STL1000 OPERATING INSTRUCTIONS GBC IS AN ACCO BRANDS COMPANY
GENERAL CORPORATION AUTOMATED DIVISION BINDING FINISHING STL-1000 SEMI-AUTOMATIC TWIN LOOP BINDER 60 Hz. SERVICE MANUAL REV 1.0 Section: pg. Table of contents………………………………..………………………..……..…..…1 1. Installation and setup preparation………………..…………..…………..…2 2. About this Manual……………….………………………………………………,,,,4 3. Specifications…………………………………………………………………......5 4. Theory of Operations…………………………………………………………….8 5. Operating instructions for keypad……………………..……………….……11 6.
19 20. 21. 22 Exploded Assembly and parts list conveyor………………..……….……63 STL- 1000 Field Problem Report Form……………………………..……… 69 Electrical Diagram………………………………………………………………70 Electrical Parts Layout…………………………………………………..….…72 NOTES………………………………………………………………………….…75 FOR YOUR SAFETY “ o “ means dereel Marty Moore Your safety as well as the safety of others is important to us at GBC. In this Service Manual and on the STL1000 itself are important safety messages. Please read these message carefully.
?? Liquid has been spilled into the STL1000 has been exposed to rain or water. ?? STL1000. ?? The STL1000 has been dropped, bumped, or dented. ?? The product does not operate normally when following the operating instructions. WARNING: SUPERVISORS PLEASE NOTE: THESE PRECAUTIONS MUST BE FOLLOWED WHEN OPERATING OR SERVICING THIS MACHINE. ?? ALL OPERATORS MUST BE PROPERLY TRAINED PRIOR TO USING THIS EQUIPMENT. ?? READ INSTRUCTION MANUAL BEFORE OPERATING OR SERVICING THIS MACHINCE.
. KEEP HANDS AND LOOSE CLOTHING AWAY FROM ALL MOVING PARTS. 1. Installation and setup Preparation Use this section to properly unpack ,set into place, and setup the STL1000. 1.1 Inspect the shipping container for any visible damage while the trucking company is still there . If you see any damage, file a damage claim with that trucking company immediately . Otherwise you may be responsible for any needed repairs. 1.2 Remove the cardboard slip cover and dispose of in accordance with local regulations. 1.
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2. About this Manual 2.1 General REV. 1 This manual is intended as a training and reference document for persons responsible for installation, service and maintenance of the STL-1000 binder. It is assumed the reader has basic mechanical and electrical troubleshooting abilities. This Service Manual, revision ( A ), covers 220 Volt, 3 Phase, 60 Hz STL-1000, version _1 system. 2.
3. Specifications Use this section to determine proper installation requirements as well as the capabilities of the STL-1000. 3.1 Purpose The STL-1000 is designed to automatically supply spool fed Twin Loop elements cut to a specified length and is automatically staged for the next book to be bound. Operator hung pre-punched documents are transported to the closing area, bound and are transported from the bind area to a stacking conveyor. 3.1.1 Dimensions Machine only: 85” L x 56” W x 50” H (2.16M x 1.
3.4 Compressed Air 8 cfm at 80 psi ( 227L/min @ 522K Pa ) 3.5 Environment Ambient air temperatures, 41 degrees F to 104 degrees F. ( 5 degrees C to 40 degrees C.) Altitude rating, up to 3280 feet ( 1000 meters ). 3.6 Noise Generation TBD 3.7 Initial Year of Manufacturing: 3.8 Productivity 1999 3.8.
The STL-1000 can successfully bind documents within the capacity of each given Twin Loop element size. Use the element size chart supplied by your Twin Loop sales representative to determine the appropriate element for the book to be bound. If book size is at the maximum for a given size use the next larger size to insure quality closure of the bound book. 3.9.2 Bind Length The STL-1000 is capable of a book bind length of a minimum of 3 inches (76mm ) and with a maximum of 13 inches (330.2mm ). 3.9.
4. Theory of Operation of the STL-1000 Conditions at Power up of the STL-1000 1. 2. Closing guard must be closed to actuate the closing guard interlock switch IS-1. IS-1 has two switches in one housing. A. One side of the IS-1 breaks main power to the E-stop. B. The other side of IS-1 is used to monitor 24 volts to the P.L.C. at X7 Which shouldn’t be illuminated. P.L.C. is in ready condition should have at least X0, X13 and Y12, or Y13. Conditions After Power up of the STL-1000 1. 2.
B. Once the entered number is reached Y6 (feed 1M) is turned off. C. Y4 energized Sol-4 (cut) which charges the air cylinder to swing the knife and drop the pawl into the element stop gear to stop rotation of the element feed shaft. At this point the feed shaft should be stopped so the knife can cut a stationary element. Through P.L.C. timer Sol-4 is deenergized through Y4 to release the knife and pawl. Conditions After Power up of the STL-1000 (Continued) 3.
A. When dereel switch is on auto, spool prox X3 illuminates when no element is present Y7 illuminates to fire 2CR which turns on 2M (dereel). B. 2. When dereel switch is on manually pressing the green button will illuminate X15 then Y7 on the P.L.C. to turn on 2CR (dereel) which turns on 2M. Pitch Selection A. When pressing 2:1 on the keypad Y12 on the P.L.C. will illuminate and fire Sol-5 to change the air cylinder to shift the feed sprocket. At this time X4 on the P.L.C.
5. STL-1000 OPERATING INSTRUCTIONS FOR KEYPAD MAIN MENU When you first power up the machine you should see the following two lines on the Keypad. B.COUNTER SETUP MENU 0 0 ( any number may appear) Line 1: “B. COUNTER:” = Batch Counter. This counter will count the number of books, which are bound on the STL1000 and display a running total. To reset this counter, use the ? arrow key to move the cursor over. When blinking, key in “0” from the numeric section of the keypad then press “ENTERS”.
Use the numeric keypad to key in the number of desired loops and press “Enter”. The range of amount of loops is limited from five (5) through forty-two (42). Line 2: “CONVEYOR STEP:” = The amount of travel desired on the Output conveyor. Use the numeric keypad to key in the amount of desired travel and press “ ENTER”. The range of travel is limited to one (1) through six (6) inches.
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6. Spool and Supply Chute Loading the Spool When viewing from the back of the machine, the spool of Twin Loop wire will rotate in a clockwise direction (See figure 6-1). For loading a new spool, the following steps are recommended: 1. Place the spool onto the two rollers with the wire unspooling from the top of the spool. 2. Make sure the end boards of the spool are riding between the flanges of the idler roller (See Figure 6-2). This will place the end boards on the knurled portion of the drive rollers. 3.
SPOOL AND SUPPLY CHUTE LOADING THE SPOOL (CONTINUED) 4. Lay the wire inside the storage chute and thread the scrap paper between both drive rollers and wind it up on the scrap take-up spool in a counter-clockwise direction (See Figure 6-3). Notes: 1. The scrap paper should be wound taunt to prevent it from breaking when the spool drive starts up. 2. The storage chute has a sensor at the bottom to control the spool drive.
7. Spool and Supply Chute Adjusting the Supply Chute The supply chute is designed to be used in three different positions (see figure 7-1). The upper position is for larger size wire -1” and 1 ¼”. The middle position is for medium sizes 9/16” through 7/8’. The lower position is for the small size wire - ¼” through ½”. The smaller sizes need more weight inside the supply chute to prevent the wire from unspooling on the bottom side of the spool.
8. Feed and Cut Feed Wheel Guide Adjustment The outboard guide on the feed wheel (see Figure 8-1) should be adjusted so that there is approximately 1/16” (.06) clearance for the wire. Make sure the outboard guide does not rub against the feed wheel. See figure 8-1 for the correct orientation of the wire.
9. Feed and Cut Height and Width Adjustment of Guides The upper and side guides should be adjusted so that the Twin Loop wire will travel back and forth freely (see Figure 9-1) but without too much room to move around. The following steps are recommended: 1. Cut a 12” long piece of Twin Loop wire element from the supply chute and use it as a set-up Sample. 2. Loosen the two adjustable handles for the upper guide and the side guides (see Figure 9-1). 3. Insert the 12” long sample as shown in Figure 9-1. 4.
FEED AND CUT HEIGHT ADJUSTMENT OF CUTTING BLOCK Using a 5/32 hex key, loosen the two (2) screws which secure the cutting block (see Figure 9-1). Adjust the height of the cutting block to allow the Twin Loop wire to pass freely under it. Tighten the screws to secure the cutting block. Note: The height of the cutting block must be adjusted for each wire size. The set-up of the feed area is now complete. To double check, insert the 12” long sample piece again, into the guides.
make it easier to load the book. Tighten the two adjusting knobs to secure the wire holder. Load book onto element and adjust rear rail in the book loading area. To adjust, loosen adjusting screws and slide up to book loosely. Tighten adjusting screws. 11. Book Transport Area At this time, check to see if the pusher will hit the rear rail or be pushed down because of rear rail interference (see figure 11-1).
12. Closing Area Adjusting the closing rail (For the following see figure 12-1). 1. Open closing guard and prop open with prop rod. 2. Loosen the adjusting screws, which secure the closing rail located in front of the closing area And slide toward the front of the machine.
3. Close the closing guard. 4. Twist the red emergency stop button located on the front of the machine to supply power to the machine. 5. Using the hand wheel on the upper right hand side of the closing head, turn hand wheel until the indicator points the proper wire size to be closed. 6. Push the pusher advance/home button on the control panel and advance the book under Closing ram (a red light will illuminate above button). 7. Open closing guard. 8.
13. CLOSING HEIGHT ADJUSTMENT To adjust height of the closing ram, the following steps are recommended: 1. The pointer for the Twin Loop Size Gauge (see Figure 13-1) will move up or down. A hand wheel is provided on the right side of the closing area. This hand wheel is to be used to adjust the height.
2. The size gauge is used to accurately adjust the closing height. After closing a sample book, you may need to make further fine adjustments to get the proper closing of the wire. See figure 13-2 for proper closing of Twin Loop elements. 3. Never cycle the closing ram under power without checking the size gauge first. FIGURE 13-1 FIGURE 13-2 14. Loading the Book Books with 2-Piece Flush Cut Covers: Stack the books with the front covers up; rotate the back cover to the top (see Figure 14-1).
FIGURE 14-1 Pick up the two covers and the body of the book; jog it on the side with the binding edge down. The back page (not the back cover) should face the operator (see figure 14-2). Align the holes with the Twin Loop tines and lay the book toward you (see figure 14-3) and press the foot pedal to cycle the STL1000. FIGURE 14-3 Loading The Book (continued) Books With Oversized or Wrap-Around Covers: Due to its design, the STL-1000 is well suited for non-standard cover styles.
Load the body of the book (front) onto the Twin Loop tines, then load the covers (folded back to back) on the tines and push the foot pedal. 15. Air Solenoid Explanation This write up is to understand the location and function of the five air solenoids (see fig 15-1) on the STL1000.
To get to the solenoids to either replace or adjust, the rear panel must be removed. Once the panel is removed, the air solenoids will be before you, working left to right. Solenoid # 1 Guard Solenoid is responsible for opening for opening and closing guard doors to allow entrance and exit of books into the closing area . Solenoid # 2 Pusher is responsible for the transporting the book from loading station to closing area and to the conveyor.
PROBLEM PROBABLE CAUSE SOLUTION Dereel unit won’t run. Dereel switch on manual. Turn collar of dereel switch to auto. Dereel unit runs on. Wire not properly routed along supply shoot. Route wire from top of spool to supply chute and up to wire cutting unit. Make sure wire is routed to pass in front of prox switch located on the supply chute. Wire tangled with scrap paper. Adjust supply chute height to prevent wire from tangling with scrap paper. Check height of spool prox switch.
Feed sprocket not turning. Worm gear clutch pad. Needs adjustment or clutch pads need cleaning. Remove collar, spring, pressure collar, key and worm gear. Clean all parts with alcohol and reassemble. Adjust tension spring to full compression. Lockout pawl too low. With the air on, adjust height of lockout pawl and adjust with height adjustment nut to just clear lockout gear. Scrap paper tearing. Scrap paper take up spool. Adjust tension spring behind panel in line with paper take up spool.
Improper number of loops. (continued) Cut length’s tails uneven. PROBLEM Locking gear. Check screws in locking gear for tightness. Counting gear. Loosen setscrew on counting gear and slightly advance clockwise and test. Repeat until proper count has been achieved. NOTE: Disregard first element after each adjustment Counting prox sensor. Rotate counting gear and check for flashing light on the PLC. Inside the control box. Check x4 for 2:1 and x10 for 3:1.
Uneven wire closure. Anvil adjustment. Loosen two socket head screws at the back of the anvil. Adjust anvil with the two hex head bolts underneath the anvil to achieve even end to end closure. NOTE: Tighten socket head screws after each adjustment to insure accurate closure. Also tighten jam nuts on the hex head after final adjustment. Wire closing with an over or under bite. Table straps. Utilize one of two table straps to control over or under bite.
Pushers won’t advance when foot switch is depressed. (continued) LS1 home switch. Remove center panel on the tabletop (section 18 drawing 2 detail #23). Located LS1 on the left side of the air cylinder Loosen the clamp, which secures LS1 to the air cylinder. Slide LS1 to the left or right until the LED on LS1 illuminates. Tighten clamp to secure to air cylinder. Depress foot switch and test for a completed cycle. Replace tabletop. Pushers advance then stop. LS2 needs to be adjusted.
Pushers advance, safety Door switch IS2. doors close, cycle stops (continued) This adjusting screw located on the exit door is used to set IS2, which completes the circuit for PLC numbers, X13 and Y3. X13 must be illuminated before Y3 circuit can be completed. Pushers advance, safety Book thickness. doors close, closing head comes down and machine cycle stops. Failure to adjust closing unit height. Book is too thick and not letting the closing ram make LS3. LS3 needs adjustment.
1. EMPTY WATER SEPARATOR DAILY A. To empty water separator, loosen bleeder valve located on the bottom of the water separator. 2. 3. CHECK AIR LINE OILER WEEKLY A. Fill only with a good quality air tool oil. B. To fill with air tool oil: 1) Disconnect air supply. 2) Remove oil reservoir cup by turning a 1/4 turn, and then pull cup downward. 3) Fill reservoir with good quality air tool oil to max line. 4) Install oil reservoir. 5) Connect air supply. OIL PUSHER AXLES BI-WEEKLY A.
direction after all of the water has drained. NOTE: a ¼ inch soft nylon tube can be attached to the end of the drain so that the water can be emptied into a container. The regulator portion (see figure 17-1) of the FRL is used to regulate the air pressure being supplied to the machine. The proper setting is 80 PSI. To adjust the pressure, pull the regulator knob down and turn clockwise to reduce the pressure and turn counter-clockwise to increase the pressure. Push the knob back up to lock it into position.
The only wear item in the feed area is the knife blade (see figure 17-2). If the wire has a burr on it after cutting, or, if a groove has worn into the cutting edge of the knife, it is time to rotate the blade. The knife blade has four cutting edges on it. To switch to a new cutting edge, the following steps are recommended: A. B. C. D. E. F. G. Disconnect air and electrical power from the machine. Remove feed cover. Using a 5/32” hex key, loosen and remove the two screws, which secure the cutting block.
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