Duplo DBM-600 User manual

INSTRUCTION MANUAL

Be sure to read this manual prior to use.

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

STITCHER FOLDER

TRIMMER

DBM-600

DBM-600T

Original instructions

Introduction

Thank you for purchasing a Duplo product.

Be sure to read this manual and "Safety Guide A" supplied with this product before use. “Safety Guide”

contains information for correct and safe use of this product.

After reading, leave the manual and “Safety Guide” at the site of use for easy reference whenever questions

related to the product arise in the future.

Symbols

In this manual, several symbols are used to indicate important warnings. Please make sure to read

instructions accompanied by these symbols. These symbols have the following meanings.

Describes instructions which must be followed in use.

Be sure to read the instructions to avoid problems due to incorrect operations.

Indicates supplementary or useful information.

Describes names of related items and supplementary instructions.

Trademark

The product name and company name used in this manual are trademarks or registered trademarks of the

respective companies.

Statement of Photobiological Safety

This product not only employs LED lamps as an indicator but also as lighting.

The LED light is conrmed with a safety standard IEC62471 and classied into the risk group 1 (low risk). The

risk group 1 (low risk) LED light does not lead to injury required such as an access restriction. However the

risk depends upon a distance between eyes and the LED lamp.

Please see a part “Name and Function” in this instruction manual that points to a place for LED lamp in the

product.

Do not stare into the LED lamp. Do not come closer to the LED lamp intentionally. A decrease in distance

between eyes and the LED light causes an increase in the risk.

For North America

Note:

In a residential area this product may cause radio interference in which case the user may be required to take

adequate measures.

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.

i

Safety Precautions

Power supply

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

Power supply : 120 V AC, 60 Hz (North America)

220 to 240 V, 50/60 Hz (EU)

• 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: DBM-600

430 W (North America)

465 W (EU)

DBM-600T

625 W (North America)

645 W (EU)

Rated current: DBM-600

4.5 A (North America)

2.5 A (EU)

DBM-600T

6.5 A (North America)

3.4 A (EU)

Operating environment

Operate this unit in the following environment.

• where the temperature range is between 5 and 35°C/41 and 95°F (–10 to 50°C/14 to 122°F in storage)

• where the humidity range is between 20 and 85% RH (10 to 90% RH in storage, however no condensation)

• which is not subject to direct sunlight

• which is subject to little or no vibration

• which is free from air-borne salt

• where there are no harmful chemicals

• where the unit is not exposed to water

ii

Safety Precautions

WARNING/CAUTION labels

"WARNING" and "CAUTION" labels are pasted on the machine to ensure user safety.

Do not remove or change them.

When the labels become dirty or are lost, be sure to contact your dealer for a new one.

For EU

iii

Safety Precautions

For North America

iv

Safety Precautions

Safety devices

[1]

[2]

[1]

[4]

[3]

No. Name Function

[1] Emergency stop switch Press this switch to stop the machine in emergencies. Turn the pressed

switch to the right to release it. While pressed, the machine will not

start and its moving parts will also not move.

[2] Top cover interlock switch L The switch is associated with the cover and it activates the interlocking

system which consists of the protective guards, the electrical circuit

and the actuators.

The hinged or sliding cover, which can be manually opened or closed,

works as an interlocking guard associated with the electrical drive

circuit so that the hazardous moving parts do not move while the

cover is opened.

[3] Top cover interlock switch R

[4] Top cover interlock switch

v

Safety Precautions

[2]

[6] [8]

[5]

[1]

[3]

[4]

[7]

No. Name Function

[1]

to

[8]

Fixed cover The cover is xed by screws to prevent hazardous parts from being

exposed. Do not remove the cover. Doing so could cause serious

injury.

vi

Safety Precautions

Memo

vii

Contents

Safety Precautions .............................................i

Power supply .................................................................................i

Operating environment ............................................................i

WARNING/CAUTION labels .....................................................ii

Safety devices .............................................................................iv

Chapter 1 Before Operation

1. Features ................................................... 1-1

1-1. Features of the DBM-600 ......................................1-1

1-2. Features of the DBM-600T ................................... 1-2

2. Names and Functions of

Components ............................................ 1-3

2-1. DBM-600 external parts ........................................1-3

2-2. DBM-600T external parts .....................................1-5

2-3. DBM-600 internal parts (stitching section) ...1-6

2-4. DBM-600 internal parts (folding section) ......1-8

2-5. DBM-600T internal parts ....................................1-10

2-6. Stitcher head ...........................................................1-12

3. Accessories ............................................1-13

3-1. Accessories for the DBM-600 ............................1-13

3-2. Accessories for the DBM-600T .........................1-14

4. DBM-600 Control Panel .......................1-15

4-1. Names of control panel .......................................1-15

4-2. Screen descriptions ..............................................1-16

4-3. Colors of the keys on the setting screen ......1-16

4-4. [Main] screen ...........................................................1-17

4-5. [Adjust] screen ........................................................1-25

4-6. [Function] screen ...................................................1-26

4-7. [Options] screen .....................................................1-31

5. DBM-600T Control Panel ..................... 1-36

5-1. Names of control panel .......................................1-36

5-2. Screen menus .........................................................1-37

6. Stitching Width ..................................... 1-38

7. Options ..................................................1-40

7-1. DBM-SSW ..................................................................1-40

7-2. DBM-LSW ..................................................................1-41

7-3. DKT-K ..........................................................................1-41

8. Workﬂow ............................................... 1-42

Chapter 2 Basic Operation

1. Turning On/Oﬀ the Power ..................... 2-1

1-1. Turning on the power ............................................2-1

1-2. Turning o the power ............................................2-2

2. Setting the Control Panel ...................... 2-3

2-1. Setting the standard size ......................................2-4

2-2. Setting the custom size .........................................2-7

3. Preparing the DBM-600 for

Operation .............................................. 2-16

3-1. Using the paper guide .........................................2-16

3-2. Attaching the parts for page insertion .........2-16

3-3. Moving the stitch release levers (for corner

stitching) ...................................................................2-17

3-4. Adjusting the paper receiver stopper

(for side stitching, corner stitching) ...............2-17

3-5. Aligning the paper passage lines ....................2-18

4. Preparing the DBM-600T for

Operation .............................................. 2-19

5. Making the Upstream Unit Ready ...... 2-20

6. Adjusting Each Section

(Step Mode) ...........................................2-20

6-1. Starting the step mode .......................................2-20

6-2. Adjusting the stitching section (when

“stitching on” has been selected) ....................2-21

6-3. Adjusting the folding section (when “folding

on” has been selected).........................................2-23

6-4. Adjusting the trimming section (when

“trimming on” has been selected) ..................2-25

7. Checking Finished Booklets ................2-25

7-1. When paper does not align ...............................2-25

7-2. When stitching and folding positions do not

align ............................................................................2-27

7-3. Adjusting stitching and folding positions

simultaneously .......................................................2-29

7-4. Adjusting the stitching width ...........................2-30

7-5. When fold is skewed ............................................2-31

7-6. When the stitching position is not at right

angle to paper ........................................................2-32

7-7. When paper does not align on the belt

stacker ........................................................................2-33

7-8. When there is a scratch on a booklet ...........2-34

7-9. Stripping occurs on the surface of a

booklet .......................................................................2-36

8. Adjusting Each Part (DBM-600) .......... 2-37

8-1. Adjusting the infeed paper holder .................2-37

8-2. Adjusting the stitching paper holder ............2-37

8-3. Adjusting the height of the stitch ejection

roller R ........................................................................2-38

8-4. Adjusting the folding roller gap ......................2-38

8-5. Adjusting the height of the insertion

roller ............................................................................2-39

8-6. Adjusting the pressure adjustment lever ....2-39

8-7. Using the fold paper holder ..............................2-40

8-8. Adjusting the ejection pressure ......................2-40

8-9. Using the paper receiving guides F and B ...2-41

viii

Contents

8-10. Using the paper guide bracket ........................2-41

8-11. Adjusting the height of the paper receiver

full loading sensor .................................................2-42

8-12. Removing booklets from the paper

receiver ......................................................................2-42

9. Adjusting Each Part (DBM-600T) ........ 2-42

9-1. Adjusting the infeed rollers ...............................2-42

9-2. Adjusting the stopper angle .............................2-43

9-3. Adjusting nished length ..................................2-43

9-4. Adjusting the press angle unit .........................2-44

9-5. Adjusting the infeed sensor height ...............2-45

9-6. Preparing for the loop stitching ......................2-45

10. Adjusting the Paper Guide Roller

Unit ........................................................2-46

10-1. Adjusting the position of the paper guide

roller unit ...................................................................2-46

10-2. Replacing with the paper guide roller unit

(small) .........................................................................2-47

11. Setting the Conveyance Belt

Timing .................................................... 2-47

11-1. Adjusting conveyance stop timing ................2-47

11-2. Adjusting conveyance restart timing ............2-47

11-3. Adjusting start timing and operating time of

the stacker belt .......................................................2-47

12. Starting Binding Operations ............... 2-48

Chapter 3 Advanced Operation

1. Sending Paper Manually ....................... 3-1

1-1. Using the DBM-600 HAND FEED KIT

(optional) ....................................................................3-1

1-2. Using the DSF-2200 HAND FEED KIT

(optional) ....................................................................3-1

2. Using the DBM-600 AIR KIT (Option) .... 3-2

3. 2-stitch Binding with 4 STITCH KIT

(option) Attached ................................... 3-2

4. Using the CALENDAR KIT (Option) ....... 3-3

5. Using the DKT-K (Option)....................... 3-3

5-1. Attaching the kicker support wheel unit .......3-3

5-2. Adjusting the position of the kicker ................3-4

5-3. Attaching the stopper ...........................................3-4

5-4. Using the sorting function ...................................3-5

6. Adjusting the Stitcher Head .................. 3-5

Chapter 4 Cleaning the Unit

1. Cleaning Each Part ................................. 4-1

1-1. Cleaning the conveyance belt and rollers .....4-1

1-2. Cleaning the LCD .....................................................4-1

1-3. Cleaning the sensor ................................................4-2

2. Emptying the Scrap Box ........................ 4-3

3. Stitcher Head .......................................... 4-4

3-1. Information on wire we specify .........................4-4

3-2. Removing wire ..........................................................4-4

3-3. Wire threading ..........................................................4-5

3-4. Installing new wire ..................................................4-7

3-5. Lubricating the stitcher head .............................4-8

Chapter 5 Trouble Guide

1. DBM-600 Error Code .............................. 5-1

1-1. Error related to emergency stop switch and

covers ...........................................................................5-1

1-2. Paper jam error .........................................................5-2

1-3. Downstream unit and motor error ...................5-2

1-4. Other errors ................................................................5-2

1-5. Errors requiring a service call ..............................5-3

2. DBM-600T Error Code ............................ 5-3

2-1. Error related to emergency stop switch,

covers, etc. ..................................................................5-3

2-2. Paper jam error .........................................................5-4

2-3. Downstream unit and motor error ...................5-4

2-4. Errors requiring a service call ..............................5-5

3. Paper Jam ................................................ 5-6

3-1. Paper jam in the DBM-600 ...................................5-6

3-2. Paper jam in the DBM-600T ................................5-8

3-3. Step ejection............................................................5-10

4. Troubleshooting ...................................5-10

4-1. Entire machine ........................................................5-10

4-2. DBM-600 stitching section ................................5-10

4-3. DBM-600 folding section ....................................5-12

4-4. DBM-600 paper receiver and the stacker ....5-14

4-5. DBM-600T trimming section ............................5-14

4-6. Problem with nished booklets ......................5-15

Chapter 6 Appendix

1. Speciﬁcations .......................................... 6-1

2. Limit on Stitching Width ........................ 6-7

1-1

Chapter 1 Before Operation

1. Features

1-1. Features of the DBM-600

• The DBM-600 is a stitcher folder that can make a booklet in the following binding methods.

[A] Saddle stitch

[B] Saddle stitch and fold

[C] Fold

[D] No stitch and no fold

[E] Side stitch

[F] Side stitch and fold

[G] Corner stitch

[H] Page insertion(*)

(*) Page insertion is a 6 to 22-page booklet consisting of a sheet of A3 (LGR) with a sheet of A4 (LTR).

[B][A] [C] [D]

[F] [G][E] [H]

1-2

Chapter 1 Before Operation

• The DBM-600T (trimmer) can be connected to the DBM-600 as a downstream unit.

DBM-600

DBM-600T

• The DBM-600 can be used as a system by connecting it to other machines such as a collator.

• When the 4 STITCH KIT (option) is installed, four stitches can be applied to a booklet.

[A] Saddle stitch

[B] Saddle stitch and fold

[C] Side stitch

[D] Side stitch and fold

[B][A] [C] [D]

• When the CALENDAR KIT (option) is installed, a calendar as shown in the gure below can be made.

1-2. Features of the DBM-600T

• The DBM-600T is a fore-edge trimmer and is used as a downstream unit of the DBM-600.

The trimming width is 1 to 25 mm/0.04 to 0.98 inch. When the number of sheets is 12 or less, up to 75

mm/2.95 inches can be trimmed.

• A head and foot trimmer can be connected to the DBM-600T as a downstream unit.

1-3

Chapter 1 Before Operation

2. Names and Functions of Components

2-1. DBM-600 external parts

parsparssparts

[1]

[2]

[15]

[3]

[4]

[7]

[8]

[5]

[6]

[9] [10] [11] [12] [13]

[14]

No. Name Function

[1] Power switch

”1-2. Turning oﬀ the power” (p.2-2)

[2] Inlet for D Link connector Insert the D Link cable of the machine equipped with a D Link unit into

this connector.

[3] Top cover R Cover for ensuring user safety. This machine will not operate if open.

1-4

Chapter 1 Before Operation

No. Name Function

[4] Control panel Use this to operate the machine.

(p.1-15)

[5] Emergency stop switch Press this switch to stop the machine in emergencies. Turn the pressed

switch to the right to release it. While pressed, the machine will not

start and its moving parts will also not move.

[6] Top cover L Cover for ensuring user safety. This machine will not operate if open.

[7] Fold misalignment adjustment Adjusts the angle of the folding side guides.

(p.2-31)

[8] Fold misalignment adjustment knob

screw

Secures the angle of the folding side guides.

(p.2-31)

[9] Paper receiver knob screw Secures the position of the paper receiver.

(p.2-17)

[10] Paper receiver stopper Stops side-stitched or corner-stitched booklets on the paper receiver.

(p.2-17)

[11] Paper receiver Receives side-stitched or corner-stitched booklets.

(p.2-17)

[12] Paper receiver booklet holder Holds down the booklets ejected to the paper receiver.

[13] Handle Used to pull the paper receiver.

[14] Paper receiver full loading sensor

height adjustment

Secures the height of the paper receiver full loading sensor.

[15] Power inlet Connector for the power cord.

1-5

Chapter 1 Before Operation

2-2. DBM-600T external parts

[6]

[7]

[5]

[4]

[1]

[2]

[3]

[8] [9]

No. Name Function

[1] Top cover Cover for ensuring user safety. This machine will not operate if open.

[2] Control panel Use this to operate the machine.

(p.1-36)

[3] Emergency stop switch Press this switch to stop the machine in emergencies. Turn the pressed

switch to the right to release it. While pressed, the machine will not

start and its moving parts will also not move.

[4] Paper guide roller unit Holds a booklet and supports the stacker.

(p.2-46)

[5] Damage prevention switch Prevents the paper guide roller unit from hitting the main unit.

(p.2-46)

[6] Kicker connector Connector for the kicker.

[7] Power inlet Connector for the power cord.

[8] Scrap box Ocuts are ejected to this box.

(p.4-3)

[9] Scrap box stopper Secures the position of the scrap box. When storing the scrap box,

push the box until it stops.

(p.4-3)

1-6

Chapter 1 Before Operation

2-3. DBM-600 internal parts (stitching section)

[5]

[6]

[7]

[8]

[11]

[10]

[9]

[13]

[14]

[1]

[2]

[10]

[4]

[3]

[15]

[3]

[4]

[12] [12]

No. Name Function

[1] Stitcher head Stitches paper with a wire.

(p.1-12)

(p.4-4)

[2] Stitch release lever Used to release stitching operations of the stitcher head. Use this for

corner stitches.

(p.2-17)

[3] CALENDAR KIT stopper Used for CALENDAR KIT (option). When paper reaches here, the

stopper goes down.

[4] Stitching side guide knob screw Used to secure the angle of the stitching side guides.

(p.2-32)

[5] Stitching side guide adjustment Used to adjust the angle of the stitching side guides.

(p.2-32)

[6] Stitch ejection roller R height

adjustment

Adjusts the height of the ejection roller R.

(p.2-38)

[7] Stitch ejection roller R knob screw Secures the ejection roller height.

(p.2-38)

[8] Stitch ejection roller R Conveys stitched paper to the folding section.

(p.1-27)(p.2-38)

[9] Stitching paper holder knob screw Secures the stitching paper holder.

(p.2-37)

[10] Stitching side guide Aligns the sides of paper conveyed to the stitching section.

(p.2-14)(p.2-25) (p.2-27)

[11]

Infeed conveyance unit Conveys paper to the stitching section.

(p.2-35)

[12]

Stitching back guide Aligns the leading and trailing edges of paper conveyed to the

stitching section.

(p.2-21)(p.2-27)

[13]

Infeed paper holder Prevents paper conveyed to the stitching section from rising.

(p.2-37)

[14]

Infeed conveyance unit lock lever Locks and releases the infeed conveyance unit.

(p.2-35)(p.5-6)

[15]

Side-stitching stopper Used during side-stitching operations. Stops paper conveyed from the

infeed section.

1-7

Chapter 1 Before Operation

[6][5]

[7]

[2]

[3]

[4]

[1]

No. Name Function

[1] Saddle-stitching stopper lock plate Secures the saddle-stitching stopper angle.

(p.2-32)

[2] Saddle-stitching stopper angle

adjustment

Adjusts the angle of the saddle-stitching stopper.

(p.2-32)

[3] Saddle-stitching stopper Used during saddle stitching operations. Stops paper conveyed from

the infeed section.

(p.2-32)

[4] Stitch ejection roller L Conveys stitched paper to the folding section.

(p.1-27)

[5] Stitching paper holder Prevents paper conveyed to the stitching section from rising.

(p.2-37)

[6] Stitching paper holder knob screw Secures the stitching paper holder.

(p.2-37)

[7] LED inner lamp LED lamp for partially lighting up inside the machine.

1-8

Chapter 1 Before Operation

2-4. DBM-600 internal parts (folding section)

[12]

[16]

[12]

[18]

[17]

[9][9] [11]

[15]

[4]

[5]

[10]

[13]

[3]

[6] [7] [8]

[2]

[1]

[14][15]

[11]

[19]

[14]

1-9

Chapter 1 Before Operation

No. Name Function

[1] Folding back guide unit Unit for aligning the leading and trailing edges of paper conveyed to

the folding section.

(p.5-7)

[2] Folding back guide Aligns the leading and trailing edges of paper conveyed to the folding

section.

(p.2-23) (p.2-25)

[3] Folding side guide Aligns the sides of the paper conveyed to the folding section.

(p.2-14)(p.2-23)

[4] Press roller Presses paper folded into two.

[5] Folding roller Folds paper into two.

(p.2-38)

[6] Fold paper holder Prevents paper conveyed to the folding section from rising.

(p.2-40)

[7] Folding stopper Stops booklets conveyed to the folding section.

(p.2-16)

[8] Fold paper holder height adjustment Adjusts the height of the fold paper holder.

(p.2-40)

[9] LED inner lamp LED lamp for partially lighting up inside the machine.

[10] Press roller gap adjustment lever Adjust the clearance (gap) between the press rollers. Use this when the

surface of a booklet is stripped.

(p.2-36)

[11]

Pressure adjustment lever Adjusts the pressure of the press roller.

(p.2-39)

[12]

Ejection pressure adjustment lever Adjusts the ejection pressure.

(p.2-40)

[13]

Press roller gap xing lever Secure the clearance (gap) between the press rollers.

(p.2-36)

[14]

Fold ejection roller gap knob screw Secures the fold ejection roller gap adjustment lever.

(p.2-36)

[15]

Fold ejection roller gap adjustment

lever

Adjust the clearance (gap) between the fold ejection rollers. Use this

when the surface of a booklet is stripped.

(p.2-36)

[16]

Fold paper holder knob screw Secures the height of the fold paper holder.

(p.2-40)

[17]

Ejection at belt Ejects paper folded into two.

[18]

Page insertion roller height

adjustment

Adjusts the height of the insertion rollers.

(p.2-16)(p.2-39)

[19]

Page insertion roller knob screw Secures the height of the insertion rollers.

(p.2-16)

1-10

Chapter 1 Before Operation

2-5. DBM-600T internal parts

[11]

[13]

[12]

[14]

[15]

[16]

[5]

[4] [3]

[6]

[7]

[1]

[2]

[9][8]

[10]

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