CCDM

CCDM
Service Manual
Self-Service
Systems
Questions and suggestions
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CCDM - Service Manual 01750062112 C

CCDM
Service Manual
Edition November 2005

Copyright © Information and trademarks
© Wincor Nixdorf International GmbH 2005
All rights, including rights of translation and

rights of reproduction by reprinting, copying
or similar methods, even of parts, are
reserved.
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All rights, including rights created by patent

grants or registration of a utility model or
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reserved.
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products mentioned in this manual are
trade names and/or trademarks of their
respective manufactures.
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produced using paper
treated with chlorine-free
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CCDM - Service Manual 01750062112 C

Contents..…………....………...…............
Introduction.............................................
Device Integration...................................
Configuration Options……….................
Overview of Components......................
Description of Components..................
Function Description..............................
Function Test..........................................
Faults.......................................................
Removal/Installation of Components...
Maintenance and Service......................
Appendix.................................................
01750062112 C CCDM - Service Manual 0-1

0-2 CCDM - Service Manual 01750062112 C
Contents
Introduction .................................................................................................. 1-1

Symbols used in this manual.......................................................................... 1-1
Important safety precautions .......................................................................... 1-1
General information........................................................................................ 1-2
Structure of the manual .................................................................................. 1-3
Outline....................................................................................................... 1-3
Supplementary documentation ................................................................. 1-3
Environmental protection................................................................................ 1-4
Disposing of used consumables ............................................................... 1-4
Labels on plastic case parts...................................................................... 1-4
Returning, recycling and disposing of used units and consumables ........ 1-4
Further information.................................................................................... 1-4
Abbreviations.................................................................................................. 1-5
Device Integration ........................................................................................ 2-1

General........................................................................................................... 2-1
Version 1 - Head module in the safe .............................................................. 2-2
Version 2 - Head module in the top part......................................................... 2-3
Configuration Options ................................................................................. 3-1

General........................................................................................................... 3-1
Head module .................................................................................................. 3-1
Cassette module ............................................................................................ 3-2
Standard cassette module (metal) (SK21.1)............................................. 3-2
Cassette module for plastic cassettes (SK21.2) ....................................... 3-2
Cassette module ProCash 3100 (SK31.0)................................................ 3-2
Cassette module ProCash 3100(xe) (SK31.1).......................................... 3-3
Overview of the Components...................................................................... 4-1

Components of the head module ................................................................... 4-2
Dispenser module ..................................................................................... 4-2
Dispenser module (01750047708) ...................................................... 4-2
Dispenser module (01750079779) ...................................................... 4-3
Rocking bar............................................................................................... 4-4
Rocking bar (01750047726) ................................................................ 4-4
Rocking bar CCDM VM2 assembled (01750079781) ......................... 4-5
Metal detection (01750076812) ................................................................ 4-6
Cover for metal detection (01750080208) ................................................ 4-7
01750062112 C CCDM - Service Manual I-1

Contents
Intermediate transport............................................................................... 4-8

Intermediate transport (01750064624)................................................ 4-8
Intermediate transport (01750079797)................................................ 4-9
Intermediate transport 2 (01750086849)........................................... 4-10
Alignment station (01750065105)........................................................... 4-11
Magnetic ink character reader ................................................................ 4-12
Magnetic ink character reader (01750054847) ................................. 4-12
Magnetic ink character reader (01750097825) ................................. 4-13
Magnetic ink character reader dummy (01750058122)..................... 4-14
Magnetic ink character reader dummy (01750097826)..................... 4-15
Cheque / cash reader ............................................................................. 4-16
Cheque / cash reader (01750064570) .............................................. 4-16
Cash reader (01750068334) ............................................................. 4-17
Cheque reader .................................................................................. 4-18
Escrow .................................................................................................... 4-19
Escrow (01750045965) ..................................................................... 4-19
Escrow (01750079818) ..................................................................... 4-20
Amplifier / controller boards .................................................................... 4-21
Amplifier / controller boards (01750066608)) .................................... 4-21
Amplifier / controller boards assy. (01750080807))........................... 4-23
Reject transport unit (01750047165) ...................................................... 4-25
Printing station (01750055172)............................................................... 4-27
Snap-in panel for document guide (01750070381) ................................ 4-28
Chassis 2 CCDM assembly (01750079819)........................................... 4-29
Back panel board (01750052539) .......................................................... 4-30
Dispenser board ..................................................................................... 4-31
Components of the cassette module............................................................ 4-32
Cheque / cash transfer mechanism ........................................................ 4-32
Cheque / cash transfer mechanism (01750063208) (old version) .... 4-32
Cheque / cash transfer mechanism (01750077519) (new version)... 4-33
Cassettes for standard cassette module (metal) (SK21.1) ..................... 4-34
Cassette 1 (SK21.1) .......................................................................... 4-34
Cassette 2 (SK21.1) .......................................................................... 4-35
Retract cassette (SK21.1) (01750063500)........................................ 4-36
Cassettes for cassette module for plastic cassettes (SK21.2)................ 4-37
Media cassette (SK21.2) (01750078600).......................................... 4-37
Media cassette (SK21.2 L) (01750078601)....................................... 4-37
Retract cassette (SK21.2) (01750078602)........................................ 4-38
Cassette lock (01750075987) ........................................................... 4-39
Cassettes for cassette module ProCash 3100 (SK31.0) ........................ 4-40
Cheque deposit box for ProCash 3100 (SK31.0) .............................. 4-40
Cassettes for cassette module ProCash 3100(xe) (SK31.1) .................. 4-41
I-2 CCDM - Service Manual 01750062112 C

Contents
Right cassette PC3100 (SK31.1)....................................................... 4-41

Left cassette PC3100 (SK31.1) ......................................................... 4-42
Separator transport ................................................................................. 4-43
Separator transport (SK21.1) for standard cassette module
(metal) ............................................................................................... 4-43
Separator transport (SK21.2) for cassette module for
plastic cassettes ................................................................................ 4-44
Separator transport (SK21.2 L) for cassette module for
plastic cassettes ................................................................................ 4-44
Separator transport (SK31.1) for cassette module
ProCash 3100(xe) ............................................................................. 4-45
Safety switch (01750065875) ................................................................. 4-46
CCDM storage board .............................................................................. 4-47
Storage board for cassette module for ProCash 3100(xe) (SK31.1). 4-47
Storage board for cassette module for plastic cassettes (SK21.2).... 4-47
Storage board for standard cassette module (metal) (SK21.1) ......... 4-48
Sensors and actuators ................................................................................. 4-49
Function elements and controls ................................................................... 4-50
Block diagram............................................................................................... 4-51
Description of Components ........................................................................ 5-1

Magnetic ink character reader........................................................................ 5-1
Structure ................................................................................................... 5-1
Function description.................................................................................. 5-1
Device integration ..................................................................................... 5-2
Cheque / cash reader..................................................................................... 5-2
Structure ................................................................................................... 5-2
Processing banknotes............................................................................... 5-3
Processing cheques.................................................................................. 5-4
Device integration ..................................................................................... 5-4
Escrow unit..................................................................................................... 5-5
Structure ................................................................................................... 5-5
Device integration ................................................................................... 5-10
Reject transport unit ..................................................................................... 5-11
Structure ................................................................................................. 5-11
Function description................................................................................ 5-12
Device integration ................................................................................... 5-13
Alignment station.......................................................................................... 5-14
Structure ................................................................................................. 5-14

Contents
Dispenser module ........................................................................................ 5-18

Structure ................................................................................................. 5-18
Function description.................................................................................... 6-1

Functions........................................................................................................ 6-1
How the CCDM works.................................................................................... 6-2
Cheque processing................................................................................... 6-2
Banknote processing ................................................................................ 6-3
LEDs .............................................................................................................. 6-5
Function buttons............................................................................................. 6-7
Description of transport paths ........................................................................ 6-8
Version with standard cassette module (metal) (SK21.1)......................... 6-8
Transport from the input / output area to the escrow unit.................... 6-8
Transport from the escrow unit to the cassette module ...................... 6-9
Transport from the escrow unit to the input / output area.................. 6-10
Transport from the input / output area to the retract cassette in the
cassette module ................................................................................ 6-11
Transport path for a rejected medium ............................................... 6-12
Version with cassette module for plastic cassettes (SK21.2) ................. 6-13
Transport from the input / output area to the escrow unit.................. 6-13
Transport from the escrow unit to the cassette module .................... 6-14
Transport from the input / output area to the retract cassette in the
cassette module ................................................................................ 6-16
Version with cassette module for ProCash 3100(xe) (SK31.1) .............. 6-18
Transport from the input / output area to the escrow unit.................. 6-18
Transport from the escrow unit to the cassette module .................... 6-19
Function Test................................................................................................ 7-1

Test button ..................................................................................................... 7-1
Calling the function codes .............................................................................. 7-1
Calling the service function codes.................................................................. 7-3
Faults............................................................................................................. 8-1
Status messages............................................................................................ 8-1
Status display ........................................................................................... 8-1
Localizing the cause of the error............................................................... 8-2
Error codes / warning codes ..................................................................... 8-3

Contents
Error messages in the area of the head module ................................. 8-5

Error messages of photosensors....................................................... 8-25
Error messages in the cassette module section................................ 8-48
Sensors and actuators ................................................................................. 8-53
Description of sensors / actuators........................................................... 8-53
Structure of brief designations........................................................... 8-53
Abbreviations for functional units or functions ................................... 8-53
Abbreviation for element types .......................................................... 8-54
Overview of sensors and actuators......................................................... 8-54
CCDM head module .......................................................................... 8-55
CCDM cassette module..................................................................... 8-59
Shutter .................................................................................................... 8-62
Dispenser module ................................................................................... 8-62
Alignment station .................................................................................... 8-64
Magnetic character reader ...................................................................... 8-65
Sensor / deposit transport....................................................................... 8-65
Escrow unit ............................................................................................. 8-66
Printing station ........................................................................................ 8-67
Reject transport unit................................................................................ 8-67
Cassette module ..................................................................................... 8-68
Removal/Installation of Components ......................................................... 9-1

General........................................................................................................... 9-1
View of the CCDM.......................................................................................... 9-1
View of the standard cassette module (metal).......................................... 9-2
View of the cassette module for plastic cassettes .................................... 9-3
View of cassette module ProCash 3100(xe)............................................. 9-4
Power interrupt ............................................................................................... 9-5
Removing the cover plate............................................................................... 9-6
Removing / inserting cassettes ...................................................................... 9-7
Standard cassette module (metal) ............................................................ 9-7
Removing / inserting the retract cassette ............................................ 9-7
Removing / inserting cassette 2 .......................................................... 9-8
Removing / inserting cassette 1 .......................................................... 9-9
Cassette module for plastic cassettes .................................................... 9-10
Removing / inserting the retract cassette .......................................... 9-10
Removing / installing a media cassette ............................................. 9-11
Cassette module ProCash 3100(xe)....................................................... 9-12
Removing / inserting left cassette...................................................... 9-12
Removing / inserting right cassette ................................................... 9-13
Opening / closing components ..................................................................... 9-14

Contents
Pulling out / pushing in the dispenser ..................................................... 9-14

Opening / closing the intermediate transport .......................................... 9-15
Opening / closing the alignment station.................................................. 9-15
Head module................................................................................................ 9-16
Dispenser module................................................................................... 9-16
Intermediate transport............................................................................. 9-18
Metal detection ....................................................................................... 9-19
Rocking bar in the dispenser module ..................................................... 9-21
Control panel .......................................................................................... 9-28
Frontload (control panel on the dispenser module)........................... 9-28
Rearload (control panel on the escrow) ............................................ 9-31
Alignment station .................................................................................... 9-32
Magnetic ink character reader ................................................................ 9-33
Amplifier / controller boards .................................................................... 9-35
Escrow unit ............................................................................................. 9-37
Reject transport unit................................................................................ 9-39
Print station............................................................................................. 9-41
Print head ............................................................................................... 9-45
Chassis ................................................................................................... 9-47
Safety switch head module..................................................................... 9-49
Cheque / cash transfer mechanism ........................................................ 9-50
Standard cassette module (metal) ............................................................... 9-51
Separator transport................................................................................. 9-51
Storage board ......................................................................................... 9-53
Cassette module for plastic cassettes.......................................................... 9-55
Safety switch cassette module ............................................................... 9-55
Separator transport................................................................................. 9-57
Storage board ......................................................................................... 9-58
Lock on media cassettes ........................................................................ 9-59
Media cassette handle............................................................................ 9-59
Cassette module ProCash 3100(xe) ............................................................ 9-61
Safety switch cassette module ............................................................... 9-61
Storage board ......................................................................................... 9-62
Maintenance and Service .......................................................................... 10-1

General ........................................................................................................ 10-1
Dispenser module ........................................................................................ 10-1
Cheque / cash reader................................................................................... 10-1
Consumables ............................................................................................... 10-2
Orders..................................................................................................... 10-2
Notes on using cleaning materials.......................................................... 10-3

Contents
Printer ribbon cartridge ........................................................................... 10-3

Print head................................................................................................ 10-3
Approved maintenance materials................................................................. 10-4
Appendix ..................................................................................................... 11-1

Technical data .............................................................................................. 11-1
General ................................................................................................... 11-1
Cassettes ................................................................................................ 11-3
Media ...................................................................................................... 11-4
Pin assignments back panel......................................................................... 11-5
X1 (power supply unit) ............................................................................ 11-5
X2 (LINE XSA Baumer sensor)............................................................... 11-6
X3 (MICR) ............................................................................................... 11-7
X4 (alignment station) ............................................................................. 11-8
X5 (storage transport - motor)................................................................. 11-9
X6 (intermediate transport - motor)......................................................... 11-9
X7 (sensor transport - motors) .............................................................. 11-10
X8 (escrow - motor) .............................................................................. 11-10
X9 (printing station - ribbon transport) .................................................. 11-11
X10 (escrow - sensors) ......................................................................... 11-12
X11 (reject transport - sensors / motors) .............................................. 11-13
X12 (sensor transport - sensors) .......................................................... 11-14
X13 (printing station - print monitoring)................................................. 11-15
X14 (dispenser print I)........................................................................... 11-16
X15 (dispenser print II).......................................................................... 11-17
X16 (controller) ..................................................................................... 11-18
X17 (amplifier I)..................................................................................... 11-21
X18 (amplifier II).................................................................................... 11-24
X19 (printing station - pinhead)............................................................. 11-26
X20 (safety switch)................................................................................ 11-27
X21 (sensor transport - switch motor 2)................................................ 11-28
X22 (sensor transport - switch motor 3)................................................ 11-28
Pin assignment amplifier ............................................................................ 11-29
X1 (amplifier - controller I)..................................................................... 11-29
X2 (amplifier - controller II).................................................................... 11-30
X4 (back panel I)................................................................................... 11-31
X5 (shutter) ........................................................................................... 11-34
X6 (V.24 PC)......................................................................................... 11-35
X7 (back panel II).................................................................................. 11-36
Assignment controller................................................................................. 11-38
X4 (back panel I - dispenser logic)........................................................ 11-38
X2 (cassette module – storage board).................................................. 11-41

Contents
X3 (amplifier) ........................................................................................ 11-43

X4 (amplifier) ........................................................................................ 11-44
X5 (system - control panel)................................................................... 11-45
X7 ......................................................................................................... 11-46
X8 (reserve) .......................................................................................... 11-47
X9 ......................................................................................................... 11-48
X10 (USB)............................................................................................. 11-50
Pin assignments storage board.................................................................. 11-51
X1 (storage cassette)............................................................................ 11-51
X2 (sensors left).................................................................................... 11-53
X3 (sensors right) ................................................................................. 11-55
X4 (DC - Motor cassette 2) ................................................................... 11-56
X5 (DC - Motor cassette 1) ................................................................... 11-56
X6 (motor distributor transport)............................................................. 11-57
X7 (motor stacking wheel cash)............................................................ 11-57
X8 (motor stacking wheel cheque) ....................................................... 11-58
X9 (motor switch control) ...................................................................... 11-58
X10 (safety switch) ............................................................................... 11-59
Pin assignment dispenser board................................................................ 11-60
X1 (back panel - dispenser print I)........................................................ 11-60
X2 (back panel - dispenser print II)....................................................... 11-61
X3 (sensors and motors to dispenser print).......................................... 11-62
X4 (metal detection to dispenser print) ................................................. 11-63
X5 (motor input / output transport)........................................................ 11-64
X6 (motor transport rollers drive) .......................................................... 11-64
X7 (motor counterrotation shaft) ........................................................... 11-65
X8 (motor cam disk).............................................................................. 11-65
X9 (foreign body sensor) ...................................................................... 11-66
X10 (photosensor - dispenser, magnet) ............................................... 11-67
X11 (control panel) ............................................................................... 11-68
X12 (ultrasound sensor) ....................................................................... 11-68
X15 (distributor print) ............................................................................ 11-69

Introduction
This service manual has been compiled for authorized service personnel only.
Symbols used in this manual

− Text following a dash represents an item in a list.
" " Text in quotation marks refers to other chapters or sections in this
document.
• Text following this symbol describes actions to be performed in the

specified order.
Text following this symbol should be given special attention in order to
avoid damage and injury.
i Text following this symbol contains general information to facilitate use

of the device and help avoid operating errors.
Important safety precautions

Before performing any work on the CCDM disconnect the device from
power and unplug the power supply cable from the CCDM (see
chapter "Removal / Installation of Components", section "Power
interrupt"). Observe the safety precautions (refer to the service manual
of the device).

General information Introduction
General information
The cheque / cash deposit module (or CCDM) is designed to be integrated in
automated teller machines and full-function self-service terminals. It consists
of the metal detection unit, dispensing station, input/output area, alignment
station, magnetic character reader, cheque/cash reader, escrow unit, print
station and cassette module.
The CCDM offers the following functions:
− Processing checks
− Processing banknotes,
− Depositing the media in the appropriate cassettes in the cassette module.
How to operate the CCDM is described in the operating manuals of the

devices which are equipped with the CCDM.

Introduction Structure of the manual
Structure of the manual
Outline
The chapter "Introduction" describes the important safety precautions, notes
concerning environmental protection and provides a list of abbreviations. It
also gives an overview of the possible functions of the CCDM.
The chapter "Device Integration" gives an overview of the possible versions
which may be used in the devices.
Views of the individual components of the CCDM, positions of the sensors,
actuators, function elements and controls as well as a block diagram
illustrating the integration of the individual units are shown in the chapter
"Overview of Components".
In the chapter "Function and Integration” you will find a description of the
functions of the components and a description of the transport paths.
CCDM testing is described in the chapter "Function test".
The next chapter lists possible malfunctions and provides information how to
eliminate them.
The next chapter "Removal / Installation of Components" provides detailed
information on how to remove and install the individual units.
The chapter "Maintenance and Service" contains information on required
maintenance work.
The last chapter "Appendix" provides technical data and pin assignments.
Supplementary documentation
For the operation and installation of the system, separate manuals are
available in several languages. These manuals can be ordered from the
publications office. They are also available in the intranet.

Environmental protection Introduction
Environmental protection
Disposing of used consumables

Please dispose of consumables according to the applicable regulations of your
country.
Labels on plastic case parts

Please do not stick any labels on plastic case parts since that would make
recycling more difficult.
Returning, recycling and disposing of used units

and consumables
Details regarding the return and recycling of used units and consumables can
be obtained from your local branch office or from our Recycling Center in
Paderborn:
Tel.: +49 (0) 52 51 8-1 80 10
Fax.: +49 (0) 52 51 8-1 80 15
Further information
can be obtained from our Environmental Protection section (Referat
Umweltschutz):
Tel.: +49 (0) 52 51 693-67 07
Fax.: +49 (0) 52 51 693-67 09
Email: referat.umweltschutz@wincor-nixdorf.com

Introduction Abbreviations
Abbreviations
CCDM Cheque / Cash Deposit Module
CCE Cheque/cash recognition module
DIN German Institute for Standardization
EC Extended Error Code
ECB European Central Bank
ESD Electrostatic Discharge
ISO International Organization for Standardization
KDIAG Components Diagnostics
LED Light-Emitting Diode
MICR Magnetic Ink Character Reader
UART Universal Asynchronous Receiver Transmitter

Abbreviations Introduction

Device Integration
General
Due to different device designs there are two versions of the CCDM.
Version 1 has the cassette module as well as the head module in the safe.
In version 2 the cassette module is located in the safe and the head module is
located in the top part of the device. The transition from the head module to
the cassette module is implemented by means of a transfer transport.
Both versions can be used in frontload as well as rearload devices.
The following sections provide an overview of the two versions.

Version 1 - Head module in the safe Device Integration
Version 1 - Head module in the safe
1 Head module
2 Cassette module

Device Integration Version 2 - Head module in the top part
Version 2 - Head module in the top part
1 Head module in the top of the unit

2 Top of the safe
3 Cheque / cash transfer mechanism
4 Cassette module

Version 2 - Head module in the top part Device Integration

Configuration Options
General
The following sections provide an overview of the various CCDM configuration
options.
Head module
Different reader modules can be integrated in the head module.
Component Part number
Cheque/cash reader (Line XSA) 01750064570
in acc. with ECB art. 6.
Cheque/cash reader (Line XSA) 01750068336
Cash reader (Line XSA) 01750068335
in acc. with ECB art. 6.
Cash reader (Line XSA) 01750068334
Cheque reader not yet released *
Magnetic ink character reader 01750054847 (revision level 4)
Magnetic ink character reader 01750097825 **
Dummy for magnetic ink character 01750058122 (revision level 4)
reader
Dummy for magnetic ink character 01750097826 ***
reader
* Cheque/cash reader 01750064570 is used in place of the cheque

reader.
** replacing magnetic ink character reader 01750054847.
*** replacing magnetic ink character reader dummy 01750058122.

Cassette module Configuration Options
Cassette module
The cassette module can be configured in different ways.
Standard cassette module (metal) (SK21.1)

Component Part number:
Distributor transport (SK21.1) 01750063430
Retract cassette (SK21.1) 01750063500
Cassette 2 (SK21.1) 01750063550
Cassette 1 (SK21.1) 01750063660
Cassette module for plastic cassettes (SK21.2)

Distributor transport (SK21.2 L) 01750091784 *
Retract cassette (SK21.2) 01750078602
Media cassette (SK21.2) 01750078600
Media cassette (SK21.2 L) 01750078601 *
* long version
Cassette module ProCash 3100 (SK31.0)

Cheque storage box (SK31.0) 01750088213

Configuration Options Cassette module
Cassette module ProCash 3100(xe) (SK31.1)

Left cassette PC3100 (SK31.1) 01750067657
Right cassette PC3100 (SK31.1) 01750078460

Cassette module Configuration Options

Overview of the Components
The following sections provide an overview of the individual components of the
CCDM, positions of the sensors, actuators, function elements and controls as
well as a block diagram illustrating the integration of the individual units.

Components of the head module Overview of the Components
Components of the head module
Dispenser module
Dispenser module (01750047708)

The figure shows the dispenser module with the rocker and the control panel.

Overview of the Components Components of the head module
Dispenser module (01750079779)

The figure shows the dispenser module with the rocker and the control panel.

Rocking bar
Rocking bar (01750047726)

Rocking bar CCDM VM2 assembled (01750079781)

Metal detection (01750076812)

The metal detection function consists of the board (01750074657) and the two
metal sensor supports (01750047758).

Cover for metal detection (01750080208)

Intermediate transport
Intermediate transport (01750064624)

Intermediate transport (01750079797)

Intermediate transport 2 (01750086849)

Alignment station (01750065105)

Magnetic ink character reader
Magnetic ink character reader (01750054847)

Magnetic ink character reader (01750097825)

Magnetic ink character reader dummy (01750058122)

Magnetic ink character reader dummy (01750097826)

Cheque / cash reader
Cheque / cash reader (01750064570)

Cash reader (01750068334)

Cheque reader
i The cheque reader is not yet released. In its place, cheque/cash

reader 01750064570 can be used.

Escrow
Escrow (01750045965)

Escrow (01750079818)

Amplifier / controller boards
Amplifier / controller boards (01750066608))

Controller board (01750052532)
X1
S4
X9
X7
X8
X5
S1
X2 X10
X4 X3

Amplifier board (01750052535)
X2
X4
X1
X7
X6 X5

Amplifier / controller boards assy. (01750080807))

Controller board 2 (01750079876)

Amplifier board (01750052535)

Reject transport unit (01750047165)

Base of reject transport unit (01750047165) revision level 5

Printing station (01750055172)

Snap-in panel for document guide (01750070381)

Chassis 2 CCDM assembly (01750079819)

The back panel assembly consists mainly of the back panel board
(01750052539) and the deposit transport (01750055175).

Back panel board (01750052539)
X16
X9 X10 X17
X13 X8
X18
X19
X1
X7
X12
X21
X22
X11 X20
X6
X2
X3
Barcode
X4
X14
X15 X5

Dispenser board
X7 X9 X12
X6
X1
X2
X3
X11
X15 X4
X8 X10 X5

Components of the cassette module Overview of the Components
Components of the cassette module
Cheque / cash transfer mechanism
Cheque / cash transfer mechanism (01750063208) (old

version)

Overview of the Components Components of the cassette module
Cheque / cash transfer mechanism (01750077519) (new

version)

Cassettes for standard cassette module (metal)

(SK21.1)
Cassette 1 (SK21.1)
Part number: Cassette capacity
01750063660 Stack height 250 mm

Cassette 2 (SK21.1)
01750063550 Stack height 250 mm

Retract cassette (SK21.1) (01750063500)

Cassettes for cassette module for plastic

cassettes (SK21.2)
Media cassette (SK21.2) (01750078600)
Media cassette (SK21.2 L) (01750078601)

Long version of media cassette SK21.2.

Retract cassette (SK21.2) (01750078602)

Cassette lock (01750075987)

The lock comprises the clamp and the cylinder lock.
Key 01750001276 belongs to the lock.

Cassettes for cassette module ProCash 3100

(SK31.0)
Cheque deposit box for ProCash 3100 (SK31.0)

Part number: 01750088213

Cassettes for cassette module ProCash 3100(xe)

(SK31.1)
Right cassette PC3100 (SK31.1)

01750078460 approx. 1000 documents

Left cassette PC3100 (SK31.1)

01750067657 approx. 1000 documents

Separator transport
Separator transport (SK21.1) for standard cassette

module (metal)

Separator transport (SK21.2) for cassette module for

plastic cassettes
Separator transport (SK21.2 L) for cassette module for

plastic cassettes
Long version of separator transport SK21.2 (01750083147)

Separator transport (SK31.1) for cassette module

ProCash 3100(xe)

Safety switch (01750065875)

CCDM storage board
Storage board for cassette module for ProCash 3100(xe)

(SK31.1)
Storage board for cassette module for plastic cassettes

(SK21.2)

Storage board for standard cassette module (metal)

(SK21.1)
X10
X4
X2
X8
X3
X9
X7
X5
X6
X1

Overview of the Components Sensors and actuators
Sensors and actuators

The position of the individual sensors and actuators is described in the chapter
"Faults", in the section "Sensors and actuators".

Function elements and controls Overview of the Components
Function elements and controls

The CCDM features a status display and a test button.
The display indicates the status of the CCDM.
The test button is used to test the CCDM. A test can only be executed if the
CCDM is pushed into the device.
The status display and the test button are located on the control panel of the
CCDM.
The following illustration shows the position of the control panel depending on
the device version.
Rearload Frontload
1
1
2
2
1 Status display 2 Test button
The status messages are described in the chapter "Faults", section "Status
messages".
CCDM testing is described in the chapter "Function test".

Magnetic Intermediate transport /
Cheque/cash character Alignment dispenser module / Metal
01750062112 C
(Interfaces) reader X4
reader / 1 station Input/output transport 2 1
detection
1 FireWire ------- (MICR)
Intermediate Separator board
Cheque reader 2 transport Dispenser board Control
2 Hotlink or X1 X2 X11
------- motor panel
Cash reader 1 Frontload
Dummy Plug adapter
Block diagram
Central power X2 X3 X4 X6 X14 X15

UART 3
supply unit UART 2 Back panel board
Overview of the Components
X1 (MICR / metal detection / ultrasonic sensor)

(CCDM version)
X20 X8 X10 X17 X18 X16 X7 X12 X21 X22 X9 X13 X19 X5 X11
Safety X4 X7 X1
switch X1 X3
Amplifier Controller Motor Motors /
ESCROW board board sensors
X2
UART 1 X2
Motors
Sensors
Motor
switch 2
Motor
switch 3
X4
X6 X5
Ribbon
transport
Printing
control
Needle head
X5 Storage Reject
Motor
trans- trans-
Sensortransport Printing station port port
Sensors Control panel
CCDM - Service Manual

V.24 Rearload
(channel 12)
System operating unit or safe
Shutter X1 Storage board

Safety
switch X10
Special
electronics
module Cassette module
User
(power source 6) guidance
System customer panel Safe
4-51
Block diagram
Block diagram Overview of the Components

Description of Components
Structure
This module basically consists of a lower part containing the decoder board
and an upper part containing the premagnetization head and the head to read
magnetic-ink characters.
The lower part also contains a mechanism to lift the magnetic heads. This
mechanism is actuated by electric lifting magnet SMG1. The magnetic heads
are lifted when banknotes pass through.
To simplify handling and maintenance the module has been split up into a
lower part and an upper part that can be swung open.
The transport rollers in the lower part are operated from the outside by a belt
drive that is powered by stepper motor SSM1 in the sensor transport. The
transport rollers in the lower part and upper part (cover) are coupled via
toothed wheels.
Function description
When a cheque passes through the characters are first magnetized by the
premagnetization head and then evaluated by the read head.
Reading is started and stopped with the SYNC signal. Scanning and transport
of the medium are synchronized with the TAKT signal.
The information that has been read (identification number of the submitted
document and other associated data) is passed to the CCE board of the
cheque / cash reader via the RS232 interface (also see the "Cheque / cash
reader" section).

Cheque / cash reader Description of Components
Device integration
The module is pushed onto a bar in the CCDM head module. An additional
pilot bar ensures correct positioning.
A cover plate ensures that the magnetic-ink character reader sits properly.
Power and data are fed in automatically via the back panel connector.
Structure
This module basically consists of the lower and upper scanner arrays, the
CCE board (cheque / cash recognition module) and the transport mechanism.
The two scanner arrays scan the front and back of a medium.
The CCE board is used to prepare and temporarily store data, and to
exchange data with the CCDM controller.
To simplify handling and maintenance the module has been split up into a
lower part and an upper part that can be swung open. Each part contains one
scanner array and one transport drive.
The transport rollers in the base part are operated from the outside by a belt
drive that is powered by stepper motor SSM1 in the sensor transport.
In the closed state, the drive of the transport rollers in the upper part is coupled
via a toothed wheel.

Description of Components Cheque / cash reader
When a medium passes through, its front and rear are scanned
simultaneously. In a transport operation, the images are captured with a
different level of illumination (red and green in the visible spectrum and
infrared) that depends on the job in question (banknote or cheque).
Scanning is started and stopped with the SYNC signal. Scanning and transport
of the medium are synchronized with the TAKT signal.
The firmware can be loaded via the RS232 interface.
The following table provides an overview of the different firmware types and
how they are used.
Firmware Usage
Main firmware Processing banknotes and / or cheques
Firewire firmware Processing cheques
Currency data Processing banknotes
Processing banknotes
Banknotes are captured with red, green and infrared illumination, and
identified and authenticated with the aid of the loaded banknote software.
The quality is checked on the basis of the following criteria at the same time:
− Missing or dog-eared corners
− Open tears
− Edge damage
− Dirt
The result of this quality check is shown a ten-level quality indicator.

Maculated banknotes are also detected.
The banknote identification data is sent to the system unit (PC) via the RS232
interface.

Cheque / cash reader Description of Components
Processing cheques
In the course of cheque processing the documents are captured with red and
green illumination.
The identification number of the submitted cheque and other associated data
are sent from the magnetic-ink character reader to the CCE board via the
RS232 interface. On the CCE board this data and the image data are turned
into a data packet that is sent to the system unit (PC) via the Firewire
interface.
Device integration
The module is pushed onto guide bolts in the CCDM head module. A cover
plate ensures that the cheque / cash reader sits properly.
Power and data are fed in automatically via the back panel connector.
The scanned data is sent to the system unit via a Hotlink interface in the case
of a cheque reader and via a Firewire interface in the case of a cheque / cash
reader or cash reader.

Description of Components Escrow unit
Escrow unit
Structure
1 Drum with stepper 6 Sensor ELS 2

motor ESM 1 7 Deflecting roller
2 Sensor ELS 5 8 Sensor ELS 1
3 Sensor ELS 3 9 Sensor ELS 4
4 Clutch 1 with tape winder 10 Deflecting roller with timing disk
5 Clutch 2 with tape winder
This module basically consists of the winding drum, two clutches with tape
winders, two deflector rollers and the transport mechanism.
The transport of documents is monitored by sensors.
Sensor ELS 1 is a discrete photosensor. From beneath the medium, an emitter
diode that is built into a transparent plastic part in the input/output opening

Escrow unit Description of Components
sends its light to one of the phototransistors located on a panel with a slot. The
photosensor is the start and end sensor for incoming and outgoing media.
Stepper motor ESM 1 is located inside the winding drum. It bears the winding
drum on one end of a shaft. A timing belt wheel is attached to the other end of
the shaft. This wheel uses a timing belt to drive the two coupling shafts with
the tape winders. The toothed belt wheels for the clutch shafts have a
freewheeling mechanism inside. When the drum is rotating to the left (i.e.
media are being unwound) the shaft is driven via the locked freewheeling
mechanism. Now the tape spooling from the drum can be wound up by the
tape reels.
The clutch connecting the clutch shaft to the tape winder is a permanent
magnet clutch (hysterisis clutch) that cannot be switched. The principle of
magnetic torque transfer makes it possible to transfer torque on the one hand
and exert a braking effect on the other hand – and that without wear and tear.
The system acts as a clutch or as a brake, depending on the direction of
rotation (winding or unwinding), with slip compensation in both cases.
A deflector roller bears a timing disk which, in conjunction with timer ELS 4,
is used to identify the speed of the tape because the transport speed of
banknotes (v = 800 mm/s) differs from that of cheques (v = 480 mm/s). The
tape speed has to be adjusted to the speed of the incoming medium. The
circumferential speed at the winding drum is roughly constant (adjusted to
cheques or banknotes), but the speed (frequency) of the stepper motor
changes.
Both tapes are 12.7 mm (1/2") wide and are impervious to the infrared light of
the photosensors in the range of about 850 nm. They have a transparent
leader section on one side, or the opaque matt section has been removed
there. Both tapes are attached congruently at the circumference of the winding
drum. The first tape on the winding drum is attached there with its transparent
section, and the one directly above is fastened with its opaque area.
The result of this is that the tape lying directly on the drum runs to the tape
winder of clutch 2 and the tape on the outside to clutch 1. Consequently hybrid
photosensor ELS 2 reports the end of the tape when there is a transition from
'covered' to 'not covered' – the tapes on the drum have been almost unwound
completely. ELS 3 indicates the beginning of the tapes when there is a
transition from 'covered' to 'not covered'.
Hybrid photosensors ELS 2 and ELS 3 also report tape tears.
Photosensor ELS 5 is only needed while media are unwinding to avoid jams
and the resultant tape damage. Photosensor ELS 5 indicates the passage of a

medium for photosensor ELS 1 which is positioned at a distance of 29 mm. If

no medium appears at photosensor ELS 1 within a short time, stepper motor
EMS1 is stopped immediately.
The escrow is used for temporary storage of media (cheques or banknotes). It
is a drum module in which the media are held on both sides by a tape and
wound together on a drum with both tapes.

Winding
Start
of winding
ELS 1
dark
ESM 1
starts
Signal
Timer
yes ELS 2
Stop or ELS 3 ELS 1
light light
no
ESM 1
stopped
End
of winding
The media are pushed by the upstream sensor transport into the input / output
opening. In the course of this they pass photosensor ELS 1 and thus trigger
the signal to start stepper motor ESM 1 which drives the winding drum.
The speed of the medium is measured with the aid of the timing disk and
photosensor ELS 4 and, depending on the medium, is adjusted to the speed of
the upstream sensor transport by controlling the speed of motor EMS 1.
The stepper motor stops when sensor ELS 1 does not recognize any further
medium or when sensors ELS 2 or ELS 3, which monitor the tapes, recognize
the tape end or a tape tear.

Unwinding
Start
of unwinding
ELS 1 + 5
light
ESM 1
starts
Signal
timer
yes ELS 2
or ELS 3 ELS 5
light dark
no
ELS1
Stop dark after
no 29mm
ja
ELS 5 + 1
light
another
medium
yes
no
ESM 1
stopped
End
of unwinding

Stepper motor ESM 1 starts.

The speed of the medium is measured with the aid of the timing disk and
photosensor ELS 4 and, depending on the medium, is adjusted to the speed
(v = 800 mm/s) of the upstream sensor transport by controlling the speed of
motor EMS 1.
The stepper motor stops when sensor ELS 1 does not recognize any other
medium within a certain time. If a medium follows another in this time the
motor will continue running
The stepper motor also stops when sensors ELS 2 or ELS 3, which monitor
the tapes, recognize the tape end or a tape tear.
Device integration
The escrow is mounted on two rails along the back panel, connected to the
back panel board with two connectors (X8 and X10), and locked with the
sensor transport.
i Technological developments have resulted in dependencies between

the escrow and the chassis.
The following table lists the configuration options.
Escrow unit Chassis

01750045607 01750079819
01750045965 compatible not compatible
01750079818 not compatible compatible
To eliminate jams, the locking lever can be released and the module can be
moved as far as it will go.
When a jam occurs, the media must be unwound from the escrow.
i If necessary, the media can be removed manually in the direction of

the sensor transport.
Make sure that the tapes are not displaced to one side.
On no account may the media be removed sideways from the escrow!

Description of Components Reject transport unit
Reject transport unit
Structure
1 Slide element 7 Flat belt for collecting tray

2 Control motor RSM 2 8 Transport motor RSM 1
3 Sensor RLS 2 9 Document stop
4 Sensor RLS 3 10 Rocker
5 Flat belt for output 11 Sensor VLS 6
6 Sensor RLS 1
This module basically consists of the slide element, control unit and transport
mechanism.
The flat belt for the collecting tray is driven by transport motor RSM 1.
Control motor RSM 2 controls the output of documents.
The transport of documents is monitored by sensors RLS 1, RLS 2, RLS 3 and
VLS 6.

Reject transport unit Description of Components
Collecting documents
1 Document 3 5 Slide element

2 Sensor RLS 1 6 Document 1
3 Document 2 7 Document stop
4 Flat belt
Up to 50 documents are collected in the reject transport and made available

for output as a bundle with a common front edge.
In this process the documents are collected beneath a curved slide element by
means of a centrally positioned flat belt. The documents are transferred on an
overlapping basis, i.e. the end of the previous document extends beyond the
beginning of the next document.
The first document is detected by sensor RLS 1 and transported forward
25 mm by the sensor transport.
When sensor RLS 1 detects the end of the document, the document is moved
forward another 15 mm.
The second document is detected by sensor RLS 1 and is pushed 25 mm
beneath the first document by the sensor transport.
When sensor RLS 1 detects the end of the second document, this document is
moved forward another 15 mm until transfer of the third document.
Other documents are collected in the same way until the last one has arrived.

Description of Components Reject transport unit
This document is moved forward until its front edge is up against the
swivelable document stop. After collection, the documents lie one on top of
another with a flush front edge.
Outputting documents
The control motor causes the flat belt for the output and the document stop to
be swung out, and the entire reject transport to be moved aside to compensate
for lateral movements of the documents while being processed in the CCDM.
The lateral movement amounts to 4.5 mm for cheques with a width between
60 mm and 103 mm. When cheques are wider than 103 mm, the reject
transport is only moved 3 mm to avoid problems in the output tray.
Then the documents are transported to the output.
Device integration
Power and data are fed in through cables via the back panel board.

Alignment station Description of Components
Alignment station
Structure
1 Photosensor VLS7 6 Motor ASM2

2 Photosensor ALS2 7 Rollers axially parallel to the drum
3 Photosensor ALS3 8 Rollers for side alignment
4 Photosensors ALS1 and ALS4 9 Deflector
5 Motor ASM1 10 Magnet AMG1
The alignment station is built like a drum with an inner and outer shell.

Description of Components Alignment station
Rollers (6) and (7) in the drum are driven by two identical stepper motors
(ASM1 and ASM2). Pressure rollers that are held by springs and not driven are
located opposite them.
Rollers (6) are driven by motor ASM1, and are arranged axially parallel to the
drum.
Rollers (7) are driven by motor ASM2 and are arranged in such a way that the
friction force exerted on the medium at the circumference of the roller runs
toward the contact surface. This makes sure that a medium can be moved
forward and sideward simultaneously through the rollers.
The switch is actuated by an electric solenoid plunger (AMG1). When the
magnet is energized the media are guided out of the drum.
Photosensor VLS7 is the intermediate transport's output sensor.
Photosensors ALS1 and ALS4 are positioned next to each other in parallel to
the drum axis. This arrangement extends the path from detection of a medium
by one of the two photosensors. When media have entered the alignment
station askew, in particular, there is a longer path to the switch for the leading
part.
The alignment station's photosensors ALS2 and ALS3 feature a panel with a
slot (see the figure below). Its switching point is roughly 0.5 mm before the
contact surface. Their distance apart in the direction of transport is less than
the smallest medium length to be processed.
1 Panel with slot 5 Photosensor ALS4

2 Photosensor ALS2 6 Medium
3 Contact surface 7 Photosensor ALS 3
4 Photosensor ALS1

Alignment station Description of Components
The following figure shows the procedure for processing a medium that has to
be aligned.
Start
Feed medium
VLS7 dark
ASM1 starts
ALS1 and ALS4 dark
ASM2 starts
ALS1 and ALS4 light

ALS1 and
ALS4 dark
ALS2, ALS3
no
and
ALS1, ALS4
dark
yes
Energize AMG1
ALS2 light
ASM2 stops
ALS1 and ALS4 lightl

t1 30 ms
t2 80 ms
ASM1 stops
AMG1 off
End

Description of Components Alignment station
In the initial state, motors ASM1 and ASM2 are without energy and
photosensors VLS7, ALS1, ALS3 and ALS4 are not covered.
Electromagnet ASM1 is without energy, i.e. the switch is in a position that
keeps the media in the drum.
When photosensor VLS7 in the upstream intermediate transport detects a
medium, motor ASM1 starts and moves the medium through the drum. The
direction of rotation within the alignment drum is always to the left.
When photosensors ALS1 and ALS4 detect the medium ('covered' state),
motor ASM2 starts and the medium is aligned with the contact surface.
The aligned medium passes through sensors ALS2 and ALS3.
If the medium is not recognized by both the photosensors ('not covered' state
for ALS2 and/or ALS3), the medium is not up against the contact surface and
therefore has to be realigned. The medium stays in the alignment drum and
runs through the alignment process again.
The medium has been aligned when both photosensors detect it ('covered'
state).
When photosensors ALS2 and ALS3 have detected that the medium has been
aligned, magnet AMG1 is energized and the switch is positioned so that the
medium can leave the alignment station.
Motor ASM2 stops when the medium passes photosensor ALS2 ('not covered'
state).
When the medium has passed photosensors ALS1 and ALS4 ('not covered'
state) motor ASM1 stops first and energization of magnet AMG1 stops shortly
afterwards.

Dispenser module Description of Components
Dispenser module
Structure
1 Swivel transport 2 6 Pressure roller shaft

2 Swivel transport 1 7 Double dispense sensor
3 Metal detection 8 Foreign body sensor
4 Lower bundle transport 9 Drive roller shaft
5 Counterrotation shaft
The dispenser module basically consists of swivel transports 1 and 2, the

lower bundle transport, the input / output transport, the metal detector and the
bundle alignment margin setter.

Description of Components Dispenser module
Dispensing procedure
If a customer has selected the transaction 'Media input', the shutter opens and
metal detection is activated.
Once the media are input, swivel transport 1, swivel transport 2 and the lower
bundle transport move the bundle towards the separating rollers (pressure
roller shaft, drive roller shaft and counterrotation shaft) and align them.
The top medium is then removed from the bundle and passed to the
intermediate transport. On its way to the intermediate transport, the medium is
checked for double dispenses and foreign objects.
From the intermediate transport, various function modules transport the
medium to the escrow, where it is temporarily stored.
This separation process is repeated until all the notes in the bundle have been
separated and have reached the drum module.
Detecting multiple or double dispenses
If the double dispense sensor detects a multiple or double dispense, further

efforts are made to separate these media. The procedure that is used is based
on the type of multiple dispense detected.
If the media are successfully separated, each separate medium is transported
to the escrow. The remaining media in the bundle are then separated.
If the media cannot be separated, first the remaining bundle and then the
multiple or double dispense are returned to the customer.
Following this, the remaining bundle can be re-inserted and the separation
process continued.
Detecting foreign objects
If a foreign object is detected, first the remaining bundle and then the medium
with the foreign object are returned to the customer.
Following this, the remaining bundle can be re-inserted and the separation
process continued.

Dispenser module Description of Components

Function Description
Functions
The CCDM is designed to be integrated in automated teller machines and full-
function self-service terminals. It enables round-the-clock cash deposit and
automated check handling.
The modular design enables use in various device configurations. The CCDM
can be deployed in both frontload and rearload units.
The CCDM may consist of the following components:
− Metal detection
− Dispenser module
− Intermediate transport
− Alignment station
− Magnetic character reader
− Cheque / cash reader
− Escrow unit
− Printing station
− Cassette module
Status and error codes are displayed on a control panel to indicate the status
of the CCDM. The status messages help to locate and take care of the source
of a fault (see section "LEDs and function buttons").
The input/output area is protected by a shutter built into the device. The
application program installed on the unit enables the use of optical indicators
on the customer panel for user guidance.
The entire handling process inside the CCDM is monitored with the help of
sensors.

How the CCDM works Function Description
The CCDM can be configured in the following ways:

Configuration Function
Cheque-in CCDM processes cheques only
Cash-in*1 CCDM processes banknotes only
Cheque / Cash-in CCDM processes cheques and banknotes
*1 In cash-in mode the banknotes will only pass through without trouble when
a ribbon cartridge is in the printer.
If there is no print station it is necessary to insert the document guide snap-
in panel (01750070381) in the pressure plate to ensure trouble-free
passage of banknotes (see the following figures).
How the CCDM works
Cheque processing
It is possible to deposit cheques in bundles of 50.
The deposited cheques are drawn in as a bundle.
The bundle is first aligned in the bundle alignment station and then separated.
The individual cheques are then aligned again in the alignment station. This
ensures that the code line (magnetic characters CMC7 or E13B) on the
cheque can then be read magnetically.
During the following transport of the cheque through the cheque/cash reader,
images (200 dpi) are recorded of the front and back of the cheque, using two
different kinds of light (red and green). These images can be stored together
with the information from the code line (magnetic characters) and additional
transaction data from the device (system unit).
If the code line is not recognized (because it is not present, or because the
cheque was entered backwards), the cheque is redirected to the reject
compartment and returned to the customer with an appropriate message.
Following the recording of the images, the cheques are stored temporarily in
an escrow unit.

Function Description How the CCDM works
The matrix printer station makes it possible to cancel the cheques by printing a
line of information on the back of the cheques.
If the transaction is confirmed, the cheques are stored in a cassette provided
for that purpose.
If the transaction is cancelled, all cheques are returned to the customer.
Banknote processing
It is possible to deposit banknotes in bundles of 50.
The deposited banknotes are drawn in as a bundle, aligned as a bundle, and
separated.
The verification of the banknotes takes place in the cheque/cash reader. Using
loadable, country-specific currency data as a reference, the authenticity of the
banknotes is checked here.
Following the check, counterfeit or suspicious banknotes are stored in the
separate retract cassette.
Since those banknotes that are determined to be genuine are then stored
temporarily in the escrow unit, it is possible to return the entire bundle if the
deposit transaction is aborted.
If the transaction is confirmed, the banknotes are stored in a cassette provided
for that purpose.
i In cash-in mode in a cheque / cash-in configuration the banknotes will

only pass through without trouble when a ribbon cartridge is in the
printer. If there is no print station it is necessary to insert the document
guide snap-in panel (01750070381) in the pressure plate to ensure
trouble-free passage of banknotes (see the following figure).

How the CCDM works Function Description
The illustration shows the pressure

plate (2) with the document guide
snap-in panel (1) in position.

Function Description LEDs
LEDs
With the help of the LEDs, the status of the CCDM is displayed. The LEDs are
located on the CCDM control panel.
The following illustration shows the position of the control panel depending on
the device version.
Rearload Frontload
1
1 2
2 3
3 4
4
1 Status display 3 LED red

2 Green LED 4 Test button

LEDs Function Description
The following table explains the individual LEDs.

LED LED Meaning Measure to be taken (reaction)
green red
Off Off No power (CCDM not in
operation)
On Off CCDM ready for
operation or warming up
On On CCDM not in operation
On Blinking CCDM not in operation Eliminate the fault (see chapter
"Faults").

Function Description Function buttons
Function buttons
The function buttons are located on the controller board.
2 1
1 Button S1 2 Button S4
The following table explains the function buttons.

Button Description
S1 RESETs the CCDM
S4 Reserved

Description of transport paths Function Description
Description of transport paths

This section presents the possible transport paths of banknotes and cheques.
Version with standard cassette module (metal)

(SK21.1)
Transport from the input / output area to the escrow unit

The following illustration shows the transport path from the input / output area
to the escrow unit.

Function Description Description of transport paths
Transport from the escrow unit to the cassette module

The following illustration shows the transport path from the escrow unit to the
appropriate cassettes in the cassette module. Deflectors in the transport paths
send the various media to the appropriate cassettes.

Transport from the escrow unit to the input / output area

The following illustration shows the transport path from the escrow unit via the
collection compartment in the reject transport facility to the input/output area.

Transport from the input / output area to the retract

cassette in the cassette module
The following illustration shows the transport path from the input/output area to
the retract cassette in the cassette module.

Transport path for a rejected medium

The following illustration shows the transport path taken by a single rejected
medium.

Version with cassette module for plastic

cassettes (SK21.2)

to the escrow unit.





Transport from the input / output area to the retract

cassette in the cassette module
The following illustration shows the transport path from the input/output area to
the retract cassette in the cassette module.


medium.

Version with cassette module for ProCash

3100(xe) (SK31.1)

to the escrow unit.






medium.


Function Test
Test button
Test runs can be started and the CCDM can be reset by pressing the Test
button on the control panel.
i A test function can always be triggered unless an error has occurred

that prevents this (for example a defective CCDM controller).
Calling the function codes

i To call the function codes, the CCDM head module must be pushed
into position (safety switch closed).
Pressing and holding the test button causes the status display to switch to the
function code. Continuing to hold down the function button changes the
display of the function code to '00', '01', '02' and '03' in turn. The meaning of
the individual function codes is explained in the following table. To start a
particular function, let go of the button when the status display shows the
corresponding function code.

Calling the function codes Function Test
Function code Function

Extended error Upon display of the extended error code
code (if available) the status display changes
to the current status of the device
(normal operation or error condition).
(See also the chapter "Faults", section
"Error codes / warning codes".)
RESET (warm
reset)
Diagnostic test The mechanical components of the
RESET CCDM are moved, one after the other.
A reset is performed if no error has
occurred.
If an error occurs, the diagnostic test is
terminated and the error code is
displayed.
You can cancel the diagnostics test by
pressing the test button briefly. A
RESET is then performed.
Photosensor The photosensors are synchronized
synchronization automatically.
Then the status display changes to the
current status of the device (normal
operation or error condition).
If an error message is displayed
following photosensor synchronization
after replacing a component, you must
first perform a 'factory synchronization'
(see section "Calling the service
function codes").
Reserved for
new functions
to

Function Test Calling the service function codes
Calling the service function codes

At present, photosensor synchronization (factory synchronization) and metal
sensor synchronization are implemented.
While the shutter is open, the metal sensor synchronization identifies new
points of operation for the metal detection. This synchronization is always
required after components have been replaced, since the replacement might
have caused a change in mechanical or electrical characteristics or in the coil
position.
i To call the service function codes, the CCDM head module must be
pulled out (safety switch activated).
Pressing and holding the test button causes the status display to switch to the
service function code.
To select photosensor synchronization and metal sensor synchronization, let
go of the button when the status display shows the function code '--'.
The synchronizations are performed when the CCDM head module is pushed
in again.
Function code Function
Photosensor Prerequisite:
synchronization – All media must have been removed
(factory from the transport paths.
synchronization) – All components must be in working
and metal sensor position.
synchronization
After pushing in the CCDM head
module, the photosensors and the
metal sensors synchronize
automatically.
Then the status display changes to the
current status of the device (normal
operation or error condition).

Calling the service function codes Function Test

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 Meaning

No display Normal operation; no fault / no warning
(Green LED on)
< constant
Function code (see chapter "Function test")
> blinking
Error code
> permanent
Warning code

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.
20, 13 19
22, 21
24, 25
26, 27
93
47
90, 91
28
92
30
96
94
48
46
95
31
32
33
34
40
41, 42, 43
50
51
10
15
11
52

Faults Status messages
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

i
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 Note
Synchronizing the Press the test button and select the function code
photosensors '03' (see chapter "Function Test").
Performing a RESET Press the test button and select the function code
'01' (see chapter "Function Test").
Restarting the Switch the device off and back on (for details see
system chapter "Basic Operation" in the operating manual).
Displaying the Press the test button and select the function code
extended error code '00' (see chapter "Function Test").
(EC) 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.

Examples of the extended error code display
Error code '17' / EC '23' as an Error code '24' / EC '102' as an

example of a 2-digit display of error example of a 4-digit display of error
code: code:
Error code Error code

display display
Automatic return to
Call Call
error code display
function code '00' Automatic return to function code '00'

error code display
Display of Display of
EC for 2-3 s EC for 2-3 s
(low byte) (high byte)
Display of
EC for 2-3 s
(low byte)

Error messages in the area of the head module

Code EC Meaning Remedy
Boot up (electronic Wait for the system to finish booting
self-test) up.
Boot up (after Wait for the system to finish booting
reset) up.
Operating system – Restart the CCDM.
error, hardware – If necessary re-load the firmware.
error – If the error reoccurs, replace the
controller.
Operating system – Restart the CCDM.
error, internal – If the error persists, re-load the
firmware error firmware.
– If the error reoccurs replace the
amplifier / controller board.
No connection to Permanent status display:
dispenser module Dispenser module 01750047708 is
installed which may cause
disturbances 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.
No connection to – Check the plug connections
amplifier board between amplifier and controller
board.
– If necessary re-load the firmware.


No connection to – Check the plug connection
stacker board between amplifier board and
controller board.
– Check the configuration of the
controller.
– Re-load the firmware of the
CCDM.
distributor transport.
Battery on – Restart the CCDM.
controller board – Delete the cassette counters and
empty the CEX.
– Perform a reset.
– Restart the system
Device – Restart the system
configuration of – Load the appropriate configuration
controller incorrect using the product-specific test
or missing software.
– If the error reoccurs, reload the
firmware.
– If the error cannot be eliminated
by means of the above steps,
replace the amplifier / controller
board.
Error on controller – Restart the system
– If necessary re-load the firmware.
– If the error cannot be eliminated,
replace the amplifier / controller
board.
No firmware – Restart the system
– If the error persists, re-load the
firmware.


Safety switch is – Check whether the CCDM (head
active 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.
safety switch.
After the LINE XSA module
i has been reconfigured, there
is a waiting period of up to
270 seconds until the CCDM
is ready for operation.
Retract documents Remove the documents from the
are stored in the input/output area.
input/output area.
Minimum Register the cassettes using the
configuration is product-specific software (e.g.
missing (at least 1 Service Operator Panel).
cash-in cassette +
retract cassette)
Operating system Wait for the system to finish loading
is loading new files the firmware.
on the CCDM
controller
Data transfer on Wait for the data transfer to finish.
RS232 interface


The application – Power down the PC / the
overloads the application.
CCDM hardware – Leave the CCDM switched on for
(too many reset five minutes.
commands per – Power up the PC / the application.
time unit)
– Inform the person who is
responsible for software.
Shutter blocked – Remove any foreign matter from
the shutter area.
– Make sure the plug of the shutter
is plugged in at the controller.
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.
– Check the plug connection on the
dispenser's board.
metal detection.
dispenser module.
Module is defective or plug has not been plugged in.


Error on swivel Swivel transport unit:
transport unit or in – Check the home position of swivel
the area of the transport units 1 and 2.
bundle alignment – 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.
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.
(VLS4).
or
swivel transport 2 in dispenser module defective.


– Drive is mechanically blocked.
(VLS8).
or
diagnostic test triggered by operator: bundle width setting
in dispenser module defective.
Media jam in – Remove any jammed media from
dispenser module the dispenser module's paper
(feed error path.
detected prior to – Perform a reset.
dispensing) – Check the cam disk position.
– Check the dispenser module's
motors.
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.


– Paper jam in I/O area -> paper feed rollers.
– Photosensor VLS2 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.
– 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).


Paper jam detected – Check paper path in dispenser
during separation module.
process. – 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.
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.
– Paper jam in paper feed roller area -> intermediate
transport.
– A paper jam has occurred in the intermediate transport
and possibly also in the alignment station.
– Motor ASM1 of alignment station does not run properly.
– A paper jam has occurred in the dispensing area.
– Motors VSM1/2/3/4 do not run properly.


– Paper jam in dispensing area or intermediate transport.
– Paper too long.
Document jam in intermediate transport or at entrance to
alignment station.
Error of hall – Check the plug connection on the
sensors dispenser's board (bottom of
dispenser module).
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.


Media jam in reject – Remove any jammed media
transport area between the reject transport and
the dispenser module or in the
reject transport.
– Check whether the belt of the
reject transport is laying on the
center of the guiding rollers.
– Replace the dispenser module
and/or the reject transport.
– Paper jam in reject path.
– Mechanical initialization of cam disk not correct due to
blocking. See error code no. 140 for details.
– Mechanical initialization of swivel transport 2 not correct.
– Photosensor VLS6 / VLS2 is defective or soiled.
– Dispensing motors VSM2/3 do not run properly.
– A paper jam has occurred in the paper path between
stacker and I/O transport.
– 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).


Error of the cam – Restart the CCDM.
disk – Check the cam disk position
(release).
necessary.
(VLS9).
or
diagnostic test triggered by operator: cam disk in dispenser
module defective.
(VLS9).


Media jam in front – Clear the media jam in the
of or in the alignment station
alignment station – Check the photosensors and the
motors in the alignment station.
– 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
Document jam in front of ALS1 during transport of
document from alignment drum -> check transport path
through drum.


Error on magnetic – Check the plug connection with
character reader the magnetic character reader.
– Replace the magnetic character
reader, if necessary.
ADDMASTER electronic is defective or not properly
connected.
Error on cheque / – Restart the CCDM.
cash reader – Restart the system
– If necessary, reload cheque / cash
reader firmware.
– If necessary, reload Firewire
firmware (for cheque & cash
configuration).
– If the error reoccurs even after the
above steps have been taken,
replace the cheque / cash reader.
Only relevant for cheque processing:
– Check if the firewire cable is connected to the PC and
the LINE XSA module.
– Check the PC's Firewire card.
Baumer module is defective.
External light in – Check whether light is falling on
cheque / cash the cheque / cash reader.
reader – Clean the scanner lines of the
cheque / cash reader.
– External light in cheque / 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.
– External light in cheque / cash reader
– Banknote level detected (light level too high due to
soiled roller or document remaining under the reader).


Communications – Re-load the firmware of the
problems with cheque / cash reader.
cheque / cash – Check and update the banknote
reader table.
– Re-load the currency data.
– Re-load the firmware.
– Replace the cheque / cash reader,
if necessary.
LINE XSA Firmware ERROR.
LINE XSA communication error ->
control logic RS232 data transfer problems.
LINE XSA data error ->
configuration data faulty / corrupt.
LINE XSA Note Table Configuration not OK.
LINE XSA Firmware ERROR.
LINE XSA syntax - context error ->
control logic RS232 data transfer problems.


Communication – Re-load the cheque / cash
problems (RS232 reader's firmware, the CCDM's
interface ) with firmware and/or the Firewire
cheque / cash firmware.
reader
No connection between RS232 interface and LINE XSA

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 LINE XSA to RS232 interface:
LINE XSA module not mounted or not properly connected
to back panel.
LINE XSA firmware and CCDM firmware not compatible.
to back panel.
Communication with sensor transport interrupted during
operation. Module does not reply within specified time limit.
to back panel.
LINE XSA firmware and CCDM firmware not compatible.


Media jam in – Clear the media jam in the area of
sensor transport the magnetic ink character reader
and up to the entry of the sensor
transport. If the error occurs
frequently, replace the magnetic
ink character reader.
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.
Slippage during transport of documents from ALS1
alignment to LINE XSA sensor, or LINE XSA 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 LINE XSA sensor during banknote
processing).
Deflector in wrong position.
Jam between sensor transport (paper deflecting units) and
in front of RLS1.
Media jam in – Clear the media jam in the sensor
sensor transport transport In particular, check the
area of the 3-way deflector.
– Check functioning of deflectors 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).


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.


Media jam in – Clear the media jam between
sensor transport sensor and deposit transport.
&
– 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).
– Document / document jam in sensor transport unit at
three-way deflector.
– SSM2 motor defective / not connected.
– SSM2 sensor defective / not connected.
or
3-way deflector (SSM2) in sensor transport defective.
– Document / document jam in sensor transport unit at
reject deflector.
– SSM3 motor defective / not connected.
– SLS4 sensor defective / not connected.
or
reject deflector (SSM3) in sensor transport defective.


Document jam – Clear the media jam between
between sensor sensor and 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 25mm).
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 cheque / cash reader.
– Check the basic position of shaft /
axis and the screw in the reject
transport unit.
– Replace the reject transport, if
necessary.
(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.


Document jam at – Perform a reset.
the escrow unit – Clear the media jam in the escrow
area.
– Replace the escrow unit, 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.
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.

Error messages of photosensors
i Photosensors VLS7, ALS1 and SLS3 can only be checked when the
CCDM components are closed.
Code EC Meaning Type of Remedy

display
Error at blinking – Carry out a photosensor
photosensor adjustment / initialization.
VLS10 – If possible, check the
photosensor using the
product-specific software
(e.g. KDIAG).
– If the error persists, replace
the dispenser module.
constant – If you can get to the
photosensor, try to clean it.
– Check the photosensor
using KDIAG.
– Synchronize the
photosensors.


display
VLS1

using KDIAG.
– Synchronize the
photosensors.


display
(e.g. KDIAG).
using KDIAG.
– Synchronize the
photosensors.


display
VLS2

using KDIAG.
– Synchronize the
photosensors.


display
VLS12

using KDIAG.
– Synchronize the
photosensors.


display
(e.g. KDIAG).
using KDIAG.
– Synchronize the
photosensors.


display
VLS 11

using KDIAG.
– Synchronize the
photosensors.


display
ALS3

using KDIAG.
– Synchronize the
photosensors.
the alignment station.


display
ALS4

using KDIAG.
– Synchronize the
photosensors.


display
ALS2

using KDIAG.
– Synchronize the
photosensors.


display
Error at blinking Cover of alignment station is
photosensor not closed:
ALS1
constant – First check whether the

cover of the alignment
station is closed properly.
– If you can get to the
using KDIAG.
– Synchronize the
photosensors.


display
Error at blinking Magnetic character reader not
photosensor closed:
SLS3
constant – First check whether the

magnetic character reader
is closed properly.
– If you can get to the
using KDIAG.
– Synchronize the
photosensors.
the magnetic character
reader.


display
SLS1

using KDIAG.
– Synchronize the
photosensors.
– If the error persists replace
the back panel incl. sensor
and storage transport.


display
ELS1

using KDIAG.
– Synchronize the
photosensors.
the escrow unit.


display
ELS5

using KDIAG.
– Synchronize the
photosensors.
the escrow unit.


display
RLS1

using KDIAG.
– Synchronize the
photosensors.
– If the error persists replace
the back panel incl. sensor
and storage transport.


display
RLS2

using KDIAG.
– Synchronize the
photosensors.
the reject transport.


display
KLS2

using KDIAG.
– Synchronize the
photosensors.
the cassette module.


display
KLS3

using KDIAG.
– Synchronize the
photosensors.


display
KLS8

using KDIAG.
– Synchronize the
photosensors.
the cassette module and/or
cassette 2 (left cassette).


display
photosensor adjustment / initialization,
KLS11

using KDIAG.
– Synchronize the
photosensors.
cassette 1 (right cassette).


display
KLS1_5

using KDIAG.
– Synchronize the
photosensors.


display
KLS2_5

using KDIAG.
– Synchronize the
photosensors.

Error messages in the cassette module section

Deflector in sensor – Clear the media jam at the entry
transport has wrong to the cassette module.
position. – Remove the media jam in the
cassette module – retract
cassette / cassette 1 (right
cassette) / cassette 2 (left
cassette) (cassettes have to
signed on again).
– 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.
reach KLS8 to cassette 1 (right cassette) using specified
path + tolerance.
reach KLS11 to cassette 2 (left cassette) using specified
path + tolerance.


Incorrect position of – Check position of deflector in
deflector in cassette module.
cassette module – Check function of deflector in
cassette module.
necessary.
– There is some paper left inside the deflector.
– Motor not connected.
– Hybrid photosensor before reset is defective.
or
deflector (KSM5) in cassette module defective.
Deflector (cassette 1 / cassette 2) is not functioning
or
deflector (KSMx) in cassette module defective.


Incorrect position of – Clear the media jam in the
deflector in direction of cassette 1 (right
cassette module cassette).
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 Permanent status display:
1 – Remove the cassette 1 and empty
it.

– Check proper fit of cassette 1
(right cassette) and re-insert
cassette 1 properly, if necessary.
– Check the plug connection
between the controller and the
cassette module.
– Replace cassette 1 (right
cassette) or replace the entire
cassette module, if necessary.
– Stacker logic not connected (plug X1).
– Stacker wheel in cassette 1 / cassette 2 is blocked.
– Cassette 1 / cassette 2 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.


Incorrect position of – Clear the media jam in the
deflector in direction of cassette 2 (left
cassette module cassette).
necessary.
Banknote does not quit KLS11 photosensor near entrance
to cassette 2 using specified path + tolerance.
Error in cassette Permanent status display:
2 – Remove the cassette 2 and empty
it.

– Check proper fit of cassette 2 (left
cassette) and re-insert cassette 2
properly, if necessary.
– Check the plug connection
between the controller and the
cassette module.
– Replace cassette 2 (left cassette)
or replace the entire cassette
module, if necessary.


Incorrect position of – Check position of deflector in
deflector in cassette module.
cassette module – Check function of deflector in
cassette module.
necessary.
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
deflector (KSMx) in cassette module defective.

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: Functional unit or function
Positions 2 to 3: Element type
Positions 4 to 5: 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 Meaning
A Alignment
D Print
E Escrow (storage on a drum)
K Cassette module
R Reject transport unit
S Sensor
V Dispenser module

Sensors and actuators Faults
Abbreviation for element types

Abbreviation Meaning
HS Hall sensor
LS Photosensor; The technical variant is not distinguished in
the abbreviation, but it can precede the designation in text
form. Example: Hybrid photosensor KLS8
MG Electromagnet
SM Stepper motor
W Deflector
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.

CCDM head module
C
B
A




CCDM cassette module

Standard cassette module (metal)
W4
KHS8 W5
KLS11
KHS9 KHS7
KHS5 KHS2
KHS4 KHS1
KHS6 KHS3

Cassette module for plastic cassettes

Cassette module ProCash 3100(xe)

Shutter
Sensor Function
LS1,LS2 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.
LS3 Checks if flap is closed.
Dispenser module
Actuator Function
VMG1 Retaining shaft magnet;
presses retaining shaft against the counterrotation shaft
VMS1 Sender coil for metal detection
VMS2 Receiver coil for metal detection
VSM1 Stepper motor input/output transport; drives the transport rollers
in swivel transport unit 1 and the transport belt in swivel
transport unit 2.
VSM2 Stepper motor for driving transport rollers;
transport roller shaft / pressure shaft
VSM3 Stepper motor for driving the counterrotation shaft
VSM4 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.
VSM5 Stepper motor for lowering/raising the hinged drive unit 1
VSM6 Stepper motor for lowering/raising the hinged drive unit 2
VSM7 Stepper motor for width setting
VSM8 Stepper motor for driving the hinged mechanism of the
counterrotation shaft and activating the pinch rollers for
separation
VSM9 Stepper motor for the lower bundle transport unit

Sensor Function
UDS Ultrasound sensor for double document
VHS1 Hall sensor foreign object detector (operator side)
VHS2 Hall sensor foreign object detector (rear panel side)
VLS1 Photosensor bundle input/bundle output
VLS2 Photosensor between input/output transport for separator unit
('Detection of last medium')
VLS3 Hybrid photosensor for monitoring lowering of hinged drive unit
1; 'Home position sensor'
VLS4 Hybrid photosensor for monitoring lowering of hinged drive unit
2; 'Home position sensor'
VLS5 Hybrid photosensor for timing disk in hinged drive unit 2
VLS6 Photosensor, empty dispensing sensor (LAM)
VLS7 Photosensor 'medium in intermediate transport'
VLS8 Hybrid photosensor for width setting; 'Home position sensor'
VLS9 Hybrid photosensor at cam for the motion of the counterrotation
shaft
'Home position sensor'
VLS10 Photosensor in input / output unit for controlling removal
VLS11 Photosensor in input / output unit for controlling insertion and
removal
VLS12 Photosensor for monitoring documents in the input/output area

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

Magnetic character reader

Actuator Function
SMG1 Electric lifting magnet for raising the magnetic head assembly
when banknotes pass.
Sensor Function
SMIC Magnetic read head and permanent magnetic head for
premagnetization
SLS3 Photosensor for magnetic read head

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

Actuator Function
SSM1 Stepper motor for driving the transport rollers and belts in the
magnetic character reader, cheque/cash reader and sensor
transport
SSM2 Stepper motor for controlling deflector W2
SSM3 Stepper motor for controlling deflector W3
VSM4 Stepper motor for driving the transport belt in intermediate
transport
KSM1 Stepper motor for driving the transport belt in deposit transport

Sensor Function
SLS1 Photosensor for recognizing a medium in sensor transport
RLS1 Photosensor for recognizing a medium between the sensor
transport and storage or reject transport;
beginning and end detector for entering and exiting medium
SLS2 Hybrid photosensor for recognizing the position of deflector 2
SLS4 Hybrid photosensor for recognizing the position of deflector 3
Deflector Function
W2 Redirection escrow unit / reject compartment or cassette
storage
W3 Redirection reject compartment / cassette storage
Escrow unit
Actuator Function
ESM1 Drive motor escrow unit;
Stepper motor inside the drum for driving the drum and the tape
winding mechanism
Sensor Function
ELS1 Beginning and end photosensor;
photosensor, beginning and end detector for entering and
exiting medium
ELS2 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.
ELS3 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.
ELS4 Hybrid photosensor for determining the tape speed
ELS5 Photosensor; prenotification for ELS1 when documents are
unwound

Printing station
Actuator Function
DSM1 Stepper motor for ribbon transport
Print head
Sensor Function
DLS1 Reflective photosensor in front of the print head (as seen from
the escrow unit)
DLS2 Reflective photosensor behind the print head for checking print
function (before/after)

Actuator Function
RSM1 Stepper motor for driving the transport belt
RSM2 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.
Sensor Function
RLS1 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
RLS2 Photosensor collecting compartment
RLS3 Hybrid photosensor for camshaft;
photosensor for controlling the rotation of the camshaft
'Detection of home position'

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

Sensor Function
KLS2 Photosensor in transport path at start of cassette module
KLS3 Photosensor in transport path before retract cassette
KLS4 Hybrid photosensor for detecting the retract cassette
KLS5 Hybrid photosensor for recognizing the position of deflector W4
(and deflector W5)
KLS6 Hybrid photosensor for recognizing the position of deflector W5
KLS8 Photosensor in transport path before cassette 1
(right cassette)
KLS9 Photosensor for monitoring the touch activation force exerted
by stack against stacking wheel 'Cash'
KLS10 Hybrid photosensor for recognizing the position of the
counterfeit notes compartment
KLS11 Photosensor in transport path before cassette 2 (left cassette)
KLS12 Photosensor for monitoring the touch activation force exerted
by stack against stacking wheel 'Cash'
KLS1_1 Hybrid photosensor for recognizing the stacking wheel position
cassette 1 for monitoring the stacking wheel position (every
120°)
KLS1_2 Hybrid photosensor in cassette 1 for detecting 'Lifting plate up'
for reporting 'Lifting plate up' position.
KLS1_3 Hybrid photosensor in cassette 1 for reporting 'Cassette 1 full'.
KLS1_4 Hybrid photosensor for detecting if there are any documents in
cassette 1.
KLS1_5 Photosensor in the plastic cassette 1 for message 'Cassette
full'
KLS2_1 Hybrid photosensor for recognizing the stacking wheel position
cassette 2 for monitoring the stacking wheel position (every
120°)
KLS2_2 Hybrid photosensor in cassette 2 for detecting 'Lifting plate up'
for reporting 'Lifting plate up' position.
KLS2_3 Hybrid photosensor in cassette 2 for reporting 'Cassette 2 full'.
KLS2_4 Hybrid photosensor for detecting if there are any documents in
cassette 2.
KLS2_5 Photosensor in the plastic cassette 2 for message 'Cassette
full'
KMS1 Microswitch for detecting cassette 1 (right cassette)

Sensor Function
KMS2 Microswitch for detecting cassette 2 (left cassette)
Deflector Function
W4 Deflector for directing medium into the retract cassette or in
cassettes 1 or 2
W5 Deflector for directing medium into cassette 1 or in cassette 2

Removal/Installation of Components
General
This chapter only describes the removal and installation of the CCDM
components.
For more information on the device please refer to the respective operating,
installation and service manuals.
Before doing any work on the CCDM, disconnect it from the power
supply and detach the plug of the power supply cable from the CCDM
(see section "Power interrupt").
Please note the safety precautions (see chapter "Introduction" in the
service manual of your device).
When working on and with electronic subassemblies and boards, be

sure to observe the ESD rules and to use ESD protection devices.
i Each time a component is replaced, the photosensors must be

synchronized (function code '03') (see chapter "Function Test", section
"Calling the function codes").
If an error message is displayed after photosensor synchronization,

the photosensors and the metal sensors must be synchronized via
factory synchronization) (see chapter "Function Test", section "Calling
the service function codes").
View of the CCDM

i The following illustrations show device views for the different
configuration options.

View of the CCDM Removal/Installation of Components
View of the standard cassette module (metal)
i In the device view the cover plate of the head module has been
removed in order to show the individual components better.
1 Amplifier board 11 LED indicator for cassette in position

2 Controller board 12 Shutter
3 Escrow unit 13 Dispenser module with rocking bar
4 Print station with print head 14 Intermediate transport
5 Retract cassette 15 Alignment station
6 Deposit transport 16 Magnetic ink character reader
7 Reject transport unit 17 Cheque / cash reader
8 Cassette 2 (SK21.1) 18 Chassis with sensor transport,
9 Cassette 1 (SK21.1) deposit transport and back panel
10 Separator transport (SK21.1) board

Removal/Installation of Components View of the CCDM
View of the cassette module for plastic cassettes
1 Retract cassette (SK21.2)

2 LED indicator for cassette in position
3 Media cassette (SK21.2)
4 Media cassette (SK21.2)
5 Separator transport (SK21.2)

View of the CCDM Removal/Installation of Components
View of cassette module ProCash 3100(xe)
1 Left cassette PC3100 (SK31.1)

2 LED indicator for cassette in position
3 Right cassette PC3100 (SK31.1)
4 Release lever for right cassette PC3100 (SK31.1)
5 Separator transport (SK31.1)
6 Release lever for left cassette PC3100 (SK31.1)

Removal/Installation of Components Power interrupt
Power interrupt
• Open the device (see chapter "Basic Operation" in the device's operating
manual).
• Power down the system.
• Switch the device off (see chapter "Basic Operation", section "Switching
the device off" in the operating manual of the device).
• Pull out the CCDM head module as far as possible (see chapter "Basic
Operation" in the device's operating manual).
Detach the connector of the power
supply cable (1).

Removing the cover plate Removal/Installation of Components
Removing the cover plate

• Open the device and pull out the CCDM head module as far as possible
(see chapter "Basic Operation" in the device's operating manual).
Remove screws (1) to (5) and remove
the cover plate (6).

Removal/Installation of Components Removing / inserting cassettes
Removing / inserting cassettes
Removing / inserting the retract cassette
• Open the device and pull out the CCDM cassette module as far as possible
Removing it:
Press the green release lever (1) and
pull the retract cassette (2) out of the
cassette module.
Inserting it:
Insert the retract cassette.
Take care that the retract cassette
clicks properly into the cassette
module.
If the retract cassette is inserted

correctly, the green LED (1) at the
separator transport lights up.
i When a new retract cassette is inserted it has to be registered via the

product-specific software.

Removing / inserting cassettes Removal/Installation of Components
Removing / inserting cassette 2
Removing it:
pull cassette (2) out of the cassette
module.
Inserting it:
Insert the cassette.
Take care that the cassette clicks
properly into the cassette module.
If cassette 2 is inserted correctly, the

green LED (1) at the separator
transport lights up.
i When a new cassette 2 is inserted it has to be registered via the


Removing / inserting cassette 1
Removing it:
module.
Inserting it:
If cassette 1 is inserted correctly, the

green LED (1) at the separator
i When a new cassette 1 is inserted it has to be registered via the


Removing / inserting the retract cassette
Removing it:
Remove the retract cassette upwards
from the cassette module by the
handle (1) (see arrow).
Inserting it:
Position the retract cassette in the
cassette module from above.
When doing so, make sure that the
retract cassette is placed correctly in
If the retract cassette is inserted

i When a new retract cassette is inserted it has to be registered via the


Removing / installing a media cassette
i The two media cassettes are removed and installed in the same way.
Removing it:
Place two fingers in the recess (1)
while pushing against the separator
transport with the thumb of the same
hand. Pull the cassette out of the
cassette module (see arrow).
Inserting it:
When the media cassette is correctly

inserted, this is indicated on the
separator transport by LED (1) lighting
up green for the right media cassette
or LED (2) lighting up green for the left
media cassette.
i When a new media cassette is installed, it must be logged in with the


Removing / inserting left cassette
Removing it:
Press the green release bolts (1) and
module.
Inserting it:
If the left cassette is inserted correctly,

the green LED (1) at the separator
i When a new left cassette is inserted it has to be registered via the


Removing / inserting right cassette
Removing it:
Press the green release bolts (1) and
module.
Inserting it:
If the right cassette is inserted

i When a new right cassette is inserted it has to be registered via the


Opening / closing components Removal/Installation of Components
Opening / closing components
Pulling out / pushing in the dispenser
Pulling it out:
Remove the screw (1).
Take hold of the grip position (1) with

the fingers of your right hand, press
the release lever in the direction
shown by the arrow with the thumb of
your right hand (2).
With your right hand, push the
separator forwards as far as possible
in the direction shown by the arrow
(3).
Pushing it in:
• Push the dispenser as far as possible in the direction of the alignment

station. Take care that the separator clicks properly into place.
• Fasten the screw again.

Removal/Installation of Components Opening / closing components
Opening / closing the intermediate transport
Opening it:
Turn the green locking lever in the
direction of the arrow (1) and swing
the intermediate transport up (2).
Closing it:
Swing the intermediate transport down
until it clicks audibly into place.
Opening / closing the alignment station
• Open the intermediate transport (see section "Opening / closing the

intermediate transport").
Opening it:
Pull up the two release levers (1) and
lift the cover of the alignment station
(2).
Closing it:
Lower the cover of the alignment
station until it clicks audibly into place.

Head module Removal/Installation of Components
Head module
i The following sections describe how to remove and install
components in the head module.
Dispenser module
manual).
• Disconnect the device from the power supply (see section "Power
interrupt").
• Pull out the dispenser (see section "Opening / closing the components").
Remove the cable from the cable
holder (1) on the rear of the dispenser
module.
Detach connectors (2) and (3).
• Lift the dispenser approx. 1 cm and remove it.
• Remove the intermediate transport (see the "Intermediate transport"

section.

Removal/Installation of Components Head module
ProCash 3000 Frontload only
Remove the securing screw (1) from

the metal bracket (2).
Lower the metal bracket (2) slightly

(see arrow) and remove it.
ProCash 3100 Frontload only
Detach connector (1).


• Frontload devices only: Remove the customer panel (see section

"Customer panel").
i You do not need to remove the control panel on ProCash 3100

Frontload.
Reinstall it by following the same steps in reverse order.
i When you have completed installation, synchronize the sensors (see

chapter "Function Test").
Check the function of the CCDM using the KDIAG testing program.

Intermediate transport
manual).
interrupt").
• Remove the dispenser (see section "Dispenser module").

Turn the locking lever in the direction

of the arrow (2) and swing the
intermediate transport up by about
30°.
Press the plastic lugs (1) and (2) down

and remove the intermediate
transport.
Reinstall it by following the same

steps in reverse order.


Metal detection
manual).
interrupt").

Unclip the cover (1) at positions (2) to
(5) and remove it.
Detach connectors (1) to (3).
Unclip the board (1) at positions (4) to

(8) and remove it.

Remove screw (1) and remove the

ground connection.
Unclip the upper metal sensor support

(2) at positions (3) and (4), lift it
slightly at the side marked with the
arrow and remove it upwards.
• Turn the dispenser.

ground connection.
Unclip the lower metal sensor support

(2) at positions (3) and (4), lift it
slightly at the side marked with the
arrow and remove it upwards.
i When you have completed installation, synchronize the metal sensors

(see chapter "Function Test", section "Calling the service function
codes").

Rocking bar in the dispenser module
manual).
interrupt").
• Remove the intermediate transport (see the "Intermediate transport"

section).
the mounting plate (4).
Remove the retaining ring (1) and

detach the retaining shaft (2) see
arrow).
Detach the timing belt (3).

Loosen the connecting shaft (1) by

turning it clockwise using an open-end
wrench (see arrow).
Frontload only

bracket.
During installation make sure

i that the bracket sits properly in
the cutouts with its angles.

Release the two catches (1) and (2)

and remove the cover.
Remove the ground connection (1).


Pull the input / output tray slightly in

the direction of the arrow and leave it
folded down.
Remove retaining rings (1) and (2).

Detach the connector (3) and lay the
cable free.
Unhook springs (4) and (5).
Unhook the pressure arm (6) toward
the middle of the device on both sides
(see arrows) and detach the two
springs.
Remove the pressure arm (6).
The crossbar (1) is fastened on each

side with two catches.
Unhook the two catches on one side

of the crossbar (see arrows).
Remove the crossbar and carefully put

it aside.

Unhook springs (1) and (2).
Detach the connector (3) and lay the

cable free.
Carefully remove the rocker (1), lifting

it up.
When removing the rocker make sure

that the storage shelf (1) stays in
position.
A pressure spring is located beneath

the storage shelf.
i Note the following comments when installing the rocker.

The rocker's porous bearings are

flattened on one side (see arrow).
Make sure that the rocker is inserted

properly.
Insert the pressure arm (1), making

sure it is the right way round.
The supports (2) must face down.
Run the cable of the connector (1)

underneath the pressure arm (3) and
in front of the spring (2).

First insert the crossbar (1) on one

side.
Make sure that the crossbar's catches

go in front of the spring (see arrow).
Check that the crossbar's catches

have locked into place correctly.
Before inserting the input / output tray,

turn the cam disk (1) until the recess is
vertical (see arrow).
Then insert the input / output tray in

such a way that, on both sides, the
leaf spring (1) lies above and the
plastic lugs lie below ...

...the shaft (1) (see arrows).

Control panel
Frontload (control panel on the dispenser module)
manual).
interrupt").

ProCash 3000 only



control panel.



ProCash 3100 only
Loosen screws (2) and (3).
Raise the control panel (4) a little and

remove it.
Remove screws (2) and (3) and

remove the control panel.
Reinstall it by following the same steps

in reverse order.


Rearload (control panel on the escrow)
manual).
interrupt").
• Remove the amplifier / controller boards (see the "Amplifier / controller

boards" section).
• Carefully separate the boards.


remove the control panel.



Alignment station
manual).
interrupt").
• Remove the cover plate (see section "Removing the cover plate").
• Pull out the dispenser (see section "Pulling out / pushing in the dispenser").
The alignment station has to be open before you can remove it.
• Open the alignment station (see section "Opening / closing the

components").
Remove the alignment station.

Make sure the new alignment station is open before you install it.


manual).
interrupt").
Before you remove the magnetic reader, the intermediate transport
and the alignment station must be open.
• Open the intermediate transport and the alignment station (see section
"Opening / closing the components").
Remove the magnetic ink character
reader.

Before you install the new magnetic reader, the intermediate transport
and the alignment station must be open.


manual).
interrupt").
Before you remove the cheque / cash reader, the intermediate
transport, the alignment station and the magnetic reader must be
open.
• Open the intermediate transport, the alignment station and the magnetic ink
character reader (see section "Opening / closing the components").
The connector only exists in the

i event of a cheque / cash reader
and of a cheque reader.
Detach the cheque / cash reader

Reinstall it by following the same steps
in reverse order.
Before you install the new cheque / cash reader, the intermediate
transport, the alignment station and the magnetic reader must be
open.


Amplifier / controller boards
manual).
interrupt").
Disconnect the plugs (1) to (5).
Remove screws (6) and (7).
Carefully detach the amplifier and

controller boards in the direction of the
arrow.
If necessary, slightly pull each board
apart alternately until the two of them
have come apart from the multiway
connector.
• Remove the control panel if necessary (see the "Control panel" section).
i Note the following comments when installing the amplifier / controller

boards.
When you assemble the amplifier

board (1) and the controller board (2),
make sure that the spacers (3) on
each side of the amplifier board are
positioned to match the spacers (4) on
each side of the controller board, as
shown in the illustration.

• Make new settings for the device configuration in KDIAG (see following
table).
i Before you can set the device configuration, the safety switch must be
activated.
ATMTYPE (Basic system)

Configuration Meaning
01 = 2100 ProCash 2100 with transfer transport
Rev. A
02 = 2150/3000 ProCash 2150 / ProCash 3000
03 = 3100 ProCash 3100
04 = 2100 ProCash 2100 with transfer transport
Rev. B
(Rev. B = transfer transport III
(01750063208) as of revision level 1)
CCDM type
01 = CCDM configuration 01 Configuration for standard cassettes
02 = CCDM configuration 02 Configuration for large cassettes
03 = CCDM configuration 99 Configuration without cassettes
Print station
M = Missing No print station
V = Available Print station is available


Escrow unit
i Escrow unit 01750079818 is not compatible with chassis

01750045607.
If you are installing this escrow, it may therefore be necessary to
replace the chassis (see section "Chassis" and the chapter
"Description of the Components“, section "Escrow unit").
manual).
interrupt").
Pull up (2) the green locking lever (1)
and hold it in this position.
Pull out the escrow as far as

possible(3).
Detach connectors (1) and (2) from

the back panel board.

Press the green locking/release lever

(1) and remove the escrow unit to the
rear in the direction shown by the
arrow.

Make sure that you do not jam the
cable (1) when pushing the escrow in.


manual).
interrupt").
• Remove the cheque / cash reader (see section "Cheque / cash reader").
• Pull out the dispenser (see section "Pulling out / pushing in the dispenser").
Remove screws (1) to (3).

Carefully pull out the reject transport.

Make sure that the switching flap (1)

sits in the fork (2) when installing the
reject transport.
Turn the switching flap into the correct
position if necessary.


Print station
manual).
interrupt").
Pull up (2) the green locking lever (1)
and hold it in this position.
Pull out the escrow as far as

possible(3).
Detach the steel crossbar (1) in the

direction of the escrow as shown (see
arrow).

Unhook the springs (1) using a spring

hook, and remove the crossbar (2).
Swing the print station (1) down by 90°

(see arrow).
Disconnect the ribbon cable (2).
Remove cable ties (1) to (3) and

separate the connection.
Unhook the print station and remove

it.
(The print station is attached to the
shaft (5) with two snap locks.)
• Remove the ribbon cartridge from the print station (refer to the operating
manual).

i Note the following comments when installing the print station.
Insert the ribbon cable (1) with the

contact surface facing down.
Position the ribbon cable in such a

way that it is not jammed or damaged
when the print station is moved up and
down.
Make sure that the spring (1) is not

overstretched when hooking it into the
crossbar.
Make sure that the plastic film (1) is

not damaged when inserting the
ribbon cartridge in the print station.
The print station has to be adjusted when it has been installed successfully.

i The gap between the print head and the print roller should be 0.50 mm
to 0.55 mm.
Check the gap between the print head

and the print roller using a feeler
gauge.
To do this, with the print station swung
down place the feeler gauge (1)
between the print head and the print
roller (see figure) from the escrow
side.
If necessary, correct the gap between

the print head and print roller by
turning the screw (1).


Print head
manual).
interrupt").
Swing the print station down and
remove the ribbon cartridge (1) (refer
to the operating manual).
Remove screws (2) and (3), and pull

the print head out slightly.
Disconnect the ribbon cable (1).

i Note the following comments when installing the print head.

Position the ribbon cable (1) in such a

way that it is not jammed or damaged
when the print station is moved up and
down.
Make sure that the plastic film (1) is

not damaged when inserting the
ribbon cartridge in the print station.
The print station has to be adjusted when it has been installed successfully.
i The gap between the print head and the print roller should be 0.50 mm
to 0.55 mm.
Check the gap between the print head

and the print roller using a feeler
gauge.
To do this, with the print station swung
down place the feeler gauge (1)
between the print head and the print
roller (see figure) from the escrow
side.

If necessary, correct the gap between

the print head and print roller by
turning the screw (1).

Chassis
i Chassis 01750079819 is not compatible with escrow unit

01750045965.
If you are installing this chassis, it may therefore be necessary to
replace the escrow unit (see section "Escrow unit" and the chapter
"Description of the Components", section "Escrow unit").
i The chassis with the sensor transport and deposit transport and the
back panel board are removed.
manual).
interrupt").

• Remove the alignment station (see section "Alignment station").
• Remove the magnetic ink character reader (see section "Magnetic ink
character reader").
• Remove the amplifier board and the controller board (see section
"Amplifier / controller board").
• Remove the escrow unit (see section "Escrow unit").
• Remove the reject transport (see section "Reject transport").

The chassis is fastened to the upper
telescopic runner at positions (1) and
(2).
Loosen these two screws on the

telescopic runner.
i The screws are not allowed to
be removed.
Remove all the necessary screws

from the upper and lower telescopic
runners (1) and (2).
If necessary, move the telescopic
runners to be able to access individual
screws, e.g. those at positions (3) and
(4).

Lift the chassis a little (1) and remove

it in the direction of the arrow (2).


Safety switch head module
manual).
interrupt").


remove the safety switch.


Cheque / cash transfer mechanism
i The service manual for the specific system describes how to remove
and install the cheque/cash transfer mechanism.

Removal/Installation of Components Standard cassette module (metal)

components in the standard cassette module (metal).
Separator transport
manual).
interrupt").
• Pull out the CCDM cassette module as far as possible (see chapter "Basic
• Remove the retract cassette, cassette 1 and cassette 2 (see section

"Removing / inserting cassettes").

Standard cassette module (metal) Removal/Installation of Components
Remove screws (1) and (2) from the

upper telescopic runner.
Remove the screw (1) from the lower

telescopic runner.
Slightly raise the distributor transport

and remove it.



Removal/Installation of Components Standard cassette module (metal)
Storage board
manual).
interrupt").
Loosen screw (1) and take off the
cover (2).
Disconnect the plug (1) from the

storage board.

Standard cassette module (metal) Removal/Installation of Components
Remove the screws (1) to (4) and

remove the motor (5).
Disconnect all plugs (1) from the

storage board.
Remove screws (2) to (5) and take out

the storage board.

When you install it, make sure that the

belt (1) is not too tight.


Removal/Installation of Components Cassette module for plastic cassettes

components in the cassette module for plastic cassettes.
Safety switch cassette module
manual).
interrupt").
• Remove the right media cassette (see section "Removing / inserting

cassettes").
Detach the spring (1) at the position
marked with the arrow on the rear of

Cassette module for plastic cassettes Removal/Installation of Components

the cover (5).
Detach the connector (1) and free the

cable along the cable channel (see
arrows).
Remove screws (1) and (2) on the

front of the cassette module and



Separator transport
manual).
interrupt").
• Remove the retract cassette and the two media cassettes (see section
"Removing / inserting cassettes").
Disconnect all the necessary plugs
from the storage board (1).
Remove or loosen the screws at
positions (2) to (5) on the telescopic
runners.
Raise the distributor transport slightly
if necessary and remove it.



Storage board
manual).
interrupt").
• Remove the retract cassette (see section "Removing / inserting cassettes").
Loosen screws (1) and (2) and lift the
cover (3) up and out.
The cover is only hooked into place at
the back.

storage board.
Remove screws (2) to (5) and take out

the storage board.



Lock on media cassettes
manual).
• Remove the media cassette (see section "Removing / inserting cassettes").

Insert the key in the lock (1) and turn it
clockwise until it stops.
Open the cover in the direction shown

by the arrow.
Remove the clip (1) in the direction of

the arrow.
Remove the lock (2) upwards.

Media cassette handle
manual).

• Remove the media cassette (see section "Removing / inserting cassettes").

Handle assy.
Order number: 01750092917
Push the lock (1) in the direction of the

arrow as far as possible and remove
the handle.
Notes for installation

Push the lock (1) as far as possible in
the direction of the arrow.
Insert the handle.
Arrest the handle by pushing the lock
back as far as possible.

Removal/Installation of Components Cassette module ProCash 3100(xe)

components in the cassette module for ProCash 3100(xe).
Safety switch cassette module
manual).
interrupt").
Disconnect the plug (1) from the
storage board.
Remove all the necessary cable ties

and free the cable.

Cassette module ProCash 3100(xe) Removal/Installation of Components



Storage board
manual).
interrupt").
Remove screws (1) to (4).
Raise the cover (5) a little and remove

it.

Removal/Installation of Components Cassette module ProCash 3100(xe)

storage board.
Remove threaded bolts (2) to (5) and

take out the storage board.



Cassette module ProCash 3100(xe) Removal/Installation of Components

Maintenance and Service
General
If a technician is called out to service the device, paper dust must be removed
from it and, at the same time, the photosensors checked and, if necessary,
cleaned. The photosensor positions are described in the chapter "Faults",
section "Sensors and actuators".
The transport belts do not require cleaning. Cleaning fluids should not be
used, as the different types of plastic will react differently to them.
The care and cleaning of the CCDM and the replacement of consumables are
the customer's task, consumables being the ribbon cartridge and the print
head. These are not covered by the maintenance contract.
Dispenser module
The two flat belts should be replaced after four years. To do this it is necessary
to replace the rocking bar (see the "Rocking bar" section in the "Removal /
Installation of components" chapter)

The glass panels of the two scanners should be cleaned with the specified
cleanser whenever a technician calls in, or at least twice a year.

Consumables Maintenance and Service
Consumables
Orders
Consumables for the system components can be ordered directly from Wincor
Nixdorf.
International
Fax: +49 (0) 5251 693 4888

E-mail: serviceslogistics@wincor-nixdorf.com
Internet: www.wincor-nixdorf.com/mediaservice

Maintenance and Service Consumables
Notes on using cleaning materials

Please note the manufacturer's specifications on the packaging and
on the enclosed information sheet. The product may be damaged or
soiled if materials are used that are not approved or if they are used
improperly.
Please dispose of the packaging and empty containers according to
the applicable regulations of your country.
Printer ribbon cartridge

Use only the specified printer ribbon cartridge. Otherwise you run the risk of
damaging the print head and the ribbon transport.
Printer ribbon cartridge Part number: 01750064638
Print head
Print head: Part number: 01750062215

Approved maintenance materials Maintenance and Service
Approved maintenance materials

The articles listed below can be ordered from us or from our service partners
via electronic channels.
Orders: http://extranet.wincor-nixdorf.com
http://www.wincor-nixdorf.com/mediaservice
E-mail for logistics
questions: mailto:serviceslogistic@wincor-nixdorf.com
E-Mail for technical
questions: mailto: servicesupport@wincor-nixdorf.com
Commercial name / product name Material number

Flat paintbrush 1" 01770005440
Universal cleaning cloth 01770005406
Screen cleansing agent ECS-260, 250 ml 01750035530
You will find a list of all the cleaning and maintenance materials approved by
Wincor Nixdorf in the intranet or extranet.
i Please note the manufacturer's specifications on the packaging and

on the enclosed information sheet.
The product may be damaged or soiled if materials are used that are
not approved or if they are used improperly.
Please dispose of the packaging and empty containers according to
the applicable regulations of your country.

Appendix
Technical data
General
Cheque processing
Character recognition: CMC-7 (DIN 66226, ISO 2033, ISO 1004)
E13-B (DIN 66226, ISO 2033)
Magnetic character line: ANSI X9
No. of characters: max. 80
Image recording: resolution: 200 dpi
Front and back sides, using red and green
light
Printing function
Print head: 9 pins
Character height: 3.2 mm
Fonts / coding: loadable character generators
Ribbon: black
Data interfaces
Controller: V.24 (RS 232) at 57600 Baud
Cash reader: V.24 (RS 232)
Cheque reader: V.24 (RS 232) and Hotlink
Cheque / cash reader: V.24 (RS 232) and Fire Wire 1394
Power supply Vcc, - 12 V, + 12 V, + 24 V, + 36 V

Technical data Appendix
Head module (rectangular-solid method)

Length: 930 mm
Width: 168 mm
Height: 210 mm
Weight: 22 kg
Cassette module (rectangular-solid method)

Length: 535 mm
Width: 170 mm
Height: 510 mm
Weight without cassettes: 10.5 kg

Length: 555 mm
Width: 185 mm
Height: 510 mm
Cassettes for cassette module (long version)

Length: 555 mm
Width: 185 mm
Height: 680 mm

Length: 635 mm
Width: 165 mm
Height: 310 mm
Input bundles
No. of media per bundle: max. 50

Appendix Technical data
Cassettes
Standard cassettes (metal)
Cassette 1 and cassette 2

Stack height: 250 mm
No. of media: < 2000 *1)
Retract cassette
No. of media: < 100
Cassettes ProCash 3100(xe)
Left and right cassette

No. of media: < 1000 *1)
Plastic cassettes
Media cassettes
No. of media: < 2000 *1)
Media cassettes (long version)
No. of media: < 3600 *1)
Retract cassette
No. of media
upper
compartment: 70
lower
compartment: 30
*1) depending on the thickness and quality of the media

Technical data Appendix
Media
Standard PC 3100(xe) Plastic
(metal)
Banknotes
Length 110 - 185 mm 110 - 185 mm
Width 60 - 98 mm 60 - 98 mm
Thickness 0.07 - 0.12 mm 0.07 - 0.12 mm
Grammage 65 - 125 g/m2 65 - 125 g/m2
Cheques
Length 140 - 240 mm 140 - 240 mm 140 - 240 mm
Width 70 - 105 mm 70 - 105 mm 70 - 105 mm
Thickness 0.07 - 0.12 mm 0.07 - 0.12 mm 0.07 - 0.12 mm
Grammage 65 - 125 g/m2 65 - 125 g/m2 65 - 125 g/m2

Appendix Pin assignments back panel
Pin assignments back panel
X1 (power supply unit)
6 Type of connector:
Molex-Mini-Fit Jr., 10M
Pin Assignment Remarks

1 Vcc
2 Vcc
3 - 12 V
4 + 12 V
5 GND
6 + 24 V
7 + 36 V
8 GND P
9 GND PP
10 NAN

Pin assignments back panel Appendix
X2 (LINE XSA Baumer sensor)
JST 16-pin, M

1 LESER_RESET
2 LESER_TXD
3 LESER_SYNC
4 LESER_CTS
5 GND
6 GND
7 Vcc
8 - 12 V
9 LESER_RXD
10 GND
11 LESER_RTS
12 LESER_TAKT
13 GND
14 + 12 V
15 Vcc
16 NC

X3 (MICR)
A1 Type of connector:
48-pin DIN, F
B1

A1 MICR_RESET
A2 MICR_RXD
A3 MICR_TXD
A4 MICR_DTR
A5 GND
A6 NC
A7 GND
A8 I_SLS3 Transmit current - Photosensor MICR
A9 GND
A10 OUT_SLS3 Output signal - Photosensor MICR
B1 MICR_DSR
B2 MICR_RTS
B3 MICR_CTS
B4 GND
B5 MICR_SYNC
B6 Vcc
B7 MAGSMG1H Magnet SMG 1
B8 MAGSMG1L
B9 GND
B10 NC

X4 (alignment station)
48-pin DIN, F
B1

A1 ASM1A Motor phase 'A' Motor 1 of alignment station
A2 ASM1B Motor phase 'B'
A3 ASM1C Motor phase 'C'
A4 ASM1D Motor phase 'D'
A5 MAG_AMG1H Magnet for switch 1
A6 MAG_AMG1L Magnet for switch 1
A7 ASM2A Motor phase 'A' Motor 2 alignment station
B1 GND
B2 GND
B3 I_ALS1 Transmit current - Photosensor (LS) in alignment
station
B4 OUT_ALS1 Output signal - Photosensor in alignment station
station
station
station

X5 (storage transport - motor)

Type of connector:
JST PH 4-pin, M
1

1 KSM1A Motor phase 'A' storage transport motor 3
2 KSM1B Motor phase 'B'
3 KSM1C Motor phase 'C'
4 KSM1D Motor phase 'D'
X6 (intermediate transport - motor)

Type of connector:
JST PH 4-pin, M
1

1 VSM4A Motor phase 'A' intermediate transport motor
2 VSM4B Motor phase 'B'
3 VSM4C Motor phase 'C'
4 VSM4D Motor phase 'D'

X7 (sensor transport - motors)

Type of connector:
JST PH 4-pin, M
1

1 SSM1A Motor phase 'A' sensor transport motor
2 SSM1B Motor phase 'B'
3 SSM1C Motor phase 'C'
4 SSM1D Motor phase 'D'
X8 (escrow - motor)
Type of connector:
JST PH 4-pin, M
1

1 ESM1A Motor phase 'A' ESCROW motor
2 ESM1B Motor phase 'B'
3 ESM1C Motor phase 'C'
4 ESM1D Motor phase 'D'

X9 (printing station - ribbon transport)

Type of connector:
JST PH 4-pin, M
1

1 DSM1A Motor phase 'A' Motor for ribbon transport
2 DSM1B Motor phase 'B'
3 DSM1C Motor phase 'C'
4 DSM1D Motor phase 'D'

X10 (escrow - sensors)
JST PHD 18-pin, M

1 Vcc
2 ELS4 Timer tape speed
3 GND
4 Vcc
5 ELS2 Tear sensor 1
6 GND
7 Vcc
8 ELS3 Tear sensor 2
9 GND
10 I_ELS1 Transmit current - photosensor print start cheque
processing
11 GND
12 OUT_ELS1 Output signal - photosensor print start cheque
processing
13 GND
14 I_ELS5
15 GND
16 OUT_ELS5
17 GND
18 NC

X11 (reject transport - sensors / motors)
JST PHD 16-pin, M

1 Vcc
2 RLS3 Photosensor bundling reject tray
3 GND
4 Vcc
5 I_RLS2 Transmit current - Photosensor -
Paper start sensor at the shutter
6 GND
7 OUT_RLS2 Output signal - Photosensor -
Paper start sensor at the shutter
8 GND
9 RSM2A Motor phase 'A' Motor bundling reject tray
10 RSM2B Motor phase 'B'
11 RSM2C Motor phase 'C'
12 RSM2D Motor phase 'D'
13 RSM1A Motor phase 'A' reject transport motor
14 RSM1B Motor phase 'B'
15 RSM1C Motor phase 'C'
16 RSM1D Motor phase 'D'

X12 (sensor transport - sensors)
JST PHD 12-pin, M

1 Vcc
2 SLS2 Photosensor - switch 2
3 GND
4 Vcc
5 SLS4 LS - switch 3
6 GND
7 OUT_RLS1 Output signal photosensor reject transport
8 GND
9 I_SLS1 Transmit current - Photosensor paper path
monitoring switch 2
10 GND
11 OUT_SLS1 Output signal - Photosensor paper path monitoring
Switch 2
12 GND

X13 (printing station - print monitoring)
JST PHD 10-pin, M

1 I_DLS1 Transmit current reflective photosensor print
monitoring
DSL1
2 GND
3 OUT_DLS1 Collector reflective photosensor print monitoring
DSL1
4 I_DLS2 Transmit current reflective photosensor print
monitoring DSL2
5 GND
6 OUT_DLS2 Collector reflective photosensor print monitoring
DSL2
7 I_RLS1 Transmit current photosensor reject transport
8 GND
9 NC
10 NC

X14 (dispenser print I)
Micromatch, 20-pin, F
20

1 VMOT_D0 Data bus to dispenser motors
2 VMOT_D1
3 VMOT_D2
4 VMOT_D3
5 VMOT_D4
6 VMOT_D5
7 VMOT_D6
8 VMOT_D7
9 VMOT_D8
10 VMOT_D9
11 VMOT_D10
12 VMOT_D11
13 MOT_AD_1 Addresses for driving motors
14 MOT_AD_2
15 MOT_AD_3
16 GND
17 GNDP
18 + 12 V
19 + 36 V
20 + 36 V

X15 (dispenser print II)
20

1 E_AD Enable A/D converter-dispenser
(foreign body sensor)
2 D_AD1 Data A/D-converter-dispenser
3 D_AD2 Data control panel
4 CLK_AD_DA Data control panel
5 D_Bed
6 STROBE_BED
7 RESETN_V
8 STROBE_IO
9 GND
10 STROBE_MOT
11 E_DA_V Enable A/D converter-dispenser
(transmit current photosensors)
12 D_DA_V Data D/A
13 LD_SHIFTV Load - Shift register of sensors
14 CLK_SHIFTV Clock - Shift register and A/D converter of
sensors
15 D_SHIFTV Data - Shift register of sensors
16 GNDP
17 GNDP
18 - 12 V
19 + 24 V
20 + 24 V

X16 (controller)
64-pin DIN, F
C1

A1 GNDP
A2 GNDP
A3 GND
A4 MOT_AD_3 Addresses for driving motors
A5 NC
A6 VMOT_D10 Data bus to dispenser motors
A12 D_AD1 Data A/D - Converter - Dispenser
A13 D_Bed Data control panel
A14 RESETN_V
A15 STROBE_MOT
A17 CLK_SHIFTV Clock - Shift register and A/D converter of
sensors
A18 D_DA_V Data D/A
A19 SICH_SCHALT Safety switch
A20 MICR_DTR
A21 MICR_CTS
A22 MICR_RXD
A23 MICR_DSR


A24 LESER_RESET V 24 LINE XSA
A25 MICR_SYNC
A26 LESER_CTS
A27 LESER_RXD
A28 LESER_RTS
A29 NAN
A30 Vcc
A31 Vcc
A32 GND
C1 GNDP
C2 GNDP
C3 NC
C4 MOT_AD_2
C5 VMOT_D11
C6 VMOT_D9
C7 VMOT_D7
C8 VMOT_D5
C9 VMOT_D3
C10 VMOT_D1
C11 E_AD Enable A/D - Converter - Dispenser
C12 D_AD2
C13 STROBE_IO
C14 E_DA_V Enable A/D - Converter - Dispenser
C15 D_SHIFTV Data - Shift register of sensors
C16 LD_SHIFTV Load - Shift register of sensors
C17 STROBE_BED
C18 CLK_AD_DA Data control panel
C19 MICR_RESET V 24 MICR
C20 MICR_TXD
C21 GND
C22 MICR_RTS
C23 GND


C24 GND
C25 LESER_TXD
C26 GND
C27 LESER_SYNC
C28 LESER_TAKT
C29 + 12 V
C30 - 12 V
C31 GND
C32 GND

X17 (amplifier I)
64-pin DIN, F
C1

A3 OUT_RLS1 Output signal photosensor
A4 SLS4 LS - switch 3
A5 NC
A6 GND
A8 OUT_ALS2 Output signal - Photosensor in alignment station
A9 MAGAMG1H Magnet for switch 1
A14 KSM1C Motor phase 'C'
A15 KSM1A Motor phase 'A' storage transport motor 3
A16 TEMP1 Pinhead
A17 NAD1 Pinhead
A18 NAD3 Pinhead
A19 NAD2 Pinhead
A20 NAD9 Pinhead
A21 NAD4 Pinhead
A22 I_RLS1 Transmit current photosensor reject transport
A23 I_DLS1 Transmit current reflective photosensor
Print monitoring DSL1


A24 DSM1C Motor phase 'C'
A25 DSM1A Motor phase 'A' Motor for ribbon transport
A26 GND
A27 GND
A28 ELS4 Timer tape speed
A29 I_ELS1 Transmit current - Photosensor print start
Cheque processing
A30 I_ELS5
A31 ESM1B Motor phase 'B'
A32 ESM1A Motor phase 'A' ESCROW motor
C1 SLS2 Photosensor - switch 2
C2 OUT_SLS1 Output signal - Photosensor paper path
monitoring
Switch 2
C3 I_SLS1 Transmit current reflective photosensor
Print monitoring DLS 1
C4 VSM4C Motor phase 'C'
C5 VSM4A Motor phase 'A' intermediate transport motor
C6 I_SLS3 Transmit current - Photosensor MICR
C7 OUT_ALS3 Output signal - Photosensor in alignment station
C8 I_ALS2 Transmit current - Photosensor (LS) in alignment
station
station
Alignment station
C11 ASM2D Motor phase 'D'
C12 ASM2B Motor phase 'B'
station
C14 MAGAMG1L Magnet for switch 1
C15 KSM1B Motor phase 'B'
C16 KSM1D Motor phase 'D'
C17 NAD5 Pinhead


C18 NAD7 Pinhead
C19 NAD6 Pinhead
C20 NAD8 Pinhead
C21 DSM1D Motor phase 'D'
C22 DSM1B Motor phase 'B'
C23 OUT_DLS1 Collector reflective photosensor print monitoring
DSL2
C24 I_DLS2 Transmit current reflective photosensor
DSL2
C26 NC
C27 ELS2 Tear sensor 1
C29 OUT_ELS1 Output signal - Photosensor print start
Cheque processing
C30 OUT_ELS5
C31 ESM1D Motor phase 'D'
C32 ESM1C Motor phase 'C'

X18 (amplifier II)
48-pin DIN, F
C1

A1 + 36 V
A2 + 24 V
A3 GNDP
A4 GNDP
A5 I_ALS4 Transmit current - Photosensor (LS) in alignment
station
A7 GND
A8 GND
A9 GND
A10 GND
A11 GND
A12 RSM2C Motor phase 'C'
A13 RSM2B Motor phase 'B'
A15 MAGSMG1H Magnet SMG 1
A16 VSM4B Motor phase 'B'
B1 + 36 V
B2 + 24 V
B3 GNDP
B4 Vcc
B5 - 12 V
B6 SSM1D Motor phase 'D'
B7 SSM1B Motor phase 'B'
B8 SSM2A Motor phase ‘A’ Switch motor 2


B9 SSM2C Motor phase 'C'
B10 SSM3A Motor phase 'A' Switch motor 3
B12 RSM1C Motor phase 'C'
B13 RLS3 Photosensor bundling reject tray
B14 OUT_RLS2 Output signal - Photosensor - Paper start sensor
at the frame
B15 I_RLS2 Transmit current - Photosensor - Paper start
sensor at the frame
B16 VSM4D Motor phase 'D'
C1 + 36 V
C2 + 24 V
C3 GNDP
C4 Vcc
C5 + 12 V
C6 SSM1C Motor phase 'C'
C7 SSM1A Motor phase 'A' sensor transport motor
C8 SSM2B Motor phase 'B'
C9 SSM2D Motor phase 'D'
C12 RSM1A Motor phase 'A' reject transport motor
C13 RSM2A Motor phase 'A' Motor bundling reject tray
C14 RSM2D Motor phase 'D'
C16 MAGSMG1L

X19 (printing station - pinhead)

Type of connector:
14-pin, tape

1 NAD7
2 NAD1
3 NAD5
4 NAD3
5 + 24 V
6 + 24 V
7 + 24 V
8 NAD2
9 NAD9
10 NAD4
11 NAD8
12 NAD6

X20 (safety switch)

Type of connector:
JST PH 3-pin, M
1

1 GND
2 SICH_SCHALT Safety switch
3

X21 (sensor transport - switch motor 2)

Type of connector:
JST PH 4-pin, M
1

1 SSM2A Motor phase ‘A’ Switch motor 2
X22 (sensor transport - switch motor 3)

Type of connector:
JST PH 4-pin, M
1

1 SSM3A Motor phase 'A' Switch motor 3

Appendix Pin assignment amplifier
Pin assignment amplifier
X1 (amplifier - controller I)
20

1 MOT_D0 Data bus to amplifier motors
2 MOT_D1
3 MOT_D2
4 MOT_D3
5 MOT_D4
6 MOT_D5
7 MOT_D6
8 MOT_D7
9 MOT_D8
10 MOT_D9
11 MOT_D10
12 MOT_D11
13 MOT_A0 Select signals for driving motors
14 MOT_A1
15 MOT_A2
16 MOT_A3
17 RESETN
18 STROBE_MOT
19 STROBE_NA
20 STROBE_IO

Pin assignment amplifier Appendix
X2 (amplifier - controller II)
20

1 SNA
2 NBZ
3 E_DA_V1 Enable D/A - converter '1'- amplifier
5 CLK_DA Clock D/A
6 D_DA Data D/A
8 CLK_SHIFTV Clock-Shift register of sensors
10 PC_RXD
11 PC_TXD
12 PC_DTR
13 PC_DSR
14 PC_RTS
15 PC_CTS
16 + 24 V
17 + 24 V
18 GND
19 DLS1_A Print contrast signal 'Analog'

X4 (back panel I)
64-pin DIN, M
C1

A3 OUT_RLS1 Output signal photosensor
A4 SLS4 LS - switch 3
A5 NC
A6 GND
A9 MAGAMG1H Magnet for switch 1
A14 KSM1C Motor phase 'C'
A15 KSM1A Motor phase 'A' storage transport motor 3
A16 TEMP1 Pinhead
A17 NAD1 Pinhead
A18 NAD3 Pinhead
A19 NAD2 Pinhead
A20 NAD9 Pinhead
A21 NAD4 Pinhead
A22 I_RLS1 Transmit current photosensor reject transport
A23 I_DLS1 Transmit current reflective photosensor


A24 DSM1C Motor phase 'C'
A25 DSM1A Motor phase 'A' Motor for ribbon transport
A26 GND
A27 GND
A28 ELS4 Timer tape speed
A29 I_ELS1 Transmit current - Photosensor print start
Cheque processing
A30 I_ELS5
A31 ESM1B Motor phase 'B'
A32 ESM1A Motor phase 'A' ESCROW motor
C1 SLS2 Photosensor - switch 2
C2 OUT_SLS1 Output signal - Photosensor paper path
monitoring
Switch 2
C3 I_SLS1 Transmit current reflective photosensor
Print monitoring DLS 1
C4 VSM4C Motor phase 'C'
C5 VSM4A Motor phase 'A' intermediate transport motor
C6 I_SLS3 Transmit current - Photosensor MICR
station
station
Alignment station
C11 ASM2D Motor phase 'D'
C12 ASM2B Motor phase 'B'
station
C14 MAGAMG1L Magnet for switch 1
C15 KSM1B Motor phase 'B'
C16 KSM1D Motor phase 'D'
C17 NAD5 Pinhead


C18 NAD7 Pinhead
C19 NAD6 Pinhead
C20 NAD8 Pinhead
C21 DSM1D Motor phase 'D'
C22 DSM1B Motor phase 'B'
DSL2
C24 I_DLS2 Transmit current reflective photosensor
DSL2
C26 NC
C29 OUT_ELS1 Output signal - photosensor print start cheque
processing
C30 OUT_ELS5
C31 ESM1D Motor phase 'D'
C32 ESM1C Motor phase 'C'

X5 (shutter)
JST PHD 10-pin, M

1 SHUTTERH Motor in shutter
2 SHUTTERL Motor in shutter
3 GNDP
4 + 12 V
5 GNDP
6 LS_SHU_GL1 Hybrid photosensor in shutter
9 GND
10 GND

X6 (V.24 PC)
DSUB 9-pin

1 NC
2 PC_RXD
3 PC_TXD
4 PC_DTR
5 GND
6 PC_DSR
7 PC_RTS
8 PC_CTS
9 GND

X7 (back panel II)
48-pin DIN, M
C1

A1 + 36 V
A2 + 24 V
A3 GNDP
A4 GNDP
A5 I_ALS4 Transmit current - Photosensor (LS) in alignment
station
A7 GND
A8 GND
A9 GND
A10 GND
A11 GND
A12 RSM2C Motor phase 'C'
A15 MAGSMG1H Magnet SMG 1
A16 VSM4B Motor phase 'B'
B1 + 36 V
B2 + 24 V
B3 GNDP
B4 Vcc
B5 - 12 V
B6 SSM1D Motor phase 'D'
B7 SSM1B Motor phase 'B'
B8 SSM2A Motor phase ‘A’ Switch motor 2


B10 SSM3A Motor phase 'A' Switch motor 3
B12 RSM1C Motor phase 'C'
B13 RLS3 Photosensor bundling reject tray
B14 OUT_RLS2 Output signal - photosensor - Paper start sensor
at
the frame
B15 I_RLS2 Transmit current - photosensor - Paper start
sensor at
the frame
B16 VSM4D Motor phase 'D'
C1 + 36 V
C2 + 24 V
C3 GNDP
C4 Vcc
C5 + 12 V
C6 SSM1C Motor phase 'C'
C7 SSM1A Motor phase 'A' sensor transport motor
C12 RSM1A Motor phase 'A' reject transport motor
C13 RSM2A Motor phase 'A' Motor bundling reject tray
C16 MAGSMG1L

Assignment controller Appendix
Assignment controller
X4 (back panel I - dispenser logic)
64-pin DIN, M
C1

A1 GNDP
A2 GNDP
A3 GND
A5 NC
A12 D_AD1 Data A/D - Converter - Dispenser module
A13 D_Bed Data control panel
A14 RESETN_V
A15 STROBE_MOT
A17 CLK_SHIFTV Clock - Shift register and A/D converter of
sensors
A18 D_DA_V Data D/A
A19 SICH_SCHALT Safety switch
A20 MICR_DTR

Appendix Assignment controller

A21 MICR_CTS
A22 MICR_RXD
A23 MICR_DSR
A24 LESER_RESET V 24 LINE XSA
A25 MICR_SYNC
A26 LESER_CTS
A27 LESER_RXD
A28 LESER_RTS
A29 NAN
A30 Vcc
A31 Vcc
A32 GND
C1 GNDP
C2 GNDP
C3 NC
C4 MOT_AD_2
C5 VMOT_D11
C6 VMOT_D9
C7 VMOT_D7
C8 VMOT_D5
C9 VMOT_D3
C10 VMOT_D1
C11 E_AD Enable A/D - converter - dispenser module
C12 D_AD2
C13 STROBE_IO
C14 E_DA_V Enable A/D - converter - dispenser module
C15 D_SHIFTV Data - Shift register of sensors
C16 LD_SHIFTV Load - Shift register of sensors
C17 STROBE_BED
C18 CLK_AD_DA Data control panel
C19 MICR_RESET V 24 MICR
C20 MICR_TXD


C21 GND
C22 MICR_RTS
C23 GND
C24 GND
C25 LESER_TXD
C26 GND
C27 LESER_SYNC
C28 LESER_TAKT
C29 + 12 V
C30 - 12 V
C31 GND
C32 GND

X2 (cassette module – storage board)
JST PHD 34-pin, M

1 CKMOT_D0 Motor data bus to cassette
2 CKMOT_D1
3 CKMOT_D2
4 CKMOT_D3
5 CKMOT_D4
6 CKMOT_D5
7 CKMOT_D6
8 CKMOT_D7
9 CKMOT_D8
10 CKMOT_D9
11 CKMOT_D10
12 CKMOT_D11
13 CKMOT_ADR0 Motor address bus to cassette
14 CKMOT_ADR1
15 CKMOT_ADR2
16 GND
17 CSTROBE_KMOT
18 GND
19 CWR_IO_K
20 GND
21 CE_DA_K Enable A/D - converter - cassettes
22 CCLK_DA_K Clock D/A
23 CD_DA_K Data D/A
24 CCLK_SHIFZ_K Clock-Shift register of sensors


25 CLD_SHIFT_K Load - Shift register of sensors
26 CD_SHIFT_K Data - Shift register of sensors
27 K_RESET
28 SICH_SCHALT_A
29 GNDP
30 GNDP
31 - 12 V
32 + 12 V
33 + 24 V
34 + 24 V

X3 (amplifier)
Micromatch, 20-pin, M
20

1 MOT_D0 Data bus to amplifier motors
2 MOT_D1
3 MOT_D2
4 MOT_D3
5 MOT_D4
6 MOT_D5
7 MOT_D6
8 MOT_D7
9 MOT_D8
10 MOT_D9
11 MOT_D10
12 MOT_D11
13 MOT_A0 Select signals for driving motors
14 MOT_A1
15 MOT_A2
16 MOT_A3
17 RESETN
18 STROBE_MOT
19 STROBE_NA
20 STROBE_IO

X4 (amplifier)
20

1 SNA
2 NBZ
5 CLK_DA Clock D/A
6 D_DA Data D/A
8 CLK_SHIFTV Clock-Shift register of sensors
10 PC_RXD
11 PC_TXD
12 PC_DTR
13 PC_DSR
14 PC_RTS
15 PC_CTS
16 + 24 V
17 + 24 V
18 GND

X5 (system - control panel)

1 Vcc
2 GND
3 BED_DATA Data control panel
4 BED_CLK
5 BED_TAS_IN
6 NC

X7
19 1 Type of connector:
Print male connector 20-pin, M
20 2

1 Vcc
2 Vcc
3 NTRST
4 GND
5 TDI
6 GND
7 TMS
8 GND
9 TCK
10 GND
11 TCK
12 GND
13 TD0 Select signals for driving motors
14 GND
15
16 GND
17 NC
18 GND
19 JTAG_SEL
20 GND

X8 (reserve)
JST PHD 14-pin, M

1 IN_RES0
2 IN_RES1
3 IN_RES2
4 DA_RES0
5 DA_RES1
6 GND
7 Vcc
8 AD_RES0
9 AD_RES3
10 OUT_RES0
11 OUT_RES1
12 OUT_RES2
13 OUT_RES3
14 OUT_RES4

X9
Jumper strip 50-pin, M

1 E_LS4
2 E_LS1
3 R_LS1
4 E_LS3
5 R_LS2
6 R_LS3
7 E_LS2
8 SNA
9 SICH_SCHALT
10 INT_MOT
11 INT_TIMER
12 INT_POS
13 INT_LS
14 FIQ
15 SH_GL1
16 SH_GL2
17 SH_GL3
18 S_LS1
19 S_LS2
20 S_LS3
21 S_LS4
22 A_LS1
23 A_LS2
24 A_LS3
25 GND
26 V_LS1


27 V_LS2
28 V_LS3
29 IRQ4
30 INT_USB
31 V_LS4
32 AD0TRIG
33 RESETIN
34 V_LS5
35 V_LS6
36 V_LS7
37 V_LS8
38 V_LS9
39 V_LS10
40 UDS1
41 UDS2
42 BED_TAS
43 BED_DATA
44 BED_CLK
45 NLB
46 NOE
47 NWE
48 NUB
49 NWDOVF
50 MCKO

X10 (USB)
USB type B 4-pin M
3 4

1 USB 5 V
2 D_P
3 D_P
4 GND

Appendix Pin assignments storage board
Pin assignments storage board
X1 (storage cassette)
JST PHD 34-pin, M

1 CKMOT_D0 Motor data bus to cassette
2 CKMOT_D1
3 CKMOT_D2
4 CKMOT_D3
5 CKMOT_D4
6 CKMOT_D5
7 CKMOT_D6
8 CKMOT_D7
9 CKMOT_D8
10 CKMOT_D9
11 CKMOT_D10
12 CKMOT_D11
13 KMOT_ADR0 Motor address bus to cassette
14 KMOT_ADR1
15 KMOT_ADR2
16 GND
17 STROBE_MOT
18 GND
19 WR_IO_K
20 GNDP
21 E_DA_K Enable A/D-converter 1-storage
22 CLK_DA_K Clock D/A

Pin assignments storage board Appendix

23 D_DA_K Data D/A
24 CLK_SHIFT_K Clock-Shift register of sensors
25 LD_SHIFT_K Load - Shift register of sensors
26 D_SHIFT_K Data - Shift register of sensors
27 RESETN
28
29 GNDP
30 GNDP
31 - 12 V
32 + 12 V
33 + 24 V
34 + 24 V

X2 (sensors left)
JST PHD 30-pin, M

1 I_KLS3 Transmit current photosensor bundle
recognition
2 OUT_KLS3 Output signal photosensor bundle recognition
3 GND Transmit current photosensor last banknote
4 I_KLS1 Output signal photosensor last banknote
5 OUT_KLS11
6 GND
7 Vcc
8 KHS4
9 GND
10 Vcc
11 KHS5
12 GND
13 Vcc
14 KLS6
15 GND
16 I_KLSRES
17 OUT_KLSRES
18 GND
19 Vcc
20 KHS6
21 GND
22 Vcc
23 KHS8
24 GND


25 Vcc
26 KHS9
27 GND
28 Vcc
29 KLS12
30 GND

X3 (sensors right)
JST PHD 24-pin, M

1 I_KLS2 Transmit current photosensor bundle
recognition
2 OUT_KLS2 Output signal photosensor bundle recognition
3 GND Transmit current photosensor last banknote
4 I_KLS8 Output signal photosensor last banknote
5 OUT_KLS8
6 GND
7 Vcc
8 KHS1
9 GND
10 Vcc
11 KHS2
12 GND
13 Vcc
14 KHS3
15 GND
16 Vcc
17 KHS7
18 GND
19 Vcc
20 KLS5
21 GND
22 Vcc
23 KLS9
24 GND

X4 (DC - Motor cassette 2)

Type of connector:
JST PH 3-pin, M
1

1 KDC2H
2 KDC2L
3 NC
X5 (DC - Motor cassette 1)

Type of connector:
JST PH 3-pin, M
1

1 KDC1H
2 KDC1L
3 NC

X6 (motor distributor transport)

Type of connector:
JST PH 4-pin, M
1

1 KSM2A Motor phase 'A' Motor distributor transport
X7 (motor stacking wheel cash)

Type of connector:
JST PH 4-pin, M
1

1 KSM3A Motor phase 'A' Motor stacking wheel cash

X8 (motor stacking wheel cheque)

Type of connector:
JST PH 4-pin, M
1

1 KSM4A Motor phase 'A' Motor stacking wheel cheque
X9 (motor switch control)

Type of connector:
JST PH 4-pin, M
1

1 KSM5A Motor phase 'A' Motor switch position

X10 (safety switch)

Type of connector:
JST PH 2M
1

1 GND
2 SICH_SCHALT Safety switch

Pin assignment dispenser board Appendix
Pin assignment dispenser board
X1 (back panel - dispenser print I)
20

1 VMOT_D0 Data bus to dispenser motors
2 VMOT_D1
3 VMOT_D2
4 VMOT_D3
5 VMOT_D4
6 VMOT_D5
7 VMOT_D6
8 VMOT_D7
9 VMOT_D8
10 VMOT_D9
11 VMOT_D10
12 VMOT_D11
13 MOT_AD_1 Addresses for driving motors
14 MOT_AD_2
15 MOT_AD_3
16 GND
17 GNDP
18 + 12 V
19 + 36 V
20 + 36 V

Appendix Pin assignment dispenser board
X2 (back panel - dispenser print II)
20

1 E_AD Enable A/D converter-dispenser
2 D_AD1 Data A/D-converter-dispenser
3 D_AD2 Data control panel
4 CLK_AD_DA Data control panel
5 D_Bed
6 STROBE_BED
7 RESETN_V
8 STROBE_IO
9 GND
10 STROBE_MOT
11 E_DA_V Enable A/D converter-dispenser
12 D_DA_V Data D/A
14 CLK_SHIFTV Clock - Shift register and A/D converter of
sensors
16 GNDP
17 GNDP
18 - 12 V
19 + 24 V
20 + 24 V

X3 (sensors and motors to dispenser print)
20

1 VSM7A Motor phase 'A' Motor width adjustment
5 VSM5A Motor phase 'A' Motor hinged transport 1
9 VSM6A Motor phase 'A' Motor hinged transport 2
13 GND
14 GND
15 VLS3 Home position sensor roller transport
16 VLS4 Home position sensor belt transport
17 VLS5 Timing wheel
18 VLS8 Width adjustment - bundle input
19 I_VLS1 Transmit current photosensor bundle recognition
20 OUT_VLS1 Output signal photosensor bundle recognition

X4 (metal detection to dispenser print)
20

1 MERK_READY
2 MERK_METALL
3 MERK_N_METALL
4 MERK_WARN0
5 MERK_WARN1
6 MERK_WARN2
7 MERK_MEAS
8 MERK_KOM
9 MERK_INIT
10 MERK_QUIT
11 MERK_CLOSE
12 GND
13 MERK_RESETN
14 MERK_PSEN
15 MERK_TXD
16 MERK_RXD
17 Vcc
18 -5V
19 GND
20 + 3.3 V

X5 (motor input / output transport)

Type of connector:
JST PH 4-pin, M
1

1 VSM1A Motor phase 'A' Motor input / output transport
X6 (motor transport rollers drive)

Type of connector:
JST PH 4-pin, M
1

1 VSM2A Motor phase 'A' Motor transport rollers

X7 (motor counterrotation shaft)

Type of connector:
JST PH 4-pin, M
1

1 VSM3A Motor phase 'A' Motor counterrotation shaft
X8 (motor cam disk)

Type of connector:
JST PH 4-pin, M
1

1 VSM8A Motor phase 'A' Motor cam disk

X9 (foreign body sensor)

1 5VREF
2 GND
3 HALL_VHS1 Foreign body sensor 1 (Hall sensor signal left)
4 5VREF
5 GND
6 HALL_VHS2 Foreign body sensor 2 (Hall sensor signal
right)
7 NC
8 NC

X10 (photosensor - dispenser, magnet)
Print male connector 14-pin, M
14 2

1 GND
2 I_VLS7 Transmit current photosensor for monitoring the
intermediate transport (pos. 15)
3 GND
4 OUT_VLS7 Output signal photosensor for monitoring the
intermediate transport (pos. 15)
5 GND
6 I_VLS6 Transmit current photosensor empty dispensing
sensor (pos. 12)
7 GND
8 OUT_VLS6 Output signal photosensor empty dispensing
sensor (pos. 12)
9 Vcc
10 VLS9 Home position sensor cam disk motor
(pos. 36)
11 GND
12
13 MAGRUECKH Magnet retaining shaft (pos. 9)
14 MAGRUECKL Magnet retaining shaft (pos. 9)

X11 (control panel)

1 Vcc
2 GND
3 D_Bed Data control panel
4 STROBE_BED
5 TAST
6 NC
X12 (ultrasound sensor)

1 P12V
2 GND
3 UDS_S1
4 UDS_S2
5 UDS_SYNC
6 UDS_RESETN

X15 (distributor print)
10

1 I_VLS10
2 OUT_VLS10
3 I_VLS2 Transmit current photosensor last banknote
4 OUT_VLS2 Output signal photosensor last banknote
5 I_VLS11
6 OUT_VLS11
7 I_VLS12
8 GND
9 OUT_VLS12
10 GND


Notes
01750062112 C CCDM - Service Manual

Published by
Wincor Nixdorf International GmbH
33094 Paderborn
Germany
Printed in Germany
Order No.: 01750062112 C 2 GB

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CCDM - Service Manual 01750062112 C

Edition November 2005

© Wincor Nixdorf International GmbH 2005

All rights, including rights of translation and

All rights, including rights created by patent

All names of hardware and software

This manual was

CCDM - Service Manual 01750062112 C

01750062112 C CCDM - Service Manual 0-1

Introduction .................................................................................................. 1-1

Device Integration ........................................................................................ 2-1

Configuration Options ................................................................................. 3-1

Overview of the Components...................................................................... 4-1

01750062112 C CCDM - Service Manual I-1

Intermediate transport............................................................................... 4-8

I-2 CCDM - Service Manual 01750062112 C

Right cassette PC3100 (SK31.1)....................................................... 4-41

Description of Components ........................................................................ 5-1

01750062112 C CCDM - Service Manual I-3

Dispenser module ........................................................................................ 5-18

Function description.................................................................................... 6-1

Function Test................................................................................................ 7-1

I-4 CCDM - Service Manual 01750062112 C

Error messages in the area of the head module ................................. 8-5

Removal/Installation of Components ......................................................... 9-1

01750062112 C CCDM - Service Manual I-5

Pulling out / pushing in the dispenser ..................................................... 9-14

Maintenance and Service .......................................................................... 10-1

I-6 CCDM - Service Manual 01750062112 C

Printer ribbon cartridge ........................................................................... 10-3

Appendix ..................................................................................................... 11-1

01750062112 C CCDM - Service Manual I-7

X3 (amplifier) ........................................................................................ 11-43

I-8 CCDM - Service Manual 01750062112 C

Symbols used in this manual

• Text following this symbol describes actions to be performed in the

i Text following this symbol contains general information to facilitate use

Important safety precautions

01750062112 C CCDM - Service Manual 1-1

How to operate the CCDM is described in the operating manuals of the

1-2 CCDM - Service Manual 01750062112 C

Structure of the manual

01750062112 C CCDM - Service Manual 1-3

Disposing of used consumables

Labels on plastic case parts

Returning, recycling and disposing of used units

1-4 CCDM - Service Manual 01750062112 C

01750062112 C CCDM - Service Manual 1-5

1-6 CCDM - Service Manual 01750062112 C

01750062112 C CCDM - Service Manual 2-1

Version 1 - Head module in the safe

2-2 CCDM - Service Manual 01750062112 C

Version 2 - Head module in the top part

1 Head module in the top of the unit

01750062112 C CCDM - Service Manual 2-3