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DS-1200 G4i Operator Manual Issue 4 - Nov 2020

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 fingers

................................................................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

Summary of Contents for DS-1200 G4i

Page 1: ...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...

Page 2: ...9 3 3 Identification 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...

Page 3: ...ker 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 5...

Page 4: ...quipment 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 Stan...

Page 5: ...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 re...

Page 6: ...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...

Page 7: ...ock safety cut off 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...

Page 8: ...ty 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 ca...

Page 9: ...ally 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...

Page 10: ...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...

Page 11: ...moveable 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...

Page 12: ...r Manual Issue 4 Nov 2020 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 fu...

Page 13: ...splayed 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...

Page 14: ...b 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 off the machine turn...

Page 15: ...b 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...

Page 16: ...ds You can change Seal mode Turn off to leave envelopes unsealed Doubles detect Turn off if thick or dark envelopes give false readings Separator wear Adjust separator gap only if needed 1 clock 0 015...

Page 17: ...oving 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 wil...

Page 18: ...st 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...

Page 19: ...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 tes...

Page 20: ...only this will feed one document into position under the reader Press Reader On to test the reader Reader Off to end the test Remove the document and replace on feed hopper Separator wear Adjust separ...

Page 21: ...mote Assistant contact your local product support specialist and then start Remote Assistant from the Help dropdown This will start TeamViewer and display an ID and Password Communicate the ID and Pas...

Page 22: ...tion 7 NOTE Paper hoppers must be loaded with stationery first before running a job See section 8 Setting up the machine for further information 1 Select Jobs button at the top To run the job currentl...

Page 23: ...23 DS 1200 G4i Operator Manual Issue 4 Nov 2020 2 Load paper and envelopes in hoppers indicated 3 Press Run See also section 4 3 The Run Screen for a full description of the controls...

Page 24: ...ow to switch the user Each user has password and access rights allocated To switch user the password must be known NOTE Available functions will depend on who you log on as See section 6 2 User Access...

Page 25: ...25 DS 1200 G4i Operator Manual Issue 4 Nov 2020 2 Select user from list and press Log On New jobs can be created by pressing New This will only be available to users with the correct access rights...

Page 26: ...anged 6 2 User Access Rights Users are allocated differing levels of access rights to allow or disallow certain functions eg change settings libraries etc The rights available to you will depend on th...

Page 27: ...ing settings Miscellaneous Saving the Job to a Jobname When defining the Document BCR or OMR definitions can be optionally enabled NOTE To use an OMR or Barcode definition it must exist as part of the...

Page 28: ...ssue 4 Nov 2020 7 1 1 Defining the mailset Selecting the envelope 1 Press Select to choose envelope from the library 2 Select the required envelope and press OK To create envelopes in the library see...

Page 29: ...les Off use only if expected doubles errors occur otherwise leave On Offset Control Insert pack offset adjusts position of document pack at insert ve moves rightwards Turn backstop offset adjusts exte...

Page 30: ...rator Manual Issue 4 Nov 2020 Selecting the document 1 Press Select to choose document from the library 2 Select the required document and press OK To create documents in the library see section 7 3 C...

Page 31: ...le Feed Always reads label then always feeds multiple set in Form Count only available on reading units Reading Fixed Multiple Mark Selects reads label then feeds multiple set in Form Count when mark...

Page 32: ...g feeder only Set action required if forms exceed the quantity set in Max at shuttle see below If set to Collate at shuttle machine will stop at the end of the oversize group Note Too many forms has d...

Page 33: ...FFPD units only Sets the number of forms to be sent to the DS1200 as opposed to the forms sent to the FFI Camera Job Name This is the name entered in the camera PC program Both names must match Camera...

Page 34: ...ise loaded tray If selected automatically raises the filled tray as soon as the cover is closed Hi Cap folder or collator only HiCap fan Turn on if optional Air Assist air separation is fitted Continu...

Page 35: ...r 1 would feed from 3 instead If more than one substitute is set all of them will feed as well as the actual Diverters Allows the substitution of any divert unit on the machine for any other Sheet div...

Page 36: ...ox or Presorted different types of frank or Dater prints current date Not used disables the franker Vertical Stacker Jog mode Set the action to trigger Jog mode Jog moves filled envelopes to an offset...

Page 37: ...from the database Mail shot Sequential non reset As Mail shot Sequential but if machine is Autoended then switched back on it will continue where it left off in the database Without non reset the mach...

Page 38: ...D mix directs some forms to FFI Inserter and some to the DS 1200 folder according to barcode FFPD always directs all forms to the FFI Inserter 2 Select the Diverts button at the top of the screen if o...

Page 39: ...Postage and metering settings are defined using a Postal Product which controls the action of the weighing scales franker or printer where fitted 1 Press the settings button for Postal Product and sel...

Page 40: ...will automatically appear as the lower weight for the following group enabling an ascending scale of postage rates to be set for the four groups For the first group click the Weight Group 1 button an...

Page 41: ...ode Select what AIMS is to be used for if applicable Options are Statistics Audit Verification Lookup FBM Verification and Lookup FBM will only be available if Job Number Control Mode is an external s...

Page 42: ...42 DS 1200 G4i Operator Manual Issue 4 Nov 2020 7 2 Creating an envelope 1 Begin creating a job see section 7 Creating a job and select an envelope 2 In the Envelope selection box press New...

Page 43: ...ver the 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 p...

Page 44: ...Operator Manual Issue 4 Nov 2020 7 3 Creating a document 1 Begin creating a job see section 7 Creating a job 2 In the Document selection box press New 3 Enter a document name 4 Select Form type usuall...

Page 45: ...l position 9 Enter the location of the label and press OK 10 if Doc Id mode is to be used select On This reads a label character and compares its string value with the string entered in Doc Id This co...

Page 46: ...ailing At the rear of the machine press the tray descend button on top of the unit Hold it until the tray has descended sufficiently Load the documents into the hoppers ensuring they are pushed fully...

Page 47: ...nd load the inserts on the track At the front of the track raise the centre guide and use the backstop to push the stack of inserts forwards so that the front ones follow the slope of the track and ma...

Page 48: ...g forwards At the front of the track raise the centre guide and use the backstop to push the stack of envelopes forwards so that the front ones follow the slope of the track and make contact with the...

Page 49: ...al by an operator The Vertical Stacker moves at the speed of the machine with no separate speed control The conveyor belt moves in indexing steps so that the envelopes overlap one another Optional sid...

Page 50: ...ed to allow the vertical stacker to be emptied and the conveyor to be run NOTE The button only operates when the machine is switched on 1 Run out button Press and release the button once to run out on...

Page 51: ...m the power source by switching off the isolator switch on the rear of the Insert Head and unplugging the mains power cable completely from the electrical power supply Ensure all safety notes detailed...

Page 52: ...at the input end of the feeder conveyor to reveal the feed wheels this also applies to the envelope feeder Clean the conveyor belts using a clean lint free cloth dampened with water Hi Cap or Std Cap...

Page 53: ...y apart They should be cleaned using only an invertible type non flammable airduster ensuring that both halves are thoroughly cleaned Sensor locations are indicated in the Track shuttle figure below T...

Page 54: ...ted is located behind the track shuttle Feeder Viewed from behind the machine Raise the cover at the input end to access the sensors Pull back the latches and raise the roller covers to access the und...

Page 55: ...55 DS 1200 G4i Operator Manual Issue 4 Nov 2020 Envelope Opener Located behind the insert head just in front of the envelope feeder Lift the black handle to gain access...

Page 56: ...56 DS 1200 G4i Operator Manual Issue 4 Nov 2020 Kicker Insert area Unlatch the blue handle and lift up the kicker to gain access...

Page 57: ...57 DS 1200 G4i Operator Manual Issue 4 Nov 2020 Turnover With the insert cover raised the sensors will be seen at the bottom of the turnover...

Page 58: ...forming operator adjustments and 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 operation cleaning mainten...

Page 59: ...he fingers stop the job in a position where the envelope is waiting to be inserted or single cycle the machine using the remote control until an envelope has appeared at the insert plate Adjust the fi...

Page 60: ...ock screws are securely fastened before continuing the job If regularly changing between different envelope types that require setting of the fingers a second set of envelope fingers can be obtained t...

Page 61: ...ollers In the event that the pick up rollers in the sheet feeder become worn or when changing between jobs with different paper types it may be necessary to replace the feed tyres These are easily rem...

Page 62: ...eder and Envelope feeder pick up roller set can be replaced in a similar way to the Sheet Feeder First remove the steel over guide by pressing the sides together to release the clips from the roller b...

Page 63: ...3 DS 1200 G4i Operator Manual Issue 4 Nov 2020 Lift the roller assembly from the left hand side to remove IMPORTANT When replacing the roller assembly make sure the drive dog is fully engaged as below...

Page 64: ...envelope stack is angled back in hopper not upright b Separator is set slightly too tight c Clean envelope opener conveyor belts d Clean envelope pickup rollers e Ensure conveyor cover is fully close...

Page 65: ...llator 1 Paper not arriv ing at OMR Bar code area a Hi Lo Cap feeder separator gap too tight fine adjust from Run screen b Sensors obscured clean on both Hi Lo Cap and collator c Roller carrier plate...

Page 66: ...all documents from track upstream and downstream and press Process one cycle button see page 11 of this document b Check shuttle bed underneath shuttle is fully lowered Feeder 1 Feeder not pick ing u...

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