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Instruction Manual
Duplo DC-645
(Slitter / Cutter / Creaser)
Version. 2 / March 2005
Correct operation and periodic maintenance are
essential for ensuring safe use of this machine.
Thoroughly read this manual before using this
machine.
P9-Y1031
1
2
1
Thank you for your purchase of the Duplo DC-645 (Slitter / Cutter / Creaser).
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.
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-645 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 automati-
cally to slit, cut, and crease a sheet of paper into the desired format with no operator intervention.
Initially, the DC-645 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-645 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.
Introduction
DC-645
Trademarks
• Apple and Macintosh are trademarks of Apple Computer, Inc., registered in the U.S. and other countries.
• Windows is the registered trademark of Microsoft
®
Corporation.
All other trademarks are the property of their respective holders.
2
Contents
Introduction ......................................................................................................................... 1
DC-645 ....................................................................................................................... 1
Notes on Safety (Please Read and Observe) ................................................................... 4
Safety Precautions ............................................................................................... 4
Warning Sticker .......................................................................................................... 7
Positioning the Machine ............................................................................................. 8
Maintenance ............................................................................................................... 9
Conventions Used in This Manual ............................................................................ 10
Chapter 1 Before Using This Machine
Part Names and Their Functions ..................................................................................... 11
Appearance .............................................................................................................. 11
Modules .................................................................................................................... 13
Control Panel ............................................................................................................ 14
LCD Panel ................................................................................................................ 15
Turning Power ON/OFF .................................................................................................... 16
Turning ON the Power .............................................................................................. 16
Turning OFF the Power ............................................................................................ 17
How to Connect the DC-645 to your Computer ............................................................. 18
Before Preparing Document ............................................................................................ 19
Definition of Programming Terms ............................................................................. 20
Chapter 2 Program JOB for DC-645 Via Computer (JOB Creator)
What is JOB Creator? ...................................................................................................... 29
Installing JOB Creator ...................................................................................................... 29
Before Installation ..................................................................................................... 29
Installing Procedures (Windows) .............................................................................. 30
Installing Procedures (Macintosh) ............................................................................ 32
Uninstall and Update JOB Creator .................................................................................. 33
Uninstalling Procedures (Windows) ......................................................................... 33
Uninstalling Procedures (Macintosh)........................................................................ 34
Updating Drivers....................................................................................................... 34
JOB Creator Settings ....................................................................................................... 35
Main Menu ................................................................................................................ 35
Creating JOB with Preview Display (“Using Program Entry Wizard”) ....................... 36
Creating a JOB By Direct Number Input (“Direct Program”) .................................... 43
Reading JOB from DC-645 (“Upload Job Data from DC-645”) ................................ 45
JOB Saved on Computer Registered On DC-645
(“Download Job Data to DC-645”) ............................................................................ 47
Setting Frequent Functions From Computer (“Function Setting”)............................. 49
Create a File Recording the DC-645 Maintenance Information
(“Upload Maintenance Data from DC-645”) ............................................................. 51
List of Messages ............................................................................................................... 52
3
2
1
Chapter 3 Programing JOB for DC-645 on Control Panel
Prior to Programming a Job ............................................................................................ 54
Customer Programmed Jobs .......................................................................................... 56
How to Program Job on Control Panel ........................................................................... 57
Chapter 4 Basic Operations
Process Documents by Selecting JOB........................................................................... 64
Automatic Set Up Using Barcodes ................................................................................. 68
Adjust Feeder .................................................................................................................... 70
Elevator level (Feed tray) .......................................................................................... 70
Separator .................................................................................................................. 70
Airflow ....................................................................................................................... 71
Print Image Skew ..................................................................................................... 71
Curled Document / Light Weight Document ............................................................. 71
FUNCTION Mode ............................................................................................................... 72
About the Waste Box ........................................................................................................ 74
Clean Feed Rollers ........................................................................................................... 75
Chapter 5 Troubleshooting
Troubleshooting Flow Chart ............................................................................................ 76
Power Does Not Turn ON ......................................................................................... 76
Cutting is Not Possible ............................................................................................. 77
OK Monitor Display and Jam Display ............................................................................. 78
Error Display ..................................................................................................................... 80
Warning Display................................................................................................................ 82
When a Paper Jam Has Occurred ................................................................................... 83
When “REJECT PAPER” is Displayed ...................................................................... 83
When “FEED JAM” is Displayed ............................................................................... 85
When “CENTER JAM” is Displayed .......................................................................... 87
When “CUTTER OR CREASE” is Displayed ............................................................ 89
When “OPTION AREA JAM” is Displayed ................................................................ 93
When “STACKER JAM” is Displayed ........................................................................ 95
When “OVER CAPACITY” is Displayed .................................................................... 97
When “REJECT AREA JAM” is Displayed ................................................................ 98
Appendix
Specifications ................................................................................................................. 100
DC-645 Specifications ............................................................................................ 100
Index ................................................................................................................................ 102
Contents
4
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.
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.
Precautions for Use
5
2
1
Notes on Safety (Please Read and Observe)
WARNING
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 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.
Caution for Grounding (Be sure to use the supplied power cord)
WARNING
Use only the power cord that is provided among the accessories.
Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.
• Use of any other power cord could result in imperfect grounding.
If grounding is imperfect and electrical leakage occurs, fire or electric shock could result.
Caution for Power Supply and Power Cord
CAUTION
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.
6
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.
Prohibition of Disassembly or Modification
WARNING
Do not move this machine by yourself.
• Please contact your service person when you wish to move the machine.
(Fine adjustment is required.)
Caution for Location
CAUTION
Do not place the machine in a place subject to direct sunlight or heating equipment such as a stove.
• It may degrade ink quality and affect printing.
The machine also may malfunction.
Avoid placing the machine in a place subject to high or low temperature or high humidity.
• The paper absorbs moisture and it may cause paper jam or wrinkles.
7
2
1
Warning Sticker
Keep the WARNING stickers clean at all times. If stickers become damaged or come off, replace them with new ones.
No. Parts No. Name Q’ty
1 L8-T1080 Warning Sticker 1 2
2 M7-T3030 Warning Sticker 2 2
Notes on Safety (Please Read and Observe)
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
1
WARNING
DO NOT put hands inside machine
while it is operating.
Hands could get caught up
or crushed.
M7-T3030
2
1
1
2
2
8
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)
9
2
1
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)
10
64
Basic Operations
This chapter describes the operating sequence from turning ON the power switch until completing
finishing process.
Chapter
4
Process Documents by Selecting JOB
This section describes the procedures to process documents by selecting each JOB manually.
Turn ON the power. (
aa
aa
a P.16 “Turning ON the Power”)
Press the <MODE> key and go to the
[SELECT] display.
Input the number of the JOB to call up, using the <Number> key.
[
SELECT
]
05:DUPLO
06:DUPLO 1
BC REG AC
∗ ∗ ∗
F
Press the <SET> key to call up the JOB of
the number input.
How to execute batch counting
• The specified number of document are processed.
Select or input a job and then press the <Number> key in
standby state (excluding SELECT/INPUT display) to input the
number of document for batch counting. (The specified
number of document is displayed in the lower right portion of
the control panel.)
∗ ∗
100/100
By pressing the <START> key, processed number of the
document is subtracted from the specified number as below.
(Ex.: When 100 documents are set, the above display appears.)
∗
∗
99/100
∗
∗
98/100
* If an error has occurred during processing, batch counting can not be executed.
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-645 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
11
11
Before Using This Machine
Before Using This Machine
This chapter contains essential information you should understand such as how to set up the system, the
names of the machine parts, etc.
Chapter 1
11
Part Names and Their Functions
Appearance
No. Name Function
1 Control panel Displays operations and statuses.
2 Waste box Receives pieces of waste paper.
3 Front cover Open to remove pieces of paper in the waste box.
4 Stacker tray Receives the finished document.
5 Scale This measures the cut and slit position, and the finish of the document.
6 Top cover 3 Open this to remove the paper jam from the cutter/crease/optional module or
to replace the optional module.
7 Top cover 2 Open this to remove the paper jam from the slitter module.
8 Top cover 1 Open this to move the upper guide or to remove the paper jam from the feed
unit.
9 Feed tray The original document is placed here.
10 USB terminal Insert a USB cable here to connect the computer and this machine.
11 AC inlet Connect the power cord.
12 Reject tray This is where the document comes when it is rejected due to double feed,
barcode error, REG. Mark error, etc.
13 Power switch Press to switch the power on and off.
Reference
page
14
74
78,82
66,69
—
89 – 94
87,88
75,
85 – 86
70,97
18,31
16
81,99
16,17
1
13
12
11
10
9
8
7
6
5
4
2
3
12
Part Names and Their Functions
No. Name Function
14
Airflow adjustment knob
This adjusts the airflow level.
15
Separator adjustment knob
This adjusts the distance between the separator and document.
16
Level adjustment knob
This adjusts the elevator height.
17
Skew adjustment wheel
This adjusts the feed angle of the document.
Reference
page
71
70
70
71
17
1514
16
13
11
Before Using This Machine
Part Names and Their Functions
Modules
No. Name
1 Slitter Module A
2 Slitter Module B
3 Slitter Module C
4 Gutter Deflector
5 Cutter Module
6 Creaser Module
7 Transport Module
(or Optional Module)
Function
Cuts off the blank-area of the further-side and front-side.
Cuts parallel in the paper feed direction.
The blank-area cut off by the slitter is dropped in the
waste box.
Cuts in a right angle in the paper feed direction.
Creases parallely in the paper feed direction.
Transports the paper to the stacker tray.
IMPORTANT
• When removing various modules of this device, always re-set the module in the sequential
order indicated in the illustration above. It is especially that the slitter module is properly
assembled, when setting slitter module A, B and C again.
Reference
page
19,54,
80,82
36,37,
72,81
54,79,80,89
54,79,81,89
36,57
1
2
3
4
5
6
7
14
Part Names and Their Functions
Control Panel
No. Name Function
1 OK Monitor The LED of the Error area flashes when detecting an Error.
2 LCD panel Displays the status of the machine.
Displays the message when an error or paper jam occurs.
3 < + / – > key Select setting of function.
4 <F> key Switches to function selecting display.
5 <MODE> key Switches modes. (operating mode, JOB selectiong mode, JOB inputing mode)
6 <SET> key Press to confirm selection / entry.
7 POWER lamp Lights up when the power is switched on.
8 <CLEAR> key Press to clear the count. Press to cancel manual programming.
9 <Number> key Press to enter print numbers and enter values during manual programming.
10 •
<JOG> keys
Press to eject the document from the machine when paper jam occured.
11 <TEST> key One (sheet) document is processed to test the current JOB details.
12 <START> key Press this to start processing the document. The <START> key light
turns green when the machine is ready to process the document in this
machine. The <START> key can be activated when the LED on the key
is green. The <START> key is inactive when the light is red. In this
case DC-645 may be running or having an error.
13 <STOP> key Press to stop automatic feeding after the current sheet is processed.
Reference
page
78,79
15,
80 – 82
58 – 63,72,73
73
58,64,75
58 – 63,73
—
—
58,59,64
58,59,83 – 98
—
64,66,69
67,78 – 82,
85 – 99
123
71011456
8 9 12 13
15
11
Before Using This Machine
Part Names and Their Functions
LCD Panel
∗ ∗
:
∗∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗
BC REG AC
∗ ∗ ∗
12
345 6
No. Name Function
1 JOB No. Displays the JOB No. currently selected.
2 JOB name Displays name of the JOB currently selected.
3 BARCODE BC is displayed when barcode reading is ON.
4
REGISTER MARK
REG is diaplayed when REG. Mark reading is ON.
5 AUTO CUT AC is displayed when AUTO CUT is ON.
6 COUNTER The number of document sheets processed with the JOB currently set, is
displayed.
Reference
page
36,58,64
36,58
37,72
37,72
37,55,72
64
16
This section describes the operating sequence from turning ON the power switch until the machine is ready to operate,
and how to turn OFF the power.
Turning ON the Power
Turning Power ON/OFF
∗ ∗
:
∗∗∗∗∗∗∗∗∗∗
BC REG AC
∗∗∗
––– J 1 –––
REJECT PAPER
Connect the “female plug” of the power cord to
the “inlet”.
Connect the “male plug” of the power cord to
the “outlet”.
Press the “ | ” side of the power switch.
The power turns ON.
The illustration on the right shows that paper remains in the
machine. If this screen is displayed, remove them.
(a P.83, “When “REJECT PAPER” is Displayed”)
The illustration on the right shows what is displayed on the
LCD panel.
17
11
Before Using This Machine
Turning Power ON/OFF
Turning OFF the Power
Press the “
KK
KK
K ” side of the power switch.
The power turns OFF.
18
How to Connect the DC-645 to your Computer
Prepare USB 2.0 Cable (A/B 4-pin).
Plug the type B connector into the DC-645 and the type A connector into the USB slot on your computer.
Computer
USB 2.0 Cable
19
11
Before Using This Machine
No. Name
1 Slitter 1 (in Slitter Module A)
2 Slitter 2 (in Slitter Module A)
3 Slitter 3 (in Slitter Module B)
4 Slitter 4 (in Slitter Module B)
5 Slitter 5 (in Slitter Module C)
6 Slitter 6 (in Slitter Module C)
7 Gutter Deflector
8 Cutter Module
9 Creaser Module
10 Transport Module
(or Optional Module)
1
7C B A8910
35
246
1...SLIT1
8...CUT
9...CREASE
3...SLIT3
5...SLIT5
6...SLIT6
4...SLIT4
2...SLIT2
Paper and Processing Position
Feed
direction
Function
Cuts off the blank-area of the further-side and front-side.
Cuts off the blank-area of the front-side.
Cuts parallel in the paper feed direction.
Cuts parallel in the paper feed direction.
Cuts parallel in the paper feed direction.
Cuts parallel in the paper feed direction.
The gutter strips cut off by slitters are dropped into the
waste box.
Cuts in a perpendicular to the paper feed direction.
Creases parallely in the paper feed direction.
Transports the paper to the stacker tray.
IMPORTANT
• When removing various modules of this device, always re-set the module in the sequential
order indicated in the illustration above. It is especially that the slitter module is properly
assembled, when setting slitter module A, B and C again.
Reference
page
60,80,82
61,80,82
40,81
54,79,80,89
54,79,81,89
36,57
Before Preparing Document
Familialize your self with the following illustrations and instructions to make your documents appropriately.
DC-645 has six slitters. Two slitters are for the margins and the remaining four slitters are for the center of the
document.
There is a guillotine cutter that performs cuts perpendicular to the paper feeding direction. DC-645 can cut up to 15
cuts on 1 document.
There is a creaser that performs creases perpendicular to the paper feeding direction. DC-645 can crease up to 10
creasing on 1 document.
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