Duplo DC-646 Service Manual

Sep. 2013

Introduction

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.
Power supply 115 VAC ± 10%, 60 Hz 230 VAC ± 10%, 50/60 Hz
Power consumption 4.0 A , 420 W 1.9 A , 400 W
Standby energy 0.74 A , 70 W 0.54 A , 73 W
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
(of operated and positions into moving parts.
Margin slitter module, center slitter module, creaser module, cutter module, rotary tool
module (option), cross perforation module (option) and rotary cutter contains tools (blades)
Otherwise, your hands/ ngers could get caught and injured.
Do not put your hands or fi ngers inside the machine while it is operating and while you are pressing the JOG key.
Otherwise, your hands/ ngers could get caught and injured.
Working clothes
• Wear clothing that enables you to work safely.
Work clothing should be close-fi tting.
alone in function checks, interlocks are deactivated, so be aware of the conditions
of related equipment, and take great care not to put your hands or fi ngers
which may cause danger. Keep your hands or fi nger off the tools (blades.)
CAUTION
Tools
• Use tools that are appropriate for the work.
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Warning Labels

2
1
1
1.
3
2.
3.
6
No. Part No. Name Q'ty
1 M7-T303* WARNING LABEL 2 L8-T107* WARNING LABEL 1 3 P9-T310* CAUTION LABEL 1
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4. 4.
4.
WARNING
4.
Use caution when working near movable parts. Disconnect power before servicing.
4.
No. Part No. Name Q'ty
4 L8-T109* WARNING LABEL 4
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5.
5.
5.
No. Part No. Name Q'ty
5 K9-T139* WARNING LABEL 3
8
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Labels of High-Voltage Warning

1. 1.
1.
No. Part No. Name Q'ty
1 U7-T102* WARNING LABEL 2
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Introduction
Operation in General
Mechanism
Adjustment
Maintenance Checks
1
2
3
4
5
Troubleshooting
HELP Mode
Others
PC Controller
6
7
8
9
10

Contents

Contents
Introduction How to Use This Service Manual Safety Instructions Warning Labels Labels of High-Voltage Warning
Chapter 1
1
Specifi cations
2
Part Names and Their Functions
3
Dimensions
Chapter 2
1
Paper Feed Section
2
Skew Adjust Section
3
Double-Feed Detection Section
4
CCD Section
5
Reject Section
6
Slot 1 Section (Margin Slitter Section)
7
Slot 2 Section
8
Slot 3 Section
9
Slot 4 Section
10
Gutter Section
11
Creaser Section
12
Cutter Section
13
Waste Box Section
14
Exit Tray
15
Main Drive Section
16
Exterior
17
Barcode
18
REG Mark
Chapter 3
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Introduction
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Operation in General
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Mechanism
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16 18 25
28 37 39 41 42 45 49 55 61 68 71 74 78 80 82 84 87 90
1 2 3 6 9
10
Slot 4 Section
11
Gutter Section
12
Creaser Section
13
Cutter Section Paper Exit Section
14
Waste Box Section
15
Main Drive Section
16
Electrical System Section
17
Chapter 4
Exterior of the Machine
1
Paper Feed Section
2
Skew Adjust Section
3
Double-Feed Detection Section
4
CCD Section (option)
5
Reject Section
6
Slot 1 Section (Margin Slitter Section)
7
Slot 2 Section
8
Slot 3 Section
9
Slot 4 Section
10
Gutter Section
11
Creaser Section
12
Cutter Section
13
Main Drive Section
14 15
Adjustment procedure
Chapter 5
1
Guaranteeing Maintenance Cycle
2
Cleaning and Oiling
3
Periodic Maintenance Check List
4
Periodic Maintenance Sequences
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Adjustment
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Maintenance Checks
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152 158 160 163 168 170 172 184
198 201 208 209 210
211 212 214 216 218 220 224 228 231 237
240 240 241 246
1
Exterior
2
Paper Feed Section
3
Skew Adjust Section
4
Double-Feed Detection Section
5
CCD Section (option)
6
Reject Section
7
Slot 1 Section (Margin Slitter Section)
8
Slot 2 Section
9
Slot 3 Section
12
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96 104 120 124 127 129 134 140 145
Chapter 6
1
Troubleshooting
2
Conditions for the Error Detection Major Cause and Preventive Action for the
3
Paper Jam
Troubleshooting
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266 286
290
Contents
Chapter 7
1
HELP Mode List
2
Accessing the HELP Mode
3
Finishing the HELP Mode
4
Setting the Other HELP Mode No.
5
Accessing the Service Personnel JOB
6
HELP Mode Description
Chapter 8
1
Position and Function of Electronic Parts
2
Service Personnel JOBs
3
Overall Wiring Layout
Chapter 9
Main Menu of PC Controller
1 2
Maintenance Menu
3
Data Folder
4
Maintenance
5
Confi rming the Version
HELP Mode
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Others
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PC Controller
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292 294 294 294 294 295
368 390 395
404 406 409 410 420
1
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1
Chapter 1
Specifi cations .................................................................................16
1 2
Part Names and Their Functions ..................................................18
3
Dimensions .....................................................................................25
Introduction
(1) Appearance ..............................................................................18
(2) Paper Eject side ....................................................................... 19
(3) Paper Eject Side (Stacker Tray) ............................................... 20
(4) Inside ........................................................................................ 21
(5) Control panel ............................................................................22
(6) LCD panel ................................................................................ 24
Chapter 1 Specifi cations
1
Specifi cations
Product type Slitter/Cutter/Creaser Floor model Feeding method Belt suction Feed tray Elevator Infeed document size Width: 210–370 mm (8.27–14.56 in)
Minimum fi nishing size Width: 48 mm (1.89 in)
Document weight Min: 110 gsm
Document type Coated, non-coated, laminated Paper curl No curl (within 5 mm) Feeder capacity 100 mm (3.93 in) Speed 30 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 width 3.2–55 mm (from the edge of a document) Gutter slit width 5.0–15.0 mm
Gutter defl ector 2 gutter defl ectors
Max number of cuts on 1 document
Minimum cut length Lead edge margin: 3 mm
Maximum number of creases on 1 document
Exit tray Drop down tray Exit tray capacity 140 mm (5.51 in) Card stacker capacity 60 mm (2.36 in) Control panel 128 dots×64 dots LCD OK monitor Panel languages Japanese, English, French, German, Italian, Spanish, Polish, Russian Job programming On the control panel or on the PC controller software Noise level Less than 80 db during a continuous operation
1
Model name DC-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 name DC-646
Standard functions PC 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)
Optional devices RTM-02 DC-646 Rotary Tool Module *
CPM-02 DC-646 Cross Tool Module OPK-02 DC-646 Optional PCB Kit * *: Standard on 230V(PRO) model
Power supply 100 VAC±10%, 50/60 Hz
Power consumption 100 V: current consumption 4.7 A , power consumption 430 W
Dimensions 230V
Weight 230V 115V 230V(PRO)
Safety standard UL
Operating temperature 10°C–30°C (50°F–86°C) Operating humidity 40%RH–70%RH (No condensation) Storing temperature 5°C–35°C (41°F–95°C) Storing humidity 20%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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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. Name Function
1
Side guide (for feed tray)
2
PC arm mount
3 Feed tray Original document is placed here. 4 Level adjustment knob Adjusts the elevator height. 5
Airfl ow adjustment knob
6
Separator adjustment knob
7 Top cover 1 Open this to move the
8 Control panel Displays operations and status. 9
Emergency stop switch
10 Top cover 2
11 Top cover 3 Open this to remove the paper jam from the cutter/crease/
12 Scale Measures 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 box Receives pieces of waste paper. 15 Reject tray This is where the document comes when it is rejected due to
16 USB terminal Used for the connection to your computer on PC controller using. 17 Skew adjustment knob Adjusts the document skew. 18 Power switch Move this up/down to turn the power on/ off. 19
Module hanger Unused module can be hung on here.
14
17 18
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. Name Function
20 AC inlet Connect the power cord here. 21 Elevator down switch Press this to lower the feed tray to the bottommost position.
2
1
1
No. Name Function
1 PC tray Place a desktop computer on this tray. (Optional on 230V model)

(2) Paper Eject side

2
3
1
No. Name Function
1 Exit tray Receives the fi nished products. 2
Side guide
3 Back guide Set this according to the document size.
(for exit tray)
Set this according to the document size.
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Chapter 1 Part Names and Their Functions
2

(3) Paper Eject Side (Stacker Tray)

2
3
5
1
4
No. Name Function
1 Guide Set 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 stacker Receives the card-sized fi nished product. (Optional on 230V model) 5 Exit tray Receives 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. Name Function
1 Margin slitter module Cuts 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 1 Cuts parallel to the document feed direction
4 Center slitter module 2 Cuts parallel to the document feed direction. * You can also install
5 Gutter defl ector 6 Creaser module Creases perpendicularly to the document feed direction. 7 Cutter module Cuts perpendicularly to the document feed direction. 8 Reject This is where the document comes when it is rejected due to double
9 Upper guide Used 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
7 8
3456
No. Name Function
1 OK Monitor The LED of the error area fl ashes when detecting an error. 2 LCD panel Displays the status of the machine.
Displays the message when an error or paper jam occurs.
3 F key Switches to function selecting screen. 4 RETURN key Switches to the previous screen. 5 CURSOR (Up) key Press 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.
8 CURSOR (Right)
key
Press to move the cursor to the right. Press to save or overwrite a JOB.
9 SET key Press to fi x selection / entry.
9
22
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Chapter 1 Part Names and Their Functions
2
141310
1
11 12
No. Name Function
10 NUMERIC key Press to enter JOB/values during manual programming. 11 CLEAR key Press to clear the count. Press to cancel manual programming. 12 SET key Press to fi x selection/entry. 13 JOG key Press to eject the document from the machine when paper jam
occurred.
14 TEST key
15 START key Press to start processing documents. The START key light turns
16 STOP key Press 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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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
1 2

REG BC
Sheets 999/999
3
No. Name Function
1 JOB No. Displays the JOB number currently selected. 2 JOB Name Displays the JOB name currently selected. 3 Counter Displays the number of document sheets processed with the JOB
currently set.
4 REG mark
REG is displayed when "REG mark reading" is ON. 5 Barcode BC 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 menu Select menu
1 2
3
Retrieve JOB Enter JOB Settings1
4 5
6
Settings2 Settings3 Adjust All
No. Name Function
1 Retrieve JOB Retrieves saved JOB. 2 Enter JOB Enters and changes JOB. 3 Settings1 Changes functions of the machine. 4 Settings2 Changes functions of the machine. 5 Settings3 Changes functions of the machine. 6 Adjust All Corrects the document position in vertical and horizontal direction
against the JOB set.
7 Cleaning mode Retrieves Cleaning mode to clean conveyance belt / conveyance
roller.
8 Return Returns to standby screen.
Select menu
Cleaning mode
7
Return
8
24
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Dimensions

Chapter 1 Dimensions
3
* With the PC arm amount attached
Dimensions in ( ): DC-646 115V, DC-646 230V(PRO)
1
2650mm
1000mm
800mm
2570mm 2510mm
800mm800mm
(240mm)
765mm
(1745mm)
1505mm
745mm
800mm
1110mm
2310mm
1650mm
3250mm
1540mm
800mm800mm
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Chapter 2
Operation in General
2
1
Paper Feed Section
1. Description
2. Operation
3. Operation of Each Part
2
Skew Adjust Section
1. Description
2. Operation
3. Operation of Each Part
3
Double-Feed Detection Section
1. Description
2. Operation
3. Operation of Each Part
4
CCD Section
1. Description
2. Operation
5
Reject Section
1. Description
2. Operation
3. Operation of Each Part
6
Slot 1 Section (Margin Slitter Section)
1. Description
2. Operation
3. Slitter Blade
4. Operation of Each Part
7
Slot 2 Section
1. Description
2. Operation
Slot 3 Section
8
1. Description
2. Operation
3. Slitter Blade
4. Operation of Each Part
9
Slot 4 Section
1. Description
2. Operation
3. Slitter Blade
4. Operation of Each Part
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28 28 28 28 37 37 37 37 39 39 39 40 41 41 41 42 42 42 42 45 45 45 45 46 49 49 49 55 55 55 55 56 61 61 61 61 62
Gutter Section
10
1. Description
2. Operation
3. Operation of Each Part
11
Creaser Section
1. Description
2. Operation
3. Operation of Each Part
Cutter Section
12
1. Description
2. Operation
3. Operation of Each Part
13
Waste Box Section
1. Description
2. Operation of Each Part
Exit Tray
14
1. Description
2. Operation of Each Part
15
Main Drive Section
1. Description
2. Operation of Each Part
16
Exterior
1. Description
2. Operation
3. Operation of Each Part
17
Barcode
1. Description
18
REG Mark
1. Description
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68 68 68 68 71 71 71 71 74 74 74 74 78 78 78 80 80 80 82 82 82 84 84 84 84 87 87 90 90
Chapter 2 Paper Feed Section
1

Paper Feed Section

1

1. Description

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
W5-Y1030
-0
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