Duplo DB-250 Service Manual Download

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Duplo DB-250

Perfect Binder

Service Manual

Summary of Contents for DB-250

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com Duplo DB 250 Perfect Binder Service Manual...

Page 2: ...PERFECT BINDER DB 250 SERVICE MANUAL SERVICE MANUAL Duplo USA Corp May 2000 Rev 2 6...

Page 3: ...ING THE GLUE TANK 7 6 5 MANUAL MODE 8 6 6 AUTO MODE 10 6 7 PADDING MODE 12 6 8 STANDBY MODE 13 Machinery Mechanism Function and Adjustment 14 1 Notching station 14 1 1 Mechanism 14 1 2 Function 14 1 3...

Page 4: ...ion 43 8 Assemble Parts List 44 Maintenance 1 Daily Cleaning Procedures 45 2 General Maintenance Procedures 45 3 Maintenance Parts List 46 Appendix A Troubleshooting Guide for Spine Adjustment 49 A1 C...

Page 5: ...to wait for the glue tank to cool down before you can restart the machine If this problem occurs again call your authorized dealer for service 2 Installing the machine 2 1 Notes on Installation Power...

Page 6: ...ue tank as shown 4 Place your DB 250 on a safe firm and solid table Then mount the cover sheet holder to the right side of the machine as shown Optional The following steps are only for your selected...

Page 7: ...1 EMERGENCY Stop all the actions of the machine Except when HOT shows on the LED display STOP flashing 2 STAND BY LED Temporarily lowers the temperature of glue tank so it won t burn the glue when the...

Page 8: ...the notching function during the bookbinding operation 5 Specification Model DB 250 Perfect Binder Maximum Book Size 12 6 x 15 75 320mm x 400mm Minimum Book Size 3 15 x 1 97 80mm x 50mm Maximum Bindin...

Page 9: ...s one minute for this example as shown 3 Melting glue is processing The status is WARM and the elapsed time is 10 minutes for this example as shown 4 After heating for a while the glue temperature has...

Page 10: ...urn the glue adjustment lock knob counter clockwise to loosen 2 Increase the amount of glue by sliding the knob to the right at the appropriate position MIN MAX Decrease the amount of glue by sliding...

Page 11: ...ion drum is rotating This will prevent glue from spilling out of the tank Glue Replacement 1 Warm up the DB 250 as described in the STARTUP section on page 5 2 Make sure the draining tray is warped by...

Page 12: ...p 1 Load book to the RIGHT of the red line Step 2 Slide the book to The far LEFT 2 Then press the CLOSE button to clamp down the book block and you will see the flashing PUSH START display Note In cas...

Page 13: ...process for the book block and cover sheet Note If you accidentally remove or drop the cover sheet during the clamping station returning to the nipping station the control panel will show COVER At th...

Page 14: ...the RIGHT of the red line then slide the book block to the far LEFT of the clamps and you will see the flashing PUSH CLOSE display 2 Then press the CLOSE button to clamp down the book block and you wi...

Page 15: ...u have to place the cover on the nipping station and press START button to recover the process Having completed one bound book the clamp will automatically open and display UNLOAD so that you can remo...

Page 16: ...amps and you will see the flashing PUSH CLOSE display Step 1 Load book to the RIGHT of the red line Step 2 Slide the book to The far LEFT 2 Then press the CLOSE button to clamp down the pad block and...

Page 17: ...accordance with Sec 6 2 Glue Adjustment 5 Repeat step 2 to 4 for more books in PAD operation 6 8 STANDBY MODE Press STANDBY button the DB 250 will temporarily lower the temperature of glue tank so it...

Page 18: ...mechanism of notching station is shown below 1 2 Function The purpose of notching is to enhance the solidification of the bookbinding The notching blade makes numerous cuts on the spine of the book so...

Page 19: ...tandard depths of the cuts are 1 mm evenly on the spine of the book You also can lift up the notching station to gain the depth of the cuts when the blade has been worn out a little bit Or you have to...

Page 20: ...e thickness of melted glue that is applied to the spine Glue Meter Glue Drum Glue adjusting Knob Glue Scraper 2 3 Adjustment Adjusting the gap for the glue meter 1 Set the glue adjusting knob to the l...

Page 21: ...Measure the distance between glue scraper and the glue drum as shown Note that the standard gap between glue scraper and the glue drum is 2 mm 3 Tighten the screws Setting the glue adjusting knob to...

Page 22: ...o form the cover around the spine of the book 3 3 Adjustment 1 During the nipping process the nipping plates must exert an even pressure on the cover in order to form a good spine 2 The nipping swing...

Page 23: ...of position disc travels through the trench of the sensor as shown below Clamping Position Bearing 1 Highest Point Range 2 Lowest Point Cover Position Position Disc 3 Sub high Point Range Binding Pos...

Page 24: ...te adjustment screws Position Adjustments on Nipping Station A The level of nipping station should be adjusted evenly on the corresponding ends to prevent tilting the nipping station surface by level...

Page 25: ...ptable spine of a book and the shape of book block after being clamped are shown below If you find different shapes such as round hollow and nail head for one end or both ends remove the clamp covers...

Page 26: ...nner pages as shown below Please refer to the spine adjustment in Appendix A for details Nipping Plate Surface Adjusting for nail head If you see the spine of the book has a nail head most of the case...

Page 27: ...tion is shown below 5 2 Function Provides driving power to move and locate the clamp station over the glue drum and notching station then return it back to the nipping station for covering and binding...

Page 28: ...CPU SSR TG200A1 TG200C2 4 CLAMP STATION 12 THERMOSTAT LEFT SENSOR LS2 5 NIPPING STATION 13 FUSE BOARD SENSOR LS3 LS4 TG200D2 6 CLAMP INNER PAGE 14 MAIN MOTOR M1 SENSOR SN1 7 NIPPING COVER 15 NIPPING M...

Page 29: ...s the highest point of the nipping station surface 6 Clamp InnerPage Sensor SN1 Detects when pages are placed in the clamp station 7 Nipping Cover Sensor SN2 Detects when cover page is placed on the n...

Page 30: ...trols the highest and lowest points of the nipping station surface 16 Notching Motor M4 Drives the notching blade to make the cuts on the spine of the book 17 Clamp Motor M6 Drives the clamps to hold...

Page 31: ...LED display After performing the WARM HOT and S TEST processes the DB 250 will display MOTOR 1 in the LED display Then you can select the following module tests by pressing OPEN or CLOSE button to to...

Page 32: ...28 4 Circuit Diagrams 4 1 Main Schematic Diagrams CPU TG200A1...

Page 33: ...29 CONTROL PANEL TG200B1...

Page 34: ...30 SSR TG200C2...

Page 35: ...31 FUSE BOARD TG200D2...

Page 36: ...ounter Clockwise CW Clockwise EMG Emergency Switch LS1 Limit Sensor 1 LS2 Limit Sensor 2 LS3 Limit Sensor 3 LS4 Limit Sensor 4 M1 Main Motor M2 Nipping Motor M4 Notching Motor M6 Clamp Motor PSR Press...

Page 37: ...33 4 3 Pin Assignments Power LED Display S Power Capacitors Heater Emergency CPU Motors Relay Fuse...

Page 38: ...ION QTY AREA 1 E4005 Compartment Pillar 1 2 E6001 Main Frame 1 3 E6019 Front Guide 1 4 E6020 Rear Guide 1 5 E6004 PCB Box Bracket 1 6 E6005 Control Panel Bracket 1 7 E6021 Front Cover 1 8 E6007 Rear C...

Page 39: ...E6405 Shipping Bracket 1 1 19 E6406 Shipping Bracket 2 1 20 E6408 Shipping Bracket 3 1 21 E8302 Glue Tank Tag 1 22 E8401 Machine Leg 4 23 E8406 Fuse PCB Cover 1 24 E6024 Notching Bottom Cover 1 25 E8...

Page 40: ...Cover 1 8 E6304B Notching Cover 1 9 E6303 Notching Position Connector 2 G3001 10 E6402 Notching Station Bracket 2 11 E7103 Notching Motor M4 1 12 E7401W Notching Motor Power Connector female 1 13 E820...

Page 41: ...E7307 Glue Tank Half Temperature Sensor 1 12 E8104 Bearing for Glue Tank Shaft 4 13 E8204 Glue Meter Spring 1 14 E8305 Glue Level Indicator 1 15 E8404 Glue Adjustment Knob 1 16 U2006 Glue Meter 1 17 U...

Page 42: ...38 4 Nipping Station Section...

Page 43: ...nter Mark 1 20 E6103 Cover Ruler Seat 1 21 E6104 Nipping Sensor Seat 1 22 E6105 Nipping Table Front Cover 1 23 E6106 Nipping Spring Bracket 1 2 24 E6107 Nipping Spring Bracket 2 2 25 E6108 Nipping Tab...

Page 44: ...40 5 Clamp Station Section...

Page 45: ...Seat 1 19 E7104 Clamp Motor M6 1 20 E7104 G Clamp Motor Gear Box 1 21 E7206 Clamp Photo Switch 1 22 E7401 M Clamp Motor Power Connector male 2 23 E8101 Clamp Worm Bearing 6000ZZ 6 G5001 G5003 G5004 24...

Page 46: ...2 W Main Motor Power Connector female 1 G4002 9 E8101 Chain Shaft Bearing 10 G4003 10 E8105 Glue Drum Bearing 1 G4004 11 E8106 Driving Shaft Slide Bearing 2 G4001 12 E9001 Sprocket Gear 1 1 13 U4007 S...

Page 47: ...5 E6016 PCB CPU Cover 1 6 E6404 Photo Switch Bracket 2 7 E7201 TG 200 CPU 1 8 E7203 TG 200 SSR 1 9 E7202 TG 200 Panel 1 10 E7204 TG 200D2 Fuse PCB 1 11 E7205 Photo Switch LS1 1 12 E7205 Photo Switch L...

Page 48: ...ble E1024 E8108 6 G1003 Nipping Hinge Shaft Assemble E1011 E8103 6 G1004 Cover Ruler Assemble E6110 E8402 6 G1005 Nipping Motor Assemble E7102 E7401 W 6 G2001 Glue Wheel Assemble U2010 U2011 4 G2002 G...

Page 49: ...to the maximum position then turn off the power of the machine 2 Take apart the clamps from the clamp station 3 Clean the residual glue that might be on the clamps 4 Install the clamps to the clamp st...

Page 50: ...RTS NO DESCRIPTION SECTION QTY E1004 Lifting Cam for Nipping Station 4 Nipping Station 1 E1008 Bearing Shaft for Lifting Bracket 4 Nipping Station 1 E1011 Hinge Seat for Nipping Station 4 Nipping Stat...

Page 51: ...on Cable 16 pin 7 Electricity 1 E7401 M Clamp Motor Power Connector male 5 Clamp Station 2 E7401 M Nip Notch Motor Power Connector male 7 Electricity 2 E7401W Notching Motor Power Connector female 2 N...

Page 52: ...lue Tank 1 U3007A Connecting Collar 2 Notching Station 8 U3009B Notching Base Adjustment Screw 2 Notching Station 3 U4007 Sprocket Shaft 2 6 Driving 3 U4026 Nipping Position Ring 4 Nipping Station 2 U...

Page 53: ...mm 18 mm and 1 1 2 40 mm in thickness of book block and do the adjustment accordingly Clamp Spine Adjustment Use the CLOSE button to hold one amount of inner pages on the clamps Then check if there i...

Page 54: ...ckwise to increase the nipping pressure then make some books to see if the spine has been improved on both sides 3 If 1 or 2 can not improve the book spine you have to do the adjustment for the clamps...

Page 55: ...se the nipping pressure then make some books to see if the spine has been improved on both sides 3 If 1 or 2 can not improve the book spine you have to do the adjustment for the clamps Slightly loosen...

Page 56: ...osen the left side bottom lock nuts then gradually tighten the left bottom screws of the clamps until there is no gap between the spine and the nipping plate surface when you close the clamps Make som...

Page 57: ...u close the clamps Make some books to see if the spine has been improved on right side E Left end nail head LL RL RR LR You have to do the adjustment for the clamps Slightly loosen the left side upper...

Page 58: ...lamps Slightly loosen the right side upper lock nuts then gradually tighten the right upper screws of the clamps until there is no gap between the spine and the nipping plate surface when you close th...

Page 59: ...surface when you close the clamps Make some books to see if the spine has been improved on both sides H Right end nail head and left end round LL RL RR LR You have to reset the clamps Loosen all the l...

Page 60: ...pping plate screws to do the fine adjustment until both sides have the same tension that can be pushing smoothly Then use the MOTOR 2 of TEST2 to hold the inner pages to check if both nipping plates c...

Page 61: ...lown to reach the lowest 2 LS3 sensor bad position 3 MT2 motor problem ERR L4 Nipping station is unable 1 MT2 fuse blown to reach the highest 2 LS4 sensor bad position 3 MT2 motor problem ERR T1 After...

Page 62: ...No M1 fuse has is functioning OK been damaged Change M1 fuse Yes Check the M1 connector capacitor and related circuits Check if clamp station Yes Check if LS2 No LS2 has been ERR L2 has returned to th...

Page 63: ...s functioning OK been damaged Change M2 fuse Yes Check the M2 connector capacitor and related circuits Check if nipping Yes Check if LS4 No LS4 has been ERR L4 has returned to the is functioning damag...

Page 64: ...Check if the heater No Heater fuse has TEMP fuse is functioning OK been damaged ERROR Change heater fuse Yes Check if the heater No Heater has been is functioning OK damaged Change heater Yes Check if...

Page 65: ...wed by START button to recover the factory settings WARNING We only recommend you to change TR1 Below are the default times for each TRx and it s description Name Default Time Range Description TR1 4...

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Duplo DB-250, Service Manual

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