D8X Service Manual
Contents
1. D8X Service Manual NRE AUDITLOK XLV B C D E F G H J K L M N R S U V Part 15059020 15097037 800397 800316 15000346 1505A001 1505310X 15009069 15052505 15053600 15053000 15053700 15053300 15053400 15053200 160001 18 15003006 15009080 15054000 15009083 15017000 15054015 6 ELECTRICAL PARTS Description XLV Keypad Display Module Medeco Key Switch Pair MGR amp Tube Lock Keyed Alike Medeco Key Switch ACO Wafer Key Switch External Power Supply Transformer D8X Can includes internal harness 15052510 Vend Board Display Cable Armored Vend Key Cable Assembly Vend Ribbon Cable Vend Assembly Includes items L Q and 800135 plastic chassis Output Sensor Cable x2 Output Sensor Transmitter Hinge Side Output Sensor Receiver Open Side Motor Board Rotor Cap x4 Motor x4 800130 Motor Gear is a separate part Lock Board Cable Lock Board Lock Cable crossover Lock Sensor includes cable 13 NRE AUDITLOK XLV 8 7 DOOR HARDWARE PARTS Eum IS D8X Service Manual NRE AUDITLOK XLV Part A Ac TrcrOmnrm ocu M N R S T U V 800135 HS1206 15097037 16000002 800224 600113 700041 800182 802. CABLE _ VEND ASSEMBLY we Ww Ww SENSOR SENSOR CABLE OUTPUT SENSOR OUTPUT SENSOR TRANSMITTER BORRO BOARD ROTOR CAP BOARD Venn between the display and vend board A short RJ45 RJ45 The vend board is mounted to the top of the vend as sembly 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 Vend Board Connectivity armored RJ45 RJ45 cable connects 92 hinge side to the can against the back interior wall This cable carries power from the external transformer and data 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 NRE AUDITLOK XLV D8X Service Manual 9 SERVICE DIP Switch Settings Set Vend Delay using segments 4 to 8 as shown in the chart below 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
3. Drop Drawer Steel Stop Bar Drop Drawer Backstop Carriage Bolt x2 Drop Drawer Backstop Washer x2 Drop Drawer Backstop Hex Nut x2 9 OTHER PARTS Description Dust Cover latchable since 2002 Dust Cover Latch Dust Cover Screw 4 40 x 1 4 x7 Dust CoverScrew 5 16 18 x 7 8 x4 Dust Cover old screw on style Dust Cover Screw 8 32 x 1 4 for old style Hinge Pin Hinge Ball Bearing Inner Door Key Lock D8X Operator s Manual Installation Instructions D8 Label 1 2 x 3 7 8 Autobank Label 3 5 x 14 25 Anchor Kit Replacement Tubes box of 80 Magnetic Tube Rack Dipstick APC Uninterruptible Power Supply 16
4. It is therefor limited to stand alone operation and only basic vending and lock control features D8X Sares D8X safes hold eight columns of ten tubes each The manager loads tubes filled with rolls of cash or coins then cashiers dispenses the tubes as needed during the course of the business day D8X safes are equipped with a manual drop drawer Drops may go into a locked interior compartment although the inner compartment is optional D8X uses Medeco keys for access control The outer door delay is fixed at 10 minutes Vend delay is set by DIP switches with a factory default value of 2 minutes If equipped with an inner compartment the inner door lock will be a key operated lock D8X Service Manual NRE AUDITLOK XLV 2 CHASSIS A DOOR The outer door is made of 3 8 inch A 36 steel The door is laser cut for a perfect fit It is equipped with a high quality low profile boltwork for the best security and most efficient operation B BODY The body is 1 4 inch steel Inner compartment optional All electrical connections via rear panel not shown C HANDLE The style handle on this safe turns 90 right clock wise to open When the handle is turned its bolts retract and lock open When the door shuts a spring loaded detent mechanism fires the bolts to lock the door and the handle automatically returns to the locked position D TUBELOCK KEY SWITCH This key switch is used to op
5. 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 8 Delay 0 Min 2 Min 4 Min 2999999 2 2 2 11 11 RU T 11 11 11 11 11 11 11 S55 gt gt 2 5 3255 3 55 5 55 55 5 5 5 5 5 5 55 5 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 recon necting power 10 Motor System Four DC motors are connected to the motor board Each motor controls vending from two columns through a gear system to a rotor cup To vend the motor turns the rotor in the appropriate direction until a tube drops into the rotor cup The motor then turns the rotor back to center alignment and the tube drops out The example below illustrates how one motor operated rotor cup vends one tube from a pair of columns CENTER ROTOR MAXIMUM RETURN ALIGNMENT ROTATION TO CENTER QO ale als O O Motors The DC motors are mounted directly to the plastics as sembly The motor gear engages the cup rotor pinion Motor wires are routed bet
6. DOOR S Used for outer door access BUY CHANGE Not used on D8X dis pl a y Check delays or error messages PGRM Not used on D8X REPORT Not used on D8X DROP SET Not used on D8X INSTA 12 3 4 used on D8X G E S C BUTTON Not used on D8X H HELP BUTTON Not used on D8X I KEY PORT Not used on D8X D8X Service Manual NRE AUDITLOK XLV 4 OPERATION ON STANDBY Place the ON STANDBY key switch in the ON position before using any operator features In the ON position this key switch allows vending unloading and opening the door Place the ON STBY switch in the STBY position to disable operator features Standby prevents unauthor ized use of vend unload and door features OPEN OUTER DOOR To open a door follow these steps 1 Press DOORS 2 Turn the Manager Key 3 A 10 minute door delay will count up on the dis play 4 Atthe end of the door delay an audible beep will sound to let you know the delay is complete 5 Turn the Manager Key to unlock the door before the access period ends 6 When the display indicates OPEN DOOR NOW turn the handle and open the door 7 soon as your business inside the safe is done shut the door The safe will automatically lock override the 10 minute door delay turn the Armor Car Override ACO Key and skip to Step 6 VEND Follow these steps to vend a tube of change from the safe 1 Press VEND 2 Pressthe number
7. button for the column you want to vend 3 The tube will drop into the dispensing tray at the bottom of the door Take your change from the tube and set the tube aside for re use 4 A vend delay will begin immediately after the tube drops No more tubes may vend until the vend delay ends LOAD To put tubes of change into the safe for vending follow these steps 1 Place the tube lock key switch in the unlocked posi tion 2 Insert tubes as desired Be sure to put each tube in the proper column 3 Use your D8 Dipstick to measure the number of tubes in order to verify tube quantities When a column contains 10 tubes no additional tubes can be loaded in that column 4 Return the tube lock to the locked position to prevent unauthorized loading UNLOAD If an error is made when loading tube inserted in wrong column or for whatever reason you need to remove all tubes from a column or columns follow these steps 1 Press UNLOAD 2 Turnthe Manager Key to initiate the 5 minute unload delay 3 When the unload delay ends an audible beep will sound and the unload access time will count down 4 Press UNLOAD again 5 Select the column to unload or press the arrow select button next to ALL to unload all columns The tubes will begin being ejected immediately To prevent a tube jam remove each tube as soon as it falls into the dispensing tray 6 Ifyou need to unload a second column repeat Steps 5 and 6 7 Toex
8. or similar object may be used to push up on the obstruction from below the assembly There is room in the tray area and space between cups and column walls to do this Slots into the columns along the back of the vend assembly allow you to use screw drivers or similar thin metal objects to walk tubes or debris up and out of the top of the as sembly If absolutely necessary motors may loosened from their mounts to allow cups to be turned by hand After clearing the tube jam power cycle the safe and verify all motors return their home positions by visually checking rotor cap alignments Tuse Lock BLockinc Ban 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 mechani cal 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 NRE AUDITLOK D8X Service Manual 6 ELECTRICAL PARTS EE EM EM 08 CAN VEND BOARD 4B DISPLAY 2 m A8 VEND 2 D VEND ASSEMBLY LOCK BOARD m 5 5 8 I
9. 0175 800153 800113 600029 800218 800152 800112 700007 600025 600027 600028 15017000 6030022 600048 700032 800186 800211 HN700 700028 800129 800231 15054015 800184 7 DOOR HARDWARE PARTS Description Vend Plastics See Electrical Parts Item K Shoulder Bolt 5 16 x4 Medeco Key Switch Pair MGR amp Tube Lock Keyed Alike Tube Blocking Bar Washer 5 16 Tube Lock Actuator Bolt Linkage Screw 10 32 x 5 16 x8 Washer 8 7 16 OD x3 Handle Bushing 3 4 7 16 ID 5 8 OD Handle Actuator Handle Spring not shown attached to handle actuator Retaining Ring Shoulder Bolt x3 Bolt x3 Bolt Cam x3 Side Bolt Actuator x2 Bottom Bolt Actuator Guide Bracket Lock Lock Screw 1 4 20 x 1 5 16 Detent Rod Assembly Detent Rod included with 600048 Detent Spring included with 600048 Detent Stand off Sleeve included with 600048 Hex Nut 8 32 included with 600048 Detent Plate Retaining Ring 3 16 Screw 5 16 x 6 32 x2 Sensor includes cable Wave Washer 7 16 not shown 15 NRE AUDITLOK XLV D8X Service Manual Part A 600764 800064 701242 701243 HB201 6201050 201 800513 800517 06030008 800328 800254 800234 800149 800151 6101001 800338 800346 800208 800268 800372 600131 16000039 1189 801082 8 MANUAL DROP DRAWER Description Drop Drawer Since SP2003028002 Small Drop Drawer Before SP2003028002 Drop Drawer Nylon Stop Stop
10. NKL CASH HANDLING NKL AUTOBANK D X SERVICE MANUAL NKL is a member of FireKing Security Group 101 Security Parkway New Albany IN 47150 USA Ph 800 528 9900 or 812 948 8400 www fireking com 2008 FireKing Security Group NKL FireKing and AuditLok are registered trademarks of FireKing Security Group Doc 801808 Rev 11 2008 NRE AUDITLOK XLV D8X Service Manual 1 INTRODUCTION SCOPE TECHNOLOGY This manual supports NKL Autobank D8X dispensing safes This manual is intended to be used by authorized service technicians only Unauthorized service will void the safe warranty and or service agreement This manual contains abbreviated operation and programming instructions Complete safe operating instructions are found in the User Manual supplied with the safe This manual contains basic theory of operation trouble shooting help repair instructions and electrical and mechanical parts information The original version of this service manual was written in 2001 and it covered all Autobank safes with AuditLok XLV electronics This updated edition covers the D8X only Other models now have their own service manu als Contemporary manufacturing is assumed unless specifically noted otherwise AuditLok XLV is an electronics package designed to control access to safe compartments and perform all control and monitoring functions required by the hard ware The D8X is not equipped with a cpu
11. al inspection of all mechanical parts when servicing a safe door Hinges The outer door is right swing hinges to the right as you look at the safe Do not use chemical cleaners on hinges Boltwork The boltwork is a relatively simple 3 point low profile style The lock is mounted on a bracket at a right angle with respect to the door surface An F guide is mounted to the lock bracket to keep the main vertical bolt linkage aligned and secure Detent The boltwork assembly includes an automatic detent The detent rod runs across the door between the inte rior door surface and the vend assembly To adjust the detent loosen the hex nut behind the brass end piece turn the end piece as needed then tighten the hex nut in place The detent should reliably catch and hold the bolts retracted when opening the door and should throw the bolts automatically when the exterior surface of the door is about flush with the chassis front surface INNER Door IF APPLICABLE The inner door is equipped with a simple key operated lock and no door sensor DISPENSING SYSTEM The dispensing system consists of the plastic vend as sembly 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 VENDING OPERATION Tubes are loaded through the openings near the top of the door Fishing is prevented by a key operated tube blocking bar Tube
12. ard On the D8X an output sensor problem is likely to go unnoticed unless you attempt to unload tubes During an unload if the sensors do not detect the beam break temporarily after tubes discharge it will only unload two tubes regardless of the actual number of tubes in the safe The problem may be beam blockage dirt on the transmitter or re ceiver physical board alignment or a failure of one of the sensor boards or cables Motor Board The motor board interfaces the motors rotor 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 Tuse JAM One of the most common service issues is a tube jam Technically a tube jam is when rotor cup position sen sors are unable detect correct motor movement The cause is usually a broken or vertical tube or other de bris inside a column blocking normal rotor movement Do not attempt to put fingers in the rotor area while a motor is moving or trying to move Before attempting to lift tubes up and out of the assembly the tube blocking bar must be in the open position and the vend board should be removed A thin screwdriver
13. e 12 2 3 5 4 12 Voc 5 12 Voc ELECTRONICS CAN The electronics can inside the D8X contains only cable harnesses for routing power to the display and data to and between the display and main vend board Can re placement requires access to the inner compartment Can REPAIR REPLACEMENT To replace disconnect power from the rear of the safe disconnect the vend and display cables from the can then remove the hex nuts holding the can in place The can should easily slide out Reverse these steps to re place the can The only replaceable part inside the D8X can is the internal harness C TRANSFORMER SAFE POWER 00 INTERNAL HARNESS DISPLAY VEND E3 E3 D8X CAN A slide bolt lock is used on outer doors today Early safes used a LaGard swing bolt lock Either lock has an internal sensor to detect if the lock is locked bolts extended or not bolts retracted An external plunger sensor detects door condition open or shut The lock is connected to a lock board via crossover RJ45 RJ45 cable VEND BOARD LOCK BOARD CABLE B LOCK BOARD J4 J5 SENSOR SENSOR a LOCK LOCK Sj 9 Door Wit Lock In this situation the bolts throw normally when the door closes but the handle can still be turned and door opened at any
14. en and close the tube lock blocking bar It is used to prevent fishing E LOAD COLUMN OPENINGS Tubes are loaded here Column 1 is to the left as you look at the front of the safe column 8 is to the right as you look at the front of the safe F LABEL Safe logo G MANUAL DROP DRAWER Pull out insert drop envelop push in The drop will fall into the inner compartment if present or the bottom of the safe if there is no inner compartment The drawer includes an anti fish feature H DRAWER HANDLE The plastic insert handle makes it easy to grab and pull the drawer out and it is nearly flush with the front of the safe to prevent accidental injury I ACO KEY SWITCH This Medeco electrical key switch is used to bypass the outer door delay for armored car service J MGR KEY SWITCH This Medeco electrical key switch is required for door access and the unload feature K AUDITLOK XLV KEYPAD The keypad features a touch membrane surface for protection from spills and a 20x4 fluorescent display L ON STBY KEY SWITCH This electrical key switch must be ON in order to perform any keypad operations M CHASSIS SERIAL NUMBER The serial number begins with SP to indicate manufac ture by the FireKing Security Products plant location early D8 safe serial numbers began with NK to indicate NKL brand The first four numbers indicate year of manufacture The next three numbers indicate week of manufacture The
15. it the Unload procedure press UNLOAD then press ESC CHECKING TUBE QUANTITIES Use your D8 Dipstick to check how many tubes are in each column 1 Place the tube lock key switch in the open posi tion 2 Insert the dipstick into the opening at the top of the column you wish to check until the stick is stopped by a tube 3 The number on the stick indicates the number of tubes in the column MANUAL DROPS Follow these steps to make a manual drop into the safe 1 Prepare your money and deposit slip by inserting them into an NKL drop envelope 2 Pull out the safe s drop drawer 3 Place the drop envelope in the drawer 4 Close the drop drawer The envelope will fall into the interior of the safe 5 To verify the envelope is secure pull the drawer back out to check that the envelope is no longer in the drawer NRE AUDITLOK XLV D8X Service Manual 9 SERVICE POWER DOOR LOCKING SYSTEM One of the most common problems with electronic products is partial or complete loss of power External power supplies are used with NKL safes so that a safe does not need to be drilled open to service the more common types of power supply failures Main Power The three level main power supply transformer output 12 V5 and 5 may easily be checked with multi meter The pin out is shown below To prevent power supply failure due to surges or spikes always use an uninterruptible power supply with your saf
16. last three numbers indicate sequential number of unit built during that week of that year N HINGE Safes have two welded hinges on which the door swings open up to 180 Do not attempt to clean hinges Commercial cleaning chemicals will cause the hinge lubricant to break down making it difficult to open or close the door O DISPENSARY TRAY When tubes are vended they drop into this tray area where they may be retrieved EXTERNAL POWER SUPPLY NOT SHOWN A power supply transformer connects to the rear panel of the safe NRE AUDITLOK XLV D8X Service Manual 3 AUDITLOK XLV KEYPAD DISPLAY NIB avi tio xcv A SCROLL BUTTONS Not used on D8X B DISPLAY This is an 80 character 4 rows 20 columns fluorescent display It can easily be read at some distance in almost any lighting condition C SELECT BUTTONS Not used on D8X D NUMERIC KEYPAD This is a standard number pad Use the ENTER button to accept an entered value Use the c a nc el button start over entering a number E MOUNTING For security the display module is mounted to the chassis or EPR using two Torx 1 25 security screws F ACTION BUTTONS action buttons apply to every safe but any given system could use almost any combination of action but tons depending on the application LO A D Not used on D8X V END Used to vend DR O P Not used on D8X UNLOA D Used to empty all tubes from a column
17. s Next check the key harness cable connection to the vend board and continuity of each of those wires If the problem is not found test the new lock to ensure the new part is functioning properly If the problem is still not found replace the lock board Lock Test Connect a 9 VDC battery between pins 5 and 8 of the RJ45 port on the lock The lock solenoid should ener gize and the slide bolt should freely slide into the lock body swing bolt should rotate into body If not the lock solenoid has failed replace the lock PIN 1 PIN 8 LOCK Key Switches The key switches are mounted in such a way that they are difficult to access directly with a meter The easiest way to check continuity is to disconnect the key harness from the vend board J6 and measure from common green at the wire harness plug Key switches are nor mally open Key switch wiring VEND BOARD J6 ON STBY KEY SWITCH YELLOW ORANGE Continuous Door ALARM Acontinuous alarm tone sounds if the lock or door sensor indicates that the door is open more than five minutes or if either sensor detects the door come open without a signal to energize the lock If the door is shut and locked and the door alarm is sounding the most likely cause is the door plunger sensor If the a sensor fails the safe will continue to alarm until repaired or power is removed The door will still operate normally with a failed sensor although the normal beeps will not be heard due
18. s are held in columns ing 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 sen sors 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 Venn 5 PLastics 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 D8X Service Manual AUDITLOK XLV 5 SERVICE ACO KEY SWITCH x ON STBY SWITCH MGR KEY SWITCH NS KEY HARNESS T DISPLAY DISPLAY CABLE D8X IC CHIP DBXCAN 58 8 DISPLAY 8 4 Lock BOARD VEND 2 MOTOR k RIBBON BOARD
19. time The problem may be the lock or the lock controller board Test for Stuck Lock Solenoid Open the safe door Press the detent to throw the bolts Disconnect the lock cable at the lock If the handle can still be turned the solenoid inside lock is stuck and the lock must be replaced If the handle can no longer be turned the lock board is the most likely problem and it should be replaced Door Won t UnLock In this situation the door is assumed to be closed and the handle cannot be turned when the lock is edly energized everything appears to work normally otherwise Any of several things may be wrong lock lock cable lock board to vend board cable lock board or vend board The most likely problem is pressure against the inside of the door making it difficult to turn the handle This problem can usually be overcome by pushing against the outside of the safe door while turn ing the handle D8X Service Manual NRE AUDITLOK XLV 9 SERVICE Drill and Repair If the door is locked shut and cannot be opened using door procedures the door must be drilled open Contact NKL Technical Service for assistance with drilling instruc tions In most cases the cause is a failed lock Drilling the door open will destroy the lock After replacing the lock test door operation with the door open press and hold the door sensor to silence the alarm If the new lock does not solve the problem test the MGR and ACO key switche
20. to the alarm condition When the plunger sensor breaks it is usually easy to see by visual inspection Lock Sensor Sensor continuity may be tested by measuring continuity between pins 3 and 2 normally open or between pins 3 and 4 normally closed at the RJ45 jack on the lock If the lock sensor fails replace the lock Door Sensor Asimple spring loaded plunger sensor is used to detect physical door status The plunger switch is normally open When the plunger switch is pressed door shut the plunger switch closes To replace the sensor re move the vend assembly remove the sensor screws disconnect the sensor wires from the cable harness back to the lock board Reverse these steps to replace the sensor Lock Crossover The cable from lock to lock board is a reverse wired crossover RJ45 RJ45 cable The lock cable is always connected to J3 on the lock board NKL uses a black crossover cable for easy identification Connecting the lock via a one to one straight through cable to the J3 port on the lock board will definitely cause lock board failure Lock BoaRD The lock board is mounted on the outer door The lock board may be replaced independently from the vend board NRE AUDITLOK XLV D8X Service Manual 9 SERVICE Outer Door MECHANICAL Door blockage loose or broken linkage or some other mechanical problem can prevent a door from opening or shutting correctly Always perform a complete visu
21. ween the motor board and the plastics and plug into the corresponding jack on the motor board Motors are operated by 12 V e and they are polarity sensitive For test purposes a standard 9 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 move ment 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 ROTOR CAP ALIGNMENT KEY ROTOR CAP END OF TRAVEL HOME GAP SENSOR TRAVEL GAP SENSOR D8X Service Manual NRE AUDITLOK XLV 9 SERVICE 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 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 Sensors are marked to avoid confusion as to which is which Output sensor wires are connected to the motor bo
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