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Introduction Thank you for your purchase of the DC-616. To ensure safe and effi cient prolonged use of this machine, read and thoroughly understand this manual before using the machine. After using this manual, be sure to keep it in a handy place to reference. Pictorial Symbols and Other Notations Used in This Manual : Introduces instructions for correct operation of the machine.
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Duplo International Ltd, Sandown Industrial Park, Mill Road, Esher, Surrey, KT108BL, United Kingdom DECLARATION DE CONFORMITE Duplo Seiko Corporation, dont le siège est situé au 353, Koudai, Kinokawa-shi, Wakayama 649-6551, Japon, déclare que le ou les produits Directive 2006/95/CE relative au matériel électrique destiné à être employé dans certaines limites de tension Directive 2006/42/CE relative aux machines Directive 2004/108/CE concernant la compatibilité...
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Disposal of Old Electrical & Electronic Equipment This symbol (the symbol of the crossed out wheeled bin) indicates that in European countries this product should not be disposed of as household waste. Please recycle where facilities exist by checking with your local authority or supplier for recycling advice.
Notes on Safety (Please Read and Observe) Safety Precautions Various symbols and pictures are used in this manual and on the labels affi xed to the machine. These symbols and pictures provide warnings and instructions to prevent danger to you or other person, and to prevent damage to offi...
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Notes on Safety (Please Read and Observe) ● Caution for Grounding WARNING ● Use only the power cord that is provided among the accessories. Insert the power cord plug fi rmly into the socket, so that proper electrical contact is effected. →...
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Notes on Safety (Please Read and Observe) ● Prohibition of Disassembly or Modifi cation WARNING ● Do not modify the machine. → Doing so may result in fi re or electric shock. ● Do not remove the rear lid, cabinet, or covers from the machine. →...
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Notes on Safety (Please Read and Observe) ● Caution for Cleaning CAUTION ● Before cleaning the machine, turn off the power switch and unplug the power cord. → If the machine is activated accidentally, it may cause injury. ● Do not use fl ammable sprays or solvents inside or near the machine. →...
Notes on Safety (Please Read and Observe) Locations of Warning Labels Keep the WARNING and CAUTION labels clean at all times. If labels become damaged or come off, contact your service person. Cutters and movable parts are inside this cover. WARNING Before opening the cover to work, unplug the power cord.
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Notes on Safety (Please Read and Observe) Part No. Name Q'ty 5 R7-T115* WARNING LABEL...
Notes on Safety (Please Read and Observe) Interlock System for Safety ● What is the interlock system for safety? It is the function for keeping you safety and for avoiding any danger operations or situations by the limitation of operation which may cause a damage to the machine or other surrounding facilities. The DC-616 is equipped with various safety functions for the case of causing any danger operations or situations, and it stops running the operation in that cases.
Contents ................Introduction ........Notes on Safety (Please Read and Observe) ............. Safety Precautions ..........Locations of Warning Labels viii ............ Interlock System for Safety ........● What is the interlock system for safety? ....Machine Dimensions and Required Space for Operation Chapter 1 Before Using This Machine ............
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Contents Chapter 3 Basic Operations ........Processing Documents by Selecting a JOB ..............Function Setting ..............Setting Functions ..........Automatic Setup Using Barcodes ..............Adjusting Feeder ............. Elevator level (Feed tray) ................ Separator ................Airfl ow ............Skew Compensation ........Adjusting for Using a Light Weight Document .........
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Chapter Before Using This Machine This chapter contains essential information you should understand such as how to set up the system, the names of the machine parts, etc............. Part Names and Their Functions ................. Appearance ..............Appearance (Feed Side) ..............
Part Names and Their Functions 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. Feed tray Original document is placed here. Scale Measures the cut and slit position, and the fi...
Part Names and Their Functions Appearance (Feed Side) Name Function Airfl ow adjustment Adjusts the airfl ow level. knob Separator adjustment Adjusts the distance between the separator and the conveyance knob belt. Skew adjustment Adjusts the document skew. knob Level adjustment Adjusts the elevator heights.
Part Names and Their Functions Appearance (Ejection Side) Name Function Perforation unit Perforates parallel to the document feed direction. (Optional on 115V model and 230V Asia model) 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.
Part Names and Their Functions Inside Name Function Double feed detection Detects double feed by ultrasonic sensor. (Optional on 115V model and 230V Asia model) CCD (Optional on 115V Reads REG mark/Barcode. model and 230V Asia model) Slitter module 1,2 Cuts side margins parallel to the document feed direction.
Part Names and Their Functions 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. CURSOR (Left/ Press to move the cursor to the left or right.
Part Names and Their Functions 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. Function setting AC: Auto cut AC is displayed when Auto cut is enabled.
Turning Power ON/OFF Turning Power ON Connect the female plug of the power cord to the Inlet Inlet. Female plug of the power cord Connect the male plug of the power cord to the outlet. Male plug of the power cord WARNING ●...
Preparation Before Use Loading Documents Loosen the stack of the documents by fl ipping through the sheets and align them. Load the documents on the feed tray and gently push them toward the inside of the machine. Adjust the feed guide according to the document Feed guide size and secure it with the fi...
Preparation Before Use Setting the Exit Tray As shown in the right fi gure, lift the exit tray. There are three setting positions of the exit tray. IMPORTANT When the fi nished document size is A3 or longer, or if the fi nished documents are adhered on the tray due to static electricity, set the exit tray in the downward position.
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Preparation Before Use Move the perforation tool assys. (See → P.14 Changing the Perforation Tool Position) Adjust the depth of the perforation tool. (See → P.15 Changing the Perforation Tool Depth) Tighten the two thumbscrews loosened in step 2. Install the perforation unit on the ejection side of the DC-616 by tightening the two perforation unit installing screws..
Preparation Before Use Removing the Perforation Unit Loosen the two perforation unit installing screws to remove the perforation unit. Attach the cover to the ejection side of the DC-616 with the thumbscrew. Feed side Install the perforation unit at the installation position under the feed tray, and tighten the two thumbscrews.
Preparation Before Use Changing the Perforation Tool Position Inside of the perforation unit. Roll assy Perforation tool assy Upper roll Loosen the two hexagon socket set screws each of Upper tool the two perforation tool assys (each side). (upper tool: 1 pce., lower tool: 1 pce.) Loosen the two hexagon socket set screws each of the three roll assys.
Preparation Before Use Tighten the 10 hexagon socket set screws loosened in step 1. Perforation tool assy Upper tool Lower tool Changing the Perforation Tool Depth Adjust the perforation toll depth by turning the depth adjustment screws on the both sides of the perforation unit.
Preparation Before Use The card stacker is optional on 230V Attaching the Card Stacker Asia model. Set the exit tray horizontally. Place the card stacker on the exit tray along the ejection side of the DC-616. REFERENCE When the perforation unit is installed, place the card stacker along the perforation unit.
Preparation Before Use Adjusting the Card Stacker Guides Select a JOB that uses the card stacker, and press and hold the TEST key. The fi nished product stops at the exit before being ejected. Slide each side guide to the ejected position of the fi...
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Preparation Before Use Press the STOP key to eject the document and adjust the back guide (for card stacker) according to the fi nished document size.
How to Connect the DC-616 to Your Computer Prepare an USB 2.0 Cable (A/B 4-pin). Plug the USB terminals into the USB port of the DC-616 and the USB port on your computer. USB cable must be within 3 m long. USB 2.0 Cable Computer REFERENCE...
Before Preparing Document The DC-616 can save up to 80 patterns of JOB. JOB contents can be programmed either via computer or on the control panel. This chapter describes items required to program a JOB. Slit : The DC-616 has six slitters. Two slitters (1, 2) are for the margins and the remaining four slitters are for the center area of the document.
Before Preparing Document Defi nition of Programming Terms Document feed direction REG mark Barcode Slit 2 Slit 1 Slit 4 Slit 3 Slit 5 Slit 6 Document feed direction First cut REG mark Barcode Crease Last cut...
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Before Preparing Document Slit / Cut / Crease Limitations Document feed direction Slit : Up to 6 slits are possible on one document. Slit 1 and Slit 2 are for cutting the margins at both side edges. : Up to 25 cuts are possible on one document. Crease : Up to 20 creases are possible on one document.
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Before Preparing Document Moving range of the slitter Document feed direction Slit 2 Slit 4 Slit 6 Slit 5 Slit 3 Slit 1 1. Moving range of the slitter 1 3.2 to 55.0 mm (The width stands at 0 when it is not set.) 2.
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Before Preparing Document REG Mark (Registration mark) (Optional on 115V model and 230V Asia model) The DC-616 automatically compensates for image drift, one of the common problems on digital printers. It detects the image drift caused on each page by reading REG mark with built-in CCD scanner and adjusts the cut / slit / crease position accordingly.
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Before Preparing Document Barcode (Automatic JOB selection) (Optional on 115V model and 230V Asia model) By adding barcode which indicates JOB number on each document, the DC-616 automatically sets up the machine and starts the job. Operator can press the START key and leave. Even if multiple types of jobs are loaded on the feed tray at one time, the DC-616 recognizes barcode on documents also with the built-in CCD scanner and automatically switches setup and fi...
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Before Preparing Document When both of REG mark and barcode are printed on one document 60 mm or shorter 35 mm 20 mm 5 mm 3 mm 3 mm 20 mm Barcode REG mark Document feed direction REG mark or barcode located out of the specifi ed printing area cannot be detected properly. Take account of the possible variation in the printed position of REG mark and barcode when they are arranged on the document.
Before Preparing Document Limit of Slit In Simple Mode, when the document width is bigger than 327.3 mm (12.8 inches) and a margin slit on the operator’s side is smaller than 3.2 mm (1/8 inch), a warning message appears and then the slit entering screen appears.
Before Preparing Document Limit of Trail Cutting Document feed direction Create a JOB so that fi nished product of less than 67.0 mm is not set up within the trail edge of 67.0 mm. Because the product of less than 67.0 mm cannot be processed as fi nished product, it is fi...
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Before Preparing Document Document feed direction Possible JOB Possible JOB Impossible JOB Possible JOB 49.0 mm 49.0 mm and more and more 49.0 mm 67.0 mm 67.0 mm and more...
Chapter Programming JOB on Control Panel This chapter describes how to program a JOB on the control panel of the DC-616..............Before Programming JOB ..........Programming a JOB on the Control Panel ..........Programming a New JOB (Advanced Mode) ..........
Before Programming JOB The DC-616 can save up to 80 patterns of JOB. This chapter describes how to program and change a JOB on the control panel of the DC-616. Before programing a JOB, accurately measure the positions of slits, cuts and creases in mm/inch. Familiarize yourself with the following instructions to make the programming process easy and trouble free.
Programming a JOB on the Control Panel The following items should be entered to program a JOB. JOB No. Select a JOB number in which the JOB currently being programmed is saved. JOB name Enter a JOB name using the NUMERIC keys for easy reference. Width Enter the width of document.
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Programming a JOB on the Control Panel Speed Select the processing speed. Selecting SLOW improves fi nishing accuracy. Air knife (Optional on 230V Asia model) Compressed air is blown out from the front of the document to loosen documents. This prevents double feed.
Programming a New JOB ( Advanced Mode) Hints for entering a JOB: ● Pressing the SET key goes on to the next step. ● Pressing the CURSOR (Up) key returns to the previous step. ● Pressing the CURSOR (Down) key goes on to the next step. ●...
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’ Clear Space, Moves the cursor to the left. Space, Moves the cursor to the right. Example: Entering DUPLO in JOB01 Press the <3> key and the CURSOR (Right) key. JOB** entry Enter JOB name * To delete a character, press the CLEAR key.
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Press the <6> key three times and the CURSOR (Right) key. JOB** entry Enter JOB name Press the SET key or the CURSOR (Down) key. DUPLO Width JOB** entry Enter the width (mm) of the document using the NUMERIC keys.
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Programming a New JOB (Advanced Mode) REFERENCE Document feed direction Slit position setting order: • Advanced mode : Slits are set in numerical order from Slit 1 to Slit 6. Enter the value for Slit2 to Slit6 in a similar way to step 16. JOB** entry When each input is complete, press the SET key.
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Programming a New JOB (Advanced Mode) Enter the value for Crease2 to Crease20 in a similar way to step JOB** entry Crease20 When each input is complete, press the SET key. ***.*mm When you require fewer than 20 creases, enter 0 after the last (0/***.*-***.*) crease setting and then press the SET key or the CURSOR (Down) key.
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● If you select Save as different JOB no. and press the SET key, a JOB** entry list of JOB number will appear on the screen. 01: DUPLO Use the CURSOR (Up) key or (Down) key to select JOB number, 02: [No Data] and press the SET key.
Programming a New JOB ( Simple Mode) Simple mode : You can set slit position in order, from the right side of the document along the document feed direction. The screen displays SlitA to SlitF. When programming a JOB in Simple Mode, slitter settings are entered in order as shown on the fi...
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Programming a New JOB (Simple Mode) REFERENCE Document feed direction Slit position setting order: • Advanced mode : Slits are set in numerical order from Slit 1 to Slit 2. • Simple mode : Slits are set in alphabetical order from Slit A to Slit F.
(Down) key to select Save as different JOB no., and then press the SET key. The message Saving JOB will appear on the screen and the 01: DUPLO changed JOB settings are saved in the memory. The display returns to the standby screen shown on the right and the JOB number and the JOB name that were just saved are displayed.
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Chapter Basic Operations This chapter describes the operating sequence from turning on the DC-616 until completing process..........Processing Documents by Selecting a JOB ................Function Setting ................Setting Functions ............Automatic Setup Using Barcodes ................Adjusting Feeder ............. Elevator level (Feed tray) ................
Processing Documents by Selecting a JOB This section describes the procedures to process documents by selecting a JOB from Retrieve JOB no. or Retrieve JOB log. Make sure the standby screen is displayed on the LCD panel. Press the F key. The Select menu screen will appear.
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Processing Documents by Selecting a JOB Load the documents on the feed tray. (→P.10 Loading Documents) Adjust the feed guide according to the document size and secure it with the fi xing screw. Set the back guide according to the document. (→P.10 Loading Documents) Lift the exit tray.
Function Setting The following functions can be set. Air knife (Optional on 230V Asia model) Compressed air is blown out from the front of the document to loosen the documents, preventing double feed. Suction power This adjusts the air amount of the suction fan. When the document is fed, it is suctioned to the conveyance belt and conveyed.
Setting Functions REFERENCE The temporarily set functions by Function Setting are valid until the power is turned OFF or another JOB is selected. The already stored JOB details are not overwritten. DBL detection and Feeder capacity are valid even after turning off the power. Turn on the power.
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Setting Functions Double detection (Optional on 115V model and 230V Asia Settings */** model) Double detection This detects double feed (two or more sheets are fed at once). Use the CURSOR (Right) or (Left) key to select ON or OFF, and press the CURSOR (Down) key.
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Setting Functions Crease depth Settings */** Use the CURSOR (Right) or (Left) key to select MAX, MID, or MIN, Crease depth and press the CURSOR (Down) key. REFERENCE • Set to MAX for heavy weight document and MIN for light weight document.
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Setting Functions Speed Settings */** Use the CURSOR (Right) or (Left) key to select FAST or SLOW, Speed and press the CURSOR (Down) key. FAST SLOW Slitter entry Settings */** Use the CURSOR (Right) key or (Left) key to select Simple mode Slitter entry or Advanced mode.
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Setting Functions REFERENCE If the message on the right appears on the screen, the result from Trail cut length the caluculation of the values of Adjust all (for both directions) and becomes invalid. Apply shrinkage is that the cut position is out of the specifi cations. Re-enter value for the cut position, or Adjust all or Apply All adjust and shrinkage.
Automatic Setup Using Barcodes By adding barcode which indicates job number on each document, the DC-616 automatically sets up the machine and starts JOB. Turn on the power. Prepare the document suiting the JOB selected, then loosen the stack of the document by fl ipping through the sheets.
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Automatic Setup Using Barcodes Attach the back guide and the side guides. Set Read Barcode to ON in Settings. Settings */** Read Barcode IMPORTANT Make sure that BC appears on the standby screen after setting. By pressing the START key, the built-in CCD reads the barcoded JOB number, then starts processing the suitable JOB.
Adjusting Feeder Elevator level (Feed tray) The elevator level should be adjusted in the following cases: a. The machine does not feed. → Turn the level adjustment knob in a counterclockwise direction (to a smaller number). The level of the elevator is raised. b.
Adjusting Feeder Skew Compensation If the fi nished products are cut obliquely, adjust the skew using the skew adjustment knob. Clockwise : Turning the knob slightly shifts the lead edge of the document toward the operator's side. Counterclockwise : Turning the knob slightly shifts the lead edge of the document toward the non-operators side.
Adjusting for Using a Light Weight Document Adjusting the Amount of Airfl ow (Shutter) When you use the light weight document, the double feed may occur even if you adjust the airfl ow adjustment knob. In that case, adjust the amount of airfl ow by opening and closing the shutter on the document feed side.
Chapter Troubleshooting This chapter describes what to do when an error has occurred and how to deal with paper jams and error messages............... When Messages Appear ............When a Paper Jam Has Occurred ..............Example: J3 Feed error ..............Example: Cutter area ..............
When Messages Appear When an error occurs, messages and fi gure appear on the LCD panel. In such cases, follow the procedures below to solve the cause. Message Status and Solution Status : There is no document on the feed tray. No document Solution : Load document on the feed tray.
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When Messages Appear Message Status and Solution Status : There is paper jam in the cut or crease area. J5 Cut, crease Solution : Remove the document from the cut or crease area and then Remove document press the STOP key. from cut/crease area to Clear...
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When Messages Appear When Messages Appear Message Status and Solution Status : Check paper jam in the exit area when the power is turned Paper in machine Remove document Solution : Remove the document from the exit area and then press the from exit tray STOP key.
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When Messages Appear Message Status and Solution Status : The machine failed to read REG mark. REG read error 4 Solution : Press the STOP key, then check REG mark position and Check REG margin slitter position. If REG mark is not printed within the position specifi...
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When Messages Appear When Messages Appear Message Status and Solution Status : When the perforation unit is installed or you select the JOB Check position that uses the perforation unit, you press the START key or of options the TEST key. Solution : Check if the option unit is correctly installed and then press to start the STOP key or the TEST key to restart processing.
When a Paper Jam Has Occurred When a paper jam has occurred, a message appears on the LCD panel. Follow the procedures below to remove the jammed document. WARNING • Do not touch the tool. Doing so may cause injury. •...
When a Paper Jam Has Occurred When a Paper Jam Has Occurred ● If the jammed document cannot be removed by the procedures on the previous page, attempt to remove the document according to the following procedures. Open the top cover and remove the jammed document using the tweezers that come with the machine.
When a Paper Jam Has Occurred Example: J7 WASTE BOX The waste box becomes full of waste during operation. J7-* Accumulation of waste may cause paper jam. Remove document from waste box to clear WARNING ● Make sure that the machine is fully stopped before removing the waste. Or your hands or fi...
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Chapter Daily Maintenance This chapter describes daily maintenance for the machine................Daily Maintenance ..............Cleaning the Slitter Tool ............. Cleaning the Conveyance Rollers ............ Cleaning the Skew Correction Belt ..................Waste Box ............About Protection of Sponge Rollers...
Daily Maintenance Clean the machine periodically to maintain its performance. WARNING ● Before cleaning, be sure to turn the power off, wait until the machine cools off and unplug the power cord. Otherwise, fi re or electric shock may occur. ●...
Daily Maintenance Cleaning the Conveyance Rollers As the DC-616 processes digital color outputs, toner etc. on the documents may adhere to the surface of the conveyance rollers of the DC-616. Accumulation of toner may affect the performance of the DC-616. In this case, clean the rollers according to the following procedures. Turn on the power.
Daily Maintenance Daily Maintenance Cleaning the Skew Correction Belt Long hours of machine use result in accumulation of paper dust. Wipe off the paper dust with a cloth while turning the skew correction belt with your hand. Open the top cover. WARNING Do not put your hands or fi...
Waste Box Slit waste accumulates in the waste box. Open the front cover and remove them periodically. Accumulation of waste may cause paper jam. Follow the instructions below for removing the waste. WARNING Be sure to confi rm that the machine is fully stopped before removing the accumulated waste to prevent your hands or fi...
About Protection of Sponge Rollers When the sponge rollers stop at the same position for a long time, they may be deformed by the pressure from the back-up rollers. To prevent from being deformed, if the machine does not operate for one hour with the power on, the rollers automatically rotate at low speed.
Specifications Model name DC-616 Product type Slitter/Cutter/Creaser Floor stand model Feeding method Belt suction Infeed document size Width: 210–330.5 mm Length: 210–670 mm* * The standard feed tray takes up to 460 mm. For longer sheet, the optional long paper tray is available. Finishing size Minimum fi...
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Specifi cations Model name DC-616 Functions 80 job memory (Refer to the setup chart Test feed for details.) Skew adjustment Apply shrinkage Adjust all Automatic job setup by reading barcode Image shift compensation by reading REG mark Options Air knife (Refer to the setup chart Double feed detection for details.)
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Specifi cations DC-616 setup for model/region 115V 115V 230V 230V 230V Item NCSA NCSA EMEA AP PRO Air knife Option Double Feed Option Option detection Option Option Perforation Unit Option Option Card Stacker Option PC Controller Option Option Option PC arm mount Option Option Option...
Index Cut position ..........33 Cutter ............32 ..............7 Cutter module ..........5 AC inlet ............4 Adjust all ..........48,51 Adjusting Feeder ........56 Daily Maintenance ........70 Adjusting for Using a Light Weight Docu- Double detection .........48,50 ment ..........58 Double feed detection ........5 Adjusting the Card Stacker Guides ..17 Advanced mode ........32,35 Airfl...
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Index Speed ..........34,40,48,52 START key ...........6 Notes on Safety (Please Read and Ob- STOP key .............6 serve) ..........iv Suction power ........48,49 NUMERIC key ..........6 TEST key .............6 Perforating position .........33 Top cover .............2 Perforation ..........39 Turning Power OFF ........9 Perforation unit ...........4 Turning Power ON ........8 Power switch ..........4 USB terminal ..........4...
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