• Author / Uploaded
• Shoaib Hassan

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1.1 Active Dispenser AFD 2.0 1.1.1 Introduction The Active Dispense is a presenter type dispenser. It picks currency or other dispensable media from dispense cassettes, stacks the media, and transports the stack of media to the consumer through a slot in the fascia of the terminal. It can present media, retract and dump it if not taken. There is a Front Load and Rear Load Active Dispense modules. Front Load and Rear Load Transports have short and long versions. The cassette options include  convenient or Secure currency cassettes  convenient, Secure, or Bin divert cassettes To gain full access to the module, a blue latch is used.

AFD 2.0

1.1.2 Main Parts Following table shows the main parts of the dispenser.

Cash Out Cassette

RRC Cassette without lock

RR Cassette with Lock

Transport Module

Stacker Module

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AFD 2.0

Picker Module

AFD Dispenser’s Controller

Dispenser unlock Module

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AFD 2.0

Over All View

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AFD 2.0

1.1.3 Function Principle of Dispenser 1.1.3.1

Picking and stacking

Firmware reads the cassette coding. Feed Modules pick the requested number of notes from cassettes. Retract/reject routines may occur. Largest banknotes picked first, smallest last. Notes placed in the Stacker Module, into the tray. Stacker sensor counts the number of arriving notes, FW compares it with the number of picked notes. 1.1.3.2

Present

Well prepared notes in the Stacker Tray are presented by Host command through the Transport Module. Notes are considered as vulnerable from this point. 1.1.3.3

Restore

After a successful Present operation, the Transport and Stacker Module returns to idle position, which is Stacking. 1.1.3.4

Retract

If customer does not remove (all) notes after timeout and represent attempts, the notes are retracted behind the shutter, then placed into the Retract compartment of the Reject/Retract cassette. 1.1.3.5

Reject

During Picking sequence, if the dimensions, or number of picked notes is not OK even after a Restack/Recovery attempt, notes are Rejected and placed into the Divert compartment of the Reject/Retract cassette. 1.1.3.6

Dump

Host can decide to dump the note stack in the Stacker Tray any time. It is placed into the Divert compartment of the Reject/Retract cassette. 1.1.3.7

Divert

During dispenser self-tests and diagnostic tests, the module picks some single notes from the Feed Modules and places them into the Divert compartment of the Reject/Retract cassette.

1.1.4 Modules of AFD Dispenser Following are the basic modules of the AFD Dispenser. 1. Stacker Module 2. Picker Module 3. Transport Module 4. Cash out cassette 5. RR cassette

1.1.5 Stacker Module 1.1.5.1

Functions of Stacker Module

Following are the functions of the stacker module.  The stacker arranges the picked media into a neat stack and lifts the stack into the transport.  The stacker module also holds the Reject/Retract Cassette.

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AFD 2.0

 

If commanded so, the Stacker Module opens and closes the exit shutter, performs single or bundle divert and dump operations. The Stacker Module includes motors for driving: 1. Transport Belts 2. Stacker Cam 3. Transport Push Plate 4. All 3 motors are stepper motors

1.1.5.2

Functions of Stacker Cam

Following are the five functions which are performed by the stacker cam.  Opens and closes divert door  Raises and lowers the money tray  Latches and unlatches the exit shutter’s security lock  Opens and closes exit shutter  Operates the reject/retract compartment partition divider 1.1.5.3

Main Parts of the Stacker module

Below pictures shows the main parts of the stacker module.

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AFD 2.0

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AFD 2.0

1.1.5.4 1.1.5.4.1

Stacker Removal & Replacement Removal

Following are the steps to remove the stacker.  Remove the transport  Disconnect the stacker sensor cable (J2).  Disconnect the motor cable connector (J1). Compress the connector lock latch, then pull the connector up.  If present, disconnect the dock switch cable (J62).  If present, remove the screw that secures the stacker to the first picker channel.  Release the stacker latch springs, then slide the stacker toward yourself and lift up the stacker to remove it. 1.1.5.4.2 Replacement Following are the steps to replace the stacker.

   

To replace the stacker, reverse the removal procedure Make sure that connector J1, J2, J62 are properly seated Make sure all sensors on the transport and stacker are clean and unblocked. After the stacker is replaced, the stacker sensor emitter is new and must be manually recalibrated. Refer to recalibrate the sensor.

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AFD 2.0

1.1.5.5

  

Removing the Stacker Sub-Assembly

Removing and replacing the divert door and stacking tray do not require removing the stacker subassembly first from the dispenser. Removing the replacing the other components of the stacker sub-assembly require that the stacker has been removed from the dispenser. Following pictures shows the stacker Sub-Assembly.

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AFD 2.0

1.1.5.6

AFD Stacker ’s Cabling

Following image shows the cabling of the stacker.

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AFD 2.0

1.1.5.7

Cam Removal and Replacement

Following is the procedure for removal and replacement of the Cam.

       

Remove the 138-tooth cam timing belt. Rotate the cam counterclockwise so that the partition drive link notch is at the 5 o'clock position Remove the partition follower assembly. Remove the cam screw and washer. Remove the cam from the pin. Make sure that the arrow on the gate actuator aligns with the notch in the frame (gate closed position) Verify that the gate actuator cam roller and the transport cam roller are in the cam groove and the cam vain is in the sensor. Position the cam with the partition drive link notch at 5 o'clock.

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AFD 2.0



After assembly, rotate the cam to verify that the tray raises before the gate actuator moves to the gate open position.

1.1.5.8

Stacker Check Points

Following image shows the points which should be while the preventive maintenance of the stacker. At every PM, Stacker Cam should be removed and cam and the below mentioned parts should be checked.

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AFD 2.0

1.1.5.9

Note Stop Adjustment



Use the small screw drive & push the pin & adjust the note stop position at 4 as shown in the image below.



Push in the note stop locking pin before moving the note stop to the desired position as shown in the image below.

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AFD 2.0

1.1.5.10 Paddle Wheel Removal & Replacement 1.1.5.10.1 Removal Following is the procedure to remove the Paddle Wheel.

    



Remove the combination gear, paddle wheel shaft, and motor pulleys. Remove the timing belt if it hasn't already come off with the pulleys, please see below picture. Remove the E-ring and bearing from the non-cam side of the paddle wheel shaft. Rotate the shaft and pull the paddle wheel shaft gently outward and upward into the bearing relief hole for easy removal from the frame. Pull the paddle wheels to remove them from the shaft.

Please note that there is a groove in the shaft for each paddle wheel. A corresponding ridge inside the paddle wheel hub engages the shaft to keep it in place.

1.1.5.10.2 Replacing of Paddle Wheel Shaft Following are the steps to replace paddle wheel shaft.

   

Lift the latch and slide the 20-groove pulley off of the shaft. Remove the bearing. Remove the E-ring. To replace the paddle wheels and the paddle wheel shaft, reverse the removal procedure.

1.1.5.11 Sensor Recalibration

The transport and stacker sensors must be calibrated if any of the following sub-assembly are replaced. 1. Transport sub-assembly 2. Stacker sub-assembly 3. Control CCA  Please note that the sensors must be clean and unblocked before the sensors are calibrated.

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AFD 2.0

1.1.5.12 Transport and Stacker Sub-Assembly Connector

The below image shows the properly seated and improperly seated connector.

1.1.6 Front –Load Transport Module 1.1.6.1

 

Main Parts

The transport is mounted on top of the stacker. The transport moves the stack of dispensable media through the exit shutter on the fascia to the consumer. The stacker first lifts the media into the transport path. The push plate and belts move the media to the front of the transport until it blocks the exit sensor. The push plate stops, the gate opens, and the belts push the stack of media through the opening to the consumer. The transport holds the media in this position until the consumer removes it. If the consumer does not remove the media, the transport can retract the media. The media can be held in escrow or deposited into the retract compartment of the divert/retract cassette.

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AFD 2.0



Following images shows the basic components of the transport module.

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AFD 2.0

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AFD 2.0

1.1.6.2 1.1.6.2.1

Removal & Replacement of transport Module Removal

Following is the procedure to remove the transport module.  Remove the divert cassette, if present.  Remove the control CCA cover.  Position the cam so that the stacker tray is in the full down position and the divert tray is over the stacker tray.  Remove the transport connector from J3 on the CCA. Un-route the cable from the stacker features.  Whenever removing or installing the lower shaft (transport), use EXTREME CAUTION not to stretch the belts any more than necessary.  Remove the lower transport shaft assembly by releasing the right side from its recess in the frame.  Once free, remove the left side from the bearing hold to remove the tension on the semi-stretch transport drive belts.  Move the divert door into a neutral position.  For the front load only, unscrew the standoff that secures the gate drive flip gear, then remove the gear. The gear is used to correct the timing.  Remove the four mounting screws (M3x6) that secure the transport.  Push the transport from the back to loosen the stacker-to-transport push plate timing belt.  Remove the transport-to-stacker inter-module timing belt and the stacker-to-transport push plate timing belt.  Lift the transport at the front and back and remove it. 1.1.6.2.2



Replacement

To replace the transport sub –assembly, reverse the removal procedure and verify the following alignments. 1. The stacker tray is in the full down position with the divert tray over the stacker tray. 2. The divert cassette is not present in the sub-assembly.

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AFD 2.0

3. 4. 5. 6. 7. 1.1.6.3

The edge of the transport frame rests in the groove of the divert door. The transport mounting holes are on the outside of the stacker. Make sure that the stacker frame locating boss is set in the slots in the transport. Make sure that index marks on the gate drive flip gear align with the arrows on the rack gears. Make sure that connector J3 is properly seated.

Transport & Stacker Alignment

Below image shows the correct and incorrect Transport to Stacker Alignment.

1.1.7 Feed / Picker Module 1.1.7.1

Main Parts

Following images shows the basic components of Feed/Picker Module.

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AFD 2.0

The stripper wheel shaft is clutched so that it only rotates in one direction. The stripper wheel is a high friction rubber wheel that prevents more than one bank note being dispensed by the feed wheels. The wheel is mounted on the end of the stripper wheel shaft and is pressed against the center feed wheel by the media cassette with a preset force. If the feed wheels pick more than one note from the stack, the extra notes will be held back (stripped) by the non-rotating stripper wheel. This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction.

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AFD 2.0

A fender covers the stripper wheel to prevent damage to the media by the stripper wheel. The take-away wheel shaft can rotate freely in both directions. The rubber take-away wheel provides friction to drive the note once it is past the stripper wheel. The take-away wheel is mounted on the end of the take-away shaft and is pressed against the center feed wheel by the media cassette with a preset force. Once the raised drive sections of the feed wheels lose contact with the picked note, the take-away wheel forces the note against the recessed rubber section of the center feed wheel, supplying the friction to drive the note past the stripper wheel. 1.1.7.2

Take Away Wheel

1.1.7.3

Take-Away spring

The take-away springs have small, bi-directional rollers that help the outside feed wheels drive the note out of the feed channel. They are spring loaded against the two outside feed wheels and operate on the same principal as the take-away wheel. When the note enters between the take-away springs and the feed wheels, the force of the take-away springs against the feed wheels provides the friction for the feed wheels to drive the note out of the feed channel. The take-away springs are not field-replaceable. 1.1.7.4

Functions of the Picker Module

Following are the functions of the picker module.

 

Reads the cassette coding. Pick media from the cassette.

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AFD 2.0



Count and grade the media.

1.1.7.5 1.1.7.5.1

Classification of Notes Mispicks:

The failure of the feed wheel cam to pick a single note from the media stack in the cassette in one rotation of the feed wheel. 1.1.7.5.2

Come Along:

An undesired second note that is in the same cycle as a desired note and is restacked. This can be caused by worn stripper, take away or feed wheels. 1.1.7.5.3

Short:

A note that is detected by the double detect system as less than half the regular note height (e.g. A lengthwise folded bill) 1.1.7.5.4

Single:

A good desired note of proper height and thickness. 1.1.7.5.5

Long:

A note that is measured at least half an inch higher than normal. 1.1.7.5.6

Early Doubles:

Two overlapped notes that are restacked. 1.1.7.5.7

Late Doubles:

Two significantly shingled notes that are restacked. 1.1.7.5.8

Late Tape:

A note that has a wrinkle or tape towards the end of the note causing the note profile to look thick. It is still dispensed 1.1.7.5.9

Actions and Notes:

When we look at the Actions and Notes for Mispicks, Actions = the number of mispicks. In other words how many times the feed wheel turned to pick up the note. Notes= the number of notes that had a mispick. Example1: If there are 4 mispick Actions on 1 Note, it means the Feed Wheel rotated 4 times to extract the 1 note. Example2: If there are 8 mispick Actions on 3 Notes, it means that the Feed Wheel rotated 8 times to get 3 notes out.

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AFD 2.0

1.1.7.6 1.1.7.6.1

Removal and Installation of Picker Module Picker Sub-assembly One and Two

Following is the procedure to remove and install the Picker Sub-Assembly one and two.  Remove all cassettes if any are present.  Remove the control CCA.  Whenever removing or installing the lower shaft (transport), use EXTREME CAUTION not to stretch the belts any more than necessary.  Remove the lower transport shaft assembly by releasing the right side from its recess in the frame.  Remove the left side from the bearing hole to remove tension on the semi-stretch vertical transport drive belts.  Set the shaft assembly aside in a safe place and secure the vertical timing belts to prevent damage to them.  Remove the screw that secures the stacker to the first picker channel, if present. Release the stacker latch springs and slide the stacker and transport unit toward the rear.  Remove the screw(s) attached to the picker that you want to remove.  Remove the transport and stacker from the picker stack.  Remove the picker motor cable and the keyboard cable. Save them to be used on the replacement subassembly.  On the picker you want to remove, release the latch springs and slide the sub-assembly toward yourself to disengage it from the pins in the sub-assembly below it, then lift the sub-assembly from the stack. 1.1.7.7

Picker Sub-assembly Three and Four

The following steps describe how to remove pickers three and four without removing the CCA, the transport, or the stacker.  Remove the lower TPR shaft assembly by releasing the right side from its recess in the frame.  Remove the left side from the bearing hole to remove tension on the semi-stretch vertical transport drive belts.  Set the shaft assembly aside in a safe place and secure the vertical timing belts to prevent damage to them.  Disconnect the keyboard cables [AFD 2.0 version]) for pickers three and four from the CCA and remove the cables from the cable route dressing.  Disconnect the motor cables [AFD 2.0 version]) for pickers three and four then remove them from the cable route dressing.  Remove the screw(s) attached to the picker that you want to remove.  On the picker above the one you want to remove, release the latch springs and slide the subassembly toward the back to disengage it from the pins in the sub-assembly below it.  Lift the picker (s) with stacker, CCA, and transport from the stack.

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AFD 2.0



On the picker you want to remove, release the latch springs and slide the sub-assembly toward the back to disengage it from the pins in the sub-assembly below it, then lift the sub-assembly from the stack.

1.1.7.8

         

Replacement of Picker module

If required, attach a motor cable and keyboard cable to the picker before assembling the picker stack. Assemble the picker stack. Make sure that the picker guides and pins are properly engaged. If removed separately, attach and secure the transport and stacker assemblies. Route the motor cables for pickers one and two as shown in above picture. Attach the control CCA. Connect the motor cables from pickers one and two to the CCA. Route and connect the motor cables from pickers three and four. Start with the sub-assembly that is farthest from the CCA. Route and connect the keyboard cables. Start with the sub-assembly that is farthest from the CCA. Install the vertical timing belts and the lower transport drive shaft assembly. Make sure that the belts are not twisted and are centered on the crown rollers. Install the CCA cover. Make sure that no cables are pinched behind the cover.

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AFD 2.0

1.1.7.9

 

    

Feed Wheel Replacement Guidelines

The Feed Wheel used in Active Dispenser module is the non-aggressive Feed Wheel. P/N: 49204018-000D The PM Kit 49-267135-000A contains a Feed Wheel, a Fender, a Stripper Wheel and a Take-away Wheel.

The maximum shelf time of the Feed Wheel assembly is 18 months. For maximum performance, install the Feed Wheel maximum after 18 months of its manufacturing date. The manufacturing date is indicated on the part's box, or on the side of the wheel. If not worn out, just dirty  clean with soapy water If visibly worn  replace Feed Wheel Use for maximum 400.000 notes dispensed

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AFD 2.0

1.1.7.10 Feed Wheel Alignment

 

After Feed Motor and/or motor coupling replacement, the Feed Wheel position should be aligned Feed Wheel alignment check should be performed in case of feed problems.



Below image shows the procedure for feed wheel alignment.

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AFD 2.0

1.1.7.11 Physical Observation to find the problematic parts in feed module:

Following images shows the parts when they are in correct state and when they are in incorrect state. Feed Wheels

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AFD 2.0

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AFD 2.0

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AFD 2.0

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AFD 2.0

1.1.8 Media/Currency Cassette Types

1.1.8.1

Reject/Retract Cassette Types

Below image shows the types of the reject bin

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AFD 2.0

1.1.8.2

Main Parts of COC:

Following are the images which shows the basic components of the COC.

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AFD 2.0

1.1.8.3

Cassettes Denomination & button settings 500:

Following is the procedure for the cassette and button settings for 500 denomination. Denomination: 500 PKR Dimensions: 147 x 65 mm  Please gently remove the coding buttons from the lower row of the cassette’s backside with a plier. (Remove the 3 buttons from CC, CC7, and CC4 positions)  Using the removed buttons, push one of them in to the H2 position as indicated with green below.  Leave the denomination button (D1) in its place.  Make sure that you have a button in the parity position (MP)

1.1.8.4

Side Guide & Upper Rail settings for PKR 500:

Following is the procedure for side guide and upper rail settings for PKR 500.  Inside the cassette lower section (body), check the Lower Side Guide settings. It should be in position 9 on the left (odd) side, and 10 on the right (even) side.



In the top (lid) of the cassette, please check the Upper Rail configuration. It should be the Upper Rail Config-6, as indicated on the below drawing.

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AFD 2.0



It means that that rail number 49-024317-000A must be clipped together with 49-024321-000A spacer and 49-023320-000A cap. You can see these part numbers written on the rails!



This is the way how these 3 rails (rail & spacer &cap) should be hooked together:

1.1.8.4.1

Configuring the Upper Rail

Rails must be installed in the lid of the cassette so that it will be configured correctly for the height of the media to be dispensed. 1.1.8.4.2

Upper Rail – Removal

Following is the procedure to remove the upper rail.  Open the cassette lid until it lies flat on the work surface.  At each of the two rail locks, use a flat blade screwdriver (or similar object) to lift and hold the rail flange above the rail lock. Slide the rail until it is past the rail lock and disengages from the eight rail latches, then remove the rail from the lid.  Repeat Step 2 for the remaining rail.

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Page 34 of 61

AFD 2.0

1 Rail hook 2 Rail lock 3 Rail mounting slot 1.1.8.4.3

 

Upper Rail - Replacement

Open the cassette lid until it lies flat on the work surface. If the rail for your media requires a cap or a spacer or both, assemble the required parts (Figure 33). Make sure that the hook in the cap engages the rail correctly, then press the parts together until they are fully seated.

Figure 3-3 Rail, Spacer, and Cap Assembly 1 Cap 2

Spacer

3

Rail

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Page 35 of 61

AFD 2.0

    

Position the rail (or rail assembly) with the ramp toward the front of the cassette and the rail flange mounting notches and mounting slots against the rail latches in the lid. Attach the rail to the rail latches nearest a rail lock as follows: a) Place your fingers on both sides of a rail mounting slot that is beside a rail lock. b) Press the rail firmly against the lid and slide the rail (or rail assembly) onto the rail latches. Repeat Step 4 for the slot beside the second rail lock. Make sure that all eight rail latches fully engage the flanges of the rail (Figure 3-4). Repeat Step 2 through Step 6 for the remaining rail. Figure 3-4 Upper Rail (or rail assembly) Installed correctly in the Cassette Lid

1 Spacer 2 Cap 3 Rail 4 Rail hook 1.1.8.5

Cassettes Denomination & button settings 1000:

Following is the procedure for the cassette and button settings for 1000 denomination Denomination: 1000 PKR Dimensions: 155 x 65 mm  Please gently remove the coding buttons from the lower row of the cassette’s backside with a plier. (Remove the 3 buttons from CC, CC7, and CC4 positions)  Using the removed buttons, push one of them in to the H2 position as indicated with green below.  Leave the denomination buttons (D1 and D0) in their place.  Make sure that you DO NOT have a button in the parity position (MP)

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AFD 2.0

1.1.8.6

Side Guide & Upper Rail settings for PKR 1000:

Following is the procedure for side guide and upper rail settings for PKR 1000.  Inside the cassette lower section (body), check the Lower Side Guide settings. It should be in position 5 on the left (odd) side, and 8 on the right (even) side.

5



8

In the top (lid) of the cassette, please check the Upper Rail configuration. It should be the Upper Rail Config-6, as indicated on the below drawing.

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Page 37 of 61

AFD 2.0



It means that that rail number 49-024317-000A must be clipped together with 49-024321-000A spacer and 49-023320-000A cap. You can see these part numbers written on the rails!



This is the way how these 3 rails (rail & spacer &cap) should be hooked together.

1.1.8.6.1

Configuring the Upper Rail

Rails must be installed in the lid of the cassette so that it will be configured correctly for the height of the media to be dispensed. 1.1.8.6.2

Upper Rail - Removal

 

Open the cassette lid until it lies flat on the work surface. At each of the two rail locks, use a flat blade screwdriver (or similar object) to lift and hold the rail flange above the rail lock (Figure 3-2). Slide the rail until it is past the rail lock and disengages from the eight rail latches, then remove the rail from the lid.  Repeat Step 2 for the remaining rail. Figure 3-2 Rail Flange Lock

1 Rail hook 2 Rail lock This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction.

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AFD 2.0

3 Rail mounting slot 1.1.8.6.3

 

Upper Rail - Replacement

Open the cassette lid until it lies flat on the work surface. If the rail for your media requires a cap or a spacer or both, assemble the required parts (Figure 33). Make sure that the hook in the cap engages the rail correctly, then press the parts together until they are fully seated. Figure 3-3 Rail, Spacer, and Cap Assembly

1 Cap 2 Spacer 3 Rail     

Position the rail (or rail assembly) with the ramp toward the front of the cassette and the rail flange mounting notches and mounting slots against the rail latches in the lid. Attach the rail to the rail latches nearest a rail lock as follows: a) Place your fingers on both sides of a rail mounting slot that is beside a rail lock. b) Press the rail firmly against the lid and slide the rail (or rail assembly) onto the rail latches. Repeat Step 4 for the slot beside the second rail lock. Make sure that all eight rail latches fully engage the flanges of the rail (Figure 3-4). Repeat Step 2 through Step 6 for the remaining rail.

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AFD 2.0

Figure 3-4 Upper Rail (or rail assembly) Installed correctly in the Cassette Lid

1 Spacer 2 Cap 3 Rail 4 Rail hook 1.1.8.7

Cassettes Denomination & button settings 5000:

Following is the procedure for the cassette and button settings for 5000 denomination Denomination: 5000 PKR Dimensions: 163 x 65 mm  Please gently remove the coding buttons from the lower row of the cassette’s backside with a plier. (Remove the 3 buttons from CC, CC7, and CC4 positions)  Using the removed buttons, push one of them in to the H2 position as indicated with green below.  Leave the denomination button (D2) in its place.  Make sure that you have a button in the parity position (MP)

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AFD 2.0

1.1.8.8 4.0.8 Side Guide & Upper Rail settings for PKR 5000: 

Inside the cassette lower section (body), check the Lower Side Guide settings. It should be in position 3 on the left (odd) side, and 6 on the right (even) side.

3

6



In the top (lid) of the cassette, please check the Upper Rail configuration. It should be the Upper Rail Config-6, as indicated on the below drawing.



It means that that rail number 49-024317-000A must be clipped together with 49-024321-000A spacer and 49-023320-000A cap. You can see these part numbers written on the rails!



This is the way how these 3 rails (rail+spacer+cap) should be hooked together:

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AFD 2.0

1.1.8.8.1

Configuring the Upper Rail

Rails must be installed in the lid of the cassette so that it will be configured correctly for the height of the media to be dispensed. 1.1.8.8.2

  

Upper Rail - Removal

Open the cassette lid until it lies flat on the work surface. At each of the two rail locks, use a flat blade screwdriver (or similar object) to lift and hold the rail flange above the rail lock (Figure 3-2). Slide the rail until it is past the rail lock and disengages from the eight rail latches, then remove the rail from the lid. Repeat Step 2 for the remaining rail. Figure 3-2 Rail Flange Lock

1 Rail hook 2 Rail lock 3 Rail mounting slot

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AFD 2.0

1.1.8.8.3

 

Upper Rail - Replacement

Open the cassette lid until it lies flat on the work surface. If the rail for your media requires a cap or a spacer or both, assemble the required parts (Figure 33). Make sure that the hook in the cap engages the rail correctly, then press the parts together until they are fully seated. Figure 3-3 Rail, Spacer, and Cap Assembly

1 Cap 2 Spacer 3 Rail



Position the rail (or rail assembly) with the ramp toward the front of the cassette and the rail flange mounting notches and mounting slots against the rail latches in the lid.  Attach the rail to the rail latches nearest a rail lock as follows: a) Place your fingers on both sides of a rail mounting slot that is beside a rail lock. b) Press the rail firmly against the lid and slide the rail (or rail assembly) onto the rail latches.  Repeat Step 4 for the slot beside the second rail lock.  Make sure that all eight rail latches fully engage the flanges of the rail (Figure 3-4).  Repeat Step 2 through Step 6 for the remaining rail. Figure 3-4 Upper Rail (or rail assembly) Installed correctly in the Cassette Lid

1 Spacer This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction.

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AFD 2.0

2 Cap 3 Rail 4 Rail hook 1.1.8.9

Cassette Coding – Currency Coding

Insert coding buttons into the indicated positions.  Insert one button into CC position  Insert one button into CC0 and one button into CC1 positions  Insert one button into D1 position  Since these add up to 4, you must insert a button into MP, to make the parity odd  Note Stop settings for all COCs is 4

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Page 44 of 61

AFD 2.0

 

You must also insert button(s) into D position(s) according to the denomination code. Then count all buttons (excluding the Media Low). The number of buttons must be uneven (odd). To ensure odd parity, you may need to insert a button in the MP position.

1.1.8.10 Cash Loading Instructions

Following instructions should be kept in mind while cash loading.  While loading new currency, the edges of the notes should be fanned along both edges multiple times in both direction. Another alternative is to run the currency through the counter or sorting machine. Make sure that none of the currency is stuck together.  When the lid is fully opened on the diebold cassettes, it provides the proper loading angle for the currency. By loading with the lid fully open notes will automatically be provided with a loading angle that provides superior picking performance. No loading tray is required, it is built into the design of the cassette.  Currency loaded under the stack or notes folded from the below side can cause dispenser error. So make sure that currency is not folded or the notes are not under the stack of the other notes.  Make sure that the notes are not sticking out from the sides, top or bottom.  While loading new currency in the form of 100 banknotes bundle, Please make sure that each bundle is opposite in orientation with the neighboring bundle

 

Do not load severely bent currency If you must load new currency with the fit currency in the same cassette, then make sure that all the fit currency is placed in front of the cassettes towards the lid hinge and new currency is placed in the back.

This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction.

Page 45 of 61

AFD 2.0

1.1.8.11 Floor Extension Spring Forces



Take reading when floor extension is flush with floor

This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction.

Page 46 of 61

AFD 2.0

Floor Extension Spring Forces

1.1.8.12 Tensioner Replacement



Move the keypad cover starting on one end and working your way down

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Page 47 of 61

AFD 2.0



If cassette slips out from the Picker Module too easy, replace the latch tensioner. If keypad cover is worn, replace that too.

1.1.8.13 Media Low Actuator:

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Page 48 of 61

AFD 2.0

1.1.8.14 Cassettes Check Points:

Following images shows the points which should be checked while preventive maintenance.

This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction.

Page 49 of 61

AFD 2.0

This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction.

Page 50 of 61

AFD 2.0

1.1.8.15 Divert Cassette:

There are two types of reject is coming with AFD dispenser: Open Reject cassette  Open cassette without lock & retract compartment  RR cassette with lock & retract compartment

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Page 51 of 61

AFD 2.0

1.1.9 Circuit Card Assembly CCA:

1.1.9.1

Main CCA Function Principle:

CCA – Circuit Card Assembly  It controls dispenser operations drives motors and receives signals from sensors  7 stepper motors in the 4-high Active Dispense module: 1. 4 picker motors 2. Push Plate motor 3. Cam motor 4. Transport motor  It contains the dispenser firmware which determines the different routines for picking, transporting, presenting, retracting, rejecting notes and also recovery routines If you replace the Active Dispense control CCA, then you must reset the Active Dispense communication. If the Active Dispense control CCA is replaced, the sensors must be manually recalibrated 1.1.9.2

Firmware:



There are typically, two layers of firmware: boot loader and primary.



The firmware controls the dispenser operations including the dispenser routines to handle USB communications, mispicks, come-along, short notes, doubles, long notes, as well as the motor drive pulse sequence commands. The firmware also reads the currency cassette information to perform and complete a dispense operation Primary firmware can be flashed (updated) from ATM software Every time the AMI is started, it compares the FW file on HDD with the FW of the module. If different versions, the file will be downloaded on the CCA, depending on the FW upgrade rule setting in ACU.

  

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AFD 2.0

1.1.9.3

   

1.1.9.4

Secure Communication:

A Trusted Platform Module (TPM) is a specialized chip that is installed on the PC motherboard for the purpose of hardware authentication. It stores keys, digital certificates and passwords. To meet PCI requirements that any new devices handling cash must use secure communication. SPEAR: Secure Protocol for Encryption and Authentication using RSA After PC motherboard replacement, Active Dispense CCA replacement and software changes the secure communication must be re-established

CCA Connections Identification:

Following image shows the connection details of CCA.

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Page 53 of 61

AFD 2.0

1.1.9.5

CCA LEDs:

Following image shows the status LED present on CCA.

1.1.9.6

LEDs Status:

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Page 54 of 61

AFD 2.0

1.1.9.7

Processor LEDs:

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Page 55 of 61

AFD 2.0

1.1.9.8

Sensors Status LEDs:

D16 – Divert cassette present ON=Cassette present, OFF=Cassette absent D18 – Exit gate (shutter) ON=Gate closed, OFF=Gate open D19 – Cam upper sensor ON=Not blocking sensor, OFF=Blocking sensor D20 – Can lower sensor ON=Not blocking sensor, OFF=Blocking sensor D21 – Exit sensor ON=Sensor blocked, OFF=Sensor not blocked D22 – Stacker sensor ON=Sensor blocked, OFF=Sensor not blocked D134 – Docking switch ON=Switch open, OFF=Switched closed

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Page 56 of 61

AFD 2.0

1.1.9.9 



Removal & Replacement: Disconnect all the cables and remove the two screws as shown in the image below.

It controls dispenser operations drives motors and receives signals from sensors  If you replace the Active Dispense control CCA, then you must reset the Active Dispense communication.  If the Active Dispense control CCA is replaced, the sensors must be manually recalibrated  Primary firmware can be flashed (updated) from ATM software  After PC motherboard replacement, Active Dispense CCA replacement and software changes the secure communication must be re-established

1.1.10 Guidelines for Preventive Maintenance Following tasks should be performed while preventive maintenance of the AFD dispenser 2.0 1. Perform all PM task listed in Picker, Stacker and Transport Module sections 2. Check the vertical belts. If you see any cracks or cuts on one of them, replace all 3 of the belts 3. Vacuum all accumulated dust from the AFD module 4. Check the AFD cable retractor, USB and Power cabling for proper routing and connection 5. Check all cabling inside safe. They may interfere with the AFD module vertical section 6. Check the horizontal position of the AFD against the fascia. Adjust if necessary. 1.1.10.1 Stacker Module:

1. 2. 3. 4. 5. 6. 7. 8. 9.

Remove stacker cam belt and cam Check cam rollers clean all parts below the cam Check all moving parts. Replace if necessary Apply a thin layer of grease to all moving parts, use white grease Check cam itself. If found scratches, replace CAM Check divert door and its operation Check exit shutter actuator arm position and gear alignment check gate smooth operation Replace paddle wheels Check note stop position, adjust if necessary

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Page 57 of 61

AFD 2.0

10. Check stacker belts and transport guides condition 11. Clean stacker sensor 12. Check reject/retract cassette, cassette present switch 13. Check stacker docking latch and cables 14. Don’t use alcohol for rubber parts 15. Use soap water type chemical to clean rubber parts. 1.1.10.2 Feed Module:

1. 2. 3. 4. 5. 6.

Remove strip wheel, take-away wheel, feed wheel assembly Vacuum all dust from the feed module clean the 4-brown roller on the platen springs Check the cassette opening pin. Replace if broken or damaged Check the smooth and correct clutch operation of the stripper pivot block Check the condition of the stripper wheel, take-away wheel and feed wheel. If worn, replace them. If not worn, just dirty, greasy, clean them with soapy water solution. 7. Check the snap latch pin’s condition. If worn, replace it 8. Check the backside of the feed module, check the note guides 1.1.10.3 Transport Module:

1. Apply a small amount of grease into push plate tracks 2. Clean the dust and dirt from the exit shutter gate 3. Apply a small amount of grease between the shutter gate and the fascia plate corners 1.1.10.4 Cassettes:

1. Try removing the cassette without pushing the blue button. If cassette slips out, replace the snap latch pin is feed module and the cassette keyboard cover 2. Remove all banknotes from the cassette and check the push plate for smooth operation 3. Check the floor extension spring forces. Adjust if necessary 4. Check the cassette tambour door. If it is severely damaged, replace the cassette 5. Check the correct closing of the cassette lid. Replace cassette if cannot close

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Page 58 of 61

AFD 2.0

1.2 AFD 2.0 Errors Dispenser’s error codes can be viewed from EJ & T/SOP. Following table shows different error codes and their description. Error Codes AFD0C106 AFD0C107 AFD0C119 AFD0C120 AFD0C121 AFD0C122 AFD0C123 AFD0C124 AFD0C125 AFD0C126 AFD0C206 AFD0C207 AFD0C219 AFD0C220 AFD0C221 AFD0C222 AFD0C223 AFD0C224 AFD0C225 AFD0C226 AFD0C306 AFD0C307 AFD0C319 AFD0C320 AFD0C321 AFD0C322 AFD0C323 AFD0C324 AFD0C325 AFD0C326 AFD0C406 AFD0C407 AFD0C419 AFD0C420

Description Cassette 1 Empty Feed wheel stuck from Cassette 1 Proximity prob has become unusable since last calibration (Cassette replace feed module Unsolicited note detected from Cassette 1 Thick Notes detected from Cassette 1 Thin Notes detected from Cassette 1 Short Notes detected from Cassette 1 Tall Notes detected from Cassette 1 Pick failure detected from Cassette 1 Proximity prob End of Life of Cassette 1, replace feed module Cassette 2 Empty Feed wheel stuck from Cassette 2 Proximity prob has become unusable since last calibration (Cassette replace feed module Unsolicited note detected from Cassette 2 Thick Notes detected from Cassette 2 Thin Notes detected from Cassette 2 Short Notes detected from Cassette 2 Tall Notes detected from Cassette 2 Pick failure detected from Cassette 2 Proximity prob End Of Life of Cassette 2, replace feed module Cassette 3 Empty Feed wheel stuck from Cassette 3 Proximity prob has become unusable since last calibration (Cassette replace feed module Unsolicited note detected from Cassette 3 Thick Notes detected from Cassette 3 Thin Notes detected from Cassette 3 Short Notes detected from Cassette 3 Tall Notes detected from Cassette 3 Pick failure detected from Cassette 3 Proximity prob End of Life of Cassette 3, replace feed module Cassette 4 Empty Feed wheel stuck from Cassette 4 Proximity prob has become unusable since last calibration (Cassette replace feed module Unsolicited note detected from Cassette 4

This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction.

1),

2),

3),

4),

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AFD 2.0

AFD0C421 AFD0C422 AFD0C423 AFD0C424 AFD0C425 AFD0C426 AFD0C506 AFD0C507 AFD0C519 AFD0C520 AFD0C521 AFD0C522 AFD0C523 AFD0C524 AFD0C525 AFD0C526 AFD0CA04 AFD0CA05 AFD0CA10 AFD0DE04 AFD0CO17 AFD0DE04 AFD0DE05 AFD0DE06 AFD0DE08 AFD0DE10 AFD0DE13 AFD0DE19 AFD0DS01 AFD0EX01 AFD0FD12 AFD0RB06 AFD0RJ01 AFD0RJ02 AFD0RJ03 AFD0RJ06 AFD0RJ07 AFD0RM10 AFD0SE01 AFD0SE02 AFD0SE03 AFD0SE04

Thick Notes detected from Cassette 4 Thin Notes detected from Cassette 4 Short Notes detected from Cassette 4 Tall Notes detected from Cassette 4 Pick failure detected from Cassette 4 Proximity prob End of Life of Cassette 4, replace feed module Cassette 5 Empty Feed wheel stuck from Cassette 5 Proximity prob has become unusable since last calibration (Cassette 5), replace feed module Unsolicited note detected from Cassette 5 Thick Notes detected from Cassette 5 Thin Notes detected from Cassette 5 Short Notes detected from Cassette 5 Tall Notes detected from Cassette 5 Pick failure detected from Cassette 5 Proximity prob End of Life of Cassette 5, replace feed module Proximity prob Interrupt Failure, replace feed module Motor Mux Failure Motor Interrupt Failure Dispense Timeout Module is Offline Dispense Timeout Count Mismatch. Notes picked not equal notes stacked Dispense by cassette from cassette that is not present Dispense by denomination from denomination that is not present Dump Failure after dispense failure Unidentified (wrong) cassette code Cassettes shuffled, must query configuration Docking Switch Open Exit sensor blocked when dispense command sent Trap Detected Money taken during operation Divert Door Can’t move to dispense position Divert Door Can’t move to reject/divert position Divert Cassette Full Divert/Retract Cassette Missing Divert Door won't move RAM Error SPEAR has not been established SPEAR mode mismatch SPEAR platform fault Platform integrity: Authorization required

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Page 60 of 61

AFD 2.0

AFD0SE05 AFD0SE13 AFD0SE18 AFD0SH01 AFD0SH02 AFD0SH07 AFD0ST01 AFD0ST04 AFD0ST05 AFD0ST07 AFD0ST08 AFD0ST09 AFD0ST26 AFD0TP04 AFD0TP07 AFD0TP08 AFD0XS07 AFD0XS08 AFD0XS09 AFD0XS26 AFD0ZZ99 AFD0XS26

Platform integrity: See SSTC Dashboard Security key generation is in progress, this is for informational purposes only Module is Unpaired Exit shutter won't close Exit shutter won't open Exit shutter won't move Stack Sensor blocked when dispense command sent Stacker Sensor Extra Notes Stacker Sensor Dirty Money tray won't move Stacker Sensor Blocked Stacker Sensor Failed Stacker Sensor at End of Life Dispense Transport Jam No forward drive (During Present to Exit) Stalled Exit Sensor Jam Exit Sensor Blocked Exit Sensor Stuck Open/Clear Exit Sensor at End Of Life Software problem. Pull a 1T and open a TI. DSA is not seeing a specific EFC but the module is reporting that it is not in an OK state. Software problem. Pull a 1T and open a TI. DSA is not seeing a specific EFC but the module is reporting that it is not in an OK state.

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Page 61 of 61