Duplo DP-S Series User manual

1
Introduction
The cause of most accidents is failure to adhere to basic safety rules and observe
safety instructions. It is important to prevent potential causes of accidents from
occurring. In order to do so, read this manual carefully, and be sure to understand
all the safety instructions and correct inspection and servicing procedures that it
provides before beginning repair or servicing work.
Repairing or servicing the machine with insufficient knowledge about it could
lead to unforeseen accidents.
It is not possible to anticipate and describe in a manual such as this every possi-
ble hazard that could arise in the course of repair and servicing. Therefore, besides
observing the safety instructions marked in this manual and on the machine's
labels, service personnel should be safety-conscious and take other safety precau-
tions as necessary. When performing repair or service work not covered by this man-
ual, you should obtain safety guidance from an appropriately knowledgeable person.
Copyright 2007
DUPLO SEIKO CORPORATION
All Rights Reserved

2
'Safety-related instructions
'Service work-related instructions
If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury is likely to
result.
If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury, or else material
damage, is likely to result.
WARNING:
CAUTION:
Examples of pictorial symbols
A " " symbol tells you that a certain action is forbidden. Precisely what
is forbidden is indicated by a picture inside the symbol (in the example
here, the picture means that disassembly is forbidden), or in writing at the
side of the symbol.
A " " symbol means that a certain action is forbidden and/or that a
specific instruction must be followed. The specific instruction is indicated
by a picture inside the symbol (in the example here, the instruction is
"Remove the power plug from the socket").
IMPORTANT:
NOTE:
Draws attention to important information. If this information is ignored
and the machine is operated or serviced incorrectly, the machine`s
performance could drop, or it could break down.
Draws attention to information that is useful for operation or maintenance
of the machine, and to information about its performance, etc.
DUsing the service manual
• This manual contains the following information: structure and function of major parts,
disassembly and reassembly procedures, specifications, and procedures for adjustment,
maintenance, inspection and corrective action. This information is current as of February
2007, and applies basically to the model DP-S850/S650/S620/S550/S520/S510 DUPRINTER.
From time to time, parts are changed to improve quality, performance or safety. Note therefore
that in some cases, certain parts or machine structure aspects described in the text or
illustrations of this manual may not be precisely the same as the product being serviced.
• Safety instructions marked with a " " (WARNINGS and CAUTIONS) are very important for
safety and must be observed.

3
Safety instructions
Safety instructions
Safety instructions
1. Cautions regarding the installation location
Installation environment
s Avoid installing the machine in places exposed to direct sunlight.
• Sunlight will cause the temperature in the machine's interior to rise, possibly leading to
malfunction of the control system.
• Sunlight could cause misoperation of the sensors.
• The heat of direct sunlight could cause deformation of the machine's plastic parts.
* Also avoid installation near to a ground glass window; light and heat penetrate such windows
although they are opaque.
s Avoid installing the machine in places subject to high or low temperature or humidity.
• High or low temperature or humidity could cause the machine to operate abnormally.
Suitable temperature and humidity ranges are:
Ambient temperature: 10y430y
Ambient humidity: 40%470%
Optimum temperature and humidity: 20y, 65%
• If the machine is installed near to faucets, water heaters or humidifiers, or in cool (sunless)
parts of a building or in the vicinity of water sources, the paper could absorb moisture and curl,
leading to misfeeds or poor image quality.
sAvoid installing the machine in places with open flames, or where reflected heat or other hot air
currents (from stoves, etc), or cold air currents from coolers, etc will strike it directly.
sAvoid installing the machine in poorly ventilated places.
sAvoid installing the machine in dusty places.
sThe machine should not be tilting when it is used.
• Install the machine so that it is level.
(The machine should be level to within 5mm in the front-rear direction, and 5mm in the lateral
direction.)
sDo not install the machine on shaky, sloping or otherwise unstable surfaces.
• The machine could fall over on such surfaces, or fall off them, causing injury.

4
Safety instructions
Warning
• The machine's power supply voltage and power consumption depend on the model. Details of this
are given in the tables below. The power supply voltage and power consumption for the machine
are given in the table below. The machine's power supply voltage is indicated on the identification
plate located on the machine's left side; the machine must be connected to a power supply of the
voltage indicated.
aOtherwise, fire or electric shock could result.
If the power supply voltage is unstable or if the power supply has insufficient capacity, the
machine may not operate normally.
Make sure that the power supply has sufficient capacity for the system as a whole, including
optional equipment.
• Use only the power cord that is provided among the accessories.
Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.
• Install the machine close to its power supply. The outlet used should be exclusively for the
machine, and have no other equipment connected to it.
If an extension cord is necessary, it should have a ground terminal, and be of the following ratings:
* For a 120V AC model: 130V, at least 15A, length not exceeding 5m.
* For a 230V AC model: 250V, at least 8A, length not exceeding 5m.
• Never tread on the power cord or pinch it between other objects, or accidents could result.
2. Cautions for installation work
• Install the machine in accordance with the installation procedure appended to this manual.
• Lock the casters after the machine is installed.
aOtherwise, the machine could move or fall over, causing injury.
• To move the machine, push it by its mounting base.
aPushing the printing (upper) part of the machine could make it fall over.
CAUTION
Using the optional printer stand
Connect to outlet of 120V AC , 60Hz, at least 15A Connect to outlet of 230V AC , 60Hz, at least 15A
With no load *
At full load
Power supply voltage
No more than 130V AC
Use power supply meeting
these requirements
At least 110V AC
Master making
Printing (Speed 5)
Standing by
Sleeping
150 W
240 W
18 W
8W
145 W
240 W
18 W
8W
140 W
230 W
18 W
8W
135 W
240 W
18 W
8W
130 W
230 W
18 W
8W
130 W
230 W
18 W
8W
Power consumption
DP-S850 DP-S650 DP-S620 DP-S550 DP-S520 DP-S510
No more than 250V AC
Use power supply meeting
these requirements
At least 210V AC
120V AC model 230V AC model
*"With no load" - when the machine is on standby.
*"At full load" - when the machine is running at maximum power consumption.

5
Safety instructions
'Precautions for safe servicing
• Always remove the power cord plug from the outlet before starting work.
aOtherwise, you could get a shock or your hands/fingers could be injured.
• However, the plug must be left connected to the outlet when performing function checks (of
individual motors, a given series of operations, or electrical circuits). When motors are
operated alone in function checks, interlocks are deactivated, so be aware of the conditions and
positions of related equipment, and take great care not to put your hands or fingers into
moving parts.
• The cutter unit contains hazardous sharp blades. Exercise great care when inspecting the cutter
unit or replacing it or its parts.
aOtherwise, your hands/fingers could be injured.
• Do not touch the rotating parts when operating the drum removal button and JOG switch or
while the machine is running.
aOtherwise, your hands/fingers could get caught and crushed between the drum and rollers.
'Working clothes
• Wear clothing that enables you to work safely.
Work clothing (overalls, etc) should be close-fitting.
Warning
'Tools
• Use tools that are appropriate for the work.
CAUTION
3. Cautions for maintenance, inspection and servicing
• The tape clusters have hazardous blades. Exercise care when inspecting or replacing the
blades.
aOtherwise, your hands/fingers could be injured.
If optional tape clusters are used

6
Safety instructions
DLocations of warning labels
The locations of the machine's warning labels are shown below. To ensure safe work, read the
labels and heed their instructions. Keep the labels clean at all times. If they become damaged or
peel off, replace them with new ones.
R8-T1110
NO. Parts No. Name Q'ty
L1-T3060
M7-T3060
R8-T3080
R8-T3010
R8-T3040
L8-T1090
Warning Label
Caution Label
Warning Label
Warning Label
Caution Label
Warning Label
1
1
1
2
1
1
View A
View A
M7-T3060
CAUTION
WARNING
● Do not remove this cover. The inside of the printer contains movable cutting instruments,
contact with which could result in injury.
L8-T1090
WARNING
Use caution when working
near movable parts.
Disconnect power before
servicing.
WARNING
Do NOT touch the drum or rollers
when you operate the jog switch.
Do NOT put hands Inside machine
while it is operatung.
Hands could get caught up or crushed.
CAUTION
Do not touch the roller below.
Your clothes etc. may be stained with ink.
R8-T1070
L1-T3060
WARNING
Do NOT put hands near the
side guides, feed rollers, slot
holes on both side frames or
below the feed tray.
Hands could get caught up
or crushed.
R8-T3080

7
Chapter 8
Chapter 7
Chapter 6
Chapter 5
Chapter 4
Chapter 3
Chapter 2
Chapter 1
HELP Mode
Others
Troubleshooting
Maintenance / Check
Standard / Adjustment
Mechanism
Description of the Operation
Introduction

9
Table of Contents
Chapter 1
zSpecifications ......................................................................12
xDimensions ..........................................................................14
cSystem Setup.......................................................................16
vPart Names and Their Functions........................................17
Chapter 2
z Scanner Section.........................................................26
x Platemaking/Master Feed/Ejection Section.............36
c Paper Feed Section ...................................................56
v Drum Driving Section................................................68
b Press Section.............................................................74
n Paper Ejection Section..............................................79
m Drum Section .............................................................85
Chapter 3
z Exterior .......................................................................98
x Scanner Section.......................................................103
c Platemaking/Master Feed/Ejection Section...........109
v Paper Feed Section..................................................116
b Drum Driving Section..............................................120
n Paper Ejection Section............................................122
m Drum Section ...........................................................127
Chapter 4
z Scanner Section.......................................................136
x Platemaking/Master Feed/Ejection Section...........138
c Paper Feed Section .................................................145
v Drum Driving Section..............................................150
b Press Section...........................................................152
n Paper Ejection Section............................................154
m Drum Section ...........................................................155
, Electrical System.....................................................158
Chapter 6
z Troubleshooting Guide ...........................................172
x Error Display ............................................................189
Chapter 7
Chapter 8
z Electrical Parts Layout and Their Functions.........282
x Overall Wiring Layout..............................................293
z HELP Mode List .......................................................194
x Overview...................................................................198
cHELP Mode Functions and Operation Procedures .......199
• Accessing HELP Modes.......................................199
• HELP Mode Descriptions .....................................200
Introduction.................................................................................1
Using the service manual ..........................................................2
Safety instructions ...............................................................3
1.Cautions regarding the installation location........................3
2.Cautions for installation work...............................................4
3.Cautions for maintenance, inspection and servicing .........5
• Locations of warning labels...................................................6
Troubleshooting
Chapter 5
z Guaranteed Periodical Maintenance......................168
x Cleaning and Oiling.................................................168
c Periodical Maintenance...........................................169
Maintenance / Check
Standards / Adjustment
HELP Mode
Others
Mechanism
Description of the Operation
Introduction

11
zSpecifications...............................................................12
xDimensions...................................................................14
cSystem Setup...............................................................16
vPart Names and Their Functions................................17
1. Machine exteriors....................................................17
2. Sectional (structural) view of the machine ...........20
3. Control Panel ..........................................................22
1
Chapter 1 Introduction

12
zSpecifications
chap.1
zSpecifications
• Specifications
Model
Model name DUPRINTER
Floor stand model
Thermal digital master making
18 sec. (A4, 100%) 18 sec. (A4, 100%)
(Pel path dir.) x (line progression dir.)
100 sheets (64gsm), 85 sheets (20lb)(80gsm)
Stencil print
Sheets, book (max. weight: 10kg)
Max. 297mm x 432mm (with optional ADF: Min. 100mm x 148mm)
290mm x 423mm 290mm x 423mm 250mm x 355mm 290mm x 423mm 250mm x 355mm
11.4" x 16.6"
* A4/Letter drum : 290mm x 207mm ( 11.4" x 8.1" )
11.4" x 16.6" 9.8" x 13.9" 11.4" x 16.6" 9.8" x 13.9"
210mm x 355mm
8.2" x 13.9"
1,500 sheets (64gsm) (1,280 sheets (20lb), 1,200 sheets (80gsm))
Level position / Take back jogger / Ditched side guides
* Height of 1,500 sheets loaded should not exceed 140mm.
Max. : 297mm x 432mm
(Main unit can feed/exit 320mm x 450mm. Stacker tray does not cover paper size larger than 297mm x 432mm.)
Min. : 100mm x 150mm (50mm x 150mm is possible with some limitations including no vertical registration 
adjustment, paper lead sensor off, attaching plastic guide on separator etc.)
Master making method
Master making interval
Resolution
Scan (input)
Print (output)
(Master punch density)
Optional ADF Capacity
64 - 128gsm Optional ADF Document weight
Flat bed scanner (ADF: optional)Scanning method
Printing method
Document type
Document size
293mm x 428mmScanning area
Image area (max.)
Feeding capacity
Stacker tray
1,500 sheets (64gsm) (1,280 sheets (20lb), 1,200 sheets (80gsm))Stacker capacity
Paper size
Paper weight 53gsm - 210gsm (45kg-180kg) 13lb (Bond) - 110b (Index)
Feeding pressure adj. (3 steps) / Separator adj. (15 steps)
45 - 130 ppm 5 steps + TOP speed 150 ppm
TOP speed: 150 ppm for B4/A4/letter/legal paper (not recommended for paper larger than B4)
Print speed
100%Zoom
Preset reduction/enlargement: 70, 81, 86, 115, 122, 141%
Adjust X:Y Proportions 50 - 500%
Margin adjust 90 - 99%
Zoom : 50 - 500%
Auto zoom: 50, 57, 61, 70, 81, 86, 100, 115, 122, 141, (163), 173, (200)%
(Auto zoom: DP-S850/S650/S620 only)
((163%) and (200%) are available on the DP-S850/S650 only.)
100%
Preset reduction/enlargement: 50, 64, 77, 121, 129, 154%
Adjust X:Y Proportions 50 - 500%
Margin adjust 90 - 99%
Zoom : 50 - 500%
Auto zoom: 50, 60, 64, 70, 77, 78, 91, 100, (121), 129, 137, 141, 154, (200), 212, 275%
(Auto zoom: DP-S850/S650/S620 only)
( (121%) and (200%) are available on the DP-S850/S650 only.
Restrictions in top speed:
* When printing on light weight paper, using TOP speed mode may cause stacking failure.
* Registration may be slightly effected.
* TOP speed may cause creasing on some type of paper.
16 sec. (A4R, 100%) 15 sec. (A4, 100%)
DP-S850 DP-S650 DP-S620 DP-S550
20 sec. (A4R, 100%)
DP-S520
20 sec. (A4R, 100%)
600 dpi x 600 dpi 300 dpi x 600 dpi400 dpi x 400 dpi400 dpi x 400 dpi 300 dpi x 600 dpi 300 dpi x 600 dpi
600 dpi x 600 dpi 300 dpi x 600 dpi400 dpi x 400 dpi400 dpi x 400 dpi 300 dpi x 600 dpi 300 dpi x 600 dpi
600 dpi x 600 dpi*600 dpi x 600 dpi400 dpi x 400 dpi400 dpi x 400 dpi 600 dpi x 600 dpi 600 dpi x 600 dpi
*The master punch density = number of holes made on one master.
DP-S510
A/B size spec
Inch size spec
Specifications are subject to change without prior notice.

zSpecifications
chap.1
13
Ink supply method
Model name DUPRINTER
Automatic control (1000ml) Color ink is also 1000ml
By replacing drum unit
Roll master automatic feed (220 masters / roll)
Automatic ejection / roll-up method (used master capacity: 55 masters)
320 x 240 full-dot matrix LCD (with contrast control)
English / French / German / Spanish / Italian / Russian / Japanese / Chinese (simplified) /
Color separation (equipped in online printer driver) (When connected online)
Multiple exposure (2, 4, 8 & 16-up, custom: max. 5x5=25-up)
Book shadow erasure (adjustable)
Confidential safeguard
Panel setting memory (9 patterns of control panel settings can be stored.)
(All programs can save up to 90 sets.)
Status LED (in 3 color)
90 t rotation
Optimize print (P-roller control according to user fs input of temperature and speed)
Automatic pressure control (according to print speed)
Initial setting (paper size when the power is turned on / print speed / document mode /
scan density / print density on booting)
Master re-make (save the data from last master making and remake master without scanning)
Document density detection
Feed heavy weight paper (standard / heavy weight ) (S550/S520/S510 only)
(S850/S650/S620: paper type is automatically detected by feed pressure setting.)
Repeat counter (default print number on/off)
Fine start (2 settings)
Pre-print
Entry of sets & prints
Energy save mode (LCD turned off in 5 min.)
Automatic power off (power is turned off by time specified.)
Ink replenishing mode
Auto - reset
Online print (USB1.1)
Document preview (S850/S650/S620 only)
Document size detection (S850/S650/S620 only)
Paper size detection (S850/S650/S620 only)
Print tray detection
Master remain monitor
Master roll detection
Used master roll capacity monitor
Used master roll full detection
Master ejection box capacity monitor
Ink detection
Heavy weight paper detection (feed tray) (S850/S650/S620 only)
Double feed detection (S850/S650/S620 only)
Document detection
Chinese (traditional) / Korean / Thai / Polish
OK monitor (LCD graphic illustration display)
Touch panel (touch sheet overlay)
Color print
Master feeding method
Master ejection method
LCD
LCD language
Other function
Detection
DP-S850 DP-S650 DP-S620 DP-S550 DP-S520 DP-S510
+/-15mm Electrical
Registration
adjustment Vertical
Horizontal
+/-10mm Electrical +/-10mm Manual
(Electrical adjustment can be controlled by 0.5mm on LCD.)
Image mode
* mm indication + inch indication. (0.xx inch)
Text, Photo, Text/Photo (2 types), Pencil, Screen (2 types)
Contrast control Scan density: 5 steps, Master density: 5 steps, Print density: 5 steps
Specifications are subject to change without prior notice.

zSpecifications
chap.1
14
Model name DUPRINTER
USB interface (standard USB1.1) (USB cable must be 3m or shorter.)
Printer driver must be installed in computer.
Windows 2000 Professional
WindowsXP Professional / Home Edition
IEEE1284 (Compatibility mode, Nibble mode) parallel interface(Optional)
Windows 98 / Me
Windows NT4.0
Windows 2000 Professional
Windows XP Professional / Home Edition
LAN-kit (optional)
(Warning: Parallel board in LAN-kit must not be connected with any other devices.)
DP-RIP (optional)
IEEE1284 parallel interface is required separately.
MacOSX10.3/10.4
Online
S3-ADF / Drum unit / A4/Letter drum / Tape cluster (TAP-11/TAP-13) Options
ROM update method
KEY-05 Key card counter (built-in type) / Master box security lock /
CF Editor
Cabinet / Cabinet door
Double feed detection kit (S550/S520/S510 only) / IEEE1284 parallel interface /
LAN kit (built-in type) / DP-RIP (optional parallel interface is required separateiy.)
1) Via PC (connect with machine by USB cable)
(USB cable: A connector (male) + B connector (male))
OS: Windows 2000 Professional
Windows XP Professional/Home edition
2) Via CF card (insert in main PCB)
DRS85 A3, 600dpi (Master ID mark)
DRS65 A3, 400dpi
DRS62 B4, 400dpi
DRS55 A3, 300x600 dpi
DRS52 B4, 300x600 dpi
DRS51 LG, 300x600 dpi
Master roll
Ink DS14L
100-240V, 50/60Hz, 2.4-1.0A
DS04LH
NDXXL, S0XAL
Standard black ink
High density black ink (SOY INK) 1000ml
Color ink (1000ml, material is the same as previous color ink)
Power source
150W
(25 degree (c)) 5% coverage documentPower consumption
Printing (Speed 5)
Master making
Standing by
Sleeping 8W
18W
240W
145W
8W
18W
240W
140W
8W
18W
230W
135W
8W
18W
240W
130W
8W
18W
230W
130W
8W
18W
230W
DP-S850 DP-S650 DP-S620 DP-S550 DP-S520 DP-S510
In use: 1360mm(W) x 688mm(D) x 1080mm(H)Dimensions
Folded: 770mm(W) x 688mm(D) x 1080mm(H)
With optional ADF attached:
In use: 1360mm(W) x 688mm(D) x 1222mm(H)
Folded: 770mm(W) x 688mm(D) x 1222mm(H)
102kg (when packed: 118kg)Weight
10 - 30 degree (C) (50 - 86 degree (F))
Specifications are subject to change without prior notice.
Operating temperature

xDimensions
chap.1
15
R8S01001
xDimensions
622
1360
510228
1080
710
980
688370
( mm )

cSystem Setup
chap.1
16
cSystem Setup
1. Before Installation
The machine and its optional equipment are set up as follows:
Documents prepared on a personal computer can be printed on this machine.
The PC interface kit is required to connect this machine to a personal computer.
DDP system
NOTE :
KEYCARD COUNTER
( KEY-05 )
: Option
TAPE CLUSTER
( TAP-11/TAP-13 )
Automatic Document Feeder
( S3-ADF )
Duplo Direct Print System
Drum unit
A3/A4 drum (Attachable to DP-S850/S650/S550 only)
LAN Unit
Personal Computer
DP-RIP
Cabinet
R8S01002e

vPart Names and Their Functions
chap.1
17
Paper feed section
Model : DP-S550 / S520
Standard
LOW HIGH
Separation pressure
Side guide
Paper feed roller
Paper separator unit
Connector (PC)
LCD brightness adjust dial
Scanner switch
Feed tray descend switch
Feed tray
Feed pressure
adjuster lever
Support tray
Scanner cover
Glass
Scale
Control panel
Caster locks
Cabinet
Front cover
High
Standard
Low
Side guide lever
Separation pressure
adjuster knob
Feed tray horizontal
registration adjuster dial
CF card connector
Press to lower the feed tray.
Use to adjust paper
feed pressure.
Open this cover to replace the ink pack
and drum unit .
Keeps the document in contact
with the document glass plate.
The document is place on this glass.
Controls brightness of the LCD.
Use to adjust the separation
pressure according to
the paper thickness.
Lock/unlock the side guide.
Side guide
HIGH:
Thin
LOW:
Thick
R8S01003e
vPart Names and Their Functions
1. Machine exteriors

vPart Names and Their Functions
chap.1
18
Master feed section
Press this button rotates the drum and stops it in
position to be removed. And then LED gose on.
Cutter
Master roll
Master cover
LED
Drum removal button
Drum handle
Ink holder
Ink puck
Scanner switch
Master Cover Release Lever
Press the lever to open the master cover
when the master roll is setted up.
Scanner unit
R8S01004e

vPart Names and Their Functions
chap.1
19
Master ejection section
Master ejection box cover
release lever
Master ejection box cover
Press to open the master ejection box cover.
Master ejection box
release lever
Press to pull out the master ejection box.
Master ejection core
Use to dispose of used master.
Connectors
(Optional)
Print tray
Use this switch when paper jam has occurred.
The drum rotates while pressing the switch and
stops when it is released.
JOG switch
Key card counter (Option)
This slot is for inserting the key card.
Power switch
Paper stacker guide
Adjust these according to the paper size.
Paper stopper
Adjust it according to the paper size.
R8S01005e