The cause of most accidents is failure to adhere to basic safety rules and observe
safety instructions. It is important to prevent potential causes of accidents from
occurring. In order to do so, read this manual carefully, and be sure to understand
all the safety instructions and correct inspection and servicing procedures that it
provides before beginning repair or servicing work.
Repairing or servicing the machine with insuffi cient knowledge about it could lead to
unforeseen accidents.
It is not possible to anticipate and describe in a manual such as this every possible
hazard that could arise in the course of repair and servicing. Therefore, besides
observing the safety instructions marked in this manual and on the machine’s
labels,
as necessary. When performing repair or service work not covered by this manual,
you should obtain safety guidance from an appropriately knowledgeable person.
Trademarks
· Windows, and Windows Vista are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries.
All other trademarks are the property of their respective owners.
service personnel should be safety-conscious and take other safety precautions
PLEASE NOTE
In the interests of upgrading our product, specifi cations 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 clarifi cation.
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■
How to Use This Service Manual
• This service manual includes the structural and functional descriptions for the major areas of
DC-646, along with the descriptions of procedures for disassembly and assembly, design
standard and adjustment, maintenance and service requirements, and actions to be taken in
the case of malfunctions. These are the information as of August, 2013.
The parts and components used are subject to change for the quality and performance
improvements, or for safety reasons. In such cases, please note that certain part of the
descriptions and/or illustrations contained in this manual may differ from the actual product.
• The marking listed below accompanied by indicates the instruction of particular importance
for safety reasons. Never fail to comply with them.
Safety instructions
●
WARNING
CAUTION
[Examples of Pictorial Symbols]
Indicates a high degree of potential danger. Failure to heed the warning
may lead to death or serious injury.
Indicates a medium degree of potential danger. Failure to heed the
caution may lead to injury or damage to property.
Δ symbol is to note that the instruction calls for close attention (including
danger and warning).
Specific hazard to be careful about is indicated in the drawing (e.g.
warning for electric shock in the case of illustration on the left).
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.”)
For maintenance operation
●
IMPORTANT :
REFERENCE
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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.
Introduces information that is useful for operation and maintenance of
the machine, or information about the machine’s performance, etc.
Safety Instructions
1. Cautions regarding the installation location
CAUTION
Installation environment
●Avoid installing the machine in places exposed to direct sunlight.
• Sunlight will cause the temperature in the machine’s interior to rise, possibly leading to
malfunction of the control system.
• Sunlight could cause misoperation of the sensors.
• The heat of direct sunlight could cause deformation of the machine’s plastic parts.
* Also avoid installation near to a ground glass window; light and heat penetrate such windows
although they are opaque.
Avoid installing the machine in places subject to high or low temperature or humidity.
●
• High or low temperature or humidity could cause the machine to operate abnormally.
Suitable temperature and humidity ranges are:
Ambient temperature : 10°C–30°C
Ambient humidity : 40%–70%
Optimum temperature and humidity : 20°C, 65%
If the machine is installed near to faucets, water heaters or humidifi ers, or in cool (sunless) parts
•
of a building or in the vicinity of water sources, the paper could absorb moisture and curl, leading
to misfeeds.
Avoid installing the machine in places with open fl ames, or where refl ected heat or other
●
hot air currents (from stoves, etc), or cold air currents from coolers, etc will strike
it directly.
● Avoid installing the machine in poorly ventilated places.
● Avoid installing the machine in dusty places.
● The machine should not be tilting when it is used.
Install the machine so that it is level. (The machine should be level to within 5 mm in the front-rear
•
direction, and 5 mm in the lateral direction.)
●Do not install the machine on shaky, sloping or otherwise unstable surfaces.
• The machine could fall over on such surfaces, or fall off them, causing injury.
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2. Cautions for installation work
WARNING
● The machine’s power supply voltage and power consumption are given in the table
below. The machine's power supply voltage is indicated on the identifi cation plate on
machine; the machine must be connected to a power supply of the voltage indicated.
→ Otherwise, fi re or electric shock could result.
If the power supply voltage is unstable or if the power supply has insuffi cient capacity, the
machine may not operate normally. Make sure that the power supply has suffi cient capacity
for the system as whole, including optional equipment.
● Use only the power cord that is provided with the accessories. Insert the power cord
plug firmly into the socket, so that proper electrical contact is made. Use of any
other power cord could result in imperfect grounding. If grounding is imperfect and
electrical leakage occurs, fi re or electric shock could result.
Install the machine close to its power supply. The outlet used should be exclusively for
●
the machine, and have no other equipment connected to it.
● Never tread on the power cord or pinch it between other objects, or accidents could
result.
CAUTION
● Install the machine in accordance with the Installation Manual supplied.
4
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3. Cautions for maintenance, inspection and servicing
WARNING
● Always remove the power cord plug from the outlet before starting work.
→ Otherwise, your hands/fi ngers could get damaged beside electrical shock.
• However, the plug must be left connected to the outlet when performing function checks
individual motors, a given series of operations, or electrical circuits). When motors are
Product type Slitter/Cutter/Creaser Floor model
Feeding methodBelt suction
Feed trayElevator
Infeed document sizeWidth: 210–370 mm (8.27–14.56 in)
Minimum fi nishing sizeWidth: 48 mm (1.89 in)
Document weightMin: 110 gsm
Document typeCoated, non-coated, laminated
Paper curl No curl (within 5 mm)
Feeder capacity100 mm (3.93 in)
Speed30 ppm: A4 LEF 2 cuts and 1 crease
Tolerance+ /- 0.2 mm on fi nished size (Business cards: + /- 0.3 mm)
Number of slitters
Side margin slit width3.2–55 mm (from the edge of a document)
Gutter slit width5.0–15.0 mm
Gutter defl ector 2 gutter defl ectors
Max number of cuts on 1
document
Minimum cut lengthLead edge margin: 3 mm
Maximum number of
creases on 1 document
Exit trayDrop down tray
Exit tray capacity140 mm (5.51 in)
Card stacker capacity 60 mm (2.36 in)
Control panel 128 dots×64 dots LCD OK monitor
Panel languagesJapanese, English, French, German, Italian, Spanish, Polish, Russian
Job programmingOn the control panel or on the PC controller software
Noise levelLess than 80 db during a continuous operation
1
Model nameDC-646
Length: 210–670 mm (8.27–26.37 in)
Length: 50 mm (1.97 in)
Max: 350 gsm
● Laminated stock or UV coated stock should be within the range
above including the lamination/UV coating.
● The crease tolerance depends on the number of creases on the
documents and their depths.
6 slitters (2 margin slitters and 4 center slitters are equipped as standard.)
● Waste strips wider than 15 mm come out on the exit tray.
Automatic control
25
Gutter cut between cards: 3 mm
Trail edge margin: 5 mm
20
16
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Chapter 1 Specifi cations
Model nameDC-646
Standard functionsPC controller software
80 job memory
Test feed
Air knife
Double feed detection
Fan register adjustment
Emergency stop switch
Waste box
Image shrinkage compensation (lengthwise)
Automatic job setup by reading Barcode *
Image drift compensation by reading REG mark *
Reject *
Card stacker *
PC arm mount *
Cleaning mode
*: Optional on 230V model
PC controller (USB connection: B-type connector)
Compatible OS:
Windows XP professional/home edition (x86 32bit only)
Windows Vista Ultimate/Business/Home basic/Home premium
Windows7 Ultimate/Professional/Home premium
Windows8 Professional/Enterprise
(Windows Vista/Windows7/Windows8: x86 32bit, x64 64bit)
CPM-02 DC-646 Cross Tool Module
OPK-02 DC-646 Optional PCB Kit *
*: Standard on 230V(PRO) model
Power supply100 VAC±10%, 50/60 Hz
Power consumption100 V: current consumption 4.7 A , power consumption 430 W
Dimensions● 230V
Weight230V115V230V(PRO)
Safety standardUL
Operating temperature10°C–30°C (50°F–86°C)
Operating humidity 40%RH–70%RH (No condensation)
Storing temperature5°C–35°C (41°F–95°C)
Storing humidity20%RH–70%RH (No condensation)
115 VAC, 50 Hz
230 VAC, 50/60 Hz
115 V: current consumption 4.0 A, power consumption 420 W
230 V: current consumption 1.9 A, power consumption 400 W
In use: 2310(W) × 765(D) × 1110(H) mm
Folded: 1650(W) × 765(D) × 1110(H) mm
● 115V/230V(PRO)
In use: 2310(W) × 1005(D) × 1110(H) mm
(90.94(W) × 39.56(D) × 43.70(H) in
Folded: 1650(W) × 1005(D) × 1110(H) mm
(64.96(W) × 39.56(D) × 43.70(H) in
Net weight
Gross weight
CE (Low Voltage Directive, Machinery Directive)
VCCI
FCC
270 kg
(595 lb)
335 kg
(738 lb)
280 kg
(617 lb)
345 kg
(760 lb)
1
285 kg
(628 lb)
350 kg
(771 lb)
1
The specifi cations are subject to change without prior notice.
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17
Chapter 1 Part Names and Their Functions
2
Part Names and Their Functions
2
(1) Appearance
7
2
12
11
10
8
9
4
21
1
3
16
20
15
13
No.NameFunction
1
Side guide (for feed tray)
2
PC arm mount
3 Feed trayOriginal document is placed here.
4 Level adjustment knob Adjusts the elevator height.
5
Airfl ow adjustment knob
6
Separator adjustment knob
7 Top cover 1Open this to move the
8 Control panelDisplays operations and status.
9
Emergency stop
switch
10 Top cover 2
11 Top cover 3Open this to remove the paper jam from the cutter/crease/
12 ScaleMeasures the cut and slit position, and the fi nished product.
13 Front cover Open this to remove the waste box. When the cover is opened,
14 Waste boxReceives pieces of waste paper.
15 Reject trayThis is where the document comes when it is rejected due to
16 USB terminalUsed for the connection to your computer on PC controller using.
17 Skew adjustment knob Adjusts the document skew.
18 Power switchMove this up/down to turn the power on/ off.
19
Module hangerUnused module can be hung on here.
14
1718
Set this according to the document size.
Install a commercial monitor arm for putting the laptop computer.
(Optional on 230V model)
Adjusts airfl ow level.
Adjusts the distance between the separator and conveyance belt.
upper guide or to remove the paper jam
from the feed unit. When the cover is opened, machine stops
running by the interlock switch.
Press this to stop the machine in emergency. Turning the switch
to the right releases the emergency stop.
Open this to remove the paper jam from the slitter/optional module
area
or to replace the optional module
When the cover is opened, machine stops running by the interlock switch.
optional module or to replace the optional module.
cover is opened, machine stops running by the interlock switch.
machine stops running by the interlock switch.
double feed, barcode error, REG mark error, etc.
(Optional on 230V model)
DC-646 Reject Option is required for ejecting document to the
reject tray.
19
.
5
6
When the
18
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Chapter 1 Part Names and Their Functions
No.NameFunction
20 AC inletConnect the power cord here.
21 Elevator down switchPress this to lower the feed tray to the bottommost position.
2
1
1
No.NameFunction
1 PC trayPlace a desktop computer on this tray. (Optional on 230V model)
(2) Paper Eject side
2
3
1
No.NameFunction
1 Exit trayReceives the fi nished products.
2
Side guide
3 Back guideSet this according to the document size.
(for exit tray)
Set this according to the document size.
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19
Chapter 1 Part Names and Their Functions
2
(3) Paper Eject Side (Stacker Tray)
2
3
5
1
4
No.NameFunction
1 GuideSet this according to the card width. (Optional on 230V model)
2 Support guide
Set this when paper alignment is poor. (Optional on 230V model)
(for card stacker)
3 Stopper assy
Set this according to the card length. (Optional on 230V model)
(for card stacker)
4 Card stackerReceives the card-sized fi nished product. (Optional on 230V model)
5 Exit trayReceives the fi nished product.
20
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(4) Inside
Paper
ejection side
Inside of top cover 2, 3
32184567
Chapter 1 Part Names and Their Functions
Paper feed
side
2
1
Inside of top cover 1
9
No.NameFunction
1 Margin slitter moduleCuts off the both margins of operator’s side and non-operator’s side.
2 Standard module *1
Rotary tool module *2
*1: DC-646 115V
DC-646 230V
*2: DC-646 230V(PRO)
3 Center slitter module 1Cuts parallel to the document feed direction
4 Center slitter module 2Cuts parallel to the document feed direction. * You can also install
5 Gutter defl ector
6 Creaser moduleCreases perpendicularly to the document feed direction.
7 Cutter moduleCuts perpendicularly to the document feed direction.
8 RejectThis is where the document comes when it is rejected due to double
9 Upper guideUsed to set the light weight document.
Conveys the document.
Perforates or scores parallel to the document feed direction
*
You can also install the center slitter module (optional) or cross
tool module (optional) here.
. * You can also install
the standard module or rotary tool module (optional) here.
the standard module or rotary tool module (optional) here.
Drops the margin cut off by the slitters into the waste box.
feed, barcode error, REG mark error, etc.
.
IMPORTANT
• When removing various modules of this machine, always re-set the module in the
sequential order indicated in the figure above. It is especially that the slitter module is
properly assembled, when setting it in the slot 2, 3, and 4 again.
• Slitter modules for DC-645 cannot be used in the DC-646.
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Chapter 1 Part Names and Their Functions
2
(5) Control panel
12
78
3456
No.NameFunction
1 OK MonitorThe LED of the error area fl ashes when detecting an error.
2 LCD panelDisplays the status of the machine.
Displays the message when an error or paper jam occurs.
3 F keySwitches to function selecting screen.
4 RETURN keySwitches to the previous screen.
5 CURSOR (Up) keyPress to move the cursor in an upper direction.
Press to retrieve the saved JOB.
6 CURSOR (Down)
key
Press to move the cursor in a lower direction.
Press to confi rm module setup and tool setup for cross tool module
and rotary tool module.
7 CURSOR (Left) key Press to move the cursor to the left.
Press to retrieve function setting.
8CURSOR (Right)
key
Press to move the cursor to the right.
Press to save or overwrite a JOB.
9 SET keyPress to fi x selection / entry.
9
22
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Chapter 1 Part Names and Their Functions
2
141310
1
1112
No.NameFunction
10 NUMERIC keyPress to enter JOB/values during manual programming.
11 CLEAR keyPress to clear the count. Press to cancel manual programming.
12 SET key Press to fi x selection/entry.
13 JOG keyPress to eject the document from the machine when paper jam
occurred.
14 TEST key
15 START keyPress to start processing documents. The START key light turns
16 STOP keyPress to return the current screen to the main screen or to stop
One (sheet) document is processed to test the current JOB details.
The processed document temporarily stops for a while at the
entrance of the card stacker for guide adjustment.
green when the machine is ready to process the document in this
machine. This key is inactive when the light is red. In this case,
the machine may be running or having an error.
processing.
15
16
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23
Chapter 1 Part Names and Their Functions
3
(6) LCD panel
● Standby screen
Continuous count
4
21
01:**********
RGB BC %
Sheets
67
5
↓
↓
↓
↓
9999
3
Batch count
12
REG BC
Sheets 999/999
3
No.NameFunction
1 JOB No.Displays the JOB number currently selected.
2 JOB NameDisplays the JOB name currently selected.
3 CounterDisplays the number of document sheets processed with the JOB
currently set.
4 REG mark
REG is displayed when "REG mark reading" is ON.
5 BarcodeBC is displayed when "barcode reading" is ON.
6%% is displayed when "Apply shrinkage" is set in "Settings3.
7 is displayed when "Adjust All" is set.
↓
↓
↓
↓
↓
↓
↓
↓
● ‘Select menu’ screen
Select menuSelect menu
1
2
3
Retrieve JOB
Enter JOB
Settings1
4
5
6
Settings2
Settings3
Adjust All
No.NameFunction
1 Retrieve JOBRetrieves saved JOB.
2 Enter JOBEnters and changes JOB.
3 Settings1Changes functions of the machine.
4 Settings2Changes functions of the machine.
5 Settings3Changes functions of the machine.
6 Adjust AllCorrects the document position in vertical and horizontal direction
against the JOB set.
7 Cleaning modeRetrieves Cleaning mode to clean conveyance belt / conveyance
Paper feed section feeds the paper into the
machine after separating each sheet of paper by
air knife. This is done through the operation of the
belt suction mechanism and the air blow duct
mechanism.
2. Operation
Air blow duct mechanism blows the compressed
air to the paper from the front side to create some
gap between the papers. The separated paper is
transferred when the shutter solenoid and the
feed motor provided in the belt suction
mechanism are turned ON.
3. Operation of Each Part
I. Level Sensor 1 (SN002)
<Operation>
• Detect the top of the paper on the feed tray
When the feed tray rises to the extent that the
actuator is lifted up by the paper, the sensor
comes to the “light blocked” state.
Once the topmost sheet of paper is detected, the
rising motion of the feed tray is stopped.
• Detect the low level of paper
The actuator comes down as the paper
level gets low until the sensor comes to the “light
through” state. Once the sensor comes to the
“light through” state, the feed tray rises until the
sensor comes to the “light blocked” state. “E02”
(elevator error) appears on the display if the
topmost paper sensor does not switch to the
“light blocked” state within 30 seconds after the
transmission of feed tray go-up command.
Level Sensor1
28
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