.

6. From the four ON/OFF displays, select:

a. ODD COUNT> ON/OFF should indicate OFF. Turn to ON only if an odd count programming

system is directing stacker operation.

b. TURN TABLE> ON/OFF controls its rotation. Touch the area until ON is displayed. To

prevent reversal, bring up OFF.

c. Squeeze ON and OFF. Touch ON to operate the Squeeze Roller.

d. Pressor(OFF)> ON/OFF (refer to 3.9 New Bundle Data Entry in this manual for a description

of Pressor settings.

Touch Page and then Main Page on the Pull Down Menu for the Main Page. The remaining controls

are:

7. BLANKING> rejects false counts caused by irregularities between leading edges of genuine

products. Sections slipped back inside a jacket or inserts lying on top can produce false counts

(Figure 2.9). Settings are AUTO or MANUAL.

Note: When ROP is entered, the setting becomes AUTO at 1" [25mm] automatically.

a. AUTO (Blanking) rejects counts produced in the first 50% of the average lap between the last

eight products detected. The lap can be as long as 12" [305mm] with a maximum blanking of

6" [153mm]. However, when product lap varies inconsistently, an overcount bundle may

develop from a high average caused by one long lap. If this is a problem, switch to MANUAL

Blanking.

Figure 2.9: Count Blanking

b. MANUAL (Blanking) is recommended for most insert runs. MANUAL blanking is adjusted

through the STATUS Page. Blanking is adjustable in 1" [25mm] steps from

25 to 100mm [1 to 4 in the display]

When in INSERT, set Blanking at -- about 1/2 average lap

During production, look at Product Lap on the STATUS Page. Using key pad and MAIN

PAGE display, enter blanking of half Product Lap Distance. Touch ENT. Experiment for the

best value.

Blanking ZoneLaser Light andCount Sensor Paths

Controls, Set-Up, and Stacker Start-Up Series 50X Stacker New Bundle Data Entry


8. PAPER SENSOR> alternates a selection between QUIPP Count Pro II laser and mechanical

sensors. Two mechanical sensor models with different page ranges are available. The "small

wheel" sensor is supplied as standard. An optional "large wheel" sensor is applied primarily to

large inserted products.

9. PAPER TOTAL> is the sum of products processed through the stacker since the last time the

readout was reset. To reset the display to zero before a run, touch PAPER TOTAL on the

Main Page and then CLR in the key pad.

10. MODE> permits alternating between ROP and INSERT which switches BLANKING as in 5b,

above. Touch the display to reverse setting.

11. MESSAGE: May display messages, explained in Section 5.3, as the action described takes

place. Messages are recorded and can be retrieved (Sec. 2.14) per suggestions, Sec. 5.3.

12. Entry is LOCKED or UNLOCKED - indicates the Lock-out Code must be entered to change

the control settings - Sec. 1.1.1.

Product Profile> is a Speed Set method of stacker set-up. Refer to Section 2.12 following.

Note: Operators' Pushbuttons on the side of the stacker control the directions and program of

stacks delivered from the stacker.

Speed-Set Recording Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


2.12 Speed-Set Recording

If a similar product is frequently run, the Product Profile Page (Figure 2.10) can store its set-up data

for later use. To store a run set-up:

1. Touch Page and Profiles on Pull Down Menu.

2. Touch an available Profile number as in Figure 2.10.

Figure 2.10: The Profile Page

3. Touch the O in the bottom RH corner of the screen. The set-up values of the just-completed run

will appear in the display.

4. Record the Profile number and product run data for later use.

2.12.1. Using Recorded PROFILE Data

To use a set up stored in the Profile Page (Figure 2.10):

1. Turn on power to the stacker. The Main Page first appears (Figure 2.2).

2. If the Profile Number is known, touch the number following the words Product Profile.

3. Enter the number of the desired Profile in the large key pad and touch ENT. The stored data

will be entered.

4. If the Profile Number is not known, touch Pages for the Pull Down Menu.

5. Touch Profile to bring up the Profile Page (Figure 2.10). Locate the number of the required

data.

6. Touch Pages for the Pull Down Menu. Touch Main.

Controls, Set-Up, and Stacker Start-Up Series 50X Stacker User Help Information


7. Touch the number following Product Profile>.

8. Enter the new Profile number (located in Step 5 above) on the key pad and touch ENT. The

stored data will be entered.

2.13 User Help Information

The 50X Series Stacker Control includes Help discussions which can be called up for almost every

item displayed on the various screens. Figure 2.11 is a typical Help discussion for the Turn or Push

Delays.

Figure 2.11: A Typical Help Screen

For example, to call up the Help discussion available for a Main Page data item:

1. Touch Help in the upper left corner of the Main Page screen.

2. Touch the backlit digits or title in question.

3. The Help discussion will appear. The word Quit is displayed in place of Help.

4. To exit the Help display, touch Quit.

2.13.1. MAIN Page Help Examples

Two examples of the available Main Page Screen Help information follow:

TABLOID/BROADSHEET

This item toggles when touched. To the right of this item is the Pages. Pages divides the pages

in half while TABLOID is displayed and when BRDSHEET is displayed, the Pages are as

entered.

Set-up and Event MESSAGES Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


PAGES

Pages are important. They govern how the stacking section carriers travel, how deep the

stacking section blades jump into the in flow of papers and how much kraft paper is fed when

used with the 3/4 bottomwrapper machine.

2.14 Set-up and Event MESSAGES

A MESSAGE line in the lower left corner of most screens provides information on the set-up

procedure. It identifies certain stacker operations for troubleshooting purposes. A list of MESSAGES

is shown in Section 5.2 with recommended corrective action in Section 5.3.

Note: Messages are time tagged and recorded as received with one exception; if two or more of

the same occurrences take place in sequence, only the last occurrence will be recorded.

If more than 100 messages have been recorded, the oldest message will be canceled.

(*) identifies occurrences recorded and signaled with the stacker alarm horn at the time of

occurrence.

(**) identifies occurrences recorded, signaled and which shut down the stacker.

No asterisk identifies occurrences only recorded.

2.14.1. The MESSAGES

MESSAGES involving the BUNDLES data entry procedure are explained in the following.

TOUCH 'CLR' TO CLEAR TOTAL

Tells operator to depress "CLR" button after touching the "PAPER TOTAL" to clear "PAPER

TOTAL".

RESULTS IN A BATCH LESS THAN 2 PAPERS

Minimum Batch Size = 2.

ENTERED RESULT TOO SMALL

Entered value less than minimum allowed.

ENTERED RESULT TOO LARGE

Entered value more than maximum allowed.

*PAPER SENSOR HAS CHANGED*

Tells operator the paper sensor was switched.

POWER-UP

Tells operator that the stacker just powered up.

**STOP BUTTON PUSHED**

STACKER IS SHUT DOWN - The operator depressed a "STOP" pushbutton.

CLEAR BUTTON PUSHED

The operator depressed a "CLEAR" pushbutton. The stacker is cycling or has just recycled.

ENTER THE THREE DIGIT CODE

The operator depressed "LOCKED" or "UNLOCKED"

Controls, Set-Up, and Stacker Start-Up Series 50X Stacker Set-up and Event MESSAGES


"ODD COUNT MODE"

Displayed when stacker is put into "ODD COUNT" programming.

*STANDARD MODE*

Displayed when stacker is taken out of "ODD COUNT"

RESULTS IN A STACK GREATER THAN 999

Displayed when stack size entered is more than 999.

Set-up and Event MESSAGES Series 50X Stacker Controls, Set-Up, and Stacker Start-Up


NOTES:



3.1 General.................................................................................................................................. 3.1


3.3 Using the Touch Screen........................................................................................................ 3.23.3.1. The Lock-out Code.................................................................................................................3.2

3.4 General Set-Up ..................................................................................................................... 3.3

3.5 Mechanical Adjustments ....................................................................................................... 3.33.5.1. Cut Edge Guide......................................................................................................................3.4

3.5.2. Batch Side Guides .................................................................................................................3.5

3.5.3. Turntable Walls ......................................................................................................................3.5




3.8 To Set-up for Production ....................................................................................................... 3.8

3.9 New Bundle Data Entry ......................................................................................................... 3.8


Table of Contents Series 50X Stacker Chapter 3 50XC Series Stacker Pressor





3.1 General

This chapter describes the Pressor features included with the 50XC Series Stacker.

3.2 The Touch Screen/Display

The touch screen/display is located on the back of the 50XC Series Stackers. It permits and

provides:

• Set-up for production

• Fine-tuning of operation

• Display of operating information

• Stacker troubleshooting suggestions

Note: The Main Page (below) and the remaining basic displays are all identified as Pages.

Figure 3.1: Main Page Bundle Display Set-up Screen

Using the Touch Screen Series 50X Stacker 50XC Series Stacker Pressor Adjustments


3.3 Using the Touch Screen

Once stacker power is on, the Main Page appears. Back-lighted data on this (and the other Pages)

can be changed. Touch the word Pages (Upper Right) on any screen to display the pull down menu

(Figure 3.2). The menu accesses the following nine (9) Main Pages:

1. Main

2. Profiles

3. Parameter

4. Status

5. IO Updates

6. Service

7. Messages

8. Set Clock

9. Pressor

Display any of these Pages by:

1. Touching Page of any display - - the Pull-down Menu appears.

2. Touching the desired Page title - - the new Page will be displayed.

3.3.1. The Lock-out Code

Refer to Section 1.1.1. if LOCKED is displayed in the lower LH corner of the screen.

Figure 3.2: The Main Page Pull-Down Menu - upper right

50XC Series Stacker Pressor Adjustments Series 50X Stacker General Set-Up


The purpose of the nine (9) Main Pages is explained below. A detailed explanation of the

functions can be found in the referenced sections in this manual.

Main - to set-up the stacker for a specific product run (3.8 & 3.9)

Profiles - the Speed-Set method of bringing up recorded past run parameters (2.12).

Parameter - permits stacker fine-tuning (4.2).

Status - displays conditions, counts and other stacker operating data (5.4).

IO Update - displays status of stacker I/O signals (5.7).

Service - offers service and maintenance instructions for stacker upkeep (4.3).

Message - displays most stacker occurrences, time stamped and recorded (5.2).

Set Clock - permits setting of date and time displayed on the screen (3.7).

Pressor - controls all Pressor adjustments (3.9).

Help information on many stacker settings can be called up and displayed as explained in

Section 2.13.

Explanation and use of the various Touch Screen Pages are referenced in Section 3.4.

3.4 General Set-Up

Set-up for production involves one-time, infrequent and daily activities:

• Mechanical Adjustments - Section 3.5

• Pneumatic Adjustments - Section 3.6

• Entering control settings - Section 3.7-9

3.5 Mechanical Adjustments

Before first-time production, adjust the stacker for the products to be handled and for other local

conditions. These adjustments are:

Mechanical Adjustments Series 50X Stacker 50XC Series Stacker Pressor Adjustments


Figure 3.3: Batch Forming Guide Adjustment Devices

3.5.1. Cut Edge Guide

Place a 3-4" [75-100mm] high stack of products on the center of a set of stacking blades. Their

cut edges should clear the cut edge guide by about 1/4 inch. When correctly set, the upper ends

of the guides will lightly push each product dropped onto the blades back against the rear of the

stack forming area. Ensure that the stack cut edge is undisturbed by the guides as the batch

drops into the turntable. Adjustment knobs are identified in Figure 3.3. Make changes in guide

position only when the stacker is idle.

CAUTIONA jam can result from setting the guide too tight and

the bypass gate could drop unexpectedly.

Side GuideLockdownKnobs

Batch Side GuideAngle Brace

Cut EdgeGuide andLockdownKnobs

50XC Series Stacker Pressor Adjustments Series 50X Stacker Mechanical Adjustments


3.5.2. Batch Side Guides

With the 3-4" (75-100mm) stack of products centered on the stacking blades, move the vertical

clear plastic side guides to within about 1/4 inch of the stack ends. Two knobs at each side of the

stacker permit this adjustment (see Figure 3.4). Maintain the guides perpendicular to the floor.

Adjust the incoming angle of the side guides so that their vertical front edges are about 1/2 inch

farther apart than their back edges using the third knob at both stacker sides (Figure 3.4).

3.5.3. Turntable Walls

Turntable walls may require position adjustment to prevent excessive slippage of the product

while in the turntable.

To check settings: Place a copy of the product to be stacked inside the turntable. About 1/4"

[6mm] clearance should remain between walls and product edges.

Figure 3.4: A-Side Table Wall and Belt Take-up Lock Handles

If readjustment is required, refer to Figures 3.4 and 3.5:

1. Each wall has two locking handles and each wall drive motor has a take-up locking

handle. Loosen the six handles involved with the two walls.

A-WallProx Sensor





A-WallDrive Motor Pressor Pneumatics

Mechanical Adjustments Series 50X Stacker 50XC Series Stacker Pressor Adjustments


Figure 3.5: View through Turntable (left) and from above (right)

2. Adjust the walls for 1/4" [6mm] clearance either side of the product. Keep them parallel to

and equidistant from the turntable centerline. Retighten the wall locking handles.

3. To tighten their drive belts, rotate the drive motors. Use a wooden lever if needed. Lock

with the two handles. The belts should be tight enough to permit only about 1/4" [6mm]

belt deflection on one side when firmly pushed in.

3.5.4. Turntable Eject Pushers

A 1/4" [6mm] clearance should remain between product ends and the two pusher sets between

which the products drop in the turntable. If clearance is incorrect, contact QUIPP Customer

Service for an optional set of pusher blade spacers. Or manufacture spacers locally; 12

required.

Turntable MIDSensor Targets

Pusher ProximitySwitches (2)

Wall DriveMotor (below) Lift Table Guide Rod Ends

Wall TensioningCylinder

Pressor PlatesCylinder

TurntableHOME Target PRESSOR Plates -

Retracted

Pusher Bars

Extended

Exit Directions

Drive Belts (2)

50XC Series Stacker Pressor Adjustments Series 50X Stacker Pneumatic Settings


3.6 Pneumatic Settings

With plant supply air from 90 to 100 psi [6.2-6.9 BAR], adjust air pressures as follows (see Figure

3.6.):

1. Main stacker to a 90 psi (left gauge).

2. Bypass Gate from 40 to 80 psi. Adjust to 40 psi for the first run. Test and observe results.

3. Turntable from 25 to 35 psi; adjust for best operation.

4. Table Up/Down; 40psi for first run, then adjust.

5. Squeeze Roller; 40psi for first run, then adjust.

The oil mister should add one drop of oil for every 10 to 20 turntable reversals. Close the Oil Drip

Adjust Knob and then open about 1/8th turn. Observe and adjust. Both the water trap and the oil

reservoir are removed by pushing down the slide latch on the side and turning the reservoir left or

right. It is quicker to fill the oil reservoir directly than through its fill port. Use 10-weight non-detergent

synthetic oil.

Figure 3.6: The Pneumatic Panel Area, Pressor Model Stackers

3.7 Control Clock & Screen Saver

Since all of the MESSAGES (discussed in Section 3.10 and 5.2) are recorded with time and date, the

internal date and time clock must be correctly set.

Note: The clock used is a 24-hour clock for example, 2:22 PM is 14:22. Since the clock is set to

Eastern Standard Time (EDT) at the QUIPP plant, you may need to reset the clock to your

time zone.

Reset as follows:

1. Power up the stacker.

2. Touch Page.

3. Touch Set Clock on Pull-down Menu: Figure 3.2.

To Set-up for Production Series 50X Stacker 50XC Series Stacker Pressor Adjustments


4. Touch the Hours number displayed; key in the hour required; key ENT.

5. Touch the Minutes number displayed; key in the minutes required; key ENT.

6. In similar way, set Seconds, Month, Day & Year.

The Screen Saver displays the time. The time delay before the screen appears is controllable or can

be eliminated.

Control the Screen Saver by turning it ON and OFF with the first line of the display. The second line

adjusts the delay before it cuts in when the computer is idle in the same way as time and date.

3.8 To Set-up for Production

Production set-up details follow.

Note: After any production run, part or all of that run set-up can be used for the new set-up. If an

existing setting on the touch screen is acceptable, simply move to the next setup step. See

also Section 2.12 for the Speed-Set alternate.

Before the first production run, review the following:

1. Ensure the stacker is in position (Sec. 1.9).

2. Ensure cabling is in place (Sec. 1.10).

3. Ensure the stacker ready for product (Sec. 3.5).

4. Ensure correct air supply (Sec. 3.6).

Refer to Sec. 2.13 for Help Information procedure.

Continue SET-UP:

1. Turn the disconnect switch to ON. The Main Page display (Figure 3.7) appears.

2. If Entry is LOCKED is displayed at the lower left, the control must be accessed using the CODE

PASSWORD. See Section 1.1.1.

The keypad permits change of numbered quantities. Data in smaller type involve modification of

stacker operation and provide further information. Values in parentheses are default values.

Production requirements are entered through the touch screen.

3.9 New Bundle Data Entry

Note: The information contained in 3.9 New Bundle Data Entry is applicable to the C Stacker only

Production set-up procedures follow. However, after any production run, the data for that run can be

recorded. Such stored run data can be called up later to be used totally or partially as needed. See

Section 2.12 for the Speed-Set procedure.

If an error is made in the set-up procedure, an explanation is displayed in the lower left of the Main

Page.

a. If the error is noticed before ENT is touched, touch CLR and enter the correct value.

b. If the error is already displayed, key in the required value and touch ENT.

Bring up the Main Page screen.

50XC Series Stacker Pressor Adjustments Series 50X Stacker New Bundle Data Entry


Figure 3.7: The Main Page Display

Entering Set-up Data

In the following procedure, assume the following;

a. Product delivered from a press - broadsheet

b. 220 Products in each final Stack (Bundle)

c. 2 Batches per Stack - reversed

d. 8 Pages per Product

e. The Pressor is to be used on first batch

f. The Pressor is not used on second batch

g. The Squeeze Roller to be ON

1. Touch the lighted numbers following (25/1)>.

2. Key the required total products required (220) in each stack (bundle) (from 2 to 999 possible).

Touch ENT.

3. Key the number of batches required (2) in each stack (1 to 9 possible). Touch ENT. The keyed-in

stack and batch count now appear to the right of the default values (25/1)> --- 220/2.

4. When TABLOID and BRDSHEET are alternating, the control is set for stacking a broadsheet

product. To stack an inserted product, touch the alternating words until TABLOID is displayed.

New Bundle Data Entry Series 50X Stacker 50XC Series Stacker Pressor Adjustments


5. Touch the number following Pages(50)>. Key in the number of pages (not sheets) in one product

(8) (4 to 500 possible). The number must be in either BRDSHEET or TABLOID pages as entered

during Step 4. Touch ENT.

6. From the four ON/OFF displays, select:

a. ODD COUNT> ON/OFF should indicate OFF. Turn to ON only if an odd count programming

system is directing stacker operation.

b. TURN TABLE> ON/OFF controls its rotation. Touch the area until ON is displayed. To

prevent reversal, bring up OFF.

c. Squeeze ON and OFF. Touch ON to operate the Squeeze Roller.

d. Pressor(OFF)> ON/OFF controls the batch press. When ON, press action is controlled

through the Pressor Page (Figure 3.8) as explained in the following.

To display the Pressor Page:

Touch Page.

Touch Pressor on pull-down menu.

The Pressor Page appears.

Figure 3.8: Pressor Adjustment Page

The five Pressor Page adjustments are used as follows:

1. Pressor/Lift (Pressor)> Pressor

50XC Series Stacker Pressor Adjustments Series 50X Stacker New Bundle Data Entry


When Pressor is ON the Main Page, the word can alternate between Lift and Pressor.

a. Lift - the table rises to receive the first batch (only) of a stack. It is not pressed.

b. Pressor - Table rises to receive first batch, drops to permit Pressor Stops to extend,

rises again to press batch against stops. Stops retract. Table drops fully for next

batch, Stops extend, table rises to press. Action continues as above with remaining

batches unless last batch press is off:

2. Press Last Batch (OFF)> OFF

Controls pressing last batch ON or OFF.

Note: If Last Batch is pressed, the press time of the previous batches will be lengthened. (See

Sec. 1.7).

In the following three controls, the time is shown in milliseconds(ms) x 10. Example:

100 x (10ms) is 1000 ms (1 second).

Experience will show the best time.

3. Batch Press Time (100) x 10ms> 100

[actually 100x10=1000 or 1 second]

the time the table is pressed up against the stops before the table is lowered. Enter 50 for

first run then adjust as needed.

4. Pressor Down Delay (40)x10ms> 40

[actually 40x10=400ms or 0.4 second]

the delay after the press action is complete before the table is lowered. Enter 20 for first run

then adjust as needed.

5. Pressor Up Delay (50)x10ms> 50

[actually 50x10=500ms or 1/2 second]

This delay permits the just received batch to be lowered below the pressor plates before

return for pressing. Enter 25 for first run then adjust as needed.

Touch Page and then Main Page on the Pull Down Menu for the Main Page. The remaining controls

are:

7. BLANKING> rejects false counts caused by irregularities between leading edges of genuine

products. Sections slipped back inside a jacket or inserts lying on top can produce false counts

(Figure 3.9). Settings are AUTO or MANUAL.

Note: When ROP is entered, the setting becomes AUTO at 1" [25mm] automatically.

a. AUTO (Blanking) rejects counts produced in the first 50% of the average lap between the last

eight products detected. The lap can be as long as 12" [305mm] with a maximum blanking of

6" [153mm]. However, when product lap varies inconsistently, an overcount bundle may

develop from a high average caused by one long lap. If this is a problem, switch to MANUAL

Blanking.

New Bundle Data Entry Series 50X Stacker 50XC Series Stacker Pressor Adjustments


Figure 3.9: Count Blanking

b. MANUAL (Blanking) is recommended for most insert runs. MANUAL blanking is adjusted

through the STATUS Page. Blanking is adjustable in 1" [25mm] steps from

25 to 100mm [1 to 4 in the display]

When in INSERT, set Blanking at -- about 1/2 average lap

During production, look at Product Lap on the STATUS Page. Using key pad and MAIN

PAGE display, enter blanking of half Product Lap Distance. Touch ENT. Experiment for the

best value.

8. PAPER SENSOR> alternates a selection between QUIPP Count Pro II laser and mechanical

sensors. Two mechanical sensor models with different page ranges are available. The "small

wheel" sensor is supplied as standard. An optional "large wheel" sensor is applied primarily to

large inserted products.

9. PAPER TOTAL> is the sum of products processed through the stacker since the last time the

readout was reset. To reset the display to zero before a run, touch PAPER TOTAL on the

Main Page and then CLR in the key pad.

10. MODE> permits alternating between ROP and INSERT which switches BLANKING as in 5b,

above. Touch the display to reverse setting.

11. MESSAGE: May display messages, explained in Section 5.3, as the action described takes

place. Messages are recorded and can be retrieved (Sec. 3.10) per suggestions, Sec. 5.3.

12. Entry is LOCKED or UNLOCKED - indicates the Lock-out Code must be entered to change

the control settings - Sec. 1.1.1.

Product Profile> is a Speed Set method of stacker set-up. Refer to Section 2.12.

Note: Operators' Pushbuttons on the side of the stacker control the directions and program of

stacks delivered from the stacker.

Blanking ZoneLaser Light andCount Sensor Paths

50XC Series Stacker Pressor Adjustments Series 50X Stacker Set-up and Event MESSAGES


3.10 Set-up and Event MESSAGES

A MESSAGE line in the lower left corner of most screens provides information on the set-up

procedure. It identifies certain stacker operations for troubleshooting purposes. A list of MESSAGES

is shown in Section 5.2 with recommended corrective action in Section 5.3.

Note: Messages are time tagged and recorded as received with one exception; if two or more of

the same occurrences take place in sequence, only the last occurrence will be recorded.

If more than 100 messages have been recorded, the oldest message will be canceled.

(*) identifies occurrences recorded and signaled with the stacker alarm horn at the time of

occurrence.

(**) identifies occurrences recorded, signaled and which shut down the stacker.

No asterisk identifies occurrences only recorded.

3.10.1. The MESSAGES

MESSAGES involving the BUNDLES data entry procedure are explained in the following.



TOTAL".


Minimum Batch Size = 2.


Entered value less than minimum allowed.

ENTERED RESULT TOO LARGE

Entered value more than maximum allowed.



POWER-UP

Tells operator that the stacker just powered up.



CLEAR BUTTON PUSHED

The operator depressed a "CLEAR" pushbutton. The stacker is cycling or has just recycled.


The operator depressed "LOCKED" or "UNLOCKED"

"ODD COUNT MODE"

Displayed when stacker is put into "ODD COUNT" programming.

Set-up and Event MESSAGES Series 50X Stacker 50XC Series Stacker Pressor Adjustments


*STANDARD MODE*

Displayed when stacker is taken out of "ODD COUNT"


Displayed when stack size entered is more than 999.


Table of Contents


4.1 Introduction............................................................................................................................ 4.1

4.2 Fine Tuning the Stacker During Production .......................................................................... 4.14.2.1. User Help Information ............................................................................................................4.1

4.2.2. The Parameter Page..............................................................................................................4.2

4.2.3. Stacking from an Inserter .......................................................................................................4.4

4.3 General Maintenance ............................................................................................................ 4.6

4.4 Scheduled and Preventive Maintenance............................................................................... 4.64.4.1. Initial Inspection .....................................................................................................................4.6

4.4.2. Daily Attention ........................................................................................................................4.6

4.4.3. Monthly and Extended Attention ............................................................................................4.7

4.4.4. Lubrication - as needed..........................................................................................................4.7

Table of Contents Series 50X Stacker Chapter 4 Start-Up and Preventive Maintenance





4.1 Introduction

The 50X should now be ready for production.

Prior to start-up, ensure that:

1. The stacker is in the correct position (Sec. 1.9).

2. Necessary cabling is in place (Sec. 1.10).

3. The stacker is mechanically ready (Sec 2.7.1 & 2).

4. Stacker power is on (Sec. 2.10).

5. Correct air pressure is set (Sec. 2.8).

6. Bundle requirements have been entered (Sec. 2.11).

7. The on-going conveyor/equipment is ready.

8. A START/CLEAR pushbutton has been pressed at which point:

the stacker will be cycled and moving components will arrive at their home positions ready for

product. If this does not occur, refer to the Troubleshooting Chapter 4.

As product arrives at the stacker, ensure that:

1. Adequate lap exists (Sec. 4.2.3, Figure 4.2 )

2. Intercept is positive and accurate (Sec. 4.2.2-d).

3. Product stacks well on the blades (Sec. 2.7.1 & 2).

4. Batches drop into turntable cleanly (Sec. 4.2.2-e).

5. Stacks deliver without distortion (Sec. 4.2.2-h).

6. Stack count is accurate (hand count some stacks).

If a problem occurs, the MESSAGE displayed at the bottom of the screen or on the MESSAGE Page

provides information as to cause. Refer to Section 2.14, 5.2 or 5.3 for suggestions concerning the

messages.

4.2 Fine Tuning the Stacker During Production

Certain stacker control functions can be modified to improve stacker operation. The functions are

accessible through the Parameter Page (Figure 4.1). This screen also displays certain other stacker

operating conditions. All are explained through the following:

4.2.1. User Help Information

The available Help discussions clarify almost all displayed numbers or conditions.

To call up a Help discussion:

1. Touch Help - upper left screen. Touch the item in question.

2. The Help discussion will appear. The word Help will change to Quit.

3. To eliminate the Help display, touch Quit.

Fine Tuning the Stacker During Production Series 50X Stacker Start-Up and Preventive Maintenance


4.2.2. The Parameter Page

Display the Parameter Page screen by touching Page of any screen. Then touch Parameter in

the Pull Down Menu. Operator-adjustable functions are shown lighted. To modify:

1. Touch the lighted figure. It reverses.

2. Enter a new value (within the range listed in the following) on the keypad.

3. Touch ENT.

The Functions are discussed on the following page.

Figure 4.1: The PARAMETER Page Display

Parameter Functions

Figures in parentheses in the following are factory set default values. To change a lighted figure,

touch it, key in a new number, and touch ENT.

a. Minimum Infeed Speed (180fpm)>

Range: 140 to 300fpm [0.7-1.5M/sec]

is the slowest infeed belt speed that drives the product against the back guides. This

speed is held when the supply conveyor speed drops below that value. Increase the

speed for light products.

Note: On applications where no conveyor speed reference exists, use this

adjustment to match the stacker infeed speed to the supply conveyor speed.

b. Left Bundles (1-9)

When delivering stacks alternately, the set number will be the quantity of stacks

delivered from the left side before the stacker delivers from the right.

Start-Up and Preventive Maintenance Series 50X Stacker Fine Tuning the Stacker During Production


c. Right Bundles (1-9)

As with item "b" above but applies to the right delivery direction.

d. Intercept Distance (43 counts)>

Range: 4 counts from value in (xx)

Sets the point at which the tips of intercept blades enter the stream in front of the

product to be intercepted. This should be about one inch (1") [25mm]. To check,

apply a bit of grease or crayon to the front bottom tip of the blades. Then:

• Set the Batch Count to 10 products.

• Generate 5 counts through the product sensor (flip sensor wheel or break the

beam).

• Release 7-8 products with 3" [75mm] lap into the stacker infeed.

• Ensure that the 6th product was intercepted and that the mark on the 5th

product where blade tip contact was made was about 1" [25mm] behind the

product leading edge.

To adjust, change the setting by one count or pulse (equals 0.24" - about 1/4" [6mm])

and check again.

e. Batch Dropping Speed (100%)>

Range: 60% to 100%

Adjusts the speed with which the stacking blades lower and pull out from beneath a

stacked batch of products. Reduce the speed somewhat with heavier products

(inserted) and with very light products to improve stack quality.

Note: Values less than 100% will increase stacker minimum cycle time.

f. Turn Delay (200ms)> [1/1000 sec.]

Range: 200 to 600ms

Permits the last products in a batch to settle in the turntable before the turntable is

rotated.

Note: Values of more than 200ms will increase the stacker minimum cycle time.

g. Pusher Delay (200ms)>

Range: 200 to 600ms

Permits the last products of the last batch of a stack dropped into the turntable to

settle before the pusher ejects the stack.

Note: Values of more than 200ms will increase the stacker minimum cycle time.

h. Pusher Speed (140fpm)> [0.8M/sec]

Range: 100 to 180fpm [0.5-0.9M/sec]

Permits adjustment of pusher velocity to match the on-going conveyor. Stacks may

distort if ejected at a velocity different than the on-going conveyor.

Note: Values of less than 140fpm [0.7M/sec]) will increase the stacker minimum

cycle time.

Fine Tuning the Stacker During Production Series 50X Stacker Start-Up and Preventive Maintenance


i. Simulation Rate (OFF)>

Range: 1000 to 99,000 papers per hour

Permits stacker operation without products while fine-tuning, testing and

troubleshooting. The rate is set in thousands. Example: 50 equals 50,000pph. See

Section 5.1.1 for the procedure.

j. Infeed Scaling Factor (100%)>

Range: 25 to 200%

Permits adjustment of stacker infeed speed relative to supply conveyor speed.

Example, a consistent 4" [102mm] product lap delivered from the supply conveyor

can be closed up on the stacker infeed by reducing the scaling factor. Make 5-10%

changes and observe results after each adjustment.

The scaling factor can also compensate for differences in conveyor encoder output

when moving the stacker to a different product supply conveyor.

k. Laser Sensitivity (80)>

Range: 60 to 85%

Higher settings for thinner products but will also pick up some wrinkles in the product.

Lower settings for larger products and to eliminate false count inputs due to rough

stock, etc.

l. Message

Displays a series of informative messages as they develop and as explained in

Sections 5.2 and 5.3.

4.2.3. Stacking from an Inserter

Stacker Infeed Speed Considerations

The conveyor delivering from an inserter usually operates at a fixed speed. If no stream speed

encoder is in use, the stacker MINIMUM INFEED SPEED control (Section 4.2.2-a) is used to

adjust stacker infeed speed to that of the inserted product conveyor. The following suggestions

apply.

1. Stacker Infeed Speed should never be slower than the supply conveyor speed. Refer to

Chart (Figure 4.3) for an appropriate Stacker Infeed Speed for a specific inserter

conveyor speed.

2. The Infeed Speed should not be less than about 140 feet per minute [0.8M/sec]. Slower

speeds may reduce stack quality.

3. If the product lap increases in the stacker infeed with a 140 fpm [0.8M/sec] Infeed Speed,

increase speed of the supply conveyor. Most inserter deliveries have manual speed

controls.

4. Refer to Figures 4-2 & 4-3. The ideal product lap from an inserter is 7" to 8"

[178-203mm].

With a lap of 6 " [152mm] or less, a gap may or may not form if the inserter misses. This

is shown in the upper half of Figure 4.2. If the following product leading edge is buried in

the trailing edge of the leading product, the following product may not be detected and an

over-count stack will result.

Start-Up and Preventive Maintenance Series 50X Stacker Fine Tuning the Stacker During Production


The bottom of Figure 3-3 shows the ideal lap - greater than 7" to 8" [178-203mm]. With a

miss, a gap will form in the stream and the sensor will be able to detect the following

product.

Figure 4.2: Typical Inserter Lap Conditions

Figure 4.3: Stacker Infeed vs. Inserter Production Rate

Insufficient Lap - 50% or less

Sufficient Lap - More than 50%

No Lap

Gap

General Maintenance Series 50X Stacker Start-Up and Preventive Maintenance


4.3 General Maintenance

The maintenance required with the QUIPP Series 50X Stackers involve:

• Scheduled, Preventative Maintenance - and

• Emergency, Detailed Maintenance

Scheduled maintenance will aid in the proper and continued satisfactory operation of the stacker.

Preventative, detailed maintenance involves prevention and correction of problems through

adjustments and parts replacement. A Troubleshooting Chapter (Chapter 5) follows to identify

problems that might occur with recommended corrective actions.

4.4 Scheduled and Preventive Maintenance

During the first hours of operation, check for initial start-up problems noted in Section 4.4.1. Correct

per instruction in Chapter 5

Include the Stacker in the regular schedule of inspection and maintenance applied to the remaining

equipment with which the stacker is associated.

4.4.1. Initial Inspection

With the first use of the stacker in production, make an initial inspection during the run to ensure:

• No loose hardware, belting or components

• No unusual sounds or vibrations

• No oil leak from the sealed gear reducers

• No loose electrical connections resulting from travel and installation vibration - tighten all.

Correct any problems. Chapter 5 Troubleshooting, will aid if a solution is not immediately

obvious.

4.4.2. Daily Attention

In addition to continuing the checks noted above:

1. Blow off the stacker with low pressure air as part of the general area clean up. Include the

- Infeed section,

- Stacking section, both front and rear, making sure that the stacking blade cam follower

tracks are clean and dry, turntable including blowing through the mat top walls and the

area below the turntable,

- Electrical enclosure by opening its door and lightly blowing away any paper dust

accumulation. Lightly blow into one end of the grill tops of the four stepper motor

amplifiers to remove paper dust from inside the units,

- Outer surface of the stacker.

2. Visually check the infeed belting. Ensure that the stacks produced are in acceptable form.

Correct any problems. Refer to Chapter 5 Troubleshooting if a solution is not obvious.

Start-Up and Preventive Maintenance Series 50X Stacker Scheduled and Preventive Maintenance


4.4.3. Monthly and Extended Attention

Conduct a detailed inspection of the stacker after the initial month of operation and at 3 to 6

month intervals, depending upon machine usage. Operate the stacker in its Simulate Mode per

Section 5.1.1. Test at a low rate (12-15,000) and at a higher rate (40-50,000).

Listen for unusual noises and watch for sluggish or erratic operation. Ensure one drop of oil for

every 20 or so turntable rotations. Adjust, repair, replace - as needed. Then:

1. Check infeed belting.

2. Check under the infeed drive motor area for gearmotor oil leakage. The gear reducer is a

sealed unit filled with synthetic oil that does not require replacement. There is no breather

plug on the reducer.

3. Check for leaking compressed air lines, fittings, pneumatic actuators and other such

components. Repair or replace.

4. Check the air set. Validate required pressure settings. Remove and clean the water trap;

ensure an adequate oil supply, both per Section 2.8.

5. Check for damaged, frayed, electrical cables and connectors.

6. Check product sensors. Refer to Sensor manuals at the end of the Main Instructions.

Carefully wipe the laser sensor window per instructions. Check the mechanical sensor for

excessive wear. The intercept of the sensor should be replaced when the four points have

worn and extend only from 1/4" to 5/16" [6-8mm] through the sensor bottom.

7. Periodically ensure there are no loose electrical connections.

Correct any other problems. Generally, after an extended period - 1 to 2 years, depending upon

daily load, replacement of worn components is more practical than their repair. Refer to Chapter

5 Troubleshooting if a solution is not obvious.

4.4.4. Lubrication - as needed

Stacking Section -- The stacking section chains should be lubricated only with a dry graphite or

molybdenum powder to prevent build up of paper dust on the units. Do not lubricate the cam

follower tracks - only blow clean.

Turntable Assembly -- With a grease gun, inject a small amount of lithium grease into both the

mounting end and the rod end universal bearings of the turntable drive cylinder - if grease fittings

are present. (Certain components are lubricated for the life of the bearing.) In addition, apply this

grease freely on both mount supports of the damping assembly opposite the cylinder.

Other Bearings -- Do not lubricate other bearings which have grease fittings. These fittings

were used by the bearing manufacturer for the initial grease application.

The Oil Mister -- As noted above, check the oil level in the air set lubricator. No. 10W non-

detergent oil is applicable. As an option, rather than adding oil through the fill hole at the top of

the oil mister, unscrew the clamping ring holding the reservoir to the housing. Fill the container

with oil directly and replace.

Scheduled and Preventive Maintenance Series 50X Stacker Start-Up and Preventive Maintenance


NOTES:


Table of Contents


5.1 General.................................................................................................................................. 5.15.1.1. How to set up SIMULATION ..................................................................................................5.1

5.2 MESSAGES .......................................................................................................................... 5.2

5.3 Recorded Messages, Possible Causes, Recommend Corrections...................................... 5.5

5.4 Status Page........................................................................................................................... 5.65.4.1. Status Page Help ...................................................................................................................5.7

5.4.2. Status Page Help Examples ..................................................................................................5.7

5.5 Indicating LIGHTS and LED's................................................................................................ 5.85.5.1. Proximity Switch Indicators ....................................................................................................5.8

5.5.2. Power Supply Indicators ........................................................................................................5.8

5.5.3. CPU in the Card Cage Indicators...........................................................................................5.9

5.5.4. Main Relay Indicators.............................................................................................................5.9

5.5.5. Infeed Motor AC Drive...........................................................................................................5.9

5.5.6. Proximity Switches Troubleshooting Procedures...................................................................5.9

5.6 A Normal Start-up Test........................................................................................................ 5.125.6.1. Initial Start-up Sequence......................................................................................................5.12

5.6.2. Operator Inputs and Checks ................................................................................................5.12

5.6.3. Sequence Completion..........................................................................................................5.13

5.7 The IO Update Page ........................................................................................................... 5.14

Table of Contents Series 50X Stacker Chapter 5 Troubleshooting





5.1 General

QUIPP Series 50X Stacker controls include aids to identify and solve problems that may develop.

HELP Information -

Refer to Section 2.13 User Help Information for details.

MESSAGES -

When an alarm sounds or the stacker shuts down, a message appears in the lower left corner of

the screen. Check Sec. 5.2 for possible cause(s).

MESSAGES Record

Touch Page 7 for the Pull Down Menu, Touch Messages. The problem may have been caused

by several occurrences. Messages are recorded First In - First Out with the last recorded as the

bottom message in the list. Messages (Section 5.2) have service suggestions detailed in Section

5.3.

The Status Page

The Status Page displays a number of stacker operating conditions which aid in identifying a

problem. Section 5.4.1 discusses this aid.

Indicating LIGHTS and LED's

Indicating lights and LED's on various stacker components identify both normal and abnormal

operation. See Section 5.5 for details.

However, before proceeding with extensive checks, first:

• Ensure correct power and air are supplied

• Ensure the product being run has been correctly set up on the Main Page screen, etc.

Then, if the problem persists, step through the Messages.

5.1.1. How to set up SIMULATION

To set up the stacker in SIMULATION, with the stacker powered up and START/CLEAR

pressed:

1. Bring up the Parameter Page

2. Press OFF to ON following Simulation Rate

3. Key in a rate up to 99 (in thousands)

4. Press ENT

To exit SIMULATION:

1. Press START/CLEAR

2. If product is detected, SIMULATION also stops

MESSAGES Series 50X Stacker Troubleshooting


5.2 MESSAGES

An EVENT MESSAGE is displayed following:

• almost all operator entries or pushbutton actions

• with many actions that should have, but did not occur, and are identified for follow up.

The messages and their explanations follow.

1. Up to 100 messages are time tagged and recorded as received, with one exception; if two or

more of the same occurrences take place in sequence, only the last such occurrences will be

recorded.

2. If more than 100 of these messages have been recorded, those beyond the 100th will be

canceled.

3. (*) identifies recorded occurrences that were alarm horn signaled at the time of occurrence.

4. (**) identifies recorded occurrences that shut down the stacker.

5. No asterisk identifies occurrences only recorded.

6. Original and newly changed values of data bits are recorded and time dated - the 3rd example

below.

7. When a control parameter is changed, the original value and the new value are both recorded.

To display recorded MESSAGES, touch Pages (in the upper right corner) and then Messages on the

Pull Down Menu. Scroll via button lower RH corner. An example of the display follows.

Figure 5.1: The Message Page

Troubleshooting Series 50X Stacker MESSAGES


The EVENT MESSAGES

Messages which may be displayed and recorded are;



TOTAL".


Minimum Batch Size = 2 - normally.


Entered value more than minimum allowed.



POWER-UP

Tells operator that stacker just powered up.

**TABLE FAILED TO HOME**

STACKER IS SHUT DOWN - due to turntable not returning to "home" position.

**TABLE FAILED TO LEAVE**

STACKER IS SHUT DOWN - Turntable failed to leave "home" position.

**TABLE FAILED TO FIND MID**

Turntable made first proximity switch but failed to find midpoint.

**K1 RELAY DEACTIVATED**

STACKER IS SHUT DOWN - Due to loss of compressed air supply.

**NO INFEED SPEED PULSES**

STACKER IS SHUT DOWN - Due to loss of infeed conveyor speed or infeed speed distance

sensor failure.

*TOB CLEAR SIGNAL*

Last papers deposited on forming batch raised the "TOP-OF-BATCH" sensor arm to top (2nd)

position.

*STACKING SECTION OVERRUNNING*

Next carrier blade set not at its home position when signaled to perform an intercept.

FACTORY SET INSTALLED

Parameter memory battery has failed; operator parameter/set-up lost.

RE-SYNCING PUSHER 'B'

Stacker cycling pusher B to "home" sensor.

RE-SYNCING PUSHER 'A'

Stacker cycling pusher A to "home" sensor.

**PUSHER 'A' FAILED TO LEAVE HOME**

STACKER IS SHUT DOWN - Pusher A did not cycle.

MESSAGES Series 50X Stacker Troubleshooting


**PUSHER 'B' FAILED TO LEAVE HOME**

STACKER IS SHUT DOWN - Pusher B did not cycle.

**PUSHER 'A' FAILED TO FIND HOME**

STACKER IS SHUT DOWN - Pusher A did not completely cycle.

**PUSHER 'B' FAILED TO FIND HOME**

STACKER IS SHUT DOWN - Pusher B did not completely cycle.

*REMOTE BATCH FUNCTION TOO SOON*

Remote batching signals (programming) arriving quicker than in 1 second.

*STACKER BATCH BUILDING*

Displayed when leaving remote (programming) control.

**STACKING SECTION MISSED HOME**

STACKER IS SHUT DOWN - Due to a stacking section not returning completely to home.

*REMOTE BATCH BUILDING*

Displayed when entering remote control (programming).

*REMOTE STACK CLEAR*

Displayed when stacker receives remote CLEAR signal.

**STACKING SECTION 'A' FAILED **

STACKER IS SHUT DOWN - Stacking Section 'A' blades did not move.

**STACKING SECTION 'B' FAILED**

STACKER IS SHUT DOWN - Stacking Section 'B' blades did not move.



CLEAR BUTTON PUSHED

The operator depressed a "CLEAR" pushbutton.


The operator pressed "LOCKED" or "UNLOCKED"

"ODD COUNT MODE"

Displayed when stacker is put into "ODD COUNT" programming mode.

*STANDARD MODE*

Displayed when stacker is taken out of "ODD COUNT" programming.

NO AIR?

Displayed when relay K1 won't close, usually due to loss of compressed air.

*DOUBLE ROTATE*

Displayed when stacker gets one "ROTATE" Signal after another too quickly.


Displayed when stack size entered is more than 999, the maximum permitted.

Troubleshooting Series 50X Stacker Recorded Messages, Possible Causes,


5.3 Recorded Messages, Possible Causes, Recommend Corrections

In the following table, single or double asterisks lead and follow the MESSAGE (* or **). A single

asterisk indicates that the message is announced only with an audible alarm. Two-asterisks indicate

the STACKER WILL SHUT DOWN (no alarm). Check Sec. 5.2 for instructions on bringing the

MESSAGES to the screen.

Messages Activated By Possible ProblemsRecommended

Corrections

*TOB CLEAR SIGNAL* Top-of Batch Sensor Products building up on stacking section

blade too fast. Top products raising the

TOB Sensor to the top (second) position.

TOB Sensor misadjusted

TOB Sensor faulty

Faulty product sensor

Increase the PAGES per copy

value on Main Page screen

(Reference - Sec.2.11)

Check and readjust sensor

Replace TOB Sensor (6.2.6)

Switch to alternate copy sensor

**STACKING SECTION

MISSED HOME**

A Stacking Section

Sensor

Product building up in infeed section

Faulty stacking section sensor (5.3.1)

Stepper Motor Failure (4.5 & on)

Motor electrical drive failure (4.5 & on)

Stepper motor I/O card faulty (4.5 & on)

Loose cables

Loose Stacking Section motor gear

Faulty drive chain

Increase MIN INFEED SPEED

Reference - Sec. 4.2.2-a

Check, replace, if needed




Check that all cables fixed

Check, tighten, if needed

Correct (6.3.2)

**TABLE FAILED TO

HOME**

A Turntable Sensor Products jamming turntable

Loss of stacker air supply

Low turntable air pressure

Faulty turntable sensor (5.5)

Check, clear obstructions

Assure air supply (2.8)

Check regulator setting (40psi)

Check sensors' adjust/replace

**PUSHER A FAILED

TO FIND HOME**

Pusher A Sensor Products jamming turntable

Faulty Pusher A Sensor - Fig. 5.3, I/O 13

Pusher A Motor Failure - " & Sec 5.5.3

Pusher electrical drive failure " "

Stepper motor I/O card faulty

Loose cables

Loose pusher motor gear

Broken motor drive belt


Check, adjust or replace




Check that all cables fixed

Check, tighten, if needed

Replace belt (2.7.3.)

**PUSHER B FAILED

TO FIND HOME**

Pusher B Sensor Similar possible problems listed just above

Fig 5.3, I/O 14

Similar corrections as above

**PUSHER A FAILED

TO LEAVE HOME**

Pusher A Sensor Similar possible problems listed above Similar corrections as above

**PUSHER B FAILED

TO LEAVE HOME**

Pusher B Sensor Similar possible problems listed above Similar corrections as above

**TABLE FAILED TO

LEAVE**

Turntable Sensor Papers jamming turntable area

Loss of plant air supply

Low air supply to turntable cylinder

Faulty turntable sensor (4.5)

Faulty turntable valve (panel Fig. 2.7)


Assure air supply

Check air regulator setting (2.8)


Check, clean, replace valve

**TABLE FAILED TO

FIND MID**

Turntable Sensor Similar possible problems listed just above Similar corrections as above

Status Page Series 50X Stacker Troubleshooting


5.4 Status Page

The Status Page (see Figure 5.2) displays certain stacker conditions - both fixed and operational.

These data aid in analyzing stacker function, determining which control element should be fine-tuned

(Sec. 3.2), providing run results, comparing one run setup with a previous one, etc.

In addition - - - a discussion (Help) for each element of data on the display can be called up as

described in Section 4.2.1.

**K1 RELAY

DEACTIVATED**

Turntable Sensor Papers jamming turntable area

Loss of stacker air supply

Low air supply to turntable cylinder

Faulty I/O circuit card

Fault in Start/Stop Circuitry (Schematics)


Assure main air supply

Check air regulator setting

Check, replace

Troubleshoot with schematics

**NO INFEED SPEED

PULSES**

Infeed Speed

Distance Sensor

Product Jam in infeed

Faulty I/O circuit card

Fault SDS Sensor


Check, replace

Check or Replace (6.2.4)

**STACKING SECTION

A FAILED**

Stacking section A

Sensors

Product jam in stacking area

Faulty stacking section A Sensor(s)

Stacking section A drive motor failed

Faulty stepper motor drive

Loose cable to driver or I/O circuit card

Faulty stepper I/O circuit card


Check, adjust, replace sens (5.5)

Check, motor (5.5)

Verify and replace (5.5)

Verify all cable connectors tight

Verify and replace

**STACKING SECTION

B FAILED**

Stacking section B

Sensors

Similar possible problems listed just above Similar corrections as above

*LAP TOO CLOSE* Laser or mechanical

product sensor

Infeed conveyor too slow for incoming

product stream

Faulty product sensor (See Appendix)

Faulty Infeed section encoder (6.2.4)

Adjust infeed conveyor speed

(4.2.2-a)


Check, repair or replace

Messages Activated By Possible ProblemsRecommended

Corrections

Troubleshooting Series 50X Stacker Status Page


Figure 5.2: The Status Page Display

5.4.1. Status Page Help

To call up the Help discussion for each of the Status Page data displays:

1. Touch Help in the upper left corner of the screen.

2. Touch the digits following the title of the value in question. A Help discussion will appear. The

word Help will change to Quit.

3. To cancel the Help display, touch Quit.

5.4.2. Status Page Help Examples

Two examples of Status Page Help are:

PAPERS PER HOUR

The rate of inputting papers in thousands per hour. Updated once a second.

BLANKING DISTANCE

The distance either entered as a constant distance or a calculated distance of one half the

average lap when AUTO is selected. If the paper sensor activates while this distance is being

counted down, then that activation of that paper sensor is ignored.

Indicating LIGHTS and LED's Series 50X Stacker Troubleshooting


5.5 Indicating LIGHTS and LED's

Operation of almost all electrical and electronic components in 500C Series Stackers provides some

indication of satisfactory operation or of a problem with the component. The following material traces

these indicators through the main elements of the stacker:

• The CONTROL

• INFEED

• STACKING SECTION

• TURNTABLE/PUSHER

Certain control components are common to all of the mechanical sections of the stacker. The method

of checking them and proceeding with follow-on check is similar.

There are indicators on:

• Proximity Switches

• Stepper Motor Drives (see Section 6.7.4.)

• Power Supplies

• CPU

• Four mechanical Relays

5.5.1. Proximity Switch Indicators

When an EVENT or Troubleshooting MESSAGE identifies a problem area, first ensure no

mechanical blockage, etc. Next, check the proximity switch in that area.

Proximity switches are activated when a metal target passes the end of the unit. An LED on the

sensor lights. Ten such sensors are in the stacker:

•. Two (2) in the Top-of-Batch Sensor assembly (See Figure 6.6 and Parts Drawing 3411-A-

24919. Servicing the TOB system is detailed in Sec. 6.2.6).

•. Four (4) in the stacking section (See Figure 6.8 and Parts Drawing 3421-A-26873).

Four (4) on the turntable assembly (See Figure 6.10 & Parts Drawing 3411-A-34290A-1).

Note: These switches are similar on all Series 50X Stackers.

Check a questionable proximity switch by exchanging it with a unit known to be good. Make a quick

check by holding a screwdriver blade on the sensing end of a unit to cause it to trip.

5.5.2. Power Supply Indicators

50X Series Stackers include three (3) DC Power Supply voltage levels. When all voltages are

present, three lights are visible behind the left most circuit card in the card cage as shown in

Figure 6.13.

1. +12 VDC -- a red light

2. - 12 VDC -- a green light

3. + 5 VDC -- an amber light

If one or more of these lights is out, refer to Section 6.7 for check procedure.

Troubleshooting Series 50X Stacker Indicating LIGHTS and LED's


5.5.3. CPU in the Card Cage Indicators

The CPU in the card cage will normally have a red LED flashing 8 to 10 times per second on its

upper end. This indicates normal operation. If this light is not operating, the 5 VDC supply is

probably lost and the CPU will not be energized. See Section 6.6.5 on checking the 5 Volt

supply. If the power supply is OK, replace the CPU.

5.5.4. Main Relay Indicators

Each of the four main relays centered on TB2 has an internal red LED that illuminates when the

relay is energized. Applications for the relays are:

1. K1 - Main Air

Always energized during operation

2. K2 - Eject Left

Energized as stacks eject Left

3. K3 - Eject Right

Energized as stacks eject Right

4. K4 - Infeed Ready

Energizes to hold Bypass Gate in place. Can be activated with BYPASS GATE pushbutton on

side of stacker

If a relay does not energize as required, as a test, exchange it with one of the adjacent units

known to be good. The relays are identical.

Relays K2 and K3 do not energize in SIMULATE or in START/CLEAR.

5.5.5. Infeed Motor AC Drive

A group of numerical indicators and lights on the Infeed Motor AC drive provides servicing aid.

The Drive provides a variable voltage/variable frequency supply to the Infeed Motor.

The indicators and lights and their function are detailed in Section 5.5.

5.5.6. Proximity Switches Troubleshooting Procedures

Action Required Response Required

With Stacker Power on Indicators... on the Proximity Switches

1. Touch end(s) of the switch(es) of the components

being checked with a screwdriver blade.

If OK, proceed to Step 2.

The LED(s) on the switches should light ---

If not, go to Step 4

2. Manually move the component target past the

switch(es)

If not, go to Step 3

The LED(s) on the switches should light ---

If OK, go to Step 6

3. Check clearance between face of switch and

target(s).

Clearance should be 0.050" to 0.100"

[0.012-0.025mm]

If not, correct clearance and recheck

Indicating LIGHTS and LED's Series 50X Stacker Troubleshooting


4. Check to ensure proper voltage is delivered to the

switch(es).

If no voltage, go to Step 5

12VDC is required between terminal 33 on TB1 and the

individual switch terminal per Drawing D3421-S-34147S1.

See also the TB1/TB2 detail drawing of Dwg D3421-S-

34147S1

If OK, check intermediate cabling/wiring

5. Check DC Power Supplies: 3 lights behind card

cage.

If OK, ensure proper intermediate wiring, then,

go to Step 6

If faulty, replace and recheck from Step 1 above.

6. Check Input of LED(s) on TB1 to proof cabling.

If correct LED flashes with movement of the component,

then go to Step 7

Correct LED(s) should light. Refer to Drawing D3421-S-

34147S for the number f the LED involved.

If correct LED does not flash, check wiring between

switch and terminal being checked.

7. Ensure that the proximity switch signal passes

through the control by bringing up the I/O PAGE (see

Figure 5.3). Move the component target past the

switch(es).

Pusher A switch is the front (left hand) one under the

turntable viewed with the turntable area door open.

Pusher A motor is to the left when the turn table is a

roughly half turn position viewed through turntable

area door (See Figure 2.5).

Pusher B switch and motor are the remaining units.

Turntable switches are located under the turntable

level as viewed through the turntable area door.

If the I/O Display does not show correct reaction

go to Step 8

Ensure alternating =On/=Off displays on the screen:

For Right stacking section switches:

Stk A Nh is "Near Home" switch

Stk A H is "Home" switch

For Left stacking section switches:

• Similar designations as Right side units.

For the Pusher switches:

• Push A is the "A" Set of motor and switch

• Push B is the "B" Set of motor and switch

For the Turntable switches:

• Tblsen A is the upper switch

• Tblsen B is the lower switch

If I/O Display checks correctly, go to step 9.

8. Check wiring between terminal board and the 23856

circuit board.

If OK, go to Step 9

If wiring faulty (loose connections or fitting); correct.

Continue to Step 10 if a problem still remains.

9. Check the 8708 circuit board(s). If problems continue, go to Step 10.



Troubleshooting Series 50X Stacker Indicating LIGHTS and LED's


10. Check the driving unit of the problem component

(stepper motor or pneumatic cylinder) to proof

cabling and device that drives the component.

a. For stepper motor final drive units: 2 stacking

and 2 turntable pusher motors are powered by 4

drives at the bottom of the electrical enclosure.

WARNING

Stepper Motor drives are motors are interchangeable

for testing purposes. However, be very careful to prevent

idle chain and stacking blades from being damaged by

those under test

a1. Check the stepper drive motor involved. Since all

motors are identical, check by exchanging

motors. It may be possible to bridge the cabling

from one motor another for check purposes.

b. For pneumatic cylinder final drive units (the

turntable and the bypass gate), 24 VDC valve

must be controlled to supply air alternately to the

two ends of the cylinder(s) as the control

requires.

Indicators ... on the stepper Motor Drives

Each Stepper Motor Drive includes:

3 green LED's

O Power - On when power applied

O Enable - On when power applied

O Active - On when drive power is supplied to the

stepper motor

2 red LED's below the red LED's

O Fault - Overheating

O Fault - Drive failure

If a red LED is on, the problem is probably with the

electrical drive. Test the drive by exchanging it with

another in the stacker via cable switching (they are both

identical). If the problem continues, ensure proper power

supply to the drive.

However, if the Stepper Motor Drive is OK,

continue with Step a1

WARNING

Stepper motors can be exchanged for checking

purposes. However, be extremely careful to prevent

damage to the idle set of stacking blades caused by the

set being driven through the substitution of the motor.

The two pneumatic cylinder actuating valves (Fig. 2.7)

have LED's that illuminate only when the valves are

energized.

Bypass Gate LED -- on when the gate is closed (up).

Turntable LED ------- normally off. Momentarily on as

turntable just begins rotation.

Turntable cylinder has its controlled air pressure normally

acting on its piston head end. When rotation is required,

the valve is momentarily reversed to permit air into the

piston rod end to start rotation. As the table rotates to its

mid-position and the two midpoint proximity targets trip

both A and B tables proximity switches, the valve is de-

energized and the piston drives the turntable to its

extreme opposite location.

If the turntable does not move as described, check the

valve, cylinder, cabling and piping.



A Normal Start-up Test Series 50X Stacker Troubleshooting


5.6 A Normal Start-up Test

Understanding a normal Start-up Sequence can aid in pinpointing a problem as described in the

following.

5.6.1. Initial Start-up Sequence

Turn on Stacker Power; (main switch Figure 1.3). Look for the following:

1. At Terminal Block TB-1 (See Dwg. D3421-S-34147 on page 7.5), one or more red LED lamps

will light.

2. At the rear of the card cage behind the left most circuit card, three lamps will light to indicate

presence of DC voltages - +12V, -12V and +5V.

3. On each Stepper drive, the top green POWER LED will light.

4. The Infeed Motor Inverter Drive unit will read 0.0.

5. After a ten second delay, the red LED on top of the CPU PC Card (8696) will flash 8 to 10

times per second. The Operators Display will light up with its initial display - the BUNDLES

set-up page.

6. The green ENABLE LED on the stepper drives will not as yet illuminate.

5.6.2. Operator Inputs and Checks

Key in BRDSHEET and ROP on the Main Page. Correct appearance of these displays confirms

that the touch screen has transmitted to both the Display Card (8698) and to the CPU card

(8696).

1. Touch IO Updates on a Pull Down Menu to check status of input and output signals.

2. Check the following Inputs on the IO Updates by moving the various components:

3. Check Stacking Section sensors Home and Near Home for both A and B sides as described

in 2, above.

4. Check the Speed Distance Sensor in the Infeed by slowly rotating the upstream infeed shaft

that has the encoder gear at its end. Input 2 should slowly flash on and off.

5. Check the product stream encoder input - if used - (Input 1) by slowly rotating the roller to

which its gear is attached.

6. Check the product sensor in the stacker infeed by waving a paper target 3 to 4 inches from

the laser sensor window and watch Input 3 for reaction. Turn the mechanical sensor wheel.

Input 9 Pusher B HOME

Input 10 Pusher A HOME

Input 11 Table Sensor A

Input 12 Table Sensor B

Input 13 Top-of-Batch A

Input 14 Top-of-Batch B

Troubleshooting Series 50X Stacker A Normal Start-up Test


7. Check the following Inputs by pressing the appropriate pushbutton on the Operators Panel:

8. Observe the required response:

9. Check Output 31 - STACKER READY. This indicator should be ON (on the IO Update Page).

Note that LED D-31 on T13-1 is not lighted since the 24VDC Power Supply has not yet been

supplied to TB-1.

10. Press START/CLEAR. The following actions will take place in sequence.

a. K1 Relay is energized; its LED on.

b. MS1 is energized and its mechanical indicator changes from 0 to 1.

c. The Infeed Motor Inverter Drive is powered up and displays a running frequency (about

39.0 Hz at an Infeed Section surface speed of 180fpm [0.9M/sec])

d. The Infeed Section belts begin to move.

e. The Turntable slowly rotates to HOME.

f. Power applies to the four stepper drives. POWER and ENABLED LED's illuminate.

g. 24VDC is applied to TB-1 output section. One or more added LED's are illuminated on

TB-1. Output D-31 (STACKER READY) must be on for the stacker to complete a START

sequence.

Note: Steps a through g will appear to have occurred instantaneously.

Both sets of stacking blades will go through one revolution and stop in the Home Position.

HOME and NEAR HOME inputs are turned on. Both pushers will slowly rotate to their HOME

positions.

5.6.3. Sequence Completion

The Stacker Start Cycle is now completed and the stacker is ready to receive product. Further

stacker action is caused by receiving the necessary number of paper counts. If any action in the

start sequence does not occur in a predetermined time period, STACKER READY Output

(Output 31 on the IO Update Page) will momentarily turn OFF. This interrupts the stacker Start/

Stop circuit and shuts the stacker down. A message on the display will describe what event

caused shutdown.

Input 24 Right (delivery)

Input 25 Alt

Input 26 Left

Input 27 Bypass (gate)

Output 21 LEFT LIGHT

Output 33 ALT LIGHT

Output 34 RIGHT LIGHT

Output 35 INFEED READY

The IO Update Page Series 50X Stacker Troubleshooting


5.7 The IO Update Page

The IO Update Page (Figure 5.3) is a listing of all inputs and outputs involved in the 50X Series

Stackers. The functions listed are coded but easily identified as:

Touch Messages on the pull-down menu to display as many as 100 recorded Messages.

Figure 5.3: The IO Update Page Display

1 Product supply conveyor encoder

2 Infeed Speed-Distance Encoder

3,4 Product Sensors

5-14 Proximity Switch functions

15 Stacking Section

16 Blanking Signal to the count input

17-28 Various control and operator inputs

31-42 Various control outputs


Table of Contents


6.1 Detailed Maintenance............................................................................................................ 6.1

6.2 Infeed Section ....................................................................................................................... 6.26.2.1. Product Carrier Belt Replacement .........................................................................................6.2

6.2.2. Infeed Drive Belt Replacement ..............................................................................................6.4

6.2.3. Infeed Drive Motor Service.....................................................................................................6.5

6.2.4. Infeed Speed-Distance Sensor ..............................................................................................6.5

6.2.5. The Product Sensors .............................................................................................................6.6

6.2.6. Top-of-Batch Sensor Assembly .............................................................................................6.7

6.3 Stacking Section.................................................................................................................... 6.86.3.1. Stacking Section Prox Sensors............................................................................................6.10

6.3.2. Stacking Section Chain Tension ..........................................................................................6.12

6.3.3. Stacking Section Stepper Motors.........................................................................................6.12

6.4 Pneumatic Elements ........................................................................................................... 6.12

6.5 The Turntable/Pusher Assembly ......................................................................................... 6.126.5.1. Turntable Rotation Functions ...............................................................................................6.13

6.5.2. Turntable Lift and Press Action ............................................................................................6.14

6.5.3. Turntable Wall/Pusher Action...............................................................................................6.15

6.5.4. Servicing the Turntable Assembly........................................................................................6.15

6.5.5. Servicing Walls/Pusher Assembly........................................................................................6.16

6.6 The Control.......................................................................................................................... 6.186.6.1. The Touch Screen................................................................................................................6.18

6.6.2. To Check Screen Touch Accuracy.......................................................................................6.18

6.6.3. Screen Characteristics Adjust ..............................................................................................6.19

6.6.4. Electrical/Electronic Enclosure.............................................................................................6.19

6.6.5. Discussion of Specific Components.....................................................................................6.21

6.7 Electrical Service................................................................................................................. 6.236.7.1. Main Supply Power ..............................................................................................................6.23

6.7.2. +12, -12, +5VDC Checks .....................................................................................................6.24

6.7.3. 24VDC Check ......................................................................................................................6.24

6.7.4. Stepper Drive Output ...........................................................................................................6.24

6.7.5. The Memory Backup Battery................................................................................................6.25

6.8 Factory Default Settings Review ......................................................................................... 6.256.8.1. BUNDLE Screen Default Settings........................................................................................6.25

6.8.2. PARAMETER Default Settings ............................................................................................6.26

6.9 Options and Configurations................................................................................................. 6.26

Table of Contents Series 50X Stacker Chapter 6 Detailed Maintenance





6.1 Detailed Maintenance

Detailed Maintenance Procedures are divided into five sections:

1. Infeed Section

2. Stacking Section

3. Turntable/Lift Floor/Pusher

4. Pneumatic Elements

5. The Control

Maintenance is simplified by the service aids available through the control:

1. The Service Page (Figure 6.1)

lists a number of drawings and added information available through the Touch Screen for

reference. Note especially the Laser Program level, the light curtain details and the blanking

setting.

2. The Message Page (Figure 5.1)

can frequently pinpoint the cause of a problem immediately.

3. The HELP Displays (Figure 2.11)

are available for practically every value or description displayed on the Touch Screen. Details in

Section 2.3.

4. An Analysis of Indicating Lights

is in Section 5.5, a discussion of the correct operation of LED indicators and a troubleshooting

sequence applicable to them.

5. Manufacturer's Instructions

for the infeed motor and the four stepper drives are located in the pocket inside the front stacker

door.

CAUTIONShut down power to the stacker at the main power

disconnect before attempting repair.

The Service Page (Figure 6.1) is accessible through the pull-down menu. Once viewed, the

individual aid item can be displayed by touching its title on the Page.

Infeed Section Series 50X Stacker Detailed Maintenance


Figure 6.1: The Service Page

The need for specific maintenance will generally be directed through MESSAGES. MESSAGES are

displayed most frequently as the result of proximity switch(es) of the stacker not being 'made' within

the time required by the control program.

Proximity sensors are discussed in the following. Use SIMULATION during the test effort (Section

5.1.1).

6.2 Infeed Section

The Infeed Section includes belts, product sensors, pneumatic components, a motor and other

hardware and electrical elements. Refer to Section 6.4 for aid with pneumatic problems. The Infeed

Motor gearbox is sealed. No oil change is required. Watch for leaks.

6.2.1. Product Carrier Belt Replacement

Infeed section product carrier belts that are worn, frayed or stretched should be replaced. If one

is faulty, replace all if they are in about the same condition.

LOWER BELTS (Bypass Gate)

1. Release bottom belts tension by removing both socket head cap screws at the ends of the

bottom front crown roller shaft (Figure 6.2).

2. Partially unscrew the two bolts holding the bottom of the electrical connector housing to the

infeed frame.

Detailed Maintenance Series 50X Stacker Infeed Section


3. Swing up the connector housing to expose the two bolts holding the right end bearing of the

upstream bypass gate roller in place. The bearing has a spacer trapped between infeed

frame and bearing.

4. Remove the two bolts and the spacer.

WARNING

Support the gate assembly to prevent damage to

opposite end of shaft or its bearings.

5. Unbolt the socket head cap screw holding the rod end of the right air cylinder to the bypass

gate arm (Figure 6.2.) Free the rod end with its pivot bushing.

Figure 6.2: Bypass Gate Crowned Roller Support

6. Remove faulty belt(s) and replace them through the gap now present between frame and

bypass gate.

7. Re-assemble: Spacer and end bearing fastener, air cylinder pivot bushing, front roller shaft

and connector housing.

8. Power up the stacker to ensure the belts are in place and tracking.

Note: Tighten the two crown roller shaft socket head screws until 1/16" to 1/8" [1.5 to 3mm]

gap remains between the upper and lower rollers - equally across the width of the roller

assemblies. The bypass gate must be up for final testing. To test, power up the stacker

but do not press the START/CLEAR pushbutton.



UPPER BELTS

Note: There are dimensional differences between the long and short infeed 50X Series

stackers. However, replacement procedures for changing their upper infeed belts are

basically the same. Only the access to the upstream shaft of the upper belt assembly is

different.

Note: In all model stackers, the mechanical product sensor must be lifted upward for access to

the left-most belt. Support the assembly against its spring load.

1. To release tension on the upper belts, remove the nut from the cap screw holding the down-

stream crown roller shaft to the shaft bracket. Support the free end of the shaft during the

following activity.

2. For 501C and 501CW Stackers, partially unscrew the two bolts holding the bottom of the

electrical connector housing to the infeed frame.

3. Swing the connector housing up to expose the two bolts holding the right end bearing of the

upstream roller of the upper belt system in place. The bearing is held against the inside of

the infeed frame.

4. For 500C and 500CW Stackers, raise the right infeed cover for access to the two bearing

bolts.

5. Remove the two bolts and spacer between bearing and infeed frame.

WARNING

Support the upper belt assembly so the opposite

ends of the shafts or their bearings are not damaged.

6. Remove faulty belt(s) and replace through the gap now present between frame and rollers.

7. Re-assemble components in reverse order.

Note: Tighten the crown roller shaft socket head screw/bolt until 1/16" to 1/8" [1.5 to 3mm] gap

exists between the two facing crowned rollers - equally across the width of the rollers.

8. Power up the stacker to ensure that the belts are firmly in place and tracking accurately.

6.2.2. Infeed Drive Belt Replacement

The infeed belts are driven by a timing belt powered by an AC gear/motor. Refer to the Parts List

and drawings associated with the Basic Infeed Assembly starting on page 7.10 and Figure 6.3 in

this chapter. To replace timing belt:

CAUTIONShut down power to stacker at main power

disconnect before attempting any repair.

1. Raise the left hand infeed cover.

2. Loosen the lock nut on the take-up assembly bolt mounted on Item 30 of the drawing.

3. Loosen nut behind idler pulley belt take-up.

4. Turn the lock nut to relieve timing belt tension.

5. Replace the belt.



6. Tighten the take-up until a deflection of no more than about one half (1/2") inch [13mm]

occurs when a two pound [0.9Kg ±] weight is placed on the mid point on the longest span in

the belt.

7. Power up the stacker to check belt operation.

6.2.3. Infeed Drive Motor Service

Should either the infeed drive motor or its gear reducer require removal for checking, the infeed

drive belt must first be loosened per Section 6.2.2. Refer to the Parts List and drawings

associated with the Basic Infeed Assembly starting on page 7.10. Then:

1. If the assembly is to be removed completely, the power cabling must be removed at the

motor terminal box.

2. Remove the Taperlock drive pulley (Items 34-35) by first removing the two set screws visible

from the outside face of the pulley. Re-insert one of the screws into the remaining threaded

hole visible on the pulley face. Slowly screw the set screw back into the hole until the outer

section of the pulley is free.

3. Remove mounting bolts holding the drive motor assembly to the infeed; remove the motor.

WARNING

The motor assembly is heavy, support it as it is being

loosened.

4. Service the assembly and remount in reverse order. Observe belt tension required per

Section 6.2.2.

6.2.4. Infeed Speed-Distance Sensor

The Speed Distance Sensor is an encoder detecting the belt speed of the infeed section belts. It

is located under the left infeed cover. See Figure 6.3. This solid state device detects the teeth in

a special gear mounted opposite the sensor and driven by the infeed drive motor.

Figure 6.3: Left Side Infeed with Speed-Distance Sensor

Drive Belt

Speed-Distance Sensor

Sensing Gear

Belt Take-up



If encoder is faulty, per the MESSAGE

**NO INFEED SPEED PULSES**

ensure 12VDC is carried to the unit, that its output voltage is correct and clearance is as noted

below. If faulty, replace. Before removal, observe the relative position of the sensor tip with

respect to the gear it senses. The notch on the sensor is parallel with the teeth of the gear.

Replace the detector with a gap of 0.01-0.025" between sensor face and the teeth [0.25 to

0.62mm].

6.2.5. The Product Sensors

Two product sensors are in the Infeed Section (Figure 6.4), a QUIPP Count Pro II laser sensor

and a mechanical sensor as alternate device. A mechanical sensor designed for ROP

application is normally supplied. However, a mechanical sensor for inserted products is available

as an option. Refer to Specifications, Section 1.5, for details on both models. Individual manuals

for the two units are located at the back of the main manual.

Figure 6.4: Laser and Small Wheel mechanical Sensor in Position

General maintenance rules which apply are:

1. Replace the laser sensor if it is found faulty. Return the faulty unit to QUIPP Customer

Service for repair. A replacement laser sensor will be correctly positioned (face parallel with

infeed area product stream below the sensor) in the existing mount.

2. With excessive wear in a mechanical sensor, miscounts may occur. Replacement parts are

available from QUIPP Customer Service

Replace star wheel of the small wheel sensor when it extends out of the sensor bottom less

than about 1/4" [6mm]. Inspect the internal pointed detent gear for wear. The star wheel will

rotate too easily if worn.

Vertical

AdjustmentMechanical Sensor Laser Sensor

TOB ProximitySwitches



The star wheel of the large wheel sensor will show wear after extensive use and must be

replaced when it no longer intercepts large inserted products. Spring tension on the wheel

can be modified some to compensate for wear.

3. If a mechanical sensor is to be removed, observe the position of the unit before removal. The

vertical position of a mechanical sensor is adjusted with a machine screw (Figure 6.4).

The small wheel sensor: There is no operating adjustment with this model other than

position. If the original sensor position was not noted, adjust as follows:

a. From the side of the infeed, sight horizontally between the three sets of upper belts at

the location of the sensor.

b. The top of the sensor should be parallel with the top span of the middle belt.

c. The bottom of the sensor should be even with the bottom span of the middle belt.

The large wheel sensor: If the original sensor position was not noted:

d. From the side of the infeed, sight horizontally between the three sets of upper belts at the

sensor location.

e. Adjust the front lower bulge of the sensor to be about even with a lower span of a side

belt.

f. Adjust the rear lower bulge to be about half way between the lower spans of the middle

and a side belt.

g. Adjust spring tension on the star wheel of the sensor itself so that the star wheel does not

"walk" along the top of the product.

Periodically check the accuracy of bundle count to ensure accurate inputs from the product

sensors.

6.2.6. Top-of-Batch Sensor Assembly

The Top-of-Batch Sensor detector arm (Figure 6.5) has three positions which involve the

stacking section. Two proximity sensors detect the second and third positions of the TOB Sensor

arm.

1. Normal - The arm is generally not touched by incoming products.

2. Intermediate - If the stacking blades are not moving down fast enough, products being

stacked press the arm upward. The first position proximity sensor is made and the stacking

blade dropping speed is increased 25%. If the batch drops away from the TOB arm, the

stack blades return to normal dropping speed. This action occurs without MESSAGE.

3. Upper - If the incoming stream forces the second proximity switch to be made, stacking

blades are driven down at full speed. If switch No. 2 contact is not broken by the time blades

reach their bottom extent, the stacker will go through a CLEAR cycle. The turntable is

cleared and the CLEARing action continues while both proximity switches are made. The

alarm sounds and the following MESSAGE is displayed:

*TOB CLEAR SIGNAL*

Increase page count as a solution.

ADJUSTMENTS - Check the TOB Sensor assembly periodically by gently pushing the sensor

arm up. The LED on the bottom proximity switch should light as the arm moves up about 1/4"

[6mm] from its normal position.

Stacking Section Series 50X Stacker Detailed Maintenance


The top switch should light when the tip of the arm is about 1/4" [6mm] from the product deflector

plate in the infeed per Figure 6.5 and Figure 6.6.

Adjust a switch "make" point by loosening the switch lock nut and screwing the entire switch in

or out as required. Section 4.5 describes the proximity switch test procedure if a switch is

thought to be faulty.

Figure 6.5: The Top-of-Batch Sensor

6.3 Stacking Section

The stacking section (Figure 6.7) includes two sets of two chains independently driven by their own

stepper motors. The chains carry two sets of stacking blades each. The tips of the two paddles in

each set of stacking blades must be on a horizontal line, parallel to the floor. The side view angle of

each set of blades must be the same.

TOB Product Sensing Arm

Top Proximity Switchshould “make” when sensor arm tip is about1/4” away from the centerback stop.

Detailed Maintenance Series 50X Stacker Stacking Section


Figure 6.6: TOB Damper Detail

If they are misaligned, carefully correct the problem. It may be necessary to remove blades from the

stacker to adjust.

Stacking Section Series 50X Stacker Detailed Maintenance


Figure 6.7: Stacking Section from Stacker Rear

6.3.1. Stacking Section Prox Sensors

Each stacking section, A and B, has two proximity sensors mounted in each outer track of each

track set per Figure 6.8. The lower sensor is the Near Home sensor and the upper unit is the

Home sensor, one set for each of the dual chain sets.

Detailed Maintenance Series 50X Stacker Stacking Section


Figure 6.8: Stacking Section Sensors

The HOME Position -- The sensors detect the cam followers which support the stacking blade

assemblies when an assembly is in the Home position. When a set of blades is ready to

intercept the next batch, the LEDs on the sides of the sensor light and the proper signal is sent

to the Control.

If the two sensors do not output their signals at the proper time, the alarm sounds, the stacker is

SHUT DOWN and the following MESSAGE is displayed:

**STACKING SECTION MISSED HOME**

The Intercept Position - If either stacking section did arrive at its HOME position but did not move

into the Intercept position in the proper time, the stacker is SHUT DOWN and the following

MESSAGE is displayed:

**STACKING SECTION "A" FAILED**

or

**STACKING SECTION "B" FAILED**

If a proximity sensors is faulty, replace by loosening its lock nut, pulling its electrical connection

and screwing the unit out of the track. The replacement unit must be returned to an identical

position, its face flush with the inside wall of the track.

Proximity Sensors

Pneumatic Elements Series 50X Stacker Detailed Maintenance


Note: If more than one sensor is to be replaced, replace the sensors one at a time to prevent

reversal of the signal cabling,

6.3.2. Stacking Section Chain Tension

To remove a chain set, loosen the tension/shock spring take-ups to provide slack (See Figure

6.7). Remove the chain connecting link to open the loop.

When repair has been made and the chain assembly is returned to position, compress both

springs to 1-15/16" [49mm] as measured between the two inner surfaces of the spring retaining

washers per Figure 6.7.

6.3.3. Stacking Section Stepper Motors

Stacking Section motors are identical. If a motor is found faulty (Section 5.5-10), replace. First

relieve drive belt tension by loosening the tensioning rod as seen on Drawing D3421-A-26873.

Remove the belt, disconnect cabling, loosen four mounting bolts and exchange the drive pulley

to the new motor. Reassemble.

WARNING

Duplicate the drive pulley clearance (compare with

the opposite motor) so that the drive belt, when

replaced, does not rub on the stacking section

framing. Tension belts for ¼" play.

6.4 Pneumatic Elements

Pneumatic cylinders drive the Infeed Bypass Gate, the Turntable and the turntable floor. During

production, LED's on valves V2 and V3 will signal normal operation. Refer to Dwg. D3421-A-34203A,

Chapter 7.

V2 - Bypass Gate - LED is always lighted.

V1 is the main air supply valve actuated by relay K1. Its only adjustment is the SLO START action of

the valve that permits air to slowly bleed into the stacker to prevent component damaged. Per Figure

2.7, a screwdriver adjust point is accessible from its top surface.

1. Turn Stacker Power OFF

2. Turn adjustment Clockwise to off

3. Open about 1/4 turn

4. Turn on Stacker Power and push START/CLEAR

The turntable should move into its home position quickly but not so fast as to bounce or jar into

position. Fine tune the air control as needed see Section 6.5.4.

6.5 The Turntable/Pusher Assembly

The turntable is rotated by a single double-acting (reversing) pneumatic cylinder (Figure 6.9) as

detailed in the drawings associated with Figure 7.20. The turntable walls are driven through timing

belts by individual stepper motors mounted to the bottom of the turntable. The motors rotate with the

turntable. Positions of turntable and the turntable walls are detected by a series of proximity sensors.

Tension belts to about ¼" play.

Detailed Maintenance Series 50X Stacker The Turntable/Pusher Assembly


Figure 6.9: Turntable and Turntable Wall Drive Components

6.5.1. Turntable Rotation Functions

The entire turntable is supported on a shaft assembly per Figure 6.9. The preset air pressure is

applied to the piston end of the cylinder to hold the turntable in its "home" position. Two proximity

switches monitor the rotating action.

Home Position - One of the sensors confirms the turntable in "home" position by detecting the

first of four turntable target. When the turntable is to rotate, the air valve is reversed, the rod end

of the piston is pressurized and the table begins to rotate. As the first target moves away, the

control is signaled the beginning of rotation. (The targets are mounted under the rim of the

turntable - clearance to the sensor - 0.050"-0.100" [1.3 to 2.6mm]).

Mid-Point - As mid-point of rotation (90°) is approached, both proximity sensors detect targets

and the cylinder air supply is reversed. Air pressure is *now applied to the cylinder piston end;

Figure 6.9.

The Turntable/Pusher Assembly Series 50X Stacker Detailed Maintenance


Figure 6.10: Turntable Midpoint Sensors

Opposite Home Position - The turntable now approaches its 180° position. When it arrives, the

the sensor is tripped by the fourth end position target. The turntable is brought to a stop by the

dual-shock absorber assembly (as detailed in drawing 34290A-2 on page 7.24 and Figure 6.9)

and the cushioning effect of the drive cylinder. The turntable position is held by its drive cylinder.

Should any of the three sensor signals not be generated within the required time, one of three

MESSAGES will be displayed, the alarm will sound and the Stacker may be SHUT DOWN with

one of the messages. The MESSAGES:

**TABLE FAILED TO LEAVE**

**TABLE FAILED TO FIND MID**

**TABLE FAILED TO HOME**

Refer to Section 5.3 for corrective suggestions.

6.5.2. Turntable Lift and Press Action

In PRESSOR Mode, with the first batch of a multibatch stack, the turntable floor rises to the

upper level of the turntable walls. The batch drops on to the floor section and is immediately

lowered sufficiently to permit the Pressor Stops to rotate into position. The table is then quickly

raised to press the batch against the Stops.

Meantime, if the individual batches are to be compensated (reversed), the Turntable has already

begun to rotate to its reversed position.

A-WallProx Sensor





A-WallDrive Motor Pressor Pneumatics



The Pressor/rotating action continues with each stack dropped into the Turntable until the last

batch is dropped into the turntable. At this point, the floor section is raised to press the entire

Stack.

If the last batch is not to be pressed (to ensure the highest stacker throughput rate), after the last

batch has dropped, the formed stack is immediately pushed out of the turntable.

6.5.3. Turntable Wall/Pusher Action

Figure 2.5 shows the turntable in a partially turned position. One pusher position sensor is visible

flush with the table surface to the left of the pusher. It detect the bottom of a pusher. Refer also to

Figure 2.6.

To push out a stack, both wall stepper motors are powered up. The walls begin to rotate and the

outer pusher leaves the pusher sensor. The walls rotate and the next pusher moves over the

pusher sensor to signal a stop to wall rotation.

If either pusher sensor fails to provide its signal at either of its required time, one of four

MESSAGES will be displayed, the alarm will sound and the Stacker will SHUT DOWN. The

MESSAGES:

**PUSHER 'A' FAILED TO LEAVE HOME**

**PUSHER 'B' FAILED TO LEAVE HOME**

**PUSHER 'A' FAILED TO FIND HOME**

**PUSHER 'B' FAILED TO FIND HOME**

6.5.4. Servicing the Turntable Assembly

The turntable support should require no service. However, if the assembly must be dismantled

for any reason, refer to the drawings associated with “7.3.4. Turntable Assembly” on page 7.22

for construction details. Note the use of Item 24, the 3/8" [20mm] machine screw, needed to

expand the crank clamp after the two locking screws are loosened.

If the table is removed from the stacker, replace it into its original position with the table top no

more than 1/8" [3mm] above the table side plates.

The drive cylinder provides a cushioning action at the end of travel into both turntable positions.

This action, with the dual-shock absorber assembly, should bring the table into home with a

smooth action. If adjustment seems necessary:

1. With stacker power on but not operating, ensure turntable air pressure is 25-35psi [3 BAR].

2. Close (clockwise) the cushioning valve screw visible at the rod end of the drive cylinder.

3. Open (counterclockwise) the valve 1/2 turn.

4. Place the stacker in slow simulate (about 10,000/hr) and check the action (see Section 6.4).

The turntable should move into both end positions smoothly and without a noticeable shock

at the end of travel.

5. Adjust the valve for satisfactory operation.

Once the cylinder is adjusted as above, the turntable should be accurately in its home position.

The small notch on the table edge indicating discharge centerline should be within 1/8 inch

[3mm] of a matching notch on the outer table shroud.

Adjust by loosening the clevis lock nut (Item 100, as shown in “7.3.4. Turntable Assembly” on

page 7.22) and turning the piston rod in or out as needed. Retighten the lock nut.

The Turntable/Pusher Assembly Series 50X Stacker Detailed Maintenance


If a shock absorber requires replacement, refer to the drawings associated with “7.3.4. Turntable

Assembly” on page 7.22 for assembly details. Duplicate the position of the original shock

absorber with the replacement.

6.5.5. Servicing Walls/Pusher Assembly

If a wall assembly drive gear (the large gear visible) must be serviced, replace it accurately.

Remove the gear by first loosening the belt take-up locking handle (Figure 6.5) and then

loosening the hold-down nut shown centered in the gear shaft, Figure 6.10

On replacement, place spacers 1-5/32" [29.3 mm] thick between the gear top and bottom of the

turntable itself. Tighten the nut. Place the drive belt in position and tighten by moving the motor

mount with a wooden pry bar until about 1/4" [6 mm] belt side play remains. Tighten the locking

handle.

Refer to Figure 6.11 for details on servicing the turntable walls and pusher assemblies. The mat

top surface material is maintained taut by individual gas springs located inside the two wall

areas.

With time, the mat top material may stretch as the material wears in. The plastic drive sprockets

may require servicing. Follow the instruction sequence on Figure 6.11 for dismantling and

sprocket replacement or shortening the mat top material.



Figure 6.11: Pusher wall service instructions.

The tool required is attached to the lower left hand area of the frame inside the turntable area.

The Control Series 50X Stacker Detailed Maintenance


6.6 The Control

Control of 50X Stackers involves three main areas:

1. The Touch Screen

2. The two Pushbutton stations

3. The Electrical/Electronic Enclosure

Sensors in the stacker provide position and condition inputs to permit operator control of certain

stacker functions.

6.6.1. The Touch Screen

Using the Touch Screen requires touching the screen on or near the number or word requiring

change. Numbers and words that can be changed must generally first be touched to change its

value. Then the required number is keyed into the keyboard and ENT is pressed to make the

change. Or, touching the word itself brings up its alternate.

The only service of the Touch Screen portion of the Stacker Control involves adjusting its

brightness and checking the accuracy of the "touch spots".

6.6.2. To Check Screen Touch Accuracy

Sensitivity of the touch screen requires that the item to be changed does actually change if the

touch is within 1/8" [3mm] of the item. Test the accuracy as follows:

1. Touch Page on any screen. Then touch Service in the pull-down menu that appears.

2. Touch Page on the Service Page and then Touch Test on the pull-down menu that appears.

3. Touch the screen (Figure 6.12) at various locations. An "X" should appear within about 1/8"

[3mm] of the point touched.

Figure 6.12: Touch Test Screen

Detailed Maintenance Series 50X Stacker The Control


If the correct action does not occur, contact QUIPP Customer Service for help. The Screen is

probably damaged and will require replacement.

To return to another Page, touch Page on the test screen to bring up the main pull-down menu.

6.6.3. Screen Characteristics Adjust

If the ambient light condition requires a brighter screen, if centering is required, etc., correct as

follows:

1. Remove the four corner mounting screws holding the screen in place. Support.

2. Withdraw the screen, supporting it with hands at either side. Note the four miniature

momentary push-button along the left inside edge marked:

Menu, Select, Up and Down

Touch Menu and Select to display the characteristic needing adjustment.

3. Increase or decrease the setting with the Up and Down PB's.

4. Replace the Screen.

Should any other problem develop involving the Touch Screen Control, contact QUIPP

Customer Service for details on correcting the problem.

6.6.4. Electrical/Electronic Enclosure

Components in the Electrical/Electronic Enclosure are identified in Figure 6.13. Discussion on

specific components continues on the next pages. To access the enclosure with power

remaining on, refer to Section 1.11.3.

CAUTIONOnly qualified electrical/electronic technicians should

work on equipment located within the electrical/

electronic enclosure.



Figure 6.13: The Electrical/Electronic Control Enclosure

Detailed Maintenance Series 50X Stacker The Control


6.6.5. Discussion of Specific Components

The Infeed Motor Inverter

See Figure 6.13 to locate the Infeed Motor Inverter Controller. Present Series 50X Stackers

utilize a GE VAT20 Inverter; earlier stackers utilize an AB model. Both inverters are discussed in

the following.

The product supply conveyor encoder provides the Inverter with a voltage varying with the

conveyor surface speed. Output from the inverter then drives the stacker infeed motor to match

the supply conveyor speed.

Allen Bradley Inverter - A manual for the Inverter is located in the stacker door pocket. Refer to

its Chapter 3 for description of its controls. Chapter 5 outlines the programming procedure if a

replacement was made.

The control Parameter Settings are preset in the replacement inverter supplied through QUIPP.

The values are as follows:

The procedure for setting them is outlined in Chapter 5 of the manual - condensed in the

following:

AB Inverter calibration

1. With power on - START/CLEAR should be on. Press ESC on the controller. A red dot will

appear to the left in the readout.

2. Press the diamond up/down keys until the two digits '57' appear left in the readout.

3. Press SEL. The red dot should begin flashing.

4. Press the diamond up/down keys until the digit '1' appears to the right of the digits '57'.

5. Press the ENT (*) key. The control is Unlocked.

To enter the Five Parameters

1. Press the diamond up/down keys until the digits '30' appear left in the readout.

2. Press SEL. The red dot will begin flashing.

3. Press the diamond up/down keys until the digits '1.0' appear at the right in the readout.

4. Press the ENT (*) key to write the new value into controller memory. The red dot will stop

flashing to confirm the entry.

5. Continue as above with the four (4) remaining Parameter Values.

The minimum and maximum infeed speed limits are set as a Speed Reference Calibration as

follows:

Param. No. Setting

57 0 - to unlock & program

30 1.0

31 1.0

33 76

42 2.4 - Motor Amps

46 3



To enter the Minimum Speed

1. Power up the stacker and set the Minimum Infeed Speed to 300 fpm per

Section 4.2.2. (sub a). Do not press a START/CLEAR Pushbutton.

2. Press ESC on the control. The small red dot will again be flashing left of the readout

indicating the control is Unlocked.

3. Press diamond up/down keys until digits '16' appear left in the readout. Read (45.2 to 52.7).

4. Press the up/down keys to bring up 76 indicating access to the Maximum Speed.

5. Press SEL. The red dot should begin to flash. This indicates that a change can now be made

in the Parameter value shown to the right.

6. Enter the value noted in step 3

7. Press the ENT (*) key to write the new value into controller memory. The red dot will stop

flashing to confirm the entry.

To Lock the Controller against further Adjustment

1. With the stacker operating, Press ESC.

2. Press the diamond up/down keys until the two digits '57' appear to the left.

3. Press SEL. The red dot should begin flashing indicating a change can now be made in the

Parameter value shown right in the readout.

4. Press the diamond up/down keys until the digit '0' appears right in the readout.Press ENT (*)

for the new value. The red dot will stop flashing to confirm the entry. The Control is now

Locked to further adjustment.

GE VAT20 Inverter - A manual for the Inverter is located in the stacker door pocket. Refer to its

Chapter 3 for description of its controls. Chapter 5 outlines the programming procedure if a

replacement was made.

The control Parameter Settings are preset in any replacement inverter supplied through the

QUIPP. The values are as follows:

GE Inverter Calibration

1. Power up the stacker. Do not press START/CLEAR.

2. Press DSP/FUN pushbutton to establish program mode and permit hanging of parameters.

3. Press UP and DOWN pushbuttons to walk through the Parameters. Bring up F01.

4. Press DATA/ENT to display the present Parameter value.

Param. No. Setting

F01 1.0

F02 1.0

F03 0

F04 0

F05 4

F06 135Hz

F10 1

F11

Detailed Maintenance Series 50X Stacker Electrical Service


5. Press UP and DOWN pushbuttons to change to the needed Parameter value as indicated in

the above listing.

6. Press DATA/ENT to enter the Parameter value. The word END will appear in the readout.

7. Press UP and DOWN pushbuttons to walk through the remaining Parameters. Check

against the list and change as described above if necessary.

8. Press DSP/FUN pushbutton to return to the Inverter RUN Mode.

9. Press one of the two Stacker START/CLEAR pushbuttons. The Stacker should operate at

the set Infeed Speed as explained involving the PARAMETER Page (Section 4.2.2).

Power Supply for +12. -12, +5VDC

The +12, -12, +5 VDCV Power Supply is part of the PC Card Cage. Three colored lights behind

the left most PC card indicate these voltages on.

If one or more of the lights are extinguished, follow the checking procedure, Section 5.5.1.

Replace the power supply - QPN 8702 - if found faulty.

6.7 Electrical Service

Several voltage measurements that aid in servicing are:

6.7.1. Main Supply Power

Check at disconnect terminals X, Z and G for correct stacker power. Then check the 2 fuses by

testing at the wire terminals indicated. Refer to Schematic D3421-S-34147S1 for circuitry

details. The three blank fuse positions are for future use.

Fuses FU-1 thru FU-8:

CB-1

for 208-230 VAC Service

for 380-460 VAC Service

CB-2 & CB-3 for 120 VAC Service

Fuse 1 - FLM 1.5A for 24VDC Pow Sup.

Fuse 2 - FTK 1A for Bundle displays

1. Red +12VDC

2. Green -12VDC

3. Amber +5VDC

Electrical Service Series 50X Stacker Detailed Maintenance


6.7.2. +12, -12, +5VDC Checks

DC voltages to the PC Cards can be measured on an Extender Card (available through QUIPP

Customer Service) in an available card cage slot. Measure against frame ground or to terminals

3-4:

6.7.3. 24VDC Check

Terminal Block TB1 can be used for continuity checks and for confirming input and output

signals and correct supply voltages to the area.

Refer to the enlarged view of TB1 on Figure 7.2 in Chapter 7. Note the +12 and +24VDC fuses

(F1 and F2) protecting components with these voltages from TB1.

If a fuse is open, an adjacent red LED (D43 or D44) will illuminate.

6.7.4. Stepper Drive Output

Normal standby of the drive is indicated by illuminated green Power and Enable LED's on each

unit. When a motor is active, the Step Active LED is illuminated.

Continuity check of cabling to and of the stepper motors themselves can be done from terminals

on J1 on the stepper drives.

Refer to Dwg. D3421-S-34147S1 to determine what is being checked on these terminals. The

letters - -

indicate the two ends of a single winding in the motor. Check on the terminals accordingly.

Resistance value of a winding (with POWER OFF and one winding end free) is typically 0.6 to

0.7 ohms. Voltage to a winding when a motor is operating is 110 VAC.

If a drive is replaced, ensure that its dip switch is set per Dwg D3421-S-34147S1. A Stepper

Drive manual is located in the pocket inside the front stacker door pocket.

Terminals Voltage

1. 1-2 +5VDC (4.75 to 5.25 id OK)

2. 3-4 0V

3. 53-54 0V

4. 55 +12VDC - +/- 1%

5. 56 -12VDC - +/- 1%

A and A

Detailed Maintenance Series 50X Stacker Factory Default Settings Review


6.7.5. The Memory Backup Battery

Operator-entered PARAMETER settings made from day to day remain in memory via battery

backup despite shut down of the stacker. The battery is located on the CPU Card 8696 and has

a life beyond 2-3 years. However, if a PARAMETER previously set is lost after stacker shut

down, the fault is probably the battery. It should be replaced.

Several options exist concerning replacement:

1. Replace the faulty CPU Card with a spare.

2. Return the original CPU Card to QUIPP Customer Service for battery replacement. A

nominal charge is applied to the replacement of a backup battery.

WARNING

Turn Power off prior to following test.

3. Replace the battery on site. HOWEVER - -

only a qualified technician should do the work. PC Cards are susceptible to extraneous

outside electrical influences that could affect its operation. Using appropriate soldering

aids, the battery can be replaced after the sponge backing to the CPU has been carefully

stripped back at the point of battery mount.

6.8 Factory Default Settings Review

The following is a review of the MAIN and PARAMETER Page screens factory default settings.

These settings are enabled if no value is entered for a specific item or if the battery backup for the

control fails.

6.8.1. BUNDLE Screen Default Settings

Stack/Batch Count 25/1

Pages 50

ODD COUNT OFF

TURN TABLE ON

BLANKING AUTO (50% of Ave. Lap)

PAPER SENSOR Laser (non-contact)

OPTION OFF

Options and Configurations Series 50X Stacker Detailed Maintenance


6.8.2. PARAMETER Default Settings

6.9 Options and Configurations

Several optional capabilities are available for use with the 50X Series Newspapers Stackers. The

Installation Configuration Page (Figure 6.14) is used to install the necessary controls for systems

added after shipment and for certain day-to-day operation.

Figure 6.14: The Configuration Page

Minimum Infeed

Speed

180 fpm

Blade Drop Speed 100%

Intercept Distance varies with stacker and sensors

Batch Drop Speed 100%

Turntable Turn Delay 200 ms

Turntable Eject Delay 200 ms

Eject Speed 140 fpm

Infeed Encoder Factor 100%

Detailed Maintenance Series 50X Stacker Options and Configurations


Bring up this screen through the SERVICE Screen -

1. Touch Configure

2. Enter the Lockout Code and touch LOCKED (lower left) to enable changes (relock after the

changes have been made)

Selections are brought up by touching the "Raised" white on black words or numbers.

Explanations are:

1. Printer Type - Touch to display the label printer used. Turn QUEUING ON when the printer is

down stream of the stacker.

2. Stacker ID Number - To identify the stacker in a Programming, Bundle Distribution System or

other Networked arrangement. Use the keyboard to enter the proper numbers.

3. Batching Type Entry - ON will place extra copies in the first (bottom) Batch(es) of multi-batch

bundles if all batches are not equal in count. OFF places these copies in the top batch.

4. Floor Equipment Control - ON displays screen developed for a specific installation to display

placement around operation of floor equipment.

5. Locked in Direction - ON locks the bundle exit direction from the stacker to that keyed in

previously. No over-riding is possible with the stacker side-mounted pushbuttons.

6. Outfeed Direction - NORMAL exits bundles to the right and the left as viewed looking at the

stacker infeed (product source to the back). The opposite setting reverses the exit indication

(left and right as viewed from the position looking at the touch screen). Outfeed rollers should

operate at 140fpm.

7. Encoder RE-sizing pulley percent - Compensates for different encoder pulley diameters when

the stacker is being moved to alternate positions having different sized pulleys. The percentage

change in pulley circumference (or diameter) from the original must be computed and keyed in

(see Sec.3.2.2-j).

8. Language - Available at present: English, Spanish, Italian and Dutch.

9. Clear to Factory Set - returns stacker control settings or initial setup in case of problems in set-

up.

To exit the screen, touch Pages, upper screen.

Options and Configurations Series 50X Stacker Detailed Maintenance


NOTES:



7.1 Diagrams and Schematics .................................................................................................... 7.1

7.2 Parts Drawings and Lists....................................................................................................... 7.1

7.3 Parts, Drawings, and Parts Lists ........................................................................................... 7.67.3.1. Main Assembly.......................................................................................................................7.6

7.3.2. Basic Infeed Assembly.........................................................................................................7.10

7.3.3. Stacking Section ..................................................................................................................7.20

7.3.4. Turntable Assembly .............................................................................................................7.22

7.3.5. Turntable Bottom Assembly .................................................................................................7.25

7.3.6. Turntable Bottom Motors......................................................................................................7.27

7.3.7. Electrical Enclosure Assembly .............................................................................................7.29

7.3.8. Powered Outfeed w/o Idler Rollers ......................................................................................7.31

7.3.9. Pneumatic Assembly............................................................................................................7.33

Table of Contents Series 50X Stacker Chapter 7 Diagrams, Schematics, and Parts List





7.1 Diagrams and Schematics

Schematic Drawings follow in the sequence listed.

All schematics have a continuing number sequence along the left side, internally in the drawings and

in sections of drawings. Interrupted wiring continued elsewhere is identified with the sequence

number at which the wiring again enters a schematic.

7.2 Parts Drawings and Lists

In the QUIPP Series 50X Newspaper Stacker Parts Lists that follow:

1. Certain components identified on drawings are not included in the Parts List. These items are not

considered field replaceable.

2. Most conventional hardware is not listed. It is generally available locally.

3. ALL Series 50X Newspaper Stackers replaceable parts that are not interchangeable are

identified in the various lists as follows:

a. 50XC applies to 500C and 501C models

b. 50XCW applies to 500CW and 501CW models

c. 500C/W applies to 500C and 500CW models

d. 501C/W applies to 501C and 501CW models

e. No Model Number applies to all models

4. Remaining parts are interchangeable and fit all Series 50X stackers.

When ordering parts, provide the stacker Serial Number, date of manufacture, the part number and

the part description. The drawing number on which the part is illustrated may also aid in part

identification.

Drawing No. Description Page

D3421-S-34147S1 Main Power, Steppers, Misc 7.3

D3421-S-34147S1 Monitors, DC Pow, Xfrm, Out Rollers 7.4

D3421-S-34147S2 TB's, Ops Stations, Lite Curtain 7.4

D3421-S-34147S2 TB 1,2 Arrgt, Laser Iface, J1, 2, 4 7.4

D3421-S-34147S2 TB1, Sensors, Control Relays 7.4

D3421-S-34147S2 Ops Stations, Safe Curtain 7.4

D3421-S-34147S3 PC Card Case, Press System 7.5

D3421-S-34147S3 Pres Details, External Inputs 7.5

D3421-S-34147S3 Touch Scr, Other Cards 7.5

QPN-100248 Operators' Panels Schematic

Parts Drawings and Lists Series 50X Stacker Diagrams, Schematics, and Parts List


Certain parts assemblies are identified in the lists with their part numbers followed by one or several

added parts in an indented form. These parts are components of the basic assembly. They are

available as replaceable items.

The remainder of this chapter shows the diagrams, schematics and parts list for the series 50X

stacker.

Drawing No. Description Page

D3421-A-33960-1 Main Assembly Right Side 7.7

D3421-A-33960-2 Main Assembly Rear View 7.8

D3421-A-33960-3 Main Assy Side Stack Guides 7.9

D3421-A-33960-4 Main Assy Stack Edge Guides @ Parts 7.9

D3421-A-26875-1 50X Series Infeed Assy Right Side 7.11

D3421-A-26875-2 50X Series Infeed Assy Top View 7.12

D3421-A-26875-3 50X Series Infeed, Left Side 7.13

D3421-A-26871-1 501 Series Infeed Assy Right Side 7.14

D3421-A-26871-2 501 Series Infeed Assy Top View 7.15

D3421-A-26871-3 501 Series Infeed, Left Side 7.16

C3411-A-24919 Top-of-Batch Sensor Assembly 7.17

C3411-A-23818 Connector Housing Assembly 7.18

D3421-A-31093-1 Sq Roller Kit - Top View Infeed 7.19

D3421-A-31093-2 Sq Roller Kit -Side View & Air System 7.19

D3421-A-26873 Stacking Section Details & Parts List 7.21

D3421-A-26873 Stacking Section Assembly 7.21

D3421-A-26873 Stacking Section Details 7.21

D3421-A-32385A-2 Turntable Top Assy Side View 7.23

D3421-A-34290A-1 Turntable Top Assy End View 7.24

D3421-A-32385A-3 TT Top Assy Overall Top View 7.26

D3421-A-32385A-4 TT Top Assy 3 Cross Section Views 7.26

D3421-A-34291-1 Turntable Bottom Assy Top View 7.26

D3421-A-34291-2 T Bot Components with Pressor Assy 7.28

D3421-A-34291-3 T Bot Components with Pressor Assy 7.28

D3421-A-33982 TT Bot Components W/O Pressor Assy 7.28

D3421-A-34148A Elect Enclosure Ass'y. 7.30

D3421-A-26863 Elec Encl: TB1, TB2, I/O's, J1-3, Misc 7.30

B3311-A-24656 Powered Outfeed W/O Idler Rollers 7.32

D3421-A-34203A Pneumatic Assy 7.34

D3421-A-33170A Pneumatic Assy Pressor Add on 7.35

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91

10

53

Kn

ob

92

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11

-23

24

2S

tee

l B

um

pe

r

10

93

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-24

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6Ta

ble

Pu

sh

In

sta

ll K

it

111

34

11

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pa

ce

r

11

71

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pre

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14

51

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ht

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al L

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um

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11

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10

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ste

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l

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or

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up

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rt

ITE

M N

O.

PA

RT N

UM

BE

RP

AR

T D

ES

CR

IPT

ION

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s,

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gs,

an

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rie

s 5

0X

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cke

rP

art

s,

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win

gs,

an

d P

art

s L

ists

Pag

e 7

.7Q

UIP

P S

YS

TE

MS

IN

C.

Pag

e 7

.7

Fig

ure

7.4

: M

ain

As

se

mb

ly (

rig

ht

sid

e)

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

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UIP

P S

YS

TE

MS

IN

C.

Pa

ge 7

.8

Fig

ure

7.5

: M

ain

As

se

mb

ly (

rea

r v

iew

)

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

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win

gs,

an

d P

art

s L

ists

Pag

e 7

.9Q

UIP

P S

YS

TE

MS

IN

C.

Pag

e 7

.9

Fig

ure

7.6

: M

ain

Ass

em

bly

(s

ide

sta

ck

gu

ide

s)

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.10

QU

IPP

SY

ST

EM

S I

NC

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ag

e 7

.10

7.3

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Basic

In

feed

Assem

bly

Basic

Infe

ed A

ssem

bly

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s L

ist

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es 5

0X

Sta

cker

rep

lace

ab

le p

art

s n

ot

inte

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ng

ea

ble

are

id

en

tifie

d in t

he

follo

win

g lis

t as:

a.

50

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......

....

....

....

....

......

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app

lies t

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1 m

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....

......

....

......

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o b

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nd 5

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od

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c.

50

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....

....

....

....

....

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....

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app

lies t

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....

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....

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lies t

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1 a

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e.

No M

od

el N

um

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r..

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....

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....

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lies t

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O.

PA

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UM

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43

To

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20

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24

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ha

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up

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29

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92

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mp

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30

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54

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29

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27

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Belt 4

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55

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31

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56

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32

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29

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8.4

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t C

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93

94

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ng

e B

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0

ITE

M N

O.

PA

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UM

BE

RP

AR

T D

ES

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IPT

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11

63

11

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10

02

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01

Idle

r R

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r R

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r B

arr

el

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ng

Cla

mp

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llar

ITE

M N

O.

PA

RT N

UM

BE

RP

AR

T D

ES

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IPT

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Part

s,

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gs,

an

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art

s L

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rie

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0X

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cke

rP

art

s,

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win

gs,

an

d P

art

s L

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e 7

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QU

IPP

SY

ST

EM

S I

NC

.P

age

7.1

1

Fig

ure

7.7

: 5

0X

Se

rie

s I

nfe

ed

, A

ss

em

bly

Rig

ht

Sid

e

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

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win

gs,

an

d P

art

s L

ists

Pag

e 7

.12

QU

IPP

SY

ST

EM

S I

NC

.P

ag

e 7

.12

Fig

ure

7.8

: 5

0X

Se

rie

s In

fee

d,

As

se

mb

ly T

op

Vie

w

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.13

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.1

3

Fig

ure

7.9

: 5

0X

Seri

es

In

feed

, L

eft

Sid

e

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.14

QU

IPP

SY

ST

EM

S I

NC

.P

ag

e 7

.14

Fig

ure

7.1

0:

50

1 S

eri

es

In

feed

, A

ss

em

bly

Rig

ht

Sid

e

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.15

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.1

5

Fig

ure

7.1

1:

50

1 S

eri

es I

nfe

ed

, A

ss

em

bly

To

p V

iew

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

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rie

s 5

0X

Sta

cke

rP

art

s,

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gs,

an

d P

art

s L

ists

Pag

e 7

.16

QU

IPP

SY

ST

EM

S I

NC

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ag

e 7

.16

Fig

ure

7.1

2:

50

1 S

eri

es

In

fee

d,

Left

Sid

e

Part

s,

Dra

win

gs,

an

d P

art

s L

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Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.17

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.1

7

Fig

ure

7.1

3:

To

p-o

f_b

atc

h S

en

so

r

To

p o

f B

atc

h S

en

so

r A

sse

mb

ly P

art

s L

ist

ITE

M N

O.

PA

RT N

UM

BE

RP

AR

T D

ES

CR

IPT

ION

13

411

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78

4A

ctu

atin

g L

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bso

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in

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art

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art

s L

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Pag

e 7

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QU

IPP

SY

ST

EM

S I

NC

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ag

e 7

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Fig

ure

7.1

4:

Co

nn

ec

tor

Ho

us

ing

As

se

mb

ly

Co

nn

ec

tor

Ho

usin

g A

ss

em

bly

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rts L

ist

ITE

M N

O.

PA

RT N

UM

BE

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AR

T D

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art

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Pag

e 7

.19

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.1

9

Fig

ure

7.1

5:

Sq

ue

eze

Ro

lle

r K

it -

To

p V

iew

In

fee

d

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s,

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win

gs,

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art

s L

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rie

s 5

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cke

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s,

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e 7

.20

QU

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ST

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NC

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7.3

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Sta

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g S

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on

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O.

PA

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UM

BE

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50

53

Ja

m N

ut

5/1

6-1

6

21

90

97

Ste

pp

er

Mo

tor

22

366

2C

lam

p C

olla

r/1

.13

23

10

21

Se

t C

olla

r/.7

5

24

10

23

Se

t C

olla

r/1

.00

25

33

37

Be

lt -

8m

m W

ide

26

38

68

Inse

rt B

ea

rin

g/0

.75

27

886

9L

ock H

ub

28

10

65

Re

tain

er/

1.6

3

29

101

4B

eari

ng

/0.7

5

30

93

98

Co

mp

ressio

n S

prin

g

31

50

05

Wa

sh

er

Fe

nd

er

39

890

8S

pa

ce

r/.1

56

Th

40

33

11

-14

52

6

33

11

-14

49

5

10

80

33

11

-14

49

4

10

30

10

29

Ch

ain

Se

ctio

n A

ssy

Sta

ckin

g A

rm L

ink

Rolle

r C

hain

Lin

k 4

0

Sta

ckin

g A

rm L

ink

Ma

ste

r L

ink 4

0

Ro

ller

Chain

40

42

33

11

-14

54

6S

en

so

r B

racke

t

43

3111

-20

16

Pu

sh

er

TT

Pro

x S

witch

44

33

11

-18

46

9

34

11

-24

78

6

34

11

-24

79

1

34

11

-24

78

7

34

11

-24

79

2

Serv

o M

oto

r C

ab

le 1

4’

RH

In

terc

ep

t B

lad

e (

50

0C

&C

W)

RH

In

terc

ep

t B

lad

e (

50

1C

&C

W)

LH

In

terc

ep

t B

lad

e (

50

0C

&C

W)

LH

In

terc

ep

t B

lad

e (

50

1C

&C

W)

Part

s,

Dra

win

gs,

an

d P

art

s L

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Se

rie

s 5

0X

Sta

cke

rP

art

s,

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win

gs,

an

d P

art

s L

ists

Pag

e 7

.21

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.2

1

Fig

ure

7.1

6:

Sta

ck

ing

Se

cti

on

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.22

QU

IPP

SY

ST

EM

S I

NC

.P

ag

e 7

.22

7.3

.4.

Tu

rnta

ble

Assem

bly

Turn

tab

le P

art

s L

ist

ITE

M N

O.

PA

RT N

UM

BE

RP

AR

T D

ES

CR

IPT

ION

13

3111

-23

52

7B

elt T

en

sio

n L

ock

14

34

21

-26

65

8

3111

-22

70

3

Co

nn

ect

Ro

d 5

00

s

Con R

od 5

00

Ws

16

3111-2

35

59

Ga

s S

prin

g S

pa

ce

r

20

3111

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51

6T

imin

g P

ulle

y

25

3111-2

01

6P

rox S

en

so

r A

ssy

27

8869

Lo

ck H

ub .

75

- 1

.50

30

311

3-8

97

6F

lex C

ab

le S

plic

e A

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31

3421-3

2165

Turn

table

Pu

sher

34

34

21

-27

16

8P

ush

er

Arm

Ho

ld P

late

36

87

05

Co

mp

ressio

n S

prin

g

37

83

12

Ma

t B

elt 1

4 W

ide

38

84

01

Sp

rocke

t 1

2T

39

1079

Beari

ng

.75 -

1.8

5

40

1014

Beari

ng

.75 -

1.6

3

41

86

15

Ga

s S

pri

ng

42

84

36

Re

tain

er

2.0

6

69

4906

Roll

Pin

74

331-1

8467

Serv

o M

oto

r C

ab

le

80

10

65

Re

tain

er

1.6

3

81

9395

Handle

Fo

llo

win

g p

art

s a

pp

ly t

o a

ll 5

00C

& 5

01C

Seri

es S

tack

ers

85

3421-3

2146

Bund

le H

old

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Brc

kt

A

86

3421-3

2147

Bund

le H

old

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Brc

kt

B

87

3421-3

2148

Top R

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forc

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rckt

94

34

21

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16

1L

ift

Ba

r S

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95

34

21

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15

5

34

21

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32

0

Lift

Pla

te

Lift

Pla

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50

0C

W

96

34

21

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28

5

34

21

-32

32

4

Exit P

late

Exit P

late

- 5

00C

W

98

34

21

-32

28

6M

at

Ru

bb

er

99

10049

1C

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15-.

75-1

.00

100

3421-3

2432

Cle

vis

101

10049

4B

eari

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.75

102

10049

5B

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ng

.5-1

.13

10

31

00

49

5S

ho

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bso

rbe

r

10

41

00

49

9R

eta

ine

r 1

.12

5

10

51

26

0R

eta

ine

r 0

.5

Pn

eu

mati

c P

an

el A

dja

cen

t M

ain

Pa

nel

10

79

84

7V

alv

e

10

81

04

4M

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r

111

10

04

72

3-p

in C

on

ne

cto

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11

21

00

60

1V

alv

e

11

36

89

74

Do

we

l P

in

11

48

95

4C

lam

p C

olla

r

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.23

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.2

3

Fig

ure

7.1

7:

Tu

rnta

ble

To

p A

ss

em

bly

- S

ide V

iew

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.24

QU

IPP

SY

ST

EM

S I

NC

.P

ag

e 7

.24

Fig

ure

7.1

8:

Tu

rnta

ble

To

p A

ss

em

bly

- E

nd

Vie

w

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.25

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.2

5

7.3

.5.

Tu

rnta

ble

Bo

tto

m A

ssem

bly

Tu

rnta

ble

Bo

tto

m A

sse

mb

ly P

art

s L

ist

ITE

M N

O.

PA

RT N

UM

BE

RP

AR

T D

ES

CR

IPT

ION

00

01

34

21

-26

66

8S

ho

ck,

Mo

un

t, C

asin

g

00

02

34

21

-32

14

1W

eld

me

nt,

Ce

nte

r T

ub

e

00

03

34

21

-33

75

3W

eld

me

nt,

Pla

te C

YL

. M

TG

. 5

00

W

00

04

34

21

-34

15

8P

in C

ran

k T

urn

tab

le

00

05

3111

-13

21

Ta

ble

Pin

Pu

ller

00

06

34

21

-32

15

8P

in,

Sh

ock,

Sta

cke

r

00

07

34

21

-26

92

2P

in,

Sh

ock,

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08

34

21

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87

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ir-C

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/2.5

Bo

re/5

.0 S

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00

09

34

21

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88

1S

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ft,

CY

L.

MT

G.

ST

KR

.40

0/4

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00

11

33

22

Be

ari

ng

/RE

/0.6

3/S

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em

ale

00

12

93

92

Re

tain

ing-R

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.50 I

D/5

100

00

13

02

66

ST

L-S

Q,

CF,

3/8

, 1

01

8

00

14

90

03

Bu

sh

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ID

/7/8

OD

X 1

” L

G

0016

98

03

Scre

w,

Hex-I

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/8-2

4 X

1-1

/4 L

G

00

17

50

20

3/8

Sp

lit L

’Wa

sh

er,

Ste

el

00

18

49

98

3/8

Fla

twa

sh

er

SA

E-S

tee

l

00

20

54

37

Ja

m N

ut/

5/8

-18

00

21

50

40

He

x N

ut/

1/4

-20

/Ste

el

00

22

53

59

HH

CS

1/4

-20

X 3

-1/2

Fu

ll T

HR

D

00

23

49

96

1/4

Fla

twa

sh

er

SA

E-S

tee

l

00

24

0112

5S

cre

w;

SH

C 3

/8-2

4X

2

00

25

93

96

Ha

nd

le/3

/8-1

6X

2.3

6 L

G

00

27

3111

-08

61

Bu

mp

er

Pla

te

00

28

34

21

-268

37

Sh

aft,

Sh

ock A

bso

rbe

rs

00

29

34

21

-26

67

5S

pa

ce

r, H

an

dle

, T

urn

tab

le

00

30

11

05

Be

arin

g/S

L/0

.75

/BR

/1.0

0/0

.75

00

31

15

07

Sh

ock A

bso

rbe

r

00

32

53

14

FH

S 3

/8-1

6 X

3/8

00

33

90

97

Mo

tor/

Ste

pp

er

S

ee

(R

)

00

34

311

3-2

57

50

Tim

ing

Pu

lley/

-Sq

ua

re M

oto

r

00

35

36

62

Co

llar/

Cla

mp

/1.1

3/A

L

0036

96

01

Be

lt/T

imin

g/H

TD

-80

0-8

M-2

0M

M

00

37

33

21

Be

arin

g/R

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.63

/ST

/Ma

le

00

39

34

21

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66

9Ta

ble

Mo

tor

Mo

un

t “A

”

00

40

34

21

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67

0Ta

ble

Mo

tor

Mo

un

t “B

”

0047

12

85

Term

inal/C

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nel/-

00

53

10

04

97

RE

T/E

XT

/51

00

/3.3

46

Sh

aft D

IA

00

66

10

05

16

Dis

c/1

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DIA

/.1

56

Th

ick

00

67

10

05

15

Bra

ke

/Ca

lipe

r/P

NE

U/S

ing

le-A

ct

00

68

34

21

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35

6C

olla

r D

isc M

TG

00

69

34

21

-34

20

0S

pa

ce

r B

rake

AS

SY

Lo

we

r T

T 5

00

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.26

QU

IPP

SY

ST

EM

S I

NC

.P

ag

e 7

.26

Fig

ure

7.1

9:

Tu

rnta

ble

Bo

tto

m A

ss

em

bly

- T

op

Vie

w

Part

s,

Dra

win

gs,

an

d P

art

s L

ists

Se

rie

s 5

0X

Sta

cke

rP

art

s,

Dra

win

gs,

an

d P

art

s L

ists

Pag

e 7

.27

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.2

7

7.3

.6.

Tu

rnta

ble

Bo

tto

m M

oto

rs

Tu

rnta

ble

Bo

tto

m M

oto

rs P

art

s L

ist

ITE

M N

O.

PA

RT N

UM

BE

RP

AR

T D

ES

CR

IPT

ION

13

42

1-2

66

68

Sh

ock M

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e

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42

1-3

42

55

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de

r M

ou

nt

43

42

1-3

41

58

Cra

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lam

p P

in

53111

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Pin

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ble

63

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21

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69

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93

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46 I

D

11

33

22

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12

93

92

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14

90

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Bu

sh

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25

93

96

Ha

nd

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27

3111

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Bu

mp

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28

34

21

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83

7S

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Sh

aft

29

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675

Ha

nd

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pace

r

30

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Be

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5

31

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90

97

Moto

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5

34

311

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35

36

62

Cla

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36

33

37

96

01

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00

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ide

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21

Be

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39

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669

Mo

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40

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Mo

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42

34

21

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52

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71

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21

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97

Calip

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art

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on

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53

10

04

97

Re

tain

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66

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05

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Dis

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67

10

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15

Pn

eu

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Bra

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68

34

21

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69

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art

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Pag

e 7

.28

QU

IPP

SY

ST

EM

S I

NC

.P

ag

e 7

.28

Fig

ure

7.2

0:

Tu

rnta

ble

Bo

tto

m M

oto

rs (

Pre

ss

or

Cy

lin

der

an

d S

up

po

rt N

on

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ss

or)

Part

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cke

rP

art

s,

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win

gs,

an

d P

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Pag

e 7

.29

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.2

9

7.3

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Ele

ctr

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nclo

su

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ssem

bly

Ele

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l E

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PA

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2100

930

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Card

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3Z

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41

00

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PU

586

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10

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96

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Pag

e 7

.30

QU

IPP

SY

ST

EM

S I

NC

.P

ag

e 7

.30

Fig

ure

7.2

1:

Ele

ctr

ica

l E

nclo

su

re

Part

s,

Dra

win

gs,

an

d P

art

s L

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rie

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Sta

cke

rP

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s,

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an

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Pag

e 7

.31

QU

IPP

SY

ST

EM

S I

NC

.P

age

7.3

1

7.3

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Po

were

d O

utf

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w/o

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ler

Ro

llers

Po

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QPN 101068 QUIPP SYSTEMS INC. MasterTOC Page 1 of 2

QUIPP Series 2100 Newspaper Sensors

1.1 General.................................................................................................................................. 1.1

1.2 Operation............................................................................................................................... 1.2

1.3 Specifications ........................................................................................................................ 1.2

1.4 Installation ............................................................................................................................. 1.3

1.5 Stacker Installation ................................................................................................................ 1.3

1.6 Operating Suggestions.......................................................................................................... 1.4

1.7 Maintenance Procedures ...................................................................................................... 1.4

1.8 Parts Replacement................................................................................................................ 1.4

1.9 Parts Lists.............................................................................................................................. 1.5

Table of Contents Series 2110 Sensor

MasterTOC Page 2 of 2 QUIPP SYSTEMS INC. QPN 101068

QPN Stock # QUIPP SYSTEMS INC. Page 1.1

QUIPP Series 2100 Newspaper Sensors

1.1 General

This instruction manual includes information for:

• Operation

• Maintenance and

• Replacement Parts - for

QUIPP Series 2100 Newspapers Sensors. These contact-type sensors are applied to Ihe detection

of newspaper products transported in a lapped stream.

Two basic models of the sensor are available. The 2110 Series Small Wheel Sensor is generally

applied lo detecting direct-from-press products. The 2150 Series Large Wheel Sensor is applied to

detecting inserted products.

Small Wheel Sensor

Detent Tension Adjustment

Operation Series 2110 Sensor QUIPP Series 2100 Newspaper Sensors

Page 1.2 QUIPP SYSTEMS INC. QPN Stock #

Large Wheel Sensor

The sensors are optionally available for operation on a variety of voltage supply levels with an

equally optional variety of outputs per product detected as specified al time of order. The selection

permits theapplication to stackers and conveyors of different manufacture and application.

1.2 Operation

QUIPP Series 2100 Newspapers Sensors ulilize a four-tooth star or cog wheel to detect the product

being counted.

2110 Series - Star Wheel mounted inside body

2150 Series - Star Wheel mounted outside body

The detecting star wheel rotates on a shaft supported by the sensor body. The sensor itself is

supported to ride directly on the stream of products.

The leading edge of a product engages a tooth and rotates the wheel on its axis. A spring-based

detent then snaps the wheel to 90 degrees beyond its initial position before the arrival of the next

product. The next tooth of the wheel is now in place to intercept the next product in the stream.

An electrical count impulse is generated with each 90 degrees of wheel rotation:

A metal pellet is imbedded in each of the four arms of the cog wheel. A Hall Effect proximity

sensor mounted in the sensor body detects each pellet as it passes to produce an output for

each 90 degree turn of the cog wheel.

The sensor can be mounted in any attitude (pitch), from the horizontal to the vertical. Sensor mounts

are available for a number of applications.

1.3 Specifications

The differences in capabilities of the two basic sensors, the 2110 Small Wheel and the 2150 Large

Wheel Series, are listed in the following:

Product Orientation

Presentation............................................................................... Folded Edge leading, exposed to

Sensor

Angularity ................................................................................... 5° (ram a perpendicular to stream

center line

Product Page Count

2110 ........................................................................................... 6 to 96 Pg Broadsheet

2150........................................................................................... 48 to 300 Pg Broadsheet

Tabloid page count is twice the Broadsheet count

Product Lap

2110 ........................................................................................... 2” Minimum

2150 .......................................................................................... 4-1/2” Minimum

Product Rate

2110 ........................................................................................... to 70,000 pph

2150........................................................................................... to 40.000 ppfi

QUIPP Series 2100 Newspaper Sensors Series 2110 Sensor Installation


Sensor Input/Output

Power Supply Required ............................................................. . 5 to 24vdc at 10ma (as spec'd)

Qutput Load ............................................................................... to 50ma. Source or Sink (as spec'd)

Sensor Specifics

Dimensions ................................................................................ 7-7/16" L x 3-3/8" H

2110 ......................................................................................... x 1-1/2” W

2150 ......................................................................................... x 2-3/4” W

Weight ........................................................................................ 2-1/2 lbs.

1.4 Installation

A Series 2100 Newspapers Sensor is usually installed in QUIPP Newspaper Stackers at the time of

shipment. Mounts available for other applications.

General requirements of a good mechanical installation include:

1. both carrier and top belts at the location of the sensor to maintain the stream against the

resistance of the sensor cog wheel

2. belting located on both sides of the stream in a vertical mount arrangement

3. adequate space between top carrier belts to accommodate the width of the sensor

4. the sensor intercepting the individual products near the centerline of the product stream.

5. the mount permits the sensor to ride with the varying thickness of the stream

6. the attitude or pitch of the sensor does not vary with the thickness of the stream

Electrical installation is accommodated with an appropriate plug for the three-wire connection - as

specified at time of order.

1.5 Stacker Installation

A Small Wheel Series 2110 Sensor is usually installed in QUIPP Newspaper Stackers coupled with a

laser sensor.

If a Series 2110 sensor is to be removed from a QUIPP slacker, observe carefully the position of the

unit before removal. The vertical position of a mechanical sensor is adjusted with a machine screw.

The small wheel sensor

If sensor position was not noted, adjust as follows:

1. From the side of the infeed, sight horizontally between the three sets of upper belts at the sensor.

2. The top of the sensor should be parallel with the top span of the middle belt.

3. The bottom of the sensor should be even with the bottom span of the middle belt.

The large wheel sensor

If the original sensor position was not noted:

1. From the side of the infeed, sight horizontally between the three sets of upper belts at the

location of the sensor.

2. Adjust the front lower bulge of the sensor to be about even with a lower span of a side belt.

Operating Suggestions Series 2110 Sensor QUIPP Series 2100 Newspaper Sensors


3. Adjust the rear lower bulge to about half way between the lower spans of the middle and a side

belt.

1.6 Operating Suggestions

Placement on the Product Stream

Both sensors should permit the intercept wheel to encounter the products as they move past the

sensor. As the product page count increases, the stream becomes thicker and the sensor will be

pressed upward slightly.

If the product is consistently large in page count, raise the sensor with its adjusting screw until it just

rides on the stream without too much resistance.

Detent Spring Adjustment

The detent springs of both sensors can be adjusted. Generally, greater pressure is more effective on

larger page count products.

With star wheel wear, an increase in the detent spring pressure may be required. Adjust so that the

star wheel is firmly stopped in an intercept position and does not "walk" along the top of the product.

See “Maintenance Procedures” section.

Ensure that the sensor itself is supported well enough to prevent disturbance of the stream.

Periodically check bundle count to ensure accurate inputs from the product sensor.

1.7 Maintenance Procedures

With excessive wear of the star wheel, miscounts may occur. Replacement parts are available from

QUIPP Customer Service. Refer to the parts drawings following.

1. Replace the small wheel sensor star wheel when it extends out of the bottom of the sensor less

than about 5/16" [8 mm]. Increased detent spring pressure may correct the problem for a time.

a. Loosen the knob (Item 7 on tlie drawing D2110-A239).

b. Move the knob slightly toward the rear of the sensor and retighten. Check results of the

adjustment.

2. Replace the star wheel of the large wheel sensor when it no longer consistently intercepts large

inserted products and when ail other adjustments have been carried out. Increased detent

pressure may help for a time. Refer to Parts Drawing C2150-A1813. Increase the pressure:

a. Loosen the set screw, Item 13.

b. Twist the spring clamp, Item 5, slightly clockwise.

c. Retighten ihe set screw and check operation

Note: Check the shaft and its bearings also for wear when a star wheel is replaced.

3. Disassembly of the sensors is quite simple. Refer to their respective parts list drawings for details

of construction.

1.8 Parts Replacement

Proximity Sensor replacement - To replace:

1. Loosen the locking nut an unscrew from sensor.

2. Screw the replacement unit into the sensor base until it touches the star wheel.

QUIPP Series 2100 Newspaper Sensors Series 2110 Sensor Parts Lists


3. Unscrew the proximity sensor 1/3 turn and tighten the locknut.

4. Test for clearance. If rubbing is noted, turn the sensor out another 1/3 turn. Tighten the nut.

Star Wheel, etc. Replacement

Small Wheel Sensor - Refer to Dwg. D2110-A0239.

1. Drive the shaft of the star wheel assembly out of the sensor housing with a drift pin.

2. If the bushings are to be replaced, drive them out.

3. Remove the side of the sensor housing. Draw the detent spring free of the star wheel area.

4. Install the new bushings but do not drive them flush with the sensor wall as yet.

5. Slide in the new star wheel (correctly oriented). Push the new shaft into place, tapping if

necessary.

6. Tap the two bushings into place, observing from below the clearance of 0.016" (about 1/64")

[0.4 mm].

7. Detent spring replacement involves loosening set screw (Item 9) and knob assembly (Item 5).

This is done with the sensor side removed. Replace and return set screw and knob to previous

positions.

Large, Wheel Sensor - Refer to Dwg. 2150-A1813.

1. Loosen star wheel/hub set screws (Items 12).

2. Withdraw the shaft from the opposite sensor side to free the star wheel assembly.

3. Remove four (4) star wheel/hub set screws.

4. Replace the two flange bushings - press fit.

5. Reassemble star wheel assembly. Convex side of wave washer should ride against the bushing.

6. Detent spring replacement involves loosening set screw (Item 13) and replacing the spring

assembly. Readjust as previously explained.

1.9 Parts Lists

Parts drawings and lists follow. When ordering parts, provide sensor:

• Model number

• Serial number

• Part Number

Provide the following information for the part ordered:

• Assembly Drawing Number Reference

• Part Item Number

• Part Number

Drawings Follow.

D2110-A0239 ............................................................................. Small Wheel Sensor

D21SO-A1813............................................................................ Large Wheel Sensor

Parts Lists Series 2110 Sensor QUIPP Series 2100 Newspaper Sensors


Figure: 1.1: Newspaper Sensor, Small Wheel Model

QPN 3421-39789 QUIPP SYSTEMS INC. MasterTOC Page 1 of 2

QUIPP Series 2230 Non-Contact Laser Sensors

Chapter 1 Introduction

1.1 General.................................................................................................................................. 1.11.1.1. Applications............................................................................................................................1.1

1.2 Operation Description............................................................................................................ 1.11.2.1. Leading Edge Count Blocking................................................................................................1.3

1.2.2. Trailing Edge Count Blocking.................................................................................................1.3

1.2.3. Operating Modes....................................................................................................................1.3

1.2.4. Conveyor Speed Compensation ............................................................................................1.4

1.3 Specifications ........................................................................................................................ 1.5

Chapter 2 Installation, Set-Up and Operation

2.1 Installation ............................................................................................................................. 2.12.1.1. Mechanical Installation...........................................................................................................2.1

2.1.2. Electrical installation...............................................................................................................2.1

Chapter 3 Troubleshooting and Maintenance

3.1 General.................................................................................................................................. 3.1

3.2 Troubleshooting..................................................................................................................... 3.1

3.3 Maintenance.......................................................................................................................... 3.2

3.4 Conclusion............................................................................................................................. 3.2

Table of Contents Series 2230 Non-Contact Laser Sensor

MasterTOC Page 2 of 2 QUIPP SYSTEMS INC. QPN 3421-39789


QPN 3421-39789 QUIPP SYSTEMS INC. Page 1.1

Chapter 1 Introduction

1.1 General

This manual contains the Operating, Maintenance and Troubleshooting instructions for QUIPP

Count-Pro 11 Series 2230 Non-contact Laser Count Sensors.

1.1.1. Applications

The Count-Pro 11 can provide the product count in-put for stackers, product totalizing systems,

waste tracking systems, label applying systems and similar applications.

The unit requires visual access to the folded leading edge of the printed product passing by in

either a lapped or a gapped stream. Certain product and stream conditions, generally normal to

most printing operations, are necessary to ensure accurate count, per Specifications. Section

1.3.

WARNINGThe beam of laser light from the sensor can be

hazardous. It can permanently damage the eyesight

of one looking directly into the sensor at the light

source - or at its reflection. Accordingly, take all

necessary precautions.

1.2 Operation Description

The QUIPP Count-Pro ll Laser Sensor includes a laser diode light source directed through a narrow

window toward the moving stream of products passing beneath the unit. Three light detectors within

the enclosure are directed to the area at which the laser beam strikes the product stream.

The detectors monitor the signature (characteristics) of the leading edges of each product passing

by. The sensor then uses the average signature as a constraint to validate the output count pulse. An

RS-232 Data Inter-face is included in the Count Pro 11 which permits sensor parameters to be

remotely monitored and adjusted.

Refer to Figure 1.1 and the explanations following.

Operation Description Count-Pro Series 2230 Laser Sensor Introduction

Page 1.2 QUIPP SYSTEMS INC. QPN 3421-39789

Figure 1.1: Theory of Operation

View 1 -- When no product is present, the laser beam passes through the product delivery plane

between carrying surface wires or belts. The three light detectors see no reflected laser light. The

sensor recognizes a gap condition.

Introduction Count-Pro Series 2230 Laser Sensor Operation Description


View 2 -- As the first product moves in and under the laser beam, all three detectors will "see" laser

light reflected back from the product surface. This produces the first product count following a gap in

the stream.

View 3 -- As the leading edge of the next product intercepts the laser beam, light detector A is no

longer illuminated by reflected laser light.

View 4 -- Detector B is next deprived of this light while C confirms presence of laser light.

This sequence of shadow and light detection coupled with other inputs produces a raw count pulse

that is further processed by the Count-Pro II before being out-putted as a valid count pulse to the

receiver.

1.2.1. Leading Edge Count Blocking

Leading Edge Count Blocking (Figure 1.2) is provided through the stacker controls. The function

blocks false counts within an adjustable 0 to 4 inches of product length following the detection of

a valid product leading edge. Blanking eliminates counts generated by wrinkles or tears in the

product and from loosely inserted jackets or loose products lying on top of the stream, etc. Refer

to the stacker manual for details on its effect and its adjustment.

Figure 1.2: Leading Edge Blocking Zone Action

1.2.2. Trailing Edge Count Blocking

Refer to Figure 1.3 Blocking of "illegal" counts generated by uneven cutoffs, extraneous

products on top, etc., near the trailing edge of a product just ahead of a stream break is carried

out by the Count Pro II sensor itself.

The normal Trailing Edge Count blocking zone dimension is 1-1/2" preceding the trailing edge of

the last product ahead of a stream break. Certain stackers provide an added TEC blocking zone

length.

1.2.3. Operating Modes

The Count Pro 11 can operate in two modes:

Line and Stacker Mode as set through a shorting jumper (P203) on the top sensor circuit board

and verified both on the sensor side and at the stacker.

Operation Description Count-Pro Series 2230 Laser Sensor Introduction


Figure 1.3: Trailing Edge Blocking Zone Action

Line Mode - produces an immediate count output on valid products detected. This capability

permits accurate tracking as needed in conveyor switch, labeling and other controls without the

speed reference DC voltage from a stacker.

Stacker Mode - The sensor itself delays count out-put for a period equal to 1-1/2" of infeed

travel. This feature allows the sensor to more accurately recognize the signature of a product

edge and to blank false counts at or near a product trailing edge when a stream gap occurs. This

all can occur as tie stacker infeed speed varies. Infeed speed is identified to the sensor by

means of a DC voltage supplied in proportion to stacker infeed speed (1VDC = 60fpm).

The sensor is capable of tracking a voltage range of 2VDC = 120fpm to 7VDC = 420fpm.

(420fpm delivery with 3" spacing approximates 100,000 products per hour.) A default voltage of

5VDC = 300fpm is developed by the sensor itself if no external signal is supplied. Stacker Mode

and the stacker-supplied Count Blocking capability operate as illustrated in Figure 1.2.

The stacker is able to display and permit adjustment of several factors involving the Count Pro II.

Several of these characteristics are:

1. Version and date of sensor software

2. Whether in Line or Stacker operating Mode

3. Edge characteristics of last product

4. Average of last 8 product edge factors

5. Sensor sensitivity can be adjusted between 60 and 85%

1.2.4. Conveyor Speed Compensation

The Leading and Trailing Edge Blocking Zones remain constant despite conveyor speed

variation when the Count Pro II is installed in a QUIPP stacker. A 2.0 to 5VDC conveyor speed

reference voltage is provided the sensor from the stacker, varying with infeed conveyor speed.

The sensor provides a DEFAULT input of 5VDC when no external reference is available.

Introduction Count-Pro Series 2230 Laser Sensor Specifications


1.3 Specifications

The following specifications apply to the Series 2230 Count-Pro II Sensor:

Permissible Product Characteristics

Max Product Count Rafe............................................................ 180,000 per hour

Max Stream Thickness ............................................................. nominal 2.5”

Max Page Count - .................................................................... 200 pages and up per the following

Refer to Figure 1.2

If top surface of product stream remains about 3.5” from laser face, the stream thickness may

increase by depressing the stream carrying surface below the nominal 4.5” dimension noted below

(drawing). Examples:

1. An overall stream thickness of 2-1/2” can include from 400 to 500 pages broadsheet on the flat,

depending upon paper stock thickness.

2. A single product page count in a heavy product stream with 4 lap wilt range from 144 pages and

up.

3. A 7-8” lap will permit product page counts exceeding 200.250 pages broadsheet.

4. A consistent, large leading edge product fold will in-crease both count accuracy and maximum

stream thickness beyond 2-1/2” because of the more defined shadow.

Min Page Count ......................................................................... 2 Pages Broadsheet (4 pg Tab) Half

folded with folded edge leading and

exposed to laser

Min Product Lap......................................................................... 1 Inch

Product Presentation ................................................................. Folded Edge Leading and Visible

Note: A cut edge leading and visible stream (direct) is acceptable providing the edge of all sheets

in the product combine into a tight group no more than 1/2” in length and the system has

Leading Edge Blocking.

A cut edge leading and hidden stream (indirect) is accept-able by directing the Count-Proll to

the opposite side of the stream where the folded edge is visible though flowing in a direction

opposite to normal.

Sensor Mount and Position

Nominal Operating Distance .................................................... Bottom surface of sensor 4.5” from

product carrying surface.

Operating Attitude ...................................................................... Bottom surface of sensor parallel to

product carrying surface except for

special cases noted.

Electrical Characteristics

Count Output Signal................................................................... 50VDC, lOOma Max from opto-

isolated open collector

Output Signal Pulse Width ......................................................... 10 ms

Power Requirements.................................................................. 11.5 to 30VDC at 200ma

Fusing ........................................................................................ internal, self-resetting

Specifications Count-Pro Series 2230 Laser Sensor Introduction


Figure 1.4: Installation Requirements

A - Nominal Height above Belts ................................................. 4.5 Inches

B - Minimum Height above Product ........................................... 3.5 Inches

C - Minimum Product Lap .......................................................... 1 Inch

D - Minimum Product Thickness ................................................ 2 Sheets

Need image


Chapter 2 Installation, Set-Up and Operation

2.1 Installation

The Count-Pro II Sensor is generally already installed in QUIPP Newspaper Stackers at the factory.

Suitable mounts can be provided for certain other applications.

2.1.1. Mechanical Installation

Installation of a Count-Pro II must be in accordance with the details of Figure 1.4

1. Parallel with the product carrying surface. (Certain applications require a slight tilt forward to

the sensor to compensate for the effect of product stream supporting rollers near or at the

location of the sensor.),

2. per the dimensions noted,

3. meeting the Product Specifications - Product Characteristics, Section 1.3,

4. with the sensor not mounted above a stream backup roller,

5. in any attitude (but be aware of possible dust build-up when mounted with window side up).

QUIPP stacker mounts maintain the sensor in correct position. If the sensor must be removed

for any reason, carefully check its position with respect to its mount so that it can be replaced

accurately. Mounting in another stacker or on a stream conveyor requires positioning per Figure

4. Especially important is the need to position the bottom surface of the sensor parallel with the

stream carrying conveyor.

FURTHER, place a laser beam absorber beyond the stream carrying surface to prevent

inadvertent exposure of the light energy to personnel. The absorber should be a black, matte-

finished target, about two (2) inches in diameter mounted at an angle to the laser to ensure no

light reflection back to the sensor.

2.1.2. Electrical installation

1. In QUIPP stackers, the Count-Pro II will al-ready have been cabled to the stacker control.

2. Installation in other applications requires wiring to a matching connector that fits the sensor

connector. Refer to wiring diagram, Figure 2.1

QUIPP Part Nos. 1127 Shell and 1229 Socket

The connector may have been shipped with the sensor or is available from the QUIPP

Customer Service/Parts Department: Phone 1-800-258-1390

3. Also required, as detailed in wiring diagram:

a. All installations: +12-24VDC main supply

b. Stacker and other applications which require accurate count for tracking purposes - a

minimum to max speed reference

Installation Count-Pro Series 2230 Laser Sensor Installation, Set-Up and Operation


Figure 2.1: Cable Connection Diagram

+ Supply 12-24V < 1

Common < 2

Cout Out Active Low < 3

Count Return < 4

0-5V Infeed Speed In < 5

Gap Output (active low) < 6

Spare < 7

RS-232 RXT < 8

RS-232 TXD < 9

RS-232 GND < 10

RS-232 CTS (not used) < 11

RS-232 (not used) < 12


Chapter 3 Troubleshooting and Maintenance

3.1 General

If count problems occur with Count-Pro II use, first eliminate factors in the stream or stacker that

might affect the count. Then, if problems continue, refer to the following material for corrective

suggestions.

Count problems may be caused for several reasons:

1. Product stream bunched or varying greatly in lap

2. Product is inserted poorly with occasional inserts riding on top of stream

3. Stacker infeed speed too high or too low relative to the feed conveyor causing erratic spacing

4. Stacker Intercept delay improperly set

5. Product conditions beyond the range of laser sensor capability or adjustments - see

Specifications.

Stream and stacker problems are discussed in the stacker manuals.The following suggestions apply

specifically to the laser sensor.

WARNINGThe beam of laser light from the sensor can be

hazardous. It can permanently damage the eyesight

of one looking directly into the sensor at the light

source - or at its reflection. Accordingly, take all

necessary precautions.

3.2 Troubleshooting

First ensure the following:

1. Power is on to the sensor at all times

2. The cable connector is firmly in place and tight

3. The mount is solidly installed

4. No loose or frayed belting or other interfering material is periodically in the laser beam

5. The beam absorber is in place and clean. Excessive dust on the absorber can produce false

counts and/or missed first paper counts following a stream gap

Then continue with the following possibilities.

When The Sensor Produces Extra Count Pulses

Extra count pulses will produce low count bundles in the stacker.

1. Check for open jackets and inserts riding on top of the jacket.

2. Check for torn or wrinkled products.

3. Increase Count Blanking dimension.

4. Lower sensor sensitivity.

5. Refer to Section 2.1.1.

Maintenance Count-Pro Series 2230 Laser Sensor Troubleshooting and Maintenance


When The Sensor Misses Valid Products

1. Missing count pulses will produce high count bundles in the stacker gapped form. A lap equal to

half the length of a product should be avoided since a missing product will produce a nose-to tail

condition.

2. Product lap is less than on inch.

3. Reduce Count Blanking if possible.

4. Ensure no inserts riding on top of the stream.

5. Increase sensor sensitivity.

6. Ensure beam absorber is clean.

3.3 Maintenance

Maintain the Count-Pro as follows:

Cleaning the Sensor Lens Face

Clean sensor lens when clouded or dusty using air or with a clean, dry cloth or one lightly

moistened with alcohol. Wipe the lens very lightly so as not to scratch its surface.

3.4 Conclusion

If a count problem persists after checking the preceding, contact the QUIPP Customer Service

Group for further aid:

1-800-258-1390

50x stacker operations manual

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