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Dbm-500 Instruction Manual - Complete Mailing Solutions

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INSTRUCTION MANUAL SYSTEM5000 Dynamic Booklet Maker DBM-500 [ for 120 V ] Be sure to read this manual prior to use. Please leave this manual at the site of use for easy reference. Applicable to the 120 V machine This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. INTRODUCTION Thank you for purchasing this Duplo equipment. To ensure correct usage, please read this instruction manual thoroughly, especially the section entitled "Safety Precautions". The aim of this instruction manual is to ensure safe and proper use of the equipment. For this reason, do not attempt to remodel, modify or adapt this equipment or to use it for any other purpose than that intended by the manufacturer. After reading, please keep this instruction manual handy for future reference. CONTENTS 1. SAFETY PRECAUTIONS ................................ 2 2. USAGE PRECAUTIONS ................................. 5 3. 2-1. Power Supply .................................................. 5 2-2. Operating Environment ................................... 5 2-3. Storage Conditions ......................................... 5 NAMES AND FUNCTIONS ............................. 6 9. VARIOUS SETTINGS .................................... 56 9-1. Fine Adjustment Menu .................................. 56 9-2. 9-3. Option Menus ................................................ 61 Accessory Menus .......................................... 63 9-4. Adjusting the Press Pressure and Conveyance Pressure ........................................................ 66 9-5. External Parts ................................................. 6 Adjusting the Saddle Stitching Guide/Side Stitching Guide .............................................. 66 3-2. Internal Parts ................................................... 8 10. ERROR MESSAGES ..................................... 67 3-3. Downstream Unit (Optional) .......................... 11 10-1. Emergency Stop ........................................... 67 3-4. Accessories ................................................... 11 10-2. Covers ........................................................... 67 4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU) ................................... 12 10-3. Paper Jam ..................................................... 68 10-4. Wire Feed Detection ..................................... 68 5. PREPARING FOR OPERATION ................... 14 3-1. 6. 7. 8. 5-1. Power ON ..................................................... 14 5-2. Operations .................................................... 15 5-3. Settings ......................................................... 19 SADDLE STITCHING PROCEDURE ............ 27 10-5. Paper Tray Full ............................................. 68 10-6. Motor Error .................................................... 69 10-7. Service Person Error ..................................... 69 10-8. Shutter .......................................................... 69 11. CORRECTING PAPER JAMS ...................... 70 6-1. Settings ......................................................... 27 12. STITCHER HEAD .......................................... 71 6-2. Changing Size ............................................... 30 6-3. Adjustments Using the Step Mode ................ 30 12-1. Names and Functions ................................... 71 12-2. Wire ............................................................... 72 6-4. Checking the Finished Set ............................ 33 12-3. Feeding the Wire ........................................... 73 SIDE STITCHING/CORNER STITCHING PROCEDURE ................................................ 38 12-4. Stitching Tests .............................................. 75 12-5. Removing Wire ............................................. 76 12-6. Adjustments .................................................. 77 7-1. 7-2. Settings ......................................................... 38 Changing Size ............................................... 41 7-3. Adjustments Using the Step Mode ................ 42 13. TROUBLESHOOTING .................................. 79 7-4. Checking the Bound State ............................ 45 14. CLEANING .................................................... 81 NO-STITCHING FOLDING PROCEDURE ... 46 15. SPECIFICATIONS ......................................... 82 8-1. Settings ......................................................... 46 8-2. Changing Size ............................................... 48 8-3. Adjustments Using the Step Mode ................ 49 8-4. Checking the Finished Set ............................ 52 12-7. Maintenance ................................................. 78 1 1. 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. This graphic symbol indicates a forbidden action. means “Do not disassemble.” means “Do not touch.” This graphic symbol indicates actions that must be performed. means “Disconnect the power plug.” WARNING: 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 touch or insert foreign objects into any rotating part during operation. This could result in injury. 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. Use only the power supply voltage specified on the main nameplate. Using other voltages could result in a fire or an electrical shock. 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. 2 1. SAFETY PRECAUTIONS Do not use flammable sprays or solvent inside or near the unit (e.g. when cleaning the unit). Such flammable gas or solvent may ignite and cause a fire or combustion. 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. 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. 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. 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. 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 the power plug or power switch with wet hands. This could result in an electrical shock. 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. 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. 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, fire or electrical shock. Disconnect the power plug from the power outlet before attempting to move this unit. Failure to do so could result in power cord damage, fire or electrical shock. 3 1. SAFETY PRECAUTIONS Safety The following shows the location of the safety devices and warning/Caution label. Top cover (Back) Top cover (Front) Emergency Stop Switch Shutter Labels are pasted to ensure the safety of users. Do not remove nor change them. Note If a label becomes dirty or missing, be sure to contact your dealer for a new one. The actual control panel and emergency stop switch of this machine may be located opposite to the locations shown in the above figure. 4 2. USAGE PRECAUTIONS 2-1. 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. 220-240V AC 50Hz/120V AC 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 : 3.8A/6.5A 2-2. Operating Environment Operate this unit in the following environment: • where the temperature range is between 5 and 35°C/41 and 95°F, • where the humidity range is between 10 and 85%RH (no dew condensation), • which is not subject to direct sunlight, • which is subject to little or no vibration, • where there are no harmful chemicals, • which is reasonably free from dust, • which is free from air-borne salt, and • where the equipment will not be exposed to water. 2-3. Storage Conditions Store this unit in the following environment: • where the temperature range is between –10 and +50°C/14 and 122°F, • where the humidity range is between 10 and 85%RH (no dew condensation), • which is not subject to direct sunlight, • which is subject to little or no vibration, • where there are no harmful chemicals, • which is reasonably free from dust, • which is free from air-borne salt, and • where the equipment will not be exposed to water. 5 3. NAMES AND FUNCTIONS 3-1. External Parts In this manual, the left side of the paper conveyance direction is indicated as L side and the right side as R side. 4 L side Paper direction 3 2 R side bl bm 6 7 8 9 1 bk No. 1 2 Name Function Main power switch Refer to “5-1. Power ON”. ( Emergency stop button Press to stop the machine in emergency. Paper being fed will stop halfway. To resume operations, remove this paper. To stop the machine normally, use the [Stop Key] on the upstream unit or this machine. To release this switch, rotate it to the right. 3 Front top cover Cover for ensuring user safety This machine will not operate if open. 4 Rear top cover Cover for ensuring user safety This machine will not operate if open. Option connector Optional power connector E port connector-1 Connects the E port cable from the upstream unit. E port connector-2 Connects the E port cable to the downstream unit. D port connector-1 Connects the D port cable from the upstream unit. D port connector-2 Connects the D port cable to the downstream unit. Power cord Supplies power to this machine. 5 6 7 8 9 bk bl bm 6 5 Refer to page 14.) Power switch Refer to “5-1. Power ON”. ( Stacker connector Connects the power cord of the belt stacker. Refer to page 14.) 3. NAMES AND FUNCTIONS bn bo ck R side L side bt bp cl cm Paper direction bs br cp cn bq No. bn bo bp bq br bs bt ck cl cm cn co cp Name cp co Function Wire reel Stitches paper Control panel Refer to “Description of Control Panel”. ( Folding stopper adjustment dial Adjusts the angle of the folding stopper to correct folding misalignment. Deflector strip Holds booklets sent to the side stitching stacker. Side stitching stacker Receives booklets which are side stitched (corner stitched). Stacker plate Receives booklets which are saddle stitched, and folded. When stacked poor due to small booklet size, use it at upper position. Belt stacker Sends booklets folded into two to the stacker plate. Connect the power cord plug of the Belt Stacker Unit to the outlet of the DBM-500 Paper guide wheel Holds paper sent to the stacker and feeds to the stacker plate. Shutter Opening for inserting the handle Normally leave closed. This machine will not operate if the shutter is open. ( Refer to pages 70 and 81.) Handle Used to remove jammed paper and clean the folding stopper Side stitching stopper Stops booklets which have been side stitched (corner stitched). Side stitching stopper adjustment knob Adjusts the position of the side stitching stopper. Ejection roller Ejects side stitched (corner stitched) booklets. Refer to page 12.) 7 3. NAMES AND FUNCTIONS 3-2. Internal Parts  Paper direction 3 1 1 3 4 2 5 2 5 6 8 7 When the conveyance roller open No. 1 2 3 4 5 6 7 8 8 Name Function Stitcher head Binds paper with wire. Side jogger Aligns the sides of paper. Side stitching stopper Rises during side stitching (corner stitching) to stop paper. Side stitching guide Prevents paper from curling during side stitching (corner stitching). Back jogger Aligns the leading and trailing edges of paper. Conveyance driven roller Helps to convey paper to the paper alignment section. Conveyance roller lifting handle Lift to remove paper jammed at the paper alignment section. Conveyance roller Conveys paper to the paper alignment section. 3. NAMES AND FUNCTIONS  Paper direction bl bn bo bl bm bk 9 bm No. 9 bk bl bm bn bo Name Function Saddle stitching stopper Rises to stop paper during saddle stitching. Ejection driven roller Helps to deliver stitched booklets to the folder. Saddle stitching guide Prevents paper from curling during saddle stitching. The height can be adjusted. ( Refer to page 66.) Folding side guide Holds both ends of booklets during folding. Ejection roller Ejects stitched booklets to the folder. Ejection roller stopper Solves the poor alignment of insert sheets in insert mode. 9 3. NAMES AND FUNCTIONS  Paper direction bq bp bq bt Roller attaching position bp bs br bs br ck bq cl No. bp bq br bs bt ck cl 10 Name Folding roller Function Roller for folding booklets into two Press roller Presses booklets folded into two. Pressure adjustment hook Adjusts the pressure of the press roller. Conveyance pressure adjustment hook Switches the conveyance pressure of booklets folded into two. Folding stopper Stops booklets during folding. Folding back guide lifting handle Lift to remove booklets when paper jams at the folding unit. Folding back guide Presses the ends of booklets during folding. cl 3. NAMES AND FUNCTIONS 3-3. Downstream Unit (Optional) DBM-500T (Optional) This machine DBM-K (Optional) DBM-LSI (Optional) 3-4. Accessories Paper guide wheel Adjusting handle Corner stitching paper holder 11 4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU) The control panel is composed of the touch panel and numerical pad. The following describes the main menu which is the standard screen displayed normally, and the numerical pad. 1 5 MAINMENU 2 6 ADJUST 3 OPTION 420. 0 x 297 . 0 7 4 bs br ACCESSOR 01 207. 0 x 277 . 0 00000 8 9 bq bn bo bk bm bp bl bt cl [Touch Panel] No. 1 2 3 4 5 cm [Numerical Pad] Name Function Main menu tab Displays the main menu. Fine adjustment menu tab Displays fine adjustment menus. ( Option menu tab Displays option menus. ( Accessory menu tab Displays accessory menus. ( Stitch setting display Displays the stitch setting of the memory number currently selected. Refer to page 56.) Refer to page 61.) Refer to page 63.) Indicates that saddle stitching is selected. Indicates that side stitching (corner stitching) is selected. Indicates that “Stitch Off” is selected. 6 Fold setting display Displays the fold setting of the memory number currently selected. Indicates that “Fold On” is selected. Indicates that “Fold Off” is selected. 12 ck 4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU) No. 7 Name Trim setting display Function Displays the trim setting of the memory number currently selected. Note: This is not displayed when not connected with the DBM-500T, or when “Fold Off” is selected. Indicates that “Head/Foot Trim On” is selected. Indicates that “Fore-edge Trim On” is selected. Indicates that “Trim Off” is selected. 8 Sheet size display Displays the paper size of the memory number currently selected in the following format. length x width 9 bk bl Finished size display Displays the finished size of the booklet processed by this machine. Memory number display Displays the memory number of the binding mode currently selected. Memory number selection key Selects the memory number. The selected memory number is displayed at “ settings are displayed at to . 5 9 bm bn bo bp bq br bs bt ck bk Memory number display”, and the Setting key Displays the setting menu of the memory number of the binding mode currently selected. Processed number display Displays the number of sets processed by this machine. Processed number clear key Clears the “Processed number display” to 0. Press for more than 1 second. Size change key Changes the settings of the memory number currently selected. Press for more than 1 second. Message display Displays messages. Numerical keys Enters values such as paper size, etc. Clear key Return key br Numerical keys” to 0. Confirms values entered using “br Numerical keys” to 0. Clears the value entered using “ Jog key Step-ejects paper forcibly. ( Refer to page 16.) Press for more than 1 second. cl Start key Starts the system. Press for more than 1 second. cm Stop key Stops the system including this machine. 13 5. PREPARING FOR OPERATION 5. PREPARING FOR OPERATION 5-1. Power ON This machine has a main power switch and a power switch. Operate the machine with the main power switch On, and the power switch " " The remote function allows this unit to turn on/off by pressing the power switch for DC-10/60,and the main power switch for DSF-2000. It means there is no need to touch the main power switch or the power switch of this unit. Note Power switch  To turn the power of this machine On/Off by itself, set the power switch to “I” and the main power switch On.  When operating the power switch, do so after turning Off the main power switch.  If an upstream unit is connected, do not turn On/Off the power of this machine by itself. This may cause the machine to operate abnormally. Be sure to turn On/Off the main power switch or the power switch of the upstream unit instead. Main power switch Power switch DBM-LS1 DBM-500T This machine LUL-HM DC-10/60 When DC-10/60 is connected DBM-LS1 DBM-500T This machine When DSF-2000 is connected 14 DSF-2000 Main power switch 5. PREPARING FOR OPERATION 5-2. Operations Memory No. MAINMENU ADJUST OPTION 420. 0 x 297 . 0 Size change key Clear key ACCESSOR 01 207. 0 x 277 . 0 00000 Processed number display Processed number clear key Message Return key Start key Stop key Jog key ❊ Memory No. The memory number consists of 1 to 12 for registering binding setting (binding mode) such as paper size, stitching, and folding to each memory. Default settings at shipment are as follows. Memory No. 1 2 3 4 5 6 7 8 9 10 11 12 Paper size (mm) (inch) 420 x 297 (A3) (17.00 x 11.00 (Double letter)) 297 x 210 (A4) (11.00 x 08.50 (Letter)) 210 x 297 (A4) (08.50 x 11.00 (Letter)) 210 x 148 (A5) (08.50 x 05.83 (Letter)) 364 x 257 (B4) (08.50 x 05.83) 257 x 182 (B5) (10.12 x 07.17) 182 x 257 (B5) (07.17 x 10.12) 431.8 x 279.4 (17.00 x 11.00) 355.6 x 215.9 (14.00 x 08.50) 215.9 x 355.6 (08.50 x 14.00) 279.4 x 215.9 (11.00 x 08.50) 215.9 x 279.4 (08.50 x 11.00) Stitching Saddle stitching Saddle stitching Side stitching Saddle stitching Saddle stitching Saddle stitching Side stitching Saddle stitching Saddle stitching Side stitching Saddle stitching Side stitching Folding Folding Folding No folding Folding Folding Folding No folding Folding Folding No folding Folding No folding Each memory number can be overwritten. Register the 12 settings usually used for convenience. Select the memory number of the binding mode to be used, change the size and begin binding. ( Refer to page 63.) Memory No. 1 to 12 can also be set so that settings are not overwritten. ( Refer to page 16.)  About Memory No. 0 Use Memory No. 0 to set a binding mode that is slightly different from the pre-set settings for the current job only. The settings set at Memory No. 0 cannot be saved. Select a memory number from Memory No. 1 to 12, and change the size. Then select Memory No. 0. The same settings as the memory number for which size was changed will be displayed. Press the [Setting key] on the touch panel, and change the binding mode using Memory No. 0. Press the [Return key] on the touch panel to confirm the settings of Memory No. 0. Change the size again to proceed with the binding work. Settings of the previously selected memory number are not updated so that the original settings can be selected again. 15 5. PREPARING FOR OPERATION ❊ Size change Size change is the process of returning guides to their standard points once, and then moving them to the positions set according to the settings of the memory number selected. Pressing the [Size Change key] changes the size. This process is required after the power is turned on, and after the memory number is changed. When the message display shows “Perform paper size change” and the [Size Change key] blinks, size change is also required. Normally, the stitcher will not return to its standard point. But pressing the [Size Change key] while pressing the [Clear key] returns the stitcher to its standard position and moves it to the set position. Pressing the [Size Change key] while pressing numerical key 0 only returns all guides to their standard positions. Note While “Perform paper size change” is displayed, this machine will not operate. ❊ Processed number display Counts up the number of sets normally processed. The display can be reset to 0 using the [Processed number clear key]. The count is reset to 0 when the power is turned off. ❊ Starting/stopping processing Pressing the [Start key] of this machine or the upstream machine starts processing. Pressing the [Stop key] ejects all paper being processed, after which this machine stops. If an error occurs during processing, this machine will stop according to the situation. If an error of the emergency stop switch, top cover, or shutter occurs during processing, the machine will also stop immediately. ❊ Step-ejection Pressing the [Jog key] binds paper left in the machine and ejects them. Perform the following procedure using the [Jog key]. 1. This machine will keep running while the [Jog key] is held down. 2. When the [Jog key] is released, paper inside the machine will to be stitched or folded, and move to next step. The machine will then wait for the next jog key operation. When paper jams inside the machine, a paper jam message appears and the machine stops. However, visually check the machine because the machine will stop due to paper jam without displaying the paper jam message in some cases. In such cases, open the top cover and remove the paper. 3. When conveyance is being carried out continuously, press the [Jog key] several time to execute stitching or folding, and eject the processed sets. If paper is forcibly ejected by the upstream unit, this machine will also perform conveyance motion. Note The paper will stop at the stitching area but this machine will not advance the paper fed. Open the top cover and remove the paper conveyed to this machine. 16 5. PREPARING FOR OPERATION ❊ Aligning the paper passage lines After preparing this machine for binding operations, check that the paper passage line is aligned to that of the upstream unit. When paper conveyed from the upstream unit is conveyed to this machine, check that there is even space between the left and right side joggers and paper. If not even, adjust the position of this machine to avoid paper jams. Move this machine at other fine adjustment screens of the fine adjustment menu, until the space becomes even. ( Refer to page 60.) Side jogger Side jogger Paper Space Space ❊ Stitching range Saddle stitching When less than 140 mm/5.51 inch, the stitching width is 70 mm/2.76 inch (minimum stitching width). The stitching width (the ratio) can be changed. ( to page 58.) Stitching position 240 (9.45) 60 60 (2.36) (2.36) 180 (7.09) Paper conveyance direction 1 Stitching position 60 60 (2.36) (2.36) For example, if the paper width is 240 mm/9.45 inch, stitching is carried out at the 60 mm/2.36 inch and 180 mm /7.09 inch positions from the paper edge. Stitching position label : 2 : When paper is more than 140 mm/5.51 inch wide, the standard stitching width is determined by the ratio of 1:2:1. Stitching width is the center to center distance between the two stitches. However, if the stitching position lies inside the stitch prohibited area, it will be set at a position avoiding this area. Pointer 1 Stitching is carried out at the positions indicated by the pointer. Normally, stitching is done at two positions. * This can be increased to four positions by factory options. Unit: mm (inch) Refer 17 14  The stitching position cannot be within 14 mm/0.55 inch from both edges of the paper.  The stitching width cannot be within 70 mm/2.76 inch. (0.55) 5. PREPARING FOR OPERATION 35 35 (2.76) (2.76) 14 Paper conveyance direction (0.55) 120 to 356 Stitching position Stitching position Center line of paper width Unstitchable area Unit: mm (inch) The stitching position is about 6 mm/0.24 inch from the leading edge of the paper, and cannot be changed vertically. The stitching position along the width of the paper is the same as saddle stitching. Paper width Side stitching (corner stitching) Paper conveyance direction Unit: mm (inch) 6 (0.24) ❊ Stitch prohibited area The position at which the folding knife and a stitch coincide is called the stitch prohibited area. During folding operations, the folding knife may bend the stitch if they touch. When a standard stitching position determined by the paper width entered is inside the stitch prohibited area, the position avoids this area automatically. Stitching position label Mark (Stitch prohibited area) A Pointer A Note When adjusting the stitching width, avoid the stitching prohibited area. Make sure the mark does not enter area A 18 5. PREPARING FOR OPERATION ❊ When paper is fed at an upstream unit (Refer to the instruction manual on upstream unit for details of manual feed) There is a need to enter values for “processed sheets” and “number of jogs” on the control panel. Refer to “Option Menu 2” on page 60 for “number of jogs” and “Option Menu 3” on page 61 for “processed sheets”.) (  Set the number of jogs to two or three times, and increase this number if paper alignment is poor.  Manual feeding from DC-10/60, DC-8/32 Set only the number of sheets to be inserted at LUL-HM at " processed sheets". When the sets with many number of sheets frequently ride over the saddle stitching stopper, press the Hand Marry key 2 on the DC-10/60 or DC-8/32 collator control panel. Normally press the key 1. It runs fast to achieve higher productivity.  Merging-collation mode with DC-10/60 or DC-8/32 Set the total number of sheets fed from the LUL-HM and the collator at “processed sheets”.  Manual feeding from DSF-2000 Insert one set of paper into the machine, and press the [Jog key] of this machine. Binding operation starts. Automatic operations can also be performed. For details, refer to "Option Menu 4" on page 61. ❊ Precautions on connecting and using DSF-2000 When using DSF-2000 in the random mode or as a barcode kit or intelligent kit, there is a need to enter the “processed sheets” on the control panel of this machine beforehand. At this time, the processed sheets differ according to the set. Enter the minimum number of sheets of each set at “processed sheets”. 5-3. Settings Perform binding settings. Select the memory number whose setting is to be changed, and press the [Setting key]. The memory number to be used can be saved at the last. If not saving, use Memory No. 0. ( Refer to page 15.) Memory No. MAINMENU ADJUST Memory number selection key OPTION 420. 0 x 297 . 0 ACCESSOR 01 207. 0 x 277 . 0 00250 Setting key
Screen 19 5. PREPARING FOR OPERATION ❊ Selecting the binding mode Select the stitchng and folding mode. 4 1 2 5 3 Set the stitching mode. To perform saddle stitching, select “1 Saddle stitching”, to perform side stitching, select “2 Side stitching”, and if not performing stitching, select “3 Stitch Off”. Select “2 Side stitching” also for corner stitching. Selecting “Saddle stitching” automatically sets the folding mode to “Fold On”. (Can be changed) Selecting “Side stitching” automatically sets the folding mode to “Fold Off” and the trimming mode to “Trim Off”. (Can be changed) Set the folding mode. To perform folding, select “4 Fold On”. If not performing folding, select “5 Fold Off”. Cancel key Next key Screen 20 Next key 5. PREPARING FOR OPERATION ❊ Entering paper size Enter the paper length and width. Standard values for the stitching/folding positions and stitching width are displayed according to the paper size entered. Pressing inside the box showing a value resets the value to 0. Enter the desired values using the [Numerical keys], and press the [Return key] on the numerical pad to confirm. Pressing the box again before pressing the [Return key] returns the original value. Note The values in this screen are original figures you entered. They remain the same no matter how finely adjusted later according to binding conditions. Paper conveyance direction 420. 0 Paper width 297. 0 Stitching position Folding position 148. 5 210. 0 210. 0 Paper length Stitching width Back key Next key Screen Entering the paper length Enter the paper length. Range of input Saddle stitching: 178.0 to 508.0 mm/7.01 to 20.00 inch (When connect with DBM-2KT: 178.0 to 500.0 mm/7.01 to 19.69 inch) Stitch Off: 178.0 to 508.0 mm/7.01 to 20.00 inch Side stitching (Corner stitching): 140.0 to 364.0 mm/5.51 to 14.33 inch (Side stitchable length: Above 182.0 mm/7.17 inch) * When set to “Fold On”: 178.0 to 364.0 mm/7.01 to 14.33 inch Entering the paper width Enter the paper width. Range of input Saddle stitching and Stitch Off: 120.0 to 356.0 mm/4.72 to 14.02 inch Side stitching (Corner stitching): 210.0 to 356.0 mm/8.27 to 14.02 inch Stitching position display Length from the paper leading edge to stitching position. When the paper length is entered, the standard stitching position will automatically be set. (Can be changed) * Standard stitching position: (Paper length ÷ 2) mm/inch Range of input Saddle stitching: 89.0 to 254.0 mm/3.50 to 10.00 inch (However, the difference with the paper length is in the range of 89 to 359 mm/3.50 to 14.24 inch) Folding position display Length from the paper leading edge to stitching position. When the paper length is entered, the standard folding position will automatically be set. (Can be changed) * Standard folding position: (Paper length ÷ 2) mm/inch Range of input 89.0 to 254.0 mm/3.50 to 10.00 inch (However, the difference with the paper length is in the range of 89 to 254 mm/3.50 to 10.00 inch) Stitching width display The width between both stitches. When the paper width is entered, the standard width will automatically be set. (Can be changed) * Standard stitching position: (Paper length ÷ 2) mm/inch However, if the paper width is less than 140 mm/5.51 inch, the stitching width will be set to 70.0 mm/2.76 inch (minimum stitching interval). The stitching position will also avoid the stitch prohibited area. Range of input From 70.0 mm/2.76 inch to (Paper width –28.0 mm/1.10 inch) Stitching cannot be carried out within 14 mm/0.55 inch from the side edges. After entering the paper size, press the [Next key] to proceed to the next step. When the binding mode is set to “Trim On”, the “Set Trimming Position” screen will appear. If set to “Trim Off”, the [Confirm Settings] screen will appear. As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper size entered is not appropriate. Pressing the [Back key] returns to the Screen Fore-edge Trim On key Trim Off key After setting the trimming mode, press the [Next key] to proceed to the [Enter Paper size] screen. Head/Foot Trim On key Trim Off key Back key Next key screen. Step 3 Setting the trimming position The finished length after Fore-edge Trimming is displayed. When the paper length is entered, the standard trimming position will automatically be displayed. The standard trimming width is 3 mm/0.12 inch. * Standard trimming position: (Paper length ÷ 2) – 3 mm/ 0.12 inch (MAX: 253 mm/9.96 inch) Here, it is displayed as “207.0/8.15” (420 ÷ 2) – 3 = 207/ (16.54 ÷ 2) – 0.12 = 8.15. If not changing this value, proceed onto the next step. To change the finished length, press the box 1 to reset the value displayed to 0, and enter the desired value. Range of input: 75.0 to 253.0 mm/2.95 to 9.96 inch (Trimming width within 75 mm/2.95 inch) Press the [Return key] to confirm the value. Pressing the box again while entering the value returns the original value. 1 Trimming width 207. 0 Back key Next key Screen After entering the trimming position, press the [Next key] to proceed to the “Confirm Settings” screen. Pressing the [Back key] returns to the screen. 29 6. SADDLE STITCHING PROCEDURE Step 4 Confirming settings Make sure that the values entered are all correct, and then press the [Return key] on the touch panel. Pressing the [Return key] saves the settings of the memory number and returns to the
screen. Pressing the [Back key] returns to the screen. 420. 0 x 297 . 0 207. 0 x 297 . 0 Back key Return key Screen 6-2. Changing Size Press the [Size Change key] for more than one second to change the size. When size change completes, a beep sounds. Note MAINMENU ADJUST OPTION ACCESSOR This machine moves left and right. 420. 0 x 297 . 0 01 207. 0 x 297 . 0 00000 Perform paper size change Size change key
Screen 6-3. Adjustments Using the Step Mode After changing the size, perform fine adjustments of each function in the step mode. When the step mode completes, the newly adjusted value is saved as the new setting of the memory number. Note 30 Values shown in the Main Menu screen are replaced by values adjusted not only in the fine adjustment screen but also in the step mode. However, the values shown in the setting screens of each Memory Number will remain the same. They show values originally entered. 6. SADDLE STITCHING PROCEDURE ❊ Starting the step mode If the DBM-500T is connected, select whether to trim sets bound in the step mode using the [Trim On/Off key]. Step mode key MAINMENU Trim On/Off key ADJUST OPTION ACCESSOR ON: Trims. Set to trim booklets. OFF: No trimming. Set to check stitching and folding positions. The setting of the [Trim On/Off key] has priority during the step mode, regardless of whether trimming has been set or not at the memory number. Pressing the [Step Mode key] in the fine adjustment menu proceeds to the screen. Pressing the [Start key] of the upstream unit or this machine conveys one set of paper from the upstream unit to the saddle stitching stopper. Screen To terminate the step mode halfway through, press the [Stop key] of this machine. Open the top cover and remove the paper remaining inside the machine. Screen ❊ Adjustments at the stitching section Adjust the positions of the side jogger and back jogger for aligning paper using the [Fine adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the joggers touch the paper edges lightly. After adjusting, press the bl [Stitch key]. Stitching is perfomed, and the booklet advances to the folding stopper. 1 2 3 4 5 bk bl Stitch key 6 8 7 9 Screen 31 6. SADDLE STITCHING PROCEDURE 1 2 3 4 5 6 7 8 9 bk bl Note Fine adjustment of side jogger The side jogger moves inward by about 1 mm/0.04 inch. Fine adjustment of side jogger The side jogger moves inward by about 0.2 mm/0.008 inch. Fine adjustment of side jogger The side jogger moves outward by about 1 mm/0.04 inch. Fine adjustment of side jogger The side jogger moves outward by about 0.2 mm/0.008 inch. Side jogger operations Activates the side jogger once. Fine adjustment of back jogger The back jogger moves backward by about 0.1 mm/0.004 inch. Fine adjustment of back jogger The back jogger moves backward by about 1 mm/0.04 inch. Fine adjustment of back jogger The back jogger moves forward by about 0.1 mm/0.004 inch. Fine adjustment of back jogger The back jogger moves forward by about 1 mm/0.04 inch. Back jogger operations Activates the back jogger once. Stitch key Stitches the set. The booklet is conveyed to the folding stopper and stops. Fine adjustments can be performed only within the range of ±5 mm/±0.20 inch after size change. If the paper size entered and that actually used differ by more than 5 mm/0.20 inch, the difference is beyond adjustment. In this case, enter the correct paper size again, and perform the size change. ❊ Adjustments at the folding section (When [Fold On] is selected) Adjust the positions of the folding side guides and folding back guides using the [Fine Adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the guides touch the booklet edges lightly. After adjusting, press the bl [Fold key]. The booklets are folded and ejected, and the step mode ends.  If ON is selected using the [Trim On/Off key] at the start of the step mode, booklets are trimmed and ejected. 1 2 3 4 5 bk Folding back guide Folding back guide Folding side guide Folding side guide blFold key 68 79 Screen “Opened state of folding back guide” 32 6. SADDLE STITCHING PROCEDURE 1 2 3 4 5 6 7 8 9 bk bl Fine adjustment of folding side guide The folding side guide moves inward by about 1 mm/0.04 inch. Fine adjustment of folding side guide The folding side guide moves inward by about 0.2 mm/0.008 inch. Fine adjustment of folding side guide The folding side guide moves outward by about 1 mm/0.04 inch. Fine adjustment of folding side guide The folding side guide moves outward by about 0.2 mm/0.008 inch. Folding side guide operations Activates the folding side guide once. Fine adjustment of folding back guide The folding back guide moves backward by about 0.1 mm/0.004 inch. Fine adjustment of folding back guide The folding back guide moves backward by about 1 mm/0.04 inch. Fine adjustment of folding back guide The folding back guide moves forward by about 0.1 mm/0.004 inch. Fine adjustment of folding back guide The folding back guide moves forward by about 1 mm/0.04 inch. Folding back guide operations Activates the folding back guide once. Fold key Booklets are ejected after folding, and the step mode ends. 6-4. Checking the Finished Set Check the sample booklets after adjustment.  When paper alignment is poor  Adjust the side jogger and back jogger again. ( Refer to page 31.)  When the stitching position and folding position do not match  Move the stitching position to the folding position Adjust the position using the [Stitch Position Fine Adjustment key]. (  Move the folding position to the stitching position Adjust the position using the [Fold Position Fine Adjustment key]. ( Refer to page 57.) Refer to page 57.)  When the stitching position and folding position match, and both are to be moved  Adjust the position using the [Stitch Position Fine Adjustment key] and [Fold Position Fine Adjustment key]. ( Refer to page 58.)  To adjust the stitching width  Adjust the position using the [Stitching Width Fine Adjustment key]. ( Refer to page 58.) 33 6. SADDLE STITCHING PROCEDURE  When folded skewed  During use, rotate the lock dial in the counterclockwise direction while holding the folding stopper adjustment dial to release the lock. Next, adjust the angle of the folding stopper using the folding stopper adjustment dial. After adjustment, rotate the lock dial in the clockwise direction while holding the folding stopper adjustment dial to lock it. Lock dial Folding stopper adjustment dial Rotate clockwise Rotate counterclockwise  If the stitching position is inside the stitching prohibited area shown on the stitching position label ( refer to page 18), folding misalignment may occur. Change the stitching width using the [Stitching Width Fine Adjustment key] and adjust so that it is outside this area. ( Refer to page 58.)  Folding misalignment may also occur if the folding side guides are set too narrow or wide. Perform adjustments in the step mode again, and check the position of the folding side guides. ( Refer to page 32.)  If the booklet rides onto the folding side guide or jams, gradually increase the value of “stitching side jogger open timing” on the option menu. The standard value is 0. ( Refer to page 61.) However, paper may jam at the stitching section if too many sheets of paper are fed. Pointer Stitching position label Stitching position label Mark (Stitch prohibited area) Pointer 34 6. SADDLE STITCHING PROCEDURE  Adjust the position of the folding back guide roller. Loosen the locknut, and move the folding back guide roller to the trail edge using the knobscrew. This holds down the booklet and prevents folding misalignment.  If folding only a few sheets which are soft, decrease the gap between the folding stoppers. Loosen the four knob screws, and lower the top folding plate. Normally use this folding plate in the raised position. When processing many sheets of paper, using with this folding plate lowered will cause paper jams. Knobscrew Lock nut Folding back guide roller Booklet Trail edge Knobscrew Folding back guide roller Locknut Adjustment dial Folding back guide roller Top folding plate Knobscrew Lock plate Knobscrew  When stitching position is not perpendicular to paper  Adjust the angle of the saddle stitching stopper.  Release the lock plate with the finger, and turn the adjustment dial. For the condition shown in the left figure A, rotate the adjustment dial in the counterclockwise direction. For the condition shown in the right figure B, rotate the adjustment dial in the clockwise direction. After adjusting, fit the lock plate into the groove on the lock dial. Figure A Figure B  When booklet alignment is poor at the belt stacker  Change the conveyance time of the belt stacker at accessory menu. ( Refer to page 65.) If there are too many sheets, or when paper is thick, set a long conveyance time.  If booklet alignment is still poor after adjusting the conveyance time, replace the paper guide wheel with one for large size paper. (Not available for paper less than 121 mm/4.76 inch)  If booklet alignment is still poor, loosen the knob screw and move the paper guide wheel to the main body. 35 6. SADDLE STITCHING PROCEDURE  When there are conveyance belt marks on the booklet  Use the belt guide kit for saddle-stitching binding.  Replace the ejection roller unit.  Release the knobscrew A so that the ejection roller unit stregth can be sdjusted using the knob. Knob screw A Strong Weak Ejection roller unit  Tighten the knobscrew B. Normally, leave it loose. Knob screw B  Attach the belt guide L or S. If the paper length is more than 170 mm and less than 297 mm, use belt guide S. If more than 297 mm to 500 mm, use belt guide L. Paper direction Belt guide L Belt guide L Paper direction Belt guide L Belt guide S 36 6. SADDLE STITCHING PROCEDURE  Attach belt guide M. Belt guide M Belt guide M  Attach filmed guides R and L. Filmed guide R Note  Belt guides L, S, and M can be used for paper width above 190 mm. They cannot be used for paper less than 190 mm. Filmed guide L  After use, remove the belt guide kit and return it to its original state.  Do not use it for side-stitching and cornerstitching. 37 7. SIDE STITCHING/CORNER STITCHING PROCEDURE 7-1. Settings Select the memory number whose settings are to be changed using the [Memory number selection key] and press the [Setting key]. The Screen 38 7. SIDE STITCHING/CORNER STITCHING PROCEDURE Step 2 Entering the paper size Enter the paper length and width. Standard values for stitching width are displayed according to the paper size entered. Pressing inside the box showing a value resets the value to 0. Enter the desired values using the [Numerical keys], and press the [Return key] on the numerical pad to confirm. Pressing the box again before pressing the [Return key] returns the original value. 2 1 3 210. 0 297. 0 148. 5 Return key Numerical keys Screen 1 Enter the length of the paper. Press the box 1, and enter “2100/08.50”. Press the [Return key] to confirm the value. Range of input: Fold Off : 140.0 to 364.0 mm/0.59 to 14.33 inch Fold On : 178.0 to 364.0 mm/7.01 to 14.33 inch (The foldable length is above 182.0 mm/7.16 inch.)  The folding position is displayed when set to [Fold On]. The value from the leading edge of the paper to the folding position is displayed. When the paper length is entered, the standard folding position will automatically be displayed. ∗ Standard folding position: (Paper length ÷ 2) mm/ inch Here, it is displayed as “105.0/4.13” (210 ÷ 2 = 105.0/ 8.27 ÷ 2 = 4.13). To change the value, press the box 4, and enter the desired value. Press the [Return key] to confirm the value. Note 2 2 3 1 210. 0 297. 0 148. 5 105. 0 4 Back key Next key Screen The box 4 is not displayed when set to “Fold Off”. Enter the width of the paper. Press the box 2, and enter “2970/11.00”. Press the [Return key] to confirm the value. Range of input: 120.0 to 356.0 mm/4.72 to 14.02 inch (The foldable width is above 210.0 mm/8.50 inch.) 39 7. SIDE STITCHING/CORNER STITCHING PROCEDURES  The stitching width is displayed. The stitching position interval is displayed. When the paper width is entered, the standard stitching width will automatically be displayed. ∗ Standard stitching width: (Paper width ÷ 2) mm/inch Here, it is displayed as “148.5/5.85” (297 ÷ 2 = 148.5/11.69 ÷ 2 = 5.85). When paper width is below 140 mm/5.51 inch, stitching width will always be 70 mm/2.76 inch. To change the value, press the box 3, and enter the desired value. For corner stitching, enter the value “Paper width –30.0 mm/1.18 inch” (stitches at the 15.0 mm/0.59 inch position from the side edge of the paper). Range of input: From 70.0/2.76 (Paper width –28.0 mm/1.10 inch) Press the [Return key] to confirm the value. After entering the paper size, press the [Next key] and proceed to the screen. If set to “Trim On”, proceed to the “Set Trimming Position” screen. As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper size entered is not appropriate. Pressing the [Back key] returns to the screen appears. The settings of the memory number selected are saved. If there is no need to save, use memory No. 0. ( Refer to page 15.) Memory No. MAINMENU ADJUST Memory number selection key OPTION 420. 0 x 297 . 0 ACCESSOR 01 210. 0 x 297 . 0 00000 Setting key
Screen The following describes the procedure for the conditions: A3 vertical (length 420 mm/17.00 inch x width 297 mm/11.00 inch), stitching Off, folding On, trimming Off. Step 1 Selecting the finishing mode Stitch Off key Select the stitching and folding mode. 1 Setting the stitching mode. Press the [Saddle Off key] to set “Stitching Off”. 2 Set the folding mode. Press the [Fold On key] and set “Fold On”. After setting the stitching/Folding mode, press the [Next key] to proceed to the [Select trimming mode] screen. Pressing the [Cancel key] cancels the values entered, and then returns to the main menu. Select the trimming mode. 3 Fold On key Set the Fore-edge Trimming mode. Press the [Trim Off key] to set “Trim Off”. To perform Fore-edge trimming, press the [Trim On key] to set “Trim On”. At this time, as the paper is not stitched, paper may deviate while trimming. Cancel key Next key Screen Next key 8. NO-STITCHING FOLDING PROCEDURE Step 2 Entering the paper size Enter the paper length and width. Standard values for the folding position are displayed according to the paper size entered. Pressing inside the box showing a value resets the value to 0. Enter the desired value using the [Numerical keys], and press the [Return key] on the numerical pad to confirm the value. Pressing the box again while entering the value returns to the original value. 1 2 420. 0 297. 0 210. 0 3 Back key Next key Return key Numerical keys Screen 1 Enter the length of the paper. Press the box 1, and enter “4200/17.00”. Press the [Return key] to confirm the value. Range of input: 178.0 to 508.0 mm/7.01 to 20.00 inch (When connect with DBM-2KT: 178.0 to 500.0 mm/7.01 to 19.69 inch)  The folding position is displayed. The value from the leading edge of the paper to the folding position is displayed. When the paper length is entered, the standard folding position will automatically be displayed. * Standard folding position: (Paper length ÷ 2) mm /inch Here, it is displayed as “210.0/08.27” (420 ÷ 2 = 210/16.54 ÷ 2 = 8.27). To change the value, press the box 3, and enter the desired value. Range of input: 89.0 to 254.0/3.50 to 10.00) (Difference with the paper length should be within 89 to 254 mm/3.50 to 10.00 inch) Press the [Return key] to confirm the value. 2 Enter the width of the paper. Press the box 2, and enter “2970/11.00”. Range of input: 120.0 to 356.0 mm/4.72 to 14.02 inch Press the [Return key] to confirm the value. After entering the paper size, press the [Next key] and proceed to the screen. As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper size entered is not appropriate. Pressing the [Back key] returns to the Screen 3 4 5 Load the same size paper as the paper of the selected memory number on the upstream unit. MAINMENU ADJUST OPTION ACCESSOR Display the