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> Accept/Reject Problems... <
 
 

A side cabinet RVM is accepting all containers into the main cabinet.

The RVM has frequent "bail sensor failed to clear" errors.

The feed wheels on one side of the feed unit are not turning.

A 3-commodity RVM displays "bin full" for the side cabinet even though the bin full sensor isn't blocked.

Containers with supplemental barcodes are rejected.

Tall 16-oz bottle-shaped cans like the red-black Budweiser are sometimes rejected and cause an additional bail reject cycle when accepted.

The RVM accepts the container onto the bail, but gets stuck there with the rollers on. The crusher never comes on.

Small aluminum cans are not accepted.

PET bottles jammed in the flattener cause PET bottles to be rejected and paid for.

PET bottles are sometimes rejected because they donít reach the bail sensor.

The PET machine accepts cans.

A can RVM fails for "crusher position sensor timeout" after removing the crusher.

The can RVM turns on the crusher, but doesn't move the bail. The display indicates "insert container" but the RVM won't accept any more containers.

Cans are sometimes not paid for when using the "can crusher timing" anti-cheat feature.

A particular can is sometimes rejected.

A can machine is accepting cans to one side only.

The Glass RVM will not accept any bottles and fails for "bail failed to clear object" after a few bottles are rejected; "not participating" or "unable to read barcode" is NOT displayed, only "rejecting".

The can/PET crusher RVM is accepting both commodities to the same bin.

The container is crushed but not paid for, the bail is stuck to the left, the RVM displays "bail sensor failed to clear".

Some containers are accepted but not paid for.

The RVM displays "unable to accept any commodity" when the cabinet door is opened.

The machine runs the feed wheels and displays "remove container", then halts.

Machine accepts container, briefly displays "REJECTING" and doesnít pay for container.

Machine rejects ALL containers WITHOUT displaying a reason like "non-participating", "unable to accept", or "unable to read barcode".

Machine displays "non-participating" even though the barcode is in the table.


A side cabinet RVM is accepting all containers into the main cabinet.
[added 7/26/13] Set RVM parameter SIDE_CABINET=2.
Make sure the bin configuration file has SILO04 defined for the side cabinet.

The RVM has frequent "bail sensor failed to clear" errors.
[added 8/18/09] Bail failures are usually caused by customers feeding flattened or partially flattened containers into the bail unit. They will then jam between the bail and rollers.
The bails will sometimes get bent upwards from these flattened containers, causing the sensors to be blocked and necks of bottles to fall between the rollers and the bail.
You can gently bend the bail unit back down to close up the gap as much as possible. It should just clear the rollers when it swings left or right. Make sure the bail is not damaged or the welds broken.
Use diagnostics #1,63 to rotate the bail back and forth.
Use diagnostic #1,74 to check the status of the bail sensor. To see the blocked/not blocked status lights of the sensor you will have to remove the side cover on the ac motor control box. Just remove the 2 front screws on the front side.
With the sensor not blocked you should have a green light on (stability and power), and a red light on (not blocked). If not, look for obstructions through the path to the reflector.
You can adjust the position of the sensor by turning one of the three outside screws to aim it towards the reflector. The adjustment on the sensor itself is the gain adjustment. To turn up, turn with a small straight screwdriver clockwise. Turn up a little at a time. Do not turn up to much or the beam may go through a clear bottle without seeing it.
The bail sensor is used to prevent cheating in some markets. You may want to turn this sensor off if it seems to cause problems. To do this, retrieve the parameters and find the BAIL_SENSOR parameter. Set to 0 to disable.

The feed wheels on one side of the feed unit are not turning.
[added 6/11/09] Check if a belt slipped off one of the wheel sprockets.

A 3-commodity RVM displays "bin full" for the side cabinet even though the bin full sensor isn't blocked.
[added 8/28/07] This can happen if the main cabinet is configured for full-by-count and the side cabinet is configured for bin full sensors and the RVM software version is prior to 5/6/03.
Workaround: configure the side cabinet for full-by-count (edit the silos table) and use a large full count such as 65000. The RVM will use the side cabinet's bin full sensor to go out of service for a bin overflow when it's full.

Containers with supplemental barcodes are rejected.
[added 4/24/06] The barcode table is probably missing the 01FFFFFFFF barcode. Click "Advanced | Search RVM for barcode", enter "01" and make sure this barcode is present. Also search for the barcode that's not being accepted to verify it's in the table. Verify via keypad command #1,13 that the scanner reads the correct barcode. Unfortunately you can't tell if the scanner is able to read the supplemental barcode, this could be the problem.

Tall 16-oz bottle-shaped cans like the red-black Budweiser are sometimes rejected and cause an additional bail reject cycle when accepted.
[updated 7/18/05] Not all bottle-shaped cans are rejected, just the very tall ones. To fix, turn the staging feature off by setting the parameter "USE_STAGING=0" and set MAX_CANCOUNT=800. Note: disabling the staging feature will slow the acceptance rate.

The RVM accepts the container onto the bail, but gets stuck there with the rollers on. The crusher never comes on.
[added 8/13/04] This can happen for several reasons:

  • If a laser "safety fail" occurred in RVM software versions prior to 12/9/97.

  • RVM versions between 8/13/98 and 7/27/99 have a bug: if a barcode was scanned whose option byte was set requiring a supplemental barcode and then the supplemental scan found a supplemental barcode but that supplemental barcode was not in the table.

  • RVM versions prior to 9/23/03 have a bug: if a non-participating container was inserted and WILDCARDSTART was set to an illegal value greater than 32767 but less than 65535.

Reloading the RVM software may solve the problem.

Small aluminum cans are not accepted.
[added 12/3/03] Reduce the ALUMTHRESHOLD parameter setting from the default value of 90 (= 0.90V) to a lower number such as 50 (=0.50V). This setting determines how much an aluminum can must reduce the value of the aluminum sensor reading before declaring the object as aluminum. Use diagnostic 23 to determine how much the aluminum sensor reading drops when a small aluminum can is inserted.

PET bottles jammed in the flattener cause PET bottles to be rejected and paid for.
[added 7/15/03] The BAIL_SENSOR parameter setting greatly impacts this problem. If the BAIL_SENSOR is disabled (set to 0) or set to 8 or greater, the RVM will not detect this problem. The default value of BAIL_SENSOR is 2 and this should fix the problem (and not slow the machine any).

Here is a description of the available settings for BAIL_SENSOR:
; Bail sensor installed? (non-zero = yes)
; 1 = sensor installed
; ADD the following values for the desired features:
; 2 = bail beam only requires momentary block before paying
; 4 = pay even if bail beam is never blocked
; 8 = bail beam doesn't have to be clear after accepting to pay

See the Vol. 8 # 9 software update for a description of bail operation.

A can RVM fails for "crusher position sensor timeout" after removing the crusher.
[added 11/12/02] The RVM must be configured as a shredder instead of a crusher to allow operation without a crusher. Also, set SH_STALL_TIME=0 to ignore crusher stalls.

The container is crushed but not paid for, the bail is stuck to the left, the RVM displays "bail sensor failed to clear".
Verify proper bail beam operation via diagnostic 74. The bail beam sensor probably needs adjustment. See tech bulletin 23 for instructions.

Some containers are accepted but not paid for.
[updated: 9/29/09] There are several reasons why this can happen:

  • If the bail sensor is blocked after the bail returns to center after accepting a container. Note: this feature only active when the BAIL_SENSOR parameter is set to less than 8.

  • If the rescan feature detects the same barcode that was just crushed after the bail returns to center. Note: the RESCAN_TIME parameter enables the rescan feature.

  • The barcode's 'value byte' could indicate this container has no value. Check the appropriate barcode table and find the barcode in question which should look like this: 4455667788,0,1,2,3". The first digit after the barcode (0 in this example) indicates the value of this container which corresponds to the DEPOSIT0 parameter. If DEPOSIT0=0 the container will not be paid for. By default, all DEPOSIT values are set to 0 except DEPOSIT0.
    Note: a fast way to detect a problem like this is to get the latest Q file from a problem site via LastCall, then run the Q file thru the Barcode Converter program and click the "value" byte column, then check the end of the list to see if all barcodes are set to a value of 0 (good) or something else (bad).

  • The "Can crusher timing" anti-cheat feature may not be detecting a can crush. See here.  (CRUSHTIME_MIN)

  •  The barcode MULTI_SCAN may not be detecting containers.

  • If taking unreadable barcodes via TAKE_UNREAD and UNREAD_VALUE points to a DEPOSIT value of 0, the container will not be paid for.

  •  If the laser scanner is disabled and the RVM is configured to pay points instead of money, make sure the ALUM_POINTS, STEEL_POINTS, and PET_POINTS are non-zero if the RVM is configured to accept these commodities (check the bin configuration via WinRVM's "Retrieve from RVM | status".

  • Reload the RVM with the latest software version.

  • If a can RVM's aluminum coil detects a can while waiting for the bail to center after accepting a can (and the staging sensor has NOT been blocked). Note: this feature only active when the COIL4CHEATDET parameter is enabled.

Set the DEBUG parameter to 1, enter service mode and insert containers. If a container isn't paid for a "cheat code" will be displayed:

1 = Coil detected can before acceptance
2 = Coil detected can after acceptance
3 = BailBlockTime fail
4 = BailClearTime fail
5 = Multi-scan: not enough time between scans
6 = Multi-scan: 2 different barcodes detected
7 = Multi-scan: not enough scans
8 = Bail beam not blocked just before accept cycle
9 = Staging/PET sensor blocked after ENTRY_DEBTIME expires
10 = Bail beam blocked after bail returned to center
11 = Bail beam blocked while machine idle
12 = Can not crushed in CRUSHDETECTIM secs

Cans are sometimes not paid for when using the "can crusher timing" anti-cheat feature.[updated: 7/2/03] 

  • An intake chute damper curtain must be installed, otherwise the can may bounce around and not fall into the crusher in time. See Tech Bulletin TB00019R for damper curtain installation.

  • If the can retainer is bent cans will fall into the bin w/o being crushed. Obviously the software will not detect a can crush if this occurs.

  • Check the crusher itself for damage. The older gearbox frames that use 3/16" bolted steel instead of the newer 1/2" welded steel frames may crack and cause the gearbox frame to twist during a crush.

  • Use RVM software 11/20/02 (or later) only. Previous versions have known payment problems with some crushers, as some crushers move slower in one direction than the other.

  • Make sure the ACCEPT_SIDE parameter is not set to 0 as this will enable the "random drop" feature, which can cause cans to land on top of the crusher plate instead of in the crusher.

  • Make sure the CRUSHTIME_MIN parameter is set correctly, as the format was changed for the 2/11/2000 version (see Software Update Vol. 8 No. 1).

  • To debug a problem at a site run the CONSOLE program (C4 on Site Controller PCs) and set the DEBUG parameter to 1 via "SETPRM:DEBUG=1" (or press F8 if using the CANKEYS.CMD from 3/6/2000 or later) to show the crusher timing. For example:
    (L5: 500,501,1) {going left-to-right, threshold=5, previous baseline=500, current baseline=501, difference=1}
    (R6: 500,500,0) {going right-to-left, threshold=6, previous baseline=500, current baseline=500, difference=0}
    (L5: 501,501,0) {going left-to-right, threshold=5, previous baseline=501, current baseline=501, difference=0}
    (R6: 500,500,0) {going right-to-left, threshold=6, previous baseline=500, current baseline=500, difference=0}
    If the last number ("difference" above) is less than the CRUSHTIME_MIN parameter, then the RVM won't pay. The CRUSHTIME_MIN parameter may need to be lowered from the default value of 1285 (5 per side). See Software Update Vol. 8 No. 1 for details.
    Remember to set DEBUG back to 0 when done viewing the debugging data via "SETPRM:DEBUG=0" (or press F9 if using the CANKEYS.CMD from 3/6/2000 or later).

PET bottles are sometimes rejected because they donít reach the bail sensor.
Disable the bail sensor by setting the BAIL_SENSOR parameter to 0. Note: this may cause other problems, see here.

The can RVM turns on the crusher, but doesn't move the bail. The display indicates "insert container" but the RVM won't accept any more containers.
[added 8-10-00] A can's pop tab or other object may be wedged by one of the crusher RPM position sensors, causing the sensor to behave erratically. Run crusher diagnostics 15 (RPM/duty cycle) and 38 (position sensors) to verify proper operation.

The RVM displays "unable to accept any commodity" when the cabinet door is opened.
[updated 7-6-06] This message can happen if the silos or parameter table was never loaded, or possibly for a memory corruption.

This can also be caused by a bad silo table. Make sure the silo table is correct, and reload it.
Check that the individual bin configuration file nnnnnnSILOS.TBL (or SInnnnnn.TBL for SC sites) on the SC for that RVM is correct. The file may be missing or the RVM's serial number (nnnnnn) may be wrong in the filename or in the RVM itself.

Make sure the REJECT_TYPES parameter is set to 0 in PARMS.TBL. 
For SC sites: run SCSETUP and make sure the serial numbers are correct, press F2 to write new tables.

You can also load a different version of RVM software (like the current version) than what's in it now. When the tables are loading, make sure no error messages are displayed.

Machine rejects ALL containers WITHOUT displaying a reason like "non-participating", "unable to accept", or "unable to read barcode".
Check the customer door locking mechanism to make sure the doors arenít bouncing. Check the bail sensor to make sure it isnít flickering.

The machine runs the feed wheels and displays "remove container", then halts.
[updated: 9/29/99] Diagnostics 70 (entry beam/customer door status) and 73 (staging sensor) should indicate "not blocked / closed" with no container present. 
For a glass or PET machine, if diagnostic 70 indicates the customer doors are open when they aren't, try manually pushing in the door switches and see if the display changes to "not blocked / closed". If so, the metal tabs on the customer doors may need to be bent slightly to make better contact with the switches.
If a can machine, diagnostic 23 (aluminum coil voltage) should indicate 2.5V +- .2V with no can present and the feed unit in the closed position. If not, open the RVM controller and adjust the "zero" potentiometer on the can detector board. Press the "A" key to reset the baseline to 2.5V. The sensor should indicate less than 1.2V with an aluminum can present, more than 3.8V with a steel can present.

Machine displays "non-participating" even though the barcode is in the table.
[updated: 1/17/05] Turn on "debug" mode by setting the DEBUG parameter to 1 via keypad function #9,20 and run the container again (donít exit service mode)- the software may display a more descriptive reason such as (container mismatch), which indicates that the material sensor may not be functioning properly (verify via diagnostics), or that container may be unusual (part aluminum/part steel, etc.), or a "cheat code" (see PARMS.TBL for description). Verify via RVM diagnostic #1, 13 that the scanner is reading the correct barcode. The barcode table may not be sorted properly. Even if you verify that the barcode table SENT to the RVM is sorted, this does not guarantee that it will work if an unsorted barcode table had been previously sent.

To fix an unsorted barcode table: perform a data collection, then use PCRVM/PCRVM485/WinRVM to clear the barcode table of the appropriate RVM. Reload the barcode table. Note that the barcode counts will be reset to zero.

Machine accepts container, briefly displays "REJECTING" and doesnít pay for container.
Check the customer door locking mechanism to make sure the doors arenít bouncing. Check the bail sensor to make sure it isnít flickering.

A particular can is sometimes rejected.
[updated: 8/7/01] Verify via diagnostic #1, 14 that the barcode is reading properly. Check the aluminum sensor operation via diagnostics 23 (make sure the baseline is around 2.5V, it goes up by 1.0V when a steel can is inserted, down by 1.0V when an alum can is inserted). If the particular can doesnít cause the sensor to move by 1.0V, then reduce the size of the ALUMTHRESHOLD or STEELTHRESHLD parameters for an aluminum or steel can, as appropriate. If the can is tiny, reduce the MINCANCOUNTS parameter value. The aluminum sensor's hardware gain setting may need to be adjusted.

The PET machine accepts cans.
Set the STAGE/PETSNSR parameter to 20. This requires the machine to get 20 PET readings from the PET sensor before accepting the container. Run diagnostic 73 and insert a can - it should NOT indicate PET. If it does, then the PET sensor is defective.

Two things must be true for a PET machine to accept a CAN:
1. The CAN barcode must be in the PET barcode table. Perhaps a wildcard barcode (...AAA) caused this problem?
2. The STAGE/PETSNSR parameter is disabled (set to 0), thus not requiring the PET sensor to detect PET for acceptance.

-OR-

The barcode that the CAN barcode is matching has the option byte set to ignore the PET sensor. The option byte is the last digit in the barcode table (o in this example): 1234567890123,x,x,x,o

If bit 0 of the option byte is set, then the PET sensor is ignored for this barcode. Bit 0 is set if the option byte is an odd number (1, 3, 5, etc.).

The can/PET crusher RVM is accepting both commodities to the same bin.

  • Verify that the deflectors bolted to the bottom of the crushers are pointing in the correct direction (they should not both be pointed into the same bin!).

  • Verify via keypad command #9,20 that the ACCEPT_SIDE parameter = 4 and not 0.

  • Verify that the USE_DIVERTER parameter = 1.

  • Verify the operation of the diverter via diagnostics 61 & 62.

  • Verify the bin configuration via keypad command #9,20. The first bin listed will indicate the commodity type for the left bin, the second is the right bin. A new silos table must be sent if this is the problem.

A can machine is accepting cans to one side only.

  • Make sure the SILOS table (bin configuration file) loaded to the machine has two bins in it. This can be verified from the RVM keypad via #9,21. Two bins should be listed.

  • The ACCEPT_SIDE parameter should NOT be set to 2 or 3 (should be set to either 1 or 4). This can be checked via keypad function #9,20.

  • Run the crusher on via #1, 15 then run the crusher position sensor diagnostic #1, 18 to make sure that both sensors consistently toggle from 0 to 1 without flickering. A flickering display indicates a bad sensor, bad or not fully plugged-in cable, or a bad RVM controller.

 

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          page last updated: 11/27/13 10:37 AM