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/ﬁ 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/ﬁ 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.

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.

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

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

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.

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

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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

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Red Red Red

1

2

Blue Blue Blue

3

4

5

SN002

1

White Yellow Yellow

2

3

2. Level Sensor 2 (SN003) <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. Only the topmost sheet of the paper is detected by the level sensor 2.

• Detect the low level of paper.

The level sensor 2 detects only the topmost sheet of paper and the level sensor 1 detects the low level of paper.

CN12-20

21

22

Chapter 2 Paper Feed Section

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

1

Level Sensor2

2

FM003

Red

1

Yellow Yellow Yellow

2

Blue Blue Blue

3

Red Red

1

2

3

Main PCB Unit

W5-V510*

5V

3

4

5

CN12-23

24

25

5V

Light not transmitted: 5V Light transmitted: 0V

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Chapter 2 Paper Feed Section

1

3. Paper Tray Sensor (SN001) <Operation>

This sensor detects paper presence or nonpresence on the feed tray. When papers are on the feed tray, the sensor detects the reflecting light. When no paper is on the feed tray, the sensor does not detect the reﬂ ecting light. Conﬁ rm the sensor state in HELP-12.

Red Red

SN001

3

White

2

1

2

Blue Blue

3

White

CN12-11

12

13

Paper Tray Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 0V Light transmitted: 5V

4. Elevator Upper Switch (SW001) <Operation>

If the topmost sheet of paper cannot be detected, and the paper feed plate continues to go up, the air suction module is pulled away from the elevator upper limit switch to come to the “OFF” state. The elevator upper limit switch stops the machine operation immediately once it comes to the “OFF” state.

Elevator Upper Switch

30

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Chapter 2 Paper Feed Section

1

5. Elevator Lower Switch 1, 2 (SW003, SW004) <Operation>

As the feed plate goes up, the angle is pulled away from the elevator lower limit switch to come to the “ON” state. As the feed plate goes down to reach the lower limit, the angle pushes the switch actuator to trigger the “OFF” state. “E02” (elevator error) appears on the display if the angle does not push the elevator lower limit switch actuator within 30 seconds after the transmission of the feed plate go-down command.

6. Elevator Motor (MT003) <Operation>

Elevator motor rotation let the feed tray move up and down.

Elevator Lower Switch1

Elevator Lower Switch2

2

Elevator Motor

SW003

SW001

Purple

Red Red

Red

2

1

Main PCB Unit

W5-V510*

5V

Purple

MT003

M

CN12-15

16

CN4

Drive2 PCB Unit

W5-V550*

1

2

Red

1

Blue

2

SW004

Red

Red Red Red

2

1

Blue Blue

2

CN5-1

2

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31

Chapter 2 Paper Feed Section

1

7. Elevator Down Switch (SW013) <Operation>

Normally the feed plate goes up and down automatically. However, it may be lowered by the elevator down switch as required, including the case of paper jam.

SW013

Yellowish green

Green

1

Green

2

1

2

Green

CN12-18

19

Elevator Down Switch

Main PCB Unit

W5-V510*

5V

ON : 0V OFF : 5V

8. Suction Solenoid (SL001) <Operation>

The suction solenoid is turned ON as the level sensor is turned ON and the paper feed is ready. Then, the valve opens to suck up the paper. The valve is closed by the timer after the transferred paper passes through the PPS2.

SL001

M

Red

1

Red

2

7

8

Red

Suction Solenoid

Drive 2 PCB Unit

W5-V550*

24V

Red

CN2-5

5

Red

6

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9. Separate Solenoid (SL002) <Operation>

When the adjustment is set at 1 through 7, the paper

• separator is raised by turning on the solenoid until the paper end passes through the separator position to prevent the double feed. After the paper passes through,

the separator is lowered so that it will not hinder

the paper transfer.

• When the adjustment is set over 7 (i.e. When it is turned clockwise to the maximum), the screw pushes the actuator of the solenoid switch to cancel the paper separator function.

• Paper separator solenoid is also canceled when the paper jam takes place.

10. Solenoid ON/OFF Switch (SW002)

Paper separator height can be altered by turning the paper separator dial from 1 (max.) to 7 (min.). When the dial is turned beyond 7, the paper separator stops its function and goes down to the lowest position.

Chapter 2 Paper Feed Section

Solenoid ON/OFF Switch

1

Separate Solenoid

2

SW002

M

SL002

Red

Drive 2 PCB Unit

W5-V550*

24V

1

2

Red

CN2-7

Red

7

8

Red

8

W5-Y1030

-0

33

Chapter 2 Paper Feed Section

1

11. Suction Fan (FM001) <Operation>

Suction fan sucks up the loaded paper by per sheet to the feed belt for conveyance at the time of paper feed.

Red Red Red Red

Black Black Black

1

2

FM001

Suction Fan

Drive 2 PCB Unit

W5-V550*

24V

5

6

1

2

CN2-1

Black

2

34

W5-Y1030

-0

12. Blow Out Fan1 (FM002),

Blow Out Fan2 (FM003)

Two blow out fans blow the air to separate papers from foreside at the time of paper feed.

FM002

Red

Black

1

2

Red

1

Black

2

3

4

Red

Black

Chapter 2 Paper Feed Section

Drive 2 PCB Unit

W5-V550*

24V

CN2-3

4

1

Blow Out Fan1

Blow Out Fan2

2

FM003

Red

Black

1

2

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35

Chapter 2 Paper Feed Section

13

1

. Feed Belt Motor (MT002)

Feed belt motor controls the feed belt driving.

Feed Motor

MT002

M

14. PPS1 (

Green

Orange

Yellow

White

Photo-emission

1 3

4 6

SN006/

Photo-receiving

1 2

3 4

SN007)

While the light goes through at the PPS sensor, LED on the control panel and the start key light up in red. “PLEASE SET PAPER” appears on the display as the start key is pressed. While the light is blocked at the PPS sensor, the start key lights up in green. * Wipe off the dirt or contamination, if any, on the

PPS sensor by some rag.

Drive 1 PCB Unit

W5-V540*

Green

Orange

Yellow

White

CN3-1

2 3 4

1 2

3 4

Transmitting

Receiving

36

SN006

SN007

W5-Y1030

Transmitting

Receiving

-0

Main PCB Unit

W5-V510*

5V

1

3

1

2

3

Red

Orange

Red

White

Blue

Red

1

Orange

2

Red

1

White

2

Blue

3

CN12-1

2

3

4

5

5V

Light not transmitted: 5V Light transmitted: 0V

2

Skew Adjust Section

1. Description

The paper, separated by air suction mechanism, is transmitted in the corrected angular position, since it is abutted to the frame by the slantingly arranged conveyer belts as it is sent the next process.

2. Operation

In the skew adjust section, the fan starts to rotate as the start key is turned ON. The conveyer belt starts to rotate just as the air suction module belt starts its rotation. It is stopped by the timer.

Chapter 2 Skew Adjust Section

2

3. Operation of Each Part

1. Skew Motor (MT004)

Skew motor controls the skew belt driving.

MT004

M

White Green Yellow

Orange

6 4

3 1

White Green Yellow

Orange

Skew Motor

Drive 1 PCB Unit

W5-V540*

White

7 6

5 4

8 7

6 5

Green

Yellow

Orange

CN3-8

7 6 5

W5-Y1030

-0

37

Chapter 2 Skew Adjust Section

2

2. Fan Register (FM005) <Operation>

Fan register suctions a paper to the skew belt for conveyance.

FM005

Red

Brown

Black

1 2 3

Red

Brown

Black

1 2 3

Reject Open Motor

12 13 14

Red

Brown

Black

Drive 2 PCB Unit

W5-V550*

CN2-12

13 14

3. PPS2 (Photo-emission

SN008/

Photo-receiving

SN009)

• Detect the top edge of the paper

PPS detects the presence or non-presence of paper by the “light-through” or the light-blocked” state of the PPS photo-receiving sensor by means of receiving from the PPS photo-emitting sensor. Then, mis-feed or paper jam is detected by the skew adjust section. If the light path between the PPS sensors is blocked by the paper (or by the dirt on the PPS sensor) when the power supply is turned ON, “J3” (FEED ERROR) appears on the display. * Wipe off the dirt or contamination, if any, on the

PPS sensor by some rag.

SN008

Transmitting

1

3

Red

Orange

Red

1

Orange

2

CN12-6

7

Transmitting

Receiving

Main PCB Unit

W5-V510*

5V

38

SN009

W5-Y1030

Receiving

-0

1

2

3

Red

Yellow

Blue

Red

1

Yellow

2

Blue

3

8

9

10

5V

Light not transmitted: 5V Light transmitted: 0V

Chapter 2 Double Feed Detection Section

3

Double-Feed Detection Section

3

1. Description

The double-feed detection sensor is provided between the air suction module and the skew adjust section (beside the PPS2). An ultrasonic sensor is used, which can deal with wider range of paper types compared with conventional mechanical sensor or photo-micro sensor. Also, no adjustment for ﬁ tting it to the particular type of paper, and no input of the paper thickness are required in the ultrasonic sensor.

Receiving

TransmittingTransmitting

2. Operation

Whenever the ultrasonic sensor detects double feed, the rejection bar opens to send out the double-fed paper to the reject tray. When the double-feed is repeated for a preset number of times, “DOUBLE FEED” appears on the display, and the machine stops the operation.

2

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39

Chapter 2 Double Feed Detection Section

3

3. Operation of Each Part

1. Double Feed Sensor ( SN004)

Whenever the ultrasonic sensor detects doublefeed, the rejection bar opens to send out the double-fed paper to the reject tray. In addition, if the double-feed is repeated for a preset number of times, “DOUBLE FEED” appears on the display, and the machine stops the operation.

Transmission SN005, Receiving

TransmittingTransmitting

Receiving

SN005

SN004

Transmit

Receiving

Red

Black

Red

Black

Transmit PCB Unit

Red

2 1

CN1-1

White

Red

White

P9-V303*

2

CN1-2 4

CN3-2 4

2

Receive PCB Unit

P9-V305*

Brown

Blue

CN1-2CN2-1 2

Brown

1

Blue

5

White

Blue Blue

White

6 7

24V Power Supply Unit

Main PCB Unit W5-V510*

CN12-27

28

40

W5-Y1030

-0

4

CCD Section

1. Description

This section reads the barcode and REG mark by CCD.

2. Operation

On the JOB using REG mark or barcode, PPS3 works to assure the correct CCD reading by temporarily stopping the paper run at the place of PPS3 and slows it. The paper conveyance speed will be accelerated after the CCD reading.

Chapter 2 CCD Section

4

2

1. PPS3 (

Photo-emission

SN010/

Photo-receiving

SN011)

•

PPS detects the presence or non-presence of paper

by the “light-through” or the light-blocked” state of

the PPS photo-receiving sensor by means of receiving

from the PPS photo-emitting sensor.

•

On the JOB using REG mark or barcode, PPS3

works to assure the correct CCD reading by

temporarily

stopping the paper run at the place of

PPS3 and slows it.

• In the operation without REG mark or barcode, PPS 3 detects the timing of passing paper.

Red

Pink

Red

Gray

Blue

1

2

1

2

3

SN010

SN011

Transmit

Receiving

1

3

1

2

3

Red

Orange

Red

Gray

Blue

CN19-1

CN13-1

Transmitting

Receiving

Main PCB Unit

W5-V510*

5V

2

5V

2

Light not transmitted: 5V

3

Light transmitted: 0V

W5-Y1030

-0

41

Chapter 2 Reject Section

5

Reject Section

5

1. Description

If the CCD detects the error in reading the barcode or the register mark, or the double-feed, the rejection bar in front of the Slot 1 opens to drop the paper into the reject tray.

2. Operation

When you turn off and on (restart) the machine, the rejection bar makes a turn. The reject HP sensor detects “light through” → “light blocked” → “light through” state by the edges of the sensor plate on the rejection bar, and the rejection bar stops. At this time, the rejection bar is closed and this is home position. If the CCD reading error of the barcode or the register mark, or the double-feed takes place, the rejection bar opens. The reject HP sensor detects “light through” → “light blocked” → “light blocked” state, and the rejection bar moves to the point of “light through” state and reject motor stops. When the rejection bar returns to the home position, the reject HP sensor detects “light through” → “light blocked” → “light through” state, and the rejection bar moves to the point of “light through” state and the reject motor stops.

Home position reject bar: closed

Reject bar: open

Home position reject bar: closed

3. Operation of Each Part

I. Rejection Home Position Sensor (SN012) <Operation>

The rejection home position sensor detects the position of the rejection bar while it returns to the home position.

1

2

3

SN012

1

2

3

Red

Yellow

Blue

Reject HP Sensor

5V

CN11-7

8

9

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

42

W5-Y1030

-0

Chapter 2 Reject Section

5

2. PPS 8 Sensor (

receiving

SN016)

Photo-emission

SN015/

Photo-

• PPS detects the presence or non-presence of paper

by the “light-through” or the light-blocked” state of

the PPS photo-receiving sensor by means of receiving

from the PPS photo-emitting sensor.

• This sensor detects paper jam in reject section.

Red

Orange

Red

Gray

Blue

1

2

3

4

5

SN015

SN016

Transmit

Receiving

1

3

1

2

3

Red

Orange

Red

Gray

Blue

CN19-7

CN13-10

11

12

Main PCB Unit

W5-V510*

5V

8

5V

Light not transmitted:5V Light transmitted:0V

2

W5-Y1030

-0

43

Chapter 2 Reject Section

5

3. Reject Open Motor (MT005) <Operation>

Reject open motor controls gating operation of reject bar.

Reject Open Motor

Drive 2 PCB Unit

W5-V550*

M

MT005

Brown Brown

Black Black

1

2

CN7-5

6

44

W5-Y1030

-0

Chapter 2 Slot 1 Section(Margin Slitter Section)

6

Slot 1 Section (Margin Slitter Section)

6

1. Description

The margin slitter is provided one each on both sides to cut the paper along the traveling direction by means of the upper and lower rotary blades. The cut-off margin is dropped into the waste box.

Margin Slitter Module

2

2. Operation

The lead screw is turned by means of the stepping motor to cause the margin slitter to move from the home position by the speciﬁ ed amount of pulse.

3. Slitter Blade

The slitter blades are constructed so that the lower blade of the slitter is tilted relative to the paper feed direction. This makes the upper and lower slitter blades contact at only one point to maintain the clean cut even after the slitter blade has worn out.

W5-Y1030

-0

45

Chapter 2 Slot 1 Section(Margin Slitter Section)

6

4. Operation of Each Part

1. Module Detection 1 Sensor (SN024) <Operation>

Module detection 1 sensor detects the presence or non-presence of margin slitter module by sensing the margin slitter module by the photo-

-micro sensor.

Red

White

Blue

1

2

3

White

SN024

1

2

3

Red

Blue

Module Detection1 Sensor

Main PCB Unit

W5-V510*

5V

CN17-1

2

3

5V

Light not transmitted: 5V Light transmitted: 0V

2. Slitter 1 Home Position Sensor (SN037) <Operation>

Slitter 1 HP sensor detects the home position of the margin slitter 1 unit by the photo-micro sensor, and controls the margin slitter 1 position based on the sensor position.

SN037

3

1

2

Red

White

Blue

1

2

3

Red

White

Blue

CN11-1

Slitter1 HP Sensor

Slitter Drive

PCB Unit

5V

W5-V520* 5V

2

Light not transmitted: 5V Light transmitted: 0V

3

46

W5-Y1030

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Chapter 2 Slot 1 Section(Margin Slitter Section)

3. Slitter 2 Home Position Sensor (SN038)

Slitter 2 HP sensor detects the home position of the margin slitter 2 unit by the photo-micro sensor, and controls the margin slitter 2 unit position based on the sensor position.

SN038

3

1

2

Red

White

Blue

1

2

3

Red

White

Blue

CN11-16

17

18

6

Slitter2 HP Sensor

Slitter Drive

PCB Unit

5V

W5-V520*

5V

Light not transmitted: 5V Light transmitted: 0V

2

4. Slitter Motor 1 (MT007)

Slitter motor 1 controls the margin slitter 1 position based on the home position by means of rotating the lead shaft.

Brown

1

Yellow

2

Green

3

White

4

MT007

M

Brown Yellow Green

White

Slitter Motor1

Slitter Drive

PCB Unit

W5-V520*

CN6-1

2 3 4

W5-Y1030

-0

47

Chapter 2 Slot 1 Section(Margin Slitter Section)

6

5. Slitter Motor 2 (MT008) <Operation>

Slitter motor 2 controls the margin slitter 2 position based on the home position by means of rotating the lead shaft.

MT008

M

Brown Yellow Green

White

1 3 4 6

Brown Yellow Green

White

Slitter Motor2

Slitter Drive

PCB Unit

W5-V520*

CN7-1

2 3 4

48

W5-Y1030

-0

7

Slot 2 Section

1. Description

Slot 2 Section is used to meet the special cutting requirements which cannot be dealt with by the cutter module or the slitter module. (Transfer module is attached to the standard model. Rotary tool module (RTM), Cross tool module (CPM) and Optional slitter module (OSM) are option.)

CPM RTM OSM

Chapter 2 Slot 2 Section

7

2

2. Operation

1. Module Detection 2 Sensor (SN025) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

1

2

3

SN025

1

2

3

Red

Yellow

Blue

CN17-4

Module Detection2 Sensor

Main PCB Unit

W5-V510*

5V

5

Light not transmitted: 5V Light transmitted: 0V

6

W5-Y1030

-0

49

Chapter 2 Slot 2 Section

7

2. Module Detection 3 Sensor (SN026) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

SN026

1

2

3

4

5

6

Red

Gray

Blue

CN17-7

Module Detection3 Sensor

Main PCB Unit

W5-V510*

5V

8

Light not transmitted: 5V Light transmitted: 0V

9

3. Module Detection 4 Sensor (SN027) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

Red

Green

Blue

SN027

1

2

3

7

8

9

CN17-10

11

12

Module Detection4 Sensor

Main PCB Unit

U7-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

50

W5-Y1030

-0

4. Module Detection 5 Sensor (SN028) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

Red

White

Blue

SN028

1

2

3

10

11

12

CN17-13

14

15

Chapter 2 Slot 2 Section

7

Module Detection5 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

2

5. Slitter 3 Home Position Sensor (SN039) <Operation>

Slitter 3 HP sensor detects the home position of the slitter 1 located on the non-operator's side by the photo-micro sensor, and controls the slitter 1 position based on the sensor position.

SN039

3

1

2

Red

Yellow

Blue

1

2

3

Red

Yellow

Blue

CN11-4

Slitter3 HP Sensor

Slitter Drive PCB Unit

W5-V520*

5V

5

6

Light not transmitted: 5V Light transmitted: 0V

W5-Y1030

-0

51

Chapter 2 Slot 2 Section

7

6. Slitter 4 Home Position Sensor (SN040) <Operation>

Slitter 4 HP sensor detects the home position of the slitter 2 located on the operator's side by the photo-micro sensor, and controls the slitter 2 position based on the sensor position.

Red

Yellow

Blue

1

2

3

SN040

3

1

2

Red

Yellow

Blue

CN11-19

20

21

Slitter4 HP Sensor

Slitter Drive PCB Unit

W5-V520*

5V

Light not transmitted: 5V Light transmitted: 0V

7. Slitter Motor 3 (MT009) <Operation>

Slitter Motor 3 controls the option unit position based on the amount of pulse from its home position by means of rotating the lead shaft.

Black

MT009

M

1

Yellow

3

Green

4

White

6

Slitter Motor3

Slitter Drive

PCB Unit

W5-V520*

5 6 7

8

CN6-5

6 7 8

52

W5-Y1030

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Chapter 2 Slot 2 Section

7

7. Slitter Motor 4 (MT010) <Operation>

Slitter Motor 4 controls the option unit position based on the amount of pulse from its home position by means of rotating the lead shaft.

Black

1

Yellow

3

MT010

M

Green

4

White

6

Slitter Motor4

2

Slitter Drive

PCB Unit

W5-V520*

CN7-5

6 7 8

W5-Y1030

-0

53

Chapter 2 Slot 2 Section

7

9. Jump Motor 1(MT022)(option) <Operation>

Jump motor controls the RTM driving when the RTM is installed in the slot 2.

MT022

Jump Motor1

Drive 4 PCB Unit

W5-V570*

10. PPS4

M

Brown

Black

(Photo-emission

SN052/

1

2

Photo-receiving

Brown

Black

SN053)

•

PPS detects the presence or non-presence of paper

by the “light-through” or the light-blocked” state of

the PPS photo-receiving sensor by means of receiving from the PPS photo-emitting sensor.

• This sensor detects paper jam in the slot 2.

CN4-1

2

Transmitting

Receiving

54

SN052

SN053

W5-Y1030

-0

Transmitting

Receiving

Main PCB Unit

W5-V510*

5V

1

3

1

2

3

Red

Pink

Red

Gray

Blue

1

3

1

2

3

Red

Orange

Blue

Gray

Blue

CN19-3

CN13-4

4

5V

5

Light not transmitted: 5V Light transmitted: 0V

6

8

Slot 3 Section

1. Description

Two center slitters are provided each on both sides to cut the paper in the traveling direction by means of the rotary blades arranged vertically side by side.

Chapter 2 Slot 3 Section

8

2

When performing special cutting which cannot be processed by the slitter module, install the RTM in the slot 3 to perform special cutting. (Slitter module is installed in the standard model.)

2. Operation

The lead screw is turned by means of the stepping motor to cause the center slitters to move from the home position by the speciﬁ ed distance.

3. Slitter Blade

The slitter blades are constructed so that the lower blade of the slitter is tilted relative to the paper feed direction. This makes the upper and lower slitter blades contact at only one point to maintain the clean cut even after the slitter blade has worn out.

RTM

W5-Y1030

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55

Chapter 2 Slot 3 Section

8

4. Operation of Each Part

1. Module Detection 6 Sensor (SN029) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

Red

Yellow

Blue

1

2

3

SN029

1

2

3

Red

Yellow

Blue

CN17-16

17

18

Module Detection6 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

2. Module Detection 7 Sensor (SN030) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

SN030

1

2

3

Red

Gray

Blue

4

5

6

Red

Gray

Blue

CN17-19

20

21

Module Detection7 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

56

W5-Y1030

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3. Module Detection 8 Sensor (SN031) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

SN031

1

2

3

Red

Green

Blue

7

8

9

Red

Green

Blue

CN17-22

23

24

Chapter 2 Slot 3 Section

Module Detection8 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

8

2

4. Module Detection 9 Sensor (SN032) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

SN032

1

2

3

Red

White

Blue

10

11

12

Red

White

Blue

CN17-25

26

27

Module Detection9 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

W5-Y1030

-0

57

Chapter 2 Slot 3 Section

8

5. Slitter 5 Home Position Sensor (SN041) <Operation>

Slitter 5 HP sensor detects the home position of the center slitter 5 unit by the photo-micro sensor, and controls the center slitter 5 unit position based on the sensor position.

Red

Gray

Blue

4

5

6

SN041

3

1

2

Red

Gray

Blue

CN11-7

Slitter5 HP Sensor

Slitter Drive PCB Unit

W5-V520*

5V

8

Light not transmitted: 5V Light transmitted: 0V

9

6. Slitter 6 Home Position Sensor (SN042) <Operation>

Center slitter 6 HP sensor detects the home position of the center slitter 6 unit by the photo-micro sensor, and controls the center slitter 6 unit position based on the sensor position.

Red

Gray

Blue

SN042

3

1

2

Red

Gray

Blue

4

5

6

CN11-22

23

24

Slitter6 HP Sensor

Slitter Drive

PCB Unit

5V

W5-V520*

5V

Light not transmitted: 5V Light transmitted: 0V

58

W5-Y1030

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7. Slitter Motor 5 (MT011) <Operation>

Slitter motor 5 controls the center slitter 5 unit position based on the home position by means of rotating the lead shaft.

Chapter 2 Slot 3 Section

Slitter Motor5

Slitter Drive

PCB Unit

W5-V520*

8

2

Gray

1

Yellow

3

Green

4

White

6

MT011

M

Gray Yellow Green

White

8. Slitter Motor 6 (MT012) <Operation>

Slitter motor 6 controls the center slitter 6 position based on the home position by means of rotating the lead shaft.

9 10 11 12

CN6-9

10 11 12

Slitter Motor6

MT012

M

Gray

Yellow

Green

White

Slitter Drive

PCB Unit

W5-V520*

1 3 4

6

Gray

Yellow

Green

White

CN7-9

10 11 12

W5-Y1030

-0

59

Chapter 2 Slot 3 Section

8

9. Jump Motor 2 (MT023)(option) <Operation>

Jump motor controls the RTM driving when the RTM is installed in the slot 3.

MT023

Jump Motor2

Drive 4 PCB Unit

W5-V570*

10. PPS5 (

M

Brown

Black

Photo-emission

SN054/

1

2

Photo-receiving

Brown

Black

SN055)

PPS detects the presence or non-presence of paper

• by the “light-through” or the light-blocked” state of

the PPS photo-receiving sensor by means of receiving from the PPS photo-emitting sensor.

• This sensor detects paper jam in slitter section.

CN4-3

4

Transmitting

Receiving

60

SN054

SN055

W5-Y1030

-0

Transmit

Receiving

5V

Main PCB Unit

1

3

1

2

3

Red Red

Pink

Red

Gray

Blue

1

3

1

2

3

CN19-5

Orange 6

CN13-7

Red

Gray

Blue

5V

8

9

U7-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

9

Slot 4 Section

1. Description

Two center slitters are provided each on both sides to cut the paper in the traveling direction by means of the rotary blades arranged vertically side by side.

Chapter 2 Slot 4 Section

9

2

When performing special cutting which cannot be processed by the slitter module, install an option module in the slot 4 to perform special cutting. (Slitter module is installed in the standard model.)

2. Operation

The lead screw is turned by means of the stepping motor to cause the center slitters to move from the home position by the speciﬁ ed distance.

3. Slitter Blade

The slitter blades are constructed so that the lower blade of the slitter is tilted relative to the paper feed direction. This makes the upper and lower slitter blades contact at only one point to maintain the clean cut even after the slitter blade has worn out.

RTM

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61

Chapter 2 Slot 4 Section

9

4. Operation of Each Part

1. Module Detection 10 Sensor (SN033)

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

Red

Yellow

Blue

13

14

15

SN033

1

2

3

Red

Yellow

Blue

CN17-28

29

30

Module Detection10 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

62

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2. Module Detection 11 Sensor (SN034) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

SN034

1

2

3

Red

Gray

Blue

16

17

18

Red

Gray

Blue

CN17-31

32

33

Chapter 2 Slot 4 Section

Module Detection11 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

9

2

3. Module Detection 12 Sensor (SN035) <Operation>

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

SN035

1

2

3

Red

Green

Blue

19

20

21

Red

Green

Blue

CN17-34

35

36

Module Detection12 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

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63

Chapter 2 Slot 4 Section

9

4. Module Detection 13 Sensor (SN036)

Option module detection sensor identiﬁ es the type of optional module by one of the detecting sensors 1, 2, 3 or 4, or by the combination of these sensors to implement the control required for the particular optional module attached.

Red

White

Blue

22

23

24

SN036

1

2

3

Red

White

Blue

CN17-37

38

39

Module Detection13 Sensor

Main PCB Unit

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

5. Slitter 7 Home Position Sensor (SN043)

Slitter 7 HP sensor detects the home position of the center slitter 7 unit by the photo-micro sensor, and controls the center slitter 7 unit position based on the sensor position.

SN043

3

1

2

Red

Black

Blue

7

8

9

Red

Black

Blue

CN11-10

11

12

Slitter7 HP Sensor

Slitter Drive PCB Unit

W5-V520*

5V

Light not transmitted: 5V Light transmitted: 0V

64

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Chapter 2 Slot 4 Section

9

6. Slitter 8 Home Position Sensor (SN044) <Operation>

Center slitter 8 HP sensor detects the home position of the center slitter 8 unit by the photomicro sensor, and controls the center slitter 8 unit position based on the sensor position.

SN044

3

1

2

Red

Black

Blue

7

8

9

Red

Black

Blue

CN11-25

26

27

Slitter8 HP Sensor

Slitter Drive PCB Unit

W5-V520*

5V

Light not transmitted: 5V Light transmitted: 0V

2

7. Slitter Motor 7 (MT013) <Operation>

Slitter motor 7 controls the center slitter 7 unit position based on the home position by means of rotating the lead shaft.

Orange

1

Yellow

2

Green

3

White

4

MT013

M

1 3 4 6

Slitter Motor7

Slitter PCB Unit

W5-V530*

CN3-1

2 3

4

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65

Chapter 2 Slot 4 Section

9

8. Slitter Motor 8 (MT014)

Slitter motor 8 controls the center slitter 8 position based on the home position by means of rotating the lead shaft.

MT014

M

Orange

Yellow

Green

White

1 3 4

6

Orange

Yellow

Green White

Slitter Motor8

Slitter PCB Unit

W5-V530*

CN3-1

2 3 4

9. Jump Motor3 (MT024)(option)

Jump motor 3 controls the RTM driving when the RTM is installed in the slot 4.

MT024

M

Brown

Black

1

2

Brown

Black

Jump Motor3

Drive 4 PCB Unit

W5-V570*

CN4-5

6

66

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Chapter 2 Slot 4 Section

9

10. PPS6-1,PPS6-2 ( Photo-receiving

SN058, SN059)

Photo-emission

SN056, SN057/

PPS detects the presence or non-presence of paper

•

by the “light-through” or the light-blocked” state of

the PPS photo-receiving sensor by means of receiving

from the PPS photo-emitting sensor.

• This sensor detects paper jam in slitter section.

Red

Orange

Red

White

Blue

1

2

1

2

3

SN056

SN058

Transmit

Receiving

1

3

1

2

3

Red

CN19-9

Orange 10

CN14-1

Red

White

Blue

Transmitting

Receiving

2

Main PCB Unit

5V

2

3

W5-V510*

5V

Light not transmitted: 5V Light transmitted: 0V

SN057

SN059

Transmit

Receiving

5V

1

3

1

2

3

Red

Orange

Red

Yellow

Blue

3

4

5

6

Red

Orange

Red

Yellow

Blue

CN19-11

12

CN14-4

5

6

5V

Light not transmitted: 5V Light transmitted: 0V

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67

Chapter 2 Gutter Section

10

Gutter Section

10

1. Description

The gutter section works to drop the gutter area of the paper cut off by the center slitter into the waste box.

2. Operation

The lead screw is turned by means of the stepping motor to cause the gutter unit to move from the home position by the speciﬁ ed distance.

3. Operation of Each Part

1. Gutter 1 Home Position Sensor (SN045) <Operation>

Gutter 1 HP sensor detects the gutter unit 1 home position by the photo-micro sensor, and controls the gutter unit 1 position based on the sensor position.

Red

White

Blue

SN045

3

1

2

1

2

3

CN11-13

14

15

Gutter1 HP Sensor

Slitter Drive PCB Unit

W5-V520*

5V

Light not transmitted: 5V Light transmitted: 0V

68

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Chapter 2 Gutter Section

10

2. Gutter 2 Home Position Sensor (SN046)

Gutter 2 HP sensor detects the gutter unit 2 home position by the photo-micro sensor, and controls the gutter unit 2 position based on the sensor position.

Red

White

Blue

SN046

3

1

2

1

2

3

CN11-28

29

30

Gutter2 HP Sensor

Slitter Drive PCB Unit

W5-V520*

5V

Light not transmitted: 5V Light transmitted: 0V

2

3. Gutter Motor 1 (MT015)

Gutter motor 1 controls the gutter unit position based on the speciﬁ ed distance from the home position by means of rotating the lead shaft.

Purple

1

Yellow

3

MT015

M

Green

4

White

6

Gutter Motor1

Slitter PCB Unit

W5-V530*

CN3-5

Purple

5

Yellow

6

Green

7

White

8

6 7 8

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69

Chapter 2 Gutter Section

10

4. Gutter Motor 2 (MT016) <Operation>

Gutter motor 2 controls the gutter unit position based on the speciﬁ ed distance from the home position by means of rotating the lead shaft.

Purple

1

Yellow

3

MT016

M

Green

4

White

6

Gutter Motor2

Slitter PCB Unit

W5-V530*

Green

White

CN3-5

6 7 8

Purple

5

Yellow

6 7 8

70

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11

Creaser Section

1. Description

Creaser module contains the lower blade having a concave (recessed) section and the upper blade having a convex (projected) section. The creaser unit works to crease the paper perpendicularly to its traveling direction.

2. Operation

The sensor plate provided coaxially with the cam detects the top dead center of the upper blade to control the DC motor. The lower blade also can move up and down by a cam. The height of the lower blade is set by the DC motor with an encoder, and is speciﬁ ed relative to the lower blade’s bottom dead center at which the sensor plate is provided. The crease depth is determined in this way.

Chapter 2 Creaser Section

11

2

3. Operation of Each Part

Crease Upper Home Position Sensor

1.

Crease upper home position sensor detects the top dead center of the creaser upper blade by sensing the light-blocking plate attached to the creaser upper blade driving cam shaft by means of the photo-micro sensor.

SN019

Red

1

Gray

2

Blue

3

Brown

1

Red

2

Orange

3

(SN019)

Brown

1

Red

2

Orange

3

CN9-7

Crease Up HP Sensor

Main PCB Unit

W5-V510*

5V

8

Light not transmitted: 5V Light transmitted: 0V

9

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Chapter 2 Creaser Section

11

2. Crease Lower Home Position Sensor (SN020) <Operation>

Crease lower home position sensor detects the bottom dead center of the crease lower blade by sensing the light-blocking plate attached on the cam shaft which adjusts the crease depth by means of the photo-micro sensor.

SN020

Red

1

Purple

2

Blue

3

13

14

15

Green

Black

Brown

13

14

15

Green

Black

Brown

CN10-1

Crease Low HP Sensor

Main PCB Unit

W5-V510*

5V

2

Light not transmitted: 5V

3

Light transmitted: 0V

3. Creaser Lower Blade Encoder Sensor (SN021) <Operation>

Creaser lower blade encoder sensor adjusts the crease depth in three levels from the lower limit position by reading out the encoder attached to the crease depth adjustment motor by means of the photo-micro sensor.

Red

Yellow

Blue

SN021

1

2

3

Red

Yellow

Blue

1

2

3

CN10-4

Crease Encoder Sensor

Main PCB Unit

W5-V510*

5V

5

Light not transmitted: 5V

6

Light transmitted: 0V

72

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Chapter 2 Creaser Section

11

4. Crease Lower Motor (MT020)

Crease lower motor rotates the encoder attached in the crease lower motor to adjust the crease depth in three steps.

MT020

M

Brown

Black

1

2

Brown

Black

Crease Low Motor

2

Drive 2 PCB Unit

W5-V550*

CN7-3

4

5. Crease Motor (MT019)

Crease motor controls the crease upper blade up and down operation.

MT019

M

Red

Blue

1

2

Red

Blue

Crease Motor

Drive 2 PCB Unit

W5-V550*

CN6-3

4

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73

Chapter 2 Cutter Section

12

Cutter Section

12

1. Description

The “Guillotine type” cutter module is provided in which the lower blade is ﬁ xed while the upper blade moves up and down to cut the paper perpendicularly to the traveling direction.

2. Operation

The rotating motion of the DC motor is transformed into the reciprocating motion of the upper blade by means of crank mechanism. A sensor is provided at the top dead center of the blade stroke, which works to apply the brake on the blade movement at every reciprocating cycle to make it stop.

3. Operation of Each Part

1. Cutter Home Position Sensor 1 (SN017) <Operation>

Cutter HP sensor 1 detects the blade bottom dead positions by sensing the light-blocking plate linked to the movement of rotary blade by means of the photo-micro sensor.

SN017

Red

3

Yellow

2

Blue

1

Purple

7

Gray

8

White

9

7

8

9

Purple

Gray

White

CN9-1

Cutter HP1 Sensor

Main PCB Unit

W5-V510*

5V

2

Light not transmitted: 5V Light transmitted: 0V

3

74

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2. Cutter Home Position 2 Sensor (SN018)

Cutter HP 2 sensor detects the blade top dead positions by sensing the light-blocking plate linked to the movement of rotary blade by means of the photo-micro sensor.

10

11

12

Black

Red

Blue

SN018

Red

3

Green

2

Blue

1

10

11

12

Black

Red

Blue

CN9-4

Main PCB Unit

W5-V510*

5V

5

Light not transmitted: 5V Light transmitted: 0V

6

Chapter 2 Cutter Section

Cutter HP2 Sensor

12

2

3. Cutter Motor (MT018)

Cutter motor controls the upper blade up and down operation.

MT018

M

Red

Blue

1

2

Red

Blue

Cut Motor

Drive 2 PCB Unit

W5-V550*

CN6-1

2

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75

Chapter 2 Cutter Section

12

4. Escape Sensor 1 (SN022) <Operation>

Escape sensor 1 detects the escape roller position by sensing the light-blocking plate attached to the escape roller by means of the photo-micro sensor.

Red

1

SN022

White

2

Blue

3

Escape Sensor1

Main PCB Unit

W5-V510*

5V

CN11-1

4

5

6

Red

White

Blue

2

3

5V

Light not transmitted: 5V Light transmitted: 0V

5. Escape Sensor 2 (SN023) <Operation>

Escape sensor 2 detects the escape roller position by sensing the light-blocking plate attached to the escape roller by means of the photo-micro sensor.

SN023

Red

1

Yellow

2

Blue

3

7

8

9

Red

Yellow

Blue

CN11-4

Escape Sensor2

Main PCB Unit

W5-V510*

5V

5

Light not transmitted: 5V

6

Light transmitted: 0V

76

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Chapter 2 Cutter Section

12

6. Escape Motor (MT017)

Escape motor controls the escape roller openingclosing operation.

MT017

M

Black

Red

2

1

Black

Red

Escape Motor

2

Drive 2 PCB Unit

W5-V550*

CN7-1

2

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77

Chapter 2 Waste Box Section

13

Waste Box Section

13

1. Description

The paper strips cut by the margin slitter, the center slitter and the cutter drops into the waste box. Once the waste full sensor detects the full of the paper strips in the waste box, paper strips full message appears on the LCD panel.

2. Operation of Each Part

1. Waste Box Sensor 1 to 4 (SN066, SN067, SN068, SN069)

Waste box sensor detects the presence or nonpresence of the paper by the “light-through” or the “light-blocked” state of the reﬂ ective sensor. It detects paper jams in the waste box area.

Waste Sensor1

Waste Sensor2

Waste Sensor3

Waste Sensor4

SN066

SN067

SN068

SN069

Main PCB Unit

W5-V510*

5V

Red

3

White

2

Blue

1

Red

3

Yellow

2

Blue

1

Red

3

White

2

Blue

1

Red

3

Yellow

2

Blue

1

2

3

4

5

6

7

8

9

10

11

12

Red

White

Blue

Red

Yellow

Blue

Red

White

Blue

Red

Yellow

Blue

CN15-2

3

4

CN15-6

7

8

CN15-10

11

12

CN15-14

15

16

5V

Light not transmitted: 0V Light transmitted: 5V

5V

Light not transmitted: 0V Light transmitted: 5V

5V

Light not transmitted: 0V Light transmitted: 5V

5V

Light not transmitted: 0V Light transmitted: 5V

78

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1. Waste Full Sensor (SN070) <Operation>

Waste full sensor is a kind of reflective sensor. It defects the reflected light by measuring the reﬂ ection from the paper strips in the waste box. This sensor detects paper jams in the waste box.

Red

White

Blue

SN070

Red

3

White

1

Blue

2

1

2

3

CN3-1

2

3

Chapter 2 Waste Box Section

Main PCB Unit

W5-V510*

5V

0V㹼5V

13

Waste Full Sensor

2

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Chapter 2 Exit Tray

14

Exit Tray

14

1. Description

Exit tray is for receiving the ﬁ nished paper discharged from the machine passing through PPS 7.

2. Operation of Each Part

1. Operation of Each Part

Exit tray receives the ﬁ nished paper. It can be set at the following three positions.

- Upper position: when you use the card stacker

- Middle position: for normal use

- Lower position: when you use paper with high static

electricity

80

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Chapter 2 Exit Tray

14

2. PPS7-1 ( PPS7-2 ( PPS7-3 (

Photo-emission Photo-emission Photo-emission

SN060/ SN061/ SN062/

Photo-receiving Photo-receiving Photo-receiving

SN063) SN064) SN065)

•

PPS detects the presence or non-presence of paper

by the “light-through” or the light-blocked” state of

the PPS photo-receiving sensor by means of receiving

from the PPS photo-emitting sensor.

• This sensor detects paper jam in exit tray section.

Red

Orange

Red

White

Blue

1

2

1

2

3

SN060

SN063

Transmit

Receiving

1

3

1

2

3

Red

Orange

Red

White

Blue

CN19-13

14

CN14-7

Main PCB Unit

W5-V510*

5V

8

Light not transmitted: 5V Light transmitted: 0V

9

Transmitting

Receiving

2

SN061

SN064

SN062

SN065

Transmit

Receiving

Transmit

Receiving

5V

1

3

1

2

3

1

3

1

2

3

Red

Orange

Red

Gray

Blue

Red

Orange

Red

Yellow

Blue

Red

Orange

Red

Gray

Blue

Red

Orange

Red

Yellow

Blue

CN19-15

16

CN14-10

11

12

CN19-17

18

CN14-13

14

15

5V

Light not transmitted: 5V Light transmitted: 0V

5V

Light not transmitted: 5V Light transmitted: 0V

3

4

5

6

5

6

7

8

9

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Chapter 2 Main Drive Section

15

Main Drive Section

15

1. Description

Stepping motors are used for activating components related to the paper cutting dimensions, paper transfer, each slitter, transversal position of the gutter. The movement of other DC motors are also controlled by the encoder attached to the motor as required.

2. Operation of Each Part

1. Main Motor 1(MT025), 2(MT026) , 3(MT027),4(MT028) and 5(MT029)

Main motors control the rollers driving related to the paper conveyance.

Main Motor4

Main Motor1

Main Motor5

Main Motor2

Main Motor3

82

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Chapter 2 Main Drive Section

15

Drive 1 PCB Unit

W5-V540*

MT025

MT026

MT027

MT029

MT028

M

Black

Green

Red Blue

Black

Green

Red

Blue

Black

Green

Red

Blue

Black

Green

Red

Blue

Green

Orange

Yellow

White

1 2

3 4

Black

Green

Red

Blue

Black

Green

Red Blue

Black

Green

Red Blue

Black

Green

Red Blue

Green

Orange

Yellow

White

1 2

3 4

1 2

3 4

1 2

3 4

1 2

3 4

1 3

4 6

CN4-1

2 3 4

CN4-5

CN5-1

CN5-5

CN6-1

2

6 7 8

2 3 4

6 7 8

2 3 4

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Chapter 2 Exterior

16

Exterior

16

1. Description

Exterior section detects the opening and closing of each cover. The machine stops immediately when the cover is opened during operations.

2. Operation

The machine stops immediately when opening of the cover is detected during operations.

3. Operation of Each Part

1. Interlock Switch 1-1, 1-2 (SW006, SW007)

Interlock switch detects the opening and closing of the front cover. The machine stops immediately when the cover is opened during operations. When the cover is closed, the cover presses the switch. When the cover is opened, the cover is off from the switch.

Interlock Switch1-1 Interlock Switch1-2

2. Cover Switch, Interlock Switch 2-1, 2-2 (SW010, SW008, SW009)

These switches detect the opening and closing of the top cover 1. The machine stops immediately when the cover is opened during operations. When the cover is closed, the cover presses the switch. When the cover is opened, the cover is off from the switch.

3. Interlock Switch 3 (SW011)

Interlock switch 3 detects the opening and closing of the top cover 2. The machine stops immediately when the cover opens during operations. When the cover is closed, the cover presses the switch. When the cover is opened, the cover is off from the switch.

Cover Switch

Interlock Switch2-1

Interlock Switch2-2

Interlock Switch3

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Chapter 2 Exterior

16

1. Interlock Switch 4 (SW012) <Operation>

Interlock switch 4 detects the opening and closing of the top cover 3. The machine stops immediately when the cover is opened during operations. When the cover is closed, the cover presses the switch. When the cover is opened, the cover is off from the switch.

11

21

SW006

SW007

31

32

22

12

31

11

21

32

22

12

Red Yellow

%OXH

White Green Black

Red Yellow Blue White Green Black

1 2 3 4 5 6

Red Red White Blue Green Black

1 2 3 4 5 6

Red White Red White

Interlock Switch4

Relay PCB Unit

W5-V580* W5-V580*

CN2-8

10 12 14

2

SW011

SW012

SW009

SW010

SW008

11

21

22

12

21

11

22

12

1

1 2

313132

32

2

Red

1

Yellow

2

Blue

3

White

4

Green

5

Black

6

Red

1

Yellow

2

Blue

3

White

4

Green

5

Black

6

1 2

3 4

5 6

Green

3

Black

4

Green

5

Black

6

Green

7

Black

8

Green

9

Black

10

Drive 2 PCB Unit

CN3-3

4 5 6 7 8 9

10

W5-V550*

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Chapter 2 Exterior

16

5. Emergency Switch (SW014) <Operation>

Emergency switch is used when you stop the machine for emergency. The machine stops immediately when you push the emergency switch during operations. The emergency stop is released by turning the pushed switch to the right.

SW014

1 2 3 4

Red

Yellow

Blue

White

1 2 3 4

Red Red

White White

CN2-1

Emergency Switch

Relay PCB Unit

2 4 6

W5-V580*

86

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17

Barcode

1. Description

By adding barcode which indicates job number on each document, DC-646 automatically set up the machine and start the job. Operator can press the START key and leave. Even if multiple typs of jobs are loaded on the feed tray at one time, DC-646 recognizes barcode on documents also with the builtin CCD reading and automatically switch setup and ﬁ nish the jobs. To use this function, each documents must have BARCODE printed on them. Please refer to following instructions for speciﬁ cations and position of BARCODE.

1. Speciﬁ cations

Barcode type : CODE-39 Start and Stop code : Required 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.

Chapter 2 Barcode

Paper feed direction

17

2

IMPORTANT

Do not enter the check digit as it can cause improper operations to the machine.

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Chapter 2 Barcode

17

2. Position of barcode

Paper feed direction: The whole BARCODE should be

within 3 to 20 mm from the lead edge.

Paper width direction: The whole BARCODE should

be within 25 to 60 mm from the

right edge * Here is the example barcode : CODE39 (*21*). (See below) 1 is the start code designator for CODE-39. (*) 2 is the 10’s digit data of the JOB number.

(Example: When the JOB number is 21, the data is “2”.)

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

(Example: When the JOB number is 21, the data is “1”.)

4 is stop code of CODE-39. (*)

1 2 3 4

35 mm

3 mm

Barcode Position Range

Barcode

60 mm or less

25 mm

20 mm

Paper feed direction

88

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3. Position of check digit

Modulus43 is the calculational procedure of check digit speciﬁ ed for CODE39. Each of 43 character types available to CODE39 are allocated each Numeric Number to be calculated after converting them to the numeric number. Here is the example calculation of check digit (*21*) in CODE39.

1 is the start code designator for CODE-39. (*) 2 is the 10’s digit data of the JOB number.

(Example: When the JOB number is 21, the data is “2”.)

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

(Example: When the JOB number is 21, the data is “1”.)

4 is stop code of CODE-39. (*)

4. Calculation procedure of check digit

Chapter 2 Barcode

1 2 3 4 5

17

2

1. Convert all the data characters to the numeric number referring the table 1.

( Except start '*' and stop '*' code.) 21→2,1

2. Add the each converted number.

2 + 1 = 3

3. Divide the number of calculated in step 2

by 43, and ﬁ nd out the remainder.

3÷43 = Remainder 3

4. Convert the remainder 3 calculated in step 3 to the character referring the table 1.

3→3

Therefore, the check digit is 3, and the data will be '*213*'.

Table 1 Modulus43 Check Digit Calculation List

Character 0 1 2 3 456789ABCDE

Value 0 1 2 3 4567891011121314

Character F G H I J K L M N O P Q R S T

Value 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Character U V W X Y Z - • $/+%

Value 30 31 32 33 34 35 36 37 38 39 40 41 42

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Chapter 2 REG Mark

18

REG Mark

18

1. Description

DC-646 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 speciﬁ cations and position of REG mark.

1. Speciﬁ cations

REG mark consists of two straight & perpendicular lines. line length : 5 mm or more / each line thickness : 0.4 mm or more / each Use pen tool etc. of your software application to draw 2 straight & perpendicular lines.

Paper feed direction

Side mark Correct for

Lead mark Correct for image drift in this direction

20mm

5mm or more

image drift in this direction

3mm

5mm or more

3mm

20mm

2. Position

Paper feed direction: The whole REG mark should be

within 3 to 20 mm from the lead

0.4mm or more

REG Mark Position Range

REG Mark

edge.

Paper width direction: The whole REG mark should

be within 3 to 20 mm from the right edge.

Right ﬁ gure shows optimum position of REG mark.

20mm

6mm

3mm

20mm

6mm

IMPORTANT

When there are scratches or stains in the printing range of the REG mark, the position may not be corrected. When the read side of the document is rough and glossy, the CCD scanner may not be able to read REG mark and barcode. (The document may diffusely reﬂ ect light.)

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3. Printing both REG mark and barcode

60 mm or shorter

Chapter 2 REG Mark

20 mm35 mm 5 mm

3 mm

18

3mm

REG MarkBarcode

5mm or more

0.4mm or more

5mm or more

3 mm

20 mm

Paper feed direction

IMPORTANT

REG marks or barcodes located out of the speciﬁ ed printing area cannot be detected properly by DC-646. Take account of the possible variation in the printed position of REG marks and barcodes when they are arranged on the paper.

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91

Chapter 2 REG Mark

18

4. Non-printable area for REG marks and barcodes

3 mm or more

35 mm

3 mm or more

Barcode

5 mm

Non-Printing Area

Paper feed direction

20 mm

3 mm or more

REG

IMPORTANT

• Any part of the image to be printed shall not enter into the gray-colored area.

• No other printings than REG mark and barcode shall enter into the gray-colored area.

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Chapter 3

Mechanism

1

Exterior

(1) Removing the Feed Cover L (2) Removing the Upper Cover L (3) Removing the Feed Cover R (4) Removing the Upper Cover R (5) Removing the Under Cover R1 (6) Remove the Under Cover R2 (7) Removing the Under Cover L (8) Removing the Top Cover 1 (9) Removing the Top Cover 2 (10) Removing the Top Cover 3

(11)

(12)

(13)

2

Paper Feed Section

(1) Removing the Belt Suction Unit

........................................

Removing the Interlock Switches 1-1, 1-2

(SW006, SW007)

Removing the Cover switch, Interlock Switches

2-1, 2-2(SW008, SW009, SW010)

Removing the Interlock Switch 3 (SW011)

..........................

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Removing the Feed Belt

1. Removing the Suction Solenoid (SL001)

2.

Removing the Feed Belt Driving Motor (MT002)

3. Removing the suction fan (FM001)

4. Removing the Paper Level 2 Sensor(SN003)

5.

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96 97 97 97 98 98 98 99 99 99

100

101 102 104 104 105 105 106 106 107

(2) Removing the Air Blow Duct

Removing the Blow Out Fans 1, 2 (FM002, FM008)

1. Removing the separate solenoid (SL002)

2.

(3) Removing the Paper Separator Cancel

Switch (SW002)

(4) Removing the Elevator Upper Limit

Switch (SW001)

Removing the Compressor (MT001)

(5) (6) Removing the SSR (AP001)

Removing the Fuse (FU001,FU002)

(7)

Removing the Paper Level 1 Sensor (SN002)

(8) (9) Removing the Elevator Lower Limit

Switches 1, 2 (SW003, SW004)

1.

Removing the Elevator Lower Limit Switch1 (SW003)

Removing the Elevator Lower Limit Switch 2 (SW004)

2.

Removing the Elevator Down Switch (SW013)

(10) (11) Removing the Elevator Motor (MT003)

and Driving Chain

(12)

Removing the Elevator Chain

(on the operator's side)

(13) Removing the Elevator Chain

(on the non-operator's side)

(14)

Removing the PPS1 (SN006, SN007)

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...

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.114

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108 109 109

110

111 111 111

112

113 113 113

115

116

117 118

3

CAUTION

•Always remove the power cord plug from the outlet before starting work.

•Cautions Regarding Disassembly and Assembly

•In principle, do not operate this machine with parts removed.

•When assembling:

•Unless speciﬁ ed otherwise, perform the disassembly procedure in reverse.

•Make sure that screw types (radius, length) and locations are correct.

•Be sure to use rosette washers when they are speciﬁ ed. (Rosette washers are used with installation screws to prevent static electricity.)

•To ensure electrical current, a rosette washer is used with the installation screw on the ground wire. Be sure to use the rosette washer during assembly.

• Photo-Emission Sensor (SN006)

• Photo-Detecting Sensor (SN007)

(15)

Removing the Paper Tray Sensor (SN001)

3

Skew Adjust Section

(1) Removing the Skew Adjust Unit

Removing the Skew Motor (MT004)

1.

(2) Removing PPS2 (SN008, SN009)

2.

Removing the Fan Register (FM005)

3. Removing the Skew Belt

• Photo-Emission Sensor (SN008)

• Photo-Detecting Sensor (SW009)

Double-Feed Detection Section

4

(1) Removing the Double-Feed Detection

Sensor (transmitting side SN005)

(2) Removing the Double-Feed Detection

Sensor (receiving side SN004)

5

CCD Section (option)

(1) Removing the CCD

Removing the PPS3 (SN010, SN011)

(2)

• Photo-Emission Sensor (SN010)

• Photo-detecting sensor (SN011)

Reject Section

6

Removing the Reject Open Motor (MT005)

(1)

Removing the Reject Delivery Module

(2)

Removing the PPS8 (SN015, SN016)

(3)

Removing the Reject HP Sensor (SN012)

(4)

Slot 1 Section (Margin Slitter Section)

7

(1)

Removing the Margin Slitter Module

1. Removing the Margin Slitter 1• 2

(2)

Removing the Slitter Motor 1 (MT007) Removing the Slitter Motor 2 (MT008)

(3) (4)

Removing the Slitter 1 HP Sensor (SN037) Removing the Slitter 2 HP Sensor (SN038)

(5)

Removing the Module Detection 1 (SN024)

(6) (7)

Removing the PPS4 (SN052, SN053)

• Photo-Emission Sensor (SN052)

• Photo-Detecting Sensor (SN052)

8

Slot 2 Section

(1) Removing the Module

Removing the Slitter Motor 3 (MT009)

(2)

Removing the Slitter Motor 4 (MT010)

(3)

Removing the Jump Motor 1 (MT022)

(4)

Removing the Slitter 3 HP Sensor (SN039)

(5)

Removing the Slitter 4 HP Sensor (SN040)

(6) (7)

Removing the Module Detection Sensors (2 to 5)

(SN025, SN026, SN027, SN028)

Removing the Jump 1 HP Sensor (SN047)

(8)

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..

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..

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..

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...

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..

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...

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.

118 118

119 120 120 121 122 122 122 122 123 124

124

125 127 127 127 127 128 129 129 130 133 133 134 134 134 136 136 137 137

138 138 138 139 140 140 140 141 141 142 142

143 144

9

Slot 3 Section

(1)

Removing the Center Slitter Module

1.

Removing the Center Slitters L • R

Removing the Slitter Motor 5 (MT011)

(2)

Removing the Slitter Motor 6 (MT012)

(3)

Removing the Slitter 5 HP Sensor (SN041)

(4)

Removing the Slitter 6 HP Sensor (SN042)

(5) (6)

Removing the Module Detection Sensors (6 to 9) (SN029, SN030, SN031, SN032)

Removing the PPS5 (SN054, SN055)

(7)

• Photo-Emission Sensor (SN054)

• Photo-Detecting Sensor (SN055)

10

Slot 4 Section

Removing the Center Slitter Module

(1)

Removing the Slitter Motor 7 (MT013)

(2)

Removing the Slitter Motor 8 (MT014)

(3)

Removing the Slitter 7 HP Sensor (SN043)

(4)

Removing the Slitter 8 HP Sensor (SN044)

(5)

Removing the Module Detection Sensors (10 to 13)

(6)

(SN033, SN034, SN035, SN036)

(7) Removing the PPS6

(SN055, SN056, SN057, SN058)

Photo-Emission Sensors (SN056, SN058)

• Photo-Detecting Sensors (SN057, SN059)

•

11

Gutter Section

Removing the Gutter Motor 1 (MT015)

(1)

Removing the Gutter Motor 2 (MT015)

(2) (3)

Removing the Gutter 1 HP Sensor (SN045) Removing the Gutter 2 HP Sensor (SN046)

(4)

12

Creaser Section

(1) Removing the Creaser Module (2)

Removing the Creaser Upper Blade Home Position Sensor (SN019) • Creaser Lower Blade Home Position Sensor (SN020)

Removing the Creaser Motor (MT019) and the Belt

(3) (4)

Removing the Creaser Lower Blade Motor (MT020) Removing the Creaser Encoder Sensor (SN021)

(5)

13

Cutter Section

(1) Removing the Cutter Module (2)

Removing the Cutter HP 1 Sensor (SN019)

• Cutter HP 2 Sensor (SN020) Removing the Cutter Motor (MT018) and the Belt

(3)

Removing the Escape Sensors 1, 2 (SN022, SN023)

(4)

Removing the Escape Sensor 1 (SN022)

• Removing the Escape Sensor 2 (SN023)

•

Removing the Escape Motor (MT017)

(5)

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....

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.......

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....

...

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...

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..

.

145 145 145 147 148 148 149

149 151 151 151 152 152 152 153 153 154

155

157 157 157 158 158 158 159 159 160 160

160 161

162 162 163 163

163 164 166 166 166 167

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14

Paper Exit Section

(1) Removing the PPS7

•

Photo-Emission Sensors (SN060, SN061, SN062) Photo-Detecting Sensors (SN063, SN064, SN065)

•

15

Waste Box Section

(1) Removing the Waste Sensors

(SN066, SN067, SN068, SN069)

(2)

Removing the Waste Full Sensor (SN070)

16

Main Drive Section

(1) Removing the Main Motor 1 (MT025)

and the Drive Belt

(2) Removing the Main Motor 2 (MT026)

and the Drive Belt

(3) Removing the Main Motor 3 (MT027)

and the Drive Belt

(4) Removing the Main Motor 4 (MT028)

and the Drive Belt

(5) Removing the Main Motor 5 (MT029)

and the Drive Belt

(6) Removing the Drive Transmission Belt

(Slots 1 to 4) (7) Removing the Back-Up Roller (8) Removing the Press Roller (9) Removing the Driving Roller (10) Removing the Escape Roller

17

Electrical System Section

(1) Removing the Control Panel (2) Removing the Main PCB Unit (3) Removing the EEPROM (4)

Removing the Slitter Drive PCB Unit .185 (5) Removing the Slitter PCB Unit (6) Removing the Drive1 PCB Unit (7) Removing the Drive2 PCB Unit (8) Removing the Drive 4 PCB Unit (9) Removing the Relay PCB Unit (10)

Removing the oscillation PCB Unit (11) Removing the Receive PCB Unit (12)

Removing the DC Power Supply Unit (5V)

Removing the DC Power Supply Unit (24V)

(13)

Removing the Cooler Fan 1 (FM004) .192

(14)

Removing the Cooler Fan 2 (FM006) .192

(15)

Removing the Cooler Fan 3 (FM007) .193

(16)

Removing the Contactors 1·2 (AP002, AP003)

(17)

Removing the Emergency Stop Switch (SW018)

(18) (19) Removing the USB PCB Unit

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.

168 168 168 168 170

170 171 172

172

173

174

175

176

177 177 179 180 181 184 184 185 185

186 186 187 188 188 189 189 190 190

194 195 196

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95

Chapter 3 Exterior

1

Exterior

1

Upper cover L

Front cover

Top cover 3 Top cover 1Top cover 2

Feed cover L

Under cover L

Feed cover R

Under cover R1

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Upper cover R

Under cover R2

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(1) Removing the Feed Cover L

1. Open the top cover 1.

2. Loosen the four screws, and remove the feed cover L.

IMPORTANT

• Be sure not to loosen the screw more than nine

times on the cover detachment.

Screw

Chapter 3 Exterior

Screw

1

(2) Removing the Upper Cover L

1. Open the top cover 2 and 3.

2. Loosen the three screws, and remove the upper cover L.

(3) Removing the Feed Cover R

1. Open the top cover 1.

2. Loosen the four screws, and remove the feed cover R.

IMPORTANT

• Be sure not to loosen the screw more than nine times on the cover detachment.

3

Screw

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97

Chapter 3 Exterior

1

(4) Removing the Upper Cover R

1. Open the top covers 2 and 3.

2. Loosen the three screws, and remove the upper cover R.

(5) Removing the Under Cover R1

1. Take out the ﬁ ve screws, and remove the under cover R1.

IMPORTANT

• Be sure not to loosen the screw more than nine

times on the cover detachment.

Screw

(6) Remove the Under Cover R2

1. Take out the six screws, and remove the under cover R2.

IMPORTANT

• Be sure not to loosen the screw more than nine

times on the cover detachment.

Screw

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Duplo DC-646 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

How to Use This Service Manual

Safety Instructions

Warning Labels

Labels of High-Voltage Warning

Contents

Part Names and Their Functions

(1) Appearance

(2) Paper Eject side

(3) Paper Eject Side (Stacker Tray)

(4) Inside

(5) Control panel

(6) LCD panel

Dimensions

Paper Feed Section

1. Description

2. Operation

3. Operation of Each Part

Skew Adjust Section

1. Description

2. Operation

3. Operation of Each Part

Double-Feed Detection Section

1. Description

2. Operation

3. Operation of Each Part

CCD Section

1. Description

2. Operation

Reject Section

1. Description

2. Operation

3. Operation of Each Part

Slot 1 Section (Margin Slitter Section)

1. Description

2. Operation

3. Slitter Blade

4. Operation of Each Part

Slot 2 Section

1. Description

2. Operation

Slot 3 Section

1. Description

2. Operation

3. Slitter Blade

4. Operation of Each Part

Slot 4 Section

1. Description

2. Operation

3. Slitter Blade

4. Operation of Each Part

1. Description

2. Operation

3. Operation of Each Part

1. Description

2. Operation

3. Operation of Each Part

1. Description

2. Operation

3. Operation of Each Part

1. Description

2. Operation of Each Part

1. Description

2. Operation of Each Part

1. Description

2. Operation of Each Part

1. Description

2. Operation

3. Operation of Each Part

1. Description

1. Description

Exterior

(1) Removing the Feed Cover L

(2) Removing the Upper Cover L

(3) Removing the Feed Cover R

(4) Removing the Upper Cover R