Officezone HD 7700 Operation Manual

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HD 7700 Setup & Operator Manual

Issue 1 December, 01

Performance Design Inc.

The Heavy Duty Ultima (HD 7700) electric punch has been designed to punch
most any job that may pass through your bindery or office. No matter what type
of binding you need to carry out, the HD 7700 can punch the job. It will punch
from 25 to 55 sheets on the 11” edge of 20lb bond (80gsm) copy paper with our
extra capacity dies or 25-40 sheets with standard dies (The number of sheets
depends upon die pattern used). The maximum punching length is a 14” (356
mm) format. Any sheet smaller can be punched for the minimum size. The HD
7700 utilizes quick-change die handles for quick die installations and removal.
Extra capacity dies come with the HD 7700 when purchased.

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Table of Contents

HD 7700 PUNCH

Topic: Page Number:

1) Important safety notice 4

2) Placing your machine in the proper location 4

3) Providing power to the machine 4

4) Die installation 5

♦ HD 7700 5
♦ Extra Capacity Die 5
♦ Comb Die 5
♦ Removing punch pins 6
♦ Die maintenance 7

5) Setting the “Accu-Set” paper stop 7

6) Punching Paper 8

♦ Palm Switch 8

7) Removing paper waste 9

8) Paper Jam 10

Optional Combo Binding Station & Modules

9) Combo Binding Station OD 3500 15

10) Attaching OD 4300 coil Inserter 17

Setup Instructions
a) Determine the correct coil size 18
b) Determine the correct size mandrel 18
c) Installing the mandrel on the machine 18
d) Adjusting the mandrel bracket 19
e) Adjusting the paper stop 19
f) Adjusting the front table / lexan guide 19
g) Forward / off / reverse switch 20
h) Inserting a coil 21
i) Drive wheel stop screw 21
j) Cutting a coil 22

11) Attaching OD 4200 Wire Closer 25

Setup Instructions
a) Determine the correct wire size 26
b) Inserting the wire into the book 26
c) Setting the closing bar height 27
d) Closing the book 27

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Topic: Page Number:

12) Attaching OD 4400 Comb Opener 29

Setup Instructions
a) Determine the correct comb size 30
b) Placing the comb onto the rake 30
c) Setting the comb opener stop 30
d) Placing the book onto the comb 31
e) Margin settings 31

Setup Illustrations

Diagram 1 Punch (Setup) 4
Diagram 2 Punch (Die Installation) 5
Diagram 3 Punch (Pin Removal) 6
Diagram 4 Punch (Paper Guide) 7
Diagram 5 Punch (Punching Paper) 8
Diagram 6 Punch (Chip Drawer) 9
Diagram 7 Punch (Paper Jam) 10
Diagram 8 Combo binding station 15
Diagram 9 Coil inserter 17
Diagram 10a Coil inserter 19
Diagram 10b Coil inserter 20
Diagram 10c Coil inserter 20
Diagram 10d Coil inserter 21
Diagram 10e Coil inserter 22
Diagram 10f Coil inserter 23
Diagram 11 Wire closer 25
Diagram 12a Wire closer 26
Diagram 12b Wire closer 27
Diagram 12c Wire closer 28
Diagram 12d Wire closer 28
Diagram 13 Comb Opener 29
Diagram 14 Comb Opener 31
Troubleshooting HD 7700 13
Troubleshooting Coil Inserter Module 23
Electrical schematic HD 7700 14
Electrical schematic Coil Inserter Module 24
Die list 11 & 12

HD 7700 Issue 1 Page 3

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1) Important Safety Notice!

Make sure you read this section very carefully! Learn to recognize
this Safety Alert Symbol. The HD 7700 has been designed to
provide a very high level of protection to an operator. Follow the
guidelines below while installing, operating and maintaining your
machine.

♦ Plug the machine into an outlet that provides a 15-amp service (16 amp for

European installations) that is protected at the customer’s circuit box.

♦ Always replace fuses or circuit breakers with the correct amperage and type.
♦ If machine cycles on its own, call dealer immediately for service.
♦ Never bypass top cover switch or reverse knob switch. Doing so may result

in personal injury!

♦ Turn power switch off before removing a die or performing maintenance.

2) Placing your machine in the proper location:

Before lifting machine, turn power off. Remove plug from electrical
supply for personal safety. The machine is very heavy! Never
attempt to lift machine by yourself. It needs two people to lift
machine. It should be lifted at each side of the back end and

each side of the front end.

Place the machine on a hard level surface placing the foot pedal on the floor in
front of the machine. Set aside some room for the books that have to be punched
and also some room for the books that had already been punched.

3) Providing power to the machine: Diagram 1

Power cord shall be certified for the country where the

machine will be installed.

Plug one end of the power cord into the back of the machine. The
other end goes into the wall outlet. Install the foot pedal plug into the

receptacle, which is located on the back of the machine. The
optional palm switch can be plugged into the same receptacle if this option is to
be used. Turn machine “On” with rocker switch located at rear of punch. The
green power indicator on front panel will be illuminated when punch is ready.

Diagram 1

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4) Die installation:

♦ HD 7700 Diagram 2

Make sure the machine is turned off before installing die. Install the die (1)
by sliding it into the opening of the machine located on the right-hand side of the
machine. Make sure the punch pin retainer assembly (2) slides into the slot of
the pusher bar. Push up on both quick-change die handles (3) and lock the die
in position. Make sure there is no paper dust in the machine die slot before
installing the die. Machine will not operate unless quick-change die handles

are in the locked position. Red die clamp indicator will go off, when
handles are in the up, locked position.

♦ Extra Capacity Die
Extra capacity dies are exactly the same as standard dies with one exception.
The opening in the die will accept more paper. These dies are used for high
production jobs and can punch from 25 to 55 sheets on the 11” edge of 20 lb.
(80gsm) bond copy paper (The number of sheets depends upon die pattern

used). Extra capacity dies come with the HD 7700 when purchased.

♦ Comb Die
Comb dies are slightly different from the rest of the dies because they have an
adjustable backstop. To change the position of the hole placement (margin) to
the back edge of the sheet, first install the die into the HD 7700 and secure the
die in place. There are four placement positions. Choose the position best suited
for your job. Pull or push on the black handle, which is part of the die. Push the

handle toward the left for the larger combs and pull it out to the right for
smaller combs. The exact position will be left up to the operator’s preference.

2

1

Diagram 2

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3

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♦ Removing Punch Pins:

Make sure the machine is turned off before
removing the die. To remove a punch pin Diagram 3

from the die, disengage both quick change
die handles and slide the die to the right until
the die is completely removed from punch.

Step 1. Remove top pin retainer by pushing
down first, and then pulling away from bottom
pin retainer to expose punch pins.

Step 2. Remove desired punch pin.

Step 3. Place edge of top pin retainer along
punch pins and press down while pulling pin
retainer back to original position.

Step 4. Install die into machine as described in
previous section.

HD 7700 Issue 1 Page 6

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♦ Die maintenance:
The die will have to be removed before maintenance can be performed. Using
the oil provided with the machine, squeeze the plastic bottle over the oil slot that
runs the entire length of the die. Too much oil can run onto the paper being
punched. After oiling, always punch scrap paper to remove excess oil!

5) Setting the Accu-Set paper stop: Diagram 4

The Accu-Set paper stop should be adjusted so the pointer of the stop lines up
with the format and type of die being used. There are two ways to set this stop.
The first is a course adjustment to bring the pointer close to the desired setting
and the second is a fine micro setting adjustment for exact registration. To set
the course adjustment, lift up on the pointer assembly and place the pointer of
the assembly close to the format and type hole pattern to be punched. After the
pointer is close to the desired setting, turn the fine adjustment knob located on
the left side of machine to bring the pointer to the exact setting. Some fine
adjustment may be necessary after the first sheet is punched.

Diagram 4

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6) Punching Paper: Diagram 5

Position the paper that has to be punched either to the left, right or on top of the
machine. This is up to the individual operator. Remove some sheets (When
punching acetate and heavier stock, punch less sheets) from the pile and
slide it down vertically into the opening of the die. When the paper is fully down,
slide it to the left so it comes in contact with the paper stop. Make sure all the
edges of the sheets are flush by tapping the top and the right hand side of the
sheets before pressing the foot pedal or pressing the palm switch. After punching
the sheets, place the paper on the punched pile making sure the sheets remain
in exact order.

Diagram 5

Use the side of your right hand to activate
punch when palm switch is installed.

Diagram 5a

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7) Removing paper waste: Diagram 6

The paper waste is removed by pulling the paper waste drawer up and toward
you. The drawer is located conveniently in the front of the punch. This drawer
should be checked frequently. Look through the clear cover while punching and
empty prior to filling up and spilling into machine.

Diagram 6

When installing chip drawer back into machine,
line up the locating pin on drawer with slot on
machine.

Diagram 6a

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8) Paper Jam: Diagram 7

The HD 7700 uses a circuit board for controlling its cycle and has the ability to
automatically reverse the punch pins to their starting position if too much acetate
or paper was inserted. There are times when punching too much acetate, the
punch pins may not reverse all the way out. Use the procedure described below
for manually reversing the machine.

When a paper jam occurs, the circuit breaker or fuse protecting the
motor may have to be reset or replaced. This is normal and allows
maximum protection for the punch motor.

♦ Locate the reverse knob on the left side of machine.

♦ If the punch stalled before pins were completely through the paper, turn

the reverse knob counterclockwise to reverse punch pins out of paper.

♦ If the punch stalled with the pins all the way through the paper and on its

return stroke, turn the reverse knob clockwise to continue the punch pins
to there starting position.

♦ Press the foot pedal or palm switch to see if the machine operates. If yes,

continue punching the job. If the machine does not function, see replacing
the fuses or resetting circuit breaker in the troubleshooting section of this
manual.

Diagram 7

HD 7700 Issue 1 Page 10