COLLATOR DFC-12/DFC-10 Instruction Manual [220-240V] ILLUSTRATION : DFC-12 DUPLO CORPORATION
DECLARATION OF CONFORMITY DUPLO CORPORATION, located at 7-6, Izumi-honcho 1-chome, Komae-shi, Tokyo 201-8666, Japan, declares that the following product, • Name of product : Collator • Models : DFC-12 and DFC-12B, 100-240V 50/60Hz DFC-10 and DFC-10B, 100-240V 50/60Hz complies with the provisions defined by the regulations listed below. • Regulation : Machinery Directive 98/37/EC under EN292-1(1991), EN292-2(1991), prEN1010-1(2002), prEN1010-4(2001), EN60204-1(1997).
1. INTRODUCTION Thank you for your purchase. To ensure correct usage, please read this instruction manual thoroughly, especially the section Safety Precautions. After reading, please store this instruction manual in a safe place for future reference. 2. TABLE OF CONTENTS 1. INTRODUCTION ............................................. 1 13. DOUBLE-FEED DETECTION FUNCTION .... 34 2. TABLE OF CONTENTS .................................. 1 14. WHEN BIN ERROR LAMPS LIGHT/BLINK . 36 3. SAFETY PRECAUTIONS ...
3. SAFETY PRECAUTIONS Always observe the cautions and warnings given below to prevent personal injury or property damage. The degree of danger and damage that could occur is indicated on two levels by the following marks. WARNING: Ignoring this mark could result in the possibility of serious injury or even death. CAUTION: Ignoring this mark could result in the possibility of injury or physical damage. The following graphic symbols indicate the various types of action to be performed or avoided.
3. SAFETY PRECAUTIONS Make sure that the combined power consumption of the appliances to be connected does not exceed the capacity rating of the power outlets or plug receptacles. Exceeding the capacity rating could cause the power outlets, plug receptacles, or power extension cords to overheat and catch fire. Remove any dust that accumulates on the power plug prongs and the surface of the plug from which the prongs extend. Accumulated dust can result in fire.
3. SAFETY PRECAUTIONS CAUTION: Always disconnect the power plug from the power outlet when the unit is not to be used for an extended period. Failure to do so could result in fire due to leakage current if the insulation should deteriorate. Install this unit on a level, stable stand or floor, with sufficient space around it. Failure to do so could result in the unit overturning and causing injury.
4. USAGE PRECAUTIONS Power supply • This equipment shall be installed near the socket-outlet where the plug on the power supply cord is easily accessible. • Make sure the power supply used is always within the following range. 100-240V AC, 50/60Hz • When you power other appliances from the same AC outlet, make sure that the combined power consumption does not exceed the power supply capacity. Rated power of this equipment : 2.8-1.2A(DFC-12) / 2.0-0.
5. FEATURES OF THIS MACHINE The DFC-12 and DFC-10 can collate paper sizes from A5 to A3SR. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ The DFC-12 can collate 12 sheets and the DFC-10 can collate 10 sheets.
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7. NAMES AND FUNCTIONS OF CONTROL PANEL PARTS bl (The panel is the DFC-12) bm bk 9 bn 8 7 bo 1 2 3 4 5 6 7 8 9 0 C 6 5 No. 1 2 3 Name Start key Stop key Preset key 4 Eject key 5 6 7 8 Clear key (C ) Numerical keys (0 to 9) Scroll key Escape key 9 Enter key bk NO.
8. PRECAUTIONS ON LOADING PAPER Fan paper sufficiently before loading on the bin. • If the paper is not separated well, mis-feed, double-feed or paper jam may occur. • Flatten folded or curled paper before stacking. Align the lead edge of the paper stock, and place it on the bin. • If the paper is not loaded neatly mis-feed, or double-feed may occur. Make sure that ink on the paper has dried completely.
9. OPERATIONS Flowchart of operations The following shows the flowchart of the basic operations. For details, refer to the text and corresponding pages. Start 1. Turn ON the power switch ( 2. Adjust the paper feed pressure • Set the paper feed pressure adjusting knob to the paper size. ( Page11) 3. Adjust the paper separation pressure • Set the paper separation pressure adjusting lever to the paper thickness. ( Page11) 4.
9. OPERATIONS 1 Turn ON the power switch. Interruptor de alimentación • Pressing "I" turns ON the power supply. Pressing "O" turns OFF the power supply. When the downstream unit is connected, turning ON the power switch of the DFC-12/10 will automatically turn ON the power of the downstream unit ON OFF as well by the remote function. Be sure to wait for more than 10 seconds when switching ON again after having switched OFF. WARNING Do not touch the power switch with wet hands.
9. OPERATIONS 4 Fixed guide Load the paper on the bins. Paper feed gate Paper Insert the paper along the fixed guide until it touches the guide of the paper feed gate lightly. • The maximum height of paper which can be stacked is 28 mm. Be careful not to overstack. Contact the movable guide lightly to the edge of the paper. Note The method of loading paper differs Movable guide Paper according to the normal mode, interleaving mode, block mode, and alternative mode. For details, refer to "10.
9. OPERATIONS 7 Adjust the side guide F to the paper size. Side guide F B5 11x17 LGL. LTR IV A4. A5 B4. B5 Paper size scale Side guide F 8 When set to the STRAIGHT mode, move the side guide B until it touches the paper receiving table. When set to the OFFSET mode, move it until it touches the side frame. Side frame Side guide B OFFSET mode STRAIGHT mode Paper receiving table 9 Set the collation mode, paper receiving method, and count display method on the control panel.
9. OPERATIONS 10 Press the Preset key. One set of paper is sent from the bin. Note If the set is not aligned properly, finely adjust the paper receiving stoppers 1 and 2, and side guide F. ( Refer to pages 12, 13.) • The paper feed error lamp of bins with no paper will light up in green.( Page 36) • This preset function differentiates between bins with paper and those without, and memorizes the length and thickness of the paper on each bin. Based on this data memorized, double-feed is detected.
10. LOADING PAPER ACCORDING TO COLLATION MODE Determine how to load paper according to the operation to be carried out after collation. See the figures below for the order of loading paper on the bins and collation pages. Note If using the downstream unit, whether to face the printed side up or down differs according to the processing method. Refer to the instruction manual of the downstream unit. 10-1.
10. LOADING PAPER ACCORDING TO COLLATION MODE 10-2. Loading paper for interleaving mode • Interleaves are inserted after every specified number of sets have been collated. • Interleaves are inserted after every 200 sets maximum. Load the interleaves at the bottommost bin. Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Páginas clasificadas Load in bin 12 for the DFC-12 and in bin 10 for the DFC-10. See the right figure for details.
10. LOADING PAPER ACCORDING TO COLLATION MODE 10-4. Loading paper for block mode The bins can be divided into two blocks (6 bins each) to collate paper in blocks. Page 1-a Page 2-a Page 3-a Page 4-a Page 5-a Page 6-a Page 1-b Page 2-b Page 3-b Page 4-b Page 5-b Page 6-b For the DFC-10, bins are divided likewise 5 bins each. Paper feed starts from bins 1 to 6 (block 1/ 2). When paper on any bin of the block runs outs, operation is stopped.
10. LOADING PAPER ACCORDING TO COLLATION MODE 10-6. Loading paper according to paper size The direction differs according to paper size. ● Paper loading direction available Paper size Direction A5 A4 A3 A3SR B5 B4 LGL LTR LGR INV ⇑ % ? ? ? ? ? ? ? ? % ⇑ ? ? X X ? X X ? X ? ? : Available X : Not available % : Available when DBM-120 and DBM-120T are connected • LGL = Legal (8.5” x 14”) LTR = Letter (8.5” x 11”) INV = Invoice (8.
11. USING THE CONTROL PANEL This section describes the contents of the LCD and how to set the collation mode, paper receiving mode, and count display method. 11-1. LCD window Collation mode menu Paper size Operating state No. of interleaves No. of processing sets ● Paper size • Set when using the downstream unit. If no downstream unit is connected, the paper size will not be displayed. • Displays the paper size saved.
11. USING THE CONTROL PANEL 11-2. Setting the collation mode Select the collation mode from NORMAL, INTERLEAVING, BLOCK, and ALTERNATIVE. • The "Block 4"cannot be selected when using the DFC-12/10 separately. • The interleaving mode cannot be selected when paper is ejected to a downstream unit. • When using the interleaving mode, set the number of interleaves. 1 Press the key and display the "Mode menu". 2 Pressing the key switches the screen between NORMAL, Int.LV., BLOCK, and ALTERNATIVE.
11. USING THE CONTROL PANEL 11-3. Setting the number of interleaves When the interleaving mode is selected, interleaves will be inserted after every specified number of sets have been collated. Enter the number of interleaves at the "Sheet Quantity" screen. Up to 200 sets can be specified to insert interleaves. 1 Press the key to display the "Sheet Quantity" screen. 4 Press the key and save the number of interleaves entered at step 3.
11. USING THE CONTROL PANEL 11-4. Setting the count display method Select the count display method from the count up display and count down display. Count up display method 1 2 3 LCD window The NO. OF SETS window counts up the number of collated sets during operations. When the required number of sets is reached, press the Stop key to stop the unit. 4 5 6 7 8 9 0 C NO.OF SETS window Operations stop when the display reaches “9999”. • Check that the NO. OF SETS window shows 0.
11. USING THE CONTROL PANEL 11-5. Setting the paper receiving method • Paper can be ejected to the paper receiving table in two ways; the OFFSET mode which sorts paper ejected onto the table into sets and Straight mode Offset mode the STRAIGHT mode which stacks sets into one pile. • Select "OPTION" when using the downstream unit. • Press the Select key and set the paper receiving mode. • When OPTION is selected, paper will not be ejected to the paper receiving table.
11. USING THE CONTROL PANEL 11-6. Other settings If the paper ejected to the downstream unit or paper receiving table is not aligned properly, or the same collation operation is repeated, perform the "Overlap", "Speed", and "Processed set repeat" settings at the "Other Settings" screen on the control panel. 5mm (0.2") Setting overlap Overlap : Small If paper ejected to the downstream unit is not aligned properly, this can be improved by shifting overlap of collated paper during ejection. 10mm (0.
11. USING THE CONTROL PANEL Setting speed For auto, the speed is adjusted automatically according to the paper size, number of sheets, overlap, paper receiving mode, and whether the downstream unit is connected or not. Delay the processing speed if the paper ejected to the downstream unit is not aligned properly or if errors occur frequently when the downstream unit is connected. Select speeds from auto, 5, 4, 3, 2, 1 (the speed drops from 5 towards 1). At shipment, “Speed” is set to “Auto”.
11. USING THE CONTROL PANEL Setting processed set repeat Set the "Initial Qty Rpt" screen to ON to repeat the same collation operation with the count down display method. The number of sets entered will be memorized and the same collation will be carried out continuously. At shipment, “Initial Qty Rpt” is set to “ON”. 1 Press the "Other settings". key to display 4 Press the key and save the repeat operations selected at step 3. *1 To redo the setting, press the other time to return to step 3.
12. CONNECTING THE DOWNSTREAM UNIT 12-1. Connecting the DBM-120 and DBM-120T Downstream units (DBM-120, DBM-120T) can be connected to the DFC-12/10 to staple, fold, and trim collated paper. Set the "Binding", "Paper size", "Custom size","Trimmer", and "After clearing paper feed errors" at the control panel. Perform the following settings after pressing the Select key on the control panel, and select "Option" ( Note page 23).
12. CONNECTING THE DOWNSTREAM UNIT Setting paper size 3 Press the key and save the paper size selected at step 2. Paper size can be selected from A3, A4, A5, B4, B5, LGR, LGL, LTR, INV, A3SR, custom 1, custom 2, and custom 3. To set custom 1 to 3, the paper length and width must be registered. For details, refer to "Setting To redo the setting, press the other time to return to step 2. the custom size" At shipment, “Paper size” is set to “A3”. 1 Press the "Paper size".
12. CONNECTING THE DOWNSTREAM UNIT Setting custom size 3 When using paper other than those specified, register the length and width of the paper. Three paper sizes can be registered (custom 1, custom 2, custom 3). Pressing the key switches between the screens for selecting length and width. At shipment, A4 size paper length and width are registered at every custom size. 1 Press the "Custom size". 2 Press the key and display the screen for selecting custom 1 to 3.
12. CONNECTING THE DOWNSTREAM UNIT 5 Enter the length or width using the numerical keys. 7 Press the key to return to the standby screen. If any previously registered size of paper length or width is remaining, key to clear to " 0 " press the first before entering the new number. The length and width ranges which can be registered differ according to the binding method.
12. CONNECTING THE DOWNSTREAM UNIT Setting trimmer Set whether or not to use the trimmer (DBM-120T) connected to DBM-120 using the following procedure.(For details on the trimmer, refer to the instruction manual for DBM-120T.) At shipment, “Trimmer” is set to “ON”. 1 Press the key and display "On-line setting". 4 Press the key and save the trimming method selected at step 3. To redo the setting, press the key an- other time to return to step 3.
12. CONNECTING THE DOWNSTREAM UNIT Setting "After clearing paper feed error" Paper conveyed to the downstream unit when paper feed error occurs (no paper, mis feed, double-feed, etc.) will be ejected without binding. In this case, operations of the DFC-12/10 can be stopped or continued according to preference. At shipment, “Error paper ejection” is set to “Stoppage”. 1 Press the key and display "On-line setting". 4 Press the key and save the operation selected at step 3.
12. CONNECTING THE DOWNSTREAM UNIT 12-2. Connecting DC-S and DC-S4 • Downstream units (DC-S, DC-S4) can be connected to the DFC-12/10 to staple and punch collated paper. • The paper sizes which can be used differ between DC-S and DC-S4. For details, refer to their instruction manuals. The special connecting kit (PS-Base) is required to connect DC-S and DC-S4. It can be purchased from the nearest Duplo dealer.
13.DOUBLE-FEED DETECTION FUNCTION Using the sensor for measuring paper thickness, the thickness of paper fed by preset settings is read as the reference data, and compared with the data of the paper collated. When the difference between those data is large, it determines that a double-feed has occurred. This function is called double-feed detection. The sensor is inside the paper feed gate of each bin.
13.DOUBLE-FEED DETECTION FUNCTION Switching the double-feed detection sensor between ON/OFF 1 Press the key and display "Double detect Set". 5 Press the sor state. key to save the sen- To redo the setting, press the key an- other time to return to step 4. 2 Press the key and display the ON/OFF state of the sensor. 6 Press the key to return to the standby screen. The sensor number corresponds to the or- 3 der of the bins from the top in the order of Press the sensor 1, 2, 3….12.
14. WHEN BIN ERROR LAMPS LIGHT/BLINK When paper feed errors occur during operations, the warning alarm sounds, and the bin error lamps on the control panel light up or blink. Refer to the solutions provided below and clear the error. Note Error lamp Cause of error When “Err1” is displayed on the NO. OF SETS window, remove the last set ejected. When “Err2” is displayed remove the last two sets. The last or the last two sets may be incomplete. 14-1.
14. WHEN BIN ERROR LAMPS LIGHT/BLINK 14-3. When an error lamp blinks in green No paper has been fed from the bin. (=Empty feed) • Fan the paper and restack again, and Strong Normal then press the Start key to restart operations. • If the error occurs again, move the Paper feed pressure adjusting knob paper feed pressure adjusting knob to the left (strong) or move the paper separation pressure adjusting lever to the left (separator pressure drops).
15. WHEN ERROR MESSAGES ARE DISPLAYED When errors occur, a warning alarm sounds, and an error message will be displayed on the LCD. 15-1. When "No Paper" is displayed There is no more paper in the bin. • Load paper in the bin where the error lamp is lit in green. Paper sensor • Check that the paper sensor lever descends when paper is stacked. Press the Start key to restart operations. Paper 15-2. When "Tray Full" is displayed The paper receiving table is full.
15. WHEN ERROR MESSAGES ARE DISPLAYED 15-3. When "Feed error" is displayed Paper has jammed at the double-feed sensor or paper feed gate. Check the bin where the error lamp is lit in red. • When paper has jammed at the paper feed ring Pull out the jammed paper to the front, and remove. • When paper has jammed at the double-feed sensor Open the conveyance cover, and remove the jammed paper. Press the Start key to restart operations. Paper feed ring Paper Paper 15-4.
15. WHEN ERROR MESSAGES ARE DISPLAYED 15-5. When "Mis-Feed" is displayed No paper has been fed. Error lamp Error • Check the bin where the error lamp is blinking in green. • Refer to "14. WHEN BIN ERROR LAMPS LIGHT/BLINK" ( page 36). Press the Start key to restart operations. 15-6. When "Double Detect" is displayed Paper has been double-fed. Error lamp • Check the bin where the error lamp is blinking in red. • Refer to "14. WHEN BIN ERROR LAMPS LIGHT/BLINK" ( 36).
15. WHEN ERROR MESSAGES ARE DISPLAYED 15-7. When "Paper Jam" is displayed Paper has jammed in the conveyance route or paper ejection gate. • Press the Eject key to eject the jammed paper. • If paper does not come out even when the Eject key is pressed, open the vertical conveyance cover and remove the jammed paper. • If paper is jammed at the paper ejection gate, pull out the paper towards the front. Press the Start key to restart operations.
15. WHEN ERROR MESSAGES ARE DISPLAYED 15-9. When "Feed Cov. Open" is displayed The vertical conveyance cover is not completely closed or when it has been opened by mistake during operations. • Close the vertical conveyance cover properly. • If opened by mistake, after closing the cover, press the Eject key to eject the paper remaining inside. Press the Start key to restart operations. Vertical conveyance cover 15-10. When "Int.
15. WHEN ERROR MESSAGES ARE DISPLAYED 15-11. When “On-line err" is displayed An error has occurred in the downstream unit. • Check the error on the control panel of the downstream unit. For details on clearing the error, refer to the instruction manual of the downstream unit. Press the Start key to restart operations.
16. TROUBLESHOOTING • When paper does not jam even though "Paper Jam" is shown in the control panel of DBM-120T • When paper is ejected without being trimmed even though "Trimming" is ON Decrease the processing speed of the collator in such cases. This can be improved by setting a slow collator speed. (Refer to "Setting speed" on page 25.) When "Bridge paper jam" is displayed in the use of two towers, even though no paper is jammed in the Bridge.
17. TROUBLESHOOTING GUIDE Symptoms Cause Solution Unit does not start even when Start key is pressed Is the vertical conveyance cover open? • Close the cover to start operations. Is the paper receiving table fully • Remove the paper. stacked with paper? Have problems occurred in the downstream unit? • Check the cause of the problem. Has preset been performed? • Be sure to press the Preset key before starting paper feed.
17. TROUBLESHOOTING GUIDE Symptoms Cannot set on control panel (Enter key is ineffective) Solution Cause Have fine adjustments been performed on the DBM-120? Clear the fine adjustment setting. (For details, refer to the DBM-120 instruction manual.) Symptoms Cause Solution The following are displayed on the LCD. Malfunction to be investigated by ser- • Turn OFF the power switch, wait vice personnel. for about 30 seconds, and then turn it ON again.
18. LCD MENU (Size cannot be changed if a downstream unit (DBM-120) is not connected.) (Page 48) (Page 48) (Page 48) (Page 49) (Page 50) (Page 50) (XX page) Proceed to the corresponding page.
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19. CLEANING THE UNIT AND REPLACING EXPENDABLE PARTS Cleaning the unit Ink or paper dust adheres to the paper feed ring or paper separator which feeds paper. Running the unit in this state will cause paper feed problems. Therefore clean periodically. 1 Press the paper feed shaft in the arrow direction, and remove the end of the paper feed shaft at the joint. Joint Remove the paper feed shaft.
20. SPECIFICATIONS Name DFC-12 DFC-10 Model Friction feed vertical collator No.
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11T-90047-02120001S-0
