DUPLO DF-990A (01) PDF MANUAL

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

! Symbol (Exclamation point in triangle): Describes instructions which must be followed in use. Be sure to read the instructions to avoid problems due to incorrect operations.

Page Symbol: Indicates supplementary or useful information.

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

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: 100 W

Rated current: 1.0 to 0.5 A

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

where the outside light does not exceed 1,500 lx

which is subject to little or no vibration

where the unit is kept away from air-borne salt

where the unit is kept away from harmful chemicals

where the unit is not exposed to water

“WARNING” and “CAUTION” labels are pasted on the machine to ensure user safety. Do not remove or change them. When the labels become dirty or are lost, be sure to contact your dealer for a new one.

The label indicates:

CAUTION: Keep away from moving parts. It could cause 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.

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

Do not fall down the folding plates. Make sure the folding plates are not subject to shock. Otherwise, the folding plates may damage, 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.

1. Open the side cover.

2. Remove the tape fixing the lever. Be sure to remove this tape, otherwise the machine cannot detect the presence of folding plate 2.

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

4. Hold folding plate 2 by the indicated label areas and insert it into the machine. Insert it with its rollers [A] moving along the rails [B] of the machine. Ensure it is attached properly as shown in the manual figure.

5. Store the T-shape hexagonal wrench in its position inside the machine.

6. Close the side cover.

7. Open the support paper feed tray to the left side.

8. Insert folding plate 1 into the main body along the set guide. Hold it with both hands. If it’s difficult to attach, check that the gear on the reverse side rotates.

9. Open the top cover gently to avoid injury.

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

11. Place the cross fold lever in its specified storage place. Moving it during operation may damage the folding roller.

12. Close the top cover.

13. Open the paper receiving tray to the right side.

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

1. Install the power cord to the machine.

2. Connect the power plug to the outlet.

WARNING: Do not touch the power plug with wet hands. Otherwise electric hazards may occur.

The touch panel is designed to touch lightly with a finger or a pen (its tip radius is 0.8 or smaller). Do not press the panel strongly with a finger or push it with any sharp objects (such as a fingernail, ball-point pen, and pin).

If you perform the following operations, the touch panel may not work even though you are touching it. Additionally, note that such operations may cause malfunction of the machine.

Operation with the tip of a nail

Operation with a foreign object placed on the touch panel

Operation with a protective sheet or sticker applied on the touch panel

Operation with the touch panel being wet

Operation with a finger wet with sweat or water

Make sure that the power plug is connected to the wall socket.

Turning on power:

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

Turning off power:

Set the power switch to the “ O “ side.

Note: Steps 1 and 6 are not necessary with the DF-999/DF-999A. Move on to steps 2 to 5.

1. Raise the paper set lever. The paper feed stand will come down.

2. Loosen the guide fixing screw.

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

4. Adjust the paper feed guide to match the paper size, setting it to touch the paper lightly. Do not press the guides too strongly, as this can cause mis-feeds. If guides are positioned incorrectly on the DF-999/DF-999A, the automatic paper size detection will not work.

5. Tighten the guide fixing screws on both sides. If not fixed, the guides may move during operation and cause misalignment.

6. Lower the paper set lever. The paper feed stand will go up to the feeding position.

Automatic rise/descent of the paper feed tray (DF-999/DF-999A):

When paper is stacked and the guides are set, the tray rises automatically when the start or test key is pressed. If using large or heavy paper, stack less paper to avoid over-stacking issues.

The operating procedure will be explained using the example of when the paper size is “A4″ and the folding mode is “Single Fold.”

1. Touch the Basic Settings key on the [Ready] screen.

2. Touch the [Standard Fold] key. For DF-999/DF-999A, the Folding Mode screen appears. For DF-990/DF-990A, the Standard Paper Size screen appears.

3. (For DF-990/DF-990A) Touch the [A4] key.

4. Touch the single fold icon key. The display returns to the Ready screen.

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

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

7. Touch the speed up or down keys to set the processing speed.

8. Adjust the position of the paper receiving tray. Set to [A] for diagonal stacking or [B] for straight stacking.

9. If applicable, attach the paper support guide [A] to the paper receiving tray.

10. Press the (test) key. Test folded paper is not counted.

11. Check the finish of the test folding. If there is misalignment, refer to “Correcting Folding Misalignment”.

12. Touch the (No. of Sheet setting) key to display the number of sheets input screen. Choose to count up or count down.

13. Press the (start) key to start folding. Press the (stop) key to interrupt or stop. Press start again to restart.

1. Turn off the power switch.

2. Disconnect the power plug from the outlet.

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 with caution so they are not lost.

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.

When the folded paper is misaligned along the sides, use the skew correction knob of the paper feed tray.

1. Check that the paper feed guides are set correctly. Gaps can cause misalignment.

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

3. Rotate the skew correction knob to adjust:

– For right-side misalignment (Folding misalignment A): Rotate the knob clockwise. The leading edge of paper on the right side will be fed earlier.

– For left-side misalignment (Folding misalignment B): Rotate the knob counterclockwise. The leading edge of paper on the left side will be fed earlier.

4. Stack paper on the paper feed tray again.

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

6. Perform a test fold.

7. After completing folding, return the skew correction knob to the standard position (pin in round hole).

For misalignment along the vertical length of the paper, adjust the positions of the folding stoppers on folding plates 1 and 2 using the [Fold Position] screen.

1. Touch the adjustment key on the [Ready] screen to open the [Fold Position] screen.

2. Use the folding position A adjustment key [+] or [-] to adjust folding plate 1. The stopper moves 0.1 mm/0.004 inch each time you press the key.

3. Use the folding position B adjustment key [+] or [-] to adjust folding plate 2.

4. You can also touch the value (e.g., A:x.x mm) to input it manually via the numeric keypad.

5. To save the adjusted value for future use:

– For standard paper, touch the Save key and then press and hold the appropriate key to save.

– For non-standard or custom folds, touch the appropriate key, then select and save the data number for the custom folding.

Cross folding is folding a single-folded paper another time. The maximum paper thickness is fine quality paper 104.7 g/m²/71.20 lbs.

Stacking Paper for Cross Fold:

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

2. Press the folded line of the single-folded paper firmly with your fingertip.

3. Raise the paper set lever (DF-990/DF-990A).

4. Loosen the guide fixing screw.

5. Stack the single-folded paper on the tray with the folded line toward the non-operator’s side. The stacking amount should be about half (25 mm/0.98 inch) of the paper feed guide height.

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

7. Lower the paper set lever (DF-990/DF-990A).

Adjusting Parts for Cross Fold:

1. Turn off the power.

2. Disconnect the power plug.

3. Take the T-handle hexagonal wrench.

4. Open the top cover.

5. Loosen the screw of the auxiliary paper feed ring using the T-handle wrench.

6. Move the auxiliary paper feed ring so that it will be on the folding line of the paper.

7. Tighten the screw and store the wrench.

8. Set the separating pressure adjustment dial to [0].

9. Set the feeding pressure adjustment lever to [3] (within the range of [3] to [5]).

10. Take out the cross fold lever.

11. Attach the cross fold lever to the paper feed guide on the left side, so the weight roller is on the folding line.

12. Close the top cover.

Operation:

1. Turn on the power.

2. Touch the single fold key on the [Ready] screen.

3. Press the test key to execute a test fold.

4. Check the finishing.

After the operation, turn off the power and return the cross fold lever and auxiliary paper feed ring to their original positions.

For Art Paper and Coated Paper:

These papers often stick together. Follow these steps:

1. Separate the paper well.

2. Align the paper.

3. Stack the paper on the feed tray. Do not stack too many sheets; about half the height of the paper feed guide (approx. 25 mm/0.98 inch) is recommended to prevent double-feeds.

4. Attach the paper feed guide.

5. Set the feeding pressure adjustment lever to [3] (or [4] or [5] if mis-feeds occur).

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

7. Press the test key to test fold.

8. Check the finish. If folding is abnormal, decrease the processing speed.

Important: After finishing, return the feeding and separating pressures to [0].

For Rough Paper and Recycled Paper:

These papers may be thin, flimsy, and prone to curling. Pay attention to the following:

Separate the 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.

During cross folding or when folding thick paper, you may need to adjust the stacker roller if paper opens upon ejection, causing misalignment or jams.

Changing Stacker Roller Height:

For thick and stiff paper that may open after folding, you can widen the space for the paper to pass in ejection.

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

2. Lift the stacker roller and move it to the [A] position shown in the manual. This raises the roller.

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

Adjusting Stacker Roller Position:

1. Touch the Stacker Roller key on the [Ready] screen.

2. The [Stacker Roller] screen will be displayed.

3. Use the [+]/[-] keys to adjust the position. A smaller value moves the roller inward; a higher value moves it outward. Setting to [0] is used for cross-folding jams and slows the processing speed.

4. Touch the test key to check the result.

5. Touch the return key to go back to the [Fold Position] screen.

6. Touch the return key again to go back to the [Ready] screen.

At maximum, three sheets of paper can be simultaneously folded together using the DF HAND FEED KIT. It is suitable for A4, B5 (For EU)/LTR (For NA) paper with a thickness of 52.3 to 81.4 g/m².

Setting up Manual Feed Mode:

1. Go to the Function Settings screen and select [M-Feed Mode].

2. Turn on M-Feed Mode, and select the Timing (Slow, Normal, Fast) and paper Size (A4, B5).

Operation:

1. Open the paper receiving tray.

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

3. Ensure [Manual Feed Mode] is set.

4. Set the paper to the hand feed paper feed guide of the hand feed paper feed tray.

5. Set the auxiliary guide to the paper side, leaving a small clearance.

6. Insert a sheet of paper to perform a test fold. The machine will feed automatically.

7. Check the finish and adjust misalignment if needed.

8. Select your counter method (Count Up or Count Down).

9. Insert paper to start folding operation. Do not insert the next paper until the machine stops.

WARNING: 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. When using alcohol, exercise precaution against fire and ventilate well.

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, rotating the ring by hand.

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

Cleaning sensors:

If a sensor is dirty, the detection function may not work. Use a non-flammable air duster.

1. Paper feed timing sensor, paper sensor, double-feed detection sensor: Open the top cover and remove dust with an air duster.

2. Paper ejection jam sensor upper: Remove dust with an air duster.

3. Paper ejection jam sensor lower: Open the side cover, remove folding plate 2, and remove dust with an air duster or wipe with a dry cloth.

Cleaning LCD touch panel:

Gently wipe the LCD touch panel of the control panel with a dry cloth.

Cleaning 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 paper separator:

If the paper separator is dirty, mis-feed or double-feed may occur. For cleaning of the paper separator, contact Duplo dealer.

(*1) DF-999/DF-999A

(*2) DF-990/DF-990A

(*) DF-999/DF-999A

General Troubleshooting for Paper Jams:

Removing Jammed Paper by Location:

Paper Feed Ring:

1. Open the top cover.

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

3. Close the top cover.

Folding Roller:

1. Take out folding plate 1.

2. Open the side cover.

3. Take out folding plate 2.

4. Open the top cover.

5. Pull out the paper while rotating the jam correction knob.

6. Close the top cover.

7. Re-insert folding plate 1 and folding plate 2.

8. Close the side cover.

Folding Plate:

Press the paper ejection key to forcibly eject paper from inside the folding plate. If this doesn’t work, remove the paper by taking out folding plate 1 or 2 as described above.

(*1) Fine quality paper 64 g/m²/43.52 lbs (Equivalent to 500 sheets). Cross folding shall be 25 mm/0.98 inch or less

(*2) *LAeq is the value added consideration of the variation with time to the A-weighted sound pressure level LpA.

(*3) Machine weight (Main body + Folding plate 1 + Folding plate 2)

(*4) Including accessories (1.0 kg/2.2 lb)

(*1) For paper that is less than 128 mm/5.04 inches (length direction), certain conditions apply regarding paper quality and processing speed.

(*2) Depending on manufacturing conditions, some paper types may be outside specifications.

(*3) Paper feed tray stacking height is 25 mm/0.98 inch or less. Depending on manufacturing conditions, it will be outside the specifications.