Pitney Bowes Relay 5000 Manual

Operator Guide
International English Edition
SV63136 Rev. B
November 1, 2015
Relay
5000/6000/7000/8000
Shipping & Mailing
Inserter
Document Inserting System
™

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.
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.
SV63136 Rev. B ©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. Connect+, SwiftStart, IntelliLink
and E-Z Seal are trademarks or registered trademarks of Pitney Bowes. Tyvek is a registered
trademark of Dupont.
Canada EMC Compliance
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.
It is certified that this system complies with all applicable Directives of the European
Union.

iSV63136 Rev. B
Table of Contents
Safety Information...........................................................................v
Warning Labels..............................................................................vi
1 • System Overview
Relay 5000/6000/7000/8000 Inserter Overview ......................... 1-3
Product Features ........................................................................ 1-3
System Components .................................................................. 1-3
Main Modules ....................................................................... 1-3
Additional Modules Available ................................................ 1-3
Control Panel Identification......................................................... 1-6
Screen Option Keys.............................................................. 1-7
Fixed Function Keys ............................................................. 1-7
Machine Action Keys ............................................................ 1-8
Change the Language Display ................................................... 1-9
How the System Works ............................................................ 1-10
Transport Deck ................................................................... 1-10
Mail Piece Path................................................................... 1-10
Pre-fold Accumulator .......................................................... 1-10
Folder.................................................................................. 1-10
Post-fold Accumulator......................................................... 1-11
Insertion Area...................................................................... 1-11
Folder Bypass Path ............................................................ 1-11
Moistener, Closer, Sealer.................................................... 1-11
System Covers ......................................................................... 1-12
Open the Covers................................................................. 1-13
Close the Covers ................................................................ 1-13
Paper Release Knobs/Levers................................................... 1-14
Feeder Tower............................................................................ 1-15
Add-On Modules....................................................................... 1-16
High Capacity Sheet Feeder (HCSF) ................................. 1-16
Flats Sealer......................................................................... 1-17
Vertical Power Stacker........................................................ 1-18
Horizontal Belt Stacker ....................................................... 1-18
Exit Transport...................................................................... 1-18
Optional Features ..................................................................... 1-18
File Based Processing ........................................................ 1-18
Exit Options ........................................................................ 1-18
Connect+ Mail Machine Interface (MMI)............................. 1-18

ii SV63136 Rev. B
Table of Contents
Access Rights........................................................................... 1-19
User Access Levels ............................................................ 1-19
Log In.................................................................................. 1-20
Log Out ............................................................................... 1-20
2 • Display Screen
Display Screen Overview............................................................ 2-3
Header Area.......................................................................... 2-4
Footer Area ........................................................................... 2-4
Status Area ........................................................................... 2-5
Navigating Options ............................................................... 2-8
Icons and Letters ........................................................................ 2-9
Envelope Icons ..................................................................... 2-9
Fold Icons ............................................................................. 2-9
Sheet Icons......................................................................... 2-10
Insert Icons ......................................................................... 2-11
Feeder Assignment Icons ................................................... 2-12
Other Icons ......................................................................... 2-12
3 • Run a Job
Powering Up ............................................................................... 3-3
Home Screen.............................................................................. 3-4
Run a Job ................................................................................... 3-5
Select a Job .......................................................................... 3-6
Set Up Feeders and Load Material....................................... 3-7
Additional Adjustments ....................................................... 3-20
Pre-Run Adjustments................................................................ 3-21
Feed a Test Envelope ......................................................... 3-21
Perform Width Adjustments (Outer Envelope Openers) ..... 3-22
Perform Length Adjustments (Inner Envelope Openers) .... 3-23
Verify Settings..................................................................... 3-24
Manual Feeder.......................................................................... 3-25
Adjust Manual Lever for Stiff Media Mode
(Relay 8000 Only).......................................................... 3-26
Run a Trial Piece ...................................................................... 3-27
Review Job Settings ........................................................... 3-29
Start the Job ...................................................................... 3-30
SwiftStart™ Jobs ........................................................................ 3-30
Running the Mail Machine Interface ......................................... 3-31
Adjust Screen Brightness and Contrast.................................... 3-33
Set the Time and/or Date.......................................................... 3-34
Refill the Sealing Solution......................................................... 3-35

SV63136 Rev. B iii
Table of Contents
4 • Scanning
Scanning Overview..................................................................... 4-3
Adjusting the Scan Heads .......................................................... 4-4
Adjusting Scan Heads for Ladder or 2D Orientation Marks.. 4-5
Setting the OMR Scanning Area............................................... 4-10
Defining the First Mark Position and Code Length ................... 4-10
Defining the Clear Zone............................................................ 4-11
Additional Information............................................................... 4-12
5 • Stoppages and Troubleshooting
Clear Material Stoppages ........................................................... 5-6
Clear a Stoppage.................................................................. 5-6
Resume the Job.................................................................... 5-6
Outsorted Material ................................................................ 5-7
Troubleshooting and Self-Help Aides ......................................... 5-7
6 • Maintenance
Routine Maintenance.................................................................. 6-3
Daily Tasks............................................................................ 6-3
Replace the Moistener Wick ................................................. 6-3
Replace the Moistener Brushes............................................ 6-5
Replace the Envelope Edge Marker Roller........................... 6-6
7 • Specications
System Specifications................................................................. 7-3
System Footprint - Dimensions............................................. 7-3
Component Specifications.......................................................... 7-4
Component Dimensions ....................................................... 7-4
Component Capacities ......................................................... 7-4
Scanning Capability (optional) .............................................. 7-6
Environmental Limits ............................................................ 7-6
Feeder Tower and Base Material Specications................... 7-7
General Information .............................................................. 7-7
Outer Envelopes ................................................................... 7-7
Inserts ................................................................................. 7-10
Sheets................................................................................. 7-11
High Capacity Sheet Feeder (HCSF) Material Specifications .. 7-12
General Information ............................................................ 7-12
Sheets................................................................................. 7-12
Materials Not Certied for Use............................................ 7-13

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SV63136 Rev. B v
Safety
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.
• 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.

vi SV63136 Rev. B
Safety
• 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.
Warning Labels
The following warning labels are on the system to alert you to potential injury that
could occur with careless operating procedures.
CAUTION
Moving mechanism can result in
personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing away
from moving parts.
CAUTION
Moving mechanism can result
in personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing
away from moving parts.
NOTICE

Contents
Relay 5000/6000/7000/8000 Inserter Overview ..........................1-3
Product Features.........................................................................1-3
System Components ...................................................................1-3
Main Modules ........................................................................ 1-3
Additional Modules Available................................................. 1-3
Control Panel Identification..........................................................1-6
Screen Option Keys............................................................... 1-7
Fixed Function Keys .............................................................. 1-7
Machine Action Keys ............................................................. 1-8
Change the Language Display ....................................................1-9
How the System Works .............................................................1-10
Transport Deck .................................................................... 1-10
Mail Piece Path.................................................................... 1-10
Pre-fold Accumulator ........................................................... 1-10
Folder .................................................................................. 1-10
Post-fold Accumulator...........................................................1-11
Insertion Area .......................................................................1-11
Folder Bypass Path ..............................................................1-11
Moistener, Closer, Sealer .....................................................1-11
System Covers ..........................................................................1-12
Open the Covers ................................................................. 1-13
Close the Covers ................................................................. 1-13
Paper Release Knobs/Levers....................................................1-14
Feeder Tower.............................................................................1-15
Add-On Modules........................................................................1-16
High Capacity Sheet Feeder (HCSF) .................................. 1-16
Flats Sealer ......................................................................... 1-17
Vertical Power Stacker ........................................................ 1-18
Horizontal Belt Stacker ........................................................ 1-18
Exit Transport ...................................................................... 1-18
Optional Features......................................................................1-18
File Based Processing......................................................... 1-18
Exit Options ......................................................................... 1-18
Connect+ Mail Machine Interface (MMI).............................. 1-18
Access Rights............................................................................1-19
User Access Levels ............................................................. 1-19
Log In................................................................................... 1-20
Log Out................................................................................ 1-20
1 • System Overview

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SV63136 Rev. B 1-3
System Overview • 1
Relay 5000/6000/7000/8000 Inserter Overview
Relay™ 5000/6000/7000/8000 are high throughput, mail creation systems
designed to handle a broad range of applications with minimum operator
setup adjustments. These systems have the ability to feed, fold, and insert
mail piece components into an outer envelope. The systems generate letters
or flats as the final mail piece. The systems also accept a variety of options
that provide a wide range of capacities and operating speeds.
Product Features
• Folds up to a maximum of 10 sheets of 20 lb. (80 gsm) with a single fold
• Supports multiple inserts into flat envelopes
• Configurable with four flexible feeder trays, that come in two types:
- Sheet trays - capable of feeding sheets
- Insert trays - capable of feeding slip/insert materials, pre-folded
inserts, thin booklets, and envelopes.
• The Relay 7000/8000 system is equipped with a High Capacity
Envelope Feeder (HCEF) that allows for greater speed and throughput.
The systems also accept material from optional upstream input devices.
System Components
Main Modules
These systems are configured with two major components:
• Feeder Tower
• Transport Deck
• Envelope Sealer
The feeder tower sends material from the feeder trays to the transport deck.
Job parameters determine whether or not the material passes through the
folder to the transport deck. If it does, numerous fold types are available, as
is the ability to insert folded material into the mail piece collation.
The system can seal envelopes (letter only) before sending the final mail
piece to a stacker unit.
Additional Modules Available
The base system configuration includes a feeder tower, transport deck, and
envelope sealer. The Relay 7000/8000 features an additional integrated
High Capacity Envelope Feeder.
Additional modules can be added to utilize the full potential of the system.
The availability of these modules and options for your inserting system
varies by region.
- High Capacity Sheet Feeder - Horizontal Belt Stacker
- Flats Sealer - Exit Scanner
- Pre-folded Insert Feeder
- Vertical Power Stacker

1-4 SV63136 Rev. B
1 • System Overview
Component Identification
Relay 7000/8000 only
Relay 5000/6000 System
2
34567
8
9
10
1
11
1Feeder Tower Trays - feed sheets or inserts to the feeder tower.
2Feeder Tower - is a two-sided tray holder/material feeder.
NOTE: If enabled, the lower left tray is assigned with the letter "A" on
the Mail Piece Icon Tree. When a High Capacity Envelope Feeder is not
part of the system conguration, this Tray is the primary tray for feeding
envelopes designated for a given job.
3Manual Feeder - allows you to manually feed stapled or unstapled
sets of up to 5 sheets of 20 lb (80gsm) paper. The machine waits
for each set to be manually fed before folding and inserting the
set automatically into the envelope. The Manual Feed option is
available during job creation. Inserts and/or sheets from other trays
can also be added to the job.

SV63136 Rev. B 1-5
System Overview • 1
4Pre-fold Accumulator - is a staging area for the material that
needs to be collated together and then sent to the folder.
5Folder - applies one of the available fold types to sheets.
6Post-fold Accumulator - is a staging area for the folded sheets to
meet any inserts that are to be included.
7Insertion Area - is the part of the transport where the collation
intended for a single addressee is inserted into an outer envelope.
8Moistener, Closer, Sealer - Brushes sweep across the envelope
flap to wet the glued area of the flap. The letter-size envelope then
moves through the closer and sealer areas of the unit to complete
the mail piece.
9Sealing Solution Bottle - is located inside an opening cover at the
front right side of the machine. It provides sealing solution to the
envelope sealing system.
10 Control Panel - allows you to run the machine and configure job
settings. It also displays the machine status and shows loading
instructions and details of the job. (Detailed information included in
this section.)
11 High Capacity Envelope Feeder (Relay 7000/8000 only) - holds
at least 500 letter-sized envelopes. It feeds directly to the insertion
area.

1-6 SV63136 Rev. B
1 • System Overview
Control Panel Identification
1
2
3
4
5
OK
Reset
Counter Help Cancel Home
Start
Trial
Piece
Clear
Deck Stop
1LED Status Indicator
2Screen Option Keys - allow you to define settings for up to 24 jobs
that you can store in the system’s memory. These keys also provide
the means to edit any of the stored jobs.
3Fixed Function Keys - allow you to access the system’s built-in
tools that appear on the screen (such as the system’s help file).
4Screen Navigation Keys - allow you to move UP/DOWN and right/
left in the Display and to apply selections that you’ve made.
5Machine Action Keys -control hardware components and
mechanical movements.

SV63136 Rev. B 1-7
System Overview • 1
Screen Option Keys
The eight screen option keys correspond to options on the screen, and
therefore have no dedicated labels. Use these keys to highlight an item in
a displayed pick list and/or to select the associated menu, item, action, or
option.
Fixed Function Keys
Each of the four fixed function keys has an assigned function that is enabled
or disabled based on the screen that displays.
Reset Counter • Piece Counter is a cumulative counter; it
increments for each completed mail piece.
• Batch Counter counts up to a set number. It
increments one count for each completed mail
piece that the system detects. The system stops
when it reaches the batch count.
• If your system has a flats sealer, the Mark Piece
Count option is available. It allows you to reset
the counter for the envelope edge mark to zero.
• Reset Both allows you to reset both the piece
counter and the batch counter to zero.
Help Select Help for information about the screen that
currently displays and for access to the entire Help
file.
Cancel Select Cancel to return to the previous screen.
Home Returns you to the Home screen for the current job.
The current job automatically includes any changes
made while editing the job. Changes are not saved
until you choose Save Job. Jobs that were changed
but not saved have an asterisk (*) next to the job
name (top of the Home screen)

1-8 SV63136 Rev. B
1 • System Overview
Machine Action Keys
The four machine action keys run the system.
Start Trial
Piece
Clear
Deck Stop
Start Press this green-colored Start key to begin running the
selected job
Trial Piece Press Trial Piece to do a test run on your job. One
complete mail piece will be prepared.
Clear Deck Press Clear Deck to rid the system of materials currently
in process in the paper paths.
NOTE: Only press Clear Deck when prompted by the system
to minimize lost material and manual mail piece generation.
Stop Press Stop to finish in-process mail.
Screen Navigation Keys
The screen navigation keys move the cursor on the
screen to highlight items in the Mail Piece Icon Tree.
The screen navigation keys consist of a two-tiered
circular button. OK
UP/DOWN and LEFT/RIGHT arrow keys, on the outer
tier of the button, move the cursor UP/DOWN and
LEFT/RIGHT on the screen.
OK button, on the inner tier of the button, applies the
selection that you made with the arrow keys.

SV63136 Rev. B 1-9
System Overview • 1
Change the Language Display
1. From the Home screen, select Menu.
2. From the Menu screen, select Change Language, a list of available
languages displays.
3. If necessary, use the Next and Previous options to view additional
languages on the list, and select the appropriate language.
4. Select Finished.
5. Press HOME to return to the Home screen.
Change Language
English International
English
North American
Français Canada
Deustch
Español
Français
Italiano
Next

1-10 SV63136 Rev. B
1 • System Overview
How the System Works
Transport Deck
The transport deck accepts material from the feeder tower and moves it
through the various modules to produce a finished mail piece.
Mail Piece Path
Material from the feeder trays comes down the feeder tower in a pre-defined
order. Material moves rapidly from one station to the next in the transport
deck to produce a finished mail piece that is dropped into a stacking bin
or onto an optional high capacity output stacker. A brief description of the
function of each module in the paper path is presented here.
Pre-fold Accumulator
The pre-fold accumulator is the first stop in the paper path. The pre-fold
accumulator is a stacking place for the material that needs to be collated
and folded. When the appropriate components for one mail piece finish
collating on the pre-fold accumulator, they move into the folder.
Folder
The stack of collated sheets exits the pre-fold accumulator and moves into
the folder. A fold is applied to the stack and the collation moves to the post-
fold accumulator.
Fold types offered:
• C Fold
• Z Fold
• Single Fold
• Double Fold
• No Fold
(An optional inverter may be used for some address location/fold type
combinations.)

SV63136 Rev. B 1-11
System Overview • 1
Post-fold Accumulator
The accumulation of folded sheets exits the folder onto the post-fold
accumulator area. Other components of the mail piece, such as a Business
reply envelope or a pre-folded insert, are added to the accumulation in the
post-fold accumulator area. When all components are present, the stack
moves to the insertion area.
Insertion Area
The contents of the mail piece meet the outer envelope at the insertion
area. The envelope arrives at the insertion area with its front face down and
flap open. Envelope openers open the envelope wide enough to allow the
contents to be slid inside.
Folder Bypass Path
The outer envelope, fed from the feeder, that will contain the collated media
runs through the bottom part of the transport deck. The route this envelope
travels is known as the folder bypass path.
Moistener, Closer, Sealer
As the envelope passes over the moistener, brushes sweep across the top
of the flap to wet the glued area of the flap. The envelope is then inverted
and slid through the closer and sealer portion of the system to complete the
mailpiece. From there, the mailpiece is dropped onto a stacker.

1-12 SV63136 Rev. B
1 • System Overview
System Covers
Transport deck covers open to provide access to the rollers in the main
paper path.
Pre-fold
Accumulator
Cover
Post-fold
Accumulator
Cover
Folder Cover Insertion Area
Cover
The three covers on the front side of the system open to provide access to
the paper release knobs.
NOTE: The tower base cover is interlocked with the main transport deck cover. You
must open the main transport deck cover before opening the tower base cover.
CAUTION
Moving mechanism can result in
personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing away
from moving parts.