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D8C
D8X

D8X 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. D8X 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 rotor cap 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

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. To remove the plastics disconnect the RJ45 cables from the can and lock board, disconnect the key harness, disconnect the tube lock yoke, remove the four shoulder bolts holding the assembly to the safe door, pull the assembly off the door and set on a static free mat. All electrical components can be stripped off the old assembly and mounted on the new assembly before reinstallation.

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

The vend board is mounted to the top of the vend assembly. Input sensors, although not used on the D8X, face into the tube channels. The main IC chip on the D8X is marked to indicate the code version.

D8 Vend Board

Vend Board Connectivity

An armored RJ45/RJ45 cable connects from J2 (hinge side) to the can against the back interior wall. This cable carries power from the external transformer and data between the display and vend board. A short RJ45/RJ45 cable connects from J7 (open side) to the lock board. A five-pin connector plugs into J6. The four wires from this connector are routed through the armored cable to the can for their protection. From there those wires are routed to the inside of the front panel to the key switches mounted there. A broad ribbon cable connects the vend board to the motor board. The ribbon cable sends power to the motors and receives sensor data from the motor board and output sensors.

Vend Board Replacement

Remove power to the safe. Disconnect J2, J7, J6, and the ribbon cable to the motor board. Remove the screws holding the vend board to the vend assembly. Reverse these steps when installing the new board. Set the DIP switches on the replacement vend board before reconnecting power.

Vend Board DIP Switch Settings

Set Vend Delay using segments 4 to 8 (#4 = 2 minutes, #5 = 4 minutes, #6 = 8 minutes, #7 = 16 minutes, #8 = 32 minutes). Two minutes is the factory default. To disable the unload delay for test purposes set switch segment 1 to ON. Be sure to reset Segment 1 to OFF when testing is complete. To allow the armor car key to be used without the manager key, set switch segment 2 to ON. Segment 3 is not used. Any time a segment of this switch is moved power must be cycled for the change to take effect.

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.

Cup & Tube Motion During Vending Cycle:
Discharge Process

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.

Cup Rotor Cap and Motor Sensor Detail:
D8 Rotor Cap

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.

Tube Lock Blocking Bar

The tube blocking bar is metal plate that is designed to prevent tube fishing. When the blocking bar is in the locked position, the tube openings are partially blocked leaving only enough room to insert a dip stick. The bar is moved out of the way via linkage yoke to a mechanical Medeco key switch. If the tube lock does not move smoothly when operating the key switch, adjust the mechanical linkage as needed. The blocking bar can only be replaced with the plastics assembly removed from the safe door.

Tube Lock Hardware:
Tubelock