Related Manuals for Duplo DocuCutter DC-545
Summary of Contents for Duplo DocuCutter DC-545
- Page 1 Duplo Docu Cutter DC-545 & DC-545HC Trimmer Training Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
- Page 2 SERVICE TRAINING MANUAL DocuCutter™ DC-545 & DC-545HC...
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Page 3: Table Of Contents
Programming Jobs ......................32 DC-545: AUTO CUT function ..................34 DC-545 Theory of Operation ..................36 Reasons for JAM and ERROR messages ................ 39 DocuCutter DC-545 Maintenance Procedures .............. 41 DocuCutter DC-545 Service Mode ................... 42 Documentation Review ......................44 Conclusion..........................45 DocuCutter 545 Training Guide ©... -
Page 4: Product Overview
The optional DC-545HC configuration includes: AF-100 autofeeder Stand The DC-545HC configuration is shown on the cover of this manual. The DocuCutter DC-545 is shown in Figure 1 below. Figure 1. The DocuCutter DC-545 © 2002, Duplo USA Corporation DocuCutter 545 Training Guide... -
Page 5: Programmable Memory
DocuCutter 545 Programmable Memory The DocuCutter 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. DocuCutter 545 Training Guide... - Page 6 DocuCutter 545 The major components of the DocuCutter 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 ©...
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Page 7: Automatic Operation Via Barcode
The operator places a single sheet of preprinted output containing a properly formatted code 39 barcode in the feed tray of the DocuCutter DC-545 (or in the feed tray of the AF-100 on HC version systems). See the DC-545 Instruction Manual for bar code and registration mark details. - Page 8 DocuCutter 545 DocuCutter DC-545 Specifications The table below provides the specifications applicable to the DocuCutter DC-545. This information is provided for reference purposes only. Maximum = 12.6" x 18" Paper size Minimum = 8.5" x 11" Finishing size Minimum = 2" x 3.5"...
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Page 9: Safety
The objective of this section is to familiarize you with the safety requirements related to the operation and servicing of the DocuCutter DC-545. By reading this section, you will gain an understanding of the important safety information relating to this product. -
Page 10: Cutter And Slitter Blades
DocuCutter 545 Cutter and Slitter Blades Because the DocuCutter DC-545 contains a series of Slitters and a Cutter, a variety of Warning Labels have been placed on the machine. You should be aware of the Warning Label locations, as shown in Figure 4 below. -
Page 11: Safety Notes
DocuCutter 545 Safety Notes The DocuCutter DC-545 has been designed and tested to meet strict safety requirements. These include safety agency examination and approval, and compliance to established environmental standards. The following notes and warnings will help to ensure your complete... -
Page 12: Maintenance Safety
Printed Wiring Boards or ESD-sensitive components are being handled. This includes activities like replacing or reseating circuit boards or connectors. The kit should also be used to prevent additional damage when circuit boards are returned for repair. © 2002, Duplo USA Corporation DocuCutter 545 Training Guide... -
Page 13: Docucutter Dc-545 Installation
• The Paper Tray should be attached to the main body of the DocuCutter DC-545 as shown in Figure Figure 5. Attaching the Paper Tray The power cord should be attached to the DocuCutter DC- 545 and a wall outlet, as shown in Figure 6. - Page 14 DocuCutter 545 Figure 6. The Power Cord Location © 2002, Duplo USA Corporation DocuCutter 545 Training Guide...
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Page 15: The Control Panel
DocuCutter 545 The Control Panel The Control Panel on the DocuCutter DC-545 performs the following functions: • Displays operation and machine status during normal operation • Indicates when problems with the machine have occurred • Allows for operator /service input to assist in jam clearance •... - Page 16 START Button is used to start processing. [RUN] Ready for processing While in the stand-alone configuration (DC-545 only, [SELECT] Manual job selection (as opposed to bar no AF-100 autofeeder) the START button is not used. code) © 2002, Duplo USA Corporation DocuCutter 545 Training Guide...
- Page 17 In the HC configuration (AF-100 autofeeder attached) cover, or the waste cover is open. the PAPER Lamp blinks when paper runs out. The JAM Lamp blinks when a paper jam has occurred. DocuCutter 545 Training Guide © 2002, Duplo USA Corporation...
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Page 18: Af-100 Operator Controls
4. Skew adjustment knob for adjusting the skew of the paper stack 5. Stoppers for holding the rear edge of the paper stack © 2002, Duplo USA Corporation DocuCutter 545 Training Guide... - Page 19 6. AUTO CUT - When using the autocut function, "AC" is displayed; "- -" is displayed when autocut is not being used. 7. COUNTER - Displays the number of pages processed. DocuCutter 545 Training Guide © 2002, Duplo USA Corporation...
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Page 20: Pwb Locations
DocuCutter 545 PWB Locations The locations of each of the Printed Wiring Boards (PWBs) in the DocuCutter DC-545 are shown in Figure Power Main Memory Switching Panel Power Supply Figure 10. PWB Locations © 2002, Duplo USA Corporation DocuCutter 545 Training Guide... -
Page 21: Switch And Sensor Locations
DocuCutter 545 Switch and Sensor Locations The DocuCutter DC-545 contains a series of Switches and Sensors to determine paper position. The locations of the Slitter Sensors within the DocuCutter DC-545 are shown in Figure 11. Option 1 Slitter Sensor Center Slitter... - Page 22 DocuCutter 545 The remaining 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 DocuCutter 545 Training Guide...
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Page 23: Paper Handling
Throughout the following paragraphs, you will be reading about Slitters, a Cutter, and a Creaser. These components are used in various combinations to finish documents in the DocuCutter DC-545. Figure 13 is provided below to help you understand the paper handling terms associated with the DocuCutter DC-545. -
Page 24: Paper Path
Left Center Slitter Lead Screw Upper Center Slitter Drive Gear Right Center Slitter Lead Screw Upper Rear Slitter Feed Roller Rear Slitter Drive Lead Screw Upper Rear Slitter Drive Gear Upper Exit Feed Roller © 2002, Duplo USA Corporation DocuCutter 545 Training Guide... -
Page 25: Slitting
DocuCutter 545 Slitting Standard configuration provides for five Slitters used in the DocuCutter DC-545. An optional sixth slitter is available. The five factory provided slitters are called: • Right Margin Slitter • Left Margin Slitter • Center Left Slitter • Center Right Slitter •... - Page 26 TO LEFT SLITTER STEPPER MOTOR SENSOR PLATE LEFT SLITTER UNIT TO RIGHT SLITTER STEPPER MOTOR KEYWAYS RIGHT SLITTER UNIT RIGHT SLITTER UNIT POSITION SHAFT SLITTER DRIVE GEARS Figure 15. Slitter Components © 2002, Duplo USA Corporation DocuCutter 545 Training Guide...
- Page 27 Once the Slitter positions are correct, the DocuCutter begins to drive the Slitter cutting drive gears, thus providing slitting energy. Then the drive rollers convey the paper through the machine. DocuCutter 545 Training Guide © 2002, Duplo USA Corporation...
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Page 28: Cutting
DocuCutter 545 Cutting The DocuCutter DC-545 uses an integrated Cutter to produce a cut (or multiple cuts) perpendicular to the paper path, as determined by the program data. The Cutter specifically enables lead and trail edge cuts so custom finished sizes and full bleed documents are obtainable. It also enables multiple cut applications such as business cards to be produced in a single pass. - Page 29 Microprocessor that the Cutter 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 the LCD indicates CUTTER LOCK.
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Page 30: Creasing
Interrupter signals the Microprocessor that the Creaser Unit has reached the home position. The Creaser 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 the LCD indicates CREASER LOCK. - Page 31 Stepper Motor control pulses. When the desired distance is reached, the Creaser Drive Motor is activated and the paper is creased. DocuCutter 545 Training Guide © 2002, Duplo USA Corporation...
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Page 32: Af-100 Theory Of Operation
OFF. 5. When the finished sheet of paper passes PPS4, signaling the sheet has exited the DC-545, the feed process repeats until the paper pile is depleted. © 2002, Duplo USA Corporation DocuCutter 545 Training Guide... -
Page 33: Programming Jobs
DocuCutter 545 Programming Jobs The DocuCutter DC-545 is manually programmable with 80 sets of available finishing program numbers. An individual set of cutting dimensions are stored and recalled by a finishing program number. You may be required to change or add finishing programs depending upon customer requirements. - Page 34 32. Press the <SET> button to retain the settings or <STOP> to discard the settings. The display will indicate “Memory Please Wait” while the information is written to the DocuCutter memory circuit. The memorization process will take approximately 10 seconds. © 2002, Duplo USA Corporation DocuCutter 545 Training Guide...
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Page 35: Dc-545: Auto Cut Function
Lead edge CUT1 To cut this part into pieces, add AUTOCUT is ‘dummy’ cuts of less than 17.0mm possible in in the program. these sections only Last CUT DocuCutter 545 Training Guide © 2002, Duplo USA Corporation... - Page 36 DocuCutter 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...
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Page 37: Dc-545 Theory Of Operation
8. After the slitters are in position, the job is performed. Go to step 13. DocuCutter 545 Training Guide © 2002, Duplo USA Corporation... - Page 38 13. The document is fed backwards until PPS2 detects its leading edge. 14. The document is fed by 0.1mm increments until the CCD detects the horizontal line of the REG Mark. © 2002, Duplo USA Corporation DocuCutter 545 Training Guide...
- Page 39 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 creasing processes. 16. The document processing begins. DocuCutter 545 Training Guide © 2002, Duplo USA Corporation...
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Page 40: Reasons For Jam And Error Messages
3 seconds since the score movement initiation, “J8 - CREASE LOCK” will be displayed. 8. If the covers are opened while the machine is running, “E1 - COVER OPEN” will be displayed. © 2002, Duplo USA Corporation DocuCutter 545 Training Guide... - 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. DocuCutter 545 Training Guide © 2002, Duplo USA Corporation...
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Page 42: Docucutter Dc-545 Maintenance Procedures
DocuCutter 545 DocuCutter DC-545 Maintenance Procedures The following Maintenance procedures are available in the DocuCutter DC-545 Field Service Manual. They are presented here for information only. ; Q W Y K N N W U G V J G I W K F G N K... -
Page 43: Docucutter Dc-545 Service Mode
DocuCutter 545 DocuCutter DC-545 Service Mode Entering the Service Mode in the DocuCutter DC-545 enables you to perform a variety of diagnostic tests. NOTE The information provided here is also available in General Procedure GP-4 of the DocuCutter DC-545 Field Service Manual. - Page 44 Fan Check (Optional AF-100) H-31 Solenoid & Feed check (Optional AF-100) H-32 Feeder Total check (Optional AF-100) H-33 SPEED UP – Prevents slitters from returning home while in REG mark correction mode. Table 2 © 2002, Duplo USA Corporation DocuCutter 545 Training Guide...
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Page 45: Documentation Review
DocuCutter 545 Documentation Review You will be required to use DocuCutter DC-545 Field Service Manual when servicing the DocuCutter DC-545 machine. The Manual contains the following sections: • Section 1 - Service Call Procedures • Section 2 - Status Indicator RAPs •... -
Page 46: Conclusion
• Understand the AF-100 operation theory. If you have any questions about the features and functions of the DocuCutter DC-545, or this manual, review the appropriate Service Manual, or the Product Operation Manual as required. © 2002, Duplo USA Corporation... - Page 47 Binding Machines Binding Supplies Laminators I.D. Accessories Boards & Easels Paper Shredders Xyron Laminators Coil Binding machines Unibind Binding Machines Fastback Binding Equipment Paper Folding Machines Laminating Pouches Guaranteed Lowest Prices on an Rotary Trimmers Clear Covers Endless Selection of Binding Systems, Laminators, Twin Loop Wire Paper Shredders, Supplies and Accessories.
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