Docu Cutter DC-545 HC/DC-545 HCEX

Transcription

1 Docu Cutter DC-545 HC/DC-545 HCEX Instruction Manual Version. 1.0 / November 2003 Correct operation and periodic maintenance are essential for ensuring safe use of this machine. Thoroughly read this manual before using this machine. Store this manual so that it can be retrieved whenever needed.

2 Introduction DC-545 HC Thank you for your purchase of the Docu Cutter DC-545 HC. To ensure safe and efficient prolonged use of this machine, read and thoroughly understand this manual before using this machine. After using this manual, be sure to keep it in a place to handy reference. 1 2 PLEASE NOTE In the interest of upgrading our products, specifications and other data given in this manual are subject to change without notice. If the manual contains anything that you do not understand, contact the manufacturer for clarification. 1

3 DC-545 HCEX Thank you for your purchase of the Docu Cutter DC-545 HCEX. To ensure safe and efficient prolonged use of this machine, read and thoroughly understand this manual before using this machine. After using this manual, be sure to keep it in a handy place to Reference. OVERVIEW The DC-545 HCEX was created to produce high-quality, customized products; greeting cards, postcards, brochures, business cards, and resized photographs. It does this by combining a number of devices that set up automatically to slit, cut, and crease a sheet of paper into the desired format with no operator intervention. Initially, the DC-545 HCEX is manually programmed with the required positions of the slits, cuts and creases and the values are stored in a memory for future recall. A CCD sensor reads the job number encoded in a barcode on the unfinished sheet. Then, the DC-545 HCEX recalls the values from memory, sets up the slitter positions, activates the cutter for lead, trail, and any intermediate cuts and any required creases. In addition, when a small 90-degree angle register mark has been printed adjacent to the barcode, the position is measured against the intended position stored in the job memory. As this mark is part of the original image, any error in its location can be compared with the stored value and used to correct the setup positions of the devices by applying a horizontal offset to the cut and crease positions, and a vertical offset to the slit positions to maintain precise finishing every time. PLEASE NOTE In the interest of upgrading our products, specifications and other data given in this manual are subject to change without notice. If the manual contains anything that you do not understand, contact the dealer for clarification. 2

4 Contents Chapter 1 Chapter 2 Chapter 3 Chapter 4 Introduction... 1 DC-545 HC... 1 DC-545 HCEX... 2 Notes on Safety (Please Read and Observe)... 5 Safety Precautions... 5 Warning Sticker... 8 Positioning the Machine... 9 Maintenance Conventions Used in This Manual Operating Instraction - DC-545 HC Part names and their functions Loading the paper Selecting/operating/stopping a job Adjustments Troubleshooting table Specifications Before Using This Machine - DC-545 HCEX Confirming the Packaged Materials How to Set up the System Part Names and Their Functions Appearance Control Panel LCD Panel Turning Power ON/OFF Turning ON the Power Turning OFF the Power Operating Instructions - DC-545 HCEX Automatic Cutting Using Bar Codes and Register Marks About the Waste Tray Troubleshooting - DC-545 HCEX Troubleshooting Flow Chart Power Does Not Turn ON Cutting is Not Possible Error Messages When a Paper Jam Has Occurred When REJECT PAPER is Displayed When FEED JAM is Displayed When CENTER JAM is Displayed Procedure of Removing Front and Rear Creaser Guides When SLITTER JAM is Displayed When CUTTER LOCK is Displayed When CREASE LOCK is Displayed

5 Contents Chapter 5 Manual Programming - DC-545 HCEX Prior to Programming a Job Definition of Programming Terms Customer Programmed Jobs Factory Preset Jobs How to Manually Program a Job Appendix - DC-545 HC / DC-545 HCEX Specifications DC-545 with HC AUTO FEEDER Specifications DC-545 with HCEX AUTO FEEDER Specifications Specifications of Reg. Mark and Bar Code How to do AUTO CUT Index

6 Notes on Safety (Please Read and Observe) Safety Precautions Various symbols and pictures are used in this manual and on the stickers affixed to the machine. These symbols and pictures provide warnings and instructions to prevent danger to you or other personnel, and to prevent damage to office property. The meanings of these symbols and pictures are explained below. 1 WARNING CAUTION Indicates a high degree of potential danger. If the warning is ignored, death or serious injury may result. Indicates a medium degree of potential danger. If the caution is ignored, medium injury or damage to property may result. 2 [Examples of Pictorial Symbols] A circle with a line through it indicates a prohibited action. The particular act prohibited is indicated by a picture inside the circle. (In the example shown here, the prohibited act is disassembly.) A black disc indicates an instruction, or sometimes a prohibited action. The instruction itself is indicated by pictorial symbols drawn in white on the disc. (In the example shown here, the instruction is Remove the plug from the outlet. ) These are particularly important safety points and should always be observed. WARNING If the machine is used after foreign matter (metal fragments, water, or liquid) has entered the machine, this may result in fire or electric shock. Turn the main unit s power switch OFF, and then remove the power plug from the outlet. Contact the sales distributor. If the machine is used after heat, smoke, strange smell, or other abnormality is detected, this may result in fire or electric shock. Turn the main unit s power switch OFF, and then remove the power plug from the outlet. Contact the sales distributor. Use only the power cord that is provided among the accessories. 5

7 Notes on Safety (Please Read and Observe) WARNING Do not modify the machine. Doing so may result in fire or electric shock. Do not remove the rear lid, cabinet, or covers from the machine. The inside of the machine contains high-voltage parts, which may cause electric shock. Do not remove or insert the power plug with wet hands. Doing so may result in electric shock. Do not damage, break, or modify the power cord. Do not place heavy objects on, tug, or unnecessarily bend the power cord. Doing so may result in fire or electric shock. Do not insert or drop metal, flammable material, or other matter through the ventilation holes into the machine interior. Doing so may result in fire or electric shock. Do not place flower vases, flowerpots, cups, or water containers (including metal containers) on top of the machine. Fire or electric shock may result if liquid spills inside the machine. Do not use a source voltage other than that specified. Do not connect two or more loads to a single outlet. Doing so may result in fire or electric shock. Do not place the machine in a humid or dusty area. Doing so may result in fire or electric shock. 6

8 Notes on Safety (Please Read and Observe) CAUTION Before moving the machine, remove the power plug from the outlet. If the cord is damaged, this may result in fire or electric shock. Remove the power plug itself, not the cord. Tugging the cord may damage it (expose conductors, or cause disconnections, etc.), resulting in fire or electric shock. 1 2 Do not place the machine in an unstable position, such as on an unsteady support or sloping area. If the machine is dropped or falls over, this could result in personal injury. 7

9 Notes on Safety (Please Read and Observe) Warning Sticker Keep the WARNING stickers clean at all times. If labels become damaged or come off, have your service representative replace them. q WARNING Do not touch blade! To remove jammed paper, use the tweezers. L8-T1100 w WARNING Cutters and movable parts are inside this cover. Before opening the cover to work, unplug the power cord. Use caution when working near cutters and movable parts. L8-T1080 No. Parts No. Name Q ty q L8-T1100 Warning Sticker 1 1 w L8-T1080 Warning Sticker 2 3 8

10 Notes on Safety (Please Read and Observe) Positioning the Machine Installing the machine on a flat, stable surface. 1 2 Avoid installing the machine in a dusty area. Avoid installing the machine in the direct sunlight or heat, such as near a stove. The machine may indicate errors due to overheating caused by sunlight. Also avoid hot, cold, or humid areas since paper may absorb moisture, causing paper jams or wrinkles. 9

11 Notes on Safety (Please Read and Observe) Maintenance Clean the exterior of the machine as described below. Tightly wring a soft cloth that has been moistened with water or neutral detergent, and wipe dirt from the machine s surface. Never use alcohol or organic solvents. Doing so may discolor or damage the machine exterior. Dust and clean the machine at least once a week to avoid breakdowns. Before cleaning, turn the power switch OFF, and then remove the power plug from the outlet. WARNING Before cleaning, remove the power plug from the outlet. Failure to do so may result in an electrical shock or a fire hazard. Prevent water and neutral cleansers from getting inside the machine. If liquids spill inside the machine, contact your agent immediately. Using the machine with water spilled inside may result in an electrical shock or a fire hazard. 10

12 Notes on Safety (Please Read and Observe) Conventions Used in This Manual Each page of descriptions in this manual of how to operate the DC-545 is set up as follows. Chapter 1 2 Title Description of operational steps Each step is described in detail. Illustrations The illustrations provide a visual reference to which keys to operate and other related conditions. Pictorial Symbols and Other Notations Used in This Manual IMPORTANT Tip Continue Page : Introduces instructions for correct operation of the machine. If these instructions are ignored, the machine may not be able to operate at optimum performance or may break down. : Introduces information that is useful for operation and maintenance of the machine, or information about the machine s performance, etc. : Indicates that the description of the operating sequence is continued on the next page. (a P.00 xxxx ) : Indicates the page number and item containing related information. 11

13 Chapter 1 Operating Instraction - DC545 HC Part names and their functions e q t w r No. Name Function Reference Page q Level adjustment lever For adjusting the level of the elevator 6 w Separator adjustment knob For adjusting the amount of space between sheets of paper 6 e Airflow adjustment knob For adjusting the amount of airflow 7 r Skew adjustment knob For adjusting the skew of the paper 7 t Stoppers For holding the rear edge of the paper stack 5 12

14 Operating Instraction - DC545 HC Part Names and Their Functions Loading the paper Fan the edge of the paper stack to separate the paper. 1 2 Set the paper stack on the feed tray. 3 Note The height of the paper stack should not exceed the "MAX" level. MAX Turn the feed guide knob to loosen, then adjust the feed guide. 13

15 Part Names and Their Functions Tighten the knob to fix the position of the guide. Set the stoppers. Selecting/operating/stopping a job Follow the instructions in the DC-545 manual to select the type of job that you want to perform, and then press START. POWER START C STOP To stop the machine, press STOP. POWER START C STOP 14

16 L8-T1080 Operating Instraction - DC545 HC Part Names and Their Functions Adjustments Elevator level ( Feed tray) The elevator level should be adjusted in the following cases. a. The machine does not feed. Lower the lever. The level of the elevator is raised. b. The machine feeds multiple sheets at once. (double feed) Raise the lever. The level of the elevator is lowered. Figure 1-1: Close-up of the level adjustment lever Separator The height of the separator should be adjusted in the following cases: a. The machine does not feed. Turn the knob in the clockwise direction (to a smaller number). The position of the separator is lowered. b. The machine feeds multiple sheets at once. (double feed) Turn the knob in the anti-clockwise direction (to a larger number). The position of the separator is raised. Figure 1-2: Location of the level adjustment lever Figure 2-1: Close-up of the separator adjustment knob WARNING Cutters and movable parts are inside this cover. Before opening the cover to work, unplug the power cord. Use caution when working near cutters and movable parts. Figure 2-2: Location of the separator adjustment knob 15

17 Part Names and Their Functions Adjusting the airflow The amount of airflow should be adjusted in the following cases: a. The machine does not feed. Turn the knob in the anti-clockwise direction (to a larger number). The amount of airflow is increased. b. The machine feeds multiple sheets at once. (double feed) Turn the knob in the clockwise direction (to a smaller number). The amount of airflow is decreased. Figure 3-1: Close-up of the airflow adjustment knob Figure 3-2: Location of the airflow adjustment knob Adjusting the amount of skew Paper may be cut at an angle if a skew in the paper arises during feeding. When this happens, correct the problem by changing the angle of the feed guide. Figure 4-1: Skew adjustment knob 16

18 Operating Instraction - DC545 HC Part Names and Their Functions Troubleshooting table Symptom Possible Cause Remedy The machine does not feed paper. The machine double feeds paper. The paper is cut at an angle or not fed straight. Paper level is too low. Paper separators are too high. Not enough airflow. Paper level is too high. Paper separators are too low. Too much airflow. The paper is skewed. Raise the elevator height by pushing the level adjustment lever downward. (See Figure 1-1) Lower the paper separators by turning the separator adjustment knob clockwise, towards a lower number. (See Figure 2-1) Increase the airflow by turning the airflow adjustment knob counter-clockwise. (See Figure 3-1) Lower the elevator height by pushing the level adjustment lever upward. (See Figure 1-1) Raise the paper separators by turning the separator adjustment knob counter-clockwise, towards a higher number. (See Figure 2-1) Decrease the airflow by turning the airflow adjustment knob clockwise, towards a lower number. (See Figure 3-1) 1. Remove the paper from the feed tray. 2. Turn the skew adjustment knob according to the instructions on the label to adjust the angle of the feed guide Specifications No. Item AF Model Floor Model 2 Model No. AF Input paper size Min.8.5 x 11 / A4 Max.12.6 x 18 / A3 <no curl in the paper> 4 Input paper weight Min.110gsm (29.3LB) Max.230gsm (85LB) 5 Media type Range: Regular copy paper to coated heavy weight paper 6 Feeding method Automatic (Air suction method) 7 Feed tray capacity 3.9 (100mm) 8 Power supply DC5V, DC24V is supplied from DC-545 main body 9 Machine dimensions 43.4 (W) x 22.7 (D) x 37.8 (H) 1102mm (W) x 576mm (D) x 960mm (H) 10 Machine weight 117.1LB (Feeder : 44.9LB, Stand : 72.2LB) 53.2kg (Feeder : 20.4kg, Stand : 32.8kg) 11 Operating temperature 41-86F (5-30 C) 12 Operating Humidity 40-70% (no condensation within this range) 17

19 Chapter 2 Before Using This Machine - DC545 HCEX This chapter contains essential information you should understand such as the materials packaged with this machine, how to set up the system, the names of the machine parts, etc. Confirming the Packaged Materials This product contains the following materials packaged together. If any material is missing, please contact your dealer. q w e r t No. Name Q ty q Power cord 1 w Instruction Manual 1 e Tweezers 1 r Screw Driver 1 t Hex L-wrench 1 18

20 Before Using This Machine - DC545 HCEX How to Set up the System This section describes the cautions and the procedure when you set up this machine. Take out the machine from the package and place the machine on a flat and stable table. WARNING Do not try to lift the machine by yourself. Two or more people are required to prevent injury and/or damage to the machine. When you open the box, be sure not to injure yourself or others with a cutter or the like. Detach the shipping bracket Attach the feed tray to the main body. Attach the paper tray to the main body. Continue Page 19

21 How to set up the System Connect the power cord to the Docu Cutter and a wall outlet. 20

22 Before Using This Machine - DC545 HCEX Part Names and Their Functions Appearance t y u r e w q No. Name Function q Control panel Displays operations and statuses. w Waste tray cover Open to remove pieces of paper left in the machine. e Waste tray Receives pieces of waste paper. r Feed tray The original document is placed here. t Feed guides Slide to match the width of the document. y Feed lamp Indicates ready condition. Turns off during cutting or when the front cover or the rear cover is opened. u Front cover Open to remove jammed paper. Reference page , 20 10, 11, , 25 21

23 Part Names and Their Functions i!0 o No. Name Function i Rear cover Open to remove jammed paper. o Paper tray Receives the finished document.!0 Power switch Press to switch the power on and off. Reference page 23, 25 10,

24 Before Using This Machine - DC545 HCEX Part Names and Their Functions Control Panel US q w e r + 1 POWER 2 3 START COVER JAM F MODE SET 7 C STOP 12 PAPER Europe!1!0 o i u y t q w e r F C 0!1!0 o i u y t No. Name Function q LCD panel Displays the status of the machine. Displays messages when an error or paper jam occurs. w <+> key Press to eject the document from the machine at the time of paper jam. <-> key Press to eject the document from the machine at the time of paper jam. During programming mode enables backward movement through the program steps. e POWER lamp Lights up when the power is switched on. r <START> key Not used when the DC-545 is operated without the autofeeder - AF-100. Also make this the last sentence. Press to start processing when the AF-100 is attached. START lamp Normally lights up in green. Lights up in red when the front cover or the rear cover is open. t <STOP> key Press to stop automatic feeding after the current sheet is processed. Press to clear jam indication after the paper is cleared. y Key pad Press to enter print numbers and enter values during manual programming. u <CLEAR> key Press to clear the count. Press to cancel manual programming. i <SET> key Press to confirm selection/entry. Used to test process a single sheet. (for systems with the AF-100 only) o <MODE> key Press to change the mode.!0 <F> key Not used.!1 COVER lamp Blinks when the front cover or the rear cover is open. JAM lamp Blinks when a paper jam has occurred. PAPER lamp Blinks when paper runs out. (systems with the AF-100 only) Reference page 16, 23, ,

25 Part Names and Their Functions LCD Panel q w e [ RUN ] P 79 BC REG AC r t y u No. Name Function q Status Displays the current status or operating mode. w Preset number Displays the preset Program (P) number. e OPTION An "*" is displayed if the AF-100 is attached. r BAR CODE When bar code reading is enabled "BC" is displayed; "- -" is displayed when bar code reading is disabled. t REGISTER MARK When using register marks reading is enabled "REG" is displayed; "- - -" is displayed when register mark reading is disabled. y AUTO CUT When using AUTO CUT is enabled "AC" is displayed; "- -" is displayed when AUTO CUT is disabled. u COUNTER Displays the number of pages processed. Reference page 15,

26 Before Using This Machine - DC545 HCEX Turning Power ON/OFF This section describes the operating sequence from turning ON the power switch until the machine is ready to operate, and how to turn OFF the power. Turning ON the Power Press the side of the power switch. The power turns ON. 12 The illustration on the right shows what is displayed on the LCD panel. ** denotes a preset number (01-80). [ RUN ] P- BC AC 2 3 The illustration on the right shows that paper remains in the machine. If this screen is displayed, remove them. (a P.25, When REJECT PAPER is Displayed ) J 1 REJECT PAPER Turning OFF the Power Press the K side of the power switch. The power turns OFF. 25

27 Chapter 3 Operating Instructions - DC545 HCEX This chapter describes the operating sequence from turning ON the power switch until completing cutting. Automatic Cutting Using Bar Codes and Register Marks This machine can read bar codes and reg. marks enabling automatic cutting and creasing. The procedure is described below. Turn ON the power. (a P.17, Turning ON the Power ) Set the feed tray. Slide the feed guides to match the document size. Set the document in the feed tray with the surface where bar codes and reg. marks are printed facing upwards. The feed lamp turns off and a beep sounds. In a few seconds, the document is fed into the machine. Tip Set the document in the direction shown in the illustration. 26

28 Operating Instructions - DC545 HCEX Automatic Cutting Using Bar Codes and Register Marks Automatic cutting and creasing start based on the information contained in the bar codes and reg. marks. The finished document is ejected. IMPORTANT Pieces of cut paper accumulate in the waste tray. Open the drawer located at the bottom of the machine and remove them periodically. Accumulation of pieces of paper may cause paper jams. 1 Tip Bar Code, Reg. Mark and AUTO CUT Options The bar code, reg. mark and AUTO CUT functions may be enabled and disabled by using the <MODE>, <SET>, <+> and <-> keys. Use the <MODE> key to advance through the menus shown on the right. Use the <SET> key to change from the BARCODE selection (ON or OFF) to the REG. MARK selection, and use the <SET> key to change from the REG. MARK to the AUTO CUT selection. [RUN] P 04 <MODE> KEY [SELECT] P 04 <MODE> KEY 23 While in the BARCODE, REG. MARK and AUTO CUT selections: Enable or disable functions with the <+> and <-> keys. If you select barcode OFF you must manually enter the desired program number while in the [SELECT] menu. IMPORTANT NOTE If select barcode ON and/or REG. MARK ON and those items are not present, the job will not process and the display will indicate a BARCODE or REG.MARK error. Make certain that these items are set properly. See the appendix (P.54) for details about positioning bar codes and register marks. Register Mark Barcode [INPUT] INPUT >SET <MODE> KEY BARCODE *ON OFF <SET> KEY REGISTER MARK *ON OFF <SET> KEY <MODE> KEY <MODE> KEY AUTO CUT *ON OFF <MODE> KEY The DC-545 is shipped from the factory with the bar code read feature turned on and the reg. mark feature turned off. If the job to be finished has reg. marks properly printed on it (as described on page 63), the cutting accuracy can sometimes be improved by additionally turning on the Reg. Mark feature. 27

29 Automatic Cutting Using Bar Codes and Register Marks Tip CCD Scan Mode How to Change the Settings in the DC-545 CCD Scan Mode Where to make the settings 1. Press the MODE key and select BARCODE. 2. Press the SET key. Switch the display from BARCODE REGISTER MARK AUTO CUT CCD SCAN. MODE 3. CCD SCAN. MODE appears on the display. Change the setting (*) with the +, and - keys. The standard setting for CCD SCAN. MODE is FAST. CCD SCAN. MODE * FAST SLOW The following conditions might cause the E4 REG MARK ERROR. q The roughness of the paper may cause the mark to be unreadable. w The REG MARK may not be sharp enough. e The paper may be dirty. If this is the case, switch the setting from FAST to SLOW. Note: Even if you switch the setting to SLOW, the conditions noted in q, w, and e may cause the E4 REG MARK ERROR. If this happens, do the operation without using the REG MARK. 28

30 Operating Instructions - DC545 HCEX About the Waste Tray Pieces of cut paper accumulate in the waste tray. Open the drawer located at the bottom left of the machine and remove them periodically. Accumulation of pieces of paper may cause paper jams. How to remove the accumulated pieces of paper is described below. WARNING Be sure to confirm that the machine is in a full stop before removing the accumulated paper to prevent your hands or fingers from being caught or pinched in the machine. Pieces of cut paper accumulate in the waste tray. Open the drawer located at the bottom of the machine and remove them periodically. Accumulation of pieces of paper may cause paper jams. Confirm that the machine is fully stopped. Open the waste tray located at the bottom left of the machine and remove the accumulated paper Tip When pieces of paper remain in the machine, open the waste tray cover located at the front of the machine and remove them. 29

31 Chapter 4 Troubleshooting - DC545 HCEX This chapter describes what to do when an error has occurred and how to deal with paper jams and error messages. Troubleshooting Flow Chart Power Does Not Turn ON If the power does not turn ON, check the following. THE MACHINE DOESN'T TURN ON. IS POWER PLUG INSERTED? YES NO IS POWER SWITCH ON? Insert the power plug securely. YES NO Turn the power switch ON. Please contact your service person. 30

32 Troubleshooting - DC545 HCEX Troubleshooting Flow Chart Cutting is Not Possible If cutting is not possible, check the following. IS THERE A MESSAGE DISPLAYED ON ERROR DISPLAY PANEL? NO Please contact your service person. YES See P.23, "Error Messages"

33 Error Messages This machine has a self-diagnosis function that displays an error message on the control panel when it determines a problem has occurred. The following shows the error message, possible causes and a description of the problem that was detected. J 1 REJECT PAPER Cause Paper is still in the machine One of the sensors (PPS1, PPS2, PPS3, or PPS4) is defective Problem detected 1. Light did not transmit through all of the sensors (PPS1, PPS2, PPS3, and PPS4) when the power was turned on. 2. Light did not transmit through all of the sensors PPS1, PPS2, PPS3, and PPS4 when the start switch was pressed while the machine was stopped and paper was in the AF-100. (Only when using DC-545HC) J 2 FEED JAM Cause Paper does not meet specifications Separator gap is too narrow(af-100) Fan (blower) airflow is insufficient (AF-100) Feed solenoid incorrect adjustment Feed solenoid is defective Feed motor is defective Shutter solenoid is defective(af-100) Feed motor is defective(af-100) Fan (suction or blower) is defective(af-100) Problem detected 1. Paper was not detected at PPS2 even though it was longer than the set length of the paper (30 mm) and it was detected at PPS1. 2. Paper was not detected at PPS1 after the specified time (about 2.5 seconds) after paper feed operation started, therefore paper feed operations were started again. Error occurs if the feed operation starts three times and paper is not detected at PPS1. 32

34 Troubleshooting - DC545 HCEX Error Messages J 3 CENTER JAM Cause Paper does not meet specifications The length of the JOB data and the paper are different. Problem detected 1. The leading edge of the paper was not detected at PPS3 even though the specified length (100 mm) had passed PPS2. 2. Paper was not released from PPS3 even though the preset registered paper length + 30 mm had passed PPS3. J 4 SLITTER OR STACK Cause Paper does not meet specifications The length of the job data and the paper are different. The stacker is full and paper can not be ejected Problem detected 1. The leading edge of the paper was not detected at PPS4 even though the specified length (500 mm) had passed PPS3. 2. Paper was not released from PPS4 even though the preset registered paper length + 50 mm had passed PPS4. J 5 OVER CAPACITY Cause There is too much paper loaded on the AF-100 feed tray. Paper level sensor is defective Actuator malfunction Main PWB unit is defective 6 Problem detected 1. Elevator lower switch was pressed after paper feed was started at DC-545HC while the paper level sensor was on. 33

35 Error Messages J 7 CUTTER LOCK Cause Paper does not meet specifications Cutter motor is defective Cutter position switch is defective Main PWB unit is defective Problem detected 1. There was no response from the cutter position switch even though the specified time (0.6 seconds) elapsed after cutting started. J 8 CREASE LOCK Cause Paper does not meet specifications Creaser motor is defective Creaser sensor is defective Main PWB unit is defective Problem detected 1. There was no response from the creaser sensor even though the specified time (2.0 seconds) elapsed after scoring started. E 1 COVER OPEN Cause Actuator (N4-L224*&N4-225*) installation is incorrect Interlock is defective Main PWB unit is defective Problem detected 1. One of the covers was open while the machine was operating. 2. One of the covers was open when the start button was pushed. 34

36 Troubleshooting - DC545 HCEX Error Messages E 2 RS232C ERROR Cause CCD is defective Main PWB unit is defective Problem detected 1. There was an abnormal transmission between the CCD and the DC-545. E 3 BARCODE ERROR Cause Bar code being used does not meet specifications CCD is defective Main PWB unit is defective Problem detected 1. The bar code could not be read even after the paper fed the specified length (50 mm) after the bar code reading operation started E 4 REG.MARK ERROR Cause Reg. mark being used does not meet specifications CCD is defective Main PWB unit is defective Problem detected 1. The reg. mark could not be read even after the paper fed the specified length (40 mm) after the reg. mark reading operation started. 2. Mark 1 was less than 4.5 mm. 6 35

37 Error Messages E 5 SLITTER ERROR *Slitter errors are numbered from 1 to 6. Cause Slitter sensor is defective Slitter positioning motor is defective Main PWB unit is defective Problem detected 1. Light did not transmit to the slitter sensor when temporarily shifting inward 8 mm to detect the home position while the slitter sensor was shielded from light and the command to move the slitter was issued. 2. The slitter did not return to the predetermined position within the specified time period (refer to the table below) after the command to move the slitter was issued. Left margin slitter Right margin slitter Left center slitter Right center slitter OP1 slitter OP2 slitter Time until detection 4.5 S 5.5 S 6.0 S 6.0 S 12.0S 6.0S (OP2: When not installed) (OP2: When installed) 6.0S (Only when OP2 is installed.) Angle Connector Sensor This image shows the optional 1 slitter sensor. You can identify the position of the slitter where the error that occurs by looking at the number in the message displayed on the LCD panel. LCD message SLITTER ERROR 1 SLITTER ERROR 2 SLITTER ERROR 3 SLITTER ERROR 4 SLITTER ERROR 5 SLITTER ERROR 6 Slitter Left margin slitter Right margin slitter Left center slitter Right center slitter OP1 slitter OP2 slitter 36

38 Troubleshooting - DC545 HCEX Error Messages E 6 DATA ERROR Cause Preset data is not registered Memory PWB unit is defective Problem detected 1. Preset data was accessed that exceeds a total of 17 AUTO CUTs (see table below), JOB cuts and scores while AUTO CUT is being used. 2. There was no information in the preset data that was accessed. 1 Distance from the leading edge of the paper to the first cut 0.0 to 16.9 mm 17.0 to 32.9 mm 33.0 to 48.9 mm 49.0 to 64.9 mm 65.0 to 80.9 mm 81.0 to 96.9 mm 97.0 to mm to mm to mm to mm to mm to mm to mm to mm to mm to mm to mm to mm Table 1: List of AUTO CUT counts AUTO CUT count Distance from the last cut to the trailing edge of the paper 0.0 to 20.9 mm 21.0 to 36.9 mm 37.0 to 51.9 mm 52.0 to 66.9 mm 67.0 to 81.9 mm 82.0 to 96.9 mm 97.0 to mm to mm to mm to mm to mm to mm to mm to mm to mm to mm to mm AUTO CUT count Example: 1. Cuts: 5 Scores: 2 First cut: 98.0 mm Length from the last cut to the trailing edge of the paper: 65.0 mm According to the table: There are 6 AUTO CUTs from the leading edge of the paper to the first cut. There are 4 AUTO CUTs from the last cut to the trailing edge of the paper. The number of cuts, scores, and AUTO CUTs is = 17. The total is more than 17, resulting in E6: DATA ERROR Cuts: 10 Scores: 4 First cut: 10.0 mm Length from the last cut to the trailing edge of the paper: 20.0 mm According to the table: There are 0 AUTO CUTs from the leading edge of the paper to the first cut. There are 0 AUTO CUTs from the last cut to the trailing edge of the paper. The number of cuts, scores, and AUTO CUTs is = 14. The total is less than 17, resulting in no error. 37

39 Error Messages E 7 CONNECTION ERROR Cause Bad connection between AF-100 and DC-545 Feed PCB unit is defective Main PWB unit is defective Problem detected 1. Can not confirm connection between AF-100 and DC-545 while machine is operating. E 8 ELEVATOR ERROR Cause Elevator upper switch is defective Elevator lower switch is defective Elevator motor is defective Paper level sensor is defective Feed PCB unit is defective Main PWB unit is defective Problem detected 1. Elevator was not detected at elevator upper switch, elevator lower switch, or paper level sensor after the specified time (* seconds) after the command to operator the elevator was issued. * 10 seconds when rising at start-up, 3.5 seconds when paper is being fed, 9 seconds when going down at shut-down NOTE : When this error occurs there is a possibility that the screws pressing on the spring, or the elevator up and down switch are damaged. 38

40 Troubleshooting - DC545 HCEX When a Paper Jam Has Occurred When a paper jam has occurred, the JAM lamp blinks and a message is displayed on the LCD panel. WARNING Do not touch the blade (with the WARNING sticker attached). Doing so may cause injury. (ap.6, Warning Sticker ) Before removing paper from under the front and rear covers, make sure the machine is fully stopped. Use the tweezers that come with the machine to prevent your hands or fingers from being caught or pinched. (ap.6, Warning Sticker ) When REJECT PAPER is Displayed If a document remains in the machine when the power is turned ON, REJECT PAPER is displayed on the LCD panel and the JAM lamp blinks. Remove the document with the following procedure. Press the <+> or <-> key to eject the document. J 1 REJECT PAPER IMPORTANT Be sure to close the front or rear cover when you operate the machine. The machine does not work if the front or rear cover is open. COVER JAM PAPER F MODE SET If the document cannot be removed with the procedure mentioned above Open the front or rear cover. Front cover 6 Rear cover Continue Page 39

41 When a Paper Jam Has Occurred Remove the jammed document using the tweezers. Close the front or rear cover. Front cover Rear cover 40

42 Troubleshooting - DC545 HCEX When a Paper Jam Has Occurred When FEED JAM is Displayed If a paper jam has occurred in the feeding unit, FEED JAM is displayed on the LCD panel and the JAM lamp blinks. Remove the jammed document with the following procedure. J 2 FEED JAM Press the <-> key and return the jammed document to the feed tray side COVER JAM PAPER F MODE SET 4 Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP If the document cannot be removed with the procedure mentioned above Open the front cover. Front cover 6 Continue Page 41

43 When a Paper Jam Has Occurred Remove the jammed document. Close the front cover. Front cover Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP 42

44 Troubleshooting - DC545 HCEX When a Paper Jam Has Occurred When CENTER JAM is Displayed If a paper jam has occurred in the machine (front), CENTER JAM is displayed on the LCD panel and the JAM lamp blinks. Remove the jammed document with the following procedure. J 3 CENTER JAM Press the <-> key and return the jammed document to the feed tray side COVER JAM PAPER F MODE SET 4 Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP If the document cannot be removed with the procedure mentioned above Open the front cover. Front cover 6 Continue Page 43

45 When a Paper Jam Has Occurred Remove the jammed document using the tweezers. Close the front cover. Front cover Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP 44

46 Troubleshooting - DC545 HCEX When a Paper Jam Has Occurred Procedure of Removing Front and Rear Creaser Guides This operation also needs to be done when the creaser or the cutters are locked. Please open the Front/Rear Cover of DC-545HC. 1 2 Front Cover Rear over 4 Loosen the 2 set-screws on both sides of Front/Rear Creaser Guides, counter clockwise 2 or 3 times. Use the Hex Driver contained in the kit. IMPORTANT The cap bolt may fall off if it is loosened more than necessary. 6 45

47 When a Paper Jam Has Occurred Please slide the guide toward q (non-operator side) then pull up toward w. Front Creaser Guide Rear Creaser Guide IMPORTANT The figures of Front and Rear Creaser Guide are similar. When installing Creaser Guide, please refer to the following figure. Rear Guide Front Guide 46

48 Troubleshooting - DC545 HCEX When a Paper Jam Has Occurred When SLITTER JAM is Displayed If a paper jam has occurred in the machine (rear), SLITTER JAM is displayed on the LCD panel and the JAM lamp blinks. Remove the jammed document with the following procedure. J 4 SLITTER OR STACK Press the <+> key and forward the jammed document to the paper tray side COVER JAM PAPER F MODE SET 4 Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP If the document cannot be removed with the procedure mentioned above Open the rear cover. 6 Rear cover Continue Page 47

49 When a Paper Jam Has Occurred Remove the jammed document. Close the rear cover. Rear cover Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP 48

50 Troubleshooting - DC545 HCEX When a Paper Jam Has Occurred When CUTTER LOCK is Displayed If a paper jam has occurred in the cutter unit, CUTTER LOCK is displayed on the LCD panel and the JAM lamp blinks. Remove the jammed document with the following procedure. Check that the paper stock is within specifications. J 7 CUTTER LOCK Press the <-> key and return the jammed document to the feed tray side COVER JAM PAPER F MODE SET 4 Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP If the document cannot be removed with the procedure mentioned above Open the front cover. Front cover 6 Continue Page 49

51 When a Paper Jam Has Occurred Remove the jammed document using the tweezers. NOTE : If you cannot remove the jammed paper with the tweezers, follow the procedure on page 45 to remove it. Close the front cover. Front cover Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP 50

52 Troubleshooting - DC545 HCEX When a Paper Jam Has Occurred When CREASE LOCK is Displayed If a paper jam has occurred in the creasing unit, CREASE LOCK is displayed on the LCD panel and the JAM lamp blinks. Remove the jammed document with the following procedure. Check that the paper stock is within specifications. J 8 CREASE LOCK Press the <+> key and forward the jammed document to the paper tray side COVER JAM PAPER F MODE SET 4 Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP If the document cannot be removed with the procedure mentioned above Open the rear cover. 6 Rear cover Continue Page 51

53 When a Paper Jam Has Occurred Remove the jammed document using the tweezers. NOTE : If you cannot remove the jammed paper with the tweezers, follow the procedure on page 45 to remove it. Close the rear cover. Rear cover Press the <STOP> key to reset the fault logic and clear the fault message. POWER START C STOP 52

54 Manual Programming - DC545 HCEX Chapter 5 Manual Programming - DC545 HCEX This chapter describes how to manually program the Docu Cutter. The Docu Cutter is manually programmable with 80 sets of job dimensions or program numbers. Each set of dimensions are stored and recalled by a program number. (a P.45, Factory Preset Jobs ) Prior to Programming a Job 1 Before programming a job carefully measure, in millimeters, the required slits, cuts and creases. See the Figure 1 for reference and Figure 2 for a detailed description of each function. Record the values in Customer Programed Jobs. Remember that all measurements, except MARK 1, are in millimeters. Familiarize yourself with the following illustrations and instructions to make the programming process easy and trouble free. IMPORTANT NOTES: There are a total of five slitters. Two slitters are for the margins and the remaining three slitters are for the center of the sheet. There is a guillotine cutter that performs cuts perpendicular to the line of the paper travel. There is creasing unit that performs creases perpendicular to the line of the paper travel. P 01? (01 80) OK? >SET Figure 1 PAPER FEEDING DIRECTION Cut Reg. Mark (Optional) Bar Code (Optional) Figure 2 Program Number Slit Crease 5 53

55 Definition of Programming Terms PAPER FEEDING DIRECTION Reg. Mark (Optional) Bar Code (Optional) Left Margin Slitter (LEFT SL) Right Margin Slitter (RGHT SL) Center Left Slitter (C.L.SL) Center Right Slitter (C.R.SL) Center Slitter (OP 1) PAPER FEEDING DIRECTION First Cut Reg. Mark (Optional) Bar Code (Optional) Crease (SCR 1) Last cut Tip Paper area before first cut and after last cut are considered to be scrap and will be chopped up for disposal in waste tray when AUTO CUT is selected. See the appendix (P.66) for information about automatic cutting. 54

56 Manual Programming - DC545 HCEX Definition of Programming Terms SHEET LAYOUTS Sheets can be laid out in portrait or landscape format. The illustration below is for a CD tray jacket. The letter (or A4) sheet is printed 2-up and fed in portrait orientation

57 Definition of Programming Terms AUTO CUT If there is no waste on the sheet, be sure to turn the AUTO CUT feature OFF. See Examples 1 and 2 below. Example 1 - When AUTO CUT must be OFF Example 2 - When AUTO CUT must be OFF AUTO CUT is turned ON and OFF in the operator menu and is a global function, i.e. it is not saved specific to a job. Jobs requiring AUTO CUT ON and OFF CANNOT mixed in the feed tray. PLEASE NOTE: When the total number of scores and cuts (including those cuts due to AUTO CUT) exceeds 17 the following message appears on LCD display: E 6 DATA ERROR If a E6 data error occurs the job must be re-designed or reprogrammed so the total number of cuts and creases do not exceed 17 56

58 Manual Programming - DC545 HCEX Definition of Programming Terms JOB DESIGN ISSUES 1) Orientation of small format (business) cards Although the smallest format supported is 88.9 x 50.8 mm, the 88.9 mm side must be in the direction of feed, otherwise the pieces will drop between the transport rollers. This is because the center slitters must be able to move across the paper path. 1 2) Arrangement of small format (business) cards on large sheets (A3+ or oversized ledger) Business cards requiring a bleed and gutter, require the use of two slitters between each card. Because more business cards are fit onto A3 or ledger in this format compared to A4 or letter, the number of slitters required will be more than the maximum of 4 available. 5 Workaround solution - arrange 12 to view on A3 or ledger, place the register mark in two positions, 210 mm apart. Print on A3, cut in half using a guillotine (or use the 545). Then place both stacks in the 545 and process as if A4 or letter. The reg. mark will enable the device to adjust and compensate both for image drift and for any inaccuracy in the guillotine cut. 57

59 Definition of Programming Terms Print, cut in half, process as if A4 or letter size 3) Cutting gutters The slitters cannot be positioned closer together than 50 mm. To perform a gutter cut of a few mm, use slitters on two adjacent shafts, not those on the same shaft. The waste between gutters will exit onto the delivery tray. 4) Location of right margin trim for A4 paper Unlike the center slitters, both margin slitters share common axis lead screws. Due to the need to support the margin slitters lead screws in the mid-area of the machine, a support was positioned approximately in the middle of the device. This means that the right trimmer cannot trim below the dimension of 200 mm from the reference (datum or nonoperator side) edge. In the worst case the image can drift up to 2 mm so the trim position should not be located less than 202 mm from the reference edge. 58

60 Manual Programming - DC545 HCEX Definition of Programming Terms Also consider that the unprintable margin of a digital press is typically 3 to 5 mm from the edge of the sheet, so the edge of the image should not be placed more than 205 mm from the reference edge. To avoid the problem of the image drifting into the unprintable margin (which would result in a white edge inside the image area), the image should possess a bleed of (typically) 2mm. With all these factors combined, it is recommended that the right trim position is located between 202 and 204 mm from the reference edge mm typically Workaround - Should a job be presented that requires a side trim of less than 200 mm, use the right center slitter, OP1, or OP2 slitter to remove the waste from the side. The waste will exit onto the delivery tray. 5) Skewed Output on Small Pieces Depending on the job layout it is possible to have skewed output when small pieces are processed. In part, this problem is due to the design of the rubber feed rollers. Each roller has cutouts that reduce the gripping and drive area for the paper. In addition, the slitter units add drag as the card contacts the slitter housing and cutter wheels. 5 Workaround - Analyze the slitter positions and reprogram the job. Switch the center and option slitter units cutting positions in order to better balance the paper as it travels through the slitters. 59

61 Customer Programmed Jobs ALL DIMENSIONS MUST BE IN MILLIMETERS PROGRAM NUMBER JOB DESCRIPTION ITEM RANGE MARK MARK 2 LEFT SL RGHT SL C.L. SL C.R. SL OP1 SL OP2 SL CUT1 *CUT2 *CUT3 *CUT4 *CUT5 *CUT6 *CUT7 *CUT8 *CUT9 *CUT10 *SCR. 1 *SCR. 2 *SCR. 3 *SCR mm 0-120mm mm 0-160mm **-320mm 0-320mm OPTION 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm 0-650mm TOTAL LENGTH 0-650mm NOTES ** OPTIONAL VALUES - IF NOT REQUIRED ENTER 0 ** VALUES OF THE C.L.SL VALUE PLUS 50 CAN BE ENTERED. THERE IS A MAXIMUM OF 10 CUTS AND 4 CREASES CONVERSION TABLE Inches Millimeters CONVERSION TABLE Inches Millimeters

62 Manual Programming - DC545 HCEX Factory Preset Jobs U.S. PROGRAM NUMBER #1* #2 #3 #4 #5 #6 #7 #8 Job Type Cut in Half SM CARD Trading 8up letter Trading 8up ledger WALLET MARK 1 MARK 2 LEFT SL RGHT SL C.L. SL C.R. SL OP1 SL OP2 SL CUT1 CUT2 CUT3 CUT4 CUT5 CUT6 CUT7 CUT8 CUT9 CUT10 SCR. 1 SCR. 2 SCR. 3 SCR. 4 TOTAL LENGTH NOTES THESE VALUES ARE CURRENT AS OF OCTOBER 2002 ALL DIMENSIONS ARE IN MILLIMETERS 8.5 X 11 inches = X millimeters 11 X 17 inches = X millimeters *Be sure to turn off AUTO CUT. 61

63 Factory Preset Jobs PROGRAM NUMBER #9 #10 #11 #12 #13 #14 #15 #16 Job Type 8 10 Pan 1up Lg Card 2up Scrapbook 2up Postcard 11up Business Card 4up Business Postcard Large Brochure MARK 1 MARK 2 LEFT SL RGHT SL C.L. SL C.R. SL OP1 SL OP2 SL CUT1 CUT2 CUT3 CUT4 CUT5 CUT6 CUT7 CUT8 CUT9 CUT10 SCR. 1 SCR. 2 SCR. 3 SCR. 4 TOTAL LENGTH NOTES THESE VALUES ARE CURRENT AS OF OCTOBER 2002 ALL DIMENSIONS ARE IN MILLIMETERS 8.5 X 11 inches = X millimeters 11 X 17 inches = X millimeters 62

64 Manual Programming - DC545 HCEX Factory Preset Jobs PROGRAM NUMBER #17 #18 #19* #20 #21 Job Type MARK 1 MARK 2 LEFT SL RGHT SL C.L. SL C.R. SL OP1 SL OP2 SL CUT1 CUT2 CUT3 CUT4 CUT5 CUT6 CUT7 CUT8 CUT9 CUT10 SCR. 1 SCR. 2 SCR. 3 SCR. 4 TOTAL LENGTH 3-Fold Brochure Tri-Cut Fourths Fold in Half Tri-Fold NOTES THESE VALUES ARE CURRENT AS OF OCTOBER 2002 ALL DIMENSIONS ARE IN MILLIMETERS 8.5 X 11 inches = X millimeters 11 X 17 inches = X millimeters *Be sure to turn off AUTO CUT. 63

65 Factory Preset Jobs Europe PROGRAM NUMBER Job Type MARK 1 Postcard 2 A Business Card 16 A4 SEF 70 Business Card 10 A4 LEF 70 Business cards full bleed x9 A4 SEF 70 Visitor badges 4 A4 70 DVD Cover on A4 70 CD Inlay on A4 70 Point of Sale Promotion piece x2 A4 70 MARK LEFT SL RGHT SL C.L. SL C.R. SL OP1 SL OP2 SL CUT CUT CUT CUT CUT CUT6 287 CUT7 CUT8 CUT9 CUT10 SCR SCR SCR SCR. 4 TOTAL LENGTH

66 Manual Programming - DC545 HCEX Factory Preset Jobs PROGRAM NUMBER Job Type MARK 1 Christmas cards 4 A3 70 Paint label 4 A3 89 Paint label instructions 2 A3 89 Business cards 20 A3 70 Folded business cards 20 A3 70 Full bleed business cards 9 SRA3 (after cut to ) 70 A3 Brochure on SRA3 70 MARK 2 LEFT SL RGHT SL C.L. SL C.R. SL OP1 SL OP2 SL CUT CUT CUT CUT CUT5 CUT CUT7 CUT8 CUT9 CUT10 SCR SCR SCR. 3 SCR. 4 TOTAL LENGTH

67 How to Manually Program a Job Turn on the machine. Repeatedly push the <MODE> key until the display indicates [INPUT]. [INPUT] INPUT >SET Push and hold the <SET> key until the display appears as shown on the right. P 01? (01 80) OK? >SET Use the ten-key pad to enter the job number. Note The numbers 1- to 21 and 72 to 80 are registered as pre-set programs at the factory. Avoid overwriting these at all costs. P 52? (01 80) OK? >SET Press the <SET> key. Perform this step if there is a reg. mark, otherwise press the <SET> key until LEFT SL is displayed then proceed to step 14. Place a PREPRINTED (with a reg. mark) sample sheet in the feed tray. PREPRINTED SAMPLE 64

68 Manual Programming - DC545 HCEX How to Manually Program a Job When the <START> key is pressed, paper starts being fed and the number displayed on the lower right side of the LCD panel begins changing. (The number normally changes from 500 through 40, depending on the position of the reg. mark.) Use the <+> key and the <-> key to move the position of the paper (Reg. mark position); adjust the numerical value on the bottom right side of the LCD panel so that it is between 40 and 200. (Adjust the numerical value displayed so that it is as small as possible.) MARK1 (40 200) This number will change as the sensor reads the vertical portion of the reg. mark. 1 Enter the three digit value from the lower left of the display using the ten key keypad. In this example the value is 52. MARK1 (40 200) This number will change when you enter the value (in this example - 052). Press the <SET> key. 5 Remove the sample paper by pressing the <-> key. Measure the distance (in millimeters) between the leading edge of the paper and the horizontal portion of the reg. mark. The value must be between 5 and 40 millimeters. 8.2mm Continue Page 65

69 How to Manually Program a Job Enter the value from step 11 using the ten key keypad. MARK2 (5 40) 08.2mm Press the <SET> key. Enter the distance from the left side of the paper to the position for the left margin slit (LEFT SL) location. This value must be between 0 and 120 millimeters. LEFT SL (0 120) 000.0mm Press the <SET> key. Enter the distance from the left side of the paper to the position for the right margin slit (RGHT SL) location. This value must be between 200 and 320 millimeters. RIGHTSL( ) 000.0mm Press the <SET> key. Enter the distance from the left side of the paper to the position for the center left slit (C.L. SL) location. This value must be between 0 and millimeters. C.L.SL ( ) 000.0mm 66

70 Manual Programming - DC545 HCEX How to Manually Program a Job Press the <SET> key. Enter the distance from the left side of the paper to the position for the center right slit (C.R. SL) location. You can enter values from the value entered for C.L.SL plus 50 mm. C.R.SL ( 320) 000.0mm 1 Press the <SET> key. Enter the distance from the left side of the paper to the position for the center (OP1 SL) slit location. This value must be between 0 and millimeters. (When OP2 SL is not attached) OP1 SL ( ) 000.0mm Press the <SET> key. 5 Enter the distance from the left side of the paper to the position for the Optional 2 SL (OP2 SL) location. You can enter values from the value entered for OP1 SL plus 50 mm. (Not displayed when OP2 SL is not attached.) OP2 SL ( 320) 000.0mm NOTE : The OP2 SL is standard equipment for the DC-545 HCEX only. Continue Page 67

71 How to Manually Program a Job Press the <SET> key. Enter the distance from the leading edge of the paper to the position for the first cut (CUT 1) location. This value must be between 0 and 650 millimeters. CUT1 ( ) 000.0mm Press the <SET> key. Enter the distance from the leading edge of the paper to the position for the second cut (CUT 2) location. This value must be between 0 and 650 millimeters. If a second cut is not required, enter a value of zero. Turn off the automatic cutting setting when not using CUT2. The machine normally does not operate. CUT2 ( ) 000.0mm Press the <SET> key. Enter the distance from the leading edge of the paper to the first score (SCR.1). It is possible to enter numerical values from 0 to 650 mm. If a score is not needed enter 0. SCR.1 ( ) 000.0mm 68

72 Manual Programming - DC545 HCEX How to Manually Program a Job Press the <SET> key. Enter the total length (in millimeters) of the sample paper. TOTAL LENGTH? 000.0mm 1 Press the <SET> key. Press the <SET> key to retain the settings or <C> key to discard the settings. The display will indicate Memory Please Wait while the information is written to the Docu Cutter memory circuit. The memorization process will take approximately 10 seconds. OVERWRITE? OK SET NO C MEMORY!! Please Wait 5 69

73 Appendix - DC545 HC/DC545 HCEX This chapter lists the specifications and an index. Specifications DC-545 with HC AUTO FEEDER Specifications Product name / Model No. Input paper size Paper size Input paper weight Finishing size Lead edge trim Trail Edge Trim Side edge trim Speed Desktop model Min.:8.5" x 11" / A4 Max.:12.6" x 18" / A3 Min.:110gsm Max.:230gsm <No curl in the paper> DC-545 with HC AUTO FEEDER Min.:2"(Width) x 3.5"(Length) <Business card size> Min.:0.125"(3.2mm) Min.:0.125"(3.2mm) Min.:0.125'(3.2mm) Max.:4.5"(114mm) Max : 9ppm (A4 lengthwise. 4-side trim. 1 score) Trim/Score tolerance +/- 0.03"(+/ mm) <With paper cutting length not exceeding 18"> Media type Feeding method Feed tray capacity Stacker Power supply Machine dimensions(mm) Range: Regular copy paper to coated heavy weight paper Automatic Feeding (Air suction method) 100mm Drop type AC120V +/- 10%, 50/60Hz, 1.0A AC230V +/- 10%, 50/60Hz, 0.6A* 1370(W) x 580(D) x 960(H) Machine weight(kg) (Main body 56.4, Feeder 20.4, Stand 32.8) 1.Four scores perpendicular to the feed direction. 2.Up to 5 cuts parallel to the feed direction. (2 x margin slitters and 3 x center slitters.) Other Features 3.Up to ten cuts perpendicular to the feed direction. 4.Automatic setting of slit, cut and score position. 70

74 Appendix - DC545 HC/DC545 HCEX Specifications DC-545 with HCEX AUTO FEEDER Specifications Product name / Model No. Input paper size Paper size Input paper weight Finishing size Lead edge trim Trail Edge Trim Side edge trim Speed Desktop model Min.:8.5" x 11" / A4 Max.:12.6" x 18" / A3 Min.:110gsm Max.:230gsm <No curl in the paper> DC-545 with HCEX AUTO FEEDER Min.:2"(Width) x 3.5"(Length) <Business card size> Min.:0.125"(3.2mm) Min.:0.125"(3.2mm) Min.:0.125'(3.2mm) Max.:4.5"(114mm) Max : 9ppm (A4 lengthwise. 4-side trim. 1 score) Trim/Score tolerance +/- 0.03"(+/ mm) <With paper cutting length not exceeding 18"> Media type Feeding method Feed tray capacity Stacker Power supply Machine dimensions(mm) Range: Regular copy paper to coated heavy weight paper Automatic Feeding (Air suction method) 100mm Drop type AC120V +/- 10%, 50/60Hz, 1.0A AC230V +/- 10%, 50/60Hz, 0.6A* 1370(W) x 580(D) x 960(H) Machine weight(kg) (Main body 56.4, Feeder 20.4, Stand 32.8) 1.Four scores perpendicular to the feed direction. 2.Up to 6 cuts parallel to the feed direction. (2 x margin slitters and 4 x center slitters.) Other Features 3.Up to ten cuts perpendicular to the feed direction. 4.Automatic setting of slit, cut and score position. 1 2 Paper Weight The DC-545 was designed to process paper from 110 gsm up to 230 gsm (grams per square meter). 110 gsm is roughly 28 lb and 230 gsm equates to 10 pt stock. Laminated Stock The DC-545 was not designed to process laminated stock and therefore it is not recommended. Paper Curl Due to the automated slitter function design, the paper path of the DC-545 is sensitive to paper curl. The paper path does not posses a flat table for the paper to travel over because the slitter units must be able to move freely from side-toside. If paper curl is causing paper jams the following are suggestions for remedying the problem: 1. Adjust the printing devices de-curler (if available) 2. Manually de-curl the stock before loading in the feed tray 3. Turn the paper over (reprogramming the job may be necessary) 4. Use different paper stock 71

75 Specifications Specifications of Reg. Mark and Bar Code 1.Reg. Mark Details (Vertical/Horizontal) Length: 5mm or more Width: 0.4mm or more 2.Bar code Bar code : CODE-39 Start/stop code : Required Check digit : Optional Minimum resolving power : 0.254mm Fine line : Thick line : 1:2.5 Bar height : 4mm or more Under the requirements listed above, the bar code width will be about 15mm. Printing Position : See P.62 to P.64 for details. Print the bar code data in the following sequence: q is the start code designator for CODE-39. w is the 10 s digit data of the program number. (Example: When the program number is 11, the data is "1".) e is the 1 s digit data of the program number. (Example: When the program number is 11, the data is "1".) r is the check digit. t is stop code of CODE-39. These figures indicate program number, with which the machine recognizes a stored setting for certain Jobs. (start from 00) 72

76 Appendix - DC545 HC/DC545 HCEX Specifications THE 'REG' (REGISTER) MARK Using a CCD sensor to read an image reference point on the sheet is a unique feature of the DC-545. The mark is similar to a cutting mark (or crop mark) for guillotines. The device does not cut on this mark, it is simply a definable shape which is easy to recognize and is easy to reproduce in the original application. The reg. mark is actually made up of two components. The vertical component is used for determining the horizontal reference point. In other words, where the image is located from left to right on the sheet. When a job is programmed into memory the first entry is MARK 1. This refers to the vertical line in the reg. mark. During the programming process the MARK 1 value is entered in pulse counts. There are two ways to obtain the proper data value for MARK 1. Obtaining the MARK 1 value can be done with the two following methods. Obtaining MARK 1 Value - Method 1 With this method, you can input the MARK 1 value through DC-545. Load the type of paper that is registered to for the feed tray when inputting the MARK 1 value, and then press the <START> key. The paper stops when it is in the vicinity where the MARK 1 value is read, move the paper forward and backward with the <+> and <-> keys to move the paper to the position where the MARK 1 value can be read. Then enter the value that is displayed on the screen. 1 2 Obtaining MARK 1 Value - Method 2 You can enter the MARK 1 value with the following method, rather than method 1, if you know the MARK 1 position. Convert the MARK 1 value to a numerical value according to the following table and enter the new value, note that the MARK 1 value is not the distance (mm) from the edge of the paper. For example, if the MARK 1 is positioned 10 mm from the edge of the paper, then the MARK 1 value is 70. MM CCD Reading 1 15+/ / / / / / / / / / / / / / / / / / / /- 1 MARK 1 CONVERSION TABLE 73

77 Specifications The second program entry is MARK 2. This refers to the horizontal line of the reg. mark and is used as the image vertical reference point. This mark determines where the image reference is located in respect to the head and foot of the page. MARK 1 MARK 2 MARK 1 corrects for errors in this direction MARK 2 corrects for errors in this direction 74

78 Appendix - DC545 HC/DC545 HCEX Specifications HOW TO MAKE A BAR CODE FOR USE WITH THE DC-545 The easiest way to create the code is with a TrueType Font. Fonts are readily available from many companies on the internet. Here are two companies which have fonts suitable for use with the DC-545 (there are many companies offering fonts). Azalea offers a free sample of code 39 and a variety of customizable options that allow printing of bar codes from Microsoft Windows or Macintosh platforms. Samples - standard font Price 149 for a single user; 298 for 2-5 Basic Font Installation Instructions The following briefly describes what is required to install a font on a Windows or Macintosh system. The font provider will supply more detailed information, these guidelines are only intended to illustrate the basics and scope of the installation process. 1 2 On a Windows PC the font is installed through the Control Panel's "Fonts" folder. On a Macintosh system select the font suitcases (for TrueType 1 fonts also select the printer outline files) and drag the fonts onto the closed System Folder icon. For OS X drag the fonts onto the Fonts folder in the Library folder. How to use a TrueType font Once installed, the font will appear in the word processing or desktop publishing application in the font selection area. Please note in MS Word, typing text surrounded by the characters * and *, automatically turns on auto format to bold text. Since this is not the intended, or useful, turn off the auto formatting by following the steps below or use the 'undo last action' after typing. 75

79 Specifications Select Options Delete *Bold* and _underline_with real formatting 76

80 Appendix - DC545 HC/DC545 HCEX Specifications Creating the Barcode Making the barcode appear on the page is extremely easy with a TrueType font. In this case we will use the example job 01. The application designer simply does the following: 1. Place a text box in the predefined area. Make sure the text box is large enough to hold the entire bar code. It may be necessary to increase the size of the text box after the font is created. 2. Type the desired job (program) number surrounded by a stop and start bit. Remember the stop and start bit are recognized in Code 39 as an * or asterisk. 3. Select the text, in this case the text will appear as: *01* 4. Change the font type in the font selection window to the name of the code 39 font. The text will appear as: *01* 5. Print a sample and make sure the font is at least 4 mm tall. If not, increase the size of the code 39 font by reselecting the barcode and increasing the font size with through the Font size selection window. 1 2 Font selection window Duplo Code 39 Font size selection window 77