Duplo DBM-400 Instruction Manual
Duplo DBM-400 Instruction Manual

Duplo DBM-400 Instruction Manual

System 4000 dynamic booklet maker sheet by sheet

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4000
System
DYNAMIC BOOKLET MAKER
DBM-400
SHEET BY SHEET (SxS)
Instruction Manual
[120V]
DUPLO CORPORATION

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Table of Contents
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Summary of Contents for Duplo DBM-400

  • Page 1 4000 System DYNAMIC BOOKLET MAKER DBM-400 SHEET BY SHEET (SxS) Instruction Manual [120V] DUPLO CORPORATION...
  • Page 2 The DBM-400 Sheet by Sheet (SxS) conforms with FCC regulations only when used in the following system configurations. System1:DB-10+DR-14+DBM-400 SxS+DBM-400T+DBM-400LS+DBM-400K System2:DB-10+DB-10TR+DBM-400 SxS+DBM-400T+DBM-400LS+DBM-400K • This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules.
  • Page 3: Table Of Contents

    INTRODUCTION Thank you for purchasing a DBM-400 sheet by sheet SxS. To ensure correct usage, please read this instruction manual thoroughly, especially the section “Safety Precautions”. After reading, please keep this instruction manual handy for future reference. CONTENTS Safety Precautions ......2 8-4.
  • Page 4: Safety Precautions

    1. Safety Precautions Always observe the following cautions and warnings to prevent personal injury and damage to properties. The degree of dangers and damages that could occur is indicated in two levels by the following symbols. WARNING: Ignoring this symbol could result in serious injury or even death. CAUTION: Ignoring this symbol could result in injury or physical damage.
  • Page 5 1. Safety Precautions Do not use flammable sprays inside or near the unit (e.g. when cleaning the unit). Flammable gas may ignite and cause fire or combustion. Make sure that the current consumption indicated on the main label does not exceed the capacity rating of the power outlet.
  • Page 6 1. Safety Precautions Warning/Caution label location...
  • Page 7: Usage Precautions

    2. Usage Precautions 2-1. Power Supply Make sure the power supply used is always within the following range. 120V AC 50Hz Plug the power cord plug directly into a wall power outlet. This equipment shall be installed near the socket-outlet where the plug on the power supply cord is easily accessible.
  • Page 8: Names And Functions Of The Parts

    3. Names and Functions of the Parts 3-1. External View L side R side Paper direction Name Function POWER Switch When the switch is turned on, power is supplied and the unit sets into the standby state. Control Panel Unit Displays instructions and messages on operating the unit.
  • Page 9: Internal Parts

    3. Names and Functions of the Parts 3-2. Internal Parts Entrance Section Function Name Guides side of the paper when stitching. Movable Side Guide Back Jog Aligns the tail end of the paper. Displays the relation between the position of the stitcher and folding knife during stitching and Stitcher Position Warning folding operations.
  • Page 10 3. Names and Functions of the Parts Stitching Section Name Function Pressure Release Lever Releases the pressure of the conveyance roller at the R side. Ejection Roller Unit Discharges stitched paper. Attach and detach the roller at the L side according to the paper width.
  • Page 11 3. Names and Functions of the Parts Folding Section Name Function Guide Use when the cover is deformed as shown in “9-8. Using the Guide after Folding”. Pressure Release Lever Releases the pressure of press rollers 2. Lever Changes and releases the pressure of press rollers 3. Press Rollers 2 Presses the fold line of the paper.
  • Page 12 3. Names and Functions of the Parts Folding Stopper Section Name Function Paper Guide Prevents the folded paper from curling. Folding Stopper Normally, remains lifted to stop the paper. The stopper goes down if not be folded.
  • Page 13: Control Panel

    3. Names and Functions of the Parts 3-3. Control Panel Control Panel 3 4 5 Lamps/Displays Operation Keys Power Lamp Select Memory Key PAPER JAM Lamp Execute Memory Key Escape Key Saddle-Stitching Lamp Function Key Side-Stitching Lamp Shift Key No-Stitching Lamp Change Key Folding Lamp Numerical Keys...
  • Page 14 3. Names and Functions of the Parts Names and Functions of Control Panel Operation Keys Display Function Select Memory Key Power Lamp Lights up when the power switch is turned on. PAPER JAM Lamp Lights up when paper feeding jam occurs. LCD) Used to select the memory number (paper size).
  • Page 15 3. Names and Functions of the Parts Operation Keys Display Function Step Mode Key Used to finely adjust the size by actually conveying paper. Step Mode Stitching When blinking, indicates that no paper is conveyed into the Area Lamp stitching area. When lit, indicates that the paper is inside the stitching area, and guides in the area can be finely adjusted.
  • Page 16: Stitching Head

    4. Stitching Head 4-1. Names and Functions of Parts...
  • Page 17: Wire

    4. Stitching Head Name Function Wire Guide Pin Guides the wire. Wire Return Stopper Unit Prevents the wire supplied from being pulled back. Felt Cleans the wire surface and lubricates slightly. Wire Return Stopper Used to remove the wire. Fixed the wire guide to the upper wire tube.
  • Page 18: Setting The Wire

    4. Stitching Head 4-3. Setting the Wire Pass the wire between the wire guide pins. Wire guide pin Wire Pass the wire through the two felts Wire and through the wire return stopper unit. Felts Set the Triangular knob at the no stitching position, insert the wire into Upper wire tube the tip of the...
  • Page 19 4. Stitching Head Insert the wire from the Upper wire tube, and feed it gently inside using Wire the pliers provided until the tip of the wire reaches the Lower wire tube. Make sure the wire is not deformed. Upper wire tube Feed wheel Lower wire tube Set the...
  • Page 20: How To Stitch Tests

    4. Stitching Head 4-4. How to Stitch Tests Turn on the power. Select memory 2, set each unit to Let- ter Saddle Stitching and Folding. For details of operations, refer to “6-2. Saddle-stitching Double Letter and Letter Paper” and “9. Binding”. Note Remove the auxiliary roller stay before carrying out the operations.
  • Page 21: Removing Wires

    4. Stitching Head 4-5. Removing Wires Rotate the triangular knob to the Triangular knob “no stitching” position. No stitching Stitching Pull out the wire upwards while press- ing down the wire adjusting stop- per. Wire adjusting Return the triangular knob to the stopper stitching position.
  • Page 22: Adjusting Parts

    4. Stitching Head 4-6. Adjusting Parts Adjusting the wire length 7Wire length adjusting knob Adjust the length of the wire after cutting it according to the thickness of the stitched paper. • Rotating the wire length adjusting knob clockwise increases the wire length. •...
  • Page 23: Stitching Range

    5. Stitching Range Stitching Position Saddle-Stitching • Stitches at the measurement shown by the pointer. Stitch position label • The number of stitches can be se- lected between one and two. Pointer • Refer to 16. Specifications for the length and width. The standard stitching position is as below: Paper When the width (W) is between 8.27 inch...
  • Page 24 5. Stitching Range Side Stitching • Stitches 0.24 inch from the edge of the paper. • The stitches along the width are the same as saddle-stitching. 0.24 (Unit: inch) Note When selecting saddle-stitching and folding, do not stitch at the 7 marked position. (8 positions) Stitch Position Label When stitching at positions other than the center along the length of the paper, refer to 8.
  • Page 25: Stitching Normal Size Paper

    Be sure to remember the following points when changing the paper size: It is impossible to input paper sizes on the DBM-400 SxS when attached to the DB-10C. (The size, however, will be displayed.) The paper size must be input on the DB-10C. For this reason, Select memory key and Execute memory are disabled on the DBM-400 SxS.
  • Page 26 Changing the paper size with the auxiliary roller stays attached does not display this error message on the DBM-400 SxS. Instead, it will be displayed on the DB-10C. To clear the error condition, press the DBM-400 SxS Escape key and then change the paper size again.
  • Page 27 After the mode has been changed, the input values of the first three (or more) sheets in the set will be stored in the buffer, and all the other sheets will be fed through the DB-10C and then stacked in the DBM-400 SxS.
  • Page 28 6.Stitching Normal Size Paper Checking paper guides • When performing saddle stitching and folding, the angle and the height of the paper guide should be adjusted if sheets fail to reach the stitching stopper. (If the paper guide presses down the paper too heavily, it will become difficult for paper to reach the stopper and the alignment of paper will be poorer.) •...
  • Page 29 6.Stitching Normal Size Paper 6-1-4 Points to remember when paper runs over the saddle stitching stopper • Function mode may be used to change the timing at which the stitching stopper rises. Changing this timing makes it possible to relieve problems which would otherwise occur when the stitching stopper fails to rise properly. (For further information, see Item 2 of 10 : Using Function Keys.
  • Page 30 6. Stitching Normal Size Paper Selecting the memory number 1) • Each time the Select Memory Key is pressed, the display on the LCD scrolls as follows. 2) • When the Select Memory Key is pressed while pressing the Shift Key, the display scrolls in the reverse.
  • Page 31: Saddle-Stitching Double Letter And Letter Paper

    6. Stitching Normal Size Paper 6-2. Saddle-Stitching Double Letter and Letter Paper Saddle-stitching Double Letter Paper 1) • Set the LCD to [*1. 17.00 x 11.00] according to the previous chapter "Selecting the Memory Number". (The LCD blinks.) 1. 17.00 x 11.00 2) •...
  • Page 32: Side-Stitching Letter Paper (No Folding)

    6. Stitching Normal Size Paper 6-3. Side-Stitching Letter Paper (No Folding) 1) • Set the LCD to [*3. 08.50 x 11.00] according to the previous chapter "Selecting the Memory Number". (The LCD blinks.) 2) • When the Execute Memory Key is pressed, the guides move. 3) •...
  • Page 33 6. Stitching Normal Size Paper 4) • The unit selected at 3) will move by 0.004 inch each Move (± =) Key or the Move (+ ≠) time the Key is pressed. It will move by 0.04 inch each time Move (±...
  • Page 34: Other Functions

    6. Stitching Normal Size Paper 8) • After completing fine adjustments of the folding area, press the Step Mode Key. • The paper will be ejected folded, and the Step Mode Folding Area Lamp and the Back Stopper Lamp will go off, and the Input Memory Lamp will light up.
  • Page 35: After Starting

    6. Stitching Normal Size Paper 6-6. After Starting To finely adjust stitching and folding positions 1) • Press the Select Parallel Movement Key, and select the stitch position or folding position. • Each time the Select Parallel Movement Key is pressed, the lamps light up in the following order. Stitching Position Lamp lights up = Only the Folding Position Lamp lights up = both lamps light up Only the...
  • Page 36: After Completing Operations

    6. Stitching Normal Size Paper 3) • To store the fine adjustment data, press the Input Memory Key. • If the data need not be stored, press the Clear Key. The Input Memory Lamp will go off. Note Parallel movement can be performed using the Step Mode Key.
  • Page 37: Memorizing

    7. Memorizing • Memory Input Lamp lights up immediately after “6-4. Fine Adjustment in Step Mode” ends or immediately after performing fine adjustments by the parallel movement. • Immediately after performing fine adjustment, to memorize the data, press the Input Memory Key. •...
  • Page 38: Numerically Inputting The Paper Size

    8. Numerically Inputting the Paper Size 8-1. Saddle-Stitching and Folding 1) • As the paper size is input in numerals, measure the paper size on the scale. For example; L=13.6 inch W=9.2 inch Paper feeding direction 2) • Select the number of the desired size to overwrite according to the previous section “Selecting the Memory Number”.
  • Page 39 8. Numerically Inputting the Paper Size 5) • Press Select Fold Key and select folding. 6) • Input the length of the paper (L) as shown below. Paper feeding direction • Using the Numerical Keys, input four digits. Example) Press the Numerical Keys in the following order.
  • Page 40 8. Numerically Inputting the Paper Size 8) • Input the width of the paper (W) as shown below. Paper feeding direction • Using the Numerical Keys, input four digits. Example) Press the Numerical Keys in the following order. However, input a value (W) between 8.27 and 14inch. Note To clear the input number to 0, press the Clear Key.
  • Page 41 8. Numerically Inputting the Paper Size 10) • Input the length [S] from the saddle stitching stopper to the stitching position. Stitching position • The length is automatically calculated (from 1:1) [L x 1/2], and the LCD displays [*5. S=06.80]. Paper feeding direction •...
  • Page 42 8. Numerically Inputting the Paper Size 12) • Next input the stitching position [A] at the R side. Stitch • The position is automatically calculated (from 1:2:1) [W x 1/4], and the LCD displays [*5. A=02.30]. Side R • To change the input, input the four digits again Paper feeding direction using the Numerical Keys.
  • Page 43 Numerical Keys. However, the input range B = (W/2+1.58) to (W– 0.6) inch and within 13.19 inch. 15) When connected to Duplo trimmer DBM-400T Note If connected to any downstream unit other than DBM- 5. F=06.67 400T or if not connected to DBM-400T, proceed to 16).
  • Page 44: Side-Stitching

    8. Numerically Inputting the Paper Size 18) • Press the Execute Memory Key and start moving the guides. • When they complete moving, the LCD displays 5. 13.60 x 09.20 [*5. 13.60x09.20] and a buzzer sounds. • To perform fine adjustment, refer to “6-4. Fine Adjustment in Step Mode”.
  • Page 45 8. Numerically Inputting the Paper Size 8) • Using the Numerical Keys, input four digits. Example) Press the Numerical Keys in the following order. However, input a value between 8.27 and 14 inch. Note To clear the input number to 0, press the Clear Key.
  • Page 46: Corner-Stitching

    8. Numerically Inputting the Paper Size 8-3. Corner-Stitching 1) • Since paper size is input using numerals, measure the paper size on the scale. For example, L=8.27 inch, W=11.69 inch. 2) • Select the number of the desired size to overwrite according to the previous section “Selecting the Memory Number”. For example, when 7 is selected, and the LCD displays [*7.
  • Page 47 8. Numerically Inputting the Paper Size When Corner-Stitching at Right Side 9) • When the Set Key is pressed, the LCD displays [*7. A=02.92]. [A] is the stitching position at the R side. 0.60 However, input a value (A) between 0.6 and (W/2– 1.58) inch.
  • Page 48 8. Numerically Inputting the Paper Size When Corner-Stitching at Left Side Steps 1 to 8 are the same. (page 44) Releasing guides Always be sure to release the guide unit when performing corner stitching on the left side. Paper feeding direction 9) •...
  • Page 49: Stitching No-Folding

    8. Numerically Inputting the Paper Size 8-4. No-Stitching No-Folding Use this mode to convey paper to the Duplo stacker through the DBM-400 SxS. 1) • Measure the width of the paper and input the value. 11) • When the Execute Memory Key is pressed, the For example, W=8.2 inch.
  • Page 50: Binding

    9. Binding 9-1. Using the Auxiliary Roller Stay • The auxiliary roller stay for applying Stitching head Folding section conveyance force to the paper can be attached to this unit at three locations. • To prevent guides from contacting each other, this unit is provided with sensors at A, B and C .
  • Page 51 9. Binding Attaching Conditions Attaching Conditions for Positions A and B ? ? ? ? ? means “attach”. m m m m m means “do not attach”. (: inch) Stitching and Folding Conditions and Paper Length Saddle-Stitching No Stitching Side-Stitching Side-Stitching Folding No Folding...
  • Page 52: Using The Auxiliary Roller Unit

    9. Binding 9-2. Using the Auxiliary Roller Unit Auxiliary Roller Unit for Center Section Auxiliary roller unit Corresponding L side R side Paper Conditions When length of paper to be saddle-stitched over 16.54 inch. When length of paper to be saddle-stitched is 16.54 inch or less.
  • Page 53: Using The Paper Ejection Roller Unit

    9. Binding 9-3. Using the Paper Ejection Roller Unit If the paper skews immediately after stitching, or if the auxiliary roller unit and paper ejection roller unit contact each other, pull the release lever attached to the head holder and move the paper ejection roller unit. •...
  • Page 54: Using The Paper Guide

    9. Binding 9-4. Using the Paper Guide When saddle-stitching paper, move Paper guide Stitching head the paper to the stitching position us- ing the step mode. Letter vertical Loosen the B knob screw, and secure Paper conveyance the paper guide at the edge of the pa- position per.
  • Page 55: Using The Back Stopper And Roller

    9. Binding Loosen the knob screw at (D), and se- cure it where the paper guide touches the paper lightly. Paper guide Paper • If the paper guide touches the paper with force, folding problems may occur. Note When performing operations other than folding, loosen the knob screw at (D), and secure paper guide separated from the paper.
  • Page 56: Using The Stitching Stopper And Folding Stopper

    9. Binding 9-6. Using the Stitching Stopper and Folding Stopper The stitching stopper and folding stopper are used for adjusting stitching and folding respectively, as well as the stitching and folding lines. The adjusting method is the same for both stoppers. •...
  • Page 57: Using The Guides After Folding

    9. Binding 9-8. Using the Guides After Folding Use these guides if the cover is deformed as shown in the figure. Loosen the knob screw, raise up the guide, and secure the knob screw. Normally, use them slightly lowered. Guide Knob screw...
  • Page 58: Using The Press Roller

    9. Binding 9-9. Using the Press Roller With performing folding operation, the press rollers 1 clip papers, the press rollers 2 and 3 reinforce the fold line. Adjust the clearances between the press rollers 1 and between press rollers 2. Adjusting the clearance of press roll- ers 1 Clearance adjusting dial...
  • Page 59: Using The Belt Stacker Unit

    9. Binding Adjusting the press rollers 3 lever • Normally perform folding operations at position A. • Set to position B when the paper stops (jams) just before press rollers 3 when folding operations are carried out at position A. The pressure will decrease.
  • Page 60 9. Binding Press 1 of the Numerical Keys and press the Set Key. This will set the mode for setting the belt conveyance time. Set the length of time by inputting one-digit numbers between 1 to 9 of Numerical Keys (approx. 0.7 to 2.3 seconds).
  • Page 61: Using Function Keys

    10. Using Function Keys Operating the Function Keys • Press the Function Key while the machine is stopping. • Press one of the Numerical Keys corresponding to the following items, and press Set Key to confirm. • Enter the value using the Numerical Keys.
  • Page 62 • Pressing 5 of the Numerical Keys displays [5. Jog Auto ON/OFF]. Set to ON when used connecting to a Duplo suction feed collator. Set to OFF when used connecting to a Duplo 5. Jog Auto ON friction feed collator.
  • Page 63 Pressing 7 of the Numerical Keys displays [7. Err Reset ON/OFF]. Use this setting to set the error message displayed when an error has occurred in DBM-400. 7. Err Reset OFF To switch between ON and OFF, press the key while pressing the Change key.
  • Page 64: Precautions Using Emergency Stop Switch

    11. Precautions Using Emergency Stop Switch The Emergency stop switch should be used only in case of emergency. Avoid excessive use of this switch. In normal operation, use the stop key on the collator. Problems during operation will automatically be detected to stop the machine. [If you press the emergency stop switch] R side Jamming may occur in the conveyer route of the collator, the...
  • Page 65: Lcd Error Messages And Corresponding Actions To Take

    12. LCD Error Messages and Corresponding Actions to Take 12-1. Error Messages When errors occur, the following error numbers are displayed on the LCD, and the arrow indicates the corresponding section. Resolve the error according to the following table. Error No. at Steps to Take Details of Error Side of Arrow...
  • Page 66: Paper Jam Display

    12. LCD Error Messages and Steps to Take Error No. at Steps to Take Details of Error Side of Arrow Overload of the moving motor of the saddle-stitching stopper Remove the obstacle. Overload of the moving motor of the back stopper Remove the obstacle.
  • Page 67: Serious Problems

    • If anything other than paper is blocking the sensor, remove it. If operations still cannot be performed even after the above, contact a Duplo service personnel. 12-3. Serious Problems • The display shows error numbers 11 to 18 at which a serious problem has occurred.
  • Page 68: Other Messages

    Turn off the power switch, and after 10 minutes, turn it on again. If displayed during operations, the guides may not be at their designated positions. Correct the guide positions using the memory number. If error No. 25 occurs frequently, contact a Duplo service personnel. When error No. 26 is displayed •...
  • Page 69: The Unit Will Stop In These Cases

    13. The Unit will Stop in These Cases The top cover is opened during operations. The safety switch works to stop the unit. Operations will start again when the cover is closed, and the start key is pressed. Note The unit will operate while it is in the step mode. When paper jams inside the unit.
  • Page 70: Cleaning

    14. Cleaning For safety purposes, be sure to turn OFF the power before starting cleaning. Cleaning the conveyance belt and roller • Moisten a cloth with water or cleaner and wipe off the dirt. • To clean the press roller and flat belt, open the Shutter, and rotate the Manual Handle clockwise.
  • Page 71: Maintenance Of The Stitching Head

    15. Maintenance of the Stitching Head Lubricate part A once a week and part B once a month with a few drops of the lubricant provided.
  • Page 72: Specifications

    16. Specifications Model name DBM-400 Sheet by Sheet Model Automatic size setting stitcher folder Paper size Saddle stitching and folding Length : 11 to 18.5 inch Width : 8.27 to 14 inch Side stitching Length : 7.88 to 9.48 inch Width : 8.27 to 14 inch...
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  • Page 76 This manual is printed on recycled paper to help protect the environment. 99S-93460-02050001S-0...

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