GBC Stl1000 User Manual
STL1000 OPERATING
INSTRUCTIONS
GBC IS AN ACCO BRANDS COMPANY
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GENERAL BINDING
CORPORATION
AUTOMATED FINISHING
DIVISION
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. Spool and Supply Chute Loading the Spool……………………………….14
7. Spool and Supply Chute Adjusting the Supply Chute………………...…16
8. Feed and cut Feed Wheel Guide Adjustment…………………………..….17
9. Feed and Cut Height and Width Adjustment of Guides……………..…..18
10. Loading Area…………………………………………………………………..…19
11. Book Transport Area……………………………………………………….…..20
12. Closing Area…………………………………………………………………...…21
13. Closing Height Adjustment……………………………………….……….…..23
14. Loading the Book…………………………………………………..………...…24
15. Air Solenoid Explanation……………………………………….…………..…26
16 Troubleshooting Guide…………………………………………..……….……27
17. Maintenance Requirements…………………………………….……….……33
18 Exploded Assembly and Parts List………………………………….….…..36
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19 Exploded Assembly and parts list conveyor………………..……….……63
20. STL- 1000 Field Problem Report Form……………………………..……… 69
21. Electrical Diagram………………………………………………………………70
22 Electrical Parts Layout…………………………………………………..….…72
NOTES………………………………………………………………………….…75
FOR YOUR SAFETY
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.
The Safety Alert symbol precedes each
safety message in thi s manual. This symbol
indicates a potential safety hazard that
could injure you or others, as well as cause
product or property damage.
This safety message means that you could be
seriously hurt or killed if you open the electrical
enclosure and ex pose yourself to hazardous voltage:
This safety message means that your hands could be
crushed and cut if you place your hands in the area of
moving parts:
The following ISO and IEC symbols appear on this
product.. Their meaning is:
“I” means Power On
“O” means Power Off
“ ! “ means emergency stop
“ o “ means dereel
Do not connect electrical power to the STL1000 or
attempt to operate it before reading this Operators
Manual or you have been fully trained as an operator.
Save the operator’s manual for future
use and referral.
Keep hands, long hair, neckties, and loose
articles away from moving parts.
Never override or attempt to defeat electrical or
mechanical interlock devices
Never insert objects or spill liquids into the
STL1000. They may contact dangerous voltage
or short out components, resulting in fire or
dangerous shock.
Connect the STL1000 only to the electrical
supply shown in the machine specification
section of this manual and the Serial/Rating label
on the equipment. Connect to a power outlet
installed near the equipment and easily
accessible.
Connect the plug only to a matching receptacle,
contact a qualified electrician to have one
installed.
Turn the STL1000 power “Off” (O) at the end of
each day.
Do not attempt to service the STL1000. Contact
an authorized GBC service representative if any
of the conditions listed below are encountered:
Marty Moore
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?? 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.
?? ONLY A TRAINED, QUALIFIED TECHNICIAN SHOULD
SERVICE THIS MACHINE.
?? DO NOT ATTEMPT SET-UP CHANGES UNLESS
FULLY TRAINED.
?? FOLLOW ALL STATE, LOCAL AND FEDERAL POWER
LOCKOUT / TAGOUT STANDARDS WHEN SERVICING
THIS EQUPIMENT.
?? HAVING MACHINE UNDER POWER WHILE MAKING
ALTERATIONS CAN RESULT IN SERIOUS BODILY INJURY.
ALWAYS DISCONNECT ELECTRICAL POWER AND AIR
SUPPLY BEFORE MAKING ALTERATIONS.
?? NEVER OPERATE MACHINE WITHOUT ALL GUARDS
IN OPERATING POSITION.
?? SAFETY GLASSES SHOULD BE WORN AT ALL TIMES WHEN
OPERATING THIS MACHINE OR MANUALLY CLIPPING WIRE.
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. 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
th ere . 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.
1.3 Cut the banding material securing the output conveyor to the shipping skid. Remove
conveyor from shipping skid and move to the location where the STL1000 is to be located
in your facility .
1.4 There are four bolts securing the STL1000 to the shipping skid (REF. FIG. 1A). These
bolts are located one in each foot pad of the STL1000. Use a ¼” Allen wrench to remove
these bolts and discard.
1.5 Locate the orange colored foot pedal secured to the shipping skid. Remove the fasteners
that secure the foot pedal to the skid and discard fasteners. Place foot pedal on the table
top of the STL1000 . CAUTION: Make sure the foot pedal will not fall off the table
top. It may damaged by falling.
1.6 Refer to fig._1A_ for fork lift points of the STL1000. Using a fork lift with a lift capacity of
700kg/2000lbs. , lift the STL1000 from the shipping skid and transport it to the operating
location.
1.7 Have your electrician hook up the appropriate power requirements. Refer to section 3 of
this manual to find the right requirements for your machine CAUTION DO NOT
APPLY POWER TO THE STL1000 !! A GBC technician will check to insure proper
power is present when installation is scheduled . YOU WILL VOID YOUR
WARRANTY IF YOU APPLY POWER.
1.8 You will need to supply compressed air to the STL1 000. Refer to section 3 of this manual
for minimum air requirements . A quick connect is supplied on the air regulator located on
the rear of the machine..
1.9 Be sure that you have TWIN LOOP WIRE and enough prepunched books to run your
machine for at least one hour . Please contact your sales representative if you have any
supply needs.
1.10 Contact GBC National service to schedule a technician to complete your installation.
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2. About this Manual REV. 1
2.1 General
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.
2.2 Document Control
It is intended that future revisions of this document will be published, please refer
to the revision number on the top of this page to determine the most recent.
2.3 Problem Solving
The path for solving problems with the STL-1000 should proceed in the following
sequence:
1) Find the description of the problem in the table in section 16
2) Evaluate the list of possible causes for the probable one.
3) Proceed to the referenced section (see 4 ) for further diagnosis. Part
replacement instructions (section 18 or 19) or adjustment instructions
(section 6 thru 14 ).
4) If problem is not properly described in the problem column of the
troubleshooting tables of section 16, reread the Theory of Operation
(section 4 ) for insight.
5) If the problem is unsolved call for support with a clear description of the
problem and the results of any unsuccessful solution you have tried.
6) Fill out and Fax the Problem Report Form (section 20 ) after solving
the problem. A strong feedback loop from service personnel is the best
way to improve the design and manufacturing of our products.
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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 1.42M x 1.27M ).
Smallest doorway machine will fit through 40” (1.016M) wide (with the removal of the
spool holder assembly). NOTE: This unit should only be removed by a GBC service
tech.
Recommended work area: 10 ft. x 10 ft. (3.05M x 3.05M).
Shipping: 65” x 91” x 60” high (1.65M x 2.31M x 1.52M).
3.2.2 Weight
Weight (machine only): 1200 lbs. (545.6Kgms.)
Shipping weight: 1350 lbs. (613.6Kgms.)
3.3 Electrical Power
2.3.1 Voltage 2.3.2 PHASE 2.3.3 Current 2.3.3 Short circuit interrupt
220 VAC, 60Hz 3 15 amps capacity: 2000 A
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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: 1999
3.8 Productivity
3.8.1 Cycle Time
The time the system takes to bind a placed document until it is ready to accept the
next document, independent of the operator, is dependent on the specified length
of the Twin Loop element.
The STL-1000 is capable of up to 1,000 books per hour.
3.8.2 Throughput
The number of documents produced in a given time period depends on element
length, document punching quality, but most importantly operator proficiency.
3.9 Book Thickness
3.9.1
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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 ).
3.9.3 Book Width
The STL-1000 is capable of transporting books with the unbound edge width of 3 ½’
(85.75mm )to 12’ (304.2mm ).
3.9.4 Hole Quality
The holes must be pre-punched in the paper and be of 2 to 1 or 3 to 1 punch pattern.
The quality of the holes has a direct relationship on the success of the operators ability to load
books on to waiting Twin Loop elements. Cleaner , crisp holes that align well from
one page to the next will speed up the process of loading books on to the STL-1000.
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4. Theory of Operation of the STL-1000
Conditions at Power up of the STL-1000
1. 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.
2. 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. Series of events after the depression of the foot switch (FS).
A. X6 on the P.L.C. will illuminate.
B. Y2 to energize Sol-2 (pusher) to advance book to closing area.
C. Y6 to energize 1CR to turn on 1M (feed motor) to feed element to be cut.
D. Y10 to energize 3CR to turn on 3M (belt) to advance element is cut.
2. During element feed cycle:
A. Either the signal from X4 (count prox 2:1) or X10 (count prox. 3:1) will be used
to count the number of element legs to the number entered into the keypad.
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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. Series of events during the book transport and closing cycle:
A. After pusher has advanced LS-2 (forward 1) will close and illuminate X1 on the
P.L.C.
B. Y5 will energize Sol 1 (door) closing doors on the closing area guard. This will
also open IS-2 at X13 and close IS-2 at Y3. (NOTE: IS-2 has two sets of
switches in one housing).
C. Y3 energizes to fire Sol-3, which charges the closing air cylinder to actuate the
closing ram to full down stroke.
D. When the ram reaches its full down stroke LS-3 (close) actuates and illuminates
X2 on the P.L.C. and releases Sol-3 through Y3 to let the ram return to its home
position. NOTE: Home position is fully up.
E. Sol -1 is deenergized through Y5, which opens the guard doors.
F. Sol -2 is deenergized through Y2. The pusher returns home and actuates LS-1,
which illuminates X0 on the P.L.C.
G. Y11 energized 4CR (conveyor 4M) to advance conveyor to a predetermined
distance through an entry from the keypad.
Conditions on a Need Basis
1. Dereel Unit
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