Duplo DocuCutter DC-545HC User manual

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Instruction Manual

Docu Cutter

DC-545 HC/DC-545 HCEX

Version. 1.0 / November 2003

Correct operation and periodic maintenance are

essential for ensuring safe use of this machine.

Thoroughly read this manual before using this

machine.

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Thank you for your purchase of the Docu Cutter DC-545 HC.

To ensure safe and efficient prolonged use of this machine, read and thoroughly understand this manual before

using this machine. After using this manual, be sure to keep it in a place to handy reference.

PLEASE NOTE

In the interest of upgrading our products, specifications and other data given in this manual are subject to

change without notice. If the manual contains anything that you do not understand, contact the manufac-

turer for clarification.

Introduction

DC-545 HC

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Thank you for your purchase of the Docu Cutter DC-545 HCEX.

To ensure safe and efficient prolonged use of this machine, read and thoroughly understand this manual before

using this machine. After using this manual, be sure to keep it in a handy place to Reference.

DC-545 HCEX

PLEASE NOTE

In the interest of upgrading our products, specifications and other data given in this manual are subject to

change without notice. If the manual contains anything that you do not understand, contact the dealer for

clarification.

OVERVIEW

The DC-545 HCEX was created to produce high-quality, customized products; greeting cards, postcards,

brochures, business cards, and resized photographs. It does this by combining a number of devices that set up

automatically to slit, cut, and crease a sheet of paper into the desired format with no operator intervention.

Initially, the DC-545 HCEX is manually programmed with the required positions of the slits, cuts and creases

and the values are stored in a memory for future recall. A CCD sensor reads the job number encoded in a

barcode on the unfinished sheet. Then, the DC-545 HCEX recalls the values from memory, sets up the slitter

positions, activates the cutter for lead, trail, and any intermediate cuts and any required creases.

In addition, when a small 90-degree angle register mark has been printed adjacent to the barcode, the position

is measured against the intended position stored in the job memory. As this mark is part of the original image,

any error in its location can be compared with the stored value and used to correct the setup positions of the

devices by applying a horizontal offset to the cut and crease positions, and a vertical offset to the slit positions

to maintain precise finishing every time.

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Contents

Introduction ......................................................................................................................... 1

DC-545 HC ................................................................................................................. 1

DC-545 HCEX ............................................................................................................ 2

Notes on Safety (Please Read and Observe) ................................................................... 5

Safety Precautions ............................................................................................... 5

Warning Sticker .......................................................................................................... 8

Positioning the Machine ............................................................................................. 9

Maintenance ............................................................................................................. 10

Conventions Used in This Manual............................................................................ 11

Chapter 1 Operating Instraction - DC-545 HC

Part names and their functions................................................................................. 12

Loading the paper .................................................................................................... 13

Selecting/operating/stopping a job ........................................................................... 14

Adjustments.............................................................................................................. 15

Troubleshooting table ............................................................................................... 17

Specifications ........................................................................................................... 17

Chapter 2 Before Using This Machine - DC-545 HCEX

Confirming the Packaged Materials ................................................................................ 18

How to Set up the System ............................................................................................... 19

Part Names and Their Functions .................................................................................... 21

Appearance .............................................................................................................. 21

Control Panel ............................................................................................................ 23

LCD Panel ................................................................................................................ 24

Turning Power ON/OFF .................................................................................................... 25

Turning ON the Power .............................................................................................. 25

Turning OFF the Power ............................................................................................ 25

Chapter 3 Operating Instructions - DC-545 HCEX

Automatic Cutting Using Bar Codes and Register Marks ............................................ 26

About the Waste Tray ....................................................................................................... 29

Chapter 4 Troubleshooting - DC-545 HCEX

Troubleshooting Flow Chart ............................................................................................ 30

Power Does Not Turn ON ......................................................................................... 30

Cutting is Not Possible ............................................................................................. 31

Error Messages ................................................................................................................. 32

When a Paper Jam Has Occurred ................................................................................... 39

When “REJECT PAPER” is Displayed ..................................................................... 39

When “FEED JAM” is Displayed .............................................................................. 41

When “CENTER JAM” is Displayed ......................................................................... 43

Procedure of Removing Front and Rear Creaser Guides ........................................ 45

When “SLITTER JAM” is Displayed ......................................................................... 47

When “CUTTER LOCK” is Displayed ....................................................................... 49

When “CREASE LOCK” is Displayed....................................................................... 51

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Chapter 5 Manual Programming - DC-545 HCEX

Prior to Programming a Job ............................................................................................ 53

Definition of Programming Terms ................................................................................... 54

Customer Programmed Jobs .......................................................................................... 60

Factory Preset Jobs ......................................................................................................... 61

How to Manually Program a Job ..................................................................................... 64

Appendix - DC-545 HC / DC-545 HCEX

Specifications ................................................................................................................... 70

DC-545 with HC AUTO FEEDER Specifications ...................................................... 70

DC-545 with HCEX AUTO FEEDER Specifications ................................................. 71

Specifications of Reg. Mark and Bar Code .............................................................. 72

How to do AUTO CUT .............................................................................................. 82

Index .................................................................................................................................. 83

Contents

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Notes on Safety (Please Read and Observe)

Safety Precautions

Various symbols and pictures are used in this manual and on the stickers affixed to the machine. These symbols and

pictures provide warnings and instructions to prevent danger to you or other personnel, and to prevent damage to office

property. The meanings of these symbols and pictures are explained below.

WARNING

Indicates a high degree of potential danger. If the warning is ignored, death or serious

injury may result.

CAUTION

Indicates a medium degree of potential danger. If the caution is ignored, medium injury or

damage to property may result.

[Examples of Pictorial Symbols]

A circle with a line through it indicates a prohibited action. The particular act prohib-

ited is indicated by a picture inside the circle. (In the example shown here, the prohibited

act is disassembly.)

A black disc indicates an instruction, or sometimes a prohibited action. The instruction

itself is indicated by pictorial symbols drawn in white on the disc. (In the example shown

here, the instruction is “Remove the plug from the outlet.”)

• These are particularly important safety points and should always be observed.

WARNING

If the machine is used after foreign matter (metal fragments, water, or liquid) has entered the

machine, this may result in fire or electric shock.

• Turn the main unit’s power switch OFF, and then remove the power plug from the outlet. Contact

the sales distributor.

If the machine is used after heat, smoke, strange smell, or other abnormality is detected, this may

result in fire or electric shock.

• Turn the main unit’s power switch OFF, and then remove the power plug from the outlet. Contact

the sales distributor.

Use only the power cord that is provided among the accessories.

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Notes on Safety (Please Read and Observe)

WARNING

Do not modify the machine.

• Doing so may result in fire or electric shock.

Do not remove the rear lid, cabinet, or covers from the machine.

• The inside of the machine contains high-voltage parts, which may cause electric shock.

Do not remove or insert the power plug with wet hands.

• Doing so may result in electric shock.

Do not damage, break, or modify the power cord.

• Do not place heavy objects on, tug, or unnecessarily bend the power cord. Doing so may result in

fire or electric shock.

Do not insert or drop metal, flammable material, or other matter through the ventilation holes into

the machine interior.

• Doing so may result in fire or electric shock.

Do not place flower vases, flowerpots, cups, or water containers (including metal containers) on top

of the machine.

• Fire or electric shock may result if liquid spills inside the machine.

Do not use a source voltage other than that specified. Do not connect two or more loads to a single

outlet.

• Doing so may result in fire or electric shock.

Do not place the machine in a humid or dusty area.

• Doing so may result in fire or electric shock.

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Notes on Safety (Please Read and Observe)

CAUTION

Before moving the machine, remove the power plug from the outlet.

• If the cord is damaged, this may result in fire or electric shock.

Remove the power plug itself, not the cord.

• Tugging the cord may damage it (expose conductors, or cause disconnections, etc.), resulting in

fire or electric shock.

Do not place the machine in an unstable position, such as on an unsteady support or sloping area.

• If the machine is dropped or falls over, this could result in personal injury.

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Notes on Safety (Please Read and Observe)

Warning Sticker

Keep the WARNING stickers clean at all times. If labels become damaged or come off, have your service representative

replace them.

No. Parts No. Name Q’ty

q L8-T1100 Warning Sticker 1 1

w L8-T1080 Warning Sticker 2 3

WARNING

Cutters and movable parts are inside this cover.

Before opening the cover to work,

unplug the power cord.

Use caution when working near cutters

and movable parts.

L8-T1080

WARNING

Do not touch blade!

To remove jammed paper,

use the tweezers.

L8-T1100

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Positioning the Machine

Installing the machine on a flat, stable surface.

Avoid installing the machine in a dusty area.

Avoid installing the machine in the direct sunlight or heat,

such as near a stove. The machine may indicate errors due

to overheating caused by sunlight. Also avoid hot, cold, or

humid areas since paper may absorb moisture, causing

paper jams or wrinkles.

Notes on Safety (Please Read and Observe)

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Maintenance

Clean the exterior of the machine as described below.

Tightly wring a soft cloth that has been moistened with

water or neutral detergent, and wipe dirt from the ma-

chine’s surface.

Never use alcohol or organic solvents. Doing so may

discolor or damage the machine exterior.

Dust and clean the machine at least once a week to avoid

breakdowns.

Before cleaning, turn the power switch OFF, and then

remove the power plug from the outlet.

WARNING

• Before cleaning, remove the power plug from the outlet.

Failure to do so may result in an electrical shock or a fire hazard.

• Prevent water and neutral cleansers from getting inside the machine. If liquids spill inside the machine,

contact your agent immediately. Using the machine with water spilled inside may result in an electrical

shock or a fire hazard.

Notes on Safety (Please Read and Observe)

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Notes on Safety (Please Read and Observe)

Conventions Used in This Manual

Each page of descriptions in this manual of how to operate the DC-545 is set up as follows.

■ Pictorial Symbols and Other Notations Used in This Manual

IMPORTANT : Introduces instructions for correct operation of the machine. If these instructions are ignored,

the machine may not be able to operate at optimum performance or may break down.

Tip : Introduces information that is useful for operation and maintenance of the machine, or

information about the machine’s performance, etc.

Continue Page

•••

: Indicates that the description of the operating sequence is continued on the next page.

(a P.00 “xxxx”) : Indicates the page number and item containing related information.

Chapter

Description of operational steps

Each step is described in detail.

Illustrations

The illustrations provide a visual

reference to which keys to operate

and other related conditions.

Title

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No. Name Function

q Level adjustment lever For adjusting the level of the elevator 6

w Separator adjustment knob For adjusting the amount of space between sheets of paper 6

e Airflow adjustment knob For adjusting the amount of airflow 7

r Skew adjustment knob For adjusting the skew of the paper 7

t Stoppers For holding the rear edge of the paper stack 5

Reference

Page

Operating Instraction - DC545 HC

Chapter 1

Part names and their functions

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Operating Instraction - DC545 HC

Loading the paper

Fan the edge of the paper stack to separate the

paper.

Set the paper stack on the feed tray.

Note

• The height of the paper stack should not exceed

the "MAX" level.

Turn the feed guide knob to loosen, then adjust

the feed guide.

MAX

Part Names and Their Functions

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Tighten the knob to fix the position of the guide.

Set the stoppers.

Selecting/operating/stopping a job

Follow the instructions in the DC-545 manual to

select the type of job that you want to perform,

and then press START.

To stop the machine, press STOP.

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POWER

START

STOP

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4

7

C

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0

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POWER

START

STOP

Part Names and Their Functions

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Operating Instraction - DC545 HC

Adjustments

Elevator level ( Feed tray)

The elevator level should be adjusted in the

following cases.

a. The machine does not feed.

→

Lower the lever. The level of the elevator is

raised.

b. The machine feeds multiple sheets at once.

(double feed)

→

Raise the lever. The level of the elevator is

lowered.

Separator

The height of the separator should be adjusted in

the following cases:

a. The machine does not feed.

→

Turn the knob in the clockwise direction (to a

smaller number). The position of the separator is

lowered.

b. The machine feeds multiple sheets at once.

(double feed)

→

Turn the knob in the anti-clockwise direction (to

a larger number). The position of the separator is

raised.

Figure 1-1: Close-up of the level adjustment lever

Figure 1-2: Location of the level adjustment lever

Figure 2-1: Close-up of the separator

adjustment knob

WARNING

Cutters and movable parts are inside this cover.

Before opening the cover to work,

unplug the power cord.

Use caution when working near cutters

and movable parts.

L8-T1080

Figure 2-2: Location of the separator

adjustment knob

Part Names and Their Functions

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Adjusting the airflow

The amount of airflow should be adjusted in the

following cases:

a. The machine does not feed.

→

Turn the knob in the anti-clockwise direction (to

a larger number). The amount of airflow is

increased.

b. The machine feeds multiple sheets at once.

(double feed)

→

Turn the knob in the clockwise direction (to a

smaller number). The amount of airflow is

decreased.

Adjusting the amount of skew

Paper may be cut at an angle if a skew in the paper

arises during feeding. When this happens, correct

the problem by changing the angle of the feed

guide.

Figure 3-1: Close-up of the airflow adjust-

ment knob

Figure 3-2: Location of the airflow adjust-

ment knob

Figure 4-1: Skew adjustment knob

Part Names and Their Functions

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Operating Instraction - DC545 HC

No. Item AF-100

1 Model Floor Model

2 Model No. AF-100

3 Input paper size Min.8.5” x 11” / A4

Max.12.6” x 18” / A3

4 Input paper weight Min.110gsm (29.3LB)

Max.230gsm (85LB)

5 Media type Range: Regular copy paper to coated heavy weight paper

6 Feeding method Automatic (Air suction method)

7 Feed tray capacity 3.9” (100mm)

8 Power supply DC5V, DC24V is supplied from DC-545 main body

9 Machine dimensions 43.4” (W) x 22.7” (D) x 37.8” (H)

1102mm (W) x 576mm (D) x 960mm (H)

10 Machine weight 117.1LB (Feeder : 44.9LB, Stand : 72.2LB)

53.2kg (Feeder : 20.4kg, Stand : 32.8kg)

11 Operating temperature 41-86F (5-30°C)

12 Operating Humidity 40-70% (no condensation within this range)

Troubleshooting table

Raise the elevator height by pushing the level adjustment

lever downward. (See Figure 1-1)

Lower the paper separators by turning the separator adjust-

ment knob clockwise, towards a lower number. (See Figure 2-1)

Increase the airflow by turning the airflow adjustment knob

counter-clockwise. (See Figure 3-1)

Lower the elevator height by pushing the level adjustment

lever upward. (See Figure 1-1)

Raise the paper separators by turning the separator adjustment

knob counter-clockwise, towards a higher number. (See Figure

2-1)

Decrease the airflow by turning the airflow adjustment knob

clockwise, towards a lower number. (See Figure 3-1)

1. Remove the paper from the feed tray.

2. Turn the skew adjustment knob according to the instruc-

tions on the label to adjust the angle of the feed guide.

The machine

does not feed

paper.

The machine

double feeds

paper.

The paper is cut

at an angle or

not fed straight.

Symptom Possible Cause Remedy

Paper level is too low.

Paper separators are too high.

Not enough airflow.

Paper level is too high.

Paper separators are too low.

Too much airflow.

The paper is skewed.

Specifications

Part Names and Their Functions

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No. Name Q’ty

q Power cord 1

w Instruction Manual 1

e Tweezers 1

r Screw Driver 1

t Hex L-wrench 1

Before Using This Machine - DC545 HCEX

This chapter contains essential information you should understand such as the materials packaged with

this machine, how to set up the system, the names of the machine parts, etc.

Chapter 2

This product contains the following materials packaged together. If any material is missing, please contact your dealer.

Confirming the Packaged Materials

qwe

r t

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Before Using This Machine - DC545 HCEX

2

How to Set up the System

This section describes the cautions and the procedure when you set up this machine.

Take out the machine from the package and place the machine on a flat and stable

table.

WARNING

• Do not try to lift the machine by yourself. Two or more people are required to prevent

injury and/or damage to the machine.

• When you open the box, be sure not to injure yourself or others with a cutter or the like.

Detach the shipping bracket.

Attach the feed tray to the main body.

Attach the paper tray to the main body.

Continue Page

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