Wincor Nixdorf CMD-V4 User manual

Cash Media Dispenser
Version 4
Service Manual
Self-Service
Systems

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Cash Media Dispenser Version 4 - Service Manual 01750060162 A
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Cash Media Dispenser
Version 4
Service Manual
Edition April 2003

Copyright © Information and trademarks
Cash Media Dispenser Version 4 - Service Manual 01750060162 A
© Wincor Nixdorf International GmbH 2003
All rights, including rights of translation and
rights of reproduction by reprinting, copying
or similar methods, even of parts, are
reserved.
Any violations give rise to a claim for
damages
All rights, including rights created by patent
grants or registration of a utility model or
design, are reserved. Delivery subject to
availability; right of technical modifications
reserved.
All names of hardware and software
products mentioned in this manual are
trade names and/or trademarks of their
respective manufactures.
This manual was
produced using paper
treated with chlorine-free
bleach

01750060162 A Cash Media Dispenser Version 4 - Service Manual 0-1
C Contents..…...…………....………...…......
1 Introduction.....................................…....
(Safety precautions, technical data)
2 Function and Integration…….................
3 Device Overview and Operation…….....
4 Getting Started............................…….....
5 Troubleshooting.....................………......
6 Removal / Installation of Components..
7 Maintenance and Service.......................
8 Pin Assignments......................………....
9 Spare Parts..........................……………..
I Index....................………………………….

0-2 Cash Media Dispenser Version 4 - Service Manual 01750060162 A

01750060162 A Cash Media Dispenser Version 4 - Service Manual C-1
Contents
Introduction ..................................................................................................1-1
Symbols used in this manual..........................................................................1-1
Important safety precautions..........................................................................1-2
General power interrupt..................................................................................1-4
Description of the device................................................................................1-5
Structure of the manual..................................................................................1-7
Outline.......................................................................................................1-7
Supplementary documentation.................................................................1-8
Technical data................................................................................................1-9
Cash media dispenser without output transport........................................1-9
Stacker....................................................................................................1-10
Output transport......................................................................................1-10
Shutter ....................................................................................................1-12
CMD controller........................................................................................1-13
4-cassette housing (without contents) ....................................................1-14
1-cassette housing (without contents) ....................................................1-14
Double dispensing unit without DDU ......................................................1-14
Double dispensing unit with DDU ...........................................................1-15
Single dispensing unit without DDU........................................................1-15
Single dispensing unit with DDU.............................................................1-15
Reject / retract cassettes ........................................................................1-16
Cash-out cassettes.................................................................................1-16
Environmental conditions........................................................................1-17
Climatic environmental conditions in accordance with EN 60721.....1-17
Mechanical environmental conditions in accordance with EN 60721 1-17
Noise emission in accordance with EN 27779 ..................................1-17
Compliance with standards and certifications.........................................1-18
Environmental protection..............................................................................1-20
Environmentally friendly product design and development.....................1-20
Saving energy.........................................................................................1-20
Disposing of used consumables.............................................................1-20
Labels on plastic case parts....................................................................1-20
Returning, recycling and disposing of used units and consumables ......1-21
Further information..................................................................................1-21
Abbreviations................................................................................................1-22
Function and Integration.............................................................................2-1
Sensors and electromechanical components.................................................2-1

Contents
C-2 Cash Media Dispenser Version 4 - Service Manual 01750060162 A
Horizontal output transport ....................................................................... 2-1
Vertical output transport............................................................................ 2-2
Stacker and output transport .................................................................... 2-3
Components of dispensing unit and cassette........................................... 2-4
Procedures in the CMD-V4 (schematic)......................................................... 2-5
Dispensing in customer direction (vertical, frontload)............................... 2-6
Bundle reject............................................................................................. 2-7
Single reject.............................................................................................. 2-8
Bundle retract when notes are not removed........................................... 2-10
Procedures in the CMD-V4.......................................................................... 2-11
Start-up behavior .................................................................................... 2-11
Controller test.................................................................................... 2-11
Firmware tt ........................................................................................ 2-11
Memory reset .................................................................................... 2-11
Determination of the device type....................................................... 2-12
Checking the cassettes..................................................................... 2-12
Checking the photosensors............................................................... 2-12
Checking the device locks................................................................. 2-12
Checking mechanical and electronic components............................ 2-13
Checking the transport paths ............................................................ 2-13
Checking the shutter ......................................................................... 2-13
Dispensing.............................................................................................. 2-14
Checking the basic state................................................................... 2-14
Double dispense/note sizes out of tolerance..................................... 2-14
Undefined notes................................................................................ 2-15
Dispensing of notes not possible....................................................... 2-15
Banknote jam .................................................................................... 2-15
Transport ................................................................................................ 2-16
Transport to waiting position ............................................................. 2-16
Bundle reject ..................................................................................... 2-16
Single reject....................................................................................... 2-16
Cash presentation (incl. waiting for removal), cash output................ 2-17
Retracting and storing banknotes...................................................... 2-17
Retracting cash without storing it ...................................................... 2-18
Cassette handling ........................................................................................ 2-19
CMD controller............................................................................................. 2-20
Position of function groups ..................................................................... 2-22
Connectors on the CMD controller ......................................................... 2-23
Logical interface...................................................................................... 2-24
Command from host system ............................................................. 2-25
Acknowledgement by the CMD-V4 ................................................... 2-25
Overview of commands.......................................................................... 2-25

Contents
01750060162 A Cash Media Dispenser Version 4 - Service Manual C-3
Control block...........................................................................................2-27
CPU...................................................................................................2-28
Memory..............................................................................................2-28
Serial interface...................................................................................2-28
Status display....................................................................................2-28
Function button..................................................................................2-28
Photosensor electronics..........................................................................2-29
Measuring banknotes with the double detection unit (DDU)...................2-30
Component control..................................................................................2-31
Dispensing unit control......................................................................2-31
Cassette control.................................................................................2-31
Stacker transport..........................................................................................2-33
Stacker transport - EEPROM.......................................................................2-35
Output transport ...........................................................................................2-36
Shutter..........................................................................................................2-37
Dispensing unit.............................................................................................2-38
4-cassette housing without dispensing units...........................................2-38
4-cassette housing with two double dispensing units and 4-channel
distributor board......................................................................................2-39
Dispensing unit with dispensing shaft and magnetic clutch...............2-40
Photosensors in the dispensing unit.......................................................2-41
Pressure sensor......................................................................................2-41
Reject / retract cassette................................................................................2-42
Cash-out cassettes.......................................................................................2-44
Device Overview and Operation .................................................................3-1
Device overview.............................................................................................3-1
Horizontal cash-out Frontload...................................................................3-2
Horizontal cash-out Rearload ...................................................................3-3
Vertical cash-out Frontload.......................................................................3-4
Vertical cash-out Rearload........................................................................3-5
1-cassette housing with single dispensing unit.........................................3-6
Function elements and controls................................................................3-7
The cassettes.................................................................................................3-8
Cash-out cassette.....................................................................................3-8
Reject / retract cassette............................................................................3-9
Removing the cassette ...........................................................................3-10
Opening the cassette..............................................................................3-11
Emptying the reject / retract cassette......................................................3-12
Setting the low cash sensor....................................................................3-13
Setting the banknote width......................................................................3-14
Removing banknotes.........................................................................3-14

Contents
C-4 Cash Media Dispenser Version 4 - Service Manual 01750060162 A
Removing the banknote rails............................................................. 3-15
Inserting the banknote rails............................................................... 3-16
Setting the banknote height.................................................................... 3-20
Filling the cash-out cassette................................................................... 3-22
Preparing the cash-out cassette........................................................ 3-22
Preparing the banknote bundles ....................................................... 3-24
Inserting banknote bundles............................................................... 3-25
Special comments for deformed banknotes...................................... 3-28
Inserting the cassette.............................................................................. 3-30
Inserting the cassette.............................................................................. 3-30
Closing the cassette.......................................................................... 3-30
Inserting the cassette........................................................................ 3-31
Cassette initialization ................................................................................... 3-32
Determining the reference value.................................................................. 3-32
Function test................................................................................................. 3-34
Start-up ......................................................................................................... 4-1
Initial start-up.................................................................................................. 4-1
Start-up after component replacement........................................................... 4-2
Electronic adjustments for the CMD-V4......................................................... 4-3
Initializing the CMD-V4................................................................................... 4-4
Jumper settings on the CMD controller .................................................... 4-5
Position of the jumper panel on the CMD controller............................ 4-5
Default settings.................................................................................... 4-7
Adjusting cash cassettes to the note size...................................................... 4-8
Filling cassettes with real cash and inserting them........................................ 4-8
Updating note parameters and cassette replenishment data......................... 4-8
Calculating reference values for the various note types ................................ 4-8
Authenticating the cash.................................................................................. 4-8
Troubleshooting........................................................................................... 5-1
Displays at startup.......................................................................................... 5-2
Displays in normal operation.......................................................................... 5-3
Dirty photosensors / sensors.................................................................. 5-17
Checking the note paths .............................................................................. 5-21
Locking/unlocking handle blocked ...............................................................5-22
Checking the vertical transport............................................................... 5-23
Checking the dispensing areas............................................................... 5-24
Checking the stacker and output transport............................................. 5-25
Removal/Installation of Components......................................................... 6-1
Pulling out / pushing in the CMD-V4.............................................................. 6-1

Contents
01750060162 A Cash Media Dispenser Version 4 - Service Manual C-5
CMD controller ...............................................................................................6-2
Stacker...........................................................................................................6-3
Horizontal output transport.............................................................................6-5
Ouput transport ProCash 2000xe RL.............................................................6-6
Output transport ProCash 2050xe..................................................................6-7
Ouput transport ProCash 2100xe RL.............................................................6-8
Shutter ProCash 2000xe RL ..........................................................................6-9
Shutter ProCash 2050xe RL ........................................................................6-10
Shutter ProCash 2100xe RL ........................................................................6-11
Shutter ProCash 2150xe RL ........................................................................6-12
Distributor board...........................................................................................6-13
Dispensing units...........................................................................................6-15
Upper dispensing unit with thickness measuring station ........................6-15
Lower dispensing unit.............................................................................6-17
Clamp...........................................................................................................6-19
Maintenance and Service ............................................................................7-1
Maintenance...................................................................................................7-1
Maintenance intervals...............................................................................7-1
Performing maintenance...........................................................................7-1
Stacker ................................................................................................7-3
Output transport...................................................................................7-3
Shutter.................................................................................................7-3
Cash-out cassettes..............................................................................7-3
Reject / retract cassette.......................................................................7-4
General................................................................................................7-4
Approved maintenance materials .............................................................7-5
Pin Assignments..........................................................................................8-1
Power supply connector (supply voltage).......................................................8-1
Safety switch..................................................................................................8-1
Basic module..................................................................................................8-1
Main motor M1 ...............................................................................................8-3
Stacker...........................................................................................................8-3
Frontload module ...........................................................................................8-5
Dispensing unit 1 (module positions 1 and 2) ................................................8-6
Cassette connector at dispensing unit 1 ........................................................8-8
Dispensing unit 2............................................................................................8-9
Cassette connector at dispensing unit 2 ......................................................8-11
Extension connector for dispensing unit 3....................................................8-12
Connector for shutter (incl. Z module)..........................................................8-14
Connector for thickness measuring station..................................................8-16

Contents
C-6 Cash Media Dispenser Version 4 - Service Manual 01750060162 A
Connection of door switch............................................................................ 8-17
Battery connector.................................................................................... 8-17
RS232C connection..................................................................................... 8-18
CMD controller............................................................................................. 8-19
4-channel distributor board........................................................................... 8-39
Spare Parts................................................................................................... 9-1
Overview of individual parts........................................................................... 9-1
Index............................................................................................................... I-1

01750060162 A Cash Media Dispenser Version 4 - Service Manual 1-1
Introduction
This service manual has been compiled for authorized service personnel only.
The operating manual, the installation guide and the service manual of the
basic device should also be read since certain details are only described in
those manuals.
Symbols used in this manual
− Text following a dash represents an item in a list.
" " Text in quotation marks refers to other chapters or sections in this
document.
• Text following this symbol describes actions to be performed in the
specified order.
Text following this symbol should be given special attention in order to
avoid damage and injury.
i
Text following this symbol contains general information to facilitate use
of the device and help avoid operating errors.

Important safety precautions Introduction
1-2 Cash Media Dispenser Version 4 - Service Manual 01750060162 A
Important safety precautions
Please read the following notes carefully before doing any work on the
device.
This device complies with the relevant safety regulations for information
processing equipment and is designed for use in a regular office environment.
− When moving the device from a cold to a warm environment, do not
operate it for at least two hours to prevent possible damage caused by
condensation.
− Only use the original packaging material to transport the device.
− The device is equipped with a safety-tested power cable which must be
connected only to a suitable grounded outlet.
− Always hold the plug when removing the power cable. Never pull the cable
itself.
− Install all cables in such a way that they will not be stepped on or tripped
over or damaged and crushed in any other way.
− Have damaged cables replaced immediately.
− Make sure that there is always free access to the sockets used or to the
electrical circuit-breakers of the house installation.
− In case of an emergency (e. g. damaged cabinets, controls or power
cables, liquids or foreign objects in the device) observe the following
instructions:
Deactivate the device immediately by:
Switching off the automatic circuit-breaker or removing the fuse inset
from the fuse holder in the distribution box of the building installation;
Disconnecting the plug connector of the power supply cable from the
grounded socket in the building installation;
Switching the power switch on the power distributor to OFF (refer to the
operating manual of the basic device);
Disconnecting power between the UPS (uninterruptible power supply)
and the device (refer to the operating manual of the basic device).

Introduction Important safety precautions
01750060162 A Cash Media Dispenser Version 4 - Service Manual 1-3
− During a thunderstorm, data transmission lines may not be connected or
disconnected.
− Only use accessories and extension components which have been
approved by us. Nonobservance can result in damage to the system or
violations of regulations concerning safety, radio interference and
ergonomical requirements.
− Note that there are only safety extra-low voltage circuits (SELV circuits) if
you want to feed voltage from an external source into prepared cables to
install additional electronics (e.g. connection for an intruder alarm system).
− To clean the device only use cleaning agents approved by Wincor Nixdorf
International GmbH (see chapter "Maintenance and Service").
Repair work
Repair work may only be carried out by authorized personnel.
Unauthorized opening of the device or repair work carried out
improperly could result in considerable danger to the user.
In case of noncompliance, Wincor Nixdorf International GmbH
excludes all liability.

General power interrupt Introduction
1-4 Cash Media Dispenser Version 4 - Service Manual 01750060162 A
Lithium batteries
There is danger of fire or explosion if the batteries are handled
incorrectly. It is therefore important to note the following points:
− Avoid short circuits.
− Never recharge the battery.
− Avoid temperatures above 100 °C.
− Do not try to open the battery by force.
− Do not allow the battery to come into contact with water or fire.
Replace only with the same or an equivalent type recommended by
Wincor Nixdorf International GmbH.
Dispose of used batteries in compliance with national regulations and
the manufacturer's specifications.
General power interrupt
i
A general power interrupt has the following effects:
–All currently running transactions are immediately aborted.
–Dispensed banknotes remain in the transport paths of the cash
media dispenser. They will be transported to the reject/retract
cassette of the CMD-V4 or they remain in the collecting position of
the clamp after the device has been turned on again.

Introduction Description of the device
01750060162 A Cash Media Dispenser Version 4 - Service Manual 1-5
Description of the device
Function and use
The most important components in an automated teller machine is the Cash
Media Dispenser (CMD-V4).
TheCMD-V4replacestheAZM-NG.TheCMD-V4andtheAZM-NGare
software-compatible but not hardware-compatible.
CMD cassettes are basically upward- and downward-compatible with some
restrictions. They are about 5 mm longer so they cannot simply be deployed in
the ProCash BBA mini 3K (up to February 2003) and the ProCash BBA UT
with a CEN safe. The ProCash BBA mini 3K requires a technical modification
forCMDcassettestobeinstalled.Theoldcassetteshavetobeusedinthe
ProCash BBA UT with a CEN safe.
This manual describes the Cash Media Dispenser, version 4.
Here are some of the characteristics of the Cash Media Dispenser:
− High functional reliability (low reject rate, detection of dispenses of two
notes)
− Convenient to use and maintain:
Electronic and mechanical adjustments have been minimized
Maintenance intervals: Every two years or after 200,000 transactions
− All known requirements for ecological reuse and disposal have been
satisfied.

Description of the device Introduction
1-6 Cash Media Dispenser Version 4 - Service Manual 01750060162 A
The CMD-V4 can be tailored to the user's specific requirements thanks to
model variants (frontload/rearload) and a variable number of dispensing units
in the various housings. The CMD-V4 can consist of the following components,
depending on the configuration:
− Stacker transport facility with or without single reject
− Horizontal/vertical output transport facility Rearload/Frontload
− 1-cassette housing with single dispensing unit
− 4-cassette housing with one double dispensing unit or two double
dispensing units
− CMD controller
− Cash-out cassette and reject / retract cassette
i
The single reject function is only available in devices which are
delivered to countries outside the European Union.

Introduction Structure of the manual
01750060162 A Cash Media Dispenser Version 4 - Service Manual 1-7
Structure of the manual
Outline
The chapter "Introduction" describes the important safety precautions. It also
gives an overview of the Cash Media Dispenser Version 4 (CMD-V4).
The features of the CMD-V4 are also described in the chapter "Introduction" in
the section "Technical data”.
In the chapter "Function and Integration" you will find a description of the
individual components of the cash media dispenser.
The "Device Overview and Operation" chapter describes, among other things,
how to change the cash-out and reject/retract cassettes, replenish the cash-
out cassette and set the banknote size.
The "Start-up" chapter explains how the CMD-V4 is initialized.
The "Troubleshooting" chapter lists the status messages that may be output,
together with explanations and action to be taken.
The next chapter "Removal/Installation of Components" provides detailed
information on how to replace the components.
The chapter "Maintenance and Service" contains information on maintenance
work to be carried out regularly.
The assignment of connector pins is described in the "Pin Assignments"
chapter.
Finally, components that can be replaced in the Cash Media Dispenser are
listed in the "Spare Parts" chapter.

Structure of the manual Introduction
1-8 Cash Media Dispenser Version 4 - Service Manual 01750060162 A
Supplementary documentation
For the operation and installation of the basic devices, separate manuals are
available in several languages which also include a short description of the
CMD-V4.
These manuals can be ordered from our print partner. They are also available
in the intranet.
Usually the manufacturers' original manuals for OEM components are included
in the shipment. They may contain more detailed information.