MULLER MARTINI

MULLER MARTINI MANUFACTURING CORP.

NEWPORT NEWS, VA 23606 USA

Operating Manual

APOLLO 1540.0410
Compensating Stacker

Serial number

Article number of Operating Manual 1540.9002.71

APOLLO Stacker 1540.0410
Safety Guidelines

1 Safety Guidelines

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Target Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Non-Compliance of Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Fundamental Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2.1 Applicable Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.2 Local Laws, Guidelines and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Notification Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3.1 Danger Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Symbols in the Operating Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Notification Symbol on Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4 Safety Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4.1 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.2 Effects on Outside Safety Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.3 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.4 Obligatory Notification and Authorization after Modifications . . . . . . . . . . . . . . 8

1.5 General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.5.1 Technical State of the Art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5.2 Other Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5.3 Authorized Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5.4 Unauthorized Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5.5 Removal of Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5.6 Authorized personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5.7 Training and Qualification (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5.8 Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5.9 Availability of Operating Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.6 Special Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.6.1 Sub-Vendor Operating Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6.2 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Safety Guidelines

1.7 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7.3 Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Safety Guidelines

1.1 General

1.1.1 Target Personnel

This chapter introduces the safety requirements which must be enforced during operation of
the MULLER MARTINI 1540 Compensating Stacker.
Anyone performing work on or with the stacker has the responsibility to read and comprehend
the chapters relevant to the job. This applies particularly to chapter «Safety Guidelines»
which is binding for all persons and all tasks.

1.1.2 Non-Compliance of Safety Guidelines

The Compensating Stacker underwent a final inspection before being shipped and has been
delivered in excellent working condition. MULLER MARTINI will not be liable for any damage
resulting from disregard of the instructions and notices in the operating manual. This applies
especially to:
• Damage due to improper use or operation.
• Damage due to disregard of safety-related instruction in the operating manual or warning
signs on the machine.
• Damage due to neglect or inadequate maintenance.

1.2 Fundamental Safety Notices

1.2.1 Applicable Area

The information, instructions and safety-related notices in this manual pertain exclusively to
the MULLER MARTINI 1540 Compensating Stacker.
If the stacker is modified, a new table of contents will be sent which shows the new
configuration.
The operating manual must correspond to the machine number on the machine nameplate.

1.2.2 Local Laws, Guidelines and Regulations

Always follow the general valid national and local safety and accident prevention laws as well
as additional operator regulation for operators.

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1.3 Notification Signs

1.3.1 Danger Symbols

This operating manual uses three notification symbols to point out other safety related and
important technical requirements.

1.3.2 Symbols in the Operating Manual

Danger Symbols

Information about dangers that can lead to death, severe

bodily harm, irreversible psychological harm or extensive
property damage.

Information about dangers that can lead to medium to light

bodily harm, psychological harm or property damage.

Notification Symbol

Information pointing out technical and efficiency require-

ments. Non-compliance may lead to malfunctions, ineffi-
ciency and possible production loss.

1.3.3 Notification Symbol on Product

The following notification symbols are used on the product itself or in its surroundings. They
point out dangers and urge common sense. These technically specific safety guidelines and
regulations must be followed at all times.

Warning - Dangerous Electric Voltage.

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Safety Guidelines

Layout 1

XXXXX = Work Area

XXXXXXXXXXXXXX
XXXXXXXXXXXXXX

XXXXXXXXXXXXXX

Safety Zone

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Safety Guidelines

1.4 Safety Concept

1.4.1 Limitations

The safety concept of the Compensating Stacker is autonomous. It does not refer to machines
in line before or after the stacker.

1.4.2 Effects on Outside Safety Concepts

If the Compensating Stacker is preceded or followed by machines not manufactured by

MULLER MARTINI, the extent of the safety concept must be regulated by a contract.
All safety elements of the Compensating Stacker must remain fully functional.
Changes to the contract must be authorized and confirmed in writing by MULLER MARTINI.

1.4.3 Basics

The safety concept is based primarily on the safe and reliable design of the machine.
Other safety levels protect based on the danger potential or safety risk.

1 step Safe design

2 step Mechanical safety elements with electrical interlock.
3 step Safety elements (EMERGENCY STOP, start-up warning signal,
etc.)
4 step Danger zone concept (Zone I)
5 step Information on safety requirements in the operating manual.

1 step
The Compensating Stacker reflects state of the art technology and all currently accepted
safety regulations.

2 step
All safety covers which can be opened without tools are electrically interlocked. If opened
the machine stops.

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Safety Guidelines

3 step
The Compensating Stacker has EMERGENCY STOP buttons. If activated the machine is
stopped. The location of activation is shown with the signal lamp.

= EMERGENCY STOP BUTTONS (Layout 1).

4 step
The Compensating Stacker has one safety zone. No safety covers can be open while the
machine is in the «RUN» or «TEST» mode. Layout 1 shows the safety zone of the
Compensating Stacker.

Zone I Compensating Stacker

5 step
Danger symbols in the operating manual and on the machine point to other safety information.

1.4.4 Obligatory Notification and Authorization after Modifications

The 1540 Compensating Stacker must not be changed technically through add-ons or
modifications without written permission by MULLER MARTINI. This includes installation or
removal of third-party controls, supply and transfer systems, which may have an effect on
the stacker.

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Safety Guidelines

1.5 General Safety Regulations

1.5.1 Technical State of the Art

The Compensating Stacker corresponds to present state of the art technology and all current
valid safety regulations. The machine was designed and built based on the following
guidelines and standards:
• EWG 89/392 Machine guidelines
Despite the above, safety risks may still exist, especially if the Compensating Stacker is
operated improperly or by unauthorized personnel.

1.5.2 Other Dangers

Any use of technical products is connected with risks. Risks that could not be eliminated by
design or protective devices are other dangers. The safety notices in this operating manual
were determined by an analysis of other risks and points out these possible dangers. If the
operator discovers additional hazards or risks during operation, he is obligated to report these
to MULLER MARTINI immediately.

1.5.3 Authorized Use

The Compensating Stacker is used exclusively for stacking books and magazines.
The operation limits and data given in the chapter «Technical Data» is binding.
The use of standard accessories is part of proper use, the same is true for observance and
strict compliance with the guidelines specified in the operating manual regarding installation,
start-up, operation, maintenance, upkeep and disposal notices.

1.5.4 Unauthorized Use

Any use other than the area originally intended and corresponding to the technical data is
considered unauthorized use. Any subsequent damages due to unauthorized use will not be
covered by any warranty or liability.

1.5.5 Removal of Safety Devices

Safety devices can only be removed if the Compensating Stacker is electrically disconnected
and is at a standstill. The covers should only be removed and reinstalled by authorized
personnel. The function of the safety switches must not be impaired.

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1.5.6 Authorized personnel

Only authorized personnel is permitted to work on or with the Compensating Stacker. Only
those persons are authorized who fulfill the minimum level of training and knowledge
requirements and whose duties have been defined.
Competency Limitations (duties)
Owner
Legally responsible, this person is in charge of the proper use of the Compensating Stacker
and for training and assignment of authorized personnel. He/she determines competency
levels and the responsibility to give instructions which are binding for his/her company.

Service Technician (MULLER MARTINI or person authorized by MM)

Installs the system for the owner mechanically and electrically and starts operation.
Instructs the machine operators and maintenance personnel on site.
Repairs the machinery.
Is entitled to access of the entire system.

Machine Operator (customer)

Sets up the machine for product to be run or changes set-up.
Starts and checks production.
Localizes errors and organizes troubleshooting.
Watches for the proper function of safety devices.
Is entitled to access of the entire system.

Maintenance Personnel (customer)

Cleans and maintains the entire system, inc. lubrication.
Repairs problems and defects assigned to maintenance personnel.
Is entitled to access of the entire system.

Support Personnel (customer)

Removes products from delivery.
Stays in delivery area. Is not permitted to reach into the machine while running.

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1.5.7 Training and Qualification (minimum)

Owner
Person trained in support and management functions.
Experienced in danger analysis and personnel supervision.
Is required to read and understand chapter "Safety Guidelines".

Service Technician
Technically related training (mechanical/electrical).
Specific internal and/or continuing educational training.

Machine Operator
Pertinent occupational training.
Participation in MULLER MARTINI training courses and received certificate.

Maintenance personnel (mechanical/electrical)

Corresponding apprenticeship.
Participation in MULLER MARTINI training courses and received certificate.

Helper
Introduced to tasks by the machine operator.

1.5.8 Maintenance Requirements

The owner of the Compensating Stacker is required to operate it only in perfect and
undamaged condition. Maintenance and repairs are described in the operating manual.
Only original replacement parts are to be used.
MULLER MARTINI will decline any and all liability if these guidelines are not followed.
After making safety devices inoperable or after electrical installation work the safety devices
must be tested for proper function before start-up of the machine.

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1.5.9 Availability of Operating Manual

One copy of the operating manual must be available for the personnel in the Compensating
Stacker area at all times.

1.6 Special Guidelines

1.6.1 Sub-Vendor Operating Manuals

The safety instructions in the operating manuals of sub-vendors (oil, glues) should be
followed.

1.6.2 Emergency Exit

The owner of the Compensating Stacker must make sure that in case of emergencies an exit
conforming to all local regulations is available for the personnel. It is especially important
that there be no doors opening against the emergency exit and that no objects are blocking
the path.

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1.7 Safety Rules

1.7.1 General

Follow the safety rules listed below. Failure to follow these

rules will expose operating personnel to the danger of
severe injury.

• Read and obey all safety instructions and operation manuals. Ask your supervisor if you
have any questions.
• Only trained operators should operate this machine.
• Only qualified mechanics should work on the mechanical portion of this equipment.
• Only qualified electricians should work on the electrical circuits in this equipment.
• Before starting the machine, make sure that no objects or persons are within the
machine's danger zone.
• Turn off the main power on the control panel and disconnect the power at its source
before performing any servicing, cleaning, or maintenance on the machine.
• Turn off the main drive motor before performing setup adjustments. After checking the
adjustments, stop the motor again before making any readjustments.
• Make sure all guards and safety devices are in place. Do not remove or disable any
guards or warning devices. Do not bypass their interlocks (fig. 1-5).
• = EMERGENCY STOP buttons. The stitcher is equipped with several emergency
stop buttons. If activated the entire line stops (Layout 1).
• Know where fire extinguishing equipment is located in your work area.
• Use only dry chemical or Halon (B:C rated) for fire emergencies on this equipment.
• Do not use water on grease, flammable liquid or electrical fires.
• Do not wear loose-fitting clothing. Tie back long hair or tuck it under a cap.
• Do not wear neckties, necklaces, rings, bracelets, wristwatches, or similar items while
operating this machinery.

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Safety Guidelines

• Always be alert around the machine.

• Keep hands away from moving parts during operation.
• Keep working area clean and perform requested maintenance work.
• Report unsafe conditions to your manager and correct them immediately.

1.7.2 Electrical System

• Switches and control boxes may only be opened by authorized per-

sonnel after turning off the main switch on the main control panel.
Use safety lock-out on main switch any time electrical work is perfor-
med.
• Never use any liquids or flammable substances in the vicinity of
electrical components.

1.7.3 Special Instructions

• Do not step onto delivery and roller tables.

• After connection of electrical lines, check emergency stop buttons.
• Use extreme caution during adjustments of flow control valves and cushions during test
program run.
• Set manual switch of magnetic valves to «0» after adjustments are completed.

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Table of Contents

1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 Set-Up and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4 Operating Elements and Display Modes . . . . . . . . . . . . 4-1

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 Decommissioning, Storage . . . . . . . . . . . . . . . . . . . . . . 9-1

10 Packing and Transport . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

12 Spare Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

13 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

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1 Product Description

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Intended Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Layer Formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.4 Production Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.5 Floor Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.6 Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 Standard Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3.1 Special Accessories (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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1 A

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1.1 Introduction

The Compensating Stacker (fig 1) is autonomous. It does not refer to machines in line before
or after the stacker.

1.1.1 Intended Purpose

The Compensating Stacker is designed only for stacking books and magazines.

The section «Technical Data» specifies it’s application range.

1.1.2 Nameplate

The nameplate 1A is located on the side of the machine and contains the Model no., Serial
no. and Year of manufacture.

The numbers on the nameplate must coincide with the

machine name and model no. listed on the cover page of
the operating manual.

MÜLLER MARTINI

MÜLLER MARTINI MANUFACTURING CORP.

Newport News, Va 23606 USA

Model
Serial No.

Year

Made in USA

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1585
1735

750...950
850
1175
800
2040
650

800 1125

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1.2 Technical Data

1.2.1 Specifications

The equipment for which these specifications were developed is designed and powered to
cycle mechanically as described. It is essential to note however, that different operating
conditions may cause some variation in the actual performance of the equipment, and
responsibility for such cannot be assumed by Muller Martini.

Type: 1540 Compensating Stacker

Run: Single signatures

Production speed: 16,000 copies / hour max., see fig. 2-1, page 2-2

Delivery height: 850 mm

33-1/2”

Infeed belt speed: Max. 1.2 meters/sec

Max. 4 feet/sec

Cycle time: 1.5 sec

(Depends on product and production mode)

Min. gap between 20 mm

single products: 25/32”

Air required: 17 Nm3/h at 6 bar

9.9 cfm at 87 psi

Ambient temperature: 0° - 45° C

32o - 113o F

Humidity: 20 - 80% not condensing

Electrical requirement: 5.0 kW

Main drive: 0.75 kW AC gearmotor

Weight: 720 kg / 1600 lbs.

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Production speed depending on format

Produktionsgeschwindigkeit Abhängig von Format
Vitesse de production en fonction du format

16

Copies per hour 15

(thousands)
Exemplare pro Stunde
(tausend) 14

Exemplaires par heur

(x 1000)
13

12

11
100 140 180 220 260 300
Dimension B in mm
Mass B in mm
Cote B en mm

= cannot run, kann nicht verarbeit werden,

cette plage ne peut pas être atteinte

4
140
280
200

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1.2.2 Sizes

Min Max Min Max

A 140 mm 450 mm 1) A 5-1/2” 17-3/4”

B 105 mm 320 mm B 4-1/8” 12-1/2”

C 1 mm 40 mm C 3/64” 1-9/16”

1. If the optional bi-directional pusher is installed, max. possible signature length is

reduced to 420 mm.

B
A

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A
A
A
A

C D
A. EMERGENCY STOP
PARA-EMERGENCIA
NOT-STOP
A ARRET D’URGENCE

A B. Interlock cover
B Cubiert de protección enclavada
Verriegelte Schutzabdeckung
A Verrouillage du capot de protection
C. Power Indicator
Lámpara de aviso “Interruptor prin
cipal conectado
“Hauptschalter ein” Anzeigelampe
Témoin de puissance
D. Main Power Switch
Interruptor principal
B
Hauptschalter
Interrupteur principal
E. Control Panel
Pupitre de mando
Bedienungspult
Pupitre de commande

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1.2.3 Layer Formation

For stack and layer heights, please refer to figure 4.

1.2.4 Production Requirements

The single products must be aligned laterally ±1 cm (±3/8”) when transported to stacker.

1.2.5 Floor Plan

Refer to figure 2.

1.2.6 Noise Level

Work area: Identified by hatched lines xxxxxx

Measuring procedure: Based on: EN 13023 J.7.2 - KL2/KL3

Measured values: max 78.6 dB

1.3 Standard Accessories

One standard set of accessories is delivered with each Compensating Stacker.

Installation set

Spare parts set

Tool set

Operating manual

Spare parts manual

1.3.1 Special Accessories (Optional)

Pneumatic gate

Bi-directional pusher

Reject gate on infeed

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2 Safety Guidelines

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2 Specific Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Safety Guidelines

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Safety Guidelines

2.1 Introduction

The safety guidelines listed below refer only to the Compensating Stacker.

It is an obligation for all persons working on or with the

Compensating Stacker to read and understand the safety
guidelines of the stacker.

2.1.1 General Safety Regulations

The instructions marked with warning symbols must be followed at all times.

Definitions of the warning symbols are described in the yellow « Safety Guidelines »
(chapter 1.3.2).

2.1.2 Specific Safety Instructions

• The Compensating Stacker has one safety zone. No safety covers can be open while
the machine is in the « RUN » or « TEST » mode. Before performing any adjustments
on the machine make sure no persons are within the danger zone of the machine.
• Use extreme caution during adjustments of the flow control valves and cushions during
test program run.
• Set manual switch of the magnetic valves to « 0 » after adjustments are complete.
• Do not use Bi-Directonal feature without proper mechanical hardware.
• Serious damage can result if proper procedures for changing pusher direction are not
followed. The main power switch must be turned OFF before changing (pusher direction)
switch.

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Safety Guidelines

2.2 Conformity

The APOLLO Stacker corresponds to present state of the art technology and all current
valid safety regulations.

The machine was designed and built based on the following guidelines and standards:

• 98/37/EC Machine Guidelines

• EWG 89/336 Electromagnetic Compatibility
• EN ISO 12100-1/2 Safety of Machines (basic terminology, methodology)
• EN 60204-1 Safety of Machines - Electrical Equipment of Machines
• EN 1010-1 Technical Safety Requirements for the Design and
EN 1010-4 Construction of Printing and Paper Converting Machines
(preliminary standard)
• EN 954-1 Safety of Machines - Safety Related Control Components

Risks still remain, and dangers to body and life, especially if the stacker is operated and
maintained by unauthorized persons or not used properly.

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Set-Up and Function

3 Set-Up and Function

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.2 Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.3 Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.3.1 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.4 Main Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.4.1 Infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.2 Reject Gate (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.3 Stacking Bin/Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.4 Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.5 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.6 Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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1 D A

C B

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3.1 Introduction

The primary components of the stacker and their functions are listed and described in this
chapter.

3.2 Set-Up

1A Infeed

1B Maintenance unit

1C Delivery

1D Control panel

2A Turntable

2B Gates (optional pneumatic gate shown)

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3 4
B

15400401_1
15340301 D C

5 A

154093099_5

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3.3 Operating Principle

3.3.1 Sequence of Operation

The 1540 stacker accepts books from a three knife trimmer or another preceding machine
into the infeed. The books are held between the infeed belts and transported to the stacking
bin.

Running single products are monitored by a photo-electrical count system 3A. The layer is
formed on the forks 4B. When the number of copies reaches the preselected value, the forks
open and the layer is dropped into the bin 4C on the turntable 4D. The compensated stack
is formed by rotating the table 180 degrees after each layer has dropped. For setting layer
formation and stack size refer to the electrical control manual. The stacks are ejected onto
a roller delivery.

The infeed belts are driven by a variable speed AC gear motor 5A. To adjust the infeed belt
speed refer to the 1540 electrical control manual. Generally, the stacker performs better if
the speed is kept at the upper end of the possible speed range.

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6 A

15400399_14
B

A
B

fig 3-1

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3.4 Main Component Descriptions

3.4.1 Infeed (6A)

Transports book from up-stream machine into stacking bin.

3.4.2 Reject Gate (Optional)

Figure 6B. Rejects mailing packets which are smaller than allowed by the machine.

3.4.3 Stacking Bin/Forks (7A)

Counts and pre-stacks book and drops them into the turntable.

3.4.4 Gates (7B)

Optional pneumatic gate shown. Accumulates the stack of books.

3.4.5 Turntable (7C)

The turntable turns 180° to compensate the stack.

3.4.6 Pusher (7D)

Pushes stack out of the gates on to the roller delivery table.

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Operating Elements and Display Modes

4 Operating Elements and Display Modes

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1.1 Categories of Operating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.2 Safety Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.2.1 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.3 Operating and Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.3.1 Electrical Operating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.2 Mechanical Operating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.4 Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.4.1 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4.2 Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Operating Elements and Display Modes

1 F A B

B C D B

A = EMERGENCY STOP buttons

NOT-AUS Tasten
Interrupteur d’ARRÊT D’URGENCE

B = Interlock Covers
Verriegelte Schutzabdeckung
Protecteur verrouillé électriquement

C = Power Indicator
«Hauptschalter ein» Anzeigelampe
Témoin d’armoire é’ectrique sous tension

D = Main Power Switch

Hauptschalter
Interrupteur

E = Control Panel
Bedienungspult
Pupitre de commande

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Operating Elements and Display Modes

4.1 Introduction

All safety, operating and display elements and their functions within the Compensating
Stacker are introduced in this chapter.

The appropriate use of the operating elements and their function in case of an error is
described in chapter 6 «Operation».

4.1.1 Categories of Operating Elements

The operating elements and their functions are segmented into electrical and mechanical
operations. In both operating modes, test mode and run mode the function of the
EMERGENCY STOP button remains the same.

4.2 Safety Elements

After the EMERGENCY STOP button has been activated,

the button must be pulled up in order to restart the
machine.

1A EMERGENCY STOP Pushing this button stops the Stacker

buttons immediately and releases all air pressure.

Do not use the E-STOP as a regular machine stop.

4.2.1 Protective Devices

The following electrically interlocked protective covers prevent operating personnel from
reaching into the machine:

1B Covers When opened the entire machine stops.

1F Hood Prevents operator from reaching inside the machine when in
operation.

All other protective devices are securely fastened down.

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2 A B C

15403099_1
D E

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4.3 Operating and Display Elements

4.3.1 Electrical Operating Elements

Control Panel (fig. 2)

For further information refer to the Electrical Control manual for the 1540 “Display/Keypad
Elements” 4.3.1, located in the control cabinet.

A LED Display Status/Display errors

B Start Button Start/Reset

C Emergency Stop Button Emergency stop

D Stop Button Stops machine

E Potentionmeter Infeed speed control

Keypad

Test Mode =
ESC/Cancel Key = T

Opens forks to push out =

Arrow Keys = current packet

Enter Key =

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3 A B 4 A

15400101_20 15400408_2

5 A 6

C
15400408_3

154093099_10

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Operating Elements and Display Modes

4.3.2 Mechanical Operating Elements

3A Handwheel Adjust for product width

3B Handwheel Adjust for product length

4A Handgrip Adjust for product thickness

5A Handgrip Adjust for product thickness

6A Blow air valve Adjust air flow, valve On/Off

6B Handwheel Adjust infeed height

6C Knob To stop machine from rolling

6D Regulator knob Adjust air pressure

4.4 Operating Mode

4.4.1 Run Mode

In this mode the machine may be started with any Start/Reset button, for a production run.
No safety covers can be open.

4.4.2 Test Mode

In this mode the machine cycles with no incoming products at a simulated variable speed.

It is activated by the keypad.

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Installation

5 Installation

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.1.1 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.1.2 Technical Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.1.3 Requirements for the Operating Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5.2 Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.1 Unpacking and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3.2 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3.3 Air Pressure Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3.4 Change Push-Out Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3.5 Installing Two Deliveries for Bi-Directional Pusher . . . . . . . . . . . . . . . . . . . . . . 11

5.4 Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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5.1 Introduction

The Compensating Stacker is an autonomous machine. It does not refer to machines in line
before or after the stacker.

5.1.1 Hazards

• The Compensating Stacker may have been damaged during trans-

portation. Before the initial start-up, check the machine according to
chapter 5.4 «Initial Start-Up».
• The EMERGENCY STOP BUTTONS only function if the stacker is
connected electrically.

5.1.2 Technical Safety Instructions

• During the installation or removal of the stacker, hands will be in

dangerous areas. The operator can be endangered by another opera-
tor’s manipulation.
• Danger of an electric shock also exists.
• Prior to performing any work on the machine the main power switch
on the control box must be turned and secured on «0».

5.1.3 Requirements for the Operating Personnel

The Compensating Stacker must be installed by a service representative of MULLER

MARTINI or by an authorized Muller Martini person.

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1 A

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5.2 Set-Up

5.2.1 Unpacking and Cleaning

Unpainted surfaces of the machine have been sprayed with rust preventative solution for
protection during transport and storage. To remove this coating use a clean cloth, soaked
with Amsco naphthol solvent 66/3 (Union Oil Co., Schaumburg, IL 30196), or equivalent.

Special unpacking or preparation-for-use instructions may be attached to the machine.

Carefully read and follow these instructions. If there is a conflict between the instructions in
this manual and those attached to the machine, those attached to the machine take
precedence.

5.2.2 Lifting

The stacker can be lifted from the pallet by using the four anchor bolts 1A located on the top
of the machine.

Transport the stacker from the pallet to the installation site. The stacker is equipped with
rollers attached to the base for easy moveability.

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2 3

15400399_6
C D
A

4 5 E

3PL

2PL

1PL

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5.3 Installation

5.3.1 Location

• Place machine on level floor, align infeed center with the center of the unit which will
feed the stacker, secure machine with spindles 2A.
• The height of the infeed is adjustable with handwheel 2B. Set it to the same height as
the conveyor to the infeed.

5.3.2 Electrical Connection

Since the controls of the 1540 stacker have been wired and checked at the factory the only
necessary installation is to bring in the main power supply line and connect it to the power
input terminals provided in the control cabinet. Make connection according to local codes
and the schematic, located in the control cabinet.

Do not modify the wiring or control circuits in any way.

Modifications of the electrical controls will void manufac-
turer’s warranty unless the work is performed be a
MULLER MARTINI service representative or is authorized
in writing by the factory.

• Connect AC power to plug 1PL, fig. 4. Connect stop circuit to plug 2PL, fig. 4. If there is
no stop signal to or from the stacker a jumper wire between terminals 1 and 2 in plug
3PL is required, fig. 5E.
• Connect plug 2PL to the feeding machines STOP CIRCUIT using the supplied interface
cable. The 1540 supplies a pair of dry-contacts for the feeding machine to detect the
RUN status of the machine. Consult the schematic for further information.

5.3.3 Air Pressure Connection

• Connect air pressure (min. 6 bar, 87 psi.) to hose barb 3C.

• Check maintenance unit 3D. Adjust pressure to 6 bar, 87 psi. The oiler should release 1
drop of oil per minute during production.

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6 C D A

15400508_1
B

15403099-16

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5.3.4 Change Push-Out Direction

Do not place the 1540 stacker into Bi-Directional mode

(Push opposite (left right) without first completing
the mechanical change over.

Serious damage can result if proper procedures for chang-

ing pusher direction are not followed. The main power
switch must be turned OFF while changing pusher direc-
tion.

Make delivery change over from right to left or left to right as follows:

1. Turn off power and secure the machine.

2. If the machine is equipped with pneumatic gates, continue, if not go to step 6.
3. Disconnect the air tube that provides air to the pneumatic gates (coil tube) from the
large tee connected to the pusher cylinder air line (refer to schematic).
4. Remove the plug in the tee on the second air line connected to the pusher cylinder
and install it into the open port on the tee that the pneumatic gate air hose was
removed from.
5. Plug the air line from the pneumatic gates into the port on the tee on the second air
line that the plug was removed from.
6. Remove the Lexan door, its hinges, brackets and limit switch from the new delivery
side of the machine.
7. Remove cover 6B next to the turntable on the new delivery side of the machine.
8. Remove the delivery table and Lexan cover.
9. Remove the delivery table brackets and re-install on the opposite side of the machine.
10. Remove the Lexan window from the upper side cover on the old delivery side of the
machine
11. Re-install the cover on the old delivery side of the machine.
12. Re-install door, hinges and limit switch on the old delivery side of the machine.
13. Re-install the Lexan window of the upper side cover on the new delivery side of the
machine.
14. Install the delivery table on the delivery brackets and adjust for proper height.
15. Remove the pusher bar bolts 6A, then remove the pusher bar with a rubber mallet.
16. Use a steel hammer to drive the roll pins in the pusher bar through to the opposite
side.

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17. Re-install the pusher bar.

18. Change setting for push out direction via key pad. Refer to electrical operating man-
ual for directions.

5.3.5 Installing Two Deliveries for Bi-Directional Pusher

1. Remove cover 5B.

2. Remove Lexan door 5C, its’ hinges 5D and the limit switch.
3. Make sure to add jumper in the proper terminals. (See electrical schematic)
4. Install second delivery.
5. Exchange pusher bar 6E.

This will reduce max. size by 30 mm.

6. Change setting for push out direction via key pad (See electrical operating manual for
directions).

5.4 Initial Start-Up

Run the following tests before starting up the stacker.

• Check the function of the safety switches after start-up. When covers are opened the
machine must stop immediately.
• Press the EMERGENCY STOP button. Machine must stop immediately.

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Operation

6 Operation

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.1 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.2 Technical Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.3 Specified Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.4 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.2.1 Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.2.2 Production Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.2.3 Machine Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6.3 Size Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6.3.1 Infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.3.2 Stack Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.3.3 Blow Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.3.4 Double Production (Two-Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3.5 Turntable Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3.6 Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3.7 Setting Layer and Packet Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3.8 Calculation of Minimum Copies Per Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.4 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.1 Undisplayed Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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6.1 Introduction

6.1.1 Hazards

In spite of all the safety measures dangers still remain which operator must remain aware of:

• All moving and rotating parts are potential safety risks. Use common
sense.
• Do not wear loose fitting clothing, tuck long hair in so it does not get
caught in moving parts.
• Push the EMERGENCY STOP button only in case of an emergency
and not as a standard machine stop.

6.1.2 Technical Safety Instructions

Dangerous areas must be touched in order to do size set-

tings. The operator can be endangered by another opera-
tors manipulation.

Always observe the safety regulations.

6.1.3 Specified Safety Instructions

• Use extreme caution during adjustments of flow control valves and cushions during test
program run
• Set manual switch of magnetic valves to «0» after adjustments are completed.
• Do not use Bi-Directional feature without proper mechanical hardware.

6.1.4 Qualified Personnel

Only qualified and trained personnel should operate the Compensating Stacker. The
qualifications and training requirements are listed in chapter 1.5.7 "Safety Guidelines" (yellow
sheets).

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1 A 2

15400604_1 15403099_6
B

3 A D 4 A

C B

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6.2 Operation

6.2.1 Machine Controls

The stacker is operated from the control panel (start/stop etc.). Adjustments on the stacker
are made for the set-up of the required product for production.

General Preparation
• Turn main switch 1A On.
• Connect air pressure to the hose barb 2A. Compressed air 6 bar / 87 psi On. Adjust if
necessary with knob 2B. Make sure there is oil in the lubricator 2C.
• Press button start button until forks move.

6.2.2 Production Start-Up

Prior to start-up of the stacker make sure no persons are

with in the machines danger zone.

• Start machine with start button 3A.

• Set speed potentionmeter 3B to low speed.
• Make size adjustments according to «Size Settings» 6.3.
• Press and hold start push button 3A for about 2 seconds or until you see the forks move
to their closed position. Should the start be unsuccessful, turn the turntable 180° by hand
and start again.
• The infeed belts start running after a time delay of about 4 seconds. This ensures that
the fork mechanism is ready before remaining books in the infeed from the previous run
are fed into it.

6.2.3 Machine Stop

Press stop push-button 3C or one of the mushroom stop buttons 3D, 4A or 4B.

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5 A 6 C B

15400408_3 15400502_2

7 8 B

A
A

15340503 15340504

9 A B 10 A

46467797 15400399_5

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6.3 Size Adjustments

6.3.1 Infeed

Use handgrips 5A and 6B to match product-thickness between the upper and lower belts.

6.3.2 Stack Unit

• Stiffen products with concave or convex shape by turning screws 7A with wrench
6C. Set roller levers 8A to match by unclamping and reclamping on shaft 8B with wrench
6C.
• Set product width with handwheel 9A and product length with handwheel 9B.

For some sizes, fork-fingers may contact side-guides. In such cases, the affected fingers
should be removed temporarily.

Scales are set to give 5 mm (3/16”) clearance around products.

6.3.3 Blow Air

• In some cases the product can be better transported in to the upper stacking bin with
blow air. The blow air is delivered through tubes which can be bent to direct the air where
needed. Turn blow air on and off, and adjust flow with knob 10A.

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11 A 12 J

15400608_11 15400399_10

13 E H 14 A

15400608_4

15400608_3
F G

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6.3.4 Double Production (Two-Up)

For double production install divider plate 11A and lower bin side plates 11B. Plates must be
cut to fit for sizes less than max. size.

6.3.5 Turntable Bin

• Loosen clamp levers 13E and 13F and set turntable bin with 1 - 5 mm
(3/64” - 3/16”) play to the product to be run. The pre-load of the tension springs 13G can
be adjusted with set collars 13H.

6.3.6 Pusher

• Adjust push out speed with flow control valve knob 12J. In order to keep the cycle time
at a minimum the pusher should return as fast as possible. Return speed can be adjusted
with flow control valve 14A.
• If the pusher cycle is too slow the machine will cut off. Increase pusher speed.

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15

9
Min. copies
per layer 8
Min. Anzahl
Exemplare 7
pro Lage
6
Nombre
d’exemplaires
min. par pile 5

1
0 2 4 6 8 10 12 14 16
Copies / Hour (Thousands)
Exemplare pro Stunde (Tausend)
Exemplaires/heure (Mille)

Cannot be run
= Kann nicht verabeitet werden
Ne peut pas étre produit

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Operation

6.3.7 Setting Layer and Packet Sizes

In the “[Link]” screen select sizes, set values for packet and layer sizes. Refer to 1540
electrical control manual.

6.3.8 Calculation of Minimum Copies Per Layer

Layer and packet sizes depend on production speed and operating conditions.

1540 Compensating Stacker: Min. cycle time *1.5 seconds.

*CYCLE TIME: The minimum cycle time is determined by the pusher cycle, it constitutes the
time necessary for the Compensating Stacker to form a stack and push it out.

Because of the reaction time delay of the mechanical and pneumatic elements of the machine
this time cannot be set lower.

Minimum number of copies [ Preselection ] = Production speed

2400

(Also see diagram 15)

Example: Minimum setting at a production speed of 14,000 c/hr.

14,000 = 6 copies - Set the value to 6 or higher.

2400

Although the value may be larger due to difficult products and slow push out speed, it cannot
be less than the value found above.

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16 A 17

C
B

15400608_4 15400612_2

18 D 19

15400612_4

15400399_10
E

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Operation

6.4 Faults

The majority of problems which may occur can be cleared by the operating personnel
(machine operator). For problems which are not listed in the chart below, please contact our
service dept. After all faults are cleared the machine can be started again from any start
button.

6.4.1 Undisplayed Faults

Problem Check Solution

Machine will not Plugs Make sure all plugs are properly seated.
start

Main switch Turn to “1”.

Mushroom stop buttons Deactivate by pulling.

All doors Close.

Pusher Move pusher to start position manually.

Turntable Manually turn it to the other end position.

Circuit breaker Activate - see fig. 19F.

Reed switches Check proper function and position.

Infeed belts do not

run
Potentiometer 3B Turn clockwise away from “0”.

NOTE: Turn main

switch off for this proce-
dure!!

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20

L
15400612_1

21 H

15400614_2

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Machine cuts itself Air pressure Set at 6 bar, 87 psi.

Off
Layer and packet preselect Preselects may not be “0”, layer setting cannot be
settings more than packet setting.

Layer preselect setting It may be too low for production speed.

Redo calculation - see Section 6.3.7.

Photocell and reflector Clean or replace if necessary.

Pusher cycle time Cycle time should be approx. 1.5 seconds.

Adjust flow control valves 16A & 18D on pusher
air cylinder.
Inspect maintenance unit 18E - see Chapter 5
“Installation”.

Reed switches Check function and position of reed switches.

Replace or reposition if necessary.

Problem Check Solution

Incorrect count of Photocell and reflector Clean or replace if necessary.
books
Gap between products Gap must be min 20 mm (25/32”) Speed up infeed
in the infeed to produce larger gap.

Layer and packet prese- Check for entered values.

lect settings

Pusher makes Air pressure Set at 6 bar, 87 psi.

excessive noise
Cylinder speed Adjust flow control valves 18D on pusher air
cyclinder.

NOTE: Total cycle time should not be more than

1.5 seconds.

Cylinder cushions Adjust cushions 16B & 17C so cylinder slows down
at the end of the stroke but does not bounce.

Rubber bumper Replace if necessary.

NOTE: Turn main

switch Off before
removing covers

Belt Tension Check and retention if necessary.

12.2005 1540.9002.71 6 - 15
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Operation

Fork makes Air Pressure Set at 6 bar, 87 psi.

excessive noise
Cylinder speed Adjust flow control valves 20K & 20L at each end of
cylinder.

Cam roller Check and re-adjust play - see Chapter 8,

“Repairs”.

Rubber bumper Adjust clearance or replace if necessary.

NOTE: Turn main

switch Off before
removing covers

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Maintenance

7 Maintenance

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1.1 Training of Maintenance Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7.2 Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7.2.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.2.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7.3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.3.1 After 8 - 12 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.3.2 After 40 - 60 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.3.3 After 160 - 200 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.4.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.4.2 Maintenance of AC-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.4.3 Belt Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.4.4 Belt Routes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.5 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.6 Customer Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Maintenance

7.1 Introduction

Regular maintenance and inspections are very important. It prevents unnecessary problems
and increases the service reliability along with the extended operating period of the machine.

Maintenance work includes cleaning, control checks and lubrication.

7.1.1 Training of Maintenance Personnel

Only authorized personnel should maintain the stacker. The qualifications and training
requirements are listed in chapter 1.5.7 «Safety Guidelines» (yellow sheets).

7.1.2 Safety Instructions

Hands will be in dangerous areas during maintenance and

repair work.

If the main switch is not in «0» position, the operator can

be endangered by another operators manipulations.

Danger of an electric shock also exists.

7.2 Equipment and Materials

7.2.1 Equipment

It is recommended that an industrial vacuum cleaner be used to clean the stacker.

7.2.2 Materials

Please refer to the section maintenance and to the lubrication chart provided at the end of
this chapter for necessary lubricating points.

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Maintenance

7.3 Maintenance Schedule

7.3.1 After 8 - 12 Operating Hours

• Clean machine and remove remaining paper from turntable.

• Clean light barriers and reflectors (Do not use solvent based cleaners).
• Check oil volume of air pressure maintenance unit.

7.3.2 After 40 - 60 Operating Hours

• Clean stacker (Do not blow dirt in bearings and delivery parts).
• Clean and check the delivery conveyor belt, if necessary replace. Belt models, lengths
and order numbers are listed chapter 8 and in the spare parts catalog.
• Start test mode, if necessary adjust rubber bumper, flow control valves and air cylinder
cushions.
• Drain the condensation from the filter on the air pressure maintenance unit before it
reaches the maximum level.

7.3.3 After 160 - 200 Operating Hours

• Check all safety and stop switches for proper function. (Run machine and activate
individual switches)
• Check AC motor
• Check all setting screws.
• Check for loose screws.

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15403099_3
15

2 4 3

15403099_7 15400706_3
6

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Maintenance

7.4 Maintenance

7.4.1 Lubrication

If maintenance work is done improperly, oil can leak onto

the floor. An oily, slippery floor increases the danger of
falling. Always perform maintenance work with the neces-
sary caution.

The lubrication interval is determined by the lubrication symbol. The explanation of the
characters and the corresponding lubricating points are described at the end of this chapter.

7.4.2 Maintenance of AC-Motor

Turn off the main power on the control panel and discon-
nect the power at its source before performing any service
on this equipment.

Only qualified electricians should work on the electrical

portion of this equipment.

Lubrication

Fig. 1,refer to manufactures instructions in the accessories section.

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Maintenance

4
4
20mm
A (3/4”)

20mm
(3/4”)

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Maintenance

7.4.3 Belt Change

• Do not touch heating elements.

• Use only recommended glue.

The procedure for cutting and gluing belts is located in the spare parts catalogue accessories
section.

• Cut old belt and place next to unrolled new belt.

• Add 20mm (¾”) for overlap = length of new belt.
• Cut new belt and skive both ends as shown in fig. 4A.
• Make sure the spliced ends travel with the product, not against it, as shown in fig. 4B.
Also see separate Habasit product information.

Order Number Type Dimension Color

0039.3044 X m Flat belt 25 x 1.2mm Green/Black

1” x 3/64”

0039.0420 X m Flat belt F1 30 x 1.2mm Green

1 3/16” x 3/64”

1504.1249.9 X m Flat belt 40 x 1.2mm Green/Black

1 9/16 x 3/64”

m = oder length in meters

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Maintenance

7.4.4 Belt Routes

Pusher Belt Route (fig. 2)

Top belt (5A)

Total quantity: 5

1 X 40mm wide, in center

4 X 25mm wide, outside

Outside bottom belts (6B)

Total quantity: 4

4 X 25mm wide

Center bottom belt (6C)

Total quantity: 1

1 X 40mm wide in center

Note: Drives jogger

7.5 Maintenance Log

A separate work sheet is provided at the end of this chapter to record scheduled maintenance
work.

7.6 Customer Service Information

If any questions should come up, please contact your local sales branch or our customer
service @ [Link]

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Maintenance

Maintenance Log After xx operating hours

8 - 12 hr 40 - 60 160 -200 hr
Counter Counter Counter
Reading Initial Reading Initial Reading Initial

Entry Instructions

After maintenance and lubrication has been

completed, the person in charge confirms the
scheduled work by entering the counter reading
and signing off.

The page accommodates one year and should

then be filed and replaced by a new page.

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Repairs

8 Repairs

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1.1 Training of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1.2 Technical Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1.3 Consequences if Safety Guidelines are Disregarded . . . . . . . . . . . . . . . . . . . . 3

8.2 Basic Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.2.2 Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.2.3 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.2.4 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8.3 Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8.3.1 Manual Activation of Electromagnetic Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.3.2 Adjusting Magnetic Slow-Start Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Repairs

8.1 Introduction

8.1.1 Training of Personnel

The following adjustments must be carried out by a service technician. Although these steps
are described in detail, participation in a class at MULLER MARTINI is still essential.

All control checks and work on the electrical installation

can only be carried out by an authorized service techni-
cian.

8.1.2 Technical Safety Notices

During the repair you may reach your hands into dangerous areas. If the main switch in the
control cabinet is not in "0" position, the operator may be endangered by another operators
manipulation. There is also danger of an electrical shock.

The following safety guidelines should always be followed:

• Carry out adjustments only when the Compensating Stacker is turned OFF. Main switch
on the control cabinet is on «0» and locked.
• All technical safety notices should be strictly followed.

8.1.3 Consequences if Safety Guidelines are Disregarded

MULLER MARTINI will decline any and all liability for injuries which can be attributed to
disregard of the safety guidelines.

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1 B

15403099_10
A

H
D

15400804_4

4 E

J
F

15400608_4 15400612_2

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Repairs

8.2 Basic Settings

• Always press the EMERGENCY STOP button before working

on the machine.
• Only qualified mechanics should work on the mechanical portion
of this equipment.

The adjustments described in this section were made at the factory and further adjustments
should not be necessary. If timing irregularities should occur, the following information may
serve as a guideline in correcting them.

8.2.1 General

Use extreme caution in performing these adjustments.

The basic settings of the 1540 Compensating Stacker were made at the factory. If necessary
they can be checked as follows:

• Start machine and run it in test mode. Prior to starting test mode check air pressure on
maintenance unit 1A. Set at 6 bar, 87 psi.

8.2.2 Pusher

• Position of reed switches 2C and 2D:

- Move cylinder rod to one end position by using manual activation of the
electromagnetic valve - see Section 8.3.1 Loosen reed switch set screws and
move reed switch in one direction until LED goes off. Now move it back in the
other direction until LED goes off again. Position reed switch in the center of the
range in which the LED is lit and tighten set screws. Move cylinder rod to the
other end position and adjust reed switch in the same manner.
- Adjust push out speed with flow control valve knob 1B and return speed with flow
control valve 4E.
- Adjust cushions 4F and 4J on air cylinder so the piston moves into the end
positions without bouncing.
- Check for wear of the rubber bumper 3H at each end of the pusher guide rod 3G,
and replace them if necessary.

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5 H J

15400806_1
C D G F E

6 K L M

8
T
15400806_2

7 N P
R

15400806_3
Q
15400612_1

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Repairs

8.2.3 Turntable

• Adjusting rubber bumpers 5A and 5B:

- Bring turntable to one end position. (Guides on table will be parallel to pusher.)
Turn bumper 6L until it touches the stop 6M. Turn the turntable away from the
bumper. Bring bumper out 5mm (0.2”) more so that it is compressed 5mm (0.2”)
under air pressure. Tighten it securely with locknut 6K. Do the same on the other
side. Make sure the cylinder never travels all the way to the end. There should
be 5mm (0.2”) play on each end. This can be adjusted by loosening nut 5H and
turning piston rod 5J.

• Position of reed switches 7P:

- Use the same method as described above in Section 8.2.2 - Pusher.
- Adjust cushions 8S and 8R and flow control valves 8Q and 8T on air cylinder so
the turntable turns to the end positions without bouncing.

• Adjusting play in cam for turntable drive:

- Release air pressure.
- Loosen the three hex head screws 5G.
- Loosen the three locknuts 5E on the set screws 5F.
- Adjust play between bearing 5C and guide 5D to 0.05 - 0.1 mm
(0.002” - 0.004”) with the three set screws 5F.
- Make sure the play is the same over the whole travel of the table. Check by
turning the table to the other end by hand.
- Tighten hex head screws 5G and locknuts 5E securely after adjustments have
been completed.

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9
E

10

11 V

15340608

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8.2.4 Forks

Set rubber bumpers and flow control valve so that the forks move with the maximum possible
speed and do not bounce in the end positions.

• Set dimension 9A to 375mm (14 49/64”). Set dimension 9E to 6.4mm (1/4”), without
rubber bumper 9F. Tighten lock nut 12-9G and install rubber bumper.
• Set dimension 10H to 671mm (26 13/32”). Plastic stop 10R should be checked for wear
and replaced when necessary.
• Set flow control valves 11V so that the forks move with maximum possible speed and do
not bounce in the end positions.

The end cushions of this cylinder are not used.

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12 A

15403099_19

13 14

D E

15341102
C

15341103

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8.3 Pneumatic System

The pneumatic schematic is located in the spare parts catalog.

After settings have been completed, all valves must be

brought back to the «0» position. Do not forget main valve
12A.

8.3.1 Manual Activation of Electromagnetic Valve

The main valve 12A and 13 is a slow start valve. The purpose is a controlled adjustable
pressure build-up after energizing and a quick exhaust of the system after de-energizing.
This prevents damage of pneumatically moved parts.

The screws 13B and 14E are for manual activation of magnetic valves with a screwdriver:
• Slot in 0-position: Basic position -The valve can be controlled electrically
• Slot in 1-position: Valve is activated -The valve cannot be controlled electrically

First the main valve 12A must be activated manually.

After the settings have been completed, all valves must be brought back to the 0-position.
Do not forget main valve 12A.

8.3.2 Adjusting Magnetic Slow-Start Valve

• Loosen set screw 13D one turn.

• Adjust time to build up the air pressure in the system with screw 13C.

Increase time -turn clockwise

Decrease time -turn counterclockwise

(Internal stops allow maximum of one turn.)

For Model 1540, start at closed position (fully counterclockwise) and open approximately 45°.
• Retighten set screw 13D.

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Decommissioning, Storage

9 Decommissioning, Storage

9.1 Introduction

This chapter describes the necessary functions which must be carried out by the operator if
the Compensating Stacker is to be stored for a time of period of 6 months or longer.

9.1.1 Definition of Time Period

Under decommissioning or storage in this chapter we understand the time period between
use of the Compensating Stacker.

9.1.2 Authorized Personnel

The machine operator or a service technician is authorized to decommission the stacker.

Decommissioning does not require additional training.

9.2 Decommissioning

• Remove electrical connections.

• Remove air pressure connection.
• Treat unpainted metal parts with a rust preventative.
• Change oil in gears.

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Decommissioning, Storage

9.3 Storage

9.3.1 Ambient Conditions]

Temperature Min./Max -20/60°-4/140° F

Humidity Min./Max. 40/70%

Cover with plastic.

9.4 Recommissioning

Per chapter 5 "Installation".

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Packing and Transport

10 Packing and Transport

10.1 Introduction

The Stacker is transported as a complete module and does not need to be disassembled.

10.1.1 Authorized Personnel

Persons with transport and forklift experience are authorized to pack and transport the
Feeder.

Decommissioning and transport do not require additional training.

10.2 Packing

The Stacker is mounted on a wooden platform for transportation.

10.2.1 Preparation

For decommissioning refer to chapter 9.

Twin Signature Feeder

• Lift stacker with forklift onto a wooden platform.
• Remove safety guards and anchor down stacker.
• Fasten all disassembled parts safely for transport.
• Tie down electrical cables on the machine.
• Use a rust preventative on all exposed metal parts.

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Packing and Transport

10.2.2 Choice of Packing

Transportation in building

No additional packing necessary

Transportation outside

Cover with plastic foil

Transportation overseas

In wooden crate, covered with plastic foil.

Add de-humidifier.

10.3 Transport

Use caution when lifting the stacker with a forklift.

Within the building

Use forklift or pallet truck with sufficient load capacity.

Outside

Make sure that the machine is secured on the truck and in the container so it cannot move
out of place.

Weight

Stacker 720kg / 1600 lbs.

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Disposal

11 Disposal

11.1 Introduction

The owner/operator is responsible for the disposal of the 1540 Compensating Stacker.

Muller Martini must be informed on decommissioning and disposal of the stacker.

11.1.1 Machine Lubricants

Drain oil in both motor and transmission of the machine and dispose of at a proper recycling
site.

11.1.2 Materials

Materials must be sorted in material groups (aluminum, iron, plastic, electrical etc.) and
disposed at the appropriate disposal site.

11.1.3 Disposal regulations

Please follow all relevant local and national laws and guidelines for disposal of the stacker.

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Disposal

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Spare Parts Catalog

12 Spare Parts Catalog

12.1 Introduction

The spare parts catalog is divided into three segments:

1. Part Numbers
2. Illistration Pages
3. Accessories

This spare parts catalog is part of the instruction manual. It is only made for the ordering of
spare parts.

12.1.1 Part Numbers

All part numbers and described parts are listed in numerical order. All parts include the
number of the page where the part is shown.

12.1.2 Illistration Pages

Structure of the chapters is divided into sections of the machine. Following as close as
possible to the papers direction of travel.

12.1.3 Accessories

These sheets include instructions and spare parts from third party suppliers, as well as norm
parts of the Müller Martini factory.

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Index

13 Index

B N
Belt Change . . . . . . . . . . . . . . . . . . . . . . 7-9 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Belt Routes . . . . . . . . . . . . . . . . . . . . . . 7-11 Noise Level . . . . . . . . . . . . . . . . . . . . . . . 1-9

C O
Calculation of Minimum Copies Per Layer . . Operating and Display Elements . . . . . . . 4-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Operating Mode . . . . . . . . . . . . . . . . . . . . 4-7
Conformity . . . . . . . . . . . . . . . . . . . . . . . 2-4 Operating Principle . . . . . . . . . . . . . . . . . 3-5
Customer Service Information . . . . . . . 7-11 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

E P
Electrical Operating Elements . . . . . . . . 4-5 Pneumatic System . . . . . . . . . . . . . . . . 8-11
Production Requirements . . . . . . . . . . . . 1-9
F Production Start-Up . . . . . . . . . . . . . . . . . 6-5
Floor Plan . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Protective Devices . . . . . . . . . . . . . . . . . . 4-3

I Q
Initial Start-Up . . . . . . . . . . . . . . . . . . . . 5-11 Qualified Personnel . . . . . . . . . . . . . . . . . 6-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Air Pressure Connection 5-7 R
Change Push-Out Direction 5-9 Requirements for the Operating Personnel .
Electrical Connection 5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Installing Two Deliveries for Bi-Directional
Pusher 5-11
Location 5-7 S
Safety Elements . . . . . . . . . . . . . . . . . . . 4-3
L Sequence of Operation . . . . . . . . . . . . . . 3-5
Layer Formation . . . . . . . . . . . . . . . . . . . 1-9 Setting Layer and Packet Sizes . . . . . . 6-11
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Size Adjustments . . . . . . . . . . . . . . . . . . . 6-7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . 7-7 Blow Air 6-7
Double Production (Two-Up) 6-9
Infeed 6-7
M Pusher 6-9
Machine Controls . . . . . . . . . . . . . . . . . . 6-5 Stack Unit 6-7
Machine Stop . . . . . . . . . . . . . . . . . . . . . 6-5 Turntable Bin 6-9
Main Component Descriptions . . . . . . . . 3-7 Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . 7-7 Special Accessories . . . . . . . . . . . . . . . . 1-9
Maintenance Log . . . . . . . . . . . . . . . . . 7-11 Specific Safety Instructions . . . . . . . . . . . 2-3
Maintenance of AC-Motor . . . . . . . . . . . . 7-7 Specifications . . . . . . . . . . . . . . . . . . . . . 1-5
Maintenance Schedule . . . . . . . . . . . . . . 7-5 Standard Accessories . . . . . . . . . . . . . . . 1-9
Mechanical Operating Elements . . . . . . . 4-7

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Index

T U
Technical Data . . . . . . . . . . . . . . . . . . . . .1-5 Unpacking and Cleaning . . . . . . . . . . . . 5-5
Training of Maintenance Personnel . . . . .7-3

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