Dors 500 User manual

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE)
ÓÑÒÐÎÉÑÒÂÎ ÄËß ÓÏÀÊÎÂÊÈ ÄÅÍÅÆÍÛÕ ÁÀÍÊÍÎÒ È ÖÅÍÍÛÕ ÁÓÌÀÃ
(ËÅÍÒÎ×ÍÛÉ ÓÏÀÊÎÂÙÈÊ)
USER MANUAL
ÐÓÊÎÂÎÄÑÒÂÎ ÏÎ ÝÊÑÏËÓÀÒÀÖÈÈ
User Manual
Version 2.0
© DORS LLC 2013
www.dors.com
ТОВ «ДОРС Україна»
04071, м. Київ, вул. Петрівська, 19
www.dors.ua
ЖШС «ДОРС Казахстан»
050000, Алматы қаласы, Қайырбеков қөшесі, 17
www.dors.kz
© OOO «ДОРС», 2013
ООО «ДОРС»
111141, Россия, Москва, ул. 1-я Владимирская, 26A
www.dors.ru
Россия, 197342, г. Санкт-Петербург, ул. Торжковская, 5,
Бизнес – центр «Оптима», офис 34.
ООО «ДОРС СПб»
Дата изготовления:
UA KZ
Дата виготовлення: Дайындалған күні:
Production date:
RUS ENG
ЕВКМ.00D500.00.00.000UM Ru-IntBlack

DEVICE FUNCTION................................................................... 4
SPECIFICATIONS...................................................................... 5
SAFETY PRECAUTIONS........................................................... 6
COMPLETE SET........................................................................ 7
APPEARANCE........................................................................... 8
OPERATION .............................................................................. 11
TECHNICAL MAINTENANCE.................................................... 18
TRANSPORTATION AND STORAGE......................................... 18
TROUBLESHOOTING................................................................ 19
ATTENTION! WHEN CONNECTING THE DEVICE TO THE
ELECTRICAL NETWORK, USE THE OUTLET HAVING A
PROTECTIVE GROUND CONTACT!
ATTENTION! IT IS PROHIBITED TO TOUCH THE
MECHANICAL MOVING PARTS OF THE DEVICE AT ITS
OPERATION!
CAUTION! DEVICE CONTAINS AN OPEN HEATING ELEMENT.
PLEASE ADHERE FIRE SAFETY REQUIREMENTS WHILE
WORKING WITH THE DEVICE
READ THIS MANUAL THOROUGHLY
BEFORE OPERATING THE DEVICE!
MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 3

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 54 MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500
DEVICE FUNCTION
Machine for binding banknotes and securities (banding machine) DORS 500
(henceforth the device) is intended for a binding of packs, note bundles and stacks
of documents with the format up to A4 by one banding stripe with its following heat
sealing.
* Banknote banding is performed with special paper-based heat-sealing tape.
2 2
Enameled paper tape (density not less then 60 g/m ), laminated by polyethylene film (density not less than 25 g/m ).
*
SPECIFICATIONS
Full tape roll size:
outer diameter not exceeding 150 mm
inner diameter (spindle) at least 50 mm
width not exceeding 40 mm
In case of using tape with the diameter less than 35 mm a service
adjustment is required.
A duration of a wrapping cycle 2,7 sec. of a pack
The time period between placing a pack 1,5 sec.
in the binding position and its release does
not exceed
The number of wrappings before 40000
a regular maintenance
Display red 4 digit LED
Power supply 220 V ±10%, 50 Hz
Possible device adjustment change in case of voltage fluctuation.
Consumption current, not more than 1,8 A
Overall dimensions, not more than
without the height of the loop holders 419x240x184 mm
with the height of the loop holders 419x240x314 mm
Operating temperature range +10 °С to +35 °С
Relative humidity of the air at the 40 % to 80 %
temperature of +25 °С
Atmospheric pressure 84 to 107 kPa
(630 to 800 mm Hg)
Precious metal content gold 0,004 g
Net weight, not exceeding 7.5 kg
Gross weight, not exceeding 8.2 kg
In order to improve the device quality, specifications and models
are subject to change without notice.

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 76 MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500
SAFETY PRECAUTIONS COMPLETE SET
1. Avoid getting of any metal object or
liquid into the device.
2. To prevent the electric shock
hazard, do not pull out the power
cord plug when your hands are
wet.
3. When disconnecting the device
from the power outlet, hold the
plug; do not pull the cord as it can
get broken or damaged.
4. To prevent the power cord damage
or any probable short circuit,
disconnect the device from the
power outlet if you want to move
the device to another position.
5. If the device has been exposed to
cold for a long time, keep it at the
room temperature for about two
hours before switching on.
6. The device is the one of a
heightened danger as it has
the parts running hot during its
operation and sharp movable
parts.
7. In case of a hazard situation
threatening with a probability to get
inju r ed , i t i s nec e ssa r y t o
disconnect the device either with
the help of the power switch or by
opening the front cover (opening of
front cover leads to switching off
the heater and movable parts of
the device).
8. Before the work start, the power
cord and the power cord plug shall
be inspected carefully. The power
cord has to be replaced in case of
any damage.
9. The following instructions should
be followed to ensure a long
successful operation of the device
without any interference of a
service engineer:
a. Do not use the device in direct
sunlight or strong electric light.
b. The device shall be installed on
an even horizontal surface.
c. Do not use the device in dusty
environment. This can impair
device operation.
d. To prevent fire or short circuit,
avoid the device installation in
such places where it may be
subjected to the impact of soot
or steam.
The packaging contains:
Machine for binding banknotes and securities
(banding machine) DORS 500................................................................... 1 pc.
Loop holders.............................................................................................. 2 pcs.
Backstop.................................................................................................... 1 pc.
Back stop screw......................................................................................... 1 pc.
Power cord................................................................................................. 1 pc.
Fuse (10A)................................................................................................. 3 pcs.
A brush for cleaning the device................................................................. 1 pc.
Operation manual...................................................................................... 1 pc.
Package.................................................................................................... 1 set

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 98 MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500
26
19
2321
22
25
20
24
1. Control panel.
2. Four digit LED display.
3. Device ready indicator.
4. Table.
5. Note sensor No. 1.
6. Loop holders.
7. Backstop.
8. Side stop.
9. Back stop screw.
10. Side stop screw.
11. Rotary grip (shank).
12. Loop availability sensor.
13. Note sensor No. 2.
14. Front cover.
15. Power connector.
16. Power switch.
17. Fuse.
18. Connector for additional
devices.
19. Tape start sensor(IR transistor
unit, receiver).
20. Tape start sensor(IR diode unit,
backlight).
21. Heating element position
sensor.
22. Heating element guide bearing.
23. Heating element guide bearing.
24. Tape drive engine.
25. Shank drive engine.
26. Loop damper.
APPEARANCE
The packaging contains:
Machine for binding banknotes and securities
(banding machine) DORS 500................................................................... 1 pcs.
Loop holders.............................................................................................. 2 pcs.
Backstop.................................................................................................... 1 pcs.
Back stop screw......................................................................................... 1 pcs.
Power cord................................................................................................. 1 pcs.
Fuse (10A)................................................................................................. 3 pcs.
A brush for cleaning the device................................................................. 1 pcs.
Operation manual...................................................................................... 1 pcs.
Package.................................................................................................... 1 set

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 11
10 MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500
1. Button "-" ("DOWN")
2. Button "SELECT"
3. Button "+" ("UP")
4. Four digit display
5. Button "AUTO"
6. Button "START"
7. Device ready indicator
1. Install the loop holders 6 (Fig. 1)
into the corresponding cutouts in
table 4 (Fig. 1).
2. Install backstop 7 (Fig. 1) into the
corresponding cutout in the table 4
(Fig.1), secure the backstop with
screw 9 as fitting the batch size.
Loosen side stop screw 8 (Fig. 1),
adjust the side stop appropriately
to achieve the required loop
tightening strength (see Fig. 5), fix
the side stop by the screw;
FUNCTIONAL PURPOSE OF THE CONTROL PANEL KEYS DEPENDS ON
THE DEVICE OPERATION MODE.
The table of Latin symbols appearing on 4 digit display
OPERATION
APPEARANCE
The side guide position:
retention strength higher
retention strength lower
Fig. 5
3. Install the binding tape. In order to
do it:
a. make a pull movement to open
front cover 14 (Fig. 1);
b. remove the roll cover 7 (Fig. 7);
c. open path 5 (Fig. 6, 8)
relocating down the lifter of roller
3 (Fig. 6, 8);
d. cut a jammed or uneven tape
0
edge across at the 90 C angle.
Install roll 6 (Fig. 7, 8) onto axis
1 (Fig. 6);
e. pass the tape around loop
damper 2 (Fig. 6, 8), here the
tape shall face the damper
with its marked side;
f. place the tape in path
5 (Fig. 6, 8), here the tape edge
should cover the tape start
sensor 4 (Fig. 6, 8);
g. close path 5 (Fig. 6, 8)
relocating up the lifter of roller
3 (Fig. 6,8);
h. fix roll 6 (Fig. 7, 8) with roll cover
7 (Fig. 7);
i. close front cover 14 (Fig. 1).
CLOSE THE FRONT COVER
FROM THE RIGHT SIDE TILL YOU
HEAR SPECIFIC CLICK.
THE REQUIRED POWER LINE
CHARACTERISTICS ARE
INDICATED IN THE
SPECIFICATIONS CHAPTER
4. Use a power cord to connect the
device to the power network.
5. Switch on the device power switch
16 (Fig.12). The readiness time of
device shall not exceed 8 seconds,
the process of self checking is
simultaneous with displaying the
caption with the software version
number. If any of the tests is failed,
there is a diagnostics message
indicating the error type instead of
t h e c a p t i o n ( s e e c h a p t e r
"TROUBLESHOOTING"). In case
of successful completion of self
dіagnostics comes the beep signal
and the device switches to the
"HAND" mode (see "Operating
modes"). If required it is possible

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 13
12 MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500
to switch to the "AUTO" mode,
with automatic start. For this,
please press the button "AUTO"
6. In case there is no loop on the
device, nL X (where "X" is the
number of the setting in agreement
with which the loop will be created)
is displayed after switching the
device on. To create the loop press
button "START". If it is required to
change the device setting before
forming the first loop - press
"SELECT" and customize settings
in accordance with the chapter
"Operating modes".
Note: a loop may be produced
during the operation by pressing
the button "SELECT" and then
button "START".
HIGH ILLUMINATION MAY CAUSE
THE "nL" ("NO LOOP") MESSAGE
TO BE DISPLAYED EVEN WHEN
THE LOOP IS THERE. THIS
HAPPENS AS A RESULT OF THE
SENSOR LIGHT OVEREXPOSURE.
IN THIS CASE, PRESS "SELECT"
TO SWITCH TO THE OPERATE
MODE
7. Place a bundle (stack, pack) on
the table surface, pressing it to the
back and side stops.
A PACK (A BUNDLE, A STACK)
SHALL BE LEVELED IN A STRICT
ACCORDANCE TO THE STOPS;
THIS DETERMINES THE QUALITY
OF PACKING.
8. In case the "AUTO" mode has
been selected, the process of
wrapping will start after covering
of note sensors No. 1 and No. 2
(see fig. 1). To start wrapping in the
"HAND" mode, press the button
"S TA R T" . In the co u rs e of
wrapping the ready indicator isn't
alight, there is displayed "РАС"
(packing) on the display of the
control panel.
Note: The device may operate in
the binding mode at covering only
one note sensor (adjustments are
made from service menu). This
allows binding the pack next to one
of the edges.
9. As soon as wrapping is completed,
a sound signal is heard and there
flashes "rd" (ready) on the display
of the control panel. Make a
pull movement to take off the pack
(the bundle, the stack) from the
table.
WHEN TAKING OFF THE
WRAPPED OBJECTS OF A
MAXIMUM SIZE, FOR EXAMPLE,
A STACK OF A4 SHEETS,
HOLD SLIGHTLY THE LOOP ON
THE OBJECT WITH TWO HANDS.
10. As soon as note sensor No. 2
(fig. 1) opens, the new loop shall
be produced and it will be possible
to wrap a new pack (a bundle, a
stack). The process of a new loop
creation being over, the readiness
indicator 7 (fig. 4) lights
continuously.
11. The work being completed, switch
off the device power switch.

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 15
14 MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500
12. In case the tape roll change is
required till the tape is over, or in
case of tape jam, or in case there is
an unused thermal tape left in the
feed path, please, do the following:
switch off the device 16 (Fig. 2),
open the front cover 14 (Fig.1).
Open the paper feed track, press
the lifter of roller down till the stop 3
(Fig. 6, 8). Pull smoothly, draw the
loop end from the grip 11 (Fig.1)
and at the same time from the feed
track 5 (Fig. 6, 8). Remove the
cover of the roll 7 (Fig. 7). Wind the
roll manually clockwise, wind the
thermal tape end and take out the
roll.
Afterwards you can set the new
roll.
Operation modes
There are three main operating
modes:
1. Mode "HAND" is set just after
switching on the device (in the
presence of the loop) or after
pressing the button "AUTO" (if the
device was in the "AUTO" mode).
In this case, the left display digit will
show "H" symbol.
In this mode, to start wrapping at
the correctly placed pack (bundle,
stack), press the "START" button.
2. To switch to the "AUTO", press the
"AUTO" button. Here the left
display digit will show "A" symbol.
In this mode, wrapping starts
automatically at the pack placed
correctly (bundle, stack).
When wrapping the packs (bundles
stacks) of different sizes, there
may be selected one of 3 presets of
the device in the "HAND" and
"AUTO" modes:
Setting 1 wrapping of the single
narrow packs.
Setting 2 wrapping of bundles
(10 packs).
Setting 3 wrapping of maximum size
objects, not exceeding A4 size (here
the left loop holder shall be set in the
left end position).
Settings 4 to 8 the user's settings, it is
possible to change parameters there.
WHEN MODIFYING THE TAPE
(ROLL) TYPE, SELECT
APPROPRIATE BINDING MODE TO
CONSIDER THE TAPE PHYSICAL
STATE (HUMIDITY, ADHESION,
DENSITY, ETC.)
The right display digit shows the
setting number (for example, "H1" a
manual mode, setting No. 1; "A2" an
automatic mode, setting No. 2). To
change the number of the setting used
at wrapping in a manual or automatic
mode, use buttons "-"/"+" The preset
parameters are stated in the table 1
(see table 2 for the description of the
parameters).
3. Pressing the "SELECT" button
calls the "SET" mode and affords
to change some parameters of
the device operation (table 2).
In the preset settings (1 to 3) the "L"
and "S" parameters cannot be
changed, the "F", "t", "r" and "Snd"
parameters can be changed only at the
specified range. All the parameters in
the user menu can be changed. The
parameter changed (4 to 8) is
displayed on the indicator by blinking.
To change (review) the parameters
values, perform the following actions:
1. Press the "SELECT" button in the
"Hand” or "Auto” modes. The
device switches to the "SET"
mode.
2. Press the "SELECT" button to
choose the parameter for setting
or reviewing.
3. Use the buttons "+" / "-" to select
the required parameter value.
4. To change the other parameter,
repeat the step 2; to exit from the
"SET" mode, press the "AUTO"
button.
Parameters change come into
effect after exit from the "SET"
mode.
Adjustment of the welding seal
overlap size
In the "AUTO" mode, press
"START" + "START" + "SELECT"
simultaneously to switch to the
adjustment of the loop size under the
claw defining the welding seal overlap
size (see fig. 9). The indicator displays
"LXXX" where XXX is the installed
tape size. The factory setting is 387.
You may change this value by pressing
the "+"/"-" buttons.
Change of the setting parameters
Figure 9 Mode of fine tuning of the
tape size under the shank
The lower value is resulted in a
narrow welding seal, however,
exceeding a certain size may cause
the glue stripe irregularities.
Recommendations on the
configuration setting values:
1. Tightening force F should be
chosen depending on the bundled
object with respect to the quality of the
tape used. High tension values may
cause tape coated layer scraping.
Loosen the tension to eliminate this
effect.
2. The "t" and "r" parameter values
should be selected with consideration
for the following:
– welding temperature "t" should
provide for the quality glue stripe
whilst avoiding the paper turning
yellow in the glue stripe area.
A proper heating shall cause the
glue layer to "melt" in the gluing
area on both layers of the tape;

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 17
16 MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500
1
2
3
35
50
80
15
20
50
8
8
8
5
6
6
6
7
7
L S F** t** r**
Table 1 Values of the parameters of the presets*
Setting
Parameter
* They may differ depending on the version.
** The parameters specified are factory reset.
• Bundle retention time "r" shall
provide for an acceptable binding cycle
whilst allowing the glue layer to cool
down completely. A lack of gluing
through the end of a binding cycle may
cause the seam to part whilst making
visible the glue layer shift marks on the
tape surface.
THE CONFIGURATION SETTINGS STORED THROUGH THE PREVIOUS
SHUTDOWN SHALL BE ENABLED AT THE UNIT STARTUP.
THE UNIT, HOWEVER, WILL START IN THE "HAND" MODE AS A
CONSIDERATION OF SAFETY PERFORMANCE.
L XX
S XX
FXX
t XX
r XX
_ or O
Allows setting of the required loop size (full) at
the range of 20...90
Parameter Description
Table 2 Parameters of the "SET" modes
DISPLAY
REAdING*
Allows setting of the required loop (final) at
the range 10...89, not exceeding the preset
size of the loop "L"
Allows setting of the required tightening force
of the pack at the range 2...15
Allows setting of the required welding
temperature at the range of 3...8
Allows setting of the required retention time of
the pack at the range of 3...15
Allows to switch on and switch off the sound
indication of the beginning and the end of
binding process.
* XX numeric value.
Loop size "L"
Loop size "S"
Tightening force of
pack "F"
Welding
temperature "t"
Time of the pack
retention for
reliable welding "r"
Sound indication
"Snd"
Table 3 Functionality of the buttons in different operating modes
Mode Button
HAND
AUTO
SET
"+" ("UP") "SELECT" "–" ("DOWN") "AUTO" "START"
Next
configuration
setting number
Next
configuration
setting number
Increase
of the parameter
value
Switching
to the "SET"
mode
Switching
to the "SET"
mode
Selection
of the next
parameter
Previous
configuration
setting number
Previous
configuration
setting number
Decrease
of the parameter
value
Switching
to the "AUTO"
mode
Switching
to the "HAND"
mode
Exit from the
"SET" mode to
the "AUTO"/
"HAND"
Start
of wrapping

MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500 1918 MACHINE FOR BINDING BANKNOTES AND SECURITIES (BANDING MACHINE) DORS 500
1. DISPLAY INDICATES: blinks in
the "HAND" or "AUTO" mode.
DESCRIPTION:
the tape in the roll is low.
ACTIONS:
prepare a new roll for
replacement when the current
one is used up.
POSSIBLE MESSAGES APPEARING IN THE COURSE OF OPERATION
cover the note
sensors 5, 13 (fig. 1).
ACTIONS:
To create the loop
(see the Operation chapter).
3. "PE”DISPLAY INDICATES:
DESCRIPTION:
paper feed path error.
ACTIONS:
charge the tape again (see
section "Operation chapter").
4. DISPLAY INDICATES: "- - - -"
(scrolling display "–").
DESCRIPTION:
the front cover 14 is open (fig. 1)
ACTIONS:
close the front cover.
THE DEVICE NEEDS SERVICE
MAINTENANCE IF "SRC”
FLASHES FOR 4 SECONDS ON
THE DISPLEY AFTER SWITCHING
THE DEVICE ON.
2. DISPLAY INDICATES: "NL X"
(where X is the configuration
setting number).
DESCRIPTION:
no loop or the object does not
TECHNICAL MAINTENANCE
Due to operation of the device it is
obligatory to clear the tape moving
path and the sensors out of dust and
paper debris after every 16 work hours
with the help of the brush (included into
the delivery set), and every 80 hours
to clear up the subassemblies, which
are available during the opened cover,
with the help of vacuum cleaner. The
heating element assembly is a
disposable part, which is subject to
natural wear depending on the
operation conditions. The heating
element is not covered by the
manufacturer's warranty. For longer
TRANSPORTATION AND STORAGE
The device shall be stored in the
manufacturer's package in a heated
and ventilated storage room at the
temperature of +5 °С to +40 °С with a
relative humidity not exceeding 80 %
at the temperature + 25 °С.
The device shall be transported in
the manufacturer's package by car or
railway (in a covered vehicles), by air in
the pressurized modules at the
temperature of -30 °С to +50 °С and
the relative air humidity to 98 % at the
temperature + 25 °С, non condensing,
atmospheric pressure between 84 and
106,7 kPa (630 to 800 mm Hg).
TROUBLESHOOTING
During initialization of the device
the following messages can appear on
the display:
1. DISPLAY INDICATES:
after the device switching on,
there is no indication on the
display.
ACTIONS:
test the power cord. Switch on
again. If there are no changes,
contact the service cen ter.
2. DISPLAY INDICATES:
"- - - -".
FAULT: the front cover is open.
ACTIONS:
close the front cover. If there
are no changes, contact the
service center.
3. DISPLAY INDICATES: "SF".
FAULT: note sensors are
dirty or covered by a foreign
object.
ACTIONS:
clean the note sensors,
remove the foreign object from
the device table. If there are no
changes, contact the service
center.
4. DISPLAY INDICATES: "utF".
FAULT: the tape drive unit is
faulty.
ACTIONS:
contact the service center.
5. DISPLAY INDICATES: "HE".
FAULT: heater drive unit is faulty.
ACTIONS:
Switch off power supply. Open
the front cover of the device, remove
the foreign objects from the heating
element position sensor and from slot
of heater knife; switch on the device.
If there are no changes, contact the
service center.
6. "CuF".DISPLAY INDICATES:
FAULT: the rotary grip drive unit is
faulty.
ACTIONS:
contact the service center.
7. DiSPLAY iNDICATES: "nP".
FAULT: there is no tape in the
device path.
ACTIONS:
set the tape roll and charge the
tape in the path according to
chapter "Operation".
8. "ERR7", DISPLAY INDICATES:
"ERR8".
FAULT: faulty heating element
sensor.
ACTIONS:
Switch off the device, open the
front cover. Check the presence of
foreign objects in heating element
position sensor and in heating
assembly. If necessary, remove
the foreign objects, close the front
cover and switch on the device.
In case of repeated error, contact
the service center.
9. "ERR1", DISPLAY INDICATES:
"ERR6".
ACTION:
switch off the device,
wait for at least 30 seconds,
switch on the device. In case of
repeated error please, contact
the service center.
operational life of the heating element,
use quality tapes only.
The unit shall not be operated in a
high dus t or humidity co nte nt
environment, and the heating element
shall be cleaned of dust, paper debris
and glue remnants on a regular basis.
Use only the brush supplied with
this unit.
Service maintenance must be
performed after every 40.000
bindings.
CAUTION! The unit cleaning and
servicing shall be performed only by
the qualified service engineers!
PRIOR TO SENDING UNIT FOR
SERVICING, POWER OFF THE
UNIT, REMOVE THE LOOP (IF
ANY) AND REMOVE THE ROLL.