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Duplo Docu Cutter DC-545

Instruction Manual

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Instruction Manual

Docu Cutter DC-545Version. 5.0 / October 2002

Correct operation and periodic maintenance are essential for ensuring safe use of this machine.Thoroughly read this manual before using this machine.

DUPLO SEIKO CORPORATION

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Thank you for your purchase of the Docu Cutter DC-545.To ensure safe and efficient prolonged use of this machine, read and thoroughly understand this manual beforeusing this machine. After using this manual, be sure to keep it in a handy place to Reference.

Introduction

PLEASE NOTEIn the interest of upgrading our products, specifications and other data given in this manual are subject tochange without notice. If the manual contains anything that you do not understand, contact the dealer forclarification.

OVERVIEW

The DC-545 was created to produce high-quality, customized products; greeting cards, postcards, brochures,business cards, and resized photographs. It does this by combining a number of devices that set up automati-cally to slit, cut, and crease a sheet of paper into the desired format with no operator intervention.

Initially, the DC-545 is manually programmed with the required positions of the slits, cuts and creases and thevalues are stored in a memory for future recall. A CCD sensor reads the job number encoded in a barcode onthe unfinished sheet. Then, the DC-545 recalls the values from memory, sets up the slitter positions, activatesthe cutter for lead, trail, and any intermediate cuts and any required creases.

In addition, when a small 90-degree angle register mark has been printed adjacent to the barcode, the positionis measured against the intended position stored in the job memory. As this mark is part of the original image,any error in its location can be compared with the stored value and used to correct the setup positions of thedevices by applying a horizontal offset to the cut and crease positions, and a vertical offset to the slit positionsto maintain precise finishing every time.

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ContentsIntroduction ......................................................................................................................... 1

Notes on Safety (Please Read and Observe) ................................................................... 3

Safety Precautions ............................................................................................... 3

Warning Sticker .......................................................................................................... 6

Positioning the Machine ............................................................................................. 7

Maintenance ............................................................................................................... 8

Conventions Used in This Manual .............................................................................. 9

Chapter 1 Before Using This MachineConfirming the Packaged Materials ................................................................................ 10

How to Set up the System ............................................................................................... 11

Part Names and Their Functions .................................................................................... 13

Appearance .............................................................................................................. 13

Control Panel ............................................................................................................ 15

LCD Panel ................................................................................................................ 16

Turning Power ON/OFF .................................................................................................... 17

Turning ON the Power .............................................................................................. 17

Turning OFF the Power ............................................................................................ 17

Chapter 2 Operating InstructionsAutomatic Cutting Using Bar Codes and Register Marks ............................................ 18

About the Waste Tray ....................................................................................................... 20

Chapter 3 TroubleshootingTroubleshooting Flow Chart ............................................................................................ 21

Power Does Not Turn ON......................................................................................... 21

Cutting is Not Possible ............................................................................................. 22

Error Messages ................................................................................................................. 23

When a Paper Jam Has Occurred ................................................................................... 25

When “REJECT PAPER” is Displayed ..................................................................... 25

When “FEED JAM” is Displayed .............................................................................. 27

When “CENTER JAM” is Displayed ......................................................................... 29

When “SLITTER JAM” is Displayed ......................................................................... 31

When “CUTTER LOCK” is Displayed ....................................................................... 33

When “CREASE LOCK” is Displayed....................................................................... 35

Chapter 4 Manual ProgrammingPrior to Programming a Job ............................................................................................ 37

Definition of Programming Terms ................................................................................... 38

Customer Programmed Jobs .......................................................................................... 44

Factory Preset Jobs ......................................................................................................... 45

How to Manually Program a Job ..................................................................................... 48

AppendixSpecifications ................................................................................................................... 54

Specifications of the Machine ................................................................................... 54

Specifications of Reg. Mark and Bar Code .............................................................. 56

How to do AUTO CUT .............................................................................................. 66

Index .................................................................................................................................. 67

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Notes on Safety (Please Read and Observe)

Safety PrecautionsVarious symbols and pictures are used in this manual and on the stickers affixed to the machine. These symbols andpictures provide warnings and instructions to prevent danger to you or other personnel, and to prevent damage to officeproperty. The meanings of these symbols and pictures are explained below.

WARNINGIndicates a high degree of potential danger. If the warning is ignored, death or seriousinjury may result.

CAUTION Indicates a medium degree of potential danger. If the caution is ignored, medium injury ordamage to property may result.

[Examples of Pictorial Symbols]

A circle with a line through it indicates a prohibited action. The particular act prohib-ited is indicated by a picture inside the circle. (In the example shown here, the prohibitedact is disassembly.)

A black disc indicates an instruction, or sometimes a prohibited action. The instructionitself is indicated by pictorial symbols drawn in white on the disc. (In the example shownhere, the instruction is “Remove the plug from the outlet.”)

• These are particularly important safety points and should always be observed.

WARNING

If the machine is used after foreign matter (metal fragments, water, or liquid) has entered themachine, this may result in fire or electric shock.• Turn the main unit’s power switch OFF, and then remove the power plug from the outlet. Contact

the sales distributor.

If the machine is used after heat, smoke, strange smell, or other abnormality is detected, this mayresult in fire or electric shock.• Turn the main unit’s power switch OFF, and then remove the power plug from the outlet. Contact

the sales distributor.

Use only the power cord that is provided among the accessories.

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WARNING

Do not modify the machine.• Doing so may result in fire or electric shock.

Do not remove the rear lid, cabinet, or covers from the machine.• The inside of the machine contains high-voltage parts, which may cause electric shock.

Do not remove or insert the power plug with wet hands.• Doing so may result in electric shock.

Do not damage, break, or modify the power cord.• Do not place heavy objects on, tug, or unnecessarily bend the power cord. Doing so may result in

fire or electric shock.

Do not insert or drop metal, flammable material, or other matter through the ventilation holes intothe machine interior.• Doing so may result in fire or electric shock.

Do not place flower vases, flowerpots, cups, or water containers (including metal containers) on topof the machine.• Fire or electric shock may result if liquid spills inside the machine.

Do not use a source voltage other than that specified. Do not connect two or more loads to a singleoutlet.• Doing so may result in fire or electric shock.

Do not place the machine in a humid or dusty area.• Doing so may result in fire or electric shock.

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CAUTION

Before moving the machine, remove the power plug from the outlet.• If the cord is damaged, this may result in fire or electric shock.

Remove the power plug itself, not the cord.• Tugging the cord may damage it (expose conductors, or cause disconnections, etc.), resulting in

fire or electric shock.

Do not place the machine in an unstable position, such as on an unsteady support or sloping area.• If the machine is dropped or falls over, this could result in personal injury.

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Warning StickerKeep the WARNING stickers clean at all times. If labels become damaged or come off, have your service representativereplace them.

No. Parts No. Name Q’tyq L8-T1100 Warning Sticker 1 1

w L8-T1080 Warning Sticker 2 3

WARNING Cutters and movable parts are inside this cover.Before opening the cover to work,unplug the power cord.Use caution when working near cuttersand movable parts.

L8-T1080

WARNING Do not touch blade!To remove jammed paper,use the tweezers. L8-T1100

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Positioning the MachineInstalling the machine on a flat, stable surface.

Avoid installing the machine in a dusty area.

Avoid installing the machine in the direct sunlight or heat,such as near a stove. The machine may indicate errors dueto overheating caused by sunlight. Also avoid hot, cold, orhumid areas since paper may absorb moisture, causingpaper jams or wrinkles.


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MaintenanceClean the exterior of the machine as described below.Tightly wring a soft cloth that has been moistened withwater or neutral detergent, and wipe dirt from the ma-chine’s surface.Never use alcohol or organic solvents. Doing so maydiscolor or damage the machine exterior.

Dust and clean the machine at least once a week to avoidbreakdowns.Before cleaning, turn the power switch OFF, and thenremove the power plug from the outlet.

WARNING• Before cleaning, remove the power plug from the outlet.

Failure to do so may result in an electrical shock or a fire hazard.• Prevent water and neutral cleansers from getting inside the machine. If liquids spill inside the machine,

contact your agent immediately. Using the machine with water spilled inside may result in an electricalshock or a fire hazard.


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Automatic Cutting Using Bar Codes and Register MarksThis machine can read bar codes and reg. marks enabling automatic cutting and creasing.The procedure is described below.

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Turn ON the power. (aaaaa P.17, “Turning ON the Power”)

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Set the feed tray.

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Slide the feed guides to match the documentsize.

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Set the document in the feed tray with thesurface where bar codes and reg. marks areprinted facing upwards.The feed lamp turns off and a beep sounds.In a few seconds, the document is fed into the machine.

Tip

• Set the document in the direction shown in theillustration.

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Operating InstructionsThis chapter describes the operating sequence from turning ON the power switch until completing

cutting.

Chapter 2


Conventions Used in This ManualEach page of descriptions in this manual of how to operate the DC-545 is set up as follows.

� Pictorial Symbols and Other Notations Used in This Manual

IMPORTANT : Introduces instructions for correct operation of the machine. If these instructions are ignored,the machine may not be able to operate at optimum performance or may break down.

Tip : Introduces information that is useful for operation and maintenance of the machine, orinformation about the machine’s performance, etc.

Continue Page ••• : Indicates that the description of the operating sequence is continued on the next page.

(a P.00 “xxxx”) : Indicates the page number and item containing related information.

Chapter

Description of operational stepsEach step is described in detail.

IllustrationsThe illustrations provide a visualreference to which keys to operateand other related conditions.

Title

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No. Name Q’ty No. Name Q’ty

q Power cord 1 r Screw Driver 1

w Instruction Manual 1 t Paper Tray 1

e Tweezers 1 y Feed tray 1

Before Using This MachineThis chapter contains essential information you should understand such as the materials packaged with

this machine, how to set up the system, the names of the machine parts, etc.

Chapter 1

This product contains the following materials packaged together. If any material is missing, please contact your dealer.

Confirming the Packaged Materials

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Before U

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achine

1

How to Set up the System

This section describes the cautions and the procedure when you set up this machine.

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Take out the machine from the package and place the machine on a flat and stabletable.

WARNING• Do not try to lift the machine by yourself. Two or more people are required to prevent

injury and/or damage to the machine.• When you open the box, be sure not to injure yourself or others with a cutter or the like.

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Detach the shipping bracket.

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Attach the feed tray to the main body.

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Attach the paper tray to the main body.

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Continue Page •••

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Connect the power cord to the Docu Cutter anda wall outlet.

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How to set up the System

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Before U

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achine

1

Part Names and Their Functions

Appearance

No. Name Function

q Control panel Displays operations and statuses.

w Waste tray cover Open to remove pieces of paper left in the machine.

e Waste tray Receives pieces of waste paper.

r Feed tray The original document is placed here.

t Feed guides Slide to match the width of the document.

y Feed lamp Indicates ready condition. Turns off during cutting or when the front cover orthe rear cover is opened.

u Front cover Open to remove jammed paper.

Referencepage

qwer

uyt

15

20

19, 20

10, 11, 1818

18

23, 25

14

ReferencepageNo. Name Function

i Rear cover Open to remove jammed paper.

o Paper tray Receives the finished document.

!0 Power switch Press to switch the power on and off.


23, 25

10,11

17

o!0

i

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Before U

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1

No. Name Function

q LCD panel Displays the status of the machine.Displays messages when an error or paper jam occurs.

w <+> key Press to eject the document from the machine at the time of paper jam.<-> key Press to eject the document from the machine at the time of paper jam.

During programming mode enables backward movement through the pro-gram steps.

e POWER lamp Lights up when the power is switched on.

r <START> key Not used when the DC-545 is operated without the autofeeder - AF-100. Alsomake this the last sentence. Press to start processing when the AF-100 isattached.

START lamp Normally lights up in green. Lights up in red when the front cover or the rearcover is open.

t <STOP> key Press to stop automatic feeding after the current sheet is processed.Press to clear jam indication after the paper is cleared.

y Key pad Press to enter print numbers and enter values during manual programming.

u <CLEAR> key Press to clear the count. Press to cancel manual programming.

i <SET> key Press to confirm selection/entry. Used to test process a single sheet. (forsystems with the AF-100 only)

o <MODE> key Press to change the mode.!0 <F> key Not used.!1 COVER lamp Blinks when the front cover or the rear cover is open.

JAM lamp Blinks when a paper jam has occurred.PAPER lamp Blinks when paper runs out. (systems with the AF-100 only)


Referencepage

16, 23,2525

25

23, 27

25

Control Panel

COVER

JAMF

PAPER

MODE SET

+

–

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

!0!1 o i u ty

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No. Name Function

q Status Displays the current status or operating mode.

w Preset number Displays the preset Program (P) number.

e OPTION An "*" is displayed if the AF-100 is attached.

r BAR CODE When bar code reading is enabled "BC" is displayed; "- -" is displayed whenbar code reading is disabled.

t REGISTER MARK When using register marks reading is enabled "REG" is displayed; "- - -" isdisplayed when register mark reading is disabled.

y AUTO CUT When using AUTO CUT is enabled "AC" is displayed; "- -" is displayedwhen AUTO CUT is disabled.

u COUNTER Displays the number of pages processed.

15, 48

19

18


Referencepage

LCD Panel

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[ RUN ] P–79 ∗ BC REG AC ∗ ∗ ∗

17

Before U

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1

This section describes the operating sequence from turning ON the power switch until the machine is ready to operate,and how to turn OFF the power.

Turning ON the Power○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the “ | ” side of the power switch.The power turns ON.

The illustration on the right shows what is displayed on theLCD panel.** denotes a preset number (01-80).

The illustration on the right shows that paper remains in themachine. If this screen is displayed, remove them.(a P.25, “When “REJECT PAPER” is Displayed”)

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Turning OFF the Power○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the “ KK ” side of the power switch.The power turns OFF.

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Turning Power ON/OFF

[ RUN ] P-∗∗ ∗ BC ––– AC ∗

––– J 1 ––– REJECT PAPER

18

Automatic Cutting Using Bar Codes and Register MarksThis machine can read bar codes and reg. marks enabling automatic cutting and creasing.The procedure is described below.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Turn ON the power. (aaaa P.17, “Turning ON the Power”)

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Set the feed tray.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Slide the feed guides to match the documentsize.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Set the document in the feed tray with thesurface where bar codes and reg. marks areprinted facing upwards.The feed lamp turns off and a beep sounds.In a few seconds, the document is fed into the machine.

Tip

• Set the document in the direction shown in theillustration.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Operating InstructionsThis chapter describes the operating sequence from turning ON the power switch until completing

cutting.

Chapter 2

19

2

Operating Instructions

Automatic Cutting Using Bar Codes and Register Marks

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Automatic cutting and creasing start based on the information contained in the barcodes and reg. marks.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

The finished document is ejected.

IMPORTANT• Pieces of cut paper accumulate in the waste tray. Open the drawer located at the bottom of

the machine and remove them periodically. Accumulation of pieces of paper maycause paper jams.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Tip

Bar Code, Reg. Mark and AUTO CUTOptionsThe bar code, reg. mark and AUTO CUT func-tions may be enabled and disabled by using the<MODE>, <SET>, <+> and <-> keys.

Use the <MODE> key to advance through themenus shown on the right.

Use the <SET> key to change from theBARCODE selection (ON or OFF) to the REG.MARK selection, and use the <SET> key tochange from the REG. MARK to the AUTO CUTselection.

While in the BARCODE, REG. MARK and AUTOCUT selections:Enable or disable functions with the <+> and <->keys.

If you select barcode “OFF” you mustmanually enter the desired program numberwhile in the [SELECT] menu.

IMPORTANT NOTEIf select barcode “ON” and/or REG. MARK “ON”and those items are not present, the job will notprocess and the display will indicate aBARCODE or REG.MARK error. Make certainthat these items are set properly. See theappendix (P.54) for details about positioning barcodes and register marks.

[RUN] P–04

<MODE> KEY

[SELECT] P–04

<MODE> KEY

[INPUT] INPUT––>SET

<MODE> KEY

BARCODE *ON OFF

<SET> KEY

<MODE> KEY

<MODE> KEY

REGISTER MARK *ON OFF

<SET> KEY

<MODE> KEY AUTO CUT *ON OFF

The DC-545 is shipped from the factory with the bar code read feature turned on and the reg.mark feature turned off. If the job to be finished has reg. marks properly printed on it (as de-scribed on page 63), the cutting accuracy can sometimes be improved by additionally turningon the Reg. Mark feature.

RegisterMark

Barcode

20

About the Waste Tray

Pieces of cut paper accumulate in the waste tray. Open the drawer located at the bottom left of the machine andremove them periodically. Accumulation of pieces of paper may cause paper jams.How to remove the accumulated pieces of paper is described below.

WARNING• Be sure to confirm that the machine is in a full stop before removing the accumulated

paper to prevent your hands or fingers from being caught or pinched in the machine.• Pieces of cut paper accumulate in the waste tray. Open the drawer located at the bottom of

the machine and remove them periodically. Accumulation of pieces of paper maycause paper jams.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Confirm that the machine is fully stopped.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Open the waste tray located at the bottom leftof the machine and remove the accumulatedpaper.

Tip

• When pieces of paper remain in the machine,open the waste tray cover located at the front ofthe machine and remove them.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

21

3

Troubleshooting

TroubleshootingThis chapter describes what to do when an error has occurred and how to deal with paper jams and error

messages.

Chapter 3

Power Does Not Turn ONIf the power does not turn ON, check the following.

IS POWER PLUG INSERTED?

THE MACHINE DOESN'T TURN ON.

IS POWER SWITCH ON?Insert the power plug securely.

Turn the power switch ON.

Please contact your service person.

NOYES

NOYES

Troubleshooting Flow Chart

22

Cutting is Not PossibleIf cutting is not possible, check the following.

IS THERE A MESSAGE DISPLAYED ON ERROR DISPLAY PANEL?

See P.23, "Error Messages".

Please contact your service person.

YESNO

Troubleshooting Flow Chart

23

3

Troubleshooting

The front or rear cover or the waste tray cover are open or thewaste tray is not seated.Close the covers and waste tray.

This is a CCD error.Remove the document in the machine and press the <STOP>key.1) Reset the machine by turning the power off and then on.2) Call for service.

This is a bar code reading error.1) Verify the document's bar code is printed clearly.2) Check the location of the bar code. See "Specifications of

Reg. Mark and Bar Code" for details.3) Remove any paper distortion/curl and try the sheet again. If

it still causes an E3, you can turn the Bar Code feature off(see page 19), manually enter the job number, and manuallyrun it.

4) Verify machine operation with other bar code documents.5) Call for service if the problem persists.

This is a reg. mark reading error.1) Verify the document's reg. mark is printed clearly.2) Check the location of the reg. mark. See "Specifications of

Reg. Mark and Bar Code" for details.3) Try the sheet again. If it still causes an E4, you can turn the

Reg. Mark feature off (see page 19), manually enter the jobnumber, and manually run it.

4) Verify machine operation with other reg. mark documents.5) Call for service if the problem persists.

This is a slitter error.Remove the document in the machine and press the <STOP>key.1) Reset the machine by turning the power off and then on.2) Using caution, open the covers, carefully check and clear

any foreign objects in all slitter units' path.3) Call for service.

The number of cuts, scores, and AUTO CUTs is too high.1) If automatic cutting is on, turn it off.2) Switch to a job for which the number of cuts or the number

of scores has been reduced.3) Contact a service person if problems occur frequently.

Message Countermeasure

––– E 1 ––– COVER OPEN

––– E 2 ––– RS232C ERROR

––– E 3 ––– BARCODE ERROR

––– E 4 –––REG. MARK ERROR

––– E 5 ––– SLITTER ERROR

––– E 6 ––– DATA ERROR

Error Messages

24

A document remains in the machine when the power is turnedON.Remove the document in the machine. (a P.25, “When“REJECT PAPER” is Displayed”)

A paper jam has occurred in the feeding unit.Remove the document in the machine and press the <STOP>key. (a P.27, “When “FEED JAM” is Displayed”)1) Using caution, open the covers, carefully check and clear

any foreign objects in the paper path.2) Make sure sheet is not deformed or curled.3) Retry job.4) Call for service if problem persists.

A paper jam has occurred in the machine (front).Remove the document in the machine and press the <STOP>key. (a P.29, “When “CENTER JAM” is Displayed”)1) Turn the DC-545 off.2) Using caution, open the covers, carefully check and clear

any foreign objects in the paper path.3) Turn the DC-545 on and retry job.4) Call for service if problem persists.

A paper jam has occurred in the machine (rear).Remove the document in the machine and press the <STOP>key. (a P.31, “When “SLITTER JAM” is Displayed”)1) Turn the DC-545 off.2) Using caution, open the covers, carefully check and clear

any foreign objects in the paper path.3) Turn the DC-545 on and retry job.4) Call for service if the problem persists.

A paper jam has occurred in the cutter unit.Remove the document in the machine and press the <STOP>key. (a P.33, “When “CUTTER LOCK” is Displayed”)1) Using caution, open the covers, check and clear any foreign

objects in the paper path.2) Check that the paper stock is within specifications.3) Call for service.

A paper jam has occurred in the creasing unit.Remove the document in the machine and press the <STOP>key. (a P.35, “When “CREASE LOCK” is Displayed”)1) Using caution, open the covers, check and clear any foreign

objects in the paper path.2) Check that the paper stock is within specifications.3) Call for service.

Error Messages

Message Countermeasure

––– J 2 ––– FEED JAM

––– J 3 ––– CENTER JAM

––– J 4 ––– SLITTER JAM

––– J 7 ––– CUTTER LOCK

––– J 8 ––– CREASE LOCK


25

3

Troubleshooting

When a Paper Jam Has Occurred

When a paper jam has occurred, the JAM lamp blinks and a message is displayed on the LCD panel.

WARNING• Do not touch the blade (with the WARNING sticker attached). Doing so may cause injury.

(aP.6, “Warning Sticker”)• Before removing paper from under the front and rear covers, make sure the machine is fullystopped. Use the tweezers that come with the machine to prevent your hands or fingers frombeing caught or pinched. (aP.6, “Warning Sticker”)

When “REJECT PAPER” is Displayed

If a document remains in the machine when the power is turned ON, “REJECT PAPER” is displayed on theLCD panel and the JAM lamp blinks.Remove the document with the following procedure.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <+> or <-> key to eject the document.

IMPORTANT• Be sure to close the front or rear cover when

you operate the machine. The machine doesnot work if the front or rear cover is open.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

� If the document cannot be removed with the procedure mentioned above

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Open the front or rear cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


COVER

JAMF

PAPER

MODE SET

+

–

Front cover

Rear cover


26

Front cover

Rear cover

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Remove the jammed document using thetweezers.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Close the front or rear cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


27

3

Troubleshooting

When “FEED JAM” is DisplayedIf a paper jam has occurred in the feeding unit, “FEED JAM” is displayed on the LCD panel and the JAMlamp blinks.Remove the jammed document with the following procedure.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <-> key and return the jammed docu-ment to the feed tray side.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <STOP> key to reset the fault logicand clear the fault message.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

� If the document cannot be removed with the procedure mentioned above○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Open the front cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


––– J 2 ––– FEED JAM

COVER

JAMF

PAPER

MODE SET

+

–

Front cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


28

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Remove the jammed document.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Close the front cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


Front cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

29

3

Troubleshooting

When “CENTER JAM” is DisplayedIf a paper jam has occurred in the machine (front), “CENTER JAM” is displayed on the LCD panel and theJAM lamp blinks.Remove the jammed document with the following procedure.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <-> key and return the jammeddocument to the feed tray side.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○



○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

––– J 3 ––– CENTER JAM

COVER

JAMF

PAPER

MODE SET

+

–

Front cover


1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


30

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


Front cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

31

3

Troubleshooting

When “SLITTER JAM” is DisplayedIf a paper jam has occurred in the machine (rear), “SLITTER JAM” is displayed on the LCD panel and theJAM lamp blinks.Remove the jammed document with the following procedure.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <+> key and forward the jammeddocument to the paper tray side.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


Open the rear cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

––– J 4 ––– SLITTER JAM

COVER

JAMF

PAPER

MODE SET

+

–

Rear cover


1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


32

Rear cover

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Remove the jammed document.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Close the rear cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

33

3

Troubleshooting

When “CUTTER LOCK” is DisplayedIf a paper jam has occurred in the cutter unit, “CUTTER LOCK” is displayed on the LCD panel and the JAMlamp blinks.Remove the jammed document with the following procedure.Check that the paper stock is within specifications.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <-> key and return the jammeddocument to the feed tray side.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○



○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

––– J 7 ––– CUTTER LOCK

COVER

JAMF

PAPER

MODE SET

+

–

Front cover


1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


34

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


Front cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

35

3

Troubleshooting

When “CREASE LOCK” is DisplayedIf a paper jam has occurred in the creasing unit, “CREASE LOCK” is displayed on the LCD panel and theJAM lamp blinks.Remove the jammed document with the following procedure.Check that the paper stock is within specifications.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <+> key and forward the jammeddocument to the paper tray side.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


Open the rear cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Rear cover

––– J 8 ––– CREASE LOCK


COVER

JAMF

PAPER

MODE SET

+

–

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


36

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Remove the jammed document using the tweez-ers.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Close the rear cover.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Rear cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


37

4

Manual P

rogramm

ing

Before programming a job carefully measure,in millimeters, the required slits, cuts andcreases. See the Figure 1 for reference andFigure 2 for a detailed description of eachfunction.

Record the values in “Customer ProgramedJobs”. Remember that all measurements,except MARK 1, are in millimeters.

Familiarize yourself with the following illustra-tions and instructions to make the program-ming process easy and trouble free.

IMPORTANT NOTES:There are a total of five slitters. Two slitters arefor the margins and the remaining threeslitters are for the center of the sheet.

There is a guillotine cutter that performs cutsperpendicular to the line of the paper travel.

There is creasing unit that performs creasesperpendicular to the line of the paper travel.

PAPER FEEDING DIRECTION

Slit

Cut

Reg. Mark(Optional)

Bar Code(Optional)

Crease

Manual ProgrammingThis chapter describes how to manually program the Docu Cutter.The Docu Cutter is manually programmable with 80 sets of job dimensions or program numbers. Each setof dimensions are stored and recalled by a program number. (a P.45, “Factory Preset Jobs”)

Chapter 4

Prior to Programming a Job

P–01? (01––80) OK?––>SET

ProgramNumber

Figure 2

Figure 1

38

Definition of Programming Terms

Tip

• Paper area before first cut and after last cut are considered to be scrap and will be choppedup for disposal in waste tray when AUTO CUT is selected. See the appendix (P.66) for infor-mation about automatic cutting.



Reg. Mark(Optional)

First Cut

Last cut

Bar Code(Optional)

Crease(SCR 1)

Reg. Mark(Optional)

Left Margin Slitter(LEFT SL)

Center Left Slitter(C.L.SL)

Center Slitter(OP 1)

Bar Code(Optional)

Right Margin Slitter(RGHT SL)

Center Right Slitter(C.R.SL)

39

4

Manual P

rogramm

ing

SHEET LAYOUTS

Sheets can be laid out in portrait or landscape format. The illustration below is for a CD tray jacket. The letter (or A4)sheet is printed 2-up and fed in portrait orientation.


40

AUTO CUT

If there is no waste on the sheet, be sure to turn the AUTO CUT feature OFF. See Examples 1 and 2 below.


AUTO CUT is turned ON and OFF in the operator menu and is a global function, i.e. it is not saved specific to a job.Jobs requiring AUTO CUT ON and OFF CANNOT mixed in the feed tray.

PLEASE NOTE: When the total number of scores and cuts (including those cuts due to AUTO CUT) exceeds 17 thefollowing message appears on LCD display:

–––E6––– DATA ERROR

If a E6 data error occurs the job must be re-designed or reprogrammed so the total number of cuts and creases do notexceed 17

Example 1 - When AUTO CUT must be OFF

Example 2 - When AUTO CUT must be OFF

41

4

Manual P

rogramm

ing

JOB DESIGN ISSUES

1) Orientation of small format (business) cards

Although the smallest format supported is 88.9 x 50.8 mm, the 88.9 mm side must be in the direction of feed, otherwisethe pieces will drop between the transport rollers. This is because the center slitters must be able to move across thepaper path.


2) Arrangement of small format (business) cards on large sheets (A3+ or oversized ledger)

Business cards requiring a bleed and gutter, require the use of two slitters between each card. Because more businesscards are fit onto A3 or ledger in this format compared to A4 or letter, the number of slitters required will be more thanthe maximum of 4 available.

Workaround solution - arrange 12 to view on A3 or ledger, place the register mark in two positions, 210 mm apart. Printon A3, cut in half using a guillotine (or use the 545). Then place both stacks in the 545 and process as if A4 or letter.The reg. mark will enable the device to adjust and compensate both for image drift and for any inaccuracy in theguillotine cut.

42

Print, cut in half, process as if A4 or letter size


3) Cutting gutters

The slitters cannot be positioned closer together than 50 mm. To perform a gutter cut of a few mm, use slitters on twoadjacent shafts, not those on the same shaft. The waste between gutters will exit onto the delivery tray.

4) Location of right margin trim for A4 paper

Unlike the center slitters, both margin slitters share common axis lead screws. Due to the need to support the marginslitters lead screws in the mid-area of the machine, a support was positioned approximately in the middle of the device.This means that the right trimmer cannot trim below the dimension of 200 mm from the reference (datum or non-operator side) edge.

In the worst case the image can drift up to 2 mm so the trim position should not be located less than 202 mm from thereference edge.

43

4

Manual P

rogramm

ing

Also consider that the unprintable margin of a digital press is typically 3 to 5 mm from the edge of the sheet, so the edgeof the image should not be placed more than 205 mm from the reference edge.

To avoid the problem of the image drifting into the unprintable margin (which would result in a white edge inside theimage area), the image should possess a bleed of (typically) 2mm.

With all these factors combined, it is recommended that the right trim position is located between 202 and 204 mm fromthe reference edge.


202-204mm

typically

Workaround - Should a job be presented that requires a side trim of less than 200 mm, use the right center slitter, OP1,or OP2 slitter to remove the waste from the side. The waste will exit onto the delivery tray.

5) Skewed Output on Small PiecesDepending on the job layout it is possible to have skewed output when small pieces are processed. In part, this problemis due to the design of the rubber feed rollers. Each roller has cutouts that reduce the gripping and drive area for thepaper. In addition, the slitter units add drag as the card contacts the slitter housing and cutter wheels.

Workaround - Analyze the slitter positions and reprogram the job. Switch the center and option slitter units cuttingpositions in order to better balance the paper as it travels through the slitters.

44

Customer Programmed Jobs

PROGRAM NUMBER

JOB DESCRIPTION

ITEM RANGE

MARK 1 40-200

MARK 2 5-40mm

LEFT SL 0-120mm

RGHT SL 200-320mm

C.L. SL 0-160mm

C.R. SL ∗∗∗**-320mm

OP1 SL 0-320mm

OP2 SL OPTION

CUT1 0-650mm

*CUT2 0-650mm

*CUT3 0-650mm

*CUT4 0-650mm

*CUT5 0-650mm

*CUT6 0-650mm

*CUT7 0-650mm

*CUT8 0-650mm

*CUT9 0-650mm

*CUT10 0-650mm

*SCR. 1 0-650mm

*SCR. 2 0-650mm

*SCR. 3 0-650mm

*SCR. 4 0-650mm

TOTAL LENGTH 0-650mm

NOTES

ALL DIMENSIONS MUST BE IN MILLIMETERS

CONVERSION TABLE

Inches Millimeters

1.0 25.4

8.5 215.9

CONVERSION TABLE

Inches Millimeters

11 279.4

17 431.8

* OPTIONAL VALUES - IF NOT REQUIRED ENTER 0** VALUES OF THE C.L.SL VALUE PLUS 50 CAN BE ENTERED.

THERE IS A MAXIMUM OF 10 CUTS AND 4 CREASES

45

4

Manual P

rogramm

ing

Factory Preset Jobs

Job Type

MARK 1

MARK 2

LEFT SL

RGHT SL

C.L. SL

C.R. SL

OP1 SL

OP2 SL

CUT1

CUT2

CUT3

CUT4

CUT5

CUT6

CUT7

CUT8

CUT9

CUT10

SCR. 1

SCR. 2

SCR. 3

SCR. 4

TOTAL LENGTH

SM CARDTrading 8up letter

Trading8up ledger WALLET 3.5 × 5 4 × 6 5 × 7

PROGRAM NUMBER #1* #2 #3 #4 #5 #6 #7 #8

47 47 47 47 47 47 47 47

9.2 9.2 9.2 9.2 9.2 9.2 9.2 9.2

0 9.5 12.7 31.8 12.7 8.3 31.8 8.3

0 269.9 266.7 247.7 203.2 271.1 0 271.1

0 136.5 76.2 95.3 76.2 135.3 0 135.3

0 0 203.2 184.2 0 0 184.2 0

0 142.9 139.7 108.0 139.7 144.1 0.0 144.1

139.7 25.4 19.1 22.2 15.2 17.1 28.6 19.1

0 190.3 108.0 111.1 101.6 106.0 130.2 196.9

0 0 114.3 123.8 188.0 114.9 149.2 0

0 0 203.2 212.7 274.3 203.8 250.8 0

0 0 0 225.4 0 0 0 0

0 0 0 314.3 0 0 0 0

0 0 0 327.0 0 0 0 0

0 0 0 415.9 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 107.4 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

279.4 215.9 215.9 431.8 279.4 215.9 279.4 215.9

NOTESTHESE VALUES ARE CURRENT AS OF OCTOBER 2002ALL DIMENSIONS ARE IN MILLIMETERS8.5 X 11 inches = 215.9 X 279.4 millimeters

11 X 17 inches = 279.4 X 431.8 millimeters

*Be sure to turn off AUTO CUT.

Cut in Half

46

Job Type

MARK 1

MARK 2

LEFT SL

RGHT SL

C.L. SL

C.R. SL

OP1 SL

OP2 SL

CUT1

CUT2

CUT3

CUT4

CUT5

CUT6

CUT7

CUT8

CUT9

CUT10

SCR. 1

SCR. 2

SCR. 3

SCR. 4

TOTAL LENGTH

Pan8 × 101up Lg Card

2up Scrapbook

2up Postcard

11up Business Card

4up Business Postcard

Large Brochure

PROGRAM NUMBER #9 #10 #11 #12 #13 #14 #15 #16

47 47 47 47 47 47 47 47

9.2 9.2 9.2 9.2 9.2 9.2 9.2 9.2

6.4 12.7 13.5 6.4 31.8 6.4 6.4 9.5

209.6 203.2 202.4 272.9 0 209.6 209.6 269.9

0 101.6 0 136.4 0 57.2 108.0 0

0 0 0 0 184.2 158.8 0 0

0 114.3 0 142.9 0 108.0 0 0

17.1 19.1 12.7 12.7 28.6 6.4 12.7 16.9

271.1 266.7 266.7 419.1 130.2 95.3 139.7 415.9

0 0 0 0 149.2 184.2 266.7 0

0 0 0 0 250.8 273.1 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 139.2 215.4 0 0 0 215.9

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

279.4 279.4 279.4 431.8 279.4 279.4 279.4 431.8

NOTESTHESE VALUES ARE CURRENT AS OF OCTOBER 2002ALL DIMENSIONS ARE IN MILLIMETERS8.5 X 11 inches = 215.9 X 279.4 millimeters

11 X 17 inches = 279.4 X 431.8 millimeters

Factory Preset Jobs

47

4

Manual P

rogramm

ing

Job Type

MARK 1

MARK 2

LEFT SL

RGHT SL

C.L. SL

C.R. SL

OP1 SL

OP2 SL

CUT1

CUT2

CUT3

CUT4

CUT5

CUT6

CUT7

CUT8

CUT9

CUT10

SCR. 1

SCR. 2

SCR. 3

SCR. 4

TOTAL LENGTH

3-FoldBrochure Fold in Half Tri-Fold

PROGRAM NUMBER #17 #18 #19* #20 #21

47 47 47 47 47

9.2 9.2 9.2 9.2 9.2

41.3 0 0 0 0

238.1 0 0 0 0

0 0 108 0 0

0 0 0 0 0

0 0 0 0 0

25.4 93.1 139.7 0 0

406.4 186.2 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

153.4 0 0 139.7 94.1

280.4 0 0 0 187.2

0 0 0 0 0

0 0 0 0 0

431.8 279.4 279.4 279.4 279.4

NOTESTHESE VALUES ARE CURRENT AS OF OCTOBER 2002ALL DIMENSIONS ARE IN MILLIMETERS8.5 X 11 inches = 215.9 X 279.4 millimeters 11 X 17 inches = 279.4 X 431.8 millimeters

*Be sure to turn off AUTO CUT.

Tri-Cut Fourths

Factory Preset Jobs

48

Turn on the machine.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Repeatedly push the <MODE> key until thedisplay indicates [INPUT].

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Push and hold the <SET> key until the displayappears as shown on the right.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Use the ten-key pad to enter the job number.

NoteThe numbers 1- to 21 and 72 to 80 are registeredas pre-set programs at the factory.Avoid overwriting these at all costs.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <SET> key.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Perform this step if there is a reg. mark, other-wise press the <SET> key until LEFT SL isdisplayed then proceed to step 14. Place aPREPRINTED (with a reg. mark) sample sheetin the feed tray.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

PREPRINTEDSAMPLE

[INPUT] INPUT––>SET

P–01? (01––80) OK?––>SET

P–52? (01––80) OK?––>SET

How to Manually Program a Job

49

4

Manual P

rogramm

ing

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

When the <START> key is pressed, paper startsbeing fed and the number displayed on thelower right side of the LCD panel begins chang-ing. (The number normally changes from 500through 40, depending on the position of thereg. mark.) Use the <+> key and the <-> key tomove the position of the paper (Reg. markposition); adjust the numerical value on thebottom right side of the LCD panel so that it isbetween 40 and 200. (Adjust the numericalvalue displayed so that it is as small as possible.)

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the three digit value from the lower left ofthe display using the ten key keypad. In thisexample the value is 52.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Remove the sample paper by pressing the <->key.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Measure the distance (in millimeters) betweenthe leading edge of the paper and the horizontalportion of the reg. mark. The value must bebetween 5 and 40 millimeters.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

MARK1 (40––200) 052 047

This number will change when you enter the value (in this example - 052).

MARK1 (40––200) 000 047

This number will change as the sensor reads the vertical portion of the reg. mark.

8.2mm



50


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the value from step 11 using the ten keykeypad.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the left side of thepaper to the position for the left margin slit(LEFT SL) location. This value must be be-tween 0 and 120 millimeters.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the left side of thepaper to the position for the right margin slit(RGHT SL) location. This value must be be-tween 200 and 320 millimeters.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the left side of thepaper to the position for the center left slit (C.L.SL) location. This value must be between 0 and160.0 millimeters.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

LEFT SL (0–120) 000.0mm

RIGHTSL(200–320) 000.0mm

C.L.SL (0–160.0) 000.0mm

MARK2 (5––40) 08.2mm

51

4

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○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the left side of thepaper to the position for the center right slit(C.R. SL) location. You can enter values fromthe value entered for C.L.SL plus 50 mm.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the left side of thepaper to the position for the center (OP1 SL)slit location. This value must be between 0 and320.0 millimeters. (When OP2 SL is not at-tached)

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the left side of thepaper to the position for the Optional 2 SL(OP2 SL) location. You can enter values fromthe value entered for OP1 SL plus 50 mm. (Notdisplayed when OP2 SL is not attached.)

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


C.R.SL (∗∗∗–320) 000.0mm

OP1 SL (0–320.0) 000.0mm

OP2 SL (∗∗∗–320) 000.0mm


52


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the leading edge of thepaper to the position for the first cut (CUT 1)location. This value must be between 0 and 650millimeters.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the leading edge of thepaper to the position for the second cut (CUT 2)location. This value must be between 0 and 650millimeters. If a second cut is not required,enter a value of zero. Turn off the automaticcutting setting when not using CUT2. Themachine normally does not operate.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the distance from the leading edge of thepaper to the first score (SCR.1). It is possible toenter numerical values from 0 to 650 mm. If ascore is not needed enter 0.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

CUT1 (0–650.0) 000.0mm

CUT2 (0–650.0) 000.0mm

SCR.1 (0–650.0) 000.0mm

53

4

Manual P

rogramm

ingHow to Manually Program a Job

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Enter the total length (in millimeters) of thesample paper.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○


○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Press the <SET> key to retain the settings or<C> key to discard the settings. The display willindicate “Memory Please Wait” while the infor-mation is written to the Docu Cutter memorycircuit. The memorization process will takeapproximately 10 seconds.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

TOTAL LENGTH? 000.0mm

OVERWRITE?OK––SET NO––C

MEMORY!! Please Wait

54

AppendixThis chapter lists the specifications and an index.

Specifications

Product name/model No. Docu Cutter DC-545

Model Desktop model

Paper size MAX. Width: 12.6" x 18" (320 mm x 457 mm)MIN. Width: 8.5" x 11" (216 mm x 279 mm)

Finishing size MIN. 2" x 3.5" (50.8 mm x 88.9 mm)(business card size)

Paper weight 110-230 g/m2 (28LB-10pt)(Poor quality or laminated paper may result in poor performance)

Front edge cutting width MIN. 0.125" (3.2 mm)

Rear edge cutting width MIN. 0.125" (3.2 mm)

Side cutting width MAX. 4.5" (114 mm)MIN. 0.125" (3.2 mm)

Cutting accuracy ±0.03" (±0.762 mm)

Cutting speed MIN. 2 ppm

Feeding method Manual feeding

Stacker Drop type

Power supply AC 120 V ±10 % 60 Hz

Current consumption 2.1A

Machine dimensions In storage : 23.2" x 22.2" x 13" (590 (W) x 565(D) x 330 (H) mm)In use : 51.2" x 22.2" x 11.8" (1300 (W) x 565 (D) x 300 (H) mm)

Machine weight Main body 128.18 LB (58 kg)

Specifications of the Machine

55

Appendix

Specifications

Paper WeightThe DC-545 was designed to process paper from 110 gsm up to 230 gsm (grams per square meter). 110 gsm is roughly28 lb and 230 gsm equates to 10 pt stock.

Laminated StockThe DC-545 was not designed to process laminated stock and therefore it is not recommended.

Paper CurlDue to the automated slitter function design, the paper path of the DC-545 is sensitive to paper curl. The paper pathdoes not posses a flat table for the paper to travel over because the slitter units must be able to move freely from side-to-side.

If paper curl is causing paper jams the following are suggestions for remedying the problem:1. Adjust the printing devices de-curler (if available)2. Manually de-curl the stock before loading in the feed tray3. Turn the paper over (reprogramming the job may be necessary)4. Use different paper stock

56

Specifications of Reg. Mark and Bar Code

1.Reg. Mark Details (Vertical/Horizontal)Length: 5mm or moreWidth: 0.4mm or more

2.Bar codeBar code : CODE-39Start/stop code : RequiredCheck digit : OptionalMinimum resolving power : 0.254mmFine line : Thick line : 1:2.5Bar height : 4mm or more

Under the requirements listed above, the bar code width will be about 15mm.

Printing Position : See P.62 to P.64 for details.

Print the bar code data in the following sequence:

q is the start code designator for CODE-39.

w is the 10’s digit data of the program number.(Example: When the program number is 11 , the data is "1".)

e is the 1’s digit data of the program number.(Example: When the program number is 11 , the data is "1".)

r is the check digit.

t is stop code of CODE-39.

These figures indicate program number, with which the machine recognizes a stored setting for certain Jobs. (start from00)

1 2 3 4 5

Specifications

57

Appendix

Specifications

THE 'REG' (REGISTER) MARK

Using a CCD sensor to read an image reference point on the sheet is a unique feature of the DC-545.

The mark is similar to a cutting mark (or crop mark) for guillotines. The device does not cut on this mark, it is simplya definable shape which is easy to recognize and is easy to reproduce in the original application.

The reg. mark is actually made up of two components. The vertical component is used for determining the horizontalreference point. In other words, where the image is located from left to right on the sheet. When a job is programmedinto memory the first entry is MARK 1. This refers to the vertical line in the reg. mark. During the programmingprocess the MARK 1 value is entered in pulse counts. There are two ways to obtain the proper data value for MARK 1.

Obtaining the MARK 1 value can be done with the two following methods.

Obtaining MARK 1 Value - Method 1With this method, you can input the MARK 1 value through DC-545. Load the type of paper that is registered to for thefeed tray when inputting the MARK 1 value, and then press the <START> key. The paper stops when it is in the vicinitywhere the MARK 1 value is read, move the paper forward and backward with the <+> and <-> keys to move the paperto the position where the MARK 1 value can be read. Then enter the value that is displayed on the screen.

Obtaining MARK 1 Value - Method 2You can enter the MARK 1 value with the following method, rather than method 1, if you know the MARK 1 position.Convert the MARK 1 value to a numerical value according to the following table and enter the new value, note that theMARK 1 value is not the distance (mm) from the edge of the paper.

For example, if the MARK 1 is positioned 10 mm from the edge of the paper, then the MARK 1 value is 70.

MM CCD Reading

1 15+/- 12 21+/- 13 27+/- 14 33+/- 15 40+/- 16 46+/- 17 52+/- 18 58+/- 19 64+/- 1

10 70+/- 111 77+/- 112 83+/- 113 89+/- 114 95+/- 115 101+/- 116 107+/- 117 113+/- 118 120+/- 119 126+/- 120 132+/- 1

MARK 1 CONVERSION TABLE

58

The second program entry is MARK 2. This refers to the horizontal line of the reg. mark and is used as the imagevertical reference point. This mark determines where the image reference is located in respect to the head and foot of thepage.

Specifications

MARK 1

MARK 2

MARK 1 corrects for errors in this

direction

MARK 2 corrects for errors in this

direction

59

Appendix

Specifications

HOW TO MAKE A BAR CODE FOR USE WITH THE DC-545

The easiest way to create the code is with a TrueType Font. Fonts are readily available from many companies on theinternet. Here are two companies which have fonts suitable for use with the DC-545 (there are many companies offeringfonts).

www.azalea.com/code39Azalea offers a free sample of code 39 and a variety of customizable options that allow printing of bar codesfrom Microsoft Windows™ or Macintosh™ platforms.

http://www.datascan.co.ukSamples - standard font Price £149 for a single user; £298 for 2-5

Basic Font Installation Instructions

The following briefly describes what is required to install a font on a Windows or Macintosh system. The font providerwill supply more detailed information, these guidelines are only intended to illustrate the basics and scope of theinstallation process.

On a Windows PC the font is installed through the Control Panel's "Fonts" folder.

On a Macintosh system select the font suitcases (for TrueType 1 fonts also select the printer outline files) and drag thefonts onto the closed System Folder icon. For OS X drag the fonts onto the Fonts folder in the Library folder.

How to use a TrueType font

Once installed, the font will appear in the word processing or desktop publishing application in the font selection area.Please note in MS Word, typing text surrounded by the characters * and *, automatically turns on auto format to boldtext. Since this is not the intended, or useful, turn off the auto formatting by following the steps below or use the 'undolast action' after typing.

60

Specifications

Select Options

Delete *Bold* and _underline_with real formatting

61

Appendix

Duplo Code 39

Fontselectionwindow

Font sizeselectionwindow

Specifications

Creating the Barcode

Making the barcode appear on the page is extremely easy with a TrueType font. In this case we will use the example job“01.” The application designer simply does the following:

1. Place a text box in the predefined area. Make sure the text box is large enough to hold the entire bar code. Itmay be necessary to increase the size of the text box after the font is created.

2. Type the desired job (program) number surrounded by a stop and start bit. Remember the stop and start bitare recognized in Code 39 as an * or asterisk.

3. Select the text, in this case the text will appear as: *01*4. Change the font type in the font selection window to the name of the code 39 font.

The text will appear as: *01*

5. Print a sample and make sure the font is at least 4 mm tall. If not, increase the size of the code 39 font byreselecting the barcode and increasing the font size with through the Font size selection window.

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Specifications

POSITIONING THE BAR CODE

NON PRINTING AREA

5 mm

10 mm

*24*

60 mm

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Appendix

10mm or more

35mm or less

60mm or less

30mm

8mm

8mm

5mm

5mm

BAR CODEREG. MARK

*a

*b

5mm or more

40mm

REG. MARK position range

5mm or more 8mm or more

*0.4mm or more

* The width of Reg. Mark line is 0.4 mm or more.

* a<=b

The above diagram shows the position relationships when document data with register marks and bar codesis created. There is a discrepancy between the document data and the printed document. If a discrepancy occurs,position the register mark so that it is in the range where the printer can print. Check the range where theprinter can print in the printer's manual.

Since the reg. mark and image shift proportionately, any error in the reg. mark position is used as error correc-tion data for image registration. The Docu Cutter 545 automatically compares the actual image position to thereference position and offsets the cutting position (horizontal shift) and slit position (vertical shift) to maintainprecise trims every time.

Specifications

1. The Register Mark and Bar Code Position when the Document Data was Created

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Non Printing Area

10mm

50mm

Non Printing Area

5mm

10mm

Specifications

2. Non-Printing Area

Reg. marks and non-printing areas

Bar codes and non-printing areas

NoteWhen combining reg. marks and bar codes take note of the position of both as well as the non-printing areas.

65

Appendix

3. Range within which the Register Mark can be Adjusted

The DC-545 compensates the position for cutting, creasing and slitting if the register mark discrepancies are withinranges such that the mark 1 value is +/- 40 (+/- 6 mm), for mark 1 (left/right) in the registered JOB data, and such thatmark 2 (up/down) is between 5 mm and 35 mm from the leading edge of the paper (see the following diagram) regard-less of the registered job data.However, even if the register mark is within the range described above, compensation cannot be done for the registermark if it is outside the range where the printer can print.

Specifications

5mm

35mm

Position of the upper limit that mark 2 of the register mark can be read

Position of the lower limit that mark 2 of the register mark can be read

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If the length of this portion is greater than 17.0 mm the waste paper will not fall into the waste tray. Add a dummy cut so that the length of the waste paper is less than 17.0 mm. Example: If the length of the waste paper is 30 mm: (Cut 2 is 100, and Cut 3 is 130)A dummy cut (Cut 3) is added, such as; Cut 2 at 100, Cut 3 at 115, and Cut 4 at 130, so that the waste paper will fall into the waste tray.

Area where automatic cutting can be done

Leading edge of the paper

First Cut

Last Cut

Specifications

How to do AUTO CUT

What is AUTO CUT?Automatic cutting is done between the leading edge of the paper and the first cut and between the last cut and thetrailing edge of the paper. Automatic cutting is not done in any other positions.

AUTO CUT ConditionsIf automatic cutting is turned on and the distance between the leading edge of the paper and the first cut is more than17.0 mm or the distance between the last cut and the trailing edge of the paper is more than 21.0 mm.

About the Waste Tray ................................................. 20Appearance ................................................................. 13Automatic Cutting Using Bar Codes andRegister Marks ............................................................ 18

Bar code ...................................................................... 18

<CLEAR> key ............................................................ 15Conventions Used in This Manual ............................... 9Confirming the Packaged Materials ........................... 10Control Panel ........................................................ 13, 15COVER lamp .............................................................. 15Customer Programmed Jobs ....................................... 44Cutting is Not Possible ............................................... 22

Definition of Programming Terms ............................. 38

Error Messages ........................................................... 23

Factory Preset Jobs ..................................................... 45Feed guides ........................................................... 13, 18Feed lamp ............................................................. 13, 18Feed tray ............................................................... 13, 18 <F> key ...................................................................... 15Front cover ...................................................... 13, 23, 25

How to Manually Program a Job ................................ 48How to Set up the System........................................... 11

Instruction Manual ...................................................... 10

JAM lamp ............................................................. 15, 25

Key pad ....................................................................... 15

LCD panel ................................................ 15, 16, 23, 25

<MODE> key ............................................................. 15Maintenance ................................................................. 8

Part Names and Their Functions ................................ 13PAPER lamp ............................................................... 15Paper tray ........................................................ 10, 11, 14Positioning the Machine ............................................... 7Power cord ............................................................ 10, 12Power Does Not Turn ON .......................................... 21POWER lamp ............................................................. 15Power switch ......................................................... 14, 17Preset number ..................................... 15, 16, 45, 46, 47Prior to Programming a Job ........................................ 37

Rear cover ....................................................... 14, 23, 25Reg. Mark ............................... 16, 18, 19, 23, 56, 63, 64

<SET> key ............................................................ 15, 48Safety Precautions ........................................................ 3Screw Driver ............................................................... 10Specifications .............................................................. 54Specifications of Reg. Mark and Bar code ................... 56Specifications of the Machine .................................... 54<START> key ............................................................. 15START lamp ............................................................... 15Status .......................................................................... 16<STOP> key ................................................... 15, 23, 27

Troubleshooting Flow Chart ....................................... 21Turning OFF the Power .............................................. 17Turning ON the Power ................................................ 17Turning Power ON/OFF ............................................. 17Tweezers ............................................................... 10, 26

Warning Sticker ............................................................ 6Waste tray ....................................................... 13, 19, 20Waste tray cover ................................................... 13, 20When a Paper Jam Has Occurred ............................... 25When “CENTER JAM” is Displayed ......................... 29When “CREASE LOCK” is Displayed ...................... 35When “CUTTER LOCK” is Displayed ...................... 33When “FEED JAM” is Displayed .............................. 27When “REJECT PAPER” is Displayed ...................... 25When “SLITTER JAM” is Displayed ........................ 31

<+> key ................................................................. 15, 25<-> key .................................................................. 15, 25

A

C

F

H

I

J

K

L

M

P

R

S

T

W

Other

B

Index

D

E

N4-Y1012

Duplo Docu Cutter DC-545 · Duplo Docu Cutter DC-545 Instruction Manual. Store this manual so that...

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