This equipment has been tested and found to comply with the limits for a Class
A digital device, pursuant to part 15 of the FCC rules. These limits are designed
to provide reasonable protection against interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and
can radiate radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause interference to radio communications.
Operation of this equipment in a residential area is likely to cause interference,
in which case the user will be required to correct the interference at his own
expense.
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. For a formal Declaration of Conformity, please
contact Pitney Bowes.
All rights reserved. This book may not be reproduced in whole or in part in any
fashion or stored in a retrieval system of any type or transmitted by any means,
electronically or mechanically, without the express, written permission of Pitney
Bowes. We have made every reasonable effort to ensure the accuracy and
usefulness of this manual; however, we cannot assume responsibility for errors
or omissions or liability for the misuse or misapplication of our products.
Due to our continuing program of product improvement, equipment and material
specifications as well as performance features are subject to change without
notice. E-Z Seal is a registered trademark of Pitney Bowes.
Page 3
Safety Information ................................................................iii
Chapter 1: System Overview
About Your System ............................................................1-3
System Configurations ............................................... 1-3
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
ii SV63176 RevB
Page 5
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.
• Use the AC power cord included with this device.
• Plug the AC power cord directly into a properly grounded wall outlet
located near the equipment and easily accessible. Failure to properly
ground the machine can result in severe personal injury and/or fire.
• The AC /power cord is the primary means to disconnect this device
from the AC supply.
• DO NOT use a wall outlet controlled by a wall switch or one that is
shared with other equipment.
• DO NOT use an adapter plug on the power cord or wall outlet.
• DO NOT remove the ground pin from the power cord.
• DO NOT route the AC power cord over sharp edges or trapped
between furniture.
• DO NOT route the power cord over sharp edges or trap it between
pieces of furniture. Make sure there is no strain on the power cord.
• If the unit becomes damaged, unplug it from the wall.
• Keep fingers, long hair, jewelry and loose clothing away from moving
parts at all times.
• Avoid touching moving parts or materials while the machine is in
use. Before clearing a jam, be sure machine mechanisms come to a
complete stop.
• Remove jammed material gently and carefully.
• DO NOT remove covers. Covers enclose hazardous parts that should
only be accessed by properly trained service personnel.
• DO NOT place lighted candles, cigarettes, cigars, etc., on the system.
• To prevent overheating, do not cover vent openings.
• Use only approved supplies.
• 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.
• Never use aerosol dusters labeled flammable and always read
instructions and safety precautions on the duster container label.
SV63176 RevB
iii
Page 6
Safety
• Operation of this equipment without periodic maintenance will inhibit
optimum operating performance and could cause the equipment to
malfunction.
• Always follow specific occupational safety and health standards for
your workplace.
• 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.
• Immediately report to service any damaged or non-functioning
components that renders the unit unsafe.
• Contact your system supplier for the following:
- Supplies
- Material Safety Data Sheets
- If you should damage the unit
- Required maintenance service schedule
CAUTION! Before you relocate a Relay 1000 with an
optional second Sheet Feeder A2 installed:
1. Unplug the power cord from the wall outlet.
2. Remove the Relay 1000 from the second Sheet
Feeder — as you lift it clear, make sure it fully
disengages from the second Sheet Feeder. Obtain
help if necessary.
iv
SV63176 RevB
Page 7
1 • System Overview
Contents
About Your System ............................................ 1-3
System Configurations ................................ 1-3
Safe Seal On/Off ....................................... 1-10
Contents
Page 8
This page is intentionally blank.
Page 9
System Overview • 1
About Your System
Your Relay 1000 is a compact folding and inserting system designed to
speed the process of mail creation. The system has a minimal number of
user adjustments and an intuitive, easy-to-use control panel.
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.
Configuration 1
• One Sheet Feeder
• One Envelope Feeder
Configuration 3
Optional
Second
Sheet
Feeder
• One Sheet Feeder
• One Envelope Feeder
• Optional Second Sheet Feeder
Configuration 2
Insert feeder
• One Sheet Feeder
• One Envelope Feeder
• One Insert Feeder
Configuration 4
Insert feeder
Optional
Second
Sheet
Feeder
• One Sheet Feeder
• One Envelope Feeder
• One Insert Feeder
• Optional Second Sheet Feeder
1-3SV63176 RevB
Page 10
1 • System Overview
Component Identification
12
11
10
12
3
4
9
8
7
Insert Cover E Release Button (Blue Button Marked E)
1
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)
2
Use this feeder to add inserts to your envelope. Material fed from
this feeder cannot be folded by the system. However, this feeder
is especially suited to pre-folded or thicker inserts.
Slot for Operator Guide
3
Store the Operator Guide in the slot provided so that it is readily
available when you need it.
Control Panel
4
This is where you enter commands and where the system
informs you of its status. See the Systems Controls section of
this chapter for a functional description of each button.
5
6
1-4 SV63176 RevB
Page 11
System Overview • 1
Moistener Tank
5
This tank contains E-Z Seal® solution or water to moisten and
seal envelope flaps. It slides out to the right for refilling and has
an oval level indicator window at the front that makes fluid level
checks quick and easy.
Lifting Handles (One Each Side)
6
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)
7
You can add this feeder to the system to enable folding and
inserting of a second sheet into the envelope. It functions in
exactly the same way as the standard sheet feeder A1.
IMPORTANT! When you use both sheet feeders A1 and A2
together, always load the address bearing sheet into sheet
feeder A2. If you fail to do this, the address won’t show in the
envelope window. Always load sheets into feeder A2 face down
and with the bottom edge of the sheet going first into the system.
Standard Sheet Feeder A1
8
This feeder enables folding and inserting of a sheet into the
envelope. Always load sheets into this feeder face down and
bottom edge first.
Manual Feeder M
9
Use this feeder to manually feed stapled sets of up to three
sheets each. The system waits for you to feed each set by hand
into this feeder before it folds and inserts the set automatically.
Always feed sheets into this feeder face down, bottom edge first.
Stacker
10
The system delivers finished pieces to this area.
Front Cover Release Button (Blue Button Marked “D”)
11
The display prompts you to press this button to release the front
cover if you need to remove jammed material.
Envelope Feeder B
12
This feeder sends envelopes into the inserting area where they
are filled with sheets or inserts from other feeders.
1-5SV63176 RevB
Page 12
1 • System Overview
System Controls
Introduction
1
2
3
4
5
Reset
Counter?
Menu / Enter
noyes
Feeder A1
Seal
No Seal
Trial Piece
Start
Feeder A2
2nd Page
Envelope Fdr B
Insert Fdr C
Fold Only
Stop
7
6
Display
1
Shows the current status of your Relay 1000 and displays
prompts and error messages.
1
Menu/Enter (see Advanced Menu Options section for details)
2
Press this button to enter the menu options. Available options:
• Reset Counter
• Change Paper Size (not available on all configurations)
• Move Address in Window
• Turn Sheet Double Detection On/Off
• Turn Insert Double Detection On/Off
• Turn Safe Seal On/Off
1-6 SV63176 RevB
Page 13
The Controls
System Overview • 1
yes ( ) and no ( ) buttons
3
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
4
Press these buttons to step through the feeders and options that
are available on your system.
Depending on your system configuration, some indicator lights
and associated feeders may be inoperable. A green indicator
means that a feeder or function is selected for use. A red indicator
means you selected an invalid combination of functions. When
you correct the selection error, the indicator(s) will change back to
green. An unlit indicator means that the feeder or function is turned
OFF.
Trial Piece
5
Press this button to run one fully collated piece as programmed
via the control panel. The envelope will not seal regardless of
whether the system has been told to seal or not. This allows
you to inspect the processed job to make sure that everything is
inserted correctly and that the address appears in the window.
The trial piece also allows the system to calibrate itself and set
the double detect feature, if selected.
IMPORTANT! Running the trial piece is an essential function
for the system to perform. You must do it before you run a
new batch of material. This allows the system to re-calibrate
for different batches of material.
Start
6
Press to begin automatic operation.
Stop
7
Press to stop automatic operation at the end of the next cycle.
About Sleep Mode
After 10 minutes of inactivity, the system enters a power-saving sleep
mode and displays Powersave On.
• Press any button to wake up the system.
• The system remembers the last job setup.
1-7SV63176 RevB
Page 14
1 • System Overview
Advanced Menu Options
To scroll through the menu options
• Press the Menu/Enter button repeatedly until you see the option you
want. OR
• Press the Menu/Enter button once and answer no to each of the
options as they appear.
• To return to the Ready screen at any time, press the Menu/Enter
button repeatedly.
Reset Counter
This option allows you to reset the counter to zero. To access it, press the
Menu/Enter button once. The screen prompts: Reset Counter?
• Press yes ( ) to reset the counter and return to the ready screen.
• Press no ( ) to go to the next menu option.
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).
1. Press the Menu/Enter button repeatedly until the display shows the
current paper size selection: Paper: 8-1/2 x 11 Change Size? or
Paper: 8-1/2 x 14 Change Size?
2. Press yes ( ) to change paper size. The display confirms the change.
Press no ( ) to go to the next menu option without changing the
paper size setting.
3. Press the Menu/Enter button repeatedly to go back to the Ready
screen.
IMPORTANT! Be sure the sheets you load are the same size you’ve set
the system to run. If you load the wrong size sheets, the system will jam.
Please note that the paper size setting applies to all the sheet feeders:
Sheet Feeder A1; the optional Sheet Feeder A2 (if your system is so
equipped); and Manual Feeder M.
CAUTION: DO NOT intermix sheet sizes in the same job. The
system will jam if you attempt to do so.
1-8 SV63176 RevB
Page 15
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. The screen displays: Shift...X (where X
is the current setting).
1. Press the Menu/Enter button repeatedly until the display shows:
Move Address in Window?
2. Press yes ( ) to enter the function. The screen displays: Shift.... X.
(X is the current setting). Pressing no ( ) takes you to the next menu
option.
3. Set the desired number using the yes ( ) and no ( ) buttons.
4. When you reach the setting you want, press the Menu/Enter button to
confirm it. This takes you to the next menu option.
5. Run another trial piece and check it.
• If the address is centered in the window, press Start to run your
job.
• If the address is not centered, repeat the procedure until you get
the result you want.
Sheet Double Detect On/Off
Use this option to turn sheet feeder double detection (Sheet DD) on or off.
• When Double Detect is turned on - the system stops automatically
when it senses a double feed (two sheets feed when only one should).
If you’re running a job with individually addressed sheets, it’s best to
turn double detection on.
• When Double Detect is turned off - the system ignores any double
feeds that may occur. You may want to leave double detection off if
you are running a mail job and occasional duplicate inserts are not a
concern.
1. Press the Menu/Enter button repeatedly until the display shows the
sheet DD status: Sheet DD is On (Off). Change?
2. Press yes ( ) to change the sheet double detect status. The display
will confirm the change. Or, Press no ( ) to go to the next menu option
without changing this setting.
1-9SV63176 RevB
Page 16
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.
• When Double Detect is turned off - the system ignores any double
feeds that may occur. You may want to leave double detection off if
you are running a mail job and occasional duplicate inserts are not a
concern.
1. Press the Menu/Enter button repeatedly until the display shows the
insert DD status: Insert DD is On (Off). Change?
2. Press yes ( ) to change the insert double detect setting. The display
confirms the change. Or, press no ( ) to go to the next option. The
double detection setting remains unchanged.
Safe Seal On/Off
This option allows you to turn safe seal on or off. If you’re having problems
with envelope flaps not sticking, try turning this option on.
Safe seal slows the system slightly, allowing more time for moisture to
transfer onto the envelope flap during the seal cycle. Some gums require
this added time to break down properly and become sticky. This function
produces a better seal on many types of envelopes.
1. Press the Menu/Enter button repeatedly until the display shows the
safe seal status: Safe Seal is On (Off). Change?
2. Press yes ( ) to change the safe seal status. The display confirms
the change. Or, press no ( ) to exit from the menu options without
changing the safe seal setting.
1-10 SV63176 RevB
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
Page 18
This page is intentionally blank.
Page 19
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). This helps
assure reliable operation and greatest productivity.
Connecting Power and Turning On
WARNING! Read all the safety information at the beginning of this guide
before connecting the system.
1. Connect the power cord to the socket on the back of the system.
2. Plug the power cord into an easily accessible power outlet.
3. Turn the power switch ON.
• After a few seconds, the message “Check Moistener’” appears on
the display. This is only a reminder to check the level; it does not
always mean that the moistener level is too low.
• The “Check Moistener” message remains there until any other
button is pressed.
IMPORTANT! As an additional reminder, the “Check Moistener”
message appears every 1,000 cycles, at the end of a batch or
when the Stop button is pressed.
• When turned ON, the system remembers the last job setup, and
automatically resets the item counter to zero.
2-3SV63176 RevB
Page 20
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.
IMPORTANT! Never open the moistener
while the system is processing material.
2. Carefully fill the moistener with
E-Z Seal® solution or water up to
the “Max” mark in the filler funnel.
We recommend E-Z Seal® to
minimize algae growth and scale
buildup.
3. Slide the moistener back into the system. From a dry state, the
moistener takes about ve minutes to become fully wet and ready for
use.
2-4 SV63176 RevB
Page 21
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.
• Both feeders are used for sheets that require folding before inserting.
• Load both feeders in exactly the same way.
1. Always fan (aerate) sheets before
you load them. This prevents
them from sticking together.
2. Tap the stack of sheets onto a
firm surface to align the edges.
3. Place the sheets into Sheet
Feeder A1 or A2 as required.
IMPORTANT! Always load sheets into
these feeders face down and bottom
edge first. The bottom edge of the
sheet is furthest into the system.
NOTE: If you use Sheet Feeders A1 and A2 at the same time, you must
load the document printed with the address into Sheet Feeder A2. If you
load the address-bearing document into Sheet Feeder A1, the address
will not be visible in the envelope window.
4. Slide the back stop in until it just
touches the paper stack.
2-5SV63176 RevB
Page 22
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. You do not need
to “shingle” or stagger the
envelope stack. The feeder
can hold up to 60 envelopes.
IMPORTANT! Load envelopes right way up and facing you. This means
that the envelope ap is on the back of the envelope and at the top. Any
other orientation will prevent the machine from inserting properly.
4. Slide the two side guides up
to the envelope stack then
slightly back them off. Use the
blue handles at the rear of the
guides when moving them.
IMPORTANT! The setting is correct when the guides do not restrict the
envelopes feeding into the system or cause them to feed at an angle
(skew).
2-6 SV63176 RevB
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.
1. Always fan (aerate) inserts
before you load them. This
prevents them from sticking
together.
2. Tap the stack of inserts onto a
firm surface to align the edges.
3. Place the insert stack into
Feeder C.
IMPORTANT!
• For pre-folded inserts, it’s normally best to load with the “closed”
edge feeding first.
• You can usually load business reply envelopes right way up and
facing you. However, if the flaps are pulled open when feeding, try
loading the envelopes with the flaps down and facing you.
4. Slide the two side guides up to
the insert stack, then slightly
back them off. Use the blue
handles at the rear of the
guides when moving them.
IMPORTANT! The setting is correct when the guides do not restrict the
envelopes feeding into the system or cause them to feed at an angle
(skew).
2-7SV63176 RevB
Page 24
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.
2-8 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
Manual Feeder M ..............................................3-16
Page 26
This page is intentionally blank.
Page 27
Run a Job ● 3
Run a Job
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
Job 1
• One Folded Sheet
• Into an Envelope
Models with an Insert Feeder
Job 3
Job 2
• One Folded Sheet
• No Envelope
Job 4
• One Folded Sheet
• One Insert
• Into an Envelope
• One Insert
• Into an Envelope
3-3SV63176 RevB
Page 28
3 ● Run a Job
Models with an Optional Second Sheet Feeder
Job 5
• Two Folded Sheets
• Into One Envelope
Job 7
Job 6
• Two Collated, Folded Sheets
• Into One Envelope
see note next page
*
Job 8
• Two Folded Sheets
• No Envelope
3-4 SV63176 RevB
• Two Collated, Folded Sheets
• No Envelope
see note next page
*
Page 29
Run a Job ● 3
Models with an Insert Feeder and Second Sheet Feeder
Job 9
• Two Folded Sheets
• One Insert
• Into an Envelope
• Two Collated, Folded Sheets
• One Insert
• Into an Envelope
Job 10
see note below
*
NOTE: Jobs marked with an asterisk (*) use the second sheet feeder, A2,
in “2nd Page” mode to feed 2-sheet collated sets. You must load sheets
into the feeder in their collated sequence: rst page, second page, rst
page, second page, etc.
3-5SV63176 RevB
Page 30
3 ● Run a Job
Job 1
• One folded sheet
• Into an envelope
• Conguration 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.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
Select 11” or 14”.
2Load sheets into Sheet
Feeder A1.
3Load envelopes in Feeder B.Load right way up and facing
4Press button to select Feeder
A1.
5Press button to select
Envelope Fdr B.
6Press button to choose Seal
or No Seal.
7Press Trial Piece button and
inspect trial piece.
8Press the Start button to run
the job.
Load face down and bottom
edge first.
you.
Make sure indicators are green.
Make sure indicators are green.
Make sure moistener has E-Z
Seal® or water.
Trial piece will not seal - this is
normal.
The Stop button will stop the
system at the end of the cycle.
3-6 SV63176 RevB
Page 31
Run a Job ● 3
Job 2
• One folded sheet
• 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.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
Select 11” or 14”.
2Load sheets into Sheet
Feeder A1.
3Press the button to select
Feeder A1.
4Press button to select Fold
Only.
5Press the Trial Piece button
and inspect trial piece.
6Press the Start button to run
job.
Load face down and bottom
edge first.
Make sure indicators are green.
Make sure indicators are green.
Check trial piece for a good fold.
The Stop button will stop the
system at the end of the cycle.
3-7SV63176 RevB
Page 32
3 ● Run a Job
Job 3
• One folded sheet
• One insert
• Into an envelope
• Conguration 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.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
Select 11” or 14”.
2Load sheets into Sheet
Feeder A1.
3Load envelopes in Feeder B. Load right way up and facing
4Load inserts into Insert
Feeder C.
5Press button to select
Feeder A1.
6Press button to select
Envelope Fdr B and Insert
Fdr C.
7Press button to choose Seal
or No Seal.
8Press the Trial Piece button
and inspect trial piece.
9Press the Start button to run
job.
3-8 SV63176 RevB
Load face down and bottom
edge first.
you.
Loading orientation depends on
item.
Make sure indicators are green.
Make sure BOTH green
indicators are lit.
Make sure moistener has E-Z
Seal® or water.
Trial piece will not seal - this is
normal.
The Stop button will stop the
system at the end of the cycle.
Page 33
Run a Job ● 3
Job 4
• One insert
• Into an envelope
• Conguration 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.
STEPACTIONTIP
1Load envelopes into Feeder B.Load right way up and facing
you.
2Load inserts into Insert
Feeder C.
3Press button to select
Envelope Fdr B and Insert
Fdr C.
4Press A1/A2 select button
until both feeders and 2nd Page are turned OFF.
5Press button to choose Seal
or No Seal.
6Press the Trial Piece button
and inspect trial piece.
7Press the Start button to run
job.
Loading orientation depends on
the item.
Make sure BOTH green
indicators are lit.
Make sure NO indicators lights
are lit for A1 or A2 or 2nd page.
Make sure moistener has E-Z
Seal® or water.
Trial piece will not seal - this is
normal.
The Stop button will stop the
system at the end of the cycle.
3-9SV63176 RevB
Page 34
3 ● Run a Job
Job 5
• Two Folded Sheets
• Into One Envelope
• Conguration 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.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
Select 11” or 14”.
2Load addressed sheets into
Sheet Feeder A2.
3Load second sheets into
Sheet Feeder A1.
4Load envelopes in Feeder B.Load right way up and facing
5Press button to select Feeder
A1 and A2.
6Press button to select
Envelope Fdr B.
7Press button to choose Seal
or No Seal.
8Press the Trial Piece button
and inspect trial piece.
9Press the Start button to run
job.
Load face down and bottom
edge first.
Load face down and bottom
edge first.
you.
Make sure BOTH green
indicators are lit.
Make sure indicators are green.
Make sure moistener has E-Z
Seal® or water.
Trial piece will not seal- this is
normal.
The Stop button will stop the
system at the end of the cycle.
3-10 SV63176 RevB
Page 35
Run a Job ● 3
Job 6
• 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.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
Select 11” or 14”.
2Load sheets into Sheet
Feeder A2. (See note above
for loading sequence.)
3Load envelopes in Feeder B.Load right way up and facing
4Press button to select Feeder
A2 and 2nd Page.
5Press button to select
Envelope Fdr B.
6Press button to choose Seal
or No Seal.
7Press the Trial Piece button
and inspect trial piece.
8Press the Start button to run
job.
Load face down and bottom
edge first.
you.
Make sure BOTH green
indicators are lit.
Make sure indicators are green.
Make sure moistener has E-Z
Seal® or water.
Trial piece will not seal- this is
normal.
The Stop button will stop the
system at the end of the cycle.
3-11SV63176 RevB
Page 36
3 ● Run a Job
Job 7
• 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.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
Select 11” or 14”.
2Load addressed sheets into
Sheet Feeder A2.
3Load second sheets in Sheet
Feeder A1.
4Press button to select Feeder
A1 and Feeder A2.
5Press button to select Fold
Only.
6Press the Trial Piece button
and inspect trial piece
7Press the Start button to run
job.
Load face down and bottom
edge first.
Load face down and bottom
edge first.
Make sure BOTH green
indicators are lit.
Make sure indicators are green.
Check trial piece for good fold.
The Stop button will stop the
system at the end of the cycle.
3-12 SV63176 RevB
Page 37
Run a Job ● 3
Job 8
• 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.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
Select 11” or 14”.
2Load sheets into Sheet
Feeder A2. See above for
loading sequence.
3Press button to select Feeder
A2and 2nd Page.
4Press button to select Fold
Only.
5Press the Trial Piece button
and inspect trial piece
6Press the Start button to run
job.
Load face down and bottom
edge first.
Make sure BOTH green
indicators are lit.
Make sure indicators are green.
Check trial piece for a good
fold.
The Stop button will stop the
system at the end of the cycle.
3-13SV63176 RevB
Page 38
3 ● Run a Job
Job 9
• Two folded sheets
• 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.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
2Load addressed sheets into
Sheet Feeder A2.
3Load second sheets into
Sheet Feeder A1.
4Load envelopes in Feeder B.Load right way up, facing you.
5Load inserts into Insert Feeder C.Loading orientation depends
6Press button to select Feeder
A1 and Feeder A2.
7Press button to select
Envelope Fdr B and Insert
Fdr C.
8Press button to choose Seal
or No Seal.
9Press the Trial Piece button
and inspect trial piece
10Press the Start button to run
job.
Select 11” or 14”.
Load face down and bottom
edge first.
Load face down and bottom
edge first.
on item.
Make sure BOTH green
indicators are lit.
Make sure BOTH green
indicators are lit.
Make sure moistener has E-Z
Seal® or water.
Trial piece will not seal - this is
normal.
The Stop button will stop the
system at the end of the cycle.
3-14 SV63176 RevB
Page 39
Run a Job ● 3
Job 10
• Two collated, folded sheets
• 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: rst page, second page, rst page, second page and so on.
Inserts are pre-folded sheets or unfolded items such as business reply
envelopes, response cards and so on.
STEPACTIONTIP
1Make sure the paper size
setting is correct.
NOTE: This setting is not
available on all models.
2Load addressed sheets into
Sheet Feeder A2. See notes
above for loading sequence.
3Load second sheets into Sheet
Feeder B.
4Load inserts into Insert Feeder C.Loading orientation depends
5Press button to select Feeder
A2 and 2nd Page.
6Press button to select
Envelope Fdr B and Insert
Fdr C.
7Press button to choose Seal or
No Seal.
8Press the Trial Piece button
and inspect trial piece
9Press the Start button to run
job.
Select 11” or 14”.
Load face down and bottom
edge first.
Load face down and bottom
edge first.
on item.
Make sure BOTH green
indicators are lit.
Make sure BOTH green
indicators are lit.
Make sure moistener has E-Z
Seal® or water.
Trial piece will not seal - this is
normal.
The Stop button will stop the
system at the end of the cycle.
3-15SV63176 RevB
Page 40
3 ● Run a Job
Manual Feeder M
Relay 1000models have a Manual Feeder M that allows you to feed
stapled sets of up to three sheets of 20 pound bond (80 g/m2). 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. You can, however, use the manual feeder along with the
envelope, insert, fold-only and sealer selections to run a variety of jobs
manually.
To use the manual feeder:
1. Set up the system as you normally would for the job you are running.
The selections shown by the indicators for Sheet Feeders A1 and/
or A2 are ignored by the system. All other selections apply to the
manual job.
2. Feed one staple set, face down
and bottom edge first, gently
into the manual feed slot. The
system automatically starts
and draws the set from you.
The system processes the set
and ejects it into the stacker in
the usual manner.
NOTES:
• Be sure to feed the set into the system squarely and gently. If you feed
it in at an angle or with force, a poor fold or jam could result.
• The first set will not seal even if you set up the system to do so. This
"trial" feature allows you to inspect the processed job to make sure
that all pieces were inserted correctly and that the address appears in
the envelope.
CAUTION! Feeding more than three sheets in a set
may damage your system.
3-16 SV63176 RevB
Page 41
4 • Clear Material
Contents
Clear Material Jams...............................................4-3
4-1
Page 42
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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,
and then carefully remove
any stalled material.
• If the display indicates
a jam beneath cover D,
press the blue button
marked D to release the
cover. Lift the cover using
the finger grips on each
side of the stacker, and
then carefully remove any
stalled material.
• When closing the cover,
latch it closed by pressing
down on the finger grips
or the central part of
the cover in front of the
envelope feeder. DO NOT
press down on the stacker.
• If the display indicates
a jam beneath cover E,
press the blue button
marked E to release the
cover. Push the cover
backwards to gain full
access, then carefully
remove any stalled
material.
Button D
Button E
SV63176 RevB 4-3
Page 44
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Page 45
5 • Troubleshooting
and Error Messages
Contents
General Troubleshooting .......................................5-3
System creates
a “box fold” when
another fold is
created off the
perforation and
buckles slightly,
creating, in effect, a
third fold.
System stops for
doubles that aren’t
there.
System feeds
doubles without
stopping.
Envelope flaps won’t
seal
1. Adjust the system fold slightly.
2. Run a trial piece and inspect the fold.
3. If there is still a box fold, access the
advanced menu options and select move address in window.
4. Change the setting higher or lower and rerun a trial piece.
5. Inspect the fold again and, if required,
change the move address in window function
until the box fold is eliminated.
• If you are running a new batch of material
that is slightly thicker or thinner than the
original material, run a new trial piece to
allow the system to recalibrate to the new
material.
• Another possible solution is to turn off double
detection if an occasional duplicate insert is
not important.
1. Make sure double detection is turned on.
2. Run a trial piece. This automatically sets the
double detector.
Try one or all of the following:
• Verify Seal is selected (green indicator lit).
• Make sure the moistener isn’t empty.
• Select safe seal mode.
Address position is
wrong or address
doesn’t appear in
envelope window.
SV63176 RevB 5-3
• Make sure the addressed sheet loaded
properly.
• Make sure the addressed sheet in Sheet
feeder A2 (if installed).
• Try adjusting the address position.
Page 48
5 • Troubleshooting and Error Messages
IssuePossible Solutions
Inserts or business
reply envelopes feed
poorly from the Insert
Feeder
Following installation
of Sheet Feeder 2,
the system doesn’t
work
Changing the orientation of the insert stack may
help.
• For pre-folded inserts, it is normally best to
load with the closed edge feeding rst.
• Business reply envelopes can normally be
loaded right way up and facing you. However,
if the aps are pulled open when feeding, try
loading with the aps down and facing you.
Make sure the system is seated correctly on
Sheet Feeder 2.
• Turn the system off, wait a few seconds and
then turn it back on.
• Remove any debris (dust, paper, etc.) from
the Sheet Feeder 2 electrical connector.
5-4 SV63176 RevB
Page 49
Troubleshooting and Error Messages • 5
Error Messages
MessageCause and Fix
CANNOT SHIFT
ADDRESSES ON
INSERT
CLOSE COVER DThe system has detected that the front cover D
CLOSE COVER EThe system has detected that the front cover E
No sheet feeder has been selected in the job
setup. The display automatically times out from
this message after two seconds and displays
the double detect On/Off menu function.
is open. Make sure cover D is closed properly.
is open. Make sure cover E is closed properly.
CHECK AREAS A1
& D
CHECK AREAS A1,
A2, & D
CHECK/CLEAR
INSERT FDR C
CHECK SHEET
FEEDER A1
Check for an unsuccessful clearance of a jam
between the sheet feeder A1 and the area
under cover D.
1. Remove the paper in sheet feeder A1.
2. Open front cover D and make sure the
system is clear of material.
3. Close front cover D.
4. Reload and then start the run.
This could be due to an unsuccessful
clearance of a jam between the sheet feeders
A1, A2 and the area under cover D.
1. Remove paper in sheet feeders A1 and A2.
2. Open front cover D and make sure the
system is clear of material.
3. Close front cover D.
4. Reload and then start the run.
Inserts failed to feed.
1. Make sure the side guides in insert feeder
C are set correctly.
2. Reload feeder C and then start the run.
Sheet feeder A1 is out of paper, failed to feed
or a jam wasn’t cleared successfully from area.
1. Remove the paper in sheet feeder A1.
2. Reload and then start the run.
SV63176 RevB 5-5
Page 50
5 • Troubleshooting and Error Messages
MessageCause and Fix
CHECK SHEET
FEEDER A2
CHECK SHEET
FEEDER A2
LIFT COVER D
REMOVE ALL
CLEAR FEEDER MThe Manual Feeder M was blocked before
CLEAR STACKER
AREA
DOUBLE FEED
CHECK FDR A1
DOUBLE FEED
CHECK FDR A2
Sheet feeder A2 is out of paper, failed to feed,
or a jam was no cleared successfully from this
area.
If there are sheets in the feeder:
1. Remove the paper in sheet feeder A2.
2. Reload and then start the run.
If the feeder is empty, load sheets.
The system has detected a material jam
between sheet feeder A2 and the area under
cover D.
1. Open the front cover D and remove all
material inside.
2. Close front cover D.
3. Remove material from sheet feeder A2.
4. Reload and start the run.
powering up the system or starting the run.
1. If there is any material in the feeder,
remove it.
2. Restart the system.
Check for a jam in the stacker area.
1. Remove any material from the stacker
area.
2. Resume the run.
The system has detected a double feed from
sheet feeder A1.
1. Remove the paper in sheet feeder A1.
2. Reload and then start the run.
The system has detected a double feed from
sheet feeder A2.
1. Remove paper in sheet feeder A2: make
sure to remove any partially fed sheets.
2. Reload and then start the run.
5-6 SV63176 RevB
Page 51
Troubleshooting and Error Messages • 5
MessageCause and Fix
FOLD ONLY
REQUIRES SHEETS
INSERT DOUBLE
FEED
LIFT COVER D
REMOVE ALL
LIFT COVER D
REMOVE ENV
NVM ERROR
CALL SERVICE
OPEN COVER E
REMOVE ALL
Fold only has been selected but no sheets,
either from feeder A1 or A2 (if applicable), have
been selected. In this state the indicators for
sheet feeder A1 will be red. Press the sheet
feeder selection button until the required feeder
is selected.
The system has detected a double feed from
the insert feeder.
1. Lift cover D.
2. Remove material.
3. Reload inserts and then start the run.
There is a jam in or near the insertion area, or
a previous jam was not cleared correctly. It can
also be caused by dust covering a sensor.
1. Open front cover D.
2. Remove any material in the system.
3. Blow out any dust that may have
accumulated in the area.
4. Close cover D and then start the run.
Check for an envelope jam under cover D.
1. Open front cover D.
2. Remove the envelope and then start the
run. If no envelope is visible:
• Remove all material that is visible in
the feeder.
• Reload and start the run.
This is an unrecoverable error with the system
software. Call Pitney Bowes for assistance.
Check for a jam under cover E.
1. Open cover E.
2. Remove any material in the system.
3. Close rear cover E and then start the run.
SV63176 RevB 5-7
Page 52
5 • Troubleshooting and Error Messages
MessageCause and Fix
SYSTEM ERROR
POWER ON/OFF
RELOAD
ENVELOPES
RELOAD INSERT
FEEDER C
REMOVE ALL FROM
D & E
1. Turn off power to the system.
2. Wait a minute and turn the power back on.
Feeder B may be out of envelopes, or an
envelope feed failed or was slow.
1. Make sure there are envelopes loaded.
• If not, reload and then start the run.
• If there are envelopes loaded, make
sure that the side guides on feeder B
are not too tight and that no more than
60 envelopes are loaded.
2. Reload feeder B and then start the run.
Insert feeder C is empty. Reload inserts and
start the run.
This could be due to a material jam in fold plate
1 or near the insertion area.
1. Open front cover D.
2. Remove any material from the area.
3. Close cover D.
4. Open rear cover E.
5. Remove any material from the area.
6. Close rear cover E and then start the run.
5-8 SV63176 RevB
Page 53
Troubleshooting and Error Messages • 5
MessageCause and Fix
REMOVE ALL FROM
M & D
REMOVE SHEET
FROM A1
REPLACE FDR A1
TRAY
SHEETS REQUIRED
SYSTEM ERROR
CALL SERVICE
There was a poor feed from manual feeder M.
1. If there is any material in manual feeder M,
remove it.
2. Open front cover D and remove any
material.
3. Close front cover D.
4. Reload and then start the run.
A sheet has failed to feed from sheet feeder A1.
1. Remove paper from A1.
2. Reload and then start the run.
Make sure that sheet feeder A1 is pushed fully
into position.
• Envelopes have been selected but no
sheet feeder was selected.
• The indicators for sheet feeder A1 and
envelopes will be red.
Press the sheet feeder selection button until the
required feeder is selected.
This is an unrecoverable system error. Call
Pitney Bowes for assistance.
SV63176 RevB 5-9
Page 54
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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
6-1
Page 56
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Page 57
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. DO NOT run perforated, NCR or coated
papers.
Insert Feeder C (optional)
Insert Size:
Width: 5 to 8-3/4”
Depth: 3-3/8 to 3-7/8”
Material Weight:
Capacity:
Type:
Envelope Feeder B
Envelope Size:Number 10 only
Material Weight:18 to 24 lb. bond
Capacity:Max: 60 envelopes, 24 lb. bond
Envelope Flap Type:Executive (triangular) flap
Envelope Flap Length:1-1/4” to 2-1/4”
Unfolded document: 18 lb. bond to 80 lb. card
stock
Tri-folded document: 18 to 24 lb. bond
Max: 60 Business Reply Envelopes, 24 lb bond
Suitable for pre-folded, single panel inserts,
business reply envelopes, etc.
Width: 9-1/2”
Depth: 4-1/8”
SV63176 RevB 6-3
Page 58
6 • Specifications
End ClearanceEnd 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 ClearanceThe contents must allow a minimum clearance
of 1/4” below the flap crease after full insertion
into the envelope.
Manual Feeder M
Stapled or unstapled sets of up to 3 sheets of 20 lb. bond paper can be
processed. Sheet Feeders A1 and A2 cannot be used in conjunction with
the Manual Feeder. Glossy/coated sheets are not recommended.
Sealer Capacity
The machine can seal up to a maximum of 1,000 envelopes between
refills.
Stacker
Stacker capacity is up to 60 filled envelopes, depending on the contents of
envelope.
Material Requirements
• Materials should be of good quality and properly stored
• Recommended storage conditions:
-64° to 77°F
-40 to 60% relative humidity
6-4 SV63176 RevB
Page 59
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
Electrical115V, 60Hz, 2.4A
Specifications • 6
Speed
Duty Cycle
Up to a maximum of 4,000 cycles per month with an average of 2,000
cycles per month and a maximum life of 120,000 cycles.
NOTE: All specifications are subject to change without notification and are
for information only.
Up to a maximum of 900 cycles per hour
SV63176 RevB 6-5
Page 60
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. DO NOT run perforated, NCR or coated
papers.
Insert Feeder C (optional)
Insert Size:
Material Weight:
Width: 127mm to 225mm
Depth: 86mm to 114mm
Unfolded document: 70gsm bond to 200gsm
card stock
Suitable for pre-folded, single panel inserts,
business reply envelopes, etc.
Width: 225mm to 235mm
Depth: 110mm to 121mm
Page 61
Specifications • 6
End ClearanceEnd 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 ClearanceThe contents must allow a minimum clearance
of 6mm below the flap crease after full insertion
into the envelope.
Manual Feeder M
Stapled or unstapled sets of up to 3 sheets of 80gsm bond paper can be
processed. Sheet Feeders A1 and A2 cannot be used in conjunction with
the Manual Feeder. Glossy/coated sheets are not recommended.
Sealer Capacity
The machine can seal up to a maximum of 1,000 envelopes between
refills.
Stacker
Stacker capacity is up to 60 filled envelopes, depending on the contents of
envelope.
Material Requirements
• Materials should be of good quality and properly stored
• Recommended storage conditions:
-18° to 25°C
-40 to 60% relative humidity
SV63176 RevB 6-7
Page 62
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 LevelRunning: <70dBA
Electrical240V, 50Hz, 1A
SpeedUp to a maximum of 900 cycles per hour
Duty Cycle
Up to a maximum of 4,000 cycles per month with an average of 2,000
cycles per month and a maximum life of 120,000 cycles.
NOTE: All specifications are subject to change without notification and are
for information only.