Duplo DocuCutter DC-545 Service Training Manual Download

Page: 1 / 47

Provided By

http://www.MyBinding.com

http://www.MyBindingBlog.com

Summary of Contents for DocuCutter DC-545

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com...

Page 2: ...SERVICE TRAINING MANUAL DocuCutter DC 545 DC 545HC...

Page 3: ...45 Installation 12 The Control Panel 14 AF 100 OPERATOR CONTROLS 17 PWB Locations 19 Switch and Sensor Locations 20 Paper Handling 22 Paper Path 23 Slitting 24 Cutting 27 Creasing 29 AF 100 Theory Of...

Page 4: ...ltiple sheet creases up to 4 Full bleed color documents are finished in a single pass with no operator intervention The DocuCutter DC 545 produces postcards greeting cards photo albums business cards...

Page 5: ...er DC 545 is manually programmable so additional jobs up to 80 total may be designed and stored for future use See Section 6 of the DocuCutter DC 545 Service Manual for programming details 4 DocuCutte...

Page 6: ...tter DC 545 are shown in Figure 2 below Figure 2 Major Components View A The remaining major components of the DocuCutter DC 545 are shown in Figure 3 below Figure 3 Major Components View B 2002 Duplo...

Page 7: ...5 reads a small 90 degree angle registration mark adjacent to the barcode It is used for cutting creasing and trimming registration correction The REG mark reference position is input during entry of...

Page 8: ...cover 80 230 gsm Front edge cutting width 0 125 Minimum Rear edge cutting width 0 125 Minimum Side cutting width 3 Maximum 0 125 Minimum Cutting accuracy 0 762 mm Cutting speed 2 ppm Minimum Feeding...

Page 9: ...under power In fact the first step in most service procedures is disconnect power cords At no time should you ever instruct an operator to touch any moving or powered internal components The only tim...

Page 10: ...e of the Warning Label locations as shown in Figure 4 below WARNING The Cutter Blade and the Slitter Blades could cause serious injury if not handled properly Always use caution when working near the...

Page 11: ...us situation ALWAYS ensure that the machine is located on a solid support surface with adequate strength for the weight of the machine NEVER use any supplies or cleaning materials for purposes other t...

Page 12: ...direct result of advances in micro circuitry technology as well as a new acknowledgment of the magnitude of the ESD problem in the electronics industry today This program will reduce field service cos...

Page 13: ...The DocuCutter DC 545 should be installed on a flat and stable surface the machine weighs 127 pounds 58 kg As a precaution on every service call be sure to verify that the customer has the machine ins...

Page 14: ...DocuCutter 545 Figure 6 The Power Cord Location 2002 Duplo USA Corporation DocuCutter 545 Training Guide 13...

Page 15: ...dicates when problems with the machine have occurred Allows for operator service input to assist in jam clearance Provides service personnel with a method of accessing the Service Mode Diagnostic Tool...

Page 16: ...lues in a positive direction During programming the Numerical Key Pad enters preset program numbers and job data The Button ejects the document from the machine at the time of paper jam In the service...

Page 17: ...E Used to toggle barcode mode on off When the values is changed the REG mark and autocut features are enabled The COVER Lamp blinks when the front cover rear cover or the waste cover is open In the HC...

Page 18: ...space between the mechanical paper separators and the top sheet of paper 3 Airflow adjustment knob for adjusting the amount of airflow used to separate the sheets in the paper stack 4 Skew adjustment...

Page 19: ...Displays the Program P number 3 OPTION An is displayed when the AF 100 is attached 4 BAR CODE When using bar codes BC is displayed is displayed when bar codes are not being used 5 REGISTER MARK When...

Page 20: ...of each of the Printed Wiring Boards PWBs in the DocuCutter DC 545 are shown in Figure 10 Power PWB Main PWB Memory PWB Switching Power Supply PWB Panel PWB Figure 10 PWB Locations 2002 Duplo USA Cor...

Page 21: ...position The locations of the Slitter Sensors within the DocuCutter DC 545 are shown in Figure 11 Option 1 Slitter Sensor Center Slitter Left Sensor Left Margin Slitter Sensor Center Slitter Right Sen...

Page 22: ...Switches and Sensors are shown below in Figure 12 Power Switch Rear Cover Switch Creaser Sensor Front Cover Switch Tray Switch Door Switch Figure 12 Switches and Sensors 2002 Duplo USA Corporation Doc...

Page 23: ...3 is provided below to help you understand the paper handling terms associated with the DocuCutter DC 545 You should note that by definition a cut or a crease is perpendicular to the direction of pape...

Page 24: ...Drive Gear 4 Upper Secondary Feed Roller 22 Lower Cutter Feed Roller 5 Right Left Margin Slitter Lead Screw 23 Lower Creaser Feed Roller 6 Upper Margin Slitter Drive Gear 24 Lower Center Slitter Feed...

Page 25: ...cutting energy for the Center Left Slitter Center Right Slitter and the Center Slitter Cutting Surfaces Each Slitter consists of a two beveled edge cutting wheels Much like a pair of scissors the two...

Page 26: ...several millimeters when the mounting screws are loosened The available movement is for factory setup and should not be changed Slitter calibration position is performed through the service menu KEYWA...

Page 27: ...n sets the Slitter position each time a sheet is processed This method provides extremely accurate performance When a job is executed each stepper motor is driven until the Slitters arrive at the home...

Page 28: ...oduced in a single pass Cutting is accomplished using the components listed below A high torque DC motor with a self contained torque enhancing transmission Long life 2 000 000 cuts replaceable precis...

Page 29: ...tter Unit has reached the home position The Cutter Unit is cycled each time the DocuCutter DC 545 is powered on If the Microprocessor fails to receive the home position signal a jam is declared and th...

Page 30: ...surface has a channel and the other surface has a ridge that fits into the channel Creasing Drive Energy is supplied to the Creaser by a high torque drive configuration Rotational energy is supplied b...

Page 31: ...e When the lead edge of the paper triggers PPS3 the microprocessor calculates the distance the paper travels via the Stepper Motor control pulses When the desired distance is reached the Creaser Drive...

Page 32: ...e paper pile is not high enough When the paper pile reaches the proper height the elevator stops raising the stack and the vacuum shutter solenoid 12 turns ON allowing vacuum pressure to pick up the t...

Page 33: ...g the number on the lower left of the LCD display panel push the button until the number changes a typical change is approximately 500 to 50 depending on the REG mark position If the REG mark goes pas...

Page 34: ...ce from the leading edge of the paper to the position for the second cut CUT 2 location This value must be between 0 and 999 millimeters If a second cut is not required enter a value of zero 27 Press...

Page 35: ...he section between the lead edge and CUT 1 and or b The section between the last CUT in the preset program and the trail edge only If you want to have the any other margin cut into pieces make sure to...

Page 36: ...cuCutter 545 IMPORTANT NOTE ON DATA ERROR When the total number of Scores Cuts and AUTO CUTS exceeds 17 E6 DATA ERROR is indicated on the LCD 2002 Duplo USA Corporation DocuCutter 545 Training Guide 3...

Page 37: ...otor feeds the document Note If PPS2 cannot detect the document after it has been fed 30mm since feed initiation J2 FEED JAM is displayed When using sheet with a Bar Code 5 The document is fed from th...

Page 38: ...according to the preset job data detected by scanning the Bar Code Note If the slitters do not move to their indicated positions within approximately 5 seconds E5 SLITTER ERROR will be displayed 11 A...

Page 39: ...ill be displayed 15 After the horizontal component of the REG Mark is scanned any required error correction is calculated Horizontal registration correction is performed during the cutting and creasin...

Page 40: ...displayed 5 If PPS4 has been blocked after the document is fed its entire length since the PPS4 detected it J4 SLITTER JAM will be displayed 6 If the Upper Blade of the cutter unit does not return to...

Page 41: ...9 If the CCD does not communicate with the Main PWB E2 RS232C ERROR will be displayed 10 If the number of cuts exceeds 10 E6 DATA ERROR will be displayed 40 DocuCutter 545 Training Guide 2002 Duplo U...

Page 42: ...sensor portions PPS2 Paper Path Sensor 2 Use a brush to clean any paper dust etc from the upper and lower sensor portions PPS3 Paper Path Sensor 3 Use a brush to clean any paper dust etc from the upp...

Page 43: ...ocedure for entering the Service Mode follows 1 If the machine is already powered on power off the machine 2 While depressing the STOP button power on the machine A buzzer will sound to indicate you a...

Page 44: ...slitter check H 16 OP1 slitter check H 17 Main motor check H 18 Score check H 19 Cutter check H 20 Slitter blade drive check H 21 LED check H 22 CCD performance check H 23 Total score counter H 24 Sli...

Page 45: ...7 Wiring Data Many of the topics described in this training guide are described in detail in the Field Service Manual As always you should make the Field Service Manual your main source for obtaining...

Page 46: ...or servicing and operating the DocuCutter DC 545 Understand the important safety precautions required when servicing the DocuCutter DC 545 Be familiar with the steps required to program jobs in to the...

Page 47: ...rdinal Samsill Universal Our Trusted Partners Binding Machines Binding Supplies Laminators I D Accessories Boards Easels Paper Shredders Xyron Laminators Coil Binding machines Unibind Binding Machines...

Search results

Summary of Contents for DocuCutter DC-545

Reviews:

Related manuals for DocuCutter DC-545

Brands by name

Popular brands

Duplo DocuCutter DC-545, Service Training Manual

Search results

Summary of Contents for DocuCutter DC-545

Reviews:

Related manuals for DocuCutter DC-545

Brands by name

Popular brands