quadient DS-200iQ User manual

INSTALL GUIDE DS-200iQ / DS-600iQ

iiINSTALL GUIDE
DS-200iQ / DS-600iQ
WARNING
Improper installation, use, adjustment, alteration, service
and or maintenance may result in property damage and
or serious bodily injury!
Ensure the important packaging information detailed
in section 1.3 Important Packaging Information and all
safety information detailed in section 1.4 Safety including
it’s sub-sections are read and understood in it’s entirety
before installation, operation, maintenance and or
servicing of this machine!

TABLE OF CONTENTS
iiiINSTALL GUIDE
DS-200iQ / DS-600iQ
1 SAFETY STANDARDS COMPLIANCE 1
1.1 About this Manual 2
1.2 Standards and Compliance 2
1.3 Important Packaging Information 2
1.4 Safety 3
1.4.1 Safety Symbols 4
1.4.2 General Safety Notes 4
1.4.3 Power Connections Safety Notes 5
1.4.4 Emergency Safety Notes 5
1.4.5 Electrical Installation Safety Notes 6
2 INTRODUCTION 7
2.1 Detachable Components 8
2.1.1 Insert Head Components 8
2.1.2 Versatile Feeder Components 8
2.1.3 Flex Folder Components 8
2.1.4 Output Conveyor Components 9
2.1.5 PC Components 9
2.1.6 Module Stands 9
3 LIFTING KIT 10
3.1 Lifting Kit 11
3.1.1 Attaching the Lifting Kit 11
3.1.1.1 Cut-out Locations 13
4 MODULE STANDS ASSEMBLY 15
4.1 Assembling the Module Stands 16
4.1.1 900mm Stand (A3-0424-A) 16
4.1.2 408mm Stand (A3-0434-A) 18
5 INSERT HEAD INSTALLATION 20
5.1 Positioning the Insert Head 21
5.2 Removing the Insert Head Covers 22
5.2.1 Drive Side Cover 22
5.2.2 Operator Side Cover 23
5.2.3 Front Output Cover 24
5.3 Attaching the Monitor Post 25
5.3.1 Attaching the Monitor 25
5.3.2 Connecting the Monitor Cables 26
5.4 BCR Hand-Scanner Installation 28
6 MODULE WIRING 31
6.1 DIP Switch Settings 32
6.2 Communications Cable Connections 33
6.3 Power Cable Connections 34
6.4 PC Equipment Connections 34
6.5 INF Output CAN Connections 35

ivINSTALL GUIDE
DS-200iQ / DS-600iQ
7 SOFTWARE AND FIRMWARE 37
7.1 ImportantCongurationSettings 38
7.2 LicenceandCongFileInstallation 39
7.2.1 SystemCongurationandReadingLicensing 39
7.2.2 AIMS-100 On-board Licensing 39
7.3 Firmware Download 40
7.3.1 Broadcast Mode 41
7.3.2 Changing Parameters 41
7.3.3 Reader Firmware Download 41
7.4 Plug and Play 42
7.5 Language Settings 43
8 DISPOSAL INSTRUCTIONS 44
8.1 End of Life 45

1INSTALL GUIDE
DS-200iQ / DS-600iQ
1
SAFETY STANDARDS COMPLIANCE

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INSTALL GUIDE
1SAFETY STANDARDS COMPLIANCEDS-200iQ / DS-600iQ
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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).
1.2 STANDARDS AND COMPLIANCE
Safety 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 Directives
Low Voltage Directive 2014/35/EU
Electromagnetic Compatibility Directive 2014/30/EU
The product presented in this guide meets the requirements of applicable directives.
AllmachinesarebuilttostrictsafetyspecicationsinaccordancewithULStandards,
Low Voltage Directive, and Electromagnetic Compatibility Directive.
For further information please contact your authorized distributor.
1.3 IMPORTANT PACKAGING INFORMATION
ATTENTION
Observe the following important packaging information prior to unpacking
the product:
1. All external packaging should be checked for signs of damage prior to
receiving and signing of goods.
2. All ShockWatch’s and Tiltwatch’s as shown in Figure 1.1 and Figure 1.2 are
attached to outside of carton sides and should be checked. Where a pallet is
dispatched individually a ‘Do not Stack Cone’ will be attached to the top of
the product.
If any indicator is RED, ‘Do not refuse shipment’ but make a notation on the
delivery note or bill of lading.
If any damage is discovered, product should remain with original packaging and
carrier should be contacted for further instructions.
3. Activated ShockWatch or TiltWatch is a sign the goods have been subject
to poor handling. There may be a risk of damage to the product and carrier
shouldbecontactedintherstinstance.

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SAFETY STANDARDS COMPLIANCE
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QDT-RND-GEN-00000159-A-00
Figure 1.1 – ShockWatch
QDT-RND-GEN-00000160-A-00
Figure 1.2 – TiltWatch
1.4 SAFETY
The information presented in this section is given as a guide to general precautions
and safety procedures that should be exercised during installation, operation,
maintenance and or servicing of this machine.
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.
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 1.4.1 Safety Symbols, and
is important these symbols are observed, and their descriptions read thoroughly to
understand their meanings.
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.

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SAFETY STANDARDS COMPLIANCE
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1.4.1 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.
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.
Important Note
Refers to the important note referenced/detailed within the
manual.
Refer to Manual
Refers to the relevant instructions referenced/detailed within the
manual.
1.4.2 GENERAL SAFETY NOTES
WARNING
▪Keep the work area around the machine clean. A minimum one metre of clear
unobstructed working space is always required around the machine.
▪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 pressing the toggle switch
locatedattherearoftheInsertHeadtotheoposition,andunpluggingthe
mains power cable completely from the electrical power supply.
▪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air-
duster only.
▪Although the manufacturer takes care to eliminate sharp edges to reduce
danger, please handle all manufactured parts 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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1.4.3 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 sound and 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.
▪A voltage of 230V may be present inside this machine. The power source can
produce enough voltage and current to be very dangerous.
▪This machine is equipped with a three-pronged plug. One of the prongs on the
plug provides a safety grounding (protective earth) feature. Ensure the plug
is always connected to a properly wired three-prong outlet. Do not use a two-
prong adapter without grounding the machine properly.
▪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 mains power supply is fused on both live and neutral sides. Service
personnel should be aware that a mains voltage can exist even if no lighted
neon shows.
1.4.4 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 from the power source, by pressing the toggle switch located
attherearoftheInsertHeadtotheoposition,andunpluggingthemains
power cable completely from the electrical power supply.

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1.4.5 ELECTRICAL INSTALLATION SAFETY NOTES
WARNING
This machine is supplied with a plugged power lead, or optionally an unterminated,
three-core lead for connection to the mains power supply.
Foranunterminatedlead,theconnectionmustonlybemadebyaqualiedelectrician,
orbyaqualiedServiceEngineer.
▪This equipment must be earthed.
▪Forcontinuedprotectionagainsttheriskofre,fusesmustonlybereplaced
by those of the same type and rating.
▪This equipment is internally fused in both Live and Neutral leads.
▪Maximum input current is 10A for 115V and 6.3A for 230V. Maximum leakage
current shall not exceed 5% of the input current.
Pluggable vs Hardwired
This machine is supplied in default ‘pluggable form’ for connection to a standard or
domestic supply. The socket outlet shall be installed near the equipment and shall be
easily accessible.
If the machine is supplied in optional ‘hardwired form’, an appropriate disconnect
device shall be provided as part of the building installation and be readily accessible.
230 Volt Machine Wire Colours 115 Volt Machine Wiire Colours
Live Brown Brown
Neutral Blue Blue
Earth Green / Yellow Green / Yellow
High Leakage Current - an earth connection is essential before
connecting to the mains power supply!

7INSTALL GUIDE
DS-200iQ / DS-600iQ
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INTRODUCTION

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2INTRODUCTIONDS-200iQ / DS-600iQ
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2.1 DETACHABLE COMPONENTS
The DS-200iQ/DS-600iQ machine is supplied on site with each module packaged
separatelyandwithstandssuppliedinat-packform.
Check that the following detachable components described in this section are
all present.
2.1.1 INSERT HEAD COMPONENTS
Kit No. A0079370 (Euro) / A0086815 (UK 230V) / A0079369 (US 115V)
Kit No. (Datacard) A0104022 (Euro) / A0104023 (UK 230V) / A0104021 (US 115V).
COMPONENT PART NO. FACTORY REF. QTY
POWER CABLE (EURO) 9100358P 162-311 2
or POWER CABLE (UK) 9100356M 162-210 2
or POWER CABLE (US) + 9100360R 162-321UL 1
or POWER CABLE (US) A0093963 A2A-A0093963 1
Other Power Cables available (not supplied)
POWER CABLE (AUS) 9113211C 162-3130 3
POWER CABLE (CH) 9113210B 162-3120 A/R
COMPONENT PART NO. FACTORY REF. QTY
CLEANING KIT AUTO 1 9101632R A3104A 1
CAP OPENER 10L BOTTLE 9110955C N0-0092-A 1
MONITOR POST ASSY A0052726 A2A-A0052726 1
DS600 OUTFEED ASSY A0086537 A2A-A0086537 1
MONITOR POST COVER ASSY A0087134 A2A-A0087134 1
IIYAMA MONITOR PLATE A0081574 B2G-A0081574 1
LOOM ASSY PC COMMS A0082017 182-A0082017 1
CABLE RJ45 COMMS 1.25M 9113538T 160-514 1
GENERIC SAFETY GUIDE A0070526 K0A-A0070526 1
IMOS ADVICE DOCUMENT A0093887 K0A-A0093887 1
AIMS ADVICE DOCUMENT A0093888 K0A-A0093888 1
EXTERNAL FLOAT SWITCH (Datacard only) 9110289J A3-0421-A 1
2.1.2 VERSATILE FEEDER COMPONENTS
The following items are supplied separate to the Versatile Feeder unit:
COMPONENT PART NO. FACTORY REF. QTY
CABLE RJ45 COMMS 1M 9105914B 160-511 1
SCREW M5 x 10MM HEX HEAD A0075528 E2A-A0075528 *
NOTE:
‘*’Quantitydependentuponmachineconguration.
2.1.3 FLEX FOLDER COMPONENTS
The following items are supplied separate to the Flex Folder unit:
COMPONENT PART NO. FACTORY REF. QTY
TOWER FEED TRAY 500 A0072994 A2A-A0072994 *
ACCUMULATOR A0079649 A2A-A0079649 1
DIVERT TRAY 9111181N A2-1377-A 1
NOTE:
‘*’Quantitydependentuponmachineconguration.
Divert Tray (A2-1377-A) is part of Accumulator (A2A-A0079649) but is packed
separately.
Units are attached together using M5 x 10mm Hex Head Screws
(E2A-A0075528), supplied assembled to the unit.

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INTRODUCTION
DS-200iQ / DS-600iQ
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2.1.4 OUTPUT CONVEYOR COMPONENTS
Optional Loose Items Kit No. A0081622.
COMPONENT PART NO. FACTORY REF. QTY
LOOM CONVEYOR 0.75M 9109918X 181-8540 1
ROLLERS 9112022P A2-1472-A 1
DEFLECTOR 9112123U G7-0195-A 1
LOBE KNOB BLACK 9110194K E0-0632-A 2
SEAL ROLLER BRACKET DR 9118920Z B2-2218-G 1
SEAL ROLLER BRACKET OP 9118921A B2-2219-G 1
CONVEYOR GUIDE SHIM 9120953S G6-0264-A 1
BAG OF FASTENERS N/A N/A 1
DS600/200 CONV USER GUIDE K1A-A0090127 1
2.1.5 PC COMPONENTS
The following PC components are supplied additional to Loose Items Kit.
COMPONENT PART NO. FACTORY REF. QTY
PC + DS HIGH END IMOS (Quadient) A0089784 184-A0089784 1
PC + DS200i IMOS S/W (Datacard) A0089786 184-A0089786 1
PC + DS HIGH END IMOS (Cardfolder) A0095519 184-A009551 1
MONITOR WIDESCREEN 22” A0082293 184-A0082293 1
2.1.6 MODULE STANDS
COMPONENT PART NO. FACTORY REF. QTY
900MM STAND (Insert Head & Flex Folder) 9109964V A3-0424-A 1
408MM STAND (Versatile Feeder) 9110491U A3-0434-A 1
1350MM STAND (Conveyor) 9110376Z A3-0432-A 1
Stands are supplied in single units of 900mm or 408mm long and are attached
togetherasrequiredtosuitthemachinecongurationasshowninFigure2.1,upto8
modules using the best combination of 900mm and 408mm stand units.
QDT-RND-GEN-00000162-A-00
Figure 2.3 – Machine conguration

10INSTALL GUIDE
DS-200iQ / DS-600iQ
3
LIFTING KIT

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3LIFTING KITDS-200iQ / DS-600iQ
REV 00
3.1 LIFTING KIT
The lifting Kit is an optional item available by ordering Part Number A3-0452-A
(9111924M), and aids in the removal of the DS-200iQ/DS-600iQ Insert Head, Flex Folder
or Versatile Feeder from it’s packaging, once the outer box has been removed.
It consists of two universal beam assemblies which attach to each end of the machine
as shown in Figure 3.1 to allow manual removal by four people.
QDT-RND-GEN-00000163-A-00
Figure 3.1 – Lifting Kit universal beam
3.1.1 ATTACHING THE LIFTING KIT
The universal beams each attach to one end of the module; one universal beam to the
front of the module and one to the rear.
NOTE:
Theuniversalbeamisttedwith2dierentlocatinglugs;foreitherinwardor
outward facing cutouts on the machine.
The front of the Insert Head and the rear of the Flex Folder have inward
facing cut-outs, all other locations have outward facing cut-outs.
1. After removing the box from the base, attach one universal beam to the front
of the module and one to the rear.
2. Attach the beam to each end of the module as shown in Figure 3.2 by locating
the appropriate lugs into the cut-outs in the chassis.
QDT-RND-OPS-00000283-A-00
Figure 3.2 – Attaching the beam
See section 3.1.1.1 Cut-out Locations for further assistance.

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LIFTING KIT
DS-200iQ / DS-600iQ
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3. After the lugs have been set to the required location, they must be secured
with the supplied M6x45 screw (E2803A) as shown in Figure 3.3.
The screw is used simply as a location pin to prevent sideways
movement of the lugs, and does not screw into place.
QDT-RND-OPS-00000284-A-00
Figure 3.3 – Location pin security screw
4. Once the beam and the screw (location pin) has been correctly located,
tighten the lockscrews on each end as shown in Figure 3.4 to secure the beam
in place.
QDT-RND-OPS-00000285-A-00
Figure 3.4 – Securing the lockscrews

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LIFTING KIT
DS-200iQ / DS-600iQ
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3.1.1.1 CUT-OUT LOCATIONS
Insert Head Cut-out Locations
Figure 3.5 and 3.6 show the front and rear cut-out locations of the Insert Head.
QDT-RND-OPS-00000286-A-00
Figure 3.5 – Insert Head front cut-out locations
QDT-RND-OPS-00000287-A-00
Figure 3.6 – Insert Head rear cut-out locations
Versatile Feeder Cut-out Locations
Figure 3.7 and 3.8 show the front and rear cut-out locations of the Versatile Feeder.
QDT-RND-OPS-00000288-A-00
Figure 3.7 – Versatile Feeder front cut-out locations
QDT-RND-OPS-00000289-A-00
Figure 3.8 – Versatile Feeder rear cut-out locations

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LIFTING KIT
DS-200iQ / DS-600iQ
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Flex Folder Cut-out Locations
Figure 3.9 and 3.10 show the front and rear cut-out locations of the Flex Folder.
QDT-RND-OPS-00000290-A-00
Figure 3.9 – Flex Folder front cut-out locations
QDT-RND-OPS-00000291-A-00
Figure 3.10 – Flex Folder rear cut-out locations

15INSTALL GUIDE
DS-200iQ / DS-600iQ
4
MODULE STANDS ASSEMBLY

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4MODULE STANDS ASSEMBLYDS-200iQ / DS-600iQ
REV 00
4.1 ASSEMBLING THE MODULE STANDS
Instructions for assembling the module stands are packed with every cabinet, and may
also be accessed via the manufacturer online knowledgebase at
https://kb.quadient.com
4.1.1 900MM STAND (A3-0424-A)
Follow the assembly instructions shown in Figure 4.1 and Figure 4.2 to assemble the 900mm Stand (A3-0424-A).
QDT-RND-OPS-00000292-A-00
Figure 4.1 – 900mm Stand (A3-0424-A) contents