Dixie Narco FLEXPAK 3000 Series User manual

FLEXPAKTM 3000
TWO-BUTTON PROGRAMMING
SET-UP / CONFIGURATION / TROUBLESHOOTING / OPERATION / PARTS
MANUAL
First Production xxxx-6208DS
December 15, 1994
Revised November 11, 1998

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TABLE OF CONTENTS
Introduction................................................................................................................................... Page 3
Models and Specifications.............................................................................................................. Page 4
Installation and Set-Up .......................................................................................................Pages 5 thru 9
Features............................................................................................................................. Pages 10 & 11
Hardware Configuration ...............................................................................................................Page 12
FlexPak3000 Audit Features.......................................................................................... Pages 13 & 14
Audit Data Available through External Electronic Counters...............................................Page 13
Audit Data Available through Service Menu......................................................................Page 14
Audit Data Available through Electronic Access................................................................Page 14
Controller Programming .................................................................................................Pages 15 thru 23
Programming Quick Reference .....................................................................................................Page 24
Troubleshooting:
Coin/Currency........................................................................................................ Pages 26 & 27
Sold-Out ..........................................................................................................................Page 28
Vending ................................................................................................................. Pages 29 & 30
Display................................................................................................................... Pages 31 & 32
Refrigeration.......................................................................................................Pages 33 thru 39
Parts Diagrams and Lists.................................................................................................Pages 40 thru 55
Sample Wiring Diagram................................................................................................................Page 56
FlexPak3000 Ardac Controllers Diagram..................................................................................Page 57
FlexPak3000 DeAmertek Controllers Diagram.........................................................................Page 58
Appendix A1 Standard Factory Module Setting - DMV 72 & 79W
Appendix A2 Standard Factory Module Setting - DMV 72N (not available at print)
Appendix A3 Sample Internal Module Layouts
Appendix A4 Package Module Row Flexibility Matrix

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INTRODUCTION
Dixie-Narco’s FlexPak3000 Vender is the next "generation" of equipment that will revolutionize the industry
by providing a piece of equipment, in three models, that will serve your entire business. The FlexPak3000 will
provide full package flexibility with increased product capacity and exceptional space-to-sales. Each of the three
models utilize standardized parts, delivery platform, and a refrigeration system that is 100% CFC-free.
The FlexPak3000 also incorporates electronics to meet the growing need for accountability, multi-pricing,
programmability, and system diagnostics. Along with these functions, DEX/UCS - communications to a hand-
held computer is required for the bottling industry to provide the ability to measure each vending location for
product performance, vender performance, and accessing accounting data. The data obtained can be used to
maximize the efficiency of the truck routes for servicing venders. DEX communications provides the bottler
security for the integrity of the "cash in" versus the "product sold".

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MODELS AND SPECIFICATIONS
DMV 72N
Dimensions: 72"H x 28"W x 32"D
Approximate Weight: Not available at print
Number of Modules per Vender (12 oz. Can): 16
Number of Modules per Vender (16 oz. Bottle): 6, four 12 oz. can modules may be added
Number of Modules per Vender (20 oz. Bottle): 6, four 12 oz. can modules may be added
DMV 72W
Dimensions: 72"H x 37"W x 32"D
Approximate Weight: 750 lbs. (Empty)
Number of Modules per Vender (12 oz. Can): 20
Number of Modules per Vender (16 oz. Bottle): 10
Number of Modules per Vender (20 oz. Bottle): 10
DMV 79W
Dimensions: 79 1/2"H x 37"W x 32"D
Approximate Weight: Not available at print
Number of Modules per Vender (12 oz. Can): 20
Number of Modules per Vender (16 oz. Bottle): 10
Number of Modules per Vender (20 oz. Bottle): 10
All weights, dimensions, and specifications listed are subject to change without notice.

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INSTALLATION AND SET-UP
Please read this manual in its entirety. Repair and maintenance of this vending machine must only be performed
by authorized and competent technical personnel. If you have any questions, please call your local bottler,
distributor, or Dixie-Narco for assistance.
Receiving Inspection
Upon receipt, inspect the FlexPak3000 for shipping damage. If there is any damage, have the driver note the
damage on the Bill of Lading and notify Dixie-Narco. Although I.C.C. regulations require that the consignee
originate shipping damage claims, Dixie-Narco will gladly help if you must file a claim.
Unpacking The Vender
Remove the stretch wrap and top covers from the vender. If flavor cards were shipped with the vender, they will
be in an envelope affixed to the back of a vender in the shipment or in the cash box.
NOTE: DO NOT STORE THE VENDER OUTDOORS WITH STRETCH WRAP ON. THIS
COULD CAUSE THE STRETCH WRAP TO BOND TO THE VENDER’S SURFACE,
WHICH COULD DAMAGE THE FINISH.
Remove the shipping boards from the bottom of the vender. The shipping boards are attached by the leveling
legs. Remove the shipping boards by unscrewing the leveling legs. This will avoid unnecessary damage to the
leveling legs or the base. A 1-1/2" "socket-type" wrench should be used on the bottom of the leveling legs. Be
sure to replace the legs after removing the shipping boards.
To open the vender, locate the door lock keys which are secured inside the coin return cup. After unlocking the
door, rotate the "T"-handle counter-clockwise until the door can be opened. Once inside, check the coin box on
the door for any additional parts, pricing labels, or information concerning factory equipped accessories. Check
the "T"-handle for proper alignment and locking functions. Check the lamps for proper installation.
WARNING: INSURE THAT POWER IS DISCONNECTED FROM THE VENDER OR THAT THE
POWER INTERRUPT SWITCH (IF PROVIDED) IS NOT DEFEATED BEFORE
INSPECTING OR REPLACING THE LAMPS. FAILURE TO COMPLY WITH THESE
INSTRUCTIONS MAY SUBJECT THE USER TO THE RISK OF INJURY OR
ELECTRICAL SHOCK WHICH CAN BE SERIOUS OR FATAL.
Electric Power Needed
Refer to the FlexPak3000 serial number plate to determine the proper voltage and frequency the machine
requires (domestically this requirement is 115 volt, 60 hertz). The vender will operate at +/- 10% of the specified
voltage for domestic models - this is between 103 volts and 127 volts. Single phase, alternating current is
required. The vender must be plugged in its own properly rated circuit with its own circuit protection
(fuse/circuit breaker).
DO NOT USE AN EXTENSION CORD.

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Ground The Vender
The FlexPak3000 is equipped with a three wire power supply cord and MUST be plugged into a properly
grounded outlet.
DO NOT REMOVE THE GROUND PIN OR IN ANY WAY BYPASS THE GROUNDING OF THE
FLEXPAK 3000. If the outlet will not accept the power cord plug, contact an electrician to install a proper
AC outlet.
WARNING: Failure to comply with these instructions may subject the user to the risk of
injury or electrical shock which can be serious or fatal.
Placing The Vender On Location
CAUTION: DO NOT TRANSPORT THE VENDER TO OR FROM THE LOCATION WHEN IT IS
LOADED WITH PRODUCT; DAMAGE TO THE VENDER MAY RESULT.
The vender must be located on a solid, flat, and level surface.
The vender must be positioned close enough to an electrical outlet that an extension cord is not required. If
securing the vender to the floor or wall is required, call the Dixie-Narco Factory Service Department for
suggestions.
Level The Vender
Level the vender. When the vender is level, the door can be opened to any position and it will not move by itself.
Open the door to several different positions before deciding that the vender is level. Make sure that all of the
leveling legs are in contact with the floor. If you cannot level the vender, select another location. Do not place
any objects under the machine.
DANGER: THE VENDER MUST BE PROPERLY LOCATED AND LEVELED TO MINIMIZE
THE RISK OF INJURY OR DEATH FROM TIPPING IN THE EVENT OF MISUSE OR
VANDALISM.
Space The Vender
Do not block the rear of the vender. Maintain a minimum of 10 cm (4 in) from the wall to insure adequate air
flow to the condenser and compressor. At the front of the vender, make sure that nothing obstructs the air
intake at the bottom of the main door. At the rear of the vender, make sure that nothing obstructs the air exhaust
at the bottom of the cabinet.
Installing Flavor Cards
The flavor cards are inserted in the selection buttons. On non-TBV machines, swing the coin changer mounting
plate away from the outer door exposing the back of the select buttons. The flavor cards are inserted in the back
of the selection buttons from either side or remove the flavor card carrier. Ensure the flavor cards are placed in
the select button flavor card carrier position that corresponds to the module in which the product is loaded.
Install the flavor card carrier back in position. In TBV machines, carefully remove the select button lens from the
select button. Insert the flavor card in the lens. Snap the lens back in position in the select button. Ensure the
flavor cards are placed in the select buttons that correspond to the module in which the product is loaded.

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Temperature Control Adjustments
Adjustment #1 - Temperature Adjustment
Turn the adjustment clockwise for colder product and counter-clockwise for warmer product. This will
change the cut-out temperature only, the cut-in temperature remains constant.
Adjustment #2 - Altitude Adjustment
Warning: Disconnect power to the vending machine before proceeding with this
adjustment.
The control is factory set for an altitude of 152 M (500 ft.). For higher altitudes, adjust the inside range
screws to prevent freeze-up of the product. Adjust the inside range screws as follows.
ALTITUDE CUTLER-HAMMER 9531N272
Meters (Feet) Turn both screws counter-clockwise
610 (2,000) 1/8 Turn
1219 (4,000) 1/4 Turn
1829 (6,000) 1/2 Turn
2438 (8,000) 5/8 Turn

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Loading Instructions
Product Vending
Dixie-Narco venders are shipped ready to vend 12 oz. cans unless another package was specified at the
time the vender was ordered. If packages other than 12 oz. cans are to be vended, contact the Dixie-
Narco Factory Service Department for the proper instructions.
The closure strip and the discharge member are set for the maximum security when vending cans. To
vend bottles, refer to the illustration below.

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Cleaning The Vender
DO NOT USE A WATER JET OR NOZZLE TO CLEAN THE VENDER
Sign Face
The polycarbonate sign face requires proper cleaning to prolong the service life of this item. It is
recommended that you periodically clean the sign as follows:
1. Rinse the sign with a soft cloth or sponge soaked in warm water.
2. If necessary, use a mild soap to loosen any dirt or grime. To prevent damage, DO NOT
SCRUB or use a brush or squeegee, as some signs have a clear ultraviolet resistant
coating to prevent yellowing.
3. Repeat the above steps as necessary, then dry using a soft cloth to prevent spotting.
Cabinet
*Wash the cabinet with a good detergent or soap mixed in warm water.
*Wax the vender often with a good grade of automobile wax.
*Any corrosion inside of the vender should be removed with fine steel wool and the area should be
painted with aluminum paint.
*Repair any scratches on painted surfaces to prevent corrosion.
WARNING: THE COMPRESSOR ELECTRICAL CIRCUIT IS ALWAYS LIVE WHEN
THE PLUG IS CONNECTED TO AN ELECTRICAL OUTLET.
Refrigeration Condenser
*Check the condenser periodically for dirt or lint build-up.
*Remove the build-up with a brush or vacuum, or blow the dirt out of the condenser with
compressed air and approved safety nozzle.
*Ensure nothing obstructs the air intake at the bottom of the main door.
*Ensure nothing obstructs the air exhaust at the rear of the cabinet.
Coin Acceptor
*Follow the coin acceptor manufacturer’s instructions on cleaning.
Lubricating The Vender
The FlexPak3000 Refrigeration System does not require any field lubrication. The hermetic refrigeration
system and fan motors are manufactured with lifetime lubrication.
Parts Needing Lubrication
Time Component Lubricant Example
Every six months Main door
(or as needed) 1. Lock Bolt & Nut Retainer Mechanics Friend
2. Hinge Pivot Points Mechanics Friend
Inner Door
1. Hinge Pivot Points Mechanics Friend
Slides
1. Top Only White Lithium Grease
Every Year Inner Door
(or as needed) 1. Door Gasket Petroleum Jelly

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FEATURES
DEX COMPATIBLE HAND-HELD INTERFACE
The vending industry (NAMA) has established an audit data protocol which is defined by DEX (Direct Exchange
of Data) and UCS (Uniform Communications Standards). This interface is a direct connection as defined by the
specification. The FlexPak3000 has provisions for an internal and external connection. The external
connection provides a limited amount of information.
20 MODULE COMPATIBLE
The FlexPak3000 cabinet controller is capable of driving up to twenty vend mechanisms independently. The
vend mechanism is 24V DC.
LOW VOLTAGE SELECT PANEL
The select panel consists of gold cross-point switches. The interface circuitry is located on the door control
board. The control board supports up to fourteen selections.
PROGRAMMABLE SPACE-TO-SALES
The programmable space-to-sales is a feature which allows modules to be assigned to select buttons. Modules
are dispensed evenly when more than one module is assigned to given select button(s).
SELECT PANEL OR HAND-HELD CONTROLLER PROGRAMMING
The FlexPak3000 has the capability to be programmed through the select panel or through the DEX port on
the door control board with the same hand-held used to access the accounting data.
LED DISPLAY (LIGHT EMITTING DIODES)
Early displays consist of four characters, utilizing seven segment LED’s for each character, to provide an alpha-
numeric display. Current displays consist of four characters, utilizing fourteen segment LED’s for each
character, to provide an alpha-numeric display.
PRICE DISPLAY
If all selections are set at the same vend price in primary pricing and secondary pricing, the vend price is shown
on the display. If multi-pricing is used, pressing any select button shows the vend price of that particular
selection on the display.
SINGLE PRICE OR MULTI-PRICE VIA THE SELECT PANEL OR HAND-HELD
Prices for each selection can be programmed either through the front select panel or through the DEX hand-held
device. For single price configuration, each selection has to be programmed for the same price. To set all
selections for the same price:
1.) Enter "S-P" mode in the menu,
2.) Set desired vend price on select button 1,
3.) Simultaneously press and hold select buttons 3 and 4 for five seconds, this will change the vend
price of all selections to the price programmed to select button 1.