Pitney Bowes Relay 1000 Operator's Manual
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Pitney Bowes Relay 1000 Operator's Manual

Pitney Bowes Relay 1000 Operator's Manual

Document inserting system
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Shipping & Mailing
Inserter
Relay
1000
™
Document Inserting System
Operator Guide
US International English Edition
SV63176 Rev. B
February 1, 2016

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Summary of Contents for Pitney Bowes Relay 1000

  • Page 1 Shipping & Mailing Inserter Relay 1000 ™ Document Inserting System Operator Guide US International English Edition SV63176 Rev. B February 1, 2016...
  • Page 2 CAUTION: Changes or modifications to this equipment not expressly approved by the party responsible for compliance (Pitney Bowes) could void the user’s authority to operate the equipment. It is certified that the equipment complies with all applicable Directives of the European Union.

  • Page 3: Table Of Contents

    Table of Contents Safety Information ..............iii Chapter 1: System Overview About Your System ............1-3 System Configurations ..........1-3 Component Identification ...........1-4 About Sleep Mode ............. 1-7 Advanced Menu Options ...........1-8 Reset Counter ............1-8 Change Paper Size (Not on All Configurations) ..1-8 Move the Address in the Window .......
  • Page 4 Table of Contents Chapter 5: Troubleshooting and Error Messages 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 ......

  • Page 5: Safety Information

    Safety Safety Information • Read all instructions before you attempt to operate the system. • Use this equipment only for its intended purpose. • Place the system close to an easily accessible wall outlet. • Place the system in an accessible location to allow for proper venting of the equipment and to facilitate servicing.
  • Page 6 - 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 cord from the wall outlet.
  • Page 7 Contents 1 • System Overview Contents About Your System ..........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 .......
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  • Page 9: About Your System

    System Configurations There are four configurations of the Relay 1000, as shown in the diagrams below. All four configurations come standard with a sheet feeder and an envelope feeder. All four can accept an optional second sheet feeder.

  • Page 10: Component Identification

    1 • System Overview Component Identification Insert Cover E Release Button (Blue Button Marked E) The display prompts you to press this button to open this cover when you need to remove jammed material Insert Feeder (not on all models) Use this feeder to add inserts to your envelope.
  • Page 11 Lifting Handles (One Each Side) Always lift the Relay 1000 using the side handles. DO NOT lift the system by any of the feeders or the stacker. Second Sheet Feeder A2 (Optional) You can add this feeder to the system to enable folding and inserting of a second sheet into the envelope.
  • Page 12 No Seal Start Trial Piece Stop Display Shows the current status of your Relay 1000 and displays prompts and error messages. Menu/Enter (see Advanced Menu Options section for details) Press this button to enter the menu options. Available options: •...

  • Page 13: About Sleep Mode

    The Controls System Overview • 1 yes ( ) and no ( ) buttons Once you’ve entered the menu using Menu/Enter, press these buttons to answer yes or no to prompts and to change (increase or decrease) settings offered by menu options. Selection Buttons and Indicator Lights Press these buttons to step through the feeders and options that are available on your system.

  • Page 14: Advanced Menu Options

    Change Paper Size (Not on All Configurations) Choose this menu option to select the paper (sheet) size you want to run. 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).

  • Page 15: Move The Address In The Window

    System Overview • 1 Move the Address in the Window This menu option allows you to change the length of the fold panel so that the address is centered in the envelope window. Make the adjustment by entering a number from 1 to 9. The higher the number, the higher the address will appear in the window.

  • Page 16: Insert Double Detect On/Off

    1 • System Overview Insert Double Detect On/Off Use this option to turn insert feeder double detection (Insert DD) on or off. • When Double Detect is turned on - the system records the thickness of the piece. When you start the run, the system automatically stops when it senses a double feed.
  • Page 17 2 • System Setup 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: Preparing And Loading

    System Setup • 2 Preparing and Loading Once you understand the subjects covered in this chapter, you can quickly set up and use the system for a variety of jobs as explained later in the Running Jobs section. IMPORTANT! Before running a job, make sure your material meets our published specifications (refer to the Specifications chapter).

  • Page 20: Fill The Moistener

    2 • System Setup Fill the Moistener The oval window on the front of the moistener provides an easy view of the current fluid level. When the fluid gets low, refill the moistener. 1. Slide the moistener out to the right.

  • Page 21: Loading The Sheet Feeders (Feeders A1 And A2)

    System Setup • 2 Loading the Sheet Feeders (Feeders A1 and A2) • Sheet Feeder A1 is common to all models and located below Manual Feeder M. • Sheet Feeder A2 is an option on all models. It allows the system to insert a second folded sheet into an envelope.

  • Page 22: Loading The Envelope Feeder (Feeder B)

    2 • System Setup Loading the Envelope Feeder (Feeder B) 1. Always fan (aerate) envelopes before you load them. This prevents them from sticking together. 2. Tap the stack of envelopes onto a firm surface to align the edges. 3. Place the envelope stack into Feeder B with the last envelope flat against the feed belts.
  • Page 23 System Setup • 2 Loading the Insert Feeder (Feeder C) If your system has Insert Feeder C, use this feeder to add additional inserts to your envelope that do not require folding by the machine. Feeder C is especially suited to feeding pre-folded or thicker inserts, such as business reply envelopes (BREs), response cards and similar materials.

  • Page 24: Remove/Install The Stacker

    2 • System Setup Remove/Install 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. SV63176 RevB...
  • Page 25 3 • Run 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: All Models

    This section assumes you understand the system features and use of the control panel. It includes 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...

  • Page 28: Models With An Optional Second Sheet Feeder

    3 ● Run a Job Models with an Optional Second Sheet Feeder Job 5 Job 6 • Two Collated, Folded Sheets • Two Folded Sheets • Into One Envelope • Into One Envelope see note next page Job 7 Job 8 •...

  • Page 29: Models With An Insert Feeder And Second Sheet Feeder

    Run a Job ● 3 Models with an Insert Feeder and Second Sheet Feeder Job 9 Job 10 • Two Collated, Folded Sheets • Two Folded Sheets • One Insert • One Insert • Into an Envelope • Into an Envelope see note below NOTE: Jobs marked with an asterisk (*) use the second sheet feeder, A2, in “2nd Page”...
  • Page 30 Into an envelope • Configuration required: any Relay 1000 NOTE: If your system has the optional 2nd sheet feeder A2, you can use it instead of A1, as long as you load and select it as described in steps 1 and 3 below.
  • Page 31 • No envelope • Configuration required: any Relay 1000 NOTE: If your system has the optional 2nd sheet feeder A2, you can use it instead of A1, as long as you load and select it as described in steps 1 and 3 below.
  • Page 32 One insert • Into an envelope • Configuration required: Relay 1000 with Insert Feeder C NOTE: Inserts are pre-folded sheets or unfolded items such as business reply envelopes, response cards and similar items. If your system has the optional 2nd sheet feeder A2, you can use it instead of Feeder A1, as long as you load and select it as described in steps 1 and 4 below.
  • Page 33 Job 4 • One insert • Into an envelope • Configuration required: Relay 1000 with Insert Feeder C NOTE: Inserts are pre-folded sheets or unfolded items such as business reply envelopes, response cards and similar materials. STEP ACTION Load envelopes into Feeder Load right way up and facing you.
  • Page 34 • Two Folded Sheets • Into One Envelope • Configuration required: Relay 1000 with optional Sheet Feeder A2 NOTE: Run the address-bearing document from Sheet Feeder A2 and a second sheet that needs folding from Sheet Feeder A1. STEP ACTION Make sure the paper size Select 11”...
  • Page 35 Two collated, folded sheets • Into one envelope • Configuration required: Relay 1000 with optional Sheet Feeder A2 NOTE: This job uses the second sheet feeder A2 in 2nd Page mode to feed two-sheet, collated sets. Load sheets into the feeder in their collated sequence: page one, page two, page one, page two and so on.
  • Page 36 • Two folded sheets • No envelope • Configuration required: Relay 1000 with optional Sheet Feeder A2. NOTE: Run the address bearing document from Sheet Feeder A2 and a second sheet that needs folding from Sheet Feeder A1. STEP ACTION Make sure the paper size Select 11”...
  • Page 37 Two collated, folded sheets • No envelope • Configuration required: Relay 1000 with optional Sheet Feeder A2. NOTE: This job uses the second sheet feeder A2 in 2nd Page mode to feed two-sheet, collated sets. Load sheets into the feeder in their collated sequence: page one, page two, page one, page two and so on.
  • Page 38 One insert • Into an envelope • Configuration required: Relay 1000 with Insert Feeder C and optional Sheet Feeder A2 NOTE: Run the address-bearing document from Sheet Feeder A2 and a second sheet that needs folding from Sheet Feeder A1. Inserts are pre-folded sheets or unfolded items such as business reply envelopes, response cards and similar materials.
  • Page 39 One insert • Into an envelope • Configuration required: Relay 1000 with Insert Feeder C and optional Sheet Feeder A2 NOTE: This job uses the second sheet feeder A2 in 2nd Page mode to feed two-sheet, collated sets. Load sheets into the feeder in collated sequence: first page, second page, first page, second page and so on.

  • Page 40: Manual Feeder M

    3 ● Run a Job Manual Feeder M Relay 1000 models have a Manual Feeder M that allows you to feed stapled sets of up to three sheets of 20 pound bond (80 g/m ). The sets are fed by hand, one set at a time, for processing by the system. When you use the manual feeder, the system automatically turns off both sheet feeders.

  • Page 41: Clear Material Jams

    4 • Clear Material Contents Clear Material Jams..........4-3...
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  • Page 43 Clear Material • 4 Clear Material Jams 1. Remove all paper from the affected feeders that are indicated on the display. 2. If necessary, clear sheets from the affected feeder. • If the display indicates a jam in the sheet feeder(s) or manual feeder areas, pull the feeder assembly from the inserter as shown,...
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  • Page 45: General Troubleshooting

    5 • Troubleshooting and Error Messages Contents General Troubleshooting ........5-3 Error Messages .............5-5...
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  • Page 47: Error Messages

    Troubleshooting and Error Messages • 5 General Troubleshooting Issue Possible Solutions Poor Folding 1. Adjust the system fold slightly. 2. Run a trial piece and inspect the fold. System creates a “box fold” when 3. If there is still a box fold, access the another fold is advanced menu options and select move address in window.
  • Page 48 5 • Troubleshooting and Error Messages Issue Possible Solutions Inserts or business Changing the orientation of the insert stack may reply envelopes feed help. poorly from the Insert • For pre-folded inserts, it is normally best to Feeder load with the closed edge feeding first. •...
  • Page 49 Troubleshooting and Error Messages • 5 Error Messages Message Cause and Fix CANNOT SHIFT No sheet feeder has been selected in the job ADDRESSES ON setup. The display automatically times out from INSERT this message after two seconds and displays the double detect On/Off menu function.
  • Page 50 5 • Troubleshooting and Error Messages Message Cause and Fix CHECK SHEET Sheet feeder A2 is out of paper, failed to feed, FEEDER A2 or a jam was no cleared successfully from this area. If there are sheets in the feeder: 1.
  • Page 51 • Reload and start the run. NVM ERROR This is an unrecoverable error with the system software. Call Pitney Bowes for assistance. CALL SERVICE OPEN COVER E Check for a jam under cover E. REMOVE ALL 1. Open cover E.
  • Page 52 5 • Troubleshooting and Error Messages Message Cause and Fix SYSTEM ERROR 1. Turn off power to the system. POWER ON/OFF 2. Wait a minute and turn the power back on. RELOAD Feeder B may be out of envelopes, or an ENVELOPES envelope feed failed or was slow.
  • Page 53 The indicators for sheet feeder A1 and envelopes will be red. Press the sheet feeder selection button until the required feeder is selected. SYSTEM ERROR This is an unrecoverable system error. Call CALL SERVICE Pitney Bowes for assistance. SV63176 RevB...
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  • Page 55 6 • Specifications 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: Specifications - U.s

    Specifications • 6 Specifications - U.S. Material Specifications - U.S. Sheet Feeders A1 and/or A2 Sheet Size: Letter (8-1/2 x 11”) or Legal (8-1/2 x 14”) Paper Weight: 20 to 24 lb. bond Capacity: Max: 80 sheets of 20 lb. bond Type: Suitable for normal copier/laser printer bond paper.
  • Page 58 6 • Specifications End Clearance End clearance between the contents and envelope must be a minimum of 1/4” on each side (1/2” overall). Take this measurement with all contents placed into the envelope. Depth Clearance The contents must allow a minimum clearance of 1/4”...

  • Page 59: System Specifications - U.s

    Specifications • 6 System Specifications - U.S. Physical Dimensions Width: 17-3/8” Depth: 20-3/4” Height: 14-3/8” without sheet feeder 2 17-3/8” with 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.

  • Page 60: Specifications - International

    6 • Specifications Specifications - International Material Specifications - International Sheet Feeders A1 and/or A2 Sheet Size: DIN A4 (297mm x 210mm) Paper Weight: 75gsm to 90gsm bond Capacity: Max: 80 sheets of 80gsm bond Type: Suitable for normal copier/laser printer bond paper.
  • Page 61 Specifications • 6 End Clearance End clearance between the contents and envelope must be a minimum of 5mm on each side (10mm overall). Take this measurement with all contents placed into the envelope Depth Clearance The contents must allow a minimum clearance of 6mm below the flap crease after full insertion into the envelope.

  • Page 62: System Specifications - International

    6 • Specifications System Specifications - International Physical Dimensions Width: 440mm Depth: 440mm Height: 365mm without sheet feeder 2 440mm 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.
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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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