Duplo DC-645 Instruction Manual

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.

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Introduction

DC-645

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.

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 automatically 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.

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.

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.

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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

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Contents

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

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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

CAUTION

[Examples of Pictorial Symbols]

• These are particularly important safety points and should always be observed.

Indicates a high degree of potential danger. If the warning is ignored, death or serious injury may result.

Indicates a medium degree of potential danger. If the caution is ignored, medium injury or damage to property may result.

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 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.”)

Precautions for Use

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.

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Notes on Safety (Please Read and Observe)

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

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

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.

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Notes on Safety (Please Read and Observe)

Prohibition of Disassembly or Modification

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.

Caution for Location

Do not move this machine by yourself.

• Please contact your service person when you wish to move the machine. (Fine adjustment is required.)

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.

WARNING

CAUTION

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Notes on Safety (Please Read and Observe)

Warning Sticker

Keep the WARNING stickers clean at all times. If stickers become damaged or come off, replace them with new ones.

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

WARNING

DO NOT put hands inside machine while it is operating.

Hands could get caught up or crushed.

No. Parts No. Name Q’ty

1 L8-T1080 Warning Sticker 1 2

2 M7-T3030 Warning Sticker 2 2

M7-T3030

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Notes on Safety (Please Read and Observe)

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.

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Notes on Safety (Please Read and Observe)

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 machine’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.

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[

SELECT

]

05:DUPLO

06:DUPLO 1 BC REG AC

∗ ∗ ∗

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.

Chapter

Title

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.

Chapter

Basic Operations

This chapter describes the operating sequence from turning ON the power switch until completing

finishing process.

Process Documents by Selecting JOB

This section describes the procedures to process documents by selecting each JOB manually.

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Turn ON the power. (

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Press the <MODE> key and go to the [SELECT] display.

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Input the number of the JOB to call up, using the <Number> key.

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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

(Ex.: When 100 documents are set, the above display appears.)

By pressing the <START> key, processed number of the document is subtracted from the specified number as below.

∗ ∗

99/100

* If an error has occurred during processing, batch counting can not be executed.

a P.16 “Turning ON the Power”)

∗ ∗

98/100

■ 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 1

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.

Part Names and Their Functions

Appearance

Before Using This Machine

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

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

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,

13 Power switch Press to switch the power on and off.

to replace the optional module.

unit.

barcode error, REG. Mark error, etc.

Reference

page

74 78,82 66,69

—

89 – 94

87,88

75,

85 – 86

70,97 18,31

16 81,99

16,17

Part Names and Their Functions

1514

No. Name Function

Airflow adjustment knob

Separator adjustment knob

Level adjustment knob

Skew adjustment wheel

This adjusts the airflow level. This adjusts the distance between the separator and document.

This adjusts the elevator height.

This adjusts the feed angle of the document.

Reference

page

Modules

Part Names and Their Functions

Before Using This Machine

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.

Reference

page

19,54,

80,82

36,37,

72,81

54,79,80,89

54,79,81,89

36,57

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.

Part Names and Their Functions

Control Panel

123

71011456

8 9 12 13

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 •

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

13 <STOP> key Press to stop automatic feeding after the current sheet is processed.

<JOG> keys

Press to eject the document from the machine when paper jam occured.

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.

Reference

page

78,79

15,

80 – 82

58 – 63,72,73

58,64,75

58 – 63,73

—

58,59,64

58,59,83 – 98

—

64,66,69

67,78 – 82,

85 – 99

LCD Panel

Part Names and Their Functions

∗ ∗ :

BC REG AC

∗∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗

∗ ∗ ∗

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.

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

REG is diaplayed when REG. Mark reading is ON.

displayed.

Reference

page

36,58,64

36,58

37,72

37,55,72

Before Using This Machine

Turning Power ON/OFF

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

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Connect the “female plug” of the power cord to the “inlet”.

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Connect the “male plug” of the power cord to the “outlet”.

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Press the “ | ” side of the power switch.

The power turns ON.

The illustration on the right shows what is displayed on the LCD panel.

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”)



∗ ∗:∗∗∗∗∗∗∗∗∗∗

BC REG AC

∗∗∗

––– J 1 ––– REJECT PAPER

Turning OFF the Power

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Press the “

The power turns OFF.

K ” side of the power switch.

Turning Power ON/OFF

Before Using This Machine

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

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.

Paper and Processing Position

...CREASE

7C B A8910

...SLIT1

...SLIT3

...SLIT5

...SLIT6

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)

Feed direction

246

...CUT

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.

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.

...SLIT4

...SLIT2

Reference

page

60,80,82

61,80,82

40,81

54,79,80,89

54,79,81,89

36,57

IMPORTANT

Before Preparing Document

Definition of Programming Terms

PAPER FEEDING DIRECTION

Barcode

(Optional)

SLIT 2

SLIT 4

SLIT 6 SLIT 5

PAPER FEEDING DIRECTION

REG. Mark (Optional)

SLIT 1

SLIT 3

First Cut

Last cut

REG. Mark (Optional)

Barcode (Optional)

Crease (CRE. 01)

Slit / Cut / Crease Limitations

There arer limitations for slit / cut / crease process on DC-645.

Before Preparing Document

CUT1

CREASE1

Paper feed direction

Slit: Up to 6 slits are possible on 1 document. Cut: Up to 15 cuts are possible on 1 document. Crease: Up to 10 creases are possible on 1 document.

SLIT2

SLIT4 SLIT6 SLIT5 SLIT3 SLIT1

Before Using This Machine

Lead margin:

3.2mm ~

Card length: 85mm ~

CUT2

CUT3

CREASE2

CUT4

Left margin:

3.2mm~40mm from left edge

Card width:

48mm~

Gutter slit : 5-15mm

Trail margin:

5mm ~

Right margin:

3.2mm~40mm from right edge

Before Preparing Document

REG. Mark (Registration mark)

DC-645 automatically compensate for image drift, one of the common problems on digital printers. It detects the image drift caused on each page by reading REG. mark with built-in CCD and adjust the cut / slit / crease position accordingly.

To use this function, each documents must have REG, mark printed on them. Please refer to following instructions for specifications and position of REG. mark.

1) Specifications REG. mark consists of 2 straight & perpendicular lines.

line length : 5 mm or more / each line thickness : 0.4 mm or more / each

Paper feed direction

Lead mark

Correct for image drift

in this direction

Correct for image drift

Side mark

in this direction

Use pen tool etc. of your software application to draw 2 straight & perpendicular lines.

2) Position Paper feed direction : The whole REG. mark should be within 3 mm ~ 20 mm from the lead edge. Paper width direction : The whole REG. mark should be within 3 mm ~ 20 mm from the right edge.

3mm

5mm or more

20mm

0.4mm or more

REG. Mark

Position Range

REG. Mark

BARCODE

By adding barcode which indicates job number on each document, DC-645 automatically set up the machine and start the job. Operator can press the START key and leave. Even if multiple types of jobs are loaded on the feed tray at one time, DC-645 recognizes barcode on documents also with the built-in CCD and automatically switch setup and finish the jobs.

Before Preparing Document

To use this function, each documents must have BARCODE printed on them. Please refer to following instructions for specifications and position of BARCODE.

1) Specifications Barcode type : CODE-39 Start and Stop code : Required Check digit : Optional Minimum resolving power : 0.254 mm Thin bar : Thick bar : 1 : 2.5 Bar height : 4 mm or more

Use barcode generator function equipped on your software application or use barcode generator software.

2) Position Paper feed direction : The whole BARCODE should be within 3 mm~ 20 mm from the lead edge. Paper width direction : The whole BARCODE should be within 25 mm~60 mm from the right edge (See below)

q is the start code designator for CODE-39.

w is the 10’s digit data of the JOB number.

(Example: When the

JOB

number is 21, the data is “2”.)

Paper feed direction

Before Using This Machine

e is the 1’s digit data of the JOB number.

(Example: When the

r is the check digit.

t is stop code of CODE-39.

POSITIONING THE BARCODE

5 mm

JOB

number is 21, the data is “1”.)

60 mm

10 mm

NON PRINTING AREA

*24*

Before Preparing Document

How to Make a Barcode for Use DC-645

The easiest way to create the code is with a TrueType Font. Fonts are readily available from many companies on the internet. Here are two companies which have fonts suitable for use with the DC-645 (there are many companies offering fonts).

www.barcodetrader.com/bct_scan_barcode.asp http://www.squaregear.net/fonts/

Free download of Barcode creating software.

http://www.datascan.co.uk

Samples - standard font Price £149 for a single user; £298 for 2 – 5

*The above is only an example of a homepage. *The above is a general homepage. Note that it may be ended or the URL may be relocated.

Before Preparing Document

Basic Font Installation Instructions

The following briefly describes what is required to install a font on a Windows or Macintosh system. The font provider will supply more detailed information, these guidelines are only intended to illustrate the basics and scope of the installation process.

On a Windows computer the font is installed through the Control Panel’s “Fonts” folder.

On a Macintosh system select the font suitcases (for TrueType 1 fonts also select the printer outline files) and drag the fonts onto the closed System Folder icon. For OS X drag the fonts onto the Fonts folder in the Library folder.

How to use a TrueType font

Once installed, the font will appear in the word processing or desktop publishing application in the font selection area. Please note in MS Word, typing text surrounded by the characters * and *, automatically turns on auto format to bold text. Since this is not the intended, or useful, turn off the auto formatting by following the steps below or use the 'undo last action' after typing.

Before Using This Machine

Before Preparing Document

Select Options

Delete *Bold* and _underline_with real formatting

Before Preparing Document

Creating the Barcode

Making the barcode appear on the page is extremely easy with a TrueType font. In this case we will use the example job “01.” The application designer simply does the following:

1. Place a text box in the predefined area. Make sure the text box is large enough to hold the entire barcode. It

may be necessary to increase the size of the text box after the font is created.

2. Type the desired job (program) number surrounded by a stop and start bit. Remember the stop and start bit

are recognized in Code 39 as an * or asterisk.

3. Select the text, in this case the text will appear as: *01*

4. Change the font type in the font selection window to the name of the code 39 font.

The text will appear as: *01*

5. Print a sample and make sure the font is at least 4 mm tall. If not, increase the size of the code 39 font by

reselecting the barcode and increasing the font size with through the Font size selection window.

Font selection window

Duplo Code 39

Before Using This Machine

Font size selection window

Before Preparing Document

When both REG.Mark and Barcode are Printed

60mm or less

5mm

3mm

Barcode

Position Range

Barcode

20mm35mm

5mm or more

0.4mm or more

REG. Mark

Position Range

REG. Mark

5mm or more

3mm

20mm

Feed Direction

Ifthereisanystainorscratchthatis0.3mmorlessintheslasharea,themarginoferrorinthefinishmay

slightlyincrease.

WhenREG.MARKand/orBARCODEareprintedoutsidethespecifiedarea,DC-645cannotdetectthem

properly.WhenpositioningtheREGmarkandBARCODEonthedocument,takethepossibilityofimage shiftintoconsideration.

Non-Printing Area

3mm or more

Theprintimageshouldnotinterferethered-coloredarea.

3mm or more

Barcode

5mm

Non Printing Area

Feed Direction

20mm35mm

REG. Mark

3mm or more

20mm

Chapter 2

Program JOB for DC-645 Via Computer (JOB Creator)

DC-645 can save 80 patterns of JOBs. JOB contents can be programmed either via computer or on the control panel. This chapter describes how to install the JOB Creator (attached to DC-645) in your computer and set up a JOB for DC-645.

What is JOB Creator?

JOB creator is a software used to setup a JOB for DC645 on computer. Installation of this software allows the user to create and edit JOBs for DC-645, with preview image of the document, as well as save JOB data and edit DC-645 settings from the computer.

Installing JOB Creator

This describes the procedures to install JOB Creator on computer.

Before Installation

Check the following before installing JOB Creator on computer.

System Requirements

The following computer specifications are necessary to run JOB Creator.

Program JOB for DC-645 Via Computer (JOB Creator)

English OS:

Windows: Windows XP Professional, Windows XP Home Edition, Windows 2000 Macintosh: Mac OS9.1 or later, OS10.1 or later (Do not run the classic environment with OSX)

Installing JOB Creator

Installing Procedures (Windows)

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Load the CD-ROM coming with DC645 in the CD-ROM drive of the computer.

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The display to specify a folder to install file appears. If you want to install the JOB Creator in a certain place, click [Browse], then specify the folder to install JOB Creator.

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The display to specify the folder to install JOB Creator in, appears. A new folder is created at the top of the list displayed. The file is then installed in that folder. To rename the folder, input the folder name from the top list. To install the JOB Creator file in an existing folder, select a voluntary folder from the bottom list.

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After specification click [Next].

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After completing the specification, click [Next]. JOB Creator installation starts.

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When installation is completed, the screen shown below appears. A JOB Creator shortcut is created on the desktop. Click [Finish] to close the installation menu.

Installing JOB Creator

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Turn ON the DC-645. Then connect the computer and DC-645 using a USB cable. (Computer USB Terminal

- DC-645 USB Terminal) (USB cable

(A to B type): The cable length must be within 3 m.)

“Found New Hardware Wizard” menu appears on the computer.

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Click the radio button of [Install from a list or specific location (Advanced)], then click [Next].

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Click the radio button of [Search for the best driver in these locations.], then click and select [Search removable media]. Click [Browse], then click [Next].

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When installation is completed, the screen shown below appears. Click [Finish] to end the Wizard.

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Installation is successful if the [Device Manager] dialog indicates that the [USB DC-645 *.*] is registered in the USB controller.

Program JOB for DC-645 Via Computer (JOB Creator)

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Driver installation starts. A warning dialog appears during installation. Click [Continue Anyway] to continue installation.

This completes the preparation and installing procedures.

Installing JOB Creator

Installing Procedures (Macintosh)

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Load the CD-ROM coming with this machine in the CD-ROM drive of your Macintosh.

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Double click the CD-ROM icon appearing on the desktop.

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Copy [DC-645 JOB Creator] to where you want to install the JOB Creator.

Mac OS9 Users → Go to “Step 4”. Mac OSX Users → Go to “Step 5”.

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ONLY for Mac OS 9: Copy the [USBDC645] on the CD-ROM coming with the package in [Extensions] folder in the [System] folder.

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Restart (reboot) the Macintosh.

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Turn ON the DC-645. Then connect the Mac and DC-645 with a USB cable (Mac USB Terminal - DC645 USB Terminal). (USB cable (A to B type): The cable length must be within 3 m.)

This completes the preparation and installing procedures.

Uninstall and Update JOB Creator

Uninstalling Procedures (Windows)

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Connect the DC-645 and computer. Select [Start] – [Settings] – [Control Panel] – [System], then open the [System Properties] dialog.

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Select the [Hardware] tab. Then click the [Device Manager] button. The [Device Manager] dialog appears.

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Go to list and find "Universal Serial Bus controllers" then double click [USB DC-645 *.*].

Tip

• Note that the [USB DC-645 *.*] will not appear in the “Universal Serial Bus controllers” list unless the DC645 is connected to the computer with a USB cable.

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Select the [Driver] tab. Then click the [Uninstall] button.

Program JOB for DC-645 Via Computer (JOB Creator)

Continue Page

•••

Uninstall and Update JOB Creator

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The [USB DC-645 *.*] uninstall confirmation dialog appears. Click [Uninstall] then click [OK].

The driver has been successfully removed if [USB DC645 *.*] no longer appears in the list of "Universal Serial Bus controllers" in the [Device Manager] dialog.

Uninstalling Procedures (Macintosh)

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Delete the [DC-645 JOB Creator *.*] copied in a voluntary folder of the Macintosh.

Mac OS9 Users → Go to “Step 2”. Mac OSX Users → This completes the driver

removal procedures.

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ONLY for Mac OS9: Remove the [USBDC645] copied in the [Extensions] folder of the [System] folder on the Macintosh.

This completes the driver removal procedures.

Updating Drivers

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Uninstall the previous driver using the driver uninstalling procedures.

For Windows go to the “Uninstalling Procedures (Windows)” on P.33. For Macintosh go to the “Uninstalling Procedures (Macintosh)” above.

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FOR WINDOWS ONLY: Disconnect the USB cable connecting the DC-645 and computer. Then reconnect the USB cable back to the DC-645 and computer.

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Install a new driver according to the Driver Install Procedures on P.31 –

32.

For Windows go to the “Installing Procedures (Windows)” on P.30. For Macintosh go to the “Installing Procedures (Macintosh)” on P.32.

JOB Creator Settings

Main Menu

This menu appears when the JOB Creator is launched. Select the sub menu to set from this main menu, for actual settings.

1 Using Program Entry Wizard

Create a JOB in Wizard format. A preview of the JOB being created is displayed. Create the JOB while checking the input details.

Program JOB for DC-645 Via Computer (JOB Creator)

2 Direct Program

Directly input the number value to create a JOB. Use this to create a JOB when the dimensions are already finalized.

3 Upload Job Data from DC-645

Read JOB from DC-645 and save in computer.

4 Download Job Data to DC-645

This sends the JOB saved on the computer to DC-645.

5 Function Setting

This is used to make settings in Function menu.

6 Upload Maintenance Data from DC-645

This creates the file that records the DC-645 status. This may be used to report the status to the service personnel.

7 Exit

This is used to quit the JOB Creator. This is the same function as the X button at the top right of the main menu.

JOB Creator Settings

Creating JOB with Preview Display

This describes the procedures to set up a JOB in Wizard format. Following items should be entered to create a JOB.

Optional Module ............................ Standard Module

Select an optional module for the job when necessary. In following JOB, standard module is selected.

JOB Number .................................. 01

Select a JOB No. in which the JOB currently being programmed is saved. In following JOB, 01 selected.

JOB Name ...................................... DUPLO1

Put a name to the JOB with your keyboard for easy reference. Following job is named “DUPLO1.”

Paper Size ....................................... 12” x 18” (304.8 mm x 457.2 mm) (Standard Size)

Enter size of the document. Standard paper size can be selected from “Standard size,” or custom size can be entered in “Custom size.” In following JOB, standard 12” x 18” is selected.

REG. Mark .................................... SIDE MARK10 mm (From right edge of document) /

LEAD MARK 10 mm (from top end of document)

Select whether to use REG MARK function or not. When using this function, enter the position of REG. Mark. In following JOB the REG. Mark is enabled and the position is 10 mm from the right edge of document and 10 mm from the lead edge of the document.

(“Using Program Entry Wizard”)

Finished Size .................................. 100mm (W) x 130mm (L)

The size of cards after processing the documents.

Cards per Document ..................... 2 (Crosswise) x 3 (Lengthwise)

Specify how many cards are to be aligned in crosswise and in lengthwise direction. In following JOB, 2 (crosswise) x 3 (lengthwise) cards are aligned.

Trim ................................................ 23.6 mm (Lead margin), 30 mm (Right margin)

Specify the position of first cut and right margin slit. In following JOB, first cut is at 23.6 mm from the lead edge, and the right margin slit is at 30 mm from the right edge of document.

Gutter Slits ..................................... 10mm (Distance between finished documents (left /

right))

When aligning 2 or 3 cards in crosswise direction, it is possible to have a gutter slit between each cards. Specify the distance between each cards. (The distance should be between 5 mm and 15 mm.) IN following job, Gutter slits are 10 mm.

JOB Creator Settings

Gutter Cuts .................................... 10 mm / 10 mm (Distance between finished documents

(top / bottom))

When aligning 2 or more cards in lengthwise direction, it is possible to have a gutter cut between each cards. The distance should be 4 mm or more. IN following job, gutter cuts are 10 mm in length.

Crease ............................................. 65 mm

Specify the position of the crease on the cards.

Barcode Reading............................ ON

Auto Cut ......................................... ON

AIR KNIFE .................................... Compressed air is blown out to loosen the document.

This is to prevent double-feed.

FAN REGISTER ........................... Document skewing in feeding area is corrected. When

processing light weight document, turn this function OFF as it may cause a paper jam in feed area.

SLIT GUIDE .................................. When any slitters are not used, these slitters act as

paper guide to stabilize the paper conveyance. Recommended for light weight document.

AUTO CUT .................................... Lead margin, trail margin, and any gutter cuts (shorter

than 85 mm) are finely cut and dropped into the waste box. When documents do not have lead margins or trail margin, this must be turned off.

CREASE DEPTH .......................... This sets the depth of the crease when creasing a

document. Set to MAX for heavy paper and MIN for light paper.

Program JOB for DC-645 Via Computer (JOB Creator)

SPEED ............................................ This is used to select HIGH / LOW processing speed.

Set to LOW for better processing precision.

Continue Page

•••

JOB Creator Settings

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Click the [Using Program Entry Wizard] button. The “Using Program Entry Wizard” input screen appears.

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From the [Optional Module] list, select the optional module to finish the JOB then click [NEXT].

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Input the JOB name of the JOB to create in the [JOB Name] list, then click [NEXT].

Tip

• The JOB name can be input with a maximum of 13 characters.

• Usable Characters Alphabets: A to Z, a to z Numbers: 0 to 9 Symbols: ! " # $ % & ' ( ) - @ [ ] ; : ,

. / + * < > ? _ and space.

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From the [JOB NO. (1-80)] list, select the JOB Number of the JOB to create, then click [NEXT].

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Select the document size before finishing. If it is a standard size, click the [Standard Size] radio button, then select the size from the list.

If it is a nonstandard size, click the [Custom Size] radio button, then input the number values of the [Width] and [Length] on the right. Click [NEXT] when the numbers are set.

Tip

• The range of number values that can be input is displayed by each input item of the JOB Creator. Use this as a guideline (reference) to create a JOB.

JOB Creator Settings

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Select whether to use a REG. Mark reading. When using a REG. Mark, then click the [REG. Mark enable] radio button. Then input the number value for [REG. Mark 1] and [REG. Mark 2] on the right.

When not using a REG. Mark, then click the [REG. Mark disable] radio button. Click [NEXT] once it is set.

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Input the finished document size in the [Width] and [Length], then click [NEXT].

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Respectively input the vertical and horizontal number of finished documents for the documents before they are cut, in the [Crosswise] and [Lengthwise] area.

Set [Crosswise] then click [NEXT] and go to [Lengthwise]. Set [Lengthwise] then click [NEXT] again to go to the next setting.

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Set the margin of the document. Input the number value of the topside margin in the [Lead Trim]. Then input the number value of the rightside margin in the [Side Trim R].

Program JOB for DC-645 Via Computer (JOB Creator)

Set [Lead Trim] then click [NEXT] and go to [Side Trim R]. Set [Side Trim R] then click [NEXT] again to go to the next setting.

Continue Page

•••

JOB Creator Settings

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Input the gutter slit width (width between each cards) (vertical cutting) of the size determined document. Input 0 if there is no gutter between cards. After inputting one number value, click [NEXT]. Then input the next number value. Set the all gutter slit widths.

When all settings are complete, click [NEXT].

Tip

• If in Step 8, Crosswise = 1, then the gutter slit width cannot be input.

• Only one gutter slit can be set if crosswise is set to 3.

• No gutter slit can be set if crosswise is set to 5 or more.

• The gutter slit cannot be changed if the “Business Card Module” is selected for the Optional Module. (Fixed value: 5 mm)

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Input the gutter cut length (horizontal cutting) of the size determined document. Input 0 if there is no distancing. After inputting one number value, click [NEXT]. Then input the next number value. Set the all gutter cut lengths.

Tip

• If in Step 8, Lengthwise = 1, then the gutter cut length cannot be input.

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Input the creasing position. Input 0 if there is no creasing necessary. After inputting one number value, click [NEXT]. Then input the next number value. Set the distance of all creasing positions.

When all settings are complete, click [NEXT].

JOB Creator Settings

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Set functions for this job by clicking the [FUNCTION] button, then open the “Function Settings” dialog. When the settings are completed, click [OK] and close the dialog. Then click [NEXT].

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The details of all the settings will appear in a list. Check to see if the JOB details are correct. If there are any numbers to modify, re-input the values at this time.

Tip

• For the “Function Settings” click the [Function] button, open the “Function Settings” dialog, then Confirm/ Modify.

Tip

• When the “Business Card Module” is selected, it is possible to adjust the business card processing position with “Option 1” of this display item.

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To register the JOB created with the DC-645 immediately, click the [DOWNLOAD] button.

Tip

• To save the JOB created on the computer as a file, click [SAVE].

Determine the file name and where to save the file. Then click [OK] to save the file. The JOB file created can be registered on the DC-645 again with “Download Job Data to DC645” of the main menu. (a P.47 to “JOB Saved on computer Registered on DC-645 [Download Job Data to DC-645]”)

Program JOB for DC-645 Via Computer (JOB Creator)

Tip

• When inputting the settings from your computer, the machine automatically judges positions of slitters and the positions sometimes differs from the description on page

19.

Tip

• The [Optional Module] cannot be modified.

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•••

JOB Creator Settings

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A registration confirmation dialog appears. Click [YES].

Tip

• When downloading JOB data to the DC-645, the JOB data is generally registered in the DC-645 memory. To update the JOB data without registering it in memory, check the “Temporary job data” check box at the bottom of this dialog. The JOB data downloaded as “Temporary job data” will be deleted when the DC-645 is turned OFF or when another JOB is selected. To download (save) the JOB data, always download the “Job data” without “Temporary job data” check marked, or save the JOB data on the computer with the JOB Creator before downloading it.

Tip

• If there is already a JOB registered in selected job number in the DC645 memory, a display appears whether to overwrite file or not.

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Click [OK] and a display indicating that the data was successfully sent, appears in approximately one second.

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The dialog appears to ask whether to test the program. To test the created job by running 1 document, set the document on the DC-645 then click [TEST]. If a test is not intended, then click [NO].

ThiscompletestheJOBcreationprocedures.

JOB Creator Settings

Creating a JOB By Direct Number Input (“Direct Program”)

With Direction program, the JOB is created by directly inputting the number value of each item, in the same manner as the JOB program of the DC-645 main unit. This describes the procedures to create a JOB with Direct Program.

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Click the [Direct Program] button. The Direct Program input menu appears.

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Input the JOB number of the JOB to create in the [JOB No. (1-80)] list.

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Input the JOB name of the JOB to create in the [JOB Name] list.

Tip

• The JOB name can be input with a maximum of 13 characters.

• Usable Characters Alphabets: A to Z, a to z Numbers: 0 to 9 Symbols: ! " # $ % & ' ( ) - @ [ ] ; : ,

. / + * < > ? _ and space.

Program JOB for DC-645 Via Computer (JOB Creator)

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From the [Optional Module] list, select the optional module to finish the JOB.

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•••

JOB Creator Settings

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Input the number value of each item to create a JOB according to the details intended.

Tip

• Slitter values cannot be changed if the “Business Card Module” is selected for the Optional Module.

Tip

• Option value cannot be set if the “Standard Module” is selected for the

Optional Module.

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Set the functions for this JOB by clicking the [FUNCTION] button, then open the “Function Settings” dialog. When the settings are completed, click [OK] and close the dialog.

This completes the JOB programming procedures. JOB registration and save can be done with the same procedures as the Wizard system. Run according to Steps 15 – 18 on page 41.

JOB Creator Settings

Reading JOB from DC-645 (“Upload Job Data from DC-645”)

This describes the procedures to read a JOB from the DC-645 memory to the JOB Creator.

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Click the [Upload Job Data from DC645] button. The display to select the JOB to read appears.

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(To upload all JOB (#1 – #80) from the DC-645 memory) Click the [ALL JOB] radio button, then click the [UPLOAD] button.

Tip

• With the above operations, JOB No. 1 – 80 is saved as 1 file.

(To select and upload only one JOB) Click the [JOB No.] radio button. Then select the JOB number to upload from the following list.

Program JOB for DC-645 Via Computer (JOB Creator)

After selecting the JOB number, click the [UPLOAD] button.

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•••

JOB Creator Settings

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A display confirming whether to start uploading the JOB will appear. Click the [YES] button.

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(To read all JOB from the DC-645 memory) A JOB successfully read display will appear. Click the [SAVE] button to save the JOB on the computer or click [END] to quit uploading the JOB.

(When selecting and uploading only ONE JOB) The details of the JOB will appear in a list.

If there are any number values to edit, input the changes at this time. To register the JOB edited with DC-645, click the [DOWNLOAD] button. To save the edited JOB on the computer, click [SAVE]. Then, designate the file name and place to save the file and then click [OK] to save. Click [BACK] to read the JOB data once again.

Tip

• The [Optional Module] cannot be modified.

Tip

• Slitter values cannot be changed if the “Business Card Module” is selected for the Optional Module.

Tip

• Option value cannot be set if the “Standard Module” is selected for the

Optional Module.

If [END] is clicked, then a display will appear confirming whether to quit reading the JOB. Click [YES].

JOB Creator Settings

JOB Saved on Computer Registered On DC-645 (“Download Job Data to DC-645”)

This section describes the procedures to register on the DC-645 a JOB saved on the computer.

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Click the [Download Job Data to DC645] button. A display appears to select a JOB file to send to the DC-645.

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Click the [File...] button. Select and click the file to register on DC-645, then click the [Open] button.

Tip

• Extension of a file saved with ONE JOB data: .djob Extension of a file saved with ALL JOB data: .dall

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Check whether the JOB file intended to register on the DC-645 is selected. Then click the [DOWNLOAD] button.

Tip

• When sending ONE JOB (with .djob extension), if that JOB number already exists in the DC-645 memory, then a display will appear whether to overwrite the existing JOB with this JOB.

IMPORTANT

• If the document file has a

extension, then the maximum JOBs that can be registered on the DC-645 are all saved. When registering a file with a

“.dall”

extension on the DC-645, all JOBs registered on the DC-645 at that time will be overwritten. A display will appear to check whether to overwrite all JOBs when sending the data.

Confirm whether it is okay to overwrite the data and if so click the [YES] button and send the data.

“.dall”

Program JOB for DC-645 Via Computer (JOB Creator)

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JOB Creator Settings

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A display indicating that the JOB was successfully transmitted appears. Click the [OK] button to quit.

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(To register only ONE JOB) When testing the JOB sent (processing one), a confirmation screen will appear. To run the test, set the document on the DC-645 then click [TEST]. If a test is not intended, then click [NO].

JOB Creator Settings

Setting Frequent Functions From Computer (“Function Setting”)

This describes the procedures to turn ON/OFF the barcode function, REG. Mark function and other functions.

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Click the [Function Setting] button. The display to turn ON/OFF the function appears.

Tip

• The current DC-645 settings will appear at this time.

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Click the [Enable] radio button for function to turn ON. Click the [Disable] radio button for functions to turn OFF.

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If you set to [Enable] on “Reject,” input the number of rejected documents to stop the JOB. Input “0” or click the [Disable] radio button if DC-645 is not to be stopped regardless of number of rejected documents.

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If you set to [Enable] on “Apply Shrinkage,” input the pri-print length and post-print length so the machine can automatically calculate the shrinkage rate and improve the JOB processing precision. Use the <Number> key to first input the document length before printing. Next, input the length of the document after printing.

Program JOB for DC-645 Via Computer (JOB Creator)

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JOB Creator Settings

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After the setting is completed, click the [OK] button.

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A display will appear to check whether to download the Function Setting Displayed contents on the DC-645.

If it is okay, then click [OK]. If it is not okay, then click [NO]. The screen will return to the [Function Setting] display.

JOB Creator Settings

Create a File Recording the DC-645 Maintenance Information

(“Upload Maintenance Data from DC-645”)

This describes the procedures to create a file recording the DC-645 Maintenance Information.

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Click the [Upload Maintenance Data from DC-645] button. A display appears to confirm whether to start reading the DC-645 Maintenance Information. Click the [YES] button.

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The Maintenance File (.dsrv extension) is saved in the same direction as the DC-645 application software.

Program JOB for DC-645 Via Computer (JOB Creator)

List of Messages

Message

Cannot enter Gutter Slits.

Cannot enter Gutter Cuts.

The above job name is invalid.

Communication Error (001) – (***)

Countermeasure

Cannot input gutter slit since the number of page layout in the horizontal-

direction is either 1 or more than 4.

Cannot input gutter cut since the number of page layout in the vertical-

direction is 1.

The JOB name contains a character that cannot be used.

The JOB Creator cannot recognize the DC-645.

Check the following.

1. Is the USB cable securely connecting the computer and DC-645?

(a P.18 “How to Connect the DC-645 to your Computer”)

2. Is the DC-645 turned ON?

3. (Macintosh OS9): Is the USB driver copied in the [Extensions] folder in

the [System] folder? Check to see if its use has been turned OFF? (a P.32 “Installing Procedures” (Macintosh)].

4. (Macintosh OSX): Is a Classic environment launched?

5. (Windows): Is [USB DC-645 Ver*.*] registered as a USB controller in

the [Device Manager] dialog? (a P.30 “Installing Procedures (Windows)”)

6. Is the USB cable shorter than 3 meters?

Communication Error (002) – (003)

Communication Error (004)

File I/O ERROR

Communication Error occurred.

1. Restart the DC-645 and computer.

2. Is the USB cable shorter than 3 meters?

Communication error occurred with DC-645 while the DC-645 and the

computer was communication, showing a “Busy / Error / Jam Warming”.

Check the LCD panel for the Error display. Correct the Error, JAM and/or

Warning according to the procedures described in “Error Display” (P.80),

“Warming Display” (P.82), and “When a Paper Jam Has Occurred” (P.83 –

99).

Retry communications after that.

(Windows) Illegal file path. Check the correct file path.

Message Countermeasure

DC-645 is busy.

ERROR on DC-645

List of Message

The DC-645 is in operation.

1. Either wait for the JOB to quit or press the <STOP> key on the DC-

645 to abort the JOB.

2. DC-645 is not ready to operate.

End the function setting, input, and JOB select mode, and go to the

Operation Mode (regular state).

3. An error has occurred with the DC-645.

Check the message displayed on the LCD panel and correct the error

according to the Troubleshooting Instructions described in this

Instruction Manual. (a P.78 “OK Monitor Display and Jam Display”) (a P.80 “Error Display”) (a P.82 “Warning Display”)

Error is detected on DC-645.

Check the LCD panel for the Error display. Correct the Error, JAM and/or

Warning according to the procedures described in “Error Display” (P.80),

“Warming Display” (P.82), and “When a Paper Jam Has Occurred” (P.83 –

99).

Program JOB for DC-645 Via Computer (JOB Creator)

Load Paper

Install the Slitter Module.

Install the Standard Module.

Install the Business Card Module.

There is no document set in the 645 feed tray.

Install the Slitter Module on DC-645.

Install the Standard Module on DC-645.

Install the Business Card Module on DC-645.

Iftheproblemisnotsolvedwiththeaboveremedies,contacttheservicepersonnel.

Chapter 3

Programing JOB for DC-645 on Control Panel

DC-645 can save 80 patterns of JOBs. Job contents can be programmed either via computer or on the control panel. This chapter describes how to program a JOB on control panel of DC-645. Following items should be entered to program a JOB.

Prior to Programming a Job

Before programming a job carefully measure, in mm, the required slits, cuts and creases. See the Figure 1 for reference and Figure 2 for a detailed description of each function.

Familiarize yourself with the following illustrations and instructions to make the programming process easy and trouble free.

IMPORTANT NOTE

There are a total of 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.

Program Number

01? (01––80 OK?––>SET

Figure 1

PAPER FEEDING DIRECTION

Cut

Barcode

(Optional)

Figure 2

)

REG. Mark (Optional)

Crease

Slit

Tip

• Record the contents of each job in “Customer Programmed Jobs” list for your easy reference.

Definition of Programming Terms

AUTO CUT

Paper area before first cut and after last cut, and area between 2 cuts which is 20 – 84.99 mm long, are considered to be waste and will be chopped up for disposal in waste box when AUTO CUT is enabled.

Leading edge of the paper

First Cut

When the distance between two cuts arre 20 – 84.99 mm long, they will be

Area where automatic

cutting can be done

Last Cut

When documents do not have lead or trail margin, (as in the example 1 and 2 below), make certain to turn OFF the AUTO CUT feature.

chopped up for smooth disposal into the waste box.

Programing JOB for DC-645 on Control Panel

Example 1 - When AUTO CUT must be OFF

Example 2 - When AUTO CUT must be OFF

Customer Programmed Jobs

ALL DIMENSIONS MUST BE IN MILLIMETERS

JOB Name JOB No.

TOTAL LENGTH PAPER WIDTH OPTION Side Mark Lead Mark SLIT1 SLIT2 SLIT3 SLIT4 SLIT5 SLIT6 CUT1 CUT2* CUT3* CUT4* CUT5* CUT6* CUT7* CUT8* CUT9* CUT10* CUT11* CUT12* CUT13* CUT14* CUT15* CRE.01* CRE.02* CRE.03* CRE.04* CRE.05* CRE.06* CRE.07* CRE.08* CRE.09* CRE.10* OPTION1 OPTION2 AIR KNIFE FAN REG. REG. MARK SLIT GUIDE AUTO CUT CREASE DEPTH SPEED

THERE IS A MAXIMUM OF 15 CUTS AND 10 CREASES

CONVERSION TABLE Inches Millimeters

1.0 225.4

8.5 215.9

CONVERSION TABLE Inches Millimeters 11 279.4 17 431.8

How to Program Job on Control Panel

Optional module ............................ Select an optional module for the job when necessary.

JOB number................................... Select a JOB no. in which the JOB currently being

programmed is saved.

JOB name ....................................... Put a name to the JOB with number keys for easy

reference.

Paper length ................................... length of document

Paper width .................................... width of document

REG MARK position .................... When using REG. mark reading:

The distance between lead edge and leadmark, and the distance between right edge and side mark.

Slit positions ................................... Distances between right edge and each slit position.

DC-645 can slit up to 6 positions on 1 document.

Cut positions .................................. Distances between lead edge and each cut positions.

DC-645 can cut up to 15 positions on 1 document.

Crease position............................... Distances between lead edge and each crease positions.

DC-645 can crease up to 10 creases on 1 document.

Option positions ............................. Distances between right edge and each option positions.

AIR KNIFE .................................... Compressed air is blown out to loosen the document.

This is to prevent double-feed.

FAN REGISTER ........................... Document skewing in feeding area is corrected. When

processing light weight document, turn this function OFF as it may cause a paper jam in feed area.

Programing JOB for DC-645 on Control Panel

SLIT GUIDE .................................. When any slitters are not used, these slitters act as

AUTO CUT .................................... Lead margin, trail margin, and any gutter cuts (shorter

CREASE DEPTH .......................... This sets the depth of the crease when creasing a

SPEED ............................................ This is used to select HIGH/LOW processing speed.

paper guide to stabilize the paper conveyance. Recommended for light weight document.

than 85mm) are finely cut and dropped into the waste box. When documents do not have lead margins or trail margin, this must be turned off.

document. Set to MAX for heavy paper and MIN for light paper.

How to Program Job on Control Panel

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Turn on the machine.

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Repeatedly push the <MODE> key until the LCD panel indicates [INPUT].

[INPUT

]

INPUT––>SET

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Press and hold the <SET> key until the LCD panel appears as shown on the right with a beep.

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Use the <Number> key pad to enter the job number.

01? (01––80 OK?––>SET

52? (01––80

)

Press the <SET> key when input is completed.

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OK?––>SET

Select the optional module for this JOB with the <+> key or <–> key.

Pressthe <SET> keywheninputiscompleted.

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OP MODULE (+,– STANDARD

)

Use the <Number> key pad to enter the JOB name. Maximum 13 letters can be entered.

Press the <SET> key when input is completed.

11→ ! → ” → # → $ → % → & → ’ → ( → ) → 1 2A→ B → C → a → b → c → 2 → A 3D→ E → F → d → e → f → 3 → D 4G→ H → I → g → h → i → 4 → G 5J→ K → L → j → k → l → 5 → J 6M→ N → O → m → n → o → 6 → M 7P→ Q → R → S → p → q → r → s → 7 → P 8T→ U → V → t → u → v → 8 → T 9W→ X → Y → Z → w → x → y → z → 9 → W 00→ * → + → , → - → . → / → : → ; → < → > → ? → @ → 0

C Clear

JOG Space, Move the cursor to the right JOG Space, Move the cursor to the left

How to Program Job on Control Panel

Example:

1. Press the < 3 > key and <JOG> key.

2. Press the < 8 > key 2 times and <JOG> key.

3. Press the < 7 > key and <JOG> key.

4. Press the < 5 > key 3 times and <JOG> key.

5. Press the < 6 > key 3 times and <JOG> key.

6. Press the <SET> key.

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Enter the total length (in mm) of the document.

Pressthe <SET> keywheninputiscompleted.

Tip

• WhenprogrammingaJOB(INPUTmode),press the<JOG>keytomovetoNEXTorPrevious display.

<JOG> key: Go to the next display

<JOG> key: Go to the previous display

Tip

• When programming a JOB (INPUT mode), press the <STOP> key to quit the JOB program and return to the regular LCD display.

52:DUPLO

12345

TOTAL LENGTH ? (

210–650)460.0mm

PREPRINTED

SAMPLE

Programing JOB for DC-645 on Control Panel

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Enter the paper width (in mm) of the document.

Pressthe <SET> keywheninputiscompleted.

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Measure the distance (in mm) between the Right edge of the paper and the vertical portion of the Side mark. Input the distance of Side mark by <Number> key. The value must be between 3 and 15 mm when REG. Mark is not used enter 0.0 mm.

PAPER WIDTH ? (

210–370)297.0mm

10mm

SIDE MARK 10.0mm (

0,3–15

)

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How to Program Job on Control Panel

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Measure the distance (in mm) between the leading edge of the paper and the horizontal portion of the REG. Mark. The value must be between 3 and 15 mim.

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Enter the value from step 9 using the <Number> key. When REG. Mark is not used, enter 0.

Pressthe <SET> keywheninputiscompleted.

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Enter the distance from the right edge of the document to the position for SLIT1. This value must be between 0 and 40 mm.

Pressthe <SET> keywheninputiscompleted.

Tip

• When selecting “Business card module” for optional module, slit positions do not need entry. Go to step 18.

Tip

• The document will be ejected if the slit position exceeds the 40 mm upper cutting limit by the margin slitter due to “REG. mark print position drift” or “Side mark entry error”.

10mm

LEAD MARK 10.0mm (

0,3–15

)

SLIT 1 10.0mm (

0– 40.0

)

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Enter the distance from the right edge of the document to the position for the SLIT 2. This value must be between 257 and 297 mm.

Pressthe <SET> keywheninputiscompleted.

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Enter the distance from the right edge of the document to the position for the SLIT 3. This value must be between 58 and 212 mm.

Pressthe <SET> keywheninputiscompleted.

SLIT 2 260.0mm (

0,257.0–297.0

)

SLIT 3 110.0mm (

0,58.0–212.0

)

How to Program Job on Control Panel

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Enter the distance from the right edge of the document to the position for the SLIT 4. The value must be (the value entered for SLIT 3 + 48 mm) or more.

Pressthe <SET> keywheninputiscompleted.

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Enter the distance from the right edge of the document to the position for the SLIT 5. This value must be between 58 and 212 mm.

Pressthe <SET> keywheninputiscompleted.

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Enter the distance from the right edge of the document to the position for the SLIT 6. The value must be (the value entered for SLIT 5 + 48 mm) or more.

SLIT 4 160.0mm (

0,158.0–212.0

)

SLIT 5 60.0mm (

0,58.0–212.0

)

SLIT 6 210.0mm (

0,108.0–212.0

)

Programing JOB for DC-645 on Control Panel

Pressthe <SET>keywheninputiscompleted.

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Enter the distance from the leading edge of the document to the position for CUT 1. This value must be smaller than the value set for paper length.

Pressthe <SET>keywheninputiscompleted.

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Enter the distance from the leading edge of the document to the position for CUT 2. This value must be bigger than the value set for CUT 1 and smaller than the value set for paper length.

If CUT 2 is not required, enter 0. When there is only 1 cut on document, AUTO CUT function must be turned off.

Press the <SET>key when input is completed. Hereafter, check the number value input, to similarly set to CUT 15.

CUT01 10.0mm (

0–460.0

)

CUT02 190.0mm (

0,95.0–460.0

)

Continue Page

•••

How to Program Job on Control Panel

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Enter the distance from the leading edge of the document to position for the first crease. A number value within the length of the paper length set can be input.

Pressthe <SET>keywheninputiscompleted. Hereafter,checkthenumbervalueinput,tosimilarlysetto CRE10.

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(The display on the right will only appear when the Optional Module in Step 8 is set to “BUSINESS” (Business Card Module)). Input the distance of the optional module processing position from the right edge of the document to the processing position.

Press the <SET>key when input is completed.

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Use the <+> key and <–> key to switch between and turn ON/OFF the compressed air blowout at the feed area to loosen the documents.

Press the <SET>key when the setting is set.

CRE.01 100.0mm (

0–460.0

)

OPTION1 5.0mm (

4.0–10.0

)

AIR KNIFE ON

OFF

∗

Tip

• Turnonthisfunctionwhenprocessing documentswithexcessivestaticelectricityor heavyweightdocuments.

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Use the <+> key and <–> key to switch between and turn ON/OFF the fan function. When this is ON, the performance of the document skew condition is improved.

Press the <SET>key when the setting is set.

Tip

• Whenthedocumentweightislight,thismay causepaperjam.Therefore,keepturnedOFF.

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Use the <+> key and <–> key to switch between and turn ON/OFF REG. Mark reading for image drift compensation.

Press the <SET>key when the setting is set.

IMPORTANT

• It is not possible to turn ON the REG. mark

(Function Mode) if either the Lead Mark or Side Mark doesn’t have a number entry (i.e. if the number entry is 0mm). Please enter a number to turn ON the REG mark function.

FAN REG.

∗

OFF

REG.MARK ON

OFF

∗

How to Program Job on Control Panel

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Use the <+> key and <–> key to switch between and turn ON/OFF the Slit Guide function. When this function is ON, the unused slitter acts as a paper transport guide.

Press the <SET>key when the setting is set.

Tip

• TurnONonlywhenthedocumentweightislight.

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Use the <+> key and <–> key to switch between and turn ON/OFF.

Pressthe <SET>keywheninputiscompleted.

SLIT GUIDE ON

AUTO CUT

OFF

∗

OFF

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Use the <+> key and <–> key to switch the creasing depth between and set MAX, Mid or MIN. The crease will be deep when MAX is set and will be shallow when MIN is set.

Pressthe <SET>keywheninputiscompleted.

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Use the <+> key and <–> key to switch between and set High or Low processing speed. Set to LOW for better processing precision.

Pressthe <SET>keywheninputiscompleted.

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Press the <SET> key to retain the settings or <C> key to cancel the settings. [MEMORY !!] is displayed when the JOB is saved on the DC-645 memory circuit.

The memorization process will take approximately 1.5 seconds.

CREASE DEPTH MAX

SPEED

MID MIN

∗

HIGH

∗

LOW

OVER WRITE ? OK( ) NO(C)

Programing JOB for DC-645 on Control Panel

MEMORY !!

Chapter 4

Basic Operations

This chapter describes the operating sequence from turning ON the power switch until completing

finishing process.

Process Documents by Selecting JOB

This section describes the procedures to process documents by selecting each JOB manually.

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Turn ON the power. (

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Press the <MODE> key and go to the [SELECT] display.

a P.16 “Turning ON the Power”)

[

SELECT

]

05:DUPLO

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Input the number of the JOB to call up, using the <Number> key.

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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.

∗ ∗

100/100

(Ex.: When 100 documents are set, the above display appears.)

By pressing the <START> key, processed number of the document is subtracted from the specified number as below.

06:DUPLO 1 BC REG AC

∗ ∗ ∗

∗ ∗

99/100

* If an error has occurred during processing, batch counting can not be executed.

∗ ∗

98/100

Process Documents by Selecting JOB

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Prepare the document suiting the JOB selected, then loosen the stack of the documents by flipping through the sheets.

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Set the document on the feed tray.

Tip

• For JOBs using a barcode or REG. Mark, place the barcode and REG. Mark printing side facing upward as in the illustration. Then set it in the feed direction.

Tip

• The height of the paper stack should not exceed the “MAX” level.

Tip

• To set paper that is vertically long, pull out the feed tray to accommodate the length of paper.

Tip

• Fully extend the hand-feeding paper-feeder for use.

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Set the side guides.

Basic Operations

Continue Page

•••

Process Documents by Selecting JOB

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As shown in the diagram, lift the stacker tray.

Tip

• When the finished document size is A3 (11” x 17”) or longer, it is recommended to set the stacker tray in the downward position.

Tip

• If the finished documents are adhere on the tray due to static electricity, set the stacker tray in the downward position.

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Install the end stopper and side guides. Set the end stopper perpendicular to the floor.

Tip

• If the document size processed is postcard or business card size, then it is better to set the “Card stacker” in place of the guide.

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Press the <START> key after confirming that the <START> key light is GREEN.

Tip

• If the <START> key light is RED. DC-645 is running a job or having an error.

123

456

789

Process Documents by Selecting JOB

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The document is processed according to the setting of the JOB selected.

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The finished document is ejected to the stacker tray.

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Press the <STOP> key to quit the process.

123

456

789

Basic Operations

Automatic Set Up Using Barcodes

By adding barcode which indicates job number on each document, DC-645 automatically set up the machine and start JOB. The procedure is described below.

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Turn ON the power. (

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Prepare the document suiting the JOB selected, then loosen the stack of the documents by flipping through the sheets.

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Set the document in the feed tray with the surface where barcodes and REG. Marks are printed facing upwards.

a P.16 “Turning ON the Power”)

Tip

• Set the document in the direction shown in the illustration.

Tip

• The height of the paper stack should not exceed the “MAX” level.

Tip

• To set paper that is vertically long, pull out the feed tray to accommodate the length of paper.

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Set the side guides.

Continue Page

•••

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As shown in the diagram, lift the stacker tray.

Tip

• When the finished document size is A3 (11” x 17”) or longer, it is recommended to set the stacker tray in the downward position.

Tip

• If the finished documents are adhere on the tray due to static electricity, set the stacker tray in the downward position.

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Install the end stopper and side guides. Set the end stopper perpendicular to the floor.

Tip

• If the document size processed is postcard or business card size, then it is better to set the “Card stacker” in place of the guide.

Automatic Set Up Using Barcodes

Tip

• If the document size processed is postcard or business card size, then it is better to set the “Card stacker” in place of the guide.

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By pressing the <START> key, the built-in CCD reads the barcoded JOB number, then starts processing the suitable JOB.

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The finished document is ejected.

Basic Operations

IMPORTANT

• Pieces of cut paper accumulate in the waste box. Open the front cover and remove them

periodically. Accumulation of pieces of paper may cause paper jams.

Adjust Feeder

Elevator level (Feed tray)

The elevator level should be adjusted in the following cases.

a. The machine does not feed.

→ Turn the knob in the clockwise direction. (to a

larger number) The level of the elevator is raised.

b. The machine feeds multiple sheets at once.

(double feed)

→

Turn the knob in the anti-clockwise direction. (to a smaller number). The level of the elevator is lowered.

Separator

The height of the separator should be adjusted in the following cases:

a. The machine does not feed.

→

Turn the knob in the clockwise direction (to a larger number). The position of the separator is lowered.

b. The machine feeds multiple sheets at once.

(double feed)

→

Turn the knob in the anti-clockwise direction (to a smaller number). The position of the separator is raised.

For Light Paper

Level adjustment knob

For Light Paper

Separator adjustment knob

For Heavy Paper

Airflow

The amount of airflow should be adjusted in the following cases:

a. The machine does not feed.

→

Turn the knob in the clockwise direction (to a larger number). The amount of airflow is increased.

b. The machine feeds multiple sheets at once.

(double feed)

→

Turn the knob in the anti-clockwise direction (to a smaller number). The amount of airflow is decreased.

Print Image Skew

If the document to cut is printed obliquely, then the finish may not be as expected. When this happens, correct the problem by changing the angle of the feed guide.

Airflow adjustment knob

Adjust Feeder

For Heavy Paper

For Light Paper

Skew adjustment knob

Curled Document / Light Weight Document

If the document is light weight paper or curled, the paper rolls up between the unit and will not be successfully fed. In such case, adjust the position of the upper guide so that the edge of the document passes under the upper guide.

Tip

• Do not use the upper guide when feeding document is not light weight or curled.

Basic Operations

Upper guide

FUNCTION Mode

Various mechanical settings are set when processing takes place.

AIR KNIFE Compressed air is blown out to loosen the document. This is to prevent double-feed.

FAN REG. Document skewing in feeding area is corrected. When processing light weight document, turn this

function OFF as it may cause a paper jam in feed area.

DOUBLE FEED This detects whether the document is double-feed. Always leave ON.

BARCORD This sets whether to execute automatic setup when reading the barcode.

REG. MARK This sets whether to detect the REG. Mark. The Document processing precision can be heightened

by detecting the REG. Mark and setting the process to the standard (home) location.

REJECT Double-fed documents or documents with inappropriate BARCODE or REG. Mark (when these

functions are on) are rejected on the reject tray automatically.

SLIT GUIDE When any slitters are not used, these slitters act as paper guide to stabilize the paper conveyance.

Recommended for light weight document.

AUTO CUT Lead margin, trail margin, and any gutter cuts (shorter than 85 mm) are finely cut and dropped into

the waste box. When documents do not have lead margins or trail margin, this must be turned off.

CREASE DEPTH This sets the depth of the crease when creasing a document. Set to MAX for heavy paper and MIN

for light paper.

SPEED This is used to select HIGH/LOW processing speed.

APPLY SHRINKAGE

In case printed documents are shrunk by heat generated on digital printer, by entering the original

paper size and paper size after shrinked, DC-645 automatically calculate the shrinkage ratio and

adjust the cutting & creasing position accordingly. This function compensate for the shrinkage in

the feed direction only.

Tip

• The DC-645 comes with a function to stop the JOB when a certain number of documents are rejected when processing the document. This function is generally set by the servicing personnel upon the initial setup. This setting can be changed from the “Settings” menu of the JOB Creator. (a P.49 “Setting Frequent Function From Computer (“Function Setting”)”)

Function Mode Flow Chart

IMPORTANT

• Functions of AIRKNIFE, FAN REG., REG.

MARK, SLIT GUIDE, AUTO CUT, CREASE DEPTH, and SPEED are also set ON/OFF when programing JOB. Settings memorized when programing JOB take priority over those by <F> key. Therefore, settings by <F> key apply only to the process which is just after the settings. Programmed settings are not overwhitten and remain as they are. On the contrary, functions of DOUBLE FEED, BARCODE, REJECT, AND APPLY SHRINKAGE are set ON/OFF only by <F> key.

AIR KNIFE

FAN. REG

DOUBLE FEED

BARCODE

REG. MARK

REJECT

SLIT GUIDE

AUTO CUT

CREASE DEPTH

SPEED

APPLY SHRINKAGE

■ Setup Procedures

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Press the <F> key to switch to the Function Mode.

FUNCTION Mode

AIR KNIFE ON

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Press the <SET> key several times, to display the Function to set.

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Set ON/OFF with the <+> key or <–> key.

OFF

∗

AIR KNIFE ON

OFF

∗

Basic Operations

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Press the <F> key to return to the regular display.

AIR KNIFE ON

OFF

∗

About the Waste Box

Pieces of cut paper accumulate in the waste box. How to remove the accumulated pieces of paper is described below.

WARNING

• Be sure to confirm that the machine is in a full stop before removing the accumulated paper to prevent your hands or fingers from being caught or pinched in the machine.

IMPORTANT

• Accumulation of pieces of paper may cause paper jams. Remove the paper scraps from the waste box described below.

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Confirm that the machine is fully stopped.

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Open the front cover located at the bottom left of the machine and remove the accumulated paper in the waste box.

Tip

• When pieces of paper remain in the machine, remove them.

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Close the front cover.

Clean Feed Rollers

As DC-645 process digital colour outputs, toner etc. on the documents may adhere to the surface of feed rollers of DC-

645. When the accumulation of such toner becomes excessive, it may effect the performance of DC-645. In this case, clean the rollers in following procedures.

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Press the “ | ” side of the power switch, while pressing the <MODE> key, to turn ON the machine. The machine is started up with the Cleaning Mode.

CLEANING MODE STOP–>POWER OFF

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Open / Close Top Cover 1. Every time the top cover (1) is opened/closed, the feed rollers turn 60 degrees. Wipe-off the toner, debris on the rollers using a tightly wrung cloth. The entire roll is cleaned around its circumference by opening/closing the top cover 6 times.

IMPORTANT

• Do not wipe the rollers with anything other

than that designated above. Use of anything else may result in mechanical malfunction.

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Press the power switch of the “ OFF the power and quit the Cleaning Mode.

K ” side to turn

Basic Operations

Chapter 5

Troubleshooting

This chapter describes what to do when an error has occurred and how to deal with paper jams and error

messages.

Troubleshooting Flow Chart

Power Does Not Turn ON

If the power does not turn ON, check the following.

THE MACHINE DOES NOT TURN ON.

IS POWER PLUG INSERTED?

IS POWER SWITCH ON?

NOYES

Turn the power switch ON.

Please contact your service personnel.

NOYES

Insert the power plug securely.

Cutting is Not Possible

If cutting is not possible, check the following.

IS THERE A MESSAGE DISPLAYED ON LCD PANEL AND OK MONITOR?

Troubleshooting Flow Chart

Please contact your service person.

YES

See P.78 “OK Monitor Display and Jam Display”,

P.80 “Error Display”, and P.82 “Warning Display”.

Troubleshooting

OK Monitor Display and Jam Display

When a paper jam or error that the machine cannot correct occurs, the OK monitor will flash where the error occurred. The LCD panel will display JAM. In such case, following the procedures below to resolve the cause.

Message Countermeasure

COVER OPEN

PLEASE SET PAPER

OVER CAPACITY (J7)

FEED JAM (J2)

The top or front cover is open.

Close the top or front cover.

There is no paper in the feed tray.

Load the feed tray with paper.

Too many document stacked in the feed tray.

Remove the document in the machine and press the <STOP> key. (a P.97 “When “OVER CAPACITY” is displayed”)

This is paper jam in the feed tray or skew correction area.

Remove the document in the machine and press the <STOP> key. (a P.85 “When “FEED JAM” is displayed”)

1. Satisfactorily fan the edge of the paper stack in the feed tray.

2. Adjust the feed. (a P.70 “Adjust Feeder”)

CENTER JAM (J3) Paper jam in the CCD or slitter area.

Remove the document in the machine and press the <STOP> key. (a P.87 “When “CENTER JAM” is displayed”)

OK Monitor Display and Jam Display

Message Countermeasure

CUTTER OR CREASE (J4) This is a paper jam in the cutter module or crease area.

Remove the document in the machine and press the <STOP> key. (a P.89 “When “CUTTER OR CREASE” is displayed”)

OPTIONAREAJAM(J5)

STACKERJAM(J6)

REJECTAREAJAM(J8) Paper jam in the reject area.

Paper jam in the optional module.

Remove the document in the machine and press the <STOP> key. (a P.93 “When “OPTION AREA JAM” is displayed”)

Paper jam in the stacker unit.

Remove the document in the machine and press the <STOP> key. (a P.95 “When “STACKER JAM” is displayed”)

Remove the document in the machine and press the <STOP> key. (a P.98 “When “REJECT AREA JAM” is displayed”)

Troubleshooting

Error Display

When an error that the machine cannot correct occurs, an Error message is displayed on the LCD panel. In such case, take measures according to the following instructions.

Message Countermeasure

RS232C ERROR (E2)

––– E 2 ––– RS232C ERROR

BARCODE ERROR (E3)

––– E 3 ––– BARCODE ERROR

REG.MARK ERROR (E4)

––– E 4 ––– REG. MARK ERROR

SLITTER ERROR (E5)

––– E 5 ––– SLITTER ERROR

* The slitter number in error is displayed.

DATA ERROR (E6)

∗

––– E 6 –––

Communication error between the CCD and the mainboard.

1. Turn OFF the power. Then turn ON the power again, to reset the machine.

2. Contact the service personnel if the ERROR message remains displayed.

This is a barcode reading error.

1. Verify the barcode on the document is printed clearly.

2. Check the location of barcode.

See “Specifications of REG. Mark and Barcode” for details.

This is a REG. Mark reading error.

1. Verify the documents REG. Mark is printed clearly.

2. Check the location of the barcode.

See “Specifications of REG. Mark and Barcode” for details.

This is a slitter module error. Remove the document in the machine and press the <STOP> key. (a P.87 “When “CENTER JAM” is displayed”)

1. Turn OFF the power. Then turn ON the power again.

2. Carefully open the Top Cover 2, then check for any paper in the operating range of slitter area. If there is any paper identified, carefully remove it.

3. Contact the service personnel.

There is no JOB programmed in selected JOB no.

1. Confirm the JOB no. and select a proper one.

2. Program a new JOB in the JOB no. if necessary.

DATA ERROR

CUTTER ERROR (E7)

––– E 7 ––– CUTTER ERROR

This is a cutter error. Remove the document in the machine and press the <STOP> key. (a P.89 “When “CUTTER OR CREASE” is displayed”)

1. Turn OFF the power. Then turn ON the power again.

2. Carefully open the Top Cover 3. Check for any paper in cutter area. If there is any paper identified, carefully remove it.

3. Contact the service personnel.

Message Countermeasure

Error Display

ELEVATOR ERROR (E8)

––– E 8 ––– ELEVATOR ERROR

CREASE ERROR (E9)

––– E 9 ––– CREASE ERROR

DOUBLE FEED (E11)

––– E 11 ––– DOUBLE FEED

REJECT ERROR (E12)

––– E 12 ––– REJECT ERROR

GUTTER ERROR (E14, 15)

––– E 14 ––– GUTTER ERROR R

This is an elevator error. Remove the document in the machine and press the <STOP> key.

1. Turn OFF the power. Then turn ON the power again, to reset the machine.

2. Contact the service personnel.

This is a creaser module error. Remove the document in the machine and press the <STOP> key. (a P.89 “When “CUTTER OR CREASE” is displayed”)

1. Turn OFF the power. Then turn ON the power again.

2. Carefully open the Top Cover 3. Check to see if there are any paper in the operation range of the creaser module. If there is any paper identified, carefully remove it.

3. Contact the service personnel.

Double-feed was detected. Remove the document in the machine, then press the <STOP> key.

1. Turn OFF the power. Then turn ON the power again, to reset the machine.

2. Satisfactorily flip through and loosen the document sheets in the feed tray.

3. Adjust the feed. (a P.70 “Adjust Feeder”)

4. The Double-Feed Error is displayed when the Double-Feed Detection is ON and Reject is OFF. By keeping Reject ON, the detected document will automatically be output to the reject tray.

This is an error in the reject area. Remove the document in the machine and press the <STOP> key. (a P.98 “When “REJECT AREA JAM” is displayed”)

1. Turn OFF the power. Then turn ON the power again.

2. Carefully open the front cover. Then check if there are any paper in the reject area. If there is any paper identified, carefully remove it.

3. Contact the service personnel.

This is displayed when the gutter guide does not return to the home position within a designated time. Remove the document in the machine and press the <STOP> key.

1. Turn OFF the power. Then turn ON the power again.

2. Carefully open Top Cover 3. Check to see if there are any paper in the operation range of the gutter deflector. If there is any paper identified, carefully remove it.

3. Contact the service personnel.

Troubleshooting

Warning Display

A warning display appears on the LCD panel when attempting to process a JOB when the machine is not ready. In such case, take measures according to the following instructions.

Message Countermeasure

CHANGE MODULE

CHANGE MODULE STANDARD

SET SLIT MODULE

COVER OPEN

BLANK DATA

A module not specified in the JOB selected is set on the machine. Set the optional module of the machine to the module displayed on the LCD panel.

There is no slitter module. Install a slitter module in the machine. One or more slitter module is not set in the machine.

The top or front cover is open. Close the top or front cover.

Program a new JOB in the JOB no. if necessary.

USB-IF SUSPENDED

USB–IF SUSPENDED

The machine is out of communication with a computer. (When a computer is in standby status or sleep status, wake up the computer and then press the <STOP> key to cancel the error.)

1. Turn OFF this machine. Then pull out and re-insert the USB cable.

2. Contact the servicing personnel.

When a Paper Jam Has Occurred

When a paper jam has occurred, the lamp blinks on the OK monitor and a message is displayed on the LCD panel.

WARNING

• Do not touch the blade (with the WARNING sticker attached). Doing so may cause injury.

(aP.7, “Warning Sticker”)

• Before removing paper make sure the machine is fully stopped. Use the pliers that come with the machine to prevent your hands or fingers from being caught or pinched. (aP.7, “Warning Sticker”)

When “REJECT PAPER” is Displayed

If a document remains in the machine when the power is turned ON, “REJECT PAPER” is displayed on the LCD panel and the lamp blinks on the OK monitor. Remove the document with the following procedure.

––– J 1 ––– REJECT PAPER

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Press the <JOG> or <JOG> key to eject the document.

IMPORTANT

• Be sure to close the top and front cover when you operate the machine. The machine does not work if the top or front cover is open.

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■ If the document cannot be removed with the procedure mentioned above

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Open the top or front cover. (When the front cover is opened) Remove the waste box.

Troubleshooting

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•••

When a Paper Jam Has Occurred

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(When opening the top cover) Remove the jammed document using your fingers or the pliers.

(When the front cover is opened) Loosen the guide screw for the paper outlet. Lift it forward and remove the paper jam.

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(When opening the top cover) Close the top cover.

(When the front cover is opened) Loosen the guide screw. Put the waste box inside. Then close the front cover.

When “FEED JAM” is Displayed

If a paper jam has occurred in the feeding area, “FEED JAM” is displayed on the LCD panel and the lamp blinks on the OK monitor. Remove the jammed document with the following procedure.

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Press the <JOG> key to eject the jammed documents.

When a Paper Jam Has Occurred

––– J 2 ––– FEED JAM

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Press the <STOP> key to reset the fault logic and clear the message.

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■ If the document cannot be removed with the procedure mentioned above

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Open the top cover 1.

Troubleshooting

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When a Paper Jam Has Occurred

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Remove the jammed document using your fingers or the pliers.

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Close the top cover 1.

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Press the <STOP> key to reset the fault logic and clear the message.

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When “CENTER JAM” is Displayed

If a paper jam has occurred in the slitter area, “CENTER JAM” is displayed on the LCD panel and the lamp blinks on the OK monitor. Remove the jammed document with the following procedure.

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Press the <JOG> key and eject the jammed document to the stacker tray side.

When a Paper Jam Has Occurred

––– J 3 ––– CENTER JAM

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Press the <STOP> key to reset the fault logic and clear the message.

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■ If the document cannot be removed with the procedure mentioned above

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Open the top cover 2.

Troubleshooting

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•••

When a Paper Jam Has Occurred

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Loosen the screws on both sides of the module with a paper jam, and lift the module.

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Remove the jammed document using your fingers or the pliers. Use pliers and be careful not to damage the blade.

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Slowly lower the module. Check to see that the pins on both sides are securely fitted in the module. Then tighten the screws.

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Close the top cover 2.

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Press the <STOP> key to reset the fault logic and clear the message.

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When a Paper Jam Has Occurred

When “CUTTER OR CREASE” is Displayed

If a paper jam has occurred in the cutter or creaser module, “CUTTER OR CREASE” is displayed on the LCD panel and the lamp blinks on the OK monitor. Remove the jammed document with the following procedure.

––– J 4 ––– CUTTER OR CREASE

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Press the <JOG> key and eject the jammed document to the stacker tray side.

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Press the <STOP> key to reset the fault logic and clear the message.

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■ If the document cannot be removed with the procedure mentioned above When uninstalling the creaser module:

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Open the top cover 3.

Troubleshooting

Continue Page

•••

When a Paper Jam Has Occurred

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Disconnect the connector of the creaser module. Then, loosen the screws on both sides of the module with a paper jam, and lift the module.

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Remove the jammed document using your fingers or the pliers.

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Slowly lower the module. Check to see that the pins on both sides are securely fitted in the module. Then tighten the screws.

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Close the top cover 3.

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Press the <STOP> key to reset the fault logic and clear the message.

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When uninstalling the cutter module:

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Prepare the cutter cover.

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Disconnect the connector of the cutter module.

When a Paper Jam Has Occurred

Cutter cover

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Unscrew the knob screws on both sides of the module. (Be careful not to lose or misplace the screws after unscrewing them.)

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Install the cutter cover on the cutter module by inserting one side of the cutter cover between the gap, as shown in the diagram.

Troubleshooting

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When a Paper Jam Has Occurred

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Screw on the knob screws that was unscrewed in Step 3, in the location shown in the diagram.

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Lift the cutter cover by holding the handle portion while lifting the cutter cover.

Disassembled cutter module

When a Paper Jam Has Occurred

When “OPTION AREA JAM” is Displayed

If a paper jam has occurred in the optional module, “OPTION AREA JAM” is displayed on the LCD panel and the lamp blinks on the OK monitor. Remove the jammed document with the following procedure.

––– J 5 ––– OPTION AREA JAM

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Press the <JOG> key and eject the jammed document to the stacker tray side.

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Press the <STOP> key to reset the fault logic and clear the message.

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■ If the document cannot be removed with the procedure mentioned above

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Open the top cover 3.

Troubleshooting

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When a Paper Jam Has Occurred

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Loosen the screws on both sides of the module with a paper jam, and lift the module.

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Remove the jammed document using your fingers or the pliers.

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Slowly lower the module. Check to see that the pins on both sides are securely fitted in the module. Then tighten the screws.

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Close the top cover 3.

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Press the <STOP> key to reset the fault logic and clear the message.

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When “STACKER JAM” is Displayed

If a paper jam has occurred around stacker unit, “STACKER JAM” is displayed on the LCD panel and the lamp blinks on the OK monitor. Remove the jammed document with the following procedure.

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Press the <JOG> key and feed the jammed document to the stacker tray side.

When a Paper Jam Has Occurred

––– J 6 ––– STACKER JAM

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Press the <STOP> key to reset the fault logic and clear the message.

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■ If the document cannot be removed with the procedure mentioned above

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Remove the jammed document.

Troubleshooting

Continue Page

•••

When a Paper Jam Has Occurred

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Press the <STOP> key to reset the fault logic and clear the message.

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When a Paper Jam Has Occurred

When “OVER CAPACITY” is Displayed

If there are too many documents set on the feed tray, “OVER CAPACITY” will be displayed on the LCD panel. Then the OK monitor light will flash. Reduce the number of documents on the feed tray.

––– J 7 ––– OVER CAPACITY

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Reduce the number of documents on the feed tray to under the maximum height permitted.

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Press the <STOP> key to reset the fault logic and clear the message.

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Troubleshooting

When a Paper Jam Has Occurred

When “REJECT AREA JAM” is Displayed

If a paper jam has occurred in the reject area, “REJECT AREA JAM” is displayed on the LCD panel and the lamp blinks on the OK monitor. Remove the jammed document with the following procedure.

––– J 8 ––– REJECT AREA JAM

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Press the <JOG> key and eject the jammed document to the reject tray side.

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Press the <STOP> key to reset the fault logic and clear the message.

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■ If the document cannot be removed with the procedure mentioned above

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Open the front cover and take out the waste box.

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Loosen the guide screw for the paper outlet. Lift it forward and remove the paper jam.

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Put the waste box inside. Then close the front cover.

When a Paper Jam Has Occurred

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Press the <STOP> key to reset the fault logic and clear the message.

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Troubleshooting

Duplo DC-645 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual