DUPLO DF-999 (01) PDF MANUAL

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

• 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, as the machine cannot detect the presence of folding plate 2 otherwise.

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 to move the stopper to the inner section. Do not hold the belt section of the folding plate 2.

4. Hold the folding plate 2 by the labeled 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.

5. Store the T-shape hexagonal wrench accessory part at the position inside the machine.

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. Hold it with both hands.

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 and direction to prevent damage to 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.

Cautions in using the touch panel:

• 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).

• The touch panel may not work correctly or may malfunction if you perform the following operations:

– 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

Screen Operation Terms:

• Touch: Lightly touching an item such as a key once with your finger.

• Press and hold: Pressing an item such as a key for more than 1 second. The press-and-hold key is surrounded by a double frame.

In this machine the buzzer sounds in confirmation when setting on the control panel or paper runs out on the paper feed tray. Classification of the sounds is as follows.

“pi”: Operational sound at the time of normal key operation

“pipi”: Warning alarm at the time of mis-operation, mis-feed of paper, or paper empty

“pii”: At the start of folding operation or end of normal folding operation. Saves changes in various settings. The time when you set the alarm has come.

“piipii”: At the occurrence of an error such as paper jam

“piipiipiipii”: At the occurrence of an error to be asked for dealer’s assistance

Paper type

Fine quality paper: 46.5 to 157 g/m² / 31.62 to 106.76 lbs

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

Paper size

Standard Paper: The standard paper can be used only when it is stacked in the machine direction.

A3/B4/A4/B5/A5/B6 (For EU), LGR/LGL/LTR/STMT/INV (For NA)

Non-standard paper

[a] 74 to 311 mm/2.91 to 12.24 inches (Width)

[b] 105.0 to 457.2 mm/4.13 to 18.0 inches (Length)

Some limitations in setting and paper quality may be applied depending on paper size. The A6, A7, or B7 paper can be used as non-standard paper (For EU).

• Paper out of specifications

• Curled paper

• Wavy paper

Paper used

• 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 causing trouble such as smearing on paper.

• Use of paper printed with special types of ink may cause the folding roller to swell or deform, and folding misalignment may occur.

• Paper may not be fed smoothly into the folding plate or deformed folding may occur depending on different environmental factors (temperature, humidity), paper ream weight, paper type, paper grain direction if curled paper is used. Make sure to flatten curled paper or paper with folded lines before use.

• Separate the sheets of paper well before stacking them.

Precautions on stacking paper

• [a] 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. If paper is protruding out from the left or right side, it is unable to detect paper size accurately. (DF-999/DF-999A)

• [b] 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 right or left side may cause such trouble as folding misalignment and jamming.

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

1. Connect the power cord.

2. Turn on the power.

3. Stack paper.

4. Configure basic settings.

5. Set paper size (DF-990/DF-990A).

6. Select folding mode.

7. Adjust feed pressure/separating pressure.

8. Set processing speed.

9. Position the paper receiving tray.

10. Perform a test fold.

11. Set the counter.

12. Start the process.

13. End the process.

14. Turn off the power.

15. Disconnect the power cord.

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.

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 in the paper until the lead edge touches the paper feed inlet lightly. Maximum paper stacking height: 46 mm/1.81 inches.

4. Adjust the paper feed guide to match the paper size, so that it touches the paper lightly.

• Do not press the paper with the paper feed guides too strongly. Otherwise, paper feed errors such as mis-feed will occur.

• If the guides are positioned incorrectly, the automatic paper size detection function will not work, and the test key and start key, etc. will not operate. (DF-999/DF-999A)

5. Tighten the guide fixing screws on both right and left sides. If the screws are not fixed, the paper feed guide moves during operation, and folding misalignment may occur.

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

When the paper feed tray is not set at the feed position, even if you press the start or test key, [Position Err Paper Feed Tray] will be displayed and operation will not start. (DF-990/DF-990A)

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

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 paper feed tray may become over stacked and may not be able to rise due to paper weight. In such cases, stack less paper.

The following procedure is an example for A4 paper and “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 setting screen is displayed. Proceed to step 4.

• For DF-990/DF-990A, the Standard Paper Size setting screen is displayed.

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

4. Touch the single fold key. Return to the Ready screen.

5. Set the feeding pressure adjustment lever to [0].

• As the value of the scale increases, the paper feed pressure increases.

• When paper mis-feed occurs, increase the pressure to [1].

• When double-feed occurs, lower the pressure from [0] to [-1].

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

• Paper separating pressure increases as the scale value increases.

• When double-feed occurs, increase the separating pressure by 0.5 on the scale.

7. Touch the processing speed down or up keys to set the processing speed. Use “Thick paper mode” for thick paper and “Thin paper mode” for thin/flimsy paper if needed.

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

9. Attach the paper support guide [A] to the paper receiving tray from the paper ejecting section, matching the concave sections on the guide with the convex section on the tray.

10. Press the Test key. Test folded paper is not counted.

11. Check the finish of the test folding for any misalignment.

12. Touch the “No. of Sheet setting” key to display the number of sheets input screen.

13. To count up, touch the count up key. To count down, use the numeric keypad to enter the number of sheets, then touch the return key.

14. Press the Start key to begin folding. Press the Stop key to interrupt or stop. Press Start again to restart.

1. Turn off the power switch. (WARNING: Do not touch with wet hands).

2. Disconnect the power plug from the outlet. (WARNING: Do not touch 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 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, correct it using 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 misalignment A, rotate the knob clockwise. The leading edge of paper on the right side will be fed earlier.

• For 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, ensuring it lightly contacts the guide plate.

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

6. Perform a test fold to check the adjustment.

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

For misalignment along the vertical length of the paper, use the folding position adjustment keys on the [Fold Position] screen to adjust. The adjustable range is typically within ±5.0 mm/0.20 inch.

Adjustment Method:

1. Touch the Adjustment key on the [Ready] screen to display the [Fold Position] screen.

2. To adjust folding plate 1:

• Use the [-] key to move the stopper in direction [a].

• Use the [+] key to move the stopper in direction [b].

3. To adjust folding plate 2:

• Use the [-] key to move the stopper in direction [c].

• Use the [+] key to move the stopper in direction [d].

The folding stopper moves 0.1 mm/0.004 inch each time you press the adjustment key. You can also press and hold the key for continuous adjustment, or touch the numerical value to input manually.

Saving the Adjusted Value:

The changed value is cleared when power is turned off. To save it for next time:

• For standard folding of standard paper, touch the Save key, then press and hold the Save key again to save the adjustment value.

• For standard or custom folding of non-standard paper, touch the Save key, then touch the Custom Folding key. Select and save the data to a custom folding number.

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. Particularly, deformed folding occurs frequently with thin, flimsy paper.

• Lower the processing speed when deformed folding occurs 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.

This method involves saving paper lengths other than standard paper and selecting a standard folding mode. The paper sizes which can be used may vary with the paper type, thickness, and printing state.

Example: Performing a letter fold on 300.0 mm length paper.

1. Touch the Basic Settings key on the [Ready] screen, then touch [Standard Fold for Non-Standard Size].

2. Using the numeric keypad, enter the paper length [300] and touch the Return key.

3. Touch the letter fold key to return to the [Ready] screen. You can then proceed with the operation.

Custom folding allows you to fold paper at any position by specifying the folding stopper positions for folding plates 1 and 2.

Operation Example (Accordion-fold, A4 paper):

1. Prepare a folding sample manually using the paper to be folded.

2. Measure the length of the folding positions of the sample (e.g., Fold1: 85.0 mm, Fold2: 95.0 mm).

3. On the [Ready] screen, touch the Custom folding key. The [Paper Length] input screen is displayed.

4. For DF-999/DF-999A, touch the Return key. For DF-990/DF-990A, touch the Standard size switching key.

5. For DF-990/DF-990A, touch the [A4] key. The [Create New Custom Fold] screen appears.

6. Touch the Folding mode selection key, then touch the accordion fold key.

7. Touch the [A: xxxx.x mm] key, use the numeric keypad to enter the folding A length [85], and touch the Return key.

8. Touch the [B: xxxx.x mm] key, use the numeric keypad to enter the folding B length [95], and touch the Return key.

9. To save the input value, touch the Save key. To continue without saving, touch the Return key. When you touch the Save key, the [Save] screen is displayed.

10. On the [Save] screen, select a location and touch the Save key again. The input value is saved, and the display returns to the [Ready] screen.

After this, proceed with the operation as you would for standard folding.

Editing Saved Data (when data is not open):

1. Touch the Basic settings key -> Touch [Custom Fold].

2. Select the data number you want to edit, then touch the Edit key.

3. Edit the values as needed and save.

Using Saved Data:

1. Touch the Basic settings key -> Touch [Custom Fold].

2. Touch the Page forward/backward keys to find your data.

3. Touch the desired data number (e.g., [06]), then touch the Open key. The display returns to the [Ready] screen with the saved data active.

Locking Saved Data:

1. Go to the [Custom Fold] saved data selection screen.

2. Select the data number you want to lock, then touch the Lock/Unlock key. A lock icon will appear.

3. Press and hold the Lock/Unlock key to release the lock.

Deleting Saved Data:

Locked data cannot be deleted. Unlock it first.

1. Go to the [Custom Fold] saved data selection screen.

2. Touch the Save key. The [Save] screen is displayed.

3. Select the number of the saved data you want to delete, then press and hold the Delete key.

4. Press the Cancel key to return to the [Ready] screen.

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

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 ensure it is folded firmly.

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

4. Loosen the guide fixing screw.

5. Stack the single-folded paper on the paper feed 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 height of the paper feed guide.

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).

Adjustment of the parts for cross fold:

1. Turn off the power switch and disconnect the plug.

2. Take the T-handle hexagonal wrench and open the top cover.

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

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

5. Tighten the screw and store the T-handle wrench in its original position.

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

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

8. Take out the cross fold lever.

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

10. Close the top cover, turn on the power, select single fold mode, press the test key, and check the finishing.

Art paper, coated paper: These often stick to each other. Follow this procedure:

1. Separate the paper well.

2. Align the paper.

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

4. Attach the paper feed guide.

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

6. Set the separating pressure adjustment dial to [2.5]. Increase by [0.5] if double-feed occurs.

7. Press the test key and check the finish. Decrease processing speed if abnormal folding occurs.

After use, return pressure settings to [0].

Rough paper, recycled paper: These may be thin, flimsy, and easy to curl.

• 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.

Changing stacker roller height: For some thick and stiff paper that may not eject smoothly.

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

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

Be sure to return the stacker roller to the standard position after completing folding operations to avoid poor alignment of ejected paper.

Adjusting stacker roller position: During cross folding or when folding thick paper, if the paper opens when ejected or a jam occurs.

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

2. The [Stacker Roller] screen is displayed.

3. Use the [+]/[-] keys to adjust the position. The smaller the value, the more the roller moves to the internal side. The higher the value, the more it moves to the outer side.

4. Touch the Test key to check the new position.

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.

The angle of the paper receiving tray can be changed to stack folded paper in two ways:

• Straight stacking: Paper is ejected straight onto the tray.

• Diagonally stacking: Paper is ejected at an angle for neat offsetting.

If you use the paper support guide when diagonally stacking paper satisfying the following conditions, the paper will be ejected and stacked neatly:

• Paper size: A4/LT

• Thickness of paper: Fine quality paper 64 g/m²/43.52 lbs, 81.4 g/m²/55.35 lbs

• Folding mode: Letter fold, Accordion fold

Thick paper mode: Set this mode when double folding B4 or larger, or thick (104.7 g/m²/71.20 lbs or more) fine quality paper. Touch the speed up key on the [Ready] screen to change the processing speed to the thickest setting. Touch the speed down key to clear the mode.

Thin paper mode: Use for thin and flimsy paper. Touch the speed down key on the top screen to change the processing speed to the thinnest setting. Touch the speed up key to clear.

Interval function: This function specifies a number of sheets to be folded, then suspends operation for a set time. Access it via the Function Settings screen.

Double-feed detection: This function reads the paper thickness to detect when more than one sheet is fed. It can be set to use an optical or ultrasonic sensor (if installed). Access it via the Function Settings screen. Test folding is required for the optical sensor.

Detection: Turns on/off paper stack detection and automatic standard size detection. Useful if the [Paper Empty] message appears incorrectly.

Initial: Sets the machine’s startup state (Normal, Last Fold, Stopper Fixed).

Initial Screen: Sets which screen is displayed when the power is turned on.

Custom Screen: Add custom keys to the top screen for quick access to frequently used screens.

Idling: Keeps the machine in a standby state without stopping the conveyance drive when an error occurs or operation is paused.

Tone: Enables or disables the buzzer for key operations.

mm/inch: Switches the unit of measurement.

LCD bright: Adjusts the screen brightness.

Number of test sheets: Sets the number of sheets fed during a test fold (1 to 3).

Language: Changes the display language.

Power saving: Sets a time for the LCD backlight to automatically turn off.

Alarm (DF-999/DF-999A): Sounds a buzzer if the machine is left unused for a specified period.

At maximum, three sheets of paper can be simultaneously folded together. Do not use smaller paper than specified (A4, B5 for EU / LTR for NA).

Operation Steps:

1. Open the paper receiving tray on the right side.

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

3. Set [Manual Feed Mode] from the function settings screen.

4. Set the paper to the hand feed paper feed guide of the hand feed paper feed tray. Do not insert it into the inlet yet.

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

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

7. Check the finish of the test fold and adjust misalignment if needed.

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

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

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 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:

Use a non-flammable air duster. Wait for about five minutes after use for any condensation to dissipate.

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

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

• 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.

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:

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 by rotating the jam correction knob.

6. Close the top cover.

7. Insert folding plate 1 and folding plate 2.

8. Close the side cover.

Folding plate:

Press the paper ejection key to forcibly eject the paper inside the folding plate. If paper is not removed, check the position of the jam and remove it by taking out the relevant folding plate (1 or 2).

Ejecting section:

Press and hold the paper ejection key to forcibly eject the paper. Forcible ejection will stop when you release the key.

Check the error code and follow the solution. If the C key is displayed, you can touch it to release the error after fixing the issue.

Warning Errors

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

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

Motor Errors

(*) DF-999/DF-999A

Paper Jam Errors

Other Errors

When the following error codes are displayed, turn the power off and on. If the error is not cleared, contact your dealer.

• E1101

• E1902

• E4210

• E4300

• E4301

• E4302

• E5011

• E5012

• E5013

• E5015

• E5770