Advertisement
Advertisement
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
observed and their descriptions read thoroughly to understand their meanings!
Ensure all safety notes detailed in section
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!
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 1
2
Table Of Contents
1.1 About this Manual .................................................................... 4
1.2 Standards and Compliance ........................................................ 4
1.3 End of Life .............................................................................. 5
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 Identification of parts ..............................................................10
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
5.1 Running an existing job ...........................................................22
6 Switching the user ............................................................................ 24
6.1 How to switch the user ............................................................24
6.2 User Access Rights ..................................................................26
7.1 Creating the Job Settings .........................................................27
7.1.1 Defining the mailset .....................................................28
7.1.2 Defining the output settings ..........................................36
7.1.3 Defining Postage/Metering settings .................................39
7.1.4 Saving the Job .............................................................41
7.2 Creating an envelope ..............................................................42
7.3 Creating a document ...............................................................44
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
9.1 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
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 3
4
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 specific 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
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 rectified 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 5
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 effort 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
, and is important these symbols are observed, and their descriptions read thoroughly to understand their meanings.
2.2 Safety Symbols
6
Description
Protective Earth (Ground)
Identifies 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
Identifies 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
Identifies 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.
Symbol
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
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 certified engineers.
• All covers contain interlock 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 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 off the isolator switch on the rear of the Insert Head and unplugging the mains power cable completely from the electrical power supply, or switching off the wall isolator switch if fitted.
• Ensure the machine is clean before use. Wipe off 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 nonflammable 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 7
8
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 certified 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 off 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-off switch and stop the machine operation (including all moving parts).
• Should a fault occur with the machine, immediately isolate the machine completely by switching off 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 off the wall isolator switch if fitted.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
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 fitted.
The software control optimises the order and flow 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 fixed 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 readingenabled 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 briefly described below:
Inserter head
Receives a collated group of documents into an insert area, inserts the pack into a waiting envelope and turns the filled envelope over for correct address position. The flap 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 fitted 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 9
Vertical Stacker
High-volume output conveyor, stacks finished 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 Identification of parts
The main parts of the machine are shown below:
10 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
1
2
Touch-sensitive monitor
Runs the IMOS operating software and responds to button pushes. a remote control is also provided, to control basic functions.
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
4
5
Envelope Feeder
Feeds envelopes to the insert head. 1m long with a 70cm long stack capacity.
It also opens the envelope flap.
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.
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 fitted, 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 flap wetter/closer to close the flap. The flap is sealed shut as the filled envelope passes through the exit.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 11
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.
12 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
to run a job directly from this screen.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 13
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
.
14
* Shuts down IMOS and PC.
† Press Run to resume.
NOTE:
Shutdown puts the machine into Standby. To switch off 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).
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
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 configuration, eg. Output Diverts. Also indicates whether the Vertical Stacker jog is on or off.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 15
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.
16
Note that each heading expands.
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 = 0.015mm).
This changes the gap on the unit and applies to all jobs: see also Gap Adjust below .
• Documents : Changes to the envelope depth, width, flap and throat.
• Wetting: changes the amount of wetting (1-8) where higher numbers give greater wetting.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
• 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 off to disable feeder.
• Doubles detect: Turn off if thick or dark documents give false readings.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 17
• Load to Reader (reading units 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 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.
18 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
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 off to disable folder.
• Doubles detect: Turn off 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 Off 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 19
Collator Fine Tuning
On the Run screen graphic, press anywhere on the Collator icon.
20
Note that each heading expands.
You can change:
• Feed control mode: Turn off to disable folder.
• Doubles detect: Turn off 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 Off 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
4.3.4 Remote Assistant
Remote Assistant allows the machine’s PC to be remotely accessed by an engineer using TeamViewer. This can help with diagnosing problems.
To use Remote 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 Password to the support engineer, and the link will then be formed between you. The support engineer will gain full control of the machine’s
PC to allow fault diagnosis.
To end the Team Viewer session, simply close the App.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 21
5 Running a job
5.1 Running an existing job
This describes running an existing job. To create a new job, see section 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 button at the top. To run the job currently showing on the Run screen, press Exit.
To run a different job instead, select it from the list and press
Accept . You will switch to the Run screen with that job.
22 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
2 Load paper and envelopes in hoppers indicated.
3 Press .
See also section
4.3 The Run Screen for a full description of the controls.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 23
6 Switching the user
6.1 How 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 Rights for further information.
1 Select button in Job or Run screen.
24 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 25
3 Enter the password with on-screen keypad and press Return. The user has now changed.
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 the username you log on as.
NOTE:
User access rights can be created or modified only if logged in at the appropriate level of user.
26 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
7 Creating a job
Creating a job involves:
• Defining the Mailset (Envelope, document & enclosures)
• Output settings
• Postage/Metering 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 document
creation. See section 7.3 Creating a document for further information.
7.1 Creating the Job Settings
1 Press in the Job screen to start defining the mailset.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 27
7.1.1 Defining the mailset
Selecting the envelope
1 Press to choose envelope from the library.
2 Select the required envelope and press OK .
To create envelopes in the library, see section
28 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
3 If required, press Settings to define envelope usage and adjustments.
Settings are described below (expand each heading as required):
Seal Mode:
Always (default); No-seal label select reads no-seal character in label;
No-seal errors - insert document, even with errors, but leave unsealed; No envelopes - documents only are processed; No-seal label select or errors
includes both the above options.
Thickness doubles:
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 extent of pack movement around turnover.
+ve moves further in.
Thick pack eject: used when thicker packs are being processed. If set to On , track speed will be limited to a maximum of 10. For track speed 1 to 6 the turnover will run at speed 6. For track speed 7 to 10, the turnover will run at speed 10.
Insert track offset: +ve moves track guide outwards to widen track. For
Feeder or Folder, applies to that unit only. For Inserter, applies to all units at once.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 29
Selecting the document
1 Press to choose document from the library.
2 Select the required document and press OK .
To create documents in the library, see section
.
30 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
3 If required, press Settings to define document usage and adjustments.
Settings shown will vary depending upon whether a feeder, folder or collator is fitted, and whether a reading unit.
Settings for a Feeder, Folder or Collator Unit are described below:
Feed control mode:
Feed always (default)
Mark Selects feeds document when select mark is read.
Reading + Fixed Multiple (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 in prime document is read (only available on reading units).
NOTE: Mark Reading (see below) must be On for any reading mode.
Form count:
Set quantity - see Feed Control Mode above.
Fold type:
Select fold type required only if you have a requirement to deviate from default.
Mark Reading:
Set mode of reading required. This will vary depending upon reader type fitted
( Off is the only available option for non-reading feeder).
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 31
Folding Control:
Address position is read-only. This is set in document setup.
Select Feed orientation required to suit the job.
Select Document orientation required to suit the job.
Fold plate lengths can only be changed if using Custom Fold - this is only available with appropriate access rights.
Change fold settings only if required. Incorrect settings will produce errors
32
Address adjust moves address up or down in envelope window. Direction will depend upon fold type.
Reading Control:
Set Reader/head Id 1 or 2 (where applicable).
Bad reads/groups: Set action required. Not available if ‘Too many’ forms
(see below) is set to Collate at Shuttle. (If unit is reading feeder, Stop at shuttle , is the only possibility).
Too many forms (reading 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 different options on Folder or Collator.
Auto Errors Diversion : For errors that would otherwise stop machine, setting to On will divert errors instead, into device selected in Bad reads/groups above. It will operate downstream of the detection point.
The mode will detect and automatically remove sequence errors and assume that the sequence error has been generated by a double document feed.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
NOTE:
Auto Errors Diversion can only operate if the document ahead of the error is still in the unit (i.e. has not passed to the insert track). For this reason the new mode will: a) b)
Only operate on an accumulator.
Not allow the use of the single cycle function.
The automatic removal destination can be: a) b)
Sheet divert.
Output envelope divert.
c) Jog/Ink mark on the vertical stacker.
It is recommended preferably to use the sheet divert to prevent errors being enveloped and leaving the inserter.
Maximum fold (forms) : (Collator only). Set the number at which ‘Too many forms will be triggered.
Max. collate : (Collator only). Set the maximum number to collate for folding together. If the group then exceeds this number, it will be split into separate packs before passing onto the track for inserting.
Max. At shuttle : Only available if ‘Too Many’ forms is Collate at shuttle .
Select number of forms allowed to collate at shuttle before error is flagged indicating hand removal required.
Max. to DS1200 : (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 Number : Automatically allocated by the software according to number of cameras fitted to the unit.
Datalogging: Set to On if datalogging is used.
Max at FFPD collate: (FFPD units only). Number of documents in FFPD collate area. Defaults to the maximum of 72. If exceeded, machine will stop and prompt removal of excess.
Group security: Set the action required for ‘possible corrupt group’, if a potential error occurs in the group.
Doubles Control:
Thickness doubles : Select whether Optical or Mechanical is being used, or
Off if expected doubles are causing misreads.
Sensitive doubles: Options are: Off / On. When set to On , operator will be forced to remove all paper from a unit if a double document is detected, and then reload it, ensuring that possibly faulty paper loading is fully corrected.
Mixed doubles: Set to On if more than one paper thickness is used in the same hopper.
Speed Control:
Unit speed: Set if it is required to vary unit speed from machine speed. Of most use on a Collator where large group sizes will take longer to collate.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 33
Autospeed: If set to On, automatically slows machine as group sizes increase.
Use if group sizes are consistent.
Offset Control:
Insert track offset: +ve moves track guide outwards to widen track. Note that this applies only to this unit for this job.
Miscellaneous: (collator only)
Lower empty tray: If selected, automatically lowers feeder tray when empty to save time when reloading (Hi-Cap folder or collator only).
Raise 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.
Continuous running mode: Turn on to allow automatic resumption of running of a Hi-Cap unit after paper is reloaded.
No accumulation overlap: Turn on if required to fully clear collate pocket of previous group before next document is fed into it.
Additional Docs:
Select document type for Additional doc 1 if some documents being fed have an attachment.
4 Repeat in similar manner for remaining units fitted.
5 If you are using Substitution Tables, press Edit Advanced.
34 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
Feeders: Allows a substitute feeder to be used instead of the selected one, eg. if feeder 1 in the ‘Actual’ column is set to feeder 3, a select feed character set to feeder 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 divert 1 is the lower tray, output divert 1 is closest to machine.
To delete all substitutions, select Clear all.
IMPORTANT:
Any substitutions set in the Job setup will apply to only to that job.
6 Press when complete.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 35
7.1.2 Defining the output settings
Settings shown will vary depending upon the machine configuration.
1 Select the Main Output button at the top of the screen.
36
Franker (if fitted) :
Franker settings: Dynamic franker options available are: Presorted or Letterbox
(different types of frank); Message (preset string is printed) or Passthrough
(franker not used); ; Letterbox 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 position on the stacker conveyor, for identification purposes
Error Handling : Select whether errors should cause the machine to stop with the error on the track at the shuttle, or at the output (ie, either on the conveyor/ stacker or diverted to a divert unit (where fitted).
Brush offset : Adjusts the degree of contact of the brush with the envelope. this may be need, for example, if you are using thick packs.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
Envelope printer (if fitted):
Job name: The job name applies to the Flexmail project that the printer is using and which the software will use when running the machine. The scripting is the
Flexmail language used in the project. Options are No printing / Sequential /
Database lookup .
Scripting mode: This defines how the printer actions the mailpiece.
Pass through/No printing: Mailpieces continue unprinted to franker or conveyor.
Mail shot/Sequential: Mailpieces will be printed with data supplied by
Flexmail database in a sequential order from top to bottom.
Matching/DB lookup: Mailpieces will be printed with data read from the column in the Flexmail database named under the Lookup option in the Edit
Printer Settings dialog box. This is defined by the characters selected in the barcode.
This allows selective data to be read 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 machine will restart at the first entry.
Matching/Dynamic DB lookup: As Matching/DB lookup except the database is not located locally on the Flexmail PC, but accessed remotely via AIMS.
Mailshot/Dynamic Sequential: As Mail shot/Sequential except the database is not located locally on the Flexmail PC, but accessed remotely via AIMS.
Lookup: The name of the column in the Flexmail database named under the
Lookup option in the Edit Printer Settings dialog box. This is defined by the characters selected in the barcode.
Weighing device (if fitted):
Weighing mode: Sets the operation of the Weighing Scale. Off (Pass through) disables the scale so documents pass through unweighed; On (Fixed) is for future development and should not be used; On (Dynamic) recieves calculated weight data from the inserter and compares it to the weighed data; if there is a disparity, an error will be flagged.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 37
Full Format Pack Divert (if fitted):
Tandem mode (FFPD units only) : Off disables FFPD mode so unit operates as a diverter.
FFPD (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 output diverts are fitted).
3 Set the divert category for Envelope divert 1, 2 & 3 and the criteria to trigger Jog 1 & 2 mode (where these are fitted).
4 Press when finished.
38 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
7.1.3 Defining Postage/Metering settings
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 select an existing product, or New to create one.
2 Enter required options as described below.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 39
Postal Product name : Enter a name for the new Postal Product.
Weight Groups : There are four weight groups, each one defining a range with a lower and upper weight, and a postage rate to be set for that range. The upper weight that you set for each group 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 and enter the upper weight of the range in grams.
Postage : Press the Postage button, and enter the rate for that group.
NOTE:
The weight of the filled envelope is determined by the weight of each inserted document, and the envelope. These are set in the Document and Envelope options in the Setup screen.
40 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
7.1.4 Saving the Job
1 Press the keyboard button and enter a job name using the on-screen keyboard.
Repeat for a brief job description for the job. This will appear in the job list.
2 If required, enter further settings as described below.
Job number control mode: If Job Numbers are being used, select how these are generated. If Manual entry (external checking) is selected, enter the job number in the box underneath.
AIMS mode: 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 source, either
Manual entry (external) or Read from prime.
Datalogging mode: Select whether Off, Standard (default) or AIMS statistics compatible.
Late divert: This uses customer’s own data file to divert using the ID field label instead of the Divert BCS Character. Options are Off (default) or On (all).
Checking: If Checker required is selected, a checker is required to login at the same time as the operator. The checker is responsible for confirming, job settings, processing etc.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 41
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 .
42 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
3 Enter an envelope name.
4 Select envelope size. If you change default dimensions, size will change to
Custom .
NOTE:
Measure envelope carefully before changing sizes.
5 Enter the paper weight and envelope thickness and weight will automatically calculate, or press Computed and enter actual figures.
6 If using a reading label on the envelope, enter the definition name.
7 The shield setting controls the amount of shielding over 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 properly picking up, move it forward.
8 If an alternative finger set is required to be used, enter its number. The operator will then be prompted to change the finger set when the job is run.
9 Wetting rate number shown is the amount of wetting applied to the envelope flap. Default is 3, maximum is 8.
10 Press when done.
The envelope is now fully defined and is available for use.
Envelopes can also be created from the Menu screen if you have appropriate access rights.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 43
7.3 Creating a document
1
Begin creating a job (see section 7 Creating a job ).
2 In the Document selection box, press New .
44
3 Enter a document name.
4 Select Form type (usually General type )
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
5 Select document size. If you change default dimensions, size will change to
Custom .
6 Enter the Address position and Paper type (standard or glossy). If the document is pre-folded, enter the number of leaves it folds into.
7 Enter the paper weight and the document thickness and weight will automatically calculate, or press Computed and enter actual figures.
8 If using barcode or OMR marked documents, enter the definition name. Press
Region of Interest to specify label position.
9 Enter the location of the label and press OK.
10 if is to be used, select compares its string value with the string entered in Doc Id . This confirms that the correct document type is used.
On . This reads a label character and
11 The shield setting controls the amount of shielding over the separator rollers, 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.
12 Press when done.
The document is now fully defined and is available for use.
Documents can also be created from the Menu screen if you have appropriate access rights.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 45
8 Setting up the machine
8.1 Loading the Folder hoppers
Before running with your selected Job, the folder must be set up and loaded with the stationery you intend to use. There is no need to make any adjustments for fold lengths, envelope stops etc., as these are all carried out automatically.
The folder is fitted with a high or standard capacity hopper. If high-capacity, the paper trolley can be withdrawn from the machine as required, e.g. for quickly changing to a trolley with different paper type for a different job.
• Ensure that the documents or inserts are orientated correctly for the type of fold and address position, ie. whether face up or down and address leading or trailing.
• 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 forward - each hopper can hold up to
5000 sheets of 80 gsm paper. The tray will rise automatically when the machine is restarted.
• Each paper hopper can also be withdrawn from the machine by gripping the latch bar, and moving the hopper rearwards on the castors. This will also allow spare, pre-loaded hoppers to be quickly moved into place, so avoiding delays in loading. The hopper has independently adjustable side guides, with three lock knobs for each. These must be set so that the paper stack is central, with approx.
1mm clearance each side all the way up .
46
When a trolley is set for a paper type, it should only be used for that paper type, to avoid readjustment. If other paper types are used, further trolleys should be obtained.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
8.2 Loading the Feeder hoppers
Feeders are used for inserts up to a maximum depth of 6” (152mm).
To load the hopper, rotate the adjustment knob to set the side guides slightly wider than the insert - allow about 1mm each side).
Slide the backstop rearwards and 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 make contact with the ribbed rollers at the front. Do not push the backstop in too tightly - it will automatically adjust to the correct tension when the machine starts operating.
1. Backstop
2. Ensure inserts are correctly orientated so they enter the envelope the right way.
3. Side guide adjustment knob
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 47
8.3 Loading the Envelope hopper
To load the hopper, rotate the adjustment knob to set the side guides slightly wider than the envelope - allow about 1mm each side).
Slide the backstop rearwards and load the envelopes on the track with flaps facing 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 ribbed rollers at the front. Do not push the backstop in too tightly - it will automatically adjust to the correct tension when the machine starts operating.
1. Backstop
2. Load envelopes stack to follow the contour of the track. Flaps must face upwards and forwards.
3. Side guide adjustment knob.
48 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
9 Vertical Stacker
9.1 About the Vertical Stacker
The Vertical Stacker receives filled envelopes from the inserter and feeds them up an inclined conveyor to a horizontal stacking conveyor, where they are gathered vertically for subsequent removal 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 side trays may be fitted to support mailroom trays for unloading the filled envelopes into.
9.2 Operation
The Vertical Stacker is fitted with a jog function. may also be fitted with an optional ink marker. This is described in section
7.1.2 Defining the output settings and
shown in extract below:
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 49
Operation is automatic, requiring the operator only to unload the conveyor as it fills up. An optional side table is available to support mail trays for the filled envelopes to be decanted into.
A run-out button is provided 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.
50
1. Run-out button
Press and release the button once to run out one envelope. Repeat for any further envelopes on the sloping track.
Press and hold the button to run out all envelopes and activate the conveyor.
NOTE:
If the conveyor is allowed to fill up without emptying, the machine will stop with an error when it is full to capacity.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
10 Operator Maintenance
10.1 Cleaning the machine
After processing large numbers of inserts, contamination can build up on the rollers, and paper dust can obscure the optical sensors, impairing efficiency.
To ensure the machine continues to operate effectively, the rollers and sensors should be cleaned periodically, and particularly if a large run is envisaged.
NOTE:
If operating problems occur, the rollers and sensors should always be cleaned first before taking further action.
WARNING
Opening any cover of the machine will trigger the interlock safety cutoff switch and stop the machine operation (including all moving parts), however power to the machine will still exist.
The machine must be completely isolated from 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 in section
including it’s sub-sections are read in it’s entirety and understood before any cleaning, maintenance and or servicing.
10.1.1 Cleaning conveyor belts
Accumulated dirt, grime and residue may build up on the surface of the Conveyor belts, specifically after a long period of use.
Periodic cleaning on the complete surface of the conveyor belts may be required.
Clean the complete surface of the belts using a lint-free cloth dampened with water.
This method will normally be sufficient, however for more stubborn soiling, the use of a foam-type surface cleaner may help.
NOTE:
The belts may be moved round using the run-off button when the mains switch is on.
Avoid using strong spirit-based cleaners or solvents, as these may damage the belts.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 51
52
10.1.2 Cleaning rollers
Periodically, all rollers, feed wheels and conveyor belts should be cleaned to remove impacted residues picked up from processing printed material. Use a clean, lint-free cloth dampened with water on all rollers, feed wheels and conveyor belts.
Clean the full width and circumference of all visible rollers and feed wheels, using the location guide below. Most rollers and wheels can be turned round by hand, though some may be quite stiff.
Feeder Interface
Located in front of the feeder. Clean the four conveyor belts on the upper conveyor, then raise this upwards to access the four lower belts.
Feeder
Raise the cover 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 Feeder
Raise the top cover to reveal the feed wheels. Also lift up the inner plate to access the rollers below.
Collator
Raise the collator cover and clean the full length of the conveyor belts of both upper and lower conveyors (release the latches and lift up the upper conveyor to access the lower conveyor). If a barcode/OMR unit is fitted, clean these conveyor belts and rollers also.
Envelope Opener
Lift up the black handle in front of the envelope feeder and raise to access the envelope opener conveyor. Clean the conveyor belts and the rollers using a clean, lint-free cloth dampened with water.
Turnover
Clean the turnover belts and also the large aluminium wheels that they run on.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
10.1.3 Cleaning sensors
The optical sensors on the machine consists of two halves, spaced slightly 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.
Track shuttle
( Viewed from behind the machine).
Open the top covers of the track stations. Raise the shuttle and the overguide to access the sensors.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 53
Folder
Open the top covers of the track stations. The folder (where fitted) 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 underside.
NOTE:
A feeder is also fitted behind the envelope opener - ensure these sensors are also cleaned in the same way.
54 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 55
Kicker/Insert area
Unlatch the blue handle and lift up the kicker to gain access.
56 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 57
11 Operator Adjustments
Prior to running a job, a number of operator adjustments may be needed.
These adjustments are:
• Setting the fingers
• Replacing feeder pick-up rollers
WARNING
Opening any cover of the machine will trigger the interlock safety cutoff switch and stop the machine operation (including all moving parts), however, power to the machine will still exist.
Take caution when performing 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, maintenance and or servicing of this machine!
11.1 Setting the fingers
Before making any adjustments to the finger settings, check the correct envelopes for the job are being used; the envelope flap depth and throat depth must accord
with the envelope settings in the job program (see section 7 Creating a job ).
Adjust the throat depth setting on the side of the Kicker to match the envelope and job setting. Tighten the lock screw when finished.
58 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
To set the 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 finger position by loosening the blue lock screws A and B.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 59
Ensure that the fingers will pass into the envelope throat when moving the finger mechanism forward.
Ensure the lock 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 to minimise job change over time.
The finger set can be removed from the left-hand and right-hand sides by removing the lock screw on the end of the finger shaft.
60 DS-1200 G4i Operator Manual Issue 4 - Nov 2020
11.2 Replacing the sheet feeder pick-up rollers
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 removed by sliding the spring loaded roller assembly to the left and lifting from the right.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 61
11.3 Replacing insert & envelope feeder pick-up rollers
The insert feeder 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 bearings.
Slide the complete spring loaded roller assembly to the right to release the drive dog on the left-hand end.
62 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.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 63
12 Troubleshooting guide
The following guide provides possible solutions to operating problems that may arise. It is not intended to provide a complete solution to all the possible problems shown, but should be used in conjunction with advice on curative action from your local service team. For a description of all error codes, see the ‘Advanced
Troubleshooting Guide’.
To assist in identification of modules referred to, see the ‘Module Identification
Guide’.
NOTE:
If persistent operating problems are occurring clean all sensors before
taking further action. See section 10.1.3 Cleaning sensors for further
information.
64
PROBLEM
Envelopes and
Insert Area
POSSIBLE SOLUTION / ACTION
1. Poor pick-up of envelopes.
2. Flaps not opening.
a) Side guides too tight - set to 1mm free play each side. b) Separator shield set too far back (to adjust, see pages 14 to 16 of this document). c) Clean envelope pick-up rollers.
a) Ensure 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 closed.
3. Fingers not inserting properly. a) Angle of fingers may need adjusting - slacken lock screw to ad just. b) Check outer fingers are narrower than envelope by 9 - 10mm each side but must be wider than insert - reduce side clearance if necessary.
4. Envelope skewed at insert. a) Check side guide clearance - should be 1mm free play each side. b) Check software for correct envelope size (see page 25 of this document).
5. Inserts not arriving at insert area. a) Side guides too tight - set to 1mm free play each side. b) Increase envelope depth in software (see section 7.2 Creating an envelope ).
6. Inserts coming out of envelope when leaving insert area.
a) Metal tape underneath kicker needs angling downwards - contact
Service Department.
7. Filled envelopes crashing at turnover eject (underneath turnover).
a) Check turnover belts are not misplaced.
8. Filled envelope failing to leave insert area. a) Wetter roller not fully lowered. b) Carrier on wetter conveyor not fully seated.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020
Hi-Cap or Std-
Cap Feeder
1. Paper not picking up or not feeding properly.
2. Doubles or stream-feeding occurring.
3. Feed overrun. a) Side guides too tight - set to 1mm free play each side (check from top to bottom - note guides are also adjustable for angularity. b) Check paper stack is pushed fully forward. c) Feed rollers dirty, especially pickup rollers. d) Separator is set too tight (to adjust, see pages 14 to 16 of this document). e) Sensors in feed area blocked or dirty. f) Ensure stationery is correctly loaded on printer prior to use, ie. prime side must be printed.
a) Check correct document information is being used in Documents and Configuration. b) Separator gap too large. c) Feed rollers dirty, especially pickup rollers. d) Check side guides and paper stack (see a) & b) in problem 1). e) Let stationery settle for 24 hours near to machine before use. f) Check relative humidity - should be 30 - 80%.
a) Pivoting feed roller carrier left in raised position - lower it. b) Paper stack support tray is lopsided - contact Service Department.
4. “Hi-cap overrun” error message appearing on screen. a) Uneven paper stack (one side higher than the other) - may be caused by uneven ink/toner laydown. Reduce stack to 250 sheets. b) Paper tray tilted due to stretched chains - contact Service Department.
Collator
1. Paper not arriving at OMR/Bar code area.
2. Paper not arriving at collator holdpoints. 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 at Hi/Lo-Cap feed area not properly latched down. d) Black conveyor belt carriers under reader head are raised - fully lower them.
a) Improper location of 2 spring-loaded shafts with white nylon rollers - also check drive pins are present. b) Main collator conveyors not fully latched down. c) Side guides on lower conveyor incorrectly set - adjust using green knob on RH side.
3. Paper crashing at entry to collate pocket (under lower conveyor).
a) Collate pocket incorrectly set for paper size (eg. Letter setting but A4 paper) - check document setup. b) Collate pocket side guides incorrectly set - adjust using green knob on RH side.
4. Paper crashing at exit from collate pocket. a) Collator not fully latched to main machine. b) Document trapped between collator exit and main machine - unlatch and withdraw to check. c) Paper excessively curled - restack and check printer (may be running too hot).
5. “Collate pocket exit jam” or “Form not arrived at collate exit” error message on screen. a) Paper not central in collate pocket - adjust side guides so that trailing edge gives 1 - 2mm clearance each side. Open collate conveyor to adjust. b) Feed in one sheet, open collate conveyor and measure clearance. c) Steel balls restricting entry - contact Service
Department to remove one or more symmetrically.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020 65
66
Folder
1. Paper not folding correctly. a) Dirty fold rollers - clean with damp cloth. b) Fold plates incorrectly set - check settings in Document and Configuration screens. c)
Change standard fold type (eg. C instead of Z) or use custom fold. d)
Check fold plates are fully latched.
2. Paper not exiting from folder correctly. a) Paper caught behind shuttle bed - raise shuttle to reveal. Clean four exit rollers at far edge of shuttle bed. b) Loose ribbon cable connector at front of shuttle. c) Metal output tapes on folder exit are incorrectly set. d) Insert track overguide incorrectly set (located above track cassette).
Insert Track
1. Shuttle stalling. a) Loose ribbon cable connector at front of shuttle. b) Metal tapes underneath shuttle incorrectly set. c) Shuttle pawls need resetting - manually pull round a few centimetres.
2. Paper crashing on insert track.
3. Insert track stall (reported on screen).
a) Insert track overguide incorrectly set (located above track cassette). b) Folded document wrong size for track - check settings in
Document screen, particularly if custom fold. c) Dirty sensors in insert track or shuttle area - clean. d) Manually check that insert track pawls can be moved.
a) Remove 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 picking up.
2. Doubles being fed, or stream feeding. a) Side guides too tight - set to 1mm free play each side. b) Ensure envelope stack is angled back in hopper, not upright. c) Dirty or glazed feed rollers - clean. d) Separator is set slightly too tight - fine adjust from Run screen. e) Check separator shield setting (if feed is slow, increase shield) - adjust in document inserter from Run screen
(see pages 14 & 15 of this document). f) Dirty sensors on feeder - clean. g) Run with inserts opposite way round or inverted. h) Check spring-loaded shaft with pickup rollers is properly located. Also check pivoting roller plate in front of this is fully latched.
a) Check correct document information is set in Configuration and
Job screens. b) Separator is set slightly too wide - fine adjust from
Run screen. c) Dirty separator rollers - clean. d) Separator needs recalibrating - perform this in document inserter from Run screen (see pages 14 to 16 of this document).
3. Inserts crashing on exit of feeder. a) Paper caught behind shuttle bed - raise shuttle to reveal. Clean conveyor belts on feeder interface. b) Loose ribbon cable connector at front of shuttle. c) Run with inserts opposite way round or inverted. d) Feeder output tapes (at far end of shuttle) incorrectly set.
DS-1200 G4i Operator Manual Issue 4 - Nov 2020

Public link updated
The public link to your chat has been updated.
Advertisement