Pitney Bowes relay 2000 Operator's Manual
Relay™ 2000
Shipping & Mailing
Inserter
Document Inserting System
Operator Guide
International English Edition
SV63139 Rev A
August 1, 2015
Statement of FCC Compliance
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.
SV63139 Rev. A ©2006, 2015 Pitney Bowes Inc.
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.
Canada
This class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme á la norme NMB-003 du
Canada.
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 this system complies with all applicable Directives of
the European Union.
Table of Contents
iiiSV63139 Rev. A
Safety ..................................................................................vii
Chapter 1 System Overview
Relay 2000 Inserter Introduction Overview .......................1-3
Product Features ...............................................................1-3
Relay 2000 Inserter (with Control Panel) -
Component Identification ................................................... 1-4
Control Panel Identification ................................................ 1-6
Control Panel Icons ...........................................................1-8
Change the Display Language ........................................1-10
Chapter 2 Program a Job
Navigate Using the Control Panel .....................................2-3
Scanning and Non-Scanning Jobs ............................. 2-4
Program a Job ...................................................................2-5
Setup Mode ................................................................ 2-5
Select the Job Number (New or Existing Job) ........... 2-5
Program a Scanning Job ........................................... 2-6
Program a Non-Scanning Job .................................. 2-14
Modify an Existing Job ..................................................... 2-22
Delete a Job ....................................................................2-22
Chapter 3 Run a Job
Run a Job ..........................................................................3-3
Verify the Inserter Has Power ............................................ 3-4
Select a Job ............................................................... 3-4
Manual Feed Jobs .............................................................3-5
Load Material .....................................................................3-6
Adjust and Load the Sheet Feeders .......................... 3-6
Adjust and Load the Envelope Feeder ....................... 3-7
Adjust and Load the Insert Feeder ............................. 3-8
Run a Trial Piece .............................................................3-10
Material Changes or Double Detect Issues
During Operation ................................................. 3-10
Start and Stop the Inserter .............................................. 3-11
Fill the Sealer ................................................................... 3-11
Table of Contents
iv SV63139 Rev. A
Adjust the Stacker ...........................................................3-12
Chapter 4 OMR Scanning
Optical Mark Recognition (OMR) ....................................... 4-3
Accuracy .................................................................... 4-3
OMR and Feeders on the Inserter ..................................... 4-3
OMR Scanning Types ........................................................4-4
Basic OMR ................................................................. 4-4
Enhanced OMR ......................................................... 4-4
OMR Mark Positions ..........................................................4-4
OMR Specifications ...........................................................4-5
Standard OMR Positions ........................................... 4-6
Offset OMR Positions ................................................. 4-7
Available OMR Marks .......................................................4-8
Benchmark ................................................................. 4-8
Safety ......................................................................... 4-8
End-of-Collation (EOC) .............................................. 4-8
Beginning-of-Collation (BOC) .................................... 4-8
Parity .......................................................................... 4-8
Re-timing Mark ........................................................... 4-8
Select Feed (SF1, SF2) ............................................. 4-9
Auto Batch ................................................................. 4-9
Wrap Around Sequence (WAS1, WAS2, WAS3) ....... 4-9
OMR Mark Grouping .......................................................4-10
C-Fold and Double-Fold Jobs .................................. 4-10
Adjust the OMR Scanner ................................................. 4-11
OMR Troubleshooting ......................................................4-12
Error Recovery for OMR Jobs .................................. 4-12
Error Recovery for Accumulation Jobs ..................... 4-12
Error Recovery for Empty Feeders .......................... 4-12
OMR Error Messages ......................................................4-13
Chapter 5 Clear Material
Clear Material ....................................................................5-3
Table of Contents
vSV63139 Rev. A
Access Areas of the Inserter for Jam Removal .................5-3
Sheet Feeders Tray - Remove and Replace .............. 5-3
Fold Plates - Remove and Replace ........................... 5-4
Insert Tray - Remove and Replace ............................ 5-4
Access the Carriage Assembly .................................. 5-4
Access to Envelope Feeder Area ............................... 5-5
Access the Envelope Exit Area .................................. 5-5
Access the Envelope Inserting/Sealing Area ............. 5-6
Access to the Sheet Feed Area ................................. 5-6
Chapter 6 Troubleshooting
General Troubleshooting ...................................................6-3
Error Messages .................................................................6-7
Chapter 7 Material Specifications
Material Specifications .......................................................7-3
Inserter Specifications .......................................................7-7
Service ...............................................................................7-8
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Safety
viiSV63139 Rev. A
Safety
Follow these precautions whenever you use your inserting system:
• 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 adapter included with this device. Third party
adapters may damage the device.
• Plug the AC adapter 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 adapter/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 line cord or wall outlet.
• DO NOT remove the ground pin from the line cord.
• DO NOT route the AC adapter power cord over sharp edges or trap it
between furniture. Make sure there is no strain on the power cord.
• 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.
Safety
viii SV63139 Rev. A
• 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.
• Before operating the main inserting machine with this device, make
sure the machine has been properly prepared and that any other
personnel in the area are standing clear of the inserter.
• 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
If your Stacker has an AC Adapter:
• Use the AC power adapter included with this device. Third party
adapters may damage the device
• To protect against electrical shock, plug the AC adapter power cord
into a properly grounded wall outlet.
• 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.
IMPORTANT: Some of the inserter features and options covered in
here may not be available on your inserter.
SV63140 Rev A
1 • System Overview
Contents
Relay 2000 Inserter Introduction Overview .....................1-3
Product Features .............................................................1-3
Relay 2000 Inserter Component Identification ................1-4
Control Panel Identification..............................................1-6
Control Panel Icons .........................................................1-8
Change the Display Language ......................................1-10
This page is intentionally blank.
System Overview • 1
1-3
SV63139 Rev. A
Relay 2000 Inserter Introduction Overview
• The Relay 2000 is a two-station inserter with one sheet feeder and
one insert feeder.
• Jobs are programmed and run via the control screen built into the
system.
• Processing speed varies depending on machine configuration.
• Your system may be equipped with OMR (Optical Mark Recognition)
scanning, depending on the model you purchased.
Product Features
The Relay 2000 inserters with a control panel offer these features:
• Envelope seal/no seal option
• Fully automatic material separation on sheet feeders
• Fully automatic setting of fold plates
• Fully automatic envelope separation
• Fully automatic double document detection (when selected)
• Fold-only option (fold without insertion)
• Manually fed, semi-automatic insertion of single and multi-sheet
collations
• Option of single fold, letter (C) fold, accordion (Z) fold or double fold
• Job recall facility
• Optical Mark Recognition (OMR) scanning
1 • System Overview
1-4 SV63139 Rev. A
Relay 2000 Inserter (with Control Panel) -
Component Identification
1
Sheet Feeder 1 - This feeder is intended for feeding material
that requires folding.
In addition, you can set sheet feeder 1 to Manual Feed. In this
mode, you can run stapled sets of up to five sheets. The inserter
waits for you to feed each set by hand into sheet feeder 1 before
folding and inserting the set automatically.
2
Display/Control Panel - This is where you enter commands
and where the inserter status is displayed through symbols
and icons.
10
2
1
3
5
6
4
9
8
7
System Overview • 1
1-5
SV63139 Rev. A
3
Insert Feeder - Use this feeder to add additional inserts to
your envelope. Material fed from this feeder cannot be folded
by the inserter. However, this feeder is especially suited to
feeding pre-folded or thicker inserts.
4
Sealer Bottle - The sealer bottle is located on the rear of the
inserter on the right side. It is under a hinged cover, labeled
with the sealer icon. The sealer bottle provides sealing
solution to the envelope sealer.
5
Envelope Inverter - Transports the envelope into the stacker
face up.
6
Drop Stacker or Output Device (not shown in image) -
Located at the exit of the inserter, this device collects finished
mailpieces. This device can be latched against the inserter when
not in use. Alternatively, a range of power stackers are available
which offer greater capacity than the standard drop stacker.
7
Fold Plate - This creates the desired fold in material
fed from
the sheet feeder. The fold plate is automatically set from the
control panel.
8
Measuring Scale — The scale is located on the left side of the
inserter near the sheet feeders; used as an aid in measuring
material and envelopes.
9
Manual Advance Knob - The knob is located inside a cover
at the lower center of the inserter. Use it to turn the inserter
mechanisms by hand to help clear a material.
10
Envelope Feeder - Feeds envelopes into the inserting area
where they are filled with material requested from the other
feeder(s).
1 • System Overview
1-6 SV63139 Rev. A
Control Panel Identification
Use the buttons on the system control panel to set up and run jobs. The
display screen shows the system status.
9
10
11
8
1
7
4
3
5
6
2
1
Clear Deck - Press to jog material through and out of the
inserter. Also use it to clear the inserter and make it ready for
automatic operation after a stoppage has occurred.
2
Trial Piece - Press to run a single test piece to check inserter
setup. You must run a trial piece before you begin automatic
operation using the Start button. If double detection is
enabled, the inserter sets itself automatically to run the trial
piece. The trial piece envelope will be unsealed and counted
as one item.
3
Delete - Press while in setup mode to delete a programmed
job from memory.
4
Setup - Press to enter the setup mode. This mode allows you
to program jobs into memory for instant recall using the Job
button.
5
Change + – - In setup mode, press to select options or set
values of inserter settings.
6
Prev ◄ ► Next - In setup mode, press to step backward or
forward through the various job settings.
System Overview • 1
1-7
SV63139 Rev. A
7
Start - Press to start automatic operation.
8
Stop - Press to stop automatic operation at the end of the
next cycle.
9
Reset Counter - Press to reset the item or batch counter.
10
Job - Press to scroll through the jobs programmed in the
inserter’s memory. You can program up to 20 jobs in the
inserter.
11
Default - Press to return the inserter to its default or standard
settings. These settings come pre-configured from the factory,
but a Pitney Bowes Service Representative can modify for
your specific application.
1 • System Overview
1-8 SV63139 Rev. A
Used on sheet feeders to signify that the feeder is on
without double detection.
Used on sheet feeders to signify that the feeder is on
with double detection.
Used on insert feeder to signify that the feeder is on
without double detection.
Used on insert feeder to signify that the feeder is on
with double detection.
Used on sheet feeder 1 to signify that the feeder is set
for manual feed.
Used on envelope feeder to signify that the feeder is on.
Indicates the setting (from 1 to 5) of the envelope stop.
Indicates that the sealer bottle needs refilling.
Indicates the envelope depth.
Indicates the sealer unit is off (envelopes not sealed).
Control Panel Icons
. . 3 . .
System Overview • 1
1-9
SV63139 Rev. A
Control Panel Icons (continued)
ABC
Indicates the sealer unit is on (automatic envelope
sealing)
Indicates a C (letter) fold is selected
Indicates a Z (accordion fold) is selected
Indicates a double fold is selected
Indicates a single fold is selected
Indicates a no-fold insert operation
Indicates a material stoppage. The position of this symbol
in the display indicates where the stoppage has occurred.
Call Pitney Bowes for service
Indicates the paper size, address orientation and fold(s)
set for sheet feeder
Indicates a material stoppage in a downstream device,
such as a power stacker.
1 • System Overview
1-10 SV63139 Rev. A
Change the Display Language
To change the language on the control panel display:
1. Open the cover to the right of the control panel display to access the
setup buttons.
2. Press Setup. The inserter prompts for an access code.
3. Press Change (+/-) to increase or decrease to access code 99.
4. Press Next (►) to select the languages option.
5. Press Change (+/-) to scroll through the available languages.
6. When the desired language displays, press Setup to select the
language and exit setup mode.
SV63139 Rev A
2 • Program a Job
Contents
Navigate Using the Control Panel ..................... 2-3
Scanning and Non-Scanning Jobs .............. 2-4
Program a Job ................................................... 2-5
Setup Mode .................................................2-5
Select the Job Number
(New or Existing Job) .............................. 2-5
Program a Scanning Job ............................2-6
Program a Non-Scanning Job ...................2-14
Modify an Existing Job..................................... 2-22
Delete a Job .................................................... 2-22
This page is intentionally blank.
Program a Job • 2
2-3SV63139 Rev. A
This section provides step-by-step instructions for setting up and saving a
new scanning or non-scanning job using the control panel. Programming a
job is typically a Supervisor activity.
Navigate Using the Control Panel
Open the hinged cover to the right of the control panel display to access
the setup buttons. Use the setup buttons to navigate the job programing
options. To help visually guide you through the programming sequence, an
asterisk (*) flashes on the control panel display next to the area being set.
• To access the setup buttons, open the hinged cover to the right of the
display screen.
• Use the Prev (◄) and Next (►) buttons to scroll through the available
settings.
• Once the desired setting displays, use the Change (+/-) buttons to
select options or set values within the settings.
2 • Program a Job
2-4 SV63139 Rev. A
Scanning and Non-Scanning Jobs
If OMR scanning functionality is enabled on your system, operators can
turn scanning on and off depending on the job. If scanning functionality is
not available on your inserter, your job setup will differ slightly.
Refer to the table below to review the steps that apply to your job type and
follow the step-by-step instructions provide in this section.
Scanning and Non-Scanning Job Sequence
Scanning Jobs Non-Scanning Jobs
Enable scanning (OMR On or Off) Disable scanning (OMR Off) if
available on your inserter. (Skip if you
inserter does not have scanning)
Set fold type Set fold type
Set main (scanning) sheet feeder Set accumulation
Set second/supplementary feeder Set sheet feeder 1
Set the sealer Set sheet feeder 2
Set paper length Set insert feeder
Set fold A /fold B Set mode type (insertion or fold)
Set envelope depth Set the sealer
Set envelope stop Set paper length
Set batch counter Set fold A /fold B
Confirm job setup Set envelope depth
Run a trial piece Set envelope stop
Set batch counter
Confirm job setup
Run a trial piece
Program a Job • 2
2-5SV63139 Rev. A
Program a Job
Setup Mode
1. Open the hinged cover to the
right of the display to access
the setup buttons.
2. Press Setup. The inserter
prompts for an access
code. (This code prevents
unauthorized personnel from
changing inserter settings).
3. Press Change (+/-) to increase
or decrease to access code 71.
4. Press Next (►) to accept the
code and advance to the next
job setting.
Select the Job Number (New or Existing Job)
When prompted for the job number, follow these steps to select or create
the job. You can select an existing job and overwrite its current settings or
you can select an unused job and program new settings.
1. Press Change (+/-) to scroll
through the job numbers
until you find the desired job
number. (To identify an unused
job, scroll through the jobs until
there are no setup symbols
displayed on the screen.)
2. Press Next (►) to accept the
job number and advance to the
first setting.
NOTE: If you use an existing job number, the old settings will be overwritten by
the new settings you are adding.
2 • Program a Job
2-6 SV63139 Rev. A
Program a Scanning Job
Enable OMR Scanning
1. When prompted, press Change (+/-) to select an OMR on settings.
(Refer to the OMR Settings table included here.)
2. Press Next (►) to accept the selection and advance to the next
setting.
OMR Scanning Settings Table
Use the OMR functions that apply to your scanning job.
OMR Settings Table
OMR Settings Description
OMR off OMR scanning is turned off for this job
OMR on OMR scanning is enabled for this job with
standard OMR mark positioning.
OMR + Sequence OMR scanning + Wrap Around Sequence
scanning is enabled for this job, with standard
OMR mark positioning.
OMR + Select feed OMR scanning + Select Feed/Autobatch
scanning for this job, with standard OMR mark
positioning.
OMR + Select feed +
Sequence
OMR scanning + Select Feed/Autobatch
+ Wrap Around Sequence scanning is
enabled for this job, with standard OMR mark
positioning.
OMR Offset on OMR scanning is turned on for this job, with
offset OMR mark positioning.
OMR Offset + Sequence OMR scanning + Wrap Around Sequence
scanning is enabled for this job, with offset
OMR mark positioning.
OMR Offset + Select feed OMR scanning + Select Feed/Autobatch
scanning is enabled for this job, with offset
OMR mark positioning.
OMR Offset + SF +
Sequence
OMR scanning + Select Feed/Autobatch +
Wrap Around Sequence scanning for this job,
with offset OMR mark positioning.
NOTE: Available options depend on the scanning functionality of your inserter.
Program a Job • 2
2-7SV63139 Rev. A
Set the Fold Type
1. Press Change (+/-) to scroll through the fold types.
2. Press Next (►) to accept the fold type selection and advance to the
next setting.
Fold Types
C - Letter Double
Only fold types C and double are available when using OMR scanning.
When the fold type is selected, the display indicates the correct orientation
of the paper for loading into the feeders:
FACE UP
HEAD FIRST
ABC
2 • Program a Job
2-8 SV63139 Rev. A
Set the Main (Scanning) Sheet Feeder
1. Press Change (+/-) to scroll through the options.
2. Press Next (►) to accept the option and advance to the next setting.
Main (Scanning) Sheet Feeder Options (Scanning Jobs)
Icon Option Description
On Double Detect Feeder on with the double detector
operating. (The double detector stops
the inserter if two or more sheets feed
simultaneously.)
On Feeder on without the double detector.
Program a Job • 2
2-9SV63139 Rev. A
Set the Insert Feeder
Select feed allows for one piece to be selectively fed from the insert feeder
(this is controlled by the OMR marks) and inserted into the envelope.
1. Press Change (+/-) to scroll through the options. (Refer to the
Additional Feeder Options, Scanning Jobs table for details.)
2. Press Next (►) to accept the selection and advance to the next
setting.
Additional Feeder Options (Scanning Jobs)
Icon Option Description
On Double Detect -
can be selected with or
without SF (Selective
Feed)
Feeder on with the double detect
operating. (Double detect stops the
inserter if two or more sheets feed
simultaneously.)
On without Double
Detect - can be selected
with or without SF
(Selective Feed)
Select feeder on without the double
detector.
Off Feeder turned off for this job.
2 • Program a Job
2-10 SV63139 Rev. A
Set the Sealer
This setting appears only if insertion mode is selected. To select whether
or not you want to seal envelopes.
1. Press Change (+/-) to toggle the option to On or Off.
2. Press Next (►) to accept the option and advance to the next setting.
Sealer Options
Icon Option Description
On Turns the sealer unit on for automatic sealing of
envelopes. Make sure the sealer water bottle is full of E-Z
Seal® or water.
Off Turns the sealer unit off. Envelopes will be ejected
unsealed.
Set Paper Length
1. Use the scale on the side of
the inserter cover to measure
the paper.
- US letter - 279mm (11 inches)
- A4 paper - 297mm
2. Press Change (+/-) to
scroll through paper lengths
(displayed in mm).
3. Press Next (►) to accept
the paper length value and
advance to the next setting.
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