Duplo DC-545 HCEX Instruction Manual Download Page 31

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Troubleshooting - DC545 HCEX

This chapter describes what to do when an error has occurred and how to deal with paper jams and error

messages.

Chapter

Power Does Not Turn ON

If the power does not turn ON, check the following.

IS POWER PLUG INSERTED?

THE MACHINE DOESN'T TURN ON.

IS POWER SWITCH ON?

Insert the power
plug securely.

Turn the power switch ON.

Please contact your service person.

YES

Troubleshooting Flow Chart

Docu Cutter(HCEX) 4_30-52

03.12.8, 3:09 PM

Summary of Contents for DC-545 HCEX

Page 1: ...whenever needed Instruction Manual Docu Cutter DC 545 HC DC 545 HCEX Version 1 0 November 2003 Correct operation and periodic maintenance are essential for ensuring safe use of this machine Thoroughl...

Page 2: ...achine After using this manual be sure to keep it in a place to handy reference PLEASE NOTE In the interest of upgrading our products specifications and other data given in this manual are subject to...

Page 3: ...the desired format with no operator intervention Initially the DC 545 HCEX is manually programmed with the required positions of the slits cuts and creases and the values are stored in a memory for fu...

Page 4: ...es and Their Functions 21 Appearance 21 Control Panel 23 LCD Panel 24 Turning Power ON OFF 25 Turning ON the Power 25 Turning OFF the Power 25 Chapter 3 Operating Instructions DC 545 HCEX Automatic Cu...

Page 5: ...d Jobs 60 Factory Preset Jobs 61 How to Manually Program a Job 64 Appendix DC 545 HC DC 545 HCEX Specifications 70 DC 545 with HC AUTO FEEDER Specifications 70 DC 545 with HCEX AUTO FEEDER Specificati...

Page 6: ...In the example shown here the prohibited act is disassembly A black disc indicates an instruction or sometimes a prohibited action The instruction itself is indicated by pictorial symbols drawn in whi...

Page 7: ...Doing so may result in fire or electric shock Do not insert or drop metal flammable material or other matter through the ventilation holes into the machine interior Doing so may result in fire or elec...

Page 8: ...ic shock Remove the power plug itself not the cord Tugging the cord may damage it expose conductors or cause disconnections etc resulting in fire or electric shock Do not place the machine in an unsta...

Page 9: ...them No Parts No Name Q ty q L8 T1100 Warning Sticker 1 1 w L8 T1080 Warning Sticker 2 3 WARNING Cutters and movable parts are inside this cover Before opening the cover to work unplug the power cord...

Page 10: ...void installing the machine in the direct sunlight or heat such as near a stove The machine may indicate errors due to overheating caused by sunlight Also avoid hot cold or humid areas since paper may...

Page 11: ...d breakdowns Before cleaning turn the power switch OFF and then remove the power plug from the outlet WARNING Before cleaning remove the power plug from the outlet Failure to do so may result in an el...

Page 12: ...um performance or may break down Tip Introduces information that is useful for operation and maintenance of the machine or information about the machine s performance etc Continue Page Indicates that...

Page 13: ...t of space between sheets of paper 6 e Airflow adjustment knob For adjusting the amount of airflow 7 r Skew adjustment knob For adjusting the skew of the paper 7 t Stoppers For holding the rear edge o...

Page 14: ...e paper stack to separate the paper Set the paper stack on the feed tray Note The height of the paper stack should not exceed the MAX level Turn the feed guide knob to loosen then adjust the feed guid...

Page 15: ...ob Follow the instructions in the DC 545 manual to select the type of job that you want to perform and then press START To stop the machine press STOP 1 4 7 C 2 5 8 0 3 6 9 POWER START STOP 1 4 7 C 2...

Page 16: ...to a smaller number The position of the separator is lowered b The machine feeds multiple sheets at once double feed Turn the knob in the anti clockwise direction to a larger number The position of t...

Page 17: ...he knob in the clockwise direction to a smaller number The amount of airflow is decreased Adjusting the amount of skew Paper may be cut at an angle if a skew in the paper arises during feeding When th...

Page 18: ...ing the separator adjust ment knob clockwise towards a lower number See Figure 2 1 Increase the airflow by turning the airflow adjustment knob counter clockwise See Figure 3 1 Lower the elevator heigh...

Page 19: ...ntial information you should understand such as the materials packaged with this machine how to set up the system the names of the machine parts etc Chapter 2 This product contains the following mater...

Page 20: ...ine on a flat and stable table WARNING Do not try to lift the machine by yourself Two or more people are required to prevent injury and or damage to the machine When you open the box be sure not to in...

Page 21: ...20 Connect the power cord to the Docu Cutter and a wall outlet How to set up the System Docu Cutter HCEX 2_18 25 03 12 8 3 09 PM 20...

Page 22: ...machine e Waste tray Receives pieces of waste paper r Feed tray The original document is placed here t Feed guides Slide to match the width of the document y Feed lamp Indicates ready condition Turns...

Page 23: ...i Rear cover Open to remove jammed paper o Paper tray Receives the finished document 0 Power switch Press to switch the power on and off Part Names and Their Functions 23 25 10 11 17 o 0 i Docu Cutte...

Page 24: ...en 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 duri...

Page 25: ...hen bar code reading is disabled t REGISTER MARK When using register marks reading is enabled REG is displayed is displayed when register mark reading is disabled y AUTO CUT When using AUTO CUT is ena...

Page 26: ...The power turns ON The illustration on the right shows what is displayed on the LCD panel denotes a preset number 01 80 The illustration on the right shows that paper remains in the machine If this s...

Page 27: ...the document size Set the document in the feed tray with the surface where bar codes and reg marks are printed facing upwards The feed lamp turns off and a beep sounds In a few seconds the document is...

Page 28: ...e BARCODE REG MARK and AUTO CUT selections Enable or disable functions with the and keys If you select barcode OFF you must manually enter the desired program number while in the SELECT menu IMPORTANT...

Page 29: ...E is FAST The following conditions might cause the E4 REG MARK ERROR q The roughness of the paper may cause the mark to be unreadable w The REG MARK may not be sharp enough e The paper may be dirty If...

Page 30: ...ing the accumulated paper to prevent your hands or fingers from being caught or pinched in the machine Pieces of cut paper accumulate in the waste tray Open the drawer located at the bottom of the mac...

Page 31: ...ssages Chapter 4 Power Does Not Turn ON If the power does not turn ON check the following IS POWER PLUG INSERTED THE MACHINE DOESN T TURN ON IS POWER SWITCH ON Insert the power plug securely Turn the...

Page 32: ...Not Possible If cutting is not possible check the following IS THERE A MESSAGE DISPLAYED ON ERROR DISPLAY PANEL See P 23 Error Messages Please contact your service person YES NO Troubleshooting Flow C...

Page 33: ...r was in the AF 100 Only when using DC 545HC J 2 FEED JAM Cause Paper does not meet specifications Separator gap is too narrow AF 100 Fan blower airflow is insufficient AF 100 Feed solenoid incorrect...

Page 34: ...b data and the paper are different The stacker is full and paper can not be ejected Problem detected 1 The leading edge of the paper was not detected at PPS4 even though the specified length 500 mm ha...

Page 35: ...tions Creaser motor is defective Creaser sensor is defective Main PWB unit is defective Problem detected 1 There was no response from the creaser sensor even though the specified time 2 0 seconds elap...

Page 36: ...ve Problem detected 1 The bar code could not be read even after the paper fed the specified length 50 mm after the bar code reading operation started E 4 REG MARK ERROR Cause Reg mark being used does...

Page 37: ...r was issued Left margin slitter Right margin slitter Left center slitter Right center slitter OP1 slitter OP2 slitter Time until detection 4 5 S 5 5 S 6 0 S 6 0 S 12 0S 6 0S OP2 When not installed OP...

Page 38: ...t cut There are 0 AUTO CUTs from the last cut to the trailing edge of the paper The number of cuts scores and AUTO CUTs is 10 4 0 14 The total is less than 17 resulting in no error Table 1 List of AUT...

Page 39: ...efective Feed PCB unit is defective Main PWB unit is defective Problem detected 1 Elevator was not detected at elevator upper switch elevator lower switch or paper level sensor after the specified tim...

Page 40: ...ng caught or pinched aP 6 Warning Sticker When REJECT PAPER is Displayed If a document remains in the machine when the power is turned ON REJECT PAPER is displayed on the LCD panel and the JAM lamp bl...

Page 41: ...40 Front cover Rear cover Remove the jammed document using the tweezers Close the front or rear cover When a Paper Jam Has Occurred Docu Cutter HCEX 4_30 52 03 12 8 3 10 PM 40...

Page 42: ...g procedure Press the key and return the jammed docu ment to the feed tray side Press the STOP key to reset the fault logic and clear the fault message If the document cannot be removed with the proce...

Page 43: ...ument Close the front cover Press the STOP key to reset the fault logic and clear the fault message When a Paper Jam Has Occurred Front cover 1 4 7 C 2 5 8 0 3 6 9 POWER START STOP Docu Cutter HCEX 4_...

Page 44: ...ing procedure Press the key and return the jammed document to the feed tray side Press the STOP key to reset the fault logic and clear the fault message If the document cannot be removed with the proc...

Page 45: ...g the tweezers Close the front cover Press the STOP key to reset the fault logic and clear the fault message When a Paper Jam Has Occurred Front cover 1 4 7 C 2 5 8 0 3 6 9 POWER START STOP Docu Cutte...

Page 46: ...the creaser or the cutters are locked Please open the Front Rear Cover of DC 545HC Front Cover Rear over Loosen the 2 set screws on both sides of Front Rear Creaser Guides counter clockwise 2 or 3 ti...

Page 47: ...rator side then pull up toward w w w w w Front Creaser Guide Rear Creaser Guide IMPORTANT The figures of Front and Rear Creaser Guide are similar When installing Creaser Guide please refer to the foll...

Page 48: ...procedure Press the key and forward the jammed document to the paper tray side Press the STOP key to reset the fault logic and clear the fault message If the document cannot be removed with the proce...

Page 49: ...e jammed document Close the rear cover Press the STOP key to reset the fault logic and clear the fault message When a Paper Jam Has Occurred 1 4 7 C 2 5 8 0 3 6 9 POWER START STOP Docu Cutter HCEX 4_3...

Page 50: ...e paper stock is within specifications Press the key and return the jammed document to the feed tray side Press the STOP key to reset the fault logic and clear the fault message If the document cannot...

Page 51: ...aper with the tweezers follow the procedure on page 45 to remove it Close the front cover Press the STOP key to reset the fault logic and clear the fault message When a Paper Jam Has Occurred Front co...

Page 52: ...he paper stock is within specifications Press the key and forward the jammed document to the paper tray side Press the STOP key to reset the fault logic and clear the fault message If the document can...

Page 53: ...paper with the tweezers follow the procedure on page 45 to remove it Close the rear cover Press the STOP key to reset the fault logic and clear the fault message Rear cover 1 4 7 C 2 5 8 0 3 6 9 POWE...

Page 54: ...s and the remaining three slitters are for the center of the sheet There is a guillotine cutter that performs cuts perpendicular to the line of the paper travel There is creasing unit that performs cr...

Page 55: ...ee the appendix P 66 for infor mation about automatic cutting PAPER FEEDING DIRECTION PAPER FEEDING DIRECTION Reg Mark Optional First Cut Last cut Bar Code Optional Crease SCR 1 Reg Mark Optional Left...

Page 56: ...Sheets can be laid out in portrait or landscape format The illustration below is for a CD tray jacket The letter or A4 sheet is printed 2 up and fed in portrait orientation Definition of Programming...

Page 57: ...requiring AUTO CUT ON and OFF CANNOT mixed in the feed tray PLEASE NOTE When the total number of scores and cuts including those cuts due to AUTO CUT exceeds 17 the following message appears on LCD d...

Page 58: ...siness cards requiring a bleed and gutter require the use of two slitters between each card Because more business cards are fit onto A3 or ledger in this format compared to A4 or letter the number of...

Page 59: ...m for A4 paper Unlike the center slitters both margin slitters share common axis lead screws Due to the need to support the margin slitters lead screws in the mid area of the machine a support was pos...

Page 60: ...Should a job be presented that requires a side trim of less than 200 mm use the right center slitter OP1 or OP2 slitter to remove the waste from the side The waste will exit onto the delivery tray 5...

Page 61: ...mm CUT7 0 650mm CUT8 0 650mm CUT9 0 650mm CUT10 0 650mm SCR 1 0 650mm SCR 2 0 650mm SCR 3 0 650mm SCR 4 0 650mm TOTAL LENGTH 0 650mm NOTES ALL DIMENSIONS MUST BE IN MILLIMETERS CONVERSION TABLE Inches...

Page 62: ...0 184 2 0 0 142 9 139 7 108 0 139 7 144 1 0 0 144 1 139 7 25 4 19 1 22 2 15 2 17 1 28 6 19 1 0 190 3 108 0 111 1 101 6 106 0 130 2 196 9 0 0 114 3 123 8 188 0 114 9 149 2 0 0 0 203 2 212 7 274 3 203...

Page 63: ...57 2 108 0 0 0 0 0 0 184 2 158 8 0 0 0 114 3 0 142 9 0 108 0 0 0 17 1 19 1 12 7 12 7 28 6 6 4 12 7 16 9 271 1 266 7 266 7 419 1 130 2 95 3 139 7 415 9 0 0 0 0 149 2 184 2 266 7 0 0 0 0 0 250 8 273 1 0...

Page 64: ...0 0 0 0 108 0 0 0 0 0 0 0 0 0 0 0 0 25 4 93 1 139 7 0 0 406 4 186 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 153 4 0 0 139 7 94 1 280 4 0 0 0 187 2 0 0 0 0...

Page 65: ...04 62 204 26 131 141 151 256 297 70 10 7 203 56 154 105 20 110 200 290 297 70 10 25 275 125 175 75 225 22 112 202 210 70 10 10 202 80 130 60 152 20 105 111 196 202 287 297 70 10 20 203 97 205 18 126 3...

Page 66: ...42 43 70 10 12 278 10 152 138 280 22 208 214 400 115 307 420 89 13 16 256 136 14 258 53 223 234 404 420 89 13 19 219 119 221 17 221 121 261 401 420 70 10 25 275 125 175 75 225 25 115 205 295 385 420...

Page 67: ...80 are registered as pre set programs at the factory Avoid overwriting these at all costs Press the SET key Perform this step if there is a reg mark other wise press the SET key until LEFT SL is disp...

Page 68: ...layed so that it is as small as possible Enter the three digit value from the lower left of the display using the ten key keypad In this example the value is 52 Press the SET key Remove the sample pap...

Page 69: ...T key Enter the distance from the left side of the paper to the position for the right margin slit RGHT SL location This value must be be tween 200 and 320 millimeters Press the SET key Enter the dist...

Page 70: ...slit location This value must be between 0 and 320 0 millimeters When OP2 SL is not at tached Press the SET key Enter the distance from the left side of the paper to the position for the Optional 2 SL...

Page 71: ...CUT 2 location This value must be between 0 and 650 millimeters If a second cut is not required enter a value of zero Turn off the automatic cutting setting when not using CUT2 The machine normally do...

Page 72: ...key Press the SET key to retain the settings or C key to discard the settings The display will indicate Memory Please Wait while the infor mation is written to the Docu Cutter memory circuit The memor...

Page 73: ...3 0 762mm 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 100mm Stack...

Page 74: ...UTO FEEDER Input paper size Desktop model Paper size Min 8 5 x 11 A4 Max 12 6 x 18 A3 Input paper weight Min 110gsm Max 230gsm No curl in the paper Finishing size Min 2 Width x 3 5 Length Business car...

Page 75: ...sition See P 62 to P 64 for details Print the bar code data in the following sequence q is the start code designator for CODE 39 w is the 10 s digit data of the program number Example When the program...

Page 76: ...ARK 1 Value Method 1 With this method you can input the MARK 1 value through DC 545 Load the type of paper that is registered to for the feed tray when inputting the MARK 1 value and then press the ST...

Page 77: ...s the image vertical reference point This mark determines where the image reference is located in respect to the head and foot of the page Specifications MARK 1 MARK 2 MARK 1 corrects for errors in th...

Page 78: ...ntosh system The font provider will supply more detailed information these guidelines are only intended to illustrate the basics and scope of the installation process On a Windows PC the font is insta...

Page 79: ...76 Specifications Select Options Delete Bold and _underline_with real formatting Docu Cutter HCEX 6_70 84 03 12 8 3 12 PM 76...

Page 80: ...necessary to increase the size of the text box after the font is created 2 Type the desired job program number surrounded by a stop and start bit Remember the stop and start bit are recognized in Code...

Page 81: ...78 Specifications POSITIONING THE BAR CODE NON PRINTING AREA 5 mm 10 mm 24 60 mm Docu Cutter HCEX 6_70 84 03 12 8 3 12 PM 78...

Page 82: ...occurs position the register mark so that it is in the range where the printer can print Check the range where the printer can print in the printer s manual Since the reg mark and image shift proport...

Page 83: ...Specifications 2 Non Printing Area Reg marks and non printing areas Bar codes and non printing areas Note When combining reg marks and bar codes take note of the position of both as well as the non p...

Page 84: ...up down is between 5 mm and 35 mm from the leading edge of the paper see the following diagram regard less of the registered job data However even if the register mark is within the range described ab...

Page 85: ...automatic cutting can be done Leading edge of the paper First Cut Last Cut Specifications How to do AUTO CUT What is AUTO CUT Automatic cutting is done between the leading edge of the paper and the fi...

Page 86: ...9 Power Does Not Turn ON 30 POWER lamp 23 Power switch 22 25 Preset number 23 24 25 Prior to Programming a Job 53 Rear cover 21 22 23 Reg Mark 24 26 27 35 53 54 57 64 72 SET key 23 64 Safety Precauti...

Page 87: ...MEMO Docu Cutter HCEX 6_70 84 03 12 8 3 12 PM 84...

Page 88: ...MEMO Docu Cutter HCEX 6_70 84 03 12 8 3 12 PM 85...

Page 89: ...MEMO Docu Cutter HCEX 6_70 84 03 12 8 3 12 PM 86...

Page 90: ...N4 Y1013...

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