Duplo DUPRINTER DP-440 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 2002
DUPLO SEIKO CORPORATION
All Rights Reserved

2
'Safety-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 January
2002, and applies basically to the model DP-440/DP-430/DP-340/DP-330 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.
Connect to outlet of 120V AC, 60Hz, at least 15A
With no load*
At full load
Power consumption
No more than 130V AC
At least 110V AC
During platemaking : 250W
During printing at speed 3 (printing speed) :230W
On standby : 60W
Power supply voltage
}
Use power supply meeting these requirements
Connect to outlet of 230V AC, 50Hz, at least 8A
With no load*
At full load
Power consumption
No more than 250V AC
At least 210V AC
During platemaking : 250W
During printing at speed 3 (printing speed) :230W
On standby : 60W
Power supply voltage
}
Use power supply meeting these requirements
* 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.
• 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

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 drum or rollers after turning on the jog switch.
• Do not put your hands or fingers inside the machine while the drum is rotating.
aOtherwise, your hands/fingers could get caught and crushed between the drum and rollers.
'Working clothes
• Wear clothing than enables you to work safely.
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 stickers
The locations of the machine's warning stickers are shown below. To ensure safe work, read the
stickers and heed their instructions. Keep the stickers clean at all times. If they become damaged
or peel off, replace them with new ones.
No. Parts No. Name Q'ty
qL1-T3060 Warning Sticker 1 1
wL5-T3020 Warning Sticker 2 2
e
r
M7-T3030
M7-T3060 Warning Sticker 3
Caution Sticker 1 1
1
M7-T3060
CAUTION
WARNING
Do NOT put hands inside machine
while it is operating.
Hands could get caught up
or crushed.
WARNING
● Do not remove this cover. The inside of the printer contains movable cutting instruments,
contact with which could result in injury.
L5-T3020
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.
WARNING
N5-T3010
Do not touch the roller below. Your clothes etc. may be stained with ink.
CAUTION
tN5-T3010 Caution Sticker 2 1
q
r
t
ew

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
zFeatures................................................................................12
xSpecifications ......................................................................14
cDimensions ..........................................................................16
vSystem Setup.......................................................................18
bPart Names and Their Functions........................................19
nOperation Procedures.........................................................26
mOption...................................................................................28
Chapter 2
z Scanner Section.........................................................32
x Platemaking/Master Feed/Ejection Section.............42
c Paper Feed Section ...................................................62
v Drum Driving Section................................................75
b Press Section.............................................................81
n Paper Ejection Section..............................................86
m Drum Section .............................................................93
, Option .......................................................................105
Chapter 3
z Exterior .....................................................................108
x Scanner Section.......................................................114
c Platemaking/Master Feed/Ejection Section...........120
v Paper Feed Section .................................................127
b Drum Driving Section..............................................132
n Paper Ejection Section............................................134
m Drum Section ...........................................................139
Chapter 4
z Scanner Section.......................................................148
x Platemaking/Master Feed/Ejection Section...........150
c Paper Feed Section .................................................158
v Drum Driving Section..............................................163
b Press Section...........................................................165
n Paper Ejection Section............................................167
m Drum Section ...........................................................169
, Electrical System.....................................................173
. Option .......................................................................182
Chapter 6
z Troubleshooting Guide ...........................................188
x Error Display ............................................................205
Chapter 7
Chapter 8
z Electrical Parts Layout and Their Functions.........298
x Overall Wiring Layout..............................................309
z HELP Mode List .......................................................208
x Overview...................................................................212
cHELP Mode Functions and Operation Procedures .......213
(1)Accessing HELP Modes......................................213
(2)Guide to the HELP Mode Descriptions..............213
• HELP Mode Descriptions .....................................214
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 stickers................................................6
Troubleshooting
Chapter 5
z Guaranteed Periodical Maintenance......................184
x Cleaning and Oiling.................................................184
c Periodical Maintenance...........................................185
Maintenance / Check
Standards / Adjustment
HELP Mode
Others
Mechanism
Description of the Operation
Introduction

11
zFeatures........................................................................12
xSpecifications...............................................................14
cDimensions...................................................................16
vSystem Setup...............................................................18
bPart Names and Their Functions................................19
1. Machine exteriors....................................................19
2. Sectional (structural) view of the machine ...........22
3. Control Panel ..........................................................24
nOperation Procedures.................................................26
1. Platemaking & Printing...........................................26
2. Multiple Image Printing / 2 IN 1 Layout Mode.......27
mOption ...........................................................................28
1. DUPRINTER Option.................................................28
(1) TAPE CLUSTER 4 .............................................28
1
Chapter 1 Introduction

12
zFeatures
chap.1
zFeatures
Size A3/B4 printing(Printing area)
DP-440/DP-430 : A3 ( 290X423mm )
DP-340/DP-330 : B4 ( 250X355mm )
1.
High-speed platemaking2.
High print quality3.
Align paper4.
High-performance lamp5.
Simple operation6.
Full range of necessary functions
q Documents are easily enlarged or reduced.
In addition to same-size printing, there are three
automatic settings for both enlargement and
reduction. Further, the margin (94% reduction)
function can be used for these automatic settings.
7.
• Zoom settings : (70, 81, 86, 115, 122, 141%)
• Same-size : (100%) printing
Size A/B models
• Free zoom : 50% -500% ( 1% )
Enlargement :141% [A4/A3, B5/B4] *4
122% [A4/B4, A5/B5]
115% [B4/A3, B5/A4] *4
Reduction : 86% [A3/B4, A4/B5] *4
81% [B4/A4, B5/A5]
70% [A3/A4, B4/B5] *4
*4:
Maximum printing area of DP-340 and DP-330
is B4(2509355mm).
• Zoom settings : (64, 74, 77, 121, 129, 141%)
• Same-size : (100%) printing
Inch size models
• Free zoom : 50% -500% ( 1% )
Enlargement :141%
129% [LTR/LDG]
121% [LGL/LDG]
Reduction : 77% [LGL/LTR] *5
74% [LDG/LGL] *5
67% [LDG/LTR]
*5: Maximum printing area of DP-340 and DP-330
is 11"914"(2509355mm).
w Self-diagnosis
The machines have self-diagnostic functions.
Messages for self-diagnosed errors, as well as
consumable part replacement prompt messages,
appear on an LCD panel.
e Book shadow erasure
Shadows in the middle or at the edges of book
documents can be erased.
r Adjusting the Printing Position(vertical)
In addition to vertical direction adjustment.
Print the first sheet of paper.(document size : A4 )
DP-440/DP-340: 21 seconds*1
DP-430/DP-330: 27 seconds*1
*1:Time required to print the first sheet of paper
after the platemaking key is pressed.
A new, originally-developed superfine thermal
head gives beautifully accurate reproductions of
fine print and halftone photographs.
Its resolution is 400dpi in the pel path direction
and 400dpi in the line progression direction.
Its resolution is 300dpi in the pel path direction
and 600dpi in the line progression direction.
DP-430/DP-330
DP-440/DP-340
Adjusting the eject enables both thin and thick
sheets of paper to be aligned neatly.
A long-life, high-brightness xenon arc lamp is
used to illuminate the documents. Since the
lamp's intensity is not affected by temperature
variation*2, printing quality at low temperatures
is greatly enhanced*3.
*2: The lamp is filled with xenon gas, which means
that it does not require heat to vaporize mercury,
as a fluorescent lamp does, and therefore its
intensity does not vary with temperature.
*3: Increased viscosity of the ink at low temperatures
results in fainter printing than at normal
temperatures.
Operation is simplified by concealing
occasionally-used keys under a panel, leaving
just the basic function keys permanently
accessible.

13
zFeatures
chap.1
User setting
q Memory Function
Equipped with a memory function (for 9
items) able to memorize frequently used
settings.
w Optimize Print
Optimal images can be printed in times of
low/high temperature by setting the
temperature and the print speed.
e Initial Paper Size setting
The paper size and print speed, etc., that
are valid when the power is turned on can
be set.
r Document Memory
The last platemaking image can be
memorized, and used later for platemaking
without having to read it out again.
8.
Special functions
The HELP mode items listed below can now also be
used in the user mode. And the power save mode can
cut power consumption.
q Sorter Fine Start
w Auto Clear
e Pre-print
r Batch Print
t Auto Power Off
y Auto LCD Off
u Long Paper mode
i Ink Circulation
o Tape Cluster ( tape inserter )
!0 Double Feed Detection
!1 Drum selection ( A3/A4 )
9.
Option
q S2-ADF
w Drum unit
e A3/A4 Drum unit
r Tape Cluster
t PC Interface kit 2
y Key card counter 4
u Postcard stacker
i Long paper unit
o Sorter
10.
t Document modes
The "Text-Photograph", "Text-Fine Lettering",
"Photograph-Fine Lettering", "Screen 1 & 2" and
"Photo Dark" Modes selecting, accommodating
printing of a wider variety of documents.
y Adjusting the contrast control
The degree of contrast for printing can be
adjusted.

14
xSpecifications
chap.1
xSpecifications
• Specifications
Model
Model name DUPRINTER DP-440 DUPRINTER DP-430 DUPRINTER DP-340 DUPRINTER DP-330
Floor model
Thermal digital master making
21 sec ( A4 100% )
400dpi 400dpi
21 sec ( A4 100% )27 sec ( A4 100% ) 27 sec ( A4 100% )
300 dpix 600 dpi 300 dpix 600 dpi
Flat bed scanner
100 sheets (64 - 128gsm)
Stencil print
MAX. 297mm x 432mm
290mm x 423mm
290mm x 423mm (A3) (11.4"x16.6") 250mm x 355mm (B4) (9.8"x14")
1,500 sheets(64gsm)
1,500 sheets (64gsm)
MAX: 297mm x 432mm With Long paper unit (service part) : Max: 540mm
MIN: 100mm x 150mm
Master making method
Master making interval
Resolution
Scanning method
ADF (Optional)
Printing method Sheets, book ( max: 10kg)Document type
Document size
Scanning area
Image area ( max)
Feeding capacity
Stacking capacity
Paper size
53gsm -210gsm (45kg-180kg)Paper weight 13lb - 110lb (Index)
Feeding pressure adj.( 3 steps )
Separator adj. ( 3 steps )
120 ppm ( 45-120 ppm, 5 steps) Within operating temperaturePrint speed 100%Zoom A/B size
Inch size
Preset reduction/enlargement: 70, 81, 86, 115, 122, 141%
94%
Zoom: 50 - 500%
Auto zoom: 70, 81, 86, 115, 122, 141%
100%
Preset reduction/enlargement: 64, 74, 77, 121, 129, 141%
94%
Zoom: 50 - 500%
Auto zoom: 64, 74, 77, 121, 129, 141%
Vertical : +/- 15mm [ shown on the LCD by 0.5(mm)]Registration adjustment Horizontal: +/- 10mm [shown on the LCD by 0.5(mm)]
Text,Photo,Text/Photo,Text Fine,Photo Fine,Screen1,Screen2,Photo DarkImage modes Contrast control : 5steps
Master making density: 5 stepsContrast control Print density: 11 steps
Automatic control (600ml, 1000ml)Ink supply method Drum unit exchangeColour print Roll master automatic feedMaster feeding method Automatic ejection/ master rolling-up methodMaster ejection method 50sheetsUsed master capacity 320 x 240 dot matrix full- dot matrix LCD ( with contrast control)LCD OK monitor ( LCD graphic)
Remainig master display function, remainig master ejection display function
* Specifications are subject to change without notice.

xSpecifications
chap.1
15
Other function
Model name DUPRINTER DP-440 / 430 / 340 / 330
Image Rotation ( 90 & 180 degree)
Colour Separation (equipped in online printer driver)
Sorter Mode setting ( sort, no sort, group)
Document Size Auto Scan
Multiple Exposure ( 2, 4, 8, & 16- up.)
Book Shadow Erasure ( adjustable)
Memory Function ( 9 pattern of settings of control panel can be stored.)
Confidential Safeguard
Initial setting (when the power is turned on.)
Optimize Print (
P-roller control according to user’s input of temperature and speed. )
Online (IEEE1284 standard bi-directional parallel interface)
NB:For USB/SCSI connection, optional interface kit II is required.
Document Memory , Auto Clear
Fine Start , Pre-print
Batch Print
Auto LCD Off
Auto Power Off
Ink Circulation
Double Feed Detection
S2-ADF [100sheets (64gsm)]Option Drum unit
Tape inserter
PC interface kit II
Key card counter 4 ( built-in type)
Cabinet( with front door)
Cabinet( open )
Power source Domestic:100V +/- 10%, 50/60Hz, 3.0A
120V :120VAC60Hz, 2.5A
230V :230VAC50Hz, 1.3 A
250W(
during plate making ),230W( during 3rd speed printing ),60W( during standby )Power consumption In use: 1374mm(W) x 738mm(D) x 1089mm(H)Dimension Folded: 753mm(W) x 738mm(D) x 1089mm(H)
With optional ADF attached:
In use: 1374mm(W) x 738mm(D) x 1228mm(H)
Folded: 753mm(W) x 738mm(D) x 1228mm(H)
119kgWeight 10 -30 degree(C)Operating temperature Parallel bi-directional interface (standard)Online Confirmed with IEEE1284 (compatibility mode, nibble mode)
Printer driver must be installed in computer
[ Windows95/98/Me, Windows NT4.0/2000,]
Printer driver must be installed in computer
[ Windows95/98/Me, Windows NT4.0/2000,]
[ Macintosh (MacOS7.6.1 - 9.1)]
I/F PCB must be installed in the main unit.
USB, SCSI interface ( optional) PC interface kit II
* Specifications are subject to change without notice.
A3/A4 drum unit (DP-440/DP-430)

cDimensions
chap.1
16
44000B
cDimensions
790.6
160
790.6
460
390
588.5
1013.9
664350
186.5477.5
226.5 483.5
620
1330
( mm )

vSystem Setup
chap.1
18
vSystem 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 4
Drum unit : Option
TAPE CLUSTER 4
Cabinet (Printer stand)
Personal computer
S2-ADF
Sorter
Duplo Direct Print System
44000C

Panel cover
Contrast adjusting dial
Scanner switch
Feed tray descend switch
Inlet
Feed tray
Feed pressure
adjuster lever
Supplemental
paper tray
Power switch
Document cover
Glass
Vertical size scale plate
Control panel
Caster locks
Cabinet
(Optional)
Feed pressure adjuster lever
Feeder guide F
Paper feed roller 1,2
Feeder guide R
Paper separator unit
Paper feed section
Feeder guide lock leverSeparat pressure adjuster screw
bPart Names and Their Functions
chap.1
19
440AAe
bPart Names and Their Functions
1. Machine exteriors

bPart Names and Their Functions
chap.1
20
Master ejection box
lid release lever
Master ejection box
lever
LED
JOG switch 1
(Drum rotator switch 1)
Master ejection core
Master ejection sectionMaster feed section
Drum bar
Drum handle
Drum securing
lever
Ink puck holder
release lever
Ink puck
Master clump
Drum section
Master cut switch
Cutter
Platen roller
Thermal head
440BBe

bPart Names and Their Functions
chap.1
21
JOG switch 2
(Drum rotator switch 2)
Paper aligning lever
Jump plate
Top blow fun
Paper stacker guide
Paper stopper
S2-ADF
connector cover
(Optional)
Interface kit II
(Optional)
Connectors (Optional)
Print tray
440CCe