Envipco FLEX Series User manual

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
i

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
ii

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.

1
-
2
Chapter 1
Introductio
n
&
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 US 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 .

1-3
Safet
y
precautions
1.4. Safety precautions
Safety for customers, machine attendants, and service technicians is paramount in the design and
continuing development of the FLEX . Read this manual carefully, and follow all of the safety rules
that itprovides.
Warning!
Never use an extension cord to supplypower to the FLEX . The FLEX
must be plugged into a proper receptacle. If you do not havethe
correct receptacle or if it is damaged, notify store personnel.
Warning!
Never service the electrical components while they are powered on.
Always follow the technical data when servicing the electrical
components.
Warning!
Mechanical components in the FLEX weigh up to 400 pounds.
Always use lifting devices to remove or replace components.
Warning!
To prevent accidental operation that can cause serious injury, only
oneperson at a time is permitted to work on or near the FLEX during
testing or maintenance.
Warning!
Always remove the keys from the machine when you are done with
service. If untrained people open the machine, they could be
seriouslyinjured.
Warning!
Do not reach into the In-Feed unit while the machine is in operation. If
you must reach into the machine, open the top door first. Opening a
door activates the safety interlock, which stops all moving parts.

1
-
4
Chapter 1
Introductio
n
&
Safety
Warning!
Use extreme caution when operating a compactor with the doors
open. Keep your body and loose clothing well away from moving
parts. Make sure that no one else is near the machine during this
process.
Warning!
Do not allow water to come in contact with the electrical components.
Warning!
Use gloves and eye protection when opening and emptying a glass
machine. Glass dust can cause eye injury.
1.5. Safety labels
This section provides the details of all of the warning labels that are on the FLEX .
1.5.1. Laser safety
The US Food and Drug Administration requires the inclusion of laser safety information and
labels, pursuant to 21 CFR , Chapter 1, Subchapter J, Laser Product Performance Standard, Section
1040.10 (h).There is no possibility of exposure to laser radiation during machine operation.
Therefore, the FLEX is a CDRH Class 1 device.The label shown in Figure 1-1 shows that the FLEX
meets Class 1 criteria.
FIGURE 1-1 Laser ComplianceLabel
When performing the scanner maintenance tests, it is possible to be exposed to HeNe (633 nm)
laser radiation levels up to Class IIIa.This maintenance test is only performed by Envipco service
technicians.The label in Figure 1-2 gives the appropriate warning. Figure 1-3 shows the location of
the laser danger label.
PRODUCT COMPLIES WITH
U.S. DHHS STANDARD 21 CFR
CHAPTER I SUBCHAPTER J
CLASS I LASER PRODUCT
PN 300406

1-5
Safet
y
labels
FIGURE 1-2. Laser DangerLabel
Laser Radiation When
Open and Interlock
Failed or Defeated.
AVOID DIRECT EYE EX OSURE
FIGURE 1-2.1. High Voltage Warning Label
FIGURE 1-3. Safety LabelLocations
DOOR INTERLOCK
LABEL
LASER DANGER
LABEL
FLEX DFF
FLEX DFF/GDS
HIGH VOLTAGE
WARNING
LABEL

1
-
6
Chapter 1
Introductio
n
&
Safety
FLEX HDS
LASER DANGER
LABEL

1-7
Safet
y
labels
1.5.2. Electrical safety
When you open the doors of the FLEX ,the safety interlock switches off the power to the motors.
However, the machine itself still has power. The door interlock label in Figure 1-4 gives the
appropriate caution. See Figure 1-3 for the location of the door interlock label.
FIGURE 1-4. Door InterlockLabel
DOOR INTERLOCK
LABEL
FLEX HDS
HIGH VOLTAGE
WARNING
LABEL

1
-
8
Chapter 1
Introductio
n
&
Safety
The FLEX contains high voltage components in the AC Motor Control Box.Therefore, it has a label
warning of its danger. Figure 1-5 shows the warning. See Figure 1-3 for the exact location of this
label.
Warning!
Always turn the Compactor Motor Disconnect Switch to the OFF
position before performing service on the FLEX .
FIGURE 1-5. Compactor Motor DisconnectLabel
1.5.3. Mechanical Safety
FLEX ’s moving parts can cause injuryif theyare operating while the doors are open.The following
warnings are meant to prevent injuries. Figure 1-6 shows the moving parts warning label. Figure 1-
7 showsits location on the inside of the lower cabinet door.
FIGURE 1-6. Moving Parts WarningLabel

1-9
Safet
y
labels
FIGURE 1-7. Moving Parts Warning LabelLocation
Twopinch-point labels warn that moving parts can injure your hands. Figure 1-8 shows the pinch-
point label. Figure 1-9 shows where these labels are located.
FIGURE 1-8. Pinch PointLabel
Keep Hands Out
Warning

1
-
10
Chapter 1
Introductio
n
&
Safety
FIGURE 1-9. Pinch Point/Keep Hands Away Label Locations
Right Access Panel
Left Access Panel
FLEX DFF
FLEX DFF/GDS
FLEX DFF
FLEX DFF/GDS
1-10

1-
11
Safet
y
labels
Intake Conveyor
Side Glass Diverter
FLEX DFF/GSD ONLY
FLEX DFF
FLEX DFF/GDS
FLEX HDS
1
-
11

1
-
12
Chapter 1
Introductio
n
&
Safety
FLEX HDS ONLY
REAR PANEL
FLEX HDS ONLY
LEFT PANEL
PINCH POINT
WARNING LABEL
KEEP HANDS AWAY
WARNING LABEL
1
-
12