DUPLO DF-850 (01) PDF MANUAL

In this manual, several symbols are used to indicate important warnings. These symbols have the following meanings:

Exclamation Point Icon: Describes instructions which must be followed in use. Be sure to read the instructions to avoid problems due to incorrect operations.

Book Icon: Indicates supplementary or useful information.

Pointing Hand Icon: Describes names of related items and supplementary instructions.

Power Supply

Make sure the power supply used is always within the following range:

Power supply: 100 to 240 V AC, 50/60 Hz

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: 125 W

Rated current: 1.3 to 0.65 A

Operating Environment

Operate this unit in the following environment:

where the temperature range is between 5 and 35°C/41 and 95°F (-5 to 45°C/23 to 113°F in storage)

where the humidity range is between 20 and 80% RH (10 to 90% RH in storage, however no condensation)

which is not subject to direct sunlight

where the outside light does not exceed 1,500 lx

which is subject to little or no vibration

which is free from air-borne salt

where there are no harmful chemicals

where the unit is not exposed to water

This device can be used to fold paper into the following six shapes:

Single fold

Double fold

Irregular accordion fold-out

Letter fold

Accordion fold

Gate fold

By using the cross folding lever, it is also possible to create cross single fold and cross letter fold. Note that the finish of cross folding is not as accurate as that of the six folding modes mentioned above.

The press release levers are attached to the unit at shipment to prevent the rubber roll from becoming distorted. Be sure to remove them when setting up the machine. The machine will be damaged if it is used without removing the lever. The two types of press levers are attached to either side of the rubber roll.

1. To remove the press release lever [A] on the non-operator’s side, push it inwards and pull it out.

2. To remove the press release lever [A] on the operator’s side, push it inwards and pull it out.

3. To remove the press release lever [B] on the non-operator’s side, push it inwards and pull it out.

4. To remove the press release lever [B] on the operator’s side, push it inwards and pull it out.

When attaching/removing the folding plate, always be sure to hold the folding plate in both hands.

1. Lower the folding plate 2 lock lever.

2. Attach the folding plate 2 to the machine. Insert the folding plate 2 so that it aligns with the slider and frame left and right pillars.

3. Lower the lock lever to fix the folding plate 2.

4. Lower the folding plate 1 lock lever. (The DF-850 folding plate 1 does not have a lock lever. Go to step 5).

5. Attach the folding plate 1 to the machine. Insert the folding plate 1 to align with the frame left and right pillars, and insert the U-shaped groove at the tip of the folding plate into the pillar at the back of the frame.

6. Lower the lock lever to fix the folding plate 1. (The DF-850 folding plate 1 does not have a control cable. Proceed to storage instructions).

7. For DF-870, connect the control cable 1 of the folding plate 1 to the connector 1.

8. For DF-870, connect the control cable 2 of the folding plate 2 to the connector 2.

Important:

Be careful not to connect the control cable to a wrong connector.

Be sure to turn off the power before connecting or disconnecting the control cable. Otherwise the unit will malfunction.

1. Open the top cover gently. Hands or fingers may be caught in the cover section.

2. Store the guide plate unit on the magnet inside the machine.

3. Store the cross folding lever at its designated position. Insert the cross folding lever into the storage pillar.

Note: After use, always be sure to insert the cross folding lever boss hole into the pillar. Motion during an action is dangerous. In addition, there is a risk of entanglement in the roller, causing damage to the machine.

Carefully store the L-shaped hex wrench together with the Instruction Manual.

The following flowchart illustrates the flow of basic operation.

DF-850 Basic Workflow:

1. Connect the power cord.

2. Turn on the power.

3. Stack paper.

4. Position the rough adjustment knob/fine adjustment knob (Folding 1) (Folding 2).

5. Position the paper feed pressure adjustment lever.

6. Position the stacker roller.

7. Perform a test fold.

8. Set the counter.

9. Start the process.

10. When the process ends, turn off the power.

11. Disconnect the power cord.

DF-870 Basic Workflow:

1. Connect the power cord.

2. Turn on the power.

3. Stack paper.

4. Select paper size.

5. Select folding mode.

6. Position the paper feed pressure adjustment lever.

7. Position the separation pressure adjustment dial.

8. Perform a test fold.

9. Set the counter.

10. Start the process.

11. When the process ends, turn off the power.

12. Disconnect the power cord.

Make sure that the power plug is connected to the wall socket. Do not touch the power plug with wet hands as it may cause electric hazards.

Turning On Power:

Set the power switch to the “I” side. Turning on the power starts the initial operation. Do not operate the machine until the initial operation stops.

Turning Off Power:

Set the power switch to the “O” side.

CAUTION: Do not put fingers inside during operation. Keep away long hair, ties, jewelry and loose clothing. It could cause injury.

1. Open the paper reception plate.

2. Open the support paper feed plate. Note: If you open the support paper feed plate before the paper reception plate, the paper reception stopper could get caught, resulting in damage. Always open the paper reception plate first.

3. Loosen the guide fixing screws.

4. Open the paper feed guides.

5. Lift the paper set lever.

6. Stack paper in the center of the paper feed tray.

– Insert paper until the paper tip part lightly bumps against the guide plate.

– Carefully separate and arrange the paper, and then place it in the paper feed tray.

– Paper maximum stacking height: 46 mm/1.8 inches.

7. Align the paper feed guides to the paper. Align the paper feed guides so that they lightly bump against the sides of the paper. Do not press too hard, as it may cause mis-feeds.

8. Tighten the guide fixing screws on both left and right.

9. Lower the paper set lever. The paper feed tray rises.

Important:

Always be sure to lower the paper set lever. If the start key is pressed while the paper set lever is up, an error message is displayed and the machine will not operate.

1. Select Paper Size (DF-870 only)

Use the custom folding key to select a paper size. Every time the key is pressed, the paper size is displayed according to the following order on the LCD display:

EU: [A3] → [B4] → [A4] → [B5] → [A5] → [B6] → [LP] → [CF] → [A3]

NA: [LGR] → [LGL] → [LTR] → [ST/IN] → [LP] → [CF] → [LGR]

2. Select Folding Mode

For DF-850:

1. While pulling up the rough adjustment knob for folding plate 1, align it to the folding form and paper size scale.

2. If needed, rotate the fine adjustment knob to align the rough adjustment knob with the scale.

3. Follow the same procedure for folding plate 2. For single folding, move the rough adjustment knob for plate 2 to the highest point.

For DF-870:

Press the folding mode key to select a folding mode. The order is: [SingleFold] → [DoubleFold] → [Fold-out] → [LetterFold] → [Accordion] → [GateFold] → [SingleFold].

3. Align Paper Feed Pressure Adjustment Lever

For DF-850: Align the lever to ≡ (thin paper). For mis-feeds, change to ≡ (thick paper).

For DF-870: Align the lever to [0]. If paper mis-feeds, change to [1]. If paper overlaps, change to [-1].

4. Align Stacker Roller Position

For DF-850: Move the stacker roller in line with the table on the machine based on paper size and fold type.

For DF-870: The stacker roller moves automatically. If paper is not ejected smoothly, you can manually adjust the S-Roller position via the control panel.

5. Align Separation Pressure Adjustment Lever (DF-870 only)

1. Open the top cover.

2. Set the separating pressure adjustment dial to [0.]. If several sheets are fed at once (double-feed), increase the pressure to [1] or [2] in steps of 0.5.

3. Close the top cover.

6. Perform Test Folding

1. Press the (test) key. Two sheets of test-folded paper are ejected.

2. Confirm the test folding finish. If misaligned, check the final sheet and refer to “Adjusting Misalignment”.

7. Set the Counter (Optional)

Press the (count) key to set the counter. You can set it to Add count mode or Subtract count mode. For subtract mode, you can set a target number of sheets.

8. Perform Folding Operation

Press the (start) key to begin the folding operation.

When using thick paper, you may need to make adjustments for proper folding and ejection.

Use the Bearing Support Lever

When using thick paper, move the bearing support lever to hold down the bearing. This prevents the rubber roller from floating up.

1. Open the top cover.

2. Rotate the bearing support lever (one on each side) in the direction of the arrow to hold down the bearing.

3. Close the top cover.

4. After processing thick paper, be sure to return the levers to their original position.

Single Folding of Thick Paper (104.7 g/m²/27.9 lb)

If corner or central area folds occur:

1. Stack paper in the paper feed tray.

2. Adjust the fold stopper position in folding plate 1.

– For DF-850: Rotate the fine adjustment knob about one-fourth turn to the right.

– For DF-870: Adjust [F1 Adjust] on the operations panel to [+ 0.4 mm].

3. Perform a test fold.

4. Set the counter and start the folding operation.

5. After the operation, return the fine adjustment knob (DF-850) or the F1 Adjust value (DF-870) to its original position to ensure clean folding of thin paper later.

Double Folding of Thick Paper (up to 104.7 g/m²/27.9 lb)

Do not use paper thicker than 127.9 g/m²/33.9 lb for double folding.

1. Perform the standard paper setup procedure.

2. Lift up the stacker roller by hand and lift the two levers attached to the stacker lever. This leaves the stacker roller floating above the belt surface.

3. Set the stacker roller position to [5] (or [4] or [3] if ejection is not smooth). On DF-870, this is done automatically.

4. Perform a test fold and confirm smooth ejection.

5. Confirm the folding finish is correct.

6. Set the counter and start the operation.

7. After the operation is ended, return the stacker roller position to [1] and lower the stacker lever to its normal position.

Custom folding allows you to specify the fold positions. The process involves measuring a sample, setting the machine, and then running the job.

1. Stack paper in the paper feed tray.

2. Manually prepare a folding sample with the paper being used.

3. Measure the folding position dimensions of the sample (Dimension A for the first fold, Dimension B for the second).

4. Set Paper Size and Folding Mode:

For DF-850:

– While pulling up the rough adjustment knob of folding plate 1, align it to the scale for Dimension A.

– Align the rough adjustment knob of folding plate 2 to the scale for Dimension B. Use the fine adjustment knobs for precise alignment.

For DF-870:

– Press the custom folding key and set the paper size to [CF].

– Enter the measured Dimension A for [CF1 Length].

– Enter the measured Dimension B for [CF2 Length].

5. Align Stacker Roller Position:

– Align the stacker roller position based on the finished size of the folded paper. Use the “Stacker roller positioning table” in the manual as a reference. For this example, it would be position “6”.

6. Perform Folding Operation:

– Perform a test fold to confirm accuracy.

– Set the counter and start the folding operation.

Cross folding is a two-step process: first, a single fold is performed, and then the single-folded paper is fed through the machine again for a second fold (either another single fold or a letter fold).

1. Paper Stacking (First Pass):

– Perform a single fold on your paper stock (e.g., B4 paper) according to the standard folding procedure.

2. Paper Stacking (Second Pass – Cross Fold):

– Use your fingertips to firmly hold down the folding line on the single-folded paper.

– Stack the single-folded paper in the paper feed tray with the fold line side pointing toward the reverse operation side. The stacking height should be about half (25 mm/0.98 inch) of the paper feed guide height.

3. Set Paper Size and Folding Mode:

– Set the paper size and mode for the second pass. For a cross single fold of B4 paper, the setting would be equivalent to a single fold of B5 paper.

– For DF-850: Align the rough adjustment knob of folding plate 1 to “Single Fold” and “B5”. Move the knob for folding plate 2 to the highest point.

– For DF-870: Press the custom folding key to set the paper size to [B5]. Press the folding mode key to set the mode to [SingleFold].

4. Auxiliary Paper Feed Ring Positioning:

– Open the top cover.

– Use the L-shaped hex wrench to loosen the screws on the auxiliary paper feed ring.

– Move the auxiliary paper feed ring so it is on the paper’s new folding line.

– Tighten the loosened screws.

5. Attaching the Cross Folding Lever:

– Remove the cross folding lever from its storage position.

– Attach the cross folding lever to the pillar on the paper feed guide so the weight roller on its tip comes to the fold line.

– Close the top cover.

6. Test and Fold:

– Perform a test fold and check the result.

– Perform the full folding operation.

7. After Operation:

– After the operation is ended, store the cross folding lever at its original position.

– Return the auxiliary paper feed ring to its original position.

Art Paper, Coated Paper

These papers can adhere to each other, making two-sheet feeds more likely. The recommended ream weight is 104.7 to 127.9 g/m².

1. Carefully separate the paper: These papers adhere more easily, so separate each sheet carefully before stacking.

2. Arrange the paper neatly.

3. Stack a smaller volume: Keep the stack in the paper feed tray to a minimum, about half the height (25 mm/0.98 inch) of the paper feed guides.

4. Adjust pressures and settings:

– Paper feed pressure: For DF-870, set to [3] (or higher to [4] or [5] if mis-feeds occur). For DF-850, set to ≡ (thick paper).

– Separation pressure (DF-870 only): Set to [2.5]. If two-sheet feeds occur, raise it in 0.5 increments.

– If mis-feeds still occur, set the [Feed Time] to [Long] in the function settings.

5. Restore settings after use: After the job, return the pressure settings to normal to avoid damaging regular paper on the next run.

Rough Paper, Recycled Paper

These papers often lack stiffness.

– Before stacking, carefully separate the paper.

– Set the processing speed to low to avoid wrinkling or abnormal folding.

– Set the paper feed pressure to low to avoid two-sheet feeds.

B7, A6 Size Paper (For EU)

These can be processed under the following conditions:

– Paper stacking orientation: Vertical stacking

– Folding form: Single fold

– Keep the processing speed as low as possible, as high speeds can cause chaining (hooked feeds).

Correcting Vertical Misalignment (Up/Down)

This is corrected by making fine adjustments to the folding stopper position.

– If folding surface A is too long, you need to shorten it.

– If folding surface A is too short, you need to lengthen it.

For DF-850: Use the Fine adjustment knob for the corresponding folding plate (1 or 2). Turn it right or left as needed.

For DF-870: Use the folding stopper adjustment keys on the control panel. Press the key for folding plate 1 or 2, then use the up/down arrow keys to adjust the [F1 Adjust] or [F2 Adjust] value. These settings are not saved when the power is turned off.

Correcting Horizontal Misalignment (Left/Right)

This is corrected using the slant correction knob.

1. Check the folding misalignment condition to see if the paper is slanted to the left or right.

2. Rotate the slant correction knob in the direction of the arrow shown in the manual’s diagram to adjust the alignment.

3. After the operation is ended, return the slant correction knob to its original position, where the pin aligns with the round hole in the paper feed tray.

To access the function settings, press the Menu key from the top screen. You can then navigate through various settings using the arrow keys.

Here are some of the key function settings:

– Operation Modes: Choose how the machine starts up. [STD] (Standard) starts with default settings. [LF] (Last fold mode) starts with the settings from the last job. [SF] (Stopper fixed mode) always starts with the same saved conditions, which is useful for repetitive jobs.

– Interval Functions: This (batch) function interrupts the process for a set time after a specified number of sheets, allowing you to remove ejected paper. You can set the number of sheets ([Interv Sht]) and the pause duration ([IntervalTime]).

– Energy-saving Setting: Set [Power Save] to [ON] and define a time ([P-Save Time]) after which the machine will enter a low-power state if left idle.

– Paper Stacking Detection Setting: If you get a [Paper Empty] error when paper is present, you can set this to [OFF].

– Buzzer Setting: Set [Tone] to [ON] or [OFF] to enable or disable the key operation sound. The buzzer will always sound for errors.

– Paper Feed Timing Setting: Set the [Feed Time] to [Long] when using long paper, thick paper, or art/coated paper to improve feeding performance.

Make sure you disconnect the power cord from the wall outlet before cleaning. Before you use the machine after cleaning, make sure that its surface is completely dry. CAUTION: Do not use flammable sprays and solvents.

Cleaning the Rubber Roll

1. Remove each folding plate.

2. Open the top cover.

3. While rotating the jam correction knob (DF-870) or the rubber roller by hand (DF-850), wipe it down with an alcohol-saturated cloth.

Cleaning Paper Feed Rings

1. Open the top cover.

2. While rotating the paper feed ring by hand in the direction of the arrow, wipe it down with an alcohol-saturated cloth.

Cleaning Paper Separator

1. Open the top cover.

2. Insert an alcohol-saturated cloth between the center paper feed ring and the paper separator.

3. Rotate the paper feed ring to clean both parts.

Cleaning Sensors

If sensors are dirty, detection may fail. Use a dust removal spray to clean the paper sensor and paper exit sensor.

Cleaning Paper Ejection Belts

1. Lift up the stacker roller by hand and lift the two levers to make the roller float.

2. Slowly push up the stacker roller to the [6] position.

3. While rotating the paper ejection belts by hand, wipe them down with an alcohol-saturated cloth.

4. Return the stacker roller to its original position.

Paper Jam at the Feed Ring

1. Raise the paper set lever to lower the paper feed tray.

2. Pull the jammed paper out towards you.

Paper Coiled Around a Rubber Roller

1. Open the top cover.

2. If the bearing support lever is engaged, rotate it to release the bearing.

3. Pull the coiled paper towards you to remove it.

– For DF-850: If the paper does not come out, use both hands to rotate the rubber roller in the direction of the arrow while removing the paper.

– For DF-870: Remove the paper while turning the jam correction knob.

4. Return the bearing support levers to their original position.

Paper Jam in a Folding Plate

1. Turn off the power.

2. Remove the folding plate where the jam occurred (Plate 1 or Plate 2).

3. Remove the jammed paper.

4. Re-attach the folding plate correctly.

– For DF-870: You can also try to forcibly eject the paper by pressing the C key while the start key is pressed down.

Paper Jam in the Ejecting Section

Simply remove the jammed paper from the ejecting section. For DF-870, you can press the test key while the stop key is pressed down to forcibly eject paper.

(*) DF-870 only

Depending on the paper characteristics, the paper may sometimes not fold correctly. In this case, check the following points:

– Do not use paper outside of specifications. This often happens particularly when using thin paper lacking stiffness.

– When abnormal folding occurs with thin paper lacking stiffness, lower the processing speed.

– Carefully separate the paper before stacking it.

– Check whether the folding plate is correctly attached.

– Because there is a possibility of static electricity occurring in the paper, use a static electricity removal spray, available on the market, on the rubber roller.

For Mis-Feed (paper not feeding):

– Increase the paper feed pressure. Check the paper feed state and raise the paper feed pressure adjustment lever by one step at a time.

– Before stacking, carefully separate the paper.

– Reduce the paper stacking volume.

For Chaining (hooked feeds):

Chaining refers to the next paper feed being linked to paper from an earlier paper feed.

– Increase the separating pressure. (DF-870 only)

– Before stacking, carefully separate the paper.

– Reduce the paper stacking volume.

Basic Specifications

(*1) Fine quality paper 64 g/m²/17.1 lb (Equivalent to 500 sheets). Cross folding shall be 25 mm/0.98 inch or less.

(*2) Including accessories.

Media Specifications

(*) For paper that is less than 182 mm/7.16 inches (length direction), certain conditions apply.

Performance and Functions

(*1) There are limits to the folding form depending on paper quality and paper size.

(*2) Based on A4 size, fine quality paper (long paper) of 81.4 g/m² using single fold.

(*3) 52.3 g/m² or less Y grain (horizontal grain) paper cannot be used.

(*4) Rough paper Y grain (horizontal grain) is outside specifications.

(*5) Fine quality paper 52.3 to 104.7 g/m².

(*6) Maximum finish length is 216 mm/8.50 inches or less.