Duplo DF-520 User manual

Duplo Folder
Please let our service people install the machine.
Instruction Manual
[230V]

1. Easy to Use
• Automatic detection of paper size (A3 to B6).
• A one touch function automatically returns the folding
stopper and stacker to their proper positions.
2. Enhanced Basic Performance
• Folding speed of 45 to 120 sheets/min.(B4, 64g/m2,
single fold).
• Loading capacity of the paper feed table: 500 sheets (B4
64g/m2)
• Paper thickness: 52.3 to 157g/m2
3. Various Memory Functions (Standard)
• Correction memory function for fixed folding (36
types).
• Registration of custom folding methods (MAX 2
memories).
4. Standard Folding of Non-standard
size Paper Can be Carried Out Easily
by Inputting Their Size on the
Keypad.
(Paper length folding mode)
5. Various Types of Paper (Art/Coated
Paper) Can be Folded by Easy
Operation.
6. Various Functions (Standard)
Ensuring Folding Accuracy and
Usability
• Test folding can be carried out.
• The counter display can be used for additions and
subtractions.
• A slant correction device is installed to straighteng
paper.
• Cross folding can be carried out.
FEATURES OF DUPLO FOLDER

1
INTRODUCTION
Thank you for your purchase. To ensure correct usage, please read this instruction manual
thoroughly,especiallythesectionSafetyPrecautions.Afterreading,pleasestorethisinstruction
manual in a safe place for future reference.
CONTENTS
1. SAFETY PRECAUTIONS...................... 2
2. USAGE PRECAUTIONS ....................... 4
2-1. POWER SUPPLY .......................................4
2-2. OPERATING ENVIRONMENT ...................4
2-3. STORAGE CONDITIONS...........................4
2-4. MAINTENANCE..........................................4
3. INSTALLING THE UNIT ........................ 5
3-1. BEFORE INSTALLATION ..........................5
3-2. INSTALLATION LOCATION.......................5
3-3. POWER SUPPLY .......................................5
3-4. COMPONENT PARTS ...............................6
3-5. REMOVING THE PRESS RELEASE
LEVER ........................................................7
3-6. ATTACHING THE PARTS..........................8
4. NAMES OF THE PARTS..................... 10
5. NAMES AND FUNCTIONS OF THE
CONTROL PANEL PARTS................. 11
6. PRECAUTIONS BEFORE USE........... 13
6-1. PAPER TO BE USED...............................13
6-2. PRECAUTIONS FOR STACKING
PAPER......................................................13
7. OPERATION PROCEDURES.............. 15
7-1. STANDARD FOLDING OF STANDARD
SIZE PAPER.............................................15
7-2. SINGLE FOLDING THICK PAPER...........21
7-3. DOUBLE FOLDING THICK PAPER .........22
7-4. CUSTOM FOLDING OF STANDARD
SIZE PAPER.............................................25
7-5. CALLING THE MEMORY .........................30
7-6. SWITCHING THE MODE USED. .............30
8. FOLDING ADJUSTMENTS AND
MEMORIZE CORRECTIONS .............. 32
8-1. ADJUSTMENT THE FOLDING SLIPPAGE
IN THE VERTICAL DIRECTION...............32
8-2. MEMORIZE THE FOLDING STOPPER
CORRECTION..........................................34
8-3. ADJUSTMENT THE FOLDING SLIPPAGE
IN THE HORIZONTAL DIRECTION .............36
9. USING ART/COATED PAPER............ 37
9-1. PRECAUTIONS FOR STACKING
PAPER......................................................37
9-2. OPERATING PRECAUTIONS..................38
10.USING NON-STANDARD PAPER
SIZE ..................................................... 40
10-1. STANDARD FOLDING PROCEDURE ..... 40
10-2. CUSTOM FOLDING PROCEDURES.......42
11.CROSS FOLDING ............................... 47
11-1. PRECAUTIONS UPON USE ....................47
11-2. CROSS FOLDING STANDARD
SIZE PAPER.............................................48
11-3. CROSS FOLDING NON-STANDARD
PAPER SIZE.............................................50
12.TROUBLESHOOTING......................... 53
12-1. PAPER IS JAMMED NEAR THE PAPER
FEED RING .............................................. 53
12-2. PAPER IS SLIPPED NEAR THE PAPER
FEED SECTION ....................................... 54
12-3. PAPER IS COILED AROUND THE
RUBBER ROLL INSIDE THE UNIT..........54
12-4. PAPER IS JAMMED AT THE FIRST
FOLDING PLATE .....................................55
12-5. PAPER IS JAMMED AT THE SECOND
FOLDING PLATE .....................................56
12-6. PAPER IS JAMMED NEAR THE
STACKER.................................................58
13.EMERGENCY STOPS......................... 59
14.ERROR MESSAGES........................... 60
15.TROUBLE SHOOTING GUIDE ........... 62
16.CLEANING THE UNIT......................... 65
16-1. CLEANING THE RUBBER ROLL.............65
16-2. CLEANING THE PAPER FEED RING .....66
17.SPECIFICATIONS............................... 67

2
WARNINGS:
Do not place metal objects or vessels containing liquids on top of the unit. The entry of
any metal object or liquid could result in fire or electrical shock.
Do not insert any metal or easily combustible object inside this unit. This could result in
fire or electrical shock.
Do not touch or insert foreign objects into any rotating part during operation. This could
result in injury.
Do not remove the cover or back panel. This unit contains high-voltage components that
could cause electrical shock.
Do not disassemble, modify or repair this unit. There is danger of fire, electrical shock or
injury. Contact your dealer when repairs are necessary.
Use only the power supply voltage specified on the main nameplate. Using other voltages
could result in fire or electrical shock.
Keep this unit and the power cord away from heaters and heater vents. Excessive heat
could melt the cover or power cord covering and result in fire or electrical shock.
Always observe the cautions and warnings explained below to prevent personal injury or
property damage.
The degree of danger and damage that could occur is indicated in two levels by the
following marks.
WARNING: Ignoring this mark could result in the possibility of serious injury
or even death.
CAUTION: Ignoring this mark could result in the possibility of injury or
physical damage.
The following graphic symbols indicate the various types of actions to be
performed or avoided.
This graphic symbol indicates a forbidden action.
means “Do not disassemble.”
means “Do not touch.”
This graphic symbol indicates actions that must be performed.
means “Disconnect the power plug.”
This graphic symbol indicates a “Caution” that must be observed.
means “Caution: high temperature.”
1. SAFETY PRECAUTIONS

3
Do not use flammable sprays inside or near the unit (e.g. when cleaning the unit).
Such flammable gas can be ignited and cause a fire or combustion.
Make sure that the current consumption listed on the main nameplate does not exceed
capacity rating of the power outlet and do not connect other equipment to this same
power outlet. Connecting other equipment could cause the power outlet to overheat and
catch fire.
Remove any dust that accumulates on the power plug prongs and the surface from
which the prongs extend. Accumulated dust can result in fire.
If any foreign object such as metal or liquid should enter this unit, immediately turn off
the power switch and disconnect the power plug from the power outlet. Failure to do so
could result in fire or electrical shock. Contact your dealer immediately.
Do not damage the power cord or power plug. (Do not scratch, alter, bend, twist, pull or
place heavy objects on the power cord or power plug.)
This could result in damage, fire or electrical shock.
Always grip the plug when disconnecting the power plug from the power outlet. Pulling
on the power cord could cause damage, resulting in fire or electrical shock.
Do not handle the power plug with wet hands. This could result in electrical shock.
Before cleaning this unit, turn off the power switch and disconnect the power plug from
the power outlet. Accidental operation of the unit during cleaning could result in injury.
CAUTIONS:
Always disconnect the power plug from the power outlet when this unit is not to be used
for an extended period. Failure to do so could result in fire due to leakage current if the
insulation should deteriorate.
Install this unit on a level, stable stand or floor, with sufficient space around it. Failure to
do so could result in the unit overturning and injury.
Do not install this unit in a location where there is excessive humidity or where contact
with water is possible. Failure to do so could result in deterioration of the insulation, fire
or electrical shock.
Disconnect the power plug from the power outlet before attempting to move this unit.
Failure to do so could result in power cord damage, fire or electrical shock.

4
2. USAGE PRECAUTIONS
+6%
2-1. POWER SUPPLY
Make sure the power supply used is always within the following range.
230V AC -10%, 50Hz
Plug the power cord plug directly into a wall power outlet.
2-2. OPERATING ENVIRONMENT
Operate this unit in the following environment.
• Temperature range: 5 to 35 °C
• Humidity range: 20 to 80% RH (no condensation)
• Avoid locations with direct sunlight
• Avoid dusty locations
• Avoid locations with vibration
• Avoid locations that are salty
• Avoid locations with special chemicals
2-3. STORAGE CONDITIONS
Store this unit in the following environment.
• Temperature range: -5 to +45 °C
• Humidity range: 20 to 90% RH (no condensation)
• Avoid locations with direct sunlight
• Avoid dusty locations
• Avoid locations with vibration
• Avoid locations that are salty
• Avoid locations with special chemicals
2-4. MAINTENANCE
To protect the characteristics of this unit, the customer should never supply oil or grease
to the parts (except when the customer is specifically requested in this instruction
manual).
Please contact your dealer in case of any problem.

5
3. INSTALLING THE UNIT
The customer should never install the machine. Please be sure to ask your dealer for
installation.
3-1. BEFORE INSTALLATION
• Turn the power of this unit off, and disconnect the power cord from the power outlet.
• Make sure that the voltage and frequency in the area to be used correspond with the unit’s
specifications.
3-2. INSTALLATION LOCATION
• Install on a base which can bear the machine’s weight.
The weight is 33 kg.
• Install on a horizontal and flat ground.
• Avoid the side of any heating such as a heater.
• Place this unit in the following environment.
• Temperature range: 5 to 35°C • Humidity range: 20 to 80%RH (no condensation)
• Avoid locations with direct sunlight • Avoid dusty locations
• Avoid locations with vibration • Avoid locations that are salty
• Avoid locations with special chemicals • Avoid locations that splash
3-3. POWER SUPPLY
• Make sure the power supply used is always within the following range.
• 230V AC -10%, 50Hz
• Plug the power cord plug directly into a wall power outlet.
• When using the same power outlet together with other elctrical products, make sure not to
over the capacity of power supply.
The fixed current is 0.5 A.
+ 6%

6
After checking that you have following parts, attach them to the unit.
12
3
3. INSTALLING THE UNIT
3-4. COMPONENT PARTS
No. Name Qty.
1
2
1
1
3
4
1
1
No. Name Qty.
First folding plate
Second folding plate
Cross folding lever
Instruction Manual
4
DUPLO CORPORATION
Duplo Folder
Please let our service people install the machine.
Instruction Manual

7
3-5. REMOVING THE PRESS RELEASE LEVER
This press release level is attached to the unit at shipment to prevent the rubber roll from
becoming distorted.
Be sure to remove it when installing the unit.
Take note that the unit will be damaged if it is used without removing the lever.
Remember to remove it in the following order when installing the unit.
1Two press release levers are inserted
in the left and right shaft edges of the
rubber roll.
2First, remove press release lever(A).
• To remove, push inwards and pull out the press
release lever, as shown in the figure.
Next, pull out press release lever(B)
as shown in the figure.
Also remove that of the operating side in the
same way.
<Operating side>
Press release lever(B)
Press release lever(A)
Press release lever(B) <Non-operating side>
Press release lever(A)
Press release lever(A)
Press release lever(B)
3. INSTALLING THE UNIT

8
1First, attach the second folding plate.
• Before starting, push the lock lever at the side of
the folding plate to “UNLOCK”.
• Next, insert the folding plate into the unit.
• After inserting it properly, push the lock lever to
“LOCK”.
2Secondly, attach the first folding
plate in the same way.
* If the paper jams inside the folding plate, turn off
the power supply, pull out the control cord of the
folding plate, push the lock lever to ''UNLOCK",
and remove the folding plate.
3After attaching the folding plates,
connect the control cord of the first
folding plate to connector No. 1 and
that for the second folding plate to
connector No. 2.
Note 1: Be sure to insert the control cords
correctly.
Note 2: Be sure to turn off the power before
connecting/disconnecting the control
cords.
3. INSTALLING THE UNIT
3-6. ATTACHING THE PARTS
Second
folding plate
Lock lever
Lock lever
First
folding plate
Stopper
Control cord 1
Control cord 2

9
3. INSTALLING THE UNIT
4Attach the cross folding lever at its
proper place.
<Parts Used>
Cross folding lever .................................................. 1
Note:
• The unit has a built-in battery to protect the different types of data memorized.
• This battery must be charged when installing the unit for the first time. To charge it, leave the power switch of the unit
on for about five hours.
• The battery will wear out when the unit has been left off continuously for about three months. Therefore turn on the
power occasionally to charge it.
• As data memorized and set will be lost when the battery has worn out, be sure to keep a copy of these data.
Cross folding lever

10
4. NAMES OFTHE PARTS
Slant adjustment
knob
Paper separator pressure
adjustment dial
Paper feed ring
Paper receiving tray
Paper receiving
stopper
Stacker roller
Auxiliary paper
feed plate
Guide
Cross folding lever
Paper feed tray
Top cove
First folding plate
Control panel
Paper feed pressure
adjustment lever
Second folding plate
Power switch
Paper set lever
Paper feed ring
(For moving)
Rubber roll
Jam correction handle
Set knob

11
No. Name Function
Start/stop button
Test button
Numberofsheets/
paper length
switch button
Clear button
Number buttons
(0 to 9)
Folding mode
select button
Speed controller
Firstfolding
stopper adjustment
button
Secondfolding
stopper adjustment
button
1
2
3
4
5
6
7
8
9
Starts/stops folding.
Each time this button is pressed, start/stop is repeated alternately.
Each time this button is pressed, the unit folds two sheets of paper and stops.
Sets the number of sheets to be folded and switches the input of the paper length.
The paper length input is memorized when it is set.
Press this button to change the number of sheets to be folded and the paper length.
Press these buttons to set the number of sheets to be folded and the paper length.
There are 6 types of standard folding methods and 2 types of custom folding methods
available.
When the power is turned on, the display lamp of the single fold mode will light up.
Each time the button on the right is pressed, the folding mode lamp display switches to
the right.
When the left button is pressed, it switches to the left.
The custom folding mode cannot be selected if no custom folding method has been
memorized.
The processing speed can be changed freely within the range of 45 to 120 sheets/min.
The processing speed increases as the knob is slid to the right and decreases as it is slid
to the left.
When the right button (+) is pressed, the folding stopper moves to the right.
When the left button (–) is pressed, the folding stopper moves to the left.
The stopper moves slightly each time the button is pressed, and continues moving
when pressed continuously until it is released.
When the right button (+) is pressed, the folding stopper moves to the right.
When the left button (–) is pressed, the folding stopper moves to the left.
The stopper moves slightly each time the button is pressed, and continues moving
when pressed continuously until it is released.
1
212345
67890C
0
12
1234561
bp bo bn bm
blbk 9 8 7 654321
5. NAMES AND FUNCTIONS OFTHE
CONTROL PANEL PARTS

12
No. Name Function
Custom folding
preset button
Standard folding
adjustmentbutton
Numberofsheets/
paper length
display window
Papersize display
window
Standard folding
indicator
Custom folding
preset indicator
bk
bl
bm
bn
bo
bp
5. NAMES AND FUNCTIONS OF THE CONTROL PANEL PARTS
This button is used to memorize the position where the folding stopper and stacker
stop. When moved in custom folding modes such as cross folding, non-standard
folding, etc.
Data for up to two custom folding settings can be memorized. Once memorized, the
data is saved even after the power is turned off.
To erase the data, keep pressing the corresponding registration button (1) or (2) until
the buzzer sounds.
This button is used to memorize the adjustment value when the folding stopper is fine-
adjusted in the standard folding mode.
Up to 36 combinations (No. of standard folding modes x paper size) of adjustment
values can be memorized.
To erase the setting, select the folding mode of the corresponding paper size to be
delected and keep pressing this button until the buzzer sounds.
This display shows the number of processed sheets (counter), the paper length input
values, error messages, etc.
This display shows the size of paper set on the paper feed tray which is detected
automatically (standard sizes of A3 to B6).
Also shows the operation status “ ” when the paper length is input.
They indicate six types of standard folding modes.
The display lamp blinks when a mode memorized for folding fine-adjustment has been
selected.
This lamp lights up when the custom folding mode is set.
This mode cannot be selected if no custom folding method has been memorized.

13
• Straighten folded or curled paper before use.
• Make sure that the ink on the paper has dried up properly
before use.
If the ink has not dried properly, it may dirty the
machine, and cause other problems such as dirtying the
folded surface with ink, etc.
6. PRECAUTIONS BEFORE USE
6-1. PAPER TO BE USED
6-2. PRECAUTIONS FOR STACKING PAPER
• If the paper is not stacked neatly on the paper feed table,
the unit will not be able to read the size of the paper
accurately and as a result, may determine the paper as
outside the standard size. Therefore, be sure to stack the
paper neatly.
The paper feed table has a built-in device for reading
paper size.
Take note that this device will not be able to read the
paper size correctly if the paper is stacked unevenly.
This may as a result cause problems.
• Automatic paper size detection can be carried out for
paper up to ±2.5 mm of the standard size paper.

14
6. PRECAUTIONS BEFORE USE
• If the paper is not stacked properly lengthwise, mis-feed
or chain feed may occur.
• When stacking just a few sheets of paper on the paper
feed tray, lower the paper set lever while pressing the
back edge of the paper.
Paper Guide plate
Paper set lever
• Adjust so that the front part of the paper touches the
paper feed ring in front lightly. (Arrow)
• The paper will be folded as shown in the figure if stacked
with the printed surface up on the paper feed tray.
• For “accordion fold” and “irregular accordion fold”, the
printed surface of some paper will be folded outwards.
Paper
Paper feed
rings
Single fold Brochure fold
Accordion fold
Letter fold
Irregular
accordion fold
Double fold

15
1Insert the power cord in the electrical
outlet and turn on the power.
• Press “I” to turn on the power.
• Press “O” to turn off the power.
When the power is turned on, the folding
stoppers rollers on the folding plates and
stacker will move to their initial setting positions.
Wait for a few seconds for this to complete
which is indicated by the sound of the buzzer.
2Raise the paper set lever and stack a
set of sheets on the paper feed tray.
• Loosen the fixing screws of the guide, and move
the guide slightly more than the width of the paper.
• Loosen the paper and stack sheets of paper neatly
on the paper feed table.
• Insert the paper until its front part touches the front
guide plate lightly.
3After pressing the guide to the side of
the paper lightly, tighten the screws
to secure the guide.
• The left and right guides move in the same
direction.
Paper can be stacked to a height of
approximately 45 mm at one time. Do not
stack too many sheets paper.
4Lower the paper set lever.
Start the various standard folding operations for standard size paper as follows.
7. OPERATION PROCEDURES
7-1. STANDARD FOLDING OF STANDARD SIZE PAPER
Power switch
Paper
Fixing screw
Paper set lever
Guide Fixing
screw
Guides Fixing screw
Fixing screw
Guides
Paper set lever

16
7. OPERATION PROCEDURES
5Press the “folding mode select”
button and select the desired fold
mode.
• When the right “folding mode select” button is
pressed, the lamp on the right of that currently lit
will light up.
• When the left one is pressed, the lamp on the left of
that currently lit will light up.
• If “custom folding” had been memorized
previously, “custom folding” modes 1 and 2 can be
selected by pressing these “folding mode select”
buttons. If no custom folding methods have been
memorized, the custom folding mode cannot be
selected and instead the standard folding mode will
be set.
6Check the paper size display.
• When paper outside the standard size is used, the
size of the paper will not be detected automatically
and consequently not displayed.
When using such a kind of paper, refer to
“Using Non-Standard Paper Size” on page 40.
1
212
67
12
1
212
67
12
345
890C

17
7Adjust the paper feed pressure
adjustment lever to “0”.
• If the paper slips and no paper is fed, raise the
paper feed pressure one level from 0 to 1.
• If several sheets of paper are fed at one time, lower
the paper feed pressure one level from 0 to –1.
When using art paper or coated paper, refer to
“Using Art /Coated Paper”on page 37.
8Open the Top cover and adjust the
separator pressure adjustment dial to
“0”.
• If several sheets of paper are fed at one time, raise
the separator pressure adjustment dial from 0 to 1
or 2.
• Adjust the separator pressure by gradually
increasing the level 0.5 each time.
When using art paper or coated paper, refer to
“Using Art /Coated Paper”on page 37.
9Close the Top cover and adjust the
speed controller for appropriate
folding speed.
7. OPERATION PROCEDURES
Paper feed pressure adjustment lever
Separator pressure adjustment dial
1
212
67
12

18
7. OPERATION PROCEDURES
10 Press the “test” button and perform
test folding.
• Two sheets of paper will be folded.
Even after two folded sheets of paper have
been ejected, the machine will not stop
working when the stop button is pressed until
the buzzer sounds and the motor inside stops
completely.
The unit will not respond to whatever button
on the control panel is pressed.
• The paper will be folded properly if it is folded
after it has reached the stopper inside the folding
plate.
• If the paper flowing into the folding plate is folded
without reaching the stopper due to conditions
such as environmental conditions (temperature,
humidity), paper quantity, its type, paper couch
conditions, folding speed, curling etc., it may not
be folded properly.
• In some cases, the paper may also coil around the
rubber roll and cause problems.
• As such problems can be corrected by slow down
the folding speed, keep slow down the speed until
the paper is folded properly.
345
890C
1
212
67
12