PFE AUTOMAILER 5 VERTICAL STACKER SET UP INFORMATION

PFE AUTOMAILER 5
VERTICAL STACKER
SET UP INFORMATION
Issue 2
NOTE: THIS DOCUMENT APPLIES TO
AUTOMAILER 5 & AUTOMAILER 5 EXP.
Vertical Stacker Setup with Automailer 5
This document explains the setup/installation procedure for using vertical stacker with
the Automailer 5 and the options available.
Hardware Setup
The vertical stacker needs to be installed in the AM5 hardware settings before it can
be used. To do this leave the run screen and go to Engineering, Hardware setup,
Select unit zero, then select edit, then scroll down the list under unit equipment and
check Vertical stacker. Then under extra settings select Dual ink marker (if the
vertical stacker is fitted with one, this option is not standard). Then save changes and
send to the unit. Go back to the run screen and press “Clear and restart” then close the
M5go application. Then re-open M5go.exe. The Vertical stacker will now be selected
in the hardware setup and the run screen will have updated to show the output
conveyor is now a vertical stacker (VS).
Setting the Configuration in AM5 for Using the Vertical Stacker
Above shows the options available in the configuration/output screen when the
vertical stacker is fitted. This allows the operator to set the vertical stacker options for
each configuration. The control mode of the jog and the dual ink marker can be set
here for error OMR/barcode etc.
Above shows the options available for the dual ink marker (ink marker 1 & ink
marker 2) as well as the VS jog. Not all options shown are applicable for all. The jog
control mode is linked to the ink marker 1 control, so if the ink marker 1 control is set
to anything other than not used then the only two options for the jog are Not Used or
copy ink marker 1 control mode e.g. Ink mark 1 = Error, then jog mode can be Error
or Not Used only
Batching
Batching for the vertical stacker now has the option to select the control mode as End
or toggle. Control mode End is the default a preferred option. This will ink mark or
jog the designated envelope specified in the Quantity field. Examples: Control Mode
End, Quantity 200, the ink marker/jog will activate every 200th envelope. Control
Mode Toggle, Quantity 200, the ink marker/jog will activate every 200 envelopes and
then not for 200 envelopes and then repeat the pattern. Batching is only available on
Ink marker 1 and the vertical stacker jog NOT on Ink Marker 2.
Other Control Modes
The vertical stacker has the same control modes as the existing ink marker. This
means they can be controlled by OMR/Barcode, Weight group, Error etc. This allows
the mail run to be split into postage regions, batches as well as indicating error tagged
Envelopes (these maybe Possible Corrupt Group(PCG) sent to the output). All
settings are the same as if you were setting up the existing ink marker or an output
divert unit
Modifications to the Vertical Stacker Hardware settings
The vertical stacker has two dc motors that can be adjusted in the hardware settings
(like all other AM5 dc motors) this allows for mechanical inaccuracies to be
eliminated. The vertical stacker dc motor hardware adjustment is found on the twiddle
screen for the Output. Accessed from the run screen. The Vertical stacker side guide
and the vertical stacker roller (output brush guide) can both be adjusted in 1mm
increments. These changes affect all jobs, as they are hardware settings.
Vertical Stacker Engineer diagnostics
The vertical stacker engineer diagnostics are located within unit zero
Note:
The vertical
stacker is not
connected to
the AM5 by
the CAN Bus
(it is a serial
link from unit
zero, so the
Engineer
diagnostics
maybe slower
to update (E.g.
Sensors may
not report their
status
instantly)
Firmware Version for the Vertical Stacker
The vertical stacker requires the AM5 to have software version 5.0.5.1 or later and
firmware version 5.01F or later. Otherwise it is not possible to select or run the
vertical stacker.
The vertical stacker also requires firmware to function. This firmware is not the same
as the rest of the AM5. It is a different file called VertStck_V5-01F.am5 (firmware for
the rest of the AM5 is Auto5_V5-01F.am5) this firmware must only be downloaded to
vertical stacker.
Downloading Firmware to the Vertical Stacker
The firmware for the vertical stacker is not downloaded via the M5go application as
the rest of the AM5. This is because the vertical stacker is not connected to the CAN
Bus. Therefore the only way to download new firmware to a vertical stacker is
serially via a laptop (or use the AM5 PC). Use PFE serial debug cable 184-176 and
connect the 4-way jst connector to J9 on the vertical stacker controller PCB. Use
HyperTerminal to download firmware. The settings for HyperTerminal are the same if
you are connecting a laptop to any of the AM5 control PCB for diagnostics (Example
below uses COMM1 this may not be the same for your laptop)
Capture trace procedure
The capture trace procedure is different for the
vertical stacker. The capture trace button on the
AM5 run screen (Press F3) will not capture any
data from the vertical stacker processor. If a
trace is need of the vertical stacker then plug the
debug lead into J9 (same as when downloading
firmware) and capture the trace from the
HyperTerminal window and save it as a text file
in an editor (e.g. Note pad)
Basic Commands for HyperTerminal
These few commands will allow a trained engineer to determine the firmware version
installed on the vertical stacker. Each command is case sensate.
*av <enter>
*u<enter>
*dd<enter>
!
This will show the current firmware version installed
This will show the hardware settings for the stacker
This will dump the data from the processor (useful if you are trying to
capture trace info from the vertical stacker and did not stop
HyperTerminal quickly enough
This will re-set the vertical stacker (if required)
Vertical Stacker Installation
The following information will allow the vertical stacker to be fitted to an existing
Automailer 5. The photographs show how the stacker bolts to its conveyor as well as
how it fits to the AM5.
The vertical stacker can be bolted directly to the AM5 or onto an output divert unit.
Attaching the vertical stacker to its output conveyor
Attach the conveyor to the wheel end of the vertical stacker as shown. Ensure the
wheel passes through the conveyor as shown. There are eight fixing screws to attach
the conveyor to the vertical stacker.
Cable routing shown for the two cables from the conveyor to the vertical stacker
module PCB. Plug these into J13 and J6 (Each cable will be marked up to indicate
where it plugs in to the vertical stacker module PCB)
Attaching the vertical stacker to the AM5
These 2 bolts attach the vertical stacker to the AM5
Wiring the Vertical Stacker
The vertical stacker requires 240v/110v to operate this can be taken from the AM5 (If
replacing a standard output conveyer use the existing power lead, the output conveyor
communications cable is no longer required) The serial cable goes from unit zero
control PCB J12 to the vertical stacker control PCB J12. THIS IS ONLY FOR
AM5Mk1. AM5 Mk2 (AM5 ExP) IS WIRED DIFFERENTLY. PLEASE SEE
SEPARATE SECTION AT HE END OF THIS DOCUMENT
Above shows the dual ink marker fitted and the required wiring. Plug the ink markers
into J12 and J14 on the splitter PCB
Vertical Stacker Adjustment
The spring tapes at the
input may need to be
adjusted for certain
envelopes to ‘kick’ the
filled envelope down
onto the bed of the VS
before the pawls take it
away.
It is critical to ensure the vertical stacker is at the correct height so the envelopes enter
the vertical stacker input consistently. To check the height place a filled envelope in
the vertical stacker input area as shown (this set up is the same if the vertical stacker
is connected to an output divert or direct on the AM5 exit) the underside of the filled
envelope needs to be level with the lower lip of the aperture of the vertical stacker to
ensure the envelope path is not restricted. After achieving ensure the stands of the VS
input and VS conveyor are levelled.
Once the height is
correct the side guide
needs to be set so that
the pocket at the input is
approx 10mm bigger
than the envelope width.
This ensures the
envelope will drop to
the bed and be picked
up by the pawls on the
stepper belt.
At the wheel end of the
conveyor the side guide
should be 1mm bigger
than the envelope width
Note
The vertical stacker input pocket is the distance from the side guide to the chassis.
Wiring a Vertical Stacker when Connected to an AM5 Mk2 (ExP)
The vertical stacker is no longer directly wired from the control PCB of unit zero to
the control PCB of the vertical stacker.
To improve the communications between the vertical stacker and the mailing machine
we now wire direct from the Automailer Pc to the control PCB of the vertical stacker
To achieve this the following items will be required (they are now standard on the
Vertical stacker BOM)
USB to serial converter
Serial Debug Lead
179-746
184-176
This picture shows the
vertical stacker
electronics panel and
the serial debug cable
in position. The other
end of the cable
attaches to the USB to
serial adaptor (which is
connected to the
Automailer PC)
The serial debug cable
plugs into J12 on the
Vertical stacker control
PCB as shown here
The USB to serial
adaptor is fitted as
shown connected to
a spare USB port on
the rear of the AM
PC.
Setting up Communication Ports
The Automailer 5 communicates via its PC to the vertical stacker. The port needs to
be configured within Automailer 5 and windows.
Follow the provided instructions to install the hardware.
To set up the USB to serial adaptor navigate to:
Control Panel – System – Hardware – Device Manager – Ports (Com & LPT) – right
click for Properties.
Please ensure that the settings for the comm. Port are as follows:
Under the Advanced setting set the COM port to the desired number. This port
number then needs to be setup in M5Go.
Setting the Com port number within M5Go.
Go to Engineering, then select External Devices then set the port number for the
TQM/vertical stacker. (This must be the same number as the setting above)
Note: Currently the M5go application can only support one external device connected
via a serial port. Please check all other external devices have the COM port set to
none.
Screen dumps used here are for illustration only. The Com Port numbers must be the
same.
Basic layout showing the vertical stacker
(See technical manual for detailed layouts and part numbers)