Pitney Bowes Relay 2500 User Manual
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Pitney Bowes Relay 2500 User Manual

Inserting system
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Shipping & Mailing
Inserting
Relay™ 2500, 3500,
4500
Inserting System
User Guide
US English Edition
SV63298 RevB
December 3, 2018

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Summary of Contents for Pitney Bowes 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 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 signed by an officer of Pitney Bowes, no license either express or implied, under any Pitney Bowes or third party’s patent, copyright or other...
  • Page 3 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 Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page iii of 7...
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  • Page 5: Table Of Contents

    Enabling Scanning (OMR or Barcode) Deleting a Job Setting the Fold Type Setting the Main Scanning Sheet Feeder Setting the Second (Supplementary) Sheet Feeder Setting the Insert Feeder Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page v of 7...
  • Page 6 9 - Reports About Reports 7 - Barcode Scanning Generating Reports for Scanning Jobs Generating Productivity Reports for Jobs About Barcode Scanning About 2D Barcode Data Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page vi of 7...
  • Page 7 Troubleshooting Touchscreen and Inserter Issues Troubleshooting Envelope Issues Troubleshooting Sheet Issues Troubleshooting Insert Issues Troubleshooting Double Detect Issues Error Messages 11 - Specifications Material Specifications Inserter Specifications Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page vii of 7...

  • Page 8: Safety

    1 - Safety In this section Safety Information Warning Labels and Cautions...

  • Page 9: Safety Information

    Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure machine mechanisms come to a complete stop. Remove jammed material gently and carefully. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 10 DO NOT route the power cord for the AC adapter over sharp edges or trap it between it between pieces of furniture. Make sure there is no strain on the power cord. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 11: Warning Labels And Cautions

    Safety Warning Labels and Cautions Pitney Bowes declines all liability in the event of material damage or bodily injury resulting from negligence in the application of these precautions in respect to handling, operating, or servicing, even if not expressly stated in these instructions.

  • Page 12: Product Overview Relay Inserter - Component Overview

    2 - Product Overview In this section Product Overview Relay Inserter - Component Overview...
  • Page 13 This section provides an overview of the hardware components and features of the three Relay inserter models - Relay 2500, Relay 3500 and Relay 4500. All Relays are equipped with pre-fold accumulation. (This module is located under the top cover of the machine).
  • Page 14 Fully automatic setting of fold plates Fully automatic envelope separation Fully automatic double document detection (when selected) Manually fed, semi-automatic insertion of single and multi-sheet collations Job recall functionality Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 7 of 174...
  • Page 15 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 Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 8 of 174...
  • Page 16 Sheet Feeder 1 - this feeder is intended for feeding material that requires folding. Side Guide Adjustment Knobs - adjusts the side guides on the envelope feeder. (This is located on the front panel of the 4500.) Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 17 Some Relay Inserters may have an optional power 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 18: Using The Touchscreen

    3 - Using the Touchscreen In this section Turning on the Touchscreen Navigating the Touchscreen Using the Touchscreen Keyboard Changing the Touchscreen Display Language Logging In Managing Operator Usernames and Passwords Changing an Existing Job Name...

  • Page 19: Turning On The Touchscreen

    ON/OFF Power Button NOTE: If the touchscreen is in sleep mode, lightly press the ON/OFF power button. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 12 of 174...

  • Page 20: Navigating The Touchscreen

    Item Description Operator Name Speed Indicator Job Name Reset Counter Setup Button Inserter Model Menu Job Options and System Messages Paper Area Name of jobs Button Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 13 of 174...
  • Page 21 Inserter Model - visual representation of the inserter Job Options and System Messages - displays job options and system errors or messages Name of jobs - tap to access the change job name screen Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 22 Flashes when the sealer bottle needs refilling Indicates the sealer unit is off (envelopes not sealed) Indicates the sealer unit is on (automatic envelope sealing) Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 15 of 174...
  • Page 23 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 16 of 174...

  • Page 24: Using The Touchscreen Keyboard

    The keyboard automatically launches when you tap in a text field to enter text. Closing the keyboard The keyboard closes when you tap the Enter arrow key on the keyboard. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 25: Changing The Touchscreen Display Language

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 18 of 174...

  • Page 26: Logging In

    2. When the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 27: Managing Operator Usernames And Passwords

    4. Tap in the Password field. When the keyboard launches, type either the Supervisor (71) or the default Operator password in the field. 5. Select File > Operators > Change from the main menu bar. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 28 5. Tap OK to close the dialog box. 6. Type the recovered password into the Password field. 7. Tap the checkmark to log in or X to exit. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 21 of 174...

  • Page 29: Changing An Existing Job Name

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 30 4 - Product Overview In this section Programming a Scanning Job Initiating Job Setup Selecting a Job Enabling Scanning (OMR or Barcode) Setting the Fold Type Setting the Main Scanning Sheet Feeder Setting the Second (Supplementary) Sheet Feeder Setting the Insert Feeder Setting the Sealer Setting the Paper Length Setting Fold A...
  • Page 31 Setting the Envelope Depth Setting the Envelope Stop Setting the Batch Counter Confirming Job Setup Running a Trial Piece Modifying an Existing Job Deleting a Job Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 24 of 174...

  • Page 32: Product Overview

    Set the sealer Set paper length Set fold A Set fold B Set envelope depth Set envelope stop Set batch counter Confirm job setup Run a trial piece Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 25 of 174...

  • Page 33: Initiating Job Setup

    * 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 34: Selecting A Job

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 35: Enabling Scanning (Omr Or Barcode)

    - Standard OMR mark positioning 2D BCR On - 2D barcode scanning on 2. Tap the >> button to accept the selection and advance to the next setting. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 28 of 174...

  • Page 36: Setting The Fold Type

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 37: Setting The Main Scanning Sheet Feeder

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 38: Setting The Second (Supplementary) Sheet Feeder

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 39: Setting The Insert Feeder

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 40: Setting The Sealer

    E-Z Seal®. Turns the sealer unit off. Envelopes will be processed unsealed. 2. Tap the >> button to accept the option and advance to the next setting. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 33 of 174...

  • Page 41: Setting The Paper Length

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 42: Setting Fold A

    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 advance to the next setting. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 43: Setting Fold B

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 44: Setting 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 45: Setting The Envelope Stop

    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.) Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 46: Setting The Batch Counter

    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 to accept the setting. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 47: Confirming Job Setup

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 40 of 174...

  • Page 48: Running A Trial Piece

    When a trial piece is requested for a job where linked feeding is enabled, both feeders must be loaded, as a trial piece will feed from each feeder. Two trial pieces are produced. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...
  • Page 49 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 42 of 174...

  • Page 50: Programming A Non-Scanning Job

    Set the sealer Set paper length Set fold A Set fold B Set envelope depth Set envelope stop Set batch counter Confirm job setup Run a trial piece Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 43 of 174...

  • Page 51: Initiating Job Setup

    * 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 52: Selecting A Job

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 53: Disabling Scanning

    If scanning (OMR or barcode) is enabled 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 54: Setting The Fold Type

    1. Tap the + and – buttons to scroll through the fold types. Fold Types Icon Fold C-fold Z-fold Double-fold Single-fold 2. Tap the >> button to accept the fold type and advance to the next setting. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 47 of 174...
  • Page 55 Product Overview Paper Orientation Depending on the fold type selected, the display shows the paper orientation for loading into the feeders. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 48 of 174...

  • Page 56: Setting Accumulation Options

    Accumulation From Suppl A single address main is fed from the main feeder, and up to 4 additional sheets can be collated from the second feeder Accumulation = (2 to 10) If Accumulation is ON, select how many pages you want to feed into each envelope. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 49 of 174...

  • Page 57: Setting The Main Sheet Feeder

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 58 When running manual feed mode, sheet feeder 2 becomes inoperable. The manual feed option is only available when Accumulation is set to OFF. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 51 of 174...

  • Page 59: Setting The Second (Supplementary) Sheet Feeder

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 60: Setting The Insert Feeder

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 61: Setting The Mode Type - Insertion Or Fold Only

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 62: Setting The Sealer

    If you selected either of the sheet feeders, continue to the Setting the Paper Length. If you are using the insert feeder only, folding is not possible; skip to Setting Envelope Depth. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 55 of 174...

  • Page 63: Setting The Paper Length

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 64: Setting Fold A

    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 advance to the next setting. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 65: Setting Fold B

    2. Tap the >> button to accept the fold value and advance to the next setting. Inserting jobs - continue to the Setting the Envelope Depth. Fold-only job - there are no more job settings, skip to Confirming the Job Setup. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 58 of 174...

  • Page 66: Setting 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 67: Setting The Envelope Stop

    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.) Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 68: Setting The Batch Counter

    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 to accept the setting. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 69: Confirming Job Setup

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 62 of 174...

  • Page 70: Running A Trial Piece

    When a trial piece is requested for a job where linked feeding is enabled, both feeders must be loaded, as a trial piece will feed from each feeder. Two trial pieces are produced. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...
  • Page 71 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 64 of 174...

  • Page 72: Modifying An Existing Job

    7. Tap the + and – buttons to scroll through the options or desired values. 8. Tap the >> button to accept the job setting. 9. Tap the Setup button to save the changes and exit setup mode. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 73: Deleting A Job

    7. Tap the X button to delete the job. The display briefly shows “Deleting Job” as the job is erased. 8. Tap the Setup button to exit job setup mode. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 74 5 - Running a Job In this section Running a Job Turn on the Inserter Turning on the Touchscreen Logging In Selecting a Job to Run Loading the Sheet Feeder Loading the Standard Envelope Feeder Loading the High Capacity Envelope Feeder Loading the Insert Feeder Running a Trial Piece Starting and Stopping the Inserter...

  • Page 75: Running A Job

    Load the sheet feeders Load the envelope feeders Load the insert feeders Run a trial piece Start the inserter Fill the sealer (if needed) Adjust the stacker (if needed) Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 68 of 174...

  • Page 76: Turn On The Inserter

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 77: Turning On The Touchscreen

    ON/OFF Power Button NOTE: If the touchscreen is in sleep mode, lightly press the ON/OFF power button. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 70 of 174...

  • Page 78: Logging In

    2. When the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 79: Selecting A Job To Run

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 80: Loading The Sheet Feeder

    1. Adjust the side guides to the width of 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 81 2. Aerate (fan) the stack of paper to ensure 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 82 4. Place the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 83 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 84: Loading The Standard Envelope Feeder

    Loading the Standard Envelope Feeder The Relay 2500 and 3500 use a standard (tray style) sheet feeder to feed the outer envelope for the job. 1. Use the side guide adjustment knob to adjust the side guides to the width of the envelopes.
  • Page 85 5. Let the wedge slide down behind the stack so the envelops are supported. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 86: Loading The High Capacity Envelope Feeder

    Loading the High Capacity Envelope Feeder The Relay 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 87 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...
  • Page 88 Running a Job 5. Press the envelope feeder loading switch again to raise the envelope stack to the normal feeding position. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 81 of 174...
  • Page 89 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 90: Loading The Insert Feeder

    Identifying the Insert - If the label indicates a range of settings, we recommend you select a higher number or letter for a thicker the insert. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 91 Running a Job 4. Set the blue separator gap lever to the number required. 5. Set the blue separator shield lever to the letter required. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 84 of 174...
  • Page 92 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 Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 85 of 174...
  • Page 93 Running a Job 8. Let the wedge (material prop) slide down the stack to support the envelopes. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 86 of 174...

  • Page 94: Running A Trial Piece

    When a trial piece is requested for a job where linked feeding is enabled, both feeders must be loaded, as a trial piece will feed from each feeder. Two trial pieces are produced. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...
  • Page 95 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 88 of 174...

  • Page 96: Starting And Stopping The Inserter

    Tap the Start button on the touchscreen to begin automatic operation. The inserter runs until it runs out of paper or you stop it. Tap the Stop button on the touchscreen to stop the inserter. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 97: Adding Sealer Solution

    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. Pitney Bowes Relay™...

  • Page 98: Adjusting The Drop Stacker

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 99 This page intentionally left blank.

  • Page 100: Omr Scanning

    6 - OMR Scanning In this section About Optical Mark Recognition (OMR) Scanning About OMR Scanning and Feeders About OMR Scanning Types About OMR Scanning Marks OMR Specifications Standard OMR Position - Diagram Adjusting the OMR Scanning Heads OMR Scanning Error Messages...

  • Page 101: About Optical Mark Recognition (Omr) Scanning

    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 envelope is low. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 102: About Omr Scanning And Feeders

    NOTE: Due to limitations of having only a single sheet feeder, OMR scanning is available for only C-fold and double-fold material on the Relay 2500. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 103: About Omr Scanning Types

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 96 of 174...

  • Page 104: About Omr Scanning Marks

    The system operates on the absence of this mark, that is, the action will take place if the mark is not read by the scanner. It is therefore indicated on the OMR code as Not EOC. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...
  • Page 105 The mark must appear on all sheets of the OMR set that requests this function. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 106 Place marks in the upper left corner of the sheet. Print marks in top-to-bottom 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 107 Place marks in the lower right corner of the sheet. 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 108: Omr Specifications

    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. There should be no print on the opposing face of the sheet immediately behind the clear zone. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 109: Standard Omr Position - Diagram

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

  • Page 110: Adjusting The Omr Scanning Heads

    3. Fold a sheet of material in half and measure the distance from the side of the sheet to the middle. A4 size sheet = 105 mm Letter size sheet = 8.5 x 11 inches (108 mm) Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 111 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). Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...
  • Page 112 5. Loosen the locking knob and set the relevant scanning 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 105 of 174...

  • Page 113: Omr Scanning Error Messages

    - Allows the operator to manually sort envelopes Mode Change Recheck Scroll at least to the paper length setting before the system accepts the job setup. Feeders Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 106 of 174...

  • Page 114: Barcode Scanning

    7 - Barcode Scanning In this section About Barcode Scanning About 2D Barcode Data Barcode Scanning Specifications About Barcode Placement Adjusting the Barcode Camera Barcode Scanning Error Messages...

  • Page 115: About Barcode Scanning

    An additional sheet or insert can be fed from other feeders with barcode scanning. 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 116: About 2D Barcode Data

    0s. For example, if the client invoice number is 8 characters long, 000000 (six 0s) must proceed the client’s invoice characters to make a total of 14 characters Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 117 NOTE: Two characters cannot be shown to represent 10 sheets, so instead the letter 'A' is used, (i.e..5, 6, 7, 8, 9, A). Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 110 of 174...

  • Page 118: Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...

  • Page 119: Barcode Scanning Specifications

    Minimum paper weight 75 - 80 gsm (20 lb) Maximum paper weight 120 gsm (32 lb) A4 and letter size sheets supported Barcodes must be printed in black on white paper only Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 112 of 174...
  • Page 120 Minimum Symbol Size: 5 mm x 5 mm Maximum Symbol Size: 10 mm x 10 mm Code Size: 16 x 16 cells (square shaped codes only) Cell sizes should all be identical Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 113 of 174...

  • Page 121: About Barcode Placement

    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 Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 122 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 Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 123 Barcode Scanning Double-fold and C-fold Applications Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 116 of 174...

  • Page 124: Adjusting The Barcode Camera

    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) Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 125: Barcode Scanning Error Messages

    Operator can manually sort envelopes in stacker Ready to Run Batch.” Mode change re- Check the sheet and insert feeder settings for check feeders the job before exiting setup mode Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 118 of 174...
  • Page 126 8 - Error Recovery and Clearing Material Jams In this section Accumulation Jobs - Error Recovery Empty Feeder - Error Recovery OMR Message - Error Recovery Clearing Material Jams Clearing Material Jams in the Sheet Feeder Clearing Material Jams in the Fold Plates Clearing Material Jams in the Insert Trays Clearing Material Jams in the Carriage Assembly Clearing Material Jams in the Envelope Feeder Area 136...

  • Page 127: Error Recovery And Clearing Material Jams

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 128: Empty Feeder - Error Recovery

    1. Re-fill the empty tray. 2. Tap the Start button to continue. 1. Tap the Stop and Clear Deck buttons. 2. Reload the feeders and proceed as prompted. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 121 of 174...

  • Page 129: Omr Message - Error Recovery

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 130: Clearing Material Jams

    (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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 131: Clearing Material Jams In The Sheet Feeder

    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 into its correct position. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 132 Error Recovery and Clearing Material Jams 4. Tap the Clear Deck button to clear the paper path of any remaining material. 5. Tap the Start button to resume operation. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 125 of 174...
  • Page 133 Once you locate the jammed material, you may need to use the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 134: Clearing Material Jams In The Fold Plates

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide...
  • Page 135 Error Recovery and Clearing Material Jams 4. Tap the Clear Deck button to clear the paper path of any remaining material. 5. Tap the Start button to resume operation. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 128 of 174...
  • Page 136 Once you locate the jammed material, you may need to use the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 137: Clearing Material Jams In The Insert Trays

    3. Replace the insert trays - slide the tray into the location guides; push until it clicks into place. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 130 of 174...
  • Page 138 Error Recovery and Clearing Material Jams 4. Tap the Clear Deck button to clear the paper path of any remaining material. 5. Tap the Start button to resume operation. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 131 of 174...
  • Page 139 Once you locate the jammed material, you may need to use the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 140: Clearing Material Jams In The Carriage Assembly

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 133 of 174...
  • Page 141 Error Recovery and Clearing Material Jams 6. Tap the Clear Deck button to clear the paper path of any remaining material. 7. Tap the Start button to resume operation. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 134 of 174...
  • Page 142 Once you locate the jammed material, you may need to use the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 143: Clearing Material Jams In The Envelope Feeder Area

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 144 7. Tap the Clear Deck button to clear the paper path of any remaining 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 145 Once you locate the jammed material, you may need to use the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 146: Clearing Material Jams In The Envelope Exit Area

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 139 of 174...
  • Page 147 Error Recovery and Clearing Material Jams 4. Tap the Clear Deck button to clear the paper path of any remaining material. 5. Tap the Start button to resume operation. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 140 of 174...
  • Page 148 Once you locate the jammed material, you may need to use the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 149: Clearing Material Jams In The Envelope Inserting And Sealing Area

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 142 of 174...
  • Page 150 Error Recovery and Clearing Material Jams 4. Tap the Clear Deck button to clear the paper path of any remaining material. 5. Tap the Start button to resume operation. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 143 of 174...
  • Page 151 Once you locate the jammed material, you may need to use the 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 152: Clearing Material Jams In The Accumulation Area

    Error Recovery and Clearing Material Jams Clearing Material Jams in the Accumulation Area 1. Grasp the blue tab and lift the first cover open. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 145 of 174...
  • Page 153 Error Recovery and Clearing Material Jams 2. Lift the next blue tab and pull that cover back. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 146 of 174...
  • Page 154 4. Lift the guide bar with the blue 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 155 6. Rotate the top cover back into place and resume operation. 7. Tap the Clear Deck button to clear the paper path of any remaining material. 8. Tap the Start button to resume operation. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 156: Reports

    9 - Reports In this section About Reports Generating Reports for Scanning Jobs Generating Productivity Reports for Jobs...

  • Page 157: About Reports

    There 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 150 of 174...

  • Page 158: Generating Reports For Scanning Jobs

    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 the current month. Job details for that scan job populates the screen. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 151 of 174...
  • Page 159 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 152 of 174...

  • Page 160: Generating Productivity Reports For Jobs

    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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 153 of 174...
  • Page 161 3. Tap the Open by File (Pages) icon at 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. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...

  • Page 162: 10 - Troubleshooting

    10 - Troubleshooting In this section Troubleshooting Touchscreen and Inserter Issues Troubleshooting Envelope Issues Troubleshooting Sheet Issues Troubleshooting Insert Issues Troubleshooting Double Detect Issues Error Messages...

  • Page 163: Troubleshooting Touchscreen And Inserter Issues

    Check that the fold selected is correct for the material size. If running heavy or light material, the envelope stop adjustment might need changing Large page count insertion may require a Service adjustment Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 156 of 174...

  • Page 164: Troubleshooting Envelope Issues

    No sealing solution Refill the sealer unit Seal mode not selected Check job setup Poor sealing Activate sealing mode Sealing felts may need to be changed Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 157 of 174...

  • Page 165: Troubleshooting Sheet Issues

    A fold is almost corresponding Adjust the fold sizes slightly to avoid this with a perforation on the sheet, situation causing a box fold or third fold Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 158 of 174...

  • Page 166: Troubleshooting Insert Issues

    Let the wedge slide down behind the insert stack for support Check the specifications in this guide Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 159 of 174...

  • Page 167: Troubleshooting Double Detect Issues

    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 Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 160 of 174...

  • Page 168: Error Messages

    CLEAR FOLD PLATE Material was detected inside the fold plate indicated on the display. Remove the fold plate and check for any material Install fold plate Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 161 of 174...
  • Page 169 If double feeds persist, request another trial piece. DOUBLE FEED CHECK A double feed has been detected from the feed tray indicated. STACKER Remove the double feed from the stacker Restart the inserter. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 162 of 174...
  • Page 170 Switch the inserter off and on and retry. If the problem persists, call for Service. TRAY EMPTY The tray indicated has no material. Reload the tray and press Start. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 163 of 174...
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  • Page 172: 11 - Specifications

    11 - Specifications In this section Material Specifications Inserter Specifications...

  • Page 173: Material Specifications

    Material Specifications All specifications are subject to change without notification and are subject to test. Overall Material Requirements For best performance, use only materials approved by Pitney Bowes Materials should be good quality and properly stored. Recommended storage conditions: 65° F (18°) to 77° F (25° C)
  • Page 174 100 lbs. (400 gsm) per set. Maximum compressed thickness after folding must not exceed 0.078 inch (2 mm). Using glossy or coated sheets is not recommended Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 167 of 174...
  • Page 175 This maximum includes any additional sheets from the supplementary feeder and / or insert feeder. The overall maximum compressed thickness of 0.078 in. (2 mm) still applies. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 176 Feed Tray Capacity Up to a maximum of 300 inserts Sealer Inserters seal up to a maximum of 1,200 envelopes between refills SafeSeal on two or more sheets Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 169 of 174...
  • Page 177 Inserts (folded) - allow a minimum clearance of 0.236 inches (6 mm), below the flap crease after it is fully inserted into the envelope. Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018...
  • Page 178 Specifications Envelope Flap and Throat Requirements Pitney Bowes Relay™ 2500, 3500, 4500 User Guide December, 2018 Page 171 of 174...

  • Page 179: Inserter Specifications

    USA and Canada: 120V, 60Hz, 6.0A Europe: 220/240V 50Hz 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 Pitney Bowes Relay™...
  • Page 180 Specifications Feeder Configurations Model Sheet Feeder Insert Feeder Envelope Feeder Relay 2500 Relay 3500 Relay 4500 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 Pitney Bowes Relay™...
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  • Page 182 3001 Summer Street Stamford, Connecticut 06926 www.pitneybowes.com SV63298 RevB ©2018 Pitney Bowes Inc. All Rights Reserved...

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