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
Web Site: www.quipp.com email: info@quipp.com Telephone: (305) 623-8700 Fax: (305)623-0980 QPN: 3421-39789-
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
Telephone (305)623-8700 - - FAX (305)623-0980 Web Site: www.quipp.com email: info@quipp.com
Copyright 2002 QUIPP SYSTEMS INC.
Table of Contents
Warranty
Warranty; Materials & Workmanship ...................................................................................Warranty.1
Defects 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
1.1 1.2
Introduction and Installation

General.................................................................................................................................. 1.1
1.1.1. 1.2.1. 1.2.2. The Lockout/Security System ................................................................................................1.1 Stacker Design.......................................................................................................................1.2 The Main Components...........................................................................................................1.2 Danger ...................................................................................................................................1.3 Warning..................................................................................................................................1.3 Caution...................................................................................................................................1.3 Note........................................................................................................................................1.3 Personal Safety......................................................................................................................1.4 Housekeeping ........................................................................................................................1.4 Operation and Maintenance...................................................................................................1.4 Mechanical .............................................................................................................................1.5 Utilities....................................................................................................................................1.5 Capacities and Capabilities....................................................................................................1.5 Controls..................................................................................................................................1.6 Ethernet Capability (If Installed) .............................................................................................1.7
Basic QUIPP 50X Series Stacker Description....................................................................... 1.1
1.3
Special Information................................................................................................................ 1.3

1.3.1. 1.3.2. 1.3.3. 1.3.4.
1.4
Safety Considerations ........................................................................................................... 1.3

1.4.1. 1.4.2. 1.4.3.
1.5
Specifications ........................................................................................................................ 1.5

1.5.1. 1.5.2. 1.5.3. 1.5.4. 1.5.5.
1.6 1.7 1.8
Stacker Performance Chart - - - - PRESS and NO PRESS .................................................. 1.7 Pre-Installation Considerations .......................................................................................... 1.10 Unpacking ........................................................................................................................... 1.10
1.8.1. 1.8.2. Lifting Stacker from the Skid ................................................................................................1.10 Reporting Shipping Related Damages.................................................................................1.10 Stacker Placement ...............................................................................................................1.11 Ongoing Conveyor ...............................................................................................................1.11 The Product Stream Encoder...............................................................................................1.11 Power Supply .......................................................................................................................1.11 Auxiliary Signals...................................................................................................................1.12 Air Supply.............................................................................................................................1.12
1.9
Mechanical Installation ........................................................................................................ 1.11

1.9.1. 1.9.2.
1.10
Utilities and Control Signals ................................................................................................ 1.11

1.10.1. 1.10.2. 1.10.3. 1.10.4.
QPN 3421-39789-
QUIPP SYSTEMS INC.
MasterTOC Page 1 of 6
Table of Contents
Series 50X Stacker
1.11
Final Pre-Setup Checks ...................................................................................................... 1.14

1.11.1. 1.11.2. 1.11.3. 1.11.4. Mechanical Inspection ......................................................................................................... 1.14 Touch Screen and Pushbuttons .......................................................................................... 1.14 Electrical/Electronic Inspection ............................................................................................ 1.14 General Inspection .............................................................................................................. 1.15
Chapter 2
2.1 2.2 2.3
Controls, Set-Up, and Stacker Start-Up

General.................................................................................................................................. 2.1 Stacker Power Switch ........................................................................................................... 2.1 Operator Controls - Pushbuttons........................................................................................... 2.1
2.3.1. 2.3.2. 2.3.3. 2.3.4. START/CLEAR (Green) ........................................................................................................ 2.2 BYPASS (White when gate is open - down).......................................................................... 2.3 STOP (Red with yellow outline) ............................................................................................. 2.3 LEFT, ALTERNATE and RIGHT (Orange) ............................................................................ 2.3
2.4 2.5 2.6 2.7
The Touch Screen/Display .................................................................................................... 2.3 Using the Touch Screen........................................................................................................ 2.4
2.5.1. The Lock-out Code ................................................................................................................ 2.4
General Set-Up ..................................................................................................................... 2.5 Mechanical Adjustments ....................................................................................................... 2.6

2.7.1. 2.7.2. 2.7.3. 2.7.4. Cut Edge Guide ..................................................................................................................... 2.6 Batch Side Guides ................................................................................................................. 2.7 Turntable Walls...................................................................................................................... 2.7 Turntable Eject Pushers ........................................................................................................ 2.8
2.8 2.9 2.10 2.11 2.12 2.13 2.14
Pneumatic Settings ............................................................................................................... 2.9 Control Clock & Screen Saver............................................................................................... 2.9 To Set-up for Production ..................................................................................................... 2.10 New Bundle Data Entry ....................................................................................................... 2.10 Speed-Set Recording .......................................................................................................... 2.14
2.12.1. Using Recorded PROFILE Data .......................................................................................... 2.14
User Help Information ......................................................................................................... 2.15

2.13.1. MAIN Page Help Examples ................................................................................................. 2.15
Set-up and Event MESSAGES ........................................................................................... 2.16

2.14.1. The MESSAGES ................................................................................................................. 2.16
Chapter 3
3.1 3.2 3.3 3.4 3.5
50XC Series Stacker Pressor Adjustments

General.................................................................................................................................. 3.1 The Touch Screen/Display .................................................................................................... 3.1 Using the Touch Screen........................................................................................................ 3.2
3.3.1. The Lock-out Code ................................................................................................................ 3.2

3.5.1. 3.5.2. 3.5.3. Cut Edge Guide ..................................................................................................................... 3.4 Batch Side Guides ................................................................................................................. 3.5 Turntable Walls...................................................................................................................... 3.5 QUIPP SYSTEMS INC. QPN 3421-39789-
Series 50X Stacker 3.5.4.
Table of Contents
Turntable Eject Pushers.........................................................................................................3.6
3.6 3.7 3.8 3.9 3.10
Pneumatic Settings ............................................................................................................... 3.7 Control Clock & Screen Saver............................................................................................... 3.7 To Set-up for Production ....................................................................................................... 3.8 New Bundle Data Entry ......................................................................................................... 3.8 Set-up and Event MESSAGES ........................................................................................... 3.13
3.10.1. The MESSAGES..................................................................................................................3.13
Chapter 4
4.1 4.2
Start-Up and Preventive Maintenance

Introduction............................................................................................................................ 4.1 Fine Tuning the Stacker During Production .......................................................................... 4.1
4.2.1. 4.2.2. 4.2.3. User Help Information ............................................................................................................4.1 The Parameter Page..............................................................................................................4.2 Stacking from an Inserter .......................................................................................................4.4
4.3 4.4
General Maintenance ............................................................................................................ 4.6 Scheduled and Preventive Maintenance............................................................................... 4.6

4.4.1. 4.4.2. 4.4.3. 4.4.4. Initial Inspection .....................................................................................................................4.6 Daily Attention ........................................................................................................................4.6 Monthly and Extended Attention ............................................................................................4.7 Lubrication - as needed..........................................................................................................4.7
Chapter 5
5.1 5.2 5.3 5.4
Troubleshooting
General.................................................................................................................................. 5.1
5.1.1. How to set up SIMULATION ..................................................................................................5.1
MESSAGES .......................................................................................................................... 5.2 Recorded Messages, Possible Causes, Recommend Corrections ...................................... 5.5 Status Page........................................................................................................................... 5.6
5.4.1. 5.4.2. Status Page Help ...................................................................................................................5.7 Status Page Help Examples ..................................................................................................5.7 Proximity Switch Indicators ....................................................................................................5.8 Power Supply Indicators ........................................................................................................5.8 CPU in the Card Cage Indicators...........................................................................................5.9 Main Relay Indicators.............................................................................................................5.9 Infeed Motor AC Drive...........................................................................................................5.9 Proximity Switches Troubleshooting Procedures...................................................................5.9 Initial Start-up Sequence......................................................................................................5.12 Operator Inputs and Checks ................................................................................................5.12 Sequence Completion..........................................................................................................5.13
5.5
Indicating LIGHTS and LED's................................................................................................ 5.8

5.5.1. 5.5.2. 5.5.3. 5.5.4. 5.5.5. 5.5.6.
5.6
A Normal Start-up Test........................................................................................................ 5.12

5.6.1. 5.6.2. 5.6.3.
5.7
The IO Update Page ........................................................................................................... 5.14
QPN 3421-39789-
QUIPP SYSTEMS INC.
Table of Contents
Series 50X Stacker
Chapter 6
6.1 6.2
Detailed Maintenance
Detailed Maintenance............................................................................................................ 6.1 Infeed Section ....................................................................................................................... 6.2
6.2.1. 6.2.2. 6.2.3. 6.2.4. 6.2.5. 6.2.6. Product Carrier Belt Replacement ......................................................................................... 6.2 Infeed Drive Belt Replacement .............................................................................................. 6.4 Infeed Drive Motor Service .................................................................................................... 6.5 Infeed Speed-Distance Sensor.............................................................................................. 6.5 The Product Sensors ............................................................................................................. 6.6 Top-of-Batch Sensor Assembly ............................................................................................. 6.7 Stacking Section Prox Sensors ........................................................................................... 6.10 Stacking Section Chain Tension.......................................................................................... 6.12 Stacking Section Stepper Motors ........................................................................................ 6.12
6.3
Stacking Section.................................................................................................................... 6.8

6.3.1. 6.3.2. 6.3.3.
6.4 6.5
Pneumatic Elements ........................................................................................................... 6.12 The Turntable/Pusher Assembly ......................................................................................... 6.12

6.5.1. 6.5.2. 6.5.3. 6.5.4. 6.5.5. Turntable Rotation Functions .............................................................................................. 6.13 Turntable Lift and Press Action ........................................................................................... 6.14 Turntable Wall/Pusher Action .............................................................................................. 6.15 Servicing the Turntable Assembly ....................................................................................... 6.15 Servicing Walls/Pusher Assembly ....................................................................................... 6.16 The Touch Screen ............................................................................................................... 6.18 To Check Screen Touch Accuracy ...................................................................................... 6.18 Screen Characteristics Adjust ............................................................................................. 6.19 Electrical/Electronic Enclosure ............................................................................................ 6.19 Discussion of Specific Components .................................................................................... 6.21 Main Supply Power.............................................................................................................. 6.23 +12, -12, +5VDC Checks..................................................................................................... 6.24 24VDC Check ...................................................................................................................... 6.24 Stepper Drive Output ........................................................................................................... 6.24 The Memory Backup Battery ............................................................................................... 6.25 BUNDLE Screen Default Settings ....................................................................................... 6.25 PARAMETER Default Settings ............................................................................................ 6.26
6.6
The Control.......................................................................................................................... 6.18

6.6.1. 6.6.2. 6.6.3. 6.6.4. 6.6.5.
6.7
Electrical Service................................................................................................................. 6.23

6.7.1. 6.7.2. 6.7.3. 6.7.4. 6.7.5.
6.8
Factory Default Settings Review ......................................................................................... 6.25

6.8.1. 6.8.2.
6.9
Options and Configurations................................................................................................. 6.26
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
Table of Contents
Chapter 7
7.1 7.2 7.3
Diagrams, Schematics, and Parts List

Diagrams and Schematics .................................................................................................... 7.1 Parts Drawings and Lists....................................................................................................... 7.1 Parts, Drawings, and Parts Lists ........................................................................................... 7.6
7.3.1. 7.3.2. 7.3.3. 7.3.4. 7.3.5. 7.3.6. 7.3.7. 7.3.8. 7.3.9. Main Assembly.......................................................................................................................7.6 Basic Infeed Assembly.........................................................................................................7.10 Stacking Section ..................................................................................................................7.20 Turntable Assembly .............................................................................................................7.22 Turntable Bottom Assembly .................................................................................................7.25 Turntable Bottom Motors......................................................................................................7.27 Electrical Enclosure Assembly .............................................................................................7.29 Powered Outfeed w/o Idler Rollers ......................................................................................7.31 Pneumatic Assembly............................................................................................................7.33
QPN 3421-39789-
QUIPP SYSTEMS INC.
Table of Contents
Series 50X Stacker
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QUIPP SYSTEMS INC.
QPN 3421-39789-
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
QPN 3421-39789-
QUIPP SYSTEMS INC.
Warranty 1
50X Series Stacker
Warranty
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.
Warranty 2
QUIPP SYSTEMS INC.
QPN 3421-39789-
Table of Contents
Chapter 1
1.1 1.2

General.................................................................................................................................. 1.1
1.1.1. 1.2.1. 1.2.2. The Lockout/Security System ................................................................................................1.1 Stacker Design.......................................................................................................................1.2 The Main Components...........................................................................................................1.2 Danger ...................................................................................................................................1.3 Warning..................................................................................................................................1.3 Caution...................................................................................................................................1.3 Note........................................................................................................................................1.3 Personal Safety......................................................................................................................1.4 Housekeeping ........................................................................................................................1.4 Operation and Maintenance...................................................................................................1.4 Mechanical .............................................................................................................................1.5 Utilities....................................................................................................................................1.5 Capacities and Capabilities....................................................................................................1.5 Controls..................................................................................................................................1.6 Ethernet Capability (If Installed) .............................................................................................1.7
Basic QUIPP 50X Series Stacker Description....................................................................... 1.1
1.3
Special Information................................................................................................................ 1.3

1.3.1. 1.3.2. 1.3.3. 1.3.4.
1.4
Safety Considerations ........................................................................................................... 1.3

1.4.1. 1.4.2. 1.4.3.
1.5
Specifications ........................................................................................................................ 1.5

1.5.1. 1.5.2. 1.5.3. 1.5.4. 1.5.5.
1.6 1.7 1.8
Stacker Performance Chart - - - - PRESS and NO PRESS .................................................. 1.7 Pre-Installation Considerations .......................................................................................... 1.10 Unpacking ........................................................................................................................... 1.10
1.8.1. 1.8.2. Lifting Stacker from the Skid ................................................................................................1.10 Reporting Shipping Related Damages.................................................................................1.10 Stacker Placement ...............................................................................................................1.11 Ongoing Conveyor ...............................................................................................................1.11 The Product Stream Encoder...............................................................................................1.11 Power Supply .......................................................................................................................1.11 Auxiliary Signals...................................................................................................................1.12 Air Supply.............................................................................................................................1.12 Mechanical Inspection..........................................................................................................1.14 Touch Screen and Pushbuttons...........................................................................................1.14 Electrical/Electronic Inspection ............................................................................................1.14 General Inspection ...............................................................................................................1.15
1.9
Mechanical Installation ........................................................................................................ 1.11

1.9.1. 1.9.2.
1.10
Utilities and Control Signals ................................................................................................ 1.11

1.10.1. 1.10.2. 1.10.3. 1.10.4.
1.11
Final Pre-Setup Checks ...................................................................................................... 1.14

1.11.1. 1.11.2. 1.11.3. 1.11.4.
QPN 3421-39789-
QUIPP SYSTEMS INC.
TOC Page 1 of 2
Table of Contents
Series 50X Stacker
Chapter 1 Introduction and Installation
TOC Page 2 of 2
QUIPP SYSTEMS INC.
QPN 3421-39789-
Chapter 1 Introduction and Installation

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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 1.1
Basic QUIPP 50X Series Stacker Description
Series 50X Stacker
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.
Page 1.2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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
CAUTION A 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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 1.3
Safety Considerations
Series 50X Stacker
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.
Page 1.4
QUIPP SYSTEMS INC.
QPN 3421-39789-
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
Rate Orientation Alignment Offcenter Deviation Minimum Lap to over 85,000 pph folded edge leading and on top of stream folded edge perpendicular to stream centerline with 5 max. deviation max " [13 mm] 2-" [63 mm]
Product Parameters
Page Count 50X Models 500W Models 6 to over 400 pg broadsheet Minimum and Maximum Product Size (W by L) 10-" to 12" by 12" x 14-" [267-305 by 305-368 mm] 10-" to 12" by 12" x 16-3/4" [267-305 to 305-420 mm]
Stacker Batch Capacities

Maximum Height Maximum Count; Pages Minimum Count; Products 12-" [317 mm] 2000 broadsheet * two (2)
* Loose folds and/or unusual inserts can result in lower maximum page counts per batch and stack.
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
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 1.5
Specifications
Series 50X Stacker
Stacker Stack (Bundle) Capacities

Maximum Height Maximum Count; Pages Maximum Count; Products Batches per Stack 16" [415 mm] 3250 * 999 1 to 9
* Loose folds and/or unusual inserts can result in lower max page counts per batch and stack.
Stacker Dynamics
Cycle Time - Pressor mode - OFF 0.92 Seconds
Cycle Time - Pressor mode - ON Batch Press Last batch press 2.5 seconds 4.0 seconds
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.
L, R, Alt, Ratioed 100-180 fpm [0.5-0.92 M/sec]
Stack Discharge Directions Push Velocity adjustable
QUIPP Product Count Sensors - Pages Broadsheet

Count-Pro II Laser sensor Mechanical sensors 6 to 400 8 to 144
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
Emergency STOP mushroom Bypass Gate Lighted Pushbuttons START LEFT ALTERNATE RIGHT clears/readies for production stacks delivered to left stacks delivered alternating stacks delivered to right pulls out for START latched (closed) or open
Page 1.6
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 1.7
Stacker Performance Chart - - - - PRESS and NO PRESSSeries 50X Stacker
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. Table 1.1: Example: Max Press Rates for 3 to 9 Batch Stacks Sample Press PPH
85,000 70,000 50,000 30,000 20,000
Minimum Quantity Products in Each Batch* None Pressed

22 18 13 7 5
All but Last Pressed

59 48 34 20 13
All Pressed
94 77 55 33 22
* Up to 3,250 Pg broadsheet, maximum in final stack.
Formula for Max Press Rate (PPH) for specific Batch counts in 3 to 9 Batch stacks when - - N = Products per Batch*
None Pressed 3600 x N 0.95 All but Last 3600 x N 2.5 All Pressed 3600 x N 4.0
Example: 6 Batch Stack of 60 Products per Batch - All Pressed Max press rate = 3600 X 60 / 4 = 54,000 PPH
Page 1.8
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 1.9
Pre-Installation Considerations
Series 50X Stacker
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 carriers 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 Customers 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.
Page 1.10
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
Mechanical Installation
1.9
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 " [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)
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 1.11
Utilities and Control Signals
Series 50X Stacker
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. CAUTION Before connecting the air supply to the stacker, blow out the supply line to clear it of foreign particles and excessive moisture.
Page 1.12
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
Utilities and Control Signals
Figure 1.3: The J-Box and the Stacker Connector Housing
The J-Box
TB1
J2 J1
J-Box Cabling
J1 - Stacker Output Signals J2 - Stacker Input Signals J3 - Main Power J6 - Product Supply Encoder Signal J6 J2 J1
J3
Locating Horn Area
J6 Pneumatic Quick Disconnect
Power Input Cable terminated with Connector J3
These cables, with appropriate lengths, lead to the Stacker Connector Housing and power supply cable.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 1.13
Final Pre-Setup Checks
Series 50X Stacker
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
Page 1.14
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 1.15
Series 50X Stacker
Note:
If no oil is present in the stacker air set, its oil reservoir must be filled before any poweron 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.
Page 1.16
QUIPP SYSTEMS INC.
QPN 3421-39789-
Table of Contents
Chapter 2
2.1 2.2 2.3

General.................................................................................................................................. 2.1 Stacker Power Switch ........................................................................................................... 2.1 Operator Controls - Pushbuttons........................................................................................... 2.1
2.3.1. 2.3.2. 2.3.3. 2.3.4. START/CLEAR (Green) .........................................................................................................2.2 BYPASS (White when gate is open - down) ..........................................................................2.3 STOP (Red with yellow outline) .............................................................................................2.3 LEFT, ALTERNATE and RIGHT (Orange).............................................................................2.3
2.4 2.5 2.6 2.7
The Touch Screen/Display .................................................................................................... 2.3 Using the Touch Screen........................................................................................................ 2.4
2.5.1. The Lock-out Code.................................................................................................................2.4

2.7.1. 2.7.2. 2.7.3. 2.7.4. Cut Edge Guide......................................................................................................................2.6 Batch Side Guides .................................................................................................................2.7 Turntable Walls ......................................................................................................................2.7 Turntable Eject Pushers.........................................................................................................2.8
2.8 2.9 2.10 2.11 2.12 2.13 2.14
Pneumatic Settings ............................................................................................................... 2.9 Control Clock & Screen Saver............................................................................................... 2.9 To Set-up for Production ..................................................................................................... 2.10 New Bundle Data Entry ....................................................................................................... 2.10 Speed-Set Recording .......................................................................................................... 2.14
2.12.1. Using Recorded PROFILE Data ..........................................................................................2.14
User Help Information ......................................................................................................... 2.15

2.13.1. MAIN Page Help Examples..................................................................................................2.15
Set-up and Event MESSAGES ........................................................................................... 2.16

2.14.1. The MESSAGES..................................................................................................................2.16
QPN 3421-39789-
QUIPP SYSTEMS INC.
TOC Page 1 of 2
Table of Contents
Series 50X Stacker Chapter 2 Controls, Set-Up, and Stacker Start-Up
TOC Page 2 of 2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 2.1
Operator Controls - Pushbuttons
Series 50X Stacker
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.
Page 2.2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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 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 The Main Page (below) and the remaining basic displays are all identified as Pages.
Note:
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 2.3
Using the Touch Screen
Series 50X Stacker
Figure 2.2: Main Page Bundle Display Set-up Screen
2.5

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.
Page 2.4
QUIPP SYSTEMS INC.
QPN 3421-39789-
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
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 2.5
Mechanical Adjustments
Series 50X Stacker
2.7
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 Batch Side Guide Angle Brace
Cut Edge Guide and Lockdown Knobs Side Guide Lockdown Knobs
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. CAUTION A jam can result from setting the guide too tight and the bypass gate could drop unexpectedly.
Page 2.6
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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 A-Drive A-Side Wall Table MID Take-up Lock Handle Prox Sensors Lock Handles
A-Wall Prox Sensor
Lift Guide Bars
B-Side Wall Drive Components
A-Wall Drive Motor
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 2.7
Series 50X Stacker
Figure 2.6: View through Turntable (left) and from above (right) Turntable MID Sensor Targets Wall Drive Motor (below) Lift Table Guide Rod Ends Wall Tensioning Cylinder Pusher Proximity Switches (2)
Pressor Plates Cylinder
Pusher Bars Turntable HOME Target
Exit Directions Drive Belts (2)
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.
Page 2.8
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 2.9
To Set-up for Production
Series 50X Stacker
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.
Page 2.10
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 2.11
Series 50X Stacker
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 Blanking Zone Laser Light and Count Sensor Paths
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.
Page 2.12
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 2.13
Speed-Set Recording
Series 50X Stacker
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.
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QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
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QUIPP SYSTEMS INC.
Page 2.15
Set-up and Event MESSAGES
Series 50X Stacker
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"
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"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.
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Page 2.17
Series 50X Stacker
NOTES:
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QUIPP SYSTEMS INC.
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Chapter 3
3.1 3.2 3.3 3.4 3.5

General.................................................................................................................................. 3.1 The Touch Screen/Display .................................................................................................... 3.1 Using the Touch Screen........................................................................................................ 3.2
3.3.1. The Lock-out Code.................................................................................................................3.2

3.5.1. 3.5.2. 3.5.3. 3.5.4. Cut Edge Guide......................................................................................................................3.4 Batch Side Guides .................................................................................................................3.5 Turntable Walls ......................................................................................................................3.5 Turntable Eject Pushers.........................................................................................................3.6
3.6 3.7 3.8 3.9 3.10
Pneumatic Settings ............................................................................................................... 3.7 Control Clock & Screen Saver............................................................................................... 3.7 To Set-up for Production ....................................................................................................... 3.8 New Bundle Data Entry ......................................................................................................... 3.8 Set-up and Event MESSAGES ........................................................................................... 3.13
3.10.1. The MESSAGES..................................................................................................................3.13
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QUIPP SYSTEMS INC.
TOC Page 1 of 2
Table of Contents
Series 50X Stacker
Chapter 3 50XC Series Stacker Pressor
TOC Page 2 of 2
QUIPP SYSTEMS INC.
QPN 3421-39789-
Chapter 3 50XC Series Stacker Pressor Adjustments

3.1 General
This chapter describes the Pressor features included with the 50XC Series Stacker.
3.2

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 The Main Page (below) and the remaining basic displays are all identified as Pages. Figure 3.1: Main Page Bundle Display Set-up Screen
Note:
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QUIPP SYSTEMS INC.
Page 3.1
Series 50X Stacker
3.3

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
Page 3.2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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
Before first-time production, adjust the stacker for the products to be handled and for other local conditions. These adjustments are:
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QUIPP SYSTEMS INC.
Page 3.3
Series 50X Stacker
Figure 3.3: Batch Forming Guide Adjustment Devices Batch Side Guide Angle Brace
Cut Edge Guide and Lockdown Knobs Side Guide Lockdown Knobs
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. CAUTION A jam can result from setting the guide too tight and the bypass gate could drop unexpectedly.
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QUIPP SYSTEMS INC.
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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 A-Drive A-Side Wall Table MID Take-up Lock Handle Prox Sensors Lock Handles
A-Wall Prox Sensor
Lift Guide Bars
A-Wall Drive Motor
Pressor Pneumatics
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.
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Page 3.5
Series 50X Stacker
Figure 3.5: View through Turntable (left) and from above (right) Turntable MID Sensor Targets Wall Drive Motor (below) Lift Table Guide Rod Ends Wall Tensioning Cylinder Pusher Proximity Switches (2)
Pressor Plates Cylinder
Pusher Bars Turntable HOME Target
PRESSOR Plates Retracted Extended
Exit Directions Drive Belts (2)
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.
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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.
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Page 3.7
Series 50X Stacker
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

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

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.
Page 3.8
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 3.9
Series 50X Stacker
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
Page 3.10
QUIPP SYSTEMS INC.
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Series 50X Stacker
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.
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QUIPP SYSTEMS INC.
Page 3.11
Series 50X Stacker
Figure 3.9: Count Blanking Blanking Zone Laser Light and Count Sensor Paths
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.
Page 3.12
QUIPP SYSTEMS INC.
QPN 3421-39789-
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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. 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" "ODD COUNT MODE" Displayed when stacker is put into "ODD COUNT" programming.
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QUIPP SYSTEMS INC.
Page 3.13
Series 50X Stacker
*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.
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QUIPP SYSTEMS INC.
QPN 3421-39789-
Table of Contents
Chapter 4
4.1 4.2

Introduction............................................................................................................................ 4.1 Fine Tuning the Stacker During Production .......................................................................... 4.1
4.2.1. 4.2.2. 4.2.3. User Help Information ............................................................................................................4.1 The Parameter Page..............................................................................................................4.2 Stacking from an Inserter .......................................................................................................4.4
4.3 4.4
General Maintenance ............................................................................................................ 4.6 Scheduled and Preventive Maintenance............................................................................... 4.6

4.4.1. 4.4.2. 4.4.3. 4.4.4. Initial Inspection .....................................................................................................................4.6 Daily Attention ........................................................................................................................4.6 Monthly and Extended Attention ............................................................................................4.7 Lubrication - as needed..........................................................................................................4.7
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QUIPP SYSTEMS INC.
TOC Page 1 of 2
Table of Contents
Series 50X Stacker
Chapter 4 Start-Up and Preventive Maintenance
TOC Page 2 of 2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
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QUIPP SYSTEMS INC.
Page 4.1
Series 50X Stacker
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.
Page 4.2 QUIPP SYSTEMS INC. QPN 3421-39789-
Series 50X Stacker
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.
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QUIPP SYSTEMS INC.
Page 4.3
Series 50X Stacker
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.
Page 4.4
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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
Insufficient Lap - 50% or less
No Lap
Sufficient Lap - More than 50% Gap
Figure 4.3: Stacker Infeed vs. Inserter Production Rate
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 4.5
General Maintenance
Series 50X Stacker
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.
Page 4.6
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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 nondetergent 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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 4.7
Series 50X Stacker
NOTES:
Page 4.8
QUIPP SYSTEMS INC.
QPN 3421-39789-
Table of Contents
Chapter 5
5.1 5.2 5.3 5.4
Troubleshooting
General.................................................................................................................................. 5.1
5.1.1. How to set up SIMULATION ..................................................................................................5.1
MESSAGES .......................................................................................................................... 5.2 Recorded Messages, Possible Causes, Recommend Corrections ...................................... 5.5 Status Page........................................................................................................................... 5.6
5.4.1. 5.4.2. Status Page Help ...................................................................................................................5.7 Status Page Help Examples ..................................................................................................5.7 Proximity Switch Indicators ....................................................................................................5.8 Power Supply Indicators ........................................................................................................5.8 CPU in the Card Cage Indicators...........................................................................................5.9 Main Relay Indicators.............................................................................................................5.9 Infeed Motor AC Drive...........................................................................................................5.9 Proximity Switches Troubleshooting Procedures...................................................................5.9 Initial Start-up Sequence......................................................................................................5.12 Operator Inputs and Checks ................................................................................................5.12 Sequence Completion..........................................................................................................5.13
5.5
Indicating LIGHTS and LED's................................................................................................ 5.8

5.5.1. 5.5.2. 5.5.3. 5.5.4. 5.5.5. 5.5.6.
5.6
A Normal Start-up Test........................................................................................................ 5.12

5.6.1. 5.6.2. 5.6.3.
5.7
The IO Update Page ........................................................................................................... 5.14
QPN 3421-39789-
QUIPP SYSTEMS INC.
TOC Page 1 of 2
Table of Contents
Series 50X Stacker
Chapter 5 Troubleshooting
TOC Page 2 of 2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 5.1
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
Page 5.2
QUIPP SYSTEMS INC.
QPN 3421-39789-
Troubleshooting
Series 50X Stacker
MESSAGES
The EVENT MESSAGES Messages which may be displayed and recorded are; 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 - normally. ENTERED RESULT TOO SMALL Entered value more than minimum allowed. *PAPER SENSOR HAS CHANGED* Tells operator the paper sensor was switched. 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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 5.3
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. **STOP BUTTON PUSHED** STACKER IS SHUT DOWN - The operator depressed a "STOP" pushbutton. CLEAR BUTTON PUSHED The operator depressed a "CLEAR" pushbutton. ENTER THE THREE DIGIT CODE 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. RESULTS IN A STACK GREATER THAN 999 Displayed when stack size entered is more than 999, the maximum permitted.
Page 5.4
QUIPP SYSTEMS INC.
QPN 3421-39789-
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 Problems Recommended Corrections
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 Increase MIN INFEED SPEED Reference - Sec. 4.2.2-a Check, replace, if needed Check, replace, if needed Check, replace, if needed Check, replace, if needed Check that all cables fixed Check, tighten, if needed Correct (6.3.2) Check, clear obstructions Assure air supply (2.8) Check regulator setting (40psi) Check sensors' adjust/replace Check, clear obstructions Check, adjust or replace Check, replace, if needed Check, replace, if needed Check, replace, if needed Check that all cables fixed Check, tighten, if needed Replace belt (2.7.3.) Similar corrections as above Similar corrections as above Similar corrections as above Check, clear obstructions Assure air supply Check air regulator setting (2.8) Check, adjust or replace Check, clean, replace valve
*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 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
**STACKING SECTION MISSED HOME**
**TABLE FAILED TO HOME**
A Turntable Sensor
Products jamming turntable Loss of stacker air supply Low turntable air pressure Faulty turntable sensor (5.5) 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 Similar possible problems listed just above Fig 5.3, I/O 14 Similar possible problems listed above Similar possible problems listed above 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)
**PUSHER A FAILED TO FIND HOME**
Pusher A Sensor
**PUSHER B FAILED TO FIND HOME** **PUSHER A FAILED TO LEAVE HOME** **PUSHER B FAILED TO LEAVE HOME** **TABLE FAILED TO LEAVE**
Pusher B Sensor Pusher A Sensor Pusher B Sensor Turntable Sensor
**TABLE FAILED TO FIND MID**
Turntable Sensor
Similar possible problems listed just above Similar corrections as above
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 5.5
Status Page
Series 50X Stacker
Troubleshooting
Messages
**K1 RELAY DEACTIVATED**
Activated By
Turntable Sensor
Possible Problems
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) Product Jam in infeed Faulty I/O circuit card Fault SDS Sensor 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
Recommended Corrections
Check, clear obstructions Assure main air supply Check air regulator setting Check, replace Troubleshoot with schematics Check, clear obstructions Check, replace Check or Replace (6.2.4) Check, clear obstructions Check, adjust, replace sens (5.5) Check, motor (5.5) Verify and replace (5.5) Verify all cable connectors tight Verify and replace
**NO INFEED SPEED PULSES** **STACKING SECTION A FAILED**
Infeed Speed Distance Sensor Stacking section A Sensors
**STACKING SECTION B FAILED** *LAP TOO CLOSE*
Stacking section B Sensors Laser or mechanical product sensor
Similar possible problems listed just above Similar corrections as above 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, adjust or replace Check, repair or replace
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.
Page 5.6
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 5.7
Indicating LIGHTS and LED's
Series 50X Stacker
Troubleshooting
5.5

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-A24919. 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). These switches are similar on all Series 50X Stackers.
Four (4) on the turntable assembly (See Figure 6.10 & Parts Drawing 3411-A-34290A-1). Note: 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.
Page 5.8
QUIPP SYSTEMS INC.
QPN 3421-39789-
Troubleshooting
Series 50X Stacker
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
Indicators... on the Proximity Switches The LED(s) on the switches should light --If not, go to Step 4 The LED(s) on the switches should light --If OK, go to Step 6 Clearance should be 0.050" to 0.100" [0.012-0.025mm] If not, correct clearance and recheck
With Stacker Power on 1. Touch end(s) of the switch(es) of the components being checked with a screwdriver blade. If OK, proceed to Step 2. 2. Manually move the component target past the switch(es) If not, go to Step 3 3. Check clearance between face of switch and target(s).
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 5.9
Series 50X Stacker
Troubleshooting
Action Required
With Stacker Power on 4. Check to ensure proper voltage is delivered to the switch(es). If no voltage, go to Step 5 5. Check DC Power Supplies: 3 lights behind card cage. If OK, ensure proper intermediate wiring, then, go to Step 6 6. Check Input of LED(s) on TB1 to proof cabling.
Response Required
Indicators... on the Proximity Switches 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-S34147S1 If OK, check intermediate cabling/wiring If faulty, replace and recheck from Step 1 above.
If correct LED flashes with movement of the component, then go to Step 7 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).
Correct LED(s) should light. Refer to Drawing D3421-S34147S for the number f the LED involved. If correct LED does not flash, check wiring between switch and terminal being checked. 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
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 8. Check wiring between terminal board and the 23856 circuit board. If OK, go to Step 9 9. Check the 8708 circuit board(s).
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. If wiring faulty (loose connections or fitting); correct. Continue to Step 10 if a problem still remains. If problems continue, go to Step 10.
Page 5.10
QUIPP SYSTEMS INC.
QPN 3421-39789-
Troubleshooting
Series 50X Stacker
Action Required
With Stacker Power on 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.
Response Required
Indicators... on the Proximity Switches 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.
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
However, if the Stepper Motor Drive is OK, continue with Step a1 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.
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 deenergized 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.
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 5.11
A Normal Start-up Test
Series 50X Stacker
Troubleshooting
5.6

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:
Input 9 Input 10 Input 11 Input 12 Input 13 Input 14 Pusher B HOME Pusher A HOME Table Sensor A Table Sensor B Top-of-Batch A Top-of-Batch B
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.
Page 5.12
QUIPP SYSTEMS INC.
QPN 3421-39789-
Troubleshooting
Series 50X Stacker
7. Check the following Inputs by pressing the appropriate pushbutton on the Operators Panel:
Input 24 Input 25 Input 26 Input 27 Right (delivery) Alt Left Bypass (gate)
8. Observe the required response:

Output 21 Output 33 Output 34 Output 35 LEFT LIGHT ALT LIGHT RIGHT LIGHT INFEED READY
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 5.13
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:
1 2 3,4 5-14 15 16 17-28 31-42 Product supply conveyor encoder Infeed Speed-Distance Encoder Product Sensors Proximity Switch functions Stacking Section Blanking Signal to the count input Various control and operator inputs Various control outputs
Touch Messages on the pull-down menu to display as many as 100 recorded Messages. Figure 5.3: The IO Update Page Display
Page 5.14
QUIPP SYSTEMS INC.
QPN 3421-39789-
Table of Contents
Chapter 6
6.1 6.2
Detailed Maintenance............................................................................................................ 6.1 Infeed Section ....................................................................................................................... 6.2
6.2.1. 6.2.2. 6.2.3. 6.2.4. 6.2.5. 6.2.6. Product Carrier Belt Replacement .........................................................................................6.2 Infeed Drive Belt Replacement ..............................................................................................6.4 Infeed Drive Motor Service.....................................................................................................6.5 Infeed Speed-Distance Sensor ..............................................................................................6.5 The Product Sensors .............................................................................................................6.6 Top-of-Batch Sensor Assembly .............................................................................................6.7 Stacking Section Prox Sensors............................................................................................6.10 Stacking Section Chain Tension ..........................................................................................6.12 Stacking Section Stepper Motors.........................................................................................6.12
6.3
Stacking Section.................................................................................................................... 6.8

6.3.1. 6.3.2. 6.3.3.
6.4 6.5
Pneumatic Elements ........................................................................................................... 6.12 The Turntable/Pusher Assembly ......................................................................................... 6.12

6.5.1. 6.5.2. 6.5.3. 6.5.4. 6.5.5. Turntable Rotation Functions ...............................................................................................6.13 Turntable Lift and Press Action ............................................................................................6.14 Turntable Wall/Pusher Action...............................................................................................6.15 Servicing the Turntable Assembly........................................................................................6.15 Servicing Walls/Pusher Assembly........................................................................................6.16 The Touch Screen................................................................................................................6.18 To Check Screen Touch Accuracy.......................................................................................6.18 Screen Characteristics Adjust ..............................................................................................6.19 Electrical/Electronic Enclosure.............................................................................................6.19 Discussion of Specific Components.....................................................................................6.21 Main Supply Power ..............................................................................................................6.23 +12, -12, +5VDC Checks .....................................................................................................6.24 24VDC Check ......................................................................................................................6.24 Stepper Drive Output ...........................................................................................................6.24 The Memory Backup Battery................................................................................................6.25 BUNDLE Screen Default Settings........................................................................................6.25 PARAMETER Default Settings ............................................................................................6.26
6.6
The Control.......................................................................................................................... 6.18

6.6.1. 6.6.2. 6.6.3. 6.6.4. 6.6.5.
6.7
Electrical Service................................................................................................................. 6.23

6.7.1. 6.7.2. 6.7.3. 6.7.4. 6.7.5.
6.8
Factory Default Settings Review ......................................................................................... 6.25

6.8.1. 6.8.2.
6.9
Options and Configurations................................................................................................. 6.26
QPN 3421-39789-
QUIPP SYSTEMS INC.
TOC Page 1 of 2
Table of Contents
Series 50X Stacker
Chapter 6 Detailed Maintenance
TOC Page 2 of 2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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. CAUTION Shut 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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.1
Infeed Section
Series 50X Stacker
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.
Page 6.2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.3
Infeed Section
Series 50X Stacker
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. 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.
Note:
1. To release tension on the upper belts, remove the nut from the cap screw holding the downstream 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: CAUTION Shut 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.
Page 6.4
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
Infeed Section
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
Speed-Distance Sensor
Sensing Gear
Belt Take-up
Drive Belt
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.5
Infeed Section
Series 50X Stacker
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 Laser Sensor
Vertical Adjustment
Mechanical Sensor
TOB Proximity Switches
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.
Page 6.6
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
Infeed Section
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.7
Stacking Section
Series 50X Stacker
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
TOB Product Sensing Arm
Top Proximity Switch should make when sensor arm tip is about 1/4 away from the center back stop.
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.
Page 6.8
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.9
Stacking Section
Series 50X Stacker
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.
Page 6.10
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
Stacking Section
Figure 6.8: Stacking Section Sensors
Proximity 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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.11
Pneumatic Elements
Series 50X Stacker
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 " 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 " play.
Page 6.12
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.13
Series 50X Stacker
A-Wall Prox Sensor
Figure 6.10: Turntable Midpoint Sensors A-Drive A-Side Wall Take-up Lock Handle Lock Handles
Table MID Prox Sensors
Lift Guide Bars
A-Wall Drive Motor
Pressor Pneumatics
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.
Page 6.14
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.15
Series 50X Stacker
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.
Page 6.16
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.17
The Control
Series 50X Stacker
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
Page 6.18
QUIPP SYSTEMS INC.
QPN 3421-39789-
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. CAUTION Only qualified electrical/electronic technicians should work on equipment located within the electrical/ electronic enclosure.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.19
The Control
Series 50X Stacker
Figure 6.13: The Electrical/Electronic Control Enclosure
Page 6.20
QUIPP SYSTEMS INC.
QPN 3421-39789-
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:
Param. No. 57 30 31 33 42 46 Setting 0 1.0 1.0 76 2.4 - Motor Amps 3 - to unlock & program
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:
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.21
The Control
Series 50X Stacker
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:
Param. No. F01 F02 F03 F04 F05 F06 F10 F11 Setting 1.0 1.0 0 0 4 135Hz 1
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.
Page 6.22
QUIPP SYSTEMS INC.
QPN 3421-39789-
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.
1. Red 2. Green 3. Amber +12VDC -12VDC +5VDC
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
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.23
Electrical Service
Series 50X Stacker
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:
Terminals 1. 1-2 2. 3-4 3. 53-54 4. 55 5. 56 Voltage +5VDC (4.75 to 5.25 id OK) 0V 0V +12VDC - +/- 1% -12VDC - +/- 1%
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 - A and A 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.
Page 6.24
QUIPP SYSTEMS INC.
QPN 3421-39789-
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 Pages ODD COUNT TURN TABLE BLANKING PAPER SENSOR OPTION 25/1 50 OFF ON AUTO (50% of Ave. Lap) Laser (non-contact) OFF
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.25
Options and Configurations
Series 50X Stacker
6.8.2.
PARAMETER Default Settings

Minimum Infeed Speed Blade Drop Speed Intercept Distance Batch Drop Speed Turntable Turn Delay Turntable Eject Delay Eject Speed Infeed Encoder Factor 180 fpm 100% varies with stacker and sensors 100% 200 ms 200 ms 140 fpm 100%
6.9

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
Page 6.26
QUIPP SYSTEMS INC.
QPN 3421-39789-
Series 50X Stacker
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 setup. To exit the screen, touch Pages, upper screen.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 6.27
Series 50X Stacker
NOTES:
Page 6.28
QUIPP SYSTEMS INC.
QPN 3421-39789-
Chapter 7
7.1 7.2 7.3

Diagrams and Schematics .................................................................................................... 7.1 Parts Drawings and Lists....................................................................................................... 7.1 Parts, Drawings, and Parts Lists ........................................................................................... 7.6
7.3.1. 7.3.2. 7.3.3. 7.3.4. 7.3.5. 7.3.6. 7.3.7. 7.3.8. 7.3.9. Main Assembly.......................................................................................................................7.6 Basic Infeed Assembly.........................................................................................................7.10 Stacking Section ..................................................................................................................7.20 Turntable Assembly .............................................................................................................7.22 Turntable Bottom Assembly .................................................................................................7.25 Turntable Bottom Motors......................................................................................................7.27 Electrical Enclosure Assembly .............................................................................................7.29 Powered Outfeed w/o Idler Rollers ......................................................................................7.31 Pneumatic Assembly............................................................................................................7.33
QPN 3421-39789-
QUIPP SYSTEMS INC.
TOC Page 1 of 2
Table of Contents
Series 50X Stacker
Chapter 7 Diagrams, Schematics, and Parts List
TOC Page 2 of 2
QUIPP SYSTEMS INC.
QPN 3421-39789-
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. Drawing No.
D3421-S-34147S1 D3421-S-34147S1 D3421-S-34147S2 D3421-S-34147S2 D3421-S-34147S2 D3421-S-34147S2 D3421-S-34147S3 D3421-S-34147S3 D3421-S-34147S3 QPN-100248
Description
Main Power, Steppers, Misc Monitors, DC Pow, Xfrm, Out Rollers TB's, Ops Stations, Lite Curtain TB 1,2 Arrgt, Laser Iface, J1, 2, 4 TB1, Sensors, Control Relays Ops Stations, Safe Curtain PC Card Case, Press System Pres Details, External Inputs Touch Scr, Other Cards Operators' Panels Schematic
Page
7.3 7.4 7.4 7.4 7.4 7.4 7.5 7.5 7.5
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.
QPN 3421-39789-
QUIPP SYSTEMS INC.
Page 7.1
Parts Drawings and Lists
Series 50X Stacker
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. Drawing No.
D3421-A-33960-1 D3421-A-33960-2 D3421-A-33960-3 D3421-A-33960-4 D3421-A-26875-1 D3421-A-26875-2 D3421-A-26875-3 D3421-A-26871-1 D3421-A-26871-2 D3421-A-26871-3 C3411-A-24919 C3411-A-23818 D3421-A-31093-1 D3421-A-31093-2 D3421-A-26873 D3421-A-26873 D3421-A-26873 D3421-A-32385A-2 D3421-A-34290A-1 D3421-A-32385A-3 D3421-A-32385A-4 D3421-A-34291-1 D3421-A-34291-2 D3421-A-34291-3 D3421-A-33982 D3421-A-34148A D3421-A-26863 B3311-A-24656 D3421-A-34203A D3421-A-33170A
Description
Main Assembly Right Side Main Assembly Rear View Main Assy Side Stack Guides Main Assy Stack Edge Guides @ Parts 50X Series Infeed Assy Right Side 50X Series Infeed Assy Top View 50X Series Infeed, Left Side 501 Series Infeed Assy Right Side 501 Series Infeed Assy Top View 501 Series Infeed, Left Side Top-of-Batch Sensor Assembly Connector Housing Assembly Sq Roller Kit - Top View Infeed Sq Roller Kit -Side View & Air System Stacking Section Details & Parts List Stacking Section Assembly Stacking Section Details Turntable Top Assy Side View Turntable Top Assy End View TT Top Assy Overall Top View TT Top Assy 3 Cross Section Views Turntable Bottom Assy Top View T Bot Components with Pressor Assy T Bot Components with Pressor Assy TT Bot Components W/O Pressor Assy Elect Enclosure Ass'y. Elec Encl: TB1, TB2, I/O's, J1-3, Misc Powered Outfeed W/O Idler Rollers Pneumatic Assy Pneumatic Assy Pressor Add on
Page
7.7 7.8 7.9 7.9 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.19 7.21 7.21 7.21 7.23 7.24 7.26 7.26 7.26 7.28 7.28 7.28 7.30 7.30 7.32 7.34 7.35
The remainder of this chapter shows the diagrams, schematics and parts list for the series 50X stacker.
Page 7.2
QUIPP SYSTEMS INC.
QPN 3421-39789-
Parts, Drawings, and Parts Lists
Series 50X Stacker
Figure 7.1: Main Power, Steppers, Misc
Page 7.3
QUIPP SYSTEMS INC.
Page 7.3
Series 50X Stacker
Figure 7.2: TBs, Ops Stations, Light Curtain
Page 7.4
QUIPP SYSTEMS INC.
Page 7.4
Series 50X Stacker
Figure 7.3: PC Card Case, Pressure System
Page 7.5
QUIPP SYSTEMS INC.
Page 7.5
Series 50X Stacker
7.3
The remainder of this section shows the parts lists and related drawings for the drawings specified earlier in this chapter.
7.3.1.
Main Assembly
Main Assembly Parts List

ITEM NO. 151 PART NUMBER PART DESCRIPTION
ITEM NO.
PART NUMBER
PART DESCRIPTION
12
3311-27113
LH Paper Deflector
15
3411-24780
Back Rib
16
3421-33822 3421-34309 3421-34218 3421-34287
Front Guard - 500 Front Guard - 501 Front Guard - 501W Front Guard - 500C
100931 1048 1049 1050 3421-28180 Count-Pro II Laser Sensor Caster - Rigid Caster - Swivel Caster - Floor Lock Chute Support
19
3311-14543
Side Guard Plexi RH
20
3311-14544
Side Guard Plexi LH
21
3311-14593
Side Chute Support
22
3311-14542
Side Plate
23
3111-0091
Plexi Shaft
24
3421-27103
Plexi Holder RH
25
3421-27104
Plexi Holder LH
26
3111-0092
Plexi Adjust Bracket
27
3111-0093
Adjust Arm
28
3111-0094
Adjust Holder
30
3421-33809
Frt Chute Mtg Bracket
31
3421-33819 3421-34284
Overflow Chute 500 Overflow Chute 501
35
3421-27193
Front Chute Flap
37
3411-24311
T-O-B Sensor Holder
40
1051
Knob
62
5471
Precision Nut
71
3411-24919
T-O-B Sensor Assy
74
3111-0203
Sensor Holder
79
2194
Roller 14.13 lg
82
3411-24781
Handle RH
83
3411-24782
Handle LH
84
3411-24786
Intercept BI LH 500-All
85
3411-24787
Intercept BI RH 500-All
84
3411-24791
Intercept BI LH 501-All
85
3411-24792
Intercept BI RH 501-All
86
3311-27112
Paper Deflector
90
3111-2016 1929-34257 3111-2016
Prox Sw Assy Push 500W Prox Sw Assy Push 501 Prox Sw Assy Push 501W
91
1053
Knob
92
3311-23242
Steel Bumper
109
3411-24376
Table Push Install Kit
111
3411-24779
Backrib Spacer
117
100941
Muffler Silencer
138
100163
Compression Latch
145
100796 Z100811
Light Crtn Trans/Recv/500/1/C Dual Light Crtn Kit/500W/1/C
150
Z3421-34203
Pneumatic Assy
Page 7.6
QUIPP SYSTEMS INC.
Page 7.6
Series 50X Stacker
Figure 7.4: Main Assembly (right side)
Page 7.7
QUIPP SYSTEMS INC.
Page 7.7
Series 50X Stacker
Figure 7.5: Main Assembly (rear view)
Page 7.8
QUIPP SYSTEMS INC.
Page 7.8
Series 50X Stacker
Figure 7.6: Main Assembly (side stack guides)
Page 7.9
QUIPP SYSTEMS INC.
Page 7.9
Series 50X Stacker
7.3.2.
Basic Infeed Assembly
Basic Infeed Assembly Parts List
Series 50X Stacker replaceable parts not interchangeable are identified in the following list as:
a. 50X ........................................applies too both 500 and 501 models
b. 50XW................................applies to both 500W and 501W models
c. 500/W .................................. applies to both 500 and 500W models
d. 501/W .................................. applies to both 501 and 501W models
e. No Model Number ........................................... applies to all models

ITEM NO. 37 38 39 40 41 42 43 44 45 46 48 49 3740 Bearing 1993 Split Collar 8272 AC Motor/.75 9393 Gear Reducer 3747 Flange Bearing 3886 Bearing Insert 3745 Flange Bearing 3311-15499 Spur Gear 3885 3884 Timing Belt (500-All) Timing Belt (501-All) 1810-13273 Timing Pulley Idler Assy Idler Roller Assy Idler Roller Barrel Bearing Clamp Collar 4084 Taperlock Hub 116 PART NUMBER PART DESCRIPTION ITEM NO. PART NUMBER PART DESCRIPTION
ITEM NO.
PART NUMBER
PART DESCRIPTION
3311-14574 3311-14575
Pivot Arm Roller-500W Pivot Arm Roller-501/W
3421-26512 3111-1767
Stacker Lifting Bar-50X Stacker Lifting Bar-50XW
3115-31002 3115-30999 1014 1001
3421-26566 3311-14573
Spacer Bushg-Bypass Gate-50X Spacer Bushg-Bypass Gate-50XW
3421-26526 3115-13410
Bearing Spacer-50X Bearing Spacer-50XW
3115-13411 3115-13411 3115-13419
Cylinder Clamp-50X Cylinder Clamp-500/W Cylinder Clamp-501/W
11
3421-26952 3421-28108
Cylinder Tubing-50X Cylinder Tubing-50XW
12
3115-23746
Drive Roller
13
3115-13425 3115-13435 1014
Idler Roller Assembly Idler Roller Bearing
14
3411-24002 3411-23719 1402
Crowned Roller Assembly Idler Roller Bearing
15
3411-23944 3411-23942 1402 50 51 52 53 54 55 56 59 106 111 112 114 115 9394 9397 3421-26779 1023 1810-13292 8728 Gate Cylinder/7.00 Timing Pulley Spacer Set Collar/1.00 Take-Up Spacer, Small Retaining Ring/1.01D Flange Bushing/1.00 8732 8829 Belt 58.45 -500/W Belt 41.75 -501/W 8731 8828 Belt 60.30 -500/W Belt 39.94 -501/W 8729 8827 Belt 55.24 -500/W Belt 45.06 -501/W 8730 8826 Belt 55.24 -500/W Belt 46.78 -501/W 1021 Set Collar/.75 1306 Clamping Collar/1.00 1328 Retainer/2.06
Idler Roller Assembly Idler Roller Bearing
16
3421-26513 3311-14577
Upper Idler Shaft-50X Upper Idler Shaft-50XW
3311-19524 3421-29714 3111-0026 3311-19506 1017 1458 1001 1028 1070 1071 5113-20311 1113 Product Sensor Mnt Assy (500) Product Sensor Mnt Assy (501) Sensor Parallel Arm Support Shaft/.75/15 Bearing/.75 Bearing/.50 Clamping Collar/.5 Clamping Collar/.750 RH Torsion Spring LH Torsion Spring Clamp Collar/.75 Modified Knob
17
3421-33859 3115-13423
Lower Dump Gate Shaft-50X Lower Dump Gate Shaft-50XW
18
34211-26510 3115-13443
Top Feed Drive Shaft-50X Top Feed Drive Shaft-50XW
19
3421-26511 3115-13444
Bottom Drive Shaft-50X Bottom Drive Shaft-50XW
20
3421-33861 3115-13445
Dump Gate Idler Shaft-50X Dump Gate Idler Shaft-50XW
21
3421-33860 3115-13446
Dump Gate Idler Shaft-50X Dump Gate Idler Shaft-50XW
24
3421-26514
Shaft Support
29
3421-26924
Probe Guide
30
3421-27508
Sprocket Tensioner Block
33
1929-29367
Magnetic Pickup Assembly
34
3741
Pulley/3.82
35
3350 8096
Taperlock Hub-50X Taperlock Hub-50XW
36
4085
Pulley/2.546
Page 7.10
QUIPP SYSTEMS INC.
Page 7.10
Series 50X Stacker
Figure 7.7: 50X Series Infeed, Assembly Right Side
Page 7.11
QUIPP SYSTEMS INC.
Page 7.11
Series 50X Stacker
Figure 7.8: 50X Series Infeed, Assembly Top View
Page 7.12
QUIPP SYSTEMS INC.
Page 7.12
Series 50X Stacker
Figure 7.9: 50X Series Infeed, Left Side
Page 7.13
QUIPP SYSTEMS INC.
Page 7.13
Series 50X Stacker
Figure 7.10: 501 Series Infeed, Assembly Right Side
Page 7.14
QUIPP SYSTEMS INC.
Page 7.14
Series 50X Stacker
Figure 7.11: 501 Series Infeed, Assembly Top View
Page 7.15
QUIPP SYSTEMS INC.
Page 7.15
Series 50X Stacker
Figure 7.12: 501 Series Infeed, Left Side
Page 7.16
QUIPP SYSTEMS INC.
Page 7.16
Series 50X Stacker
Figure 7.13: Top-of_batch Sensor

Top of Batch Sensor Assembly Parts List
ITEM NO. 1 2 6 7 0312 8938 3111-815 3411-24784 PART NUMBER PART DESCRIPTION Actuating Lever Prox Switch Assy Shock Absorber Steel Hinge Pin
Page 7.17
QUIPP SYSTEMS INC.
Page 7.17
Series 50X Stacker
Figure 7.14: Connector Housing Assembly

Connector Housing Assembly Parts List
ITEM NO. 2 3 4 5 1421 1423 3831 8694 7119 7725 PART NUMBER PART DESCRIPTION Service Connection 19 Pin Jack Male 10 Pin Jack Female 3-Pin Connector Quick disconnect - Air - Male Quick disconnect - Air - Female
Page 7.18
QUIPP SYSTEMS INC.
Page 7.18
Series 50X Stacker
Figure 7.15: Squeeze Roller Kit - Top View Infeed
Page 7.19
QUIPP SYSTEMS INC.
Page 7.19
Series 50X Stacker
7.3.3.
Stacking Section
Stacking Section Parts List
ITEM NO.
PART NUMBER
PART DESCRIPTION
3311-14502
Shaft Sprocket
3311-14503
Shaft/.75/6.25
3411-25334
Shaft Adjustment
3311-14505
Idler Bearing 1.63/Sprocket/40
3421-26508
Top Support Shaft
3421-26509
Bottom Support Shaft
3311-24394
Threaded Tension Rod
10
3111-24516
Timing Pulley 54T
11
3313-25750
Timing Pulley - Motor
14
3311-14512R 3311-14524R 3111-0142 5581 5003 5579 3311-14512L 3311-14524L 3111-0142 5581 5003 5579
RH Stacking Arm Assy RH Stack Arm Casting Cam Follower Assy Shoulder Bolt 1/4x1 #10 Precision Washer Nylock Nut 10-24 LH Stacking Arm Assy LH Stack Arm Casting Cam Follower Assy Shoulder Bolt 1/4x1 #10 Precision Washer Nylock Nut 10-24
16
3421-36503
Motor Mount Pivot Rod
17
3421-36507
Threaded Take-up Rod
18
3421-36504
Motor Mt Take-up Ring
19
1081
Retainer/.75
20
5053
Jam Nut 5/16-16
21
9097
Stepper Motor
22
3662
Clamp Collar/1.13
23
1021
Set Collar/.75
24
1023
Set Collar/1.00
25
3337
Belt - 8mm Wide
26
3868
Insert Bearing/0.75
27
8869
Lock Hub
28
1065
Retainer/1.63
29
1014
Bearing/0.75
30
9398
Compression Spring
31
5005
Washer Fender
39
8908
Spacer/.156 Th
40
3311-14526 3311-14495 1080 3311-14494 1030 1029
Chain Section Assy Stacking Arm Link Roller Chain Link 40 Stacking Arm Link Master Link 40 Roller Chain 40
42
3311-14546
Sensor Bracket
43
3111-2016
Pusher TT Prox Switch
44
3311-18469 3411-24786 3411-24791 3411-24787 3411-24792
Servo Motor Cable 14 RH Intercept Blade (500C&CW) RH Intercept Blade (501C&CW) LH Intercept Blade (500C&CW) LH Intercept Blade (501C&CW)
Page 7.20
QUIPP SYSTEMS INC.
Page 7.20
Series 50X Stacker
Figure 7.16: Stacking Section
Page 7.21
QUIPP SYSTEMS INC.
Page 7.21
Series 50X Stacker
7.3.4.
Turntable Assembly
Turntable Parts List
ITEM NO.
PART NUMBER
PART DESCRIPTION
13
3111-23527
Belt Tension Lock
14
3421-26658 3111-22703
Connect Rod 500s Con Rod 500Ws
16
3111-23559
Gas Spring Spacer
20
3111-24516
Timing Pulley
25
3111-2016
Prox Sensor Assy
27
8869
Lock Hub .75 - 1.50
30
3113-8976
Flex Cable Splice Assy
31
3421-32165
Turntable Pusher
34
3421-27168
Pusher Arm Hold Plate
36
8705
Compression Spring
37
8312
Mat Belt 14 Wide
38
8401
Sprocket 12T
39
1079
Bearing .75 - 1.85
40
1014
Bearing .75 - 1.63
41
8615
Gas Spring
42
8436
Retainer 2.06
69
4906
Roll Pin
74
331-18467
Servo Motor Cable
80
1065
Retainer 1.63
81
9395
Handle
Following parts apply to all 500C & 501C Series Stackers
85
3421-32146
Bundle Holder Brckt A
86
3421-32147
Bundle Holder Brckt B
87
3421-32148
Top Reinforce Brckt
94
3421-32161
Lift Bar Shaft
95
3421-32155 3421-32320
Lift Plate Lift Plate - 500CW
96
3421-32285 3421-32324
Exit Plate Exit Plate - 500CW
98
3421-32286
Mat Rubber
99
100491
Cylinder 15-.75-1.00
100
3421-32432
Clevis
101
100494
Bearing .75
102
100495
Bearing .5-1.13
103
100495
Shock Absorber
104
100499
Retainer 1.125
105
1260
Retainer 0.5
Pneumatic Panel Adjacent Main Panel
107
9847
Valve
108
1044
Muffler
111
100472
3-pin Connector
112
100601
Valve
113
68974
Dowel Pin
114
8954
Clamp Collar
Page 7.22
QUIPP SYSTEMS INC.
Page 7.22
Series 50X Stacker
Figure 7.17: Turntable Top Assembly - Side View
Page 7.23
QUIPP SYSTEMS INC.
Page 7.23
Series 50X Stacker
Figure 7.18: Turntable Top Assembly - End View
Page 7.24
QUIPP SYSTEMS INC.
Page 7.24
Series 50X Stacker
7.3.5.
Turntable Bottom Assembly
Turntable Bottom Assembly Parts List
ITEM NO.
PART NUMBER
PART DESCRIPTION
0001
3421-26668
Shock, Mount, Casing
0002
3421-32141
Weldment, Center Tube
0003
3421-33753
Weldment, Plate CYL. MTG. 500W
0004
3421-34158
Pin Crank Turntable
0005
3111-1321
Table Pin Puller
0006
3421-32158
Pin, Shock, Stacker
0007
3421-26922
Pin, Shock, Stacker
0008
3421-26878
Air-CYL/2.5 Bore/5.0 Stroke
0009
3421-33881
Shaft, CYL. MTG. STKR.400/400C
0011
3322
Bearing/RE/0.63/ST/Female
0012
9392
Retaining-Ring/3.50 ID/5100
0013
0266
STL-SQ, CF, 3/8, 1018
0014
9003
Bushing 5/8 ID/7/8 OD X 1 LG
0016
9803
Screw, Hex-ID.3/8-24 X 1-1/4 LG
0017
5020
3/8 Split LWasher, Steel
0018
4998
3/8 Flatwasher SAE-Steel
0020
5437
Jam Nut/ 5/8-18
0021
5040
Hex Nut/1/4-20/Steel
0022
5359
HHCS 1/4-20 X 3-1/2 Full THRD
0023
4996
1/4 Flatwasher SAE-Steel
0024
01125
Screw; SHC 3/8-24X2
0025
9396
Handle/3/8-16X2.36 LG
0027
3111-0861
Bumper Plate
0028
3421-26837
Shaft, Shock Absorbers
0029
3421-26675
Spacer, Handle, Turntable
0030
1105
Bearing/SL/0.75/BR/1.00/0.75
0031
1507
Shock Absorber
0032
5314
FHS 3/8-16 X 3/8
0033
9097
Motor/Stepper
See (R)
0034
3113-25750
Timing Pulley/ -Square Motor
0035
3662
Collar/Clamp/1.13/AL
0036
9601
Belt/Timing/HTD-800-8M-20MM
0037
3321
Bearing/RE/0.63/ST/Male
0039
3421-26669
Table Motor Mount A
0040
3421-26670
Table Motor Mount B
0047
1285
Terminal/Channel/-
0053
100497
RET/EXT/5100/3.346 Shaft DIA
0066
100516
Disc/12 DIA/.156 Thick
0067
100515
Brake/Caliper/PNEU/Single-Act
0068
3421-32356
Collar Disc MTG
0069
3421-34200
Spacer Brake ASSY Lower TT 500
Page 7.25
QUIPP SYSTEMS INC.
Page 7.25
Series 50X Stacker
Figure 7.19: Turntable Bottom Assembly - Top View
Page 7.26
QUIPP SYSTEMS INC.
Page 7.26
Series 50X Stacker
7.3.6.
Turntable Bottom Motors
Turntable Bottom Motors Parts List
ITEM NO.
PART NUMBER
PART DESCRIPTION
3421-26668
Shock Mount
3421-32141
Center Tube
3421-34255
Cylinder Mount
3421-34158
Crank Clamp Pin
3111-1321
Pin Puller Table
3421-32185
Crank Clamp
3421-26922
Shock Pin
3421-26877
Cylinder 5/2.5
3421-27481
Pivot Shaft
10
9383
Bearing - 3.346 ID
11
3322
Bearing 0.63
12
9392
Retaining Ring
14
9003
Bushing
25
9396
Handle
27
3111-0861
Bumper Plate
28
3421-26837
Shock Absorb. Shaft
29
3421-26675
Handle Spacer
30
1105
Bearing - 0.75
31
1507
Shock Absorber
33
9097
Motor 0.75
34
311-25750
Timing Pulley
35
3662
Clamp Collar
36
3337 9601
Belt 8mm - All Std 500s Belt 8mm - All Wide 500s
37
3321
Bearing - 0.63
39
3421-26669
Motor Mount A
40
3421-26670
Motor Mount B
Note: Following Parts apply to Pressor Models
42
3421-32163
Disc Cylinder Mount
43
3421-32164
Clevis Rod Pin
48
100492
Cylinder 13x2
51
1250
Retainer
52
3421-33196
Rod End
68
100516
12 Disc
69
100515
Caliper Brake
70
3421-32356
Disc Mtg Collar
71
3421-34297
Caliper Plate
Note: Following Parts apply to Non-Pressor Models
53
100497
Retainer
66
100513
Disc/12 Dia
67
100515
Pneumatic Caliper Brake
68
3421-32356
Disc Mount Collar
69
3421-34200
Brake Spacer
Page 7.27
QUIPP SYSTEMS INC.
Page 7.27
Series 50X Stacker
Figure 7.20: Turntable Bottom Motors (Pressor Cylinder and Support Non-Pressor)
Page 7.28
QUIPP SYSTEMS INC.
Page 7.28
Series 50X Stacker
7.3.7.
Electrical Enclosure Assembly
Electrical Enclosure Parts List
ITEM NO.
PART NUMBER
PART DESCRIPTION
100930
I/O Card W-RS232
Z100508
Input DAC Card
100778
CPU
8698
Video Interface Card
9359
Video Card
100958
Stepper I/O Card
100777
Touch Screen
10
1258
Sonalert
11
1599
Pressure Actuator
12
1600
Limit Sw SPDT
14
100935
Stepper Drive
15
100796
Lite Curt. Controller
15
100811
Lite Curtain Kit
20
Z100962
Electrical Kit
22
3311-16664
Mech Sensor Cable
Page 7.29
QUIPP SYSTEMS INC.
Page 7.29
Series 50X Stacker
Figure 7.21: Electrical Enclosure
Page 7.30
QUIPP SYSTEMS INC.
Page 7.30
Series 50X Stacker
7.3.8.
Powered Outfeed w/o Idler Rollers
Powered Outfeed Parts List
ITEM NO.
PART NUMBER
PART DESCRIPTION
3577
Roller/2.25/14.2
10
7056
Contactor
11
7057
Surge Suppressor w/Diode
12
8359
Capacitor/Motor-Run/4mfd
13
8360
Ccap/Terminal/Oval
14
8361
Strac/Mtg/Oval Cap
22
8885
Conn/Fig/Recpt/15A/125V
23
7689
Plug 125V/15A Twistlock
Page 7.31
QUIPP SYSTEMS INC.
Page 7.31
Series 50X Stacker
Figure 7.22: Powered Outfeed
Page 7.32
QUIPP SYSTEMS INC.
Page 7.32
Series 50X Stacker
7.3.9.
Pneumatic Assembly
Pneumatic Assembly Parts List
ITEM NO.
PART NUMBER
PART DESCRIPTION
100957
Filter Reg/LUB/Gauge STKR 500
100956
30FT Start Valve / Stacker 500
100952
Regulator / Stacker 500
100953
Gauge/60PSI/Regulator/STKR 500
100951
Gauge/100PSI/Regulator/STKR 500
100950
Valve ASSY / Stacker 500
100959
Valve/P/3/2/1N/S/.125 NPT/24V
3421-34049
Panel, Pneumatic Stacker 500
3421-34213
Hinge MOD. PNEU. Panel STKR500
Page 7.33
QUIPP SYSTEMS INC.
Page 7.33
Series 50X Stacker
Figure 7.23: Pneumatic Assembly-Basic
Page 7.34
QUIPP SYSTEMS INC.
Page 7.34
Series 50X Stacker
Figure 7.24: Pressor Add-on Pneumatics
Page 7.35
QUIPP SYSTEMS INC.
Page 7.35
Series 50X Stacker
Page 7.36
QUIPP SYSTEMS INC.
Page 7.36
QUIPP Series 2100 Newspaper Sensors

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 General.................................................................................................................................. 1.1 Operation............................................................................................................................... 1.2 Specifications ........................................................................................................................ 1.2 Installation ............................................................................................................................. 1.3 Stacker Installation ................................................................................................................ 1.3 Operating Suggestions.......................................................................................................... 1.4 Maintenance Procedures ...................................................................................................... 1.4 Parts Replacement................................................................................................................ 1.4 Parts Lists.............................................................................................................................. 1.5
QPN 101068
QUIPP SYSTEMS INC.
Table of Contents
Series 2110 Sensor
QUIPP SYSTEMS INC.
QPN 101068

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
QPN Stock #
QUIPP SYSTEMS INC.
Page 1.1
Operation
Series 2110 Sensor
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
Page 1.2
QUIPP SYSTEMS INC.
QPN Stock #
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.
QPN Stock #
QUIPP SYSTEMS INC.
Page 1.3
Operating Suggestions
Series 2110 Sensor
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.
Page 1.4
QUIPP SYSTEMS INC.
QPN Stock #
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 Assembly Drawing Number Reference Part Item Number Part Number
Provide the following information for the part ordered:
Drawings Follow. D2110-A0239 ............................................................................. Small Wheel Sensor D21SO-A1813............................................................................ Large Wheel Sensor
QPN Stock #
QUIPP SYSTEMS INC.
Page 1.5
Parts Lists
Series 2110 Sensor
Figure: 1.1: Newspaper Sensor, Small Wheel Model
Page 1.6
QUIPP SYSTEMS INC.
QPN Stock #
QUIPP Series 2230 Non-Contact Laser Sensors Chapter 1

1.1 1.2
Introduction
General.................................................................................................................................. 1.1
1.1.1. 1.2.1. 1.2.2. 1.2.3. 1.2.4. Applications............................................................................................................................1.1 Leading Edge Count Blocking................................................................................................1.3 Trailing Edge Count Blocking.................................................................................................1.3 Operating Modes....................................................................................................................1.3 Conveyor Speed Compensation ............................................................................................1.4
Operation Description............................................................................................................ 1.1
1.3
Specifications ........................................................................................................................ 1.5
Chapter 2
2.1
Installation, Set-Up and Operation

Installation ............................................................................................................................. 2.1
2.1.1. 2.1.2. Mechanical Installation...........................................................................................................2.1 Electrical installation...............................................................................................................2.1
Chapter 3
3.1 3.2 3.3 3.4
Troubleshooting and Maintenance

General.................................................................................................................................. 3.1 Troubleshooting..................................................................................................................... 3.1 Maintenance.......................................................................................................................... 3.2 Conclusion............................................................................................................................. 3.2
QPN 3421-39789
QUIPP SYSTEMS INC.
Table of Contents
Series 2230 Non-Contact Laser Sensor
QUIPP SYSTEMS INC.
QPN 3421-39789
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. WARNING The 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.
QPN 3421-39789
QUIPP SYSTEMS INC.
Page 1.1
Count-Pro Series 2230 Laser Sensor
Introduction
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.
Page 1.2
QUIPP SYSTEMS INC.
QPN 3421-39789
Introduction
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.
QPN 3421-39789
QUIPP SYSTEMS INC.
Page 1.3
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.
Page 1.4
QUIPP SYSTEMS INC.
QPN 3421-39789
Introduction
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 optoisolated open collector Output Signal Pulse Width ......................................................... 10 ms Power Requirements.................................................................. 11.5 to 30VDC at 200ma Fusing ........................................................................................ internal, self-resetting
QPN 3421-39789
QUIPP SYSTEMS INC.
Page 1.5
Specifications
Introduction
Figure 1.4: Installation Requirements
Need image
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
Page 1.6
QUIPP SYSTEMS INC.
QPN 3421-39789
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.
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, mattefinished 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
QPN 3421-39789
QUIPP SYSTEMS INC.
Page 2.1
Installation
Installation, Set-Up and Operation
Figure 2.1: Cable Connection Diagram

+ Supply 12-24V Common Cout Out Active Low Count Return 0-5V Infeed Speed In Gap Output (active low) Spare RS-232 RXT RS-232 TXD RS-232 GND RS-232 CTS (not used) RS-232 (not used) <1 <2 <3 <4 <5 <6 <7 <8 <9 < 10 < 11 < 12
Page 2.2
QUIPP SYSTEMS INC.
QPN 3421-39789
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. WARNING The 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.
QPN 3421-39789
QUIPP SYSTEMS INC.
Page 3.1
Maintenance
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
Page 3.2
QUIPP SYSTEMS INC.
QPN 3421-39789

50X Stacker Operations Manual

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QUIPP Series SJ50X Newspaper Stackers Operations and Maintenance Manual

QUIPP SYSTEMS, INC.

QUIPP Series SJ50X Newspaper Stackers

QUIPP SYSTEMS, INC.

Copyright 2002 QUIPP SYSTEMS INC.

Introduction and Installation

Basic QUIPP 50X Series Stacker Description....................................................................... 1.1

Special Information................................................................................................................ 1.3

Safety Considerations ........................................................................................................... 1.3

Specifications ........................................................................................................................ 1.5

1.6 1.7 1.8

Mechanical Installation ........................................................................................................ 1.11

Utilities and Control Signals ................................................................................................ 1.11

QUIPP SYSTEMS INC.

Series 50X Stacker

Final Pre-Setup Checks ...................................................................................................... 1.14

Controls, Set-Up, and Stacker Start-Up

2.4 2.5 2.6 2.7

General Set-Up ..................................................................................................................... 2.5 Mechanical Adjustments ....................................................................................................... 2.6

2.8 2.9 2.10 2.11 2.12 2.13 2.14

User Help Information ......................................................................................................... 2.15

Set-up and Event MESSAGES ........................................................................................... 2.16

50XC Series Stacker Pressor Adjustments

General Set-Up ..................................................................................................................... 3.3 Mechanical Adjustments ....................................................................................................... 3.3

Series 50X Stacker 3.5.4.

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

3.6 3.7 3.8 3.9 3.10

Start-Up and Preventive Maintenance

General Maintenance ............................................................................................................ 4.6 Scheduled and Preventive Maintenance............................................................................... 4.6

Indicating LIGHTS and LED's................................................................................................ 5.8

A Normal Start-up Test........................................................................................................ 5.12

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

QUIPP SYSTEMS INC.

Series 50X Stacker

Stacking Section.................................................................................................................... 6.8

Pneumatic Elements ........................................................................................................... 6.12 The Turntable/Pusher Assembly ......................................................................................... 6.12

The Control.......................................................................................................................... 6.18

Electrical Service................................................................................................................. 6.23

Factory Default Settings Review ......................................................................................... 6.25

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

QUIPP SYSTEMS INC.

Series 50X Stacker

Diagrams, Schematics, and Parts List

QUIPP SYSTEMS INC.

Series 50X Stacker

This page intentionally left blank

QUIPP SYSTEMS INC.

Defects and Workmanship

OEM Warranties -QUIPP-installed Components

QUIPP SYSTEMS INC.

50X Series Stacker

Faulty Maintenance Exception

QUIPP SYSTEMS INC.

Introduction and Installation

Basic QUIPP 50X Series Stacker Description....................................................................... 1.1

Special Information................................................................................................................ 1.3

Safety Considerations ........................................................................................................... 1.3

Specifications ........................................................................................................................ 1.5

1.6 1.7 1.8

Mechanical Installation ........................................................................................................ 1.11

Utilities and Control Signals ................................................................................................ 1.11

Final Pre-Setup Checks ...................................................................................................... 1.14

QUIPP SYSTEMS INC.

Series 50X Stacker