Envipco U48DFF User manual

ULTRA Series Service Manual

May 6, 2014

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............................................................ 1-5

1.5.3 Mechanical Safety ....................................................... 1-6

Chapter 2

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

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

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

2.1.2 ULTRA Configurations .............................................. 2-1

2.1.3 ULTRA Specifications................................................. 2-3

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

2.2 Operating the ULTRA ............................................................... 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....................................................................................... 3-2

3.2.1 Door Interlock ............................................................ 3-2

3.2.2 Bin Full Sensor............................................................ 3-3

3.2.3 ULTRA and ULTRA 48 Cabinets .............................. 3-3

3.2.4 ULTRA HDS Cabinet ................................................ 3-4

3.3 Sensor Tunnel ............................................................................ 3-4

3.3.1 RGB LED Light.......................................................... 3-6

3.3.2 Scanners ...................................................................... 3-6

3.3.3 Motorized Conveyor and Rollers................................. 3-6

3.3.4 Materials Sensors......................................................... 3-7

3.3.5 PET Sensor ................................................................. 3-7

3.3.6 Light Curtain .............................................................. 3-7

3.4 Rear Feed.................................................................................... 3-8

3.5 Compactors ................................................................................ 3-10

3.5.1 PET Compactor.......................................................... 3-10

3.5.2 Can Compactor .......................................................... 3-11

3.5.3 Glass Compactor......................................................... 3-12

3.6 Bins ............................................................................................ 3-12

3.7 RVM Controller Box.................................................................. 3-13

3.7.1 RVM Controller Box Electrical Components.............. 3-13

3.7.2 RVM Controller Box Electronic Components ............ 3-16

3.8 AC Motor Control Box .............................................................. 3-21

3.8.1 Terminal Block ........................................................... 3-21

3.8.2 Variable Frequency Drive............................................ 3-21

3.8.3 Compactor 230V Three-Phase Connector .................. 3-22

3.8.4 208-240V Single-Phase AC Power Output ................. 3-22

3.8.5 Safety Loop Override .................................................. 3-22

3.8.6 Compactor Motor Disconnect .................................... 3-23

3.8.7 Mechanical Counter.................................................... 3-23

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.................................................................... 4-7

4.4.1 Processes Tab .............................................................. 4-7

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................................................................. 4-12

4.4.6 Config Tab.................................................................. 4-13

4.5 Sensors and Thresholds............................................................... 4-15

4.5.1 Sensors ........................................................................ 4-15

4.5.2 Thresholds .................................................................. 4-18

4.6 RVM Communications .............................................................. 4-19

4.6.1 Physical Connections .................................................. 4-20

4.6.2 File Transfers............................................................... 4-20

4.7 Software Theory of Operation .................................................... 4-21

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 In-Feed Unit ............................................................... 5-5

5.3.9 Rear Feed .................................................................... 5-6

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

Contents

5.3.11 Bin Overflow Sensors .................................................. 5-7

5.3.12 Scanners ...................................................................... 5-7

Chapter 6

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

6.1 Introduction ............................................................................... 6-1

6.2 ULTRA’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 Glass Crusher Repair................................................... 6-9

6.5.3 Chain Replacement..................................................... 6-10

6.5.4 Sensor Replacement .................................................... 6-10

i

List of Figures

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

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

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

Door Interlock Label...................................................................................................1-5

Compactor Motor Disconnect Label...........................................................................1-6

Moving Parts Warning Label ......................................................................................1-6

Moving Parts Warning Label Location........................................................................1-7

Pinch Point Label........................................................................................................1-7

Pinch Point Label Locations (Rear Access Panel).........................................................1-8

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

ULTRA 48 Configuration ..........................................................................................2-2

ULTRA 48 Main Components ...................................................................................3-1

ULTRA HDS Main Components...............................................................................3-2

ULTRA 48 Cabinet ....................................................................................................3-4

Sensor Tunnel (Left Side View)...................................................................................3-5

Sensor Tunnel (Right Side View) ................................................................................3-5

Conveyors and Rollers.................................................................................................3-6

Light Curtain Sensor Array .........................................................................................3-7

Rear Feed Front View .................................................................................................3-8

Rear Feed Rear View...................................................................................................3-9

PET Compactor..........................................................................................................3-10

Can Compactor ..........................................................................................................3-11

Glass Compactor.........................................................................................................3-12

RVM Controller Box Electrical Components..............................................................3-13

RVM Controller Box Connectors ...............................................................................3-15

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

PC Board Layout ........................................................................................................3-17

MC1 Board Layout.....................................................................................................3-18

MC5 Board Layout.....................................................................................................3-18

MD5 Board Layout.....................................................................................................3-19

Printer Assembly .........................................................................................................3-20

ULTRA 48 AC Motor Control Box Components.......................................................3-21

Variable Frequency Drive............................................................................................3-22

Shop Mode .................................................................................................................4-2

Technician Interface (Default) ....................................................................................4-3

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

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

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

Service Mode Time Out Screen ..................................................................................4-6

Diagnostics - Processes Tab.........................................................................................4-7

Diagnostics - Miscellaneous Options Tab ...................................................................4-9

List of Figures

ii

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

Diagnostics - Ultra-48 Tab .........................................................................................4-11

Actuators Controlled by the MC5 Board ....................................................................4-12

Diagnostics - RS-485 Tab ...........................................................................................4-12

Diagnostics - Config Tab ............................................................................................4-13

Loading a Configuration File ......................................................................................4-14

Edit Configuration Entry ............................................................................................4-14

Main tab - Sensors ......................................................................................................4-16

MC1 Thresholds.........................................................................................................4-19

Software Processes Overview .......................................................................................4-22

Circuit Board Locations ..............................................................................................4-23

Open Door Screen ......................................................................................................5-2

Hecon X56 Printer......................................................................................................5-5

RVM Controller and Printer.......................................................................................6-7

Slide Printer Forward ..................................................................................................6-8

Printer Placed on the Front of its Mounting Bracket...................................................6-8

Hard Drive Location...................................................................................................6-9

Master Link Clip Placement........................................................................................6-10

PET sensor side view (cover removed).........................................................................6-11

Example of the sensor spacing on a gear ......................................................................6-12

1-1

Chapter 1

Introduction & Safety

1.1. Foreword

Welcome to ULTRA. The most versatile reverse vending machine on the market today, ULTRA’s flexible

design, modern user interface, high capacity, and ultra-fast container processing make it an attractive

solution for any redemption center.

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

Envipco’s ULTRA series of reverse vending machines. Always refer to this manual when performing these

tasks.

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.

1.3. Users

This section defines the terms that refer to the people who interact with the ULTRA and their level of

access to the machines.

Warning!

Service and most maintenance tasks are the sole responsibility of

Envipco and should only be performed by Envipco or other authorized

maintenance personnel.

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 the equipment.

Note:

Notes highlight information or give additional data necessary to per-

form a test or step.

Chapter 1 Introduction & Safety

1-2

1.3.1. Customer

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

interaction with the 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

ULTRA.

1.3.2. Sponsor

The “sponsor” refers to the owner or lessee of the ULTRA. In US states with bottle deposit laws, the

ULTRA’s 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.

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 printer paper

• maintains the supply of printer paper and commodity bags

• empties the commodity bins

• initiates service calls

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

empty the commodity bins.

1.3.4. Service Technician

A service technician is trained by Envipco to maintain and repair the ULTRA. No other person shall

repair or perform internal maintenance on the ULTRA.

Warning!

The sponsor, along with the machine attendants and service techni-

cians, are responsible for ensuring that both cabinet doors are locked

and secure while customers have access to the machines.

Warning!

Envipco is not responsible for damages or injuries incurred when unau-

thorized repairs are performed on the ULTRA.

1-3

Safety precautions

1.4. Safety precautions

Safety for customers, machine attendants, and service technicians is paramount in the design and con-

tinuing development of the ULTRA. Read this manual carefully, and follow all of the safety rules that it

provides.

Warning!

Never use an extension cord to supply power to the ULTRA. The ULTRA

must be plugged into a proper receptacle. If you do not have the 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 compo-

nents.

Warning!

Mechanical components in the ULTRA 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 one

person at a time is permitted to work on or near the ULTRA during test-

ing or maintenance.

Warning!

Always remove the keys from the machine when you are done with ser-

vice. If untrained people open the machine, they could be seriously

injured.

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.

Chapter 1 Introduction & Safety

1-4

1.5. Safety labels

This section provides the details of all of the warning labels that are on the ULTRA.

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

ULTRA is a CDRH Class 1 device. The label shown in Figure 1-1 shows that the ULTRA meets Class 1

criteria.

FIGURE 1-1. Laser Compliance Label

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 techni-

cians. The label in Figure 1-2 gives the appropriate warning. Figure 1-3 shows the location of the laser

danger label.

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.

CLASS I LASER PRODUCT

CHAPTER I SUBCHAPTER J

PN 300406

U.S. DHHS STANDARD 21 CFR

PRODUCT COMPLIES WITH

1-5

Safety labels

FIGURE 1-2. Laser Danger Label

FIGURE 1-3. Safety Label Locations

1.5.2. Electrical safety

When you open the doors of the ULTRA, 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 Interlock Label

#81+&&+4'%6';'':21574'

1RGPCPF+PVGTNQEM

(CKNGFQT&GHGCVGF

.CUGT4CFKCVKQP9JGP

Door Interlock

Label

Laser Danger

Label

Chapter 1 Introduction & Safety

1-6

The ULTRA 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.

FIGURE 1-5. Compactor Motor Disconnect Label

1.5.3. Mechanical Safety

ULTRA’s moving parts can cause injury if they are 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

shows its location on the inside of the lower cabinet door.

FIGURE 1-6. Moving Parts Warning Label

Warning!

Always turn the Compactor Motor Disconnect Switch to the OFF posi-

tion before performing service on the ULTRA.

1-7

Safety labels

FIGURE 1-7. Moving Parts Warning Label Location

Two pinch-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 Point Label

Keep Hands Out

War nin g

Chapter 1 Introduction & Safety

1-8

FIGURE 1-9. Pinch Point Label Locations (Rear Access Panel)

Pinch Point

Labels

2-1

Chapter 2

Specifications

2.1. General Specifications

ULTRA is Envipco’s series of high speed reverse vending machines. There are three main configurations:

ULTRA 48, ULTRA HDS, and ULTRA HDS 48.

2.1.1. Serial Label

The configuration of an ULTRA is listed on its serial label. The serial label is located on the right side of

the cabinet. Figure 2-1 is an example of a serial label. It is a label for an ULTRA 48 Can Machine.

FIGURE 2-1. Example Serial Label

ULTRA model numbers follow this scheme:

• U48MF - ULTRA Can Flattener

• U48PF - ULTRA PET Flattener

• U48GC - ULTRA Glass Crusher

• U48GSD - ULTRA Glass Soft Drop

• U48DFF - Dual Can/PET flattening ULTRA

2.1.2. ULTRA Configurations

There are three main configurations of the ULTRA: ULTRA 48, ULTRA HDS, and ULTRA HDS 48.

ULTRA 48 is a standard capacity RVM that is compliant with the Americans with Disabilities Act (ADA).

Figure 2-2 shows the overall configuration of the

ULTRA 48. The ULTRA HDS is the high capacity ver-

sion of the ULTRA. The ULTRA HDS may accept up to two commodity types per top (or “head”) cabi-

net. All configurations of the

ULTRA HDS have large lower cabinets and commodity bins.

Chapter 2 Specifications

2-2

FIGURE 2-2. ULTRA 48 Configuration

2-3

General Specifications

2.1.3. ULTRA Specifications

Table 2-1 lists the specifications for the three configurations of the ULTRA: the ULTRA 48, ULTRA HDS,

and ULTRA HDS 48.

TABLE 2-1. ULTRA Specifications

ULTRA 48 (ADA) ULTRA HDS ULTRA HDS 48 (ADA)

Overall

dimensions

74"h × 32"w × 42"d

187.96 cm × 81.28 cm ×

106.68 cm

82.5"h × 100"w × 54"d

209.55 cm × 254.00 cm ×

137.16 cm

77.5"h × 100"w × 56"d

196.85 cm × 254 cm ×

142.25 cm

Weight

1,020 pounds (463 kg) 1,800 pounds (817 kg) 1,800 pounds (817 kg)

Power

• 208-240VAC 3Ø, 60HZ, 20A

service,

NEMA L15-20R recep-

tacle (

STD)

• 400

VAC 3Ø, 50HZ, 3A ser-

vice

• 208-240

VAC 3Ø, 60HZ, 20A

service

NEMA L15-20R recep-

tacle (

STD)

• 400

VAC 3Ø, 50HZ, 3A ser-

vice

• 208-240

VAC 3Ø, 60HZ, 20A

service

NEMA L15-20R recep-

tacle (

STD)

• 400

VAC 3Ø, 50HZ, 3A ser-

vice

Container

size

• Plastic - up to 3L

• Aluminum - up to 1L

• Glass - up to 1.3L

• Plastic - up to 3L

• Aluminum - up to 1L

• Glass - up to 1.3L

• Plastic - up to 3L

• Aluminum - up to 1L

• Glass - up to 1.3L

Speed

Up to 42 containers per minute Up to 42 containers per minute Up to 42 containers per minute

Bin

capacity

• Cans: 3,244

• Plastic bottles: 942

• Glass bottles (soft drop): 199

• Glass bottles (crushed): 485

• Cans: 10,000

• Plastic bottles: 2,333

• Glass bottles (soft drop): 1,283

• Cans: 9,200

• Plastic bottles: 2,036

• Glass bottles (soft drop): 1,120

Data

connection

LAN interface (Ethernet TCP/IP) LAN interface (Ethernet TCP/IP) LAN interface (Ethernet TCP/IP)

Materials

accepted

• aluminum/steel

•

PET

• glass

• aluminum/steel and

PET

• glass

• aluminum/steel and

PET

• glass

Scanners

Ring laser scanner system Ring laser scanner system Ring laser scanner system

Compactor

options

• Can-WAVE

• PIN-PET

• Glass crusher or glass soft-drop

• Can-

WAVE

• PIN-PET

• Glass soft-drop

• Can-

WAVE

• PIN-PET

• Glass soft-drop

Optional

equipment

• Loyalty card reader

• Audible or visual alert

• External alarm

• Loyalty card reader

• Audible or visual alert

• External alarm

• Loyalty card reader

• Audible or visual alert

• External alarm

Chapter 2 Specifications

2-4

2.1.4. Power Requirements

Table 2-2 shows the power requirements by RVM model. All models receive single-phase power from

the outlet, regardless of whether the outlet is three-phase or single-phase.

2.2. Operating the ULTRA

The ULTRA is easy to use. The display gives instructions and recycling information to the customer. The

illuminated In-Feed changes color: It is green when the machine is ready to accept containers and red

when the customer should not insert containers.

2.2.1. Usage

When a customer approaches the machine with a used beverage container:

1. The customer places the container into the In-Feed.

2. The front conveyor moves the container into the machine.

3. As the container passes under the scanners, the scanners read the bar code. If the

scanners cannot read the bar code, rollers turn the container to find the bar code.

4. While moving along the conveyor belt, a PET sensor determines if the container is

PET plastic, and a metal sensor determines if the container is an aluminum or steel

can.

5. If the RVM rejects the container, the conveyor reverses to return the container to

the customer. It displays a message instructing the customer to remove the con-

tainer and gives the reason for rejection. The following are reasons for rejection:

• The ULTRA does not accept that type of container. For example, a machine

that only accepts PET will not accept glass.

• The scanner cannot read the bar code, because the container is damaged or

does not have a bar code.

• The bar code is readable but not in the RVM’s database of acceptable contain-

ers.

• If the user inserted more than one container at a time, the RVM rejects the

containers.

TABLE 2-2. RVM Power Requirements

Product Voltage (VAC) Amperage (A) Frequency (Hz)

ULTRA 48 Can RVM 208/240V 1-phase 7 60

ULTRA 48 PET RVM 208/240V 1-phase 7 60

ULTRA 48 Glass Crush RVM 208/240V 1-phase 3.5 60

ULTRA 48 Glass Soft Drop RVM 208/240V 1-phase 1 60

ULTRA 48 Can/PET RVM 208/240V 1-phase 7 60

ULTRA HDS Can/PET RVM 208/240V 1-phase 10 60

ULTRA HDS Glass Soft Drop RVM 208/240V 1-phase 1 60

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Envipco U48DFF, U48GC, U48GSD, U48MF, U48PF, ULTRA Series User manual

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