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ferag MTS2 Operating Instructions Manual

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OPERATING INSTRUCTIONS
MTS2
SYSTEM
Ferag AG
Zürichstrasse 74
CH-8340 Hinwil
Phone +41 44 938 60 00
Fax +41 44 938 60 60
info@ferag.com
www.ferag.com
39012123.001 / ENG

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Summary of Contents for ferag MTS2

  • Page 1 OPERATING INSTRUCTIONS MTS2 SYSTEM Ferag AG Zürichstrasse 74 CH-8340 Hinwil Phone +41 44 938 60 00 Fax +41 44 938 60 60 info@ferag.com www.ferag.com 39012123.001 / ENG...
  • Page 2 Sections 6.1.3 and 6.1.4 expanded 001/T (ger) 21.11.2012 series added (MTS) P. Blum These operating instructions cover the following products: Designation of Abbreviation Prod. no. Series product Extraction unit ENT-MTS2/SMS2-1TR ENT-MTS2/SMS2-2TR 29.74.02 39010374 ENT-MTS2/SMS2-3TR MultiStack MTS2-LI 29.71.31 39010375 MTS2-RE 29.71.32 39010514...
  • Page 3 Preventive maintenance __________________________ 12 Planning bundling _______________________________ 12 3.2.1 Check production mode and product size ____________ 12 3.2.2 Production output for the MTS2 ____________________ 13 3.2.3 Diagram: Number of pages per stack________________ 17 Setup ________________________________________ 18 Setting up the release control (ALS)_________________ 18...
  • Page 4 Cleaning the light barriers and light sensors___________33 4.5.2 Setting up the printer_____________________________33 Setting up the strapping machine (BM)_______________33 Setting up the skewed copy detector (SBE) ___________34 Operation _____________________________________35 Control panel for ZF-MTS2 with ALS ________________35 1.1.1 Product flow ___________________________________37 5.1.1 Production selection _____________________________38 Product format__________________________________38 Operating the MTS2 _____________________________39 5.3.1...
  • Page 5 6.1.2 Clearing the MTS2 ______________________________ 45 6.1.3 Stopping the MTS2 ______________________________ 45 6.1.4 Switching the MTS2 off___________________________ 46 Entering the product data _________________________ 46 6.2.1 MTS2 without FVA ______________________________ 46 6.2.2 MTS2 with FVA (optional)_________________________ 47 6.2.3 Entering the production data ______________________ 47...
  • Page 6 Introduction Field of application The MultiStack system is used mainly in mailrooms in the newspaper and magazine production sectors. The MultiStack is used to form bundles for dispatch. These are assembled from individual products through to collected, film- wrapped collections. Intended audience This instruction manual is intended for persons who are familiar with the system’s production and operation settings.
  • Page 7 Safety Accidents can only be prevented by strict observance of the following safety instructions. 1. Installations and machines may only be operated by persons trained to do 2. Do not allow access to untrained personnel and visitors. 3. Before starting the machine, take time to read through all the documents carefully.
  • Page 8 Correct usage The MTS2 system must only be used in the production of newspapers and magazines. It must NOT be used for any other purpose. FERAG accepts no liability whatsoever for accidents or damage arising from incorrect use of the machine or plant.
  • Page 9 Safety instructions specific to this machine 2.5.1 MTS2 / ZF-MTS2 S522 S520 S521 Emergency stop EMERGENCY STOP (at last ZF) EMERGENCY STOP Emergency stop Q200 Q200 ZF-MTS_201 39012123.001 Safety 9 / 59...
  • Page 10 Risk of injury. - If a door safety switch is tripped during production, the MTS2 and any machines connected to it will stop. - All covers must be fitted and secured in place before production starts.
  • Page 11 Pictograms on the machines Main switch Q1 (+01) Switches the system on and off. The system will stop if the safety circuit is interrupted. Every door that is monitored has this sign by it. Parts are still live even when the machine is switched off.
  • Page 12 Preparation Preventive maintenance On all machines in the bundling area: - Remove paper residues from all machines (use vacuum cleaner). Blow inaccessible areas clean with compressed air. - Inspect the conveyor belts, guides etc. for damage and check that they are operating correctly.
  • Page 13 3.2.2 Production output for the MTS2 The following nomograms apply for 1:1 production mode (= 1 copy per gripper): NOT PROGRAMMED, i.e. STANDARD production Bundle height H = 350 mm Calculation formulae: Production speed (cop/h) x cycle (s) Number of MTSs =...
  • Page 14 Copies per STANDARD Copies per STANDARD Copies per STANDARD stack with 1 MTS stack with 2 MTSs stack with 3 MTSs 10,000 15,000 20,000 25,000 30,000 35,000 36,000 40,000 45,000 50,000 55,000 60,000 65,000 70,000 72,000 75,000 80,000 85,000 90,000 ** min.
  • Page 15 The following nomograms apply for 2:1 production mode (= 2 copies per gripper): NOT PROGRAMMED, i.e. STANDARD production Bundle height H = 350 mm Calculation formulae: Production speed (cop/h) x cycle (s) Number of MTSs = 3600 (s) x copies per standard stack Production speed (cop/h) x cycle (s) Copies per STANDARD stack = 3600 (s) x Number of MTSs...
  • Page 16 Copies per Copies per STANDARD Copies per STANDARD STANDARD stack with 1 MTS2 stack with 2 MTS2s stack with 3 MTS2s 5,000 10,000 7,500 15,000 10,000 20,000 12,500 25,000 15,000 30,000 17,500 35,000 18,000 36,000 20,000 40,000 22,500 45,000 25,000...
  • Page 17 Notes on the tables: Guide value for Guide value for stack height: max. bundle height: 2000 pages max. 3000 pages (broadsheet) (broadsheet) Please note the following for production planning: The minimum number of copies per stack to prevent overflows. The cycle times for finishing must be taken into account The ideal stack height to keep the bundles stable (see diagram "Number of pages per stack").
  • Page 18 ALS-MTS2 column. MTS_Sys_004 Selecting the production mode • Select the right production mode on the ALS's CONTROL PANEL (see section entitled "Operating the ALS-MTS2"): • "Remote" mode For producing programmed bundles • "Autonomous" mode For producing standard bundles (without LIM) Setting up the LineMaster (LIM) •...
  • Page 19 ZF-MTS2 4.3.1 Motorised format adjustment MTS2_Sys_001 Setting the side joggers: The copy stream should have approx. 2 mm play on each side between the lateral belts. • The distance between the lateral belts can be adjusted using the rotary switch (1).
  • Page 20 The distance (product width) between the lateral belts is automatically set according to the product format entered on the MTS2's control panel, and can be seen on the scale (3). Fine adjustment during production: • Turn the rotary switch (1) in the correct direction until the required width is reached.
  • Page 21 4.3.3 Moving the swivel belt MTS2_Sys_003 The swivel belt (1) is operated from the MTS's control panel. Before moving the swivel belt, ensure that there are no people or objects in the area through which it is to be moved. •...
  • Page 22 Setting up the MTS 4.4.1 Moving the MTS MTS2_Sys_004 • Position the MTS in front of the ZF-MTS, and use two dowel pins (1) to fix it in the sleeves in the floor. • Use the levelling feet (2) to lift the MTS off the floor far enough to allow the rollers (3) to rotate freely.
  • Page 23 4.4.2 Height of infeed belt ELB Setting: • Set the height of the pressure belt using the scale (4). Make the settings when the infeed belt is empty, or the pressure belt height display will not be correct. Reference values for preliminary setting: MTS2_Sys_442 <...
  • Page 24 4.4.3 Copy bending plates Set using the scale (2) according to the product thickness (including inserts): MTS_Sys_443 Motorised adjustment: • Adjust the height of the copy bending plates with rotary switch (1). Automatic adjustment (option): Enter the height of the copy MTS2_Sys_442_1 bending plates on the control panel.
  • Page 25 4.4.4 Stack compartment Recommendation: Length = product length + 5 Width = product width + 10 mm To set: Set the format using the scales (1) (product length) and (2) (product width). Motorised format adjustment • The length of the stacking zone (position of the vibrating jogger aligning plate) and the width of the stacking zone (distance...
  • Page 26 220 – 210 340 – 330 210 – 200 330 – 320 200 – 190 320 – 310 MTS2, for fixed format: • Unfasten the clamping screws (1). • Withdraw the fork blade (2) from the holder (3) and swap it out.
  • Page 27 MTS2, for variable formats: Quick-change system: • Push in the spreader tool (4). • Pull the fork out of the holder. • Insert the new fork into the holder. Check that the retaining springs latch into place properly. MTS_615.jpg You may need to select the relevant format group in the data records list, see section 4.4.9...
  • Page 28 4.4.6 Lifting table plate Fit the lifting table plate (2), to suit the product format. • The lifting table plate is fixed in place by two quick-release fasteners (1). For product lengths of 150 – 230 mm, use plate (1). For product lengths of 230 –...
  • Page 29 Ejector Setting the product length Ejector distance: Product length + 10 mm The setting can only be made if the MTS2 is stopped. After production has started, check: Products or stacks must fall horizontally onto the lifting table. Product length...
  • Page 30 Setting to product width The four ejector plates (1) are automatically positioned on the basis of the format width entered on the control panel. 4.4.8 Lateral belts in the accumulation area Distance between the lateral belts: Format length + 5 mm Manual setting (option): Use the handwheel (1) to set the belts against the scale,(2) =...
  • Page 31 4.4.9 Selecting the format group (option) A data record is created in the format group for each fork set. The data record contains the following information: The minimum / maximum formats for the fork set The fork length The length of the lifting table bed (important for avoiding collisions with minimum format) Data record 39012123.001...
  • Page 32 • Press the Service button (1). Service • Press the Data record list button (2). • Select the data record (3). • Confirm by pressing the button (4). 32 / 59 Setup 39012123.001...
  • Page 33 Setting up the topsheet producer (DBH) Topsheet producer (DBH) Strapping machine 4.5.1 Cleaning the light barriers and light sensors • Switch off the machine. • Clean the light barriers, reflectors and light sensor: Blow with compressed air and wipe with a soft clean cloth. 4.5.2 Setting up the printer See separate instruction manual for the thermal printer.
  • Page 34 Setting up the skewed copy detector (SBE) 10 mm 10 mm S1/H1 S2/H2 S3/H3 S4/H4 • Check the format settings. • Correct if necessary, using the hand crank (1) for manually adjusted SBEs or use the control panel (2) for motorised SBEs. 34 / 59 Setup 39012123.001...
  • Page 35 Operation Control panel for ZF-MTS2 with ALS Symbol colour states Grey: Machines that are configured, but are not being used for the current production. Green: Machine is ready for operation and is used for production. Blue: Used for current production but is not ready, e.g. set-up not complete or not started.
  • Page 36 Button / Function Description symbol Switch ALS to Switches the ALS to active or active inactive (toggle button). Toggles between Autonomous and Remote LIM mode and vice versa. Allocates machines to the lines (see Product flow point 0) Configured These machines are available within the system: Name of the machine Released products in this machine...
  • Page 37 5.1.1 Product flow Press the button in the footer bar. Only possible if ALS local mode is active. Button Function Description Switch Products are allocated to the machine on / selected machine. The colour of the button indicates the operating status (see point 5.1).
  • Page 38 5.1.2 Production selection • Press the Production preselection button. "Production selection" menu The value (3) of a parameter can be changed by selecting the parameter (1) and then pressing the Enter button (2) Product format "Product format" menu: Pressing button (2) opens an entry screen, where you can enter the new format.
  • Page 39 Operating the MTS2 5.3.1 Menu structure Home Product counter Format Drive axes Service axes Node Software info Alarm Alarm Alarm list Object Parameters Service Data backup/restore Format System values Bundle list EtherCat terminals Service axes Commands Production data Drive axes...
  • Page 40 5.3.2 General machine functions: Button Function Description Start Starts the MTS2. The lifting table, turntable, fork loop, ejector and lateral belts on the accumulation area are initialised. Stop Stops the MTS2. Functions are allowed to complete. Remote Toggles between Autonomous and LIM mode and vice versa.
  • Page 41 Button Function Description CLEAR Stops the release of copies. Copies that have already been released are bundled and ejected to the main exit. The button flashes during the clearing process. The button is only visible after the MTS has been started. Vacuum Switches the vacuum on / off (option)
  • Page 42 Button Function Description Pressing unit Switches the stack pressing (lifting / turntable) on / off. (option) This can only be used if this option is installed. Turn Turning motion for turntable. This button is only visible after the machine has been started. Infeed Opens / closes the infeed belt.
  • Page 43 5.3.4 "Production selection" menu Press the button on the toolbar. The "Data input" displays and buttons for number of copies and number of stacks only appear in stand-alone or autonomous mode. "Production selection" menu • The settings for the number of copies and number of stacks per bundle and the number of pages per product.
  • Page 44 Feeder (only for MTS2 with swivelling feeder) The active feeder is identified. • Use "Line up/down" to select the required feeder. • Press to confirm You can also select the feeder from the home page by using the TRx buttons.
  • Page 45 Production sequence 6.1.1 Switching on the MTS2 • Close all service doors and covers on the MTS2 and ZF-MTS2, and release the emergency stop buttons, if necessary. • Switch on at the main switch on the ZF-MTS2 column. • Press the "START" button.
  • Page 46 6.1.4 Switching the MTS2 off After ending production: • Stop the MTS2 • Turn off the ZF-MTS2's main switch on the column, if there is one present. • Turn off the main switch on the MTS2's electrical cabinet. Entering the product data 6.2.1...
  • Page 47 6.2.2 MTS2 with FVA (optional) • In the "Production selection" menu (see page 38), correct the page count received from the LineMaster (LIM) if the thickness varies significantly due to supplements. • In page 1 of the "Sheet settings" menu, enter the sheet length and sheet width.
  • Page 48 Emergency stop button, door safety switch Pressing the emergency stop button or opening a service door or cover on the MTS2 or ZF-MTS2 stops the MTS2 and the ZF-MTS2 immediately. The horn sounds, and the lower orange signal lamp on the indicator column and the "ERROR"...
  • Page 49 Topsheet producer DBH DBH with "Microplex" For printer settings please refer to the printer manual. 7.1.1 Loading paper Two paper feeders are used for an uninterrupted printing process. When the paper in one of the feeders runs out, the printer automatically switches to the other feeder.
  • Page 50 Procedure: - Open the printer cover. - For the lower feed, release the latching lever (1) and pull the paper feed right out. - Open the tractor cover (2) on the paper feed. - Take care not to actuate the micro-switch (3) when loading the paper.
  • Page 51 7.1.2 Paper jam, remove paper Procedure: - Switch off the printer; this releases or raises the thermal head. - Open the tractor cover (this is only possible on the upper feed) . - Push the red lever (1) in the direction indicated by the arrow and at the same time pull the paper backwards out of the...
  • Page 52 Operating the DBH The DBH is powered by the MTS, so it does not have its own main switch. It is switched on automatically together with the MTS and ZF-MTS2. Optional Button Function Description STOP No function, since the DBH is controlled by the MTS.
  • Page 53 Indicator lamp display: Orange signal lamp: Conveyor fault Optimising the bundle height When the topsheet is applied, the plunger should not touch the bundle, but should take the sheet as close as possible to the bundle. Parameters can be used to optimise this setting. Procedure: •...
  • Page 54 Operating the accumulation belt (BPR) Button Function Description Immediately stops a BPR that is running. As a STOP result, the upstream machines (e.g. MTS) switch to "Overflow" (or possibly bundle diversion). The BPR is ready and accepts bundles arriving START from the upstream machine =>...
  • Page 55 • If, when the error is rectified, no emergency stop buttons are pushed in and no protective doors or covers are open, the MTS2 reverts to "Started" status. • If the emergency stop button was pushed in or a protective door or cover was opened to rectify the error, the MTS must be restarted as after an emergency stop.
  • Page 56 Common faults Fault Possible causes Remedy Machine stops or Emergency stop button • Release the does not start pressed and/or emergency stop service door open button • Close the service door Conveyor was ASA jam switch has • Remove the paper. stopped by MTS tripped.
  • Page 57 Strapping machine Accumulation belt (BundlePacer type) Instruction manual Control Panel Topsheet producer Double roller pressing unit Control system Automatic format adjuster Light-emitting diode Higher-level control MTS2 MultiStack Skewed copy detector Conveyor TR-ST Conveyor controller ZF-MTS2 Feeder to MultiStack 39012123.001 Appendix...
  • Page 58 9.1.2 Reference documents Machine type Type of manual Instruction manual for the MultiStack ZF-MTS Instruction manual for the feeder Operating instructions for the controller Instruction manual for the topsheet producer 58 / 59 Appendix 39012123.001...
  • Page 59 Elekt. Prüfkleber ISO 9001 ISO 9001 Preventive maintenance service: FERAG offers a number of different services. Please contact our Service department in Hinwil, Switzerland. Training courses FERAG offers training courses for your technicians, either at FERAG in Hinwil, Switzerland, or at your company premises.

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