Duplo INSTRUCTION MANUAL User manual

INSTRUCTION MANUAL

SYSTEM5000

Dynamic Booklet Maker

DBM-500

[ for 120 V ]

Be sure to read this manual prior to use.

Please leave this manual at the site of use for easy reference.

Applicable to the 120 V machine

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC

Rules.

These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a

commercial environment.

This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the

instruction manual, may cause harmful interference to radio communications.

Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required

to correct the interference at his own expense.

1

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

2. USAGE PRECAUTIONS ................................. 5

2-1. Power Supply ..................................................5

2-2. Operating Environment ...................................5

2-3. Storage Conditions .........................................5

3. NAMES AND FUNCTIONS ............................. 6

3-1. External Parts .................................................6

3-2. Internal Parts................................................... 8

3-3. Downstream Unit (Optional).......................... 11

3-4. Accessories................................................... 11

4. NAMES AND FUNCTIONS OF CONTROL

PANEL (MAIN MENU)................................... 12

5. PREPARING FOR OPERATION................... 14

5-1. Power ON .....................................................14

5-2. Operations ....................................................15

5-3. Settings .........................................................19

6. SADDLE STITCHING PROCEDURE ............ 27

6-1. Settings .........................................................27

6-2. Changing Size............................................... 30

6-3. Adjustments Using the Step Mode................30

6-4. Checking the Finished Set ............................33

7. SIDE STITCHING/CORNER STITCHING

PROCEDURE ................................................ 38

7-1. Settings .........................................................38

7-2. Changing Size............................................... 41

7-3. Adjustments Using the Step Mode................42

7-4. Checking the Bound State ............................45

8. NO-STITCHING FOLDING PROCEDURE ... 46

8-1. Settings .........................................................46

8-2. Changing Size............................................... 48

8-3. Adjustments Using the Step Mode................49

8-4. Checking the Finished Set ............................52

CONTENTS

Thank you for purchasing this Duplo equipment. To ensure correct usage, please read this

instruction manual thoroughly, especially the section entitled "Safety Precautions".

The aim of this instruction manual is to ensure safe and proper use of the equipment.

For this reason, do not attempt to remodel, modify or adapt this equipment or to use it for any other

purpose than that intended by the manufacturer.

After reading, please keep this instruction manual handy for future reference.

9. VARIOUS SETTINGS.................................... 56

9-1. Fine Adjustment Menu ..................................56

9-2. Option Menus................................................ 61

9-3. Accessory Menus.......................................... 63

9-4. Adjusting the Press Pressure and Conveyance

Pressure........................................................ 66

9-5. Adjusting the Saddle Stitching Guide/Side

Stitching Guide.............................................. 66

10. ERROR MESSAGES..................................... 67

10-1. Emergency Stop ...........................................67

10-2. Covers........................................................... 67

10-3. Paper Jam..................................................... 68

10-4. Wire Feed Detection ..................................... 68

10-5. Paper Tray Full .............................................68

10-6. Motor Error ....................................................69

10-7. Service Person Error..................................... 69

10-8. Shutter ..........................................................69

11. CORRECTING PAPER JAMS ...................... 70

12. STITCHER HEAD .......................................... 71

12-1. Names and Functions ...................................71

12-2. Wire............................................................... 72

12-3. Feeding the Wire........................................... 73

12-4. Stitching Tests ..............................................75

12-5. Removing Wire .............................................76

12-6. Adjustments .................................................. 77

12-7. Maintenance .................................................78

13. TROUBLESHOOTING .................................. 79

14. CLEANING .................................................... 81

15. SPECIFICATIONS ......................................... 82

INTRODUCTION

2

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

damage.

The degree of danger and damage that could occur is indicated on 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 action 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.”

WARNING:

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 a fire or an electrical shock.

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

a fire or an 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 an electrical shock.

Do not disassemble, modify or repair this unit. There is a 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 a fire or an 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 a fire or an electrical shock.

1. SAFETY PRECAUTIONS

3

1. SAFETY PRECAUTIONS

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

unit).

Such flammable gas or solvent may ignite and cause a fire or combustion.

Make sure that the combined power consumption of the appliances to be connected

does not exceed the capacity rating of the power outlets or plug receptacles. Exceeding

the capacity rating could cause the power outlets, plug receptacles, or power extension

cords to overheat and catch a fire.

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

from which the prongs extend. Accumulated dust could result in a fire.

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

unit off at the power switch and disconnect the power plug from the power outlet. Failure

to do so could result in a fire or an 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, a fire or an electrical shock.

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

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

Do not touch the power plug or power switch with wet hands. This could result in an

electrical shock.

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

plug from the power outlet. Accidental operation of the unit during cleaning could result

in injury.

CAUTION:

Always disconnect the power plug from the power outlet when the 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 causing injury.

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

with water is possible. Poor choice of location 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

1. SAFETY PRECAUTIONS

Emergency Stop Switch

Shutter

Top cover (Front)

Top cover (Back)

Safety

The following shows the location of the safety devices and warning/Caution label.

NoteNote

Labels are pasted to ensure the safety of users. Do not remove nor change them.

If a label becomes dirty or missing, be sure to contact your dealer for a new one.

The actual control panel and emergency stop switch of this machine may be located opposite to the locations shown

in the above figure.

5

2. USAGE PRECAUTIONS

2-1. Power Supply

• This equipment shall be installed near the socket-outlet where the plug on the power

supply cord is easily accessible.

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

220-240V AC 50Hz/120V AC 60Hz

•When you power other appliances from the same AC outlet, make sure that the combined

power consumption does not exceed the power supply capacity.

Rated power of this equipment : 3.8A/6.5A

2-2. Operating Environment

Operate this unit in the following environment:

• where the temperature range is between 5 and 35°C/41 and 95°F,

• where the humidity range is between 10 and 85%RH (no dew condensation),

• which is not subject to direct sunlight,

• which is subject to little or no vibration,

• where there are no harmful chemicals,

• which is reasonably free from dust,

• which is free from air-borne salt, and

• where the equipment will not be exposed to water.

2-3. Storage Conditions

Store this unit in the following environment:

• where the temperature range is between –10 and +50°C/14 and 122°F,

• where the humidity range is between 10 and 85%RH (no dew condensation),

• which is not subject to direct sunlight,

• which is subject to little or no vibration,

• where there are no harmful chemicals,

• which is reasonably free from dust,

• which is free from air-borne salt, and

• where the equipment will not be exposed to water.

6

3. NAMES AND FUNCTIONS

bm

9

7

8

6

bk

bl

5

4

3

2

1

L side

R side

Paper direction

3-1. External Parts

No. Name Function

1

Main power switch Refer to “5-1. Power ON”. ( Refer to page 14.)

2

Emergency stop button Press to stop the machine in emergency. Paper being fed will stop halfway. To resume

operations, remove this paper. To stop the machine normally, use the [Stop Key] on

the upstream unit or this machine.

To release this switch, rotate it to the right.

3

Front top cover Cover for ensuring user safety

This machine will not operate if open.

4

Rear top cover Cover for ensuring user safety

This machine will not operate if open.

5

Option connector Optional power connector

6

E port connector-1 Connects the E port cable from the upstream unit.

7

E port connector-2 Connects the E port cable to the downstream unit.

8

D port connector-1 Connects the D port cable from the upstream unit.

9

D port connector-2 Connects the D port cable to the downstream unit.

bk

Power cord Supplies power to this machine.

bl

Power switch Refer to “5-1. Power ON”. ( Refer to page 14.)

bm

Stacker connector Connects the power cord of the belt stacker.

In this manual, the left side of the paper conveyance direction is indicated as L side and the right side as R side.

7

3. NAMES AND FUNCTIONS

No. Name Function

bn

Wire reel Stitches paper

bo

Control panel Refer to “Description of Control Panel”. ( Refer to page 12.)

bp

Folding stopper adjustment dial Adjusts the angle of the folding stopper to correct folding misalignment.

bq

Deflector strip Holds booklets sent to the side stitching stacker.

br

Side stitching stacker Receives booklets which are side stitched (corner stitched).

bs

Stacker plate Receives booklets which are saddle stitched, and folded.

When stacked poor due to small booklet size, use it at upper position.

bt

Belt stacker Sends booklets folded into two to the stacker plate.

Connect the power cord plug of the Belt Stacker Unit to the outlet of the DBM-500

ck

Paper guide wheel Holds paper sent to the stacker and feeds to the stacker plate.

cl

Shutter Opening for inserting the handle Normally leave closed.

This machine will not operate if the shutter is open. ( Refer to pages 70 and 81.)

cm

Handle Used to remove jammed paper and clean the folding stopper

cn

Side stitching stopper Stops booklets which have been side stitched (corner stitched).

co

Side stitching stopper adjustment Adjusts the position of the side stitching stopper.

knob

cp

Ejection roller Ejects side stitched (corner stitched) booklets.

cl

cn

bq

bn

bo

bp

br

bs

bt

co

ck

cp

cm

L side

R side

Paper direction

8

3. NAMES AND FUNCTIONS

No. Name Function

1

Stitcher head Binds paper with wire.

2

Side jogger Aligns the sides of paper.

3

Side stitching stopper Rises during side stitching (corner stitching) to stop paper.

4

Side stitching guide Prevents paper from curling during side stitching (corner stitching).

5

Back jogger Aligns the leading and trailing edges of paper.

6

Conveyance driven roller Helps to convey paper to the paper alignment section.

7

Conveyance roller lifting handle Lift to remove paper jammed at the paper alignment section.

8

Conveyance roller Conveys paper to the paper alignment section.

3-2. Internal Parts

4

5

6

2

8

7

5

2

1

33



Paper direction

When the conveyance roller open

9

3. NAMES AND FUNCTIONS

No. Name Function

9

Saddle stitching stopper Rises to stop paper during saddle stitching.

bk

Ejection driven roller Helps to deliver stitched booklets to the folder.

bl

Saddle stitching guide Prevents paper from curling during saddle stitching.

The height can be adjusted. ( Refer to page 66.)

bm

Folding side guide Holds both ends of booklets during folding.

bn

Ejection roller Ejects stitched booklets to the folder.

bo

Ejection roller stopper Solves the poor alignment of insert sheets in insert mode.

bm

bn

bk

9

bl

bo



Paper direction

10

3. NAMES AND FUNCTIONS

No. Name Function

bp

Folding roller Roller for folding booklets into two

bq

Press roller Presses booklets folded into two.

br

Pressure adjustment hook Adjusts the pressure of the press roller.

bs

Conveyance pressure adjustment Switches the conveyance pressure of booklets folded into two.

hook

bt

Folding stopper Stops booklets during folding.

ck

Folding back guide lifting handle Lift to remove booklets when paper jams at the folding unit.

cl

Folding back guide Presses the ends of booklets during folding.

bt

bq

cl

Roller attaching position

ck

cl

bq

br

bs

bp



Paper direction

bs

11

3. NAMES AND FUNCTIONS

3-3. Downstream Unit (Optional)

3-4. Accessories

This machine

DBM-500T (Optional)

DBM-K (Optional)

DBM-LSI (Optional)

Adjusting handle

Paper guide wheel

Corner stitching paper holder

12

4. NAMES AND FUNCTIONS OF CONTROL

PANEL (MAIN MENU)

The control panel is composed of the touch panel and numerical pad.

The following describes the main menu which is the standard screen displayed normally, and the numerical pad.

[Numerical Pad][Touch Panel]

MAINMENU ADJUST OPTION ACCESSOR

01

00000

420. 0

x

297 . 0

207. 0

x

277 . 0

9bkbmbpbn bo

bs

bt

bq

br

ckcl cmbl8

1526374

No. Name Function

1

Main menu tab Displays the main menu.

2

Fine adjustment menu tab Displays fine adjustment menus. ( Refer to page 56.)

3

Option menu tab Displays option menus. ( Refer to page 61.)

4

Accessory menu tab Displays accessory menus. ( Refer to page 63.)

5

Stitch setting display Displays the stitch setting of the memory number currently selected.

Indicates that saddle stitching is selected.

Indicates that side stitching (corner stitching) is selected.

Indicates that “Stitch Off” is selected.

6

Fold setting display Displays the fold setting of the memory number currently selected.

Indicates that “Fold On” is selected.

Indicates that “Fold Off” is selected.

13

4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU)

No. Name Function

7

Trim setting display Displays the trim setting of the memory number currently selected.

Note: This is not displayed when not connected with the DBM-500T, or when “Fold Off”

is selected.

Indicates that “Head/Foot Trim On” is selected.

Indicates that “Fore-edge Trim On” is selected.

Indicates that “Trim Off” is selected.

8

Sheet size display Displays the paper size of the memory number currently selected in the following

format.

length x width

9

Finished size display Displays the finished size of the booklet processed by this machine.

bk

Memory number display Displays the memory number of the binding mode currently selected.

bl

Memory number selection key Selects the memory number.

The selected memory number is displayed at “

bk

Memory number display”, and the

settings are displayed at

5

to

9

.

bm

Setting key Displays the setting menu of the memory number of the binding mode currently

selected.

bn

Processed number display Displays the number of sets processed by this machine.

bo

Processed number clear key Clears the “Processed number display” to 0.

Press for more than 1 second.

bp

Size change key Changes the settings of the memory number currently selected.

Press for more than 1 second.

bq

Message display Displays messages.

br

Numerical keys Enters values such as paper size, etc.

bs

Clear key Clears the value entered using “

br

Numerical keys” to 0.

bt

Return key Confirms values entered using “

br

Numerical keys” to 0.

ck

Jog key Step-ejects paper forcibly. ( Refer to page 16.)

Press for more than 1 second.

cl

Start key Starts the system.

Press for more than 1 second.

cm

Stop key Stops the system including this machine.

14

5. PREPARING FOR OPERATION

5-1. Power ON

This machine has a main power switch and a power

switch.

Operate the machine with the main power switch On, and

the power switch "

"

The remote function allows this unit to turn on/off by

pressing the power switch for DC-10/60,and the main

power switch for DSF-2000.

It means there is no need to touch the main power switch

or the power switch of this unit.

NoteNote



 To turn the power of this machine On/Off by

itself, set the power switch to “I” and the main

power switch On.



 When operating the power switch, do so after

turning Off the main power switch.



 If an upstream unit is connected, do not turn

On/Off the power of this machine by itself.

This may cause the machine to operate

abnormally.

Be sure to turn On/Off the main power switch

or the power switch of the upstream unit

instead.

Main power switch

Power switch

DBM-LS1 DBM-500T This machine LUL-HM DC-10/60

DBM-LS1 DBM-500T This machine DSF-2000

When DC-10/60 is connected

When DSF-2000 is connected

Main power switch

Power switch

5. PREPARING FOR OPERATION

15

5. PREPARING FOR OPERATION

5-2. Operations

❊ Memory No.

The memory number consists of 1 to 12 for registering binding setting (binding mode) such as paper size, stitching, and

folding to each memory.

Default settings at shipment are as follows.

01

00000

420. 0

x

297 . 0

207. 0

x

277 . 0

MAINMENU ADJUST OPTION ACCESSOR

Return keyProcessed

number clear key

Start key Stop key

Clear keyMemory No. Size change key

MessageProcessed

number display

Jog key

Each memory number can be overwritten.

Register the 12 settings usually used for convenience.

Select the memory number of the binding mode to be used, change the size and begin binding. (

Refer to page 16.)

Memory No. 1 to 12 can also be set so that settings are not overwritten. (

Refer to page 63.)



 About Memory No. 0

Use Memory No. 0 to set a binding mode that is slightly different from the pre-set settings for the current job only.

The settings set at Memory No. 0 cannot be saved.

Select a memory number from Memory No. 1 to 12, and change the size. Then select Memory No. 0. The same settings as

the memory number for which size was changed will be displayed.

Press the [Setting key] on the touch panel, and change the binding mode using Memory No. 0.

Press the [Return key] on the touch panel to confirm the settings of Memory No. 0.

Change the size again to proceed with the binding work.

Settings of the previously selected memory number are not updated so that the original settings can be selected again.

Memory No. Paper size (mm) (inch) Stitching Folding

1 420 x 297 (A3) (17.00 x 11.00 (Double letter)) Saddle stitching Folding

2 297 x 210 (A4) (11.00 x 08.50 (Letter)) Saddle stitching Folding

3 210 x 297 (A4) (08.50 x 11.00 (Letter)) Side stitching No folding

4 210 x 148 (A5) (08.50 x 05.83 (Letter)) Saddle stitching Folding

5 364 x 257 (B4) (08.50 x 05.83) Saddle stitching Folding

6 257 x 182 (B5) (10.12 x 07.17) Saddle stitching Folding

7 182 x 257 (B5) (07.17 x 10.12) Side stitching No folding

8 431.8 x 279.4 (17.00 x 11.00) Saddle stitching Folding

9 355.6 x 215.9 (14.00 x 08.50) Saddle stitching Folding

10 215.9 x 355.6 (08.50 x 14.00) Side stitching No folding

11 279.4 x 215.9 (11.00 x 08.50) Saddle stitching Folding

12 215.9 x 279.4 (08.50 x 11.00) Side stitching No folding

16

5. PREPARING FOR OPERATION

❊ Size change

Size change is the process of returning guides to their standard points once, and then moving them to the positions set

according to the settings of the memory number selected. Pressing the [Size Change key] changes the size.

This process is required after the power is turned on, and after the memory number is changed. When the message display

shows “Perform paper size change” and the [Size Change key] blinks, size change is also required. Normally, the stitcher

will not return to its standard point.

But pressing the [Size Change key] while pressing the [Clear key] returns the stitcher to its standard position and moves it

to the set position.

Pressing the [Size Change key] while pressing numerical key 0 only returns all guides to their standard positions.

NoteNote

While “Perform paper size change” is displayed, this machine will not operate.

❊ Processed number display

Counts up the number of sets normally processed. The display can be reset to 0 using the [Processed number clear key].

The count is reset to 0 when the power is turned off.

❊ Starting/stopping processing

Pressing the [Start key] of this machine or the upstream machine starts processing. Pressing the [Stop key] ejects all

paper being processed, after which this machine stops. If an error occurs during processing, this machine will stop according

to the situation. If an error of the emergency stop switch, top cover, or shutter occurs during processing, the machine will

also stop immediately.

❊ Step-ejection

Pressing the [Jog key] binds paper left in the machine and ejects them.

Perform the following procedure using the [Jog key].

1. This machine will keep running while the [Jog key] is held down.

2. When the [Jog key] is released, paper inside the machine will to be stitched or folded, and move to next step. The

machine will then wait for the next jog key operation.

When paper jams inside the machine, a paper jam message appears and the machine stops. However, visually check the

machine because the machine will stop due to paper jam without displaying the paper jam message in some cases. In

such cases, open the top cover and remove the paper.

3. When conveyance is being carried out continuously, press the [Jog key] several time to execute stitching or folding, and

eject the processed sets.

NoteNote

If paper is forcibly ejected by the upstream unit, this machine will also perform conveyance motion.

The paper will stop at the stitching area but this machine will not advance the paper fed.

Open the top cover and remove the paper conveyed to this machine.

17

5. PREPARING FOR OPERATION

Stitching position label

Pointer

60

(2.36)

60

(2.36)

60

(2.36)

60

(2.36)

180 (7.09)

240 (9.45)

Paper conveyance direction

Stitching position

1 : 2 : 1

Unit: mm (inch)

❊ Stitching range

Saddle stitching

Stitching is carried out at the positions indicated by the

pointer.

Normally, stitching is done at two positions.

*

This can be increased to four positions by factory

options.

Paper

Space Space

Side joggerSide jogger

❊ Aligning the paper passage lines

After preparing this machine for binding operations, check

that the paper passage line is aligned to that of the

upstream unit.

When paper conveyed from the upstream unit is conveyed

to this machine, check that there is even space between

the left and right side joggers and paper.

If not even, adjust the position of this machine to avoid

paper jams.

Move this machine at other fine adjustment screens of the

fine adjustment menu, until the space becomes even.

(

Refer to page 60.)

When paper is more than 140 mm/5.51 inch wide, the

standard stitching width is determined by the ratio of 1:2:1.

Stitching width is the center to center distance between

the two stitches. However, if the stitching position lies

inside the stitch prohibited area, it will be set at a position

avoiding this area.

For example, if the paper width is 240 mm/9.45 inch,

stitching is carried out at the 60 mm/2.36 inch and 180 mm

/7.09 inch positions from the paper edge.

When less than 140 mm/5.51 inch, the stitching width is

70 mm/2.76 inch (minimum stitching width).

The stitching width (the ratio) can be changed. (

Refer

to page 58.)

18

5. PREPARING FOR OPERATION

Stitching position label Mark (Stitch prohibited area)

Pointer

Make sure the mark does not enter area A

A

❊ Stitch prohibited area

The position at which the folding knife and a stitch

coincide is called the stitch prohibited area.

During folding operations, the folding knife may bend the

stitch if they touch.

When a standard stitching position determined by the

paper width entered is inside the stitch prohibited area, the

position avoids this area automatically.

NoteNote

When adjusting the stitching width, avoid the

stitching prohibited area.

120 to 356

14

(0.55)

14

(0.55)

35

(2.76)

35

(2.76)

Center line of paper width

Paper conveyance direction

Stitching position

Unstitchable area

Unit: mm (inch)

 The stitching position cannot be within 14 mm/0.55 inch

from both edges of the paper.

 The stitching width cannot be within 70 mm/2.76 inch.

6 (0.24)

Paper conveyance direction

Paper width

Unit: mm (inch)

Side stitching (corner stitching)

The stitching position is about 6 mm/0.24 inch from the

leading edge of the paper, and cannot be changed

vertically.

The stitching position along the width of the paper is the

same as saddle stitching.

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Duplo INSTRUCTION MANUAL User manual

Duplo INSTRUCTION MANUAL User manual

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