Pitney Bowes Relay 5000 Manual

Operator Guide
International English Edition
SV63136 Rev. A
August 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 accor-
dance 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 re-
quired 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. A ©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 trade-
mark 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. A
Table of Contents
Contact Information List................................................ v
USA Contacts .................................................................................v
Canada Contacts............................................................................v
Contacts in other countries.............................................................v
1 • Introduction ............................................................1-1
A Note to the Operator................................................................ 1-2
About Your System ..................................................................... 1-2
System Features................................................................... 1-2
System Components ............................................................ 1-2
Standard Systems ...................................................................... 1-3
System Options .......................................................................... 1-4
Safety Information....................................................................... 1-5
Warning Labels........................................................................... 1-6
2 • Meet the Inserting System.....................................2-1
System Components .................................................................. 2-2
Feeder Tower.............................................................................. 2-4
Feeder Trays............................................................................... 2-5
Sheet Trays........................................................................... 2-5
Insert Trays ........................................................................... 2-6
Manual Feeder............................................................................ 2-7
Transport Deck ........................................................................... 2-8
Mail Piece Path..................................................................... 2-8
Pre-fold Accumulator ............................................................ 2-8
Folder.................................................................................... 2-9
Post-fold Accumulator .......................................................... 2-9
Insertion Area........................................................................ 2-9
Folder Bypass Path .............................................................. 2-9
Moistener, Closer, Sealer...................................................... 2-9
About the Control Panel............................................................ 2-10
Screen Option Keys............................................................ 2-10
Fixed Function Keys ........................................................... 2-11
Machine Action Keys .......................................................... 2-13
Screen Navigation Keys ..................................................... 2-13
Display Screen.......................................................................... 2-14
Header Area........................................................................ 2-14
Status Area ......................................................................... 2-15
Access Rights........................................................................... 2-20
Logging In ........................................................................... 2-21
Logging Out ........................................................................ 2-21

ii SV63136 Rev. A
Table of Contents
About System Covers............................................................... 2-22
Opening the Covers............................................................ 2-23
Closing the Covers ............................................................. 2-23
About the Paper Release Knobs/Levers................................... 2-24
About Add-On Modules............................................................. 2-24
3 • Basic Operation......................................................3-1
Connecting to Power .................................................................. 3-2
Powering Up ............................................................................... 3-2
Home Screen.............................................................................. 3-3
Job Overview.............................................................................. 3-4
Selecting the Job ........................................................................ 3-5
Setting Up Feeders and Loading Materials ................................ 3-6
Attaching Trays to the Feeder Tower .................................... 3-6
Removing Trays from the Feeder Tower............................... 3-7
Loading Material into the Trays............................................. 3-8
Loading the High Capacity Envelope Feeder (HCEF) ........ 3-13
Making Pre-Run Adjustments .................................................. 3-18
Adjusting the Envelope Openers ........................................ 3-18
Running a Trial Piece................................................................ 3-22
Reviewing the Job Settings ................................................ 3-24
Starting the Job......................................................................... 3-25
SwiftStart™ Jobs ........................................................................ 3-25
Using SwiftStart™............................................................... 3-26
Creating a Job .......................................................................... 3-26
Job Options............................................................................... 3-30
Envelope Options ............................................................... 3-30
Fold Options ....................................................................... 3-32
Sheet Options ..................................................................... 3-33
Insert Options ..................................................................... 3-36
Editing a Job............................................................................. 3-40
Modifying Job Settings........................................................ 3-41
Editing an Item.................................................................... 3-41
Adding an Item.................................................................... 3-42
Moving an Item ................................................................... 3-44
Deleting an Item.................................................................. 3-45
4 • Advanced Operation ..............................................4-1
Overview..................................................................................... 4-2
Using the Alphanumeric Matrix ................................................... 4-2
Saving a Job .............................................................................. 4-3
Deleting a Job............................................................................. 4-4
Assigning User IDs and Passwords............................................ 4-5
Enabling and Disabling the High Capacity Sheet Feeder
(HCSF)........................................................................................ 4-5

SV63136 Rev. A iii
Table of Contents
5 • Troubleshooting and Maintenance.......................5-1
Adjusting Screen Brightness and Contrast................................. 5-2
Setting the Time and/or Date ...................................................... 5-3
Changing the Language ............................................................. 5-4
Refilling the Sealing Solution...................................................... 5-5
Handling Material Stoppages...................................................... 5-5
Clearing a Stoppage ............................................................. 5-5
Resuming the Job................................................................. 5-6
Handling Outsorted Material ................................................. 5-6
Troubleshooting Tables............................................................... 5-7
Routine Maintenance................................................................ 5-17
Daily Tasks.......................................................................... 5-17
Replacing the Moistener Wick ............................................ 5-17
Replacing the Moistener Brushes....................................... 5-19
6• Specications..........................................................6-1
Overview..................................................................................... 6-2
System Specifications................................................................. 6-2
Component Specifications.......................................................... 6-4
Feeder Tower and Base Material Specifications......................... 6-6
General Information .............................................................. 6-6
Outer Envelopes ................................................................... 6-6
Inserts ................................................................................... 6-9
Sheets................................................................................. 6-10
High Capacity Sheet Feeder (HCSF) Material Specifications .. 6-11
General Information ............................................................ 6-11
Sheets................................................................................. 6-11
Materials Not Certied for Use............................................ 6-12
7 • Add-On Modules.....................................................7-1
About the Add-On Modules......................................................... 7-2
High Capacity Sheet Feeder (HCSF) ......................................... 7-2
Loading the HCSF ................................................................ 7-3
Adjusting the HCSF Guides.................................................. 7-5
Flats Sealer................................................................................. 7-7
Replacing the Envelope Edge Marker Roller........................ 7-8
File Based Processing .......................................................... 7-9
Exit Options ................................................................................ 7-9
Connect+ MMI .................................................................... 7-10
Vertical Power Stacker ....................................................... 7-13
Horizontal Belt Stacker ....................................................... 7-13
Exit Transport...................................................................... 7-13

iv SV63136 Rev. A
Table of Contents
8 • Scanning .................................................................8-1
Scanning Overview..................................................................... 8-2
OMR ..................................................................................... 8-2
BCR ...................................................................................... 8-2
Physical Specications
for 2D Data Matrix Barcodes ................................................ 8-5
Supported Square and Rectangular Formats ....................... 8-5
Scanning Features................................................................ 8-8
Supported ECC (Error Correction Code) Levels................. 8-10
Setting Up a New Scan Configuration ...................................... 8-11
Setting Up an OMR Scan Conguration ............................. 8-11
Setting Up a BCR Scan Conguration................................ 8-14
Editing a Scan Configuration .................................................... 8-18
Editing an OMR Scan Conguration................................... 8-18
Editing a BCR Scan Conguration...................................... 8-19
Copying a Scan Configuration.................................................. 8-20
Deleting a Scan Configuration.................................................. 8-20
Reviewing a Scan Configuration............................................... 8-21
Viewing the Job List.................................................................. 8-21
Assigning a Scan Configuration to an Existing Job ................. 8-22
Adjusting the Scan Heads ........................................................ 8-24
Adjusting the Scan Heads for Ladder or
2D Orientation Marks.......................................................... 8-24
Adjusting the Scan Heads for Picket Orientation Marks ..... 8-27
OMR Specifications .................................................................. 8-29
OMR Print and Placement Specifications ................................ 8-30
OMR Placement Specications for Feeder Tower
(Ladder Orientation)............................................................ 8-30
OMR Print and Placement Specifications ................................ 8-31
OMR Placement Specications for HCSF
(New Scan Kit F790250 - Ladder Orientation) ................... 8-31
Barcode Specifications ............................................................ 8-32
Barcode Print and Placement Specifications ........................... 8-33
1D Barcode Placement Specications for Feeder Tower ... 8-33
Barcode Print and Placement Specifications ........................... 8-34
1D Barcode Placement Specications for HCSF................ 8-34
Barcode Print and Placement Specifications ........................... 8-35
1D Barcode Print and Placement Specications for HCSF 8-35
Barcode Print and Placement Specifications ........................... 8-36
1D Barcode Placement Specications for HCSF................ 8-36
Barcode Print and Placement Specifications ........................... 8-37
2D Barcode Placement Specications for HCSF................ 8-37

SV63136 Rev. A v
Table of Contents
Setting the OMR Scanning Area............................................... 8-38
Defining the First Mark Position and Code Length ................... 8-38
Defining the Clear Zone............................................................ 8-39
Additional Information............................................................... 8-40
BCR and OMR Mark Levels ..................................................... 8-40
Basic Level ......................................................................... 8-41
Enhanced Integrity Level .................................................... 8-43
Enhanced Integrity Level
Selective Operations Level ................................................. 8-45
Appendix A • Glossary ............................................... A-1
Basic Terms ...............................................................................A-2
Material References..............................................................A-2
Machine Functions................................................................A-3
Icon Glossary..............................................................................A-4
Envelope Icons .....................................................................A-4
Fold Icons .............................................................................A-5
Sheet Icons...........................................................................A-5
Insert Icons ...........................................................................A-6
Feeder Assignment Icons .....................................................A-7
Other Icons ...........................................................................A-7

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v
SV63136 Rev. A
Contact Information List
USA Contacts
Product Name - Relay™ 5000/6000/7000/8000
• For frequently asked questions, go to: www.pb.com and click on Customer Support.
• To place requests for service or training, go to: www.pb.com and click on My Account.
• To order supplies and accessories, call the Supply Line™at: 1.800.243.7824 or go to: www.
pb.com and click on Online Store.
• To view and pay invoices online, go to: www.pb.com and click on My Account.
• To view inventory, go to: www.pb.com and click on My Account.
• For direct questions, call: 1.800.522.0020. Customer Service Representatives are available
Monday through Friday, 8:00 AM - 8:00 PM ET.
• To obtain Material Safety Data Sheets, call the Supply Line™or go to: www.pb.com and click on
Customer Support.
Canada Contacts
Product Name - Relay™ 5000/6000 or Relay™ 7000/8000
▪ For frequently asked questions or to order supplies, go to: www.pitneybowes.ca
▪ For direct questions, call: 1.800.672.6937. Customer Service Representatives are available
Monday through Friday, 8:30 AM - 4:00 PM ET.
Contacts in other countries
Contact information will be given either on a sticker on the system or in a separate document
supplied with your system.

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SV63136 Rev. A
Contents
A Note to the Operator.................................................................1-3
About Your System ......................................................................1-3
System Features .........................................................................1-3
System Components ............................................................. 1-3
Standard Systems .......................................................................1-4
System Options ...........................................................................1-5
Safety Information .......................................................................1-6
Safety Information (continued) ........................................................... 1-7
Warning Labels............................................................................1-7
1 • Introduction

SV63136 Rev. A
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SV63136 Rev. A 1-3
Introduction • 1
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.
System Features
• The inserter can fold up to a maximum of 10 sheets of 20 lb. (80 gsm)
with a single fold, subject to test.
• The inserter supports multiple inserts into flat envelopes.
• The inserter supports marking of every nth envelope if the flats sealer is
present on the system.
• The systems can be configured 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 dedicated High
Capacity Envelope Feeder (HCEF) that allows for greater speed and
throughput. The systems also accept material from optional upstream
input devices.
System Components
The systems are configured with two major components:
• Feeder Tower
• Transport Deck
The feeder tower sends material from the feeder trays to the transport deck.
Depending on the job parameters, the material may or may not need to
pass through the folder into the transport Deck. If it does, the system offers
numerous types of folds and the ability to insert the folded material into the
appropriate position in the mail piece collation.
The system can also seal the envelope (letter only) before sending the final
mail piece to a stacking unit.
About Your
System
It is important to be familiar with this guide as it will enable you to utilize the
system to its full potential, while keeping problems to a minimum.
NOTE: The availability of add-ons and options for your inserting system
varies by region. Refer to your system supplier for availability details.
A Note to the
Operator

1-4 SV63136 Rev. A
1 • Introduction
Relay 6000 (HCSF is optional)
Relay 5000
Relay 7000
Relay 8000
Letter and Flats Drop Stacker
(standard on all systems)
Standard
Systems
IMPORTANT Model and feature availability varies by country. Contact your
machine supplier for more information. This guide covers all models and
features. Information included in this guide does not guarantee availability of a
particular model or feature within your country.

SV63136 Rev. A 1-5
Introduction • 1
Fold Expansion Kit
(Document Inverter)
High Capacity Sheet
Feeder (HCSF)
Vertical Power
Stacker
Exit Transport
Belt StackerTandem Belt Stacker
Connect+
System Options
(Furniture, designed
specifically for the
system, is also
available.)
Flats Sealer
IMPORTANT Model and feature availability varies by country. Contact your
machine supplier for more information. This guide covers all models and features.
Information included in this guide does not guarantee availability of a particular
model or feature within your country.

1-6 SV63136 Rev. A
1 • Introduction
Follow these precautions whenever you use your inserting system:
• Read all instructions before you attempt to operate the system. Keep the
Operator Guide accessible for quick reference.
• 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 power cord supplied with the machine and plug it into a properly
grounded wall outlet that is located near the machine and easily
accessible. Failure to properly ground the machine can result in severe
personal injury and/or fire.
• The power cord wall plug is the primary means of disconnecting the
machine 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.
• Make sure the area in front of the wall outlet into which the machine is
plugged is free from obstruction.
• 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.
• 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. If you should damage the unit, contact your
system supplier. Refer to the Contact Information List at the front of this
guide for more information.
• If the unit becomes damaged, unplug it from the wall, then contact your
system supplier. Refer to the Contact Information List at the front of this
guide for more information.
• 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 place lighted candles, cigarettes, cigars, etc., on the system.
• To prevent overheating, do not cover vent openings.
• Use only approved supplies, in particular aerosol duster. Improper
storage and use of aerosol dusters or flammable aerosol dusters, can
cause an explosive-like condition that could result in a 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
Information

SV63136 Rev. A 1-7
Introduction • 1
• To obtain supplies and/or Material Safety Data Sheets, contact your
system supplier. Refer to the Contact Information List at the front of this
guide for more information.
• Operation of this equipment without periodic maintenance will inhibit
optimum operating performance and could cause the equipment to
malfunction. Contact your system supplier for the required service
schedule.
• 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. If you should damage the unit, contact your
system supplier. Refer to the Contact Information List at the front of this
guide for more information.
• This device is not intended for use in the direct field of view at visual
display workplaces. To avoid incommoding reflexions at visual display
workplaces, this device must not be placed in the direct field of view.
If your stacker has an AC adapter to power the stacker:
• Use only the AC adapter designed specifically for the stacker. Third-party
AC adapters may damage the stacker.
• To protect against electrical shock, plug the AC adapter power cord into
a properly grounded wall outlet.
• DO NOT route the AC adapter cable over sharp edges or trap it between
furniture.
Safety
Information
(continued)
Warning Labels The following warning labels are attached to modules on the system to alert
you to potential injury that could occur with careless operating procedures.
These same labels will be shown throughout the manual as they apply to
the various modules that are discussed in that section.
NOTICE
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.

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SV63136 Rev. A
Contents
System Components ...................................................................2-3
System Components (continued) ................................................2-4
Feeder Tower...............................................................................2-5
Feeder Trays ...............................................................................2-6
Sheet Trays ........................................................................... 2-6
Insert Trays............................................................................ 2-7
Manual Feeder ............................................................................2-8
Transport Deck ............................................................................2-9
Mail Piece Path...................................................................... 2-9
Pre-fold Accumulator ............................................................. 2-9
Folder .................................................................................. 2-10
Post-fold Accumulator ......................................................... 2-10
Insertion Area ...................................................................... 2-10
Folder Bypass Path ............................................................. 2-10
Moistener, Closer, Sealer .................................................... 2-10
About the Control Panel ............................................................2-11
Screen Option Keys..............................................................2-11
Fixed Function Keys ............................................................ 2-12
Fixed Function Keys (continued) ......................................... 2-13
Machine Action Keys ........................................................... 2-14
Screen Navigation Keys ...................................................... 2-14
Display Screen ..........................................................................2-15
Header Area ........................................................................ 2-15
Status Area .......................................................................... 2-16
Status Area (continued) ....................................................... 2-17
Status Area (continued) ....................................................... 2-18
Status Area (continued) ....................................................... 2-19
Status Area (continued) ....................................................... 2-20
Access Rights............................................................................2-21
Access Rights (continued).........................................................2-22
Logging In............................................................................ 2-22
Logging Out ......................................................................... 2-22
About System Covers................................................................2-23
Opening the Covers............................................................. 2-24
Closing the Covers .............................................................. 2-24
About the Paper Release Knobs/Levers ...................................2-25
About Add-On Modules .............................................................2-25
2 • Meet the Inserting
System

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