Envipco U48DFF Service Manual Download

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ULTRA Series Service Manual

May 6, 2014

Summary of Contents for U48DFF

Page 1: ...ULTRA Series Service Manual May 6 2014...

Page 2: ......

Page 3: ...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...

Page 4: ...ed 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...

Page 5: ...sholds 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 R...

Page 6: ...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 Control...

Page 7: ...s 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...

Page 8: ...ration 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 Slid...

Page 9: ...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 t...

Page 10: ...he 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 clea...

Page 11: ...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...

Page 12: ...rforming 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 l...

Page 13: ...terlock 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...

Page 14: ...tor 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...

Page 15: ...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...

Page 16: ...Chapter 1 Introduction Safety 1 8 FIGURE 1 9 Pinch Point Label Locations Rear Access Panel Pinch Point Labels...

Page 17: ...del 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 Configuration...

Page 18: ...Chapter 2 Specifications 2 2 FIGURE 2 2 ULTRA 48 Configuration...

Page 19: ...o 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 Pla...

Page 20: ...ntainer 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 di...

Page 21: ...nd makes updates to the machines when necessary The ULTRA also keeps track of the brands and number of containers that the machine processes Envipco s Data Accounting System DAS uses this data to pay...

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Page 23: ...oduction This section describes all of the hardware components of the ULTRA See Figure 3 1 for a view of the main components of the ULTRA 48 and Figure 3 2 for a view of the main components of the ULT...

Page 24: ...and a door interlock sensor The number and size of the lower commodity bins depends on the RVM s config uration The cabinets can be installed in a free standing through the wall or recessed configurat...

Page 25: ...the top rear of the cabinet Since the glass bins are shorter than the can and PET bins a glass machine s bin full sensor is installed in a lower position than in the can and PET machines 3 2 2 2 ULTRA...

Page 26: ...ities Thereisonehead for every two commodity cabinets Each head has a rear access panel to allow service of the components in the rear The commodity cabinets have levelers to facilitate installation a...

Page 27: ...3 5 Sensor Tunnel FIGURE 3 4 Sensor Tunnel Left Side View FIGURE 3 5 Sensor Tunnel Right Side View...

Page 28: ...r as if it was one larger scanner This scheme provides a wide scanning range to find a container s bar code without having to take the time to rotate the container See Figure 3 4 to see the location o...

Page 29: ...ing a beam of light through the container and receiving the dis torted beam on the other side If the container is PET the receiver recognizes its light pattern The RVM uses this information for sortin...

Page 30: ...n 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...

Page 31: ...up with one of the plates the Sorting Cylinder is in the correct position to accept a container This positionisknownas the index position FIGURE 3 9 Rear Feed Rear View Note InFigure 3 9 theSortingCyl...

Page 32: ...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 PET Compactor The AC motor turns three shafts one for the pad...

Page 33: ...s 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...

Page 34: ...it Six car bide tipped screws in the top of the frame puncture bottles that do not fall flat into the unit A proxim ity sensor monitors the crusher speed by monitoring the RPM of the large gear on the...

Page 35: ...e commodity counts and customer payout data 3 7 1 RVM Controller Box Electrical Components The RVM Controller Box contains electrical components that power the RVM electronics See Figure 3 13 for an o...

Page 36: ...tart its shutdown program The PC starts its shutdown program after ten seconds The shutdown process saves the RVM data so there is not any loss of data 4 Even after the PC shuts down the battery still...

Page 37: ...X Sensor Scanner Array power to the scanners display and the In Feed sensors Rear Conveyor power to the rear conveyor In Feed power to the In Feed rollers and conveyor LED power to the In feed LED lig...

Page 38: ...tronic components of the RVM Controller Box These items are described in the sections below FIGURE 3 15 RVM Controller Box Electronic Components 3 7 2 1 PC Board The PC board is a Mini ITX circuit boa...

Page 39: ...a detailed discussion of how these boards work in concert with the RVM software See Section 4 7 Software Theory of Operation on page 4 21 MC1 Board controls the safety interlock and the compactor See...

Page 40: ...Chapter 3 Hardware Components 3 18 FIGURE 3 17 MC1 Board Layout FIGURE 3 18 MC5 Board Layout...

Page 41: ...3 19 RVM Controller Box FIGURE 3 19 MD5 Board Layout...

Page 42: ...rinter Assembly 3 7 2 5 Video Display The display is a 10 4 inch VGA monitor with touch screen When the machine is ready to accept containers it gives instructions to the user The RVM may also be conf...

Page 43: ...hich control the two compactor motors FIGURE 3 21 ULTRA 48 AC Motor Control Box Components 3 8 1 Terminal Block This component receives the incoming single phase AC power from the power cord It is loc...

Page 44: ...tion 6 3 VFD Status Messages on page 6 5 3 8 3 Compactor 230V Three Phase Connector This is the output for the 230V three phase power The harness that provides power to the compactor motor plugs into...

Page 45: ...itch this to the Off position it takes about 10 seconds for the power to drain from the VFD The compactor may still be in motion during this time frame In the ULTRA HDS this switch removes power from...

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Page 47: ...o be configured to require a PIN Once in this mode store personnel may review machine information re print a receipt and clean the In Feed conveyors and rollers Service Mode This mode starts once the...

Page 48: ...Technician Interface gives quick access to the most common tasks Diagnostic Program gives access to Actuators Sensors and Thresholds Configuration editor allows advanced users to edit the RVM s confi...

Page 49: ...n It gives quick access to routine service tasks on the RVM Each number in Figure 4 2 corresponds to the list below 1 Download Q File This option saves the Q File to your jump drive When you tap this...

Page 50: ...nts Dialog Box 3 Upload Barcodes Use this option to search the Jump Drive for the RVM s bar code table and upload it to the machine It uploads the appropriate file for that particular machine based on...

Page 51: ...n Section 4 4 on page 4 7 6 Edit Parameters This option is not yet implemented 4 3 3 Exiting Service Mode ToexitServiceMode gototheTechnicianInterfacescreen andtapReleaseJumpDrive Youwillthen see a bu...

Page 52: ...Chapter 4 RVM Software 4 6 FIGURE 4 6 Service Mode Time Out Screen...

Page 53: ...ives an overview of ULTRA s software processes Each column provides options for a different process It displays the version of each process and some options for each The Save Config and Quit buttons a...

Page 54: ...printer by removing and restoring power to it Reset soft Resets the printer s software 4 4 2 Misc Tab The Misc tab shown in Figure 4 8 gives the following options Touchscreen options You can Re apply...

Page 55: ...ns for the processes controlled by the MC1 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 Thresh...

Page 56: ...orward and Reverse buttons are gray by default Toactivatethesebuttons insertandturntheinterlockoverridekey andthenpress the receipt button Once active you can use the buttons to run the compactor for...

Page 57: ...e Sorting Cylinder Use the Left Bin button to move the Sorting Cylinder in the clockwise direction Use the Right Bin button to turn it in the counter clockwise direction Barcode Rollers Refers to the...

Page 58: ...The Multidrop Bus MDB uses the RS 485 serial protocol On the MDB each client board MC1 and MC5 has a hexadecimal number assigned to it This tab allows you to Detect Clients Get Client List Re Initial...

Page 59: ...nd SaveAs buttons to load and save configurations in other locations To load a configuration file tap on the desired file and click the Load button that is on or next to the file name as shown in Figu...

Page 60: ...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 FIGURE 4 15 Edit Configuration Entry To ad...

Page 61: ...n example Figure 4 16 shows all of the sensors controlled by the MC1 Board See Table 4 1 on page 4 16 for the full list of MC1 sensors and Table 4 2 on page 4 17 for the full list of MC5 sensors In th...

Page 62: ...whether MC1 detects an under voltage on the 24V circuit SAFETY_CUTOFF_24V Reports OK if all of the open door sensors are closed CIRCUIT_BREAKER_1 Compactor 1 trip status SAFETY_OVERRIDE Set when safet...

Page 63: ...in cabinet bin reset button status ANALOG_INPUT_1 Optional analog input Not currently in use COMPACTOR1_BLOCKED Compactor 1 stall status as inferred by MC1 COMPACTOR1_PADDLE Compactor 1 paddle block a...

Page 64: ...his from sensor input MATERIAL_GLASS Reports whether glass is detected MC5 infers this from sensor input _SENSOR_INPUT1 Reserved input _SENSOR_INPUT2 Reserved input _SENSOR_INPUT3 Reserved input _RESE...

Page 65: ...o state change from decoder wheel COMPACTOR1_PADDLE paddle sync time not used yet 20130222 COMPACTOR1_TIMEOUT compactor auto switch off duration COMPACTOR1_STARTTIME suppress blocked detection on sta...

Page 66: ...outside of the machines When a site connects to Envipco any of the RVMs can act as a site controller If connected by cellular modem data transfers occur even if one or more of the RVMs cannot connect...

Page 67: ...h cellular modem is simplified by this summary 1 The RVM reaches its connection time It collects QFiles and logs from all of the RVMs that it can connect with 2 After a certain wait time it packages a...

Page 68: ...Chapter 4 RVM Software 4 22 FIGURE 4 18 Software Processes Overview...

Page 69: ...4 23 Software Theory of Operation FIGURE 4 19 Circuit Board Locations...

Page 70: ...play Process communicates with the display 3 Printer Process The Printer Process communicates with the printer 4 Hardware Process The Hardware Process directs all of the other hardware in the RVM thro...

Page 71: ...ce 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: ...e ments that are possible This not only helps with future PM but it also improves the overall appearance of the machine 5 3 1 Cleaning Mode At each visit run Cleaning Mode to clean the Feed Belt Rolle...

Page 73: ...soft terry cloth and mild detergent 3 To minimize the appearance of scratches wax the lens with carnauba wax 4 Wash the metal portions of the exterior with a rag and hot soapy water Then rinse and dr...

Page 74: ...w these steps 1 Go into the Diagnostic Program 2 Switch to the Misc tab 3 Tap on Calibrate 4 Follow the on screen prompts 5 3 6 Printer Follow these tips to keep the printer in working order Keep the...

Page 75: ...n the feed belt and rollers using Cleaning Mode See Section 5 3 1 Cleaning Mode on page 5 2 2 Clean the scanner windows with glass cleaner and a soft cloth Do not use any other cleaner on the scanner...

Page 76: ...con nectors 5 3 9 Rear Feed Follow these steps to keep the Rear Feed in working order 1 Clean the Sorter Belt using Cleaning Mode See Section 5 3 1 Cleaning Mode on page 5 2 2 Make sure that the belt...

Page 77: ...ver spray If you see any dripping there is too much lubricant on the gear 3 Inspect all of the carbide tips to check that they are in place and tight 4 Turn the power on and turn on the door interlock...

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Page 79: ...d connections If that fails replace the RVM controller 9005 Hardware Init Cabinet not closed RVM not operational Close all Doors The RVM will not operate because the safety interlock is activated Adoo...

Page 80: ...power If this error persists there may be a problem with the compactor or the AC motor 9018 Compactor 1 jammed RVM not operational Contact Envipco Support The RPM sensor on compactor 1 detected that t...

Page 81: ...to a certain number of containers before going into this state Empty the bins 9220 All bins full Call Staff Bin full sensors are blocked for all bins Empty the bins 9300 Printer Error Call Staff Gener...

Page 82: ...ed elevator isn t working Check for jams Inspect the harnesses Test the In Feed Actuators with the Diagnostic Program Ultra 48 Service Mode 9703 Feed Ctrl Error Sorter failed Contact Envipco Support T...

Page 83: ...lythe ribbon cable that connects the two sides of the light curtain across the Sensor Tunnel Test it with the Diagnostic Program Ultra 48 Sensors 9711 Feed Ctrl Error PET Sensor 1 Contact Envipco Supp...

Page 84: ...tion button until it is set to VGA Check that the data and power harnesses are secure If the picture is off center use the Diagnostic Program Misc Touchscreen to calibrate the screen If the touch scre...

Page 85: ...power switch in the off position and the cover off screw the new RVM Controller Box into the machine 15 Screw the existing hard drive into the new RVM Controller Box 16 Screw new RVM Controller Box t...

Page 86: ...Chapter 6 Troubleshooting Repairs 6 8 FIGURE 6 2 Slide Printer Forward FIGURE 6 3 Printer Placed on the Front of its Mounting Bracket...

Page 87: ...place the carbide tips on the crusher bars follow these steps 1 Using a roll punch push the screw out of the crusher bar 2 Put some green Loctite on the new tip 3 Push it in If you need to replace the...

Page 88: ...ip in the proper position according to the chain s direction of rotation See Figure 6 5 FIGURE 6 5 Master Link Clip Placement 6 5 4 Sensor Replacement Certain sensors need to be configured when you in...

Page 89: ...ange the Show drop box to Sensors 3 Find the PET sensor in the list 4 Remove the PET sensor back cover revealing the PET sensor adjustment screws Refer to Figure 6 6 5 Set the sensor for dark operatio...

Page 90: ...e sensor out of the holder 4 Thread the replacement sensor into position until it makes contact with either the gear tooth or the plate whichever is applicable Back out to the appropriate clear ance d...

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