Faults

Status messages
Status display
The current status of the CCDM, including any faults that may have occurred, is shown on the status display. The status display shows the following messages, depending on the type of display: Status display No display (Green LED on) Meaning Normal operation; no fault / no warning Function code (see chapter "Function test") constant Error code blinking Warning code permanent

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Status messages

Faults

Localizing the cause of the error

The numbers in the figure below represent the error and warning codes shown on the status display. The numbers are positioned on the diagram in such a way as to make it easier to locate the source of the error. The exact position of the photosensors and motors referred to in the code tables can be found in the section "Overview of sensors and actuators" in the appendix. The error codes of the photosensors (codes 60 to 89) are not included in this figure.

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28 24 25 22 21 20 13 19 31 32 33 34 10 11 15

30

51

41 42 43
46 47

50 48 52

26 27

90 91 96

CCDM - Service Manual

94 92 95 93

Status messages

55%

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Status messages Faults

Error codes / warning codes

Only check plug connections and only replace components when no voltage is being applied!
If components need to be replaced to clear a fault, please refer to

the relevant section in the chapter "Removal/Installation of Components". When a component has been replaced, always synchronize the photosensors. After clearing a media jam, always perform a reset.

How to execute measures Remedy Synchronize the photosensors Performing a RESET Restarting the system Displaying the extended error code (EC) Note Press the test button and select the function code '03' (see chapter "Function Test"). Press the test button and select the function code '01' (see chapter "Function Test"). Switch the device off and back on (for details see chapter "Basic Operation" in the operating manual). Press the test button and select the function code '00' (see chapter "Function Test"). The extended error code is shown on the status display as follows: First high byte (2-3 seconds) (only in case of 4-digit error code), then low byte (2-3 seconds). For details refer to the examples on the following page. Next, the two-digit error code is displayed again.

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Faults Examples of the extended error code display Error code '17' / EC '23' as an example of a 2-digit display of error code: Error code '24' / EC '102' as an example of a 4-digit display of error code: Status messages

Error code display

Error code display

Automatic return to error code display

Call function code '00'

Automatic return to error code display

Call function code '00'

Display of EC for 2-3 s (low byte)

Display of EC for 2-3 s (high byte)

Display of EC for 2-3 s (low byte)

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Status messages Faults

Error messages in the area of the head module

Code EC Meaning Boot up (electronic self-test) Boot up (after reset) Operating system error, hardware error Operating system error, internal firmware error Remedy Wait for the system to finish booting up. Wait for the system to finish booting up. Restart the CCDM. If necessary re-load the firmware. If the error reoccurs, replace the controller. Restart the CCDM. If the error persists, re-load the firmware. If the error reoccurs, replace the controller. Permanent status display: Dispenser module 01750047708 is installed which may cause incidents in the dispensing area. Replacement with an up-to-date dispenser module is recommended. Blinking status display: Check the cable connection between the dispenser module and the back panel. Restart the CCDM. Replace the dispenser module. If the error reoccurs, replace the chassis of the CCDM. Check the plug connections between amplifier and controller board. If necessary re-load the firmware. Restart the CCDM. If the error reoccurs, replace the controller.

No connection to dispenser module

No connection to amplifier board

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Faults Code EC Meaning No connection to stacker board Status messages Remedy Check the plug connection between amplifier board and controller board. Check the configuration of the controller. Re-load the firmware of the CCDM. Restart the CCDM. If the error reoccurs, replace the distributor transport. Restart the CCDM. Delete the cassette counters and the CEX. Perform a reset. Restart the system If the error reoccurs, replace the controller. Restart the system Load the appropriate configuration using the product-specific test software. If the error reoccurs, reload the firmware. If the error cannot be eliminated by means of the above steps, replace the controller. Restart the system If necessary re-load the firmware. If the error cannot be eliminated, replace the amplifier / controller board. Restart the system If the error persists, re-load the firmware.

Battery on controller board empty

Device configuration of controller incorrect or missing

Error on controller

No firmware

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Status messages Code EC Meaning Safety switch active Faults Remedy Check whether the CCDM (head module and cassette module) is pushed into the device correctly (locking mechanism!) and whether the safety switch is correctly bridged. Check the connection cable between the safety switch and the back panel. If the red LED (DLOC) lights up, too, reset the DLOC first, then pull the device out and push it in again. The device is only ready for operation once this procedure was carried out. Restart the CCDM. If the error reoccurs, replace the safety switch. After the XSA module has i been reconfigured, there is a waiting period of up to 270 seconds until the CCDM is ready for operation. Remove the documents from the input/output area. Register the cassettes using the product-specific software (e.g. Service Operator Panel).

Retract documents are stored in the input/output area. Minimum configuration is missing (at least 1 cash-in cassette + retract cassette) Operating system is loading new files on the CCDM controller Data transfer on RS232 interface

Wait for the system to finish loading the firmware.

Wait for the data transfer to finish.

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Faults Code EC Meaning The application overloads the CCDM hardware (too many reset commands per time unit) Status messages Remedy Power down the PC / the application. Leave the CCDM switched on for five minutes. Power up the PC / the application. Perform a reset. Shutter blocked Remove any foreign matter from the shutter area. Make sure the plug of the shutter is plugged in at the controller. Perform a reset. If the error reoccurs, replace the shutter. Mechanical blocking / foreign matter, Plug has not been plugged in, Shutter is defective. Error of the metal Check the plug connection on the detection unit metal detection unit. Restart the CCDM. If the error reoccurs, replace the dispenser module. Module is defective or plug has not been plugged in.

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Status messages Code EC Meaning Error on swivel transport unit or in the area of the bundle alignment Faults Remedy Swivel transport unit: Check the home position of swivel transport units 1 and 2. Inspect photosensors VLS3 and VLS4. Inspect motors VSM5 and VSM6. Replace the dispenser module, if necessary.

Bundle alignment: Check whether the bundle alignment is clear. Inspect photosensors VLS8 and motor VSM7. Replace the dispenser module, if necessary. Swivel transport 1 / 2 is mechanically blocked. Home position photosensor is defective or soiled (VLS3 / VLS4). Transport error: motor does not run properly (VSM5 / VSM6). Swivel transport is mechanically blocked. Home position photosensor is defective or soiled (VLS3). Transport error: motor does not run properly (VSM5).

or diagnostic test triggered by operator: swivel transport 1 in dispenser module defective. Swivel transport is mechanically blocked. Home position photosensor is defective or soiled (VLS4). Transport error: motor does not run properly (VSM6). or diagnostic test triggered by operator: swivel transport 2 in dispenser module defective.

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Faults Code EC Status messages Meaning Remedy Drive is mechanically blocked. Home position photosensor is defective or soiled (VLS8). Transport error: motor does not run properly (VSM7). or diagnostic test triggered by operator: bundle width setting in dispenser module defective. Remove any jammed media from Media jam in the dispenser module's paper dispenser module path. (feed error detected prior to Perform a reset. dispensing) Check the cam disk position. Check the dispenser module's motors. Restart the CCDM. Replace the dispenser module, if necessary. Paper jam in I/O transport area. Photosensor VLS2 or VLS5 is defective or soiled. Semi-rotary actuator motor does not run properly (VSM1). Swivel transport is not lowered due to blocking etc. (VSM6 / VLS4). Stacker table is not on top due to blocking or defect (VSM8 / VLS9). or diagnostic test triggered by operator: dispenser module defective. A paper jam has occurred in the dispensing / I/O area. Photosensor VLS2 is defective or soiled. Motors VSM1/2/3 do not run properly. See error code no. 0100 for details.

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Status messages Code EC Faults Meaning Remedy Paper jam in I/O area -> paper feed rollers. Photosensor VLS2 / VLS6 is defective or soiled. Transport error: motors VSM1/2/3 do not run properly. Swivel transport is not lowered due to blocking etc. (VSM6 / VLS4). Stacker table is not on top due to blocking or defect (VSM8 / VLS9). Swivel transport 2 is defective (VSM1). Clock wheel in swivel transport (VLS5) is defective or soiled. Dispensing comb is blocked. A paper jam has occurred in the paper path between stacker and I/O transport, or paper is too long. Photosensor VLS2 is defective or soiled. Transport errors: motors (RSM1 / VSM1 / VSM2) do not run properly. Incorrect cam disk position caused by jam or defect: Transport rollers should plunge through stacker table I/O transport (VSM8 / VLS9). Swivel transport 2 is not on top due to blocking etc. (VSM6 / VLS4).

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Faults Code EC Meaning Paper jam detected during separation process. Status messages Remedy Check paper path in dispenser module. Clean the photosensors in the dispensing area of the dispenser module. Carry out a photosensor adjustment / initialization. Reset the photosensors to the default values, if necessary. Check the dispenser module's motors, if necessary. Restart the system Replace the dispenser module, if necessary. Foreign objects or dirt detected at VLS6 or VLS7 prior to dispensing process. A paper jam has occurred in the paper feed roller area, or paper is too long. Photosensor VLS6 is defective or soiled. Transport error: motors VSM2/3/4 do not run properly. Paper jam in paper feed roller area -> intermediate transport. Photosensor VLS7 is defective or soiled Transport error: motors VSM2/3/4 do not run properly. A paper jam has occurred in the intermediate transport and possibly also in the alignment station. Photosensor VLS7 is defective or soiled. Motors VSM2/3/4 do not run properly. Motor ASM1 of alignment station does not run properly. A paper jam has occurred in the dispensing area. Photosensor VLS6 is defective or soiled. Motors VSM1/2/3/4 do not run properly. See error code no. 0105 for details.

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Status messages Code EC Faults Meaning Remedy Paper jam in dispensing area or intermediate transport. Paper too long. Photosensor VLS6 is defective or soiled. Motors VSM2/3/4 do not run properly. See error code no. 0103 for details. See error code no. 0105 for details. Document jam in intermediate transport or at entrance to alignment station. Paper jam detected Remove the media jam in the dispenser module and reset the Dduring separation Loc using the product-specific process. software. Restart the system Carry out a photosensor adjustment / initialization. Replace the dispenser module, if necessary. Media jam in front of VLS2 during bundle output from intermediate transport to I/O box Media jam under the VLS6 during bundle output from intermediate transport to I/O box Media jam in front of VLS6 during bundle output from intermediate transport to I/O box. Media jam in front of VLS12 during bundle output from intermediate transport to I/O box. Media jam in front of VLS2 during bundle output from intermediate transport to I/O box.

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Faults Code EC Meaning Error of hall sensors Status messages Remedy Check the plug connection on the dispenser's board (bottom of dispenser module). Restart the system Replace the dispenser module, if necessary. Hall sensor element 1 is defective or plug is not plugged in. Soiled roller, or paper remaining in roller. Hall sensor element 2 is defective or plug is not plugged in. Soiled roller, or paper remaining in roller.

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Status messages Code EC Meaning Media jam in reject transport area Faults Remedy 0116, 0180, 0182 Remove any jammed media between the reject transport and the dispenser module. Make sure the rocker is assembled in the correct position in relation to the axis inside the dispenser module (dispenser module has to be removed for this purpose). Check the motors of the dispenser module and the reject transport. Restart the CCDM. Replace the dispenser module and/or the reject transport. 0171: Remove any jammed media between the reject transport and the dispenser module or in the reject module. Check whether the belt of the reject transport is laying on the center of the guiding rollers. Restart the CCDM. Replace the dispenser module and/or the reject transport. Paper jam in reject path. Mechanical initialization of cam disk not correct due to blocking. Mechanical initialization of swivel transport 2 not correct. Photosensor VLS6 / VLS2 is defective or soiled. Dispensing motors VSM2/3 do not run properly. Media jam stacker => I/O transport

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Faults Code EC Status messages Meaning Remedy A paper jam has occurred in the paper path between stacker and I/O transport. Photosensor VLS6 is defective or soiled. Transport errors: motors (RSM1 / VSM1) do not run properly. Incorrect cam disk position caused by jam or defect: I/O stacker should be lowered to ensure free reject path (VSM8 / VLS9). Swivel transport 2 is not on top due to blocking etc. (VSM6 / VLS4). Media jam found in front of VLS12 during reject box clearing => I/O box. Error of the cam Restart the CCDM. disk Check the cam disk position (release). Replace the dispenser module, if necessary. Drive is mechanically blocked. Home position photosensor is defective or soiled (VLS9). Transport error: motor does not run properly (VSM8). or diagnostic test triggered by operator: cam disk in dispenser module defective. Drive is mechanically blocked. Home position photosensor is defective or soiled (VLS9). Transport error: motor does not run properly (VSM8).

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Status messages Code EC Meaning Media jam in front of or in the alignment station Faults Remedy Clear the media jam in the alignment station Check the photosensors and the motors in the alignment station. Carry out a photosensor adjustment / initialization. Perform a reset Replace the alignment station, if necessary. Document in front of ASL1 or ALS1 is defective (keeps detecting document) -> motor AMS1 possibly defective as a result of which document is not removed from position in front of ASL1. or diagnostic test triggered by operator: alignment station defective. Document jam between alignment station and sensor module or in AMG1 deflector. No document jam. However, document transport caused problems (too much slippage or too much friction). Check transport path 'Intermediate Transport Exit' 'Alignment Station' 'Sensor Transport Entrance'. Document jam in the alignment drum (document remains in drum). Document jam in front of ALS1 during transport of document in the alignment drum Media jam in front of ALS1 during transport of media from alignment drum -> check transport path through drum.

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Faults Code EC Meaning Error magnetic character reader Status messages Remedy Check the plug connection with the magnetic character reader. Restart the CCDM. Replace the magnetic character reader, if necessary. ADDMASTER electronic is defective or not properly connected. Error on check / cash reader
Restart the CCDM. Restart the system If necessary, reload check / cash

reader firmware.
If necessary, reload Firewire

firmware (for check & cash configuration). If the error reoccurs even after the above steps have been taken, replace the check / cash reader. Only relevant for check processing: Check if the firewire cable is connected to the PC and the BEB module. Check the PC's Firewire card. BEB module is defective. External light in Check whether light is falling on check / cash the check / cash reader. reader Clean the scanner lines of the check / cash reader. Carry out a photosensor adjustment / initialization. Restart the system External light in check / cash reader Banknote level detected (light level too high due to soiled roller or document remaining under the reader). Transport pulse missing or outside of admissible tolerance. Banknote level detected (light level too high due to soiled roller or document remaining under the reader).

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Status messages Code EC Meaning Communications problems with check / cash reader Remedy
Re-load the firmware of the check /

Faults

cash reader.
Check and update the banknote

table.
Re-load the currency data. Re-load the firmware. Restart the CCDM. Restart the system Replace the check / cash reader, if

necessary. BEB firmware error. BEB communication error -> control logic RS232 data transfer problems. BEB data error -> configuration data faulty / corrupt. BEB note table configuration not Ok. BEB firmware error. BEB syntax - context error -> control logic RS232 data transfer problems.

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Faults Code EC Meaning Communication problems (time-out) (RS232 interface ) with check / cash reader Status messages Remedy Re-load the check / cash reader's firmware, the CCDM's firmware and/or the Firewire firmware. Restart the system Replace the check / cash reader and / or the back panel incl. storage and sensor transport (logic error). No connection between RS232 interface and BEB interface: Sensor transport not mounted or not properly connected. 'Back panel board' connector has interrupted communication with sensor transport during operation. Module does not reply within specified time limit. Communication errors from BEB to RS232 interface: BEB module not mounted or not properly connected to back panel. BEB firmware and CCDM firmware not compatible. Communication errors RS232 interface with BEB module: BEB module not mounted or not properly connected to back panel. Communication with sensor transport interrupted during operation. Module does not reply within specified time limit. BEB module not mounted or not properly connected to back panel. BEB firmware and CCDM firmware not compatible.

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Status messages Code EC Meaning Media jam in sensor transport Faults Remedy Clear the media jam in the sensor transport In particular, check the area of the 3-way deflector. Diagnostic test triggered by operator: sensor transport defective. Document deflecting unit in alignment station is not functioning; blocked. Photosensor SLS3 is defective or soiled The three-way deflector has returned a document to the alignment module during transport from escrow unit to cassettes or reject tray. Document jam in entrance area of sensor transport: Clear the media jam in the area of the MIC reader and up to the entry of the sensor transport. If the error occurs frequently, replace the MIC reader. Only until version 11xx! Slippage during transport of documents from ALS1 alignment to BEB sensor, or BEB sensor document message issued at the wrong time, so that the document message can no longer be allocated to a specific document. Note could not be identified due to various reasons (event message from BEB sensor during banknote processing). Deflector in wrong position. Jam between sensor transport (paper deflecting units) and in front of RLS1.

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Faults Code EC Meaning Media jam in sensor transport Status messages Remedy Clear the media jam in the sensor transport In particular, check the area of the 3-way deflector. Check functioning of deflectors in sensor transport unit. Restart the CCDM. If the deflectors cannot be addressed correctly, replace the back panel including deposit transport and sensor transport, if necessary (logic error). Document jam between ALS1 and SLS1. Malfunction of three-way deflector (during transport from alignment station). Malfunction of three-way deflector (during transport from the escrow unit). Document jam in area SLS1-> document deflecting units -> escrow unit / reject transport.

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Status messages Code & EC Meaning Media jam in sensor transport Faults Remedy Clear the media jam between sensor and deposit transport. Restart the CCDM. Check functioning of deflectors and motors in sensor transport unit. If the deflectors cannot be addressed correctly, replace the back panel including deposit transport and sensor transport, if necessary (logic error). Media jam in sensor transport unit at three-way deflector. SSM2 motor defective / not connected. SSM2 sensor defective / not connected. or diagnostic test triggered by operator: 3-way deflector (SSM2) in sensor transport defective. Media jam in sensor transport unit at reject deflector. SSM3 motor defective / not connected. SLS4 sensor defective / not connected. or diagnostic test triggered by operator: reject deflector (SSM3) in sensor transport defective.

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Faults Code EC Status messages Meaning Remedy Document jam Clear the jam between sensor and between sensor reject transport. transport and reject Perform a reset. transport Document jam between sensor transport and cassettes / reject transport under RSL1 sensor. Document too short (smaller than 25 mm (0.98")). Jam between sensor transport (paper deflecting units) and behind RLS1. Initialization error Check the reject transport's plug of reject transport connection. To check it first remove the check / cash reader. Check the basic position of shaft / axis and the screw in the reject transport unit. Restart the CCDM. Replace the reject transport, if necessary. Drive is mechanically blocked. Home position photosensor is defective or soiled (RLS3). Transport error: motor does not run properly (RSM2). or Diagnostic test triggered by operator: reject transport defective. Document jam Clear the media jam between between sensor sensor and storage or reject transport and transport. storage / reject Restart the CCDM. transport Document jam between sensor transport and cassettes / reject transport under RSL1 sensor. Banknote does not quit RLS1 photosensor using specified path and tolerance.RLS1. After passing RLS1, the banknote does not reach KLS2 to cassette module using specified path and tolerance.

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Status messages Code EC Meaning Document jam at the escrow unit Faults Remedy Perform a reset. Clear the media jam in the escrow area. Replace the drum module, if necessary. Document jam at escrow unit ELS1 or Diagnostic test triggered by operator: escrow unit defective. Malfunction of deflector. Document has over 2 cm transport slippage / document is jammed under ELS1. During unwinding one document is missing due to external intervention. Jam during unwinding; distance is greater than twice the maximum length of banknotes. Drive blocked, ESM1 motor not connected, motor logic defective, ELS3 fails to detect beginning of tape. Escrow error: A media jam with subsequent initialization has caused documents to be shifted behind the last reachable position on the SCROW drum and can only be removed manually. CAUTION: Do not turn the ESCROW further than the last visible note/check, as the ESROW will otherwise be destroyed! Remove the documents in the ESCROW and reset the D-Loc. Restart the CCDM. Carry out a photosensor adjustment / initialization. Replace the dispenser module, if necessary. Banknote from escrow unit does not reach RLS1 Escrow tape Check the tape of the escrow unit. defective Perform a reset. Replace the escrow unit. Torn band or full drum; tape no longer under ELS2. Band torn; tape no longer under ELS2.

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Faults Status messages

Error messages of photosensors

i
Code

Photosensors VLS7, ALS1 and SLS3 can only be checked when the CCDM components are closed. EC Meaning Error photosensor in dispenser Remedy If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the dispenser. Blinking: VLS10 out of service Constant: VLS10 in dispenser soiled
Blinking: VLS1 out of service Constant: VLS1 in dispenser soiled Blinking: VLS7 out of service Constant: VLS7 in dispenser soiled Blinking: VLS2 out of service Constant: VLS2 in dispenser soiled Blinking: VLS12 out of service Constant: VLS12 in dispenser soiled Blinking: VLS6 out of service Constant: VLS6 in dispenser soiled Blinking: VLS11 out of service Constant: VLS11 soiled

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Status messages Code EC Meaning Error photosensor in alignment station Faults Remedy If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the alignment station. Blinking: ALS3 out of service Constant: ALS3 soiled
Blinking: ALS4 out of service Constant: ALS4 soiled Blinking: ALS2 out of service Constant: ALS2 soiled Blinking: ALS1 out of service Constant: ALS1 soiled First check whether the cover of the alignment station is

closed properly. Magnetic character reader not closed: Blinking: SLS3 out of service Constant: SLS3 soiled

First check whether the magnetic character reader is closed properly. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the magnetic character reader.

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Faults Code EC Meaning Error at photosensor SLS1: Blinking: SLS1 out of service Constant: SLS1 soiled Status messages Remedy If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists replace the back panel incl. sensor and storage transport. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the escrow. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the escrow. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists replace the back panel incl. sensor and storage transport.

Error at photosensor ELS1: Blinking: ELS1 out of service Constant: ELS1 soiled Error at photosensor ELS5: Blinking: ELS5 out of service Constant: ELS5 soiled Error at photosensor RLS1: Blinking: RLS1 out of service Constant: RLS1 soiled

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Status messages Code EC Meaning Error at photosensor RLS2: Blinking: RLS2 out of service Constant: RLS2 soiled Error at photosensor KLS2: Blinking: KLS2 out of service Constant: KLS2 soiled Error at photosensor KLS3: Blinking: KLS3 out of service Constant: KLS3 soiled Error at photosensor KLS8: Blinking: KLS8 out of service Constant: KLS8 soiled Faults Remedy If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the reject transport. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the cassette module. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the cassette module. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the cassette module.

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Faults Code EC Meaning Error at photosensor KLS11: Blinking: KLS11 out of service Constant: KLS11 soiled Error at photosensor KLS1_5: Blinking: KLS1_5 out of service Constant: KLS1_5 soiled Error at photosensor KLS2_5: Blinking: KLS2_5 out of service Constant: KLS2_5 soiled Status messages Remedy If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the cassette module and/or cassette 1. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the cassette module and/or cassette 1. If you can get to the photosensor, try to clean it. Check the photosensor using KDIAG. Synchronize the photosensors. If the error persists, replace the cassette module and/or cassette 1.

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Status messages Faults

Error messages in the cassette module section

Code EC Meaning Deflector in sensor transport has wrong position. Remedy Clear the media jam between transfer transport and cassette module. Remove the media jam in the cassette module - retract / banknote / check cassette (cassettes have to signed on again). Restart the system Replace the cassette module, if necessary. Deflector in sensor transport has wrong position. or Diagnostic test triggered by operator: cassette module defective. Banknote does not quit KLS2 photosensor near module entrance using specified path + tolerance. Banknote detected near module entrance (KLS2) does not reach KLS3 to retract cassette using specified path + tolerance. Banknote detected near module entrance (KLS2) does not reach KLS8 to cassette 1 using specified path + tolerance. Banknote detected near module entrance (KLS2) does not reach KLS11 to cassette 2 using specified path + tolerance.

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Faults Code EC Meaning Incorrect position of deflector in cassette module Status messages Remedy Check position of deflector in cassette module. Check function of deflector in cassette module. Perform a reset. Restart the system Replace the cassette module, if necessary. There is some paper left inside the deflector. Motor not connected. Hybrid photosensor before reset is defective. or diagnostic test triggered by operator: deflector (KSM5) in cassette module defective. Deflector (cassette 1 / cassette 2) is not functioning or diagnostic test triggered by operator: deflector (KSMx) in cassette module defective.

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Status messages Code EC Meaning Incorrect position of deflector in cassette module Faults Remedy Remove the media jam in the direction of cassette 1 (standard check cassette). Restart the system Replace the cassette module, if necessary. Incorrect position of deflector in cassette module Banknote does not quit KLS8 photosensor near entrance to cassette 1 using specified path + tolerance. Error in cassette 1 Permanent status display: Remove the cassette 1 and empty it. Blinking status display: Check proper fit of cassette 1 and re-insert cassette 1 properly, if necessary. Check the plug connection between the controller and the cassette module. Restart the CCDM. Replace cassette 1 or replace the entire cassette module, if necessary. Stacker logic not connected (plug X1). Stacker wheel in banknote cassette / check cassette blocked. Banknote cassette / check cassette is not fully inserted (magnet on stacker wheel does not trigger hall sensor). Belt between stepper motor and stacker wheel has come off / is torn. Home position magnet on stacker wheel is missing / has fallen off. Hall sensor is defective / not connected.

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Faults Code EC Meaning Incorrect position of deflector in cassette module Status messages Remedy Clear the media jam in the direction of cassette 2 (cash box). Restart the system Replace the cassette module, if necessary. Incorrect position of deflector in cassette module Banknote does not quit KLS11 photosensor near entrance to cassette 2 using specified path + tolerance. Error in cassette 2 Permanent status display: Remove the cassette 2 and empty it. Blinking status display: Check proper fit of cassette 2 and re-insert cassette 2 properly, if necessary. Check the plug connection between the controller and the cassette module. Restart the system Replace cassette 2 or replace the entire cassette module, if necessary.

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Status messages Code EC Meaning Incorrect position of deflector in cassette module Faults Remedy Check position of deflector in cassette module. Check function of deflector in cassette module. Perform a reset. Restart the system Replace the cassette module, if necessary. Incorrect position of deflector in cassette module Banknote does not quit the photosensor near KLS33 entrance of retract cassette using the specified path + tolerance. Switching between retract cassettes is not functioning or diagnostic test triggered by operator: deflector (KSMx) in cassette module defective.

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Faults Sensors and actuators

Sensors and actuators

Description of sensors / actuators
Structure of brief designations
These elements are named in accordance with the following principle: Position 1: Positions 2 to 3: Positions 4 to 5: Functional unit or function Element type Sequential number of the element

Example: KHS10 Designation of the 10th Hall sensor in the cassette module Exception: For the deflectors in the transport paths taken by the media, there is no encoding of functions or functional units. Instead, they are designated by a sequential number (e.g. W1).

Abbreviations for functional units or functions

Abbreviation A D E K R S V Meaning Alignment Print Escrow (storage on a drum) Cassette module Reject transport unit Sensor Dispenser module

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Sensors and actuators Faults

Abbreviation for element types

Abbreviation CE HS LS Meaning Scan line Hall sensor Photosensor; The technical variant is not distinguished in the abbreviation, but it can precede the designation in text form. Example: Hybrid photosensor KLS8 Electromagnet Microswitch Stepper motor Ultrasound sensor for double dispensing Deflector

MG MS SM UDS W

Overview of sensors and actuators

The following illustrations provide an overview of the CCDM sensor and actuator positions. The meaning of each of the sensors / actuators are described in the following sections.

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Faults Sensors and actuators

CCDM head module

Chassis II and VM2

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Sensors and actuators Faults

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Faults Sensors and actuators

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Sensors and actuators Faults

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Faults Chassis P and VM3 Sensors and actuators

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Sensors and actuators Faults

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Faults Sensors and actuators

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Sensors and actuators Faults

CCDM cassette module

Cassette module for plastic cassettes
KLS 11 KLS 3 KLS 2 KSM 2 W4 KLS 4 KSM 4 KSM 7 W5 KSM 3 KLS 5 KLS 1_4 KLS 1_2 KLS 1_1 KSM 5 KSM 6 KLS 6 KLS 8 KLS 10

KLS 2_5 KLS 2_4 KLS 2_2 KLS 2_1

KLS 1_5

KSM 1

KSM 2

2
KLS 2_3 KDC 2 KDC 1 KLS 1_3

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Faults Cassette module ProCash 3100(xe) Sensors and actuators

Safety switch

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Cassette 2

Cassette 1

Controller

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Sensors and actuators Faults

Shutter
Sensor LS1,LS2 Function LS1 Shaft in the positions 'Open' and 'Closed'. LS2 Partly open and in combination with the hybrid photosensor LS1 it detects which of the two possible final positions has been reached. Checks if flap is closed.

LS3

You will find more detailed descriptions in the respective system manuals.

Dispenser module
Actuator VMG1 VMS1 VMS2 VSM1 Function Retaining shaft magnet; presses retaining shaft against the counterrotation shaft Sender coil for metal detection Receiver coil for metal detection Stepper motor input/output transport; drives the transport rollers in swivel transport unit 1 and the transport belt in swivel transport unit 2. Stepper motor for driving transport rollers; transport roller shaft / pressure shaft Stepper motor for driving the counterrotation shaft Stepper motor for driving the transport belts in the intermediate transport; the motor is located on the chassis behind the motor RSM2 of the reject transport unit. Stepper motor for lowering/raising the hinged drive unit 1 Stepper motor for lowering/raising the hinged drive unit 2 Stepper motor for width setting Stepper motor for driving the hinged mechanism of the counterrotation shaft and activating the pinch rollers for separation Stepper motor for the lower bundle transport unit

VSM2 VSM3 VSM4

VSM5 VSM6 VSM7 VSM8

VSM9

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Faults Sensor UDS VHS1 VHS2 VLS1 VLS2 VLS3 VLS4 VLS5 VLS6 VLS7 VLS8 VLS9 Sensors and actuators Function Ultrasound sensor for double document Hall sensor foreign object detector (operator side) Hall sensor foreign object detector (rear panel side) Photosensor bundle input/bundle output Photosensor between input/output transport for separator unit ('Detection of last medium') Hybrid photosensor for monitoring lowering of hinged drive unit 1; 'Home position sensor' Hybrid photosensor for monitoring lowering of hinged drive unit 2; 'Home position sensor' Hybrid photosensor for timing disk in hinged drive unit 2 Photosensor, empty dispensing sensor (LAM) Photosensor 'medium in intermediate transport' Hybrid photosensor for width setting; 'Home position sensor' Hybrid photosensor at cam for the motion of the counterrotation shaft 'Home position sensor' Photosensor in input / output unit for controlling removal Photosensor in input / output unit for controlling insertion and removal Photosensor for monitoring documents in the input/output area Photosensors for monitoring document edges in the input/output area

VLS10 VLS11 VLS12 VLS13, VLS14

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Sensors and actuators Faults

Alignment station
Actuator AMG1 ASM1 ASM2 Sensor ALS1 ALS2 ALS3 ALS4 Deflector W1 Function Electrical solenoid plunger for deflector 1 Stepper motor for driving transport rollers Stepper motor for driving alignment rollers Function 1st photosensor for recognizing a medium in the transport path 1st photosensor with slit stop for monitoring the alignment of checks on the surface of the drum 2nd photosensor with slit stop for monitoring the alignment of checks on the surface of the drum 2nd photosensor for recognizing a medium in the transport path Function Deflector check alignment/further transport

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Faults Sensors and actuators

Magnetic ink character reader

Actuator SMG1 Function Electric lifting magnet for raising the magnetic head assembly when banknotes pass. Function Magnetic read head and permanent magnetic head for premagnetization Photosensor for magnetic read head

Sensor SMIC SLS3

Check / cash reader

Sensor CCE1 CCE2 Function Scanner line for the bottom of the medium Scanner line for the top side of the medium

Sensor / deposit transport

Actuator SSM1 Function Stepper motor for driving the transport rollers and belts in the magnetic character reader, check/cash reader and sensor transport Stepper motor for controlling deflector W2 Stepper motor for controlling deflector W3 Stepper motor for driving the transport belt in intermedia transport Stepper motor for driving the transport belt in deposit transport

SSM2 SSM3 VSM4 KSM1

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Sensors and actuators Sensor SLS1 RLS1 Faults Function Photosensor for recognizing a medium in sensor transport Photosensor for recognizing a medium between the sensor transport and storage or reject transport; beginning and end detector for entering and exiting medium only chassis P: Photosensor for recognizing a medium between the sensor transport and storage or reject transport. This photosensor is parallel to the RLS1. Hybrid photosensor for recognizing the position of deflector 2 Hybrid photosensor for recognizing the position of deflector 3 Function Redirection escrow unit / reject compartment or cassette storage Redirection reject compartment / cassette storage

DLS1

SLS2 SLS4 Deflector W2 W3

Escrow unit
Actuator ESM1 Function Drive motor escrow unit; Stepper motor inside the drum for driving the drum and the tape winding mechanism Function Beginning and end photosensor; Photosensor, beginning and end detector for entering and exiting medium Hybrid photosensor for monitoring the upper tape; the photosensor serves to recognize the beginning and end of the tape or a rip in the tape. Hybrid photosensor for monitoring the lower tape; the photosensor serves to recognize the beginning and end of the tape or a rip in the tape. Hybrid photosensor for determining the tape speed Photosensor; prenotification for ELS1 when documents are unwound

Sensor ELS1

ELS2

ELS3

ELS4 ELS5

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Faults Sensors and actuators

Printing station
Actuator DSM1 Print head Sensor DLS1 DLS2 Function Stepper motor for ribbon transport

Function Reflective photosensor in front of the print head (as seen from the escrow unit) (only chassis II) Reflective photosensor behind the print head for checking print function (before/after) (only chassis II)

Reject transport
Actuator RSM1 RSM2 Function Stepper motor for driving the transport belt Stepper motor for bundling in reject compartment; for moving reject storage sideways, for lifting and lowering the belt drive and for moving the note stop. Function Photosensor recognizing beginning/end of medium; Photosensor for recognizing a medium between the sensor transport and stacker or reject transport; photosensor, beginning and end detector for entering and exiting medium Photosensor collecting compartment Hybrid photosensor for camshaft; photosensor for controlling the rotation of the camshaft 'Detection of home position'

Sensor RLS1

RLS2 RLS3

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Sensors and actuators Faults

Cassette module
Actuator KDC1 KDC2 KSM2 KSM3 KSM4 KSM5 KSM6 KSM7 Sensor KHS1 KHS2 KHS3 KHS4 KHS5 KHS6 KHS7 KHS8 KHS9 Function DC motor for adjusting the plate in the cassette 1 (right cassette) DC motor for adjusting the plate in the cassette 2 (left cassette) Stepper motor for driving the separator transport and driving the check/cash transfer mechanism Stepper motor for driving the stacking wheel in cassette 1 (right cassette) Stepper motor for driving the stacking wheel in cassette 2 (left cassette) Stepper motor for controlling the retract deflector and the media deflector Stepper motor for controlling the cassette 1 or cassette 2 deflector Stepper motor for activating the counterfeit notes compartment Function Hall sensor for stacking wheel position cassette 1 (right cassette) for monitoring the stacking wheel position (every 120) Hall sensor cassette 1 'Plate up' for detecting position 'Plate up' Hall sensor cassette 1 'Plate down' for detecting position 'Plate down' (cassette full) Hall sensor for stacking wheel position cassette 2 (left cassette) for monitoring the stacking wheel position (every 120) Hall sensor cassette 2 'Plate up' for detecting position 'Plate up' Hall sensor cassette 2 'Plate down' for detecting position 'Plate down' (cassette full) Hall sensor for cassette 1 (right cassette) present Hall sensor for retract cassette present Hall sensor for cassette 2 (left cassette) present

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Faults Sensor KLS2 KLS3 KLS4 KLS5 KLS6 KLS8 KLS9 KLS10 KLS11 KLS12 KLS1_1 Sensors and actuators Function Photosensor in transport path at start of cassette module Photosensor in transport path before retract cassette Hybrid photosensor for detecting the retract cassette Hybrid photosensor for recognizing the position of deflector W4 (and deflector W5) Hybrid photosensor for recognizing the position of deflector W5 Photosensor in transport path before cassette 1 (right cassette) Photosensor for monitoring the touch activation force exerted by stack against stacking wheel 'Cash' Hybrid photosensor for recognizing the position of the counterfeit notes compartment Photosensor in transport path before cassette 2 (left cassette) Photosensor for monitoring the touch activation force exerted by stack against stacking wheel 'Cash' Hybrid photosensor for recognizing the stacking wheel position cassette 1 for monitoring the stacking wheel position (every 120) Hybrid photosensor in cassette 1 for detecting 'Lifting plate up' for reporting 'Lifting plate up' position. Hybrid photosensor in cassette 1 for reporting 'Cassette 1 full'. Hybrid photosensor, digital: The hybrid photosensor inside the cassette reports: The cassette contains checks / banknotes Sharp GP1A71A: The switch is activated by the operator, outward optical marking (green/black) and electrically to the system. Photosensor in the plastic cassette 1 for message 'Cassette full' Hybrid photosensor for recognizing the stacking wheel position cassette 2 for monitoring the stacking wheel position (every 120) Hybrid photosensor in cassette 2 for detecting 'Lifting plate up' for reporting 'Lifting plate up' position. Hybrid photosensor in cassette 2 for reporting 'Cassette 2 full'.

KLS1_2 KLS1_3 KLS1_4

KLS1_5 KLS2_1

KLS2_2 KLS2_3

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Sensors and actuators Sensor KLS2_4 Faults Function Hybrid photosensor, digital: The hybrid photosensor inside the cassette reports: The cassette contains checks / banknotes Sharp GP1A71A: The switch is activated by the operator, outward optical marking (green/black) and electrically to the system. Photosensor in the plastic cassette 2 for message 'Cassette full' Cassette 1: The microswitch is located in the cassette. If the cassette is in the device and the cassette door is opened, the switch also opens and reports: 'Door open'. If the cassette is removed - plug connection interrupted message the same as if door is opened. Cassette 2: The microswitch is located in the cassette. If the cassette is in the device and the cassette door is opened, the switch also opens and reports: 'Door open'. If the cassette is removed - plug connection interrupted message the same as if door is opened. Function Deflector for directing medium into the retract cassette or in cassettes 1 or 2 Deflector for directing medium into cassette 1 or in cassette 2

KLS2_5 KMS1

KMS2

Deflector W4 W5

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