Envipco FLEX Series Manuale utente

FLEX Series ServiceManual

March 16, 2016

Contents

List of Figures ............................................. i

Chapter 1

Introduction & Safety ................................. 1-1

1.1

Foreword .................................................................................... 1-1

1.2

Symbols Used............................................................................. 1-1

1.3

Users ..................................................................................................

1-1

1.3.1

Customer..................................................................... 1-2

1.3.2

Sponsor .............................................................................

1-2

1.3.3

Machine Attendants .................................................... 1-2

1.3.4

Service Technician...................................................... 1-2

1.4

Safety precautions ...................................................................... 1-3

1.5

Safety labels ............................................................................... 1-4

1.5.1

Laser safety................................................................. 1-4

1.5.2

Electrical safety .......................................................... 1-7

1.5.3

Mechanical Safety ...................................................... 1-8

Chapter 2

Specifications

.................................................

2-1

2.1

General Specifications ............................................................... 2-1

2.1.1

Serial Label................................................................. 2-1

2.1.2

FLX Configurations.................................................... 2-1

2.1.3

FLEX Specifications................................................... 2-3

2.1.4

Power Requirements................................................... 2-4

2.2

Operating the FLEX................................................................... 2-4

2.2.1

Usage ................................................................................

2-4

2.2.2

Container Accounting................................................. 2-5

2.2.3

Service Interruptions................................................... 2-5

Contents

Chapter 3

Hardware Components ............................. 3-1

3.1

Introduction .......................................................................................

3-1

3.2

Cabinet ....................................................................................... 3-3

3.2.1

Door Interlock............................................................. 3-3

3.2.2

Bin Full Sensor ........................................................... 3-4

3.2.3

FLEX and FLEX Tri Cabinets.................................... 3-4

3.2.4

FLEX HDS Cabinet.................................................... 3-5

3.3

Sensor Scanner ........................................................................... 3-6

3.3.1

Scanners...................................................................... 3-7

3.3.2

Motorized Conveyor ........................................................

3-7

3.3.3

Materials Sensors........................................................ 3-8

3.3.4

PET Sensor ................................................................. 3-8

3.3.5

Load Cell FLEX ......................................................... 3-8

3.3.6

Load Cell FLEX HDS ................................................ 3-8

3.3.7

Camera/Laser.............................................................. 3-8

3.4

Sorting Cylinder ......................................................................... 3-11

3.5

Compactors................................................................................. 3-13

3.5.1

PET Compactor .......................................................... 3-13

3.5.2

Can Compactor ........................................................... 3-14

3.5.3

Can/PET Compactor................................................... 3-15

3.6 Bins............................................................................................. 3-15

3.7

RVM Controller Box.................................................................. 3-16

3.7.1

RVM Controller Box Electrical Components............. 3-16

3.7.2

RVM Controller Box Electronic Components ........... 3-20

3.8

AC Motor Control Box .............................................................. 3-24

3.8.1

Terminal Block ........................................................... 3-26

3.8.2

Variable Frequency Drive .......................................... 3-26

3.8.3

Compactor 230V Three-Phase Connector.................. 3-27

3.8.4

208-240V Single-Phase AC Power Output ................ 3-27

3.8.5

Safety Loop Override ................................................. 3-27

3.8.6

Compactor Motor Disconnect .................................... 3-28

3.8.7

Mechanical Counter.................................................... 3-28

Chapter 4

RVM Software ............................................ 4-1

4.1

Introduction .......................................................................................

4-1

4.2

Shop Mode ................................................................................. 4-1

4.3

Service Mode ............................................................................. 4-2

4.3.1

Starting Service Mode ................................................ 4-2

4.3.2

Using the Technician Interface................................... 4-3

4.3.3

Exiting Service Mode ................................................. 4-5

4.4

Diagnostic Program.................................................................... 4-6

4.4.1

Processes Tab.............................................................. 4-6

4.4.2

Misc Tab ..................................................................... 4-8

4.4.3

Main Tab..................................................................... 4-9

4.4.4

Ultra-48 Tab................................................................ 4-10

4.4.5

RS-485 Tab................................................................. 4-13

4.4.6

Config Tab .................................................................. 4-14

4.5

Sensors and Thresholds.............................................................. 4-16

4.5.1

Sensors ..............................................................................

4-16

4.5.2

Thresholds.........................................................................

4-20

4.6

RVM Communications .............................................................. 4-21

4.6.1

Physical Connections.................................................. 4-22

4.6.2

File Transfers .............................................................. 4-22

4.7

Software Theory of Operation ................................................... 4-23

Chapter 5

Maintenance

...................................................

5-1

5.1

Introduction .......................................................................................

5-1

5.2

Maintenance Responsibilities..................................................... 5-1

5.2.1

Service Technician Responsibilities........................... 5-1

5.2.2

Store Responsibilities ................................................. 5-2

5.3

Component Maintenance ........................................................... 5-2

5.3.1

Cleaning Mode............................................................ 5-2

5.3.2

Cabinet and Doors ...................................................... 5-3

5.3.3

Harnesses ..........................................................................

5-3

5.3.4

RVM Controller Box .................................................. 5-4

5.3.5

Display ..............................................................................

5-4

5.3.6

Printer................................................................................

5-4

5.3.7

AC Motor Control Box............................................... 5-5

5.3.8

Sensor Display............................................................ 5-5

5.3.9

Compactors................................................................. 5-6

5.3.10

Bin Overflow Sensors ......................................................

5-7

5.3.11

Scanners ............................................................................

5-7

Contents

Chapter 6

Troubleshooting & Repairs ....................... 6-1

6.1

Introduction .......................................................................................

6-1

6.2

FLEX’s Error Messages............................................................. 6-1

6.3

VFD Status Messages ................................................................ 6-5

6.4

Troubleshooting Other Conditions............................................. 6-6

6.4.1

Display Not Functional............................................... 6-6

6.5

Repairs........................................................................................ 6-6

6.5.1

Swapping an RVM Controller.................................... 6-6

6.5.2

Chain Replacement..................................................... 6-8

6.5.3

Sensor Replacement.................................................... 6-8

6.5.4

Frequently Used Options............................................ 6-11

List of Figures

Laser Compliance Label .......................................................................1-4

Laser Danger Label...............................................................................1-5

High Voltage Warning Label. ..............................................................1-5

Safety Label Locations .........................................................................1-5

Door Interlock Label.............................................................................1-7

Compactor Motor Disconnect Label ....................................................1-8

Moving Parts Warning Label................................................................1-8

Moving Parts Warning Label Location.................................................1-9

Pinch Point Label..................................................................................1-9

Pinch Point Label Locations.................................................................1-10

Example Serial Label............................................................................2-1

FLEX Configuration .............................................................................2-1

FLEX Main Components ......................................................................3-1

FLEX HDS Main Components.............................................................3-2

FLEX Cabinet .......................................................................................3-3

Sensor Scanner Display (Right Side View). .........................................3-6

Sensor Scanner Display (Left Side View) ............................................3-6

Conveyor ..............................................................................................3-7

Load Cell FLEX ...................................................................................3-9

Load Cell FLEX HDS ..........................................................................3-9

Camera/Laser........................................................................................3-10

Sorting Cylinder (Front View) .............................................................3-11

Sorting Cylinder (Rear View)...............................................................3-12

PET Compactor.....................................................................................3-13

Can Compactor .....................................................................................3-14

Can/PET Compactor .............................................................................3-15

RVM Controller Box Electrical Components.......................................3-16

RVM Controller Box Connectors .........................................................3-18

RVM Controller Box ElectronicComponents ......................................3-20

PC Board Layout ..................................................................................3-21

MC5 Board Layout ...............................................................................3-22

MD5 Board Layout...............................................................................3-22

Printer Assembly...................................................................................3-23

FLEX AC Motor Control Box Components .........................................3-24

FLEX HDS AC Motor Control Box Components ................................3-25

MC1 Board Layout ...............................................................................3-26

Variable Frequency Drive.....................................................................3-26

Shop Mode............................................................................................4-1

Technician Interface (Default) ..............................................................4-2

Download Q-File Dialog Boxes............................................................4-3

Reset Counts Dialog Box......................................................................4-4

Exiting Service Mode ...........................................................................4-5

Service Mode Time Out Screen............................................................4-5

List of Figures

Diagnostics - Processes Tab..................................................................4-6

Diagnostics - Miscellaneous OptionsTab.............................................4-8

Diagnostics - MainTab.........................................................................4-9

Diagnostics – Untra-48Tab...................................................................4-10

Diagnostics – RS-485 Tab ....................................................................4-13

Diagnostics - Config Tab ......................................................................4-14

MC1 Sensors.........................................................................................4-17

MC5 Sensors.........................................................................................4-18

Thresholds ............................................................................................4-20

Software Theory of Operation..............................................................4-23

Cleaning Mode .....................................................................................5-2

FLEX Error Messages ..........................................................................6-1

VFD Status Messages...........................................................................6-5

Frequently Used Options ......................................................................6-11

1-1

Chapter 1

Introduction & Safety

1.1.

Foreword

Welcome to

FLEX

. The most versatile reverse vending machine on the market today, the

FLEX

-ible

design, modern user interface, small footprint, and ease of container processing make it an

attractive solution for any redemptioncenter.

This manual contains the information for the operation, cleaning, installation, and maintenance of

Envipco’s

FLEX

series of reverse vending machines. Always refer to this manual when performing

these tasks.

Warning!

Service and most maintenance tasks are the sole responsibility of

Envipco and should only be performed by Envipco or other

authorizedmaintenance personnel.

1.2.

Symbols Used

Warning symbols indicate the levels of danger involved with some of the procedures described in

this manual. Please familiarize yourself with these symbols, and heed the instructions that

accompany them.

Warning!

Warnings provide information which, if not followed, could result in

injury or, in extreme cases, even death.

Caution!

Cautions provide information which, if not followed, could cause

dam- age to theequipment.

Note:

Notes highlight information or give additional data necessary to per-

form a test or step.

1.3.

Users

This section defines the terms that refer to the people who interact with the

FLEX

and their level of

access to themachines.

Chapter

Introductio

Safety

1.3.1.

Customer

The term “customers” refers to users who redeem containers in exchange for payment.Their level

of interaction with the

FLEX RVM

is confined to inserting containers into the machine, viewing

instructions and advertisements on the video screen, pressing the payment button, and removing

the voucher from the receipt chute. Customers must not place their hands into the In-Feed or have

access to the inside of the

FLEX

1.3.2.

Sponsor

The “sponsor” refers to the owner or lessee of the

FLEX

. In

states with bottle deposit laws, the

FLEX

sponsor is usually a retailer that sells beverages that have container deposits. The sponsor is

responsible for maintaining a list of redeemable containers (the “bar code table”), notifying

Envipco of updates to the bar code table, and requesting custom messages appearing on the

LCD

and printed vouchers.

Warning!

The sponsor, along with the machine attendants and service

technicians, are responsible for ensuring that both cabinet doors

are locked and secure while customers have access to the

machines.

1.3.3.

Machine Attendants

“Machine attendant” refers to anyone that does one or more of the following tasks:

•

••

•cleans the outside of the machine

•

••

•replaces the printerpaper

•

••

•maintains the supply of printer paper and commodity bags

•

••

•empties the commoditybins

•

••

•initiates servicecalls

Machine attendants need the top door key to change the printer paper and the bottom door key to

empty the commoditybins.

1.3.4.

Service Technician

A service technician is trained by Envipco to maintain and repair the

FLEX

. No other person shall

repair or perform internal maintenance on the

FLEX

Warning!

Envipco is not responsible for damages or injuries incurred when

unauthorized repairs are performed on the

FLEX

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