FKI Tech Info

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D8X Only
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D8C Vend
Max Vend
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Max Vend Electrical
D8C Electrical
V1/V2 Electrical
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D8C Vend Assembly
D8X Vend Assembly
Hopper System
MEI 3900 Validators
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JCM Validators

Parts Lists
Max Vend
V1/V2
D8C
D8X

AuditLok XLV Max Vend Hopper System

Theory of Operation

Max Vend is equipped with four or six hoppers depending on the model. One wheel assembly is used for pennies, nickels and dimes and another is used for quarters and tubes (other wheel hardware may be used for certain foreign coins such as Canadian $1 and $2 coins). All hoppers operate the same regardless of wheel size. The wheel assembly is belt driven by a DC motor mounted under the storage chute. Each notch in the wheel assembly grabs a coin roll or tube as it rotates through the storage chute section. When the wheel turns, the coin roll or tube at the exit chute rolls out from the front of the hopper assembly. As it does, it triggers a pair of reflective optic sensors which verify the vend. On one side of the wheel assembly, a small earth magnet is mounted next to each notch. As the wheel rotates, a magnetic sensor mounted to the hopper case detects wheel rotation. These optic and magnetic sensors allow the Hopper Board to control motor action and accurately track and report vending activity.

Max Vend Hopper Diagram

Hopper Replacement

In most cases it is necessary to remove a hopper from the safe in order to replace any of the components on the hopper.
1. Open the door.
2. Slide out the desired hopper shelf.
3. Reach behind the desired hopper and disconnect the hopper harness.
4. Remove the two hex-bolts (3/16 Allen wrench required) from under the front end of the hopper.
5. Slide the hopper forward and lift it off the shelf.
6. Reverse these steps to install a hopper.

Can to Hopper Cable Harness

One 8-wire harness runs from each hopper to the Hopper Board. All harnesses run bundled together around the rear wall of the safe from the can to the shelves. Three harnesses run in a set through a common retracting conduit on each shelf. The retracting conduit protects the harnesses when the shelves are pulled in and out. All harnesses are replaced as a complete set.

Max Vend Harness Routing

Hopper Cable Harness

This 8-wire harness installed on the hopper is partially armored where the harness runs along the outside surface of the hopper. The red/black pair run to the motor and connect via pressure-fit spades. The Orange/Purple pair run to the magnetic sensor pin-connector. The sensor is mounted on the inside surface of the hopper case. The yellow/green and white/green pairs connect to the sensor board mounted on a bracket over the exit chute.

Hopper

Belt Replacement

1. Remove the hopper (see Hopper Replacement procedure above).
2. Remove all rolls or tubes from the hopper.
3. Remove the nose and sensor cover brackets.
4. Remove the pulley guide plate.
5. Loosen the motor mount nuts.
6. Slide the belt off the motor pulley.
7. Remove all remaining screws from the right side of the hopper then remove and set aside the right side wall from the hopper.
8. Remove the old belt from the wheel assembly.
9. Put the new belt over the first hub of the wheel assembly.
10. Slide the belt onto the motor pulley.
11. Replace the right wall, sensor cover bracket, and nose bracket.
12. Proceed to Belt Tension Adjustment Step 4.

Hopper

Wheel - Magnet - Sensor Replacement

1. Remove the hopper (see Hopper Replacement procedure above).
2. Remove all rolls or tubes from the hopper.
3. Remove the nose and sensor cover brackets.
4. Remove the pulley guide plate.
5. Loosen the motor mount nuts.
6. Slide the belt off the motor pulley.
7. Remove all remaining screws from the right side of the hopper then remove and set aside the right side wall from the hopper.
8. Lift the wheel assembly out of the hopper.
9. Repair or replace the wheel assembly (transfer the belt), shim or replace defective magnet, or replace the magnetic sensor as needed.
10. Insert the axle into the left wall axle bushing.
11. Slide the belt onto the motor pulley.
12. Replace the right wall, sensor cover bracket, and nose bracket.
13. Proceed to Belt Tension Adjustment Step 4.

Motor Replacement

1. Remove the hopper (see Hopper Replacement procedure above).
2. Disconnect the motor wires.
3. Remove the pulley guide plate.
4. Loosen the motor mount nuts.
5. Slide the belt off the motor pulley.
6. Remove the motor bracket.
7. Loosen the pulley set screw and slide the pulley off the motor shaft.
8. Remove the motor from its bracket and replace, but do not tighten the motor mount nuts.
9. Replace the pulley and tighten the pulley set screw.
10. Replace the motor bracket.
11. Slide the belt onto the motor pulley.
12. Reconnect the motor wires.
13. Proceed to Belt Tension Adjustment Step 4.

Belt Tension Adjustment

1. Remove the hopper (see Hopper Replacement procedure above).
2. Remove the pulley guide plate.
3. Loosen the motor mount nuts.
4. Using your right hand, reach into the cavity over the motor and pull the motor until the belt is tight.
5. Tighten the motor mount nuts with your left hand.
6. After the motor mount nuts are tight you may release the motor and extract your hand.
7. Rotate the wheel by hand. It should be difficult but not impossible to turn, with no belt slippage.
8. Replace the pulley guide plate.
9. Replace the hopper (see Hopper Replacement procedure above).
10. Verify operation.

Optic Sensor Replacement

1. Remove the hopper (see Hopper Replacement procedure above).
2. Remove the nose and sensor cover brackets.
3. Disconnect the sensor wire at the 4-pin connector.
4. Remove the sensor bracket.
5. Remove the sensor board from the bracket.
6. Mount the new sensor board to the bracket.
7. Replace the bracket.
8. Replace the nose and sensor cover brackets.
9. Replace the hopper (see Hopper Replacement procedure above).
10. Verify operation.

Hopper Vend Test

Before performing testing basic operation each hopper must have rolls/tubes (physically and via software Load procedure). You may test vending with the door open by holding in the interlock switch during the entire operation. To verify proper vending operation: vend one roll/tube from each hopper, one hopper at a time. Ensure the correct hopper vends, verify only one roll/tube is vended, and check each receipt for correct information.
Wrong Hopper Vends: The most likely cause is incorrect cable connections at the Hopper Board.
No Motor Response: If one motor does not energize: check for a loose harness connection at the Hopper Board, at the rear of the hopper, or a loose motor wire connection. If no motors energize: check the power supply, interlock switch, and Hopper Board fuse continuity. The interlock switch is normally open (it is closed when the door is closed).
Motor Runs, No Rolls/Tubes Vended: Check for physical blockage. Check belt tension and wear.
Hopper Empty: When the hopper is physically empty, the output sensor is unable to detect a tube/roll exiting. The motor will run for up to seven seconds or until a tube/roll is detected at the exit chute. The obvious symptom is that no change is vended. If no tube/roll is detected, the vend receipt will not charge the user for the amount not received and the vend receipt will indicate that the amount actually vended did no match the request. If the hopper count reaches zero, it will not attempt to vend even if it has tubes/rolls.
Motor Runs Seven Seconds: If the motor runs normally for about 7 continuous seconds and more than one roll/tube is vended, the problem is either the magnetic sensor or the optic sensor (or a sensor wire).
Extra Change Vended: If one or more extra tubes/rolls vend, there is a problem with output sensor. If the hopper motor consistently runs the full seven seconds (vending multiple tubes/rolls), the sensor board probably needs to be replaced. If it only happens intermittently, the problem is more likely to be a false reflection.

Optic Sensor Test

The best way to test an optic sensor board is to take one (that is known to work) from a different hopper and swap it for the suspect sensor board. If the known good sensor solves the problem, replace the defective sensor board.

Magnetic Sensor Test

Disconnect the cable harness to the hopper. Check continuity of the magnetic sensor at its connector leads. When a magnet at least partially in front of the sensor you should measure closed. When the wheel is rotated until the sensor is between magnets you should measure open. If the sensor does not ever indicate closed and the wheel magnets appear to be installed properly, replace the magnetic sensor. If at least some magnets cause the switch to close but one or more do not, check the gap between the sensor and the magnets. It may be necessary to use a washer to shim the magnet closer to the sensor. If the gap is no more than an eighth of an inch and the sensor still does not detect a magnet but does detect other magnets, replace the magnet.

Sensor Cable Test

If the magnetic sensor check is good and installing a known good optic sensor board does not solve the problem, check continuity of the cable harness by swapping connections at the hopper board. If the problem moves with the cable, the harness is defective. If the problem remains with the hopper, check continuity of individual wires on the hopper.

Intermittent Vending Errors

Check for chipped paint on what should be flat black surfaces on the wheel and on the hopper in the area near the optical sensors. Check belt tension. Check sensor cable continuity. Check optic and magnetic sensors.

Hopper Board LED's & Connectors

The Hopper Board manages hopper operation under the direction of the CPU. The following describes items on the Hopper Board:
DS1 LED: Main PIC Communication Indicator.
DS2 LED: Main PIC Heartbeat.
DS3 LED: Motor 2 On.
DS4 LED: Motor 1 On.
DS5 LED: Motor 4 On.
DS6 LED: Motor 3 On.
DS7 LED: Motor 6 On.
DS8 LED: Motor 5 On.
DS9 LED, DS10 LED: unused.
DS11 LED: FPGA Communication Indicator.
DS12 LED: Heartbeat.
DS13 LED: Analog PIC Communication Indicator
JP1: 3-pin jumper port. A two-pin shunt must be installed at J1 connecting the pins closest to the fuse (pins 2 & 3) to enable RS232 communication with the CPU assembly via J13. Pins 1 & 2 enable RS485 (J11) communication which is not used by the CPU.
JP2: unused.
J1: Factory programming only.
J2: Factory programming only.
J3: Hopper 3 cable harness.
J4: Hopper 1 cable harness.
J5: Hopper 4 cable harness.
J6: Hopper 3 cable harness.
J7: Hopper 6 cable harness.
J8: Hopper 5 cable harness.
J11: RS485 CPU control (unused).
J13: RS232 CPU control.
J14: Power input from external transformer.
J15: Interlock switch.
J16: Power output to CPU.
J17: Factory programming only.
FC1 Fuse: Field replaceable 15A 250V fuse.
SW1 Switch: unused.