on an inconsistent basis, the acceptor accepts the bill but does not pay anything out and the hopper does not shut down therefore there is no payout error message
There are number things it could be. What model changer is it?
What kind of validator are you using?
I see you recently replaced a payout switch, you could have not got it installed correctly. Did you ever get your counter issue resolved?
You need to provide a little more information.
on an inconsistent basis, the acceptor accepts the bill but does not pay anything out and the hopper does not shut down therefore there is no payout error message
That wouldn't be a hopper payout issue. Most likely your validator needs to be serviced, it's trying to reject the bill but can't so it's cycling to clear and dumps the bill into the stacker. If you catch it happening, look to see if the bill is loose in the stacker instead of packed in as it should be.
on an inconsistent basis, the acceptor accepts the bill but does not pay anything out and the hopper does not shut down therefore there is no payout error message
Like Randy articulated ... the make & model is very relevant!
On our two Standard Changemaker 600EFs ... if this happens we can track & read previous messages. If the last message shows "bill held" it points towards the acceptor not being able to reject the bill & rather than shutting down the acceptor ... it always puts it in the middle column of our 3 column "sorting of the bill denominations" stackers. On a related side note: We look forward to the day when there will be just 3 denominations to work with ... 5s, 10s & $20s. If there had not been an accumulated pummeling of the reality of inflation ... then it would not be quite as compelling.
If he’s using a Mars validator that’s not set right it won’t shut down the changer when there is a Hopper error or any error for that matter. If he’s using a worn out XE validator that’s putting some of the bills on top of the stacker pusher plate it will eventually shut down the changer with a validator error. He needs to supply a little more information.