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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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Notes on Safety (Please Read and Observe)
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 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.
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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Notes on Safety (Please Read and Observe)
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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Notes on Safety (Please Read and Observe)
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.
Notes on Safety (Please Read and Observe)
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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.
Notes on Safety (Please Read and Observe)
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Notes on Safety (Please Read and Observe)
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
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
Part Names and Their Functions
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11OperatingInstractio
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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.
b. The machine feeds multiple sheets at once.
(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
Part Names and Their Functions
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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.
b. The machine feeds multiple sheets at once.
(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
Part Names and Their Functions
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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
Part Names and Their Functions
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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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1BeforeUsingThisMachine-DC545
HCEX
2
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, 18
18
18
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.
Part Names and Their Functions
23, 25
10,11
17
o!0
i
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1BeforeUsingThisMachine-DC545
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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)
Part Names and Their Functions
Referencepage
16, 23,
25
25
25
23, 27
25
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
+
1
4
7
C
2
5
8
0
3
6
9
!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.
15, 48
19
18
Part Names and Their Functions
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 Using Bar Codes and Register Marks
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.
Automatic Cutting Using Bar Codes and Register Marks
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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4Trou
bleshooting-DC545HCEX
J 3 CENTER JAM
Cause
Paper does not meet specifications
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
Paper does not meet specifications
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
Paper does not meet specifications
Cutter motor is defective
Cutter position switch is defective
Main PWB unit 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
Paper does not meet specifications
Creaser motor is defective
Creaser sensor is defective
Main PWB unit 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
Main PWB unit 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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4Trou
bleshooting-DC545HCEX
E 2 RS232C ERROR
Cause
CCD is defective
Main PWB unit 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
Main PWB unit 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
Main PWB unit 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
Main PWB unit 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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6
2
1
4Trou
bleshooting-DC545HCEX
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
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6
2
1
4Trou
bleshooting-DC545HCEX
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
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Front cover
Rear cover
Remove the jammed document using the
tweezers.
Close the front or rear cover.
When a Paper Jam Has Occurred
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6
2
1
4Trou
bleshooting-DC545HCEX
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.
If the document cannot be removed with the procedure mentioned above
Open the front cover.
When a Paper Jam Has Occurred
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
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Remove the jammed document.
Close the front cover.
Press the key to reset the fault logic
and clear the fault message.
When a Paper Jam Has Occurred
Front cover
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
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6
2
1
4Trou
bleshooting-DC545HCEX
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.
Remove the jammed document with the following procedure.
Press the key and return the jammed
document to the feed tray side.
Press the key to reset the fault logic
and clear the fault message.
If the document cannot be removed with the procedure mentioned above
Open the front cover.
J 3 CENTER JAM
COVER
JAM
F
PAPER
MODE SET
+
Front cover
When a Paper Jam Has Occurred
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
Continue Page
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Remove the jammed document using the
tweezers.
Close the front cover.
Press the key to reset the fault logic
and clear the fault message.
When a Paper Jam Has Occurred
Front cover
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
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6
2
1
4Trou
bleshooting-DC545HCEX
When a Paper Jam Has Occurred
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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When a Paper Jam Has Occurred
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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6
2
1
4Trou
bleshooting-DC545HCEX
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.
Remove the jammed document with the following procedure.
Press the key and forward the jammed
document to the paper tray side.
Press the key to reset the fault logic
and clear the fault message.
If the document cannot be removed with the procedure mentioned above
Open the rear cover.
J 4 SLITTER OR STACK
COVER
JAM
F
PAPER
MODE SET
+
Rear cover
When a Paper Jam Has Occurred
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
Continue Page
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Rear cover
Remove the jammed document.
Close the rear cover.
Press the key to reset the fault logic
and clear the fault message.
When a Paper Jam Has Occurred
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
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6
2
1
4Trou
bleshooting-DC545HCEX
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.
Press the key to reset the fault logic
and clear the fault message.
If the document cannot be removed with the procedure mentioned above
Open the front cover.
J 7 CUTTER LOCK
COVER
JAM
F
PAPER
MODE SET
+
Front cover
When a Paper Jam Has Occurred
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
Continue Page
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Remove the jammed document using the
tweezers.
NOTE :
If you cannot remove the jammed paper with
the tweezers, follow the procedure on page 45 to
remove it.
Close the front cover.
Press the key to reset the fault logic
and clear the fault message.
When a Paper Jam Has Occurred
Front cover
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
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6
2
1
4Trou
bleshooting-DC545HCEX
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.
Press the key to reset the fault logic
and clear the fault message.
If the document cannot be removed with the procedure mentioned above
Open the rear cover.
Rear cover
J 8 CREASE LOCK
When a Paper Jam Has Occurred
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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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.
Press the key to reset the fault logic
and clear the fault message.
Rear cover
1
4
7
C
2
5
8
0
3
6
9
POWER START
STOP
When a Paper Jam Has Occurred
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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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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.
PAPER FEEDING DIRECTION
PAPER FEEDING DIRECTION
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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1
5ManualProgramming-DC545HCEX
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.
Definition of Programming Terms
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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.
Definition of Programming Terms
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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1
5ManualProgramming-DC545HCEX
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.
Definition of Programming Terms
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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Print, cut in half, process as if A4 or letter size
Definition of Programming Terms
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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1
5ManualProgramming-DC545HCEX
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.
Definition of Programming Terms
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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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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1
5ManualProgramming-DC545HCEX
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.
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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
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
Factory Preset Jobs
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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
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
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.
Tri-Cut Fourths
Factory Preset Jobs
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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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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
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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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5ManualProgramming-DC545HCEX
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
How to Manually Program a Job
Continue Page
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How to Manually Program a Job
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.
Enter the distance from the left side of the
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.
Enter the distance from the left side of the
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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5ManualProgramming-DC545HCEX
Press the key.
Enter the distance from the left side of the
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.
Enter the distance from the left side of the
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.
Enter the distance from the left side of the
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.
How to Manually Program a Job
C.R.SL (320) 000.0mm
OP1 SL (0320.0) 000.0mm
OP2 SL (320) 000.0mm
Continue Page
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How to Manually Program a Job
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.
Enter the distance from the leading edge of the
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.
Enter the distance from the leading edge of the
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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5ManualProgramming-DC545HCEX
How to Manually Program a Job
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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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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1
Appen
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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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