Cassida PRO Series User manual

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
Zeus
2-POCKET CURRENCY
DISCRIMINATOR
SERVICE MANUAL
· Specifications
· Assembly
· Procedures
· Troubleshooting
· Quality Testing
· Parts Information

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
1. OVERVIEW
1.1. Introduction from Cassida USA
1.2. Cross Section Side View Diagram
1.3. Specifications
1.4. Communication Ports / Pin-Outs
1.4.1. Serial/RS232
1.4.2. RJ11
1.4.3. RJ45
1.4.4. USB-A
1.4.5. USB-C
1.5. Accessories
1.6. Required Tools for Disassembly
1. 7. Definitions and Terms
1.8. Main PBA Connector Detail
1.9. Mecha PBA Connector Detail
1.10. Circuit Block Diagram
2. QUALITY CONTROL TESTING
2.1. Software Version Check and Update
2.2. Sensor and Mechanical Check
2.3. Currency and Function Check
3. PROCEDURES
3.1. Battery Replacement
3.2. Dust Cover Tension Adjustment
3.3. Re-aligning ADF Rollers
3.4. Dust Cover Hook Replacement
3.5. Connecting Remote Display
3.6. CIS Calibration
3 . 7. Hopper Sensor Calibration
3.8. Double Sensor Calibration
3.9. Adjustments after PBA Replacement
4. DISASSEMBLY
4.1. Side Covers (Left / Right)
4.2. Assembly Bank Note Guide
4.3. Assembly Hopper and Top Panel
4.4. Upper Door
4.5. Fly Wheel
4.6. Encoder Disk
4 . 7. Assembly Lower Guide
4.8. Assembly Power Supply
4.9. Main Motor
4.10. Assembly Reject Pocket
4 .11. Dust Cover
4.12. Assembly Guide CIS Upper
4.13. Assembly Guide CIS Lower
4.14. Assembly Stacker
4.15. PBA Replacement
4.16. Roller Replacement
4.17. Guide Reject Pocket Replacement
5. TROUBLESHOOTING GUIDE
5.1. PS Sensor Errors
5.2. Read/ID Errors
5.3. ID Errors
5.4. “ReStartRecognitionAPP” Error
5.5. Upgrading (When EMERGENCY
Screen is displayed)
5.6. Settings (Reset after Power Down/
Start-up Issues)
6. SERVICE MENU GUIDE
6.1. Starting Test Menu
6.2. Diagnosis
6.3. Program Update
6.4. Adjustments
6.5. Backup and Restore
6.6. Reports Clear
6 . 7. Statistics Report
6.8. Log Data
6.9. Data Download
6.10. Software Version
APPENDIX I: Spare Parts List
APPENDIX II: Error Codes/Messages
APPENDIX III: Contact Information
APPENDIX IV: Return Merchandise Authorization
APPENDIX V: Notices
This service manual is confidential and
exclusively for the use of current Cassida
PRO Series partners and their technicians.
This manual shall not be shared with outside
sources including but not limited to end users,
competitors, social media, or marketing
channels. No part of this document shall
be reproduced in whole or in part without
written permission from Cassida Corporation.
TABLE OF CONTENTS

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
OVERVIEW
INTRODUCTION FROM CASSIDA USA
Thank you for partnering with Cassida PRO to sell and service the industry leading counterfeit
detection equipment. Cassida PRO is proud to provide the best in class recognition and detection
and dedicated service to our partners. Please visit our partner page listed below for the most up to
date software, manuals, and information regarding our PRO Series products.
http://cassidapro.com/partner/
In addition, should you need further assistance including tech-to-tech troubleshooting, parts
ordering, or general inquiries, please call our service center at:
1-888-800-0303
(Option 1)
(Option 1)
The following nomenclature will be used to show
shortcuts and menu navigation throughout the service
menu:
[#] Denotes the number key to press to access the menu
option
-> Denotes the next number in the sequence to reach the
final menu
All shortcut keys given are assuming that the technician has
already opened the service menu. The headings given are the
default options set on the product as it is shipped. Actions will
be printed in bold text.
1.
1.1.
1

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
CROSS SECTION SIDE VIEW DIAGRAM
1. Hopper Sensor
2. PS1 Sensor
3. Upper Cover
4. Back Light
5. Magnetic Sensor
6. PS2 Sensor
7. Lower Cover
8. Dust Drawer
9. Image Sensor
10. Reject Sensor
11 . Diverter
12. Stacker Sensor
Receiver/Reflector SensorEmitter
1.2.
9
10
11
12
1
2
3
4
5
6
7
8
2

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
MODEL CASSIDA PRO Zeus
COUNTING SPEED 800/1000 Bill/Min
HOPPER CAPACITY 500+ Notes
REJECT CAPACITY 100 Bills
STACKER CAPACITY 200 Bills
DETECTION METHODS MG, Full-Line UV, Double-Sided IR, High Definition
Color CIS, Color Spectrum Analysis
BILL SIZE RANGE 4.7” x 2.4” - 7.1” x 3.5”
(120 x 60mm to 180 x 90 mm)
POWER SUPPLY 100-240V/50-60Hz
WEIGHT 16.84 lbs (7.6 kg)
DIMENSIONS 10.8” W x 9.8” D x 12”H
(276*250*305 mm)
FUNCTIONS INCLUDED Mix Mode
Sort Mode
Count Mode
Face Mode
Orientation Mode
Value Sort Mode
Add Feature
Strap Feature
(by denomination, by count, by custom)
OPTIONAL FEATURES: Bar Code Mode
Bar Code + Cash Mode
Serial Capture Mode
SPECIFICATIONS 1.3.
3

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
CONNECTIVITY / PORTS
RS-232 - SERIAL CONNECTION
1) CONNECTION WITH A PC
• Connection to a PC for remote printing is possible by using the serial port on the back
of the discriminator. An RS232 male – RS232 female cable may be used to directly
connect to a serial port on a PC. An RS232 male – USB-A converter cable may also
be used to connect the discriminator serial port to a PC USB port. Both cables are
available at most electronic retailers
Example of RS232 male - USB-A converter cable:
Communication data format:
This is available in the ZEUS Protocol
Manual. If you need this information,
please contact Support@CassidaPro.
com.
1.4.
1.4.1.
1. AC
2. Serial Port (Printing)
NULL MODEM
3. RJ12 (Remote Display)
4. RJ45 (Network PortGND)
5. USB-B (PC Connection Port)
6. USB-A (Programming Update and
Export Port)
AC
Serial Port
RJ 12
RJ45
USB-B
USB-A
4

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
RS-232 - SERIAL CONNECTION
2) CONNECTION WITH A PRINTER
• The Zeus interfaces with many printers, and has customizable options for the serial port
data output setup. Due to the large variety of supported devices, the below pin-out
is given for the Rx, Tx, and GND pins. All other pins are not connected (NC). Custom
cables may be created or ordered using the below pin-out.
The RS232 Port Pin-out is as follows:
1. NC
2. Tx (Zeus -> Printer)
3. Rx (Printer -> Zeus)
4. NC
5. GND
6. NC
7. NC
8. NC
9. NC
• You may also elect to use a standard RS232 cable, which requires a Null Modem
adapter (female to male converter) at the end of RS232 male – RS232 female cable.
Null modem adapters are available from most electronics retailers.
Example of RS232 female to male converter:
RJ11
1) CONNECTION WITH A CUSTOMER DISPLAY (remote display)
Required cable: RJ11 to RJ11 cable
2) CONNECTION WITH A PC
Required cable: RJ11 to RS232 female (RS232 PC Port)
• The RJ11 to RS232 female cable is a custom cable.
• Please contact Cassida PRO for pricing and availability.
1.4.1.
1.4.2.
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CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
RJ45 (LAN)
1) CONNECTION WITH A PC
Required cable: LAN Cable (LAN PC Port)
• Communication data format: TBD. API manual available upon request.
USB-A
1) CONNECTION FOR USB EXTERNAL STORAGE
Connection for USB external storage
• USB memory file system must FAT32 format.
USB-B
1) CONNECTION WITH A PC
Required cable: USB-B – USB-A (USB-A PC Port)
• Communication data format: API manual available upon request.
• Requires Windows Driver (linux-cdc-acm.inf) which can be provided by
Cassida PRO Tech Support upon request.
Example of USB-B – USB-A cable:
1.4.3.
1.4.4.
1.4.5.
6

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
ACCESSORIES
· Extended Bill Guides
·External Display
·Universal Cash Handling Thermal Printer
·Cassida Air Duster
·CleanBill Pro Cleaning Cards
·CleanPro Cleaning Swabs
*Please contact Cassida PRO for pricing and availability of the items above.
REQUIRED TOOLS FOR SERVICE AND DISASSEMBLY
#2 Screwdriver (+)
2.5mm Screwdriver (-)
2mm and 2.5mm Hex key
(Allen Key)
5.5mm, 7mm, and 13mm Wrench (Span-
ner)
Tweezers
Long/Needle Nose Pliers
100mm Cable Ties
Angle Cutters
1.5.
1.6.
7

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
DEFINITIONS AND TERMS
• ADF ROLLER: Automatic Document Feeder Roller - located in hopper area,
responsible for feeding bills into unit
• Hopper: Either the top or back of the currency counter unit, where stacks of currency
are placed for feeding
• Reject Pocket: Location where rejected and suspect bills are passed to during sort
and count operations
• Stacker: Area where currency is passed during sorting or counting upon meeting the
sort or detection criteria
• CIS: Contact Imaging Sensor - image sensors almost in direct contact with the object to
be scanned. CIS is widely used in optical identification technology.
• UV Sensor: Ultraviolet Sensor - Sensors used to verify luminescence or fluorescence
counterfeit features in certain currencies
• IR Sensor: Infrared Sensor - Sensors used to verify IR ink counterfeit features (either
transmissive or reflective) in certain currencies
• MG Sensor: Magnetic Sensor - Sensors that use magnetic fields to verify counterfeit
features in certain currencies
• Double: A misfeed error where two banknotes pass through the unit at the same time,
or the unit detects a discrepancy in thickness of banknote
• Chain: A misfeed error where two banknotes pass through the unit too closely after
one another, so that the unit cannot differentiate the two bills
1.7.
8

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
MECHA PBA CONNECTOR DETAIL 1.9.
MAIN PBA CONNECTOR DETAIL 1.8.
9

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
CIRCUIT BLOCK DIAGRAM 1.10.
10

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
QUALITY CONTROL TESTING
When servicing units or attempting to diagnose issues, the service engineer may test the
machines according to the procedures described below. This report summarizes what
should be checked and how. The following tests are suggested to be performed as a first
pass to check overall unit health. These checks are similar to the Cassida PRO in-house QC
process and cover the majority of the functions and diagnostic features provided by the
Zeus.
SOFTWARE VERSION CHECK AND UPDATE
To check the software version on the unit:
1) Enter the Service Menu -> [9] S/W Version
2) The first line on this screen will tell you the software version in date code, plus
the product index in parentheses. Standard software for the Zeus is (1); anything
else is a custom release.
To update the software on the unit:
3) Connect a USB external storage device (formatted as FAT32) to back of unit’s
USB-A port loaded with the latest software found at cassidapro.com/partner
4) Go into Service Menu -> [2] Program Update
5) Select the desired software file either by pressing the associated number on the
keypad, or using the up and down arrows and pressing [SET] key.
6) The screen will prompt you to verify you want to continue. Press the [YES]
key to proceed. DO NOT TURN OFF UNIT WHILE UPDATING.
7) After update is complete, enter the Service Menu -> [4] Backup & Restore.
Make sure there are no bills in the Stacker pocket.
8) Select [4] Rebuild Software. There will be a prompt to continue. This option
pushes the newly loaded software to the auxiliary hardware and initializes and
syncs all internal components. Failure to perform this step may result in improper
operation.
9) After screen returns to Main Menu, enter the Service Menu -> [4] Backup &
Restore again.
10) Select [3] Factory Default Setting. There will a prompt to continue. Unit will go
back to Main Menu when finished.
NOTE: If you do not perform steps 8 to 10, the unit will not recognize some features and
you will experience unusual errors or side effects.
2.
2.1.
11

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
SENSOR AND MECHANICAL CHECKS
NOTE: as of this edition of the service manual, each sensor test in the Diagnosis -> Sensor
Detail menu will change color from white to BLUE to indicate test was performed and
passed. If an error is detected by the Zeus, the failed sensor will display in RED. These
colors will be reset once the menu is exited.
SENSOR TEST
This test quickly checks the health of various mechanical parts and sensors.
1) Enter Service Menu -> [1] Diagnosis -> [7] Sensor Detail
2) Check Main Motor by pressing [1] FW or [3] BW (Forwards and Backwards,
respectively), then stop the motor by pressing [2]
3) Check the Diverter by pressing [4] Rejector and then [5] Stacker several times
back and forth. An audible ‘click’ should be heard when the solenoid engages.
4) Check the Wing Motor by pressing [7] Wing and then press [7] again to stop
the motor.
5) Check the Power Supply Fan by pressing [8] Fan and then press [8] again to
stop the fan.
6) Check the Dust Cover. Open Dust Cover (gently press center tab downward
until clear cover locks in place) then press [9] to close. Repeat several times. To
adjust the tension, see procedure [3.2 Dust Cover Tension Adjustment]
7) Check ADF (pickup position sensor). Figure 2 below shows the correct
alignment of pickup roller and ADF roller. When B position of ADF rubber starts
showing, the position A of pickup rubber is better if it is on highest position. And
when position of A is at right position, ADF value in sensor detail menu becomes
‘1’. Check this value while turning the pickup roller.
2.2.
[Fig. 1]
12

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
2.2.SENSOR AND MECHANICAL CHECKS
8) Notes will slip and may cause feed errors and jamming.
• Manually turn the Pickup Roller (it does not matter in which direction) until
you can barely see the white section of the ADF Roller. You should be able
to see just one of the white “gear” teeth on this section exposed from the
front.
• The ADF Roller (back roller with a white urethane teeth section) and Pickup
Roller (front roller with a black teeth section) are both located on the top
of the unit, as part of the hopper. The rollers must be aligned such that a
banknote will touch one of the roller teeth from either roller at any point
in time. Otherwise, the banknote may feed incorrectly, slip, or feed askew.
There should only be 5 to 7 teeth showing from the front side. If there are
8 or more teeth visible, or you do not see any teeth, the rollers need to be
realigned.
9) Upper Door (PS1 Sensor)
• Open the upper door and check the value of L and R.
• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.
10) Lower Door (PS2 Sensor)
• Open the upper door and check the value of L and R.
• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.
11 ) Double Sensor
• Open the upper door and check the value of L and R.
• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.
• With the door closed, the values of L and R should be around 2000. Any
value above 1000 will still operate correctly in most cases.
• With the door open, the values of L and R should both be 4095.
12) Hopper (Hopper Sensor)
• Open the upper door and check the value of L and R.
• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.
• With no obstructions, the value of Hopper should be ‘0’ and Diff should be
< 100
• Cover the hopper sensor and the value should change to Hopper ‘1’ and
Diff to >1000.
13) Rejector (Reject Pocket Sensor)
• Open the upper door and check the value of L and R.
• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.
• With no obstructions, the value of the reject sensor should be ‘0’ and Diff
should be >1000.
• Cover the reject sensor and the value should change to Rejector ‘1’ and
Diff to <100
14) Stacker (Stacker Pocket Sensor)
• Open the upper door and check the value of L and R.
13

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
KEYPAD TEST
1) Go into Service Menu -> [1] Diagnosis -> [8] Keypad Test
2) Press every key until ZEUS displays “Keypad Press Test: OK” and the [EXIT] key
becomes available. Press [EXIT] to return to the service menu.
• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.
• With no obstructions, the value of the stacker sensor should be ‘0’ and Diff
should be >1000.
• Cover the stacker sensor and the value should change to Stacker ‘1’ and
Diff to <100
SENSOR AND MECHANICAL CHECKS 2.2.
[Fig. 2]
14

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
CURRENCY AND FUNCTION CHECKS
MIX MODE (BASIC CURRENCY RECOGNITION)
• Run a stack of same-denomination bills, split evenly into the 4 possible orientations
(ex. face to the right, face to the left, back to the right, back to the left). Do this
for each denomination, from $1 to $100. The amount of bills used depends on
availability, but Cassida recommends testing with a large quantity of bills (100 per
denomination).
FUNCTION MODE TESTS
NOTE: Use 2 bills of each denomination (14 bills total) to perform the following mode
tests.
1) Sort
2) Count
3) Face
4) Orientation
5) VALUSORTTM
PRINT FUNCTION
• After performing any of the currency tests, the Menu hotkey will become Print.
Connect a thermal printer to the serial port in the back of the unit. Press the Print
hotkey, and the summary will be printed. Check to make sure the currency (i.e.
USD), date, and time are correct.
DETAILED SENSOR INFORMATION
SCANNING QUALITY TEST
NOTE: This test checks feeding quality, image quality, RGB histograms, and position, MG,
IR, UV sensors. Enter the Service Menu -> [1] Diagnosis ->[5] Scanning Quality
• Count 10 to 30 notes. The display will show double sensor output first. Graphical
information is assigned to numeric keys. Press each number repeatedly to scroll
through the values and tolerances of each sensor individually
[1] Double sensor output
[2] Magnetic sensor output
[3] Position sensor output
[4] Scanned image
[5] CIS shading waveforms
The [0] and [8] keys are commonly used to enlarge the screen (Key [0]) or to reduce the
screen (Key [8]). The [ADD] and [STRAP] keys are used to scroll the display left or right.
• In every display, the assigned numeric key itself acts like a next/previous key. For
example: Display the Magnetic sensor output by pressing Key [3], then the key
[3] is used to show ‘display for all Magnetic sensors’ -> ‘display for Left Magnetic
sensor’ -> ‘display for Center Magnetic sensor’ -> etc.
1) Check Double Sensor
• Select this display by pressing in Service Menu -> [1] Diagnosis -> [5]
2.3.
15

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
CURRENCY AND FUNCTION CHECKS
Scanning Quality -> [1] DBL. An example of passing double sensors is
displayed below:
2.3.
Normal - The waveform above was acquired after counting three $1 bills.
• In this waveform, you should check ‘DbL’ (Red) and ‘DbR’ (Blue) signals to
ensure there are three swings with similar depth resulting from counting the
3 notes.
Abnormal - If there is no signal check related parts
·Double Sensor,
· Harnesses
·Mecha board
2) Check Magnetic Sensors
• Select this display by pressing in Service Menu -> [1] Diagnosis -> [5]
Scanning Quality -> [2] MG. An example of passing sensors for three $1
notes is displayed below:
In this menu, you may check the magnetic head signals for scanned notes. ‘dbR’(Blue)
shows the note is passing the magnetic sensors. There are three channels of magnetic
sensors, MHL(Left), MHC(Center), and MHR(Right).
16

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
CURRENCY AND FUNCTION CHECKS
When you press Key [2] you will then see each magnetic head individually. Below is an
example of the MHL on a passing sensor.
2.3.
In this test, you should confirm whether magnetic sensor output is within range, and falls
within the expected detection envelope for each note scanned.
Abnormal - If the signal seems flat, out of range, or outside of the scan
envelop check:
·Magnetic Sensors
·Mecha PBA
·Cable Connections
3) Check Position Sensors and Main motor
• Select this display by pressing in Service Menu -> [1] Diagnosis -> [5]
Scanning Quality -> [3]Position Sensors. The below image shows a passing
scan and position.
• Default screen pictured below:
This graph displays adf encoder (light blue), ps1L (blue) and ps2L (blue in lower position),
ps1R (red) and ps2R (red in lower position), npm (yellow) signals.
In Fig. 6, the machine’s counting speed is plotted along the vertical axis called NPM (Notes
Per Minute), and horizontal axis shows times. The teal square wave is the signal from the
encoder used to determine physical position of the ADF rollers. The red and blue pulses for
each PS1 and PS2 sensor are the sensed position of the note in the bill transport path.
[Fig. 6]
17

CassidaPRO Zeus: Service Manual
2018 Cassida Corporation. All rights reserved.
Rev: 09/05/2018
cassidapro.com/partner/
Normal - The signal (yellow) varies but is approximately 1000 npm on
average. The teal square wave is uniform except for the first and last pulses
which will be longer.
Abnormal - If it cannot reach the 1,000 npm level, uneven encoder spacing,
or misaligned PS1 and PS2 pulses check:
• The holes of the encoder wheel to assure they are not blocked or bent
• Encoder Board and (PBA_ENCODER)
• Mecha Board (PBA_MECHA)
• A loose Drive Belt can also cause the bills to not count at the 1,000 npm
level.
• PS1 or PS2 reflectors may be cracked due to foreign objects passed
through bill transport path
• Wiring may be loose or damaged
CURRENCY AND FUNCTION CHECKS 2.3.
4) Check Image Sensor
• Select this window by pressing Service Menu -> [1] Diagnosis -> [5] Scanning
Quality -> [4]Images. An example of a passing scan is displayed below.
Note that only one bill may be displayed at a time. It is suggested to use a
high denomination to verify that enhanced security features are available for
viewing.
This menu allows you to check the actual images acquired by the CIS image sensor, UV,
and IR full line scanning images, and back light source. Ensure that each quadrant has an
image, and that no repetitive artifacts are visible in the display of each separate image.
Abnormal - If repetitive noise, colored bars, or missing images are noted
check:
·CIS sensor flat ribbon cable for damage
·Cable connections to MAIN board
·CIS sensor for debris, dirt, damage, or cracking
·UV/IR emitters for debris, dirt, damage, or cracking
·Calibration waveforms
18