FaultsStatus messages Status display The current status of the CCDM, including any faults that may have occurred, is shown on the status display. The status display shows the following messages, depending on the type of display: Status display No display (Green LED on) Meaning Normal operation; no fault / no warning Function code (see chapter "Function test") constant Error code blinking Warning code permanent < > > 01750062112 D CCDM - Service Manual 8-1 Status messages Faults Localizing the cause of the error The numbers in the figure below represent the error and warning codes shown on the status display. The numbers are positioned on the diagram in such a way as to make it easier to locate the source of the error. The exact position of the photosensors and motors referred to in the code tables can be found in the section "Overview of sensors and actuators" in the appendix. The error codes of the photosensors (codes 60 to 89) are not included in this figure. 8-2 CCDM - Service Manual 01750062112 D Faults 01750062112 D 40 28 24 25 22 21 20 13 19 31 32 33 34 10 11 15 30 51 41 42 43 46 47 50 48 52 26 27 90 91 96 CCDM - Service Manual 94 92 95 93 Status messages 55% 8-3 Buy Now to Create PDF without Trial Watermark!! Status messages Faults Error codes / warning codes Only check plug connections and only replace components when no voltage is being applied! – If components need to be replaced to clear a fault, please refer to i the relevant section in the chapter "Removal/Installation of Components". – When a component has been replaced, always synchronize the photosensors. – After clearing a media jam, always perform a reset. How to execute measures Remedy Synchronize the photosensors Performing a RESET Restarting the system Displaying the extended error code (EC) Note Press the test button and select the function code '03' (see chapter "Function Test"). Press the test button and select the function code '01' (see chapter "Function Test"). Switch the device off and back on (for details see chapter "Basic Operation" in the operating manual). Press the test button and select the function code '00' (see chapter "Function Test"). The extended error code is shown on the status display as follows: First high byte (2-3 seconds) (only in case of 4-digit error code), then low byte (2-3 seconds). For details refer to the examples on the following page. Next, the two-digit error code is displayed again. Created by eDocPrinter PDF Pro!! 8-4 CCDM - Service Manual 01750062112 D Buy Now to Create PDF without Trial Watermark!! Faults Examples of the extended error code display Error code '17' / EC '23' as an example of a 2-digit display of error code: Error code '24' / EC '102' as an example of a 4-digit display of error code: Status messages Error code display Error code display Automatic return to error code display Call function code '00' Automatic return to error code display Call function code '00' Display of EC for 2-3 s (low byte) Display of EC for 2-3 s (high byte) Display of EC for 2-3 s (low byte) Created by eDocPrinter PDF Pro!! 01750062112 D CCDM - Service Manual 8-5 – Restart the CCDM. hardware error Operating system error. – Check the plug connections between amplifier and controller board.Buy Now to Create PDF without Trial Watermark!! Status messages Faults Error messages in the area of the head module Code EC Meaning Boot up (electronic self-test) Boot up (after reset) Operating system error. – If the error reoccurs. – If the error reoccurs. – Restart the CCDM. replace the controller. Replacement with an up-to-date dispenser module is recommended. – Restart the CCDM. replace the controller. replace the chassis of the CCDM. – If necessary re-load the firmware. – Replace the dispenser module. – If the error reoccurs. – Restart the CCDM. No connection to dispenser module No connection to amplifier board Created by eDocPrinter PDF Pro!! 8-6 CCDM . replace the controller. re-load the firmware. internal firmware error Remedy Wait for the system to finish booting up. – If the error persists.Service Manual 01750062112 D . Wait for the system to finish booting up. – If the error reoccurs. Permanent status display: Dispenser module 01750047708 is installed which may cause incidents in the dispensing area. Blinking status display: – Check the cable connection between the dispenser module and the back panel. – If necessary re-load the firmware. replace the controller. – Restart the system – If the error reoccurs. – If the error reoccurs. – Restart the CCDM. – Check the configuration of the controller.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning No connection to stacker board Status messages Remedy – Check the plug connection between amplifier board and controller board.Service Manual 8-7 . – Restart the CCDM. – If the error reoccurs. – Restart the system – If necessary re-load the firmware. replace the controller. – Re-load the firmware of the CCDM. replace the amplifier / controller board. – Delete the cassette counters and the CEX. re-load the firmware. – If the error cannot be eliminated. – Perform a reset. replace the distributor transport. Battery on controller board empty Device configuration of controller incorrect or missing Error on controller No firmware Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . – Restart the system – Load the appropriate configuration using the product-specific test software. – Restart the system – If the error persists. reload the firmware. – If the error cannot be eliminated by means of the above steps. there is a waiting period of up to 270 seconds until the CCDM is ready for operation. Remove the documents from the input/output area. Minimum configuration is missing (at least 1 cash-in cassette + retract cassette) Operating system is loading new files on the CCDM controller Data transfer on RS232 interface Wait for the system to finish loading the firmware. Service Operator Panel). replace the safety switch. – If the error reoccurs. – Restart the CCDM. then pull the device out and push it in again. – Check the connection cable between the safety switch and the back panel.g. reset the DLOC first. too. Register the cassettes using the product-specific software (e. The device is only ready for operation once this procedure was carried out.Service Manual 01750062112 D . – If the red LED (DLOC) lights up. Wait for the data transfer to finish.Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Safety switch active Faults Remedy – Check whether the CCDM (head module and cassette module) is pushed into the device correctly (locking mechanism!) and whether the safety switch is correctly bridged. Created by eDocPrinter PDF Pro!! 8-8 CCDM . After the XSA module has i been reconfigured. Retract documents are stored in the input/output area. Error of the metal – Check the plug connection on the detection unit metal detection unit. – If the error reoccurs. – Power up the PC / the application.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning The application overloads the CCDM hardware (too many reset commands per time unit) Status messages Remedy – Power down the PC / the application. – Mechanical blocking / foreign matter. – Perform a reset. Shutter blocked – Remove any foreign matter from the shutter area. – Make sure the plug of the shutter is plugged in at the controller.Service Manual 8-9 . Module is defective or plug has not been plugged in. – Restart the CCDM. replace the dispenser module. – Shutter is defective. – Leave the CCDM switched on for five minutes. – Perform a reset. – Plug has not been plugged in. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . replace the shutter. – If the error reoccurs. Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Error on swivel transport unit or in the area of the bundle alignment Faults Remedy Swivel transport unit: – Check the home position of swivel transport units 1 and 2. – Home position photosensor is defective or soiled (VLS4). Home position photosensor is defective or soiled (VLS3 / VLS4). or diagnostic test triggered by operator: swivel transport 2 in dispenser module defective. – Replace the dispenser module. if necessary. Transport error: motor does not run properly (VSM5 / VSM6). – Replace the dispenser module. – Swivel transport is mechanically blocked. Swivel transport 1 / 2 is mechanically blocked. – Transport error: motor does not run properly (VSM6). or diagnostic test triggered by operator: swivel transport 1 in dispenser module defective. Created by eDocPrinter PDF Pro!! 8-10 CCDM .Service Manual 01750062112 D . Transport error: motor does not run properly (VSM5). if necessary. Swivel transport is mechanically blocked. Home position photosensor is defective or soiled (VLS3). – Inspect photosensors VLS3 and VLS4. – – – – – – Bundle alignment: – Check whether the bundle alignment is clear. – Inspect photosensors VLS8 and motor VSM7. – Inspect motors VSM5 and VSM6. Buy Now to Create PDF without Trial Watermark!! Faults Code EC Status messages Meaning Remedy – Drive is mechanically blocked. dispensing) – Check the cam disk position. – Stacker table is not on top due to blocking or defect (VSM8 / VLS9). 0100 for details. – Home position photosensor is defective or soiled (VLS8). – Replace the dispenser module. (feed error detected prior to – Perform a reset. – Photosensor VLS2 or VLS5 is defective or soiled.Service Manual 8-11 . – Paper jam in I/O transport area. if necessary. – A paper jam has occurred in the dispensing / I/O area. – Transport error: motor does not run properly (VSM7). – or diagnostic test triggered by operator: dispenser module defective. – Swivel transport is not lowered due to blocking etc. – Motors VSM1/2/3 do not run properly. or diagnostic test triggered by operator: bundle width setting in dispenser module defective. (VSM6 / VLS4). – Photosensor VLS2 is defective or soiled. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . – Semi-rotary actuator motor does not run properly (VSM1). – Remove any jammed media from Media jam in the dispenser module's paper dispenser module path. See error code no. – Restart the CCDM. – Check the dispenser module's motors. – Transport errors: motors (RSM1 / VSM1 / VSM2) do not run properly. – Stacker table is not on top due to blocking or defect (VSM8 / VLS9). – Photosensor VLS2 / VLS6 is defective or soiled. – Transport error: motors VSM1/2/3 do not run properly. – Dispensing comb is blocked. – A paper jam has occurred in the paper path between stacker and I/O transport. – Incorrect cam disk position caused by jam or defect: Transport rollers should plunge through stacker table I/O transport (VSM8 / VLS9). (VSM6 / VLS4). – Swivel transport 2 is defective (VSM1). – Photosensor VLS2 is defective or soiled. – Swivel transport 2 is not on top due to blocking etc. – Clock wheel in swivel transport (VLS5) is defective or soiled. – Swivel transport is not lowered due to blocking etc. (VSM6 / VLS4). Created by eDocPrinter PDF Pro!! 8-12 CCDM .Service Manual 01750062112 D .Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Faults Meaning Remedy – Paper jam in I/O area -> paper feed rollers. or paper is too long. if necessary. – Motor ASM1 of alignment station does not run properly. – Motors VSM1/2/3/4 do not run properly. – A paper jam has occurred in the dispensing area. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . – Photosensor VLS7 is defective or soiled. – Reset the photosensors to the default values. – Photosensor VLS6 is defective or soiled. – A paper jam has occurred in the intermediate transport and possibly also in the alignment station. – Foreign objects or dirt detected at VLS6 or VLS7 prior to dispensing process. if necessary. 0105 for details. See error code no. if necessary.Service Manual 8-13 .Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Paper jam detected during separation process. – Check the dispenser module's motors. – Clean the photosensors in the dispensing area of the dispenser module. – Carry out a photosensor adjustment / initialization. – Motors VSM2/3/4 do not run properly. – Photosensor VLS7 is defective or soiled – Transport error: motors VSM2/3/4 do not run properly. – Paper jam in paper feed roller area -> intermediate transport. Status messages Remedy – Check paper path in dispenser module. – Restart the system – Replace the dispenser module. – Transport error: motors VSM2/3/4 do not run properly. – A paper jam has occurred in the paper feed roller area. – Photosensor VLS6 is defective or soiled. or paper is too long. See error code no. – Restart the system – Carry out a photosensor adjustment / initialization. – Paper too long. – Replace the dispenser module. software. Paper jam detected – Remove the media jam in the dispenser module and reset the Dduring separation Loc using the product-specific process. 0105 for details.Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Faults Meaning Remedy – Paper jam in dispensing area or intermediate transport. – Photosensor VLS6 is defective or soiled. if necessary. – Motors VSM2/3/4 do not run properly. Media jam in front of VLS2 during bundle output from intermediate transport to I/O box Media jam under the VLS6 during bundle output from intermediate transport to I/O box Media jam in front of VLS6 during bundle output from intermediate transport to I/O box. Media jam in front of VLS12 during bundle output from intermediate transport to I/O box. Created by eDocPrinter PDF Pro!! 8-14 CCDM .Service Manual 01750062112 D . See error code no. Media jam in front of VLS2 during bundle output from intermediate transport to I/O box. 0103 for details. Document jam in intermediate transport or at entrance to alignment station. Soiled roller. Hall sensor element 2 is defective or plug is not plugged in. Hall sensor element 1 is defective or plug is not plugged in. Soiled roller. or paper remaining in roller. – Restart the system – Replace the dispenser module. if necessary. or paper remaining in roller. – – – – Created by eDocPrinter PDF Pro!! 01750062112 D CCDM .Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Error of hall sensors Status messages Remedy – Check the plug connection on the dispenser's board (bottom of dispenser module).Service Manual 8-15 . – Check the motors of the dispenser module and the reject transport. Photosensor VLS6 / VLS2 is defective or soiled.Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Media jam in reject transport area Faults Remedy 0116. Mechanical initialization of cam disk not correct due to blocking. – Replace the dispenser module and/or the reject transport. – Check whether the belt of the reject transport is laying on the center of the guiding rollers. 0182 – Remove any jammed media between the reject transport and the dispenser module. 0171: – Remove any jammed media between the reject transport and the dispenser module or in the reject module. Media jam stacker => I/O transport – – – – – – Created by eDocPrinter PDF Pro!! 8-16 CCDM . – Make sure the rocker is assembled in the correct position in relation to the axis inside the dispenser module (dispenser module has to be removed for this purpose).Service Manual 01750062112 D . Dispensing motors VSM2/3 do not run properly. – Restart the CCDM. 0180. – Replace the dispenser module and/or the reject transport. – Restart the CCDM. Paper jam in reject path. Mechanical initialization of swivel transport 2 not correct. – Transport error: motor does not run properly (VSM8). – Home position photosensor is defective or soiled (VLS9). – Home position photosensor is defective or soiled (VLS9).Buy Now to Create PDF without Trial Watermark!! Faults Code EC Status messages Meaning Remedy – A paper jam has occurred in the paper path between stacker and I/O transport.Service Manual 8-17 . – Media jam found in front of VLS12 during reject box clearing => I/O box. – Transport errors: motors (RSM1 / VSM1) do not run properly. disk – Check the cam disk position (release). – Replace the dispenser module. if necessary. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . – Drive is mechanically blocked. – Transport error: motor does not run properly (VSM8). – Incorrect cam disk position caused by jam or defect: I/O stacker should be lowered to ensure free reject path (VSM8 / VLS9). – or – diagnostic test triggered by operator: cam disk in dispenser module defective. Error of the cam – Restart the CCDM. (VSM6 / VLS4). – Drive is mechanically blocked. – Swivel transport 2 is not on top due to blocking etc. – Photosensor VLS6 is defective or soiled. Document jam in front of ALS1 during transport of document in the alignment drum Media jam in front of ALS1 during transport of media from alignment drum -> check transport path through drum.Service Manual 01750062112 D . Created by eDocPrinter PDF Pro!! 8-18 CCDM . However. Document in front of ASL1 or ALS1 is defective (keeps detecting document) -> motor AMS1 possibly defective as a result of which document is not removed from position in front of ASL1. Check transport path 'Intermediate Transport Exit' – 'Alignment Station' – 'Sensor Transport Entrance'. if necessary. Document jam in the alignment drum (document remains in drum). Document jam between alignment station and sensor module or in AMG1 deflector. – Perform a reset – Replace the alignment station. document transport caused problems (too much slippage or too much friction).Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Media jam in front of or in the alignment station Faults Remedy – Clear the media jam in the alignment station – Check the photosensors and the motors in the alignment station. No document jam. – Carry out a photosensor adjustment / initialization. or diagnostic test triggered by operator: alignment station defective. reload check / cash reader firmware. replace the check / cash reader. – Restart the CCDM. – If the error reoccurs even after the above steps have been taken. – Restart the system – If necessary. – Restart the system – External light in check / cash reader – Banknote level detected (light level too high due to soiled roller or document remaining under the reader). reader – Clean the scanner lines of the check / cash reader. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . – Replace the magnetic character reader. – Check the PC's Firewire card. ADDMASTER electronic is defective or not properly connected.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Error magnetic character reader Status messages Remedy – Check the plug connection with the magnetic character reader. – Carry out a photosensor adjustment / initialization. Error on check / cash reader – Restart the CCDM.Service Manual 8-19 . reload Firewire firmware (for check & cash configuration). – Banknote level detected (light level too high due to soiled roller or document remaining under the reader). BEB module is defective. Only relevant for check processing: – Check if the firewire cable is connected to the PC and the BEB module. – If necessary. if necessary. – Transport pulse missing or outside of admissible tolerance. External light in – Check whether light is falling on check / cash the check / cash reader. BEB firmware error. BEB firmware error. – Restart the CCDM. BEB note table configuration not Ok.Service Manual 01750062112 D . BEB communication error -> control logic RS232 data transfer problems. – Check and update the banknote table. – Re-load the firmware. BEB data error -> configuration data faulty / corrupt.context error -> control logic RS232 data transfer problems. – Restart the system – Replace the check / cash reader. BEB syntax . if necessary. – Re-load the currency data. Created by eDocPrinter PDF Pro!! 8-20 CCDM .Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Communications problems with check / cash reader Remedy – Re-load the firmware of the check / Faults cash reader. storage and sensor transport (logic error). the CCDM's firmware and/or the Firewire firmware. – Module does not reply within specified time limit.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Communication problems (time-out) (RS232 interface ) with check / cash reader Status messages Remedy – Re-load the check / cash reader's firmware. Communication errors RS232 interface with BEB module: BEB module not mounted or not properly connected to back panel. BEB firmware and CCDM firmware not compatible. Module does not reply within specified time limit. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . Communication with sensor transport interrupted during operation. Communication errors from BEB to RS232 interface: BEB module not mounted or not properly connected to back panel.Service Manual 8-21 . No connection between RS232 interface and BEB interface: – Sensor transport not mounted or not properly connected. – 'Back panel board' connector has interrupted communication with sensor transport during operation. – Restart the system – Replace the check / cash reader and / or the back panel incl. BEB module not mounted or not properly connected to back panel. BEB firmware and CCDM firmware not compatible. Document jam in entrance area of sensor transport: Clear the media jam in the area of the MIC reader and up to the entry of the sensor transport. – Photosensor SLS3 is defective or soiled The three-way deflector has returned a document to the alignment module during transport from escrow unit to cassettes or reject tray. so that the document message can no longer be allocated to a specific document. Diagnostic test triggered by operator: sensor transport defective.Service Manual 01750062112 D . Only until version 11xx! Slippage during transport of documents from ALS1 alignment to BEB sensor.Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Media jam in sensor transport Faults Remedy – Clear the media jam in the sensor transport In particular. or BEB sensor document message issued at the wrong time. If the error occurs frequently. Created by eDocPrinter PDF Pro!! 8-22 CCDM . blocked. Deflector in wrong position. – Document deflecting unit in alignment station is not functioning. replace the MIC reader. Jam between sensor transport (paper deflecting units) and in front of RLS1. check the area of the 3-way deflector. Note could not be identified due to various reasons (event message from BEB sensor during banknote processing). – Check functioning of deflectors in sensor transport unit. if necessary (logic error). Document jam in area SLS1-> document deflecting units -> escrow unit / reject transport. – Restart the CCDM.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Media jam in sensor transport Status messages Remedy – Clear the media jam in the sensor transport In particular. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . replace the back panel including deposit transport and sensor transport. Malfunction of three-way deflector (during transport from the escrow unit). check the area of the 3-way deflector. Malfunction of three-way deflector (during transport from alignment station).Service Manual 8-23 . Document jam between ALS1 and SLS1. – If the deflectors cannot be addressed correctly. – SSM3 motor defective / not connected. or diagnostic test triggered by operator: 3-way deflector (SSM2) in sensor transport defective. – Media jam in sensor transport unit at reject deflector. – Check functioning of deflectors and motors in sensor transport unit. – SSM2 sensor defective / not connected. if necessary (logic error). Created by eDocPrinter PDF Pro!! 8-24 CCDM . – Media jam in sensor transport unit at three-way deflector.Buy Now to Create PDF without Trial Watermark!! Status messages Code & EC Meaning Media jam in sensor transport Faults Remedy – Clear the media jam between sensor and deposit transport. replace the back panel including deposit transport and sensor transport. – SLS4 sensor defective / not connected. or diagnostic test triggered by operator: reject deflector (SSM3) in sensor transport defective. – SSM2 motor defective / not connected.Service Manual 01750062112 D . – Restart the CCDM. – If the deflectors cannot be addressed correctly. if necessary. – Drive is mechanically blocked. Document jam – Clear the media jam between between sensor sensor and storage or reject transport and transport. To check it first remove the check / cash reader. – Transport error: motor does not run properly (RSM2). Document too short (smaller than 25 mm (0. or Diagnostic test triggered by operator: reject transport defective. storage / reject – Restart the CCDM. – Home position photosensor is defective or soiled (RLS3). After passing RLS1. transport Document jam between sensor transport and cassettes / reject transport under RSL1 sensor. the banknote does not reach KLS2 to cassette module using specified path and tolerance. – Replace the reject transport.RLS1. transport Document jam between sensor transport and cassettes / reject transport under RSL1 sensor. Jam between sensor transport (paper deflecting units) and behind RLS1. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . – Check the basic position of shaft / axis and the screw in the reject transport unit. transport and reject – Perform a reset. Initialization error – Check the reject transport's plug of reject transport connection. Banknote does not quit RLS1 photosensor using specified path and tolerance. – Restart the CCDM.Service Manual 8-25 .98")).Buy Now to Create PDF without Trial Watermark!! Faults Code EC Status messages Meaning Remedy Document jam – Clear the jam between sensor and between sensor reject transport. – Carry out a photosensor adjustment / initialization. as the ESROW will otherwise be destroyed! – Remove the documents in the ESCROW and reset the D-Loc.Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Document jam at the escrow unit Faults Remedy – Perform a reset. ESM1 motor not connected. Escrow error: A media jam with subsequent initialization has caused documents to be shifted behind the last reachable position on the SCROW drum and can only be removed manually. – Replace the escrow unit. if necessary. motor logic defective. – Clear the media jam in the escrow area. Document jam at escrow unit ELS1 or Diagnostic test triggered by operator: escrow unit defective. Band torn. – Restart the CCDM. tape no longer under ELS2. Document has over 2 cm transport slippage / document is jammed under ELS1.Service Manual 01750062112 D . Jam during unwinding. Banknote from escrow unit does not reach RLS1 Escrow tape – Check the tape of the escrow unit. – Replace the drum module. Torn band or full drum. CAUTION: Do not turn the ESCROW further than the last visible note/check. Drive blocked. tape no longer under ELS2. distance is greater than twice the maximum length of banknotes. – Replace the dispenser module. defective – Perform a reset. ELS3 fails to detect beginning of tape. Malfunction of deflector. During unwinding one document is missing due to external intervention. if necessary. & Created by eDocPrinter PDF Pro!! 8-26 CCDM . EC Meaning Error photosensor in dispenser Remedy – If you can get to the photosensor. – Check the photosensor using KDIAG. replace the dispenser.Buy Now to Create PDF without Trial Watermark!! Faults Status messages Error messages of photosensors i Code Photosensors VLS7. – Blinking: VLS10 out of service – Constant: VLS10 in dispenser soiled – Blinking: VLS1 out of service – Constant: VLS1 in dispenser soiled – Blinking: VLS7 out of service – Constant: VLS7 in dispenser soiled – Blinking: VLS2 out of service – Constant: VLS2 in dispenser soiled – Blinking: VLS12 out of service – Constant: VLS12 in dispenser soiled – Blinking: VLS6 out of service – Constant: VLS6 in dispenser soiled – Blinking: VLS11 out of service – Constant: VLS11 soiled Created by eDocPrinter PDF Pro!! 01750062112 D CCDM .Service Manual 8-27 . try to clean it. – If the error persists. – Synchronize the photosensors. ALS1 and SLS3 can only be checked when the CCDM components are closed. – Check the photosensor using KDIAG. try to clean it. – If the error persists. Created by eDocPrinter PDF Pro!! 8-28 CCDM . replace the magnetic character reader.Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Error photosensor in alignment station Faults Remedy – If you can get to the photosensor.Service Manual 01750062112 D . replace the alignment station. – Synchronize the photosensors. – Blinking: ALS3 out of service – Constant: ALS3 soiled – Blinking: ALS4 out of service – Constant: ALS4 soiled – Blinking: ALS2 out of service – Constant: ALS2 soiled – Blinking: ALS1 out of service – Constant: ALS1 soiled – First check whether the cover of the alignment station is closed properly. – If you can get to the photosensor. – Check the photosensor using KDIAG. – Synchronize the photosensors. Magnetic character reader not closed: Blinking: SLS3 out of service Constant: SLS3 soiled First check whether the magnetic character reader is closed properly. – If the error persists. try to clean it. Error at photosensor ELS1: Blinking: ELS1 out of service Constant: ELS1 soiled Error at photosensor ELS5: Blinking: ELS5 out of service Constant: ELS5 soiled Error at photosensor RLS1: Blinking: RLS1 out of service Constant: RLS1 soiled Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . try to clean it. try to clean it. replace the escrow. – Synchronize the photosensors. – Synchronize the photosensors. – Check the photosensor using KDIAG. sensor and storage transport. – Check the photosensor using KDIAG. try to clean it. – Check the photosensor using KDIAG. – If you can get to the photosensor. – Synchronize the photosensors. – If the error persists replace the back panel incl.Service Manual 8-29 . replace the escrow. sensor and storage transport. – If you can get to the photosensor. – Check the photosensor using KDIAG.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Error at photosensor SLS1: Blinking: SLS1 out of service Constant: SLS1 soiled Status messages Remedy – If you can get to the photosensor. – Synchronize the photosensors. – If the error persists. – If the error persists replace the back panel incl. – If you can get to the photosensor. try to clean it. – If the error persists. try to clean it. – Check the photosensor using KDIAG. – If you can get to the photosensor. – If the error persists. – Check the photosensor using KDIAG. – Synchronize the photosensors. Created by eDocPrinter PDF Pro!! 8-30 CCDM .Service Manual 01750062112 D . – Check the photosensor using KDIAG. – If the error persists. – Synchronize the photosensors. – Check the photosensor using KDIAG.Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Error at photosensor RLS2: Blinking: RLS2 out of service Constant: RLS2 soiled Error at photosensor KLS2: Blinking: KLS2 out of service Constant: KLS2 soiled Error at photosensor KLS3: Blinking: KLS3 out of service Constant: KLS3 soiled Error at photosensor KLS8: Blinking: KLS8 out of service Constant: KLS8 soiled Faults Remedy – If you can get to the photosensor. – Synchronize the photosensors. replace the cassette module. replace the reject transport. replace the cassette module. replace the cassette module. – If you can get to the photosensor. try to clean it. try to clean it. – If the error persists. – Synchronize the photosensors. try to clean it. – If the error persists. – If you can get to the photosensor. Service Manual 8-31 . – If you can get to the photosensor. – Check the photosensor using KDIAG.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Error at photosensor KLS11: Blinking: KLS11 out of service Constant: KLS11 soiled Error at photosensor KLS1_5: Blinking: KLS1_5 out of service Constant: KLS1_5 soiled Error at photosensor KLS2_5: Blinking: KLS2_5 out of service Constant: KLS2_5 soiled Status messages Remedy – If you can get to the photosensor. try to clean it. – If you can get to the photosensor. – If the error persists. – If the error persists. try to clean it. try to clean it. replace the cassette module and/or cassette 1. – Synchronize the photosensors. – Synchronize the photosensors. – Check the photosensor using KDIAG. – Check the photosensor using KDIAG. replace the cassette module and/or cassette 1. – If the error persists. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . replace the cassette module and/or cassette 1. – Synchronize the photosensors. Buy Now to Create PDF without Trial Watermark!! Status messages Faults Error messages in the cassette module section Code EC Meaning Deflector in sensor transport has wrong position. or Diagnostic test triggered by operator: cassette module defective. – Remove the media jam in the cassette module . Remedy – Clear the media jam between transfer transport and cassette module.Service Manual 01750062112 D . Banknote detected near module entrance (KLS2) does not reach KLS11 to cassette 2 using specified path + tolerance. Banknote detected near module entrance (KLS2) does not reach KLS3 to retract cassette using specified path + tolerance.retract / banknote / check cassette (cassettes have to signed on again). – Restart the system – Replace the cassette module. Created by eDocPrinter PDF Pro!! 8-32 CCDM . Banknote detected near module entrance (KLS2) does not reach KLS8 to cassette 1 using specified path + tolerance. if necessary. Deflector in sensor transport has wrong position. Banknote does not quit KLS2 photosensor near module entrance using specified path + tolerance. if necessary. Deflector (cassette 1 / cassette 2) is not functioning or diagnostic test triggered by operator: deflector (KSMx) in cassette module defective. – Motor not connected. – Restart the system – Replace the cassette module. – There is some paper left inside the deflector. – Perform a reset. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . – Hybrid photosensor before reset is defective. or diagnostic test triggered by operator: deflector (KSM5) in cassette module defective. – Check function of deflector in cassette module.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Incorrect position of deflector in cassette module Status messages Remedy – Check position of deflector in cassette module.Service Manual 8-33 . – Replace cassette 1 or replace the entire cassette module. Hall sensor is defective / not connected.Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Incorrect position of deflector in cassette module Faults Remedy – Remove the media jam in the direction of cassette 1 (standard check cassette). if necessary. Stacker logic not connected (plug X1).Service Manual 01750062112 D . – – – – – – Created by eDocPrinter PDF Pro!! 8-34 CCDM . Home position magnet on stacker wheel is missing / has fallen off. – Restart the CCDM. Blinking status display: – Check proper fit of cassette 1 and re-insert cassette 1 properly. if necessary. Stacker wheel in banknote cassette / check cassette blocked. Error in cassette 1 Permanent status display: – Remove the cassette 1 and empty it. Belt between stepper motor and stacker wheel has come off / is torn. – Restart the system – Replace the cassette module. – Check the plug connection between the controller and the cassette module. Incorrect position of deflector in cassette module Banknote does not quit KLS8 photosensor near entrance to cassette 1 using specified path + tolerance. Banknote cassette / check cassette is not fully inserted (magnet on stacker wheel does not trigger hall sensor). if necessary. – Restart the system – Replace cassette 2 or replace the entire cassette module. if necessary. – Restart the system – Replace the cassette module. Blinking status display: – Check proper fit of cassette 2 and re-insert cassette 2 properly.Service Manual 8-35 . – Check the plug connection between the controller and the cassette module. if necessary. Incorrect position of deflector in cassette module Banknote does not quit KLS11 photosensor near entrance to cassette 2 using specified path + tolerance. if necessary. Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . Error in cassette 2 Permanent status display: – Remove the cassette 2 and empty it.Buy Now to Create PDF without Trial Watermark!! Faults Code EC Meaning Incorrect position of deflector in cassette module Status messages Remedy – Clear the media jam in the direction of cassette 2 (cash box). – Perform a reset.Service Manual 01750062112 D . – Check function of deflector in cassette module. if necessary. – Restart the system – Replace the cassette module. Incorrect position of deflector in cassette module Banknote does not quit the photosensor near KLS33 entrance of retract cassette using the specified path + tolerance. Switching between retract cassettes is not functioning or diagnostic test triggered by operator: deflector (KSMx) in cassette module defective. Created by eDocPrinter PDF Pro!! 8-36 CCDM .Buy Now to Create PDF without Trial Watermark!! Status messages Code EC Meaning Incorrect position of deflector in cassette module Faults Remedy – Check position of deflector in cassette module. Service Manual 8-37 . Instead.Buy Now to Create PDF without Trial Watermark!! Faults Sensors and actuators Sensors and actuators Description of sensors / actuators Structure of brief designations These elements are named in accordance with the following principle: Position 1: Positions 2 to 3: Positions 4 to 5: Functional unit or function Element type Sequential number of the element Example: KHS10 Designation of the 10th Hall sensor in the cassette module Exception: For the deflectors in the transport paths taken by the media.g. there is no encoding of functions or functional units. they are designated by a sequential number (e. W1). Abbreviations for functional units or functions Abbreviation A D E K R S V Meaning Alignment Print Escrow (storage on a drum) Cassette module Reject transport unit Sensor Dispenser module Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Faults Abbreviation for element types Abbreviation CE HS LS Meaning Scan line Hall sensor Photosensor. Example: Hybrid photosensor KLS8 Electromagnet Microswitch Stepper motor Ultrasound sensor for double dispensing Deflector MG MS SM UDS W Overview of sensors and actuators The following illustrations provide an overview of the CCDM sensor and actuator positions. Created by eDocPrinter PDF Pro!! 8-38 CCDM .Service Manual 01750062112 D . but it can precede the designation in text form. The meaning of each of the sensors / actuators are described in the following sections. The technical variant is not distinguished in the abbreviation. Service Manual A B C 8-39 .Buy Now to Create PDF without Trial Watermark!! Faults Sensors and actuators CCDM head module Chassis II and VM2 Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Faults A Created by eDocPrinter PDF Pro!! 8-40 CCDM .Service Manual 01750062112 D . Buy Now to Create PDF without Trial Watermark!! Faults Sensors and actuators B Created by eDocPrinter PDF Pro!! 01750062112 D CCDM .Service Manual 8-41 . Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Faults C Created by eDocPrinter PDF Pro!! 8-42 CCDM .Service Manual 01750062112 D . Buy Now to Create PDF without Trial Watermark!! Faults Chassis P and VM3 Sensors and actuators Created by eDocPrinter PDF Pro!! 01750062112 D CCDM .Service Manual 8-43 . Service Manual 01750062112 D .Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Faults Created by eDocPrinter PDF Pro!! 8-44 CCDM . Buy Now to Create PDF without Trial Watermark!! Faults Sensors and actuators Created by eDocPrinter PDF Pro!! 01750062112 D CCDM .Service Manual 8-45 . Service Manual 01750062112 D .Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Faults CCDM cassette module Cassette module for plastic cassettes KLS 11 KLS 3 KLS 2 KSM 2 W4 KLS 4 KSM 4 KSM 7 W5 KSM 3 KLS 5 KLS 1_4 KLS 1_2 KLS 1_1 KSM 5 KSM 6 KLS 6 KLS 8 KLS 10 3 KLS 2_5 KLS 2_4 KLS 2_2 KLS 2_1 KLS 1_5 KSM 1 KSM 2 2 KLS 2_3 KDC 2 KDC 1 KLS 1_3 1 Created by eDocPrinter PDF Pro!! 8-46 CCDM . Buy Now to Create PDF without Trial Watermark!! Faults Cassette module ProCash 3100(xe) Sensors and actuators Safety switch Created by eDocPrinter PDF Pro!! 01750062112 D CCDM .Service Manual Cassette 2 Cassette 1 Controller 8-47 . LS2 Function LS1 Shaft in the positions 'Open' and 'Closed'. drives the transport rollers in swivel transport unit 1 and the transport belt in swivel transport unit 2. Checks if flap is closed. Dispenser module Actuator VMG1 VMS1 VMS2 VSM1 Function Retaining shaft magnet. the motor is located on the chassis behind the motor RSM2 of the reject transport unit. presses retaining shaft against the counterrotation shaft Sender coil for metal detection Receiver coil for metal detection Stepper motor input/output transport. LS2 Partly open and in combination with the hybrid photosensor LS1 it detects which of the two possible final positions has been reached. LS3 i You will find more detailed descriptions in the respective system manuals. Stepper motor for lowering/raising the hinged drive unit 1 Stepper motor for lowering/raising the hinged drive unit 2 Stepper motor for width setting Stepper motor for driving the hinged mechanism of the counterrotation shaft and activating the pinch rollers for separation Stepper motor for the lower bundle transport unit VSM2 VSM3 VSM4 VSM5 VSM6 VSM7 VSM8 VSM9 Created by eDocPrinter PDF Pro!! 8-48 CCDM .Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Faults Shutter Sensor LS1. Stepper motor for driving transport rollers. transport roller shaft / pressure shaft Stepper motor for driving the counterrotation shaft Stepper motor for driving the transport belts in the intermediate transport.Service Manual 01750062112 D . 'Home position sensor' Hybrid photosensor for timing disk in hinged drive unit 2 Photosensor. VLS14 Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . empty dispensing sensor (LAM) Photosensor 'medium in intermediate transport' Hybrid photosensor for width setting.Buy Now to Create PDF without Trial Watermark!! Faults Sensor UDS VHS1 VHS2 VLS1 VLS2 VLS3 VLS4 VLS5 VLS6 VLS7 VLS8 VLS9 Sensors and actuators Function Ultrasound sensor for double document Hall sensor foreign object detector (operator side) Hall sensor foreign object detector (rear panel side) Photosensor bundle input/bundle output Photosensor between input/output transport for separator unit ('Detection of last medium') Hybrid photosensor for monitoring lowering of hinged drive unit 1. 'Home position sensor' Hybrid photosensor at cam for the motion of the counterrotation shaft 'Home position sensor' Photosensor in input / output unit for controlling removal Photosensor in input / output unit for controlling insertion and removal Photosensor for monitoring documents in the input/output area Photosensors for monitoring document edges in the input/output area VLS10 VLS11 VLS12 VLS13. 'Home position sensor' Hybrid photosensor for monitoring lowering of hinged drive unit 2.Service Manual 8-49 . Service Manual 01750062112 D .Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Faults Alignment station Actuator AMG1 ASM1 ASM2 Sensor ALS1 ALS2 ALS3 ALS4 Deflector W1 Function Electrical solenoid plunger for deflector 1 Stepper motor for driving transport rollers Stepper motor for driving alignment rollers Function 1st photosensor for recognizing a medium in the transport path 1st photosensor with slit stop for monitoring the alignment of checks on the surface of the drum 2nd photosensor with slit stop for monitoring the alignment of checks on the surface of the drum 2nd photosensor for recognizing a medium in the transport path Function Deflector check alignment/further transport Created by eDocPrinter PDF Pro!! 8-50 CCDM . Buy Now to Create PDF without Trial Watermark!! Faults Sensors and actuators Magnetic ink character reader Actuator SMG1 Function Electric lifting magnet for raising the magnetic head assembly when banknotes pass. check/cash reader and sensor transport Stepper motor for controlling deflector W2 Stepper motor for controlling deflector W3 Stepper motor for driving the transport belt in intermedia transport Stepper motor for driving the transport belt in deposit transport SSM2 SSM3 VSM4 KSM1 Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . Function Magnetic read head and permanent magnetic head for premagnetization Photosensor for magnetic read head Sensor SMIC SLS3 Check / cash reader Sensor CCE1 CCE2 Function Scanner line for the bottom of the medium Scanner line for the top side of the medium Sensor / deposit transport Actuator SSM1 Function Stepper motor for driving the transport rollers and belts in the magnetic character reader.Service Manual 8-51 . This photosensor is parallel to the RLS1. beginning and end detector for entering and exiting medium only chassis P: Photosensor for recognizing a medium between the sensor transport and storage or reject transport. beginning and end detector for entering and exiting medium Hybrid photosensor for monitoring the upper tape.Service Manual 01750062112 D . Hybrid photosensor for determining the tape speed Photosensor.Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Sensor SLS1 RLS1 Faults Function Photosensor for recognizing a medium in sensor transport Photosensor for recognizing a medium between the sensor transport and storage or reject transport. Hybrid photosensor for monitoring the lower tape. Photosensor. Hybrid photosensor for recognizing the position of deflector 2 Hybrid photosensor for recognizing the position of deflector 3 Function Redirection escrow unit / reject compartment or cassette storage Redirection reject compartment / cassette storage DLS1 SLS2 SLS4 Deflector W2 W3 Escrow unit Actuator ESM1 Function Drive motor escrow unit. Stepper motor inside the drum for driving the drum and the tape winding mechanism Function Beginning and end photosensor. the photosensor serves to recognize the beginning and end of the tape or a rip in the tape. prenotification for ELS1 when documents are unwound Sensor ELS1 ELS2 ELS3 ELS4 ELS5 Created by eDocPrinter PDF Pro!! 8-52 CCDM . the photosensor serves to recognize the beginning and end of the tape or a rip in the tape. Service Manual 8-53 . for lifting and lowering the belt drive and for moving the note stop. photosensor for controlling the rotation of the camshaft 'Detection of home position' Sensor RLS1 RLS2 RLS3 Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . Function Photosensor recognizing beginning/end of medium. for moving reject storage sideways. Photosensor for recognizing a medium between the sensor transport and stacker or reject transport. beginning and end detector for entering and exiting medium Photosensor collecting compartment Hybrid photosensor for camshaft.Buy Now to Create PDF without Trial Watermark!! Faults Sensors and actuators Printing station Actuator DSM1 Print head Sensor DLS1 DLS2 Function Stepper motor for ribbon transport Function Reflective photosensor in front of the print head (as seen from the escrow unit) (only chassis II) Reflective photosensor behind the print head for checking print function (before/after) (only chassis II) Reject transport Actuator RSM1 RSM2 Function Stepper motor for driving the transport belt Stepper motor for bundling in reject compartment. photosensor. Service Manual 01750062112 D .Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Faults Cassette module Actuator KDC1 KDC2 KSM2 KSM3 KSM4 KSM5 KSM6 KSM7 Sensor KHS1 KHS2 KHS3 KHS4 KHS5 KHS6 KHS7 KHS8 KHS9 Function DC motor for adjusting the plate in the cassette 1 (right cassette) DC motor for adjusting the plate in the cassette 2 (left cassette) Stepper motor for driving the separator transport and driving the check/cash transfer mechanism Stepper motor for driving the stacking wheel in cassette 1 (right cassette) Stepper motor for driving the stacking wheel in cassette 2 (left cassette) Stepper motor for controlling the retract deflector and the media deflector Stepper motor for controlling the cassette 1 or cassette 2 deflector Stepper motor for activating the counterfeit notes compartment Function Hall sensor for stacking wheel position cassette 1 (right cassette) for monitoring the stacking wheel position (every 120°) Hall sensor cassette 1 'Plate up' for detecting position 'Plate up' Hall sensor cassette 1 'Plate down' for detecting position 'Plate down' (cassette full) Hall sensor for stacking wheel position cassette 2 (left cassette) for monitoring the stacking wheel position (every 120°) Hall sensor cassette 2 'Plate up' for detecting position 'Plate up' Hall sensor cassette 2 'Plate down' for detecting position 'Plate down' (cassette full) Hall sensor for cassette 1 (right cassette) present Hall sensor for retract cassette present Hall sensor for cassette 2 (left cassette) present Created by eDocPrinter PDF Pro!! 8-54 CCDM . Hybrid photosensor in cassette 2 for reporting 'Cassette 2 full'. digital: The hybrid photosensor inside the cassette reports: The cassette contains checks / banknotes Sharp GP1A71A: The switch is activated by the operator.Buy Now to Create PDF without Trial Watermark!! Faults Sensor KLS2 KLS3 KLS4 KLS5 KLS6 KLS8 KLS9 KLS10 KLS11 KLS12 KLS1_1 Sensors and actuators Function Photosensor in transport path at start of cassette module Photosensor in transport path before retract cassette Hybrid photosensor for detecting the retract cassette Hybrid photosensor for recognizing the position of deflector W4 (and deflector W5) Hybrid photosensor for recognizing the position of deflector W5 Photosensor in transport path before cassette 1 (right cassette) Photosensor for monitoring the touch activation force exerted by stack against stacking wheel 'Cash' Hybrid photosensor for recognizing the position of the counterfeit notes compartment Photosensor in transport path before cassette 2 (left cassette) Photosensor for monitoring the touch activation force exerted by stack against stacking wheel 'Cash' Hybrid photosensor for recognizing the stacking wheel position cassette 1 for monitoring the stacking wheel position (every 120°) Hybrid photosensor in cassette 1 for detecting 'Lifting plate up' for reporting 'Lifting plate up' position. Hybrid photosensor.Service Manual 8-55 . outward optical marking (green/black) and electrically to the system. KLS1_2 KLS1_3 KLS1_4 KLS1_5 KLS2_1 KLS2_2 KLS2_3 Created by eDocPrinter PDF Pro!! 01750062112 D CCDM . Photosensor in the plastic cassette 1 for message 'Cassette full' Hybrid photosensor for recognizing the stacking wheel position cassette 2 for monitoring the stacking wheel position (every 120°) Hybrid photosensor in cassette 2 for detecting 'Lifting plate up' for reporting 'Lifting plate up' position. Hybrid photosensor in cassette 1 for reporting 'Cassette 1 full'. Buy Now to Create PDF without Trial Watermark!! Sensors and actuators Sensor KLS2_4 Faults Function Hybrid photosensor. If the cassette is in the device and the cassette door is opened. If the cassette is removed . Photosensor in the plastic cassette 2 for message 'Cassette full' Cassette 1: The microswitch is located in the cassette. outward optical marking (green/black) and electrically to the system. the switch also opens and reports: 'Door open'.plug connection interrupted message the same as if door is opened.plug connection interrupted message the same as if door is opened. digital: The hybrid photosensor inside the cassette reports: The cassette contains checks / banknotes Sharp GP1A71A: The switch is activated by the operator. Function Deflector for directing medium into the retract cassette or in cassettes 1 or 2 Deflector for directing medium into cassette 1 or in cassette 2 KLS2_5 KMS1 KMS2 Deflector W4 W5 Created by eDocPrinter PDF Pro!! 8-56 CCDM . If the cassette is in the device and the cassette door is opened.Service Manual 01750062112 D . Cassette 2: The microswitch is located in the cassette. the switch also opens and reports: 'Door open'. If the cassette is removed .