DC545HC Docucutter Instr

8/9/2019 DC545HC Docucutter Instr

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Store this manual so that it can be retrieved whenever needed.

Instruction Manual

Docu Cutter

DC-545 HC/DC-545 HCEXVersion. 1.0 / November 2003

Correct operation and periodic maintenance are

essential for ensuring safe use of this machine.Thoroughly read this manual before using this

machine.


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Thank you for your purchase of the Docu Cutter DC-545 HC.

To ensure safe and efficient prolonged use of this machine, read and thoroughly understand this manual before

using this machine. After using this manual, be sure to keep it in a place to handy reference.

PLEASE NOTEIn the interest of upgrading our products, specifications and other data given in this manual are subject to

change without notice. If the manual contains anything that you do not understand, contact the manufac-

turer for clarification.

IntroductionDC-545 HC


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Chapter 5 Manual Programming - DC-545 HCEX

Prior to Programming a Job............................................................................................ 53

Definition of Programming Terms ................................................................................... 54

Customer Programmed Jobs.......................................................................................... 60

Factory Preset Jobs......................................................................................................... 61

How to Manually Program a Job..................................................................................... 64

Appendix - DC-545 HC / DC-545 HCEX

Specifications................................................................................................................... 70

DC-545 with HC AUTO FEEDER Specifications ...................................................... 70

DC-545 with HCEX AUTO FEEDER Specifications ................................................. 71

Specifications of Reg. Mark and Bar Code .............................................................. 72

How to do AUTO CUT .............................................................................................. 82

Index.................................................................................................................................. 83

Contents


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Notes on Safety (Please Read and Observe)

Safety Precautions

Various symbols and pictures are used in this manual and on the stickers affixed to the machine. These symbols and

pictures provide warnings and instructions to prevent danger to you or other personnel, and to prevent damage to office

property. The meanings of these symbols and pictures are explained below.

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

injury may result.

CAUTIONIndicates a medium degree of potential danger. If the caution is ignored, medium injury or

damage 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 prohibited

act is disassembly.)

A black disc indicates an instruction, or sometimes a prohibited action. The instruction

itself is indicated by pictorial symbols drawn in white on the disc. (In the example shown

here, 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 the

machine, this may result in fire or electric shock.

Turn the main units 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 may

result in fire or electric shock.

Turn the main units 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.


Do not place flower vases, flowerpots, cups, or water containers (including metal containers) on top

of 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 single

outlet.


Do not place the machine in a humid or dusty area.



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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 Sticker

Keep the WARNING stickers clean at all times. If labels become damaged or come off, have your service representative

replace them.

No. Parts No. Name Qty

q 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

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

q

w


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Positioning the Machine

Installing 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 due

to overheating caused by sunlight. Also avoid hot, cold, or

humid areas since paper may absorb moisture, causing

paper jams or wrinkles.



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Maintenance

Clean the exterior of the machine as described below.

Tightly wring a soft cloth that has been moistened with

water or neutral detergent, and wipe dirt from the ma-chines surface.

Never use alcohol or organic solvents. Doing so may

discolor 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 then

remove 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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Conventions Used in This Manual

Each 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 machines performance, etc.

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

(aP.00 xxxx) : Indicates the page number and item containing related information.

Chapter

Description of operational steps

Each step is described in detail.

Illustrations

The illustrations provide a visualreference to which keys to operate

and other related conditions.

Title


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e

r

q

wt

No. Name Function

q Level adjustment lever For adjusting the level of the elevator 6

w Separator adjustment knob For adjusting the amount of space between sheets of paper 6

e Airflow adjustment knob For adjusting the amount of airflow 7

r Skew adjustment knob For adjusting the skew of the paper 7

t Stoppers For holding the rear edge of the paper stack 5

ReferencePage

Operating Instraction - DC545 HC

Chapter1

Part names and their functions


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11OperatingInstractio

n-DC545HC

Loading the paper

Fan the edge of the paper stack to separate the

paper.

Set the paper stack on the feed tray.

Note The height of the paper stack should not exceed

the "MAX" level.

Turn the feed guide knob to loosen, then adjust

the feed guide.

MAX

Part Names and Their Functions


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Tighten the knob to fix the position of the guide.

Set the stoppers.

Selecting/operating/stopping a job

Follow the instructions in the DC-545 manual to

select the type of job that you want to perform,

and then press START.

To stop the machine, press STOP.

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

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4

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C

2

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0

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9

POWER START

STOP



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n-DC545HC

Adjustments

Elevator level ( Feed tray)

The elevator level should be adjusted in the

following cases.

a. The machine does not feed.

Lower the lever. The level of the elevator is

raised.

b. The machine feeds multiple sheets at once.

(double feed)

Raise the lever. The level of the elevator is

lowered.

Separator

The height of the separator should be adjusted in

the following cases:

a. The machine does not feed.

Turn the knob in the clockwise direction (to a

smaller number). The position of the separator is

lowered.


(double feed)

Turn the knob in the anti-clockwise direction (toa larger number). The position of the separator is

raised.

Figure 1-1: Close-up of the level adjustment lever

Figure 1-2: Location of the level adjustment lever

Figure 2-1: Close-up of the separatoradjustment knob

WARNING Cuttersandmovablepartsareinsidethiscover.Beforeopeningthecovertowork,unplugthepowercord.Usecautionwhenworkingnearcuttersandmovable parts.

L8-T1080

Figure 2-2: Location of the separatoradjustment knob



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Adjusting the airflow

The amount of airflow should be adjusted in the

following cases:

a. The machine does not feed. Turn the knob in the anti-clockwise direction (to

a larger number). The amount of airflow is

increased.


(double feed)

Turn the knob in the clockwise direction (to a

smaller number). The amount of airflow is

decreased.

Adjusting the amount of skew

Paper may be cut at an angle if a skew in the paper

arises during feeding. When this happens, correct

the problem by changing the angle of the feed

guide.

Figure 3-1: Close-up of the airflow adjust-ment knob

Figure 3-2: Location of the airflow adjust-ment knob

Figure 4-1: Skew adjustment knob



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n-DC545HC

No. Item AF-100

1 Model Floor Model

2 Model No. AF-100

3 Input paper size Min.8.5x 11/ A4

Max.12.6x 18/ A3

4 Input paper weight Min.110gsm (29.3LB)

Max.230gsm (85LB)5 Media type Range: Regular copy paper to coated heavy weight paper

6 Feeding method Automatic (Air suction method)

7 Feed tray capacity 3.9(100mm)

8 Power supply DC5V, DC24V is supplied from DC-545 main body

9 Machine dimensions 43.4(W) x 22.7(D) x 37.8(H)

1102mm (W) x 576mm (D) x 960mm (H)

10 Machine weight 117.1LB (Feeder : 44.9LB, Stand : 72.2LB)

53.2kg (Feeder : 20.4kg, Stand : 32.8kg)

11 Operating temperature 41-86F (5-30C)

12 Operating Humidity 40-70% (no condensation within this range)

Troubleshooting table

Raise the elevator height by pushing the level adjustment

lever downward. (See Figure 1-1)

Lower the paper separators by turning the separator adjust-

ment knob clockwise, towards a lower number. (See Figure 2-1)

Increase the airflow by turning the airflow adjustment knob

counter-clockwise. (See Figure 3-1)

Lower the elevator height by pushing the level adjustment

lever upward. (See Figure 1-1)

Raise the paper separators by turning the separator adjustment

knob counter-clockwise, towards a higher number. (See Figure

2-1)

Decrease the airflow by turning the airflow adjustment knob

clockwise, towards a lower number. (See Figure 3-1)

1. Remove the paper from the feed tray.

2. Turn the skew adjustment knob according to the instruc-

tions on the label to adjust the angle of the feed guide.

The machine

does not feed

paper.

The machine

double feeds

paper.

The paper is cut

at an angle or

not fed straight.

Symptom Possible Cause Remedy

Paper level is too low.

Paper separators are too high.

Not enough airflow.

Paper level is too high.

Paper separators are too low.

Too much airflow.

The paper is skewed.

Specifications



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No. Name Qty

q Power cord 1

w Instruction Manual 1

e Tweezers 1

r Screw Driver 1

t Hex L-wrench 1

Before Using This Machine - DC545 HCEXThis 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.

Chapter2

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

Confirming the Packaged Materials

q w e

r t


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1BeforeUsingThisMachine-DC545

HCEX

2

How to Set up the System

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

Take out the machine from the package and place the machine on a flat and stable

table.

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.

Detach the shipping bracket.

Attach the feed tray to the main body.

Attach the paper tray to the main body.

Continue Page


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Connect the power cord to the Docu Cutter and

a wall outlet.

How to set up the System


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HCEX

2


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

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20

19, 20

10, 11, 18

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23, 25


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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.


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o!0

i


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HCEX

2

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 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 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 key Press to clear the count. Press to cancel manual programming.

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

o key Press to change the mode.!0 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,

25

25

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23, 27

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Control Panel

US

COVER

JAM

F

PAPER

MODE SET

+

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

!0!1 o i u ty

w e rq

Europe

F

+

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4

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C

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0

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!0!1 o i u ty

w e rq


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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.

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Referencepage

LCD Panel

yt u

w eq

r

[ RUN ] P79 BC REG AC


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Automatic Cutting Using Bar Codes and Register Marks

This machine can read bar codes and reg. marks enabling automatic cutting and creasing.

The procedure is described below.

Turn ON the power. (aaaaaP.17, Turning ON the Power)

Set the feed tray.

Slide the feed guides to match the document

size.

Set the document in the feed tray with the

surface where bar codes and reg. marks are

printed 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 Instructions - DC545 HCEX

This chapter describes the operating sequence from turning ON the power switch until completingcutting.

Chapter3


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3OperatingInstruction

s-DC545HCEX


Automatic cutting and creasing start based on the information contained in the bar

codes 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 CUT

OptionsThe bar code, reg. mark and AUTO CUT func-tions may be enabled and disabled by using the, , and keys.

Use the key to advance through themenus shown on the right.

Use the key to change from theBARCODE selection (ON or OFF) to the REG.MARK selection, and use the 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 OFFyou mustmanually enter the desired program numberwhile in the [SELECT] menu.

IMPORTANT NOTEIf select barcode ONand/or REG. MARK ONand those items are not present, the job will not

process 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] P04

KEY

[SELECT] P04

KEY

[INPUT]INPUT>SET

KEY

BARCODE*ON OFF

KEY

KEY

KEY

REGISTER MARK*ON OFF

KEY

KEYAUTO 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


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Tip

CCD Scan ModeHow to Change the Settings in the DC-545 CCDScan Mode

Where to make the settings

1. Press the MODEkey and select BARCODE.2. Press the SETkey.

Switch the display from BARCODEREGISTER MARKAUTO CUTCCD SCAN. MODE

3. CCD SCAN. MODEappears on the display.

Change the setting (*) with the +, and - keys.

The standard setting for CCD SCAN. MODE isFAST.

The following conditions might cause the E4 REG MARK ERROR.q The roughness of the paper may cause the mark to be unreadable.wThe REG MARK may not be sharp enough.eThe paper may be dirty.

If this is the case, switch the setting from FAST to SLOW.

Note:Even if you switch the setting to SLOW, the conditions noted in q, w, and emay cause theE4 REG MARK ERROR. If this happens, do the operation without using the REG MARK.


CCD SCAN. MODE* FAST SLOW


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3OperatingInstruction

s-DC545HCEX

About the Waste Tray

Pieces of cut paper accumulate in the waste tray. Open the drawer located at the bottom left of the machine and

remove 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 ofthe 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 left

of the machine and remove the accumulated

paper.

Tip

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


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Troubleshooting - DC545 HCEX

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

Chapter4

Power Does Not Turn ON

If 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 powerplug securely.

Turn the power switch ON.

Please contact your service person.

NOYES

NOYES

Troubleshooting Flow Chart


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4Trou

bleshooting-DC545HCEX

Cutting is Not Possible

If cutting is not possible, check the following.

IS THERE A MESSAGE DISPLAYEDON ERROR DISPLAY PANEL?

See P.23, "Error Messages".

Please contact your service person.

YESNO

Troubleshooting Flow Chart


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This machine has a self-diagnosis function that displays an error message on the control panel when it determines a

problem has occurred. The following shows the error message, possible causes and a description of the problem that

was detected.

J 1 REJECT PAPER

Cause

Paper is still in the machine

One of the sensors (PPS1, PPS2, PPS3, or PPS4) is defective

Problem detected

1. Light did not transmit through all of the sensors (PPS1, PPS2, PPS3, and PPS4) when the power was turned on.

2. Light did not transmit through all of the sensors PPS1, PPS2, PPS3, and PPS4 when the start switch was pressedwhile the machine was stopped and paper was in the AF-100. (Only when using DC-545HC)

J 2 FEED JAM

Cause

Paper does not meet specifications

Separator gap is too narrow(AF-100)

Fan (blower) airflow is insufficient (AF-100)

Feed solenoid incorrect adjustment

Feed solenoid is defective

Feed motor is defective

Shutter solenoid is defective(AF-100)

Feed motor is defective(AF-100)

Fan (suction or blower) is defective(AF-100)

Problem detected

1. Paper was not detected at PPS2 even though it was longer than the set length of the paper (30 mm) and it was

detected at PPS1.

2. Paper was not detected at PPS1 after the specified time (about 2.5 seconds) after paper feed operation started,therefore paper feed operations were started again. Error occurs if the feed operation starts three times and paper

is not detected at PPS1.

Error Messages


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J 3 CENTER JAM

Cause


The length of the JOB data and the paper are different.

Problem detected

1. The leading edge of the paper was not detected at PPS3 even though the specified length (100 mm) had passed

PPS2.

2. Paper was not released from PPS3 even though the preset registered paper length + 30 mm had passed PPS3.

J 4 SLITTER OR STACK

Cause


The length of the job data and the paper are different.

The stacker is full and paper can not be ejected.

Problem detected

1. The leading edge of the paper was not detected at PPS4 even though the specified length (500 mm) had passed

PPS3.

2. Paper was not released from PPS4 even though the preset registered paper length + 50 mm had passed PPS4.

J 5 OVER CAPACITY

Cause

There is too much paper loaded on the AF-100 feed tray.

Paper level sensor is defective

Actuator malfunction

Main PWB unit is defective

Problem detected

1. Elevator lower switch was pressed after paper feed was started at DC-545HC while the paper level sensor was on.

Error Messages


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J 7 CUTTER LOCK

Cause


Cutter motor is defective

Cutter position switch is defective


Problem detected

1. There was no response from the cutter position switch even though the specified time (0.6 seconds) elapsed after

cutting started.

J 8 CREASE LOCK

Cause


Creaser motor is defective

Creaser sensor is defective


Problem detected1. There was no response from the creaser sensor even though the specified time (2.0 seconds) elapsed after scoring

started.

E 1 COVER OPEN

Cause

Actuator (N4-L224*&N4-225*) installation is incorrect

Interlock is defective


Problem detected

1. One of the covers was open while the machine was operating.

2. One of the covers was open when the start button was pushed.

Error Messages


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E 2 RS232C ERROR

Cause

CCD is defective


Problem detected

1. There was an abnormal transmission between the CCD and the DC-545.

E 3

BARCODE ERRORCause

Bar code being used does not meet specifications

CCD is defective


Problem detected

1. The bar code could not be read even after the paper fed the specified length (50 mm) after the bar code reading

operation started.

E 4 REG.MARK ERROR

Cause

Reg. mark being used does not meet specifications

CCD is defective


Problem detected

1. The reg. mark could not be read even after the paper fed the specified length (40 mm) after the reg. mark reading

operation started.

2. Mark 1 was less than 4.5 mm.

Error Messages


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E 5 SLITTER ERROR*Slitter errors are numbered from 1 to 6.

Cause

Slitter sensor is defective

Slitter positioning motor is defective


Problem detected

1. Light did not transmit to the slitter sensor when temporarily shifting inward 8 mm to detect the home position

while the slitter sensor was shielded from light and the command to move the slitter was issued.

2. The slitter did not return to the predetermined position within the specified time period (refer to the table below)

after the command to move the slitter was issued.

Left margin slitterRight margin slitterLeft center slitterRight center slitterOP1 slitter

OP2 slitter

Time until detection4.5 S5.5 S6.0 S6.0 S

12.0S 6.0S(OP2: When not installed) (OP2: When installed)

6.0S (Only when OP2 is installed.)

This image shows the optional 1 slitter sensor.

Angle

Sensor

Connector

LCD message SlitterSLITTER ERROR 1 Left margin slitterSLITTER ERROR 2 Right margin slitterSLITTER ERROR 3 Left center slitterSLITTER ERROR 4 Right center slitterSLITTER ERROR 5 OP1 slitterSLITTER ERROR 6 OP2 slitter

You can identify the position of the slitter where the error that occurs by looking at the number in the message displayed

on the LCD panel.

Error Messages


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E 6 DATA ERROR

Cause

Preset data is not registered

Memory PWB unit is defective

Problem detected

1. Preset data was accessed that exceeds a total of 17 AUTO CUTs (see table below), JOB cuts and scores while

AUTO CUT is being used.

2. There was no information in the preset data that was accessed.

Example:

1. Cuts: 5 Scores: 2 First cut: 98.0 mm

Length from the last cut to the trailing edge of the paper: 65.0 mm

According to the table: There are 6 AUTO CUTs from the leading edge of the paper to the first cut.

There are 4 AUTO CUTs from the last cut to the trailing edge of the paper.

The number of cuts, scores, and AUTO CUTs is 5 + 2 + 6 + 4 = 17.

The total is more than 17, resulting in E6: DATA ERROR.

2. Cuts: 10 Scores: 4 First cut: 10.0 mm

Length from the last cut to the trailing edge of the paper: 20.0 mm

According to the table: There are 0 AUTO CUTs from the leading edge of the paper to the first cut.

There are 0 AUTO CUTs from the last cut to the trailing edge of the paper.

The number of cuts, scores, and AUTO CUTs is 10 + 4 + 0 = 14.

The total is less than 17, resulting in no error.

Table 1: List of AUTO CUT countsDistance from theleading edge of thepaper to the first cut

0.0 to 16.9 mm17.0 to 32.9 mm33.0 to 48.9 mm49.0 to 64.9 mm65.0 to 80.9 mm81.0 to 96.9 mm

97.0 to 112.9 mm113.0 to 128.9 mm129.0 to 144.9 mm145.0 to 160.9 mm161.0 to 176.9 mm177.0 to 192.9 mm193.0 to 208.9 mm209.0 to 224.9 mm225.0 to 240.9 mm241.0 to 256.9 mm257.0 to 272.9 mm273.0 to 288.9 mm

AUTO CUT count

01234567891011121314151617

Distance from thelast cut to the trailingedge of the paper

0.0 to 20.9 mm21.0 to 36.9 mm37.0 to 51.9 mm52.0 to 66.9 mm67.0 to 81.9 mm82.0 to 96.9 mm

97.0 to 111.9 mm112.0 to 126.9 mm127.0 to 141.9 mm142.0 to 156.9 mm157.0 to 171.9 mm172.0 to 186.9 mm187.0 to 201.9 mm202.0 to 216.9 mm217.0 to 231.9 mm232.0 to 246.9 mm247.0 to 261.9 mm

AUTO CUT count

0234567891011121314151617

Error Messages


39/90


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39

6

2

1

4Trou


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 PAPERis displayed on the

LCD 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 whenyou 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.

J 1 REJECT PAPER

COVER

JAM

F

PAPER

MODE SET

+

Front cover

Rear cover

Continue Page


41/90

40

Front cover

Rear cover

Remove the jammed document using the

tweezers.

Close the front or rear cover.



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41

6

2

1

4Trou


When FEED JAMis Displayed

If a paper jam has occurred in the feeding unit, FEED JAMis displayed on the LCD panel and the JAM

lamp 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 key to reset the fault logic

and clear the fault message.


Open the front cover.


J 2 FEED JAM

COVER

JAM

F

PAPER

MODE SET

+

Front cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

Continue Page


43/90

42

Remove the jammed document.

Close the front cover.




Front cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


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43

6

2

1

4Trou


When CENTER JAMis Displayed

If a paper jam has occurred in the machine (front), CENTER JAMis displayed on the LCD panel and the

JAM lamp blinks.


Press the key and return the jammed

document to the feed tray side.





J 3 CENTER JAM

COVER

JAM

F

PAPER

MODE SET

+

Front cover


1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

Continue Page


45/90

44


tweezers.





Front cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


46/90

45

6

2

1

4Trou



Procedure of Removing Front and Rear Creaser Guides

This operation also needs to be done when the creaser or the cutters are locked.

Please open the Front/Rear Cover of DC-545HC.

Front Cover Rear over

Loosen the 2 set-screws on both sides of Front/Rear Creaser Guides, counter clockwise

2 or 3 times. Use the Hex Driver contained in the kit.

IMPORTANTThe cap bolt may fall off if it is loosened more than necessary.


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46


Please slide the guide toward qqqqq(non-operator side) then pull up toward wwwww.

Front Creaser Guide Rear Creaser Guide

IMPORTANT

The figures of Front and Rear Creaser Guide are similar.

When installing Creaser Guide, please refer to the following figure.

Rear Guide

Front Guide


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2

1

4Trou


When SLITTER JAMis Displayed

If a paper jam has occurred in the machine (rear), SLITTER JAMis displayed on the LCD panel and the

JAM lamp blinks.


Press the key and forward the jammed

document to the paper tray side.




Open the rear cover.

J 4 SLITTER OR STACK

COVER

JAM

F

PAPER

MODE SET

+

Rear cover


1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

Continue Page


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48

Rear cover

Remove the jammed document.

Close the rear cover.




1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


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49

6

2

1

4Trou


When CUTTER LOCKis Displayed

If a paper jam has occurred in the cutter unit, CUTTER LOCKis displayed on the LCD panel and the JAM

lamp blinks.

Remove the jammed document with the following procedure.Check that the paper stock is within specifications.

Press the key and return the jammed

document to the feed tray side.





J 7 CUTTER LOCK

COVER

JAM

F

PAPER

MODE SET

+

Front cover


1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

Continue Page


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50


tweezers.

NOTE :

If you cannot remove the jammed paper with

the tweezers, follow the procedure on page 45 to

remove it.





Front cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP


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51

6

2

1

4Trou


When CREASE LOCKis Displayed

If a paper jam has occurred in the creasing unit, CREASE LOCKis displayed on the LCD panel and the

JAM lamp blinks.

Remove the jammed document with the following procedure.Check that the paper stock is within specifications.

Press the key and forward the jammed

document to the paper tray side.




Open the rear cover.

Rear cover

J 8 CREASE LOCK


COVER

JAM

F

PAPER

MODE SET

+

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP

Continue Page


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52

Remove the jammed document using the tweez-

ers.

NOTE :

If you cannot remove the jammed paper with

the tweezers, follow the procedure on page 45 to

remove it.

Close the rear cover.



Rear cover

1

4

7

C

2

5

8

0

3

6

9

POWER START

STOP



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1

5ManualProgramming-DC545HCEX

Before programming a job carefully measure,

in millimeters, the required slits, cuts and

creases. See the Figure 1 for reference andFigure 2 for a detailed description of each

function.

Record the values in Customer Programed

Jobs. 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 are

for the margins and the remaining three

slitters are for the center of the sheet.

There is a guillotine cutter that performs cuts

perpendicular 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 Programming - DC545 HCEXThis 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. (aP.45, Factory Preset Jobs)

Chapter5

Prior to Programming a Job

P01? (0180)OK?>SET

Program

Number

Figure 2

Figure 1


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54

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)


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55

1


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.



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56

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 the

following message appears on LCD display:

E 6 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 not

exceed 17

Example 1 - When AUTO CUT must be OFF

Example 2 - When AUTO CUT must be OFF


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57

1


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, otherwise

the pieces will drop between the transport rollers. This is because the center slitters must be able to move across the

paper 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 than

the maximum of 4 available.

Workaround solution - arrange 12 to view on A3 or ledger, place the register mark in two positions, 210 mm apart. Print

on 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 the

guillotine cut.


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58

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 two

adjacent 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 margin

slitters 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 the

reference edge.


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59

1


Also consider that the unprintable margin of a digital press is typically 3 to 5 mm from the edge of the sheet, so the edge

of 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 the

image 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 from

the 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 Pieces

Depending on the job layout it is possible to have skewed output when small pieces are processed. In part, this problem

is due to the design of the rubber feed rollers. Each roller has cutouts that reduce the gripping and drive area for the

paper. 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 cutting

positions in order to better balance the paper as it travels through the slitters.


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60

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

1.0 225.4

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


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61

1


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 CARDTrading8up 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

NOTES

THESE VALUES ARE CURRENT AS OF OCTOBER 2002

ALL DIMENSIONS ARE IN MILLIMETERS

8.5 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

U.S.


63/90

62

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 10

1up 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

NOTES





Factory Preset Jobs


64/90

63

1


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

NOTES





*Be sure to turn off AUTO CUT.

Tri-Cut Fourths

Factory Preset Jobs


65/90

62

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

Business

Card 16

A4 SEF

Postcard

2 A4

DVD

Cover on

A4

CD Inlay

on A4

PROGRAM

NUMBER

Europe

24 26 27 28 29 30 32 33

70

10

64

202

62

204

62

204

26

131

141

151

256

297

70

10

7

203

56

154

105

20

110

200

290

297

70

10

25

275

125

175

75

225

22

112

202

210

70

10

10

202

80

130

60

152

20

105

111

196

202

287

297

70

10

20

203

97

205

18

126

30

132

140

242

297

70

10

17

203

15

205

15

205

18

288

146

160

297

70

10

82

202

80

204

80

204

33

273

153

297

70

10

13

203

113

103

18

285

103

188

273

297

Business

Card 10

A4 LEF

Visitorbadges 4A4

Businesscards full

bleed x9

A4 SEF

Point of Sale

Promotion

piece x2 A4

Factory Preset Jobs

63-2


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63

1

5ManualProgramming-

DC545HCEX

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

Christmas

cards 4

A3

Business

cards 20

A3

Foldedbusiness

cards 20

A3

PROGRAM

NUMBER 36 37 39 40 41 42 43

70

10

12

278

10

152

138

280

22

208

214

400

115

307

420

89

13

16

256

136

14

258

53

223

234

404

420

89

13

19

219

119

221

17

221

121

261

401

420

70

10

25

275

125

175

75

225

25

115

205

295

385

420

70

10

25

275

125

175

75

225

25

205

385

115

295

420

70

10

30

210

95

145

80

160

22

112

120

210

218

308

320

70

10

10

307

8

309

8

309

20

440

230

450

Paint label

4 A3

Paint label

instructions

2 A3

Full bleedbusiness cards9 SRA3(after cut to320220)

A3

Brochure

on SRA3

Factory Preset Jobs

63-3


67/90

64

Turn on the machine.

Repeatedly push the key until the

display indicates [INPUT].

Push and hold the key until the display

appears 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 key.

Perform this step if there is a reg. mark, other-

wise press the key until LEFT SL is

displayed then proceed to step 14. Place a

PREPRINTED (with a reg. mark) sample sheet

in the feed tray.

PREPRINTEDSAMPLE

[INPUT] INPUT>SET

P01? (0180) OK?>SET

P52? (0180) OK?>SET

How to Manually Program a Job


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65

1


When the key is pressed, paper starts

being fed and the number displayed on the

lower right side of the LCD panel begins chang-

ing. (The number normally changes from 500through 40, depending on the position of the

reg. mark.) Use the key and the key to

move the position of the paper (Reg. mark

position); adjust the numerical value on the

bottom right side of the LCD panel so that it is

between 40 and 200. (Adjust the numerical

value 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 this

example the value is 52.

Press the key.

Remove the sample paper by pressing the

key.

Measure the distance (in millimeters) between

the leading edge of the paper and the horizontal

portion of the reg. mark. The value must be

between 5 and 40 millimeters.

MARK1 (40200)052 047

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

MARK1 (40200)

000 047

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

8.2mm


Continue Page


69/90

66


Enter the value from step 11 using the ten key

keypad.

Press the key.

Enter the distance from the left side of the

paper to the position for the left margin slit(LEFT SL) location. This value must be be-

tween 0 and 120 millimeters.

Press the key.


paper to the position for the right margin slit

(RGHT SL) location. This value must be be-

tween 200 and 320 millimeters.

Press the key.


paper to the position for the center left slit (C.L.

SL) location. This value must be between 0 and

160.0 millimeters.

LEFT SL (0120) 000.0mm

RIGHTSL(200320) 000.0mm

C.L.SL (0160.0) 000.0mm

MARK2 (540) 08.2mm


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67

1


Press the key.


paper to the position for the center right slit

(C.R. SL) location. You can enter values from

the value entered for C.L.SL plus 50 mm.

Press the key.


paper to the position for the center (OP1 SL)

slit location. This value must be between 0 and

320.0 millimeters. (When OP2 SL is not at-

tached)

Press the key.


paper to the position for the Optional 2 SL

(OP2 SL) location. You can enter values from

the value entered for OP1 SL plus 50 mm. (Not

displayed when OP2 SL is not attached.)

NOTE :

The OP2 SL is standard equipment for the DC-545 HCEX only.


C.R.SL (320) 000.0mm

OP1 SL (0320.0) 000.0mm

OP2 SL (320) 000.0mm

Continue Page


71/90

68


Press the key.

Enter the distance from the leading edge of the

paper to the position for the first cut (CUT 1)

location. This value must be between 0 and 650

millimeters.

Press the key.


paper to the position for the second cut (CUT 2)

location. This value must be between 0 and 650

millimeters. If a second cut is not required,

enter a value of zero. Turn off the automatic

cutting setting when not using CUT2. The

machine normally does not operate.

Press the key.


paper to the first score (SCR.1). It is possible to

enter numerical values from 0 to 650 mm. If a

score is not needed enter 0.

CUT1 (0650.0) 000.0mm

CUT2 (0650.0) 000.0mm

SCR.1 (0650.0)

000.0mm


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1



Press the key.

Enter the total length (in millimeters) of the

sample paper.

Press the key.

Press the key to retain the settings or

key to discard the settings. The display will

indicate Memory Please Waitwhile the infor-

mation is written to the Docu Cutter memory

circuit. The memorization process will take

approximately 10 seconds.

TOTAL LENGTH? 000.0mm

OVERWRITE?OKSET NOC

MEMORY!! Please Wait


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Appendix - DC545 HC/DC545 HCEX

This chapter lists the specifications and an index.

Specifications

Product name / Model No. DC-545 with HC AUTO FEEDER

Input paper size Desktop model

Paper size Min.:8.5" x 11" / A4

Max.:12.6" x 18" / A3

Input paper weight Min.:110gsm

Max.:230gsm

Finishing size Min.:2"(Width) x 3.5"(Length)

Lead edge trim Min.:0.125"(3.2mm)

Trail Edge Trim Min.:0.125"(3.2mm)

Side edge trim Min.:0.125'(3.2mm)Max.:4.5"(114mm)

Speed Max : 9ppm (A4 lengthwise. 4-side trim. 1 score)

Trim/Score tolerance +/- 0.03"(+/- 0.762mm)


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dix-DC545HC/DC545HCEX

Specifications

Paper WeightThe DC-545 was designed to process paper from 110 gsm up to 230 gsm (grams per square meter). 110 gsm is roughly

28 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 path

does 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 tray

3. Turn the paper over (reprogramming the job may be necessary)

4. Use different paper stock

Product name / Model No. DC-545 with HCEX AUTO FEEDER

Input paper size Desktop model

Paper size Min.:8.5" x 11" / A4

Max.:12.6" x 18" / A3

Input paper weight Min.:110gsm

Max.:230gsm

Finishing size Min.:2"(Width) x 3.5"(Length)

Lead edge trim Min.:0.125"(3.2mm)

Trail Edge Trim Min.:0.125"(3.2mm)

Side edge trim Min.:0.125'(3.2mm)

Max.:4.5"(114mm)

Speed Max : 9ppm (A4 lengthwise. 4-side trim. 1 score)

Trim/Score tolerance +/- 0.03"(+/- 0.762mm)


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Specifications of Reg. Mark and Bar Code

1.Reg. Mark Details (Vertical/Horizontal)

Length: 5mm or moreWidth: 0.4mm or more

2.Bar code

Bar code : CODE-39

Start/stop code : Required

Check digit : Optional

Minimum resolving power : 0.254mm

Fine line : Thick line : 1:2.5

Bar 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:

qis the start code designator for CODE-39.

wis the 10s digit data of the program number.

(Example: When the program number is 11 , the data is "1".)

eis the 1s digit data of the program number.

(Example: When the program number is 11 , the data is "1".)

ris the check digit.

tis stop code of CODE-39.

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

00)

1 2 3 4 5

Specifications


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The second program entry is MARK 2. This refers to the horizontal line of the reg. mark and is used as the image

vertical reference point. This mark determines where the image reference is located in respect to the head and foot of the

page.

Specifications

MARK 1

MARK 2

MARK 1 corrects for errors in this

direction

MARK 2 corrects for errors in this

direction


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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 the

internet. Here are two companies which have fonts suitable for use with the DC-545 (there are many companies offering

fonts).

www.azalea.com/code39

Azalea offers a free sample of code 39 and a variety of customizable options that allow printing of bar codes

from Microsoft Windowsor Macintoshplatforms.

http://www.datascan.co.uk

Samples - 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 provider

will supply more detailed information, these guidelines are only intended to illustrate the basics and scope of the

installation 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 the

fonts 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 bold

text. Since this is not the intended, or useful, turn off the auto formatting by following the steps below or use the 'undo

last action' after typing.


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Specifications

Select Options

Delete *Bold* and _underline_with real formatting


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Specifications

Duplo Code 39

Font

selection

window

Font size

selection

window

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. It

may 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 bit

are 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 by

reselecting 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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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 more8mm or

more

*0.4mm or more

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

* a


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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

Note

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


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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 within

ranges such that the mark 1 value is +/- 40 (+/- 6 mm), for mark 1 (left/right) in the registered JOB data, and such that

mark 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 register

mark if it is outside the range where the printer can print.

Specifications

5mm

35mm

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

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


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If the length of this portion is greater than17.0 mm the waste paper will not fall intothe waste tray. Add a dummy cut so thatthe length of the waste paper is less than17.0 mm.Example: If the length of the waste paperis 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 at130, so that the waste paper will fall intothe waste tray.

Area where automaticcutting 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 the

trailing edge of the paper. Automatic cutting is not done in any other positions.

AUTO CUT Conditions

If automatic cutting is turned on and the distance between the leading edge of the paper and the first cut is more than

17.0 mm or the distance between the last cut and the trailing edge of the paper is more than 21.0 mm.


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About the Waste Tray ................................................. 29

Appearance ................................................................. 21

Automatic Cutting Using Bar Codes and

Register Marks ............................................................ 26

Bar code ...................................................................... 26

key ............................................................ 23

Conventions Used in This Manual .............................. 17

Confirming the Packaged Materials ........................... 18

Control Panel ........................................................ 21, 23

COVER lamp .............................................................. 23Customer Programmed Jobs ....................................... 60

Cutting is Not Possible ............................................... 31

Definition of Programming Terms.............................. 54

Error Messages ........................................................... 32

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

Feed guides ........................................................... 13, 26

Feed lamp ............................................................. 13, 26

Feed tray ............................................................... 13, 26

key ...................................................................... 23

Front cover ...................................................... 21, 23, 25

How to Manually Program a Job ................................ 64

How to Set up the System........................................... 19

Instruction Manual...................................................... 18

JAM lamp ............................................................. 23, 39

Key pad ....................................................................... 23

LCD panel ................................................ 23, 24, 25, 27

key ............................................................. 23

Maintenance ............................................................... 10

Part Names and Their Functions ................................ 21

PAPER lamp ............................................................... 23

Paper tray .............................................................. 18, 19

Positioning the Machine ............................................... 9

Power Does Not Turn ON .......................................... 30

POWER lamp ............................................................. 23

Power switch......................................................... 22, 25

Preset number ................................................. 23, 24, 25

Prior to Programming a Job ........................................ 53

Rear cover ....................................................... 21, 22, 23

Reg. Mark ................... 24, 26, 27, 35, 53, 54, 57, 64, 72

key ............................................................ 23, 64

Safety Precautions ........................................................ 5

Screw Driver ............................................................... 18

Specifications.............................................................. 70

Specifications of Reg. Mark and Bar code ................... 72

Specifications of the Machine .................................... 70

key ............................................................. 23

START lamp ............................................................... 23

Status .......................................................................... 24

key ................................................... 23, 41, 47

Troubleshooting Flow Chart ....................................... 30

Turning OFF the Power .............................................. 25

Turning ON the Power ................................................ 25

Turning Power ON/OFF ............................................. 25

Tweezers ............................................................... 18, 39

Warning Sticker ............................................................ 8

Waste tray ....................................................... 21, 27, 29

Waste tray cover ................................................... 21, 29

When a Paper Jam Has Occurred ............................... 39

When CENTER JAMis Displayed ......................... 43

When CREASE LOCKis Displayed ...................... 51

When CUTTER LOCKis Displayed ...................... 49

When FEED JAMis Displayed .............................. 41

When REJECT PAPERis Displayed ...................... 39

When SLITTER JAMis Displayed ........................ 47

key....................................................................... 23

key........................................................................ 23

A

C

F

H

I

J

K

L

M

P

R

S

T

W

Other

B

Index

D

E


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