Duplo DF-505N User manual

Duplo Folder

DF-505N

Instruction Manual

DUPLO CORPORATION

[120V]

Please let our service people install the machine.

This page is a blank page.

1

CONTENTS

1. Safety Precautions............................... 2

2. Usage Precautions............................... 4

2-1. Power Supply............................................. 4

2-2. Operating Environment.............................. 4

2-3. Storage Conditions .................................... 4

2-4. Maintenance .............................................. 4

3. Installing the Unit................................. 5

3-1. Removing the Press Release Lever .......... 5

3-2. Component Parts....................................... 6

3-3. Bearing support levers............................... 6

3-4. Attaching the Parts .................................... 7

4. Names of the Parts .............................. 8

5. Names and Functions of the

Control Panel Parts.............................. 9

6. Precautions before Use..................... 10

6-1. Paper to Be Used .................................... 10

6-2. Precautions for Stacking Paper ............... 10

7. Operation Procedures ....................... 12

7-1. Fixed Folding of Fixed Paper................... 12

7-2. Single-Folding Paper Neatly .................... 17

7-3. Single-Folding Hard Paper Neatly ........... 19

7-4. Double Folding Thick Paper .................... 20

7-5. Folding 5 (W) x 7 (L) Medium

Thickness Paper (Below 81.4 g/m

2

)......... 23

7-6. Specil Folding of Fixed Paper.................. 26

8. Folding Adjustments ......................... 29

8-1. Adjusting the Folding Slippage in the

Vertical Direction...................................... 29

8-2. Adjusting the Folding Slippage in the

Horizontal Direction ................................. 31

9. Using Non-Fixed Paper...................... 32

9-1. Fixed Folding Procedures........................ 32

10.Cross Folding ..................................... 34

10-1. Precautions upon Use ............................. 34

10-2. Cross Folding of Fixed Paper .................. 34

10-3. Cross Folding of Non-Fixed Paper .......... 37

11.Troubleshooting................................. 42

11-1. Paper has Jammed near the Paper

Feed Ring ................................................ 42

11-2. Paper has Slipped near the Paper Feed

Section..................................................... 42

11-3. Paper has Coiled around the Rubber Roll

inside the Unit ..........................................43

11-4. Paper has Jammed at the First Folding

Plate......................................................... 43

11-5. Paper has Jammed at the

Second Folding Plate............................... 44

11-6. Paper has Jammed near the Stacker ...... 45

12.Emergency Stops............................... 46

13.Troubleshooting Guide...................... 47

14.Cleaning the Unit................................ 50

14-1. Cleaning the Rubber Roll......................... 50

14-2. Cleaning the Paper Feed Ring ................ 51

15.Specifications..................................... 52

INTRODUCTION

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

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

manual in a safe place for future reference.

2

1. SAFETY PRECAUTIONS

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 fire or electrical shock.

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

fire or electrical shock.

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

result in injury.

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

could cause electrical shock.

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

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

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

Always observe the cautions and warnings 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.”

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

means “Caution: high temperature.”

3

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

Such flammable gas 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 fire.

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

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

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

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

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

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

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

This could result in damage, fire or electrical shock.

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

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

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

Before cleaning this unit, turn 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.

1. Safety Precautions

4

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.

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 : 1.5A

2-2. Operating environment

Operate this unit in the following environment:

• where the temperature range is between

5 and 35°C,

• where the humidity range is between 20

and 85%RH (no dew condensation),

• which is not subject to direct sunlight,

• which is subject to little or no vibration,

2-3. Storage conditions

Store this unit in the following environment:

• where the temperature range is between

–10 and 50°C, (no dew condensation)

• where the humidity range is between 10

and 90%RH (no dew condensation),

• which is not subject to direct sunlight,

• which is subject to little or no vibration,

2-4. Maintenance

To protect the special features of this unit, the customer should never apply oil or grease to

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

manual).

Please contact your dealer in case of any problem.

• 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.

• 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.

5

3. INSTALLING THE UNIT

3-1. REMOVING THE PRESS RELEASE LEVE

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

becoming distorted.

Be sure to remove it when installing the unit.

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

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

1 Two press release levers are inserted in the left and right shaft edges of the rubber

roll.

2 First remove press release lever(A).

• To remove, push inwards and pull out the press release lever (A), as shown in the figure.

Also remove that of the operating side in the same way.

• Next, pull out press release lever(B) as shown in the figure.

Also remove that of the operating side in the same way.

Press release lever (A)

Press release lever (B)

Press release lever (A)

Press release lever (B)

Press release lever (A)

Press release lever (B)

<Non-operating side>

6

3. INSTALLING THE UNIT

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

3-2. COMPONENT PARTS

No.

Name

Qty. No.

Name

Qty.

First folding plate

Second folding plate

Cross folding lever

Instruction Manual

Guide plate unit

1

2

3

4

5

1

12

3

54

3-3. BEARING SUPPORT LEVERS

Bearing support lever

Support the bearing with the two bearing support levers.

• Rotate the lever in the arrow direction and support the bearing.

<Non-operating side>

7

3. INSTALLING THE UNIT

1 First, attach the second folding plate.

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

the folding plate to “UNLOCK”.

• Next, insert the folding plate into the unit.

• After inserting it properly, push the lock lever to

“LOCK”.

2 Attach the first folding plate in the

same way.

* As the first folding plate is not provided with a lock

lever, it only needs to be inserted into the unit.

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

power, push the lock lever to "UNLOCK", and

remove the folding plate. (Only for second folding

plate.)

3-4. ATTACHING THE PARTS

3 Attach the cross folding lever at its

proper place.

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

Second folding plate

First folding plate

Cross folding lever

8

4. NAMES OF THE PARTS

First folding plate

Control panel

Second folding plate

Power switch

Paper set lever

Paper receiving tray

Paper receiving

stopper

Stacker roller

Auxiliary paper

feed plate

Paper feed table

Guide

Top cover

Rubber roll

Paper feed ring

(For moving)

Paper feed ring

Paper feed pressure

adjusting knob

Slant correction

paper feed knob

9

1

2

3

4

5

6

5. NAMES AND FUNCTIONS OF THE

CONTROL PANEL PARTS

Reset button

Counter

Table of Stacker

Roller Positions

Start button

START

Stop button

STOP

Power supply

lamp

The counter is reset to "0" when the reset button is pressed.

Counts and shows the number of sheets that have been folded.

The stacker rollers of the paper discharge section are positioned differently according

to the paper size and folding style.

Refer to this table for the appropriate positions.

When this button is pressed, the unit starts-up and folding operations can be carried out.

When this button is pressed, the unit stops.

Lights up when the power switch is ON.

No.

Name Function

10

6. PRECAUTIONS BEFORE USE

• Straighten folded or curled paper before use.

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

before use.

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

machine, and cause other problems such as dirtying the

folded surface with ink.

• If curled paper is used, depending on the environmental

condition(temperature, humidity), paper quantity, paper

type, paper couch condition, folding speed, etc. it may

not flow smoothly into the folding plate or may not be

folded properly.

• Should such problems occur, reduce the folding speed or

straighten the paper before continuing use.

6-1. PAPER TO BE USED

6-2. PRECAUTIONS FOR STACKING PAPER

• Problems such as folding slippage and paper jam etc.

will ariseif the paper is not stacked neatly on the paper

feed table. Therefore, be sure to stack the paper neatly.

11

6. PRECAUTIONS BEFORE USE

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

or chain feed may occur.

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

feed table, lower the paper set lever while pressing the

back edge of the paper.

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

paper feed ring in front lightly.(Arrow)

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

with the printed surface up on the paper feed table.

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

printed surface of some paper will be folded outwards.

Paper

Guide plate

Paper set lever

Paper

Paper feed rings

Single fold Double fold Letter fold Brochure foldIrregular accordion fold Accordion fold

12

Start the various fixed folding operations for fixed paper as follows.

7. OPERATION PROCEDURES

7-1. FIXED FOLDING OF FIXED PAPER

1 Insert the power cord in the electrical

outlet and turn on the power.

• Press “ I ” to turn on the power.

• Press “O” to turn off the power.

2 Raise the paper set lever and place

some paper on the paper feed table.

• Loosen the fixing screws of the guide, and move

the guide slightly with a space lift between the

guide and the paper.

• Loosen the paper and stack them neatly at the

center of the paper feed table.

• Insert the paper until its front part touches the front

guide plate lightly.

3 After pressing the guide to the side of

the paper lightly, tighten the screws

to secure the guide.

Paper can be stacked to a height of

approximately 2 inch at one time. Do not stack

too many sheets of paper.

4 Lower the paper set lever.

Power switch

Paper set lever

Paper

Guide

Fixing screw

Fixing

screw

Guide

Fixing screw

Paper set lever

13

5 Adjust the rough adjustment knob of

the folding plates to the mark of any

folding mode.

• Adjust the rough adjustment knobs of first and

second folding plates to the desired marks

according to the style in which the paper is to be

folded.

• The rough adjustment knob can be moved freely

by pulling it up.

Although the rough adjustment knob can be

moved up and down, it cannot be rotated.

• After adjusting the position of this knob, be sure to

rotate the fine adjustment knob several times.

6 Set the paper feed pressure adjusting

knob to “thin paper”.

* If the paper slips, and no paper is conveyed, raise

the paper feed pressure from “thin paper” to “thick

paper”.

7. OPERATION PROCEDURES

Rough adjustment knob Rough adjustment knob

Second folding plate First folding plate

Rough adjustment knob

Fine adjustment knobFine adjustment knob

Second folding plate First folding plate

Paper feed pressure adjusting knob

14

7 Set the position of the stacker rollers.

• Referring to the table of stacker roller positions,

position the stacker rollers.

As the figures in this table of stacker roller

positions are approximations, select the best

position taking into consideration the folding

speed and paper quality.

7. OPERATION PROCEDURES

Table of Stacker Rollers Positions

Length of Paper Fold

7 — 8-1/2 inch

6 — 7 inch

5 — 6 inch

4 — 5 inch

1-5/8 — 4 inch

Folding Mode

LD : Single Fold, Irregular Accordion Fold, Brochure Fold

Single fold of paper bigger than LD.

LG : Irregular Accordion Fold, Brochure Fold

LT : Single Fold, Irregular Accordion Fold, Brochure Fold

LD : Letter Fold, Accordion Fold

LG : Letter Fold, Accordion Fold

LD : Double Fold

LT : Double Fold, Letter Fold, Accordion Fold

LG : Double Fold

Number

1

2

3

4

5

Stacker rollers

15

7. OPERATION PROCEDURES

8 Press the start button to test the

folding.

Set the paper on the paper feed table, and with the

paper set lever raised, press the start button. The

paper feed ring slips and the machine stops. Press

the start button after lowering the paper set lever.

• The paper will be folded properly if it is folded after

it has reached the stopper inside the folding plate.

• In some cases, the paper flowing into the folding

plate may be folded before it reaches the stopper due

to conditions such as environmental conditions

(temperature, humidity), its quantity, its type, paper

couch conditions, folding speed, etc., and therefore

not be folded properly.

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

rubber roll and cause problems.

• This phenomenon may occur when different paper

quantity, type, and couch conditions are used.

• Check that the paper has been folded properly.

Check from the second piece of paper folded.

Paper for testing folding

16

• If the sheets of paper have not been folded

satisfactorily, refer to the following steps.

1 If there is folding slippage in the vertical direction,

rotate the fine adjustment knob and correct the

folding slippage.

Refer to “8-1. Adjusting the folding slippage in the

vertical direction”.

2 If the folding has slipped in the horizontal

direction:

Rotate the “slant correction knob” and adjust the

folding slippage.

Refer to “8-2. Adjusting the folding slippage in the

horizontal direction”.

Check the folding slippage in the horizontal

direction with the second sheet of test fold

sample.

9 After completing all preparations,

start operation.

• Press the start button.

10 The unit stops automatically when

there is no more paper on the paper

feed table.

7. OPERATION PROCEDURES

Fine adjustment knobFine adjustment knob

Second folding plate First folding plate

Slant correction knob

17

7. OPERATION PROCEDURES

11 To interrupt or to stop operation,

press the stop button.

1 While looking at the scale, roughly adjust the stopper of first folding plate to the

paper size.

1 Slide the rough adjustment knob of first folding plate while lifting it up, move the stopper to the single-folding

position for the paper size, and set the stopper.

2 After adjusting the position of the rough adjustment knob, be sure to rotate the fine adjustment knob to the left and

right several times and make sure that they are engaged properly.

7-2. SINGLE-FOLDING PAPER NEATLY

In DF-505N, paper is single-folded by folding plate 1. The rough adjustment knob of

folding plate 2 must therefore be set to ''Press" position as shown in the figure.

To single-fold paper, perform the following procedure.

Rough adjustment knob

Fine adjustment knob

18

7. OPERATION PROCEDURES

2 Adjust the stopper of second folding plate.

1 While lifting the rough adjustment knob of second folding plate, slide it to the ''Press" position shown in the figure

and set it there.

2 Rotate the fine adjustment knob to the left until the rough adjustment knob presses against it lightly but completely.

Note : Rotating the fine adjustment knob excessively will result in paper jamming, improper folding, and other

mechanical malfunctions.

3 Start folding operations hereafter using the normal procedure.

If the above problem occurs, it means that the stopping position of the stopper is too apart. Rotate the fine adjustment knob to

the left until the folding stopper lightly but completely presses against it.

WHAT TO DO WHEN :

When single-folding paper, if the folding stopper (rough adjustment knob) of second folding plate is not at the correct

position, the following problems may occur according to the type of paper used (thickness, paper quality, etc.)

If the paper is thin (no hardness) ........ A crease about 0.59 inch from the folded line of the paper parallel to it will be formed.

Rough adjustment knob

Fine adjustment knob

Second folding plate

0.59inch

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Duplo DF-505N User manual

Duplo DF-505N User manual

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