Pitney Bowes relay 3000 User manual

Relay™3000/4000
User Guide
International English Edition
SV63138 Rev. A
August 1, 2015
Document Inserting Systems with
Touch Screen and Barcode Scanning
Shipping & Mailing
Inserter

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. Use only a shielded interface
cable to operate this equipment with a printer or other peripheral device.
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.
SV63138 Rev. A August 1, 2015
©2006, 2015 Pitney Bowes Inc. All rights reserved. This guide 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 specications as well as performance features are subject to change
without notice. Your inserter system may not have some of the features
described in this book.
E-Z Seal is a registered trademark of Pitney Bowes Inc. ENERGY STAR is a
registered trademark of the United States Environmental Protection Agency.
It is certified that the equipment complies with all applicable Directives
of the European Union. The touch screen and main inserting system
contain a radio frequency transmitting device that is in compliance with
the European Union’s Directive 1999/5/EC on Radio Equipment and
Telecommunications Terminal Equipment and the mutual recognition of
their conformity.
LED SAFETY
LED emission according to EN 62471
Relay 3000/4000 is UL approved (US) and CUL approved (Canada).

Table of Contents
iSV63138 Rev. A
Safety ................................................................................... v
Chapter 1 System Overview
Relay Inserter Introduction ................................................1-3
Inserter Component Identification......................................1-4
Touch Screen Display Identification...................................1-6
Control Panel Icons ...........................................................1-8
Turn the Touch Screen On/Off.........................................1-10
Use the Touch Screen Keyboard..................................... 1-11
Change the Display Language ........................................ 1-11
Touch Screen Usernames and Passwords......................1-12
Rename Default Usernames.................................... 1-12
Change an Existing Operator Password.................. 1-13
Recover an Existing Operator Password ................. 1-13
Rename an Existing Default Job .....................................1-14
Inserter Control Reports (on the Touch Screen)..............1-15
Report Data.............................................................. 1-15
Access Reports........................................................ 1-16
Archive Reports ....................................................... 1-17
Print Reports ............................................................ 1-17
Chapter 2 Program a Job
Navigate Using the Touch Screen .....................................2-3
Scanning and Non-Scanning Jobs............................. 2-4
Program a Job ...................................................................2-5
Log In ......................................................................... 2-5
Enter Supervisor Access Code .................................. 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.....................................................2-23
Delete a Job ....................................................................2-23

Table of Contents
ii SV63138 Rev. A
Chapter 3 Run a Job
Run a Job ..........................................................................3-3
Verify the Inserter Has Power............................................3-4
Turn On the Touch Screen.................................................3-4
Log In.................................................................................3-4
Select a Job ............................................................... 3-5
Manual Feed Jobs .............................................................3-6
Load Material.....................................................................3-7
Adjust and Load the Sheet Feeders .......................... 3-7
Adjust and Load the Envelope Feeder....................... 3-8
Adjust and Load the Insert Feeder........................... 3-10
Run a Trial Piece .............................................................3-12
Trial Pieces and Linked Feeding.............................. 3-12
Material Changes or Double Detect Issues
During Operation................................................. 3-12
Start and Stop the Inserter ..............................................3-13
Fill the Sealer...................................................................3-14
Adjust the Stacker ...........................................................3-14
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

Table of Contents
iiiSV63138 Rev. A
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
Z-Fold and Single-Fold Jobs.....................................4-11
Adjust the OMR Scanner.................................................4-12
OMR Troubleshooting......................................................4-14
Error Recovery for OMR Jobs.................................. 4-14
Error Recovery for Accumulation Jobs..................... 4-14
Error Recovery for Empty Feeders .......................... 4-14
OMR Error Messages......................................................4-15
Chapter 5 Barcode Scanning
Barcode Scanning .............................................................5-3
How Barcode Scanning Works .................................. 5-3
1D and 2D Barcode Scanning ................................... 5-3
Jobs with Barcode Scanning...................................... 5-4
Barcode Options................................................................5-4
Basic Barcode Reading ............................................. 5-4
Enhanced Barcode Reading ...................................... 5-4
Barcode Placement Specifications ....................................5-5
Barcode Placement Areas ........................................ 5-5
Barcode Zones - Clear and Blank.............................. 5-7
2D Barcode Camera Setup ...............................................5-8
Turn On the 2D Barcode Camera .............................. 5-8
Adjust the Position of the 2D Barcode Camera ......... 5-9
2D Barcode Scanning Final Checklist .............................5-10
Barcode Error Messages................................................. 5-11
2D Barcode Specifications ..............................................5-12
Paper Specifications ............................................... 5-12
2D Barcode Specifications....................................... 5-12

Table of Contents
iv SV63138 Rev. A
Chapter 6 Clear Material
Clear Material ....................................................................6-3
Access Areas of the Inserter for Jam Removal .................6-3
Sheet Feeders Trays - Remove and Replace............ 6-3
Fold Plates - Remove and Replace ........................... 6-4
Insert Tray - Remove and Replace ............................ 6-4
Access the Carriage Assembly .................................. 6-4
Access to Envelope Feeder Area............................... 6-5
Access the Envelope Exit Area .................................. 6-5
Access the Envelope Inserting/Sealing Area ............. 6-6
Access to the Sheet Feed Area ................................. 6-6
Chapter 7 Troubleshooting and Error Messages
General Troubleshooting ...................................................7-3
Changing the Sealer Unit Felts .................................. 7-7
Error Messages .................................................................7-9
Chapter 8 Material Specifications
Material Specifications.......................................................8-3
Inserter Specifications .......................................................8-7
Service...............................................................................8-8

Safety
v
SV63138 Rev. A
Safety Information
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
vi SV63138 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 this
content may not be available on your inserter.

SV63138 Rev A
1 • System Overview
Contents
Relay Inserter Introduction .........................................1-3
Inserter Component Identification...............................1-4
Touch Screen Display Identification............................1-6
Control Panel Icons ....................................................1-8
Turn the Touch Screen On/Off....................................1-10
Use the Touch Screen Keyboard................................1-11
Change the Display Language ...................................1-11
Touch Screen Usernames and Passwords.................1-12
Rename or Create an Operator Username......... 1-12
Change or Create an Existing
Operator Password ........................................ 1-12
Recover an Existing Operator Password ............ 1-13
Change a Job Name...................................................1-13
Inserter Control Reports (on the Touch Screen).........1-14
Report Data......................................................... 1-14
Access Reports................................................... 1-15
Archive Reports .................................................. 1-16
Print Reports ....................................................... 1-16

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