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Instruction Manual

Duplo DC-645

 (Slitter / Cutter / Creaser)

Version. 2 / March 2005

Correct operation and periodic maintenance are 
essential for ensuring safe use of this machine.
Thoroughly read this manual before using this 
machine.

P9-Y1031

Summary of Contents for DC-645

Page 1: ...Manual Duplo DC 645 Slitter Cutter Creaser Version 2 March 2005 Correct operation and periodic maintenance are essential for ensuring safe use of this machine Thoroughly read this manual before using...

Page 2: ...uired positions of the slits cuts and creases and the values are stored in a memory for future recall A CCD sensor reads the job number encoded in a barcode on the unfinished sheet Then the DC 645 rec...

Page 3: ...JOB Creator What is JOB Creator 29 Installing JOB Creator 29 Before Installation 29 Installing Procedures Windows 30 Installing Procedures Macintosh 32 Uninstall and Update JOB Creator 33 Uninstalling...

Page 4: ...ut the Waste Box 74 Clean Feed Rollers 75 Chapter 5 Troubleshooting Troubleshooting Flow Chart 76 Power Does Not Turn ON 76 Cutting is Not Possible 77 OK Monitor Display and Jam Display 78 Error Displ...

Page 5: ...instruction itself is indicated by pictorial symbols drawn in white on the disc In the example shown here the instruction is Remove the plug from the outlet These are particularly important safety poi...

Page 6: ...may result in fire or electric shock Caution for Grounding Be sure to use the supplied power cord WARNING Use only the power cord that is provided among the accessories Insert the power cord plug firm...

Page 7: ...on WARNING Do not move this machine by yourself Please contact your service person when you wish to move the machine Fine adjustment is required Caution for Location CAUTION Do not place the machine i...

Page 8: ...icker 1 2 2 M7 T3030 Warning Sticker 2 2 Notes on Safety Please Read and Observe WARNING Cutters and movable parts are inside this cover Before opening the cover to work unplug the power cord Use caut...

Page 9: ...n a dusty area Avoid 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...

Page 10: ...once a week to avoid 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...

Page 11: ...nt is subtracted from the specified number as below Ex When 100 documents are set the above display appears 99 100 98 100 If an error has occurred during processing batch counting can not be executed...

Page 12: ...ment 6 Top cover 3 Open this to remove the paper jam from the cutter crease optional module or to replace the optional module 7 Top cover 2 Open this to remove the paper jam from the slitter module 8...

Page 13: ...adjusts the airflow level 15 Separator adjustment knob This adjusts the distance between the separator and document 16 Level adjustment knob This adjusts the elevator height 17 Skew adjustment wheel...

Page 14: ...n The blank area cut off by the slitter is dropped in the waste box Cuts in a right angle in the paper feed direction Creases parallely in the paper feed direction Transports the paper to the stacker...

Page 15: ...key Press to enter print numbers and enter values during manual programming 10 JOG keys Press to eject the document from the machine when paper jam occured 11 TEST key One sheet document is processed...

Page 16: ...2 JOB name Displays name of the JOB currently selected 3 BARCODE BC is displayed when barcode reading is ON 4 REGISTER MARK REG is diaplayed when REG Mark reading is ON 5 AUTO CUT AC is displayed whe...

Page 17: ...C J 1 REJECT PAPER Connect the female plug of the power cord to the inlet Connect the male plug of the power cord to the outlet Press the side of the power switch The power turns ON The illustration o...

Page 18: ...17 1 1 Before Using This Machine Turning Power ON OFF Turning OFF the Power Press the K K K K K side of the power switch The power turns OFF...

Page 19: ...8 How to Connect the DC 645 to your Computer Prepare USB 2 0 Cable A B 4 pin Plug the type B connector into the DC 645 and the type A connector into the USB slot on your computer Computer USB 2 0 Cabl...

Page 20: ...waste box Cuts in a perpendicular to the paper feed direction Creases parallely in the paper feed direction Transports the paper to the stacker tray IMPORTANT When removing various modules of this dev...

Page 21: ...PAPER FEEDING DIRECTION Barcode Optional First Cut Last cut REG Mark Optional Crease CRE 01 REG Mark Optional SLIT 2 SLIT 4 SLIT 6 SLIT 5 Barcode Optional SLIT 1 SLIT 3 Definition of Programming Terms...

Page 22: ...ase Up to 10 creases are possible on 1 document SLIT2 CUT1 CREASE1 CREASE2 CUT2 CUT3 CUT4 SLIT4 SLIT6 SLIT5 SLIT3 SLIT1 Lead margin 3 2mm Card length 85mm Trail margin 5mm Left margin 3 2mm 40mm from...

Page 23: ...irection Lead mark Correct for image drift in this direction Side mark Correct for image drift in this direction 1 Specifications REG mark consists of 2 straight perpendicular lines line length 5 mm o...

Page 24: ...ith the built in CCD and automatically switch setup and finish the jobs To use this function each documents must have BARCODE printed on them Please refer to following instructions for specifications...

Page 25: ...use with the DC 645 there are many companies offering fonts www barcodetrader com bct_scan_barcode asp http www squaregear net fonts Free download of Barcode creating software http www datascan co uk...

Page 26: ...lect the font suitcases for TrueType 1 fonts also select the printer outline files and drag the fonts onto the closed System Folder icon For OS X drag the fonts onto the Fonts folder in the Library fo...

Page 27: ...26 Select Options Delete Bold and _underline_with real formatting Before Preparing Document...

Page 28: ...y 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 39 as a...

Page 29: ...EG Mark 3mm or more 3mm or more If there is any stain or scratch that is 0 3 mm or less in the slash area the margin of error in the finish may slightly increase When REG MARK and or BARCODE are print...

Page 30: ...reator Before Installation Check the following before installing JOB Creator on computer System Requirements The following computer specifications are necessary to run JOB Creator English OS Windows W...

Page 31: ...isplayed The file is then installed in that folder To rename the folder input the folder name from the top list To install the JOB Creator file in an existing folder select a voluntary folder from the...

Page 32: ...ation Advanced then click Next Click the radio button of Search for the best driver in these locations then click and select Search removable media Click Browse then click Next Driver installation sta...

Page 33: ...tall the JOB Creator Mac OS9 Users Go to Step 4 Mac OSX Users Go to Step 5 ONLY for Mac OS 9 Copy the USBDC645 on the CD ROM coming with the package in Extensions folder in the System folder Restart r...

Page 34: ...rocedures Windows Select the Hardware tab Then click the Device Manager button The Device Manager dialog appears Go to list and find Universal Serial Bus controllers then double click USB DC 645 Tip N...

Page 35: ...move the USBDC645 copied in the Extensions folder of the System folder on the Macintosh This completes the driver removal procedures Uninstall the previous driver using the driver uninstalling procedu...

Page 36: ...er value to create a JOB Use this to create a JOB when the dimensions are already finalized 3 Upload Job Data from DC 645 Read JOB from DC 645 and save in computer 4 Download Job Data to DC 645 This s...

Page 37: ...her to use REG MARK function or not When using this function enter the position of REG Mark In following JOB the REG Mark is enabled and the position is 10 mm from the right edge of document and 10 mm...

Page 38: ...in feeding area is corrected When processing light weight document turn this function OFF as it may cause a paper jam in feed area SLIT GUIDE When any slitters are not used these slitters act as paper...

Page 39: ...andard Size radio button then select the size from the list If it is a nonstandard size click the Custom Size radio button then input the number values of the Width and Length on the right Click NEXT...

Page 40: ...size in the Width and Length then click NEXT Respectively input the vertical and horizontal number of finished documents for the documents before they are cut in the Crosswise and Lengthwise area Set...

Page 41: ...to 5 or more The gutter slit cannot be changed if the Business Card Module is selected for the Optional Module Fixed value 5 mm Input the gutter cut length horizontal cutting of the size determined do...

Page 42: ...n page 19 Tip The Optional Module cannot be modified JOB Creator Settings Continue Page Tip For the Function Settings click the Function button open the Function Settings dialog then Confirm Modify Ti...

Page 43: ...ays download the Job data without Temporary job data check marked or save the JOB data on the computer with the JOB Creator before downloading it Tip If there is already a JOB registered in selected j...

Page 44: ...ibes the procedures to create a JOB with Direct Program Click the Direct Program button The Direct Program input menu appears From the Optional Module list select the optional module to finish the JOB...

Page 45: ...leted click OK and close the dialog This completes the JOB programming procedures JOB registration and save can be done with the same procedures as the Wizard system Run according to Steps 15 18 on pa...

Page 46: ...tton The display to select the JOB to read appears To upload all JOB 1 80 from the DC 645 memory Click the ALL JOB radio button then click the UPLOAD button Tip With the above operations JOB No 1 80 i...

Page 47: ...he details of the JOB will appear in a list If there are any number values to edit input the changes at this time To register the JOB edited with DC 645 click the DOWNLOAD button To save the edited JO...

Page 48: ...en button Tip Extension of a file saved with ONE JOB data djob Extension of a file saved with ALL JOB data dall Tip When sending ONE JOB with djob extension if that JOB number already exists in the DC...

Page 49: ...ed appears Click the OK button to quit To register only ONE JOB When testing the JOB sent processing one a confirmation screen will appear To run the test set the document on the DC 645 then click TES...

Page 50: ...jected documents to stop the JOB Input 0 or click the Disable radio button if DC 645 is not to be stopped regardless of number of rejected documents Click the Enable radio button for function to turn...

Page 51: ...button A display will appear to check whether to download the Function Setting Displayed contents on the DC 645 If it is okay then click OK If it is not okay then click NO The screen will return to th...

Page 52: ...the procedures to create a file recording the DC 645 Maintenance Information Click the Upload Maintenance Data from DC 645 button A display appears to confirm whether to start reading the DC 645 Main...

Page 53: ...Is the USB driver copied in the Extensions folder in the System folder Check to see if its use has been turned OFF a P 32 Installing Procedures Macintosh 4 Macintosh OSX Is a Classic environment launc...

Page 54: ...ion Mode regular state 3 An error has occurred with the DC 645 Check the message displayed on the LCD panel and correct the error according to the Troubleshooting Instructions described in this Instru...

Page 55: ...feeding direction DC 645 can cut up to 15 cuts on 1 document There is a creaser that performs creases perpendicular to the paper feeding direction DC 645 can crease up to 10 creasing on 1 document Tip...

Page 56: ...is enabled Definition of Programming Terms Example 1 When AUTO CUT must be OFF Example 2 When AUTO CUT must be OFF When documents do not have lead or trail margin as in the example 1 and 2 below make...

Page 57: ...T10 CUT11 CUT12 CUT13 CUT14 CUT15 CRE 01 CRE 02 CRE 03 CRE 04 CRE 05 CRE 06 CRE 07 CRE 08 CRE 09 CRE 10 OPTION1 OPTION2 AIR KNIFE FAN REG REG MARK SLIT GUIDE AUTO CUT CREASE DEPTH SPEED ALL DIMENSIONS...

Page 58: ...stances between lead edge and each crease positions DC 645 can crease up to 10 creases on 1 document Option positions Distances between right edge and each option positions AIR KNIFE Compressed air is...

Page 59: ...hown on the right with a beep Turn on the machine Repeatedly push the MODE key until the LCD panel indicates INPUT 1 1 1 2 A B C a b c 2 A 3 D E F d e f 3 D 4 G H I g h i 4 G 5 J K L j k l 5 J 6 M N O...

Page 60: ...th in mm of the document Press the SET key when input is completed How to Program Job on Control Panel TOTAL LENGTH 210 650 460 0mm PAPER WIDTH 210 370 297 0mm SIDE MARK 10 0mm 0 3 15 10mm Measure the...

Page 61: ...positions do not need entry Go to step 18 Tip The document will be ejected if the slit position exceeds the 40 mm upper cutting limit by the margin slitter due to REG mark print position drift or Sid...

Page 62: ...ength Press the SET key when input is completed Enter the distance from the leading edge of the document to the position for CUT 2 This value must be bigger than the value set for CUT 1 and smaller th...

Page 63: ...n function When this is ON the performance of the document skew condition is improved Press the SET key when the setting is set Tip When the document weight is light this may cause paper jam Therefore...

Page 64: ...econds CREASE DEPTH MAX MID MIN OVER WRITE OK NO C MEMORY Use the key and key to switch between and turn ON OFF Press the SET key when input is completed AUTO CUT ON OFF Use the key and key to switch...

Page 65: ...1 BC REG AC F Press the SET key to call up the JOB of the number input How to execute batch counting The specified number of document are processed Select or input a job and then press the Number key...

Page 66: ...Mark place the barcode and REG Mark printing side facing upward as in the illustration Then set it in the feed direction Tip The height of the paper stack should not exceed the MAX level Tip To set pa...

Page 67: ...stacker tray in the downward position Install the end stopper and side guides Set the end stopper perpendicular to the floor Press the START key after confirming that the START key light is GREEN Tip...

Page 68: ...4 The document is processed according to the setting of the JOB selected The finished document is ejected to the stacker tray Press the STOP key to quit the process 1 2 3 4 5 6 7 8 9 C 0 Process Docum...

Page 69: ...are the document suiting the JOB selected then loosen the stack of the documents by flipping through the sheets Set the document in the feed tray with the surface where barcodes and REG Marks are prin...

Page 70: ...ed documents are adhere on the tray due to static electricity set the stacker tray in the downward position Install the end stopper and side guides Set the end stopper perpendicular to the floor Tip I...

Page 71: ...n the knob in the anti clockwise direction to a smaller number The level of the elevator is lowered The height of the separator should be adjusted in the following cases a The machine does not feed Tu...

Page 72: ...ecreased Airflow If the document to cut is printed obliquely then the finish may not be as expected When this happens correct the problem by changing the angle of the feed guide Print Image Skew If th...

Page 73: ...easing a document Set to MAX for heavy paper and MIN for light paper SPEED This is used to select HIGH LOW processing speed APPLY SHRINKAGE In case printed documents are shrunk by heat generated on di...

Page 74: ...key FUNCTION Mode F AIR KNIFE ON OFF Setup Procedures Press the SET key several times to display the Function to set Press the F key to switch to the Function Mode F AIR KNIFE ON OFF AIR KNIFE ON OFF...

Page 75: ...ow WARNING Be sure to confirm that the machine is in a full stop before removing the accumulated paper to prevent your hands or fingers from being caught or pinched in the machine About the Waste Box...

Page 76: ...the machine The machine is started up with the Cleaning Mode Open Close Top Cover 1 Every time the top cover 1 is opened closed the feed rollers turn 60 degrees Wipe off the toner debris on the roller...

Page 77: ...s and error messages Chapter 5 Troubleshooting Flow Chart Power Does Not Turn ON If the power does not turn ON check the following IS POWER PLUG INSERTED THE MACHINE DOES NOT TURN ON IS POWER SWITCH O...

Page 78: ...ing is not possible check the following Troubleshooting Flow Chart IS THERE A MESSAGE DISPLAYED ON LCD PANEL AND OK MONITOR Please contact your service person YES NO See P 78 OK Monitor Display and Ja...

Page 79: ...no paper in the feed tray Load the feed tray with paper Too many document stacked in the feed tray Remove the document in the machine and press the STOP key a P 97 When OVER CAPACITY is displayed Thi...

Page 80: ...m Display OPTION AREA JAM J5 STACKER JAM J6 Paper jam in the optional module Remove the document in the machine and press the STOP key a P 93 When OPTION AREA JAM is displayed Paper jam in the stacker...

Page 81: ...G Mark and Barcode for details E 4 REG MARK ERROR SLITTER ERROR E5 This is a slitter module error Remove the document in the machine and press the STOP key a P 87 When CENTER JAM is displayed 1 Turn O...

Page 82: ...e document sheets in the feed tray 3 Adjust the feed a P 70 Adjust Feeder 4 The Double Feed Error is displayed when the Double Feed Detection is ON and Reject is OFF By keeping Reject ON the detected...

Page 83: ...IT MODULE There is no slitter module Install a slitter module in the machine One or more slitter module is not set in the machine SET SLIT MODULE COVER OPEN The top or front cover is open Close the to...

Page 84: ...caught or pinched aP 7 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 lamp blinks on...

Page 85: ...paper outlet Lift it forward and remove the paper jam When opening the top cover Remove the jammed document using your fingers or the pliers When opening the top cover Close the top cover When the fr...

Page 86: ...onitor Remove the jammed document with the following procedure When a Paper Jam Has Occurred J 2 FEED JAM If the document cannot be removed with the procedure mentioned above Open the top cover 1 Pres...

Page 87: ...6 When a Paper Jam Has Occurred Press the STOP key to reset the fault logic and clear the message Close the top cover 1 Remove the jammed document using your fingers or the pliers 1 2 3 4 5 6 7 8 9 C...

Page 88: ...the jammed document to the stacker tray side When CENTER JAM is Displayed If a paper jam has occurred in the slitter area CENTER JAM is displayed on the LCD panel and the lamp blinks on the OK monitor...

Page 89: ...mmed document using your fingers or the pliers Use pliers and be careful not to damage the blade Slowly lower the module Check to see that the pins on both sides are securely fitted in the module Then...

Page 90: ...lear the message When CUTTER OR CREASE is Displayed If a paper jam has occurred in the cutter or creaser module CUTTER OR CREASE is displayed on the LCD panel and the lamp blinks on the OK monitor Rem...

Page 91: ...with a paper jam and lift the module Remove the jammed document using your fingers or the pliers Slowly lower the module Check to see that the pins on both sides are securely fitted in the module The...

Page 92: ...the cutter module Prepare the cutter cover Install the cutter cover on the cutter module by inserting one side of the cutter cover between the gap as shown in the diagram Unscrew the knob screws on bo...

Page 93: ...am Has Occurred Screw on the knob screws that was unscrewed in Step 3 in the location shown in the diagram Lift the cutter cover by holding the handle portion while lifting the cutter cover Disassembl...

Page 94: ...jammed document to the stacker tray side When OPTION AREA JAM is Displayed If a paper jam has occurred in the optional module OPTION AREA JAM is displayed on the LCD panel and the lamp blinks on the O...

Page 95: ...the module Remove the jammed document using your fingers or the pliers Slowly lower the module Check to see that the pins on both sides are securely fitted in the module Then tighten the screws Close...

Page 96: ...links on the OK monitor Remove the jammed document with the following procedure J 6 STACKER JAM Press the STOP key to reset the fault logic and clear the message Press the JOG key and feed the jammed...

Page 97: ...96 When a Paper Jam Has Occurred Press the STOP key to reset the fault logic and clear the message 1 2 3 4 5 6 7 8 9 C 0...

Page 98: ...tray OVER CAPACITY will be displayed on the LCD panel Then the OK monitor light will flash Reduce the number of documents on the feed tray J 7 OVER CAPACITY Press the STOP key to reset the fault logi...

Page 99: ...OK monitor Remove the jammed document with the following procedure J 8 REJECT AREA JAM If the document cannot be removed with the procedure mentioned above Open the front cover and take out the waste...

Page 100: ...ey to reset the fault logic and clear the message Put the waste box inside Then close the front cover Loosen the guide screw for the paper outlet Lift it forward and remove the paper jam 1 2 3 4 5 6 7...

Page 101: ...Margin slit width 3 2 mm 40 0 mm from paper edge Gutter slit width 5 mm 15 mm Gutter strips wider than 15 mm are output on the stacker tray Cuts document Max 15 cuts Min cut length Lead edge cut 3 2 m...

Page 102: ...within 3m The cable and computer should be prepared by customer Standard features Max 80 job program memory Proof feed mode process 1 sheet Job program interface Air knife Skew adjustment Double feed...

Page 103: ...68 Message JOB Creator 52 53 Message DC 645 78 82 AC inlet 11 16 Adjust Feeder 70 Adjustment Knob 12 70 71 Adjustment Wheel 12 71 Airflow 71 AUTO CUT 55 72 BARCODE 23 28 BARCODE reading 15 49 72 Basic...

Page 104: ...RT key 64 66 69 STOP key 67 78 82 85 99 Safety Precautions 4 Save 41 46 47 Scale 11 Separator 70 Separator Adjustment Knob 12 70 Side Guide 65 68 Skew 71 Skew Adjustment Wheel 12 71 SLIT 19 21 Slitter...

Page 105: ...MEMO...

Page 106: ......

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