Asahi Seiko CD Series User manual
AsahiSeiko(Europe)LtdProductInformation
CardDispenserTechnicalInformationPage1
IssueG–March2006
CD SERIESCARD DISPENSERS
Warning:Thisproductcontainsunprotectedmovingpartsandisintendedfor
inclusionwithinahostmachine.Manufacturersareresponsibleforincorporating
thissub-assemblywithinahostmachineandmustobserve theinstallationand
safetyinstructionsasdetailedinSection2.8.
AsahiSeiko(Europe)LtdProductInformation
CardDispenserTechnicalInformationPage2
IssueG–March2006
TableofContents
SectionPageNo.
1.Introduction..........................................................................................4
2.Operation..............................................................................................5
2.1CardSize Range............................................................................5
2.2CartridgeSizesand DataTables..................................................5-7
2.3Accessories....................................................................................8
2.4Dispensing Time............................................................................8
2.5EnvironmentalConditions..............................................................8
2.6Installation.....................................................................................8
2.7Removing and ReplacingtheCartridge..........................................8
2.8SafetyandMaintenance..............................................................8-9
3.ElectricalInformation........................................................................10
3.1SupplyVoltage............................................................................10
3.2CurrentConsumption...................................................................10
3.3Connector....................................................................................10
3.4ConnectorPinFunctions..............................................................11
3.5Inputand OutputCircuits............................................................12
3.6TimingSequence Charts–CircuitBoard9102........................13-14
3.7TimingSequence Charts–CircuitBoard9603........................15-17
3.8Re-TryDipSwitchSettings....................................................17-18
4.ElectricalTestResults.........................................................................19
4.1General........................................................................................19
4.2RelevantStandardsUsedasBasisforTests.................................19
4.3ProductsTested...........................................................................19
4.4TestResults.................................................................................19
4.5InstructionsforUse.....................................................................20
5.AdjustmentProcedure andTroubleshooting....................................21
5.1General........................................................................................21
5.2Tools...........................................................................................22
5.3AdjustmentProcedure.............................................................23-25
5.4Troubleshooting......................................................................25-26
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Table of Contentscontinued
6.PartsListingsand ExplodedDiagrams..............................................27
6.1CD-200.................................................................................27-29
6.2CD-1000.................................................................................30-32
6.3CD-1100.................................................................................33-35
7.DimensionalDrawings........................................................................36
7.1CD-200......................................................................................36
7.2CD-1000......................................................................................37
7.3CD-1300......................................................................................38
8.DocumentControl..............................................................................39
AsahiSeiko(Europe)LtdProductInformation
CardDispenserTechnicalInformationPage4
IssueG–March2006
1. INTRODUCTION
TheCDcarddispenserseriescoveradiverserangeofapplicationsfromplastic
telephonecardsand paperdebitcardstopull-taband break-openstyletickets.
Thesedispensersarewidelyusedthroughouttheworldinavarietyofapplications
including transportation,gaming andthetelephoneindustry,wheretheyhavegaineda
reputationforhigh qualityandreliability.
Compactconstruction,easycontroland aninnovativemechanismmaketheseproducts
idealforanyapplicationthatdemandserror-free dispensing.
Aselectionofstandardcartridgesizesensureoptionsareavailabletosuitallcustomer
requirements.
Pleasenote:Someoftheinformationcontainedherein,refers toearlyCDmodels.
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IssueG–March2006
2. OPERATION
Themechanismdispensescardsfromacartridgeusinganelectronically-controlledDC
motortodriverollersviaagearboxandtoothedbelts.
Cardsaretakenondemand fromthebottomofthestackbyaclutch-drivenroller
assemblyand offeredforwardviathecardguidetoafeederroller.
Thecardcontinuesitspassageforwardthrough themechanismaidedbyfeedingand
dischargerollersthatpresentittothedeliverypointtoawaitremovalbythecustomer.
Proximitysensorsdetectcardsinthedischargepathandtheemptystate,inhibiting
furtherdemandswhiletheseconditionspersist.
Accuratesingledispensing isachievedby meansofareverseroller, adjustedinrelation
tothethicknessofthecardtobedispensed.
Intheeventofapayoutfailure(monitoredby thepayoutsensor) orcardjam,the
mechanismentersa“joggle” routinewithreverseandforwardmovementsinan
attempttosuccessfullydispenseacard.
Thenumberofreversalscanbepresetby meansofdipswitchesmountedonthecircuit
boardtoamaximumof8onthe9603circuitboardand 15onthe9102circuitboard.
2.1CardSizeRange
Thecarddispensermostsuitableforyourapplicationcanbeselectedfromour
productrangeusingametricverniercallipertotakeaccuratemeasurementsof
cardlength, widthandthickness:
See thedatachartsinSection2.2forspecificapplications.
2.2CartridgeSizes
Arangeofcartridgesizesareavailabletoextendthecapacityofthestandard
CD-1000dispenser.Fordetailsofoptionsandcardcapacities,seeproductdata
tables2.2.2to2.2.4.
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IssueG–March2006
CD-200
ApplicableCards PaperorPolyester
CreditCardSize
CardWidth(mm) 53-58
CardLength(mm) 76-86
CardThickness (mm) 0.2-1.0
CardCapacity* 90-450
Overall Height(mm) 180
EffectiveHeight(mm)90
Overall Width(mm) 93.2
Overall Length(mm) 155
WeightEmpty(Kg) 1.8
Table2.2.1
CD-1000
ApplicableCards PaperorPolyestercreditcardsize
Cassetteoptions 1000-2301000-3001000-445
CardWidth(mm) 52-56 52-56 52-56
CardLength(mm) 79-89 79-89 79-89
CardThickness (mm) 0.2-1.0 0.2-1.0 0.35-1.0
CardCapacity* 140-700 200-1000350-1000
OverallHeight(mm) 230 300 445
EffectiveHeight(mm) 140 210 355
OverallWidth(mm) 93.2 93.2 93.2
OverallLength(mm) 155 155 155
WeightEmpty(Kg) 2.1 2.2 2.4
Table2.2.2
*Anapproximatecardcapacitycanbeobtainedbydividingtheeffectiveheightby
thecardthickness.
Pleasenotethatdifficultieshavebeenexperiencedwithcardseparationwhen
usingthetaller cartridgestodispensethincards.Fullevaluationofeach
customercardmust becarriedoutbyAsahiSeikopriortosale,toallowusto
guaranteesuitabilityforanyapplication.
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CD-1100
ApplicableCards Pull Tabcards
Cassetteoptions CD-1100/445
CardWidth(mm) 46-49
CardLength(mm) 100-112
CardThickness(mm) 0.35-1.0
CardCapacity* 350-1000
Overall Height 445.4
EffectiveHeight(mm) 355
Overall Width(mm) 93.2
Overall Length(mm) 177
WeightEmpty(Kg) 2.5
Table2.2.3
CD-1300
Applicablecards Largepaperorpolyester
Cassetteoptions CD1300/340
Cardwidth(mm) 62-65
CardLength(mm) 82-92
CardThickness(mm) 0.2–1.0
CardCapacity* 250-1200
OverallHeight(mm) 340
EffectiveHeight(mm) 250
Overall Width(mm) 102.2
OverallLength(mm) 157
WeightEmpty(Kg) 2.3
Table2.2.4
*Anapproximatecardcapacitycanbeobtainedbydividingtheeffectiveheightby
thecardthickness
Pleasenotethatdifficultieshavebeenexperiencedwithcardseparationwhen
usingthetaller cartridgestodispensethincards.Fullevaluationofeach
customercardmust becarriedoutbyAsahiSeikopriortosale,toallowusto
guaranteesuitabilityforanyapplication.
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2.3Accessories
AsahiSeiko candevelopaccessoriesspecificallytosuittheneedsofthe
customer,providingthatthequantitymakesthisaviableproposition.Past
developmentshaveincludedlowlevelwarning sensorsandspecialheight
cartridges.
2.4DispensingTime
Thestandarddispensetimeis2.0secondsapproximatelybuta1.2second
optionisavailablefortheCD-200.Howeveritisrecommendedthatthincards
aredispensedattheslowerspeedof2.0secondspercard.
2.5Environmentalconditions
Temperature:-10°Cto+40°C
Humidity:30-90%RHavoidingcondensation
Location:Withinasuitablecabinet
2.6Installation
Thecarddispenserisdesignedtobeincorporatedwithinasuitablecabinet
mountedwithin2°ofvertical.Detailsofelectricalconnectionsaregivenin
Section3.0.
2.7Removingand replacingthecartridge
Releasethespring-loadedcatchlocatedonthemainchassisatthefrontright-
hand sideofthedispenserand pullthecartridgebackapproximately12mm to
clearthelocatinglugsbeforelifting clearofthemechanism.
Replacing isareversalofremovalbuttakecaretoensurethattheguidesonthe
sideofthecartridgearecorrectlylocatedoverthemechanismsideplatesand
thelugsaresituatedinsidetherecessesofthemainchassis before slidingitinto
thefittedposition.
2.8SafetyandMaintenance
2.8.1Controlcircuitrymustbearrangedtodisconnectpowertothe
mechanismwhenthehostmachine/cabinetisopenedforservicing.
2.8.2Overcurrentprotectiontothemechanismmustbeprovidedbythehost
machine.
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IssueG–March2006
2.8.3Servicing andmaintenancestaffmustbeadequatelytrainedand aware
ofthehazardspresentedbytherollersand drivebelts.Themotor
createssufficienttorquethrough itsreductiongeartotrapfingers,hair
and clothingoftheunwary.
2.8.4Neverholdthedispenserbythecartridgealoneasitcouldbecome
detached,allowing themechanismtofall causingpossibleinjuryor
damage.
2.8.5Avoidtheinclusionofforeignobjectssuchastape,rubberbandsand
wireasthesecouldcausethemachinetojam.
2.8.6Keepmechanismclearofcontaminants.Oilyoradhesivesubstances
will seriouslyaffecttheperformanceofthedispenser.
2.8.7Ensurethedispenseriscorrectlycalibratedforthecardstobedispensed
aspersistentdispensingproblemsleadtoacceleratedwearonthe
components.
Calibrationdetailsarerecordedonthesideofthedispensereitherasa
cardcodeconsisting ofthreeletters(thiscodeisuniquetoeach
customer’scards)orthecardthickness inmillimetres. Re-calibration
shouldonlybeundertakenusingtheproceduredetailedinsection
5ofthisdocument.
2.8.8Ensureelectricalinterfaceconnectionsareinaccordancewithvalues
detailedinsection3asexcessvoltageorcurrentwilldamagethemotor
orcontrolcircuitry.
2.8.9Routinemaintenanceshouldbeundertakenevery2monthsor10,000
operationswhicheveristhesooner:
• Wipethesurfaceoftheclutchroller(atthebaseofthecardstack)
withanalcohol-impregnatedclothorpad.
• Cleandustfromtheopto-sensor(mountedatthefrontofthe
mechanismbelowthepayoutpoint)withasmall brushorsuitable
aerosolduster.
• Checkthedrivebeltsforwearand adjustment(1-2mmdeflection
whenlightpressureisappliedtothelongestedge).
• Checkforaccuratedispensingasincorrectadjustmentforcard
thickness cancauseacceleratedwearonthemechanism.
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3. ELECTRICALINFORMATION
3.1SupplyVoltage
12VoltsDC± 10%
24VoltsDC± 10%
3.2 CurrentConsumption
1.3Ampat24VoltsDC(Peak)
1.8Ampat12VoltsDC(Peak)
0.1AmpIdlecurrent
3.3 Connector
A12pinconnectortypeELP-12islocatedonashortleadattherearofthe
dispenserand connectstotypeELR-12Vinthecustomer’sunit.These
connectorsareavailablefromthefollowingsupplier:-
JST(UK)Ltd.
Connector:ELR-12V
Pin:SLM-01T-1.3E
Figure3.3.1
Figure3.3.2(Pinlayoutviewedfromfront)
ELR12V ELP-12
Latch
159
2610
3711
4812
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3.4ConnectorPinFunctions
S-12B-XH-A
PCB
Connector
ELP-12/ELR-12
Connectors SIGNALNAME SIGNAL
TYPE DESCRIPTION
1 1 0 Volts Supply Ground
2 2 12 or24 VoltsDC Supply Power(±10%)
3 3 CardPayoutRef. Input Ground
4 4 CardPayoutSignal Input ActiveLow
8 5 CardPayoutOK Signal Output Opencollector
7 6 CardPayoutOK SignalRef. Output Pull-upresistor
5 7 CardStuckResetSignal Input ActiveLow
6 8 CardStuckResetSignalRef. Input Ground
10 9 CardStuckSignal Output Opencollector
9 10 CardstuckSignalRef. Output Pull-upresistor
12 11 EmptySignal Output Opencollector
11 12 EmptySignalRef. Output Pull-upresistor
Important: Pleasenotethatsomeofthepinoutputshavebeentransposed
fromtheS12B-XH-Aprintedcircuitboardconnectortothe
ELP-12/ELR-12connectors.Thismustbeobservediftheuser
wishestoremovetheELP-12connectorinordertowirethe
carddispenserdirectlyintothehostmachine.
ELR-12/
ELP-12 S-12B-XH-A
PCBConnector
11
22
33
44
58
67
75
86
910
109
1112
1211
Host
Machine
Card
Dispenser
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3.5Inputand OutputCircuits
Since itsintroduction,thecarddispenserhasbeenfittedwithtwodifferent
circuitboards,themostrecentbeing theCD-9603.Itiseasytoidentifywhich
circuitboardisfittedasthemodelnumberisprintedonthecircuitboard(either
CD-9102orCD-9603).
3.5.1 CircuitBoardCD-9102
(Max.Voltage30VMax. Current50mA)
InputCircuitOutputCircuit
3.5.2 CircuitBoardCD-9603
InputCircuitOutputCircuit
6
10
12
5
9
11
5V
10k
10K
100R
4
7
3
8
Signal
Reference
12V
1K
4.7K
Pull-up
Signal
6
10
12
5
9
11
Pull-up
Signal
470
Ω
5V
5V
Signal
Reference
4
7
3
8
10KΩ
10K
Ω
10KΩ
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3.6TimingSequenceChartsCircuitBoard9102(nottoscale)
3.6.1 NormalOperation
Note:Allow160mSminimumafter“cardpayoutOK”signalbefore
requestingnextcard.
3.6.2 Failuretodispensewithin4seconds
Note:Thenumberofre-triescanbesetbydipswitchesmountedonthecircuit
board. (SeeTable3.8.1foroptionsavailable)
NextRequest
MAX4S
1.0S
ON
ON
ON
ON
1.0S
CardPayoutOKSignal
CardPayoutSignal
Motor(Forward)
Clutch(Solenoid)
Motor(Reverse)
CardTaken
ON
ON
ON
0.5S
0.5S
1.0S
MAX4S
160mS
CardPayoutOK Signal
CardPayoutSignal
Motor(Forward)
Clutch(Solenoid)
CardTaken
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3.6.3 ContinuousDispensing
3.6.4 DispenseFailure(Cardnotdispensedafterre-try)
Note:The“cardstuck”signalisactivatedwhenthepresetnumberof
re-triesisexceeded.Whenthe“cardstuck”signalisactivated,remove
theobstructionand providethe“cardstuckreset”signal.
CardPayoutOKSignal
CardPayoutSignal
Motor(Forward)
Clutch(Solenoid)
CardTaken CardTaken
ON
ON
>160mS
ON
ON 0.5S
0.5S
1.0S
ON
CardPayoutOKSignal
CardPayoutsignal
Motor(Forward)
Motor(Reverse)
Clutch(Solenoid)
CardStuckResetSignal
CardStuckSignal
MAX
4S
MAX
4S
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3.7TimingSequenceChartsCircuitBoard9603
3.7.1. NormalOperation
CardPayoutSignal(Input) Card Taken
PayoutOKSignal(Output)
Beambroken
PayoutSensorSignal
MAX 4S 1S
Motor(Forward) ON OFF
Clutch(Solenoid) ON OFF
EmptySignal(Output)
Lastcard dispensed
3.7.2. Failuretodispensewithinfourseconds
CardPayoutSignal(input)
PayoutOKSignal(output)
PayoutSensorSignal
MAX4S 1S
Motor(Forward) ON OFF ONOFF
0.5S 1S 0.5S
Motor(Reverse) ON
Clutch(Solenoid) ON OFF
Note:Thenumberofretriescanbesetto8maximumbydipswitches.
(See Table3.8.2)
Starttopayout
1RetryCycle
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3.7.3. Continuousdispensing
CardPayoutSignal(Input)
PayoutOKSignal(output)
PayoutSensorSignal
Motor(Forward) ON
ON ON
Clutch(Solenoid) ON
ON
ON
EmptySignal(Output) Lastcard dispensed
Successivepayoutdemandscanbemadeassoonasthecardisremoved.
3.7.4. DispenseFailure (Cardnotoperatingthepayoutsensor)
CardPayoutSignal(Input)
PayoutOKSignal(Output)
PayoutSensorSignal
MAX 4S
Motor(Forward) OFFON OFF
0.5S 1S
0.5S
Motor(Reverse)
Clutch(Solenoid) OFF
CardStuckSignal(Output)
ResetSignal(input)
Remove card jam
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3.7.5. DispensingProblemorfailure toremovecard(PayoutSensoroperated)
CardPayoutSignal(Input)
PayoutOKSignal(Output)
PayoutSensorSignal Remove card
MAX 4S
Motor(Forward) ON OFF
Clutch(Solenoid) ON OFF
CardStuckSignal(Output) 3S
Forany sensorproblem, jamorfailuretoremovecard, theCardStucksignalflashes.
3.8Re-TryDipSwitchSettings
3.8.1 CircuitBoard9102
NoofTries DipSwitch
1234
1 ON OFF OFF OFF
2 OFF ON OFF OFF
3 ON ON OFF OFF
4 OFF OFF ON OFF
5 ON OFF ON OFF
6 OFF ON ON OFF
7 ON ON ON OFF
8 OFF OFF OFF ON
9 ON OFF OFF ON
10 OFF ON OFF ON
11 ON ON OFF ON
12 OFF OFF ON ON
13 ON OFF ON ON
14 OFF ON ON ON
15 ON ON ON ON
Continuous OFF OFF OFF OFF
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3.8.2 CircuitBoard9603
No.ofTries DipSwitch
12
1 OFF OFF
2 ON OFF
4 OFF ON
8 ON ON
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4. ELECTRICALTEST RESULTS
4.1General
Europeandirective forElectro-MagneticCompatibility(EMC)89/336/EEC.
OurinterpretationoftheEMCdirectiveisthatourproductsarenotintendedto
be“placedonthemarketasasinglecommercialunitforfinaluse”,and theonly
mandatoryprovisionistoincludeinstructionsforuse.
However,todemonstratetoourcustomersthatourproductswillnotaffectthe
abilityofthehostmachinetocomply,wehavecarriedouttesting tothe
applicablestandards.
The12v&24vversionsofthecarddispenserareelectricallysimilarwiththe
exceptionofanadditionalvoltageregulatoronthecircuitboardofthe24v
version(Latermodelsuseadualvoltagecontrolboard.)anddifferentmotor
andsolenoidwindings.
The24v versionwasconsideredtorepresentthe‘worstcase’situationand
selectedfortesting
4.2RelevantStandardsusedasBasisfortests
EN55014:1993
EN55014-2:1997
EN55022:1995
EN61000-4-3:1997
4.3ProductsTested
CD-1000(24volt)fittedwithCircuitboard9603
4.4TestResults
Allproductstestedcompliedwiththestandardslistedinsection4.2.
Acertificateofcomplianceand fulltestreportisheldatthecompany’s
Europeanoffice at:AsahiHouse,NorthFarmRoad,TunbridgeWells,Kent
TN23DRand canbeinspectedbyarrangement.
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4.5Instructionsforuse
Testswereundertakenwiththecarddispenserchassisbondedtoearthand6m
ofunscreenedcableconnecting signaland controlleads.
Manufacturersincorporating carddispensersintheirproductsarestrongly
advisedtofollowthetestconfigurationand notexceedtherecommendedcable
lengthtoensureEMCcompliance.
Additionalinformationrelating tohealthand safetyiscontainedinSection2.8.
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