Professional Documents
Culture Documents
TP09311011 Rev 00
E De La Rue 2001
6000 Prelims
May 2001 Page 1
1.4 Record of Amendments
Records of Amendments should not be inserted on any page other
than an Amendment Record Sheet.
Prelims 6000
Page 2 May 2001
RECORD OF AMENDMENTS
TECHNICAL DATE
BRIEF DESCRIPTION
BULLETIN No. AMENDED
6000 Prelims
May 2001 Page 3
RECORD OF AMENDMENTS
TECHNICAL DATE
BRIEF DESCRIPTION
BULLETIN No. AMENDED
Prelims 6000
Page 4 May 2001
CONTENTS
Title Page
Duty of Confidence
Record of Amendments
Maintaining CE Compliance
Section 1 General Detector Information
6000 Prelims
May 2001 Page 5
IMPORTANT – THE FOLLOWING SECTION ON SAFETY MUST BE UNDER-
STOOD AND STRICTLY ADHERED TO BY ALL SERVICING AND OPERATING
PERSONNEL.
2.3 Weight
Care must be taken when lifting items weighing 20kg or over during
refitting. The fitting of such items should be regarded as a two person
task.
All items of clothing such as ties, loose overalls and long hanging
jewellery should be removed. Long hair should be tied up.
Prelims 6000
Page 6 May 2001
2.6 Light Emissions
The safety precautions for detectors which emit U.V. light or lasers
must be followed in accordance with the instructions in the relevant
detector manuals.
2.9 EMC
Various parts of the machine, particularly those items supplied by
mains power, but also including PCB’s, contactors, etc. are housed in
EMC (Electro–Magnetic Compatibility) shielded boxes. The machine
external covers also form part of a general EMC shield. To comply
with EMC regulations, it is important that these shields and covers are
always fitted and secure when the machine is in operation.
2.10 Solvents
All fluids used for cleaning purposes must be non – toxic and must
comply with the relevant COSHH and Health And Safety regulations.
2.11 Pneumatics
Before attempting any maintenance or servicing on the pneumatics
system ensure that the air supply is removed. Should it be necessary
to carry out any fault finding on the machine while the pneumatics are
functioning, extreme caution should be exercised.
6000 Prelims
May 2001 Page 7
3. MAINTAINING CE COMPLIANCE
Any installation practices, modifications or maintenance procedures
carried out which are not in accordance with the requirements of, or
approved by De La Rue Cash Systems, will nullify the CE
certification of this product and could lead to prosecution.
Prelims 6000
Page 8 May 2001
Section 1
___________________________
General Detector Information
4000 Section 1
May 2001 Page 1
CONTENTS
Para Page
1. INTRODUCTION 4
1.1 Note Authentication and Assessment System 4
______________________________________________
2. DESCRIPTION 6
2.1 Detector Interface Board 6
______________________________________________
3. MAINTENANCE 6
______________________________________________
4. FAULT DIAGNOSIS 8
4.1 Error Messages 8
4.2 Preliminary 8
4.3 Test For Transport System Integrity 8
______________________________________________
5. DETECTOR SYSTEM DIAGNOSTICS - GENERAL 9
5.1 Introduction 9
5.2 General Protocol Details 10
5.3 Access Code 12
______________________________________________
6. DETECTOR SYSTEM DIAGNOSTICS -
FUNCTION 1 ‘CONFIGURATION’ 14
6.1 Option 1 ‘Load Configuration’ 14
6.2 Option 2 ‘List Configuration’ 14
6.3 Option 3 ‘Edit Configuration’ 15
______________________________________________
7. DETECTOR SYSTEM DIAGNOSTICS -
FUNCTION 2 ‘SYSTEM DIAGNOSTICS’ 23
7.1 Option 11 ‘Display Status’ 23
7.2 Option 12 ‘View Memory’ 25
7.3 Option 13 ‘Change Memory’ 25
7.4 Option 21 ‘Show Engineer’s Log’ 25
7.5 Option 22 ‘Test a Function’ 26
7.6 Option 23 ‘Print truth Table’ 26
7.7 Option 24 ‘Show 1mm Counter’ 26
7.8 Option 31 ‘Configurator Contents’ 26
7.9 Option 32 ‘Configurator Details’ 26
7.10 Option 33 ‘Configurator Self Test’ 26
7.11 Option 34 ‘Configuration Verify’ 26
7.12 Option 41 ‘RAM Test’ 26
7.13 Option 42 ‘EPROM Checksum Test’ 26
7.14 Option 00 ‘End’ 26
______________________________________________
Section 1 4000
Page 2 May 2001
CONTENTS (continued)
Para Page
8. DETECTOR SYSTEM DIAGNOSTICS -
FUNTION 3 ‘DETECTOR DIAGNOSTICS’ 31
8.1 Option 11 ‘List Detector Names’ 31
8.2 Option 12 ‘List Trace Measure Codes’ 31
8.3 Option 13 ‘List Cull Text Codes’ 31
8.4 Option 14 ‘List Error Codes’ 31
8.5 Option 21 ‘Show Algorithm Data’ 32
8.6 Option 22 ‘List Algorithm Text Codes’ 32
8.7 Option 23 ‘Show DAC Settings’ 32
8.8 Option 24 ‘Show Audio Calibration’ 32
8.9 Option 31 ‘Detector Controller’ 33
8.10 Option 00 ‘End’ 36
______________________________________________
9. DETECTOR SYSTEM DIAGNOSTICS -
FUNCTION 4 ‘TRACE DATA’ 39
9.1 Trace System General Details 39
9.2 Option 11 ‘Examine Note Trace Data’ 40
9.3 Option 12 ‘Examine Histogram Trace Data’ 42
9.4 Option 13 ‘Examine Trace Measure Table’ 42
9.5 Option 21 ‘Set Note Trace Conditions’ 45
9.6 Option 22 ‘Set Up Histogram Trace’ 46
______________________________________________
Tables
Table 1 Trace Measure Data 43
______________________________________________
Illustrations
Figure 1 Detector Interface Board Block Diagram 7
______________________________________________
Figure 2 Detector System Diagnostics Flow Chart 13
______________________________________________
Figure 3 Configuration Flow Chart 21
______________________________________________
Figure 4 System Diagnostics Flow Chart 27
______________________________________________
Figure 5 Detector Processor Decision Process 29
______________________________________________
Figure 6 Detector Diagnostics Flow Chart 37
______________________________________________
Figure 7 Trace Data Flow Chart 47
______________________________________________
4000 Section 1
May 2001 Page 3
1. INTRODUCTION
Information applicable to all note authentication and assessment
detectors is given in this Section, and information applicable to a
specific detector only is given in the corresponding sections which
follow.
Detectors
The standard range of detectors comprise the following.
Operation
Once the operating process is selected, the detector processor passes
to the detector interface the decision parameters applicable to both the
process selected and the type and location of the detectors interfaced.
The detector processor collates the discrete decisions arising from all
detectors in order to obtain for each note a composite decision. This is
compared with the appropriate process truth table in order to make the
note routeing decision, which is passed on to the transport processor.
Section 1 4000
Page 4 May 2001
Parameter Adjustment
Whilst the operator can adjust fitness parameters at the keyboard, the
Site Engineer can adjust decision parameters, including truth tables,
after entering the appropriate pass code. These adjustments can be
carried out only when the machine is in the standby mode.
Following any access to the configurable data, the detector issue level
held in the detector processor is automatically updated.
Upon request, the following data can be printed out:
l Process information
l Detector settings
Self Check
Upon switch-on of the machine, change of process and at certain other
times, the machine checks that all aspects of the interface and
associated detector heads are fully functional. Any malfunction is
reported through the intercommunication system to inform the operator
or Engineer. If a printer is fitted a diagnostic print-out can be obtained
if any check fails.
Detector Processor
The detector and transport processors are identical with only firmware
differences. The detector processor is responsible for the following:
l Holding a permanent record of the detector operating routine.
l Holding a semi-permanent record of detector calibration parame-
ters, which are amended automatically to off-set variations.
l Holding a semi-permanent record of the Customer’s detector pack-
age layout and operational requirements.
l Holding a semi-permanent record of the Establishment’s note char-
acteristics, which can be amended by the Service Engineer.
l Holding a current record of the findings of the detector interrogation.
l Maintaining the detector configuration table for use by itself, by the
detector interface, and by the transport processor.
l Supporting the operation of each detector.
l Providing the combined findings of all detectors with a destination
code.
l Monitoring the performances of itself and the detector interface.
l Supporting the keyboard manipulation of configuration data, whilst
enforcing multi-level access by operator and Engineer, and logging
in a History file in non-volatile memory those changes that affect the
machine’s security arrangements.
l Decoding the process selection and priming the detectors
accordingly.
l Supporting the security key arrangement to ensure configuration
integrity.
4000 Section 1
May 2001 Page 5
2. DESCRIPTION
3. MAINTENANCE
It is necessary to carry out the routine transport adjustments first, as
the transport must function correctly before the detectors can be cor-
rectly set. If a detector requires re-adjustment at another time then it is
at least necessary to ensure that the transport (flat) belts adjustment is
correct first.
Section 1 4000
Page 6 May 2001
Figure 1 Detector Interface Board - Block Diagram
4000 Section 1
May 2001 Page 7
4. FAULT DIAGNOSIS
Error number 34 indicates that the detector is not ready. This indication
may be caused by a disengagement of a connector of the detector sys-
tem. (Refer to the block diagram in the corresponding detector section).
4.2 Preliminary
The performance of the detectors is affected by the performance of the
note transport system. Therefore, before investigating specific detector
faults, it is necessary to check for proper operation of the note transport
system. This check is described under the following heading.
Ensure that, if any part of the detector system is renewed, the Setting
Up procedure of the corresoponding Appendix is subsequently carried
out.
Cleanliness
Check that all transport sensors and the detector are clean. If any item
is found to be excessively dirty, then remind the supervisor or operator
of the importance of thorough daily cleaning.
Note Feeder
Check that the note feeder adjustments are correct. Observe whether
the feeder gives any multiple feeds. Multiple feeds can be identified by
counting the number of notes in the cull pocket and comparing the count
with the number of notes in the transport trace (diagnostic function 09
in the diagnostics menu, set up to trace culls only).
Note Transport
Visually check the condition of the note transport belts. Check the set-
ting of the belt tensions at each of the drive capstans.
Ensure all rollers move freely.
Culls
Use the transport note trace to determine whether the transport
processor is culling the notes. Use the detector processor note trace to
determine whether the detector processor is culling the notes. If either
Section 1 4000
Page 8 May 2001
processor is initiating the culls then investigate and correct with
appropriate action against the cull reason.
Service Report
This should include a statement verifying that the test for system
integrity is completed and include also details of all corrective actions
taken.
5.1 Introduction
The detector processor supports a user interface, via the Cobra 4004
keyboard and display. This section details the detector processor func-
tions available through keyboard operation to the operator,
supervisor and engineer, and provides a guidance as to their usage.
A summary of the detector system diagnostics is given in the flow chart
of Figure 2.
Functions (a) and (c) are specifically selected from within the machine
diagnostic environment. Function (b) is transparent to the operator and
is entered via a supervisor configuration screen.
4000 Section 1
May 2001 Page 9
5.2 General Protocol Details
As far as is possible, certain protocols have been adopted throughout
all keyboard and display activities.
a) ‘->’ (right cursor key) - use of this key is generally reserved for
stepping on to the next phase of an operation (e.g. display next
block of memory).
b) ‘<-’ (left cursor key) - where the operation permits, use of this key
steps back to the previous phase of an operation (e.g. display
previous block of memory).
Text Input
Where text input is required, the operator is presented with the following
information.
!”£$%&’()*+,-./0123456789:;<=>?@
ABCDEFGHIJKLMNOPQRSTUVWXYZ[ ] _’
abcdefghijklmnopqrstuvwxyz
END
Text is entered by positioning the cursor under the required character
and pressing ‘ENTER’. Cursor movement is achieved by using the
cursor control keys. As each character is added to the string it is
displayed at the bottom left of the screen. Pressing ‘CLEAR’ will cause
the most recently entered character to be cancelled from the string.
Once the required text string has been entered, moving the cursor
under the word ‘END’ and pressing ‘ENTER’ will terminate the entry.
Where text strings are limited to a specified number of characters (as
Section 1 4000
Page 10 May 2001
stacker titles), the text entry will be automatically terminated when the
required number of characters have been entered.
The masks are in binary format, each bit of the mask having a
ignificance appropriate to its application. Individual bits may be toggled
on and off by entering their bit number. Bit numbers may be referenced
to 0 or 1 depending on the application.
Fault Reporting
Normal fault reporting is controlled by the transport processor. Fault
codes 1000 to 40999 have been reserved for detector and detector
processor faults. The first two digits of the error code refers to the of-
fending detector (for example: 1xxx = detector 1, 12xxx= detector 12).
Error codes which begin with 40xxx refer to the detector processor itself.
The remaining three digits represent the actual error code logged.
Option 2 will delete the currently displayed fault and report on the next
most recent fault logged. A fault code of 0 implies no more faults
logged.
Option 3 will print a complete list of all faults logged, together with its ex-
planation.
Option 0 will return the operator to the routine from which the faults
menu was called.
4000 Section 1
May 2001 Page 11
5.3 Detector Processor Menu.
This is the top level of the detector processor diagnostics routines and
is entered after the access authority has been established. After
selection the operator is presented with the following menu, refer to fig-
ure 2.
Section 1 4000
Page 12 May 2001
DETECTOR SYSTEM
DIAGNOSTICS ACCESS
AUTHORITY 0
1 2 3 4 0
4000 Section 1
May 2001 Page 13
6. DETECTOR SYSTEM DIAGNOSTICS -
FUNCTION 1 ‘CONFIGURATION’
Access authority required: 0
This option will force the loading of the configuration file from the
configuration EPROM. Any configuration data held in the system
memory will be overwritten. A warning message is displayed first;
pressing ‘ENTER’ carries out the option whereas pressing ‘CLEAR’
aborts the operation.
Page 1:
Configuration list menu (lev. 2)
Master table 1: History 2
Processes 3: Notes 4
Detectors 5: Transport 6
Proc. titles 7: End 0
change menu ->
Page 2:
Configuration list menu (lev. 2)
Complete list 1: Cond. ptrs 2
Note base tbl. 3: End 0
<- change menu
On selection of the required listing option the operator is first given the
choice to list all of the defined data tables, or select a specific table for
listing. The operator is then prompted to select either the display or the
printer for output.
Section 1 4000
Page 14 May 2001
6.3 Option 3 ‘Edit Configuration’
Access authority required: 3
Page 1:
Configuration edit menu (lev. 2)
Create config. 1: Master tbl. 2
Process data 3: Note data 4
Detector data 5: Transp. data 6
Proc. titles 7: End 0
change menu ->
Page 2:
Configuration edit menu (lev. 2)
Edit title 1: Cond. ptrs. 2
Note base data 3: End 0
<- change menu
Option 1 - ‘List table’ - this option enables the master table to be listed
to either the display or the printer.
Option 4 - ‘Speed’ - modify the nominal transport speed for the machine
as known by the detector processor.
4000 Section 1
May 2001 Page 15
Option 7 - ‘Mod. Det. mask’ - modify the machine detector mask.
Setting a bit in the mask to zero will switch the corresponding detector
off for ALL processes.
Option 0 - ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
Each option prompts the user for the data required to implement the
edit.
Option 1 ‘List table(s)’ - this option will enable all or specific process
data tables to be listed to either the display or the printer. If the CLEAR
key is pressed whilst displaying these tables, it will take the operator
back to the previous level.
Option 2 ‘Add process’ - this option will create a new process data table
if the user supplied process identity is unique.
Option 5 ‘Add title ref’ - change the reference to the process title table.
The new title reference will only be accepted if the process table already
exists.
Option 6 ‘Mod. Det.mask’ - modify the detector mask for the given
process. Setting a bit in the mask to zero, will switch the corresponding
detector off.
Option 7 ‘Find table’ - find the address for the given process data table.
If the process table cannot be found then an address of 0 will be
displayed.
Option 8 ‘Mod note dest.’ - modify a note’s destination for the various
grades, for the process and note selected.
Option 9 ‘Mod. cond. ptr’ - modify the condition pointer mask which
defines which, if any, of the sensitivity pointers are to be automatically
offered to the operator at process selection. Setting a bit in the mask to
zero will disable the corresponding pointer for operator adjustment.
Section 1 4000
Page 16 May 2001
Option 0 ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
Each option prompts the user for the data required to implement the
edit.
Option 1 ‘List table(s)’ - this option will enable all or specific note data
tables to be listed to either the display or the printer.
Option 2 ‘Add note’ - this option will create a new note data table if the
user supplied note identity is unique.
Option 4 ‘Find table’ - find the address for the given note data table. If
the note table cannot be found then an address of 0 will be displayed.
Option 5 ‘Note size’ - change the default note size. This note size
applies only to note tables whose configured dimensions, length or
width, is zero. This option does not make any changes to the
configuration file, but simply changes the default values held by the
detector processor.
Option 6 ‘Mod. data sort’ - modify the data reduction type for each grade
of a note. This enables the operator to change the data reduction to
either AND, OR, NAND or NOR data sort.
Option 0 ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
Option 1 ‘List table(s)’ - this option will enable all or specific detector
data tables to be listed to either the display or the printer.
Option 2 ‘Add detector’ - this option will create a new detector data table
if the user supplied detector identity is valid (1 to 32) and unique.
4000 Section 1
May 2001 Page 17
Option 3 ‘Add criterion’ - add a new detector criterion to a detector table
entry. The new criterion will only be created if the identity is unique
within the context of the detector chosen.
Option 5 ‘Find table’ - find the address for the given detector data table.
If the detector table cannot be found then an address of 0 will be
displayed.
Option 8 ‘Det. read time’ - modify the time at which the detector
processor will read the results from a detector. If this time is set to zero,
the detector processor will calculate a read time based on the detector
position and the note length.
Option 0 ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
Option 1 ‘List table(s)’ - this option will enable all or specific transport
processor data tables to be listed to either the display or the printer.
Option 2 ‘Add table’ - this option will create a new transport data table if
the user supplied identity is unique.
Option 3 ‘Find table’ - find the address for the given transport data table.
If the transport cannot be found then an address of 0 will be displayed.
Option 4 ‘Edit table’ - this enables the user to modify a stacker data
entry for a given transport processor data table.
Option 5 ‘Add stacker’ - create a new stacker entry into a given transport
data table. The new stacker number must be unique within the
specified transport data table and must be in the range 1 to 15.
Option 0 ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
Section 1 4000
Page 18 May 2001
Option 7, page 1 ‘Process Titles’
This option enables the process title data tables to be edited or created.
On selection, the following options menu is displayed.
Process title menu (level 3)
List table(s) 1: Add table 2
Find table 3: Edit title 4
End 0
Option 1 ‘List table(s)’ - this option will enable all or specific process title
data tables to be listed to either the display or the printer.
Option 2 ‘Add table’ - this option will create a new process title data table
if the user supplied identity is unique. The user will be required to enter
a new title string for each language defined in the master table.
Option 3 ‘Find table’ - find the address for the given title data table. If
the title table cannot be found then an address of 0 will be displayed.
Option 0 ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
Option 1 ‘List table(s)’ - this option will enable all or specific condition
pointer data tables to be listed to either the display or the printer.
Option 2 ‘Add table’ - this option will create a new condition pointer data
table if the table identity is unique.
Option 3 ‘Find table’ - find the address for the given condition pointer
data table. If the condition pointer table cannot be found then an
address or 0 will be displayed.
Option 0 ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
4000 Section 1
May 2001 Page 19
Option 3, page 2 ’Note Base Data’
This option enables the note base data tables to be edited or created.
On selection, the following options menu is displayed.
Note base data menu (level 3)
List tbls. 1: Add table 2
Find table 3: Mod note offset 4
Edit text 5: End 0
Option 1 ‘List table(s)’ - this option will enable all or specific note base
data tables to be listed to either the display or the printer.
Option 2 ‘Add table’ - this option will create a new note base data table
if the table identity is unique.
Option 3 ‘Find table’ - find the address for the given note base data
table. If the note base table cannot be found then an address of 0 will
be displayed.
Option 4 ‘Mod note offset’ - modify the value of the note base offset.
Option 5 ‘Edit table text’ - This option is not used by Cobra machine.
Option 0 ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
Option 0 ‘End’
Selecting this option will return the operator to the ‘Configuration menu
(level 1)’.
Option 0 ‘End’
Selecting this option will return the operator to the ‘Detector Processor
menu (level 0)’.
Section 1 4000
Page 20 May 2001
CONFIGURATION
Access Authority 0
1 2 3 4 5 0
Access 0 0 3 0
Authority
Page 2
Page 1 3 Page 2
1 2 3 4 5 6 7 0 1 2 3 0
Master History Processes Notes Detectors Transport Process End Edit Condition Note Base End
Table Titles Table Pointers Data
Page 2
Page 2 1 2 3 4 5 0
1 2 3 0 List Add Find Mod Edit End
Tables Table Tables Note Table
Complete Condition Note End Offset Text
List Pointer Base Page 2
Table 1 2 3 4 5 0
1 2 3 4 5 6 7 0
Create Master Process Note Detector Transport Process
Configuration Table Data Data Data Data End
Titles
Page 1 Page 1
1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 0 1 2 3 4 5 0
List Add Note Add List Add Detector End List End
Tables Title Find Mod End Tables Find Tables Find
Table Cond Ptr Criterion Table Position
Ref Table
Mod
Add Add TP Mod Det Note Add Table Edit Title
Process Ref Mask Add Edit Detector Detector
Dest Detector Parameters Name Read Time
Page 1:
Sys. diagnostics 1 (level 1)
Display status 11
View memory 12
Change memory 13
End 00
change menu ->
Page 2:
Sys. diagnostics 2 (level 1)
Show engineer’s log 21
Test a function 22
Print truth table 23
Show 1mm counter 24
End 00
<- change menu ->
Page 3:
Sys. diagnostics 3 (level 1)
Configurator contents 31
Configurator details 32
Configurator self test 33
Configuration verify 34
End 00
<- change menu ->
Page 4:
Sys. diagnostics 4 (level 1)
RAM test 41
EPROM checksum test 42
End 00
<- change menu
Selection of the required option is made by entering the two- digit option
numbers from any page. A summary of the system diagnostics is given
in the flow chart of Figure 4.
4000 Section 1
May 2001 Page 23
The following data is currently listed.
Section 1 4000
Page 24 May 2001
7.2 Option 12 ‘View Memory’
Access authority required: 0
This option enables the operator to list the detector processor system
memory, to either the printer or the display.
If output to the printer has been selected, the operator is prompted for
a start and end address of the memory area of interest.
If output to the display has been selected the operator is prompted for
a start address only. The first 6 words, starting from the address
specified, are then output to the screen. The operator then has the
following options.
-> = display next 6 locations
<- = display previous 6 locations
CLEAR = end operation
This option enables the operator to modify the contents of the detector
processor system memory. After selecting the required address, the
operator is presented with the following menu (for example address
20088 has been chosen).
Pressing ‘ENTER’ will enable the operator to modify the contents of the
address shown. The new data must be entered in hexadecimal format.
4000 Section 1
May 2001 Page 25
7.5 Option 22 ‘Test a Function’
Access authority required: 3
This option displays the count value contained in the 1mm counter
maintained by the detector processor. The Cobra transport system pro-
vides the clock signal which is synchronised each time the machine is
started.
Section 1 4000
Page 26 May 2001
SYSTEM DIAGNOSTICS
ACCESS AUTHORITY 0
para 7.1 7.2 7.3
11 12 13
Page 1 Change
Display View
Status Memory Memory
Access
Authority 0 0 3
Page 2
Show Engineers Test a Function Print Truth Table 1mm
Log Counter
Access
Authority 0 0 0 0
EPROM
Page 4 END
RAM Test Check Sum
Test
Access
Authority 0 0
4000 Section 1
May 2001 Page 27
This page deliberately left blank
Section 1 4000
Page 28 May 2001
Start
Fail
Pass Pass Pass Pass
Fail
Pass
Note 2 Grade
1
Fail
Pass
Note 3 Grade
1
Fail
Unclassified
Page 1
Det. Diagnostics 1 level 1)
List detector names 11
List trace measure codes 12
List cull text codes 13
List error codes 14
End 00
Change menu ->
Page 2
Det. Diagnostics 2 (level 1)
Show algorithm data 21
List algorithm text codes 22
Show DAC settings 23
Show audio calibration 24
End 00
<- change menu
Page 3
Det. Diagnostics 3 (level 1)
Detector Controller 31
Selection of the required option is made by entering the two- digit option
numbers from any page. A summary of the detector diagnostics is
given in the flow chart of Figure 6.
This option will provide a list of all detector numbers declared in the con-
figuration file together with the detector names.
4000 Section 1
May 2001 Page 31
8.5 Option 21 ‘Show Algorithm Data’
Access authority required:0
The detector system produces a true or false reply, for each algorithm
and parameter combination. Each reply occupies a single bit in the
reply word associated with the detector in question. The significance of
each bit is determined by the time order in which the detector
configuration is performed. The first algorithm result is associated with
the least significant bit.
Section 1 4000
Page 32 May 2001
8.9 Option 31 ‘Detector Controller’
a) Test output FIFO - checks the operation of the control lines on the
detector processor output FIFO.
b) Test input FIFO - checks the operation of the control lines on the
detector processor input FIFO.
This option enables the operator to send a single 16 bit data word to a
detector controller. On selection the operator is prompted for the
controller number, the data word to be sent and the allowed timeout.
The detector controller response is displayed on the screen.
Note: The data word sent to the controller will only be echoed if it is a
valid function code. This option may cause several errors to be logged
depending on the data word sent.
4000 Section 1
May 2001 Page 33
Type 0 (e.g. Soil, Holes and Tears).
Each of the detector controllers is configured to perform certain process
dependent tasks (algorithms). Each detector controller task consists of
an algorithm number plus a list of associated algorithm parameters.
The algorithm number defines the type of operation (e.g.soil, tape etc.)
The parameters are numerical constants which are accessed during the
execution of the algorithm. The significance and number of the param-
eters is dependent upon the algorithm to which they are associated.
This option will force all detector controllers to perform a hard reset.
Any valuable data held by the detector controllers will be lost.
This option will also reset some of the detector processor hardware, as
a result the transport processor will log a detector processor communi-
cations fault and terminate the direct communications mode. Such ac-
tion will not corrupt data in the detector processor, which should recover
fully.
This function is very often used in the setting up of detectors, and allows
the sampled response from a detector for the last note traced, to be
displayed. For detailed information refer to the relevant detector service
manual. The response can be displayed as numerical data or as
graphical data.
Section 1 4000
Page 34 May 2001
The numerical format is byte orientated, with an address and 8 bytes of
data per line. Use of the right and left arrows allow the address to be
incremented and decremented respectively.
If output to the screen has been selected, data is output from the
engineer’s log start address and is formatted as an address followed by
8 data bytes. The operator then has the following options:
-> = display next 48 bytes
<- = display previous 48 bytes
DELETE = end operation
4000 Section 1
May 2001 Page 35
Option 34 ‘Controller A/D Conversion’
This option will list all valid trace measure codes, together with the
associated text to either the screen or the printer.
This option will list all valid algorithm codes together with the associated
text to either the screen or the printer.
This option will list all valid cull codes, together with the associated text
to either the screen or the printer.
This option will list all valid error codes, together with the associated text
(long and short) to either the screen or the printer.
This option will provide a list of all detector numbers declared in the
configuration file together with the detector name.
Section 1 4000
Page 36 May 2001
DETECTOR DIAGNOSTICS
Access Authority 0
11 12 13 14 21 22 23 24 31 0
List Detector List Trace List Cull List Error Show List Show DAC Show Audio Detector End
Names Measure Text Codes Codes Algorithm Algorithm Settings Calibration Controller
Codes Data Text Codes
Access
Authority3 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
Page 1
Data trace menu (level 1)
Examine note trace data 11
Examine histogram trace data 12
Examine trace measure table 13
End 00
Change menu ->
Page 2
Data trace menu 2 (level 1)
Set note trace conditions 21
Set up histogram trace 22
End 00
<- change menu
l note destination
4000 Section 1
May 2001 Page 39
2 Feed stop request bit pending - the detector processor had
requested a feed stop and was waiting for the transport to
comply.
3 Suspect - the note concerned was routed to a stacker
declared as a suspect stacker.
4 Transport processor cull - the transport processor culled the
note before it reached sensor E.
It should be noted that the trace buffer is cleared at each feed start and
at process selection.
Note - defines the note position within the trace buffer. Note 0 is the
latest note to be traced, with subsequent notes numbered -1, -2, -3 and
so on. The operator is always presented with the latest note first.
Selection of other notes in the trace buffer is made using the ‘<-’ and
‘->’ cursor keys (less and more recent respectively).
Datum time - this is the note’s datum time with respect to sensor A. It
may be used to cross refer detector processor trace data with transport
processor trace data.
The third and fourth lines are reserved to explain the destination reason
flags. These lines will be blank if no destination reason flags are set.
Section 1 4000
Page 40 May 2001
Pressing ‘ENTER’ enables the detector replies and measures for the
current note to be examined. The data is formatted as follows.
d01........1111.0 PATT
d02.........1.0.0 THIK
The detector replies that are required to categorise a note for this grade
are listed as a bitwise representation of the detector response. Each bit
of a reply is the result of a single criterion. A “.” in any position implies
that the reply associated with that position is of no significance. A ‘1’ in
any position implies that the algorithm associated with that position
passed the required test, a ‘0’ implies a failure. The overall result for the
note or grade being examined is displayed after the data reduction type.
The detector processor decision process is shown in Figure 5.
If a printed copy of the note trace data has been requested, the number
of trace entries to be output is requested. The print-out shows the most
recent note entry in the buffer at the top of the list. Each note trace entry
is formatted to occupy four lines on the print-out. Only those detectors
in use are included in the list. A typical note entry will be listed as
follows.
4000 Section 1
May 2001 Page 41
9.3 Option 12 ‘Examine Histogram Trace Data’
This option enables the detector histogram data to be displayed. The
histogram must previously have been defined, using the ’set up
histogram trace’ option (paragraph 9.6). A histogram display begins
with a data table. For example:
5 detector number
22 trace measure number
1000 notes traced
1 under range
0 over range
138 histogram median
The trace measure number reflects the selected measure which the
detector has been returning for tracing. The under and over range
numbers define the total number of notes that were outside the defined
range of the histogram. The histogram median corresponds to that
measure which effectively splits the population into two equal totals.
The option of clearing down the accumulated histogram data (e.g. after
each run) is offered.
In the first column is displayed the measure value. The second column
represents the number of entries for the associated measure value.
The third column depicts the percentage of the total number of notes
traced has so far been plotted, including the current row. Finally a visual
bar chart representation of the number of notes falling into each
measured category is displayed. The number of stars in each column
is scaled according to the requirements of the most populated category.
Section 1 4000
Page 42 May 2001
TABLE 1 : TRACE MEASURE DATA
Measure Description Measure Page No.
No.
THICKNESS
(not used) 1 page 1
doubles channel 1 count 2
doubles channel 2 count 3
thickness prime error 4
U.V. BRIGHT
UV Bright count 7 page 2
MAG INK
mag ink count 8
MAG THREAD
thread 1 start 9
thread 1 end 10
thread 2 start 11
thread 1 centre 12
METAL THREAD
thread 1 start 13 page 3
thread 1 end 14
thread 2 start 15
thread 1 centre 16
LENGTH
note length 20
length prime error 21
Inboard singles average 23 page 4
(cont.)
Inboard doubles average 24
4000 Section 1
May 2001 Page 43
TABLE 1 : TRACE MEASURE DATA (continued)
Measure Description Measure Page No.
No.
Outboard singles average 25
Outboard doubles average 26
Result for thick setup 27 page 5
Metal thread thread 1 start 28
Metal thread thread 1 end 29
Metal thread thread 2 start 30
Metal thread thread 1 centre 31
l.e. miss. corner size 32
t.e. miss. corner size 33 page 6
Hole type 34
Diamond hole size 35
MRTA thread position 36
Section 1 4000
Page 44 May 2001
TABLE 1 : TRACE MEASURE DATA (continued)
Measure Description Measure Page No.
No.
H&T leading corner threshold 60
H&T trailing corner threshold 61
H&T mm of screw adjustment 62
SURF detector reply 63 page 11
08
01000
End ->
This menu enables the operator to define the trace measure number for
each detector configured for the currently selected process. This
measure will be returned by the detector as part of its reply. It will be
traced, both in the note trace buffer and in the histogram for this detector
(if defined). Typing ‘ENTER’ without changing the trace measure
number or ‘->’ will move the display on to the next detector number.
4000 Section 1
May 2001 Page 45
9.6 Option 22 ‘Set Up Histogram Trace’
This option enables the operator to define the structure of a detector
measure histogram. The operator is prompted to enter the following
information.
1. Detector number
2. Minimum measure value to be traced
3. Maximum measure to be traced
4. Resolution of the histogram (difference between
adjacent histogram columns)
5. Detector trace measure number to be traced
Section 1 4000
Page 46 May 2001
TRACE DATA ı
AUTHORITY 0ı
Page 1ı Page 2ı
11ı 12ı 13ı 21ı 22ı 00ı
Examine Nota ı Examine ı Examine Trace ı Set Note Trace ı Set Up ı ENDı
Trace Dataı Histogram ı Measure Dataı Conditionsı Histogram ı
Trace Dataı Traceı
0ı 0ı 0ı 0ı 0ı
Access ı
Authorityı
4000 Section 1
May 2001 Page 47
Section 1 4000
Page 48 May 2001
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SCHEDULE 1
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END
No
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Is LVDT armature free to
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Renew armature
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No
Is fault repaired?
Yes
Is fault repaired?
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No
START
Renew Front-end
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START
Yes
Is fault repaired? START
No
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áë=ã~ÇÉK==qÜáë=áë=íç=Éå~ÄäÉ=íÜÉ=ë~ãÉ=î~äìÉ=íç=ÄÉ=êÉJáåëí~íÉÇ=çå=ÅçãéäÉJ
íáçå= =íÜìë=éêÉëÉêîáåÖ=íÜÉ=áåíÉÖêáíó=çÑ=íÜÉ=ïÉ~ê=áåÇáÅ~íçêK
qç=~Çàìëí=íÜÉ=isaq=Åçáä=éçëáíáçå=~ÑíÉê=êÉéä~ÅÉãÉåí=çÑ=íÜÉ=ÄÉ~êáåÖ=é~Ç=çê=
Åçáä=éêçÅÉÉÇ=~ë=ÑçääçïëW
~F oÉãçîÉ=ihN=çå=íÜÉ=ÑêçåíJÉåÇ=Äç~êÇK
ÄF fÑ=íÜÉ=ÉñáëíáåÖ=é~Çë=~êÉ=íç=ÄÉ=êÉJìëÉÇI=åçíÉ=íÜÉ=iba ë=íÜ~í=~êÉ=ÅìêJ
êÉåíäó=áääìãáå~íÉÇK
ÅF fÑ=~=åÉï=ÄÉ~êáåÖ=é~Ç=áë=íç=ÄÉ=ìëÉÇI=~Çàìëí=íÜÉ=Åçáä=ìé=çê=Ççïå=íç=
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qÜÉ=iba ë=Åçìåí=áå=Äáå~êóI=~åÇ=íÜÉ=î~äìÉ=ëÜçìäÇ=ÄÉ=Å~äÅìä~íÉÇ=Äó=
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lk lk lk lk lk NOQ
lk lk lk lk lk lk NOR
lk lk lk lk lk lk NOS
lk lk lk lk lk lk lk NOT
lk NOU
lk lk NOV
lk lk NPM
lk lk lk NPN
lk lk NPO
lk lk lk NPP
ÇF fÑ=íÜÉ=ÉñáëíáåÖ=ÄÉ~êáåÖ=é~Ç=áë=ÄÉáåÖ=êÉJìëÉÇI=íÜÉå=íÜÉ=Åçáä=ëÜçìäÇ=ÄÉ=
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l= mìí=Ñçìê=Ä~åâåçíÉë=íçÖÉíÜÉê=íç=ÅêÉ~íÉ=~=ëáåÖäÉ=íÉëí=ÇçÅìãÉåí=MKRãã=
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tÜÉå=íÜÉ=ëÉííáåÖ=ìé=çÑ=íÜÉ=ÇÉíÉÅíçê=Ü~ë=ÄÉÉå=ÅçãéäÉíÉÇI=êÉJÉëí~ÄäáëÜ=
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~=íê~áäáåÖ=ÉÇÖÉ=ÅçêåÉêJÑçäÇ=~ë=ïÉää=~ë=í~éÉI=íÜÉå=áíë=êÉéäó=ïçìäÇ=ÄÉ=MMMb=
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q~ÄäÉ=RW=aÉíÉÅíçê=`ìää=`çÇÉë
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UMMN kçíÉ=éêáãáåÖ=î~äìÉ=íçç=ä~íÉ=ïêí=íêìÉ=äÉ~ÇáåÖ=ÉÇÖÉ
UMMO kçíÉ=íçç=íÜáÅâ
UMMP kçíÉë=ÅìääÉÇ=ÄÉÅ~ìëÉ=çÑ=~=Öìäé=ÑÉÉÇ
UMMS rå~ÄäÉ=íç=ÑáåÇ=åçíÉ=íê~áäáåÖ=ÉÇÖÉ
UMMT kçíÉ=íê~áäáåÖ=ÉÇÖÉ=~äêÉ~Çó=éêÉëÉåí
QKNM eçï=íç=ëÉí=ìé=~=qÜáÅâåÉëë=aÉíÉÅíçê=qê~ÅÉ=jÉ~ëìêÉ
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pÉÅíáçå=O QMMM=aÉíÉÅíçêë
m~ÖÉ=NU j~ó=OMMN
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qê~ÅÉ=ãÉ~ëJ aÉëÅêáéíáçå
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O qçí~ä=ÇçìÄäÉë=Åçìåí=`eN=EåçåJÅçåíáÖìçìëF=EããF
P qçí~ä=ÇçìÄäÉë=Åçìåí=`eO=EåçåJÅçåíáÖìçìëF=EããF
Q mêáãáåÖ=Éêêçê=EëÉÉ=kçíÉ=NF
PT mÉ~â=åçJåçíÉ=äÉîÉä=`eN
PU mÉ~â=åçJåçíÉ=äÉîÉä=`eO
PV ^Åíì~ä=åçíÉ=äÉîÉä=`eN
QM ^Åíì~ä=åçíÉ=äÉîÉä=`eO
QN oçääáåÖ=~îÉê~ÖÉ=äÉîÉä=`eN
QO oçääáåÖ=~îÉê~ÖÉ=äÉîÉä=`eO
QP mâJmâ= êìåJçìí =`eN=EëÉÉ=åçíÉ=OF
QQ mâJmâ= êìåJçìí =`eO=EëÉÉ=åçíÉ=OF
QR `çãéìíÉÇ=ëáåÖäÉë=íÜêÉëÜçäÇ=`eN
QS `çãéìíÉÇ=ëáåÖäÉë=íÜêÉëÜçäÇ=`eO
QT `çãéìíÉÇ=ÇçìÄäÉë=íÜêÉëÜçäÇ=`eN
QU `çãéìíÉÇ=ÇçìÄäÉë=íÜêÉëÜçäÇ=`eO
QV iÉ~ÇáåÖ=ÅçêåÉê=ÑçäÇ=ëáòÉ=EããF
RM qê~áäáåÖ=ÅçêåÉê=ÑçäÇ=ëáòÉ=EããF
RN q~éÉ=ëáòÉ=EããF
RO `êçëë=í~éÉ=ëáòÉ=EããF
RP d~é=áåÅêÉ~ëÉ=`eN=EëÉÉ=åçíÉ=OF
RQ d~é=áåÅêÉ~ëÉ=`eO=EëÉÉ=åçíÉ=OF
Note: 1.The priming error is the difference between the detected note
leading edge position and the position based on priming. This error is
a signed byte, e.g 2 =+2, 1 = +1, FF = -1, FE = -2 etc
A positive priming error means that the actual note position is late with
respect to the priming. Should the priming error exceed +12, the note
is culled (8000 or 8001) and no trace measures are recorded.
QKNN eçï=íç=sáÉï=íÜÉ=qê~ÅÉ=jÉ~ëìêÉ=q~ÄäÉ
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ÇF pÉäÉÅí=bñ~ãáåÉ=qê~ÅÉ=jÉ~ëìêÉ=q~ÄäÉ=W=NP
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ÅF oÉãçîÉ=íÜÉ=íïç=ëáÖå~ä=äÉ~Çë=Ñêçã=íÜÉ=íÜáÅâåÉëë=ÇÉíÉÅíçê=ÑêçåíJÉåÇ=
Äç~êÇI=~åÇ=Å~êÉÑìääó=íÜêÉ~Ç=íÜÉëÉ=íïç=äÉ~Çë=íÜêçìÖÜ=íÜÉ=Ñê~ãÉ=ëç=
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qÜÉ=íÜáÅâåÉëë=ÇÉíÉÅíçê=ÑêçåíJÉåÇ=Äç~êÇ=áë=ãçìåíÉÇ=áå=íÜÉ=êáÖÜíJÜ~åÇ=
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pÉÅíáçå=O QMMM=aÉíÉÅíçêë
m~ÖÉ=OM j~ó=OMMN
Front end board
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qÜáÅâåÉëë
aÉíÉÅíçê
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Figure 5 Calibration Document
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Section 4
___________________________
Vision Detector
Para Page
1. BRIEF DESCRIPTION 4
______________________________________________
2. PRINCIPLES OF OPERATION 5
2.1 Structure 5
2.2 Detector Head 6
2.3 ISA Interface Card 7
2.4 PC Card 7
2.5 System PSU 7
______________________________________________
3. FAULT-FINDING GUIDE 8
______________________________________________
4. SETTINGS AND ADJUSTMENTS 8
4.1 Adding/Replacing a Captured Note Image 8
4.2 Masking Out 9
4.3 To Add a Note 10
4.4 Links, Switches, Connectors & Configuration 10
4.5 Pattern Controller PCB 10
4.6 VISION System 11
______________________________________________
5. ROUTINE MAINTENANCE 16
5.1 Operator Undertaking 16
5.2 Service Engineer Undertaking 16
5.3 Service Engineer Undertaking (calibration) 17
5.4 Off-site Service 23
______________________________________________
6. REMOVAL AND REPLACEMENT 23
6.1 Detector Head 23
6.2 Vision PC 24
______________________________________________
7. ILLUSTRATED PARTS LIST 25
______________________________________________
Tables
Table 1 Fault Finding Guide 8
______________________________________________
Table 2 Result Codes 20
______________________________________________
Illustrations
Figure 1 Vision Detector in Cobra 4004 Chassis 4
______________________________________________
Figure 2 Vision System - Block Diagram 5
______________________________________________
Figure 3 Vision Detector Head 6
______________________________________________
Figure 4 Pattern Controller Configuration 10
______________________________________________
Figure 5 Note Images Captured Before & After Calibration 17
______________________________________________
Figure 6 VISION Captured Image of Calibration Document 18
______________________________________________
Figure 7 Code 0x000/0x400 Calibration Successful 21
______________________________________________
Figure 8 Code 0x0001/0x4001 - Minimum Amplitude
Error Detected 21
______________________________________________
Figure 9 Code 0x0002/0x4002 - Maximum Amplitude
Error detected 22
______________________________________________
Figure 10 Code 0x0003/0x4003 - Maximum Deviation
Error Detected 22
______________________________________________
Figure 11 Vision Head Location 23
______________________________________________
Figure 12 Vision PC 24
______________________________________________
Figure 13 Vision Detector 25
______________________________________________
Vision Detector
2.1 Structure
The Vision detector comprises five main hardware elements:
l Head Motherboard
l PC Card
l System PSU
The Vision detector is isolated from the system into which it is integrated
by means of optical isolation for the Note Present and Transport Clock
interface signals. The detector also has a separate floating DC power
supply.
l Detector Head
l PC Chassis
l A line scan CCD array plus interface electronics together with its
mounting system, adjustment mechanisms and lens assembly.
l A light source.
l An optical prism.
l An optical filter.
a) Enclosure
The enclosure is painted black to minimise internal reflected light
and is sealed to provide dust–proofing. Separate electrical
connections are provided for:
Head power – circular multi-pole connector
CCD data – 50-way SCSI2 connector
b) CCD Array
The CCD array comprises a linear group of photo–diodes or
sensing elements. Each photo–diode produces a charge
proportional to the light incident upon it.
e) Head Motherboard
The head motherboard provides an interface to the CCD array and
an A/D converter which digitises the CCD information captured for
transmission to the system ISA interface card. The head mother-
board communicates with the ISA interface card through the 50 way
SCSI2 connector.
2.4 PC Card
The PC card is a complete PC system with serial and parallel I/O, VGA
output and disk interfaces. The applications software uses the data
from the ISA Interface card. All software runs under Windows 95
operating system.
The PC has one serial port (COM2) dedicated to the Third Party
Detector interface, which is a conduit for detection setup instructions to
the PC and for detection results in the other direction. A higher
specification PC card is required for the additional detection functions
listed in paragraph 1.
All other faults must be referred, in the first instance, to the DLR service
department. Detector Processor faults (those formatted X9XX) are not
covered here.
The ‘BNoteDAQ.ini’ file is found in the windows directory, the other files
are in the ‘country’ directory in c:/databases.
Note: The configurator will require a change for the machine to be able
to recognise and process the note. The new note must be evaluated for
any features that other detectors will be expected to detect.
h) Select the GO button on the tool bar in the Vision test program.
j) Confirm that the captured image of the note does not have any
irregularities or defects and that there are green lines on all four
edges. Also check that it is possible to zoom in and out of the image
using the mouse buttons.
b) Select f the FILE menu and go to the file to be masked and open it.
Use the mouse buttons to zoom in and out of the note image.
d) Place the mouse pointer over the area to be masked and hold down
the left mouse button whilst dragging over the area to be masked
(the area will go purple, although some areas may look as though
they have been missed).
To unmask areas use the right mouse button.
e) When the desired result is achieved, save the file and forward a
copy of the file to the Pattern Capture Department.
If the note has not been evaluated before (security features, sort levels)
then DLR Walton Road will need to evaluate it; unless it is purely for out-
sorting on its pattern.
All settings are made either by mechanical adjustment of the head itself,
or by parameters within the ‘BNoteDAQ.ini’ file in the c:\WINDOWS
directory of the VISION system PC. A description of the function of the
‘BNoteDAQ.ini’ file parameters is made below:
Note: All other parameters within the ‘BNoteDAQ.ini’ file either do not
concern the operation of the classification system or are not intended to
be altered within the current system specification. No attempt should be
made to change these.
a) Clean off any dirt/dust from the external optical faces of the
detector.
Note: Care should be taken when replacing lamps as they may still be
hot. The lamps should be handled with a clean cotton cloth, and only
after they have been allowed to cool down. The fitment of the lamps are
similar to that of a plug and socket. Firm gentle force on he lamps will
remove or replace them.
d) Check the belts for correct tension. Replace any belts that are worn
or damaged.
Note: This calibration routine is only required when Vision is used for
functions in addition to Note Classification i.e graffiti.
a) To set the system gain, such that a note of fixed reflectivity will upon
capture, produce an image of a specified amplitude.
b) To normalise the output of the detector head, such that the effects
of an uneven illumination profile and of note presentation due to the
main transport belt and O–rings, are removed.
To achieve the above requires the feeding and image capture of a cali-
bration document. This image is then processed and a correction factor
for each used pixel of the detectors line scan array is calculated. These
coefficients are then stored on the VISION system PC and downloaded
to the head at process selection time. To facilitate this calibration proc-
ess, the ‘head FPGA software’ fitted to the head motherboard in position
U9, should be V1.14 or later.
Figure 5 illustrates the effect that this process has on a typical captured
image.
Figure 5 Note Images Captured Before (left) & After (right) Calibration
(for illustrative purposes only)
Items required
The following items are required to carry out the calibration procedure:
a) A supply of the VISION calibration document (DLR part number
02390250). If the document becomes damaged or marked and
cannot be cleaned, it must be replaced. It is recommended that
several calibration documents are kept available.
b) Cleaning materials – a dry, lint free soft cloth to clean the VISION
detector head prism, and an alcohol based cleaning fluid and cloth
or towel for cleaning the feeder Stripper wheel and Contra roller.
Procedure
To calibrate the VISION detector proceed as follows:
a) Obtain a VISION detector calibration document (DLR part number
02390250). With the exception of the diagonal line on one face,
this document should be free from defect, marks, stains, scratches
etc. The purpose of this document is to present a uniformly
reflective surface to the VISION detector as any mark or damage
will degrade the effectiveness of the calibration process. The
typical appearance of the calibration document post–capture by
the VISION detector is shown in Figure 6.
Note: This image is for information purposes only and cannot be ob-
served in normal operation.
To observe the image:
Results
The calibration algorithm can return one of the result codes listed in
Table 2, after having processed the image of the calibration document.
If required, these can be examined in the Detector Processor trace data
buffer.
0x0003/ Image breached the Maximum Deviation One lamp failed. Check/replace lamps.
0x4003 threshold. In this instance the document will
be routed to the fail pocket.
Dirt on prism. Check/clean prism.
Dirt on/damaged Check/clean/ replace
calibration docu- calibration
document.
ment.
Wrong calibration Check/replace
document. calibration
document.
Bad rotational/ verti- Check & adjust on a
cal alignment of the setting up jig (off site).
array.
b) Check all the internal and external optical faces of the detector.
Fixing
bolts
a) Remove the three bolts (Figure 11) securing the Detector Head to
the back plate.
c) Remove the ribbon cable and connector from the side of the unit.
Figure 12 Vision PC
To remove the Vision PC proceed as follows:
a) Remove the four cables and connectors from the rear of the PC.
b) Remove the power supply cables from the side of the PC.
Lamp Quartz
Guide
Melinex Assembly
RH Vision Head
Para Page
1. BRIEF DESCRIPTION 4
______________________________________________
2. PRINCIPLES OF OPERATION 4
______________________________________________
3. FAULT FINDING GUIDE 7
3.1 Error Messages 7
3.2 Preliminary 7
3.3 To Test For Transport Integrity 7
3.4 Fault Finding Procedure 8
3.5 Error CODES 8
3.6 To Mask Out All Detectors Except Optical Pattern 9
3.7 To Detect Note Profile 11
3.8 Detector Reply Codes 12
______________________________________________
4. SETTINGS AND ADJUSTMENTS 13
4.1 Mechanical Settings 13
4.2 Electrical Settings 14
4.3 Head Amaplifier Board 14
4.4 Optical Trigger Board 15
______________________________________________
5. ROUTINE MAINTENANCE 16
5.1 Daily Routine Maintenance By Operator 16
5.2 6 Monthly Maintenance By Service Engineer 16
______________________________________________
6. REMOVAL AND REPLACEMENT 17
6.1 Detector Head Lens 17
______________________________________________
7. ILLUSTRATED PARTS LIST 23
______________________________________________
Illustrations
Figure 1 Optical Pattern Det. General Block Diagram 5
______________________________________________
Figure 2 Optical Pattern Det. Detailed Block Diagram6
______________________________________________
Figure 3 Fault Diagnostic Flowchart 10
______________________________________________
Figure 4 Example Pattern & Trigger Waveform 11
______________________________________________
Figure 5 Test Document 14
______________________________________________
Figure 6 Pattern Detector Head 18
______________________________________________
Figure 7 Light Path 19
______________________________________________
Figure 8 Melinex Guide Setting 209
______________________________________________
Figure 9 Head Components 21
______________________________________________
Figure 10 Head Assembly 21
______________________________________________
Figure 11 Pattern Head Setting 22
______________________________________________
2. PRINCIPLES OF OPERATION
Light from an optical ‘fishtail’ shines on the banknote as it passes the
detector head and creates a reflection of varying magnitude, deter-
mined by the pattern on the note. This reflected light is converted into
a current output by a photo-diode fitted to the optical fibre termination
on top of the detector head.
The current output from the photo diode is converted into an analogue
voltage, which is then filtered on the Reflective Head Amplifier board.
The filtered outpu is then sampled on the Sliding Correlator board.
As the banknote approaches the detector, two photo-transistors (in the
Trigger Block beneath the detector) detect the leading edge and provide
the Sliding Correlator with a trigger signal. The Sliding Correlator uses
this signal to determine the accurate position of the note.
A block diagram of the detector system is shown in Figure 1. A more
detailed block diagram of the system is shown in Figure 2.
The current output from the photo-diode is applied to the Head amplifier
board via pins 1 & 2 of PL2. The signal is converted to a negative
voltage and amplified by the pre-amplifier U1, the gain of which is set by
RV2. A positive d.c. level, also applied to the pre-amplifier input, can be
adjusted by RV1 to offset the signal and prevent saturation occurring.
The output of the pre-amplifier is fed to an analogue to digital converter
on the Sliding Correlator board via a low-pass filter. The analogue input
voltage, representing the note pattern, is sampled and correlated with
stored references for nominal note alignment positions, and for a
number of ‘slide’ positions either side of the nominal. The advantage of
this technique is such that for any pattern mis-registration, or small
positional inaccuracy, automatic compensation is efficiently achieved.
The Optical Trigger board comprises two identical channels, and
therefore only one is described with references to the second in
parentheses, ( ). Light emission from the detector head causes the
photo-transistor to conduct, and it’s output go high. The high voltage
threshold level is set by RV1 (RV2), and applied to the non-inverting
input of U1/1 (U1/2). The output of U1/1 (U1/2) is also high and is
applied to PL1 pin 1.
When a note passes the detector head, the level of light received by the
photo-transistor is greatly reduced, causing it to conduct less. This
reduces the voltage level to U1/1 (U1/2), and switches the output of U1/
1 (U1/2) to low.
The negative-going output from U1/1 (U1/2) changes the high level on
PL1 pin 1 to a low and becomes the TRIGGER signal on the Sliding
Correlator board. The leading edge of the note informs the Correlator
that a note is present at the detector head.
The high level (no note) at the input of U1/1 (U1/2) is also used to
provide an input to U1/3 (U1/4). The output of this device is high and
provides a trigger READY signal (active high).
The READY signal will go low if a note remains under the detector head
for longer than expected, if the diodes are obscured, or if the lamp fails.
SK3
SK1 SK2
SCHEDULE 3
SCHEDULE 12
SCHEDULE 5
SK12
J21
J3
Sliding Correlator Board
Mother/Distribution Board
3.2 Preliminary
The performance of the detectors is affected by the performance of the
transport system. Therefore, before investigating specific detector
faults, it is necessary to check for correct operation of the transport
system, as described in paragraph 3.3.
Cleanliness
Check that all transport sensors, and the detector are clean. If any item
is found to be dirty, then remind the supervisor or operator of the
importance of thorough daily cleaning.
Transport clock
Using the Transport diagnostic program, check that both the voltage
and the speed of the transport clock are satisfactory.
If the transport clock fails this test, check that the area around the
transport sensor and timing disc is clear, and that the timing sensor is
oriented correctly before deciding to renew parts.
Note feeder
Check that the Note Feeder adjustments are correct. Observe whether
the feeder gives any multiple feeds. These can be identified by counting
the number of notes in the Cull pocket, and comparing the count with
the number of notes in the transport trace (Diagnostic function 09 in the
Diagnostics menu – set up to trace culls only).
Belt slip
Use the Transport diagnostic to check that the slip is within
specification. Check whether the detector processor slip log shows any
anomalies. If there are no signs of anomalies, but the slip is greater
than specified limits, then check belt tensions, condition and
cleanliness. Detector and sensor positions should not be changed.
Service report
This should include a statement verifying that the test for system
integrity is completed, and also details of all corrective actions taken.
i. Mechanical
d) If these steps fail to identify the fault, follow the diagnostic flowchart
of Figure 3.
Replace Sliding
Correlator PCB
iii. Note the number for the Optical Pattern Detector, and Exit.
e) Select Configuration
j) The second row of 1’s and 0’s represents the state of each detector,
enabled (1) or disabled (0), Detector 1 first on the right hand side.
Note the current form of this detector mask so that it can be
re-established later. To disable an enabled detector, and vice-
versa, enter the detector number. Ensure that the Optical Pattern
Detector is the only detector enabled.
The machine is now ready to run with all detectors masked out, except
the Optical Pattern Detector.
Replace Auto
Trigger assembly Is Trigger
and set up Auto present?
Trigger board No
Yes
No
Yes
END
The specific Detector Replies from the Pattern Detector will depend
upon the pattern set installed, and the notes being fed. The replies can
only be checked by referring to the pattern set installed. Each face and
orientation of each denomination/issue of note is assigned a pattern
code number.
The pattern detector can cull notes if it cannot classify the note. In this
instance a “pattern suspect” code of 3F (hexadecimal) is returned.
Note: The detector can only output a pattern code relevant to the
patterns in the pattern set. Therefore whether the Detector Reply
matches that of the correct denomination in the pattern set can only be
checked by referring to the installed pattern set itself.
a) Remove the retaining circlip, the M6 crinkle washer and the plain
washer from the end of the pivot arm, and place to one side.
b) Slacken the two M3x5 set screws in the detector head and withdraw
the pivot pin from the support bracket, taking care with the nylon
washer.
d) When the head is assembled (see Figure 10) squeeze the faces X
and Y together until the nylon washer is held tight between the inner
faces of the head and support bracket. Tighten the two set screws
to lock the head to the pivot pin. Replace the two M6 washers and
the circlip, renewing as necessary.
The following procedure ensures the correct setting of the Pattern De-
tector head in relation to the transport belt, and must be carried out be-
fore attempting any electrical setting or adjustment.
a) Check that the detector head is at 90º to the machine backplate (see
Figure 11).
b) The gap between the head and the belt should be zero, i.e. with the
transport running, the belt should just contact the head without
being deflected.
c) To obtain the Head set position, slacken the latch and support
bracket securing screws to friction tightness, and position the
components accordingly. Tighten the screws on completion.
d) Check that the Melinex guide is parallel to the Head at the point
where they make contact. To adjust the guide, loosen to friction
tightness, the two adjustment screws and the clamp screw (see
Figure 8). Tighten the screws on completion.
e) Run the transport system to ensure the notes lie flat when passing
beneath the head.
lLight source
Approx 12mm
Black drafting
Polyart 2
tape (matt)
(DLRS 01001589)
(DLRS 02340016)
c) Use a Cobra Spray Brush to ensure that the light emitting surface of
the head is clean of dirt and ink.
b) Manually wind the test document through the transport until the
black area is directly beneath the head.
d) Manually wind the test document through the transport until a white
area is directly beneath the head.
f) NOTE that RV1 and RV2 interact with each other, and therefore
continued fine adjustment of both may be necessary to achieve the
above voltages.
a) Visually inspect the Pattern Head, Melinex note guide and Trigger
assembly for mechanical damage. Renew defective parts.
b) Check the lamp source and light pipes. Renew the lamp.
c) Check the belts for correct tension. Renew if they are worn or
damaged.
c) Hold the optical face of the pattern head squarely on the paper and
rub back and forth until the surface is even in appearance.
f) Wet the felt pad with water and place on a flat surface.
g) Apply half the contents of the polish sachet evenly to the felt pad.
h) Rub the optical face along the felt pad until high lustre is achieved
evenly along the face (add more polish if necessary).
k) Empty the contents of both syringes into the mixing cup and mix
thoroughly.
m) Position the lens onto the Pattern Head, apply pressure to remove
air bubbles, and hold in position using elastic bands.
Mounting
Block
Pattern
Sub-Plate
Set Screws
Pivot Pin
Circlip Nylon ‘O’ Ring
Washer
Face X
Face Y
Pattern
Head
Locking
Clip
90 ° Transport
Belt
Mounting
Block
90°
Para Page
1. BRIEF DESCRIPTION 3
____ _________________________________________
2. PRINCIPLES OF OPERATION 4
2.1 UV Bright Detection 4
2.2 Test Points 5
2.3 Wiring Schedules 5
______________________________________________
3. FAULT FINDING GUIDE 9
3.1 Fault Finding Procedure 9
3.2 To Mask Out All Detectors Except UV Detector 9
3.3 How To Set Up UV Trace Measure 10
3.4 How To View Trace Measure Table 11
3.5 Detector Reply Codes 11
______________________________________________
4. SETTINGS AND ADJUSTMENTS 12
4.1 Mechanical Settings 12
4.2 Electrical Settings 12
______________________________________________
5. REMOVAL AND REPLACEMENT 14
5.1 Detector Head Removal 14
5.2 Detector Head Replacement 14
______________________________________________
6. ILLUSTRATED PARTS LIST 15
______________________________________________
Tables
Table 1 Test Points 5
______________________________________________
Table 2 LED Status 9
______________________________________________
Illustrations
Figure 1 UV Bright Detector 3
______________________________________________
Figure 2 Elements of the Detector Head 3
______________________________________________
Figure 3 General Block Diagram 4
______________________________________________
Figure 4 Detector System - Detailed Block Diagram 7
______________________________________________
Figure 5 Fault Diagnostic Routine 8
______________________________________________
The U.V. Bright detector identifies banknotes that give abnormally high
fluorescent responses to ultra-violet light.
REFERENCE
PHOTO-DIODE
SENSING
PHOTO-DIODE
UV PASS
FILTER
BLUE PASS
FILTER
U.V. Tube
Direction of Travel
Banknote
SCHEDULE 27
SK5 SCHEDULE 5
J16
Mother / Distribution
UV Lamp Driver Assembly
MAINS
From the a.c. mains supply at the terminal block, a constant current
supply for the U.V. lamp is derived on the U.V. Lamp Driver board of the
U.V. Lamp Driver assembly, by a rectifier and current sink TR1. This
supply is routed through pins 3 and 4 of the board and pins 1 and 4 of
the U.V. Lamp board of the detector head, and thence to the lamp.
Lamp starter components are on the U.V. Lamp board.
1 OV
2 0V
3 0V
4 0V
6 +5V
7 +5V
10 PL17 / 9 +15V
11
12
13 PL17 / 8 -15V
14
Is Detector Yes
Ready?
No
Is Fault Yes
Repaired?
Place photyocopy
No
or writing paper Carry out setting-
under detector up procedure END
head
Check UV Bright
board power
supply
Is fluorescence
seen on note
Is Fault Yes
Repaired?
Check UV Lamp
Driver board
output No
(330V dc off-load) END
Renew UV Bright
board
Is output No
available?
Yes
Is Fault Yes
Repaired?
Renew UV Lamp Renew UV Lamp
board Driver board No
END
Yes
END
a) Remove the three screws securing the head cover and remove the
cover.
b) Check all connections between the detector head and the Mother/
distribution board and the U.V. Lamp Drive board.
c) Run the machine without any notes in the transport, and observe
the state of the red and green LED’s on the U.V. Bright board.
Table 2 shows the action to take in response to the LED status.
iii. Note the number for the U.V. Bright Detector, and Exit.
e) Select Configuration
j) The second row of 1’s and 0’s represents the state of each detector,
enabled (1) or disabled (0), detector 1 is first on the right hand side.
Note the current form of this detector mask so that it can be re-
established later. To disable an enabled detector, and vice-versa,
enter the detector number. Ensure that the U.V. Bright Detector is
the only detector enabled.
The machine is now ready to run with all detectors masked out, except
the U.V. Bright Detector.
k) The display re-prompts with the same question to confirm the trace
measure – Press Enter again.
*This is the total number of mm samples – along the length of the note
– that were above the UV Bright threshold (as set by RV1). Note that if
a UV pointer (Sort Levels menu) is available, this will be scaled in
‘percentage of note length’. Remember therefore to convert the pointer
setting to actual measurements when assessing trace measure results.
f) The start of the Trace Measure table is displayed. Use the following
keys to view the required trace measure:
Press SHIFT and > to page forward.
Press SHIFT and < to page backward.
Press CLEAR to exit.
Note is
l A trimpot adjuster
l 250 genuine (U.V. dull) banknotes for each denomination that the
machine will sort.
a) Remove the three screws securing the head cover and remove the
cover.
Do not replace the cover at this stage as access is required for the
electrical adjustments.
a) 1If the head cover is not already removed, remove the three screws
securing the cover, and remove the cover to expose the board.
b) Power up the Cobra 4004, and ensure that the U.V. lamp is ON.
d) Connect the DVM to TP1 and TP2 (0 Volt) and check for a reading
of 1.6V ±0.1V. Adjust RV2 if necessary to satisfy the check.
i) Take care to shield the U.V. detector when the front cover is open,
since the red LED can easily be turned on by stray light, and adjust
RV1 until the red LED just goes OFF.
l) If any notes are rejected, re-adjust RV1 half a turn clockwise, and
repeat the run. If a small number of notes are repeatedly rejected,
manually hold them under the U.V. detector head to check for an
obvious denomination – if such notes are found, remove them from
the pack.
o) If any detectors were masked out, then mask them back in.
a) Remove the three screws securing the head cover and remove the
cover.
b) Disconnect the connector SK2 from the U.V. Bright board, and the
connector SK1 from the U.V. Lamp board.
c) Support the Detector Head assembly, and remove the two screws
securing the assembly to the machine back-plate. Withdraw the
assembly.
Figure 6 UV Detector
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SCHEDULE P
SK 2
PL 2
Front-end Board
SCHEDULE 3 SK 1
SK12
J12
Microphone
Detector Interface J5 PL17 SK17
Power Supply Unit
Board
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Section 8
___________________________
Soil Detector
Para Page
1. BRIEF DESCRIPTION 4
______________________________________________
2. PRINCIPLES OF OPERATION 5
2.1 Reference Tile 5
2.2 Detector Head 5
2.3 Front-end Board 6
2.4 Detector Controller Board 6
2.5 Soft Start Lamp Supply Board 6
2.6 Wiring Schedules 7
______________________________________________
3. FAULT FINDING GUIDE 10
______________________________________________
4. SETTINGS AND ADJUSTMENTS 12
4.1 General 12
4.2 Preliminary Checks 12
4.3 Reference Tile 14
4.4 Detector Head 14
4.5 Front-end Board 15
4.6 Detector Reply Codes 16
4.7 To Mask Out All Detectors Except Soil 16
______________________________________________
5. ROUTINE MAINTENANCE 17
5.1 6 Monthly Maintenance By Service Engineer 17
______________________________________________
6. REMOVAL AND REPLACEMENT 18
6.1 Reference Tile Assembly 18
6.2 Detector Head 18
______________________________________________
7. ILLUSTRATED PARTS LIST 19
______________________________________________
Tables
Table 1 Detector Reply Codes 16
______________________________________________
Illustrations
Figure 1 Upper and Lower Soil Detectors 4
______________________________________________
Figure 2 System Block Diagram 5
______________________________________________
Figure 3 Soft Start Lamp Supply Board 7
______________________________________________
Figure 4 Fault Diagnosis Routine 11
______________________________________________
Figure 5 Front End Board - Position of Controls 13
______________________________________________
Figure 6 Soil Detector 19
______________________________________________
The soil detectors are shown in Figure 1, and the principal components
are shown in the block diagram in Figure 2.
Detector controller
Head
Detector Interface J5 J14 SK14
Board Power Supply Unit
Light
Mother / Distribution Board
TILE
l Glass filter windows to allow light to leave and enter the head
l Checking that the outputs from the head are within an acceptable
range.
l Running the software algorithms that determine the soil state of the
note
l Communicating with the rest of the machine via the detector proc-
essor board
White
SCREEN PL2 / 2 SCREEN
Check condition
and adjustment of
major components
Is fault
repaired
?
Replace Detector
Controller board
Is fault
Yes repaired
?
No
Replace Front-
end board
Is fault
Yes repaired
?
No
Was head
replaced Yes
?
No
Replace detector
head
Is fault
Yes repaired No
?
END
Consult
’Technical Services’
4.1 General
Two soil detectors are normally fitted, with one detector head above the
note path, and one detector head below, so that both sides of a
banknote are viewed.
As the adjustments for the two detector heads and the two front-end
boards are identical, the following procedure describes the setting up of
one system only. When adjusting both systems, they may be adjusted
together at each step.
Adjustments to RV1 and RV2 of the front-end board are intended to set
the system close to the centre of its operating range of voltages. This
operating range is very wide, and is intended to cover all subsequent
variations between lamps, lamp ageing effects, and the effects of dust
build-up on the heads during normal use.
c) Between the power supply and the soft-start lamp supply board
d) Between the soft-start lamp supply board and the detector head
Ensure that the Reference tile opposite the Detector head, and all
windows on the Detector head, are clean, dust-free and undamaged.
If necessary, clean them with a SLIGHTLY DAMP clean cloth.
The following tools are necessary, in order to carry out the electrical
adjustments:
l A trimpot adjuster
a) Loosen to friction tightness, the two mounting bolts that secure the
tile’s mounting bracket to the back plate.
b) Move the bracket, so that the white reference tile is in the plane of
the contacting faces of the transport drive.
b) Ensure that the illumination area (filament image and halo) is fully
within the glazed area of the tile. If necessary, move the tile as
described in paragraph 4.3.
c) Place a strip of masking tape onto the back plate, so that the
distance from the head to the reference tile may be marked during
the course of this procedure.
e) Close the machine front cover. Measure the voltage between test
points TP23 and TP1 on the front-end board. Adjust the position of
the head in relation to the reference tile, whilst maintaining the face
of the head parallel to the tile, and re-measure the voltage between
TP23 and TP1.
f) Repeat the above step to find the position of the head which gives
the maximum voltage.
ii. Ensure that any dirt dislodged from other parts of the machine
is cleaned off the faces of the head and tile.
b) Set RV1 and RV2 (see Figure 5) to the fully clockwise position
(minimum gain).
c) Disconnect the connector from PL1 on the soft start lamp supply
board to remove power from the lamp.
d) Ensure that the shorting links between pins 1 & 2 of LK2 and LK3
are in position.
e) Select a machine process that uses the soil detector, and initiate a
calibration cycle, by making the machine start to feed banknotes.
h) Connect the connector to PL1 on the soft start lamp supply board to
restore power to the lamp.
j) Connect the negative lead of the DVM to TP23 (0V), and the
positive lead to pin 7 of device U3.
The detector is split into an upper and a lower soil detector with both
parts having a unique Detector name and Reply.
UPPER LOWER
Detector Names : Operator = DS1 = DS2
Engineer = SOLU = SOLL
The reason why the machine displays either 0000 or 4000 is that bit 14
is toggled between notes.
iii. Note the number for the Soil Detector, and Exit.
e) Select Configuration.
The machine is now ready to run with all detectors masked out, except
the Soil Detector.
5. ROUTINE MAINTENANCE
b) Carefully inspect the reference tile. Renew the tile assembly if there
are scratches, chips, cracks, or there is discolouration.
c) Inspect the windows on the face of the head without removing the
head from the machine. Renew the head is any of the windows are
cracked, chipped or loose. Light scratching of the windows is
tolerable provided that the patch of illumination on the tile is free of
excessive distortion and colouration.
d) Replace the lamp in the head by a new, unused lamp. At the same
time, ensure that there is no dirt preventing the lamp assembly from
seating properly in the head.
e) If either the tile or the head is renewed, carry out the full setting-up
procedure described in paragraph 4.
a) Remove the two bolts securing the assembly to the back plate.
a) Disconnect the cable from the detector head at the front end board.
c) Remove the assembly from the machine, taking carel to pass the
cable through the holes in the metalwork.
2000Hr
Life Lamp
Soil Detector
Head Assembly
Para Page
1. BRIEF DESCRIPTION 4
______________________________________________
2. PRINCIPLES OF OPERATION 4
2.1 Detector System 5
2.2 Magnetic Ink Detection 5
2.3 Magnetic Thread Detection 6
2.4 Test Points 6
2.5 Wiring Schedules 8
______________________________________________
3. FAULT FINDING GUIDE 9
3.1 Error Messages 9
3.2 Preliminary 9
3.3 Transport System Integrity 9
3.4 Fault Finding Procedure 10
3.5 Detector Reply Codes 12
______________________________________________
4. SETTINGS AND ADJUSTMents 13
4.1 Mechanical Adjustments 13
4.2 Electrical Adjustments 14
4.3 To Mask Out All Detectors Except Twin Mag. Ink 17
______________________________________________
5. REMOVAL AND REPLACEMENT 18
______________________________________________
6. ILLUSTRATED PARTS LIST 19
______________________________________________
Tables
Table 1 Detector Test Points 6
______________________________________________
Table 2 Detector Reply Codes (mag ink) 12
______________________________________________
Table 3 Detector Reply Codes (mag thread) 12
______________________________________________
Illustrations
Figure 1 Twin Magnetic Ink Detector 4
______________________________________________
Figure 2 Permanent Magnet 5
______________________________________________
Figure 3 Twin Mag. Ink - General Block Diagram 6
______________________________________________
Figure 4 Twin Mag. Ink - Detailed Block Diagram 7
______________________________________________
Figure 5 Fault Diagnostic Routine 11
______________________________________________
Figure 6 Location of Detector Heads 13
______________________________________________
Figure 7 Location of Test Points & Potentiometers 15
______________________________________________
Figure 8 Magnetic Head Detector 19
______________________________________________
2. PRINCIPLES OF OPERATION
On its path around the note transport system, the banknote passes a
permanent magnet mounted near the lower right-hand corner of the
transport (see Figure 2), and the magnetic features of the note retain
some magnetism.
When the note passes the twin heads of the detector (see Figure 1), the
level of magnetism on the banknote is measured.
Low going pulses on the LOW MAG output indicates magnetic ink
detected. A /READY function is derived from the zero-volt return on the
Detector board, and routed to buffer U5 of the Detector interface board.
SCHEDULE 8
SK 13
J13
J13 / 1 0V
J13 / 2 0V
J13 / 3 0V
J13 / 4 0V
J13 / 6 + 5V
J13 / 7 + 5V
3.2 Preliminary
The performance of the detectors is affected by the performance of the
transport system. Therefore, before investigating specific detector
faults, it is necessary to check for correct operation of the note transport
system.
Cleanliness
Check that all transport sensors and detectors are clean. If any item is
found to be excessively dirty, remind the supervisor and operator of the
importance of thorough daily cleaning.
Transport clock
Using the transport diagnostic, check that both the voltage and speed
of the transport clock are satisfactory.
If the transport clock fails the above test, check that the area around the
timing sensor, and timing disc is clear, and that the timing sensor is
orientated correctly before deciding to renew parts.
Note feeder
Check that the note feeder adjustments are correct. Observe whether
the feeder gives any multiple feeds. Multiple feeds can be identified by
counting the number of notes in the cull pocket, and comparing the
count with the number of notes in the transport trace (Diagnostic
function 09, set up to trace culls only).
Belt slip
Use the transport diagnostic to check that the slip is within specification.
Check whether the detector processor slip log shows any anomalies. If
there are no signs of anomalies, but the slip is greater than the allowed
limits, then check belt tensions, condition and cleanliness. Detector and
sensor positions should not be changed.
Service report
The service report should include a statement verifying that the test for
system integrity is completed. The report should also include details of
all corrective actions taken.
a) Check all connections between the detector heads and the Mother/
Distribution Board.
No
Yes
No
No
Contact
Technical Services
END
Reply MAG
If the detector finds a magnetic thread in any of the above areas of note,
then it sets the reply as detailed in Table 3.
l A test pack of banknotes with the magnetic ink feature and magnetic
thread for each denomination that the machine is required to
process.
l A trimpot adjuster.
a) The heads must be in line with each other, and perpendicular to the
back plate.
c) The PCB bracket should be positioned such that the heads are in
the same plane as the note transport system, and such that a ban-
knote just contacts the face of the heads, without distorting, as it
passes.
2.0 mm
2.0 mm
MOUNTING BRACKET
TRANSPORT BELTS
d) The melinex guide should be set such that it lays flat against the
face of the heads. The point of contact should be just prior to the
heads’ centre line.
Magnet assembly
e) The face of the magnet should be 1.5mm to 2.0 mm away from the
lower surface of the nearest belt.
To gain access to the detector board, remove the cover of the die-cast
box. The location of test points and adjustment potentiometers is
shown in Figure 7.
In the following procedure, those steps that involve the use of an oscil-
loscope are marked with an asterisk, ‘ ’.
*
To set up the twin magnetic ink detector proceed as follows:
a) Mask out all the detectors except the twin magnetic ink detector,
see paragraph 4.3.
c) Connect beam 1 probe to J13 pin 11, and the signal return clip to
*
TP1. Pin 11 gives a negative-going pulse as the leading edge of a
note passes under the head, and a positive-going pulse as the
trailing edge passes under the head.
h) Feed the pack of notes without the magnetic ink feature, and check
that all the notes are culled. Check on the oscilloscope that the
*
magnetic ink features are not displayed.
i) Re-feed the pack of test notes fed at step g, using a different, but
allowable orientation. Check that no notes are culled. If necessary
re-adjust RV1 just sufficiently to satisfy the check.
q) Feed the pack of notes without the magnetic thread feature, and
check that all the notes are culled. Check on the oscilloscope that
*
the magnetic thread features are not displayed.
r) Re-feed the pack of test notes fed at step p, using a different, but
allowable orientation. Check that no notes are culled. If necessary
re-adjust RV2 just sufficiently to satisfy the check.
iii. Note the number for the Twin Magnetic Ink Detector, and Exit.
e) Select Configuration.
j) The second row of 1’s and 0’s represents the state of each detector,
enabled (1) or disabled (0), Detector 1 is first on the right hand side.
Note the current form of this detector mask so that it can be re-
established later. To disable an enabled detector, and vice-versa,
enter the detector number. Ensure that the Twin Magnetic Ink
Detector is the only detector enabled.
The machine is now ready to run with all detectors masked out, except
the Twin Magnetic Ink Detector.
a) Unplug the detector head cable at the connector behind the back
plate.
b) Remove the two bolts securing the head bracket to the back plate
99981987 Magnet
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DETECTOR
FRONT-END
CONTROLLER
BOARD
DETECTOR HEAD
HEAD AMPLIFIER
BOARD
GLASS
WINDOW LENS
BANKNOTE
Direction of travel
REFERENCE TILE
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ÅÜÉÅâ=íÜáë=êÉÖìä~íÉÇ=ëìééäóI=ãÉ~ëìêÉ=íÜÉ=îçäí~ÖÉ=~í=miPI=êÉÑÉêÉåÅÉÇ=íç=
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HNOKMs R œ=MKRs
JNOKMs S œ=MKRs
pÉÅíáçå=NM QMMM=aÉíÉÅíçêë
m~ÖÉ=S j~ó=OMMN
Figure 3 Front-end Board
QMMM=aÉíÉÅíçêë pÉÅíáçå=NM
j~ó=OMMN m~ÖÉ=T
PKP mêÉäáãáå~êó
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íê~åëéçêí=ëóëíÉãK==qÜÉêÉÑçêÉI=ÄÉÑçêÉ=áåîÉëíáÖ~íáåÖ=ëéÉÅáÑáÅ=ÇÉíÉÅíçê=
Ñ~ìäíëI=áí=áë=åÉÅÉëë~êó=íç=ÅÜÉÅâ=Ñçê=ÅçêêÉÅí=çéÉê~íáçå=çÑ=íÜÉ=åçíÉ=íê~åëéçêí=
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pÉÅíáçå=NM QMMM=aÉíÉÅíçêë
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pÉêîáÅÉ=êÉéçêí
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êáíó=áë=ÅçãéäÉíÉÇI=~åÇ=~äëç=ÇÉí~áäë=çÑ=~ää=ÅçêêÉÅíáîÉ=~Åíáçåë=í~âÉåK
PKR c~ìäí=cáåÇáåÖ=mêçÅÉÇìêÉ
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~F `ÜÉÅâ=~ää=ÅçååÉÅíáçåë=ÄÉíïÉÉå=íÜÉ=ÇÉíÉÅíçê=ÜÉ~Çë=~åÇ=íÜÉ=cêçåíJ
ÉåÇ=Äç~êÇK
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Check
START Detector
Controller Memory
Is Note
profile detected
?
Yes
Repeat setting-up
procedure
No
Is fault
Yes repaired
?
No
Replace
front-end board
Is fault
Yes repaired
?
No
Replace
Detector head
assembly
Is fault
Yes repaired
?
No
Replace
Detector controller board.
If fault persists contact
Technical Services.
END
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l qêáãéçí=~ÇàìëíÉê
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Figure 5 Part of Front-end Board Showing LK2
`~äáÄê~íáçå
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Note: It is possible that during this routine, LED A, which was OFF,
turns ON. It is not necessary to re-adjust RV2a as the setting will still
be within specification.
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Note: It is possible that during this routine, LED A, which was OFF,
turns ON. It is not necessary to re-adjust RV2b as the setting will still
be within specification.
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