DT-900 Inline Tabber

with DF915/920

Operation Manual

Duplo U.S.A. Corporation Revision 1.45

3050 S. Daimler Street 12/12/2005
Santa Ana, CA. 92705
Tel : 949-752-8222
Fax: 949-752-7766
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 Table of Content
SECTION 1...................................................................................................................................... 4
Introduction to the DT-900 Inline Tabber .............................................................................................. 4
General Description ............................................................................................................................................... 4
Specifications......................................................................................................................................................... 4
Major Components and assemblies ....................................................................................................................... 5

SECTION 2...................................................................................................................................... 6
Becoming familiar with the control panel .............................................................................................. 6
Control Panel ......................................................................................................................................................... 6
Reference for Control Panel functions................................................................................................................... 6

SECTION 3...................................................................................................................................... 9
Tab Set Up & Fine Tune........................................................................................................................... 9
Single tab application ............................................................................................................................................ 9
Preparing the liner.................................................................................................................................................. 9
Routing liner upward ............................................................................................................................................11
Fine tune tab position........................................................................................................................................... 12
Fine Tuning Flat Tab............................................................................................................................................ 13
Take Up Spool ..................................................................................................................................................... 13
Removing used tab liner from the Take-Up Spools: ............................................................................................ 13
Tab out detection.................................................................................................................................................. 14
Error recovery...................................................................................................................................................... 14

SECTION 4.................................................................................................................................... 15
Operators Trouble Shooting Guide....................................................................................................... 15

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 SECTION 1

Introduction to the DT-900 Inline Tabber

General Description
The DT-900 is designed to be operational inlined with Duplo’s DF-915 & DF-920 folders to
apply either 1 or 2 tabs on the open end of the media. The type of tab this tabber supports is
pin fed with 1” repeat. White and clear tabs are compatible with the DT-900.

Specifications

Speed: Up to 16.,400 pieces per hour with folder.

Up to 18,000 pieces per hour with optional feeder.
Media thickness: Up to 1/8" (44 pages booklet)
Media size: W6" ~ 11" / H 4" ~ 5 1/2"
Weight: 86 lbs
Dimensions: L21" x W18" x H13"
Stacking tray capacity: 6 inches
Electricity: 115V / 60Hz, 1.6A
Options: DT-900C conveyer, AF-900 feeder, 8 ½” flipper
plate
Type of tab: Pin fed, 1 inch repeat, round or rectangle, paper or
clear, 3 inches core.
Tab capacity: 10,000 tabs
Take-up spool capacity: 5,000 tabs
Error detections: Cover open, jam, out of tab
Additional function: Count up counter, batch count, flat tap, bypass,
2-speed settings.

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Major Components and assemblies
Side view of machine

Tab Spool Holder

Safety cover handles

Locking handle

Arm Assy.

Tractor Assy.

Flipper Plate

Take- up Spool clip

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 SECTION 2

Becoming familiar with the control panel

Control Panel

Figure 1

Reference for Control Panel functions

Keys Operation

• Start the tabber.

Press

• Stop the tabber.

Press

• Allow one media to pass

Press . without tabbing.

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 • Display current batch
count setting.
Press & hold down . = batch count amount

• Turn batch count on/off.

Press & hold down and press

• Set batch count amount.

Press & hold down and press .

• Clear paper path.

Press & hold down .

• Display tab setting.

Press & hold down .

• Select tab function.

= no tabbing
Press & hold down and press . = regular tabbing
= flat tabbing

• Initializing the tab’s

Press & hold down and positing for set up.
for 2 seconds.

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 • Fine tune tab position.
Press & hold down and press .

• Display current speed

Press & hold down . setting.

• Select speed.
Speed 1 = slow
Press & hold down and press . Speed 2 = fast

• Clear error.
Press .

• Clear “take up spool full”

Press & hold down for 2 seconds. warning.

• Reset counter.
Press & hold down and press .

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 SECTION 3

Tab Set Up & Fine Tune

Single tab application

Place only one Tab Liner into one of the Tractor Head, if you switch tabbing from dual
to single, remove undesired Tab Liner from the corresponding Tractor Head. Turn off
then back on to initialize the sensors. The DT-900 will detect only one tab liner
installed on the Tractor Assy.. The procedure for dual tabbing is the same, except
use 2 tab liners, 1 for each tractor head.

Preparing the liner

1. Pull tab liner from spool and remove the 1st 16 tabs and mark the top edge of the 17th,
18th and 19th tab. Marking the top portion of tabs will allow you to have better visual
alignment when fine adjusting its set up position. The 17th tab will become the 1st tab
to be dispensed.

Figure 2

Mark here with a pen to see the

tab’s position for adjustments. The 1st hole of the liner is to be inserted
into the 1st Pin on the Tractor Assy.

Remove the 1st 16 tabs

Always Cut the Tab Liner at this
then place the liner into
position before it is loaded into the
the Tractor Assy..
Tractor Assy.

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Routing the liner downward
2. Insert the Tab Liner through
the slot on top of Safety Figure 3
Cover “A”.
3. Open Safety Covers “A” &
“B”.
4. Open Tractor Assy. Front
Gates. Refer to figure 4.
5. Unlock the tractor lock
lever and slide to desired
position. Lock the tractor
when adjustment is Insert Slot
completed.

6. Place the liner into the

Cover “B” Cover “A”
tractor pins (make sure that
the 1st set of holes on the
liner is placed on the 1st Drive Pin) and close the Tractor Front Gates. The 1st
drive-pin has to be aligned with the index line, if drive pin is above or below the index,
press & hold down “Tab” then press the “↑” or ”↓“ key to move the 1st pin in position.
Figure 4

7. Press & hold down “Tab” then press “Enter” to select .

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8. Press & hold down “Tab” and “Reset” for 2 seconds.
This will feed the liner through the gap between Separator Bar and Tab Deflector.
If the liner didn’t feed between the separator and deflector then do this manually.
Figure 5

Locking
Handle

Liner

Deflector

Tractor Assy.
Separator

Routing liner upward

9. Unlock the Tractor Assy by lifting up on the Tractor Locking Handle then lay Tractor
Assy down.

10. Pull tab liner up from the other side of the separator bar. Refer to figure 6 for tab
routing.

11. Up right the Tractor Assy and lock it with the Locking Handle.

12. Open the Rear Gates (figure 6) of the Tractor Assy.

13. Pull upward on the tab liner and place it into the Drive Pin. Make sure that the liner
is tightly fit around the separator bar.

14. Close the Rear Gates of the Tractor Assy.

15. Again press & hold down “Tab ” and “Reset” for two seconds. This will bring the first

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 tab into position and ready for separation. To double check its position, the top of the
first tab should be at level with the Upper Shroud Assy. (Figure 6). If the first tab is too
far away from this position, it may cause jams.

Fine tune tab position

16. Press & hold down “Tab” then press “↑” or “↓” key to fine tune. The ratio of tab
placement has to be less or equal to 50/50 i.e. 47/53, 45/55…. .For clear tab, the ratio
has to be 50/50 to receive good tab wrap around.

Example:

50 45

50 55
Fold Line

17. Pull tab liner upward and over the Rod (Figure 6) then slip it through the Take-up
spool clip.
18. Press the “→” key to wind and tighten the liner on the take-up spool.
19. Adjust stopper position on the Flipper Plate to Media size.

20. Close Safety Covers “A” & “B”.

Rod Figure 6

Used Liner
Take-up Clip Tractor Assy Front Gate

A: Top of Upper Shroud

B: Top of the First Tab
Tractor Assy Rear
Point A and B should be Gate
level.
Separator Bar

Top Shroud
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21. Press the Test Key on the DF-915/920 folder to test 2 pieces of media through the tabber unit,
check the tab wrap around on the edge of media to assure that the placement is 50/50. If not,
then repeat step 16.

Fine Tuning Flat Tab

22. Press & hold down “Tab” then press “Enter” to select .

23. Press the Test Key from the DF-915/920 folder to feed 2 pieces of media. Check
tabbing for appropriate positioning.
24. Press & hold down the "Tab" key then press either the "↑" or "↓" to adjust tab
positioning. Repeat step 2 & 3 until tab is at desired position.

Take Up Spool
The Take-Up Spool assy. is designed to collect the used tab liner automatically while the
tabber is in operation. Refer to Figure 7 for the location of the take up spool shaft.
There is an inner counter in the DT-900 that will STOP OPERATION of the machine
every time the counter accumulates 5,000 tabs. The LED display will flash and show
“FULL” to remind operator to remove used tab liner roll. To reset the inner counter,
press & hold down “Reset” for two seconds.

Removing used tab liner from the Take-Up Spools:

1. Open Safety Cover “B”. Spring Loaded Cylinder
2. Pull back on empty tab liner to get some slack
(get enough slack so that you can reapply the Figure 7

empty liner back to the Take-Up Spools, at

least 16”- 16 tabs).
3. Locate the spring loaded Cylinder that is on
each end of the Take-Up Clips (Figure 7).
4. Push/pull back on the spring loaded Cylinder
to release the Take-Up Spools and pull
towards the frame of the tabber. (figure 7).
5. Remove empty Tab Liner from spools. Flipper plate
6. Perform the opposite to reinstall the Take-Up
Take-up clip
Spool.
7. To reapply used tab liner, take the slack that you created prior to removal of the
Take-Up Spool, insert the leading end of the liner into the Take-Up Spool clip.

8. Press & hold down “→ “ to wind and tighten the spool.

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Tab out detection
There are “Tab out” detecting sensor installed on each Tractor Assy, the tabber will
automatically stop when any tab roll is empty.

Error recovery
Press & hold down “→” or “←” to clear media inside the tabber. If the jam is too difficult
to clear, then open cover and remove media manually.

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Operators Trouble Shooting Guide
Error Message/Status
1. “E2/E3/E4 Er”
2. ”P2 Er”
3. “P3 Er”
4. “P4/P5 Er”
5. “t Er”
6. ”FFFF” on display
7. Media not tabbing.
8. Tab position on media is
not consistent.
9. Nothing on Display
SECTION 4
Symptom
1. Paper on the path when
turn on the machine.
2. Sensor detects infra red.
1. Media did not get to
sensor 2.
2. Media not folded well.
1. Counter display
incorrect count.
1. Tab liner jump off the
tractor.
2. Paper jam at tabber exit.
1. Tab liner break.
2. Tab spool empty.
3. Tab liner not in position
1. Logic board error
1. Tractor not moving.
1. Tab used is not 1” pitch.
2. Dirty Sensors.
3. Tractor assy. not lock.
4. Tabbing position
floating.
1. Power cord unplugged.
2. Power switch off.
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Solutions
1. Remove media.
2. Keep machine away
from infra red emitting
light.
1. Check media
2. Check folder setting
1. Clean sensor.
1. Check tab liner and
reinstall.
2. Lay tractor assy. down
to check for any
remaining tab on the
paper path, deflector or
upper shroud.
1. Reinstall
2. Reload tab spool.
3. Check liner position at
tab out sensor located
above the tractor head.
1. Call for service
1. Tab setting has to be
1516 for tabbing or
1L00 for flat tabbing.
1. Use 1516 pin fed tab
with 1” pitch.
2. Clean sensor with air
duster.
3. Make sure tractor head
assy. lock in position.
4. Lay tractor assy. down
to check any remaining
tab on the paper path,
deflector or upper
shroud.
1. Plug power cord.
2. Turn power switch on.