Duplo INSTRUCTION MANUAL Instruction Manual

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INSTRUCTION MANUAL

SYSTEM5000

Dynamic Booklet Maker

DBM-500

[ for 120 V ]

Be sure to read this manual prior to use.

Please leave this manual at the site of use for easy reference.

Applicable to the 120 V machine

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

INTRODUCTION

Thank you for purchasing this Duplo equipment. To ensure correct usage, please read this instruction manual thoroughly, especially the section entitled "Safety Precautions".

The aim of this instruction manual is to ensure safe and proper use of the equipment. For this reason, do not attempt to remodel, modify or adapt this equipment or to use it for any other purpose than that intended by the manufacturer.

After reading, please keep this instruction manual handy for future reference.

1. SAFETY PRECAUTIONS................................ 2

2. USAGE PRECAUTIONS ................................. 5

2-1. Power Supply ..................................................5

2-2. Operating Environment ...................................5

2-3. Storage Conditions ......................................... 5

3. NAMES AND FUNCTIONS ............................. 6

3-1. External Parts ................................................. 6

3-2. Internal Parts................................................... 8

3-3. Downstream Unit (Optional).......................... 11

3-4. Accessories................................................... 11

4. NAMES AND FUNCTIONS OF CONTROL

PANEL (MAIN MENU)................................... 12

5. PREPARING FOR OPERATION................... 14

5-1. Power ON ..................................................... 14

5-2. Operations ....................................................15

5-3. Settings .........................................................19

6. SADDLE STITCHING PROCEDURE ............ 27

6-1. Settings .........................................................27

6-2. Changing Size............................................... 30

6-3. Adjustments Using the Step Mode................ 30

6-4. Checking the Finished Set ............................33

7. SIDE STITCHING/CORNER STITCHING

PROCEDURE ................................................ 38

7-1. Settings .........................................................38

7-2. Changing Size............................................... 41

7-3. Adjustments Using the Step Mode................ 42

7-4. Checking the Bound State ............................ 45

8. NO-STITCHING FOLDING PROCEDURE ... 46

8-1. Settings .........................................................46

8-2. Changing Size............................................... 48

8-3. Adjustments Using the Step Mode................ 49

8-4. Checking the Finished Set ............................52

9. VARIOUS SETTINGS.................................... 56

9-1. Fine Adjustment Menu ..................................56

9-2. Option Menus................................................ 61

9-3. Accessory Menus.......................................... 63

9-4. Adjusting the Press Pressure and Conveyance

Pressure........................................................ 66

9-5. Adjusting the Saddle Stitching Guide/Side

Stitching Guide.............................................. 66

10. ERROR MESSAGES..................................... 67

10-1. Emergency Stop ........................................... 67

10-2. Covers........................................................... 67

10-3. Paper Jam..................................................... 68

10-4. Wire Feed Detection ..................................... 68

10-5. Paper Tray Full ............................................. 68

10-6. Motor Error ....................................................69

10-7. Service Person Error..................................... 69

10-8. Shutter .......................................................... 69

11. CORRECTING PAPER JAMS ...................... 70

12. STITCHER HEAD .......................................... 71

12-1. Names and Functions ...................................71

12-2. Wire............................................................... 72

12-3. Feeding the Wire........................................... 73

12-4. Stitching Tests ..............................................75

12-5. Removing Wire ............................................. 76

12-6. Adjustments .................................................. 77

12-7. Maintenance ................................................. 78

13. TROUBLESHOOTING .................................. 79

14. CLEANING .................................................... 81

15. SPECIFICATIONS ......................................... 82

1. SAFETY PRECAUTIONS

Always observe the cautions and warnings given below to prevent personal injury or property damage.

The degree of danger and damage that could occur is indicated on two levels by the following marks.

WARNING: Ignoring this mark could result in the possibility of serious injury

or even death.

CAUTION: Ignoring this mark could result in the possibility of injury or

physical damage.

The following graphic symbols indicate the various types of action to be performed or avoided.

This graphic symbol indicates a forbidden action.

means “Do not disassemble.” means “Do not touch.”

This graphic symbol indicates actions that must be performed.

means “Disconnect the power plug.”

WARNING:

Do not place metal objects or vessels containing liquids on top of the unit. The entry of any metal object or liquid could result in a fire or an electrical shock.

Do not insert any metal or easily-combustible object inside this unit. This could result in a fire or an electrical shock.

Do not touch or insert foreign objects into any rotating part during operation. This could result in injury.

Do not remove the cover or back panel. This unit contains high-voltage components that could cause an electrical shock.

Do not disassemble, modify or repair this unit. There is a danger of fire, electrical shock or injury. Contact your dealer when repairs are necessary.

Use only the power supply voltage specified on the main nameplate. Using other voltages could result in a fire or an electrical shock.

Keep this unit and the power cord away from heaters and heater vents. Excessive heat could melt the cover or power cord covering, and result in a fire or an electrical shock.

1. SAFETY PRECAUTIONS

Do not use flammable sprays or solvent inside or near the unit (e.g. when cleaning the unit). Such flammable gas or solvent may ignite and cause a fire or combustion.

Make sure that the combined power consumption of the appliances to be connected does not exceed the capacity rating of the power outlets or plug receptacles. Exceeding the capacity rating could cause the power outlets, plug receptacles, or power extension cords to overheat and catch a fire.

Remove any dust that accumulates on the power plug prongs and the surface of the plug from which the prongs extend. Accumulated dust could result in a fire.

If any foreign object such as metal or liquid should enter this unit, immediately turn the unit off at the power switch and disconnect the power plug from the power outlet. Failure to do so could result in a fire or an electrical shock. Contact your dealer immediately.

Do not damage the power cord or power plug. (Do not scratch, alter, bend, twist, pull or place heavy objects on the power cord or power plug.) This could result in damage, a fire or an electrical shock.

Always grip the plug when disconnecting the power plug from the power outlet. Forcibly pulling on the power cord could cause damage, resulting in a fire or an electrical shock.

Do not touch the power plug or power switch with wet hands. This could result in an electrical shock.

Before cleaning this unit, turn the unit off at the power switch and disconnect the power plug from the power outlet. Accidental operation of the unit during cleaning could result in injury.

CAUTION:

Always disconnect the power plug from the power outlet when the unit is not to be used for an extended period. Failure to do so could result in fire due to leakage current if the insulation should deteriorate.

Install this unit on a level, stable stand or floor, with sufficient space around it. Failure to do so could result in the unit overturning and causing injury.

Do not install this unit in a location where there is excessive humidity or where contact with water is possible. Poor choice of location could result in deterioration of the insulation, fire or electrical shock.

Disconnect the power plug from the power outlet before attempting to move this unit. Failure to do so could result in power cord damage, fire or electrical shock.

1. SAFETY PRECAUTIONS

Safety

The following shows the location of the safety devices and warning/Caution label.

Top cover (Back)

Top cover (Front)

Emergency Stop Switch

NoteNote

Shutter

Labels are pasted to ensure the safety of users. Do not remove nor change them. If a label becomes dirty or missing, be sure to contact your dealer for a new one.

The actual control panel and emergency stop switch of this machine may be located opposite to the locations shown in the above figure.

2. USAGE PRECAUTIONS

2-1. Power Supply

• This equipment shall be installed near the socket-outlet where the plug on the power

supply cord is easily accessible.

• Make sure the power supply used is always within the following range.

220-240V AC 50Hz/120V AC 60Hz

•When you power other appliances from the same AC outlet, make sure that the combined

power consumption does not exceed the power supply capacity.

Rated power of this equipment : 3.8A/6.5A

2-2. Operating Environment

Operate this unit in the following environment:

• where the temperature range is between 5 and 35°C/41 and 95°F,

• where the humidity range is between 10 and 85%RH (no dew condensation),

• which is not subject to direct sunlight,

• which is subject to little or no vibration,

• where there are no harmful chemicals,

• which is reasonably free from dust,

• which is free from air-borne salt, and

• where the equipment will not be exposed to water.

2-3. Storage Conditions

Store this unit in the following environment:

• where the temperature range is between –10 and +50°C/14 and 122°F,

• where the humidity range is between 10 and 85%RH (no dew condensation),

• which is not subject to direct sunlight,

• which is subject to little or no vibration,

• where there are no harmful chemicals,

• which is reasonably free from dust,

• which is free from air-borne salt, and

• where the equipment will not be exposed to water.

3. NAMES AND FUNCTIONS

3-1. External Parts

In this manual, the left side of the paper conveyance direction is indicated as L side and the right side as R side.

L side

Paper direction

R side

No. Name Function

Main power switch Refer to “5-1. Power ON”. ( Refer to page 14.)

Emergency stop button Press to stop the machine in emergency. Paper being fed will stop halfway. To resume

Front top cover Cover for ensuring user safety

Rear top cover Cover for ensuring user safety

Option connector Optional power connector

E port connector-1 Connects the E port cable from the upstream unit.

E port connector-2 Connects the E port cable to the downstream unit.

D port connector-1 Connects the D port cable from the upstream unit.

D port connector-2 Connects the D port cable to the downstream unit.

Power cord Supplies power to this machine.

Power switch Refer to “5-1. Power ON”. ( Refer to page 14.)

Stacker connector Connects the power cord of the belt stacker.

operations, remove this paper. To stop the machine normally, use the [Stop Key] on the upstream unit or this machine. To release this switch, rotate it to the right.

This machine will not operate if open.

3. NAMES AND FUNCTIONS

R side

L side

Paper direction

No. Name Function

Wire reel Stitches paper

Control panel Refer to “Description of Control Panel”. ( Refer to page 12.)

Folding stopper adjustment dial Adjusts the angle of the folding stopper to correct folding misalignment.

Deflector strip Holds booklets sent to the side stitching stacker.

Side stitching stacker Receives booklets which are side stitched (corner stitched).

Stacker plate Receives booklets which are saddle stitched, and folded.

Belt stacker Sends booklets folded into two to the stacker plate.

Paper guide wheel Holds paper sent to the stacker and feeds to the stacker plate.

Shutter Opening for inserting the handle Normally leave closed.

Handle Used to remove jammed paper and clean the folding stopper

Side stitching stopper Stops booklets which have been side stitched (corner stitched).

Side stitching stopper adjustment Adjusts the position of the side stitching stopper.

knob

Ejection roller Ejects side stitched (corner stitched) booklets.

When stacked poor due to small booklet size, use it at upper position.

Connect the power cord plug of the Belt Stacker Unit to the outlet of the DBM-500

This machine will not operate if the shutter is open. ( Refer to pages 70 and 81.)

3. NAMES AND FUNCTIONS

Paper direction



3-2. Internal Parts

When the conveyance roller open

No. Name Function

Stitcher head Binds paper with wire.

Side jogger Aligns the sides of paper.

Side stitching stopper Rises during side stitching (corner stitching) to stop paper.

Side stitching guide Prevents paper from curling during side stitching (corner stitching).

Back jogger Aligns the leading and trailing edges of paper.

Conveyance driven roller Helps to convey paper to the paper alignment section.

Conveyance roller lifting handle Lift to remove paper jammed at the paper alignment section.

Conveyance roller Conveys paper to the paper alignment section.

3. NAMES AND FUNCTIONS



Paper direction

No. Name Function

Saddle stitching stopper Rises to stop paper during saddle stitching.

Ejection driven roller Helps to deliver stitched booklets to the folder.

Saddle stitching guide Prevents paper from curling during saddle stitching.

Folding side guide Holds both ends of booklets during folding.

Ejection roller Ejects stitched booklets to the folder.

Ejection roller stopper Solves the poor alignment of insert sheets in insert mode.

The height can be adjusted. ( Refer to page 66.)

3. NAMES AND FUNCTIONS

Paper direction



bq bp

Roller attaching position

No. Name Function

Folding roller Roller for folding booklets into two

Press roller Presses booklets folded into two.

Pressure adjustment hook Adjusts the pressure of the press roller.

Conveyance pressure adjustment Switches the conveyance pressure of booklets folded into two.

hook

Folding stopper Stops booklets during folding.

Folding back guide lifting handle Lift to remove booklets when paper jams at the folding unit.

Folding back guide Presses the ends of booklets during folding.

3-3. Downstream Unit (Optional)

DBM-500T (Optional)

3. NAMES AND FUNCTIONS

DBM-K (Optional)

DBM-LSI (Optional)

This machine

Paper guide wheel

3-4. Accessories

Adjusting handle

Corner stitching paper holder

4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU)

The control panel is composed of the touch panel and numerical pad. The following describes the main menu which is the standard screen displayed normally, and the numerical pad.

1526374

MAINMENU ADJUST OPTION ACCESSOR

420. 0

207. 0

297 . 0

277 . 0

00000

9bkbmbpbn bo

ckcl cmbl8

[Numerical Pad][Touch Panel]

No. Name Function

Main menu tab Displays the main menu.

Fine adjustment menu tab Displays fine adjustment menus. ( Refer to page 56.)

Option menu tab Displays option menus. ( Refer to page 61.)

Accessory menu tab Displays accessory menus. ( Refer to page 63.)

Stitch setting display Displays the stitch setting of the memory number currently selected.

Indicates that saddle stitching is selected.

Indicates that side stitching (corner stitching) is selected.

Indicates that “Stitch Off” is selected.

Fold setting display Displays the fold setting of the memory number currently selected.

Indicates that “Fold On” is selected.

Indicates that “Fold Off” is selected.

4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU)

No. Name Function

Trim setting display Displays the trim setting of the memory number currently selected.

Note: This is not displayed when not connected with the DBM-500T, or when “Fold Off” is selected.

Indicates that “Head/Foot Trim On” is selected.

Indicates that “Fore-edge Trim On” is selected.

Indicates that “Trim Off” is selected.

Sheet size display Displays the paper size of the memory number currently selected in the following

Finished size display Displays the finished size of the booklet processed by this machine.

Memory number display Displays the memory number of the binding mode currently selected.

Memory number selection key Selects the memory number.

Setting key Displays the setting menu of the memory number of the binding mode currently

Processed number display Displays the number of sets processed by this machine.

Processed number clear key Clears the “Processed number display” to 0.

Size change key Changes the settings of the memory number currently selected.

Message display Displays messages.

Numerical keys Enters values such as paper size, etc.

Clear key Clears the value entered using “br Numerical keys” to 0.

Return key Confirms values entered using “br Numerical keys” to 0.

Jog key Step-ejects paper forcibly. ( Refer to page 16.)

Start key Starts the system.

Stop key Stops the system including this machine.

format. length x width

The selected memory number is displayed at “bk Memory number display”, and the settings are displayed at 5 to 9.

selected.

Press for more than 1 second.

5. PREPARING FOR OPERATION

5-1. Power ON

This machine has a main power switch and a power switch. Operate the machine with the main power switch On, and the power switch " The remote function allows this unit to turn on/off by pressing the power switch for DC-10/60,and the main power switch for DSF-2000. It means there is no need to touch the main power switch or the power switch of this unit.



 To turn the power of this machine On/Off by

NoteNote



itself, set the power switch to “I” and the main power switch On.



 When operating the power switch, do so after



turning Off the main power switch.



 If an upstream unit is connected, do not turn



On/Off the power of this machine by itself. This may cause the machine to operate abnormally. Be sure to turn On/Off the main power switch or the power switch of the upstream unit instead.

Power switch

Main power switch

Power switch

DBM-LS1 DBM-500T This machine LUL-HM DC-10/60

When DC-10/60 is connected

DBM-LS1 DBM-500T This machine DSF-2000

Main power switch

When DSF-2000 is connected

5-2. Operations

MAINMENU ADJUST OPTION ACCESSOR

5. PREPARING FOR OPERATION

Clear keyMemory No. Size change key

420. 0

207. 0

297 . 0

277 . 0

00000

number display

number clear key

MessageProcessed

Return keyProcessed

❊ Memory No.

The memory number consists of 1 to 12 for registering binding setting (binding mode) such as paper size, stitching, and folding to each memory. Default settings at shipment are as follows.

Memory No. Paper size (mm) (inch) Stitching Folding

1 420 x 297 (A3) (17.00 x 11.00 (Double letter)) Saddle stitching Folding 2 297 x 210 (A4) (11.00 x 08.50 (Letter)) Saddle stitching Folding 3 210 x 297 (A4) (08.50 x 11.00 (Letter)) Side stitching No folding 4 210 x 148 (A5) (08.50 x 05.83 (Letter)) Saddle stitching Folding 5 364 x 257 (B4) (08.50 x 05.83) Saddle stitching Folding 6 257 x 182 (B5) (10.12 x 07.17) Saddle stitching Folding 7 182 x 257 (B5) (07.17 x 10.12) Side stitching No folding 8 431.8 x 279.4 (17.00 x 11.00) Saddle stitching Folding

9 355.6 x 215.9 (14.00 x 08.50) Saddle stitching Folding 10 215.9 x 355.6 (08.50 x 14.00) Side stitching No folding 11 279.4 x 215.9 (11.00 x 08.50) Saddle stitching Folding 12 215.9 x 279.4 (08.50 x 11.00) Side stitching No folding

Start key Stop key

Jog key

Each memory number can be overwritten. Register the 12 settings usually used for convenience. Select the memory number of the binding mode to be used, change the size and begin binding. ( Memory No. 1 to 12 can also be set so that settings are not overwritten. (



 About Memory No. 0



Use Memory No. 0 to set a binding mode that is slightly different from the pre-set settings for the current job only. The settings set at Memory No. 0 cannot be saved. Select a memory number from Memory No. 1 to 12, and change the size. Then select Memory No. 0. The same settings as the memory number for which size was changed will be displayed. Press the [Setting key] on the touch panel, and change the binding mode using Memory No. 0. Press the [Return key] on the touch panel to confirm the settings of Memory No. 0. Change the size again to proceed with the binding work.

Settings of the previously selected memory number are not updated so that the original settings can be selected again.

Refer to page 63.)

Refer to page 16.)

5. PREPARING FOR OPERATION

❊ Size change

Size change is the process of returning guides to their standard points once, and then moving them to the positions set according to the settings of the memory number selected. Pressing the [Size Change key] changes the size. This process is required after the power is turned on, and after the memory number is changed. When the message display shows “Perform paper size change” and the [Size Change key] blinks, size change is also required. Normally, the stitcher will not return to its standard point. But pressing the [Size Change key] while pressing the [Clear key] returns the stitcher to its standard position and moves it to the set position. Pressing the [Size Change key] while pressing numerical key 0 only returns all guides to their standard positions.

NoteNote

While “Perform paper size change” is displayed, this machine will not operate.

❊ Processed number display

Counts up the number of sets normally processed. The display can be reset to 0 using the [Processed number clear key]. The count is reset to 0 when the power is turned off.

❊ Starting/stopping processing

Pressing the [Start key] of this machine or the upstream machine starts processing. Pressing the [Stop key] ejects all paper being processed, after which this machine stops. If an error occurs during processing, this machine will stop according to the situation. If an error of the emergency stop switch, top cover, or shutter occurs during processing, the machine will also stop immediately.

❊ Step-ejection

Pressing the [Jog key] binds paper left in the machine and ejects them. Perform the following procedure using the [Jog key].

1. This machine will keep running while the [Jog key] is held down.

2. When the [Jog key] is released, paper inside the machine will to be stitched or folded, and move to next step. The machine will then wait for the next jog key operation. When paper jams inside the machine, a paper jam message appears and the machine stops. However, visually check the machine because the machine will stop due to paper jam without displaying the paper jam message in some cases. In such cases, open the top cover and remove the paper.

3. When conveyance is being carried out continuously, press the [Jog key] several time to execute stitching or folding, and eject the processed sets.

If paper is forcibly ejected by the upstream unit, this machine will also perform conveyance motion.

NoteNote

The paper will stop at the stitching area but this machine will not advance the paper fed. Open the top cover and remove the paper conveyed to this machine.

Paper

Space Space

Side joggerSide jogger

❊ Aligning the paper passage lines

After preparing this machine for binding operations, check that the paper passage line is aligned to that of the upstream unit. When paper conveyed from the upstream unit is conveyed to this machine, check that there is even space between the left and right side joggers and paper. If not even, adjust the position of this machine to avoid paper jams. Move this machine at other fine adjustment screens of the fine adjustment menu, until the space becomes even. (

Refer to page 60.)

❊ Stitching range

5. PREPARING FOR OPERATION

Saddle stitching

Stitching is carried out at the positions indicated by the pointer. Normally, stitching is done at two positions.

This can be increased to four positions by factory

options.

When paper is more than 140 mm/5.51 inch wide, the standard stitching width is determined by the ratio of 1:2:1. Stitching width is the center to center distance between the two stitches. However, if the stitching position lies inside the stitch prohibited area, it will be set at a position avoiding this area.

For example, if the paper width is 240 mm/9.45 inch, stitching is carried out at the 60 mm/2.36 inch and 180 mm /7.09 inch positions from the paper edge.

Pointer

Stitching position

Paper conveyance direction

Stitching position

Stitching position label

(2.36)

180 (7.09)

240 (9.45)

(2.36)

1 : 2 : 1

When less than 140 mm/5.51 inch, the stitching width is 70 mm/2.76 inch (minimum stitching width).

The stitching width (the ratio) can be changed. ( to page 58.)

Unit: mm (inch)

Refer

5. PREPARING FOR OPERATION

6 (0.24)

Paper conveyance direction

Paper width

Unit: mm (inch)

 The stitching position cannot be within 14 mm/0.55 inch

from both edges of the paper.

 The stitching width cannot be within 70 mm/2.76 inch.

Side stitching (corner stitching)

The stitching position is about 6 mm/0.24 inch from the leading edge of the paper, and cannot be changed vertically. The stitching position along the width of the paper is the same as saddle stitching.

Paper conveyance direction

120 to 356

Center line of paper width

Stitching position

Unstitchable area Unit: mm (inch)

(0.55)

(2.76)

(0.55)

❊ Stitch prohibited area

The position at which the folding knife and a stitch coincide is called the stitch prohibited area. During folding operations, the folding knife may bend the stitch if they touch. When a standard stitching position determined by the paper width entered is inside the stitch prohibited area, the position avoids this area automatically.

NoteNote

When adjusting the stitching width, avoid the stitching prohibited area.

Stitching position label Mark (Stitch prohibited area)

Pointer

Make sure the mark does not enter area A

5. PREPARING FOR OPERATION

❊ When paper is fed at an upstream unit

(Refer to the instruction manual on upstream unit for details of manual feed)

There is a need to enter values for “processed sheets” and “number of jogs” on the control panel.

Refer to “Option Menu 2” on page 60 for “number of jogs” and “Option Menu 3” on page 61 for “processed sheets”.)

(

 Set the number of jogs to two or three times, and increase this number if paper alignment is poor.

 Manual feeding from DC-10/60, DC-8/32

Set only the number of sheets to be inserted at LUL-HM at " processed sheets". When the sets with many number of sheets frequently ride over the saddle stitching stopper, press the Hand Marry key 2 on the DC-10/60 or DC-8/32 collator control panel. Normally press the key 1. It runs fast to achieve higher productivity.

 Merging-collation mode with DC-10/60 or DC-8/32

Set the total number of sheets fed from the LUL-HM and the collator at “processed sheets”.

 Manual feeding from DSF-2000

Insert one set of paper into the machine, and press the [Jog key] of this machine. Binding operation starts. Automatic operations can also be performed. For details, refer to "Option Menu 4" on page 61.

❊ Precautions on connecting and using DSF-2000

When using DSF-2000 in the random mode or as a barcode kit or intelligent kit, there is a need to enter the “processed sheets” on the control panel of this machine beforehand. At this time, the processed sheets differ according to the set. Enter the minimum number of sheets of each set at “processed sheets”.

5-3. Settings

Perform binding settings. Select the memory number whose setting is to be changed, and press the [Setting key]. The memory number to be used can be saved at the last. If not saving, use Memory No. 0. (

Refer to page 15.)

Memory No.

MAINMENU ADJUST OPTION ACCESSOR

420. 0x297 . 0

207. 0

Memory number selection key

277 . 0

00250

<Main Menu> Screen

Setting key

5. PREPARING FOR OPERATION

❊ Selecting the binding mode

Select the stitchng and folding mode.

Set the stitching mode. To perform saddle stitching, select “ stitching”, to perform side stitching, select “ stitching”, and if not performing stitching, select “ Stitch Off”. Select “

Selecting “Saddle stitching” automatically sets the folding mode to “Fold On”. (Can be changed) Selecting “Side stitching” automatically sets the folding mode to “Fold Off” and the trimming mode to “Trim Off”. (Can be changed)

Side stitching” also for corner stitching.

Saddle

1 2 345

Side

Set the folding mode. To perform folding, select “

Fold On”. If not performing folding, select “

Fold Off”.

Selecting “Fold Off” sets the trimming mode to “Trim Off”.

After setting the binding mode, press the [Next key] to proceed to the [Select trimming mode] screen. Pressing the [Cancel key] cancels the values entered, and then returns to the main menu. Select the trimming mode.

Set the Fore-edge trim. To perform trimming, select “

Trim On”. If not to perform trimming, select “

Trim Off”. (When DBM-500T is not connected, or when “Fold Off” is selected, “Trim On” cannot be selected.)

Set the Head/Foot Trim. To perform trimming, select “

select “ (When “ Trim On” cannot be selected.)

Trim On”. If not to perform trimming,

Trim Off”.

Fore-edge Trim Off” is selected, “

Next keyCancel key

<Select Binding Mode> Screen

6 7

After setting the trimming mode, press the [Next key] to proceed to the [Enter paper size] screen.

<Select Trimming Mode> Screen

Next keyBack key

❊ Entering paper size

Paper width

Stitching position

Folding position

297. 0

420. 0

210. 0

148. 5

Next key

Back key

Stitching width

Paper length

Paper conveyance direction

<Enter Paper Size> Screen

Enter the paper length and width. Standard values for the stitching/folding positions and stitching width are displayed according to the paper size entered. Pressing inside the box showing a value resets the value to 0. Enter the desired values using the [Numerical keys], and press the [Return key] on the numerical pad to confirm. Pressing the box again before pressing the

[Return key] returns the original value.

5. PREPARING FOR OPERATION

NoteNote

Entering the paper length Enter the paper length.

Entering the paper width Enter the paper width.

Stitching position display Length from the paper leading edge to stitching position.

Folding position display Length from the paper leading edge to stitching position.

Stitching width display The width between both stitches.

The values in this screen are original figures you entered. They remain the same no matter how finely adjusted later according to binding conditions.

Range of input Saddle stitching: 178.0 to 508.0 mm/7.01 to 20.00 inch

Range of input Saddle stitching and Stitch Off: 120.0 to 356.0 mm/4.72 to 14.02 inch

When the paper length is entered, the standard stitching position will automatically be set. (Can be changed)

Standard stitching position: (Paper length ÷ 2) mm/inch

Range of input Saddle stitching: 89.0 to 254.0 mm/3.50 to 10.00 inch (However, the difference with the paper length is in the range of 89 to 359 mm/3.50 to 14.24 inch)

When the paper length is entered, the standard folding position will automatically be set. (Can be changed)

Standard folding position: (Paper length ÷ 2) mm/inch

Range of input 89.0 to 254.0 mm/3.50 to 10.00 inch (However, the difference with the paper length is in the range of 89 to 254 mm/3.50 to 10.00 inch)

When the paper width is entered, the standard width will automatically be set. (Can be changed)

Standard stitching position: (Paper length ÷ 2) mm/inch

However, if the paper width is less than 140 mm/5.51 inch, the stitching width will be set to

70.0 mm/2.76 inch (minimum stitching interval). The stitching position will also avoid the stitch prohibited area. Range of input From 70.0 mm/2.76 inch to (Paper width –28.0 mm/1.10 inch) Stitching cannot be carried out within 14 mm/0.55 inch from the side edges.

(When connect with DBM-2KT: 178.0 to 500.0 mm/7.01 to 19.69 inch) Stitch Off: 178.0 to 508.0 mm/7.01 to 20.00 inch Side stitching (Corner stitching): 140.0 to 364.0 mm/5.51 to 14.33 inch

(Side stitchable length: Above 182.0 mm/7.17 inch)

When set to “Fold On”: 178.0 to 364.0 mm/7.01 to 14.33 inch

Side stitching (Corner stitching): 210.0 to 356.0 mm/8.27 to 14.02 inch

After entering the paper size, press the [Next key] to proceed to the next step. When the binding mode is set to “Trim On”, the “Set Trimming Position” screen will appear. If set to “Trim Off”, the [Confirm Settings] screen will appear. As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper size entered is not appropriate. Pressing the [Back key] returns to the <Select Trimming Mode> screen.

5. PREPARING FOR OPERATION

❊ Setting the Fore-edge Trimming position (When DBM-500T is connected and [Trim On] is selected)

Displaying the trimming position

This is the finished length after Fore-edge Trimming. When the paper length is entered, the standard stitching position will automatically be set. (Can be changed)

Standard trimming position: (Paper length ÷ 2) – 3

mm/0.12 inch (MAX: 253 mm/9.96 inch)

Pressing inside the box showing a value resets the value to 0. Enter the finished length using the [Numerical keys] on the numerical pad, and then press the [Return key] to confirm. Pressing the box again before pressing the [Return key] returns the original value.

Range of input: 75.0 to 253.0 mm/2.95 to 9.96 inch (Trimming width should be within 75 mm/2.95 inch)

After entering the Fore-edge Trimming position, press the

[Next key].

When the trimming mode is set to “Trim On”, the “Set Head/Foot Trimming Position” screen will appear. If set to “Trim Off”, the [Confirm Settings] screen will appear. Pressing the [Back key] returns to the <Enter paper size> screen.

Trimming width

207. 0

Back key

<Set Trimming Position> Screen

Next key

❊

Setting the Head/Foot Trimming position (Available only when [Trim On] is selected

both in the Fore-edge trim, and Head/Foot Trim modes while DBM-2KT is connected. )

Displaying the Head Trimming position

Displaying the Foot Trimming position

Margin widths to be Head/Foot trimmed are displayed. When the paper width is entered, the standard stitching position will automatically be set. (Can be changed)

Standard trimming width: 10 mm/0.40 inch

Range of input: 0 and 1.0 to 25.0 mm/0 and 0.04 to

0.98 inch When "0" is input, the machine does not operate.

3 1

10. 0

277. 0

10. 0

<Set Trimming Position> Screen

Next keyBack key

5. PREPARING FOR OPERATION

Displaying the Head/Foot trimming positions

The finished width after Head/Foot trimming is displayed. When the paper width is entered, the standard trimming position will automatically be set. (Can be changed) Standard width after trimming = (Width - 20 mm/0.79 inch)

Pressing inside the box showing a value resets the value to 0. Enter the finished width using the [Numerical keys] on the numerical pad, and then press the [Return key] to confirm. Pressing the box again before pressing the [Return key] returns the original value.

Range of input: from a figure ( Sheet width - Margin width ) to specified Sheet width ( 120 to 356 mm/4.72 to 14.02 inch)

After inputting the Head/Foot trimming positions, press the [Next key] to proceed to the [Confirm Settings] screen. Pressing the [Back key] returns to the <Enter Fore-edge trimming position> screen.

❊ Confirming settings

Make sure that the values entered are all correct, and then press the [Return key] on the touch panel. Pressing the [Return key] saves the settings of the memory number and returns to the “Main Menu” screen. Pressing the [Back key] returns to;

1. the "Set Head/Foot Trimming Positions" screen, when the trimming mode is set to "Head/Foot Trim On",

2. the [Enter Fore-edge Trimming Positions] screen, when set to"Head/Foot Trimming Off", and "Fore-edge Trimming On",

3. the "Enter Paper Size" screen, when set to "Head/Foot Trimming Off", and "Fore-edge Trimming Off".

420. 0x297 . 0

207. 0

277 . 0

Return keyBack key

<Confirm Setting> Screen

❊

Adjusting the position of the paper guide wheel when the trimmer is not connected

Where the fore-edge of booklets touches the outlet as shown, set the wheels at about 30 mm/1.18 inch from the book spine. Loosen the setscrew and move the paper guide wheel.

NoteNote

If the booklet is widely open, and cannot be conveyed properly, move the paper guide wheel closer to the outlet.

Paper guide wheel

Setscrew

Stacker

DBM-500

Outlet

Booklet

Setscrew

Book spine

30 mm (1.18 inch)

DBM-500

Fore-edge

Outlet

5. PREPARING FOR OPERATION

❊ Size change

Press the [Size Change key] for more than one second to change the size. When size change completes, a beep sounds.

NoteNote

This machine moves left and right.

MAINMENU ADJUST OPTION ACCESSOR

420. 0

207. 0

297 . 0

277 . 0

00000

Perform paper size change

<Main Menu> Screen

❊ Adjustments using the step mode <Fine adjustment menu>

After changing the size, perform fine adjustments of each function in the step mode. When the step mode completes, the newly adjusted value is saved as the new setting of the memory number. Load actually bound paper into the upstream unit, and prepare to start adjustments.

NoteNote

Values shown in the Main Menu screen are replaced by values adjusted not only in the fine adjustment screen but also in the step mode. However, the values shown in the setting screens of each Memory Number will remain the same. They show values originally entered.

Size change key



 Starting the step mode



When the DBM-500T is connected, select whether to trim sets bound in the step mode using the [Trim On/Off key].

On: Trims. Set to trim booklets. Off: No trimming. Set to check stitching and folding

positions.

The setting of the [Trim On/Off key] has priority during the step mode, regardless of whether trimming has been set or not at the memory number used.

Pressing the [Step Mode key] in the fine adjustment menu proceeds to the <Stitcher Adjustment> screen.

Step Mode key Trim On/Off key

MAINMENU ADJUST OPTION ACCESSOR

<Fine Adjustment Menu> Screen

<Stitcher Adjustment> Screen

+ 60 hidden pages

Duplo INSTRUCTION MANUAL Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

CONTENTS

1. SAFETY PRECAUTIONS

Safety

2. USAGE PRECAUTIONS

2-1. Power Supply

2-2. Operating Environment

2-3. Storage Conditions

3. NAMES AND FUNCTIONS

3-1. External Parts

3-2. Internal Parts

3-3. Downstream Unit (Optional)

3-4. Accessories

4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU)

5. PREPARING FOR OPERATION

5-1. Power ON

5-2. Operations

5-3. Settings