Envipco FLEX LS User manual

FLEX LS
USER MANUAL
Edition 2110

FLEX LS | USER MANUAL | 2
Executive Summary.......................................................................................3-4
Glossary ..........................................................................................................5-6
CHAPTER 1
Introduction & Safety ...................................................................................7
1.1 Machine description .........................................................................7
1.1.1 Placement ...............................................................................8
1.1.2 Usage ........................................................................................8
1.1.3 Service interruptions .............................................................8
1.2 Safety background information ......................................................9
1.2.1 Examples of a warning, caution, and note.......................9
1.3 General safety precautions...............................................................10
1.4 Electrical safety ..................................................................................11
1.4.1 Electrical safety labels..........................................................12
1.5 Mechanical safety ..............................................................................13
1.5.1 Mechanical safety labels ......................................................13
CHAPTER 2
Maintenance & Service .................................................................................18
2.1 Introduction........................................................................................18
2.2 Cleaning...............................................................................................18
2.3 Emptying Bins.....................................................................................19
2.4 Keys.......................................................................................................20
2.5 Printer ..................................................................................................20
2.5.1 Ordering Paper ......................................................................20
2.5.2 Receiving and securing paper ............................................20
2.5.3 Changing the printer paper ................................................20
2.6 Servicing the FLEX..............................................................................22
2.6.1 Maintenance provider responsibilities ..............................22
2.7 Product acceptance...........................................................................23
CHAPTER 3
Installation......................................................................................................25
3.1 RVM power requirements.................................................................25
3.2 Product location.................................................................................25
3.3 Functional check procedures ..........................................................25
3.3.1 Attendant training and demonstration.............................25
CONTENTS

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Envipco’s FLEX LS was designed for locations with low redemption rates or limited space. The FLEX LS
is a cost eective, compact solution that processes aluminium, steel and plastic containers through
one opening. Only 60cm (24”) wide, the FLEX LS is half the size of a vending machine and delivers the
industry’s best container densification: It holds up to 900 containers.
INTENDED USE
The machine is used exclusively for redeeming one-way empty beverage containers in the form of plastic
bottles (e.g. PET) up to 3 litres, aluminium cans up to 1 litre. The machines are typically installed at sales
outlets (supermarkets, stores) or at return points.
FORESEEABLE MISUSE
Objects other than those specified are inserted; for example non-returnable containers or containers not
covered by any return system; full or partially filled bottles or cans, bottles filled with flammable liquids,
plastic bags, waste or personal objects (rings, cell phones, wallets, etc.).
SAFETY
Safety for store customers, store personnel, and Envipco technicians is paramount in the design and
continuing development of the FLEX LS. Follow all safety precautions and safety information that warn
against bypassing or overriding the safety devices. The FLEX LS is equipped with a low powered Class
II laser and with motor driven reduction devices. There is no possible exposure to laser light during
machine operation. The machine’s laser scanners are similar to the UPC scanners at a supermarket check-
out. When the machine is secure and in operation, no harmful light is radiated. The US Food and Drug
Administration requires the inclusion of laser safety information and labels pursuant to 21 CFR,
Chapter 1, Sub-chapter J, Laser Product Performance Standard, Section 1040.10 (h). The FLEX Scanners
meet the safety requirements of IEC/EN 60825-1 Class 1 (Public Health England Standard BS 60825-1).
MACHINE SPECIFICATIONS
The FLEX LS accepts both PET (plastic bottles) and aluminium or steel cans. Envipco’s PIN-WAVE™
compactor provides superior densification, allowing for less bin changes. Its narrow 600mm (24”) width
conserves space, and its 1840mm (72”) height matches that of vending machines. It has a standard line
cord and does not require a special electrical outlet.
HOW IT WORKS
If a container is rejected, the conveyor returns it to the customer, who must remove the container from
the machine. If a container is accepted, the machine credits the value of the container to the amount
due the customer and displays it on the front panel of the machine. The customer receives a voucher as
payment for containers by pressing the green payment button or may select to donate the accumulated
amount to a specified charitable organisation.
Should the machine malfunction while serving a customer and a voucher is due the customer, the
machine will pay the customer before going o-line. Should a power outage occur, the machine retains
the amount due the customer. When power is restored, the machine pays the customer. Safeguards in the
software prevent double payment in the event of a machine malfunction or loss of power.
EXECUTIVE SUMMARY

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CARE OF THE MACHINE
Cleanliness is the most important factor in the reliable operation of the FLEX LS. Both store personnel and
Envipco technicians have a responsibility to clean and maintain the machine. The store must perform
daily tasks such as cleaning the scanner glass, sensors, and belts. Envipco performs major cleaning and
maintenance of the machine on a regular schedule.
RETAILER INFORMATION
Two keys are provided with each installation. One key opens the storage bin door and the other opens the
upper front door of the machine. Both keys are required to service the machine.
The FLEX LS is equipped with a printer as standard equipment. Store personnel must install paper in the
printer as needed.
INSTALLATION
The machine requires an outlet on a dedicated circuit. Each machine requires a minimum of 100mm (4”)
of clearance in the back of the machine to allow room for the power cord plug and strain relief. 1220mm
(48”) of clearance is required in front of the machine to allow for unloading the bins. There must be 10mm
(1/2”) on the left side and 10mm (1/2”) on the right side to allow for servicing the machine.
Note: Only authorized service personnel may perform machine installations.
TRAINING
Envipco will conduct training for the machine attendants. All machine attendants and the store managers
should attend this training session. The topics include: general operation, installing paper in the printer,
removing and replacing the full bags or bins, performing minor troubleshooting, care and cleaning of the
machine, access levels to the machine, and performing minor safety inspections.

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BAR CODE A graphical representation of a product number that a bar code scanner can read. North
America uses the 12-digit Universal Product Code (UPC) standard, and Europe uses the 13-digit European
Article Numbering (EAN) standard.
BAR CODE DATABASE A list that is stored on the RVM controller, which contains the bar codes the
machine accepts. There is one table for all commodity types.
BINS Containers located in the bottom section of the FLEX LS cabinet that stores the commodity.
COMPACTOR A device that reduces the volume of the redeemed containers.
COMMODITY Flattened containers processed through the FLEX LS machine.
CUSTOMER Refers to the user of the FLEX LS that is redeeming bottles and cans.
DIVERTER A device used to separate containers based on color or material type.
DOOR INTERLOCK Software in the RVM controller that shuts down power to the compactor when the
machine’s doors are open. This can only be overridden by a technician using a maintenance key switch.
EAN European Article Numbering standard of bar codes, which has 13 digits and is used outside of the
USA and Canada.
ENVIPCO Environmental Products Corporation.
HARNESS A bundle of wires that carry power and data between the machine components.
IDENTIFICATION LABEL Label on the back of the FLEX LS that gives vital information about the machine,
including its part number, model number, date of manufacture, and power requirements.
INFEED UNIT The acceptance mechanism of the FLEX LS, which includes a metal chassis, three scanners,
sensors, and light curtain.
LCD Liquid Crystal Display, which is installed in all RVMs. It displays messages such as “insert container”
and “out of service”. Its messages are useful for diagnostics.
MONITOR ROM This software boots the RVM and starts the RVM software.
PARAMETER A setting in the RVM that can be changed based on the needs and wishes of the retailer. For
example, the MAXPAY parameter defines how much money to accumulate before automatically paying
the customer.
GLOSSARY

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PET Polyethylene Teraphthalate, which is the plastic that is used to make drink containers.
PIN Personal Identification Number, which is used to access the service functions of the RVM.
RETAILER Refers to the “owner” of the FLEX LS, which is usually a grocery store.
REQUEST PAYMENT BUTTON The green button on the front of the FLEX LS, which the customers use to
request a voucher as payment.
RVM Reverse Vending Machine, which refers to the FLEX LS as a whole.
RVM CONTROLLER Computer that runs the software that is used to control the FLEX LS.
RVM CONTROLLER BOARD The main printed circuit board of the the RVM controller.
RVM SOFTWARE image file The main RVM software program that controls most of the machine’s
operations. It is started by the Monitor ROM.
SCANNER Laser device that reads the bar codes.
SERVICE MODE The RVM controller mode in which technicians can perform diagnostics and service the
machine. If a machine is in service mode, it will prevent calls to the regional service host.
UNATTENDED MODE The RVM controller mode that does not allow diagnostic functions or machine
service. In this mode, customers can redeem containers and the RVM can communicate through the site
control device to the regional service host. The machine should be in this mode whenever a technician is
not present.
UPC Universal Product Code, which is the standard bar code format for USA and Canada.
VOUCHER The printed ticket that the RVM gives to the customer in place of cash. The store gives the
customer cash or makes a charitable donation in exchange for the voucher.

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1.1. MACHINE DESCRIPTION
The FLEX LS provides an excellent solution for container recycling. While recycling bins are popular, users
often cause contamination by placing trash into bins. Also, they must be emptied frequently. The FLEX LS
solves these problems by sorting and compacting recyclable PET, aluminium and steel containers. It
rejects all other items.
FIGURE 11. FLEX LS DUAL PLASTIC & CANS  NO GLASS
PRINTER OUTPUT
PAYMENT BUTTON
LCD SCREEN
UPPER CABINET DOOR
COMMODITY CABINET DOOR
CONTAINER INFEED
CHAPTER 1 – Introduction & Safety
COMMODITY CABINET DOOR LOCK
UPPER CABINET DOOR LOCK

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FIGURE 12. FLEX LS TRI PLASTIC, GLASS & CANS
PRINTER OUTPUT
PAYMENT BUTTON
LCD SCREEN
UPPER CABINET DOOR
PET/CAN COMMODITY CABINET DOOR
CONTAINER INFEED
GLASS COMMODITY CABINET DOOR
LOWER DOOR LOCKS
UPPER DOOR LOCKS
UPPER SIDE CABINET DOOR

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1.1.1. PLACEMENT
The FLEX LS may be placed in a vending bank or next to single vending machines. The narrow width
conserves space, and its height matches that of vending machines.
1.1.2. USAGE
By design, the FLEX LS and FLEX LS Tri are easy to use. The LCD screen provides instructions and recycling
information to the user. The machine’s sponsor can request custom messaging on the LCD.
When a user approaches the machine with a used PET, aluminium, or steel beverage container:
1. The user places the container into the feed unit bar code up.
2. The conveyor moves the container into the machine.
3. As the container passes under the scanners, the scanners read the bar code.
4. While moving along the conveyor belt, the PET sensor determines if the container is PET plastic,
and the metal sensor determines if the container is an aluminium or steel can.
5. If the RVM rejects the container, the conveyor reverses to return the container back to the user. It
displays a message instructing the user to remove the container. The message also tells the user why
the container was rejected. The following are reasons for rejection:
• The materials sensors do not detect a steel or aluminium can or a PET plastic bottle.
• The bar code is readable but not in the RVMs database of acceptable containers.
• The scanner cannot read the bar code, because the container is damaged, missing a bar
code, or the bar code is not facing upwards.
6. If the container is acceptable, the conveyor moves the container into the sorting cylinder,
which turns to push the container into the compactor.
7. The compactor runs; the container is crushed.
8. The crushed container falls into the bin below.
9. The RVM gives credit to the user for the container.
1.1.3. SERVICE INTERRUPTIONS
If the FLEX LS malfunctions while servicing a customer and money is due to the customer, the FLEX LS
automatically pays the customer before going out of service. In the case of a power outage, the machine
retains the amount due to the customer. When the machine turns on, the customer can push the “request
payment” button to receive payment. The software prevents double payment if there is a machine
malfunction or machine shutdown. In the case of a printer malfunction, the amount due to the customer
will remain on the LCD until the printer problem is fixed and a receipt is printed.

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1.2. SAFETY BACKGROUND INFORMATION
Envipco is not responsible for any resulting damage or injury when unauthorized people perform
maintenance on the FLEX LS. Always lock the cabinet and remove the keys when you are finished working
on the machine.
This manual emphasizes safety with the use of warnings, cautions and notes:
• Warnings provide information which, if not followed, could result in injury or, in extreme
cases, even death.
• Cautions provide information which, if not followed, could cause damage to the
equipment.
• Notes highlight information or give additional data necessary to perform a test or step.
1.2.1. WARNING, CAUTION, AND NOTE SYMBOLS:
Warning Symbol
Caution Symbol
Note Symbol

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1.3. GENERAL SAFETY PRECAUTIONS
Always follow these safety precautions during all phases of installation, operation, service, and
maintenance of the FLEX LS:
WARNING!
This appliance is not intended for use by
persons (including children) with reduced
physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been
given supervision or instruction concerning use of
the appliance by a person responsible for their
safety. Children should be supervised to ensure
that they do not play with the appliance.
WARNING!
Mechanical components in the FLEX weigh
up to 400 pounds(200 kg). Always use
lifting devices to remove or replace components,
especially the compaction unit.
WARNING!
Never service the electrical components
while they are powered on, unless the
technical data specifically tells you to do so.
Always follow the technical data when servicing
the electrical components.
WARNING!
Never bypass a fuse in any of the FLEX
machines.
WARNING!
To prevent accidental operation that can
cause serious injury, only one person at
a time is permitted to work on or near the FLEX
during testing or maintenance of the compactors.
WARNING!
Use extreme caution when operating a
compactor with the doors open. Keep
your body and loose clothing well away from
moving parts.
WARNING!
Moving parts hazard in area of the rotating
sorter. Do not reach deep into the infeed shaft,
machine could tip forward and cause injuries.
WARNING!
Moving parts hazard in area of the diverter
flap. Do not reach deep into the infeed shaft.
WARNING!
Moving parts hazard in area of the infeed
belts and sorter. Do not reach deep into
the infeed shaft.
WARNING!
Moving parts hazard in the area of the
rotary compactor. Do not reach deep into
the infeed shaft.
WARNING!
Always remove the keys from the
machine when you are done with service.
If untrained people open the machine, they could
be seriously injured.
WARNING!
Never slide out the RVM controller when
the compactor is not installed in the FLEX. The
machine could tip forward and cause injuries.

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1.4. ELECTRICAL SAFETY
Avoid operating the machine while any cabinet door is open. When any of the cabinet doors are open,
use extreme caution while maintaining, cleaning, or performing service on the machine. To ensure that
the equipment continues to operate safely, Envipco performs a safety inspection at least every six months.
FIGURE 14. HIGH VOLTAGE WARNING LABEL  RVM CONTROLLER
DOOR INTERLOCK LABEL
DANGER LABEL

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1.4.1. ELECTRICAL SAFETY LABELS
High voltage labels warn against opening the RVM controller box or the AC motor control box.
Figure 1-5 shows the label that is displayed inside the front door of the machine.
FIGURE 15. HIGH VOLTAGE WARNING LABEL  RVM CONTROLLER
FIGURE 16. HIGH VOLTAGE WARNING LABEL  A/C MOTOR CONTROL BOX
HIGH VOLTAGE WARNING
HIGH VOLTAGE WARNING

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1.5. MECHANICAL SAFETY
For best performance, Envipco performs mechanical safety inspections every six months.
WARNING!
Use extreme caution when operating the compactor with the doors open.
Keep body and loose clothing well away from moving parts.
1.5.1. MECHANICAL SAFETY LABELS
Pinch point labels warn against hand hazards from the compaction unit. Figure 1-7 and Figure 1-8 show
the locations of these labels in the right and left side access panels of the FLEX LS machine.
FIGURE 17. SAFETY LABELS IN RIGHT SIDE ACCESS PANEL
KEEP HANDS AWAY WARNING
PINCH POINT WARNING

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FIGURE 18. SAFETY LABELS IN THE LEFT SIDE ACCESS PANEL
FIGURE 19. SAFETY LABEL INTAKE CONVEYOR
KEEP HANDS AWAY WARNING
PINCH POINT WARNING
KEEP HANDS AWAY WARNING

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FIGURE 110. SAFETY LABEL SIDE GLASS DIVERTER
FIGURE 111. SAFETY LABEL COMMODITY DOORS
KEEP HANDS AWAY FROM
MOVING PARTS WARNING

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FIGURE 112. SAFETY LABEL FRONT DOORS
WARNING Moving parts start automa�cally and may cause harm. Keep hands away from moving parts!
Do not insert hazardous materials, as they may cause fire or injury.
Las partes móviles se inician automá�camente y pueden causar daño. Mantenga las manos alejadas de las piezas móviles!
No introduzca materiales peligrosos, ya que pueden provocar un incendio o lesiones.
MOVING PARTS SAFETY LABEL
WARNING
Moving parts start automa�cally and may cause harm. Keep hands away from moving parts!
Do not insert hazardous materials, as they may cause fire or injury.
Las partes móviles se inician automá�camente y pueden causar daño. Mantenga las manos alejadas de las piezas móviles!
No introduzca materiales peligrosos, ya que pueden provocar un incendio o lesiones.

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2.1. INTRODUCTION
This section is the primary source of information for the retailer, but it is not the only source of
information. Maintenance technicians and supervisors are ready to answer questions, give assistance, or
provide information on the use, care, and operation of the FLEX LS and FLEX LS Tri machines.
Access to the service area is restricted to persons having knowledge and practical experience with this
appliance, in particular as far as safety and hygiene are concerned.
2.2. CLEANING
Envipco recommends the following cleaning tasks are performed daily to keep the FLEX LS running
smoothly between maintenance visits:
CAUTION!
Using harsh cleaners and abrasives to clean the FLEX LS will damage the surfaces. Use hot soapy
water or a good quality Ammonia Free light detergent.
WARNING!
Do Not attempt to move the sorter unit or gain access to the compaction device. Keep hands
away from the compactor, intake chute, and discharge area.
WARNING!
Do Not attempt to clean this appliance with a waterjet. Always follow the cleaning instruction.
• Cabinet - Clean the cabinet to maintain a neat and clean appearance.
• In-feed area - Clean any syrup and debris that is on the conveyor.
• Scanners - Clean and dry the scanner lens using a soft microfiber cloth.
• Bins - Sweep up any debris from the floor when the bins are removed.
• Sensors - Clean the bin full sensor lens, PET sensors, feed sensors, monitor screen and reflectors
with a soft microfiber cloth and AMMONIA FREE light detergent. Always spray cleaners on the
cloth when cleaning.
SEE FIGURES 21 FOR THE LOCATION OF COMPONENTS TO BE CLEANED
CHAPTER 2 – Maintenance & Service

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FIGURES 21 COMPONENTS TO BE CLEANED
BELTS
CAN BINPET BIN
SENSORS
REFLECTORS
3 SCANNERS

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SERVICING THE FLEX LS
2.3. EMPTYING BINS
All FLEX LS models track the amount of commodity in the bins one of two ways.
1.) Bin full sensors will bring the machine out of service until the full bins are emptied.
2.) The FLEX LS and FLEX LS Tri can be set to go “Bin full by count” after a predetermined num-
ber of containers have been processed. Do the following to clear counts after the full bins
have been emptied:
• Open the upper door
• The Info screen appears. See Figure 2-3
• Press the ‘Clear bin’ button to clear bin count as
shown in Figure 2-3
• Close all doors and the machine will return to
custom ‘holdscreen’.
FIGURE 23. CLEAR BIN FULL BY COUNTS