Duplo DSF-2000 Maintenance Manual

Brand: Duplo

Model: DSF-2000

Type: Maintenance Manual

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Duplo DSF-2000

Sheet Feeder

Maintenance Manual

SHEET FEEDER

DSF-2000

MAINTENANCE MANUAL

99T-M12M0-0107-0

TABLE OF CONTENTS

CHAPTER 1 MECHANISM

1. Outline of Mechanism of This Machine...........1-2

2. Paper Feed Mechanism..................................1-5

3. Paper Feeder A...............................................1-9

4. Paper Feeder B...............................................1-13

5. Reversal Section.............................................1-15

6. Conveyance Bridge Section............................1-19

7. Upper Door Section ........................................1-20

8. Lower Door Section ........................................1-21

9. End Mark Detection Section ...........................1-22

10. Double-feed Detection Section .......................1-25

11. Adjusting the Tension of the Timing Belt ........1-26

12. Structure of Conveyance Rollers and

Conveyance Guides........................................1-28

13. Paper Feed Count of Paper Feeder A ............1-29

14. Maintenance ...................................................1-30

CHAPTER 2 ELECTRICAL

COMPONENTS

1. Block Diagram of Structure and Outline of

Each Block ......................................................2-2

2. Errors and Causes ..........................................2-9

3. Maintenance Menu .........................................2-12

4. Precautions on Replacing the MC Unit ...........2-15

5. Precautions on Replacing Fuses ....................2-16

6. LCD Map.........................................................2-17

7. Overall Schematic Diagram ............................2-27

8. Wiring Diagram ...............................................2-28

1-1

99T-M12M0-0107-0

CHAPTER 1

MECHANISM

1. Outline of Mechanism of This Machine...........1-2

1-1. Operations of Machine during Count

Processing Mode and When Using

End Mark (Count Mode) ........................1-2

1-2. Operations of Machine during Random

Processing Mode ...................................1-2

1-3. Positions of Main Parts ..........................1-3

2. Paper Feed Mechanism ..................................1-5

2-1. Outline of Paper Feed Mechanism ........1-5

2-2. Suction Conveyance Section.................1-6

2-3. Solenoid Valve.......................................1-7

2-4. Separator Air Box ..................................1-7

2-5. Separator ...............................................1-8

2-6. Paper Feed Conveyance .......................1-8

3. Paper Feeder A...............................................1-9

3-1. Detection of No-paper............................1-10

3-2. Side Guide A..........................................1-11

3-3.

Paper Feed Tray Up and Down Section ...

1-12

3-4. Greasing the Secondary Conveyance

Roller of the Paper Feed Section...........1-12

4. Paper Feeder B...............................................1-13

4-1. Detection of No-paper............................1-13

4-2.

Paper Feed Tray Up and Down Section ...

1-13

4-3. Greasing the Secondary Conveyance

Roller of the Paper Feed Section...........1-14

5. Reversal Section .............................................1-15

5-1. Mechanism ............................................1-16

5-2. Replacing the Clutch..............................1-17

5-3. Adjusting the Gate Solenoid and

Stopper ..................................................1-18

5-4. Reversal Counter...................................1-18

6. Conveyance Bridge Section............................1-19

6-1. Replacing the Paper Ejection Sensor

and Microswitch .....................................1-19

6-2. Adjusting the Magnet Catcher ...............1-19

6-3. Greasing the Secondary Conveyance

Roller .....................................................1-19

7. Upper Door Section ........................................1-20

7-1. Removing Procedure .............................1-20

7-2. Adjusting the Magnet Catcher ...............1-20

7-3. Greasing the Secondary Conveyance

Roller .....................................................1-20

8. Lower Door Section ........................................1-21

8-1. Removing Procedure .............................1-21

9. End Mark Detection Section ...........................1-22

9-1. Outline ...................................................1-22

9-2. Replacing the End Mark Sensor ............1-23

9-3. Adjusting the Light-emitting Volume of

the End Mark Sensor

(Maintenance Menu)..............................1-24

9-4. Cleaning.................................................1-24

10. Double-feed Detection Section .......................1-25

10-1. Adjusting the Light-emitting Volume in

Use of Thick Paper and Thin Paper

(Maintenance Menu)..............................1-25

11. Adjusting the Tension of the Timing Belt ........1-26

12. Structure of Conveyance Rollers and

Conveyance Guides........................................1-28

13. Paper Feed Count of Paper Feeder A ............1-29

14. Maintenance ...................................................1-30

1-2

99T-M12M0-0107-0

1. OUTLINE OF MECHANISM OF THIS MACHINE

1-1. Operations of Machine during Count Processing Mode and When Using End

Mark (Count Mode)

(1) Perform the required settings for count processing or using the end mark on the control panel.

(2) Memorize the characteristics of the paper in the machine by test feeding the paper.

(3) Press the start button to start operations.

(4) The number of sheets for one set is fed from the paper feeder A and sent to the downstream processing unit.

(At this time, it is possible to use the reversal mechanism to turn paper inside out when sending it to the

downstream processing unit.)

(5) When using the end mark, the machine will check that the last sheet of paper in the set from the paper feeder A

has an end mark on it. If no end mark, the machine will stop.

(6) Cover paper is fed from the paper feeder B, and the execute processing signal is sent to the downstream

processing unit.

(7) The paper for the next set is fed from the paper feeder A after the time required by the downstream processing

unit to perform operations.

(8) When the number of sets set has been processed, the machine will stop.

1-2. Operations of Machine during Random Processing Mode

(1) Perform the required settings for random processing on the control panel.

(2) Memorize the characteristics of the paper with the end mark in the machine by test feeding the paper.

(3) Press the start button to start operations.

(4) Paper is fed from the paper feeder A and sent to the downstream processing unit.

(5) When paper with the end mark is fed, cover paper will be fed from the paper feeder B, and the execute processing

signal will be sent to the downstream processing unit.

(6) The paper for the next set is fed from the paper feeder A after the time required by the downstream processing

unit to perform operations.

(7) The machine will stop when the paper feed tray A or B runs out of paper.

1-3

99T-M12M0-0107-0

1-3. Positions of Main Parts

Operating side

Reversal clutch 2

Remote board

Reversal clutch 1

Gate solenoid

Paper feed clutch

Frame F

Control panel

Reversal counter

Power board

Paper feed clutch

1-4

99T-M12M0-0107-0

Non-operating side

Index sensor for end mark

Paper feed tray A up/down motor

Frame B

Upper limit switch A

Upper door switch

Suction fan

Double-feed detection sensor

Suction solenoid

Separator fan

Conveyance motor

Paper ejection

sensor

Reversal sensor

(light-receiving side)

(Black cover)

Reversal sensor

(light-emitting side)

(Gray cover)

Suction fan

Main board

Separator fan

Suction solenoid

Lower door switch

Double-feed detection sensor

Plate

Upper limit switch B

Lower limit switch unit B

Lower limit

switch unit A

Paper feed tray B

up/down motor

1-5

99T-M12M0-0107-0

2. PAPER FEED MECHANISM

2-1. Outline of Paper Feed Mechanism

(1) Press the start button to operate the machine. With the paper feed tray’s up and down mechanism, the paper on

the paper feed tray rises up to the position detected by the level sensor.

(2) Then the paper feed tray goes down to a certain position and stops.

(3) The paper separator DC fan starts to separate the paper and have the paper surfaced.

(4) If the top surfaced sheet of paper is not at the position where the actuator is pressed, the paper feed tray rises up

to the position where the top surfaced sheet can be detected by the level sensor and stops.

(5) The suction DC fan starts operation and the top surfaced sheet of paper is sucked into the suction belt.

(6) The electromagnetic clutch attached to the end of the conveyance shaft starts to rotate the conveyance shaft and

at the same time the suction belt starts to feed the paper.

In case that, in addition to the topmost sheet of paper, the top second sheet is almost fed, the separator works to

keep the second sheet left at the right position so that only the topmost sheet of paper is fed.

Remark : The ON time of the electromagnetic clutch can be changed on the control panel. It is currently set as follows.

Setting of suction belt drive time (electromagnetic clutch ON time)

Setting

Value

Suction Belt Drive Time

(electromagnetic clutch

ON time)

Distance Moved by Suction Belt

(when connecting the

DBM-120 Sheet by Sheet)

Conveyance Speed 1350 mm/s

0.08 sec.

0.09 sec.

0.12 sec.

0.15 sec.

0.18 sec.

0.21 sec.

Approx. 54 mm (2.13")

Approx. 61 mm (2.40")

Approx. 81 mm (3.19")

Approx. 101 mm (3.98")

Approx. 122 mm (4.80")

Approx. 142 mm (5.59")

Distance Moved by Suction Belt

(when connecting the DBM-250 Sheet by

Sheet or DBM-400 Sheet by Sheet)

Conveyance Speed 1450 mm/s

Approx. 58 mm (2.28")

Approx. 65 mm (2.56")

Approx. 87 mm (3.43")

Approx. 109 mm (4.29")

Approx. 131 mm (5.16")

Approx. 152 mm (5.98")

Double-feed detection sensor

Separator air box

Conveyance shaft

Suction box

Microswitch

Level sensor

Actuator

Paper

Suction belt

Separator

(Detection of upper limit

position of paper feed tray)

Paper feed conveyance roller

1-6

99T-M12M0-0107-0

2-2. Suction Conveyance Section

The suction conveyance section consists of the

suction belt, suction box, conveyance shaft, and

electromagnetic clutch to rotate the conveyance

shaft.

The DC fan is the suction source to suck the paper.

When the DC fan starts to operate, the suction box is

in a suction state. Air is fed through the some square

holes on the suction box. When the suction box is in

the suction state, the paper is sucked into the suction

belt. The electromagnetic clutch attached to the end

of conveyance shaft starts to rotate the conveyance

shaft and at the same time the suction belt starts to

move.

At a fixed time after rotation of conveyance shaft, the

suction box is in the release state.

Suction belts

Frame B

Frame F

Electromagnetic clutch

Conveyance shaft

Suction box

DC fan

To remove the suction conveyance section, remove the connector of the bundled wire for no-paper detection,

bracket with DC fan, electromagnetic clutch, bearing, pass the conveyance shaft through the hole of the removed

bearing, and move it.

(When removing the suction conveyance section of the paper feeder A, remove the side guide A as well.)

Electromagnetic clutch, bracket, bearing

Frame F

Pass through hole of removed bearing

Remove

Frame B

DC fan, bracket

Remove

1-7

99T-M12M0-0107-0

2-3. Solenoid Valve

The valve is used to switch the suction box to the

suction/release state. Use the DC solenoid to switch

the suction/release state.

A large square hole is on the bottom of the suction

box. The suction/release state is set by opening and

closing the hole with the valve head.

It is the release state (see Figure A) with the square

hole open. It is the suction state (see Figure B) with

the square hole closed.

As air is fed slightly through the suction belt with the

square hole open, the paper is not sucked.

Usually the suction box is in the release state. When

the electromagnetic clutch is connected, in other

words, when the paper is being fed, the box is in the

suction state.

Adjustments

When the DC solenoid is ON (see Figure B), the

valve head perfectly covers the square hole on the

suction box.

When the DC solenoid is ON (see Figure B) and the

valve head perfectly covers the square hole, move

the solenoid base up and down and fix it so that the

space L between the frame and plunger on the

solenoid is “0”.

Apply grease to the lever fulcrum, and contact

surface of the lever and valve head.

Figure A

Figure B

2-4. Separator Air Box

The separator air box is filled with air when the DC

fan starts to operate. Air is discharged out of three

ducts to separate the paper on the paper feed tray.

The shutter is used to adjust the size of the duct and

the volume of air to separate the paper.

The rack near the frame engages with the pinion on

the shaft end of the adjusting knob. Rotate the

adjusting knob to move the shutter.

Adjustments

The adjusting knob is attached to the pinion shaft with

the set screw.

Match the shutter position with the pointer of the

adjusting knob.

Fix the adjusting knob so that the pointer of the knob

is at “1” when moving the shutter in the direction of an

arrow to stop it.

Slots

DC solenoid (plunger)

DC solenoid (frame)

Frame

Space: L

Shutter

3 slots

Rack

Pointer

Adjusting knob

Frame

Paper separator DC fan

Separator air box

Ducts

Lever

Link

Bottom of suction box

Valve head

DC solenoid

Solenoid base

1-8

99T-M12M0-0107-0

2-5. Separator

When the sheets of paper are double-fed with the

suction belt, the separator keeps the top second or

more sheets of paper from being fed.

The separator moves up and down against the

suction belt. Therefore adjust the space between the

tip end of the separator and the surface of the suction

belt.

Adjust the separator position with the adjusting knob.

When the lever on the shaft end of the adjusting knob

rotates, the bracket with the tilt plate moves via the

link. The separator moves up and down with the tilt

plate.

The separator is made of urethane.

Adjustments

The adjusting knob is attached to the shaft with the

set screw. The lever to operate the separator is

attached to the end of the shaft.

Match the separator position with the pointer of the

adjusting knob.

Move the bracket with the tilt plate in the direction of

an arrow to stop it. In other words, the lever and link

are positioned level as shown in the figure. Then fix

the adjusting knob so that the pointer of the knob is at

“7”.

2-6. Paper Feed Conveyance

Inserts paper sent from the suction belt between the rollers and conveys the paper.

Using the conveyance shaft equipped with the paper feed conveyance rollers as a driving shaft, the secondary

conveyance rollers are pushed against the paper feed conveyance rollers by the leaf springs.

There are three secondary conveyance rollers at the paper feeder A and two at the paper feeder B.

The fixing holes on the bracket differ between paper feeders A and B. Secure at the positions shown in the following

figure.

Paper feeder A Paper feeder B

3 secondary conveyance rollers

Bracket

Secure at inner hole

Adjusting knob

Pointer

Frame

Lever

Link

Bracket

Tilt plates

Separator air box

Separators

2 secondary conveyance rollers

Bracket

Secure at top of slot

1-9

99T-M12M0-0107-0

3. PAPER FEEDER A

Conveyance shaft

Sensor cover

T mark sensor ass’y

Paper feed inlet A upper

Paper feed inlet

A lower

Paper feed section secondary

conveyance roller

Reinforcement A lower

Upper door

1-10

99T-M12M0-0107-0

3-1. Detection of No-paper

Whether there is the paper on the paper feed tray or not is detected.

The light-receiving sensor board is mounted to the bracket of the suction conveyance section together with the

sensor plate. (Same sensor board as the paper feeder B)

To replace it, remove the suction conveyance section.

The light-emitting sensor board is mounted to the reinforcement A lower.

To replace it, remove the sensor cover. (Take note that it differs from the sensor board of the paper feeder B)

Size detection sensors

Frame B

Frame F

Reinforcement A lower

LED P.W.B. unit

Sensor cover

97J-8013X

(light-emitting side)

Sensor board for detecting no-paper

(light-receiving side)

Bracket

Sensor plate

1-11

99T-M12M0-0107-0

3-2. Side Guide A

Guide to hold paper on the paper feed tray to prevent the paper from shifting to the operating side.

As the racks at the top and bottom are engaged with the top and bottom gears of the moving shaft, they move

parallelly. The side guide A can be moved by rotating the moving dial.

Reinforcement A upper

Secure with FR screw (M4)

Gear

Rack

Moving angle T

Slide block T

Spacer

Moving shaft

Slide block D

Secure with screw (M2.6)

Reinforcement A lower

Moving angle D

Gear

1-12

99T-M12M0-0107-0

3-3. Paper Feed Tray Up and Down Section

The paper feed tray is raised and lowered by the rotation of the sprocket of the up/down shaft and the pulling of the

paper feed tray by the chain. The other chain is a spring which pulls the paper feed tray in the rising direction at all

times. The up/down shaft is driven using a DC motor and decelerated by a worm gear.

When the paper feed tray moves up, the position of the tray is detected with the actuator of the level sensor and the

tray stops at the detected position. When the tray moves down, the tray touches the microswitch (lower limit switch

A), and the tray stops at the position.

Adjustments

Adjust the position of the lower limit switch unit A to determine the lower limit position of the paper feed tray.

To maintain a clearance of 217 to 223 mm (8.54" to 8.78") between the paper feed tray and suction belt when the

paper feed tray is at the bottommost position, adjust the attaching position of the lower limit switch unit A.

Adjust the parallelity of the paper feed tray using the nuts attached to the left and right joints.

Loosen the top nut once, adjust the height of the paper feed tray using the bottom nut, and then tighten the top nut

to secure. If the paper feed tray does not become parallel, the chain and sprocket of the up/down shaft may not be

engaged properly. Engage properly and then adjust.

3-4. Greasing the Secondary Conveyance Roller of the Paper Feed Section

This roller is pre-greased. When the grease runs out, a whistle-like buzzer is sounded.

To reach the secondary conveyance roller with the hand for greasing, remove the upper door, end mark sensor

(upper), double-feed detection sensor, conveyance shaft, paper feed inlet A upper, and paper feed inlet A lower, etc.

Holder

2 washers

96G-1124X

12N sprocket

Key

Gear

Worm gear

Worm wheel

Washer

96G-1124X

Gear

12N sprocket

Key

Oil seal

Holder

Chain

Joint

Nuts

Set collar

Worm gear

Even

Collar

Frame F

Frame B

Up/down shaft

Bearing (6201ZZNR)

Bearings (6201ZZNR)

Washer

96G-1124X

Washer

96G-1124X

(Fix so that movement of shaft is between

0.2 to 0.5 mm (0.008" to 0.02"))

Motor

1-13

99T-M12M0-0107-0

4. PAPER FEEDER B

4-1. Detection of No-paper

Whether there is the paper on the paper feed tray or not is detected.

The light-receiving sensor board is mounted to the bracket of the suction conveyance section together with the

sensor plate. (Same sensor board as the paper feeder A)

To replace it, remove the suction conveyance section.

The light-emitting sensor board is mounted to the sensor stay.

To replace it, remove the sensor stay. (Take note that it differs from the sensor board of the paper feeder A)

4-2. Paper Feed Tray Up and Down

Section

The paper feed tray is driven via the rack on the tray

when the pinion connected to the motor rotates.

When the paper feed tray moves up, the position of

the tray is detected with the actuator of the level

sensor and the tray stops at the detected position.

Adjustments

Adjust the position of the lower limit switch unit B to

determine the lower limit position of the paper feed

tray.

The installation hole of the lower limit switch unit B is

a slotted hole so that the position is adjusted. Fix the

lower limit switch unit B at the position as far as the

unit goes in the direction of an arrow.

Adjust the play by the rack in the up and down

directions after it has been attached to less than 1

mm (0.04") by adjusting the play by the motor unit

and motor bracket or motor bracket and frame when

attaching them.

Suction conveyance section

Sensor stay

Bracket

Lower door

Reversal auxiliary guide

Paper feed section

secondary conveyance roller

Pinion

Slots

Microswitch

Lower limit switch

unit B

Paper feed

tray

Motor unit

Motor bracket

Rack

1-14

99T-M12M0-0107-0

4-3. Greasing the Secondary Conveyance Roller of the Paper Feed Section

This roller is pre-greased. When the grease runs out, a whistle-like buzzer is sounded.

The fixing screw of the bracket to which the secondary conveyance roller is attached can be seen when the lower door

and reversal auxiliary guide are removed. Remove the bracket first before greasing.

1-15

99T-M12M0-0107-0

5. REVERSAL SECTION

Gate

Reversal sensors

Reversal roller 1

Reversal roller 2

Reversal auxiliary guide

Solenoid

Reversal

counter

Stopper

1-16

99T-M12M0-0107-0

5-1. Mechanism

Mechanism which turns paper fed from the paper feeder A inside out when ejecting.

(1) Select the reversal mode and start the machine. The reversal switching gate is switched by the solenoid.

(2) The two clutches operate together so that reversal roller shaft 1 and reversal roller shaft 2 rotate in the direction

to send the paper downwards.

(3) All the paper is sent to the conveyance route of the paper feeder B. When the rear edge of the paper passes the

reversal sensor, reversal roller shaft 1 and reversal roller shaft 2 rotate in the opposite direction to send the paper

to the conveyance bridge.

When clutch A is connected and clutch B is open, the reversal roller rotates in the direction to send the paper to

the conveyance bridge. When clutch B is connected and clutch A is open, it will rotate in the direction to send the

paper downwards.

Frame F

Clutch B

Frame B

Adjusting washer

M8W

Idler gear

Gear 1

Gear 2

Spacer

98X-4152X

Spacer

98X-4152X

Spacer

98X-4152X

t1 × 8 × 16

Reversal roller shaft 2

Reversal roller shaft 1

1-17

99T-M12M0-0107-0

5-2. Replacing the Clutch

Clutches A and B of the reversal section need to be replaced about a million times of reversals.

To replace, remove the bracket, rotating stopper A, transmission shaft gear, collar B, key B, clutch B, reversal shaft

gear, and clutch A (collar A, field core, key A, rotor, gear). Attach the clutch B gear to the new clutch.

Push collars A and B towards the clutch and secure.

Idler gear

Reversal roller shaft 1

Reversal shaft gear

Key B

Key A

Gear section

Rotor section

Field core section

Clutch A

Collar A

Transmission shaft gear

Bracket

Bearing

Transmission shaft

Collar B

Idler gear

Rotating stopper A

Clutch A

Rotating stopper B

Clutch B

Bearing

Clutch B

Clutch B gear

Frame F

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Duplo DSF-2000 Maintenance Manual

Duplo DSF-2000 Maintenance Manual

Duplo DSF-2000 Maintenance Manual

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