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Pitney Bowes Relay 1000, Operator'S Manual, Page: 7 / 64

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Summary of Contents for Relay 1000

Page 1: ...Relay 1000 Shipping Mailing Inserter Document Inserting System Operator Guide US International English Edition SV63176 Rev B February 1 2016 ...

Page 2: ... or in part in any fashion or stored in a retrieval system of any type or transmitted by any means electronically or mechanically without the express written permission of Pitney Bowes We have made every reasonable effort to ensure the accuracy and usefulness of this manual however we cannot assume responsibility for errors or omissions or liability for the misuse or misapplication of our products...

Page 3: ...nsert Double Detect On Off 1 10 Safe Seal On Off 1 10 Chapter 2 System Overview Preparing and Loading 2 3 Connecting Power and Turning On 2 3 Fill the Moistener 2 4 Loading the Sheet Feeders Feeders A1 and A2 2 5 Loading the Envelope Feeder Feeder B 2 6 Remove Install the Stacker 2 8 Chapter 3 Run a Job Run a Job 3 3 All Models 3 3 Models with an Insert Feeder 3 3 Models with an Optional Second Sh...

Page 4: ...ages General Troubleshooting 5 3 Error Messages 5 5 Chapter 6 Specifications Specifications U S 6 3 Material Specifications U S 6 3 System Specifications U S 6 5 Specifications International 6 6 Material Specifications International 6 6 System Specifications International 6 8 ...

Page 5: ...route the AC power cord over sharp edges or trapped between furniture DO NOT route the power cord over sharp edges or trap it between pieces of furniture Make sure there is no strain on the power cord If the unit becomes damaged unplug it from the wall Keep fingers long hair jewelry and loose clothing away from moving parts at all times Avoid touching moving parts or materials while the machine is...

Page 6: ... cabinet encloses hazardous parts Immediately report to service any damaged or non functioning components that renders the unit unsafe Contact your system supplier for the following Supplies Material Safety Data Sheets If you should damage the unit Required maintenance service schedule CAUTION Before you relocate a Relay 1000 with an optional second Sheet Feeder A2 installed 1 Unplug the power cor...

Page 7: ...stem 1 3 System Configurations 1 3 Component Identification 1 4 Advanced Menu Options 1 8 Reset Counter 1 8 Change Paper Size 1 8 Move the Address in the Window 1 9 Sheet Double Detect On Off 1 9 Insert Double Detect On Off 1 10 Safe Seal On Off 1 10 ...

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Page 9: ... diagrams below All four configurations come standard with a sheet feeder and an envelope feeder All four can accept an optional second sheet feeder Configuration 1 One Sheet Feeder One Envelope Feeder Configuration 2 Insert feeder One Sheet Feeder One Envelope Feeder One Insert Feeder Configuration 3 Optional Second Sheet Feeder One Sheet Feeder One Envelope Feeder Optional Second Sheet Feeder Co...

Page 10: ...is feeder to add inserts to your envelope Material fed from this feeder cannot be folded by the system However this feeder is especially suited to pre folded or thicker inserts 3 Slot for Operator Guide Store the Operator Guide in the slot provided so that it is readily available when you need it 4 Control Panel This is where you enter commands and where the system informs you of its status See th...

Page 11: ...do this the address won t show in the envelope window Always load sheets into feeder A2 face down and with the bottom edge of the sheet going first into the system 8 Standard Sheet Feeder A1 This feeder enables folding and inserting of a sheet into the envelope Always load sheets into this feeder face down and bottom edge first 9 Manual Feeder M Use this feeder to manually feed stapled sets of up ...

Page 12: ... 7 6 4 1 Display Shows the current status of your Relay 1000 and displays prompts and error messages 2 Menu Enter see Advanced Menu Options section for details Press this button to enter the menu options Available options Reset Counter Change Paper Size not available on all configurations Move Address in Window Turn Sheet Double Detection On Off Turn Insert Double Detection On Off Turn Safe Seal O...

Page 13: ...ece Press this button to run one fully collated piece as programmed via the control panel The envelope will not seal regardless of whether the system has been told to seal or not This allows you to inspect the processed job to make sure that everything is inserted correctly and that the address appears in the window The trial piece also allows the system to calibrate itself and set the double dete...

Page 14: ...n You can set your Relay 1000 to process letter size sheets 8 1 2 x 11 inches or legal size sheets 8 1 2 x 14 inches 1 Press the Menu Enter button repeatedly until the display shows the current paper size selection Paper 8 1 2 x 11 Change Size or Paper 8 1 2 x 14 Change Size 2 Press yes to change paper size The display confirms the change Press no to go to the next menu option without changing the...

Page 15: ...ial piece and check it If the address is centered in the window press Start to run your job If the address is not centered repeat the procedure until you get the result you want Sheet Double Detect On Off Use this option to turn sheet feeder double detection Sheet DD on or off When Double Detect is turned on the system stops automatically when it senses a double feed two sheets feed when only one ...

Page 16: ...ange the insert double detect setting The display confirms the change Or press no to go to the next option The double detection setting remains unchanged Safe Seal On Off This option allows you to turn safe seal on or off If you re having problems with envelope flaps not sticking try turning this option on Safe seal slows the system slightly allowing more time for moisture to transfer onto the env...

Page 17: ...p Contents Preparing and Loading 2 3 Connecting Power and Turning On 2 3 Fill the Moistener 2 4 Loading the Sheet Feeders Feeders A1 and A2 2 5 Loading the Envelope Feeder Feeder B 2 6 Remove Install the Stacker 2 8 ...

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Page 19: ...g of this guide before connecting the system 1 Connect the power cord to the socket on the back of the system 2 Plug the power cord into an easily accessible power outlet 3 Turn the power switch ON After a few seconds the message Check Moistener appears on the display This is only a reminder to check the level it does not always mean that the moistener level is too low The Check Moistener message ...

Page 20: ...oistener out to the right IMPORTANT Never open the moistener while the system is processing material 2 Carefully fill the moistener with E Z Seal solution or water up to the Max mark in the filler funnel We recommend E Z Seal to minimize algae growth and scale buildup 3 Slide the moistener back into the system From a dry state the moistener takes about five minutes to become fully wet and ready fo...

Page 21: ...d them This prevents them from sticking together 2 Tap the stack of sheets onto a firm surface to align the edges 3 Place the sheets into Sheet Feeder A1 or A2 as required IMPORTANT Always load sheets into these feeders face down and bottom edge first The bottom edge of the sheet is furthest into the system NOTE If you use Sheet Feeders A1 and A2 at the same time you must load the document printed...

Page 22: ...tagger the envelope stack The feeder can hold up to 60 envelopes IMPORTANT Load envelopes right way up and facing you This means that the envelope flap is on the back of the envelope and at the top Any other orientation will prevent the machine from inserting properly 4 Slide the two side guides up to the envelope stack then slightly back them off Use the blue handles at the rear of the guides whe...

Page 23: ...ck of inserts onto a firm surface to align the edges 3 Place the insert stack into Feeder C IMPORTANT For pre folded inserts it s normally best to load with the closed edge feeding first You can usually load business reply envelopes right way up and facing you However if the flaps are pulled open when feeding try loading the envelopes with the flaps down and facing you 4 Slide the two side guides ...

Page 24: ...stall the Stacker To remove the stacker 1 Pivot the stacker up slightly 2 Pull the stacker away from the system To install the stacker 1 Place the stacker pivots against the mounting studs 2 Push the stacker gently until it snaps into position ...

Page 25: ...un a Job Contents Run a Job 3 3 All Models 3 3 Models with an Insert Feeder 3 3 Models with an Optional Second Sheet Feeder 3 4 Models with an Insert Feeder and Second Sheet Feeder 3 5 Manual Feeder M 3 16 ...

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Page 27: ...ncludes images that identify the various jobs you can run on the Relay 1000 and a table of quick steps to set up and run each job All Models Job 1 One Folded Sheet Into an Envelope Job 2 One Folded Sheet No Envelope Models with an Insert Feeder Job 3 One Folded Sheet One Insert Into an Envelope Job 4 One Insert Into an Envelope ...

Page 28: ...an Optional Second Sheet Feeder Job 5 Two Folded Sheets Into One Envelope Job 6 Two Collated Folded Sheets Into One Envelope see note next page Job 7 Two Folded Sheets No Envelope Job 8 Two Collated Folded Sheets No Envelope see note next page ...

Page 29: ...Into an Envelope Job 10 Two Collated Folded Sheets One Insert Into an Envelope see note below NOTE Jobs marked with an asterisk use the second sheet feeder A2 in 2nd Page mode to feed 2 sheet collated sets You must load sheets into the feeder in their collated sequence first page second page first page second page etc ...

Page 30: ...models Select 11 or 14 2 Load sheets into Sheet Feeder A1 Load face down and bottom edge first 3 Load envelopes in Feeder B Load right way up and facing you 4 Press button to select Feeder A1 Make sure indicators are green 5 Press button to select Envelope Fdr B Make sure indicators are green 6 Press button to choose Seal or No Seal Make sure moistener has E Z Seal or water 7 Press Trial Piece but...

Page 31: ...e paper size setting is correct NOTE This setting is not available on all models Select 11 or 14 2 Load sheets into Sheet Feeder A1 Load face down and bottom edge first 3 Press the button to select Feeder A1 Make sure indicators are green 4 Press button to select Fold Only Make sure indicators are green 5 Press the Trial Piece button and inspect trial piece Check trial piece for a good fold 6 Pres...

Page 32: ... is not available on all models Select 11 or 14 2 Load sheets into Sheet Feeder A1 Load face down and bottom edge first 3 Load envelopes in Feeder B Load right way up and facing you 4 Load inserts into Insert Feeder C Loading orientation depends on item 5 Press button to select Feeder A1 Make sure indicators are green 6 Press button to select Envelope Fdr B and Insert Fdr C Make sure BOTH green in...

Page 33: ...r C Loading orientation depends on the item 3 Press button to select Envelope Fdr B and Insert Fdr C Make sure BOTH green indicators are lit 4 Press A1 A2 select button until both feeders and 2nd Page are turned OFF Make sure NO indicators lights are lit for A1 or A2 or 2nd page 5 Press button to choose Seal or No Seal Make sure moistener has E Z Seal or water 6 Press the Trial Piece button and in...

Page 34: ... Feeder A2 Load face down and bottom edge first 3 Load second sheets into Sheet Feeder A1 Load face down and bottom edge first 4 Load envelopes in Feeder B Load right way up and facing you 5 Press button to select Feeder A1 and A2 Make sure BOTH green indicators are lit 6 Press button to select Envelope Fdr B Make sure indicators are green 7 Press button to choose Seal or No Seal Make sure moisten...

Page 35: ...le on all models Select 11 or 14 2 Load sheets into Sheet Feeder A2 See note above for loading sequence Load face down and bottom edge first 3 Load envelopes in Feeder B Load right way up and facing you 4 Press button to select Feeder A2 and 2nd Page Make sure BOTH green indicators are lit 5 Press button to select Envelope Fdr B Make sure indicators are green 6 Press button to choose Seal or No Se...

Page 36: ...available on all models Select 11 or 14 2 Load addressed sheets into Sheet Feeder A2 Load face down and bottom edge first 3 Load second sheets in Sheet Feeder A1 Load face down and bottom edge first 4 Press button to select Feeder A1 and Feeder A2 Make sure BOTH green indicators are lit 5 Press button to select Fold Only Make sure indicators are green 6 Press the Trial Piece button and inspect tri...

Page 37: ...1 Make sure the paper size setting is correct NOTE This setting is not available on all models Select 11 or 14 2 Load sheets into Sheet Feeder A2 See above for loading sequence Load face down and bottom edge first 3 Press button to select Feeder A2 and 2nd Page Make sure BOTH green indicators are lit 4 Press button to select Fold Only Make sure indicators are green 5 Press the Trial Piece button a...

Page 38: ...essed sheets into Sheet Feeder A2 Load face down and bottom edge first 3 Load second sheets into Sheet Feeder A1 Load face down and bottom edge first 4 Load envelopes in Feeder B Load right way up facing you 5 Load inserts into Insert Feeder C Loading orientation depends on item 6 Press button to select Feeder A1 and Feeder A2 Make sure BOTH green indicators are lit 7 Press button to select Envelo...

Page 39: ... available on all models Select 11 or 14 2 Load addressed sheets into Sheet Feeder A2 See notes above for loading sequence Load face down and bottom edge first 3 Load second sheets into Sheet Feeder B Load face down and bottom edge first 4 Load inserts into Insert Feeder C Loading orientation depends on item 5 Press button to select Feeder A2 and 2nd Page Make sure BOTH green indicators are lit 6 ...

Page 40: ...y the indicators for Sheet Feeders A1 and or A2 are ignored by the system All other selections apply to the manual job 2 Feed one staple set face down and bottom edge first gently into the manual feed slot The system automatically starts and draws the set from you The system processes the set and ejects it into the stacker in the usual manner NOTES Be sure to feed the set into the system squarely ...

Page 41: ...4 1 4 Clear Material Contents Clear Material Jams 4 3 ...

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Page 43: ... indicates a jam beneath cover D press the blue button marked D to release the cover Lift the cover using the finger grips on each side of the stacker and then carefully remove any stalled material When closing the cover latch it closed by pressing down on the finger grips or the central part of the cover in front of the envelope feeder DO NOT press down on the stacker Button D If the display indi...

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Page 45: ...5 1 5 1 5 Troubleshooting and Error Messages Contents General Troubleshooting 5 3 Error Messages 5 5 ...

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Page 47: ...at aren t there If you are running a new batch of material that is slightly thicker or thinner than the original material run a new trial piece to allow the system to recalibrate to the new material Another possible solution is to turn off double detection if an occasional duplicate insert is not important System feeds doubles without stopping 1 Make sure double detection is turned on 2 Run a tria...

Page 48: ... closed edge feeding first Business reply envelopes can normally be loaded right way up and facing you However if the flaps are pulled open when feeding try loading with the flaps down and facing you Following installation of Sheet Feeder 2 the system doesn t work Make sure the system is seated correctly on Sheet Feeder 2 Turn the system off wait a few seconds and then turn it back on Remove any d...

Page 49: ...ea under cover D 1 Remove the paper in sheet feeder A1 2 Open front cover D and make sure the system is clear of material 3 Close front cover D 4 Reload and then start the run CHECK AREAS A1 A2 D This could be due to an unsuccessful clearance of a jam between the sheet feeders A1 A2 and the area under cover D 1 Remove paper in sheet feeders A1 and A2 2 Open front cover D and make sure the system i...

Page 50: ...ide 2 Close front cover D 3 Remove material from sheet feeder A2 4 Reload and start the run CLEAR FEEDER M The Manual Feeder M was blocked before powering up the system or starting the run 1 If there is any material in the feeder remove it 2 Restart the system CLEAR STACKER AREA Check for a jam in the stacker area 1 Remove any material from the stacker area 2 Resume the run DOUBLE FEED CHECK FDR A...

Page 51: ...insertion area or a previous jam was not cleared correctly It can also be caused by dust covering a sensor 1 Open front cover D 2 Remove any material in the system 3 Blow out any dust that may have accumulated in the area 4 Close cover D and then start the run LIFT COVER D REMOVE ENV Check for an envelope jam under cover D 1 Open front cover D 2 Remove the envelope and then start the run If no env...

Page 52: ...e run If there are envelopes loaded make sure that the side guides on feeder B are not too tight and that no more than 60 envelopes are loaded 2 Reload feeder B and then start the run RELOAD INSERT FEEDER C Insert feeder C is empty Reload inserts and start the run REMOVE ALL FROM D E This could be due to a material jam in fold plate 1 or near the insertion area 1 Open front cover D 2 Remove any ma...

Page 53: ...T FROM A1 A sheet has failed to feed from sheet feeder A1 1 Remove paper from A1 2 Reload and then start the run REPLACE FDR A1 TRAY Make sure that sheet feeder A1 is pushed fully into position SHEETS REQUIRED Envelopes have been selected but no sheet feeder was selected The indicators for sheet feeder A1 and envelopes will be red Press the sheet feeder selection button until the required feeder i...

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Page 55: ...ations Contents Specifications U S 6 3 Material Specifications U S 6 3 System Specifications U S 6 5 Specifications International 6 6 Material Specifications International 6 6 System Specifications International 6 8 ...

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Page 57: ...sert Feeder C optional Insert Size Width 5 to 8 3 4 Depth 3 3 8 to 3 7 8 Material Weight Unfolded document 18 lb bond to 80 lb card stock Tri folded document 18 to 24 lb bond Capacity Max 60 Business Reply Envelopes 24 lb bond Type Suitable for pre folded single panel inserts business reply envelopes etc Envelope Feeder B Envelope Size Number 10 only Width 9 1 2 Depth 4 1 8 Material Weight 18 to 2...

Page 58: ...Manual Feeder M Stapled or unstapled sets of up to 3 sheets of 20 lb bond paper can be processed Sheet Feeders A1 and A2 cannot be used in conjunction with the Manual Feeder Glossy coated sheets are not recommended Sealer Capacity The machine can seal up to a maximum of 1 000 envelopes between refills Stacker Stacker capacity is up to 60 filled envelopes depending on the contents of envelope Mater...

Page 59: ...h sheet feeder 2 Weight 38 lb Noise Level Running 70dBA Electrical 115V 60Hz 2 4A Speed Up to a maximum of 900 cycles per hour Duty Cycle Up to a maximum of 4 000 cycles per month with an average of 2 000 cycles per month and a maximum life of 120 000 cycles NOTE All specifications are subject to change without notification and are for information only ...

Page 60: ...ptional Insert Size Width 127mm to 225mm Depth 86mm to 114mm Material Weight Unfolded document 70gsm bond to 200gsm card stock Trifolded document 70gsm to 90gsm bond Capacity Max 60 Business Reply Envelopes 90gsm bond Type Suitable for pre folded single panel inserts business reply envelopes etc Envelope Feeder B Envelope Size DL Mailer only Width 225mm to 235mm Depth 110mm to 121mm Material Weigh...

Page 61: ...Manual Feeder M Stapled or unstapled sets of up to 3 sheets of 80gsm bond paper can be processed Sheet Feeders A1 and A2 cannot be used in conjunction with the Manual Feeder Glossy coated sheets are not recommended Sealer Capacity The machine can seal up to a maximum of 1 000 envelopes between refills Stacker Stacker capacity is up to 60 filled envelopes depending on the contents of envelope Mater...

Page 62: ...m with sheet feeder 2 Weight 17kg Noise Level Running 70dBA Electrical 240V 50Hz 1A Speed Up to a maximum of 900 cycles per hour Duty Cycle Up to a maximum of 4 000 cycles per month with an average of 2 000 cycles per month and a maximum life of 120 000 cycles NOTE All specifications are subject to change without notification and are for information only ...

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Page 64: ...3001 Summer Street Stamford CT 06926 0700 www pitneybowes com SV63176 RevB 2016 Pitney Bowes Inc All Rights Reserved ...

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