MyBinding DC-545HC Service Manual

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Duplo Docu Cutter

DC-545HC

Service Manual

SERVICE MANUAL

Ver.1

DOCU CUTTER

DC-545HC

Be sure to read this manual carefully, so that you repair and service this machine safely and correctly. Do not begin work until you have thoroughly understood the contents of this manual. Repairing or servicing the machine with insuffeicient knowledge about it could lead to unforeseen accidents or falls in the machine's performance or quality.

DUPLO SEIKO CORP.

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 insufficient 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, service personnel should be safety-conscious and take other safety precautions as necessary. When performing repair or service work not covered by this manual, you should obtain safety guidance from an appropriately knowledgeable person.

Safety instructions

1.Cautions regarding the installation location

Safety instructions

Installation environment

s 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.

s 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: 5˚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 humidifiers, 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 or poor image quality.

s Avoid installing the machine in places with open flames, or where reflected heat or other hot air

currents (from stoves, etc), or cold air currents from coolers, etc will strike it directly.

s Avoid installing the machine in poorly ventilated places. s Avoid installing the machine in dusty places.

s 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 5mm in the front-rear direction, and 5mm in the lateral direction.)

s 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.

Safety instructions

2. Cautions for installation work

Warning

• The machine’s power supply voltage and power consumption depend on the model. Details of this are given in the tables below. The power supply voltage and power consumption for the machine are given in the table below. The machine’s power supply voltage is indicated on the identification plate located on the machine’s left side; the machine must be connected to a power supply of the voltage indicated.

a Otherwise, fire or electric shock could result.

If the power supply voltage is unstable or if the power supply has insufficient capacity, the machine may not operate normally. Make sure that the power supply has sufficient capacity for the system as a whole, including optional equipment.

* 120V AC model

Power supply voltage

With no load* At full load

Power consumption

No more than 130V AC At least 110V AC

During operation : 90W In standby : 15W

Connect to outlet of 120V AC, 60Hz, at least 15A

Use power supply meeting these requirements

}

* 230V AC model

Power supply voltage

With no load* At full load

Power consumption

* “With no load” - when the machine is on standby. * “At full load” - when the machine is running at maximum power consumption.

No more than 250V AC At least 210V AC

During operation : 90W In standby : 15W

Connect to outlet of 230V AC, 50Hz, at least 8A

Use power supply meeting these requirements

}

• Use only the power cord that is provided among the accessories. Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.

• 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. If an extension cord is necessary, it should have a ground terminal, and be of the following ratings:

* For a 120V AC model: 130V, at least 15A, length not exceeding 5m. * For a 230V AC model: 250V, at least 8A, length not exceeding 5m.

• 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 procedure appended to this manual.

Using the stand

• Lock the casters after the machine is installed. a Otherwise, the machine could move or fall over, causing injury.

• To move the machine, push it by its mounting base. a Pushing the DC-545 could make it fall over.

Safety instructions

3. Cautions for maintenance, inspection and servicing

Warning

Precautions for safe servicing

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

aOtherwise, you could get a shock or your hands/fingers could be injured.

• However, the plug must be left connected to the outlet when performing function checks (of individual motors, a given series of operations, or electrical circuits). When motors are operated alone in function checks, interlocks are deactivated, so be aware of the conditions and positions of related equipment, and take great care not to put your hands or fingers into moving parts.

• The cutter unit and slitter unit contain hazardous sharp blades. Exercise great care when inspecting the cutter unit or replacing it or its parts.

aOtherwise, your hands/fingers could be injured.

• Do not touch the drum or rollers after turning on the jog switch.

• Do not put your hands or fingers inside the machine while the drum is rotating.

aOtherwise, your hands/fingers could get caught and crushed between the drum and rollers.

Working clothes

• Wear clothing than enables you to work safely.

CAUTION

Tools

• Use tools that are appropriate for the work.

Safety instructions

Warning Sticker

Keep the WARNING stickers clean at all times. If labels become damaged or come off, have your service representative replace them.

Do not touch blade!

WARNING

To remove jammed paper, use the tweezers.

L8-T1100

WARNING

No. Parts No. Name Q’ty

q L8-T1100 Warning Sticker 1 1 w L8-T1080 Warning Sticker 2 3 e L8-T1090 Label Caution 2

Use caution when working near movable parts. Disconnect power before servicing.

Cutters and movable parts are inside this cover. Before opening the cover to work, unplug the power cord. Use caution when working near cutters and movable parts.

L8-T1080

WARNING

L8 T1090

Safety instructions

Introduction

Description of Operation

Mechanical

Standard Adjustments

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Maintenance Checks

Troubleshooting

HELP Mode

Miscallaneous

Chapter 5

Chapter 6

Chapter 7

Chapter 8

Table of Contents

Introduction ....................................................... 1

Safety instructions............................................ 2

1. Cautions regarding the installation

location .......................................................... 2

2. Cautions for installation work ...................... 3

3. Cautions for maintenance, inspection and

servicing ........................................................ 4

Warning Sticker................................................. 5

Chapter 1 Introduction

z Specifications ............................................. 10

x Dimensions ................................................. 11

c Part Names and Functions ........................ 12

v Work Flow .................................................... 15

b Options ........................................................ 16

Chapter 2 Description of Operation

z Paper Feed Unit .......................................... 18

x CCD Mechanism ......................................... 30

c Margin Slitter............................................... 32

v Guillotine Cutter Unit ................................. 34

b Creaser Unit ................................................ 35

n Center Slitter ............................................... 37

m Paper Eject Tray .......................................... 39

, Main Drive ................................................... 40

. Skew Adjustment Mechanism ................... 43

⁄0 BAR CODE .................................................. 44

⁄1 REGISTER MARK ....................................... 45

Chapter 4 Standard Adjustments

z LCD Panel.................................................... 94

x Slitter Position ............................................ 95

c Cutter Registration ..................................... 98

v Creaser Calibration .................................. 100

b CCD Horizontal Line Alignment .............. 102

n Adjusting Crease Depth........................... 104

m Feed Solenoid Adjustment ...................... 105

, Gate Solenoid Adjustment (Without the

DC-545HC)................................................. 106

. Cutter Assembly Perpendicularity

Adjustment................................................ 107

⁄0 Creaser Perpendicularity Adjustment .... 108

⁄1 CCD Vertical Line Alignment ................... 109

⁄2 Elevator Switch Height Adjustment........ 111

⁄3 Cover Switch (AF-100 : 1 position,

DC-545 : 2 positions)................................ 112

⁄4 Shutter Solenoid....................................... 113

⁄5 Creaser Sensor Plate Adjustment........... 118

Chapter 5 Maintenance Checks

z Cleaning and Oiling.................................. 120

x Periodic Maintenance Check List............ 120

Chapter 6 Troubleshooting

z T roubleshooting Guide............................. 124

x Error Display ............................................. 132

Chapter 3 Mechanical

z Exterior ........................................................ 49

x Feed Section ............................................... 52

c CCD Section................................................ 59

v Margin Slitter Section................................. 60

b Cutter Section ............................................. 67

n Creaser Section .......................................... 69

m Center Slitter Section ................................. 71

, Driving Section ........................................... 79

. Electric Section........................................... 85

Chapter 7 Help Mode

z HELP Mode List ........................................ 140

x Functions and operation procedures for

each HELP mode ...................................... 141

c HELP Description ..................................... 142

v Select Language for Displays ................. 150

Chapter 8 Miscallaneous

z Job List...................................................... 152

Position and Function of Electronic Parts ..

c Overall Wiring Diagram ............................ 161

156

Chapter 1 Introduction

z Specifications ............................................ 10

x Dimensions ................................................ 11

c Part Names and Functions ....................... 12

1. Appearance........................................... 12

2. Operation Panel.................................... 14

v Work Flow................................................... 15

1. Operations ............................................ 15

b Options ....................................................... 16

Chap.1

z Specifications

Product name/Model No. DC-545 with HC AUTO FEEDER

Input paper size Min.: 8.5” x 11”/A4

Max.: 12.6” x 18”/A3 Input paper weight Min.: 110 gsm, Max.: 230 gsm <No curl in the paper> Finishing size Min.: 2” (Width) x 3.5” (Length) <Business card size> Lead edge trim Min.: 0.125” (3.2 mm) Trail edge trim Min.: 0.125” (3.2 mm) Side edge trim Min.: 0.125” (3.2 mm), Max.: 4.5” (114 mm) Speed Max.: 9 ppm (A4 lengthwise, 4-side trim, 1 crease) Trim/Crease tolerance ± 0.03” (± 0.762 mm)

<With paper cutting length not exceeding 18”> Media type Range: Regular copy paper to coated heavy weight paper Feeding method Automatic Feeding (Air suction method) Feed tray capacity 100 mm Stacker Drop type Power supply AC 120 V ±10%, 50/60 Hz, 1.0 A

AC 230 V ±10%, 50/60 Hz, 0.6 A Machine dimensions (mm) 1376 (W) x 576 (D) x 948 (H) Machine weight (kg) 109.6 (Main body 56.4, Feeder 20.4, Stand 32.8)

1. Four creases perpendicular to the feed direction.

Other Features 2. Up to ten cuts perpendicular to the feed direction.

3. Automatic setting of slit, cut and crease position.

x Dimensions

Chap.1

x Dimensions

Chap.1

c Part Names and Functions

1. Appearance

Guide Plate

Blower Air ADJ Knob

Feed Tray

Guide Plate

Separator ADJ Knob

Feeder Cover

Cover (front)

Cover (rear)

Exit Tray

Operation Panel

Stand

Door

Caster

Feeding Section

Separator

Chap.1

c Part Names and Functions

Level ADJ Lever

Blower Air ADJ Knob

CCD

Margin Slitter

Flat Belt

Feed Tray

Guide Plate

Separator ADJ Knob

Skew ADJ Knob

Center Slitter

2nd Roller

Cutter

Creaser

Chap.1

c Part Names and Functions

2. Operation Panel

w e rq

START

STOP

COVER JAM PAPER

POWER

+ –

MODE SET

1 4 7

2 5 8

3 6 9

!0!1 o i u ty

No. Name Function

q LCD panel Displays the status of the machine.

Displays messages when an error or paper jam occurs.

w <+> key Press to eject the document from the machine at the time of paper jam.

<-> key Press to eject the document from the machine at the time of paper jam. During

programming mode enables backward movement through the program steps.

e POWER lamp Lights up when the power is switched on. r <START> key Not used when the DC-545 is operated without the autofeeder - AF-100. Press

to start processing when the AF-100 is attached.

START lamp Normally lights up in green. Lights up in red when the front cover or the rear

cover is open.

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

Press to clear jam indication after the paper is cleared.

y Key pad Press to enter print numbers and enter values during manual programming. u <CLEAR> key Press to clear the count. Press to cancel manual programming. i <SET> key Press to confirm selection/entry. Used to test process a single sheet. (for

systems with the AF-100 only)

o <MODE> key Press to change the mode. !0 <F> key The AF-100 Feed Tray lowers while the <F> + <-> keys are being pressed. !1 COVER lamp Blinks when the front cover or the rear cover is open.

JAM lamp Blinks when a paper jam has occurred. PAPER lamp Blinks when paper runs out. (systems with the AF-100 only)

v Work Flow

1. Operations

V arious Settings

Chap.1

v Work Flow

INPUT

BAR CODE

AUTO CUT

Setting the paper

Select the Program

Except when bar code is on.

.....................................How to create job programs

........................ When to use bar codes

............When to use register marks

...........................When to use AUTO CUT

<Start> Key

Finish

Chap.1

v Work Flow b Options

MODE switching is shown next.

[RUN] P–04

<MODE> KEY

[SELECT] P–04

<MODE> KEY

[INPUT]

––

INPUT

>SET

<MODE> KEY

BARCODE *ON OFF

<SET> KEY

AUTO CUT *ON OFF

<SET> KEY

<MODE> KEY

b Options

Setting the Optional Slitter 2

Chapter 2 Description of Operation

z Paper Feed Unit ......................................... 18

1. Description............................................ 18

2. Operation .............................................. 18

3. Operation of each unit ......................... 19

(1) Fan (Blower) ............................................ 19

(2) Fan (Suction)............................................ 20

(3) Paper Level Sensor .................................. 21

(4) Suction Unit and Feed Motor................... 22

(5) Separator Gap .......................................... 23

(6) Elevator Motor .........................................24

(7) Elevator Upper Switch............................. 25

(8) Elevator Lower Switch ............................ 26

(9) Paper Detection Sensor ............................27

(10) Feed Solenoid ........................................ 28

(11) Feed Stepping Motor.............................. 29

x CCD Mechanism ........................................ 30

1. Description............................................ 30

2. Operation .............................................. 30

c Margin Slitter.............................................. 32

1. Description............................................ 32

2. Operation .............................................. 33

v Guillotine Cutter Unit................................. 34

1. Description............................................ 34

2. Operation .............................................. 34

b Creaser Unit ............................................... 35

1. Description............................................ 35

2. Operation .............................................. 35

n Center Slitter .............................................. 37

1. Description............................................ 37

2. Operation .............................................. 37

m Paper Eject Tray......................................... 39

1. Description............................................ 39

, Main Drive................................................... 40

1. Description............................................ 40

2. Operation .............................................. 41

. Skew Adjustment Mechanism .................. 43

1. Description............................................ 43

⁄0 BAR CODE.................................................. 44

1. Description............................................ 44

⁄1 REGISTER MARK....................................... 45

z Paper Feed Unit

1. Description

The paper loaded on the feed tray is raised by the elevator motor. When the paper is in the required position, a jet of air from a fan in front of the paper causes several sheets of paper to rise up. The suction unit pulls up the top sheet only, and then the feed motor drives the suction belt to transfer the paper. When the paper from the AF-100 reaches the PPS1 in the DC-545, the paper is transferred to the paper path by the press roller and the feed stepping motor. A separator mechanism is used to prevent two or more sheets from being transferred at one time.

Suction Assembly

Feed Tray

Feed Motor

Fan (Suction)

Elevator Motor

Fan (Blower)

Elevator Upper SW

Elevator Lower SW

Level Sensor

2. Operation

1) Processing starts (processing does not start if there is no paper). The fan (blower) and the fan (suction) start running.

2) The feed tray starts rising.

3) The feed tray stops when the paper level sensor turns on (light is not transmitted).

4) The shutter solenoid operates and the shutter opens and the paper is sucked onto the suction unit.

5) The feed motor starts and the suction belt begins turning to transfer the paper.

6) The feed motor stops when the paper reaches PPS1 (light is not transmitted). If paper does not reach PPS1 within about 2.5 seconds, the elevator falls repeating operations 3) to 5) until the paper level sensor turns off (light is transmitted). If the operation is repeated three times before the paper reaches PPS1, a J2: FEED JAM error occurs and the machine stops.

\See page 132

Chap.2

z Paper Feed Unit

3. Operation of each unit

(1) Fan (blower)

Description

Paper on the feed tray is transferred to the blower and several sheets are floated up. The airflow of the blower is adjusted by changing the position of the shutter and fan unit. The level the paper is floated up is adjusted by changing the airflow of the blower and the paper level sensor. The fan (blower) is usually running during processing.

Operation

The blower airflow can be increased by turning the knob so the numbers increase. The gap between the shutter and the fan increases, which increases the air intake and therefore increases the amount of air blown out. The blower airflow can be decreased by turning the knob so the numbers decrease. The gap between the shutter and the fan decreases, which decreases the air intake and therefore decreases the amount of air blown out.

Circuit diagram

Shutter

Fan (Blower)

Knob

Chap.2

z Paper Feed Unit

RED

BLACK

CN2-3

24V

FAN(Exhaust)

GND

24V

CN1-1CN1-1

-3

-12

CN11-10

-19

-3

-12

-17

-18

-4

FAN(Blower)

N4-X105*

Feed P.W.B. unit

N4-V303*

Main P.W.B. unit

N4-V300*

(2) Fan (Suction)

Description

Air near the suction belt is sucked in, and then blown out on the right side of the AF-100. The fan (suction) is usually running during processing.

Circuit diagram

Fan(Suction)

Chap.2

z Paper Feed Unit

RED

BLACK

CN3-1

24V

FAN(Intake)

GND

24V

CN1-1CN1-1

-2

-12

CN11-10

-19

-2

-12

-17

-18

-3

FAN(Suction)

N4-X105*

Feed P.W.B. unit

N4-V303*

Main P.W.B. unit

N4-V300*

(3) Paper Level Sensor

Description

The paper level sensor controls the elevator motor to determine the position of the feed tray by detecting the position of the topmost sheet of paper on the feed tray.

Status Output

Light not transmitted 5V Light transmitted 0V

To reduce the force of the suction, move the adjustment lever towards q to increase the gap between the suction belt and the paper. To increase the force of the suction, move the adjustment lever towards w to decrease the gap between the suction belt and the paper.

Turn the lever towards q if the paper is double feed. Turn the lever towards w if the paper is not being sucked on to the suction unit.

Circuit diagram

Chap.2

z Paper Feed Unit

Level Sensor

Level Sensor Adjustment Lever

RED

BLUE

YELLOW

CN4-11

-12

GND

Level Sensor

GND

CN1-11CN1-11

-12

-14

CN11-10

-12

-14

-17

-13

Level Sensor

CA021

Feed P.W.B. unit

N4-V303*

Main P.W.B. unit

N4-V300*

Chap.2

z Paper Feed Unit

(4) Suction Unit and Feed Motor

Description

Because the fan (suction) is running during processing, when the shutter solenoid is on, the topmost sheet of paper on the feed tray is sucked on to the suction unit. The feed motor starts running about 0.3 seconds after the shutter solenoid turns on, and the suction belt turns and transfers the paper to the DC-545.

Circuit diagram

Shutter (inner)

Shutter Solenoid

RIGHT BLUE

RED

CN2-7

24V

solenoid

Feed

GND

CN1-1CN1-1

-6

-7

CN11-10

-19

-6

-7

-12

-17

24V

-18

-8

Shutter Solenoid

FEED MOTOR

N4-X101*

Feed P.W.B. unit

N4-V303*

Main P.W.B. unit

N4-V300*

SOL

BROWN

BLACK

CN2-9

-10

N4-X104*

Chap.2

z Paper Feed Unit

(5) Separator Gap

Description

The separator gap is a mechanism between the separator and the suction belt that allows paper that is sucked on to the suction unit to be transferred one sheet at a time to the paper path. This gap is regulated by turning the knob to raise and lower the separator.

Turn the knob so that the numbers increase to make the gap narrower. The separator rises and the gap narrows. Turn the knob so that the numbers decrease to make the gap wider. The separator falls and the gap widens.

Raise the separator if the paper being transferred is double feed. Lower the separator if paper is mis-feeding.

Separator

Separator Adjustment Knob

Chap.2

z Paper Feed Unit

(6) Elevator Motor

Description

The elevator motor raises and lowers the feed tray. When there is no paper on the feed tray, the feed tray lowers until it triggers the elevator lower SW. However, if paper is loaded on the feed tray while it is lowering (paper sensor is not transmitting light), the elevator motor stops and the feed tray stops lowering. The feed tray rises until the paper level sensor is on (light is not transmitted) while paper is being fed. During a paper feed retry operation, the feed tray continues to lower until the paper level sensor goes off (light is transmitted) for a period. Then the feed tray rises until the paper level sensor goes on (light is not transmitted). If paper does not reach the elevator upper switch, elevator lower switch, or paper level sensor after a set time (*) after the elevator operation, an E8: ELEVATOR ERROR occurs. * 10 seconds when rising at start, 3.5 seconds during

paper feed operations, 9 seconds when lowering at stop

\See page 138

Circuit diagram

Elevator Motor

BROWN

BLACK

CN2-5

24V

ELEVATOR1

ELEVATOR2

GND

24V

CN1-1CN1-1

-4

-5

CN11-10

-19

-4

-5

-17

-18

-6

Elevator Motor

N4-X106*

Feed P.W.B. unit

N4-V303*

Main P.W.B. unit

N4-V300*

Chap.2

z Paper Feed Unit

(7) Elevator Upper Switch

Description

The feed tray stops when the angle that is attached to the chain that raises and lowers the feed tray turns the micro switch on. The feed tray is determined to be at its upper limit when the micro switch is on, and the feed tray will not rise any higher.

Circuit diagram

Elevator Upper SW

PURPLE

CN4-3

-4

Elevator Upper SW

GND

CN1-9CN1-9

-11

-12

CN11-10

-11

-12

-17

ELEVATOR UPPER SW

LA028

Feed P.W.B. unit

N4-V303*

Main P.W.B. unit

N4-V300*

5V5VON:0V

OFF:5V

Chap.2

z Paper Feed Unit

(8) Elevator Lower Switch

Description

The feed tray stops when the screw that is attached to the chain that raises and lowers the feed tray turns the micro switch on. The feed tray is determined to be at its lower limit when the micro switch is on, and the feed tray will not go any lower. If the elevator lower switch is on because there is too much paper loaded on the feed tray, and the paper level sensor is on (light is not transmitted), then a J5: OVER CAPACITY error occurs.

\See page 133

Circuit diagram

Elevator Lower SW

ORANGE

CN4-1

-2

Elevator Lower SW

GND

CN1-10CN1-10

-11

-12

CN11-10

-11

-12

-17

ELEVATOR LOWER SW

LA028

Feed P.W.B. unit

N4-V303*

Main P.W.B. unit

N4-V300*

5V5VON:0V

OFF:5V

Feed PPS Photo Diode

Feed PPS Photo Transistor

Chap.2

z Paper Feed Unit

(9) Paper Detection Sensor

Description

The paper detection sensor detects whether or not there is paper on the feed tray. If there is no paper, the elevator goes to its lower level and stops. When there is not paper (light is transmitted) the LED (PAPER) on the operation panel blinks.

Status Output

Paper is present

(light is not transmitted) Paper is not present

(light is transmitted)

Circuit diagram

BROWN BLUE

CN4-7

-8

GND

Feed PPS

GND

CN1-11CN1-11

-12

-13

CN11-10

-12

-13

-17

Feed PPS Photo Diode

Feed PPS Photo Transistor

N4-W109*

Feed P.W.B. unit

N4-V303*

Main P.W.B. unit

N4-V300*

Paper is present :5V

Paper is not present :0V

WHITE BLUE

CN4-9

-10

N4-W206*

+ 145 hidden pages

MyBinding DC-545HC Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual