Duplo DF-520 User manual

Duplo Folder

Please let our service people install the machine.

Instruction Manual

[230V]

1. Easy to Use

• Automatic detection of paper size (A3 to B6).

• A one touch function automatically returns the folding

stopper and stacker to their proper positions.

2. Enhanced Basic Performance

• Folding speed of 45 to 120 sheets/min.(B4, 64g/m

2

,

single fold).

• Loading capacity of the paper feed table: 500 sheets (B4

64g/m

2

)

• Paper thickness: 52.3 to 157g/m

2

3. Various Memory Functions (Standard)

• Correction memory function for fixed folding (36

types).

• Registration of custom folding methods (MAX 2

memories).

4. Standard Folding of Non-standard

size Paper Can be Carried Out Easily

by Inputting Their Size on the

Keypad.

(Paper length folding mode)

5. Various Types of Paper (Art/Coated

Paper) Can be Folded by Easy

Operation.

6. Various Functions (Standard)

Ensuring Folding Accuracy and

Usability

• Test folding can be carried out.

• The counter display can be used for additions and

subtractions.

• A slant correction device is installed to straighteng

paper.

• Cross folding can be carried out.

FEATURES OF DUPLO FOLDER

1

INTRODUCTION

Thank you for your purchase. To ensure correct usage, please read this instruction manual

thoroughly, especially the section Safety Precautions. After reading, please store this instruction

manual in a safe place for future reference.

CONTENTS

1. SAFETY PRECAUTIONS...................... 2

2. USAGE PRECAUTIONS ....................... 4

2-1. POWER SUPPLY .......................................4

2-2. OPERATING ENVIRONMENT ...................4

2-3. STORAGE CONDITIONS...........................4

2-4. MAINTENANCE..........................................4

3. INSTALLING THE UNIT ........................ 5

3-1. BEFORE INSTALLATION ..........................5

3-2. INSTALLATION LOCATION.......................5

3-3. POWER SUPPLY .......................................5

3-4. COMPONENT PARTS ...............................6

3-5. REMOVING THE PRESS RELEASE

LEVER ........................................................7

3-6. ATTACHING THE PARTS..........................8

4. NAMES OF THE PARTS..................... 10

5. NAMES AND FUNCTIONS OF THE

CONTROL PANEL PARTS................. 11

6. PRECAUTIONS BEFORE USE........... 13

6-1. PAPER TO BE USED...............................13

6-2. PRECAUTIONS FOR STACKING

PAPER......................................................13

7. OPERATION PROCEDURES.............. 15

7-1. STANDARD FOLDING OF STANDARD

SIZE PAPER.............................................15

7-2. SINGLE FOLDING THICK PAPER...........21

7-3. DOUBLE FOLDING THICK PAPER .........22

7-4. CUSTOM FOLDING OF STANDARD

SIZE PAPER.............................................25

7-5. CALLING THE MEMORY .........................30

7-6. SWITCHING THE MODE USED. .............30

8. FOLDING ADJUSTMENTS AND

MEMORIZE CORRECTIONS .............. 32

8-1. ADJUSTMENT THE FOLDING SLIPPAGE

IN THE VERTICAL DIRECTION...............32

8-2. MEMORIZE THE FOLDING STOPPER

CORRECTION..........................................34

8-3. ADJUSTMENT THE FOLDING SLIPPAGE

IN THE HORIZONTAL DIRECTION .............36

9. USING ART/COATED PAPER............ 37

9-1. PRECAUTIONS FOR STACKING

PAPER......................................................37

9-2. OPERATING PRECAUTIONS..................38

10.USING NON-STANDARD PAPER

SIZE ..................................................... 40

10-1. STANDARD FOLDING PROCEDURE .....40

10-2. CUSTOM FOLDING PROCEDURES....... 42

11.CROSS FOLDING ............................... 47

11-1. PRECAUTIONS UPON USE ....................47

11-2. CROSS FOLDING STANDARD

SIZE PAPER.............................................48

11-3. CROSS FOLDING NON-STANDARD

PAPER SIZE.............................................50

12.TROUBLESHOOTING......................... 53

12-1. PAPER IS JAMMED NEAR THE PAPER

FEED RING .............................................. 53

12-2. PAPER IS SLIPPED NEAR THE PAPER

FEED SECTION ....................................... 54

12-3. PAPER IS COILED AROUND THE

RUBBER ROLL INSIDE THE UNIT..........54

12-4. PAPER IS JAMMED AT THE FIRST

FOLDING PLATE .....................................55

12-5. PAPER IS JAMMED AT THE SECOND

FOLDING PLATE .....................................56

12-6. PAPER IS JAMMED NEAR THE

STACKER.................................................58

13.EMERGENCY STOPS......................... 59

14.ERROR MESSAGES........................... 60

15.TROUBLE SHOOTING GUIDE ........... 62

16.CLEANING THE UNIT......................... 65

16-1. CLEANING THE RUBBER ROLL............. 65

16-2. CLEANING THE PAPER FEED RING .....66

17.SPECIFICATIONS............................... 67

2

WARNINGS:

Do not place metal objects or vessels containing liquids on top of the unit. The entry of

any metal object or liquid could result in fire or electrical shock.

Do not insert any metal or easily combustible object inside this unit. This could result in

fire or electrical shock.

Do not touch or insert foreign objects into any rotating part during operation. This could

result in injury.

Do not remove the cover or back panel. This unit contains high-voltage components that

could cause electrical shock.

Do not disassemble, modify or repair this unit. There is danger of fire, electrical shock or

injury. Contact your dealer when repairs are necessary.

Use only the power supply voltage specified on the main nameplate. Using other voltages

could result in fire or electrical shock.

Keep this unit and the power cord away from heaters and heater vents. Excessive heat

could melt the cover or power cord covering and result in fire or electrical shock.

Always observe the cautions and warnings explained below to prevent personal injury or

property damage.

The degree of danger and damage that could occur is indicated in two levels by the

following marks.

WARNING: Ignoring this mark could result in the possibility of serious injury

or even death.

CAUTION: Ignoring this mark could result in the possibility of injury or

physical damage.

The following graphic symbols indicate the various types of actions to be

performed or avoided.

This graphic symbol indicates a forbidden action.

means “Do not disassemble.”

means “Do not touch.”

This graphic symbol indicates actions that must be performed.

means “Disconnect the power plug.”

This graphic symbol indicates a “Caution” that must be observed.

means “Caution: high temperature.”

1. SAFETY PRECAUTIONS

3

Do not use flammable sprays inside or near the unit (e.g. when cleaning the unit).

Such flammable gas can be ignited and cause a fire or combustion.

Make sure that the current consumption listed on the main nameplate does not exceed

capacity rating of the power outlet and do not connect other equipment to this same

power outlet. Connecting other equipment could cause the power outlet to overheat and

catch fire.

Remove any dust that accumulates on the power plug prongs and the surface from

which the prongs extend. Accumulated dust can result in fire.

If any foreign object such as metal or liquid should enter this unit, immediately turn off

the power switch and disconnect the power plug from the power outlet. Failure to do so

could result in fire or electrical shock. Contact your dealer immediately.

Do not damage the power cord or power plug. (Do not scratch, alter, bend, twist, pull or

place heavy objects on the power cord or power plug.)

This could result in damage, fire or electrical shock.

Always grip the plug when disconnecting the power plug from the power outlet. Pulling

on the power cord could cause damage, resulting in fire or electrical shock.

Do not handle the power plug with wet hands. This could result in electrical shock.

Before cleaning this unit, turn off the power switch and disconnect the power plug from

the power outlet. Accidental operation of the unit during cleaning could result in injury.

CAUTIONS:

Always disconnect the power plug from the power outlet when this unit is not to be used

for an extended period. Failure to do so could result in fire due to leakage current if the

insulation should deteriorate.

Install this unit on a level, stable stand or floor, with sufficient space around it. Failure to

do so could result in the unit overturning and injury.

Do not install this unit in a location where there is excessive humidity or where contact

with water is possible. Failure to do so could result in deterioration of the insulation, fire

or electrical shock.

Disconnect the power plug from the power outlet before attempting to move this unit.

Failure to do so could result in power cord damage, fire or electrical shock.

4

2. USAGE PRECAUTIONS

+6%

2-1. POWER SUPPLY

Make sure the power supply used is always within the following range.

230V AC

-10%

, 50Hz

Plug the power cord plug directly into a wall power outlet.

2-2. OPERATING ENVIRONMENT

Operate this unit in the following environment.

• Temperature range: 5 to 35 °C

• Humidity range: 20 to 80% RH (no condensation)

• Avoid locations with direct sunlight

• Avoid dusty locations

• Avoid locations with vibration

• Avoid locations that are salty

• Avoid locations with special chemicals

2-3. STORAGE CONDITIONS

Store this unit in the following environment.

• Temperature range: -5 to +45 °C

• Humidity range: 20 to 90% RH (no condensation)

• Avoid locations with direct sunlight

• Avoid dusty locations

• Avoid locations with vibration

• Avoid locations that are salty

• Avoid locations with special chemicals

2-4. MAINTENANCE

To protect the characteristics of this unit, the customer should never supply oil or grease

to the parts (except when the customer is specifically requested in this instruction

manual).

Please contact your dealer in case of any problem.

5

3. INSTALLING THE UNIT

The customer should never install the machine. Please be sure to ask your dealer for

installation.

3-1. BEFORE INSTALLATION

• Turn the power of this unit off, and disconnect the power cord from the power outlet.

• Make sure that the voltage and frequency in the area to be used correspond with the unit’s

specifications.

3-2. INSTALLATION LOCATION

• Install on a base which can bear the machine’s weight.

The weight is 33 kg.

• Install on a horizontal and flat ground.

• Avoid the side of any heating such as a heater.

• Place this unit in the following environment.

• Temperature range: 5 to 35°C • Humidity range: 20 to 80%RH (no condensation)

• Avoid locations with direct sunlight • Avoid dusty locations

• Avoid locations with vibration • Avoid locations that are salty

• Avoid locations with special chemicals • Avoid locations that splash

3-3. POWER SUPPLY

• Make sure the power supply used is always within the following range.

• 230V AC

-10%

, 50Hz

• Plug the power cord plug directly into a wall power outlet.

• When using the same power outlet together with other elctrical products, make sure not to

over the capacity of power supply.

The fixed current is 0.5 A.

+ 6%

6

After checking that you have following parts, attach them to the unit.

1

2

3

3. INSTALLING THE UNIT

3-4. COMPONENT PARTS

No.

Name Qty.

1

2

1

3

4

1

No. Name Qty.

First folding plate

Second folding plate

Cross folding lever

Instruction Manual

4

DUPLO CORPORATION

Duplo Folder

Please let our service people install the machine.

Instruction Manual

7

3-5. REMOVING THE PRESS RELEASE LEVER

This press release level is attached to the unit at shipment to prevent the rubber roll from

becoming distorted.

Be sure to remove it when installing the unit.

Take note that the unit will be damaged if it is used without removing the lever.

Remember to remove it in the following order when installing the unit.

1 Two press release levers are inserted

in the left and right shaft edges of the

rubber roll.

2 First, remove press release lever(A).

• To remove, push inwards and pull out the press

release lever, as shown in the figure.

Next, pull out press release lever(B)

as shown in the figure.

Also remove that of the operating side in the

same way.

Press release lever(B)

Press release lever(A)

Press release lever(B)

<Non-operating side>

Press release lever(A)

Press release lever(B)

3. INSTALLING THE UNIT

8

1 First, attach the second folding plate.

• Before starting, push the lock lever at the side of

the folding plate to “UNLOCK”.

• Next, insert the folding plate into the unit.

• After inserting it properly, push the lock lever to

“LOCK”.

2 Secondly, attach the first folding

plate in the same way.

* If the paper jams inside the folding plate, turn off

the power supply, pull out the control cord of the

folding plate, push the lock lever to ''UNLOCK",

and remove the folding plate.

3 After attaching the folding plates,

connect the control cord of the first

folding plate to connector No. 1 and

that for the second folding plate to

connector No. 2.

Note 1: Be sure to insert the control cords

correctly.

Note 2: Be sure to turn off the power before

connecting/disconnecting the control

cords.

3. INSTALLING THE UNIT

3-6. ATTACHING THE PARTS

Second

folding plate

Lock lever

First

folding plate

Stopper

Control cord 1

Control cord 2

9

3. INSTALLING THE UNIT

4 Attach the cross folding lever at its

proper place.

Cross folding lever .................................................. 1

Note:

• The unit has a built-in battery to protect the different types of data memorized.

• This battery must be charged when installing the unit for the first time. To charge it, leave the power switch of the unit

on for about five hours.

• The battery will wear out when the unit has been left off continuously for about three months. Therefore turn on the

power occasionally to charge it.

• As data memorized and set will be lost when the battery has worn out, be sure to keep a copy of these data.

Cross folding lever

10

4. NAMES OF THE PARTS

Slant adjustment

knob

Paper separator pressure

adjustment dial

Paper feed ring

Paper receiving tray

Paper receiving

stopper

Stacker roller

Auxiliary paper

feed plate

Guide

Cross folding lever

Paper feed tray

Top cove

First folding plate

Control panel

Paper feed pressure

adjustment lever

Second folding plate

Power switch

Paper set lever

Paper feed ring

(For moving)

Rubber roll

Jam correction handle

Set knob

11

No.

Name Function

Start/stop button

Test button

Number of sheets/

paper length

switch button

Clear button

Number buttons

(0 to 9)

Folding mode

select button

Speed controller

First folding

stopper adjustment

button

Second folding

stopper adjustment

button

1

2

3

4

5

6

7

8

9

Starts/stops folding.

Each time this button is pressed, start/stop is repeated alternately.

Each time this button is pressed, the unit folds two sheets of paper and stops.

Sets the number of sheets to be folded and switches the input of the paper length.

The paper length input is memorized when it is set.

Press this button to change the number of sheets to be folded and the paper length.

Press these buttons to set the number of sheets to be folded and the paper length.

There are 6 types of standard folding methods and 2 types of custom folding methods

available.

When the power is turned on, the display lamp of the single fold mode will light up.

Each time the button on the right is pressed, the folding mode lamp display switches to

the right.

When the left button is pressed, it switches to the left.

The custom folding mode cannot be selected if no custom folding method has been

memorized.

The processing speed can be changed freely within the range of 45 to 120 sheets/min.

The processing speed increases as the knob is slid to the right and decreases as it is slid

to the left.

When the right button (+) is pressed, the folding stopper moves to the right.

When the left button (–) is pressed, the folding stopper moves to the left.

The stopper moves slightly each time the button is pressed, and continues moving

when pressed continuously until it is released.

When the right button (+) is pressed, the folding stopper moves to the right.

When the left button (–) is pressed, the folding stopper moves to the left.

The stopper moves slightly each time the button is pressed, and continues moving

when pressed continuously until it is released.

1

2

1234

5

67890C

0

12

1234561

bp

bo

bn

bm

blbk 9 8 7

6

54321

5. NAMES AND FUNCTIONS OF THE

CONTROL PANEL PARTS

12

No.

Name Function

Custom folding

preset button

Standard folding

adjustment button

Number of sheets/

paper length

display window

Paper size display

window

Standard folding

indicator

Custom folding

preset indicator

bk

bl

bm

bn

bo

bp

5. NAMES AND FUNCTIONS OF THE CONTROL PANEL PARTS

This button is used to memorize the position where the folding stopper and stacker

stop. When moved in custom folding modes such as cross folding, non-standard

folding, etc.

Data for up to two custom folding settings can be memorized. Once memorized, the

data is saved even after the power is turned off.

To erase the data, keep pressing the corresponding registration button (1) or (2) until

the buzzer sounds.

This button is used to memorize the adjustment value when the folding stopper is fine-

adjusted in the standard folding mode.

Up to 36 combinations (No. of standard folding modes x paper size) of adjustment

values can be memorized.

To erase the setting, select the folding mode of the corresponding paper size to be

delected and keep pressing this button until the buzzer sounds.

This display shows the number of processed sheets (counter), the paper length input

values, error messages, etc.

This display shows the size of paper set on the paper feed tray which is detected

automatically (standard sizes of A3 to B6).

Also shows the operation status “ ” when the paper length is input.

They indicate six types of standard folding modes.

The display lamp blinks when a mode memorized for folding fine-adjustment has been

selected.

This lamp lights up when the custom folding mode is set.

This mode cannot be selected if no custom folding method has been memorized.

13

• Straighten folded or curled paper before use.

• Make sure that the ink on the paper has dried up properly

before use.

If the ink has not dried properly, it may dirty the

machine, and cause other problems such as dirtying the

folded surface with ink, etc.

6. PRECAUTIONS BEFORE USE

6-1. PAPER TO BE USED

6-2. PRECAUTIONS FOR STACKING PAPER

• If the paper is not stacked neatly on the paper feed table,

the unit will not be able to read the size of the paper

accurately and as a result, may determine the paper as

outside the standard size. Therefore, be sure to stack the

paper neatly.

The paper feed table has a built-in device for reading

paper size.

Take note that this device will not be able to read the

paper size correctly if the paper is stacked unevenly.

This may as a result cause problems.

• Automatic paper size detection can be carried out for

paper up to ±2.5 mm of the standard size paper.

14

6. PRECAUTIONS BEFORE USE

• If the paper is not stacked properly lengthwise, mis-feed

or chain feed may occur.

• When stacking just a few sheets of paper on the paper

feed tray, lower the paper set lever while pressing the

back edge of the paper.

Paper

Guide plate

Paper set lever

• Adjust so that the front part of the paper touches the

paper feed ring in front lightly. (Arrow)

• The paper will be folded as shown in the figure if stacked

with the printed surface up on the paper feed tray.

• For “accordion fold” and “irregular accordion fold”, the

printed surface of some paper will be folded outwards.

Paper

Paper feed

rings

Single fold Brochure fold

Accordion fold

Letter fold

Irregular

accordion fold

Double fold

15

1 Insert the power cord in the electrical

outlet and turn on the power.

• Press “I” to turn on the power.

• Press “O” to turn off the power.

When the power is turned on, the folding

stoppers rollers on the folding plates and

stacker will move to their initial setting positions.

Wait for a few seconds for this to complete

which is indicated by the sound of the buzzer.

2 Raise the paper set lever and stack a

set of sheets on the paper feed tray.

• Loosen the fixing screws of the guide, and move

the guide slightly more than the width of the paper.

• Loosen the paper and stack sheets of paper neatly

on the paper feed table.

• Insert the paper until its front part touches the front

guide plate lightly.

3 After pressing the guide to the side of

the paper lightly, tighten the screws

to secure the guide.

• The left and right guides move in the same

direction.

Paper can be stacked to a height of

approximately 45 mm at one time. Do not

stack too many sheets paper.

4 Lower the paper set lever.

Start the various standard folding operations for standard size paper as follows.

7. OPERATION PROCEDURES

7-1. STANDARD FOLDING OF STANDARD SIZE PAPER

Power switch

Paper

Fixing screw

Paper set lever

Guide

Fixing

screw

Guides

Fixing screw

Guides

Paper set lever

16

7. OPERATION PROCEDURES

5 Press the “folding mode select”

button and select the desired fold

mode.

• When the right “folding mode select” button is

pressed, the lamp on the right of that currently lit

will light up.

• When the left one is pressed, the lamp on the left of

that currently lit will light up.

• If “custom folding” had been memorized

previously, “custom folding” modes 1 and 2 can be

selected by pressing these “folding mode select”

buttons. If no custom folding methods have been

memorized, the custom folding mode cannot be

selected and instead the standard folding mode will

be set.

6 Check the paper size display.

• When paper outside the standard size is used, the

size of the paper will not be detected automatically

and consequently not displayed.

When using such a kind of paper, refer to

“Using Non-Standard Paper Size” on page 40.

1

2

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12

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34

5

890C

17

7 Adjust the paper feed pressure

adjustment lever to “0”.

• If the paper slips and no paper is fed, raise the

paper feed pressure one level from 0 to 1.

• If several sheets of paper are fed at one time, lower

the paper feed pressure one level from 0 to –1.

When using art paper or coated paper, refer to

“Using Art /Coated Paper” on page 37.

8 Open the Top cover and adjust the

separator pressure adjustment dial to

“0”.

• If several sheets of paper are fed at one time, raise

the separator pressure adjustment dial from 0 to 1

or 2.

• Adjust the separator pressure by gradually

increasing the level 0.5 each time.

When using art paper or coated paper, refer to

“Using Art /Coated Paper” on page 37.

9 Close the Top cover and adjust the

speed controller for appropriate

folding speed.

7. OPERATION PROCEDURES

Paper feed pressure adjustment lever

Separator pressure adjustment dial

1

2

12

67

12

18

7. OPERATION PROCEDURES

10 Press the “test” button and perform

test folding.

• Two sheets of paper will be folded.

Even after two folded sheets of paper have

been ejected, the machine will not stop

working when the stop button is pressed until

the buzzer sounds and the motor inside stops

completely.

The unit will not respond to whatever button

on the control panel is pressed.

• The paper will be folded properly if it is folded

after it has reached the stopper inside the folding

plate.

• If the paper flowing into the folding plate is folded

without reaching the stopper due to conditions

such as environmental conditions (temperature,

humidity), paper quantity, its type, paper couch

conditions, folding speed, curling etc., it may not

be folded properly.

• In some cases, the paper may also coil around the

rubber roll and cause problems.

• As such problems can be corrected by slow down

the folding speed, keep slow down the speed until

the paper is folded properly.

34

5

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1

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Duplo DF-520 User manual

Duplo DF-520 User manual

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