Envipco ULTRA Series Service Manual
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Envipco ULTRA Series Service Manual

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ULTRA Series Service Manual
May 6, 2014

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  • Page 1 ULTRA Series Service Manual May 6, 2014...

  • Page 3: Table Of Contents

    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 ...............
  • Page 4 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............
  • Page 5 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 ..............
  • Page 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..................

  • Page 7: List Of Figures

    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...
  • Page 8 List of Figures 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...

  • Page 9: Introduction & Safety

    Warning! Service and most maintenance tasks are the sole responsibility of Envipco and should only be performed by Envipco or other authorized maintenance personnel. 1.2. Symbols Used Warning symbols indicate the levels of danger involved with some of the procedures described in this manual.

  • Page 10: Customer

    ’s sponsor is usually a retailer that sells beverages that have container deposits. The sponsor is ULTRA 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 and printed vouchers.

  • Page 11: Safety Precautions

    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 . Read this manual carefully, and follow all of the safety rules that it ULTRA provides. Warning! Never use an extension cord to supply power to the .

  • Page 12: Safety Labels

    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...

  • Page 13: Electrical Safety

    Safety labels Laser Danger Label FIGURE 1-2. .CUGT 4CFKCVKQP 9JGP 1RGP CPF +PVGTNQEM (CKNGF QT &GHGCVGF #81+& &+4'%6 ';' ':21574' Safety Label Locations FIGURE 1-3. Door Interlock Label Laser Danger Label 1.5.2. Electrical safety When you open the doors of the , the safety interlock switches off the power to the motors.

  • Page 14: Mechanical Safety

    Chapter 1 Introduction & Safety contains high voltage components in the Motor Control Box. Therefore, it has a label ULTRA 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 posi- tion before performing service on the...

  • Page 15: Moving Parts Warning Label Location

    Safety labels Moving Parts Warning Label Location FIGURE 1-7. Keep Hands Out Warning 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. Pinch Point Label FIGURE 1-8.

  • Page 16: Pinch Point Label Locations (Rear Access Panel)

    Chapter 1 Introduction & Safety Pinch Point Label Locations (Rear Access Panel) FIGURE 1-9. Pinch Point Labels...

  • Page 17: Specifications

    Chapter 2 Specifications 2.1. General Specifications is Envipco’s series of high speed reverse vending machines. There are three main configurations: ULTRA , and ULTRA ULTRA HDS ULTRA HDS 2.1.1. Serial Label The configuration of an is listed on its serial label. The serial label is located on the right side of ULTRA the cabinet.
  • Page 18 Chapter 2 Specifications ULTRA 48 Configuration FIGURE 2-2.

  • Page 19: Ultra Specifications

    General Specifications 2.1.3. ULTRA Specifications Table 2-1 lists the specifications for the three configurations of the : the ULTRA ULTRA ULTRA HDS ULTRA HDS ULTRA Specifications TABLE 2-1. ULTRA 48 (ADA) ULTRA HDS ULTRA HDS 48 (ADA) 74"h × 32"w × 42"d 82.5"h ×...

  • Page 20: Power Requirements

    Chapter 2 Specifications 2.1.4. Power Requirements Table 2-2 shows the power requirements by model. All models receive single-phase power from the outlet, regardless of whether the outlet is three-phase or single-phase. RVM Power Requirements TABLE 2-2. Product Voltage (VAC) Amperage (A) Frequency (Hz) 48 Can 208/240...

  • Page 21: Container Accounting

    When done redeeming containers, the customer presses the payment button. The printer prints a voucher. 2.2.2. Container Accounting contains a list of acceptable beverage containers in a bar code database. Envipco gathers this ULTRA information from the machine’s sponsor and beverage distributors and makes updates to the machines when necessary.
  • Page 22 Chapter 2 Specifications Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________...

  • Page 23: Hardware Components

    Chapter 3 Hardware Components 3.1. Introduction This section describes all of the hardware components of the . See Figure 3-1 for a view of the ULTRA main components of the 48 and Figure 3-2 for a view of the main components of the ULTRA ULTRA ULTRA 48 Main Components...

  • Page 24: Cabinet

    Chapter 3 Hardware Components ULTRA HDS Main Components FIGURE 3-2. 3.2. Cabinet ’s cabinet comprises a top cabinet (also called the “head”) and the commodity storage cabi- net(s) below. The top cabinet houses the ’s In-Feed, Sorting Cylinder, compactor, and all of its elec- tronic and electrical components.

  • Page 25: Bin Full Sensor

    Cabinet 3.2.2. Bin Full Sensor To prevent commodity from overflowing the bins, each lower cabinet has a bin full sensor. If a sensor detects that a bin is full, the machine stops collecting the commodity whose bin is full. If the machine only collects one type of container, and its bin is full, the machine goes out of service and displays an appropriate message.

  • Page 26: Ultra Hds Cabinet

    Chapter 3 Hardware Components ULTRA 48 Cabinet FIGURE 3-3. 3.2.4. ULTRA HDS Cabinet cabinet is configured to meet the requirements of the sponsor. It has a minimum of ULTRA HDS one top cabinet (called the “head”) and two commodity cabinets on the bottom. The design is scalable: can be configured as a long row of s that collect all commodities.
  • Page 27 Sensor Tunnel Sensor Tunnel (Left Side View) FIGURE 3-4. Sensor Tunnel (Right Side View) FIGURE 3-5.

  • Page 28: Rgb Led Light

    Chapter 3 Hardware Components 3.3.1. RGB LED Light that is mounted to the front of the Sensor Tunnel gives the customer a visual cue of when RGB LED to insert containers: It turns green when the is ready to accept containers, and it turns red when the customer should stop inserting containers.

  • Page 29: Materials Sensors

    Sensor Tunnel 3.3.4. Materials Sensors By the time a container reaches the end of the front conveyor, it passes five retro-reflector materials sen- sors. As shown in Figure 3-4 on page 3-5, the emitters are lined up along the left side of the In-Feed, and the reflectors are across from the emitters along the right side of the In-Feed.

  • Page 30: Rear Feed

    Chapter 3 Hardware Components 3.4. Rear Feed The Rear Feed comprises the Sorting Cylinder and rear conveyor assemblies. The rear conveyor receives the container from the front conveyor belt. An aluminum sensor underneath the front of the rear con- veyor belt detects whether the container is aluminum. If the container is accepted, the Sorting Cylinder assembly turns to push a container into a compactor after the conveyor belt pulls it in.

  • Page 31: Rear Feed Rear View

    Rear Feed As shown in Figure 3-9, the rear of the Sorting Cylinder has a proximity sensor which detects the posi- tion of four metal plates arranged in a circle around the cylinder. When the sensor lines up with one of the plates, the Sorting Cylinder is in the correct position to accept a container.

  • Page 32: Compactors

    Chapter 3 Hardware Components 3.5. Compactors There are three different compactors: , can, and glass. The compactors can be run by a 208-240 3-phase motor, depending on the site requirements. Each compactor has a proximity sensor that monitors the speed of the rollers, allowing the rvm controller to calculate whether there is a sorter jam 3.5.1.

  • Page 33: Can Compactor

    Compactors 3.5.2. Can Compactor motor turns three shafts: one for the paddles that pull the cans into the compaction chamber, and two for the rollers that flatten the cans. The two rollers have a wave pattern stamped into them, which effectively flattens the cans. Figure 3-11 shows the Can Compactor. Can Compactor FIGURE 3-11.

  • Page 34: Glass Compactor

    Chapter 3 Hardware Components 3.5.3. Glass Compactor As shown in Figure 3-12, seven crusher bars transverse the crusher shaft. Each crusher bar has four car- bide-tipped screws (two on each side of the shaft) to concentrate pressure on the glass. When the shaft rotates clockwise, the crusher bars push the bottle against metal protrusions inside of the unit.

  • Page 35: Rvm Controller Box

    RVM Controller Box 3.7. RVM Controller Box Controller Box contains the computer components that run the machine. It governs machine activity and monitors the speed and safety of operation. Additionally, the hard drive stores all of the software and data that runs the machine and data accounting processes: the list of valid bar codes, parameters and configuration, the commodity counts, and customer payout data.
  • Page 36 Chapter 3 Hardware Components power supply - This is an uninterruptible power source ( ) for the • Controller. power supply - powers the scanners through the scanner • power supply - provides power to the printer and motors • Battery access panel - allows easy access to replace the backup battery •...

  • Page 37: Rvm Controller Box Connectors

    RVM Controller Box Power and Bus - receives power from the Motor Control Box • Sorting Cylinder - provides power to the Sorting Cylinder • Scanner - data connection for the Scanner • Sensor Scanner Array - power to the scanners, display, and the In-Feed sensors •...

  • Page 38: Rvm Controller Box Electronic Components

    Chapter 3 Hardware Components 3.7.2. RVM Controller Box Electronic Components Figure 3-15 shows the locations of the electronic components of the Controller Box. These items are described in the sections below. RVM Controller Box Electronic Components FIGURE 3-15. 3.7.2.1. PC Board board is a Mini- circuit board that performs data processing and communications and controls the hardware controller boards.

  • Page 39: Pc Board Layout

    RVM Controller Box PC Board Layout FIGURE 3-16. 3.7.2.2. Hard Drive The hard drive is connected to the board, and stores all of the ’s data, including the bar code table and counts, the software, and configuration. 3.7.2.3. Hardware Controller Boards These custom boards control the motors in the .
  • Page 40 Chapter 3 Hardware Components MC1 Board Layout FIGURE 3-17. MC5 Board Layout FIGURE 3-18. 3-18...
  • Page 41 RVM Controller Box MD5 Board Layout FIGURE 3-19. 3-19...

  • Page 42: Printer Assembly

    Chapter 3 Hardware Components 3.7.2.4. Printer has a Hecon 56 thermal printer with cutter. It prints payment receipts and may ULTRA be configured to print coupons. Printer Assembly FIGURE 3-20. 3.7.2.5. Video Display The display is a 10.4 inch monitor with touch screen. When the machine is ready to accept containers, it gives instructions to the user.

  • Page 43: Ac Motor Control Box

    AC Motor Control Box 3.8. AC Motor Control Box Motor Control Box houses the electrical components. Figure 3-21 shows the components and connectors of the Motor Control Box. The connectors that are used for development ULTRA and testing are not labeled. Motor Control Box differs in that it has two Variable Frequency Drives with corre- ULTRA HDS AC sponding fuse blocks, which control the two compactor motors.

  • Page 44: Compactor 230V Three-Phase Connector

    Chapter 3 Hardware Components amount of time, the shuts down power to the compactor motor. This functionality replaces the old mechanical motor protectors. It also soft-starts the compactor motor: it starts with a 0.5 second acceler- ation, which prolongs the life of the compactor motor. Variable Frequency Drive FIGURE 3-22.

  • Page 45: Compactor Motor Disconnect

    AC Motor Control Box 3.8.6. Compactor Motor Disconnect This switch controls the power going to the compactor motor through the Variable Frequency Drive. It does not remove power from the Motor Control Box or any other part of the machine. Also, note that after you switch this to the Off position, it takes about 10 seconds for the power to drain from the .
  • Page 46 Chapter 3 Hardware Components Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 3-24...

  • Page 47: Chapter 4 Rvm Software

    Chapter 4 RVM Software 4.1. Introduction series introduces new software and electronics hardware to Envipco’s s. There are three ULTRA software modes on the : Customer/Acceptance Mode, Shop Mode, and Service Mode. ULTRA Customer/Acceptance Mode - This refers to the software that runs and displays •...

  • Page 48: Service Mode

    Chapter 4 RVM Software Shop Mode FIGURE 4-1. 4.3. Service Mode Service Mode allows technicians to perform in-depth diagnostics and maintenance tasks on the To access this mode, the technician must have a pre-programmed drive (known as the Jump Drive) and a corresponding Service Mode comprises these programs: Technician Interface - gives quick access to the most common tasks.

  • Page 49: Using The Technician Interface

    Service Mode Technician Interface (Default) FIGURE 4-2. 4.3.2. Using the Technician Interface Figure 4-2 shows the default Technician Interface screen. It gives quick access to routine service tasks on Each number in Figure 4-2 corresponds to the list below: Download Q-File. This option saves the Q-File to your jump drive. When you tap this button, you see the dialog box pictured in Figure 4-3.

  • Page 50: Download Q-File Dialog Boxes

    Chapter 4 RVM Software . When the download is complete, you will see the message “The Q-File has been written to the memory stick.” Note: If the software count doesn’t match what you entered, you will get an error. In this case, check to make sure that your entry is correct. If it is correct, check the re-define meter check box, as shown in Figure 4-3.

  • Page 51: Exiting Service Mode

    Service Mode RVM Software. This option expands the Technician Interface to include advanced options to create and restore software backups and to upload new software. These options are described in Section 6 on page 4-5. Start Diagnostic. This option starts the Diagnostic Program, which is described in Section 4.4 on page 4-7.
  • Page 52 Chapter 4 RVM Software Service Mode Time Out Screen FIGURE 4-6.

  • Page 53: Diagnostic Program

    Diagnostic Program 4.4. Diagnostic Program The Diagnostic Program allows you to test components and configure the . The topics in this sec- tion correspond with the tabs in the Diagnostic Program: Processes • Misc • Main • Ultra-48 • RS-485 •...

  • Page 54: Misc Tab

    • the local area network and its connection to Envipco’s servers. The test takes up to 5 minutes, and a window pops up to show the communication statistics. Flash Firmware - Facilitates firmware updates of the circuit boards (Light Cur- •...

  • Page 55: Main Tab

    Diagnostic Program Diagnostics - Miscellaneous Options Tab FIGURE 4-8. 4.4.3. Main Tab The Main tab, shown in Figure 4-9, contains options for the processes controlled by the 1 board: safety interlock, compactor(s), relays, and lights. The default screen shows the options for the Actuators. Click on Actuators to switch to Sensors or Thresholds.

  • Page 56: Ultra-48 Tab

    Chapter 4 RVM Software Selected Client - Switches between the boards on the Multidrop Bus. M 1 is • found in the hexadecimal number range between 40 and 4 FW Version - Indicates the firmware version of the 1 board. •...

  • Page 57: Diagnostics - Ultra-48 Tab

    Diagnostic Program Diagnostics - Ultra-48 Tab FIGURE 4-10. Note: Check in the Service Mode box to use the actuator buttons. The following is a list of the Ultra-48 actuators: Feed Belt - Refers to the front feed belt. Use the buttons to advance the belt for- •...

  • Page 58: Tab

    Chapter 4 RVM Software Actuators Controlled by the MC5 Board FIGURE 4-11. 4.4.5. RS-485 Tab -485 tab contains the Hardware Process options. The Multidrop Bus ( ) uses the -485 serial protocol. On the , each client board ( 1 and 5) has a hexadecimal number assigned to it.

  • Page 59: Config Tab

    Diagnostic Program 4.4.6. Config Tab The Config tab allows advanced users to edit the ’s configuration files. Any changes that you save to the files in this tab are permanently written to the configuration files. Figure 4-13 shows the Config tab as it appears when you tap on it.

  • Page 60: Edit Configuration Entry

    Chapter 4 RVM Software Loading a Configuration File FIGURE 4-14. File Entry To edit an option, highlight the line and then click the Edit... button to the right. You will see the edit window, as shown in Figure 4-15. For entries that are integers, you can use the +10, +1, -10, or -1 but- tons to increase or decrease the value as desired.

  • Page 61: Sensors And Thresholds

    Sensors and Thresholds The Copy... button makes a duplicate of the selected entry, and the Delete button deletes the selected entry. Note: In order to save changes to the configuration file, tap the Save button and restart the software. To find an entry in the current file, enter some text in the field underneath the Find button. Then, click the Find button.
  • Page 62 Chapter 4 RVM Software Main tab - Sensors FIGURE 4-16. MC1 Sensors TABLE 4-1. Sensor Description BIN_A_FULL_SIDECAB Reports the status of the HDS bin full sensor. BIN_B_FULL_SIDECAB Reports the status of a second HDS bin full sensor (if one exists). RETURN_CHUTE Not used.
  • Page 63 Sensors and Thresholds MC1 Sensors TABLE 4-1. Sensor Description SAFETY_LOOP_BROKEN Set when any cabinet door is open (#1-#4). CAN_FLATENER1_POS_B Not used. CAN_FLATENER2_POS_B Not used. CAN_FLATENER2_POS_A Not used. CAN_FLATENER1_POS_A Not used. BAIL_OCCUPIED Not used. BUTTON3 Not used. BUTTON2 Not used. BUTTON1 Not used.

  • Page 64: Thresholds

    Chapter 4 RVM Software MC5 Sensors TABLE 4-2. Sensor Description SENSOR_ENTRY_2 Status of second material sensor. SENSOR_SCAN Status of third material sensor. SENSOR_EXIT_1 Status of fourth material sensor. SENSOR_EXIT_2 Status of fifth material sensor. ELEVATOR_UP Reports whether the rear feed elevator is up. ELEVATOR_DOWN Reports whether the rear feed elevator is down.

  • Page 65: Rvm Communications

    COMPACTOR2_TO_FAST shortest allowed time w/o state change from decoder wheel 4.6. RVM Communications This section describes how the s communicate with each other and with the servers at Envipco to do the following: 4-19...

  • Page 66: Physical Connections

    An internet connection facilitates the transfer of incoming and outgoing files between the s on site and the server at Envipco. One of the machines acts as a site control device: it receives files from Envipco and distributes them to the other...

  • Page 67: Software Theory Of Operation

    The software process by which QFiles and logs are collected from the s and sent to Envipco through cellular modem is simplified by this summary: reaches its connection time. It collects QFiles and logs from all of the s that it can connect with.
  • Page 68 Chapter 4 RVM Software Software Processes Overview FIGURE 4-18. 4-22...
  • Page 69 Software Theory of Operation Circuit Board Locations FIGURE 4-19. 4-23...
  • Page 70 Chapter 4 RVM Software Board is the “master” controller board of the machine. It is a Mini- board running the Linux operating system, and it is located in the Controller Box. It runs these software processes: The Main Control Process, the Diagnostic Program, the Printer Process, the Display Process, and the Hard- ware Process.

  • Page 71: Maintenance

    Notify your supervisor. To prevent the machine from becoming damaged or going out of service, Envipco can evaluate the problem and recommend corrective actions. Cleaning the machine is very important. Dirt and syrup are not only unattractive, but they can also interfere with machine operation.

  • Page 72: Store Responsibilities

    Chapter 5 Maintenance 5.2.2. Store Responsibilities The store is responsible for changing the printer paper and emptying the commodity bins. The store must not have access inside of the rear access panel of the machine. 5.3. Component Maintenance This section lists the tasks to do on each visit. In addition, do any extra cleaning or cosmetic improve- ments that are possible.

  • Page 73: Cabinet And Doors

    Component Maintenance Tap the Cleaning Mode icon (shown in Figure 5-1). The Feed Belt motor will start. Using a spray bottle, lightly spray the belt with hot water. Dry the belt with a towel. Tap the Cleaning Mode icon, and the Rollers will start turning. Using a spray bottle, lightly spray both rollers with hot water.

  • Page 74: Rvm Controller Box

    Chapter 5 Maintenance 5.3.4. RVM Controller Box Follow these steps to check that the Controller continues to function properly: Check that the cover is securely closed. • Clean the screen on the exhaust fan. If the machine processes glass, remove the •...

  • Page 75: Ac Motor Control Box

    Component Maintenance Hecon X56 Printer FIGURE 5-2. 5.3.7. AC Motor Control Box Visually inspect the power cord and receptacle for damage. If needed, replace the damaged parts or call for electrical service. 5.3.8. In-Feed Unit Follow these procedures to keep the In-Feed unit in working order: Clean the feed belt and rollers using Cleaning Mode.

  • Page 76: Rear Feed

    Chapter 5 Maintenance Clean the sensors, including emitters, receivers, and the reflectors with a soft cloth and glass cleaner. Calibrate the sensors: Hold down the calibration button for a few seconds until the indicator light starts blinking. Do not hold it any longer, or the sensor will enter programming mode.

  • Page 77: Bin Overflow Sensors

    Component Maintenance Dry out the bottom of the machine. Replace the storage bins. Make sure all components are dry before powering the machine. 5.3.10.1. Glass Crusher There are six grease-fitting points on the Glass Crusher: four in the front (bearing &...
  • Page 78 Chapter 5 Maintenance Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________...

  • Page 79: Troubleshooting & Repairs

    Check harnesses and connections. If that out after 30 seconds. fails, replace the controller. RVM not operational Contact Envipco Support 9001 Bus-Electronic is not responding No micro controllers were Check harnesses and connections. If that found on the system bus.
  • Page 80 Compactor 1 went into over- with the compactor or the motor. RVM not operational load and shut down the Contact Envipco Support compactor power. 9017 Breaker Compactor2 triggered The Variable Speed Drive for If this error persists, there may be a problem...
  • Page 81 Motor Control Box. RVM not operational onds. (Time limit is custom- ized) Contact Envipco Support 9120 Barcode Scanner Problem! The barcode scanner is not Check the scanner harnesses and the scanner responding. . Test the scanners with the Diagnostic...
  • Page 82 Cause Troubleshooting 9307 Printer Power Failure Printer does not have adequate Check the printer harness. power. RVM not operational Contact Envipco Support 9308 Printer No Response Printer communications error. Check the printer harness. RVM not operational Contact Envipco Support 9309 Printer Not connected or wrong Printer communications error.

  • Page 83: Vfd Status Messages

    Clean sensor lens and reflector. Calibrate sen- sor failure. sor. Test the sensor with the Diagnostic Pro- Light Sensor 5 gram (Ultra-48 / Sensors). Contact Envipco Support 9709 Feed Ctrl Error The receipt button has failed. Check if the button is jammed.

  • Page 84: Troubleshooting Other Conditions

    If you see any other error messages on the status display, contact Envipco. 6.4. Troubleshooting Other Conditions This section explains troubleshooting steps for conditions that do not result in an error message.
  • Page 85 Repairs Remove the cover for the Controller. Unplug the hard drive. Remove the hard drive from the Controller by unscrewing the mount from Controller Box. Take the hard drive out of the machine, and set it aside. Unplug the electrical and data wires from the Controller Box.
  • Page 86 Chapter 6 Troubleshooting & Repairs Slide Printer Forward FIGURE 6-2. Printer Placed on the Front of its Mounting Bracket FIGURE 6-3.

  • Page 87: Glass Crusher Repair

    Repairs Hard Drive Location FIGURE 6-4. 6.5.2. Glass Crusher Repair Warning! Make sure to disconnect power to the compactor before attempting any repairs. If the glass crusher stalls often, check that all of the carbide tips are present: Four on each crusher bar: two on each side of the shaft •...

  • Page 88: Master Link Clip Placement

    Chapter 6 Troubleshooting & Repairs Screw the nuts back on. 6.5.3. Chain Replacement If you need to replace a chain on a compactor or the Sorting Cylinder, follow these steps: Remove the chain cover, and position the chain so that the master link is in posi- tion on the upper chain sprocket.
  • Page 89 Repairs Press and hold the button for at least ten seconds. The light will switch from blinking rapidly to blinking slowly. Release the switch. The light should blink 5 times. Press the button three times. The sensor should now blink two times. The light stops blinking after about 15 seconds and then remains on.
  • Page 90 Chapter 6 Troubleshooting & Repairs its position and speed. Adjust the sensors to protect these components. The following table describes the locations of the proximity sensors: Proximity Sensor Locations TABLE 6-2. Component Proximity Sensor Location Clearance Can flattener Above gear ¾...
  • Page 91 Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-13...
  • Page 92 Chapter 6 Troubleshooting & Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-14...
  • Page 93 Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-15...
  • Page 94 Chapter 6 Troubleshooting & Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-16...
  • Page 95 Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-17...
  • Page 96 Chapter 6 Troubleshooting & Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-18...
  • Page 97 Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-19...
  • Page 98 Chapter 6 Troubleshooting & Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-20...
  • Page 99 Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-21...
  • Page 100 Chapter 6 Troubleshooting & Repairs Notes: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ 6-22...

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