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NCR 5633 Currency Dispenser

1. Door Shutter Spring Standard Plastic Cassette im i Mi Q O O NCR 5633 Currency Dispenser Service Manual 4 39 Maintenance Instructions Cleaning Cleaning Clean the cassette with a cloth dampened with water For stubborn marks and grease try a clean cloth dampened with isopropyl alcohol Do not use any other cleaning agents or abrasives 4 40 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Replacing Dispenser Modules Replacing Dispenser Modules There are a number of modules that may be replaced with the dispenser in an ATM depending on the mounting arrangements e For top mounting the control board and pick modules e For bottom mounting the control board spray module and a pick module except the lower or only pick module Me The control board is secured by 4 screws and is behind a Replacing the Control metal panel which is secured by 4 screws Access to the Board control board is gained by removing the metal panel After fitting the new control board ensure that the configuration switches have been correctly set NCR 5633 Currency Dispenser Service Manual 4 41 Maintenance Instructions Replacing Dispenser Modules es The spray module is secured to the pick module
2. O O NI q Pare o kh o o fo o Ode 5 5 o 04 O O o 5 E D Jo u O purge o cc OLE OC D om D Il JSR o ce currency currency cassette 1 48 NCR 5633 Currency Dispenser Service Manual present position of stack Dispenser Functional Description The Dispense Operation Rear access dispenser path of purge notes purge bin currency currency cassette A normal dispense operation consists of picking transporting and spray presenting individual bills into a customer access tray When the dispenser receives a dispense command the firmware first checks the sensors and then turns on the main motor and looks for the location of the first cassette to dispense from The main motor drives the transports in all the pick modules and in the spray module It also drives the vacuum pump on each pick module The pick arms of all modules are driven along with the transport During the firmware search for the cassette the main motor comes up to speed The normal dispense operation can be broken down into the following sequence of operations NCR 5633 Currency Dispenser Service Manual 1 49 Dispenser Functional Description The Dispense Operation 1 50 The host ATM issues a dispense command specifying the number of bills to be picked from each cassette The firmware checks all transport sensors are not blocked and the divert gate is in the reject
3. Truck Door Rachet Slide Rachet Lever Door Lockout Lever The base of the cassette holds the truck door and its retraction mechanism the pusher ratchet slide and lever The shape of the base forms rails which slide into the cassette guides in the pick module 1 6 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Containers a Cassette Operation The above illustration shows the components of the dispenser pick module which mate with the cassette When the cassette is inserted into the dispenser the prongs of the pick module keyplate enter the holes in the base of the cassette and push against locking pawls on the truck door The door is pushed into the cassette base leaving the front open to permit the currency to be picked from the cassette and dispensed Several other actions happen as the truck door is opened e The door shutters are disengaged from the door and are pushed back by the pick line NCR 5633 Currency Dispenser Service Manual 1 7 Dispenser Functional Description Containers Fe Pusher Operation e The fingers next to the currency separator brushes drop down clear of the currency stack The function of these fingers is to prevent notes at the front of the stack being dragged down by the opening door e The ratchet slide attached to the door lowers the ratchet lever so that it disengages from the pusher pawl As the currency is dispensed the pusher moves forward under spri
4. present position of stack purge bin currency currency cassette x The pick modules of the dispenser fit vertically below Pick Module the spray module to allow one two three or four pick positions Pick position number 1 is immediately below the spray module number 2 is below number 1 number 3 below number 2 and 4 below 3 1 14 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Mechanical Description There are two types of pick module the single pick module holds one currency cassette and the double pick module holds two cassettes one above the other Functions of the Pick Module Pick modules provide support for currency cassettes identify the inserted cassettes open the front of the inserted cassettes lift picks bills one by one from the cassettes detect when currency is running low transport the bills to the pick module above or to the spray module NCR 5633 Currency Dispenser Service Manual 1 15 Dispenser Functional Description Mechanical Description 1 16 The components of the pick modules which achieve the above functions are cassette guides and latch mechanism cassette present and identity sensors pick module keyplate pick action components pick arms suction cups pick solenoids and timing disks pick sensors cassette low sensors gear driven transport The following description applies to a single pick module with the differences for the dou
5. Transport sensors These consist of 5 lines that come from the transport sensors through buffers and are fed to the NCR 5633 Currency Dispenser Service Manual 1 35 Dispenser Functional Description Control Board microcontroller s Port 1 and A D inputs These are as follows Feed sensor P5 1 and P1 1 Exit sensor P5 2 and P1 0 Divert position sensor P5 3 and P1 2 Reject bin present sensor P5 5 Timing Disk sensor P1 4 ALSO INT1 INPUT Cassette sensors These consist of 20 lines that come from the Cassette ID and Cassette low PCBs and are mapped as follows F000H Read Only Comms ID Cassette Sensor detect 0 Low 1 Not Low BIT 4 Cassette One Low sensor BIT 5 Cassette Two Low sensor Bit 6 Cassette Three Low sensor Bit 7 Cassette Four Low sensor E000H Read Only Cassette ID 1 2 Sensor detect 0 Present 1 Absent BIT 0 Cassette One ID 1 BIT 1 Cassette One ID 2 BIT 2 Cassette One ID 3 BIT 3 Cassette One ID 4 BIT 4 Cassette Two ID 1 BIT 5 Cassette Two ID 2 1 36 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Control Board BIT 6 Cassette Two ID 3 BIT 7 Cassette Two ID 4 8000H Read Only Cassette ID 3 4 Sensor detect 0 Present 1 Absent BIT 0 Cassette Three ID 1 BIT 1 Cassette Three ID 2 BIT 2 Cassette Three ID 3 BIT 3 Cassette T
6. 1 DIV_DRV 2 1 42 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Connector Interfaces The pick solenoids connect through connector J11 PICK_1_DRV 3 1 PICK_2_DRV 4 2 24V 24V The Transport Sensors connect through connector J2 EXIT_SENS 1 2 EXIT_LED 3 4 DIV_GATE 5 6 DIV_LED 7 8 FEED 9 10 FEED_LED 11 12 TIM_DISK 13 14 TIM_DISK_LED 15 16 REJ_BIN_PRES 17 18 N C 19 20 N C 21 22 MOTOR ON 23 24 The pick 1 sensors c LMP1_DRV 1 2 GND 3 4 N C 5 6 CASS_LOW1 7 8 GND 9 10 NCR 5633 Currency Dispenser Service Manual GND 4242424242424 24 OS Q Q Q Q Q Q Q a Z Z aa 5V onnect through connector J3 N C PICK_SENS1 2 PICK_SENS1 1 GND N C 1 43 Dispenser Functional Description Connector Interfaces The pick 2 sensors connect through connector J4 LMP2_DRV 1 2 N C GND 3 4 PICK_SENS2 2 N C 5 6 PICK_SENS2 1 CASS_LOW2 7 8 GND GND 9 10 N C The pick 3 4 sensors connect through connector J4 CASS_ID3 1 1 2 GND CASS_ID3 2 3 4 PICK_SENS3 2 CASS_ID3 3 5 6 PICK_SENS3 1 CASS_ID3 4 7 8 GND GND 9 10 CASS_LOW3 LMP3_DRV 11 12 GND LMP4_DRV 13 14 GND CASS_ID4 1 15 16 CASS_LOW4 CASS_ID4 2 17 18 GND CASS_ID4 3
7. 19 20 PICK_SENS4 2 CASS _ID4 4 21 22 PICK_SENS4 1 GND 23 24 GND Pe Remote Diagnostics Connector is a 8 way dual 4 1 44 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Connector Interfaces 5V 1 2 uPTXD N C 3 4 uPRXD TEST RESET 5 6 LED1 GND 7 8 LED2 NCR 5633 Currency Dispenser Service Manual 1 45 Dispenser Functional Description Firmware Description 1 46 Firmware Description The firmware provides the facility to deliver bills from the currency cassettes to the cardholder This is a single stage operation that picks bills from the selected currency cassette and presenting them to the cardholder Command Comments Status Reports sensor and cassette related information for the top cassette Purge Attempts to clear the transport of bills Dispense Dispense notes from only the top cassette Test Dispense Picks and rejects notes from only the top cassette Reset Causes a firmware reset of the dispenser Last Status Reports the status of the last Dispense Test Dispense or Purge command Configuration Returns the current hardware and Status firmware configuration and whether or not this is a multi cassette dispenser Sensor Picks a bill from the top cassette and Diagnostics report its parameters Multi cassette Status Reports sensor and cassette related information for a multi cassette di
8. KEY GND NIAI Ot B amp N 24V The power connection is located as follows NCR 5633 Currency Dispenser Service Manual 2 5 Installation Power Connection 2 6 NCR 5633 Currency Dispenser Service Manual Installation Interface Connection Interface Connection The dispenser interface connector is positioned at the bottom of the control board It is a 25 way male D type connector NCR 5633 Currency Dispenser Service Manual 2 7 Installation Interface Connection The pin connections are as follows XRES 13 25 COMM _ID1 COMM_IDO 12 24 GND E1 11 23 COMM 51 GND 10 22 COMM 50 EO 9 21 DB N C 8 20 5V GND 7 19 DA N C 6 18 OOO CTS 5 17 LRTS RTS 4 16 LCTS RXD 3 15 LTXD TXD 2 14 LRXD N C 1 Pe This interface is designed to the EIA RS 232 C standard Electrical Connections The dispenser is configured as DTE data terminal equipment and uses a subset of the handshake circuits RS 232 C is the default interface if no selection or enable links are present The connector configuration for this interface is as follows Pin 1 SCRN Cable screen Pin 2 TXD Transmitted data FROM the dispenser Pin 3 RXD Received data TO the dispenser 2 8 NCR 5633 Currency Dispenser Service Manual Installation Interface Connection Pin 4 RTS Request to send FROM the dispenser This circuit will become active ON
9. NCR NCR 5633 Currency Dispenser Service Manual B006 0000 6086 01 00 00 Jan 1999 The product described in this book is a licensed product of NCR Corporation Trademark Information It is the policy of NCR Corporation NCR to improve products as new technology components software and firmware become available NCR therefore reserves the right to change specifications without prior notice All features functions and operations described herein may not be marketed by NCR in all parts of the world In some instances photographs are of equipment prototypes Therefore before using this document consult with your NCR representative or NCR office for information that is applicable and current To maintain the quality of our publications we need your comments on the accuracy clarity organization and value of this book Address correspondence to NCR Financial Solutions Ltd Kingsway West Dundee DD2 3XX UK Copyright 1999 By NCR Corporation Dayton Ohio U S A All Rights Reserved Canadian Class A Device Declaration Federal Communications Commission FCC Radio Frequency Interference Statement Note This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates
10. 10V when the dispenser is waiting to transmit Pin 5 CTS Clear to send TO the dispenser This circuit is made active by the host controller in response to an ON state on RTS The dispenser will only transmit after the CTS is active Deactivating CTS in the middle of a message will temporarily halt the transmission until both RTS and CTS become active again Pin 7 GRD Communications ground Pins 2 3 4 5 and 7 should be connected to their namesakes on a DCE data communication equipment interface If the RTS and CTS handshake option is not required pins 4 and 5 must be connected together The polled interface may be selected by linking pin 22 to pin 10 In this case the transmitter must be enabled by linking CTS to RTS pins 4 and 5 and a communications identity address must be selected using pins 12 24 and 25 Identity Pin 12 ID0 Pin 25 ID1 0 30H0 1 31H Pin 24 2 32H Pin 24 3 33H Pin 24 Pin 24 NCR 5633 Currency Dispenser Service Manual 2 9 Installation Interface Connection es The signal ground connection on pin 7 is connected to Electrical Characteristics of Interfaces 2 10 the dispenser ground via a 100 ohm series resistor If this causes unacceptable voltage loss pin 10 may be used instead This provides a direct connection to the dispenser ground but may reduce noise immunity The logic level interfaces are designed to use the standard TTL voltage threshold
11. B4 A4 E8 E8 128 5 04 B5 A4 E7 E8 129 5 08 B5 A4 E7 E8 130 5 12 B5 A5 E7 E7 131 5 16 B5 A5 E7 E7 132 5 20 B5 A5 E7 E7 133 5 24 B6 A5 E6 E7 134 5 28 B6 A5 E6 E7 135 5 32 B6 A6 E6 E6 136 5 36 B6 A6 E6 E6 137 5 40 B6 A6 E6 E6 138 5 44 B6 A6 E6 E6 139 5 48 A5 B5 E5 E5 140 5 52 A5 B5 E5 E5 141 5 56 A5 B5 E5 E5 142 5 60 A5 B5 E5 E5 143 5 64 A5 B5 E5 E5 144 5 68 A6 B5 E4 E5 NCR 5633 Currency Dispenser Service Manual 4 15 Maintenance Instructions Cassette Adjustments 4 16 Currency Length Note Guide E Spacer mm in L H R H L H R H 145 5 72 A6 B5 E4 E5 146 5 76 A6 B6 E4 E4 147 5 80 A6 B6 E4 E4 148 5 83 A6 B6 E4 E4 149 5 87 A7 B6 E3 E4 150 5 90 A7 B6 E3 E4 151 5 94 A7 B6 E3 E4 152 5 98 A7 B7 E3 E3 153 6 02 A7 B7 E3 E3 154 6 06 A8 B7 E2 E3 155 6 10 A8 B7 E2 E3 156 6 14 A8 B8 E2 E2 157 6 18 A8 B8 E2 E2 158 6 22 A8 B8 E2 E2 159 6 26 A9 B8 El E2 160 6 30 A9 B8 El E2 161 6 34 A9 B9 El El 162 6 38 A9 B9 El El 163 6 42 A9 B9 El El 164 6 46 A10 B9 E El 165 6 50 A10 B9 E El NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments Currency Length Note Guide E Spacer mm in L H R H L H R H 166 6 54 A10 B10 E 167 6 58 A10 B10 E 169 6 66 All B10 Nil E E 168 6 62 A10 B10 E E E E 170 6 70 All B10 NII
12. D mn l eee LE Belt A KD an rae o Kan ni in oO P Xe CX Pressure Pick Wheel Al Arm Line o Timing Marks Pick Wheel pe asher Pressure J B Wheel _L 59 Line NX Pick Wheel 4 Manually turn the drive pulley until timing mark D is aligned with the mark on the pump link as shown in detail C 5 Turn the pick wheel line until the cut away portion of the pick wheels face the front of the module and the leading edge of the pick wheels just touch the pressure wheels as shown in detail B 4 8 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Dispenser Adjustments 6 On the other side of the module align the notches in the pick wheel drive gear with the pin in the pick wheel line and slide it on the shaft being careful not to move the pick wheel and pressure wheel lines Replace the retaining clip 7 Repeat steps 3 to 6 for the lower pick module if fitted z If two pick modules are fitted this adjustment sets the Relative Timing of relative timing of the pick modules with each other Pick Modules 1 Onthe upper pick module rotate the drive pulley until the timing mark U is aligned with the pump link timing mark m Br LP Belt safe Puley AA moa P Ss Oy E potion Pump Link os Timing Mark pmp on Timing Mark Pump Link Lower Drive Cluster Upper Drive Cluster NCR 5633 C
13. uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications Le pr sent appareil num rique n met pas de bruits radio lectriques d passant les limites applicables aux appareils num riques de la classe A prescrites dans le R glement sur le brouillage radio lectrique dict par le minist re des Communications du Canada NCR 5633 Currency Dispenser Service Manual jii Me This equipment must be installed and used in strict Information to User Caution accordance with the manufacturer s instructions However there is no guarantee that interference to radio communications will not occur in a particular commercial installation If this equipment does cause interference which can be determined by turning the equipment off and on the user is encouraged to consult an NCR service representative immediately NCR Corporation is not responsible for any radio or television interference caused by unauthorised modifications of this equipment or the su
14. w Cassette pei S Four mechanical adjustments are provided Currency Width Currency length across the width of the cassette Currency width the internal height of the cassette Note low sensing two values Cassette identification code four values The note guides in the body of the cassette bear against spacer blocks known as E spacers These blocks have to be cut to certain lengths so that the note guides are supported the correct distance apart corresponding to the length of the currency being dispensed To simplify the task of fixing the position of the note guides the 4 12 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments currency length is translated into note guide and E spacer codes read off from the table given under the heading Currency Length Guide Codes and E Spacer Settings The codes correspond to markings on the floor of the currency compartment on the note guides themselves and on the E spacers Note Guides Currency Length A pair of note guides is marked with the letter A on one and B on the other The guides can be used in either the left or right position as shown in the following diagram This gives the full currency length range of e 120mm 4 72 in to 172 mm 6 77 in Nota Guide Note oe Nop Guide Note f Guide Mon The letters A and B in the columns of the code table tell you which guide has to be placed to the left and which to t
15. 2 Solenoid Output uPPICK_SOL2 P4 5 AC Motor Output uPDC_MOTOR P4 6 AC Motor Pulse uMOT_PULSE P4 7 N C P5 0 Pick Module 1 Sensor Input uPPICK_SENS1 P5 1 Feed Sensor Input uPFEED P5 2 Exit Sensor Input uPEXIT_SENS P5 3 Divert Gate Sensor Input uPDIV_POS P5 4 Pick Module 2 Sensor Input uPPICK_SENS2 P5 5 Reject Bin Present Sensor Input uPREJ_BIN_PRES P5 6 Pick Module 3 Sensor Input uPPICK_SENS3 P5 7 Pick Module 4Sensor Input uPPICK_SENS4 Ports P1 P3 and P4 are assigned as individual bits Outputs to these ports should therefore be performed as bit operations to avoid accidental corruption of other bits 1 30 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Control Board Reset puts all IO ports to input condition except P5 which is input only They are pulled high by internal pull ups Pe The memory mapping is performed by a 3 to 8 way Memory Map decoder for write and read signals The Memory Map is as follows Code Area Data Area FFFF Comms Config FFFF Inputs F000 Cassette ID 1 2 Inputs E000 Link 5 Switches D000 32K 64K Opacity Two Code Area Switches C000 Opacity One Switches B000 Opacity Four Switches A000 Opacity Three Switches 9000 Cassette ID 3 4 Inputs 8000 0000 32K Ram Area 0000 NCR 5633 Currency Dispenser Service Manual 1 31 Dispen
16. Dispenser Functional Description Control Board e LED1 P4 0 D4 e LED2 P4 1 D3 For these LEDs 0 switches a LED off and 1 switches a LED on Also the state of the Level 0 LEDs is indeterminate on power up 1 40 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Connector Interfaces Connector Interfaces MM Serial Input Connector J8 for interfacing the control Communications board to the Terminal This is a 25 way D type male Interface connector XRES 13 25 COMM_ID1 COMM_IDO 12 24 GND ET 11 23 COMM_S1 GND 10 22 COMM_SO EO 9 21 DB N C 8 20 5V GND 7 19 DA N C 6 18 OOO CTS 5 17 LRTS RTS 4 16 LCTS RXD 3 15 LTXD TXD 2 14 LRXD N C 1 Ms The Control Board receives power via a power Power connector J6 GND 1 5V 2 GND 3 NCR 5633 Currency Dispenser Service Manual 1 41 Dispenser Functional Description Connector Interfaces 5V KEY GND NS Ot BR 24V EE The Cassette 1 ID board connects through connector Dispenser Interface J10 CASS_ID1 1 1 CASS_ID1 2 2 CASS_ID1 3 3 CASS_ID1 4 4 GND 5 The Cassette 2 ID board connects through connector J9 CASS_ID2 1 1 CASS_ID2 2 CASS_ID2 3 CASS_ID2 4 O1 amp ND GND The divert solenoid connects through connector J1 24V
17. Each Pick Module 4 6 Relative Timing of Pick Modules 4 9 Main Motor Drive Belt Tension 4 10 Drive Segment Timing 4 11 Cassette Adjustments 4 12 Currency Length Adjustment 4 12 Note Guides Currency Length 4 13 E Spacer Currency Length 4 14 Guide and E Spacer Setting 4 14 Procedure 4 17 Example 4 18 Currency Width Adjustment 4 22 Currency Width Spacer Codes 4 23 Procedure 4 25 Example 4 26 NCR 5633 Currency Dispenser Service Manual Table of Contents Maintenance Instructions Matching Cassette Bodies And Lids 4 28 Note Low Sensing Adjustment 4 28 Cassette Identification Code 4 31 Magnet Marking and Position 4 31 Example 4 32 Preventative Maintenance 4 34 Pick Modules 4 34 Suction Cups 4 35 Currency Media Containers 4 35 Lubrication 4 36 Lubricant Type 4 36 General Instructions 4 36 Spray Module 4 38 Pick Module 4 38 Cassette 4 38 Cleaning 4 40 Replacing Dispenser Modules 4 41 Replacing the Control Board 4 41 Replacing the Spray Module 4 42 Replacing the Pick Module 4 42 Replacing Cassette Components 4 44 Special Tools 4 44 Cassette Body Components 4 45 Door Shutters 4 45 NCR 5633 Currency Dispenser Service Manual Table of Contents Maintenance Instructions Brushes Fingers and Magnetic Transfer Plates 4 46 Cassette Handle and Latch 4 48 Pusher Pawl 4 48 Separating the Cassette Base and Body 4 50 Pusher Springs 4 51 Cassette Base Components 4 51 Truck Door Assembly 4 52 Pusher Ratchet 4 52 N
18. High 4 High Cassette U28 U34 Type 1 U23 U25 Type 2 U25 Type 3 U17 Type 4 Note On a two high dispenser currency cassette types 3 and 4 can be used however the Set Opacities command must be used to configure the thresholds otherwise all notes will be rejected The Get Opacities command can be used to confirm the threshold s being used If the values have been configured using the Set Opacities command on either type of board then these will be stored in NVRAM and used in place of the values set on the switch packs NCR 5633 Currency Dispenser Service Manual 4 5 Maintenance Instructions Dispenser Adjustments Dispenser Adjustments This section describes the adjustments for the dispenser Me This sets the relationship of the pick arms to the pick Internal Timing of wheels Each Pick Module 1 If two pick modules are fitted remove the drive belt shown Belt _ _ 4 6 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Dispenser Adjustments 2 On the other side of the pick module remove the drive gears from the pick wheel lines as shown a O Pick Wheel ANO E 68 gt Drive Gear O O NCR 5633 Currency Dispenser Service Manual 4 7 Maintenance Instructions Dispenser Adjustments 3 Turn the pick wheel line in the upper or only pick module until the pick wheels are not touching the pressure wheels as shown in detail A Drive Ge WY Sam Y Pulley pE
19. Parts NCR 5633 Currency Dispenser Service Manual Replaceable Parts On Site Replacements On Site Replacements NCR recommends an on site replacement philosophy at a module level based on the expected failure rates For the 5633 dispenser the following parts are recommended to be replaced on site and then returned to a repair centre for rework NCR Part Number Description 445 0639532 Spray Module 120V F A 445 0639533 Spray Module 230V F A 445 0639534 Spray Module 120V R A 445 0639535 Spray Module 230V R A 445 0639237 Dispenser Control Board 445 0638138 Single Pick Unit 277 0009574 Vacuum Cup NCR 5633 Currency Dispenser Service Manual B 1 Replaceable Parts On Site Replacements B 2 NCR 5633 Currency Dispenser Service Manual Cut D NCR User Feedback Form Title NCR 5633 Currency Dispenser Service Manual Number B006 0000 6086 Release 01 00 00 Date Jan 1999 NCR welcomes your feedback on this publication Your comments can be of great value in helping us improve our information products You may send your comments electronically to the Information Products Department at Dundee See over for details Circle the numbers below that best represent your opinion of this publication Ease of use 5 4 3 2 1 0 5 Excellent Accuracy 5 43 2 1 0 4 Good Clarity 5 43 2 1 0 3 Adequate Completeness 5 43 2 1 0 2 Fair Organization 5 43 2 1 0 1 P
20. RS 232 port are tabulated below Mode From To Non Polled No Links Polled Pin 10 Gnd Pin 22 COMM _S0 Pin4 RTS Pin5 CTS E The transport mechanism is operated by an AC motor Actuator Outputs Control of this motor is handled by the 80C562 and a 1 34 NCR 5633 Currency Dispenser Service Manual sensor Inputs Dispenser Functional Description Control Board 7407 buffer The function of this signal is as follows a logic 0 on this port will cause the AC Motor to switch on The uMOT_PULSE signal must be pulsed to keep the motor running It retriggers a monostable circuit which would disable the motor after a short delay This is used as part of the anti runaway protection The Pick lamps are controlled by the PWM function in the microprocessor refer to Philips Data Sheet for 80C562 Micro processor for further details The divert solenoids are operated by a circuit which feeds full power to energise the solenoid and then feeds pulses of power to retain the solenoid The pick solenoids are hard fired There are three distinct Sensor inputs on the Control board Pick sensor double detect inputs Transport sensor Inputs and Cassette inputs Double Detect Sensors These consist of 2 lines that come from the pick sensors through analogue buffers and are fed to the microcontroller s A D inputs These are as follows Pick Sensor 1 P5 0 Pick sensor 2 P5 4 Pick Sensor 3 P5 6 Pick Sensor 4 P5 7
21. arm suction cups then hit and hold the end bill within the cassette Cassette Pick Wheels Pick Sensor e As the pick arms start to swing up and away from the cassette a bill is removed through the rear cassette separator from the cassette e The pick arms then swing up and away from the cassette to position the bill just above the pick wheels NCR 5633 Currency Dispenser Service Manual 1 19 Dispenser Functional Description Mechanical Description 1 20 e The picked bill is taken up between the pick and pressure wheels and fed into the transport section A Cassette Pressure Wheel Os Pick Arm TTN Bills A Bill Transport from Lower Casssettes As Fitted O w yy Pick Wheels Pick Sensor The above pick and feed operation repeats until the bill count of good bills at the pick sensor equals the number given by the dispense command Double Detect Sensor Each pick module carries one sensor which is mounted between the module pick mechanism and transport section The light source is a filament bulb and the detector is a photodiode This sensor detects bill opacity and width and enables the on board firmware to determine whether a picked bill is good or bad undersize oversize or a double NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Mechanical Description Detection of two bills having been picked together
22. by 4 Replacing the Spray Module Replacing the Pick Module screws 2 each side After fitting the new spray module ensure that the timing adjustments are correctly set The spray module needs to be removed first to gain access to the pick modules in a bottom mounted dispenser For top mounted dispensers the pick modules need to be removed from the bottom to gain access If there is only one pick module removing the spray module will allow the pick module to be replaced If there are two or more pick modules the pick modules need to be separated NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Replacing Dispenser Modules 1 Remove the drive belt linking the two pick modules 2 Remove the 8 screws 4 each side securing the two pick modules together Belt _ 3 Reassemble the dispenser with the new pick module 4 Replace the drive belt ensuring that timings are set NCR 5633 Currency Dispenser Service Manual 4 43 Maintenance Instructions Replacing Cassette Components Special Tools Replacing Cassette Components Two special tools are available to help in dismantling the cassette These simplify the disassembly and reduce the possibility of damage to components caused by the use of normal hand tools The tools are e The pusher pawl wedge Part No 445 0598365 e The cassette base dismantlin
23. depends on the reduced amount of light transmitted through the bills as compared to the inherent translucency of a single bill The degree of translucency or the amount of light that passes through a single bill is predetermined and a hexadecimal coded value for each cassette type When a bill passes between the lamp and the photo diode the intensity of the light detected by the sensor is amplified and converted into a digital voltage reading The processor then compares this reading with the hexadecimal value and determines whether the pick operation was successful or not If not the divert solenoid diverts the bill into the reject bin NCR 5633 Currency Dispenser Service Manual 1 21 Dispenser Functional Description Mechanical Description Cassette Low Sensor The cassette low sensor consists of a reed switch attached to the pick module keyplate The reed switch is held on a bracket which projects into the open door of the cassette It operates when a permanent magnet attached to the cassette currency pusher mechanism approaches the front of the cassette as the currency is dispensed In the plastic cassette the position of this magnet can be set in two positions to actuate the switch when 75 50 or 200 50 notes are left in the cassette 1 22 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Mechanical Description ee The spray module is mounted directly above the pick Spray Module module The m
24. e Critical Failures Inconvenience Failures An inconvenience failure is a failure which is inconvenient to the cardholder or ATM operator owner but does not prohibit use of the dispenser on a practical basis Reject Rate This is considered to be an inconvenience failure if the rate exceeds 1 5 of items dispensed Reject rate is specified as the number of rejected items divided by the total number of items dispensed while operating at average workload see section 8 0 Inconvenience Failure Rate This is specified as the number of inconvenience failures divided by the number of items dispensed stated as a decimal number NCR 5633 Currency Dispenser Service Manual A 3 Specifications Dispenser Specifications A 4 Types of Inconvenience Failure e Transaction correct but delayed in reaching the customer due to a malfunction such as a pick fail It is assumed that recovery has been achieved by adopting the highest level of error recovery provided by the module and operating system Failure Rate 11 5x 10 e Transaction incorrect due to a malfunction but has been detected and reported Failure Rate 3 0x 10 e Transaction incorrect due to a malfunction but has not been detected in the module Failure Rate 0 5x 10 6 Critical Failures A critical failure is a failure or combination of failures which renders the module unusable until that failure has been repaired or recovered through intervention
25. holding a bundle of approximately 100 notes in one hand and separating out with the other While separating out the currency should be checked for obvious defects such as e Adhesive tape on the surface of the currency Staples pins or any foreign matter attached to the currency Torn or limp notes with pin holes Two or more notes stuck together Corner folds straighten as required Folded notes New or uncirculated currency should be separated fanned out several times before loading into the cassette Any notes considered unacceptable should be removed To replenish the money in the currency cassette proceed as follows 1 Lift the catch on the right hand side of the currency cassette and pull the cassette out of the terminal NCR 5633 Currency Dispenser Service Manual 3 1 Operating Instructions Replenishing the Currency Cassettes 2 Push the cassette latch hasp down and then pull the bottom of the latch towards you 3 Lift the latch up a small amount Pull the top of the latch towards you then hinge it down 3 2 NCR 5633 Currency Dispenser Service Manual Operating Instructions Replenishing the Currency Cassettes 4 Raise the lid and applying slight pressure at the front of the lid to help disengage the tags remove the lid from the cassette base NCR 5633 Currency Dispenser Service Manual 3 3 Operating Instructions Replenishing the Currency Cassettes 5 Lift the pusher arms and
26. individual ATMs e Lower usage ATMs 150 dispense operations daily 1 bill per pick module per operation replace suction cups annually e Medium usage ATMs 250 dispense operations daily 2 bill per pick module per operation replace suction cups every six months e Higher usage ATMs 350 dispense operations daily 3 bill per pick module per operation replace suction cups every three months Ne Clean the purge bin and all cassettes including spare Currency Media cassettes both inside and out Containers Note Pay particular attention to the front door of the cassette NCR 5633 Currency Dispenser Service Manual 4 35 Maintenance Instructions Lubrication Lubrication This section describes the lubrication of the currency dispenser during component replacement The following lubricants are recommended Lubricant Type Lubricant Type A No 2 General Purpose Oil B Synthetic Lubricating Grease NCR Part No 009 0004618 100gm containers For No 2 General Purpose Oil any one of the following lubricants can be used e Shell Oil Co Donax T 6 e Mobil Oil Co Mobil ATF 220 e Exxon Oil Co ATF or Esso ATF Pe The following general instructions must be observed General Instructions Use clean lubricants from properly labelled containers 2 Satisfactory operation of mechanical components depends upon proper lubrication Follow the specific lubrication instructions in the following paragraphs in d
27. move the pusher to the rearmost position by pushing against the pusher LIFT DO NOT SQUEEZE 3 4 NCR 5633 Currency Dispenser Service Manual Operating Instructions Replenishing the Currency Cassettes 6 Latch the pusher in the rear position by applying gentle pressure near the base of the pusher then releasing the pusher arms 7 Align the edges of the notes in both planes by holding a bundle loosely between the fingers and thumbs of both hands and tapping lightly on a flat surface then tapping the note ends NCR 5633 Currency Dispenser Service Manual 3 5 Operating Instructions Replenishing the Currency Cassettes 8 It is recommended that the cassette be placed at an angle so that each note stack can be loaded without it falling over For example stand the cassette at an angle and against a wall as shown Load the notes into the cassette Note When loading the cassette alternate packs bundles of 100 notes as shown and make sure that any bowed notes are loaded with the bow towards the pusher 3 6 NCR 5633 Currency Dispenser Service Manual Operating Instructions Replenishing the Currency Cassettes 9 Continue loading until the required amount is loaded or an 11 6 in stack is loaded This maximum stack size is indicated by the maximum load point label on the inside of the cassette 10 Lift the pusher arms and push the pusher and the note stack upwards until the currency stack touches the front supp
28. of an acceptable quality 3 Slide the empty bin back into the terminal until it clicks in place 3 10 NCR 5633 Currency Dispenser Service Manual es _ _ _ Pick Module E Main Transport Operating Instructions Clearing Dispenser Jams Clearing Dispenser Jams The procedure for clearing a jam depends on where the jam is within the dispenser e The pick module e The spray module The jam can be at any of the cassettes present in the dispenser 1 Lift the catch on the right side of the currency cassette and pull the cassette out of the terminal 2 Reach inside the hole vacated by the cassette and remove any jammed bills 3 Push the cassette back into the dispenser until it latches into place 1 Look in the transport on top of the spray module to locate the jammed bill 2 Carefully remove the jammed bill from within the transport 3 Once the bill has been removed from the transport make sure that the transport belts are still located on top of the pulleys NCR 5633 Currency Dispenser Service Manual 3 11 Operating Instructions Clearing Dispenser Jams 3 12 NCR 5633 Currency Dispenser Service Manual Table of Contents Maintenance Instructions Chapter 4 Maintenance Instructions Calibrating the Dispenser 4 1 Preparation 4 1 Equipment 4 1 Currency 4 2 Running The Test 4 3 Determine Threshold 4 4 Configuring Opacity Threshold 4 4 Dispenser Adjustments 4 6 Internal Timing of
29. position If not the firmware terminates the operation with an error indication The firmware checks that the first specified cassette is not low on bills If this cassette is low on bills the firmware searches for another cassette of the same type search order is from the top cassette downwards If another cassette of the same type is found and is not low on bills it is used However if the cassette is also low on bills or another cassette is not found the first specified cassette is used The transport motor is switched on and the pick solenoid of the selected cassette is energized to provide vacuum to the pick mechanism suction cups The selected pick module picks a bill which is fed through the module pick sensor to the transport section As the bill passes through the pick sensor the sensor output is used to check that a single bill has been picked This is achieved by Measuring and comparing the bill opacity threshold with the relevant opacity value stored in RAM If four consecutive readings are below the threshold the bill is determined to be a double bill Detecting the leading and trailing edges of the bill to check the width of the bill against a fixed value maintained by the on board firmware If the bill is determined to be a double oversize undersize or an extra bill it is recorded as bad otherwise it is good The picked bill is transported through the count sensor to the divert gate If the bill
30. 171 6 74 All B11 Nil Nil 172 6 78 All B11 Nil NII Procedure The procedure for adjusting the cassette to currency length is as follows 1 Measure the length of the currency Read off the E spacer codes from the table Cut the E spacers Insert the E spacers in the cassette Put the note guides into the cassette Check that the triangular parts on the note guides point to the numbers on the floor of the cassette corresponding to the note guide codes NCR 5633 Currency Dispenser Service Manual 4 17 Maintenance Instructions Cassette Adjustments Example The following example adjusts the cassette for currency 120mm 4 72in long Proceed as follows 1 Measure the length of the new currency 120 mm 2 Refer to the code table and using the currency length read the guide code and the E spacer setting for the currency For 120 mm the left hand guide code is B3 and the right hand guide code is A3 The spacers have a setting of E9 for the left hand guide and E9 for the right hand guide 3 Move the pusher fully forward 4 Unscrew and remove the clamps securing the note guides to the cassette floor 4 18 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments 5 Slightly raise the rear end of the guide over the embossed numbers push the guide towards the rear and lift it out of the cassette Take care not to damage or bend the spring fingers 6 Unclip and remov
31. 25 Maintenance Instructions Cassette Adjustments Example This example adjusts the cassette for currency 67 mm 2 64 in wide 1 Open the cassette and remove the lid 2 Remove the two note guides from the lid by undoing the cross head screws from the Yellow spacers then remove the E spacers from the note guides 3 Remove the Yellow spacers from the lid by pressing in the two spring legs of each spacer then pushing them out of the lid 4 Measure the width of the new currency 5 Read the spacer codes for that currency width from the code table 6 Set four new Yellow and six new E spacers to their spacer codes For 67 mm the Yellow spacer should be set to C8 and the E spacer to E10 7 Put the spacers on a work surface so that you can read the letters and numbers embossed on their sides 8 The E spacers have the letter E and the numbers 1 to 15 embossed on them refer to the example given in the currency length adjustment The code E10 means that the E spacer is to be cut just above the number 10 Use a sharp knife to cut the six E spacers 4 26 NCR 5633 Currency Dispenser Service Manual 9 10 11 Maintenance Instructions Cassette Adjustments The Yellow spacers are embossed on one side with two sets of numbers 1 to 12 reading in opposite directions One end has the letter C on it and the other has the letter D see the illustration below For the code C8 you count from the C end and with a sharp knife cut the spa
32. 3 D6 E8 73 2 87 C6 E8 74 2 91 D5 E7 NCR 5633 Currency Dispenser Service Manual 4 23 Maintenance Instructions Cassette Adjustments A Yellow E Spacer RRI one Spacer Code Code 75 2 95 D5 E7 76 2 99 C5 E6 77 3 03 D4 E6 78 3 07 D4 E6 79 3 11 C4 E5 80 3 15 D3 E5 81 3 12 D3 E5 82 3 23 C3 E4 83 3 27 D2 E3 84 3 31 D2 E3 85 3 35 C2 E3 86 3 39 D1 E2 87 3 43 D1 Nil 88 3 46 C1 Nil 89 3 50 D Nil 90 3 54 Nil 91 3 58 C Nil 92 3 62 Nil 93 3 66 Nil 94 3 70 Nil 95 3 74 Nil NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments Yellow E Spacer Currency Width Spacer Code mm in Code 96 3 78 Nil 97 3 82 Nil 98 3 86 Nil 99 3 90 Nil 100 3 94 Nil Procedure Adjust the cassette for currency width as follows 1 Measure the width of the currency Read off from the table the codes for the E spacers and yellow spacers Cut six E spacers and four yellow spacers Put a locking wedge into the first gap in each of the yellow spacers Lubricate the wedge with soap to ease insertion Clip the yellow spacers into their locations in the cassette lid Screw three E spacers to each note guide Screw the note guides to the yellow spacers with the cut outs in the note guides facing out NCR 5633 Currency Dispenser Service Manual 4
33. 5 Bits 0 7 C000H Read function Opacity Configuration Switches Bank 2 U25 Bits 0 7 B000H Read function Opacity Configuration Switches Bank 1 U34 Bits 0 7 A000H Read function Opacity Configuration Switches Bank 4 U7 Bits 0 7 9000H Read function Opacity Configuration Switches Bank 3 U15 Bits 0 7 E000H Read Only Cassette ID 3 4 Sensor detect BIT 0 0 Cassette Three ID 1 Present 1 Cassette Three ID 1 Not Present BIT 1 0 Cassette Three ID 2 Present 1 Cassette Three ID 2 Not Present BIT 2 0 Cassette Three ID 3 Present 1 Cassette Three ID 3 Not Present NCR 5633 Currency Dispenser Service Manual 1 33 Dispenser Functional Description Control Board Region Allocation BIT 3 0 Cassette Three ID 4 Present 1 Cassette Three ID 4 Not Present BIT 4 0 Cassette Four ID 1 Present 1 Cassette Four ID 1 Not Present BIT 5 0 Cassette Four ID 2 Present 1 Cassette Four ID 2 Not Present BIT 6 0 Cassette Four ID 3 Present 1 Cassette Four ID 3 Not Present BIT 7 0 Cassette Four ID 4 Present 1 Cassette Four ID 4 Not Present EE The control board handles communication using the RS Communication Ports 232 protocol The communication protocol is selected by jumpers in the communications connector RS 232 Communication Port The signals for this communication port are implemented using buffers The strappings for the
34. 5 and EN 55022 Class A radiated and conducted limits within the following margins e Radiated emission margin 4dBuV m e Conducted emission margin 20dBuV QP IEC 1000 4 2 with the following test levels e Air discharge 8kV e Contact discharge 4kV AC Power 115VAC 10 5 5A RMS 20A surge 230V AC 10 3A RMS 10A surge NCR 5633 Currency Dispenser Service Manual A 1 Specifications Dispenser Specifications DC Power e 5V 45 1 5A e 24V 5 2A MM Mamun noise emission level 84dBA Accoustic Noise ee The weights of the component parts of the dispenser are Weight Basic unit empty media containers 17 5kg Currency cassette empty 3 2kg Currency cassette full 6kg Reject bin empty 0 37kg Reject bin full 0 41kg E The dimensions of the dispenser are Dimensions Width without mounting feet 300mm with mounting feet 330mm Height 1 cassette 310mm 2 cassette 445mm 3 cassette 580mm 4 cassette 715mm Depth 475mm Me The environment is specified as existing within the host Environment ATM A 2 NCR 5633 Currency Dispenser Service Manual Reliability Data Specifications Dispenser Specifications e Normal operating range Temperature Dry bulb 10 C to 50 C Change 10 C per hour maximum Dew point 26 C maximum Humidity Relative 20 to 80 Change 10 per hour maximum no condensation Reliability is expressed in terms of e Inconvenience Failures
35. 51 Appendix A Specifications Dispenser Sp CHIA TONER MN et A 1 CUFTENCY nn ne ete A 1 Reject BIN annees nus A 1 EME dental et eee A 1 ESD ann n nr a strate tee A 1 Power Requirements ss ae ae A 1 Accoustic Noise A 2 WV CIE erste esol sag et nad nEn A 2 Dimensions manne tet deeb a a A 2 Environment nes eeeheseer e A 2 Reliability Data teh casi nn Ver A 3 Appendix B Replaceable Parts On Site Replacements ss n nu B 1 NCR 5633 Currency Dispenser Service Manual Table of Contents User Feedback Form NCR 5633 Currency Dispenser Service Manual xi Table of Contents xii NCR 5633 Currency Dispenser Service Manual Ss Purpose Audience See Organisation About This Manual Preface Preface This manual contains the information required to maintain the 5633 Currency Dispenser It includes a functional description of the dispenser adjustment procedures calibration procedures internal cabling parts identification strapping details power requirements and mechanical installation in the host This manual is intended for design engineers who will be designing a host cabinet for the dispenser and for service engineers who will be maintaining the dispenser The manual is organised into five chapters and three appendixes as follows Chapter 1 Functional Description Containers description cassette identification security levels specification currency media path of notes through dispenser arra
36. CR 5633 Currency Dispenser Service Manual Table of Contents Maintenance Instructions NCR 5633 Currency Dispenser Service Manual EE Preparation Maintenance Instructions Calibrating the Dispenser Calibrating the Dispenser For proper operation of the currency dispenser the correct opacity setting must be configured correctly Otherwise there is a risk of dispensing double notes The following procedure shows how to determine the opacity thresholds and how to set them using the opacity switch packs The following must be available before commencing the calibration of the dispenser Equipment e Dispenser Power Supply PC loaded with the rework tool RS232 cable attached to PC and dispenser Currency Cassette configured for the notes under test e Thirty two notes made up as described below Configure the dispenser and the PC as described in the NCR 5301 Currency Dispenser Rework Support Tool User Guide Check the communications switch pack is set to the default values of switches 1 2 and 3 down with all others up The communication switch packs are U15 on the two high control board and U35 on the four high control board NCR 5633 Currency Dispenser Service Manual 4 1 Maintenance Instructions Calibrating the Dispenser 4 2 Currency Note It is important that the notes used are new notes since these are generally lighter than used notes Using used notes may result in an opacity threshold which is lowe
37. Cassette Adjustments set towards the handle of the cassette then it is set for the 200 note setting refer to the following figure To change the note low setting proceed as follows 1 Open the cassette and remove the lid NCR 5633 Currency Dispenser Service Manual 4 29 Maintenance Instructions Cassette Adjustments 2 Press the flaps of the note low block together until they touch then pull the block upwards and out of the pusher body 3 Turn the block around so that the pips face the opposite way then insert the block back into the pusher 4 30 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments 4 Press down firmly until the block clicks into place Me This section explains how to place the magnets on the Cassette Identification cassette to achieve the identification codes Code Magnet Marking and Position It is essential that the magnets are pointing in the correct direction therefore each magnet has a marked end a red dot to indicate which way round it should be installed in the housing Red Dot Red Dot NCR 5633 Currency Dispenser Service Manual 4 31 Maintenance Instructions Cassette Adjustments Note Early magnets were square section Both types are interchangeable The following table shows the location and orientation of the four magnets to produce the four cassette identification codes The magnet position in the table corresponds to the nu
38. Critical failure rate is the maximum number of design manufacture and user dependent critical failures that are allowable for a specified amount of items dispensed A Critical Failure is defined as the number of failures divided by the total number of items dispensed expressed as a decimal number The reciprocal of this number is the mean number of items dispensed between failures NCR 5633 Currency Dispenser Service Manual Specifications Dispenser Specifications The example shown below is for a 4 high dispenser at 24 hours per day and workload of 280 transactions a day with 2 5 items dispensed per transaction Transaction Related Time Related Mean Items Failure Rate per Mean Time Failure Rate Dispensed P Between Failures Annum Between Failure Hours 3 34 x 10 6 299 4 K 0 05 175k Total Failure Rate Transaction Related Time Related per Annum 0 853 0 05 0 903 e Reliability of other combinations can be calculated by addition of module failure rates as required Customer clearable failure rate will be 75 of total Service call failure rate will be 25 of total NCR 5633 Currency Dispenser Service Manual A 5 Specifications Dispenser Specifications A 6 NCR 5633 Currency Dispenser Service Manual Table of Contents Replaceable Parts Appendix B Replaceable Parts On Site Replacements B 1 NCR 5633 Currency Dispenser Service Manual Table of Contents Replaceable
39. General Description ccdaks eat seessnes 1 28 Hardware Overview ccccccssccssssessscescecsscecesseeensees 1 29 NCR 5633 Currency Dispenser Service Manual vil Table of Contents vil M MOrT MAD nn hs 1 31 LAON nn nn 1 32 Communication Ports 1 34 Actuator QutputS 4h ee ented nga enero Antone 1 34 S nsor PN PUB err annee i 1 35 User Configuration SWitches sesss 1 37 Reset Conditions ccccccccesecssscessscessecescecesseeeneees 1 39 Diap OSHC LEEDS eines ns brasse 1 39 Connector Interfaces 1 41 Communications Interface 1 41 POWER iis chiro O 1 41 Dispenser Interface siennes 1 42 Diagnostic Interface isc caisicaiseitaiesteemanmetet 1 44 Firmware Descriptions isa 1 46 The Dispense Operanonves Ses ni eine dent 1 48 Chapter 2 Installation Mounting Dispensers tentant 2 1 Power Conme Onnie a AR A R n A 2 5 Interface Connection cccccessseceseeessecessecessseesscecesseceseees 2 7 Electrical Connections cccccesceessceessecesecesseeeseeeees 2 8 Electrical Characteristics of Interfaces 0068 2 10 Chapter 3 Operating Instructions Replenishing the Currency Cassettes 3 1 Emptying the Purge Bin ssteesiec s eine tnt 3 10 Clearing Dispenser JamMs sels 3 11 NCR 5633 Currency Dispenser Service Manual Table of Contents Pick Module ss den aves 3 11 Mai Transporten a a 3 11 Chapter 4 Maintenance Instructions Calibrating the Dispenser ssasccissisnsianvcvoassnscecstaosrstanstonssn
40. Maintenance Instructions Lubrication ee b ricate as follows All plastic bearings before assembly with A Lubricate as follows Spray Module S Pick Module N e e o e o Drive segment inside hub pivot stud with A Gears turning on stationary stud on the stud in the bore with B Cam cluster bore and pivot stud with B Pick line bearing faces with B Pick line hub bearing surface with B Plastic bearings before assembly with A Cassette latch stud with B E ybricate the cassette as follows with B Cassette see the shaded parts of the illustrations below Base plastic moulding e Truck door guides and track e Lockout lever track e Door link track Door link both sides at lockout lever stud track Left and right hand door shutter springs sparingly Note The door shutter springs must be lubricated to prevent corrosion Be careful that no lubricant can be picked up by the currency 4 38 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Lubrication Truck Door Guides Truck Door Track Door Liink Track Lockout Lever Track Door Link
41. ation Products Kingsway West Dundee Scotland DD2 3XX O Cut
42. ble pick described where necessary Currency Cassette Guides and Latch The currency cassette rests on metal rails on the side frames of the pick module Upper plastic guides on the side frames and the spring loaded catch hold the cassette firmly in position Cassette Present and Identity Sensors A printed circuit board on the side of the pick module carries four eight on the double pick reed switches These switches are in close proximity to the inserted currency cassette and they are influenced by the magnetic fields of small permanent magnets in a housing on the side of the cassette One of the magnets is always kept in the same position so that it operates the reed switch SW1 in the single pick module SW1 for the upper cassette of the double pick module and SW5 for the lower cassette to produce a cassette present signal Switches SW2 SW3 and SW4 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Mechanical Description SW6 SW7 SW8 are actuated when magnets are present in the corresponding three position in the cassette The magnets can be moved within the housing or left out so that certain combinations of reed switches SW2 SW3 SW4 are operated This achieves a binary code which is used to identify the cassette as type 1 2 3 or 4 When the currency cassette is inserted into a pick module in any position in the dispenser it signals its identity via the reed switches The firmware i
43. bstitution or attachment of connecting cables and equipment other than those specified by NCR Such unauthorized modifications substitutions or attachments may void the user s authority to operate the equipment The correction of interference caused by such unauthorized modifications substitutions or attachments will be the responsibility of the user NCR 5633 Currency Dispenser Service Manual Revision Record Date Page Description of Change Jan 1999 All Initial release NCR 5633 Currency Dispenser Service Manual vi NCR 5633 Currency Dispenser Service Manual Table of Contents Contents About This Manual Pr face is ni AREA Ce ten xiii PULP OSC anse nn nn EEEE xiii DA DL D Lei a Le TT RE Te xiii Organisation ii eerie NS se xiii Related Information Products cccccsceesseceseeeeees xiv Chapter 1 Dispenser Functional Description Introduction is eiaeaen ea e nt dE aits 1 1 CONEAITIEES EREKET 1 2 The Cassette Lid cccccccccccsscssssecessecssseeeecesssecsseeeeaes 1 5 The Cassette Body ss iae a 1 5 The Cassette Bas nant ane nn sa nt 1 6 Cassette Operation inerte 1 7 P sh r Op ration ssh nn 1 8 Cassette Identification Code 1 9 Mechanical Deserip ton visiscvcsnccon nes icasonasteoonaavaaves 1 13 Path Of Notes 1 13 Pick Module naei itinira aaia nie 1 14 Spray VIO WIG icin Oh ice ees me 1 23 Control Board sy Gssccedaiscncservceieni AE AEA 1 28
44. cassette lid NCR 5633 Currency Dispenser Service Manual 4 33 Maintenance Instructions Preventative Maintenance ss Pick Modules Preventative Maintenance At each service call the Field Engineer should carry out cleaning tasks and check for wear on timing belts and moving parts Particular attention should be paid to the pick arm suction cups Note Vacuum the dust from all areas of the currency dispenser e Check that the reed switch housing is not cracked replace if necessary Note A note low condition may not be identified if the read switch housing is damaged e Inspect the pick lines for broken nozzles Replace the pick line if broken cracked or bent e Check and replace suction cups if necessary Read the Suction Cups section shown over e Check alignment and clean incandescent lamp and sensor e Inspect the dispenser for worn or broken gears Replace gears where necessary If gears are worn check that all circlips on the associated shaft are in place Lateral movement of shafts occur accelerating gear wear when circlips fall off e Lubricate the pick modules and check their mechanical adjustment refer to the LUBRICATION section in this chapter e Ensure pick modules are properly timed 4 34 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Preventative Maintenance Suction Cups The following information is provided as a guide to formulating replacement schedules for
45. cer just above the number 8 so that you are left with end C and segments 1 to 8 Flush the spacer surfaces by removing any burrs left after cutting Fit a locking wedge into the first gap in the cut yellow spacer see the following illustration 12 Install the four new Yellow spacers by pressing the legs of the spacer together and pushing them into the apertures in the cassette lid 13 Screw three new E spacers to each lid note guide 14 Screw the lid note guides to the yellow spacers on the lid make sure the cut outs on the note guides are facing out NCR 5633 Currency Dispenser Service Manual 4 27 Maintenance Instructions Cassette Adjustments Ne Prevent lids being put on bodies set for a different Matching Cassette currency by one of the recommended marking systems Bodies And Lids e Apply small stick on labels of the same colour to the lid and the body e Write the currency value in indelible ink on the interior surfaces of the lid and the body Pe The note low block provides the dispenser subsystem Note Low Sensing with an indication of a note low condition The block can Adjustment be set to give two note low settings e 75 50 notes e 200 50 notes The settings are indicated by spherical pips on the flaps of the block If the pips are towards the truck door end of the cassette it is set for the 75 note setting If the pips are 4 28 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions
46. ctrical Characteristics of Interfaces 2 10 NCR 5633 Currency Dispenser Service Manual Table of Contents Installation NCR 5633 Currency Dispenser Service Manual Installation Mounting Dispenser Mounting Dispenser The dispenser is designed to be mounted in a host ATM There are two methods of mounting the dispenser at the top or at the bottom Top mounting is achieved using four M6 screws two on either side of the dispenser There are two pairs of holes provided on each side but only one from each pair needs to be used to mount the dispenser NCR 5633 Currency Dispenser Service Manual 2 1 Installation Mounting Dispenser Left side mounting locations 2 2 NCR 5633 Currency Dispenser Service Manual Installation Mounting Dispenser Right side mounting locations NCR 5633 Currency Dispenser Service Manual 2 3 Installation Mounting Dispenser Bottom mounting is achieved using four M4 screws two on either side of the dispenser The dispenser is attached to its shipping pallet via these holes M4 Screws 2 4 NCR 5633 Currency Dispenser Service Manual Installation Power Connection Power Connection The power for the dispenser must conform to the following specification e AC Power 1 115VAC5 5A RMS 20A surge 230VAC 3A RMS 10A surge Live 1 Earth 2 Neutral 3 e DC Power 2 5V 5 1 5A 24V 5 2A GND 1 5V GND 5V
47. d Magnetic Transfer Plates The plastic mouldings of the right and left separator brushes retain the currency fingers and note low magnet transfer plates in position at the front of the cassette Remove these as follows 1 Open and remove the cassette lid 2 Open the truck door using a pick module keyplate 3 Hold the pusher back clear of the front of the cassette 4 Grasp the head of a separator brush between the thumb and forefinger and pull forward At the same time push down on the brush clip in the slot directly behind the brush bristles with a small screwdriver blade 4 46 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Replacing Cassette Components 5 The magnetic transfer plate and currency finger drop out as the brush comes clear of the cassette Note The currency fingers and magnetic transfer plates can be placed at either side but the brushes are right and left handed Replace the transfer plates and currency fingers in the cassette as follows 1 Turn the cassette upside down and support it on one hand using this hand to hold the pusher back 2 With your free hand put the magnetic transfer plate into its recess next to the pusher guide slot Use the fingers of your hand supporting the cassette to guide the transfer plate into place 3 Hang the currency finger on its location NCR 5633 Currency Dispenser Service Manual 4 47 Maintenance Instructions Replacing Casse
48. d the PC Load the cassette with the sixteen double bills at the front of the cassette and insert in the top pick module Run the rework tool by selecting the Hawk icon on the desktop or clicking on the Start Menu then Programs menu then Hawk From the main menu screen select the Single Denomination Option by pressing function key F1 or by clicking on the Single Denomination button Select sensor diagnostic command by pressing function key F6 or by clicking on the Sensor Diagnostic command button The dispenser will perform a divert gate test and also pick and purge a note The response reported on the screen displays the opacity value as a hex number and a decimal number in parenthesis after it along with the bill width and the divert gate timing Record the opacity value NCR 5633 Currency Dispenser Service Manual 4 3 Maintenance Instructions Calibrating the Dispenser EE Determine Threshold a O Configuring Opacity Threshold 6 Repeat for all doubles and record the opacity value from each command Note The above procedure is required to be performed for each denomination of currency to be dispensed Different denominations of notes must not be mixed in a cassette Take the highest value obtained from the sixteen doubles and add four to it This is now the opacity threshold value for that denomination only This value should be converted to an eight bit binary pattern to determine the opacity switch pack setting T
49. d timing belts It also drives the vacuum pump on each pick module NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Mechanical Description Motor Control Circuit The motor control circuits are located on the dispenser control board attached to the side of the dispenser NCR 5633 Currency Dispenser Service Manual 1 27 Dispenser Functional Description Control Board A General Description Control Board The Electronics are designed around the 80C562 Microprocessor which is a derivative of 80C51 architecture and technology The Control Board Electronics has to perform a number of distinct functions AC Motor Transport Pick Control Cassette Identification Divert Gate Sensors Comms This is based around the Philips 80C562 microcontroller full details of which can be found in the Philips Data Sheet for 80C562 Micro processor There is addressing available for up to 64K of code memory EPROM and 64K of Data memory SRAM This design uses 64K EPROM and 32K of SRAM residing in the lower half of the data area The board will also accept 32K EPROM s requiring a resistor jumper to be moved The EPROM contains Level 0 diagnostics and executable code The SRAM contains variables buffers and other data SRAM is battery backed A Level 0 diagnostic interface is implemented using 2 LED indicators on ports P4 0 P4 1 on the 80C562 The selection of memory mapped peripherals and ports is acc
50. dentifies each cassette and so is able to select the proper one for dispensing bills of a specific denomination Pick Module Keyplate When the cassette is inserted into the dispenser the prongs of the pick module keyplate enter the holes in its base The cassette door is pushed into the cassette base leaving the front open to permit the currency to be picked and dispensed Pick Action Each pick module carries one pick solenoid a vacuum pump and a pick mechanism The pick solenoid is energized to plug the air intake of the vacuum pump so that vacuum is applied to the suction cups The pick solenoid stays energized when multiple bills are picked from the same cassette In each pick cycle one bill is picked and fed into the transport mechanism In the case of failure to pick a bill the pick solenoid stays energized for an additional three or four cycles After the first failure to pick a search is made for another cassette of the same type which is not low on bills The search order is from the top cassette position downwards If the pick sensor has still not detected a bill the motor is turned off for approximately one second then another NCR 5633 Currency Dispenser Service Manual 1 17 Dispenser Functional Description Mechanical Description 1 18 pick attempt is made If this fails the motor is turned off for 10 seconds and one more attempt is made to pick a bill If no bill has been picked after three attempts of four or f
51. e the four E spacers from the base of the cassette Turn the two E spacers at the handle end of the cassette through 90 degrees before pulling upwards E Spacers 2 off L H Side 2 off R H Side NCR 5633 Currency Dispenser Service Manual 4 19 Maintenance Instructions Cassette Adjustments 10 11 12 Hold a new E spacer on a work surface so that the letter E and the numbers 1 to 15 can be read Use a sharp knife to cut the spacer just above the number 9so that you are left with a spacer that has the letter E and segments up to number 9 Cut three more E9 spacers see the following illustration to give you two for the right hand side and two for the left hand side Flush the spacer cut surfaces by removing any burrs left after cutting Snap in the four new E spacers in the correct positions in the floor of the cassette Insert the note guides back into the cassette hard against the E spacers Check that the pointers at either end of the guides are pointing at the code numbers for the new currency For this example the left hand guide B should be pointing at the number 4 20 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments 3 and the right hand guide A should also be pointing at the number 3 Refer to the following figure for an example of the left hand guide Triangular Indicator Set at 3 13 Screw in the note guide clamps until they are finger tigh
52. ens 4 1 Pr pa ao sens notons nus 4 1 Romaine The Tests ES Annee 4 3 Determine Threshold 4 4 Configuring Opacity Threshold ccceeeeeees 4 4 Dispenser AdSense des de nr 4 6 Internal Timing of Each Pick Module 000 4 6 Relative Timing of Pick Modules 4 9 Main Motor Drive Belt Tension 4 10 Drive Segment TIMIDE nine 4 11 Cassette Adjustments aici ac rcnn clean 4 12 Currency Length Adiistmient sts see 4 12 Currency WidiiAdjJustmentss ses 4 22 Matching Cassette Bodies And Lids 4 28 Note Low Sensing Adjustment c c cceeeees 4 28 Cassette Identification Code 4 31 Preventative Maintenance cccccsessscceceeesssesssteaeeeeens 4 34 Pick Modules unissent rise 4 34 Currency Media Containers ccccceee sees 4 35 Lubrication s ssl 4 36 E bricant T ype sen rs a nn 4 36 General Instructions 4 36 Spray Modes nent nn 4 38 Pick Module e ae aite alaa aa a aE 4 38 Cassette E E E T mnt nd 4 38 NCR 5633 Currency Dispenser Service Manual ix Table of Contents Cl anin ac ET RE DES TP RE tad 4 40 Replacing Dispenser Modules cccccseseseseseseseseeeseees 4 41 Replacing the Control Board 4 41 Replacing the Spray Module uu cceseeeeseeees 4 42 Replacing the Pick Module 4 42 Replacing Cassette Components 4 44 Special Folie ant messe 4 44 Cassette Body Components num 4 45 Cassette Base Components unis 4
53. etail 3 Avoid excessive lubrication Apply only that amount which will provide a thin coating on the entire bearing area or surface unless otherwise specified 4 36 NCR 5633 Currency Dispenser Service Manual Caution 10 Maintenance Instructions Lubrication All parts to be lubricated must be free from dust corrosion and metal chips Lubricate bearing areas and surfaces during assembly unless conditions caused by subsequent handling are detrimental for example accumulation of chips grit and so on to the proper operation of the part In those cases lubrication should be applied after assembly Apply lubricants using the most convenient method when none is specified that is by brushing dipping or oil can Spraying is not recommended Lubricate all spring hooks and spring studs with lubricant B Working clipped or riveted assemblies should not be lubricated before riveting but only after all processes handling or storage involving exposure to dirt or serious atmospheric contamination are past On assemblies that have shafts on which one or more moving parts are assembled lubricate both the shaft and the hub areas on each part with the specified lubricant Lubricants can cause serious deterioration of rubber Avoid contamination of drive belts and drive rolls Make sure that no lubricant spills on to the teeth of gears as this may impair their performance NCR 5633 Currency Dispenser Service Manual 4 37
54. g a slot in the bottom of the body to push the currency stack to the front of the cassette into the pick position The currency stack is held between the left and right hand note guides which adjust to suit currency of different lengths The front ends of the note guides have spring fingers which help to separate the notes as they are picked from the stack Incorporated in the pusher is the note low block magnet which operates a reed switch in the pick module This magnet can be set to two settings A housing on one side of the cassette body contains four magnets which again operate reed switches on the pick module to signal the cassette identification code Also in the body compartment are the left and right spring loaded door shutters the currency separator brushes and fingers On the outside of the body are the lid latch and cassette carrying handle the projecting lug which is used to latch the cassette into the pick module and the embossed cassette identification code label NCR 5633 Currency Dispenser Service Manual 1 5 Dispenser Functional Description Containers Me The illustration below shows the components inside the Door Link
55. g fixture Part No 445 0589012 Orders for each item should be directed in the normal manner to e Domestic WSPC Peachtree City Georgia e International Service Parts Distribution Centre Nobel Road Dundee Scotland Additionally to carry out the following dismantling procedures you will require a pick module keyplate 4 44 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Replacing Cassette Components PN The following illustration shows the components of the Cassette Body Components cassette body with the base removed The only components of the body which require you to remove the base are the pusher springs Separator Magnetic Transfer Door Shutter Brush Plates Ei ss RARE ALLA tL SAA USANA NAY AAAA ana aes THE Door Shutter Fingers Pusher Pusher Base Spring Door Shutters The left and right truck door shutters are removable when the truck door is open 1 Open and remove the cassette lid 2 Open the truck door using a pick module keyplate 3 Unclip the flat metal springs of the door shutters and slide the shutters back out of their tracks Note The shutters and their tracks are marked R H right hand and L H left hand NCR 5633 Currency Dispenser Service Manual 4 45 Maintenance Instructions Replacing Cassette Components Brushes Fingers an
56. hanged so that for example the dispenser will dispense two different denomination notes from the four cassettes that is with two cassettes set to Code 1 and two to Code 2 1 10 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Containers The identification code of a cassette is set by up to four magnets contained in a plastic housing attached to the cassette side frame by a clip as shown in the following figure The cassette has space in the plastic housing for six magnets positions A B 1 2 3 and 4 but only four positions 1 2 3 and 4 are currently used The magnets interact with four reed switches located on a printed circuit board attached to the frame of the dispenser pick module associated with the cassette location in the dispenser subsystem The four reed switches have the following functions e Depending on whether a magnet is installed or not and the orientation of the magnet in positions 2 3 and 4 three of the reed switches provide a code representing the cassette identification number e The magnet in position 1 interacts with the fourth reed switch to provide another code that indicates to the currency dispenser subsystem that the cassette is present NCR 5633 Currency Dispenser Service Manual 1 11 Dispenser Functional Description Containers 1 12 Cassettes of any type can be placed in any pick module The dispenser identifies each cassette by the interaction of magnets on
57. he right The number 1 to 12 after the letter corresponds to the numbers embossed on the floor of the currency compartment at front and back A triangular pointer at the front of the note guide and a triangular mark at the rear should line up with the same number as given in the look up table Note The spring fingers on the note guide are at the front truck gate end NCR 5633 Currency Dispenser Service Manual 4 13 Maintenance Instructions Cassette Adjustments E Spacer Currency Length The spacer shown in the following figure is embossed on one side with the letter E and the numbers 1 to 15 and is known as the E spacer The E spacer is designed to snap in to position without the use of tools The E spacer codes in the table tell you where to cut the two right hand and two left hand E spacers You cut off the segments with higher numbers than the code The procedure and example given after the code table should make this clear Guide and E Spacer Setting Currency Length Note Guide E Spacer mm in L H R H LH R H 120 4 72 B3 A3 E9 E9 121 4 76 B3 A3 E9 E9 122 4 80 B3 A3 E9 E9 123 4 84 B4 A3 E8 E9 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments Currency Length Note Guide E Spacer mm in L H R H L H R H 124 4 88 B4 A3 E8 E9 125 492 B4 A4 E8 E8 126 4 96 B4 A4 E8 E8 127 5 00
58. his is the pattern that should be set on the switch pack where there is a binary 0 the switch should be off up and where there is a binary 1 the switch should be on down The least significant bit on the switch pack is switch 1 and the most significant bit is switch 8 The switches are numbered on the switch pack as 1 to 8 and switch 1 is at the bottom of the switch pack when the board is mounted on the dispenser For example The opacity threshold for US dollars is ODH 1339 When expressed as a binary pattern this is 00001101 This results in a switch pack setting of switches 1 3 and 4 on and all others off The opacity threshold is configured by setting a switch pack on the dispenser control board The correct switch pack to set is determined by the following rules 4 4 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Calibrating the Dispenser e Ifthe dispenser is being used as a De La Rue replacement with only the standard Single Denomination Dispense commands being used then switch pack for type 1 is always used With these commands notes are only dispensed from the top pick module and any other cassettes are ignored The switch packs used on the two and four high boards are 2 high U28 4high U34 e Ifthe extended multi cassette command set is used the switch packs always refer to the cassette type The switch packs used on the two and four high boards are 2
59. hree ID 4 BIT 4 Cassette Four ID 1 BIT 5 Cassette Four ID 2 BIT 6 Cassette Four ID 3 BIT 7 Cassette Four ID 4 he main processor has 5 banks of 8 switches for setting User Configuration Switches a user configuration These switches are defined as follows Opacity Opacity Configuration Switches Bank 1 U34 SW 1 SW8 Bits 0 7 BOOOH Opacity Configuration Switches Bank 2 U25 SW 1 SW8 Bits 0 7 CO00H Opacity Configuration Switches Bank 3 U15 SW 1 SW8 Bits 0 7 COO0H Opacity Configuration Switches Bank 4 U7 SW 1 SW8 Bits 0 7 C000H NCR 5633 Currency Dispenser Service Manual 1 37 Dispenser Functional Description Control Board 1 38 The default opacities are read from the four opacity switch packs on the control board The value is read as a hex byte with switch 1 the switch closest to the edge of the control board providing the least significant bit and switch 8 the switch furthest from the edge of the control board providing the most significant bit An opacity setting of 0 on the switchpack that is all switches up will cause all bills to be accepted as single bills An opacity value greater than 80H that is switch 8 down will cause all bills to be rejected as doubles Note If the opacity settings on the switchpack for cassette type 1 is set to FFH that is all the switches down then the NVRAM on the control board will be re initialised The settings should then be set
60. is NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description The Dispense Operation Good the divert solenoid is energized to pass the bill through the exit sensor to the customer access tray The solenoid remains energized as long as good bills are sensed Bad the solenoid de energizes to pass the bill through to the reject bin overfill sensor to the reject bin e As the picked bill travels through the dispenser its passage is monitored by the pick count reject bin overfill and exit sensors These sensors control the following jam timers Time under pick sensor Time from pick sensor to count sensor Time under count sensor Time from count to reject overfill Time under reject overfill sensor Time from count to exit sensor Time under exit sensor If any predetermined bill passage time is exceeded a jam is deemed to have occurred and the operation is terminated with an error indication e The process of picking bills is repeated until the bill count of good bills at the pick sensor equals the dispense command bill count e Astatus message is transmitted to the host ATM NCR 5633 Currency Dispenser Service Manual 1 51 Dispenser Functional Description The Dispense Operation 1 52 NCR 5633 Currency Dispenser Service Manual Table of Contents Installation Chapter 2 Installation Mounting Dispenser 2 1 Power Connection 2 5 Interface Connection 2 7 Electrical Connections 2 8 Ele
61. its side with four reed switches on each pick module Cassette types are identified in the following way Front of Cassette Reed Switches Rear of Cassette door end S1 S2 3 S4 handleend 0 0 1 1 Cassette type 1 0 1 1 0 Cassette type 2 0 1 0 1 Cassette type 3 0 0 0 0 Cassette type 4 Magnet present switch contacts made 0 Magnet present switch contacts open 1 More than one cassette of a particular type can be installed The dispenser treats all cassettes with the same type as one logical cassette Selection order is from the uppermost pick module downwards NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Mechanical Description Mechanical Description The dispenser consists of from one to four pick modules beneath a spray module In the following description the components are described in the order they are encountered by notes passing through the dispenser The path of notes through the dispenser is shown in the Path Of Notes following diagrams Front access dispenser path of purge notes present position of stack 3 E OOZ o cal o o o o Omg Le a o i O o o o 2T 1 purge Alo as ne he JS ee 2 currency currency cassette NCR 5633 Currency Dispenser Service Manual 1 13 Dispenser Functional Description Mechanical Description Rear access dispenser path of purge notes
62. ive pick cycles a status code identifying the pick failure is sent to the host ATM Vacuum Pump Each vacuum pump has two functions e To provide vacuum to the suction cups for picking a bill e To provide an air blast to blow the dust off the pick sensor AIR BLAST VACUUM VACUUM HOSE VACUUM HOSE AIR OUTLET PUMP OUTLET VACUUM LINE DRIVE spring PUMP VACUUM PICK SEGMENT SEGMENT PLUNGER PLUG SOLENOID Vacuum is applied to the suction cups when the pick solenoid is energized and the air intake to the pump is plugged During the forward stroke the pump plunger is spring driven which allows for reserve vacuum capacity in case of a minor leakage in the vacuum line When the required vacuum capacity is reached the spring flexes and the pump plunger does not move any further Also during the forward stroke a small jet of air is blown on the pick sensor to avoid the accumulation of dust NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Mechanical Description Pick Mechanism Operation After receipt of a valid dispense command the divert module transport motor energizes to drive all the dispenser transport sections and swing the pick arms back and forth The following pick operation occurs at the selected pick module e As the pick arm suction cups are about to hit the cassette mounted bills the pick solenoid energizes and the vacuum pump operates to apply vacuum to the suction cups e The pick
63. k Module 1 14 Functions of the Pick Module 1 15 Currency Cassette Guides and Latch 1 16 Cassette Present and Identity Sensors 1 16 Pick Module Keyplate 1 17 Pick Action 1 17 Double Detect Sensor 1 20 Cassette Low Sensor 1 22 Spray Module 1 23 Transport Belts and Sensors 1 23 Transport Sensors 1 25 Main Timing Disk 1 25 NCR 5633 Currency Dispenser Service Manual Table of Contents Dispenser Functional Description NCR 5633 Currency Dispenser Service Manual Feed Sensor 1 26 Exit Sensor 1 26 Purge Bin Location Components 1 26 Divert Gate 1 26 Main Motor 1 26 Motor Control Circuit 1 27 Control Board 1 28 General Description 1 28 Hardware Overview 1 29 Memory Map 1 31 I O Map 1 32 Communication Ports 1 34 RS 232 Communication Port 1 34 Actuator Outputs 1 34 Sensor Inputs 1 35 Double Detect Sensors 1 35 Transport sensors 1 35 Cassette sensors 1 36 User Configuration Switches 1 37 Opacity 1 37 Configuration 1 38 Reset Conditions 1 39 Diagnostic LEDs 1 39 Connector Interfaces 1 41 Communications Interface 1 41 Power 1 41 Dispenser Interface 1 42 Diagnostic Interface 1 44 Table of Contents Dispenser Functional Description Firmware Description 1 46 The Dispense Operation 1 48 NCR 5633 Currency Dispenser Service Manual Table of Contents Dispenser Functional Description NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Introduction Introduction The 5633 dispenser presen
64. mbers 1 to 4 moulded into the plastic inside the housing Magnet Position Cassette Type Le 9514 E xX 2 E 3 Be D x Note1 X magnet inserted 0 magnet not present Note 2 The bar above or below the X indicates whether the magnet should be placed in the housing with the marked end up or down respectively Note 3 Although seven binary codes are possible with the three positions of magnets those shown are the only ones recognized by the dispenser subsystem Any other code set in will not be identified Example When it is required to change the identification code of a cassette for example a cassette set to code 1 to code 3 so that two cassettes can dispense notes of the same denomination perform the following procedure 1 Open and remove the cassette lid NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments 2 Release the clip holding the plastic housing to the cassette side frame and remove the plastic housing complete with the magnets from the cassette 3 Remove the magnet from position 2 4 Replace the magnet in the housing in position 3 with the red dot facing down to set the cassette code to type 3 There should be no magnets in positions 2 and 4 5 Attach the housing complete with the magnets to the cassette frame using the clip released in step 1 The housing should be inserted with the longer of the two legs towards the handle end of the cassette 6 Close the
65. ng pressure to keep the stack of currency in position The pick line has an eccentric motion which tends to push the currency stack back into the cassette against the action of the pusher It is to permit this to and fro motion that the ratchet lever disengages from the pusher when the cassette is in the dispenser When the pusher moves close to the front of the cassette the magnet in its base comes alongside metal plates under the floor of the currency compartment These plates strengthen the magnetic field and transfer it to operate a reed switch on the pick module keyplate This switch signals that the currency in the cassette is running low Removal of the cassette from the dispenser automatically closes and latches the front door and the interior of the cassette can only be reached by opening the top access lid The ratchet is raised by the action of the door closing and is again in a position where it will engage with the pusher pawl In this way the pusher is locked close to the currency stack so that the currency is held in place while the cassette is being carried To load currency into the cassette the pusher is manually moved fully to the rear and locked until the currency is put in It is then released against the back of the currency stack to keep it under pressure You move the pusher by lifting the pusher pawl arms sliding it to the rear and then holding it in that position while lowering the arms 1 8 NCR 5633 Currency Dispense
66. ngement of sensors power up reset initialisation and opacity detection Chapter 2 Installation How to mount the dispenser in a host strapping details and calibration procedures Chapter 3 Operating Instructions How to load cassettes into dispenser and clearing jams Chapter 4 Maintenance Instructions Calibrating procedures adjustment procedures interpreting level 0 diagnostics preventative NCR 5633 Currency Dispenser Service Manual xiii About This Manual Preface maintenance procedures and module replacement procedures Appendix A Specifications Detailed specifications for the dispenser environmental physical dimensions media weight power supply interface and cabling EMC Appendix B Replaceable Parts Provides a list of the recommended parts to replace on site ee CR 5031 Currency Dispenser Rework Support Tool User s Related Information Products XIV Guide B006 0000 6049 This guide provides information on the rework test tool that is required to calibrate the dispenser It also contains details on spare parts NCR 5633 Currency Dispenser Service Manual Table of Contents Dispenser Functional Description Chapter 1 Dispenser Functional Description Introduction 1 1 Containers 1 2 The Cassette Lid 1 5 The Cassette Body 1 5 The Cassette Base 1 6 Cassette Operation 1 7 Pusher Operation 1 8 Cassette Identification Code 1 9 Mechanical Description 1 13 Path Of Notes 1 13 Pic
67. odule houses the reject bin and carries the following major assemblies Reject bin present switch Transport motor and transport section Count sensor Divert gate solenoid a two position divert gate and divert gate position sensors The spray module caters for the longest width notes and utilizes an induction motor A constant transport drive speed is obtained by using different sized drive pulleys Transport Belts and Sensors The following diagrams show the belt and transport sensor arrangements for spray module The numbers allocated to the sensors appear in the control board signal names NCR 5633 Currency Dispenser Service Manual 1 23 Dispenser Functional Description Mechanical Description Front access dispenser feed sensors exit sensors purge bin pick sensor double detect currency currency cassette 1 24 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Mechanical Description Rear access dispenser exit sensor divert feed sensor purge bin sensor detect currency currency cassette Transport Sensors On the way along the transport the progress of the stack of bills is monitored by infra red sensors and their related LEDs In the dispenser the number of sensors is the same for front and rear access versions Main Timing Disk The main timing disk pulley is driven by toothed belt from the main motor Thirty si
68. omplished by a 3 to 8 way decoder The mapped devices consist of buffers used to interface to various 1 28 NCR 5633 Currency Dispenser Service Manual Hardware Overview Dispenser Functional Description Control Board Sensors Comms Control hardware diagnostic switches and user switches The 80C562 processor operates at a clock frequency of 14 7456 MHz The processor has its integrated IO ports assigned as follows Port Assignment P0 0 P0 7 Multiplexed Low Address Data Bus D0 7 P2 0 P2 7 High Address Bus A8 15 P1 0 Exit Sensor Input uPEXIT_SENS P1 1 Feed Sensor Input uPFEED P1 2 Divert Position Sensor Input uPDIV_POS P13 Pick 3Solenoid Output uPPICK_SOL3 P1 4 Timing Disk Sensor Input uPTIM_DISK P1 5 Connected to P1 6 pulled high P1 6 Connected to P1 5 pulled high P1 7 Pick 4Solenoid Output uPPICK_SOL4 P3 0 Serial Comms Receive uPRXD P3 1 Serial Comms Transmit uPTXD P3 2 N C P3 3 Timing Disk Sensor Input uPTIM_DISK P3 4 Serial Comms Clear to Send uPCTS P3 5 Serial Comms Ready to Send uPRTS P3 6 Data memory Write Strobe WRb NCR 5633 Currency Dispenser Service Manual 1 29 Dispenser Functional Description Control Board Port Assignment P3 7 Data memory Read Strobe RDb P4 0 LED Indicator 1 P4 1 LED Indicator 2 P4 2 Divert Solenoid Output uPDIV_SOL P4 3 Pick 1 Solenoid Output uPPICK_SOL1 P4 4 Pick
69. oor Appearance 5 4 3 2 1 0 0 Not Applicable Examples 543210 Illustrations 5 A amp A 3 2 10 Job performance 543210 Question resolution 543210 Overall satisfaction 543210 Indicate the ways you feel we could improve this publication Q Improve the table of contents Q Add more better quick reference aids Q Improve the overview introduction Q Add more examples Q Improve the organization Q Add more illustrations Q Improve the index Q Add more step by step procedures L Make it less technical Q Add more troubleshooting information Q Make it more concise brief L Add more detail Write any additional comments you may have below and on additional sheets if necessary Include page numbers where applicable Fold Use the following addresses to send your comments electronically to the Information Products Department at Dundee WWW http www ncr com product infoprod dundeeip e mail Information Products Dundee ncr com If we may contact you concerning your comments please fill in the information below Name Organisation Company Address Phone Fax Thank you for your evaluation of this publication Fold the form where indicated tape please do not staple affix stamp and drop in the mail F8763 0695 eles a Eerie En uel Se ete eee EE Le us rate eee ONE de dE tte etre ere etes ee ES ae Me te US dre NCR NCR Financial Systems Ltd Inform
70. ort then release the pusher arms The NCR 5633 Currency Dispenser Service Manual 3 7 Operating Instructions Replenishing the Currency Cassettes currency should remain between the front support and the pusher in an upright position neatly stacked between the cassette guides ne 11 Insert the tongues on the cassette lid into the slots in the cassette base as shown and then lower the lid on to the cassette base 3 8 NCR 5633 Currency Dispenser Service Manual Operating Instructions Replenishing the Currency Cassettes 12 Lift the latch up and forward until it hooks on to the lid latch block rs Ty TA A 7 k Sy VY We 13 Pull the latch down and forward until it clicks into the locked position 14 If required seal latch 15 Push the refilled cassette firmly into the dispenser until it clicks into place NCR 5633 Currency Dispenser Service Manual 3 9 Operating Instructions Emptying the Purge Bin Emptying the Purge Bin To empty the purge bin proceed as follows 1 Lift the latch on the left hand side of the currency purge bin and then pull the bin out of the terminal 2 Remove the purged currency from the bin Note that this currency is still classed by the terminal as being available to the customer Unless the currency is damaged or of poor quality it should be replaced in the cassette for dispensing Damaged or poor quality notes should be replaced by notes
71. ple tool to be used to open the cassette Reject currency is diverted to the purge bin in the dispenser The purge bin is provided with open security Both the currency cassettes and the purge bin remain seal fast secure when the ATM is opened The cassettes are moulded in high impact polycarbonate in three major parts the lid the body and the base NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Containers Cassettes adjust to hold the range of sizes of bills dispensed by the currency dispenser Minimum Maximum Width Length Width Length 65mm 120mm 95mm 172mm 2 56in 4 72in 3 74in 6 77in NCR 5633 Currency Dispenser Service Manual 1 3 Dispenser Functional Description Containers The illustration shows the open currency cassette looking from the rear handle end towards the front truck door end Lid Spacers Currency Length Note Guide Cassette Door Body Shutter Pusher Pusher Pawl Cassette ID Code Magnet Housing Cassette Na Note Low Base X Block NCR 5633 Currency Dispenser Service Manual ca ary The Cassette Lid ae A The Cassette Body Dispenser Functional Description Containers The lid hooks into locating slots at the front of the body and is latched at the rear It holds note guides and spacers which adjust to suit currency width The cassette body holds the currency It contains a spring loaded pusher mechanism which moves alon
72. ponents Truck Door Assembly Unhook the truck door assembly from the ratchet slide and lift it out of the base Pusher Ratchet Remove the pusher ratchet mechanism as follows 1 Lift out the rubber bumper at the rear of the base Push the lower slide to the rear while holding the top ratchet until the slide projects about 4 mm 0 16in from the rear of the ratchet Lift the ratchet from the front and remove Pull the slide out of the base towards the front NCR 5633 Currency Dispenser Service Manual Table of Contents Specifications Appendix A Specifications Dispenser Specifications Currency Reject Bin EMC ESD Power Requirements Accoustic Noise Weight Dimensions Environment Reliability Data Inconvenience Failures Critical Failures NCR 5633 Currency Dispenser Service Manual A 1 A 1 Table of Contents Specifications NCR 5633 Currency Dispenser Service Manual Currency Reject Bin es Q ESD Power Requirements Specifications Dispenser Specifications Dispenser Specifications The dispenser is capable of dispensing new or used currency of the follwing dimensions Minimum Maximum Width 65mm 2 56in 95mm 3 74in Length 120mm 4 72in 172mm 6 77in Thickness 0 06mm 0 002in 0 26mm 0 01in Tolerance on bill dimensions is 2mm 0 078in Cassette capacity up to 295mm of new or used 11 61in bills Capacity of 50 bills FCC CFR47 part 1
73. r Service Manual Dispenser Functional Description Containers so that the pusher pawl engages with the ratchet There is one locking detent on the extreme rear end of the ratchet Caution Lift the pusher pawl arms do not squeeze LIFT DO NOT SQUEEZE 4 2 E Fach currency cassette shipped with a dispenser is set Cassette Identification with a code that can be read by the dispenser software so Code that the cassette can be identified regardless of its position in the dispenser The software matches the cassette code to a specific denomination of currency Cassettes with the same code will be loaded with notes of the same value NCR 5633 Currency Dispenser Service Manual 1 9 Dispenser Functional Description Containers The cassette can be identified by writing the currency denomination on the inside or outside of both the body and lid using an indelible ink pen e A Colour coded stick on labels 10 mm x 15 mm 0 4 in x 0 6 in approximately e B Numerics for denoting cassette identification type e C Recessed areas for either marking with indelible ink pens or for attaching adhesive labels to denote currency denomination etc at the discretion of the financial institution e D Alphas for denoting additional cassette identification types or for same use as B The cassettes provided with the four position dispenser are each set to a different code that is Code 1 Code 2 Code 3 and Code 4 These can be c
74. r than a value which new notes can give The opacity thresholds must be performed for each denomination of the currency to be dispensed Different denominations of notes must not be mixed in a single cassette Also different issues of a denomination may be different physical parameters and they must not be mixed if the opacity values are different It is necessary to prepare doubles using all possible com binations of note orientation Since each note can be ori ented in four different positions within the cassette the total number of combinations is sixteen To prepare all of these combinations first layout sixteen single notes in the orientations shown in layer 1 then add a second layer of single notes in the orientations shown in layer 2 This will produce the required sixteen different orienta tions of doubles These should be taped together along the leading edge with a gap at the middle where the note passes over the pick sensor Layer 1 A B C D A B C D Layer 2 A A A A B B B B Layer 1 A B C D A B C D Layer 2 C C C C D D D D NCR 5633 Currency Dispenser Service Manual Se Running The Test Maintenance Instructions Calibrating the Dispenser Where Front Side Up Correct orientation Front Side Up Opposite orientation Reverse Side Up Correct orientation DAS Reverse Side Up Opposite orientation Power on the dispenser an
75. rew in pins end A Base B Locating dowels C Front screw pins D Rear push_pins 6 Check that the front screw pins and rear push pins enter the snap in features on both sides of the base near each corner under the external guide 4 50 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Replacing Cassette Components 7 Screw in the two front pins until the body of the cassette parts from the base 8 Push in the two rear pins while pushing the body up from the base with your thumbs 9 Lift the cassette body from the base Note Steps 2 and 3 of this procedure need only be done if the currency guides are covering any of the screws in the floor of the cassette Pusher Springs With the base separated from the body the pusher springs can be unhooked and removed Ne The illustration shows the components inside the base of Cassette Base the tamper indicating cassette Components Door Link Rubber Bumper Truck Door Rachet Slide Rachet Lever Door Lockout Lever NCR 5633 Currency Dispenser Service Manual 4 51 Maintenance Instructions Replacing Cassette Com
76. s High greater than 2V Low less than 0 8V Note The voltage on the logic interface must not exceed the dispenser s 5V supply voltage by more than 0 5V The host s input circuits may be standard TTL no pull up resistors are required However any pull ups used must be at least 1K any pull downs used must not exceed 1K The dispenser has two types of input circuit e The RXDL circuit may be driven by a standard LSTTL output the input incorporates a TTL gate with a 10K pull up e The CTSL and RST input incorporates an HCT TTL gate with a 1K pull down resistor This circuit may be driven by an open collector TTL driver for example 7407 with a 470R pull up resistor Note If the handshake circuits are not used CTSL and RTSL then the standard LSTTL devices are capable of driving the interface NCR 5633 Currency Dispenser Service Manual Table of Contents Operating Instructions Chapter 3 Operating Instructions Replenishing the Currency Cassetttes 3 1 Emptying the Purge Bin 3 10 Clearing Dispenser Jams 3 11 Pick Module 3 11 Main Transport 3 11 NCR 5633 Currency Dispenser Service Manual Table of Contents Operating Instructions NCR 5633 Currency Dispenser Service Manual Operating Instructions Replenishing the Currency Cassettes Replenishing the Currency Cassettes Before loading the currency into a cassette it must be prepared correctly as follows Used currency should be prepared by
77. ser Functional Description Control Board E The memory mapped IO region of the map is allocated I O Map as follows Region Allocation FOOOH Read Only Comms ID Cassette Sensor detect BIT 0 0 Comms S0 1 BIT 1 0 Comms S1 1 BIT 2 0 Comms IDO 1 BIT 3 0 Comms ID1 1 BIT 4 0 Cassette One Low 1 Cassette One NOT Low BIT 5 0 Cassette Two Low 1 Cassette Two NOT Low BIT 6 0 Cassette Three Low 1 Cassette Three NOT Low BIT 7 0 Cassette Four Low 1 Cassette Four NOT Low E000H Read Only Cassette ID 1 2 Sensor detect BIT 0 0 Cassette One ID 1 Present 1 Cassette One ID 1 Not Present BIT 1 0 Cassette One ID 2 Present 1 Cassette One ID 2 Not Present BIT 2 0 Cassette One ID 3 Present 1 Cassette One ID 3 Not Present 1 32 NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Control Board Region Allocation BIT 3 0 Cassette One ID 4 Present 1 Cassette One ID 4 Not Present BIT 4 0 Cassette Two ID 1 Present 1 Cassette Two ID 1 Not Present BIT 5 0 Cassette Two ID 2 Present 1 Cassette Two ID 2 Not Present BIT 6 0 Cassette Two ID 3 Present 1 Cassette Two ID 3 Not Present BIT 7 0 Cassette Two ID 4 Present 1 Cassette Two ID 4 Not Present D000H Read function Link 5 Configuration Switches U1
78. spenser NCR 5633 Currency Dispenser Service Manual Dispenser Functional Description Firmware Description Command Comments Multi cassette Purge Attempts to clear the transport of bills and reports the status per cassette type Multi cassette Dispense Dispenses bills from more than one cassette in a single transaction and reports the status per cassette type Multi cassette Test Dispense Picks bills from more than one cassette in a single transaction and reports the status per position Multi cassette Last Status Reports the last response based on cassette type Multi cassette Picks a bill from a specified cassette Sensor and report its parameters Diagnostics Set Opacity Set the opacity values for each cassette type Get Opacity Reports the configured opacity values Set Bill Dispense Sets the dispensing order by cassette Order types Get Bill Dispense Reports the configured dispense Order order NCR 5633 Currency Dispenser Service Manual 1 47 Dispenser Functional Description The Dispense Operation The Dispense Operation The following description is of a successful dispense operation It explains the interaction between the firmware and the mechanical and electrical components of the dispenser The diagram below shows the path taken by the notes through the dispenser Front access dispenser path of purge notes present position of stack
79. t NCR 5633 Currency Dispenser Service Manual 4 21 Maintenance Instructions Cassette Adjustments ET Currency Width Adjustment Welding Peg 10 off Note Guide ge Currency widths between 55 mm 2 17 in and 100 mm 3 94 in can be accommodated in the cassette The currency width adjustment is made by cutting the ten spacers between the upper note guides and the lid Six of these spacers are the same as the currency length E spacers and four are known as yellow spacers Each note guide has three E spacers and two yellow spacers screwed to it The yellow spacers clip into the lid to fasten the note guide assemblies to it The spacers are embossed with letters and numbers along the sides You cut away segments to leave only the ones with the code numbers read from the Currency Width Spacer Codes table The procedure and example given after the code table should make this clear 4 22 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Cassette Adjustments Currency Width Spacer Codes Yellow E Spacer ea oo Spacer Code Code 55 2 17 C12 E15 56 2 20 D11 E14 57 2 24 D11 E14 58 2 28 C11 E14 59 2 32 D10 E13 60 2 36 D10 E13 61 2 40 C10 E12 62 2 44 D9 E12 63 2 48 D9 E12 64 2 52 C9 E11 65 2 56 D8 E11 66 2 60 D8 E11 67 2 64 C8 E10 68 2 68 D7 E9 69 2 72 D7 E9 70 2 76 C7 E9 71 2 80 D6 E8 72 2 8
80. to the correct value before using the dispenser to dispense bills Configuration Link 5 Configuration Switches U15 SW 1 SW8 Bits 0 7 DO00H Switch Meaning if set to 1 1 Baud rate see below Baud rate see below Not used Not used Not used Not used 2 3 4 5 Not used 6 7 8 Enable encryption NCR 5633 Currency Dispenser Service Manual Reset Conditions Diagnostic LEDs Dispenser Functional Description Control Board Switch 2 Switch 1 Baud Rate 0 0 1200 0 1 2400 1 0 9600 1 1 4800 where 0 up and 1 down The Control board can be reset in a number of ways Power On Reset This happens on the Control board when the power is applied A resistor capacitor network holds the processor in reset until approximately 400mS after applying power which is long enough for Vcc to stabilise Test Reset This is a reset generated on the RDI test connector J12 Terminal Reset This is a reset generated by the host using the XRES line on the D Type connector This Reset will cause the 80C562 processor and all resettable devices on the board to be reset The Control board provides 2 LEDs for State of health Diagnostic use Diagnostics writes to the LEDs on power up to provide status information on the Control Board The LEDs are accessed by writing to individual bits of Port 4 on the processor NCR 5633 Currency Dispenser Service Manual 1 39
81. ts a stream of bills in up to four denominations to the cardholder A detect and purge system controls the movement of currency along the transport Misfed or damaged currency is diverted into a purge bin The dispenser operates as an intelligent module under the control of its own on board microprocessors It communicates with the host ATM central processing unit over an RS 232 C bus The dispenser consists of the following modules e Pick and spray module This module picks an item from the currency cassette and transports it to the exit slot It monitors the movement of the item through the transport There is detection of multiple items and diverting of reject items to the purge bin e Control board This provides the control for the main functions of the dispenser and interface to the host ATM The board controls sensors solenoids and motors to control the sensing and presenting of notes which includes control for a divert mechanism and transport drive On power on the board will execute level 0 diagnostics which report using LEDs e Media containers These are the currency cassettes and the purge bin NCR 5633 Currency Dispenser Service Manual 1 1 Dispenser Functional Description Containers 1 2 Containers Currency in the dispenser is contained in currency cassettes which are used to transport currency to and from the dispenser The cassette security is provided by a seal on the lid latch This requires a sim
82. tte Components 4 Slide the brush in until its clip engages Cassette Handle and Latch Exert pressure on one leg of the handle until the pin at that side becomes free The cassette latch is riveted in position and is not replaceable for security reasons Pusher Pawl Detach the pusher paw from the cassette body using a pusher pawl wedge shown in the following illustration 1 Press the flaps of the low note magnet block together and lift the block out of the pusher 4 48 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Replacing Cassette Components 2 Insert the pusher pawl wedge into the slots in the top cap of the pusher 3 Press down on the wedge to release the four clips which secure the top cap and spring until the top cap springs out 4 Remove the spring and pusher NCR 5633 Currency Dispenser Service Manual 4 49 Maintenance Instructions Replacing Cassette Components Separating the Cassette Base and Body Separate the cassette base from the body in the following order 1 Remove the cassette lid 2 Unscrew and remove the currency length guide clamps 3 Slightly lift the rear of the currency length guides and push the guides to the rear until they unclip Remove the guides 4 Remove the five screws in the floor of the cassette 5 Place the cassette top up on the cassette base dismantling fixture so that it is held by the locating dowels and the truck door is at the sc
83. urrency Dispenser Service Manual 4 9 Maintenance Instructions Dispenser Adjustments 2 On the lower pick module rotate the drive pulley until the timing mark L is aligned with the pump link timing mark 3 Refit the drive belt ensuring that the alignment of steps 1 and 2 are maintained ee On the spray module loosen the transport motor Tension 1 Adjust the belt tension to give a mid span deflection of 3mm 0 12in for a force of 3 Newtons applied at mid span 4 10 NCR 5633 Currency Dispenser Service Manual Maintenance Instructions Dispenser Adjustments 2 Maintaining this adjustment tighten the transport motor mounting screws Ne This is to clarify the correct position of the pick module Drive Segment Timing drive segment with respect to the vacuum pick line segment Vacuum Hose J GS Vacuum Line Drive Segment Segment Note The teeth of the drive segment must be above the vacuum line segment teeth NCR 5633 Currency Dispenser Service Manual 4 11 Maintenance Instructions Cassette Adjustments Currency Length Adjustment Cassette Adjustments Note The terms left and right in the following adjustments and tables of settings apply to the cassette when looked at from the front the truck door end You will have to move the pusher during some of the following adjustments refer to the caution given in the section Pusher Operation
84. x holes around the periphery of the timing disk create the timing pulses from an opto electronic sensor The output of the sensor is used to measure the movement of the bills as far as the exit sensor and as a reference in the measurement of bill NCR 5633 Currency Dispenser Service Manual 1 25 Dispenser Functional Description Mechanical Description 1 26 width The interval between the interrupts represents a distance travelled by the bill of approximately 2 mm Feed Sensor The feed sensor detects bills as they are fed from the transport section and presented to the divert gate The firmware initiates a divert gate operation timing sequence every time a good bill reaches this sensor Exit Sensor The last sensor on the transport is the exit sensor which verifies that bills have passed the divert gate and are on their way to the customer access tray Purge Bin Location Components The purge bin is held in the spray module so that it is accessible from the same position as the currency cassettes It is supported by guide rails and is locked in position by a latch A microswitch attached to the side frame on the spray module is operated by the inserted purge bin to inform the electronics system that the bin is in place Divert Gate The divert gate position sensors are mounted so as to detect movement of the divert gate Main Motor The main motor provides mechanical drive to the spray module and all pick modules via toothe

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