Suzohapp ICS User manual

Intelligent Coin System
ICS

Rev 1.17 (Preliminary release)
2
Contents
Introduction............................................................................................................................................. 5
Using the ICS............................................................................................................................................ 6
Check if ICS is getting powered ........................................................................................................... 6
Check the cctalk connection and Reset the ICS................................................................................... 6
Fill the ICS with coins........................................................................................................................... 6
Tube Stock........................................................................................................................................... 6
Start Payout......................................................................................................................................... 7
Payout by amount (recommended).................................................................................................... 7
1 ICS Operation........................................................................................................................................ 8
1.1 The ICS Coin Bulk Filling Process ................................................................................................... 8
1.2 The Coin Sorting Process .............................................................................................................. 9
1.2.1 Coin sorting Start criteria ..................................................................................................... 10
1.2.2 Coin sorting Stop criteria...................................................................................................... 10
1.2.3 ICS Coin In amounts.............................................................................................................. 10
1.2.4 Disabling Tubes..................................................................................................................... 10
1.3 The Payout Process ..................................................................................................................... 11
1.3.1 Payout amount monitoring .................................................................................................. 12
1.3.2 Power Fail............................................................................................................................. 13
1.4 The Coin Tubes ............................................................................................................................ 13
1.4.1 Tube Coin Type..................................................................................................................... 13
1.4.3 Tube Stock Correction .......................................................................................................... 14
1.4.4 Tube Status........................................................................................................................... 14
1.4.5 Tube Emptying...................................................................................................................... 15
1.4.6 Tube Counters ...................................................................................................................... 15
1.4.7 ICS Error Status..................................................................................................................... 16
1.4.8 Request Error Status............................................................................................................. 17
1.5 ICS Maintenance.......................................................................................................................... 17
1.6 ICS Tilt Detection ......................................................................................................................... 17
2 General commands ............................................................................................................................ 18
2.1 General system commands ......................................................................................................... 18
3 Detailed ICS commands explanation.................................................................................................. 19
3.1 Header 70: ICS specific command............................................................................................... 19
3.2 System Commands...................................................................................................................... 19

Rev 1.17 (Preliminary release)
3
3.2.1 Command 92 (5C Hex) Get System Mode............................................................................ 19
3.2.2 Command 93 (5D Hex) Set System Mode ............................................................................ 19
3.3 Payout related commands .......................................................................................................... 20
3.3.0 Command 20: Dispense coins .............................................................................................. 20
3.3.1 Command 21: Get payout event counter............................................................................. 20
3.3.2 Command 22: Dispense Amount of Money ......................................................................... 21
3.3.3 Command 23: Abort Payout................................................................................................. 21
3.3.4 Command 77: Get Status Payout Amount ........................................................................... 22
3.4 Coin Tube Commands.................................................................................................................. 23
3.4.1 Command 30: Get Tube Level Status ................................................................................... 23
3.4.2 Command 31: Get Tube Stock.............................................................................................. 24
3.4.3 Command 32: Tube Get Coins Paid...................................................................................... 25
3.4.4 Command 33: Tube Get Coins UnPaid ................................................................................. 25
3.4.5 Command 34: Tube Get Coins Remaining............................................................................ 25
3.4.6 Command 35: Tube Get Status............................................................................................. 26
3.4.7 Command 36: Tube Get Name............................................................................................. 26
3.4.8 Command 37: Tube Set Name.............................................................................................. 26
3.4.9 Command 38: Empty Tube................................................................................................... 26
3.4.10 Command 39: Get Tube Life Total Paid Counter................................................................ 27
3.4.13 Command 47: Tube Enable ................................................................................................ 27
3.4.14 Command 48: Tube Disable ............................................................................................... 27
3.5 Coin Sorting Commands .............................................................................................................. 28
3.5.1 Command 53: Start Sorting.................................................................................................. 28
3.5.2 Command 54: Stop Sorting................................................................................................... 28
3.5.3 Command 55: Get ICS Sorting Status (Obsoleted command).............................................. 29
3.5.4 Command 56: SET_SORTING_STOP_CRITERIA..................................................................... 30
3.5.5 Command 57: GET_SORTING_STOP_CRITERIA ................................................................... 30
3.5.6 Command 58: SET_SORTING_START_CRITERIA ................................................................... 30
3.5.7 Command 59: GET_SORTING_START_CRITERIA .................................................................. 31
3.5.8 Command 90: ICS_SET_SORTER_OUTPUTS ......................................................................... 31
3.5.9 Command 91: ICS_GET_SORTER_INPUTS ............................................................................ 31
3.6 Coin Totals In/Out Commands .................................................................................................... 32
3.6.1 Command 71: Set Total Coins In .......................................................................................... 32
3.6.2 Command 72: Get Total Coins In.......................................................................................... 32

Rev 1.17 (Preliminary release)
4
3.6.3 Command 73: Clear Total Coins Out .................................................................................... 33
3.6.4 Command 74: Get Total Coins Out....................................................................................... 33
3.6.5 Command 75: Get Total Amount In ..................................................................................... 33
3.6.6 Command 76: Get Total Amount Out .................................................................................. 33
3.6.7 Command 78: Empty ICS...................................................................................................... 34
3.6.8 Command 79: Get ICS Empty Status .................................................................................... 34
3.7 Updating Firmware ICS................................................................................................................ 35
3.7.1 Command 139: Begin Firmware Upgrade............................................................................ 35
3.7.2 Command 140: Upload Firmware ........................................................................................ 36
3.7.3 Command 138: Finish Firmware Upgrade............................................................................ 37
4 ICS Setup............................................................................................................................................. 38
4.1 ICS mode command..................................................................................................................... 38
4.2 ICS and Coin Acceptor with a Sorter ........................................................................................... 38
4.3 ICS and Coin Acceptor with 2 Escrow Units attached ................................................................. 38
4.4 System Initialization .................................................................................................................... 39
4.4.1 Hopper Only Mode............................................................................................................... 39
4.4.2 Hopper + Coin Acceptor with attached sorter ..................................................................... 39
4.4.3 Hopper + Coin Acceptor + Escrow Sorter Units.................................................................... 39
4.5 Initialization Flowchart................................................................................................................ 40
4.6 Dispense Coins or Amount Flowchart ......................................................................................... 43
4.7 ICS Emptying Flowchart............................................................................................................... 45
4.8 ICS Floating Command Sequence Example ................................................................................. 46
5 Connector........................................................................................................................................... 50
6 Specifications...................................................................................................................................... 51
6.1 General........................................................................................................................................ 51
6.2 Integration................................................................................................................................... 52
6.3 Filling ........................................................................................................................................... 52
6.4 Handling & Transport .................................................................................................................. 52
7 Dimensions......................................................................................................................................... 53
8 Optional Add-Ons............................................................................................................................... 55
............................................................................................................................................................... 56
Revision history ..................................................................................................................................... 57

Rev 1.17 (Preliminary release)
5
Introduction
The Intelligent Coin System (ICS) is a patented innovative coin handling machine designed and
produced by SUZOHAPP. The ICS is different from a “traditional” coin systems. The ICS can process
up to 8 different coins without the need of pre-sorting the coins by the user. The ICS is always
standby for the next payout by using the idle time or during payout to pre-sort the coins.
The ICS can handle up to 1300 coins of different sizes, sort these automatically and determine how
the payout needs to be divided with the coins available. Because of the ICS construction, it can
payout 4 coins at the same time. This ensures a fast payout for the consumer.
The compact design of the ICS makes it easily integrated into smaller payout machines like self-
checkout registers or parking ticket machines without the need of custom coin routing.
The ICS can be used in many applications, for example: self-checkout stations for supermarkets,
parking ticket machines, money changers, vending, amusement and gaming machines.
Payout can be done by a direct coin payout command from each coin tube (in total 8) or using the
payout amount command, in which the ICS calculates the changing amount of coins based on the
current tube stock levels.
Highlighted features:
•Payout speed consistency (buffer stock)
•Payout redundancy
•Compact design
•Mixed coin sorter & payout system
•Customizable for country specific coin mix
•Bulk capacity ≈ 1300 coins (in euro mix)
•Coin diameter 15 –32,5mm
•Coin thickness 1,3 –3,25mm
•Cost reduction in final machine

Rev 1.17 (Preliminary release)
6
Using the ICS
This chapter explains the steps needed to start using the ICS.
A fast way to start is using the cctalk interface (SUZOHAPP part nr 107-0251) plus a 3 wire cable
connecting the cctalk interface board to the ICS (SUZOHAPP part nr 157-0350) and a 12V power
supply (SUZOHAPP part nr 150-0072).
The ICS can be evaluated using a ICS-TestProgram that runs on a PC (please request from technical
service)
Check if ICS is getting powered
When the ICS receives between 12V and 24V and no errors are present the blue indicator LED will be
on.
Check the cctalk connection and Reset the ICS
Send the RESET command to the ICS. If the command is ACK'ed then the cctalk interface works and
the ICS will reset. You will hear the coin rejector solenoid clicking.
Fill the ICS with coins
See Table 1: Examples of best mix for the bulk of euro coins in the ICS.
Note that it is not necessary to start sorting of the coins into the tubes manually. The user must set the
number of coins put into the ICS for each denomination using the SET_TOTAL_COINS_IN command
(71 Dec). Depending on the setting ‘start sorting after Reset or after Set Total Coins In’ the sorting will
start immediately after the SET_TOTAL_COINS_IN command or after the RESET command. Note
that the sorting is always started automatically after a payout command if necessary. This ICS will
keep sorting coins into the tubes even after a payout has finished, until the tubes are full or a sort
timeout occurs.
Tube Stock
After sorting starts, coins fall into the tube. When a coin enters the tube it first interrupts the ‘count
sensor’, located at the top of the tube. This sensor is used for stock accounting and tube overflow
management.
During the fall into the tube, the coin passes a second sensor, called the ‘full level sensor’, located in
the middle of the tube. This sensor is used to indicate that the tube is full and is also used to correct
the tube stock when necessary.
The tube stock has a minimum level of 2 coins. This is to prevent the tube running empty during a
payout. If the tube runs empty while a new coin falls into the tube, it could create a tube payout jam.

Rev 1.17 (Preliminary release)
7
Start Payout
Payout can be done in 2 ways: Payout by denomination and payout by amount.
- Payout by denomination (see Table 4, command 20 Dec) gives to user precise control over the nr of
coins to payout from the tubes.
- Payout by amount (command 22 Dec). This is the recommended way of dispensing coins from the
ICS, since the ICS is able to see which tubes should payout coins in terms of their stock, status and
availability.
Payout by denomination (not recommended)
Before a payout from a tube is started, the user must check if the tube can be used for payout (not in
error, enough coins in the ICS or tube, etc). If a tube is full, it is recommended to use it on a regular
basis, so that the tube stock will be synchronized to it’s real stock level as indicated by the tube level
sensors in the tube. In some cases, when the tube is not used for a long time, it might occur that,
during sorting, a coin slips over the coin rejector and falls into an already full tube. Eventually the
tube will set it’s count sensor blocked status bit. When this happens, the user is strongly
recommended to payout from this tube as soon as possible so that the stock level drops again and
new coins falling into the tube are detected again. Keep using a full tube until the full level sensor
becomes free again allowing the tube stock to be synchronized again.
Payout by amount (recommended)
This is the recommended payout method for the ICS. The ICS automatically calculates which tubes
should be used for the requested amount to pay. Tubes that are overfull with coins will be used first,
reducing any potential problems due to tubes becoming overfull. Tubes that can’t be used for a
payout are automatically discarded. Based on the stock levels in the tube, the most economic and
fastest payout is calculated.
Note that in both payout methods, the ICS will start automatically filling the tubes when necessary.
No need to use the START_SORTING command, to start sorting manually.

Rev 1.17 (Preliminary release)
8
1 ICS Operation
The Intelligent Coin System (ICS) is a compact payout unit designed to payout small amounts of coins.
Typical use is the payout of change money that is not possible via the (smallest) notes. So, in case of
euro’s, an ICS payout is typical less than 10 euro.
The ICS unit can be used as a payout device only, in which case the ICS has to be filled with coins
manually, or as part of a coin (recycling) system, in which case the ICS is filled typically through a coin
acceptor. The coin bulk inside the ICS are sorted into 8 tubes from which a payout can be done.
1.1 The ICS Coin Bulk Filling Process
Filling the ICS with coins needs some attention. In order to get the best payout results, all payout
tubes must be filled with enough coins, so that after sorting all tube stock levels are approximately
the same. After some payouts, the coin tubes stock will fall below a certain level and the ICS will start
sorting coins again from the bulk inside into to tubes. Ideally all tubes will be refilled to the full level
again during sorting. The sorting process is optimized by filling the ICS with an optimum amount of
each coin denomination. Table 1 shows some ICS euro coin filling examples.
Euro In
1ct
2ct
5ct
10ct
20ct
50ct
100ct
200ct
Total
coins In
€ 98,10
40
35
25
30
25
35
30
20
240
€ 196,20
80
70
50
60
50
70
60
40
480
€ 392,00
160
140
110
120
100
140
120
80
970
€ 488,50
200
170
140
150
120
170
150
100
1200
Table 1: Examples of best mix for the bulk of euro coins in the ICS
Not only the optimal mix of the different coin denominations should be taken into account, also the
total amount of bulk coins inside the ICS should be considered. If the ICS is filled to its maximum level
(1300 coins), the coin sorting process will be less optimal. Filling it up to 70 percent of its maximum
level gives better results.
If the coins inside the ICS are fed through a coin acceptor that is connected to the ICS (ICS operation
mode = 1), then the ICS may disable coin acceptance of a certain coin type in order to maintain the
best mix of total coins inside the ICS. If, for example, the max nr of 2 euro coins inside the ICS is 60
for the current best mix of all coins, then the coin acceptor will sort the 2 euro coin to the cashbox if
the total amount of 2 euro coins is more or equal then 60, although the ICS may not be full yet. The
ICS will try to maintain the best mix of coins to operate optimally.
So, the ICS fills the coin tubes in an optimal way if the bulk of coins inside the ICS have an ideal mix of
each coin denomination. Then the chance that all tubes will be filled again to their full level during
sorting will be highest. Smart payout algorithms make sure that all tube coins have no large stock
differences. So, if one tube is empty, most likely all other tubes are also at low stock level and the
next sorting process will fill all tubes as much and efficient as possible.
If the ICS is used in a coin recycle system (ICS receives coins via a coin acceptor), then the ICS may
only accept coins into the ICS if the total coins in is below 1300. See Table 1.

Rev 1.17 (Preliminary release)
9
1.2 The Coin Sorting Process
Table 2 shows the ICS coin sorting commands
Header
Command
53
DISC_MOTOR_START
54
DISC_MOTOR_STOP
55
GET_SORTING_STATUS
56
SET_SORTING_STOP_CRITERIA
57
GET_SORTING_STOP_CRITERIA
58
SET_SORTING_START_CRITERIA
59
GET_SORTING_START_CRITERIA
71
ICS_SET_TOTAL_COINS_IN
72
ICS_GET_TOTAL_COINS_IN
73
ICS_CLEAR_TOTAL_COINS_OUT
74
ICS_GET_TOTAL_COINS_OUT
75
ICS_GET_TOTAL_AMOUNT_IN
76
ICS_GET_TOTAL_AMOUNT_OUT
77
ICS_GET_STATUS_AMOUNT_PAYOUT
78
ICS_EMPTY_ICS
79
ICS_GET_LEVEL_STATUS
Table 2: ICS Coin Sorting Commands
A payout is realized by 8 separate coin tubes inside the ICS. One tube can hold typically around 20-30
coins. The tubes are filled via a coin sorting system from a large cup inside the ICS.
The cup with unsorted coins can be filled manually or via a coin acceptor.
When the coin sorting process is started, a large disc inside the ICS starts rotating and moves the
coins to the start of a sorting rail with increasing recesses. The coins will then fall along the rail. Small
coins are sorted out at the start of the rail and the large coins at the end of the rail. Under the rail are
the 8 tubes located, that store the sorted coins.
When a certain coin tube gets full, a solenoid at the start of the rail will push any additional coins
from the rail back into the cup preventing the coin tube to flood. A diameter sensor located at the
start of the rail determines the coin type and actives the solenoid if the tube for that coin type is full.
In order to get an optimal coin sorting process, the user should fill the ICS with an optimum mix of all
coin denominations. Some optimal coin in mix values for the ICS are listed above. The number of
coins for each coin type can be set with the ICS_SET_TOTAL_COINS_IN command and can be
retrieved with the ICS_GET_TOTAL_COINS_IN command.

Rev 1.17 (Preliminary release)
10
1.2.1 Coin sorting Start criteria
If one of the tubes stock falls below 80% of its full level stock, the ICS will start sorting again, so it will
keep the tubes as full as possible.
1.2.2 Coin sorting Stop criteria
Once the coin sorting process is started, and the tubes are being filled again, the sorting process will
stop if all tubes have reached at least 80% of the full level stock (see Table 3 ), or after a certain
timeout period typical (7 –14 sec) in which no more coins have been sorted anymore into the tubes.
Coin
1ct
2ct
5ct
10ct
20ct
50ct
100ct
200ct
Full Level
31
30
30
26
24
21
22
23
Table 3: Tube Full Level Settings for Euro
The sorting process can also be started manually using the DISC_MOTOR_START and
DISC_MOTOR_STOP commands.
Note that tube filling stops after 4 coins, when the tube was empty at the start. When the tube
has paid 1 or more coins, it will be filled to its normal full level automatically. This is done to minimize
any coin jams that could occur when filling a tube from an empty state.
1.2.3 ICS Coin In amounts
The total amount of money inside the ICS can be retrieved using the ICS_GET_TOTAL_COINS_IN or
ICS_GET_TOTAL_AMOUNT_IN commands. If no coin acceptor is connected to the cctalk peripheral
extension bus then the amount of coins in must be set manually using the ICS_SET_TOTAL_COINS_IN
command.
1.2.4 Disabling Tubes
A tube (or coin) can be disabled from being filled by sending the TUBE_DISABLE command. All coins
for this tube will then be rejected and will be ignored during the sorting process.