Duplo EX-2000 User manual

Brand: Duplo

Model: EX-2000

Category: Folding machines

Type: User manual

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Duplo Express

Sealer EX-2000

Service Manual

Introduction

Symbols and Notations in this manual

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. Ignoring the warning may result in death or

serious injury of personnel.

CAUTION

Indicates a medium degree of potential danger. Ignoring the caution may result in injury of

personnel or damage to properties.

Examples of pictorial symbols

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

prohibited is indicated by a picture inside the circle. ( In the example on the right

indicates ‘disassembly is prohibited.’

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 on the right indicates ‘Remove the plug from the outlet.’

Other Notations

IMPORTANT Notes on faulty operation/maintenance which can damage products or disturb

its performance.

REF. Information in regards to the performance of the product, operation or maintenance.

Introduction 1

1. Specifications 5

2. Parts names and their functions 6

3. Paper flow and operating principle 7

4. Operating sequence 8

5. Circuits and their operation 8

6. Maintenance and adjustments 11

7. HELP mode 20

8. Error message displays 23

9. Electrical parts 26

Contents

1. Specifications

No. Item Specification Remarks

1 Type Desktop

2 Model name EX-2000

Paper size

Length 279.4 (11”) - 355.6mm (14”)

Width 210mm - 215.9mm (8.5”)

Finished size

Length 93.1mm - 48.5mm

Width 210mm - 215.9mm (8.5”)

24lb 90g/ - 32lb 120g/

Paper type

Envelop paper with pressure sensitive adhesive along

the edges of the front

* Do not use envelop paper with pressure sensitive

adhesive applied overall.

7000 sheets/hour FAST

Processing speed

8.5”×11”

Z-fold envelop

5000 sheets/hour SLOW

Under operating

temperature

Feed system

Friction feed system based on rubber rollers and paper

separation plate

Feed capacity 200 Z-fold (accordion fold) envelopes (thickness: 28lb)

Fold types V-fold, C-fold, Z-fold, EZ-fold, EC-fold

1st panel 60mm - 266.7mm

10 Fold size

2nd panel 60mm – 118.5mm

11 Stacker type Gravity stacker

12 Stacker capacity 200 Z-fold (accordion fold) envelopes (thickness: 28lb)

Functions & safety

system

Test operation

Paper detection

JAM detection for all paper paths

Cover interlock

Manual feed

Double feed detection

Speed selection

Batch count

Dimensions

[In use] 756mm D ×701 W ×533 H

[Folded] 633 D ×465 W ×403 H

5 Weight 54kg (folder: 22.5kg, sealer: 31.5kg)

6 Power source AC115 ±10 60Hz 3A

7 Power consumption 330W

Operating

temperature

10 – 30

Operating humidity

40 – 70% (No condensation)

Notice: Specifications are subject to change for improvement without notice.

2. Parts names and their functions

No. Name Function

1 Feed pressure

adjuster lever

Adjusts feed pressure according to paper thickness. Normally set to

“Standard”.

2 Paper feed guides Makes smooth paper transport by adjusting the guides to the paper size.

3 Double feed detection

adjuster knob

Adjusts double feed detection according to paper thickness.

4 Paper set lever Lower this lever before loading paper and raise it to start operation.

5 Control panel Use keys for operation. The display shows the current operational status.

6 Power switch Press the “I” to turn on and “” to turn off.

7 Folding tray 1 Used for all foldings (Z-fold, C-fold, V-fold)

8 Folding tray 2 Used for Z-fold and C-fold. Install the turn guide for V-fold.

9 Support tray Used when setting paper.

10 Handle slot Insert the handle to remove jammed paper or clean the rubber rollers.

11 Stacker stopper Adjust this stopper according to ejected paper.

12 Stacker guide Adjust these guides according to ejected paper.

13 Safety cover Open this cover to adjust the transport guide or to remove jammed paper.

PPS sensor 1

Paper

tray

Paper

3. Paper flow and operating principle

3-1 Folding section

1 Papers loaded on the feed tray are separated to 1

sheet by the separator unit when being fed by the

paper feed ring.

(The timing for feeding the paper is controlled by the

PPS 1 which senses paper flow.)

2 In the double feed detecting section, the paper presses

up the upper double feed detection roller when it passes

between the rollers. When the upper roller is pressed

up higher than reference position, double feed is detected

and the machine stops.

(Error message ‘DOUBLE FEED’ will appear in the display.)

3 The paper passed through the double feed detection

section is fed to the folding tray 1 by the folding rollers

1 and 2, and stops at the stopper. The stopped paper

sags and is fed to the path between the folding rollers

2 and 3, and then is fed to the folding tray 2.

Support tray

Paper feed ring

Paper tray

PPS sensor 1

(light receiving)

Paper separator unit

PPS sensor 1

(light emitting)

Double feed

detection roller

Folding roller 1

Folding roller 2

Folding tray 1

Folding roller

Folding roller 3

PPS sensor 2

(light receiving)

PPS sensor 2

(light emitting)

Ejection

roller

Parts name

Double feed

detection roller

Folding roller 3

Folding roller 1

Folding tray 1

Folding roller 2

4 The paper fed to the folding tray 2 sags by bumping

the stopper as well as the flow in the folding tray 1,

and is fed to the path between the folding rollers 3

and 4, and then is fed to the sealer section by the

ejection roller.

(When V-fold is executed, the paper is fed directly

to the path between the folding rollers 3 and 4 from

the folding tray 1 by leading with the turn guide.)

3-2 Sealer section

1. The paper fed to the sealer section touches the stopper,

and is fed to the pressure roller section by the feed

rollers and roller.

2. The temporary sealed part in the folding section of the

paper fed is peeled off by the bracket F (upper and lower)

installed adjacent to the feed roller, and then is fed to the

pressure roller section.

3. The paper is applied by strong pressure between the

pressure rollers, and pressure sensitive adhesive

parts are adhered.

Folding tray 2

Folding roller 2

Stopper

Folding roller 4

Stopper

PPS sensor 3

(light receiving)

PPS sensor 3

(

ht emittin

Feed roller

Pressure roller (lower)

Pressure roller (upper)

Bracket F (lower)

Bracket F (upper)

Parts names

Roller

Feed roller

Roller

Pressure

roller

(

)

Pressure roller

(lower)

Folding

roller 3

Bracket F (upper)

Bracket F (lower)

4. Operating sequence

5. Circuits and their operation

Paper empty SW circuit

A sensor is installed on the feed tray

and detects paper empty.

PPS1 circuit

PPS1 is installed in the paper feeding section,

and detects that the paper is properly fed.

PPS2 circuit

PPS2 is installed in front of the eject roller,

and detects that the paper is ejected.

PPS3 circuit

PPS3 is installed at the back of the feed roller,

and detects that the paper is properly fed.

6. Maintenance and adjustments

●Exterior

* Remove the folding plate, support tray, stacker guides, and the stacker stopper before starting maintenance.

●Removing covers

[Side cover R assy]

Remove the 4 screws in the circles in the photographes 1, 2,

and 3. Disconnect the connectors (yellow, yellow, white,

white) interlock swtich connecting

to the machine, and then remove

the cover R.

[Side cover L]

Remove the 2 screws in the circles in the phototgraph 4.

Remove the side cover L with lifting up.

Refer to the photograph 5 for installing the side cover L.

Fit the stay hole at the lower part of the side cover L on the screw

of the rubber foot at the lower part of the frame. (2 points)

Side cover L

Sealer cover 2

Sealer cover 1

Side cover R (lower)

Side cover R assy

Interlock switch connecto

Photograph 1

Photograph 3 Photograph 2

Photograph 5

Photograph 4

[Sealer cover 1]

Remove the 3 screws (3mm taptight) indicated in the right

photograph and remove the cover toward you.

[Sealer cover 2]

Remove the 3 screws in the circles in the right photographes,

Disconnect the connectors (yellow, yellow, white, white) of

the interlock switch connecting to the machine, and then

remove the sealer cover 2 with lifting up.

●Maintenance

[Folder side]

Paper feed section

Slide the paper feed ring assy in the direction of the arrow in the

right photograph.

After joint part is released, extend the paper feed guides, and

pull out the joint toward you.

Loosen the set screw and remove the paper feed ring. (3 pcs.)

For installing, follow the reverse procedure.

Interlock switch connecto

Loosen the screw.

Take out to the direction of the arrow.

Tighten the set screw so that it fits the counterbore of

the paper feed shaft.

Paper feed rings should be r eplaced as a set (3 pcs.).

Mixture of old ring and new one may cause skew.

Replacing the main PCB

Remove the 10 connectors and the 4 screws

and then remove the main PCB.

Replacing the main motor

Remove the 4 screws indicated in the right photograph,

and remove the rear cover.

Remove the 4 nuts indicated in the

photograph 1, and remove the main

motor toward the arrow in the

photograph 2.

Caution should be taken for the belt tension when installing the motor.

(Adjust the motor position by applying load of 300g to the midpoint of

the belt between the pulleys so that a slack (3mm±1mm) can be made.)

Main PCB

Rear cover

Photograph 1

Photograph 2

Connector Screw

Replacing the flat belt

Remove the 3 screws indicated in the photograph

(left side), and then remove the bracket.

Take out the paper feed clutch from the

bush in the photograph (right side).

Loosen the 2 screws indicated in the right

photograph to move the tension roller, and

then remove the belt.

For installing the belt, follow the reverse procedure.

(Adjust the position of the tension roller by applying load of 300g

to the indicated place in the right photograph so that a slack

(1mm±0.5mm) can be made.)

[Sealer side]

Replacing motor and electrical parts

1. Remove the timing belt for driving conveyer. (no adjustment)

2. Loosen the 4 screws in the circles in the photograph 1, and remove the timing belt for driving roller

3. Remove the C ring and then remove the pulley unit (idler) in the photograph 1.

4. Remove the 4 screws in the squres in the photographs1 and 2.

Bracket

Paper feed

clutch

Photograph 2

Timing belt for driving conveyer

Pulley unit (idler)

Photograph 1

Roller driving belt

5. Remove the encoder sensor and PPS3 cable,

and then take out the cabinet 2 by lifting it up

as shown in the right photograph.

6. Inside of the cabinet 1 is as shown

in the right photograph.

(Refer to the circuit diagram on page

28.)

Replacing conveyer belt

1. Remove the 4 screws indicated in the photograph 1

to remove the cabinet 2 and the conveyer unit.

2. Remove the screw in the circle in

the photograph 2 to pull out the shaft.

Remove the stopper.

(Do not lose the plastic balls (2 pcs.) by the side of

thumb screw and the sliders (2 pcs.) at both sides.)

3. Remove the screws in the squres in the photographs

2 and 3, and then remove the upper cover.

4. Remove the screws in the circles in the photograph 4,

and then remove the pipes.

Remove the bearing stopper installing the roller, and

then remove the roller.

5. Replace the belt. After replacing the belt,

Install the roller and the pipes. Adjust the

belt tenstion with the tension in the squres.

(A slack should be 1±0.5mm when pulling up

the place indicated with a blue arrow by the

force of 400g.)

Cabinet 1

Cabinet 2

C gear moto

Circuit protector

Fan motor

Power relay

SSR

Capacitor

Photograph 1

Photograph

Photograph 2

Photograph 4 Roller Pipes

Replacing scraper

Remove the 4 screws indicated in the right photograph,

and then remove the both bracket Rs.

(Both the upper bracket R and the lower one are the same.)

Remove the screws indicated in the right

photograph, and then replace the scraper.

After replacing it, install the scraper so that

it appears by 7mm from the edge of the

bracket.

[Adjustments]

Adjusting double feed detection unit

Parts names

1. Turn the eccentric pin until the gap between the upper

and lower detection rollers is at the maximum setting.

Insert a sheet of 70kg (approximately) paper between

the detectio rollers.

2. Turn the eccentric pin until it touches the hole,

Then fasten it with the screw.

3. Adjustment completes when the lever does not move

by running a sheet of paper between the detection

rollers and it moves by running 2 sheets of paper.

Folding roller 2

Folding roller 1

Detection roller

(lower)

Detection roller

(upper)

Hole

Eccentric pin

Lever

Photo sensor

Fulcrum

Supporting point

Eccentric

Enlarged

veiw

There should be no gap.

Paper

Adjusting folding roller

1. Loosen the 2 screws holding the bearing holder of each roller.

Slide the folding rollers 1 and 3 along the elongate hole taking

the roller 2 as reference so that these rollers are pressed up the

roller 2.

2. Adjust the folding roller 4 taking the folding roller 3 adjusted in

the step 1 as reference.

* Each roller should be symmetrical to the left and right, and

there should be no gap between rollers. (Asymmetrical roller

pressure causes snaking or wrinkling.)

* After adjustment, a roller should rotate without flat belt and all rollers should drive together.

Adjusting pressure of pressure roller

1. Turn the screw shaft for adjusting pressure

until the top edge of the shaft touches the

pin top.

2. Turn the screw shaft clockwise with a handle

for 180 from the contact position in the step 1.

(symmetrical to the left and right)

* Turning the screw shaft clockwise increases

the pressure.

* Turning the screw shaft counterclockwise

decreases the pressure.

Note: Asymmetrical roller pressure causes snaking or uneven

pressurizing.

Adjusting interlock switc

Handle slot, sealer side

Safety cover

Folding tray 1

Folding tray 2

Handle slot, folder side

* 2 pcs. of micro switch (5V, 24V) are set at each 5 interlock

switches. The machine operates only when all the micro switches are ON.

Circuit diagram

Screw shaft

Belleville

spring

Bearing holder

Care should taken for installed

direction of belleville spring.

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Duplo EX-2000 User manual

Brand: Duplo

Model: EX-2000

Category: Folding machines

Type: User manual

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Duplo EX-2000 User manual

Duplo EX-2000 User manual

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