Pitney Bowes Relay 5000 User manual

Document Inserting System
Quick Start Guide
International English Edition
SV63135 Rev. A
August 1, 2015
Shipping & Mailing
Inserter
Relay
5000/6000/7000/8000
™

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 modications to this equipment not expressly
approved by the party responsible for compliance (Pitney Bowes) could
void the user’s authority to operate the equipment.
Canada EMC Compliance
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme à la norme NMB-003
du Canada.
SV63135 Rev. A August 1, 2015
©2005, 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 this system complies with all applicable
Directives of the European Union.

Quick Start Guide
3SV63135 Rev. A
Important Safety Notes
Follow these basic safety precautions when operating this machine:
• 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 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.
• If the unit becomes damaged, unplug it from the wall, then contact
your Customer Service Representative.
• 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.

Quick Start Guide
4 SV63135 Rev. A
• 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.
• To obtain supplies and/or Material Safety Data Sheets, contact your
Customer Service Representative.
• Operation of this equipment without periodic maintenance will inhibit
optimum operating performance and could cause the equipment to
malfunction. Contact your Customer Service Representative 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.

Quick Start Guide
5SV63135 Rev. A
Component Identification
Relay 5000/6000 Inserting System
Component Descriptions
#Component Description
1Tower Feeder Trays - feed sheets and/or inserts to the
Feeder Tower.
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.
2Feeder Tower - is a two-sided Tray holder/material feeder.
Component Descriptions continued
1
2
3 4 567
8
9
10
Relay 7000/8000
Only
11

Quick Start Guide
6 SV63135 Rev. A
#Component Description
3Manual Feeder - allows you to manually feed stapled or
unstapled sets of up to 5 sheets of 20 lb (80gsm) paper. The
inserter 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.
4Pre-fold Accumulator - is a staging area for the material that
needs to be collated together and then sent to the folder unit.
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 envelope then moves
through the closer and sealer areas to complete the mail piece.
9Sealing Solution Bottle - is located inside an opening cover at
the front right side of the inserter. 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 inserter status and shows loading
instructions and details of the job
11 High Capacity Envelope Feeder (Relay 7000/8000 only) -
holds at least 500 letter-sized envelopes and feeds directly to the
insertion area.
Drop Stacker (available on all units, not shown) collects and
neatly stacks finished mail pieces that exit the system. The drop
stacker can be unlatched from the system when it is not needed
Power Stacker (optional, not shown) - collects and neatly stacks
finished mail pieces that exit the system. The power stacker is
mounted to the system

Quick Start Guide
7SV63135 Rev. A
Control Panel
Screen Option Keys
Use the eight keys on the right side of the display screen to:
• Highlight an item in a displayed pick list and/or
• Select the associated menu, item, action, or option.
Use the four keys under the display screen to:
• Reset Counters accesses the Reset Counters screen that allows you
to zero the Piece Counter or reset the Batch count.
• Help accesses information about the screen that currently displays
and it provides access to the Help Topic Index that allows you to
navigate to other topics.
• Cancel returns you to the previous screen. If you have made changes
or defined settings on the screen you are cancelling, these will be lost.
• Home returns you to the Home screen. The Home screen is the
starting point for running a job. Once you select Home, changes you
made prior to selecting Home will be saved.
Screen Navigation Keys
Screen Option Keys
Inserter Action Keys

Quick Start Guide
8 SV63135 Rev. A
Screen Navigation Keys
• Use the UP/DOWN and LEFT/RIGHT arrow keys to move the highlight
on the screen in those directions.
• Press OK whenever you want to apply a selection that you made using
the arrow keys.
Inserter Action Keys
Use the four keys along the bottom of the control panel to run the
system and control its mechanical movement:
• Start causes the selected job to start running.
• Trial Piece allows you to do a test run on your job. One complete mail
piece is prepared. This allows you to verify that your job settings are
correct, that the mail piece looks the way you want it to look, and that
the system is functioning properly.
NOTES:
- Even if the job calls for a sealed mail piece, the trial piece
will be unsealed for easy inspection.
- Double Detect is set for trial pieces, so be sure to examine
the contents of t he mail piece.
• Clear Deck rids 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 completes pieces in process.

Quick Start Guide
9SV63135 Rev. A
Mail Piece Icon Tree
When you run, view, or create a job, a Mail Piece Icon Tree displays on
the control panel. This tree describes the information available and assists
you in loading and running a job. A list of all the icons is provided here.
Mail Piece Icon Tree Example
Window Envelope loaded flap
down, flap first.
Envelope sealing turned on,
loaded into Feeder G.
C Fold selected.
Top address loaded Face Up, fed
Top First, loaded into Feeder C.
Double Detect is on.
Additional Sheet - (No address)
loaded Face Up, fed Top First
loaded into Feeders B and D;
Feeders B and D are linked.
(Linked Trays will always be
on the same side of the Tower.)
Double Detect is on.
Reply Envelope loaded Flap Side
Down, fed Flap First, loaded into
Feeder A.
B
D
C
G
A

Quick Start Guide
10 SV63135 Rev. A
Envelope Icons
Tower Feeder
Orientation: flap side
down, flap first.
HCEF*
Orientation: flap side
down, flap last.
Non-Window Letter
Envelope
Window Standard Flap
Envelope
Window Forward Flap
Letter Envelope
Window Bottom Flap
Letter Envelope
Non-Window Flat
Envelope N/A
Window Standard Flap
Flat Envelope N/A
Window Forward Flap
Flat Envelope N/A
Window Bottom Flap
Flat Envelope N/A
*High Capacity Envelope Feeder

Quick Start Guide
11SV63135 Rev. A
Sheet Icons
Orientation:
face up, top
first.
Orientation:
face up,
bottom first.
Orientation:
face down,
top first.
Orientation:
face down,
bottom first.
Sheet, Not
Personalized
Sheet, Top
Address
Sheet, Middle
Address
Sheet, Bottom
Address
Multiple
Sheets, Not
Personalized
Multiple
Sheets, Top
Address
Multiple
Sheets, Middle
Address
Multiple
Sheets, Bottom
Address

Quick Start Guide
12 SV63135 Rev. A
Insert Icons
Orientation:
face up, top
first.
Orientation:
face up,
bottom first.
Orientation:
face down,
top first.
Orientation:
face down,
bottom first.
Slip or Generic
Insert
Reply
Envelope N/A N/A N/A
Reply Card
Mulitple Slips
or Generic
Inserts
Multiple Reply
Envelopes N/A N/A N/A
Multiple Reply
Cards
Orientation:
closed edge
first.
Pre-Folded
Insert
Multiple
Pre-Folded
Inserts
Orientation:
bound edge
first.
Letter
Booklet
Mutiple
Letter
Booklets

Quick Start Guide
13SV63135 Rev. A
Feeder Assignment Icons
Feeder assignment is indicated by a letter in a grey square to the right of
the job item icon in the Mail Piece Icon Tree. The letter that appears in the
grey square will vary, depending upon the assigned feeder.
Single Feeder Assignment is indicated by one grey square. A
Linked Feeder Assignment is indicated by two grey squares. A
B
NOTE: The table below provides a list of all possible Feeder
assignments. The Feeders available to you will vary, depending
upon your system conguration.
Feeder
Letter Location Position
AFeeder Tower Bottom left feeder
BFeeder Tower Bottom right feeder
CFeeder Tower Top left feeder
DFeeder Tower Top right feeder
G High Capacity Envelope Feeder (HCEF) N/A
J High Capacity Sheet Feeder 1 (HCSF) Bottom feeder
K High Capacity Sheet Feeder 1 (HCSF) Top feeder
L High Capacity Sheet Feeder 2 (HCSF) Bottom feeder
M High Capacity Sheet Feeder 2 (HCSF) Top feeder
Fold Icons
No Fold
C Fold
Z Fold
Single Fold
Double Fold

Quick Start Guide
14 SV63135 Rev. A
Other Icons
Error Icon - appears in pop-up messages on display screen.
Indicates message is an error message.
Warning Icon - appears in pop-up messages on display
screen. Indicates message is a warning message.
Seal On Icon - appears in Mail Piece Icon Tree if sealing is
on.
Double Detect Icon - appears in Mail Piece Icon Tree if double
detect is on.

Quick Start Guide
15SV63135 Rev. A
Running a Job
1. From the Home screen, select Menu > Jobs > Select Another Job.
(If you do not see the job you need, contact your supervisor to define a
new job.)
2. Using the Mail Piece Icon Tree on the display, load the feeder trays
with materials specified for the selected job:
• Make sure you fan or aerate the material before loading
• Adjust the Side Guides using the Side Guide Adjustor
3. Make Pre-Run Adjustments. (Refer to Operator Guide for detailed
steps on each of these procedures):
• Adjust the Envelope Openers
• Adjust High Capacity Sheet Feeder Guides (optional)
• Adjust Scan Head (optional)
4. If the job requires sealing, make sure the sealer bottle has solution
(located under the front right hand side cover of the machine). If
necessary, fill the bottle with sealing solution (we recommend Pitney
Bowes® E-Z Seal® sealing solution for best results).
5. Press Trial Piece to “test run” one mail piece for your job. (Refer to the
Operator Guide for detailed steps on each of these procedures):
• Verify the integrity of the mail piece by visually inspecting the trial
piece to confirm the presence of all materials and accuracy of the
collation order.
• Make needed adjustments and run another trial piece to ensure
job accuracy.
6. When the trial piece is OK, press Start to begin running the job.
7. Be sure to keep the Feeder Trays full with the job-specific material while
the machine is running.

Quick Start Guide
16 SV63135 Rev. A
Troubleshooting Tips
• If an error message appears, follow the prompts on the display. If
you cannot resolve the error, contact your supervisor or refer to the
Operator Guide.
• If a material stall occurs within the machine, follow the prompts on the
display to open the appropriate cover and remove the stalled piece. If
necessary, manually advance material through and out of the machine.
NOTE: The machine has safety interlocks on its covers,
whereby the machine will not run when a cover is open. Make
sure you close all covers before resuming operation.
• Verify you have selected the correct job.
• Verify you have the correct material for your job (inserts, sheets,
envelopes).
• Verify your material conforms to the material specifications of the
machine '(refer to the Operator Guide).

Quick Start Guide
17SV63135 Rev. A
If You Need Assistance
• For basic operation questions, use the built-in Help file that is
accessed with the Help key on the Control Panel.
• For more detailed troubleshooting or setup help, consult the Operator
Guide on the CD.
USA Contacts
Product Name - Relay 5000/6000 or Relay 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.

This page is intentionally blank,

3001 Summer Street
Stamford, CT 06926-0700
www.pitneybowes.com
SV63135 Rev. A
©2015 Pitney Bowes Inc.
All Rights Reserved