P5000 Series Powered Stacker Quick Troubleshooting Guide

Here is a Detailed Troubleshooting Guide for the P5000 series “SureStak” Powered Paper Stacker.

NOTE: Note that the Powered Paper Stacker has been designed to work with forms lengths ranging from 5 to 12 inches (12.7 to 30.45 cm) long. Any lengths used above or below this range can create error messages and/or unpredictable behavior.

1. Upon new installation of printer or when the AC Power Cable has been reinstalled into the printer’s AC Power Connector, verify that all cables are properly seated in the back of the power stacker control panel.

2. From the rear Control Panel, perform and observe the following:

a) Green LED should be ON.

b) Press the ON LINE/OFF LINE key and observe the Yellow LED. Yellow LED should come ON when printer is online. Yellow LED should be OFF when printer is offline.

c) Press the first down arrow D (PAPER ADVANCE key) and the printer should do

a form Feed every time it gets pressed down.

d) Press and release the up arrow C and the elevator should go up.

e) Press and release the bottom down arrow D and elevator should go down.

3. Disable the Power Stacker in the MAINT/MISC sub-menu. With the printer offline, use the rear Stacker Control Panel to move the stacker up by using the up arrow C. The stacker will move upward and automatically stop when it reaches its highest position. Do not force it upward.

4. Using the heaviest form available on site (i.e. six-part form), slide the form over the paper path and into the stacker throat. It should be able to go through the stacker throat without having to force it. If the six-part form cannot go through the stacker throat, refer to the STACKER JAM Fault message below.

5. With the Power Stacker still at its highest position, enable the Power Stacker in the MAINT/MISC sub-menu. Put the printer online, the elevator should go automatically to its lowest position possible (depending on how much paper has been stacked).

6. Using the rear Stacker Control Panel, press the first down arrow D (PAPER ADVANCE key) from the top until at least 3 to 5 forms have been fed through the stacker throat. Make sure there are no faults. If there is a fault, the Paper-In Sensor is failing and needs to be checked (loose or dirty). If no faults are present, insert the forms inside the printer tractors and stacker throat and feed enough forms from the rear panel to allow for proper folding to take place on the stacker base.

7. In the DIAGNOSTICS sub-menu, go to Printer Tests and choose “Shift Recycle” and begin  the test. Observe that both rows of the rubber paddles are rotating to the inside direction and the pinch rollers are rotating in a downward direction.

8. Run “E’s + TOF” for about 10 pages. Stacker should stack and fold paper without errors.

9. Move frame up approximately 1 inch and cover emitter with opaque or black tape. From a PC or other available host, run a continuous job (i.e. multiple print screens). Note that the elevator should start to advance upward about 1/4” every 3 seconds until it reaches the topmost position. The printer display should read “Fault Condition Stacker Full” when the elevator reaches the top.

10. Lower the elevator by pressing the bottom down arrow D on the rear Stacker Control Panel. It should stop at its bottom position without motor noise. If motor noise is apparent, see STACKER CHATTERS AT THE UPPER OR LOWER LIMIT and Stacker Motor Check procedures below.

11. Set elevator to its lowest position depending on the amount of paper stacked on the bottom. Run a Self Test and induce a “PAPER JAM” condition before the stacker throat. A “Fault Condition Paper Jam” should be displayed on the Front Panel display.

12. If, at this point, the Power Stacker has not failed any test, this will complete the Confidence Check. If any error(s) occur or reoccurs, check overall connections at both the Stacker Control Panel and the CMX PCBA. Follow Troubleshooting procedures listed in this guide and in the Maintenance Manual. Once operational, clear the Error Log and place the printer online.

The SureStak Power Stacker is a factory-installed option for the P52XX Cabinet models. Since almost all of the Stacker Assembly is inside of the cabinet, it is recommended that the Stacker Assembly should be removed from the printer in order to perform proper maintenance and to replace most of its components.

The following is a quick reference on removing and re-installing the Stacker Assembly. Please familiarize yourself with the detailed instructions and illustrations found in the P5000 Maintenance Manual. Failure to perform proper procedures as listed in the Maintenance Manual can cause irreparable damage to the Stacker Assembly.

1. Power off the printer and unplug the AC power cord.

2. Remove the paper tent.

3. Remove the paper fence.

4. Remove the paper deflector.

5. Remove the three screws and washers from the Stacker Control Panel.

6. Close the top cover, remove the four cables from the back of the Stacker Control Panel and remove the Stacker Control Panel Assembly.

7. Remove the two 5/32 x 3/4 inch screws and washers securing the vertical rails to upper frame cross-member at the rear of the cabinet.

8. Raise the elevator assembly.

9. Each vertical rail is secured to the stacker base by two screws. Loosen by one turn, but DO NOT REMOVE, these screws that secure the vertical rails to the stacker base. Damage to these rails may result.

10. Remove the four 7/64 x 1/2 inch screws and washers securing the base plate to the cabinet floor. Lower the elevator assembly to its lowest position.

11. Tilt the vertical rails toward the front of the printer until they both clear the upper frame cross-member. Slide the Stacker Assembly to the rear and angle it out of the cabinet.

1. Power the printer off and unplug the AC power cord.

2. Remove any paper.

3. Loosen the three paper path hold-down screws. Slide the paper path to the left and lift it off of the card cage.

4. Connect the Power Stacker logic cable P103 to connector J17 on the CMX controller board.

5. Disconnect the power supply cable from connector J101 on the CMX controller board.

6. Connect power supply cable connector P101 to the stacker power cable, then connect the

stacker power cable to connector J101 on the CMX controller board.

7. Route the stacker power cable and the stacker logic cable in front of the CMX board and through the cutout beneath the card cage fan.

8. Loosen by one turn, but DO NOT REMOVE, each set of two screws that secure the vertical rails to the stacker base.

The Power Stacker Assembly mounts to the rear upper frame cross-member and to the cabinet floor. It is a snug fit. During installation, take care to avoid scratching the painted surfaces or damaging the stacker, especially the vertical rails.

9. Position the elevator assembly at the bottom of the vertical rails.

10. Insert the vertical rails inside and under the upper frame cross-member, then slowly swing the base of the stacker assembly into the cabinet.

11. Work the stacker base rearward and engage the upper brackets of the vertical rails under the upper frame cross-member.

12. Align the holes in the vertical rail brackets with the holes in the upper frame cross-member.

13. Align the holes in the stacker base with the holes in the cabinet floor.

14. Install two 5/32 x 3/4 inch screws and washers to secure the vertical rails to the upper frame cross-member.

15. Install four 7/64 x 1/2 inch screws and washers to secure the stacker base to the cabinet floor.

16. Tighten the four screws on the vertical rails you had loosened in step 8. When installed correctly the stacker vertical rails should be both parallel to each other and vertical.

17. Install the paper fence.

18. Gather the rail cable, frame cable, logic cable and power cable. Make sure these cables are routed outboard of the elevator assembly.

19. Connect the stacker cables to the rear of the Stacker Control Panel Assembly.

20. Close the top cover and position the Stacker Control Panel Assembly.

21. Bundle and tie wrap the Stacker Control Panel cables to the printer frame so they do not catch in the stacker mechanism as it moves up and down. Route the stacker rail and frame cables so they move without snagging as the elevator moves up and down.

22. Install the paper deflector on the vertical rails with the angled portion toward the front of the printer.

23. Install the paper path over the card cage.

24. Plug in AC power cord and turn on printer.

25. Load paper. Test stacker by performing confidence check.

To assure that the displayed error message is the actual problem and not erroneous, do the following:

1. Disable the Power Stacker in the MAINT/MISC sub-menu. Save this setting in the POWER-UP CONFIG. Sub-menu. Cycle power on the printer.

a) Does the same error display or has it changed?

b) Print the Error Log from the DIAGNOSTICS sub-menu. Are there other nonroutine error messages posted in this log (i.e. Shuttle Jam, 48V PWR FAIL, etc.)?

Diagnose accordingly.

2. Enable the Power Stacker in the MAINT/MISC sub-menu. Save this setting in the POWER-UP CONFIG. Sub-menu. Cycle power on the printer.

A. Stacker Fault: The elevator cannot reach either the top or bottom position switch before timing out.

1. Check for and remove obstructions preventing elevator movement.

2. Operate the power stacker. While operating, check that:

a) All motors are operating.

b) The paddles are rotating.

c) The elevator moves slowly and without obstruction.

d) The timing belts are undamaged and the belt pulleys are not slipping.

e) The extension springs are attached and undamaged, not bent or stretched.

f) The drive rollers are not damaged.

g) The constant force springs are tightly mounted and undamaged.

3. Tighten pulley set screws and/or replace damaged components as necessary.

4. Check for mis-aligned stacker rails. Adjust the stacker rails if they are not vertical and parallel.

5. Check the stacker limit switches, see procedure below.

6. Disable the power stacker in the MAINT/MISC sub-menu. If the message occurs, replace the CMX board.

7. Power off the printer. Remove the paper path. Disconnect the stacker cables from the CMX controller board, stacker assembly, and the stacker control panel.

a) Check cables for cuts, breaks, or damaged pins.

b) Check cables for continuity.

8. Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel.

B. Stacker Full: The Powered Paper Stacker has reached full capacity.

1. Remove the paper from the stacker and continue printing.

2. Check the stacker limit switches, see procedure below.

3. If the stacker limit switches are okay, power off the printer.

a) Remove the paper path. Disconnect the stacker cables from the CMX controller board, stacker assembly, and the stacker control panel.

b) Check cables for cuts, breaks, or damaged pins. Check continuity of cables.

4. Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel.

C. Stacker Jam: Paper is bunching above the elevator or the paper motion detector is not working properly.

1. Remove the Paper Jam.

2. Power off the printer. Check that the wheel of the stacker paper motion detector rests against the rear brace of the paper throat. Also make sure the wheel rotates freely.

a) If necessary, gently bend the brace toward the paper motion detector wheel until the wheel contacts the brace.

b) Clean the stacker paper motion detector and detector wheel.

NOTE: Because of the detector’s location in the paper throat, the use of canned air to clean both the detector’s wheel and the optical sensor may be much easier and thorough than using a brush.

3. Power on the printer. Operate the power stacker. While the stacker is operating check that:

a) All motors are operating and the paddles are rotating.

b) The elevator moves smoothly and without obstruction.

c) The timing belts are undamaged and the belt pulleys are not slipping.

d) The extension springs are attached and undamaged (not bent or stretched).

e) The drive rollers are not damaged.

4. Tighten pulley set screws and/or replace damaged components as necessary.

5. Power off the printer. Remove the paper path. Disconnect stacker cables from the CMX controller PCBA, stacker assembly, and the stacker control panel.

a) Check cables for cuts, breaks, or damaged pins.

b) Check cables for continuity.

6. Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel.

1. Turn printer off and check that the Control Panel Cable or other obstruction is not obstructing stacker motion. Remove obstruction or reroute Control cable.

2. Stacker rails may be mis-aligned. Verify that they are both vertical and parallel. Adjust if necessary.

3. By moving the elevator up and down by hand, check that the limit switches are being tripped at both the highest and lowest limits of travel.

a) The limit switches can be adjusted a little by gently bending contact arms.

b) Replace the switch if the adjustment cannot be made with minor bending of the contact arms.

4. Turn the printer on. Make sure that the stacker is enabled and is operating. Check that:

a) All motors are operating.

b) The paddles are rotating.

c) The elevator moves smoothly and without obstruction.

d) The timing belts are undamaged and the belt pulleys are not slipping.

e) The extension springs are attached and undamaged and not bent or stretched.

f) The drive rollers are not damaged.

g) The constant force springs are tightly mounted and not damaged.

5. Tighten pulley set screws and/or replace damaged components as necessary.

1. Turn the printer off and check that the Control Panel Cable or other obstruction is not obstructing stacker motion. Remove obstruction or reroute Control cable.

2. Stacker rails may be mis-aligned. Verify that they are both vertical and parallel. Adjust if necessary.

3. Power on the printer. Operate the power stacker. Verify that:

a) All motors are operating.

b) The paddles are rotating.

c) The elevator moves smoothly and without obstruction.

d) The timing belts are undamaged and the belt pulleys are not slipping.

e) The extension springs are attached and undamaged and not bent or stretched.

f) The drive rollers are not damaged.

g) The constant force springs are tightly mounted and undamaged.

4. Check the stacker limit switches, see procedure below.

5. Check the stacker motors, see procedure below.

6. Remove the paper path. Disconnect stacker cables from the CMX controller board, stacker assembly, and the stacker control panel.

a) Check cables for cuts, breaks or damaged pins.

b) Check cables for continuity.

7. Replace any cable that is damaged or fails the continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel.

1. Power off the printer. Inspect all stacker LEDs for dust, chaff, or dirt. Clean the stacker LEDs and the sight tubes in the LED mounts.

2. Power on the printer. If the stacker elevator moves by itself, replace the stacker LEDs.

1. Stacker is disabled in the MAINT/MISC CONFIGURATION MENU.

2. Stacker logic cable is bad or not properly connected (P103 to connector J17 on the CMX controller board).

3. Bent pins on CMX logic cable connector (J17) or on the control panel logic cable connector (J7).

4. Flash software is below minimum level to recognize power stacker.

Note: This procedure tests the motion limit switches at the top and bottom of the vertical rails.

You will usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.

1. Power off the printer, open the rear cabinet door and unload the power stacker. Move the elevator up and down by hand, checking that it moves smoothly and without chattering or shuddering.

2. Eliminate causes of chattering or shuddering, such as:

a) Loose, damaged, or broken constant force springs.

b) Bent or mis-aligned rails.

c) Any obstructions in the elevator path.

3. Move the elevator up and down by hand. Check that the limit switches are physically tripped when elevator reaches both the top and bottom of travel.

4. If necessary, gently bend the contact arms to adjust the limit switches. If you cannot adjust a switch that requires adjustment, replace it.

5. To gain access to the stacker rail cable and limit switches, do the following:

a) Unfasten the cable clamp holding the stacker control panel cables.

b) Disconnect stacker rail cable connector P107 from connector J3 on the back of the stacker control panel.

c) Locate pin 1 of connector P107.

d) Check the stacker rail cable and limit switches for continuity and shorts.

e) Check continuity of the switches when open and closed. By using J3 on the stacker control panel STK FULL = upper limit switch; STK LIMIT = bottom limit switch, the following can be checked:

pin 2 = STK FULL SWT pin 4 = STK LIMIT SWT

pin 3 = FULL SWT RET pin 5 = LIMIT SWT RET

6. Replace the stacker rail cable if it is damaged or fails continuity test.

7. Replace any switch that fails continuity test.

Note: This procedure tests the four stacker motors and their cables. You will usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.

1. Power off the printer.

2. Open the rear cabinet door.

3. Unfasten the cable clamp holding the stacker control panel cables.

4. Disconnect stacker rail cable connector P107 from connector J3 on the back of the stacker control panel.

5. Disconnect stacker frame cable connector P102 from connector J4 on the rear of the stacker control panel.

6. Locate pin 1 of connector P107 and connector P102.

7. Check both cables for pin damage, continuity, and shorts.

8. Check all motors for 15.2 +/- 1.5 W resistance per phase. All 4 motors are the same:

Motor Assy, Power Stacker - p/n 158446-001

pin 1 = red

pin 2 = yellow Measure pin 1 to pin 2 for Phase A

pin 3 = orange Measure pin 3 to pin 4 for Phase B

pin 4 = brown

a) Elevator Motor Assy Connector J3 - pins 6,7,8,9

b) Rear Paddle Motor Assy (M1) Connector J4 - pins 2,3,4,5

c) Front Paddle Motor Assy (M2) Connector J4 - pins 6,7,8,9

d) Pinch Roller Motor Assy Connector J4 - pins 11,12,13,14

Reference SureStak Power Stacker Control Panel PCBA Wire Data for further information regarding motor signal pin-out.

9. Replace any cable that is damaged or fails continuity test.

10. Replace any motor that fails the resistance check.