quadient DS-1200 G4i User manual

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DS-1200 G4i Operator Manual Issue 4 - Nov 2020
WARNING
Improper installation, operation, adjustment, alteration, servicing and or
maintenance may result in property damage and or serious bodily injury!
Ensure all safety symbols described in section 2.2 Safety Symbols are
observed and their descriptions read thoroughly to understand their
meanings!
Ensure all safety notes detailed in section 2.3 Safety Notes including
it’s sub-sections are read in it’s entirety and understood before any
installation, operation, maintenance and or servicing of this machine!
Failure to comply to all safety notes and procedures set out in this manual
may result in property damage and or serious bodily injury!

2DS-1200 G4i Operator Manual Issue 4 - Nov 2020
Table Of Contents
1 Introduction ....................................................................................... 4
1.1 About this Manual.................................................................... 4
1.2 Standards and Compliance........................................................ 4
1.3 End of Life .............................................................................. 5
2 Safety ................................................................................................. 6
2.1 Safety Information................................................................... 6
2.2 Safety Symbols ....................................................................... 6
2.3 Safety Notes ........................................................................... 7
2.3.1 General Safety Notes..................................................... 7
2.3.2 Power Connections Safety Notes ..................................... 8
2.3.3 Emergency Safety Notes ................................................ 8
3 Description of machine ....................................................................... 9
3.1 Overview of machine................................................................ 9
3.2 Description of operation............................................................ 9
3.3 Identication of parts ..............................................................10
4 Control Panel .................................................................................... 12
4.1 The Menu Screen....................................................................12
4.2 The Job Screen.......................................................................13
4.3 The Run Screen......................................................................14
4.3.1 The Run Screen displayed .............................................14
4.3.2 Counter settings ..........................................................15
4.3.3 Fine tuning of settings ..................................................16
4.3.4 Remote Assistant .........................................................21
5 Running a job ................................................................................... 22
5.1 Running an existing job ...........................................................22
6 Switching the user............................................................................ 24
6.1 How to switch the user ............................................................24
6.2 User Access Rights..................................................................26
7 Creating a job ................................................................................... 27
7.1 Creating the Job Settings.........................................................27
7.1.1 Dening the mailset .....................................................28
7.1.2 Dening the output settings ..........................................36
7.1.3 Dening Postage/Metering settings.................................39
7.1.4 Saving the Job.............................................................41
7.2 Creating an envelope ..............................................................42
7.3 Creating a document...............................................................44

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8 Setting up the machine..................................................................... 46
8.1 Loading the Folder hoppers ......................................................46
8.2 Loading the Feeder hoppers .....................................................47
8.3 Loading the Envelope hopper ...................................................48
9 Vertical Stacker ................................................................................ 49
9.1 About the Vertical Stacker........................................................49
9.2 Operation ..............................................................................49
10 Operator Maintenance .................................................................... 51
10.1 Cleaning the machine ............................................................51
10.1.1 Cleaning conveyor belts ..............................................51
10.1.2 Cleaning rollers ..........................................................52
10.1.3 Cleaning sensors ........................................................53
11 Operator Adjustments .................................................................... 58
11.1 Setting the ngers ................................................................58
11.2 Replacing the sheet feeder pick-up rollers ................................61
11.3 Replacing insert & envelope feeder pick-up rollers .....................62
12 Troubleshooting guide .................................................................... 64

4DS-1200 G4i Operator Manual Issue 4 - Nov 2020
1 Introduction
1.1 About this Manual
Disclaimer
The data contained herein is the most current known to the manufacturer at the
time of preparation and is believed to be accurate.
It should not be construed as guaranteeing specic properties of the products as
described or suitability for a particular application.
This guide is published without any warranty. Improvements and changes to the
online guide (if applicable) necessitated by typographical errors, inaccuracies of
current information, or improvements to programs and or equipment, may be made
at any time and without notice.
Such changes will, however, be incorporated into new editions of the PDF version of
this guide (if applicable).
Current Version
Issue 4 - Nov 2020
1.2 Standards and Compliance
Compliance and Legal Markings
Environmental Legal Compliance
This product complies with EU Directive 2012/19/EU, Waste of Electrical and
Electronic Equipment (WEEE), in all EU member states
This product complies with EU Directive 2011/65/EU, Restriction of Hazardous
Substances (RoHS), in all EU member states.
This product complies with FCC 47CFR Part 15B Class A, Federal Communications
Commission (FCC), in all states and territories of the United States.
Applicable EU Directives
Low Voltage Directive 2014/35/EU
Electromagnetic Compatibility Directive 2014/30/EU

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DS-1200 G4i Operator Manual Issue 4 - Nov 2020
1.3 End of Life
The objectives of the European Community’s environment policy are, in particular,
to preserve, protect and improve the quality of the environment, protect human
health and utilise natural resources prudently and rationally.
That policy is based on the precautionary principle and principles that preventive
action should be taken, that environmental damage should as a priority be rectied
at the source.
Separate collection of waste is the precondition to ensure reuse and recycling of
waste that is generated at the disposal of electrical or electronic equipment and
is necessary to achieve the chosen level of protection of human health and the
environment within the European Community (EC).
More particularly, certain materials and components of electrical waste, and
electronic equipment need selective treatment as their injudicious handling or
disposing of on or into land, water, or air would represent a major threat to the
environment and human health.
In order to facilitate collection and treatment separated from normal domestic
waste, electrical and electronic equipment is marked with the following WEEE
Directive logo:
Do not mix with normal domestic waste.
Please use the subjoined return or
collection system dedicated to electrical
and electronic waste.
Equipment produced after
August 13 2005
Not only are you by law not allowed to dispose of the waste equipment via other
waste-streams, but we encourage you to actively contribute to the success of such
collection and to the common good and better quality of life of present and future
generations.
For more information on the correct disposal of this product please contact your
local dealer.

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2 Safety
2.1 Safety Information
The information presented in this chapter is given as a guide to general precautions
that should be exercised during installation, operation, maintenance or servicing.
Whilst every eort has been made to ensure completeness of this document,
owners, operators, and service technicians of this machine are reminded of their
responsibilities to comply with all relevant legislations including Risk/COSHH
Assessments if applicable and Approved Codes of Practice.
To ensure the correct and safe usage of this machine and its components, you
must read and adhere to all installation, operating, maintenance and or servicing
instructions, and safety notes.
Always be aware of all warnings and notes that are listed within this manual or
noted anywhere on the machine itself. Various symbols are used in this manual,
and on the product itself to ensure correct usage, to prevent danger to the user and
others, and to prevent property damage.
The meanings of these symbols are described in section 2.2 Safety Symbols, and
is important these symbols are observed, and their descriptions read thoroughly to
understand their meanings.
2.2 Safety Symbols
Description Symbol
Protective Earth (Ground)
Identies terminals intended for connection to external
conductors, or protective earth (ground) electrodes, protecting
against electric shock in case of a fault.
Caution - Risk of Electric Shock
Identies equipment with a hazard of electric shock.
Caution - Moving Parts
Indicates the instructional safeguard to keep away from moving
parts.
Caution - Laser Beam
Indicates warning of a laser beam. Observe the rated class of
laser beam where possible.
Caution - Heavy Object
Indicates the object is heavy, adhere to the safety instructions
for provisions of lifting and moving.
Caution - Fuse
Identies equipment that is fused. Observe correct fuse ratings
where possible before replacing.
Caution/Warning
Indicates a situation in which minor, moderate, or serious injury
could occur because of the hazard present.

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2.3 Safety Notes
Prior to carrying out any installation, operation, maintenance or servicing
procedures on this machine, ensure you have fully observed and understood all
safety notes detailed in this section.
The following safety notes are given to ensure safe installation, operation,
maintenance and or servicing of this machine.
2.3.1 General Safety Notes
WARNING
• Keep the work area around the machine clean. A minimum one metre of clear
unobstructed space is required around the machine at all times.
• The machine must be used only as intended by the manufacturer and should not
be tampered with or altered in any form.
• The machine must be operated, maintained and or serviced only by trained and
authorised personnel.
• Do not operate the machine unless all of the covers are in place and
undamaged, and all warning labels are in place and legible. If any external
cover is damaged, it must be replaced only by authorised personnel or certied
engineers.
• All covers contain interlock safety cut-o switches. Do not try to bypass the
interlock safety switches, and do not attempt to operate the machine without
covers, or if any of the interlock safety switches are inoperable.
• Do not wear any loose clothing or jewellery, and long hair must be tied back
or tucked under a hat when working near the machine, as they may become
caught in any one of the moving parts resulting in injury.
• Before any cleaning, maintenance and or servicing, the machine must be
completely isolated from the power source, by switching o the isolator switch
on the rear of the Insert Head and unplugging the mains power cable completely
from the electrical power supply, or switching o the wall isolator switch if tted.
• Ensure the machine is clean before use. Wipe o any paper dust built up outside
the cabinets. If paper dust is collecting inside the machine, open the covers and
vacuum it out gently or use an invertible type nonammable airduster only.
• Although the manufacturer takes care to reduce danger. Please handle steel
sheets with care to avoid any risks of cutting.
• When the machine is not in use, the mains power cable should be completely
disconnected from the electrical power supply, stored and positioned safely.

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2.3.2 Power Connections Safety Notes
WARNING
• Ensure any isolation or disconnect device, including the mains power supply
remain unobstructed at all times.
• Ensure the mains power cable and its connectors are undamaged. Should any
electrical cable become damaged do not operate the machine, and ensure
any damaged electrical cable is replaced with a correctly certied and rated
replacement by the manufacturer.
• Hazardous voltages are present inside this machine. The power source can
produce enough voltage and current to be very dangerous.
• The machine must be earthed. Never remove the third prong from the plug.
The safety grounding (protective earth) feature provides extra protection in the
event of an electrical problem.
• The incoming mains power supply is fused. Service personnel should be aware
that a mains voltage can still exist.
• When the machine is switched o at the isolator switch on the rear of the Insert
Head, some sections of the machine will still be live with the following symbol
used in these areas.
2.3.3 Emergency Safety Notes
WARNING
• Opening any cover of the machine will trigger the interlock safety cut-o switch
and stop the machine operation (including all moving parts).
• Should a fault occur with the machine, immediately isolate the machine
completely by switching o the isolator switch on the rear of the Insert Head
and unplugging the mains power cable completely from the mains electrical
power supply, or switching o the wall isolator switch if tted.

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3 Description of machine
3.1 Overview of machine
This machine an advanced, high-volume folding and inserting machine.
Its modular construction allows up to 16 feeder/folder units to be tted.
The software control optimises the order and ow of documents for collating on the
track before insertion of the pack into the envelope.
All fold and adjustments take place automatically according to the requirements
programmed in by the operator.
3.2 Description of operation
The function of the machine is to fold forms to ‘C’, ‘Z’, ‘V’ or double forward fold,
either singly, in xed multiples or in varying groups. Enclosures such as inserts,
reply envelopes etc. may be added. Folded forms and enclosures are collated on
the track as they travel towards the insert area before insertion into the envelope.
Forms may be inserted without sealing the envelope for subsequent checking or
hand insertion.
There is a batch processing facility, allowing a preset number of cycles to be
completed before the machine automatically stops.
The machine is Barcode/2D/QR code/OMR/OCR compatible for use with reading-
enabled feeders or folders, allowing a group of forms to be collated in an
accumulator prior to folding. A number of barcode symbologies may be read.
The machine consists of a number of modules, depending upon the build ordered -
these modules are briey described below:
Inserter head
Receives a collated group of documents into an insert area, inserts the pack
into a waiting envelope and turns the lled envelope over for correct address
position. The ap is then closed and sealed.
Feeder
Feeds shortform inserts (cards, reply envelopes, booklets etc.) onto the track
for subsequent insertion. Flat material feeder is also available, for more rigid
material or booklets. Feeders can be reading enabled.
Folder
Folds single documents separately, or if reading-enabled, in groups, collating
the documents in the shuttle. Available in Hi-Cap (5000-sheet) or Standard
Cap (2000-sheet) versions.
Collator
Collates multiple documents in an accumulator before folding as a group
(up to 8 sheets C or Z fold, 10 sheets V fold). May be tted with an op-
tional 2-bin sheet diverter. Available in Hi-Cap (5000-sheet) or Standard Cap
(2000-sheet) versions. Reading or non-reading versions available.

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Vertical Stacker
High-volume output conveyor, stacks nished envelopes vertically on a mov-
ing conveyor for subsequent removal. Jog feature allows separation of groups
or batches.
A number of output devices such as envelope printer, franker, full-format inserter
and output diverter are also available.
The machine is equipped with PC controlled operating software from where jobs
can be programmed and run. The number of jobs that can be programmed is
limited only by the capacity of the PC. Input is via touch-screen monitor or optional
keyboard/mouse.
No manual setting of the fold plates or envelope closer is required, these being
adjusted automatically according to the settings in the selected program.
3.3 Identication of parts
The main parts of the machine are shown below:

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1 Touch-sensitive monitor
Runs the IMOS operating software and responds to button pushes. a remote
control is also provided, to control basic functions.
2 Vertical Stacker
Holds up to 800 envelopes (DL) for long version, or 400 envelopes for short
version. Fitted with a sensing conveyor that operates on demand to move the
envelope stack forward.
3 Envelope Feeder
Feeds envelopes to the insert head. 1m long with a 70cm long stack capacity.
It also opens the envelope ap.
4 Insert Feeder
Feeds inserts up to 152mm depth, cards, BR envelopes etc. Available with
either a standard or high capacity conveyor. Reading version is available.
5 Hi-Cap/Standard-Cap Feeder
Fits behind an accumulator or folder to feed full sized forms up to 406mm depth.
Capacity of Hi-Cap unit is up to 5000 sheets of 80gsm, Standard-Cap is 2000
sheets. Hi-Cap version has removeable trolley.
6 Accumulator
Collates forms into an accumulator and then delivers them as a group to a
folder, or if too many to fold, diverts the excess. The accumulated group is
then fed to a folder. Accumulation capacity is up to 20 forms, or 8 for folding
together.
7 Diverter
Fitted between an accumulator and folder, it receives forms diverted from the
accumulator, either because of an error condition or an oversize group.
8 Folder
Folds up to 8 forms in C, Z fold, and up to 10 forms in V or double-fold.
3-plate design, and fold plate settings are automatic. Used as an autonomous
unit, or in conjunction with an accumulator. Reading version is available.
9 Track Pair
Up to 8 track pairs can be tted, supporting up to 16 feed/fold units. Includes
the insert track and a shuttle to feed inserts or folded forms onto the track.
10 Insert Head
Receives document stack and inserts it into an envelope using a kicker.
Envelope is then turned over for correct orientation and passes to a ap
wetter/closer to close the ap. The ap is sealed shut as the lled envelope
passes through the exit.

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4 Control Panel
4.1 The Menu Screen
The Menu screen can only be accessed if you have the correct
access rights.
To access, select
Libraries functions are described in detail further in this document.

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DS-1200 G4i Operator Manual Issue 4 - Nov 2020
4.2 The Job Screen
This is the screen displayed after logging on.
See also section 4.3.1 The Run Screen displayed.
Press ‘Help’ to access this document. Press ‘Remote Assistant’ to
access assistance via Team Viewer - see Remote Assistant for further
details.
See section 5.1 Running an existing job to run a job directly
from this screen.

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4.3 The Run Screen
4.3.1 The Run Screen displayed
This is the screen you will see after an existing job has been selected in the Job
Menu, or after pressing the Run screen button.
See also section 4.2 The Job Screen.
* Shuts down IMOS and PC.
†Press Run to resume.
NOTE:
Shutdown puts the machine into Standby. To switch o the machine,
turn the Isolator switch located at the rear of the Insert Head to the OFF
position.
Press F4 to display the counts at all available exits.
(Only available with appropriate access rights).

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4.3.2 Counter settings
Job Count
Press the Job Count button on the Run screen
Output Count
Press the Output Count button on the Run screen
This cycles through the main output count, and the counts for the output devices,
depending upon the machine conguration, eg. Output Diverts. Also indicates
whether the Vertical Stacker jog is on or o.

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4.3.3 Fine tuning of settings
Fine adjustments apply only to current job.
Inserter Fine Tuning
On the Run screen graphic, press anywhere on the Inserter icon.
Note that each heading expands.
You can change:
• Seal mode: Turn o to leave envelopes unsealed.
• Doubles detect: Turn o if thick or dark envelopes give false readings.
• Separator wear: Adjust separator gap only if needed (1 clock = 0.015mm).
This changes the gap on the unit and applies to all jobs: see also Gap Adjust
below.
• Documents: Changes to the envelope depth, width, ap and throat.
• Wetting: changes the amount of wetting (1-8) where higher numbers give
greater wetting.

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• Gap Adjust: Adjusts the separator gap for this document only (1 clock =
0.015mm). Note that this is relative to Separator Wear, and adds to or
subtracts from that setting. The setting is saved with this document and
remains for future uses.
• Shield: This controls the amount of shielding over the lower separator roller,
and should not normally require adjustment. However, if stream-feeding
or erratic double feeds occur, try moving the shield back (ie. reducing the
percentage). If envelopes are not properly picking up, move it forward.
The shield is initially set in the inserter unit setup in the Envelopes screen.
Adjustments will increment or decrement this initial setting.
NOTE:
These settings apply only to the information stored with the job named at
the top of the dialog box, except for Separator Wear.
When all adjustments are complete, press OK.
Feeder Fine Tuning
On the Run screen graphic, press anywhere on the Feeder icon.
Note that each heading expands.
You can change:
• Feed control mode: Turn o to disable feeder.
• Doubles detect: Turn o if thick or dark documents give false readings.

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• Load to Reader (reading units only): this will feed one document into
position under the reader. Press Reader On to test the reader, Reader O to
end the test. Remove the document and replace on feed hopper.
• Separator wear: Adjust separator gap only if needed (1 clock = 0.015mm).
This changes the gap on the unit and applies to all jobs: see also Gap Adjust
below.
• Documents: Changes to the insert depth & width.
• Gap Adjust: Adjusts the separator gap for this document only (1 clock =
0.015mm). Note that this is relative to Separator Wear, and adds to or
subtracts from that setting. The setting is saved with this document and
remains for future uses.
• Shield: This controls the amount of shielding over the lower separator roller,
and should not normally require adjustment. However, if stream-feeding
or erratic double feeds occur, try moving the shield back (ie. reducing the
percentage). If documents are not properly picking up, move it forward.
The shield is initially set in the inserter unit setup in the Fine Tuning screen.
Adjustments will increment or decrement this initial setting.

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Folder Fine Tuning
On the Run screen graphic, press anywhere on the Folder icon.
Note that each heading expands.
You can change:
• Feed control mode: Turn o to disable folder.
• Doubles detect: Turn o if thick or dark documents give false readings.
• Address adjust: Adjustment up or down of address position in envelope
window.
• Load to Reader (reading units only): this will feed one document into
position under the reader. Press Reader On to test the reader, Reader O to
end the test. Remove the document and replace on feed hopper.
• Separator wear: Adjust separator gap only if needed (1 clock = 0.015mm).
This changes the gap on the unit and applies to all jobs: see also Gap Adjust
below.
• Documents: Changes to the insert depth & width.

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Collator Fine Tuning
On the Run screen graphic, press anywhere on the Collator icon.
Note that each heading expands.
You can change:
• Feed control mode: Turn o to disable folder.
• Doubles detect: Turn o if thick or dark envelopes give false readings.
• Address adjust: Adjustment up or down of address position in envelope
window.
• Load to Reader (reading units only): this will feed one document into
position under the reader. Press Reader On to test the reader, Reader O to
end the test. Remove the document and replace on feed hopper.
• Separator wear: Adjust separator gap only if needed (1 clock = 0.015mm).
This changes the gap on the unit and applies to all jobs: see also Gap Adjust
below.
• Documents: Changes to the insert depth & width.
• Gap Adjust: Adjusts the separator gap for this document only (1 clock =
0.015mm). Note that this is relative to Separator Wear, and adds to or
subtracts from that setting. The setting is saved with this document and
remains for future uses.