DUPLO DF-980 (01) PDF MANUAL

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

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

Memo: Indicates supplementary or useful information.

Ref: Describes names of related items and supplementary instructions.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

– Reorient or relocate the receiving antenna.

– Increase the separation between the equipment and receiver.

– Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

– Consult the dealer or an experienced radio/TV technician for help.

The marks used to describe hazardous operations and handling are as follows:

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.

Triangle Symbol: This mark indicates a “Warning” or “Caution”. A graphic may be shown inside the mark to describe the warning or caution more specifically.

Circle with a line through it: This mark indicates a forbidden action. A graphic may be shown inside the mark to describe the forbidden action more specifically.

Solid Circle: This mark indicates actions that must be performed. A graphic may be shown inside the mark to describe the action to be performed more specifically.

Power Supply Range:

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

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

Rated current (Rated power): 1 to 0.5 A (88 W)

When you power other appliances from the same AC outlet, make sure that the combined power consumption does not exceed the power supply capacity.

WARNINGS:

– Use only the power supply voltage specified on the main nameplate. Using other voltages could result in a fire or an electrical shock.

– 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 a fire.

Operate this unit in the following environment:

• where the temperature range is between 5 and 35°C / 41 and 95°F (-10 to 50°C / 14 to 122°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

• which is reasonably free from dust

• 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

WARNINGS:

– Keep this unit and the power cord away from heaters and heater vents. Excessive heat could melt the cover or power cord covering, and result in a fire or an electrical shock.

– Do not place metal objects or vessels containing liquids on top of the unit. The entry of any metal object or liquid could result in a fire or an electrical shock.

– Do not insert any metal or easily-combustible object inside this unit. This could result in a fire or an electrical shock.

– Do not use flammable sprays inside or near the unit (e.g. when cleaning the unit). Such flammable gas may ignite and cause a fire or combustion.

CAUTIONS:

– Do not install this unit in a location where there is excessive humidity or where contact with water is possible. Poor choice of location could result in deterioration of the insulation, a fire or an electrical shock.

– 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.

– Disconnect the power plug from the power outlet before attempting to move this unit. Failure to do so could result in power cord damage, a fire or an electrical shock.

– 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 a fire due to leakage current if the insulation should deteriorate.

WARNINGS:

– Do not damage the power cord or power plug. Do not scratch, alter, bend, twist, pull or place heavy objects on the power cord or power plug. This could result in damage, a fire or an electrical shock.

– Do not touch the power switch with wet hands. Otherwise electric hazards may occur.

– Do not remove the cover or back panel. This unit contains high-voltage components that could cause an electrical shock.

– Do not disassemble, modify or repair this unit. There is a danger of fire, electrical shock or injury. Contact your dealer when repairs are necessary.

– If any foreign object such as metal or liquid should enter this unit, immediately turn the unit off at the power switch and disconnect the power plug from the power outlet. Failure to do so could result in a fire or an electrical shock. Contact your dealer immediately.

– Before cleaning this unit, turn the unit off at the power switch and disconnect the power plug from the power outlet. Accidental operation of the unit during cleaning could result in injury.

– If the unit emits smoke, unusual heat or unusual odors, immediately turn the unit off at the power switch and disconnect the power plug from the power outlet. Failure to do so could result in a fire or an electrical shock. Contact your dealer immediately.

– Remove any dust that accumulates on the power plug prongs and the surface of the plug from which the prongs extend. Accumulated dust could result in a fire.

– Always grip the plug when disconnecting the power plug from the power outlet. Forcibly pulling on the power cord could cause damage, resulting in a fire or an electrical shock.

– Do not touch or insert foreign objects into any rotating part during operation. This could result in injury.

CAUTION:

– Because of its structure, there are tiny protruding objects inside the unit. Be careful when putting your hand inside the unit. This could result in injury.

• This machine is designed to fold paper into six popular folding modes: Single fold, Double fold, Irregular accordion fold-out, Letter fold, Accordion-fold, and Gate fold.

• Use the cross fold lever to fold single folded paper further into standard folding. (To perform cross fold with the DF-970, the DF CROSS FOLD UNIT (option) is needed).

• Use the DF HAND FEED KIT (option) to bind and fold at maximum three sheets of paper simultaneously.

Before installation:

• Do not drop the folding plates. Make sure the folding plates are not subject to shock. Otherwise, the folding plates may be damaged, resulting in poor folding accuracy.

• The machine may make loud sounds while operating according to the processing speed and paper used due to its paper-folding mechanism.

• Be sure to move this machine with the bottom surface of this machine held by two persons.

Installation procedures:

1. Open the side cover.

2. Remove the tape fixing the interlock lever. The interlock does not function when using the machine without removing the tape.

3. Check that the folding stopper does not protrude from the cover on the paper feeding side of the folding plate 2. If it does, rotate the gear in the direction of the arrow to move the folding stopper to the inner section of the cover. Do not hold the belt section of folding plate 2, as this could cause a malfunction.

4. Insert the folding plate 2 into the main body of the machine, holding it with both hands. Ensure it is attached properly.

5. Store the T-shape hexagonal wrench (accessory part) at the position inside the machine as shown in the figure.

6. Close the side cover.

7. Open the support paper feed tray to the left side from the operator’s view point.

8. Insert the folding plate 1 into the main body of the machine along with the set guide, holding it with both hands.

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

10. Rotate the jam correction handle to check that the folding roller rotates smoothly.

11. Place the cross fold lever as shown in the figure. (Provided as an option for the DF-970). Be sure to store it at the specified place and in the specified direction to prevent damage.

12. Close the top cover.

13. Open the paper receiving tray to the right side seen on the operating side.

14. Attach the auxiliary paper ejection guide to the stacker roller.

Connecting power cord:

1. Install the power cord to the machine. Do not touch the power plug with wet hands.

2. Connect the power plug to the outlet.

(*) :Provided as an option for the DF-970.

Paper type:

• Fine quality paper : 52.3 to 157 g/m² / 14 to 40 lb

• Rough paper, Stencil paper, Recycle paper, Specific art paper, Specific coated paper

Paper size (Standard Paper):

Non-standard paper:

• Width: 74 to 311 mm / 2.91 to 12.24 inches

• Length: 105 to 457.2 mm / 4.13 to 18.0 inches

• The A6, A7, or B7 paper can be used as non-standard paper.

Paper that cannot be used with this machine:

• Paper out of specifications

• Curled paper

• Wavy paper

• Make sure that the printing ink on the paper has dried completely prior to use. Wet ink or ink that is not completely dried may stain the folding roller. Use of paper printed with special types of ink may cause the folding roller to swell or deform.

• Paper may not be fed smoothly if curled. Make sure to flatten curled paper or paper with folded lines before use.

• Separate the sheets of paper well before stacking them.

• Do not stack the sheets of paper on the paper feed tray with the sides of sheets unaligned or some sheets protruding from the stack. This machine has an automatic standard paper size detection function (DF-980), so if paper is protruding, it may be detected incorrectly.

• Processing with sheets unaligned on the right or left side may cause folding misalignment and jamming.

• Do not stack paper on the paper feed tray with the lead and trail edges unaligned or some sheets protruding out.

• Processing with sheets unaligned on the lead and trail edges may lead to unstable feed causing such trouble as mis-feed and double-feed.

First, make sure that the power plug is connected to the wall socket.

Turning on the power:

Set the power switch to the “I” side. Do not touch the power switch with wet hands as electric hazards may occur.

Turning off the power:

Set the power switch to the “O” side.

Steps 1 and 6 are not necessary with the DF-980. Move on to steps 2 to 5.

1. Raise the paper set lever (DF-970). The paper feed stand will come down to the paper stacking position.

2. Loosen the guide fixing screw.

3. Stack paper on the paper feed tray. Push in the paper until the lead edge touches the paper feed inlet lightly. The maximum paper stacking height is 46 mm/1.81 inches.

4. Adjust the paper feed guide to match the paper size. Set the paper feed guide so that it touches the paper lightly. Do not press too strongly. For DF-980, if guides are positioned incorrectly, automatic paper size detection will not work.

5. Tighten the guide fixing screws on both right and left sides to prevent folding misalignment.

6. Lower the paper set lever (DF-970). The paper feed stand will go up to the paper feeding position.

Automatic rise/descent of the paper feed tray (DF-980):

When paper is stacked on the paper feed tray, the paper feed guides are set, and the start or test key is pressed, the paper feed tray rises automatically. When using large or heavy paper, the tray may not rise due to weight; in such cases, stack less paper. The tray descends automatically when paper is removed or runs out during operation (unless Detect OFF is set).

When using the DF-980, start from step 2. When using the DF-970, start with step 1, and move on to step 3.

1. Select the size of standard paper used with the paper size select key (DF-970).

2. Check the paper size display on the screen. If the paper size is not displayed, the paper feed guide may not be positioned correctly (DF-980).

3. Press the folding mode key to select the desired folding mode.

4. Set the feeding pressure adjustment lever to [0]. Increase to [1] for mis-feeds, or decrease to [-1] for double-feeds.

5. Set the separating pressure adjustment dial to [0]. For double-feeds, increase the separating pressure by 0.5 on the scale.

6. Press the ▲ or ▼ key to set the processing speed. Adjust speed for thick or thin paper as needed.

7. Adjust the position of the paper receiving tray. Set to [A] to stack diagonally or [B] to stack straight.

8. If stacking diagonally, attach the paper support guide to the paper receiving tray.

9. Press the test key. It will fold two sheets of paper. For DF-980, if it doesn’t start, check paper feed guide setting. For DF-970, check if the paper set lever is lowered.

10. Check the finish of the test folding. If there is misalignment, correct it.

11. Select the method of using the counter. “Count Up” starts from 0. “Count Down” requires you to enter the number of sheets to be processed.

12. For “Count Down”, press the keypad to enter the number of sheets to be processed.

13. Press the start key to start folding. Press the stop key to interrupt or stop. The machine stops automatically when paper runs out.

1. Turn off the power switch.

2. Disconnect the power plug from the outlet. Do not touch the plug with wet hands.

3. Remove the power cord from this machine.

4. Close the support paper feed tray.

5. Remove the auxiliary paper ejection guide and paper support guide. Store them carefully.

6. Return the height of the stacker roller to the standard position.

7. Hang the hook section of the paper receiving tray.

8. Hang the auxiliary paper ejection guide on the paper receiving tray.

Adjustment in the right and left direction:

1. Check that the paper feed guides are set correctly.

2. Remove the paper stacked on the paper feed tray.

3. Rotate the skew correction knob to adjust. Clockwise rotation makes the right side feed earlier. Counter-clockwise makes the left side feed earlier.

4. Stack paper on the paper feed tray.

5. Tighten the guide fixing screw on the paper feed guide.

6. Perform a test fold.

7. After completing operations, return the skew correction knob to the standard position.

Adjustment in the up and down direction:

Adjust the positions of the folding stopper of folding plates 1 and 2 to correct the misalignment.

1. Press the stopper adjustment key of the folding plate you wish to adjust.

2. Press the ◄ or ► key to set the adjustment value (e.g., [+0.5]). The folding stopper moves by 0.1 mm/0.004 inch per press.

3. Press the Enter key. The changed value is set. To register this value permanently (so it’s not cleared on power off), press and hold the Enter key for a few seconds until the buzzer sounds.

The paper may not be folded properly due to the characteristics of paper. In such cases, check the following points:

• Do not use paper outside the specifications. Deformed folding occurs frequently with thin, flimsy paper.

• Lower the processing speed for thin and flimsy paper.

• Separate paper well prior to stacking.

• Stack paper on the paper feed tray after aligning well, and set the paper feed guides at the correct positions. Also tighten the fixing screws of the paper feed guides firmly.

1. Press the menu key to display [Paper Size Set].

2. Press the Enter key.

3. Press the ◄ or ► key to select [Man].

4. Press the Enter key.

5. Press the ▼ key to select [P Length].

6. Press the Enter key.

7. Input the paper length on the keypad. Setting range is 105.0 to 457.2 mm / 4.13 to 18.00 inches.

8. Press the Enter key. The inputted value will be set.

9. Press the Cancel key to return to the main screen.

The procedures after this are the same as for standard folding.

Custom folding allows you to fold paper at any position by specifying the folding stopper positions. The length of the folded plane is restricted: Folding plate 1: 42 to 325 mm / 1.65 to 12.80 inches; Folding plate 2: 0*/47 to 217 mm / 0*/1.85 to 8.54 inches (*0 for single folding).

Operation steps (example for accordion-fold):

1. Prepare a folding sample manually.

2. Measure the length of each folding position (Fold1 and Fold2).

3. Press the menu key to display [Custom Set].

4. Input a registration number (01-20 for DF-980, 01-10 for DF-970) using the keypad or arrow keys.

5. Press the Enter key. [P Length] can now be changed.

6. Input the paper’s total length using the numerical keypad and press Enter.

7. The cursor moves to [Fold1]. Input the measured length for Fold1 and press Enter.

8. The cursor moves to [Fold2]. Input the measured length for Fold2 and press Enter.

9. Press the Enter key again. The display will return to the top screen with the custom settings active.

To use the registered data, press the custom folding key (DF-980) or paper size select key (DF-970) to select the registered number.

Locking Registered Data:

1. In the [Custom Set] screen, select the registration number to be locked.

2. Press the stop key. A lock icon will be displayed. Press the stop key again to release the lock.

Clearing Registered Data:

1. In the [Custom Set] screen, select the registration number to be cleared.

2. Press the clear key for about two seconds. A buzzer sounds and the data is cleared.

Cross fold is folding a single-folded paper another time. The maximum paper thickness is fine quality paper 104.7 g/m²/28 lb. Note that double-feed detection does not operate during cross fold (set to OFF for DF-980).

Cross fold of standard paper:

1. Single fold standard paper according to the standard procedure.

2. Press the folded line of the single-folded paper with your fingertip to make it firm.

3. Raise the paper set lever (DF-970).

4. Loosen the guide fixing screw.

5. Stack the single-folded paper on the paper feed tray with the folded line toward the anti-operating side. Max stacking amount is 25 mm/0.98 inch.

6. Attach the paper feed guide lightly and tighten the fixing screws.

7. Lower the paper set lever (DF-970).

8. Adjust internal parts: Turn off power, open the top cover, move the auxiliary paper feed ring to the folding line, set separating pressure dial to [0], and feeding pressure lever to [3].

9. Attach the cross fold lever to the paper feed guide on the left side, with its weight roller on the folding line.

10. Close the top cover, turn on power, and set to single folding mode.

11. Press the test key to test fold and check the finish.

After cross fold operation, return the auxiliary paper feed ring and store the cross fold lever in their original positions.

Art paper, coated paper:

These papers often stick together, resulting in double-feed. Follow this procedure:

1. Separate paper well and align the paper.

2. Stack the paper on the paper feed tray. Do not stack too many sheets (approx. half the height of the paper feed guide, or 25 mm/0.98 inch).

3. Attach the paper feed guide.

4. Set the feeding pressure adjustment lever to [3]. If mis-feed occurs, increase to [4] or [5].

5. Set the separating pressure adjustment dial to [2.5]. If double-feed occurs, increase by [0.5] at a time.

6. Press test key, check finish. If abnormal folding occurs, decrease processing speed.

7. After finishing, return feeding and separating pressure settings to [0].

Rough paper, recycled paper:

This paper can be thin and flimsy. Pay attention to the following:

• Separate paper well before stacking.

• Set the processing speed as low as possible.

• Set the paper feed pressure as low as possible.

• Set the paper separating pressure as low as possible.

Some thick and stiff paper may not eject smoothly because it opens after folding. Change the stacker roller height to widen the space for ejection.

1. Remove the auxiliary paper ejection guide and paper support guide.

2. Lift the stacker roller and hold it with your hand to move it to the raised [A] position shown in the figure.

Note: After completing folding operations, be sure to return the stacker roller to the standard position. Leaving it in the raised state will result in poor alignment of ejected paper.

The angle of the paper receiving tray of this machine can be changed. The folded paper can be stacked in two ways:

• Straight stacking: Paper is stacked neatly in a straight pile.

• Diagonally stacking: Paper is ejected at an angle, creating an offset stack. Using the paper support guide can help with neat diagonal stacking under specific conditions (Paper size: A4/LT; Thickness: 64 g/m²/16 lb to 81.4 g/m²/22 lb; Folding mode: Letter fold, Accordion fold).

Thick paper mode:

Use for double folding B4 or larger, or thick (104.7 g/m²/28 lb or more) paper.

1. Press the ► key on the top screen to set the processing speed to [5].

2. Press the ▼ key. The processing speed display reverses, and the thick paper mode is set.

Press the ▲ key to clear the thick paper mode.

Thin paper mode:

Use for thin and flimsy paper like rough or recycled paper.

1. Press the ◄ key on the top screen to set the processing speed to [1].

2. Press the ▲ key. The processing speed display reverses, and the thin paper mode is set.

Press the ▼ key to clear the thin paper mode.

This function reads the thickness of paper on a test fold and detects when more than one sheet is fed.

1. Press the menu key to display [D-Feed Detect].

2. Select [Set] and press Enter. Choose [ON] and press Enter.

3. Select [Thickness] and press Enter. Choose [Thin] or [Thick] and press Enter. [Thin] is the normal setting. Use [Thick] if false double-feed detection occurs.

4. Press the Cancel key to return to the top screen. An icon will be displayed.

5. Press the Test key. The machine will learn the paper thickness. The icon will change to indicate the test has been performed.

Important Notes:

• Perform a test fold every time you change paper.

• The function may not work properly if printing is uneven or paper is misaligned.

• Double-feed will not be detected for paper 250 mm/9.84 inches or less in length.

Make sure you disconnect the power cord from the wall outlet before cleaning. Do not use flammable sprays and solvents.

Cleaning paper feed rings and folding rollers:

1. Open the top cover.

2. For the paper feed ring, clean with a cloth moistened with alcohol while rotating the ring by hand.

3. For the folding roller, remove folding plate 1. Clean the roller with a cloth moistened with alcohol while rotating the jam correction knob.

Cleaning the LCD:

• Wipe the LCD on the control panel with a dry cloth.

Cleaning the stacker belt:

1. Remove the auxiliary paper ejection guide.

2. Wipe the stacker belt with a cloth moistened with alcohol while rotating it by hand.

Cleaning the sensor:

• Remove dust from the infeed sensor, the paper ejection sensor (front) and the paper ejection sensor (back) by blowing air with a non-flammable air duster.

Cleaning the paper separator:

• If the paper separator is dirty, paper slippage or double-feed may occur. For cleaning, contact your Duplo dealer.

Warning error:

Motor error:

Paper jam error:

Errors requiring a service call:

If the following codes are displayed, turn the power off and on. If the error is not cleared, contact a Duplo dealer: E130, E240, E340, E840, E910, E930, E940.

Paper feed ring:

1. Open the top cover.

2. Slowly remove the jammed paper near the paper feed ring.

3. Close the top cover. If paper cannot be pulled out easily, first remove all paper from the feed tray.

Folding roller / Folding plate:

Forcible Ejection: Hold on the Cancel key, and press the Clear key. This will forcibly eject paper inside the folding plate.

If paper is still jammed:

1. Take out folding plate 1.

2. Open the side cover and take out folding plate 2.

3. Open the top cover.

4. Pull out the paper by rotating the jam correction knob.

5. Close the top cover.

6. Insert folding plate 1 and folding plate 2.

7. Close the side cover.

Ejecting section:

• Hold on the Cancel key, and press the Test key to forcibly eject paper.