FKI Tech Info

Operation
D8X Only
D8C Vend/Load/Unload
Drops & Buy Change
Door Operation
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D8C Vend
Max Vend
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Max Vend Electrical
D8C Electrical
V1/V2 Electrical
Power
Lock Systems
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

D8C Vend Assembly Service

Theory of Operation

The dispensing system consists of the plastic vend assembly, tube blocking bar and key lock, vend board, motor board, motors, output sensors, and associated cables. D8C units hold up to 80 tubes in the vending mechanism. Tubes are loaded through the openings near the top of the door. Fishing is prevented by a key operated tube blocking bar. Tubes are held in columns according to their value. The assembly has four DC motors. Each motor serves two columns. Optic sensors on the motor board detect motor travel. At rest the motor sensors should indicate the cup is centered between columns. Tubes are vended out to the dispensing tray at the bottom of the door. As tubes dispense they pass through and break an optic beam. This beam allows the safe to count tubes during an unload operation.

System Diagram:
D8C Vending System Electrical Diagram

Cup & Tube Motion During Vending Cycle:
Discharge Process

Cup Rotor Cap and Motor Sensor Detail:
D8 Rotor Cap

Vend Plastics Assembly Replacement

The vend assembly body parts are constructed using patented plastics technology for tight tolerances and long sturdy life. If the plastics break the entire assembly can be replaced. Observe static precautions at all times when handling electronics.
1. Open the outer door and activate the detent to prevent accidental closure.
2. Remove power from the safe.
3. Disconnect all RJ45 cables to the vend board.
4. Remove the blocking bar yoke.
5. Remove the four shoulder bolts holding the assembly to the safe door.
6. Pull the assembly off the door and set it on a static free mat.
7. Strip off electrical components from the old assembly and mount them on the new assembly.
8. Reverse the above steps to install the replacement assembly.
9. After reconnecting all cables, apply power and verify that the CPU detects the vend assembly and outer door lock board. If not, perform a Device Search. DO NOT close the safe door until you verify lock operation.

Tube Lock Hardware:
Tubelock

Tube Jam

A tube jam occurs when a motor is unable to complete its normal vend cycle. This is most often due to a tube or some foreign object being stuck inside a column such as when a tube falls in vertically. Before attempting to clear a tube jam by lifting tubes up and taking them out through the front of the safe be sure to remove Vend Board and set it aside to avoid input sensor damage. A vertical tube can be removed then by “walking” it up the column channel using a pair of long thin screwdrivers. Any horizontal tubes above the vertical tube (or whatever debris is blocking the channel) must be taken out through the front openings.

Vend Board Replacement

The Vend Board is mounted to the top of the vend assembly. Vend settings are stored in nonvolatile memory on the vend board. Input sensors face into the tube channels and are independently replaceable. Vend Power and Vend data cables (both are in the armored cable harness) connect to J2 and J3 on the left side of the vend board. Vend Power and Vend Data are interchangeable, but both must be connected for proper operation. The lock board data cable must be connected to Vend Board J4. A ribbon cable connects the Vend Board to the Motor Board to control the motors and sense cup position and output sensor status.
1. Open the outer door and activate the detent to prevent accidental closure.
2. Remove power from the safe.
3. Disconnect all RJ45 cables to the Vend Board.
4. Remove the Vend Board.
5. Install the replacement Vend Board.
6. After reconnecting all cables, apply power and verify that the CPU detects the vend assembly and outer door lock board. If not, perform a Device Search. DO NOT close the safe door until you verify lock operation.

D8 Vend Board

Input Sensors

Two “flag” type optic input sensors per column are mounted to the back of the Vend Board. Spring loaded flags allow the optic sensors to detect when a tube is loaded. Both sensors must activate in the proper order during the Load procedure in order to count. If an input sensors fails (broken flag, missing, etc), the safe will not count tubes when they are loaded. Check the load receipt and Cash Report to verify input sensor operation. If an input sensor is broken, bent out of position or is missing, the most likely reason is attempted fishing or failure to remove the Vend Board when fixing a tube jam. To replace an input sensor, remove the Vend Board and simply slide the defective sensor out of its socket and slide in the replacement sensor.

Input Sensor

Motor System

Four motors (12 VDC) are connected to the motor board. Polarity determines the direction of rotation. Each motor controls vending from two columns. The motor gear turns the rotor cup in the appropriate direction until a tube drops into the cup. The motor then turns the cup back to center and the tube drops out. A cap is mounted to the cup shaft where it extends through the motor board. The cap is notched so that it can indicate to a pair of optic sensors when the cup is at the center or end of travel positions. When the Vend Board powers up it initializes the motors by checking and/or setting the cups to their center “home” position.

Motors

The DC motors are mounted directly to the plastics assembly. The motor gear engages the cup rotor pinion. Motor wires are routed between the motor board and the plastics then plug into the corresponding jack on the motor board. Motors are operated by 12 VDC and they are polarity sensitive. For test purposes a standard 9 VDC battery may be used to attempt to move a motor. To move a rotor cup by hand, first remove the motor mounting screws and loosen the motor from the rotor.

Motor Board Cup Sensors

Optic sensors on the motor board track rotor cup movement to ensure proper operation. The rotor shaft cup extends through the motor board. A cap is installed on the end of the rotor shaft. This cap has a small notch on one side and a large notch on the other side. The small notch is used by one sensor to detect center “home” position and the large notch is used by the other sensor to detect the maximum travel limit. The shaft and cap are keyed to ensure correct alignment. The cap is pressure fit and anchored with a Phillips head screw. In the event a cup cap sensor fails, replace the motor board.

Motor Board

The motor board interfaces the motors, cup position sensors, and output sensors with the vend board. To replace the motor board disconnect the output sensors, motor wires, and the ribbon cable from the vend board. Remove each rotor cap and note which cap came from which rotor. Remove the anchor screws and replace the board. After reinstalling the screws, carefully reinstall the rotor caps. It works best if you put the same cap back on the same rotor. Reconnect all cables.

Output Sensors

The output sensor is made up of two small circuit boards mounted to either side of the vend assembly such that they hang from the bottom. One side transmits a beam of light across the empty space beneath the assembly and the other senses the beam. The purpose of the output sensor is to detect and verify when a tube is dispensed during a Vend or Unload event.

Unverified Vend

An output sensor problem (in rare cases a motor board problem) is indicated by the error message “Unverified Vend” on vend receipts when tubes do actually vend. Another indication is failure to detect tubes as indicated by the Unload receipt. An output sensor problem may be caused by sensor failure, improper sensor mounting, debris or dirt blocking the sensor receiver or transmitter, or a sensor wire problem. If the source of the problem cannot be determined by visual inspection, replace both sensor modules. Sensor modules are marked to avoid confusion as to which is which. Output sensor wires are connected to the motor board.