Pitney Bowes Relay 2500 User Manual Download | Manualshive

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About Barcode Scanning

Barcode applications support mailpiece integrity by ensuring proper mailpiece assembly. Barcodes
contain specific instructions about your mailpiece and can be printed on the front of your primary sheet
set. Information like record number, page number, and page total can be contained in the code.

How 2D Barcode Scanning Works

2D barcode scanning is an optional feature. If your machine is equipped with 2D barcode scanning, a 2D
barcode camera takes a picture of the barcode and then decodes the information to create instructions
for building that particular mailpiece.

When the barcode sheet is fed, the information in the barcode gets sent to the inserter. The inserter
checks this information and verifies that the correct sheet is fed and inserted into the envelope. If a sheet
is skipped or if the sheets get out of sequential order, the inserter stops processing and displays an error.

Barcode Scanning Jobs - Feeding and Folds

l

Sheet Feeder 1 (the top feeder) holds the sheets with the barcodes printed on them for C-folds
and double-folds.

l

Sheet Feeder 2 (the bottom feeder) holds the sheets with barcodes printed on them for Z-folds
and single-folds.

l

Multiple sheets can be inserted into an envelope with barcode scanning. The number of sheets
inserted into an envelope is determined by the information in the barcode.

l

An additional sheet or insert can be fed from other feeders with barcode scanning.

l

When processing sheets using single fold, the set size can be adjusted to enable the processing of
heavier sheets.

NOTE:

The Relay 2500 can process C-folds and double-folds with barcode scanning.

Barcode Scanning

Pitney Bowes

Relay™ 2500, 3500, 4500 User Guide

December, 2018

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Summary of Contents for Relay 2500

Page 1: ...Shipping Mailing Inserting Relay 2500 3500 4500 Inserting System User Guide US English Edition SV63298 RevB December 3 2018 ...

Page 2: ...itute an infringement of intellectual property rights of Pitney Bowes and Pitney Bowes assumes no responsibility for any such use of the information 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 Except as provided in writing duly ...

Page 3: ...s associated with the Relay 2500 3500 and 4500 Inserting Systems Version History Document Part Number Release Date Comments SV63298 Rev A October 1 2018 Preliminary draft SV63298 Rev B December 3 2018 Initial release About this Book Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page iii of 7 ...

Page 4: ...This page intentionally left blank ...

Page 5: ... the Sealer 33 Setting the Paper Length 34 Setting Fold A 35 Setting Fold B 36 Setting the Envelope Depth 37 Setting the Envelope Stop 38 Setting the Batch Counter 39 Confirming Job Setup 40 Running a Trial Piece 41 Programming a non Scanning Job 43 Initiating Job Setup 44 Selecting a Job 45 Disabling Scanning 46 Setting the Fold Type 47 Setting Accumulation Options 49 Setting the Main Sheet Feede...

Page 6: ...code Data 109 Barcode Scanning Specifications 112 About Barcode Placement 114 Adjusting the Barcode Camera 117 Barcode Scanning Error Messages 118 8 Error Recovery and Clearing Material Jams Accumulation Jobs Error Recovery 120 Empty Feeder Error Recovery 121 OMR Message Error Recovery 122 Clearing Material Jams 123 Clearing Material Jams in the Sheet Feeder 124 Clearing Material Jams in the Fold ...

Page 7: ...velope Issues 157 Troubleshooting Sheet Issues 158 Troubleshooting Insert Issues 159 Troubleshooting Double Detect Issues 160 Error Messages 161 11 Specifications Material Specifications 166 Inserter Specifications 172 Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page vii of 7 ...

Page 8: ...1 Safety In this section Safety Information 2 Warning Labels and Cautions 4 ...

Page 9: ...other equipment l DO NOT use an adapter plug on the line cord or wall outlet l DO NOT remove the ground pin from the line cord l DO NOT route the AC adapter power cord over sharp edges or trap it between furniture Make sure there is no strain on the power cord l If the unit becomes damaged unplug it from the wall Operation l Only trained personnel are permitted to operate this equipment Training m...

Page 10: ...d supplies l To reduce the risk of fire or electrical shock DO NOT attempt to remove covers or disassemble the control panel or its base The cabinet encloses hazardous parts l Improper storage and use of aerosol dusters or flammable aerosol dusters can cause an explosive like condition that could result in personal injury and or property damage Always read instructions and safety precautions on th...

Page 11: ...he application of these precautions in respect to handling operating or servicing even if not expressly stated in these instructions Caution Moving mechanisms may result in personal injury Keep hands long hair ties jewelry and loose clothing away from moving parts Safety Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 4 of 174 ...

Page 12: ...2 Product Overview In this section Product Overview 6 Relay Inserter Component Overview 8 ...

Page 13: ... one operation It works the same for all fold types Relay Model Comparison Hardware Components Relay 2500 Relay 3500 Relay 4500 Sheet Feeder 1 2 2 Envelope Feeder shingle tray 1 shingle tray 1 elevator 1 Insert Feeder 1 1 1 Integrated operator touchscreen yes yes yes The touchscreen is a WiFi enabled device If clients choose to utilize this network connection it is the responsibility of the client...

Page 14: ...eal option l Fold options single fold C fold Z fold double fold l Fold only option fold without insertion l Fully automatic material separation on sheet feeders l Fully automatic setting of fold plates l Fully automatic envelope separation l Fully automatic double document detection when selected l Manually fed semi automatic insertion of single and multi sheet collations l Job recall functionalit...

Page 15: ... Area 9 Power Switch 3 Insert Feeder 10 Measuring Scale 4 Sealer Bottle 11 Envelope Feeder 5 Envelope Inverter 12 Sheet Feeder 2 6 Drop Stacker 13 Sheet Feeder 1 7 Fold Plate 1 and 2 14 Side Guide Adjustment Knobs Not visible in this image Located in the back of the inserter Document Inserter Vertical Stacker DIVS power stacker option available Product Overview Pitney Bowes Relay 2500 3500 4500 Us...

Page 16: ...rop stacker l Fold Plate 1 and 2 create the desired fold in material fed from the sheet feeder s the fold plates are automatically set from the touchscreen l Manual Advance Knob turns the inserter mechanisms manually to help clear material located under a cover on the front left lower corner of the inserter l Power Switch turns the inserter on and off This is located on the front panel of the 4500...

Page 17: ...er vertical stacker that is attached at the exit of the inserter Envelopes are stacked on top of each other with the newest envelope on the bottom This keeps completed mailpieces in the same order as they are processed Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 10 of 174 ...

Page 18: ...ction Turning on the Touchscreen 12 Navigating the Touchscreen 13 Using the Touchscreen Keyboard 17 Changing the Touchscreen Display Language 18 Logging In 19 Managing Operator Usernames and Passwords 20 Changing an Existing Job Name 22 ...

Page 19: ...is located on the top left of the touchscreen Press and hold the power button for a few seconds to turn the touchscreen on or off ON OFF Power Button NOTE If the touchscreen is in sleep mode lightly press the ON OFF power button Using the Touchscreen Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 12 of 174 ...

Page 20: ...ouchscreen elements Integrated Touchscreen Item Description Item Description 1 Operator Name 6 Speed Indicator 2 Job Name 7 Reset Counter 3 Setup Button 8 Inserter Model 4 Menu 9 Job Options and System Messages 5 Paper Area 10 Name of jobs Button Using the Touchscreen Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 13 of 174 ...

Page 21: ...dress orientation Item Description Item Description 1 Paper Length mm 4 Closed or Open Envelope 2 Fold Lines mm 5 Address Orientation 3 Envelope Depth mm l Speed Indicator number of mailpieces produced per hour l Reset Counter tap to reset the item counter it ascends for each completed mailpiece that exits the machine l Inserter Model visual representation of the inserter l Job Options and System ...

Page 22: ...if the feeder is not being used the icon does not display Indicates when an insert feeder is being used if the feeder is not being used the icon does not display Indicates sheet order and quantity order of sheets in the feeder and number of sheets accumulated from that feeder This icon displays next to the setting you are programming or changing to help guide you through the setup process Flashes ...

Page 23: ...icates a C fold is selected Indicates a Z fold is selected Indicates a double fold is selected Indicates a single fold is selected A warning symbol displays on the insert model indicating a material stoppage the position of the symbol indicates where the stoppage has occurred Using the Touchscreen Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 16 of 174 ...

Page 24: ...keyboard automatically launches when you tap in a text field to enter text Closing the keyboard l The keyboard closes when you tap the Enter arrow key on the keyboard Using the Touchscreen Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 17 of 174 ...

Page 25: ...3 Select Language Program from the main menu bar A screen opens displaying country flags associated with available languages 4 Tap the flag that represents the language you want to display on the touchscreen The flag screen closes automatically and the new language displays 5 Tap the checkmark 6 Log in with your password or tap X to exit Using the Touchscreen Pitney Bowes Relay 2500 3500 4500 User...

Page 26: ...st of operators dialog opens highlight an Operator and tap the checkmark 3 Tap in the Password field When the keyboard launches type the password in the field 4 Tap the checkmark to log in Using the Touchscreen Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 19 of 174 ...

Page 27: ...or 8 MDP8 Operator 4 MDP4 Operator 9 MDP9 Operator 5 MDP5 Operator 10 MDP10 Default Operator Usernames NOTE The Supervisor password is 71 Creating operator usernames renaming default usernames You can rename a default Operator username to customize for your users 1 Double tap the inserter icon on the touchscreen desktop 2 When the List of operators dialog displays highlight a default Operator to r...

Page 28: ...eckmark to accept the password 8 Tap the checkmark to log in or X to exit Recovering lost operator passwords This is a supervisor activity 1 Double tap the inserter icon on the touchscreen desktop 2 When the List of operators dialog opens select the Operator associated with the lost password and tap the checkmark 3 Tap in the Password field When the keyboard launches type the Supervisor password 7...

Page 29: ...ield When the keyboard launches type either the Supervisor 71 or the Operator password in the field 5 Tap the checkmark 6 Tap the Name of jobs button 7 When the Name of jobs list opens highlight a job and tap Change 8 Tap in the New Job Name field and type the new job name 9 Tap the checkmark to accept the new job name 10 Tap the checkmark to log in or X to close the Name of jobs window Using the ...

Page 30: ...Paper Length 34 Setting Fold A 35 Setting Fold B 36 Setting the Envelope Depth 37 Setting the Envelope Stop 38 Setting the Batch Counter 39 Confirming Job Setup 40 Running a Trial Piece 41 Programming a non Scanning Job 43 Initiating Job Setup 44 Selecting a Job 45 Disabling Scanning 46 Setting the Fold Type 47 Setting Accumulation Options 49 Setting the Main Sheet Feeder 50 Setting the Second Sup...

Page 31: ...ing the Envelope Depth 59 Setting the Envelope Stop 60 Setting the Batch Counter 61 Confirming Job Setup 62 Running a Trial Piece 63 Modifying an Existing Job 65 Deleting a Job 66 Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 24 of 174 ...

Page 32: ...Initiate job setup l Select a job l Enable scanning OMR On or Off l Set fold type l Set the main scanning sheet feeder l Set the second sheet feeder l Set the insert feeder l Set the sealer l Set paper length l Set fold A l Set fold B l Set envelope depth l Set envelope stop l Set batch counter l Confirm job setup l Run a trial piece Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide De...

Page 33: ...r Access Code field counts up or down to display the password code entered Item Description Item Description 1 Setup Button 4 Keypad 2 Job Options and Settings 5 Enter Key 3 Fast Scroll Buttons 6 Enter Access Code Field These keys are used as a fast forward to move through large changes in job setup settings 4 Tap to accept the access code and advance to the job settings Product Overview Pitney Bo...

Page 34: ...t the desired job The job name in the screen banner changes to display the current jobs 2 Tap the to accept the job and advance to the first setting option NOTE If you use an existing job the old settings will be overwritten with the new settings selected Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 27 of 174 ...

Page 35: ...nd Sequence Standard OMR mark positioning OMR Select feed OMR scanning Select feed Autobatch Standard OMR mark positioning OMR Select feed Sequence OMR scanning Select feed Autobatch Wrap Around Sequence OR barcode Standard OMR mark positioning 2D BCR On 2D barcode scanning on OMR and Barcode Settings 2 Tap the button to accept the selection and advance to the next setting Product Overview Pitney ...

Page 36: ... fold Single fold Fold Types 2 Tap the button to accept the fold type and advance to the next setting Paper Orientation Depending on the fold type selected the display shows the paper orientation for loading into the feeders Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 29 of 174 ...

Page 37: ...e job options Icon Option Description Feeder On Feeder on Double Detect Feeder running double detect Double detect stops the inserter if two or more sheets are fed simultaneously SF Select Feed Select feed on Select feed tells a feeder to feed one extra sheet per envelope NOTE If there is no feeder icon displayed the feeder is not active for this job 2 Tap the button to accept the option and advan...

Page 38: ... double detect Double detect stops the inserter if two or more sheets are fed simultaneously Select Feed Select feed on Select feed tells a feeder to feed one extra sheet per envelope NOTE If there is no feeder icon displayed the feeder is not active for this job 2 Tap the button to accept the options and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide Dec...

Page 39: ...eeder running double detect Double detect stops the inserter if two or more sheets are fed simultaneously Select Feed On Select Feed on Select feed tells a feeder to feed one extra sheet per envelope NOTE If there is no feeder icon displayed the feeder is not active for this job 2 Tap the button to accept the option and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500...

Page 40: ...tion Description On Turns the sealer unit on for automatic sealing of envelopes Make sure the sealer bottle is full of E Z Seal Off Turns the sealer unit off Envelopes will be processed unsealed 2 Tap the button to accept the option and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 33 of 174 ...

Page 41: ...per l US letter 279 mm 11 inches l A4 paper 297 mm 2 Tap the and buttons to scroll through paper lengths displayed in mm 3 Tap the button to accept the paper length value and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 34 of 174 ...

Page 42: ...tting 1 To change the standard fold setting tap the and buttons until the length of required fold displays NOTE The inserter automatically limits your options to available specifications on your inserter As the length of fold A is changed the dimensions of fold B change automatically to keep within the correct paper length and inserter specifications 2 Tap the button to accept the fold value and a...

Page 43: ...ption and advance to the next setting If you want to change the setting 1 Tap the and buttons until the length of fold required displays A star icon displays next to the fold panel you are setting 2 Tap the button to accept the fold value and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 36 of 174 ...

Page 44: ...cover to measure the envelope depth 2 Tap the and buttons to scroll through the measurements displayed in mm 3 Tap the button to accept the value and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 37 of 174 ...

Page 45: ... heavier insert requires a higher setting 1 Tap the and buttons to scroll through the envelope stop positions 2 Tap the button to accept the position and advance to the next setting NOTE After the envelope stop is set the setting displays on the bottom of the inserter model on the touchscreen For example 3 for position 3 Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 P...

Page 46: ... number of items processed until you tap Reset Counter Tap the Start button to begin processing the next batch of mailpieces To set the batch counter 1 Tap the and buttons to toggle the batch mode to On or Off NOTE If the batch counter is set to on the inserter prompts for batch quantity The default quantity is 50 but any value can be selected up to 999 by tapping the and buttons 2 Tap the button ...

Page 47: ...3 When the setup changes are complete tap the Setup button to accept the new settings and exit setup mode The touchscreen displays the new job settings with the message Trial Piece Required 4 Test the setup by running a trial piece NOTE The inserter retains job settings until they are changed or deleted even when the power is disconnected Product Overview Pitney Bowes Relay 2500 3500 4500 User Gui...

Page 48: ...ngs a Tap the Setup button on the main screen b Log in with Supervisor password 71 c Tap the buttons to scroll to the setting you wish to modify d Tap the and buttons to scroll to the desired option 3 When the setup changes are complete tap the Setup button to accept the new settings and return to run mode The inserter saves the job with the new settings 4 Run another trial piece to test the modif...

Page 49: ...oo Low C fold Decrease Fold A Increase Fold A and increase Fold B by the same amount Z fold Increase Fold A Decrease Fold A and increase Fold B by the same amount Single fold Increase Fold A Decrease Fold A Double fold Decrease Fold A Increase Fold A It is recommended that the fold is only adjusted by 0 20 inches 5 mm each time Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December...

Page 50: ...sable scanning OMR Off Skip this step if your inserter does not have scanning l Set fold type l Set accumulation l Set main sheet feeder l Set second sheet feeder l Set insert feeder l Set mode type insertion or fold l Set the sealer l Set paper length l Set fold A l Set fold B l Set envelope depth l Set envelope stop l Set batch counter l Confirm job setup l Run a trial piece Product Overview Pit...

Page 51: ...r Access Code field counts up or down to display the password code entered Item Description Item Description 1 Setup Button 4 Keypad 2 Job Options and Settings 5 Enter Key 3 Fast Scroll Buttons 6 Enter Access Code Field These keys are used as a fast forward to move through large changes in job setup settings 4 Tap to accept the access code and advance to the job settings Product Overview Pitney Bo...

Page 52: ...t the desired job The job name in the screen banner changes to display the current jobs 2 Tap the to accept the job and advance to the first setting option NOTE If you use an existing job the old settings will be overwritten with the new settings selected Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 45 of 174 ...

Page 53: ...led on your system set it to OMR off 1 When prompted tap the and buttons to select OMR off 2 Tap the button to accept the selection and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 46 of 174 ...

Page 54: ...roll through the fold types Icon Fold C fold Z fold Double fold Single fold Fold Types 2 Tap the button to accept the fold type and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 47 of 174 ...

Page 55: ...Orientation Depending on the fold type selected the display shows the paper orientation for loading into the feeders Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 48 of 174 ...

Page 56: ...one page can be fed from each feeder Accumulation from Main Multiple sheets will be folded together and inserted into the envelope Up to 5 sheets for C folds Z folds up to 10 sheets for single folds a service adjustment may be required to run more than 8 sheets and up to 3 sheets for double folds Accumulation From Suppl A single address main is fed from the main feeder and up to 4 additional sheet...

Page 57: ...are fed simultaneously Manual Feed Manually feeds collated sets only available on sheet feeder 1 The inserter waits for manual insertion of each set into sheet feeder 1 after which it will fold and insert the set automatically Linked Feeding On only available on Relay 3500 and 4500 models Linked feeding on Feed comes from the first sheet feeder and when empty automatically switches feeding from th...

Page 58: ...y switches between feeders About the Manual Feed Option l The manual feed setting allows you to run stapled sets of up to five sheets a maximum of 100 lbs 400 gsm per set The maximum compressed thickness of the set after folding must not exceed 0 08 inches 2 mm l The inserter waits for manual insertion of each set into sheet feeder 1 after which it will fold and insert the set automatically l When...

Page 59: ...On Feeder on Double Detect Feeder running double detect Double detect stops the inserter if two or more sheets are fed simultaneously NOTE If there is no feeder icon displayed the feeder is not active for this job 2 Tap the button to accept the option and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 52 of 174 ...

Page 60: ...eeder running double detect Double detect stops the inserter if two or more sheets are fed simultaneously Select Feed On Select Feed on Select feed tells a feeder to feed one extra sheet per envelope NOTE If there is no feeder icon displayed the feeder is not active for this job 2 Tap the button to accept the option and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500...

Page 61: ... job l Insertion mode activates the envelope feeder for a normal inserting job l Fold Only mode turns the envelope feeder off and sets the inserter to act as a folding module To set the mode type 1 Tap the and buttons to toggle between the options 2 Tap the button to accept the mode type and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Pag...

Page 62: ...ealing of envelopes Make sure the sealer bottle is full of E Z Seal Off Turns the sealer unit off Envelopes will be ejected unsealed 2 Tap the button to accept the option and advance to the next setting l If you selected either of the sheet feeders continue to the Setting the Paper Length l If you are using the insert feeder only folding is not possible skip to Setting Envelope Depth Product Overv...

Page 63: ...per l US letter 279 mm 11 inches l A4 paper 297 mm 2 Tap the and buttons to scroll through paper lengths displayed in mm 3 Tap the button to accept the paper length value and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 56 of 174 ...

Page 64: ...tting 1 To change the standard fold setting tap the and buttons until the length of required fold displays NOTE The inserter automatically limits your options to available specifications on your inserter As the length of fold A is changed the dimensions of fold B change automatically to keep within the correct paper length and inserter specifications 2 Tap the button to accept the fold value and a...

Page 65: ...g 1 Tap the and buttons until the length of fold required displays A star icon displays next to the fold panel you are setting 2 Tap the button to accept the fold value and advance to the next setting l Inserting jobs continue to the Setting the Envelope Depth l Fold only job there are no more job settings skip to Confirming the Job Setup Product Overview Pitney Bowes Relay 2500 3500 4500 User Gui...

Page 66: ...cover to measure the envelope depth 2 Tap the and buttons to scroll through the measurements displayed in mm 3 Tap the button to accept the value and advance to the next setting Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 59 of 174 ...

Page 67: ... heavier insert requires a higher setting 1 Tap the and buttons to scroll through the envelope stop positions 2 Tap the button to accept the position and advance to the next setting NOTE After the envelope stop is set the setting displays on the bottom of the inserter model on the touchscreen For example 3 for position 3 Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 P...

Page 68: ... number of items processed until you tap Reset Counter Tap the Start button to begin processing the next batch of mailpieces To set the batch counter 1 Tap the and buttons to toggle the batch mode to On or Off NOTE If the batch counter is set to on the inserter prompts for batch quantity The default quantity is 50 but any value can be selected up to 999 by tapping the and buttons 2 Tap the button ...

Page 69: ...3 When the setup changes are complete tap the Setup button to accept the new settings and exit setup mode The touchscreen displays the new job settings with the message Trial Piece Required 4 Test the setup by running a trial piece NOTE The inserter retains job settings until they are changed or deleted even when the power is disconnected Product Overview Pitney Bowes Relay 2500 3500 4500 User Gui...

Page 70: ...ngs a Tap the Setup button on the main screen b Log in with Supervisor password 71 c Tap the buttons to scroll to the setting you wish to modify d Tap the and buttons to scroll to the desired option 3 When the setup changes are complete tap the Setup button to accept the new settings and return to run mode The inserter saves the job with the new settings 4 Run another trial piece to test the modif...

Page 71: ...oo Low C fold Decrease Fold A Increase Fold A and increase Fold B by the same amount Z fold Increase Fold A Decrease Fold A and increase Fold B by the same amount Single fold Increase Fold A Decrease Fold A Double fold Decrease Fold A Increase Fold A It is recommended that the fold is only adjusted by 0 20 inches 5 mm each time Product Overview Pitney Bowes Relay 2500 3500 4500 User Guide December...

Page 72: ... the password code entered 3 Tap the button to accept the code and advance to the job selection 4 Tap the and buttons to display the job you wish to modify 5 Tap the button to accept the job selection and advance to the job programming settings 6 Tap the and button to scroll through the setting s 7 Tap the and buttons to scroll through the options or desired values 8 Tap the button to accept the j...

Page 73: ...nts up or down to display the password code entered 3 Tap the button to accept the code and advance to the job selection 4 Tap the and buttons to display the job you wish to delete 5 Tap the X button to delete the job The display shows Do you want to delete this application 6 Tap the checkmark 7 Tap the X button to delete the job The display briefly shows Deleting Job as the job is erased 8 Tap th...

Page 74: ...0 Logging In 71 Selecting a Job to Run 72 Loading the Sheet Feeder 73 Loading the Standard Envelope Feeder 77 Loading the High Capacity Envelope Feeder 79 Loading the Insert Feeder 83 Running a Trial Piece 87 Starting and Stopping the Inserter 89 Adding Sealer Solution 90 Adjusting the Drop Stacker 91 ...

Page 75: ...ouchscreen l Log into the system l Select a job l Load the sheet feeders l Load the envelope feeders l Load the insert feeders l Run a trial piece l Start the inserter l Fill the sealer if needed l Adjust the stacker if needed Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 68 of 174 ...

Page 76: ...er outlet near the machine and is easily accessible 3 Turn the power switch to the ON position Relay 4500 Model shown here NOTE On Relay Inserter 2500 and 3500 models the power switch is located on the front left side of the inserter under the envelope feeder Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 69 of 174 ...

Page 77: ...ton is located on the top left of the touchscreen Press and hold the power button for a few seconds to turn the touchscreen on or off ON OFF Power Button NOTE If the touchscreen is in sleep mode lightly press the ON OFF power button Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 70 of 174 ...

Page 78: ...e List of operators dialog opens highlight an Operator and tap the checkmark 3 Tap in the Password field When the keyboard launches type the password in the field 4 Tap the checkmark to log in Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 71 of 174 ...

Page 79: ...un 1 Tap the Job menu button to scroll through the jobs keep tapping until the job you want displays You can also tap the Default Job button most used job if you want to run the inserter with the default job settings 2 Begin loading material follow the steps in the next section Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 72 of 174 ...

Page 80: ...the material Once the guides are touching both sides of the material turn the side guide control 1 4 turn in the opposite direction This sets the correct clearance between the guides and the material Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 73 of 174 ...

Page 81: ...re that individual sheets are not stuck together 3 Jog the stack of paper back into alignment The display indicates the correct orientation of the paper Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 74 of 174 ...

Page 82: ...stack of paper onto the feed deck Allow the deck to move down and the top of the stack of paper to slide under the feed roller Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 75 of 174 ...

Page 83: ... will feed collated sets one at a time by hand as required 1 Before running a manual feed job pull back the lever This opens the feed mechanism for manual feed operation NOTE Return this lever to its normal position when the feeder is used for automatic operation Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 76 of 174 ...

Page 84: ...ides to the width of the envelopes 2 Once the guides are touching both sides of the envelope turn the adjustment knob 1 4 turn in the opposite direction This sets the correct clearance between the guides and the envelope 3 Aerate and fan the stack of envelopes so the individual envelopes are not stuck together Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 77 of 174 ...

Page 85: ...k that the lead edge of the first envelope is under the front feed roller and the stack of envelopes is shingled on the deck 5 Let the wedge slide down behind the stack so the envelops are supported Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 78 of 174 ...

Page 86: ...4500 uses a high capacity elevator style envelope feeder to feed the outer envelopes 1 Press the envelope feeder loading switch to lower the envelope feeder platform Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 79 of 174 ...

Page 87: ...nob 1 4 turn in the opposite direction This sets the correct clearance between the guides and the envelope 3 Aerate the stack of envelopes and fan it so the individual envelopes are not stuck together 4 Place the stack of envelopes into the feeder with the flap side UP and flap LAST Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 80 of 174 ...

Page 88: ...5 Press the envelope feeder loading switch again to raise the envelope stack to the normal feeding position Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 81 of 174 ...

Page 89: ...nvelope feeder loading switch to lower the feeder platform 2 Load envelopes as described earlier in this section 3 Press the envelope feeder loading switch again The envelope stack rises to the normal feeding position and continues to process automatically Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 82 of 174 ...

Page 90: ...e insert turn the adjustment knob 1 4 turn in the opposite direction This sets the correct clearance between the guides and the insert 3 Refer to the labels located on the insert feeder and match the insert type slip reply envelope pre folded booklet with the icon and color Identifying the Insert If the label indicates a range of settings we recommend you select a higher number or letter for a thi...

Page 91: ...Set the blue separator gap lever to the number required 5 Set the blue separator shield lever to the letter required Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 84 of 174 ...

Page 92: ...ng orientation can vary depending on the inserts Load inserts using these orientation guidelines Insert Type Orientation Slip Face up bottom edge first Reply Envelope Face up top edge first Pre folded Face up closed edge first Booklet Face up bound edge first Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 85 of 174 ...

Page 93: ...8 Let the wedge material prop slide down the stack to support the envelopes Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 86 of 174 ...

Page 94: ...tings a Tap the Setup button on the main screen b Log in with Supervisor password 71 c Tap the buttons to scroll to the setting you wish to modify d Tap the and buttons to scroll to the desired option 3 When the setup changes are complete tap the Setup button to accept the new settings and return to run mode The inserter saves the job with the new settings 4 Run another trial piece to test the mod...

Page 95: ...too Low C fold Decrease Fold A Increase Fold A and increase Fold B by the same amount Z fold Increase Fold A Decrease Fold A and increase Fold B by the same amount Single fold Increase Fold A Decrease Fold A Double fold Decrease Fold A Increase Fold A It is recommended that the fold is only adjusted by 0 20 inches 5 mm each time Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2...

Page 96: ... on the touchscreen to begin automatic operation The inserter runs until it runs out of paper or you stop it l Tap the Stop button on the touchscreen to stop the inserter Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 89 of 174 ...

Page 97: ...le with the solution to the level indicated 4 Place the sealer bottle in position in the inserter and close the cover NOTE If the sealer unit was completely empty allow time for the fresh solution to soak through the sealer before resuming operation This helps ensure a good seal NOTE We recommend Pitney Bowes E Z Seal to minimize algae growth and scale build up Running a Job Pitney Bowes Relay 250...

Page 98: ...rear of the stacker and adjust the stacker to one of the preset positions 2 Lower the lever to lock the stacker into position NOTE When not in use the stacker can be raised and latched vertically against the exit area of the inserter Running a Job Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 91 of 174 ...

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Page 100: ...ark Recognition OMR Scanning 94 About OMR Scanning and Feeders 95 About OMR Scanning Types 96 About OMR Scanning Marks 97 OMR Specifications 101 Standard OMR Position Diagram 102 Adjusting the OMR Scanning Heads 103 OMR Scanning Error Messages 106 ...

Page 101: ...re different OMR marks on a document as it is fed through the system Tracking of these marks enhances mail piece integrity by assuring the documents that belong together a set stay together throughout the inserting process Accuracy OMR scanning on this inserter uses extensive error checking This means insertion accuracy is very high The probability of the wrong set of sheets being inserted into an...

Page 102: ... sheets from one feeder with or without a supplementary sheet and an insert A supplementary sheet and folded insert are nested with the first collation in the envelope Because OMR applications allows each envelope to contain tailored contents the collated set will allow the address bearing sheet to show through the window on the envelope This ensures that each set of sheets is addressed to the cor...

Page 103: ...ets at selected points in a run and or select whether the other feeders are used l Provides a higher level of mailpiece integrity so that sensitive documents are not sent to the wrong customer l Offers the Select feed option This options feeds an additional sheet from the supplementary sheet feeder or insert feeder on command from the OMR code OMR Scanning Pitney Bowes Relay 2500 3500 4500 User Gu...

Page 104: ...ust be allocated to an OMR Code Benchmark This is a mandatory mark It must be the first mark of the code and appear on every page within the set Safety This is a mandatory mark that improves the integrity of your mail piece It is automatically placed immediately after the benchmark End of Collation EOC This mark indicates that this sheet is the last sheet fed within the collation or set the addres...

Page 105: ...erial from the feeder holding the supplementary sheets inserts on a set by set basis Therefore select feed cannot be used on a single station inserter Use Select Feed 1 marks are in the primary sheet feeder to select material from the supplementary sheet feeder For C and double fold the primary feeder is sheet feeder 1 For Z and single fold the primary feeder is Sheet Feeder 2 Use Select Feed 2 ma...

Page 106: ...end nearest to the sensor These are followed by one two or three groups of marks where each group comprises three data marks followed by a fixed mark Each data mark is present or absent as required to reflect the desired function Each code must end with a re timing mark The Basic OMR mode uses only Group 1 The Enhanced OMR mode uses Group 1 plus Group 2 and or Group 3 as needed for a particular jo...

Page 107: ...eet Print marks in bottom to top order Print sheets in normal collation order The first sheet processed in each set is the address sheet and the last sheet processed is the last of each set OMR Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 100 of 174 ...

Page 108: ...osition must be evenly spaced at least 0 118 inch 3 mm apart l The area around the marks the clear zone should be kept clear from print and any other marks that the scanner might read in error l There should be no print on the opposing face of the sheet immediately behind the clear zone OMR Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 101 of 174 ...

Page 109: ...gram Position OMR marks l C fold and Double fold top scanning top left corner l Z fold and Single fold bottom scanning bottom right corner OMR Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 102 of 174 ...

Page 110: ...inserter 2 Remove both sheet feeder 2 and the fold plate below sheet feeder 2 to find the scanning head for of sheet feeder 2 mounted to the front of the inserter Item Description 1 Top Sheet Feeder Scanner 2 Bottom Sheet Feeder Scanner 3 Fold a sheet of material in half and measure the distance from the side of the sheet to the middle l A4 size sheet 105 mm l Letter size sheet 8 5 x 11 inches 108...

Page 111: ... measurement from the half fold measurement Folding Example l Half fold measurement for an A4 size sheet is 105 mm l If the distance from the edge of the form to the middle of the scan dash marks is 10 mm the scanning head setting will be 95 mm 105 mm 10 mm OMR Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 104 of 174 ...

Page 112: ... head to the correct setting Locking Knob 6 Re tighten the locking knob 7 If you adjusted the bottom sheet feeder scanner install both sheet feeder 2 and the fold plate OMR Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 105 of 174 ...

Page 113: ...ected pages other than the first of set were expected OMR Parity Error Code doesn t have an even number of marks OMR Sequence Error Sequence number is not sequential with the previous page fed Therefore sheets are in the wrong order or missing OMR SF marks Inconsistent Selective feed and Autobatch marks at positions 7 to 9 are different from those on the previous sheet of this set OMR SF not in Us...

Page 114: ... Scanning In this section About Barcode Scanning 108 About 2D Barcode Data 109 Barcode Scanning Specifications 112 About Barcode Placement 114 Adjusting the Barcode Camera 117 Barcode Scanning Error Messages 118 ...

Page 115: ...ed and inserted into the envelope If a sheet is skipped or if the sheets get out of sequential order the inserter stops processing and displays an error Barcode Scanning Jobs Feeding and Folds l Sheet Feeder 1 the top feeder holds the sheets with the barcodes printed on them for C folds and double folds l Sheet Feeder 2 the bottom feeder holds the sheets with barcodes printed on them for Z folds a...

Page 116: ...ters can be made up from a numbers like an account number employee number invoice number or reference number The inserter expects these characters to be the same on every sheet within the prime sheet set scanned sheets within the completed outer envelope These characters do not need to ascend or descend throughout the print run All 14 characters must be used If the number the client is referring t...

Page 117: ...e is completed and exited 6 SF2 Stop Select Feeds Insert from Insert Feeder and stops the machine once the mailpiece is completed and exited 7 SF1 SF2 Stop Select Feeds an additional Sheet from Sheet Feeder 2 and Insert from the Insert Feeder then stops the machine once the mailpiece is completed and exited Value and Function of Character 15 Character Position 16 Page Numbering This character is u...

Page 118: ...this is the last sheet fed for that envelope End of Collation process The inserter ejects the envelope out through the exit area Character Position 18 Wrap Around Sequence Ascending This character is a sequential number that cycles from 0 7 throughout the print run The inserter will stop and declare an error if a page is missing or the sheet set is out of sequential order Barcode Scanning Pitney B...

Page 119: ...aper l A 6 mm clear zone is required around the barcode l No other datamatrix barcodes can be placed in the area in front of the controlling barcode or within 25 mm behind or to either side of it l Only alpha numeric characters are supported Paper Sheets These specifications provide details about what type of paper should be used when printing barcodes l Minimum paper weight 75 80 gsm 20 lb l Maxi...

Page 120: ... Maximum Module Size 0 63 mm l Type ECC 200 standards l Minimum Symbol Size 5 mm x 5 mm l Maximum Symbol Size 10 mm x 10 mm l Code Size 16 x 16 cells square shaped codes only l Cell sizes should all be identical Barcode Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 113 of 174 ...

Page 121: ...ional barcodes in the areas around the primary barcode Those zones are described in this section Clear Zone The clear zone is the area immediately around the barcode This area on both facing and reverse sides of the sheet should be kept clear from all other print punched holes and perforations Clear Zone Barcode Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 114 of 174 ...

Page 122: ... Feed scannng feature is being used When Select Feed is turned on with single and Z folds only the controlling barcode must be printed within 18 30 mm of the leading edge If multiple barcodes are printed on a sheet no other barcodes can be printed within 25 mm of the controlling barcode and the leading edge of the paper Single Fold and Z fold Applications Barcode Scanning Pitney Bowes Relay 2500 3...

Page 123: ...Double fold and C fold Applications Barcode Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 116 of 174 ...

Page 124: ...2D barcode printed on it 2 Place the folded edge on the 0 located on the camera adjusting guide 3 Use the blue knob on the camera bracket assembly to move the camera arrow into position centered in the middle of the barcode Blue Adjustment Knob not visible here Barcode Scanning Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 117 of 174 ...

Page 125: ... or correct your sheet sequence OMR Sequence error Sequence number in barcode is not sequential with the previous page fed Add missing sheets and or correct the sheet sequence OMR SF Marks Inconsistent n a Not used for barcode jobs OMR Set to Large Sheet set contains too many sheets Refer to fold types and thickness limits in this guide OMR End of Batch Ready to Run Indicates machine has stopped f...

Page 126: ...l Jams in the Sheet Feeder 124 Clearing Material Jams in the Fold Plates 127 Clearing Material Jams in the Insert Trays 130 Clearing Material Jams in the Carriage Assembly 133 Clearing Material Jams in the Envelope Feeder Area 136 Clearing Material Jams in the Envelope Exit Area 139 Clearing Material Jams in the Envelope Inserting and Sealing Area 142 Clearing Material Jams in the Accumulation Are...

Page 127: ...rea ejects into the stacker You must manually remove the remaining pages of the set from the feeder 3 Fold insert the remaining pages into the envelope 4 Tap the Start button to resume operation once you determined the cause of the stoppage Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 120 of 174 ...

Page 128: ...ructions that scroll across the display 1 Re fill the empty tray 2 Tap the Start button to continue OR 1 Tap the Stop and Clear Deck buttons 2 Reload the feeders and proceed as prompted Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 121 of 174 ...

Page 129: ...The remaining pages of the current set will feed fold and eject into the stacker Manually insert into the envelope if necessary 3 The FIRST page of the NEXT set will pre feed into the feed rollers and stop Pull the sheet back to the normal feed position 4 Tap the Start button to resume operation Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Pa...

Page 130: ...r Deck function NOTE After you remove the material sometimes the machine may display a message instructing you to remove pages or envelopes from the inserter This message displays in the Job Options and System Messages area on the touchscreen above the inserter model The inserter will not run until all the instructions are followed Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 ...

Page 131: ...the material forward NOTE Avoid pulling pages backwards out of the machine towards the sheet feeder It is better to clear sheet feeder jams by moving material forward and removing it from the accumulator area 3 Replace the sheet feeder trays a Place the tray into its location guides in the side frames b Lift the rear of the tray slightly and push it into the inserter The tray automatically drops i...

Page 132: ...ck button to clear the paper path of any remaining material 5 Tap the Start button to resume operation Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 125 of 174 ...

Page 133: ...e manual advance knob to manually feed paper out of the grip of feed rollers The manual advance knob is located behind the drop down cover at the left front of the inserter Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 126 of 174 ...

Page 134: ...the jammed material If necessary use the manual advance knob to move the material forward 3 Replace the fold plates a Pull the two catches on the underside of the plate outward to release b Slide the plate into its location guides and release the catches to lock the plate in position Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 127 of 17...

Page 135: ...ck button to clear the paper path of any remaining material 5 Tap the Start button to resume operation Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 128 of 174 ...

Page 136: ...e manual advance knob to manually feed paper out of the grip of feed rollers The manual advance knob is located behind the drop down cover at the left front of the inserter Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 129 of 174 ...

Page 137: ...ter 2 Remove the jammed material If necessary use the manual advance knob to move the material forward 3 Replace the insert trays slide the tray into the location guides push until it clicks into place Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 130 of 174 ...

Page 138: ...ck button to clear the paper path of any remaining material 5 Tap the Start button to resume operation Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 131 of 174 ...

Page 139: ...e manual advance knob to manually feed paper out of the grip of feed rollers The manual advance knob is located behind the drop down cover at the left front of the inserter Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 132 of 174 ...

Page 140: ...he jam 1 Remove the insert feeder 2 Remove fold plate 2 3 Pull out the carriage assembly 4 Remove the jammed material If necessary use the manual advance knob to move the material forward 5 Reinstall the carriage assembly Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 133 of 174 ...

Page 141: ...ck button to clear the paper path of any remaining material 7 Tap the Start button to resume operation Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 134 of 174 ...

Page 142: ...e manual advance knob to manually feed paper out of the grip of feed rollers The manual advance knob is located behind the drop down cover at the left front of the inserter Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 135 of 174 ...

Page 143: ...NOTE Envelope jams in the Envelope Feeder area may be hard to see After lifting the envelope feed rollers carefully reach under the rollers to feel for jammed material 4 Relatch the feed rollers after you remove the jam 5 Release the envelope area feed rollers and let them rest in position 6 Push the rollers firmly down until they latch into position Error Recovery and Clearing Material Jams Pitne...

Page 144: ...aining material 8 Tap the Start button to resume operation NOTE You can get better access to this area by removing fold plate 1 and sheet feeder 2 Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 137 of 174 ...

Page 145: ...e manual advance knob to manually feed paper out of the grip of feed rollers The manual advance knob is located behind the drop down cover at the left front of the inserter Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 138 of 174 ...

Page 146: ...ess to the jammed material 2 Remove the jammed material If necessary use the manual advance knob to move the material forward 3 Close the access door make sure to latch it firmly in position Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 139 of 174 ...

Page 147: ...ck button to clear the paper path of any remaining material 5 Tap the Start button to resume operation Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 140 of 174 ...

Page 148: ...e manual advance knob to manually feed paper out of the grip of feed rollers The manual advance knob is located behind the drop down cover at the left front of the inserter Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 141 of 174 ...

Page 149: ...pe inverter access door 2 The points identified here can be unlatched to allow access to jammed material 3 Remove the jammed material If necessary use the manual advance knob to move the material forward Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 142 of 174 ...

Page 150: ...ck button to clear the paper path of any remaining material 5 Tap the Start button to resume operation Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 143 of 174 ...

Page 151: ...e manual advance knob to manually feed paper out of the grip of feed rollers The manual advance knob is located behind the drop down cover at the left front of the inserter Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 144 of 174 ...

Page 152: ...g Material Jams in the Accumulation Area 1 Grasp the blue tab and lift the first cover open Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 145 of 174 ...

Page 153: ...2 Lift the next blue tab and pull that cover back Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 146 of 174 ...

Page 154: ...handle to expose the paper path Verify there is no paper is currently in the paper path 5 Pivot the guide bar back into place using the blue handle be sure it clicks into place Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 147 of 174 ...

Page 155: ...e operation 7 Tap the Clear Deck button to clear the paper path of any remaining material 8 Tap the Start button to resume operation Error Recovery and Clearing Material Jams Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 148 of 174 ...

Page 156: ...9 Reports In this section About Reports 150 Generating Reports for Scanning Jobs 151 Generating Productivity Reports for Jobs 153 ...

Page 157: ... are reports for scan and non scanning jobs These reports can be generated viewed saved or printed using the touchscreen NOTE It is the client s responsibility to connect their touchscreen to their wireless network if they want to print reports Reports Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 150 of 174 ...

Page 158: ...outside the current calendar month can be accessed using the archived reports steps These reports are only available for scanning jobs Generate a report for a scan job within the current calendar month 1 Double tap the Reports icon on the touchscreen desktop 2 To select a date within the current calendar month tap the Open by date icon at the top of the screen 3 Select the date on the calendar of ...

Page 159: ...a scan job outside the current calendar month 1 Double tap the Reports icon on the touchscreen desktop 2 To select a date outside the current calendar month tap the Open by File Pages icon at the top of the screen 3 Browse for the desired CSV file PITNEY Inserter Control Archiving ANR 4 Highlight the file and tap Open Job details for that scanning job populate the screen Reports Pitney Bowes Relay...

Page 160: ...orts include job name operator start and finish dates and times job duration type of fold insert mode envelope sealing number of mailpieces average speed number of failures and number of stoppages To generate a productivity report 1 Double tap the Reports icon on the touchscreen desktop 2 Tap the Statistics icon at the top of the screen Reports Pitney Bowes Relay 2500 3500 4500 User Guide December...

Page 161: ...the top of the screen 4 When the calendar opens tap the date A productivity report opens and displays job summary information for all the jobs run that day Reports Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 154 of 174 ...

Page 162: ...is section Troubleshooting Touchscreen and Inserter Issues 156 Troubleshooting Envelope Issues 157 Troubleshooting Sheet Issues 158 Troubleshooting Insert Issues 159 Troubleshooting Double Detect Issues 160 Error Messages 161 ...

Page 163: ... the power switch on Inserter not operating l Cover open l Feed trays or fold plates not located correctly l Verify all covers are closed check display for cover information l Remove and relocate all feeders and fold plates l Verify all feeders and fold plates are in correct position and seated Insertion issues Outer envelope contents are not entering the envelope correctly l Check the envelope tr...

Page 164: ...envelopes flap side up with the flap feeding last Envelopes Fail to Open l Envelopes loaded incorrectly l Poor envelope quality l Load envelopes flap side up with the flap feeding last l Check the envelopes are not stuck due to excessive dampness l Try a new box of envelopes Envelope Sealing Issues l No sealing solution l Seal mode not selected l Poor sealing l Refill the sealer unit l Check job s...

Page 165: ...pected l Manual feed mode is selected l Sheets loaded incorrectly l Check job setup and manual feed lever position l Make sure to fan stack before loading Address in Wrong Position in Envelope Window l Address bearing sheets incorrectly loaded l Folds incorrectly set l Load sheets so that the address appears through the envelope window l Check job setup Poor Folding l A fold is almost correspondin...

Page 166: ...p l Set guides to sheet width and back off 1 4 turn l Verify the two insert feeder adjustments number and letter settings are set correctly for the type of insert being run l Make sure to fan the stack before loading It may help to change the orientation of the insert stack l Let the wedge slide down behind the insert stack for support l Check the specifications in this guide Troubleshooting Pitne...

Page 167: ...tect status double detect icon appears alongside all items where the double detect is operational l Check that the envelopes are not curled Try a new box of envelopes Make sure to fan stack before loading l Run a trial piece whenever a new batch of material is loaded to recalibrate double detect the new batch might be of slightly different thickness Troubleshooting Pitney Bowes Relay 2500 3500 450...

Page 168: ...nder the envelope feed rollers CHECK FOLD PLATE Fold plate indicated is not located correctly Remove fold plate and relocate CHECK INVERTER Envelope inverter unit has not set to its correct position l Open the inverter cover and check for material l Close the cover and restart CHECK LAST MAILPIECE Envelope has failed to open l Check the envelopes are loaded correctly l Reload the envelopes and res...

Page 169: ...ide of the inserter and remove any material l Close cover and restart CLOSE COVER Cover indicated is not fully closed Close the indicated cover and restart the inserter CLOSE MAN ADV COVER The manual advance knob door is not fully closed Close the door DEFLECTOR ERROR The function of half fold is not possible due to a fault Remove fold plates and check for any material DOUBLE FEED A double feed ha...

Page 170: ...ength displayed l If correct request another trial piece SET LEVER The manual feed lever is in the incorrect position for the mode of running l Move the manual feed lever to the correct position left position manual right automatic STREAM FEED The inserter detected two sheets fed together from the feed tray indicated l Remove the material from the inserter Reload and restart the inserter STREAM FE...

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Page 172: ...11 Specifications In this section Material Specifications 166 Inserter Specifications 172 ...

Page 173: ...ality and properly stored l Recommended storage conditions l 65 F 18 to 77 F 25 C l 40 to 60 relative humidity Sheet Feeders Sheet Sizes Minimum sheet size Maximum sheet size Width 7 inches 178 mm 9 inches 229 mm Length 7 inches 178 mm 16 inches 406 mm Paper Weights Minimum Maximum Non OMR 18 lb 70 gsm 32 lb 120 gsm OMR 18 lb 70 gsm 32 lb 120 gsm Specifications Pitney Bowes Relay 2500 3500 4500 Us...

Page 174: ... lb 120 gsm Feed Tray Capacity Maximum of 325 sheets of 20 lb 80 gsm paper Manual Feed Mode For manual feed applications sheet feeder 1 is used plus the insert feeder if required l Inserter processes stapled sets of up to five sheets of 20 lb bond 80 gsm up to a maximum total weight of 100 lbs 400 gsm per set l Maximum compressed thickness after folding must not exceed 0 078 inch 2 mm l Using glos...

Page 175: ...d types C C fold Z Z fold S Single fold D Double fold NOTES l You can use the sheet limits above with one additional sheet from the supplementary feeder plus one insert only if total mail piece contents do not exceed 0 078 in 2 mm total compressed thickness can be used l For single fold only using 18 lb to 20 lb 70 80 gsm paper only you can get a maximum 10 items in an envelope This maximum includ...

Page 176: ...0 lbs 180 gsm Inserts of up to a maximum compressed thickness of 0 078 inches 2 mm NOTE Pre folded or single panel inserts should be fed from the insert feeder Double Document Detector Material Range Minimum Maximum 16 lbs 60 gsm 32 lbs 120 gsm Feed Tray Capacity l Up to a maximum of 300 inserts Sealer l Inserters seal up to a maximum of 1 200 envelopes between refills l SafeSeal on two or more sh...

Page 177: ...b 90 gsm envelopes End Clearance l End clearance between insert and envelope minimum of 0 236 inches 6 mm at each side l Overall a minimum of 0 472 inches 12 mm l Take this measurement with all documents placed in the envelope Depth Clearance l Inserts unfolded allow a minimum clearance of 0 118 inches 3 mm below the flap crease after it is fully inserted into the envelope l Inserts folded allow a...

Page 178: ...Envelope Flap and Throat Requirements Specifications Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 171 of 174 ...

Page 179: ...ystem running Electrical l USA and Canada 120V 60Hz 6 0A l Europe 220 240V 50Hz l Japan 100V 50 60Hz Cycle Speed These speeds are dependent on inserter condition operator skill fold type and material quality Model Cycle Speed per hour Relay 2500 2 500 Relay 3500 3 000 Relay 4500 3 500 Specifications Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 172 of 174 ...

Page 180: ... Relay 2500 1 1 1 Relay 3500 2 1 1 Relay 4500 2 1 1 high capacity Fold Options Model Fold Types Relay 2500 Single C Z Double Relay 3500 Single C Z Double Relay 4500 Single C Z Double Specifications Pitney Bowes Relay 2500 3500 4500 User Guide December 2018 Page 173 of 174 ...

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Page 182: ...SV63298 RevB 2018 Pitney Bowes Inc All Rights Reserved 3001 Summer Street Stamford Connecticut 06926 www pitneybowes com ...

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