Duplo DC-616 Service Manual
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Duplo DC-616 Service Manual

Slitter / cutter / creaser
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SLITTER / CUTTER / CREASER
DC-616
Apr. 2014
Revision 0
DUPLO DC-616 S2-Y1540

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Summary of Contents for Duplo DC-616

  • Page 1 SLITTER / CUTTER / CREASER DC-616 Apr. 2014 Revision 0 DUPLO DC-616 S2-Y1540...

  • Page 3: Introduction

    Introduction The cause of most accidents is failure to adhere to basic safety rules and observe safety instructions. It is important to prevent potential causes of accidents from occurring. In order to do so, read this manual carefully, and be sure to understand all the safety instructions and correct inspection and servicing procedures that it provides before beginning repair or servicing work.

  • Page 4: How To Use This Service Manual

    ■ How to Use This Service Manual • This service manual includes the structural and functional descriptions for the major areas of DC-616, along with the descriptions of procedures for disassembly and assembly, design standard and adjustment, maintenance and service requirements, and actions to be taken in the case of malfunctions.

  • Page 5: Safety Instructions

    Safety Instructions 1. Cautions regarding the installation location CAUTION Installation environment ● Avoid installing the machine in places exposed to direct sunlight. • Sunlight will cause the temperature in the machine’s interior to rise, possibly leading to malfunction of the control system. •...
  • Page 6 2. Cautions for installation work WARNING ● The machine’s power supply voltage and power consumption are given in the table below. The machine's power supply voltage is indicated on the identifi cation plate on machine; the machine must be connected to a power supply of the voltage indicated. →...
  • Page 7 3. Cautions for maintenance, inspection and servicing WARNING ● Always remove the power cord plug from the outlet before starting work. → Otherwise, your hands/fi ngers could get damaged beside electrical shock. • However, the plug must be left connected to the outlet when performing function checks (of individual motors, a given series of operations, or electrical circuits).

  • Page 8: Warning Labels

    ■ Warning Labels Part No. Name Q'ty L1-T108* WARNING LABEL 2 L1-T111* (EU) 2 S2-T105* WARNING LABEL 6 M7-T303* WARNING LABEL 2 M7-T307* (EU) 4 S2-T115* WARNING LABEL 2 S2-Y1540...
  • Page 9 Part No. Name Q'ty 5 R7-T115* WARNING LABEL 1 S2-Y1540...
  • Page 10 Part No. Name Q'ty L8-T109* WARNING LABEL 1 L8-T112* (EU) S2-Y1540-0...
  • Page 11 Introduction Operation in General Mechanism Adjustment Maintenance Checks Troubleshooting HELP Mode Others PC Controller...

  • Page 12: Table Of Contents

    Contents Contents .......... Introduction Maintenance Checks Chapter 5 ..... ■ How to Use This Service Manual ........Safety Instructions 1 Guaranteeing Maintenance Cycle ............. ■ Warning Labels 2 Cleaning and Oiling ... 3 Periodic Maintenance Check List ....Introduction Chapter 1 4 Recommended Parts List...
  • Page 13 Chapter 1 Introduction ........1 Specifi cations ... 2 Part Names and Their Functions ......... 1. Appearance ........ 2. Ejection Side ....3. Appearance (Ejection side) ........4. Inside ....... 5. Control Panel ........6. LCD Panel ........3 Dimensions...

  • Page 14: Specifi Cations

    Chapter 1 1 Specifi cations 1 Specifi cations Model name DC-616 Product type Slitter/Cutter/Creaser Floor stand model Feeding method Belt suction Infeed document size Width: 210–320 mm Length: 210–670 mm* * The standard feed tray takes up to 460 mm. For longer sheet, the optional long paper tray is available.
  • Page 15 The specifi cations are subject to change without prior notice. Paper Curl Due to the automated slitter function, the paper path of the DC-616 is sensitive to paper curl. If paper curl is causing paper jams, the following are suggestions for remedying the problem: 1.

  • Page 16: Part Names And Their Functions

    Chapter 1 2 Part Names and Their Functions 2 Part Names and Their Functions 1. Appearance Name Function Control panel Displays operations and status. Exit tray Receives the fi nished products. Waste box Receives pieces of waste paper. Front cover Open this to remove the waste box.

  • Page 17: Ejection Side

    Chapter 1 2 Part Names and Their Functions 2. Appearance (Feed Side) Name Function Airfl ow adjustment knob Adjusts airfl ow level. Separator adjustment Adjusts the distance between the separator and conveyance belt. knob Skew adjustment knob Adjusts the document skew. Level adjustment knob Adjusts the elevator height.

  • Page 18: Appearance (Ejection Side)

    Chapter 1 2 Part Names and Their Functions 3. Appearance (Ejection side) Name Function Perforation unit Perforates parallel to the document feed direction. Side guide Receives the processed documents. Back guide Receives the processed documents. USB terminal Used for the connection to your computer on PC Controller using. AC inlet Connect the power cord here.

  • Page 19: Inside

    Chapter 1 2 Part Names and Their Functions 4. Inside Name Function Double feed detection Detects double feed by the ultrasonic sensor. (Option) section CCD section Reads out REG Mark/Barcode. (Option) Slitter module 1,2 Cuts side margins parallel to the document feed direction.

  • Page 20: Control Panel

    Chapter 1 2 Part Names and Their Functions 5. Control Panel Name Function Displays the status of the machine. LCD panel Displays the message when an error or paper jam occurs. F key Switches to function selecting screen. RETURN key Switches to the previous screen.

  • Page 21: Lcd Panel

    Chapter 1 2 Part Names and Their Functions 6. LCD Panel ● Standby screen Name Function JOB No. Displays the JOB number currently selected. JOB Name Displays the JOB name currently selected. Displays the number of document sheets processed with the JOB Counter currently set.

  • Page 22: Dimensions

    Chapter 1 3 Dimensions 3 Dimensions Unit: mm S2-Y1540...

  • Page 23: Chapter 2 Operation In General

    Chapter 2 Operation in General ......1 Paper Feed Section ........1. Description ........2. Operation ....3. Operation of Each Part 2 Double Feed Detection Section (Option) ........1. Description ........2. Operation ....3. Operation of Each Part ........

  • Page 24: Paper Feed Section

    Chapter 2 1 Paper Feed Section 1 Paper Feed Section 1. Description Paper feed section feeds the paper into the machine after separating each sheet of paper by air knife. This is done through the operation of the air suction mechanism and the air blow duct mechanism.
  • Page 25 Chapter 2 1 Paper Feed Section <Circuit diagram> Main PCB unit Level sensor CN2-10 Yellow Yellow Blue Blue Light not transmitted: 5V Light transmitted: 0V 2. Elevator Upper Limit Switch <Operation> If the topmost sheet of paper cannot be detected, and the feed tray continues to go up, the air suction unit is pulled away from the elevator upper limit switch to come to the “OFF”...
  • Page 26 Chapter 2 1 Paper Feed Section 4. Elevator Lower Switch <Operation> As the feed tray goes up, the angle is pulled away from the elevator lower limit switch to come to the “OFF” state. As the feed tray goes down to reach the lower limit, the angle pushes the switch actuator to trigger the “ON”...
  • Page 27 Chapter 2 1 Paper Feed Section 6. Shutter Solenoid <Operation> The suction solenoid is turned ON as the level sensor is turned ON and the paper feed is ready. Then, the valve opens to suck up the paper. The valve is closed by the timer after the transferred paper passes through the PPS2.

  • Page 28: Double Feed Detection Section (Option)

    Chapter 2 2 Double-Feed Detection Section (Option) 2 Double Feed Detection Section (Option) 1. Description The double feed detection sensor is provided at the ejection side of feed belt. An ultrasonic sensor is used, and no adjustment for fi tting it to the particular type of paper, and no input of the paper thickness are required.

  • Page 29: Ccd Section

    Chapter 2 3 CCD Section 3 CCD Section 1. Description This section reads the barcode and REG mark by CCD. 2. Operation On the JOB using REG mark or barcode, PPS2 works to assure the correct CCD reading by temporarily stopping the paper run at the place of PPS2 and slows it.

  • Page 30: Margin Slitter Section

    Chapter 2 4 Margin Slitter Section 4 Margin Slitter Section 1. Description The margin slitter is provided (slitter 1, 2) on both sides to cut the paper along the traveling direction by means of the rotary blades. The cut-off margin is dropped into the waste box.
  • Page 31 Chapter 2 4 Margin Slitter Section <Circuit diagram> Slitter HP1 sensor Main PCB unit Blue CN2-3 White Slitter HP2 sensor Blue CN3-3 Pink Light not transmitted: 5V Light transmitted: 0V 2. Margin Jam Sensor <Operation> The system stops the machine when a sensor cannot detect light for more than fi...

  • Page 32: Center Slitter Section

    Chapter 2 5 Center Slitter Section 5 Center Slitter Section 1. Description Two pairs of center slitters (slitter 3–6) are provided to cut the paper in the traveling direction by mean of the rotary blades arranged vertically side by side. 2.
  • Page 33 Chapter 2 5 Center Slitter Section <Circuit diagram> Main PCB unit Slitter HP3 sensor Purple CN2-5 Blue Light not transmitted: 5V Light transmitted: 0V Slitter HP4 sensor Gray CN3-5 Blue Light not transmitted: 5V Light transmitted: 0V Slitter HP5 sensor Yellow CN2-8 Blue...
  • Page 34 Chapter 2 5 Center Slitter Section 2. PPS3 <Operation> • PPS detects the presence or non-presence of paper by the “light-through” or the “light-bloced” state of the PPS photo-receiving sensor by means of receiving from the PPS photo-emitting sensor. • PPS3 detects the passing paper and paper jam in the slitter area.

  • Page 35: Cutter Section

    Chapter 2 6 Cutter Section 6 Cutter Section 1. Description The “Guillotine type” cutter module is provided in which the lower blade is fi xed while the upper blade moves up and down to cut the paper perpendicularly to the traveling direction. 2.
  • Page 36 Chapter 2 6 Cutter Section 2. Cutter Motor <Operation> Cutter motor controls the upper blade up and down operation. <Circuit diagram> Cutter motor Drive PCB unit CN6-3 Black Black S2-Y1540...

  • Page 37: Creaser Section

    Chapter 2 7 Creaser Section 7 Creaser Section 1. Description Creaser module contains the lower blade having a concave (recessed) section and the upper blade having a convex (projected) section. The creaser unit works to crease the paper perpendicularly to its traveling direction.

  • Page 38: Operation Of Each Part

    Chapter 2 7 Creaser Section 3. Operation of Each Part 1. Crease Lower Blade Home Position Sensor <Operation> This sensor detects the crease home position by sensing the sensor plate attached to the eccentric shaft by means of the photo-micro sensor. <Circuit diagram>...
  • Page 39 Chapter 2 7 Creaser Section 3. Creaser Lower Blade Encoder Sensor <Operation> Creaser lower blade encoder sensor adjusts the crease depth in three levels from the lower limit position by reading out the encoder attached to the crease depth adjustment motor by means of the photo-micro sensor. <Circuit diagram>...
  • Page 40 Chapter 2 7 Creaser Section 5. Crease Motor <Operation> Crease motor controls the crease upper blade up and down operation. <Circuit diagram> CREASE MOTOR Drive PCB unit CN6-1 Black Black 6. Crease Low Motor <Operation> Crease low motor rotates the encoder attached in the crease lower motor to adjust the crease depth in three steps.

  • Page 41: Main Drive Section

    Chapter 2 8 Main Drive Section 8 Main Drive Section 1. Description Stepping motors are used for activating components related to the paper cutting dimensions, paper transfer, each slitter, transversal position of the gutter. The movement of other DC motors are also controlled by the encoder attached to the motor as required.

  • Page 42: Exit Tray

    Chapter 2 9 Exit Tray 9 Exit Tray 1. Description Exit tray is for receiving the fi nished paper discharged from the machine. The exit tray can be set at four different heights. Normally the tray is set at the middle height position. Upper position is to install the Card Stacker.

  • Page 43: Exterior

    Chapter 2 10 Exterior 10 Exterior 1. Description Exterior section detects the opening and closing of each cover. The machine stops immediately when the cover is opened during operations. 2. Operation The machine stops immediately when opening of the cover is detected during operations. 3.
  • Page 44 Chapter 2 10 Exterior <Circuit diagram> Front cover interlock switch Main PCB unit Brown Brown CN7-2 Brown Brown Rear cover interlock switch Relay Top cover interlock switch Drive PCB unit CN14-1 Brown Brown Brown Brown S2-Y1540...

  • Page 45: Barcode

    Operator can press the START key and leave. Even if multiple types of jobs are loaded on the feed tray at one time, DC-616 recognizes barcode on documents also with the built- in CCD reading and automatically switch setup and fi...
  • Page 46 Chapter 2 11 Barcode 2. Position of barcode Paper feed direction: The whole BARCODE should be within 3 to 20 mm from the lead edge. Paper width direction: The whole BARCODE should be within 25 to 60 mm from the right edge. * Here is the example barcode: CODE39 (*21*).
  • Page 47 Chapter 2 11 Barcode 3. Position of check digit Modulus43 is the calculational procedure of check digit specifi ed for CODE39. Each of 43 character types available to CODE39 are allocated each Numeric Number to be calculated after converting them to the numeric number.

  • Page 48: Reg Mark

    Chapter 2 12 REG Mark 12 REG Mark 1. Description DC-616 automatically compensate for image drift, one Paper feed direction of the common problems on digital printers. It detects the image drift caused on each page by reading REG mark with built-in CCD and adjust the cut/slit/crease position accordingly.
  • Page 49 IMPORTANT REG marks or barcodes located out of the specifi ed printing area cannot be detected properly by DC-616. Take account of the possible variation in the printed position of REG marks and barcodes when they are arranged on the paper.
  • Page 50 Chapter 2 12 REG Mark 4. Non-printable area for REG marks and barcodes 5 mm 35 mm 20 mm 3 mm or more Non-Printing Area 20 mm 3 mm 3 mm more more Barcode REG Mark Paper feed direction IMPORTANT •...

  • Page 51: Mechanism

    Chapter 3 Mechanism ....... 1 Exterior of the Machine 3 Double Feed Detection Section (Option) (1) Removing the Cover F (on control panel side) (1) Removing the Ultrasonic Sensor Unit ......(2) Removing the Cover F2 Unit (on control panel side) 4 CCD Section (Option) ....
  • Page 52 ......9 Main Drive Section (1) Removing the Main Motor and the Drive Belt (2) Removing the Driving Roller (Upper) (3) Removing the Driving Roller (Lower) ..(4) Removing the Perforation Tool ....10 Electrical System Section .... (1) Removing the Control Panel ..

  • Page 53: Exterior Of The Machine

    Chapter 3 1 Exterior 1 Exterior of the Machine (9) Top cover interlock switch (7) Top cover (1) Cover F (2) Cover F2 unit (10) Front cover interlock switch (11) Exit interlock switch (3) Cover R2 (4) Cover (5) Cover R (6) Plate (8) Cover (Power supply)

  • Page 54: Removing The Cover R2

    Chapter 3 1 Exterior (1) Removing the Cover F (on control panel side) 1. Open the top cover. Screw 2. Take out the three screws, and remove the cover F. Screw Screw (2) Removing the Cover F2 Unit (on control panel side) 1.

  • Page 55: Removing The Cover

    Chapter 3 1 Exterior (4) Removing the Cover 1. Loosen the thumbscrew, and remove the cover. Thumbscrew (5) Removing the Cover R 1. Open the top cover. 2. Take out the three screws, and remove the cover R. Screw Screw Screw (6) Removing the Plate 1.
  • Page 56 Chapter 3 1 Exterior (8) Removing the Cover (Power supply) 1. Take out the six screws, and pull out the cover. * Be sure to work with thepower cord removed. Screw Screw Screw Screw Screw Screw (9) Removing the Top Cover Interlock Switch 1.

  • Page 57: Removing The Exit Interlock Switch

    Chapter 3 1 Exterior (10) Removing the Front Cover Interlock Switch 1. Open the front cover. 2. Take out the two screws, and remove the front cover interlock switch with the bracket. Screw Screw 3. Remove the two faston terminals. 4.

  • Page 58: Paper Feed Section

    Chapter 3 2 Paper Feed Section 2 Paper Feed Section (1) Removing the Paper Separation Plate 1. Take out the two screws, and remove the paper separation plate with the unit. Screw Screw (2) Removing the Belt Suction Unit 1. Open the top cover. (See→P.52) 2.
  • Page 59 Chapter 3 2 Paper Feed Section ● Removing the Shutter Solenoid 1. Disconnect the connector. Connector 2. Take out the two screws, and remove the shutter solenoid with the bracket. Screw Screw 3. Take out the two screws, and remove the shutter solenoid.

  • Page 60: Removing The Feed Motor

    Chapter 3 2 Paper Feed Section (3) Removing the Feed Motor 1. Open the top cover. 2. Remove the cover F2 unit. (See→P.52) 3. Disconnect the connector from the motor. (See→P.56) 4. Remove the belt suction unit. Connector 5. Take out the two screws, and remove the feed motor.

  • Page 61: Removing The Compressor

    Chapter 3 2 Paper Feed Section (5) Removing the Compressor 1. Remove the power cord plug. 2. Take out the three screws, and remove the cover R2. (See→P.52) (See→P.53) 3. Remove the plate. 4. Take out the four screws securing the compressor. (Secured from the backside.) 5.

  • Page 62: Removing The Compressor Fuse

    Chapter 3 2 Paper Feed Section (6) Removing the Compressor Fuse CAUTION ● Be sure to remove the power cord plug from the outlet before starting the work. ● Replace the compressor fuse for exclusive use of the rating that showed in the label. Otherwise, fi...

  • Page 63: Removing The Paper Level Sensor

    Chapter 3 2 Paper Feed Section (7) Removing the Paper Level Sensor 1. Remove the cover R2. (See→P.52) 2. Disconnect the sensor connector. Connector 3. Take out the two screws, and remove the paper level sensor. Screw Screw 4. Take out one screw, and remove the shaft ASSY. 5.

  • Page 64: Removing The Elevator Upper Limit Switch

    Chapter 3 2 Paper Feed Section (8) Removing the Elevator Upper Limit Switch 1. Remove the cover R2. (See→P.52) 2. Disconnect the connector. 3. Take out the nut, and remove the elevator upper limit switch with the bracket. 4. Take out the two screws, and remove the elevator upper limit switch.

  • Page 65: Removing The Elevator Motor

    Chapter 3 2 Paper Feed Section (10) Removing the Elevator Motor 1. Move the elevator to the upper limit, and turn off the power. 2. Remove the cover R2. (See→P.52) Banding band 3. Disconnect the motor connector. 4. Remove the banding band. Screw Connector 5.

  • Page 66: Removing The Pps1

    Chapter 3 2 Paper Feed Section (11) Removing the PPS1 1. Move the elevator to the upper limit (HELP Mode: 17), and turn off the power. 2. Take out one screw, and remove the sensor with the bracket. Screw 3. Take out one screw, and remove the sensor. * After the installation, perform the sensor operation check in HELP Mode: 11.

  • Page 67: Removing The Elevator Down Switch

    Chapter 3 2 Paper Feed Section (12) Removing the Elevator Down Switch (See→P.52) 1. Remove the cover F2 unit. 2. Disconnect the switch connector. Screw 3. Take out the two screws, and remove the elevator down switch with the angle. Screw Connector 4.

  • Page 68: Removing The Blow Fan

    Chapter 3 2 Paper Feed Section 4. Take out the four screws securing the paper feed unit. * Do not loose the collars and washers. Screw Screw Screw Screw 5. Disconnect the PPS1 connector, and remove the paper feed unit. * Adjust the indicator to "0"...

  • Page 69: Double Feed Detection Section (Option)

    Chapter 3 3 Double Feed Detection Section 3 Double Feed Detection Section (Option) (1) Removing the Ultrasonic Sensor Unit * The ultrasonic sensor unit cannot be disassembled. (Sensor installation angle is a factory setting.) Screw Screw 1. Remove the cover R2. (See→P.52) 2.

  • Page 70: Ccd Section (Option)

    Chapter 3 4 CCD Section 4 CCD Section (Option) (1) Removing the CCD 1. Remove the cover (power supply) and cover R. (See→P.53) * Be sure to work with the power cord removed. 2. Disconnect the connector (CN8). * Make sure that the terminals do not interfere each other at the time of installation.

  • Page 71: Removing The Pps2

    Chapter 3 4 CCD Section (2) Removing the PPS2 ● Photo-emission sensor 1. Open the top cover. 2. Take out the three screws, and remove the hinge of the top cover. Screw Screw Screw 3. Take out the two screws, and remove the sensor with the bracket.

  • Page 72: Margin Slitter Section

    Chapter 3 5 Margin Slitter Section 5 Margin Slitter Section (1) Removing the Margin Slitter Module 1. Open the top cover. 2. Remove the cover R and cover F. (See→P.52) (See→P.53) 3. Remove the timing belt of the two lead shafts. 4.
  • Page 73 Chapter 3 5 Margin Slitter Section 9. Take out the screw, and pull out the two slide shafts. * Do not damage the ball bearings at the time of installation. * Take note of the orientation of the D cutting in the shaft point at the time of installation.
  • Page 74 Chapter 3 5 Margin Slitter Section 2. Take out the two screws (each), and remove the Screw lids (two places, right and left). Screw 3. Pull out the upper blade unit. 4. Remove the spring T. Spring T 5. Take out the two screws (each), and remove the Screw lids (two places).
  • Page 75 Chapter 3 5 Margin Slitter Section (2) Removing the Margin Slitter Position Motor/Belt 1. Open the front cover. 2. Disconnect the two motor connectors. Connector Connector (See→P.53) 3. Remove the cover R. 4. Remove the timing belt. 5. Take out the four screws, and remove the motor. * After the installation, perform the motor operation check in HELP Mode: 31.
  • Page 76 Chapter 3 5 Margin Slitter Section (3) Removing the Margin Slitter Home Position Sensor 1. Remove the cover F. (See→P.52) 2. Remove the cover R. (See→P.53) 3. Take out one screw (each), and remove the sensor with the bracket. 4. Take out one screw (each), and remove the sensor from the bracket.

  • Page 77: Removing The Margin Jam Sensor

    Chapter 3 5 Margin Slitter Section (4) Removing the Margin Jam Sensor • Photo-emission sensor 1. Remove the cover F. (See→P.52) 2. Take out one screw, and remove the sensor with the bracket. Screw • Photo-detecting sensor 3. Remove the cover R. (See→P.53) 4.

  • Page 78: Center Slitter Section

    Chapter 3 6 Center Slitter Section 6 Center Slitter Section (1) Removing the Center Slitter Module 1. Open the top cover. 2. Remove the cover R and cover F. (See→P.52) (See→P.53) 3. Remove the two slitter driving shafts and the timing belts.
  • Page 79 Chapter 3 6 Center Slitter Section 8. Take out the screw, and pull out the two slide shafts. * Do not damage the ball bearings at the time of installation. * Take note of the orientation of the D cutting in the shaft point at the time of installation.
  • Page 80 Chapter 3 6 Center Slitter Section 2. Take out the two screw, and separate the housing. Screw Screw 3. Take out the two screw, and remove the plate. 4. Take out the two screw, and remove the guide. Screw Screw 5.
  • Page 81 Chapter 3 6 Center Slitter Section 8. Remove the spring T. Spring T 9. Take out the two screw (each), and remove the lids Screw (two places). * Take note of the correct orientation of the Screw eccentric shaft at the time of installation. 10.
  • Page 82 Chapter 3 6 Center Slitter Section 3. Remove the cover R. (See→P.53) 4. Remove the timing belt. 5. Take out the four screws, and remove the motor. * After the installation, perform the motor operation check in HELP Mode: 31. (HELP Mode : 31→P.149) (3) Removing the Center Slitter Home Position Sensor 1.

  • Page 83: Removing The Pps3

    Chapter 3 6 Center Slitter Section (4) Removing the PPS3 ● Photo-emission sensor 1. Open the top cover. Screw 2. Remove the cover R. Screw 3. Take out the two screws, and remove the sensor cover. 4. Take out the two screws, and remove the sensor with the bracket.

  • Page 84: Removing The Gutter On/Off Sensor

    Chapter 3 6 Center Slitter Section (5) Removing the Gutter ON/OFF Sensor 1. Remove the cover F. (See→P.52) 2. Remove the cover R. (See→P.53) 3. Disconnect the sensor connector. 4. Take out the screw, and remove the sensor with the bracket.

  • Page 85: Cutter Section

    Chapter 3 7 Cutter Section 7 Cutter Section (1) Removing the Cutter Module 1. Open the top cover. (See→P.52) (See→P.53) 2. Remove the covers F, R. 3. Disconnect the motor connector. Screw 4. Take out one screw, and draw out the home position sensor bracket.

  • Page 86: Removing The Cutter Home Position Sensor

    Chapter 3 7 Cutter Section (2) Removing the Cutter Home Position Sensor (See→P.53) 1. Remove the cover R. 2. Take out the two screws, and remove the sensor with the bracket. 3. Take out one screw, and remove the sensor. * Adjustment required at the time of installation (See→P.107) S2-Y1540...

  • Page 87: Creaser Section

    Chapter 3 8 Creaser Section 8 Creaser Section (1) Removing the Creaser Motor and the Belt 1. Remove the covers F, R. (See→P.52) (See→P.53) 2. Disconnect the motor connector. Screw 3. Loosen the motor fi xing screws, and remove the timing belt.

  • Page 88: Removing The Crease Blade

    Chapter 3 8 Creaser Section (3) Removing the Crease Blade (See→P.52) (See→P.53) 1. Remove the covers F, R. Screw 2. Take out one screw, and remove the sensor plate. 3. Take out one screw, and remove the bearing presser. Screw 4.
  • Page 89 Chapter 3 8 Creaser Section (4) Removing the Crease Lower Blade Home Position Sensor 1. Remove the cover F. (See→P.52) 2. Take out the two screws, and remove the sensor with the bracket. 3. Remove the sensor from the bracket. * Adjustment required at the time of installation (See→P.106) (5) Removing the Crease Lower Blade Motor...
  • Page 90 Chapter 3 8 Creaser Section (6) Removing the Creaser Lower Blade Encoder Sensor (See→P.52) 1. Remove the cover F. 2. Take out the screw, and remove the sensor with the bracket. Screw 3. Remove the sensor from the bracket. * Adjustment required at the time of installation (See→P.106) S2-Y1540...

  • Page 91: Removing The Pps4

    Chapter 3 8 Creaser Section (7) Removing the PPS4 ● Photo-emission sensor 1. Remove the covers F, R. (See→P.53) (See→P.52) Screw Screw 2. Take out the fi ve screws, and remove the Screw reinforcing plate. Screw Screw 3. Take out one screw, and remove the sensor. * After the installation, perform the sensor operation Screw check in HELP Mode: 11.

  • Page 92: Main Drive Section

    Chapter 3 9 Main Drive Section 9 Main Drive Section (1) Removing the Main Motor and the Drive Belt (See→P.52) 1. Remove the cover F. 2. Take out the two screws, and loosen the pulley bracket. Screw 3. Take out the three screws, and remove the pulley cover.
  • Page 93 Chapter 3 9 Main Drive Section 6. Take out the four screws, and remove the motor with bracket. Screw Screw Screw Screw 7. Loosen the hexagon socket set screw, and remove Hexagon the gear. socket set screw * Adjustment required at the time of installation (See→P.108) (2) Removing the Driving Roller (Upper) (See→P.52) (See→P.53)

  • Page 94: Removing The Driving Roller (Lower)

    6. Draw out the roller. (4) Removing the Perforation Tool 1. Take out the two black thumbscrews, and remove Thumbscrew the perforation unit from the DC-616. 2. Loosen the two white thumbscrews on the rear side Thumbscrew of the perforation unit.
  • Page 95 Chapter 3 9 Main Drive Section 3. Loosen the two screws securing the stoppers of the 1. Loosen the nut. perforation tool depth adjustment screws. (approx. 3 mm) First loosen the nut, and then loosen the screws. 2. Loosen the screw. 4.
  • Page 96 Chapter 3 9 Main Drive Section 5. Take out the two screws of the joint securing the shaft (upper). Screw 6. Slide the joint in step 5 in the direction of the arrow, and remove the shaft (upper) from the unit. Joint 7.
  • Page 97 Chapter 3 9 Main Drive Section 8. Attach the shaft (upper) to the unit in the reverse order to steps 5 and 6. Screw 9. Move the upper tools so that the both right and left perforation tools fi t in the grooves of the lower tools, and move the roll assys to hold the paper.

  • Page 98: Electrical System Section

    Chapter 3 10 Electrical System Section 10 Electrical System Section (1) Removing the Control Panel WARNING ● Always remove the power cord plug from the outlet before replacing a PCB Unit. 1. Open the top cover. Connector (See→P.52) 2. Remove the cover F. 3.

  • Page 99: Removing The Main Pcb Unit

    Chapter 3 10 Electrical System Section (3) Removing the Main PCB Unit WARNING Screw Screw Connector ● Always remove the power cord plug from the outlet before replacing a PCB Unit. 1. Remove the cover. (See→P.54) Connector 2. Disconnect 10 connectors. 3.

  • Page 100: Removing The Main Drive Pcb Unit

    Chapter 3 10 Electrical System Section (5) Removing the Main Drive PCB Unit WARNING ● Always remove the power cord plug from the outlet before replacing a PCB Unit. Screw 1. Remove the cover F. (See→P.52) 2. Disconnect three connectors. 3.

  • Page 101: Adjustment

    Chapter 4 Adjustment ..... 1 Exterior of the Machine (1)Top cover interlock switch adjustment 100 (2)Front Cover interlock switch adjustment ..(3)Exit interlock switch adjustment ......2 Paper Feed Section ... (1)Shutter solenoid adjustment (2)Elevator upper limit switch adjustment ..... (3)Elevator lower limit switch ..

  • Page 102: Exterior Of The Machine

    Chapter 4 1 Exterior of the Machine 1 Exterior of the Machine (1)Top cover interlock switch adjustment (2)Front Cover interlock switch adjustment (3)Exit interlock switch adjustment 1. Adjust “a” to be 0.5 mm while the switch is turned ON. 2. Perform the operation check in HELP Mode:11. (HELP Mode : 11→P.137) "a"...

  • Page 103: Paper Feed Section

    Chapter 4 2 Paper Feed Section 2 Paper Feed Section (1)Shutter solenoid adjustment 1. Adjust the bracket installation position, so that the throttle opening “a” is at 80-90 degrees when the solenoid is turned ON. 2. Install the bracket parallel so that the actuator moves smoothly.

  • Page 104: Ccd Section

    Chapter 4 3 CCD Section 3 CCD Section (1)CCD 1. Fix CCD in about the center of a long hole. 2. Perform REG. mark read out position adjustment in HELP Mode: 45. (HELP Mode : 45→P.152) (2)PPS2 1. Perform the operation check in HELP Mode:11. (HELP Mode : 11→P.137) S2-Y1540...

  • Page 105: Margin Slitter Section

    Chapter 4 4 Margin Slitter Section 4 Margin Slitter Section (1)Margin slitter home position sensor adjustment 1. Check the sensor operation in HELP Mode:11,26. 2. Feed the test paper through the machine applying the (HELP Mode : 11→P.137) Service person JOB. (HELP Mode : 26→P.145) 3.

  • Page 106: Center Slitter Section

    Chapter 4 5 Center Slitter Section 5 Center Slitter Section (1)Center slitter home position sensor adjustment 1. Check the sensor operation in HELP Mode:11, 26. 2. Feed the test paper through the machine applying the (HELP Mode : 11→P.137) Service person JOB. (HELP Mode : 26→P.145) 3.

  • Page 107: Cutter Section

    Chapter 4 6 Cutter Section 6 Cutter Section (1)Cutter motor adjustment 1. Perform the operation check in HELP Mode: 29. (HELP Mode : 29→P.148) 2. Feed the test paper through the machine applying the Service person JOB. 3. Adjust the slide installation position (skew). 4.

  • Page 108: Creaser Section

    Chapter 4 7 Creaser Section 7 Creaser Section (1)Creaser motor and belt adjustment 1. Move the motor installation position, and adjust the belt tension to 6 mm/10N. 2. Perform the operation check in HELP Mode: 27. (HELP Mode : 27→P.146) 3.

  • Page 109: Creaser Home Position Sensor

    Chapter 4 7 Creaser Section (4)Creaser home position sensor 1. Perform the operation check in HELP Mode: 27. (HELP Mode : 27→P.146) 2. Feed the test paper through the machine applying the Service person JOB. 3. Adjust the crease position and depth in HELP Mode: 47, (HELP Mode : 47→P.154) (HELP Mode : 48→P.155) S2-Y1540...

  • Page 110: Main Drive Section

    Chapter 4 8 Main Drive Section 8 Main Drive Section (1)Main motor drive belt adjustment 1. Move the pulley bracket installation position, and adjust the belt tension to 10 mm/10N. 2. After the adjustment, perform the operation check in HELP Mode: 41. (HELP Mode : 41→P.150) S2-Y1540...

  • Page 111: Chapter 5 Maintenance Checks

    Chapter 5 Maintenance Checks ..1 Guaranteeing Maintenance Cycle ......2 Cleaning and Oiling ........(1) Cleaning ........(2) Oiling ..3 Periodic Maintenance Check List ....4 Recommended Parts List...

  • Page 112: Guaranteeing Maintenance Cycle

    Chapter 5 1 Guaranteeing Maintenance Cycle 2 Cleaning and Oiling 1 Guaranteeing Maintenance Cycle After the delivered item, visit customer periodically and guide the DC-616 operation. 2 Cleaning and Oiling (1) Cleaning 1. Slitter section and cutter section Clean with a brush or a dry cloth.

  • Page 113: Periodic Maintenance Check List

    Chapter 5 3 Periodic Maintenance Check List 3 Periodic Maintenance Check List 6-month Periodic Checks Section to be checked Description Description Sensors Cleaning Use a brush to clean any paper dust, etc. Timing belt Checking Inspect Belts for signs of wear or loss of tension. Replace any cracked or worn belts, and retention as required.

  • Page 114: Recommended Parts List

    Chapter 5 4 Recommended Parts List 4 Recommended Parts List Part No. Part name MTBF Remarks S2-A114* BELT 1 million sheets Coated paper/230 gsm AJ233 TIMING BELT AK049 ROLLER CHAIN N4-K212* SEPARATER PLATE P9-F104* UPPER BLADE 2 million sheets Coated paper/230 gsm P9-F107* LOWER BLADE UNIT 2 million sheets...
  • Page 115 Chapter 5 4 Recommended Parts List MTBF Part No. Part name Remarks R8-W122* CABLE UNIT:SW1 S2-W233* BUNDLED CABLE UNIT SWITCH P9-X101* STEPPING MOTOR P9-X102* STEPPING MOTOR S2-X101* MOTOR S2-X103* STEPPING MOTOR LA051 MICRO SWITCH 1,000,000 times N4-X103* UI028 FUSE S2-X105* AIR POMP 115 V S2-X106*...

  • Page 117: Chapter 6 Troubleshooting

    Troubleshooting Chapter 6 ....... 1 Troubleshooting (1) When “NO DOCUMENT” is Displayed (2) When “J2 FEED JAM” is Displayed (3) When “J3 FEED ERROR” is Displayed ..(4) When “J4 Slitter” is displayed (5) When “J5 Cut.crease” is displayed ..(6) When “J6 Exit tray”...

  • Page 118: Troubleshooting

    Chapter 6 1 Troubleshooting 1 Troubleshooting (1) When “NO DOCUMENT” is Displayed cause/failed step check item action area page YES Go to step 2. Are any documents on the Feed tray Load the documents on the feed tray? feed tray. Check the setting of the YES Go to step 3.

  • Page 119: When "J3 Feed Error" Is Displayed

    Chapter 6 1 Troubleshooting (3) When “J3 FEED ERROR” is Displayed cause/failed step check item action area page • Remove the paper inside • Paper jam in the machine the machine. Inside the (feed tray unit). • Check that the paper machine •...

  • Page 120: When "J6 Exit Tray" Is Displayed

    Chapter 6 1 Troubleshooting (6) When “J6 Exit tray” is displayed cause/failed step check item action area page Remove the paper inside Paper jam in the machine Inside the the machine. (stacker tray unit or waste machine box unit) NO Go to step 2. YES Go to step 3.
  • Page 121 Chapter 6 1 Troubleshooting (9) When “E02 Elevator” is Displayed cause/failed step check item action area page Check that the elevator YES Go to step 2. Elevator lower lower switch works properly limit switch NO Replace the switch. in HELP Mode: 17. Check that the elevator YES Go to step 3.

  • Page 122: When "E07 Connect Error" Is Displayed

    Chapter 6 1 Troubleshooting (12) When “E07 Connect error” is displayed cause/failed step check item action area page Check that the connection YES Reconnect properly. Main PCB/Drive between the main PCB (CN6) and the drive PCB NO Go to step 2. (CN3) is correct.
  • Page 123 Chapter 6 1 Troubleshooting (15) When “REG MARK ERROR” is displayed cause/failed step check item action area page YES Go to step 2. Is the REG mark printed on Document Change the document to the document? the proper one. YES Go to step 3. Is the REG mark bad Document printing?

  • Page 124: Conditions For The Error Detection

    Chapter 6 2 Conditions for the Error Detection 2 Conditions for the Error Detection No paper PPS1 is in the “light through” state when the <START> or <TEST> key is pressed. J2 Feed tray Both the elevator lower/upper limit switches are turned on. J3 Feed error The paper does not reach the PPS2 even if the feeding operation is performed for three times.
  • Page 125 Chapter 6 2 Conditions for the Error Detection Slitter 1-6 lock Within 12 seconds after the slitter driving signal is output, the slitter does not reach the HP or it does not move from the HP after reaching the HP (detection period: 12 seconds). Cutter lock Within 2 seconds after the cutter driving signal is output, the cutter does not reach the HP or it does not move from the HP after reaching the HP.

  • Page 126: Major Cause And Preventive Action For The Paper Jam

    Chapter 6 3 Major Cause and Preventive Action for the Paper Jam 3 Major Cause and Preventive Action for the Paper Jam Avoid using the following types of paper: • Torn paper or paper with large holes • Paper held together with a clip or staples •...

  • Page 127: Slitter Blade Intersection Correction

    Chapter 6 4 Slitter Blade Intersection Correction 4 Slitter Blade Intersection Correction When a heavy weight document is jammed in the margin slitter area and the center slitter area, if you pull out the document by force, the slitter upper blade and the lower blade may intersect each other.
  • Page 128 Chapter 6 4 Slitter Blade Intersection Correction 4. Push the shaft in the direction of the arrow to correct the intersecting upper blade. REFERENCE The right figure shows that the upper blade and the lower blade intersect. Pushing the shaft in without sliding the lid may damage the upper blade and the lower blade.

  • Page 129: Chapter 7 Help Mode

    Chapter 7 HELP Mode 1 HELP Mode List ........128 2 Accessing the HELP Mode ..... 129 3 Finishing the HELP Mode ....... 129 4 Setting the Other HELP Mode No... 129 5 Accessing the Service Person JOB ..129 6 HELP Mode Description ......

  • Page 130: Help Mode List

    Chapter 7 1 HELP Mode List 1 HELP Mode List Function Category Page (1) Display the ROM (FPGA) version. ROM version display HELP00 (2) ROM version upgrade ROM version upgrade (1) Display the count HELP02 counter (2) Reset the count HELP04 (1) Display the jam count (reset) counter HELP07 (1) Display the error count (reset)

  • Page 131: Accessing The Help Mode

    Chapter 7 2 Accessing 3 Finishing the HELP Mode 4 Setting the Other HELP No. 5 Accessing the Service Person JOB 2 Accessing the HELP Mode 1. When the machine is in use, put it in the standby mode and turn OFF the power switch before accessing the HELP Mode.

  • Page 132: Help Mode Description

    Chapter 7 6 HELP Mode 6 HELP Mode Description HELP Mode: 00 1. Function (1) ROM version display H00 Version ck. • Main: The ROM version of the Main PCB is displayed. ▼ • Panel: The ROM version of the control panel PCB is displayed. Main:V X.XX Panel:V...
  • Page 133 The USB Serial Converter is not available in Macintosh. 1. When the machine is in use, put it in the standby mode and turn off the power. 2. Connect your computer and the DC-616 with the USB cable. 3. Turn on the power switch. H00 Version ck.
  • Page 134 9. Select a fi le, and click [OPEN]. 10. [Normal] is selected. Click [Start]. Upgrading starts. 11. When the download completes, the message [Complete] appears. Click [OK]. 12. Turn off the power of DC-616, then turn on the power again. S2-Y1540...
  • Page 135 Chapter 7 6 HELP Mode HELP Mode: 02 1. Function (1) Display the count H02 Total count • Total number of paper feed is displayed in 8 digits numeral. ▼ Paper count Total: XXXXXXXX Reset: XXXXXXXX • Total number of cutting is displayed in 8 digits numeral. H02 Total count ▼...
  • Page 136 Chapter 7 6 HELP Mode 2. Operating Procedure (1) Display the count 1. Access the HELP Mode “02”, and press the <START> key. 2. Press the UP/DOWN cursor key to switch pages. Total: Total count is shown. 3. Press the <STOP> key. It will return to the HELP Mode selection screen.
  • Page 137 Chapter 7 6 HELP Mode HELP Mode : 04 1. Function (1) Display on the jam count H04 Jam count • Display the jam count of each item. ▼ J4 Slitter XXXX 2. Operating Procedure (1) Check on the paper jam count 1.
  • Page 138 Chapter 7 6 HELP Mode HELP Mode : 07 1. Function (1) Display the error count H07 Error count • Display the error count of each item. ▼ E01 CCD error XXXX 2. Operating Procedure (1) Display the error count 1.
  • Page 139 Chapter 7 6 HELP Mode HELP Mode : 11 1. Function (1) Sensor switch check H11 Sens. ck. • Status of the sensor switch ON: 0 / OFF: 1 is displayed. ▼ PPS1 PPS2 PPS3 2. Operating Procedure (1) Sensor switch check 1.
  • Page 140 Chapter 7 6 HELP Mode HELP Mode : 13 1. Function (1) DIP switch check H13 Dip sw ck. • Status of the DIP switch is displayed. ▼ Dip sw:1 2 3 4 • Because DIP SW1 is used for version-up, it cannot be verifi ed in HELP Mode “13”.
  • Page 141 Chapter 7 6 HELP Mode HELP Mode : 15 1. Function (1) Double feed detection check H15 D feed check • Double feed detection result is verifi ed. Value: 0:1sheet 1: more 2. Operating Procedure (1) Double feed detection check 1.
  • Page 142 Chapter 7 6 HELP Mode HELP Mode : 16 1. Function (1) Control panel check H16 Panel check • Check that the NUMERIC keys on the control panel work Key:Buzzer on correctly. • Check that the buzzer of the keys on the control panel sounds SET:LCD LED on correctly.
  • Page 143 Chapter 7 6 HELP Mode HELP Mode : 17 1. Function (1) Paper feed elevator operation test H17 Elevator ck. • The correct operation of the paper feed elevator is verifi ed. Level sen. : • The status of the paper level sensor and the elevator lower limit switch are verifi...
  • Page 144 Chapter 7 6 HELP Mode HELP Mode : 18 1. Function (1) Fan motor operation test H18 Air check • The proper function of suction motor is verifi ed. • The proper function of blower motor is verifi ed. ↑: Suction fan ↓:Blow out fan 2.
  • Page 145 Chapter 7 6 HELP Mode HELP Mode : 19 1. Function (1) Feed motor operation test H19 Feed check • Operate the feed motor. (2) Shutter solenoid operation test :Feed belt on • Operate the shutter solenoid. ↓:Sol. on 2. Operating Procedure (1) Feed motor operation test 1.
  • Page 146 Chapter 7 6 HELP Mode HELP Mode : 20 1. Function (1) Compressor operation test H20 Air knife • Operate the compressor. ↑:On 2. Operating Procedure (1) Compressor operation test 1. Access the HELP Mode “20”, and press the <START> key. 2.
  • Page 147 Chapter 7 6 HELP Mode HELP Mode : 26 1. Function (1) Slitter operation test • Move the slitter to its home position. Slitter run ck. • The proper function of the slitter operation is verifi ed. ↑:Hp ck. ↓:Run test 2.
  • Page 148 Chapter 7 6 HELP Mode HELP Mode : 27 1. Function (1) Creaser upper blade motor operation test H27 Cre. mot ck • The proper function of the creaser upper blade motor is verifi ed. • The proper function of the creaser upper blade home position Cre.
  • Page 149 Chapter 7 6 HELP Mode HELP Mode : 28 1. Function (1) Creaser lower blade motor operation test H28 Cre. low ck. • The proper function of the creaser lower blade motor is verifi ed. Cre. low.sen. : • The proper function of the creaser lower blade home position is verifi...
  • Page 150 Chapter 7 6 HELP Mode HELP Mode : 29 1. Function (1) Cutter motor operation test H29 Cut mot ck. • The proper function of the cutter motor is verifi ed. Cut hp.sen. : Cut enc.sen. : ↑↓:Cut mot. on 2.
  • Page 151 Chapter 7 6 HELP Mode HELP Mode : 31 1. Function (1) Slitter operation test (1~6) H31 MSL&SLOT mot • The proper function of the slitter motor is verifi ed. Slit: 2 3 4 5 6 ←→:Select ↑↓: Slit on 2.
  • Page 152 Chapter 7 6 HELP Mode HELP Mode : 41 1. Function (1) Main motor operation test H41 Main mot.ck. • The proper function of the main motor is verifi ed. :Main mot.on 2. Operating Procedure (1) Main motor operation test 1.
  • Page 153 Chapter 7 6 HELP Mode HELP Mode : 43 1. Function (1) Clear the JOB, counter H43 Initialize • The contents and history of the JOB (01-80) and the reset ↑+↓:All clear counter are reset. • The contents and history of the JOB (01-80) is reset. SET+C:JOB clear 2.
  • Page 154 Chapter 7 6 HELP Mode HELP Mode : 45 1. Function (1) REG. mark read out position adjustment • REG. mark read-out position is adjusted. PPS2 CCD dist. XX . X XX . X JOB: 2. Operating Procedure (1) REG. mark read out position adjustment 1.
  • Page 155 Chapter 7 6 HELP Mode HELP Mode : 46 1. Function (1) Cutting position adjustment • The cutting position is adjusted. PPS3 -Cut dist. Distance: SET:Save 2. Operating Procedure (1) Cutting position adjustment 1. Set the skew adjusting dial at “0”. 2.
  • Page 156 Chapter 7 6 HELP Mode HELP Mode : 47 1. Function (1) Creasing position adjustment • The creasing position is adjusted. Cut-Crease dist. Distance: SET:Save 2. Operating Procedure (1) Creasing position adjustment 1. Set the skew adjusting dial at “0”. 2.
  • Page 157 Chapter 7 6 HELP Mode HELP Mode : 48 1. Function (1) Creasing depth adjustment H48 Crease depth • The creasing depth is adjusted. High Mid SET:Save 2. Operating Procedure (1) Creasing depth adjustment 1. Set the skew adjusting dial at “0”. 2.
  • Page 158 Chapter 7 6 HELP Mode HELP Mode : 49 1. Function (1) Margin and center slitter positions adjustment H49 Slit adjust • Positions of each margin (S1, S2) and center slitter (S3 – S6) are adjusted. XXX XXX XXX XXX XXX JOB:MSL,SLOT3,4 2.
  • Page 159 4:xx.xx mm 4:xx.xxmm 5:xx.xx mm 5:xx.xxmm 8. Press the <SET> key , then DC-616 calculates the magnifi cation automatically for working out the adjustment values of HELP Mode “50”. And also the values are input on HELP Mode “49”. S2-Y1540...
  • Page 160 Chapter 7 6 HELP Mode 9. Proceed the Service person JOB84 again to check for slitters run following the adjustment values properly. The setting of Service person JOB84 MSL: 25 mm 1: 50 mm 2: 50 mm 3: 50 mm 4: 50 mm 5: 50 mm * If the slitter position is still incorrect, go back to the step 7 and...
  • Page 161 Chapter 7 6 HELP Mode HELP Mode : 52 1. Function (1) Main motor transfer distance adjustment • Transfer distance of the main motor is adjusted. Main motor adj. SET:Save 2. Operating Procedure (1) Main motor transfer distance adjustment 1. Set the skew adjusting dial at “0”. 2.
  • Page 162 Chapter 7 6 HELP Mode HELP Mode : 58 1. Function (1) Adjust the suction fan air volume. H58 Fan duty Max Mid SET:Save 2. Operating Procedure (1) Adjust the suction fan air volume. 1. Access the HELP Mode “58”, and press the <START> key. 2.
  • Page 163 Chapter 7 6 HELP Mode HELP Mode : 59 1. Function (1) Adjust the margin jam detecting sensor. J7 Time Set XXXXmsec Set:Save 2. Operating Procedure (1) Adjust the margin jam detecting sensor. 1. Access the HELP Mode “59”, and press the <START> key. 2.
  • Page 164 Chapter 7 6 HELP Mode HELP Mode : 60 1. Function (1) Optional function setting H60 Option • Air knife Air knife • Double feed detecting sensor • CCD Dl.feed sen • Perforation unit 2. Operating Procedure (1) Optional function setting 1.
  • Page 165 Chapter 7 6 HELP Mode HELP Mode : 61 1. Function (1) Serial number setting • Serial number is set. Set serial no. XXXXXXXXX SET:Save 2. Operating Procedure (1) Serial number setting 1. Access the HELP Mode “61”, and press the <START> key. 2.
  • Page 166 Chapter 7 6 HELP Mode HELP Mode : 62 1. Function (1) Display the error record. H62 Err record • Error record is displayed in order. ▼ Latest (Latest 3 errors) Error No: 0006-DA JOB No:01 2. Operating Procedure (1) Display the error record. 1.
  • Page 167 Chapter 7 6 HELP Mode HELP Mode : 63 1. Function (1) LCD panel contrast adjustment • LCD panel contrast is adjusted. LCD contrast SET:Save 2. Operating Procedure (1) LCD panel contrast adjustment 1. Access the HELP Mode “63”, and press the <START> key. 2.
  • Page 168 Chapter 7 6 HELP Mode HELP Mode : 98 1. Function (1) Special setting H98 Special ▼ ● Cancelling limits of slit position, cut position, and paper width ▼ Cut limit off Slit limit off WidthLim.330.5 2. Operating Procedure (1) Special setting 1.

  • Page 169: Others

    Chapter 8 Others 1 Position and Function of Electronic Parts ........1. Switches ......2. PPS sensors ........3. Sensors ....4. Motors, Fan, Solenoid ..... 5. PCB Units • Power Supply ........6. Others ... 8. Connector VR/Fuse Layout .......

  • Page 170: Position And Function Of Electronic Parts

    Chapter 8 1 Position and Function of Electronic Parts 1 Position and Function of Electronic Parts 1. Switches Part Name Elevator Lower Limit Switch Interlock switch Top cover Interlock switch Cover switch Elevator Lower Limit Switch Elevator Upper Limit Switch Exit Interlock switch S2-Y1540...

  • Page 171: Pps Sensors

    Chapter 8 1 Position and Function of Electronic Parts 2. PPS sensors Part Name PPS1 PPS2 (Photo-emission) PPS2 (Photo-detecting) PPS3 (Photo-emission) PPS3 (Photo-detecting) PPS4 (Photo-emission) PPS4 (Photo-detecting) S2-Y1540...

  • Page 172: Sensors

    Chapter 8 1 Position and Function of Electronic Parts 3. Sensors Part Name Ultrasonic Sensor Paper Level Sensor Margin Slitter 1 Home Position Sensor Margin Slitter 2 Home Position Sensor Margin Jam Detecting Sensor Gutter ON / OFF sensor Center Slitter 5 Home Position Sensor Cutter Home Position Sensor 10 Creaser Lower Blade Encoder Sensor 11 Creaser Lower Blade Home Position Sensor...

  • Page 173: Motors, Fan,Solenoid

    Chapter 8 1 Position and Function of Electronic Parts 4. Motors, Fan,Solenoid Part Name Main Motor Driver Feed Motor Suction fan Shutter Solenoid Blow out fan Elevator Motor Margin Slitter 1 Position Motor Margin Slitter 2 Position Motor Center Slitter 3 Position Motor 10 Center Slitter 4 Position Motor 11 Center Slitter 5 Position Motor 12 Center Slitter 6 Position Motor...

  • Page 174: Pcb Units • Power Supply

    Chapter 8 1 Position and Function of Electronic Parts 5. PCB Units • Power Supply Part Name Panel PCB unit Receive PCB Oscillation PCB USB connector board Drive PCB Unit Power supply unit Main PCB unit Main motor drive PCB unit S2-Y1540...

  • Page 175: Others

    Chapter 8 1 Position and Function of Electronic Parts 6. Others Part Name Fuse Compressor Relay PCB UNIT Appliance inlet Varistor Terminal blocks S2-Y1540...

  • Page 176: Connector Vr/Fuse Layout

    Chapter 8 1 Position and Function of Electronic Parts 8. Connector VR/Fuse Layout 1. Main PCB Unit (S2-V500*) CN14 2. Panel PCB Unit (S2-V311*) S2-Y1540...
  • Page 177 Chapter 8 1 Position and Function of Electronic Parts 3. DRIVE PCB Unit (S2-V321*) CN11 CN10 4. Main Motor Drive PCB Unit (BZ008) S2-Y1540...
  • Page 178 Chapter 8 1 Position and Function of Electronic Parts 5. Power Supply Unit 24V (UA040) 6. Double Feed Detect PCB Unit Oscillation PCB (P9-V303*) Receive PCB (P9-V305*) Oscillation PCB Receive PCB S2-Y1540...
  • Page 179 Chapter 8 1 Position and Function of Electronic Parts 7. USB PCB Unit (R8-V347*) 8. Fuse (0216002XP) Rating of fuse : 250 V, 2 A CAUTION Fuse : Use the proper type of fuse when replacing. Otherwise, fi re may occur. S2-Y1540...

  • Page 180: Service Person Jobs

    Chapter 8 2 Service Person JOBs 2 Service Person JOBs Use to check the Use to adjust the H-46: Use to cut. H-49: Use to adjust H-50: Use to adjust parallelity of the H-47: Use to adjust the slit position. the position of the vertical enlargement right margin.
  • Page 181 Chapter 8 2 Service Person JOBs Use to check plain Use to check Use to check Use to check Use to check paper. REG. Mark REG. Mark skew of processing Use to adjust function function perforation unit accuracy of double-feed sensor. business cards.
  • Page 182 Chapter 8 2 Service Person JOBs Use to adjust the This is used to check Use to check Use to adjust the Use to check the vertical enlargement the barcode reading gutter defl ector . performance. 55 mm margin. magnifi cation) of and to reset the H-52.
  • Page 183 Chapter 8 2 Service Person JOBs Use to check center crease on the business cards produced from A3 paper. JOB Name A3 58×85 CCR Paper size 297×420 JOB number PAPER WIDTH TOTAL LENGTH Side Mark Lead Mark SLIT1 SLIT2 293.2 SLIT3 61.2 SLIT4...

  • Page 184: Overall Wiring Layout

    Chapter 8 Overall Wiring Layout Overall Wiring Layout Overall Wiring Layout 1/2 Model:DC-616 VX-52-1A3 ELEVATOR Light green Light green DOWN SW Option White SLITTER HP3 Blue Purple Blue SLITTER HP5 Yellow Blue Yellow Blue White Light blue SLITTER HP1 Blue...
  • Page 185 Chapter 8 Overall Wiring Layout Overall Wiring Layout 2/2 VX-52-1A3 Model:DC-616 ELEVATER UPPER LIMIT Brown 2 Brown SWITCH Brown 1 Brown ELEVATER Blown Brown 1 Brown MOTOR Black Black Black Black 2 Black BLOW FAN SUCTION Black Black Black Light blue...

  • Page 187: Chapter 9 Pc Controller

    1. Contents of Data Folder ........4 Maintenance 1. Confi rming Saved Maintenance Data 2. Uploading the Maintenance Data of DC-616 3. Setting Up the Machine to Be Connected .... 4. Set Up Language to Be Used 5. Set Up the Other Language Than Existing Ones to Be Used ....

  • Page 188: Main Menu Of Pc Controller

    For service person use only. This is used for setting the machine MAINTENANCE etc. Password is required to access. SELECT This reads the saved JOBs on the DC-616. Select one from them. Job Detail Input JOB details are displayed. DOWNLOAD This sends the JOB saved on the computer to the DC-616.
  • Page 189 Stacker Setup Then click [Stop] or [Test] to eject it to the Exit tray. At that time, if you click [Start], the DC-616 ejects it to the exit tray and then continues the JOB. Select the [Connect] check box to control function limit of the Connect control panel on the DC-616.

  • Page 190: Maintenance Menu

    Chapter 9 2 Maintenance Menu 2 Maintenance Menu 1. Maintenance Data Item Function Open Maintenance To confi rm the maintenance data saved in computer. Data File Upload Maintenance To load the maintenance data saved in DC-616 into the PC. Data from DC-616 S2-Y1540...

  • Page 191: Option Module

    Chapter 9 2 Maintenance Menu 2. Option Module Item Function Setting of connected Check the box of the optional modules. device S2-Y1540...

  • Page 192: Language Setting

    Chapter 9 2 Maintenance Menu 3. Language Setting Item Function LANGUAGE Set the language to be used on the screen. EDIT Edit the messages. IMPORT Import the message fi les. DELETE Delete the message fi les. SELECT Name of the message fi le. Language Displays the current set language.

  • Page 193: Data Folder

    3 Data Folder 1. Contents of Data Folder Folder Name File/Folder Name Function *.res File of icon data. Duplo.exe Application software. HistoryJob.H616 File of processed history data. HistoryJob.S616 File of JOB entering history data. LanguageEn.ini Language fi le of English.

  • Page 194: Maintenance

    Chapter 9 4 Maintenance 4 Maintenance 1. Confi rming Saved Maintenance Data Open the saved fi le in computer to confi rm the maintenance data. 1. The main menu screen appears. Click [MAINTENANCE]. 2. Enter the password ‘630304’, and click [YES]. If you click [NO], the screen will return to the one on step 1.
  • Page 195 Chapter 9 4 Maintenance 4. Select the fi le name and fi le type. Click [Open]. 5. The contents of maintenance data appears. Click [Save as .CSV fi le.]. The imported data will be saved as CSV fi le in the computer. If you click [END], the screen returns to the one in step 3.

  • Page 196: Uploading The Maintenance Data Of

    Chapter 9 4 Maintenance 2. Uploading the Maintenance Data of DC-616 1. Process the step 1 to 2 in the “Confi rming the mainte- nance data”. 2. Select [Upload Maintenance Data from DC-616], and click [OK]. If you click [Cancel], the screen returns to the previ- ous one.

  • Page 197: Setting Up The Machine To Be Connected

    2. Click [OPTION MODULE] tab. 3. Check the box of option modules which is installed in DC-616. Click [OK] after confi rmation of the check box. If you click [CANCEL], the checked option modules are canceled. And the screen returns to the main menu.

  • Page 198: Set Up Language To Be Used

    Chapter 9 4 Maintenance 4. Set Up Language to Be Used Set the language to be displayed on PC Controller. 1. Proceed along the step 1 to 2 in the “Confi rming the maintenance data”. 2. Click [LANGUAGE] tab. 3. Click to display the language list, and select one language you want to use.

  • Page 199: Set Up The Other Language Than Existing Ones To Be Used

    Chapter 9 4 Maintenance 5. Set Up the Other Language Than Existing Ones to Be Used 1. Proceed along the step 1 to 2 in the “Setting Up Language to Be Used” when you require to use the other language than existing languages. 2.
  • Page 200 Chapter 9 4 Maintenance Here are the descriptions how to create a new message fi le. 4-1. Click 4-2. Click a low you want to edit. (Right fi gure shows the topmost low as an example.) KEY : Shows “KEY” (Symbol for administration) which is allocated on each messages.
  • Page 201 Chapter 9 4 Maintenance 5. After edit complete, click 6. Enter the fi le name of the new data you edited, and save the message fi le. IMPORTANT Save the message fi le in text format (*.txt). Click [Save]. If you click [Cancel], the screen returns to the one in step 4 without saving operation.
  • Page 202 Chapter 9 4 Maintenance 9. Select the fi le saved in step 6, and click [OPEN]. (The right fi gure shows an example of selecting “duplo” fi le.) The message fi le will be imported in the PC controller, and the fi le name will be added in the list of the other language selecting box.

  • Page 203: Deleting The Message File

    Chapter 9 4 Maintenance 13. The message ‘Restart the application.' appears. Click [OK]. Application is fi nished automatically. Restart the PC controller. And it runs with the set language you have changed. Clicking [Cancel] returns to the screen of step 11. 6.

  • Page 204: Confi Rming The Version

    1. Descriptions The following programs need up-version when it is required. 1. DC-616 PC Controller V*.** It needs up-version when adding the optional equipment on DC-616. 2. Duplo seiko corp. (usbdc616) USB ***** driver It does not need up-version normally.
  • Page 205 Chapter 9 5 Confi rming the Version 2. Click [Control panel]. • Windows 7 / Vista 1. Click [Start], and then click [Control Panel] in the menu. The ‘Control Panel’ appears. 2. Click [Hardware and Sound]. 3. Click [Device Manager]. S2-Y1540...
  • Page 206 Chapter 9 5 Confi rming the Version 4. ‘USB DC-616 *.*' is registered in 'Universal Serial Bus controller' of 'Device Manager' dialog. The part ‘*.*' of 'USB DC-616 *.*' is the version of driver. After the confi rmation, close the window.
  • Page 207 Double-click [Hardware] tab, and then click [De- vice Manager]. 5. ‘USB DC-616 *.*’ is registered in ‘Universal Serial Bus controller’ of ‘Device Manager’ dialog. The part ‘*.*’ of ‘USB DC-616 *.*’ is the version of driver. After the confi rmation, close the window. S2-Y1540...

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