Avery Dennison Power Stacker User manual

User / Service Manual Power Stacker
10/06 Rev. 1.09 1
Manual
Power Stacker

User / Service Manual Power Stacker
10/06 Rev. 1.09 2
Contents
Contents...............................................................................................................................2
General.................................................................................................................................3
Copyright..........................................................................................................................................3
What is a "power stacker" ? .............................................................................................................3
Initiation................................................................................................................................4
Unpacking ........................................................................................................................................4
Assembling the Power Stacker ........................................................................................................5
Mounting the option to the TDI.........................................................................................................6
Assemble light cover........................................................................................................................7
Set up mode.........................................................................................................................8
Modes of operation - operation.............................................................................................9
Activating the sensor........................................................................................................................9
Adjusting the label width.................................................................................................................10
Adjusting the label length...............................................................................................................10
Magazine full..................................................................................................................................11
Information printout / parameter .........................................................................................12
Parameter Menu TDI......................................................................................................................12
Status printout ....................................................................................................................13
Status reports.....................................................................................................................14
ST04 Power stacker full .................................................................................................................14
Overview - Status reports...............................................................................................................15
Maintenance, cleaning and service....................................................................................19
Maintenance and cleaning .............................................................................................................19
Service............................................................................................................................................19
CPU board............................................................................................................................... 19
Micro switch ............................................................................................................................ 20
Reflex Sensor.......................................................................................................................... 20
Stepper motor ......................................................................................................................... 21
Diagrams............................................................................................................................22
Cable drawings...............................................................................................................................23
Circuit diagram CPU board ............................................................................................................27
Component diagram CPU board....................................................................................................28
Spare parts list....................................................................................................................29
Index...................................................................................................................................39

User / Service Manual Power Stacker
10/06 Rev. 1.09 3
General
Copyright
This Manual and its contents are subject to copyright. The publisher’s prior written consent
must be obtained for reproduction of the manual as a whole or part thereof.
Names are generally given without any reference to existing patents, registered patterns or
designs, or trademarks. The omission of a corresponding note does not imply that the names
can be used freely. All trademarks are acknowledged.
The manufacturer reserves the right to technical and other alterations without prior notice.
The publisher cannot warrant the accuracy of the content of this manual.
Note: Please follow the notes shown in this text - it will help to cover all situations and
keep your engine working.
If in the manual is used the name TDI - it is as well meant the
Xxtreme !
What is a "power stacker" ?
The power stacker is used as an option for the TDI. It is replacing the magazine witch is OK
for lower quantities – using higher quantities or smaller label, special short label request the
power stacker.
Similar to the TDI – the power stacker is equipped with a stepper motor driven platform to
store the label on. As more label are printed as lower is the position of the platform.

User / Service Manual Power Stacker
10/06 Rev. 1.09 4
Initiation
Unpacking
•remove packing parts - take care of documentation and parts
•remove option from packaging
•the option consists out of
-the power stacker
-the platform (disassembled)
-a cover to protect the sensor from light
-a magnetic label stopper

User / Service Manual Power Stacker
10/06 Rev. 1.09 5
Assembling the Power Stacker
The power stacker is disassembled in the box when you receive it . Before you can use it you
have to assemble the platform !
Move the platform – the plastic part in front has to show to the printer side – on the two axles
coming out of the cover of the power stacker. Move it against the front plate. The axles will
show around 1 mm out of the platform.
Then clip the lock washer to the two axles (as shown on the pictures). The power stacker is
now ready for use with the TDI.
Attention: Please check if the security cover is mounted to the guiding axle (see picture)
of the media guiding.
axles

User / Service Manual Power Stacker
10/06 Rev. 1.09 6
Mounting the option to the TDI
Attention: The power stacker can be mounted to the TDI mechanically from SN
01859xxxx.xxx on – but the TDI has to be equipped with the necessary wiring.
You can easily see if your TDI is equipped with the wires (there has to be a
diode connector on the rear side of the TDI).
Move the guiding axle into the guiding holes of the TDI (see picture) – as well move the front
plate part of the power stacker into the slot of the TDI ! Both units have to stay together
without any distance (see picture).
After you have mounted the power stacker to the TDI – the electrical connection has to be
done.
Attention: Never connect the power stacker to the TDI – if the TDI is powered on !
Always switch OFF POWER before you connect the power stacker – as
well wait after power off around 2 minutes before connecting.
If you do not – both units can be damaged !

User / Service Manual Power Stacker
10/06 Rev. 1.09 7
Move the diode connector into the plug on the rear side of the TDI !
Attention: If your TDI is not equipped with a connector like that – the unit can be
retrofitted easily. Please call your service technician, this work can not be
done by yourself.
Assemble light cover
To protect the sensor (infra red) in the power stacker against normal light – a light cover is
delivered together with the power stacker.
If you recognise that light is influencing your power stacker, maybe the platform is moving up
and down without reason, you should mount the light cover ! We recommend to mount the
cover in every case.
Remove the film from the glue parts – remove the film from the complete cover and stick it to
the cover of the TDI (as shown on the picture)
light cover
diode connector

User / Service Manual Power Stacker
10/06 Rev. 1.09 8
Set up mode
The power stacker is working separately – only the power is used from the TDI.

User / Service Manual Power Stacker
10/06 Rev. 1.09 9
Modes of operation - operation
Activating the sensor
Depending to the used label size (special the label length is important) the power stacker is
working in two different modes !
To understand that you should understand the principal – how the power stacker is working.
The unit is using reflex infra red sensor to check the height of the label stack – or if there is a
label !
Switching on the power stacker (via the TDI) with an empty platform and the platform is
down, the power stacker is moving up the platform until the first sensor is covered by the
platform -–the power stacker is ready for work. If now the second sensor is covered by
printed labels -the platform is moving down automatically.... the sensor is becoming free
again ... the next label is covering it ... and so on.
Depending to the label length a different stack mode is necessary. Short label need less
height to fall down properly then longer label. To compensate this different mode a second
pair of sensor is attached to the unit. The sensor pair can be selected with the attached
switch.
As a rule – label with less then 100 mm should use the upper sensor pair – longer label
should use the lower pair.
Attention: Switch in upper position means pair 1 – lower position pair 2 !
sensor 1
sensor 2
platform
label
sensor pair 1
sensor pair 2

User / Service Manual Power Stacker
10/06 Rev. 1.09 10
Adjusting the label width
To be sure that the stacker is working properly – the width of the expected label has to be
adjusted on the power stacker.
Attention: Never use the exact label width – adjust always 1 –2 mm more to the guiding.
The label should never be squeezed – but secure guided.
The media width is adjusted with a guiding witch is movable in both directions (see picture) it
can be moved on a axle to the different width of the label.
The moving parts of the guiding are used to adjust the guiding to the different sensor 8short
label – long label).
Adjusting the label length
As the label width – the label length has to be adjusted. The reason for is the speed of the
label after leaving the printer. The label is not falling down – it is moving with the same speed
the printer has used. So we have to stop the label in the right position to form a stack looking
properly.
Therefore the label stopper is used. Two different units are used with the poser stacker – one
for short label (not longer then the cover) one for longer label – sticks to the platform itself.
Both are delivered with the power stacker. Please take care that you do not squeeze the
label.
Stopper

User / Service Manual Power Stacker
10/06 Rev. 1.09 11
Magazine full
After the stack of label has reached the maximum – the platform is down in the lowest
position. This position is sensed via a micro switch (see picture) – the power stacker stops
and as well the printer is stopped witch a message on the display.
Removing a part of the stack (or the complete stack) the power stacker is moving up
automatically into the upper end position – the print job can be started again.
Attention: Start by accepting the message in the display again the print job.
end switch

User / Service Manual Power Stacker
10/06 Rev. 1.09 12
Information printout / parameter
Parameter Menu TDI
OFFLINE
INFO PRTP IFAC SYSP JCLR SCLR OTHR
STA0
STA1
STA2
STA3
DOT1
DOT2
PUNO
BCHI
UPCA
PSPD
MTYP
MLEN
MWID
XPOS
YPOS
SSPD
GAP
PORT
SPOL
BMOD
BAUD
PARI
DBIT
SBIT
HAND
PRID
EMUL
NACH
SENS
PUNS
FMOD
OMOD
SMOD
MMOD
EXTR
CODE
HRES
CLCK
USMD
LREP
CSET
MEND
SCAN
SERR
DOWN
LCLR
ADJS
MCHK
SCHK
PCHK
FACT
SERV
NULL
HADJ
ACSC
Standard / standard
Nur für Service / for service only
ICLR
LPOS
nur mit Scanner / with scanner only
SECF
nur mit Image Card Software / with image card software only
CCLR
Nur mit Color Option / with color option only

User / Service Manual Power Stacker
10/06 Rev. 1.09 13
Status printout
Are available – please use the media necessary for the printout !

User / Service Manual Power Stacker
10/06 Rev. 1.09 14
Status reports
Following status messages are the most important for the power stacker – all other are
shown below.
ST04 Power stacker full
Action: Remove label partly or complete

User / Service Manual Power Stacker
10/06 Rev. 1.09 15
Overview - Status reports
ST 00 ST 15 head sensor not found (system will be locked)
ST 01 NOVRAM error (factory set) ST 16 applicator home position not found
ST 02 NOVRAM write error ST 17 dispenser pressure roller not closed
ST 03 no material in SNGL sensor ST 18 dispenser backing paper rewinder full
ST 04 stacker full ST 19 applicator – touch down not found
ST 05 material end ST 20 EASY PLUG wrong command (imedeate)
ST 06 printhead overheated ST 21 EASY PLUG wrong command between #ER and #Q
ST 07 ribbon end ST 22 EASY PLUG command without #ER
ST 08 gap not found ST 23 EASY PLUG not known command
ST 09 ST 24 receive error RS 232
ST 10 ramcard error ST 25 spooler overflow
ST 11 ramcard error ST 26 EASY PLUG wrong size or print adjustment
ST 12 ST 27 EASY PLUG counter overflow
ST 13 barcode reading error or media broken for rewinder ST 28 EASY PLUG field outside print area
ST 14 cut sensor not found, dispenser second feeder, nothing ST 29 EASY PLUG logo number doesn’t exist

User / Service Manual Power Stacker
10/06 Rev. 1.09 16
ST 30 EASY PLUG logo buffer to small ST 45
ST 31 EASY PLUG logo number error ST 46
ST 32 EASY PLUG postbarcode not OK ST 47
ST 33 EASY PLUG range command #PA to #IM wrong ST 48
ST 34 COLOR PANEL color code not found ST 49
ST 35 COLOR PANEL logo does not fit to the card ST 50 no read of scanner
ST 36 COLOR PANEL color card not found or programmable ST 51 scanner not programmable (system will be locked)
ST 37 ST 52 stacker full (standard)
ST 38 ST 53
ST 39 EASY PLUG speedo error ST 54
ST 40 receive error RS 232 ST 55
ST 41 receive error RS 232 ST 56
ST 42 ST 57
ST 43 ST 58
ST 44 ID matrix barcode error ST 59 acess denied for setting printer to zero

User / Service Manual Power Stacker
10/06 Rev. 1.09 17
ST 60 memory allocation error (system will be locked) ST 75
ST 61 font allocation error (system will be locked) ST 76
ST 62 update or numberfield overflow ST 77
ST 63 ST 78
ST 64 ST 79
ST 65 ST 80 EASY CARD wrong name of file in #FO command
ST 66 ST 81 EASY CARD field number not found
ST 67 ST 82 EASY CARD syntax of #YT or #YB command wrong
ST 68 wrong board installed for selected peripherie option ST 83 EASY CARD number of data field to big
ST 69 interrupt error (system stands) ST 84 EASY CARD quantity of variable characters = 0
ST 70 TDI stepper does not respond ST 85 EASY CARD no card found
ST 71 headstrobe checksum wrong (system will be locked) ST 86 DATA BASE not enough space for index file
ST 72 speedo system error ST 87 DATA BASE no possibility to build index file
ST 73 speedo scaling wrong ST 88 DATA BASE no possibility to sort index file
ST 74 ST 89 DATA BASE barcode onformation nor found in

User / Service Manual Power Stacker
10/06 Rev. 1.09 18
ST 90 database contains identical records
ST 91 barcode not readable
ST 92
ST 93
ST 94
ST 95
ST 96 EASY CARD undefined error
ST 97 EASY PLUG undefined error
ST 98 INTERFACE undefined error
ST 99 SYSTEM undefined derror
just warning – self confirming
must be confirmed by the user
POFF
FAIL
SCAN
OPEN
LOC
K
DAT
A
STOP
SNGL
WAIT
HOST
INIT
DOWN
UP
.LDR
.EMU
.SYS
SORT
----
LOAD
Power OFF
–
p
rinter is switched OFF
Ima
g
e card could not be formatted
Scanner was unable to decode the information
cover o
p
en
–
switch is o
p
en
the
p
rinter is locked
data receive mode
p
rinter in STOP mode
p
rinter in sin
g
le start mode
p
rinter in wait condition
p
rinter sto
pp
ed b
y
host
p
rinter is initialised
TDI table
g
oes u
p
TDI table
g
oes down
p
rinter in loader mode
p
rinter in emulation mode
p
rinter in s
y
stem mode
data base information is sorted
p
rinter was switched on to earl
y
after
p
ower down
barcodes loaded from card

User / Service Manual Power Stacker
10/06 Rev. 1.09 19
Maintenance, cleaning and service
Maintenance and cleaning
Clean as a standard printer – sometimes the sensor should be cleaned from paper dust.
Service
Service parts of the power stacker are – CPU board, micro switch, reflex sensor and maybe
the stepper motor.
CPU board
The used board in the power stacker is an intelligent board – holding a CPU with the
necessary program. The power stacker is working on it’s on.
Below you will find a picture of the CPU board showing the connector placing.
Stepper motor
JP1
Sensor 2
CN 1
Sensor 3 CN 2
Sensor 4
CN 4
Sensor 1
CN 3
Limit switch
(stacker full)
CN 6
Connection TDI J1
X3
Fuse F1
2 AT
Group switch
CN 7

User / Service Manual Power Stacker
10/06 Rev. 1.09 20
The sensor pairs placed in the front plate are numbered as following
Micro switch
The micro switch (lower end position) can be removed after the cover of the power stacker is
removed and the wire is removed from the CPU board.
Reflex Sensor
The sensor pairs are glued into the front plate ( with Loctite ....) and a special part. If one of
the sensor is defect it has to be removed carefully, the hole has the be cleaned and the new
sensor glued in.
Attention: The sensor has to stay 1 mm behind the front plate.
sensor 1mm
behind the plate
sensor 1
sensor 2
sensor 3
sensor 4