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Hamilton Hopper HSH, Hopper HSH-60Q, Hopper HSH-A, Hopper HSH-XT-Q, Hopper SMART User manual

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Document #101-0240 1 04/22/2013
Hamilton Hopper Manual
Document #101-0240 2 04/22/2013
CONTENTS
ABOUT THIS MANUAL ................................................................3
I. INTRODUCTION .................................................................................................... 4
II. CAPACITY .............................................................................................................. 5
III. OPERATION ......................................................................................................... 6
IV. LOADING AND UNLOADING ........................................................................... 7
To Fill Hopper ............................................................................................................................7
To Empty Hopper .......................................................................................................................7
V. MAINTENANCE .................................................................................................... 8
VI. TROUBLESHOOTING ........................................................................................ 9
VII. SMART HOPPER TROUBLESHOOTING ................................................... 10
VIII. HOPPER RUN TEST ........................................................................................11
Hamilton Hopper .....................................................................................................................11
Smart Hopper ...........................................................................................................................11
Diagram A ................................................................................................................................12
IX. SMART HOPPER HANDHELD ....................................................................... 13
Dispensing Coins .....................................................................................................................13
Show Counters .........................................................................................................................14
Clear Counters .........................................................................................................................14
Errors ........................................................................................................................................15
HAMILTON HOPPER .............................................................................................. 16
Hamilton Hopper Assembly .....................................................................................................17
Hamilton Hopper Assembly Chart ...........................................................................................18
Hamilton Hopper Wiring Harness ...........................................................................................19
SMART HOPPER ...................................................................................................... 20
Smart Hopper Assembly ..........................................................................................................21
Smart Hopper Assembly Chart ................................................................................................22
Smart Hopper Wiring Harness .................................................................................................23
HOPPER BOWL ........................................................................................................ 24
Hopper Bowl Assembly ...........................................................................................................25
LIMITED WARRANTY AGREEMENT OF HAMILTON MANUFACTURING CORP. ......... 26
Document #101-0240 3 04/22/2013
ABOUT THIS MANUAL
This manual will provide the operator with important information about installing and maintaining
the Hamilton Smart Hopper. To obtain assistance from the manufacturer, please call (800) 837-5561
or (419) 867-4858.
When calling for assistance, it is very important to have serial numbers readily available. Please
record these numbers in the spaces provided. It is important to account the serial numbers for each
hopper.
Hopper Model #________________________________________
Hopper Serial #_________________________________________
Please complete the warranty card, which was included with your machine, and return it to the
manufacturer.
Document #101-0240 4 04/22/2013
I. Introduction
The Hamilton Hopper was not only designed for large quantities of coins, it was also designed to withstand
the most rugged of environments. The hopper contains minimal moving parts for reduced wear, virtually zero
adjustments, and an all Lexan® and stainless steel construction to weather the harshest of environments. The
Hamilton Hopper comes in many different congurations for dispensing a variety of coins and metal tokens.
Among the possibilities are coins that range in size from the small U.S. dime to the large 1 1/8” token. Many
foreign coins will also work in the Hopper. It is important to specify what type of coin is to be dispensed when
ordering so the correct conguration will be shipped to you.
Document #101-0240 5 04/22/2013
II. CAPACITY
Hamilton Mfg. Corp. produces several different styles of Hoppers to meet the varying demands of Hamilton
customers requirements. These Hoppers differ in holding capacity. The Hoppers are shown in the table below,
where it is assumed that quarters are being dispensed.
For all of these models, the Hopper reports that it is empty when the coins no longer cover the two sensing
plates in the bottom of the Hopper bowl. This usually occurs when there are approximately 70-125 quarter-sized
coins remaining. These numbers will vary depending on the actual coins remaining. These numbers will vary
depending on actual coin being dispensed. The HTK Smart Hopper also provides a low coin status. This status
occurs when only the long sensor is covered.
MODEL # QUARTERS $ QUARTERS CHANGER APPLICATION
HSH 4800 $1,200 Most Changers
HSH-A 3200 $800 Auto Cashiers
HSH-60Q 2400 $600 ER-60 Changers
HSH-XT-Q 8000 $2,000 2000V Changers
SMART 4800 $1,200 HTK ONLY
Document #101-0240 6 04/22/2013
III. OPERATION
To dispense the coins, the Hopper uses a Coin Wheel mounted to the Hopper Motor. This Coin Wheel is a round
disc with semi-circular cutouts arranged around the outer edge. As the wheel rotates with the motor, coins fall
into the cutouts and are lifted past the count switch and through the exit chute. If coins are picked up in every
cutout, a dispensing rate of 5 coins per second is achieved.
The Coin Counting Mechanism utilizes a pair of switches that are actuated by coins as they exit the Hopper.
One switch directly triggers the 120VAC counter mounted on the Hopper. The other switch manipulates the
controllers “Coin Drop” input. The normally closed contacts are opened as a coin passes under the switch. This
opening of the “Coin Drop” circuit is observed as a coin vends.
The Coin Level Mechanism takes advantage of the conductivity of metallic coins. Since the Coin Wheel is
connected to earth, and logic grounds through the case of the motor, a connection can be made from the Coin
Wheel through the coins to the stainless sensing that are connected to the Controller. When the coins no longer
touch the sensing strips, the circuit is open and the Hopper is observed as empty. When the Hopper does go
empty, there will still be approximately 70-125 quarter sized coins left in the Hopper Bowl. Note: this number
will vary based on the coin size being dispensed.
Diagram A on page 12 indicates where the “Manual Run” Toggle Switch is located. Also pictured in Diagram
A this the bracket that encases the Toggle Switch. There is also a thumbscrew that ts into this bracket and
prevents the switch from being activated. The thumbscrew must be removed and the Toggle Switch ipped to
its “ON” position. To stop the motor, turn the “Manual Run” Toggle Switch back to its “OFF” position and re-
insert the thumbscrew.
Note: In several of Hamilton’s changers the main harness has a single quick disconnect connector that disables
the hopper run switch. If the manual run switch is required connect connector, otherwise it is Hamilton’s recom-
mendation that the connector should remain disconnected when hopper run switch is not required.
The “Smart Hopper” has a few variations. The rst one is that the Smart Hopper only has “ONE” coin count-
ing this switch. This is the switch that manipulates the controllers “Coin Drop” input. The second switch on
the Smart Hopper is not required because there is no counter on the hopper. The other variation is there is no
“Manual Run” Toggle Switch, therefore shown on Diagram A on page 12 will show where to connect the Hand-
held. The Handheld function allows one to conduct a “Manual Run”, show counters, clear counters, and conduct
maintenance (clear errors).
Document #101-0240 7 04/22/2013
IV. LOADING AND UNLOADING
To Fill Hopper
To ll the Hopper with coins, tilt the Hopper partially towards you and insert the Hopper Load Rivet through
the hole in the Hopper bracket. (Refer to Diagram A on page 12). Pour coins into the top of the Hopper. Hop-
per may also be removed to be lled as well. Note: Hopper will become heavy when attempting to put Hopper
back in machine. Note: When lling hopper make sure the coin bafe is pushed down.
CAUTION! Use only clean , dry coins. Remove all debris from coins before
loading into Hopper.
To Empty Hopper
Tilt the Hopper all the way towards you and dump the coins into a container. Note: This process can make the
container heavy and hard to handle. Therefore, turn off power to machine,and disconnect harness. Then tilt
hopper back, while tilting back lift hopper rod out of hopper bracket. With the container on the oor dump
coins into container.
Document #101-0240 8 04/22/2013
V. MAINTENANCE
The plastic parts in the Hopper are formed of Lexan®. GE’s recommendation for cleaning the plastic parts is to
use normal household cleaners. DO NOT USE; gasoline, high alkaline solutions, benzene acetone, carbon
tetrachloride, methyl ketone, muraitic acid, or electrical contact cleaner as THEY WILL DAMAGE THE
PLASTIC.
CAUTION: This Hopper DOES NOT NEED TO BE OILED. Oil causes dirt
to accumulate and certain oils may damage the plastic components. Any lu-
brication in the Hopper can result in a faulty payout.
It is recommended that the Hopper is cleaned on a monthly basis,but this may vary depending on circumstances
and usage. Disassembly of the Hopper is required for proper cleaning.
CAUTION: Disconnect all power to the machine and remove the Hopper
before attempting any service.
To remove the Hopper from the machine and clean it, follow the steps below:
1. Empty all the coins from the Hopper.
2. Disconnect all power from the machine.
3. Unplug the Main Harness from the bottom of Hopper.
4. Tilt the top of the Hopper backwards slightly, then lift up and forward to remove the Hop-
per Assembly from the cabinet.
5. Use a Phillips screwdriver to remove (4 or 8) #8 x 1/4” self-tapping screws that hold the
cover on to the Outer Housing.
6. Note: If applicable remove the hopper rod (handle) by removing the (2) 1/4 x 20 screws.
7. Swing the Coin Bafe up and out of the Outer Housing.
8. Remove the Coin Bafe from the Outer Housing .
9. Sweep all debris out of the Hopper with a CLEAN paintbrush.
10. Dampen a cloth and apply a household cleaner to all surfaces inside the Coin Bowl.
Scrub if required.
11. Dampen a clean cloth and wipe up any remaining residue.
12. Reassemble the Coin Hopper and re-install into the machine.
13. Restore power to the machine.
Document #101-0240 9 04/22/2013
VI. TROUBLESHOOTING
SITUATION PROBABLE CAUSE CORRECTION
Wash prices set incorrectly Check wash prices
Perform HOPPER RUN TEST (See page 11)
Contact the manufacturer for assistance
Coin or foreign material lodged in HOPPER Clear obstruction in HOPPER
Broken connection in wire between
CONTROLLER and HOPPER motor
Locate and repair connection
Output missing from CONTROLLER Contact the manufacturer for assistance
Foreign material in HOPPER Remove foreign material
Output weak from CONTROLLER Contact the manufacturer for assistance
Wash prices set incorrectly Check wash prices
Coins fall back into HOPPER after counting Perform HOPPER RUN TEST (See page 11)
CPU misreads coin count Contact the manufacturer for assistance
Error detected by CONTROLLER
Check error message on CONTROLLER and refer to
CONTROLLER Manual.
HOPPER not counting coins
Underpayment of
change, CONTROLLER
does go into “OUT OF
SERVICE”
Overpayment of
change
HOPPER does not run
at all to pay back
change
HOPPER runs slowly
Underpayment of
change, CONTROLLER
does not go into “OUT
OF SERVICE”
Document #101-0240 10 04/22/2013
VII. Smart Hopper Troubleshooting
Handheld Port: This port allows a user to connect the Handheld to the hopper and clear an error. Note:
TXD: Sending Status of Hopper to Controller. The status can indicate that the hopper is idle or in an error state.
The TXD status led indicator is Green.
RXD: Controller is requesting the status of the hopper or is sending a command for a payout. The RXD status
led indicator is Red.
Empty 1: Displays that the status that the hopper is low. This can also be considered warning indicator. The
Empty 1 indicator is Yellow
Empty 2: Displays the status that the hopper is empty. This is considered a hard error and therefore, coins will
not be dispensed until issue is resolved. The Empty 2 indicator is Yellow.
Note: In this state both Empty 1 and Empty 2 will have their indicator led’s on.
Drop: Indicates the status of coin switch. In a normal state the led is off. When a payout is in progress the Drop
led will ash once for each coin that is dispensed from the Hopper. If a coin is stuck under the switch with the
switch in the up position the Drop indicator will stay on steady until issue is resolved. The Drop led indicator is
Yellow.
Address: This is pre-set by the factory when machine is built. The address dip switches denes the hopper ad-
dress which is critical when setting hopper contents and change rules in the controller. Example with all three
of the dip switches in the “Up” or “Off” position this denes the hopper with address 1. When dip switch 1 is in
the “Down” or “On” and the other two dip switches in the “Off” position this denes the hopper with address 2.
Diag: When the led is on solid there are no errors or in an idle state. When a Hopper error occurs the status of
the DIAG led will change from solid to ashing a number of times, followed by a short pause. The number of
ashes will indicate the error that has occurred. For example. The DIAG. will ash twice and then a short pause.
Flash twice again and a short pause. The 2 ashes indicate the error of unexpected coin drop. The DIAG led is
green
2 Flashes = Unexpected Coin Drop 3 Flashes = Hopper Coasting
4 Flashes = Hopper TimeOut 5 Flashes = Drop Switch Stuck 6 Flashes = Watchdog Reset
Power: This indicates that there is power at the Hopper. The Power led is Red
Document #101-0240 11 04/22/2013
VIII. HOPPER RUN TEST
The Hopper Run Test is a test that can be used to determine if a Hopper is counting coins correctly.
Hamilton Hopper
1. Obtain a large number of coins (500 if possible) that the Hopper is congured to
dispense, and count them carefully to determine the exact number of coins.
2. Empty Hopper completely and make note of the count on the Hopper’s mechanical
counter.
3. Dump in all of the counted coins and turn the Manual Run Switch to the “ON” position.
Run the Hopper until every coin has been dispensed.
4. Check to see if the Hopper’s mechanical counter matches the previous count plus the
number of coins that were just dispensed.
5. Repeat the test as necessary.
Smart Hopper
1. Obtain a large number of coins (500 if possible) that the Hopper is congured to dispense
and count them carefully to determine the exact number of coins.
2. Empty Hopper completely.
3. Connect Handheld to Hopper.
4. Press F2 to display “Show Counters”. Make note of the “Temp” number.
5. Dump in all of the counted coins
6. Press F1 to display “Manual Run” options.
7. Press F2 to determine the amount of coins to be dispensed in “Edit Dispense #”. Then
using the keypad numbers enter the amount of coins to be dispensed. (i.e. 250)
8. Press F1 to “Dispense XXX”
9. Hopper will dispense the selected amount of coins
10. Once dispensing is complete then Press F2 to display “Show Counters”
11. Check the “Temp” totals to verify the correct count.
Document #101-0240 12 04/22/2013
Diagram A
Document #101-0240 13 04/22/2013
IX. SMART HOPPER HANDHELD
This section will allow one to navigate through the handheld connected to a Smart Hopper to conduct one of the
following processes; dispense coins, display counters, clear counters, or clear errors.
Model:SmartHopper
Version:2.02
Address1
F1ManualRun
F2ShowCounters
F3ClearCounters
F4Maintenance
Dispensing Coins
PressF1forManualRun
Nextscreendisplay:
F1DispenseX
F2EditDispense#
F3Run15seconds
ESC=Back1-9
PressF1toDispenseX
Nextscreendisplays:
DispensingXcoins
Payoutcomplete
ESC=Back1-9F1=X
Pressing F1 again will dispense the same amount of coins. Pressing a number on the keypad from 1-9 will auto-
matically dispense that numeric value.
PressF2toEditDispense#
Nextscreendisplays:
CoinstoDispense
X
ESC=Back<=Enter=>
The value that can be added can be 0 to 250. Once your selection is complete select right arrow to save your
choice. Once one saves their choice this now populates F1 Dispense X. (i.e 250 coins now displays F1 Dispense
250).
Document #101-0240 14 04/22/2013
PressF3forRun15seconds
Nextscreendisplays:
RunMotor15Seconds
MotorisON
ESC=ABORT
Whenmotorstops.
Nextscreendisplays:
RunMotor15Seconds
MotorisOFF
ESC=Back
Show Counters
PressF2todisplaycounters
Nextscreendisplays:
TempCNT=XXX
PermCNT=XXX
Runtime=XXXXX
Clear Counters
PressF3toclearcounters
Nextscreendisplays:
ClearCounters
Areyousure(Y/N)?
PressYtoclearcounts
Nextscreendisplays:
CountsCleared!
Afteracoupleofsecondsthescreenwillautomaticallygobacktomainmenu
Note:Clearingcountsonlyclearsthe“TempCNT”.ThePermCNT’sarenon-resettable
PressNtonotclearcounts
Thescreenwillautomaticallygobacktomainmenu.
Document #101-0240 15 04/22/2013
Errors
PressF4forMaintenance
PressF2forErrorInfo
Nextpagedisplays:
MaxDrops=1
F2ErrorHistory
MaxDrops:Themaximumnumberofunexpectedcoinsdropsbeforetriggeringunexpectedpayouterror
PressF2forErrorHistory
Nextscreendisplays:
ERR2=X
ERR3=X
ERR4=X
ESC=Back<=Page=>
Selectingtheright>advancestothenextpage
Nextpagedisplays:
ERR5=X
ERR6=X
ESC=Back<=Page=>
ERR2=UnexpectedCoinDrop ERR3=HopperCoasting
ERR4=HopperTimeout ERR5=DropSwitchStuck
ERR6=WatchdogReset
PressF3toclearerror
PressingF3willautomaticallycleartheerrorontheHopper
Document #101-0240 16 04/22/2013
HAMILTON HOPPER
Document #101-0240 17 04/22/2013
Hamilton Hopper Assembly
Document #101-0240 18 04/22/2013
Hamilton Hopper Assembly Chart
Document #101-0240 19 04/22/2013
Hamilton Hopper Wiring Harness
Document #101-0240 20 04/22/2013
SMART HOPPER
/