Bill Alignment Dispenser

BILL ALIGNMENT DISPENSERS
Contents
Bill Alignment Dispensers
Chapter 12.8
INTRODUCTION ...................................................................................................... 12.8-1

AREAS OF CHANGE........................................................................................... 12.8-1
PICK MODULES .................................................................................................. 12.8-2
SINGLE AND DUAL CONFIGURATION (P86) ................................................ 12.8-2
GENERAL DESCRIPTION ....................................................................................... 12.8-3

OPERATIONAL ENVIRONMENT ..................................................................... 12.8-3
VARIANTS ........................................................................................................... 12.8-3
CONTAINERS ...................................................................................................... 12.8-3
Currency Cassette.............................................................................................. 12.8-3
Purge Bin........................................................................................................... 12.8-4
SECURITY ............................................................................................................ 12.8-5
Standard Security .............................................................................................. 12.8-5
Tamper Indicating ............................................................................................. 12.8-5
Cash Security..................................................................................................... 12.8-5
SPECIFICATIONS ................................................................................................ 12.8-6
Currency Dimensions........................................................................................ 12.8-6
Test Media......................................................................................................... 12.8-6
Power Requirements ......................................................................................... 12.8-8
Weight ............................................................................................................... 12.8-8
Dispenser Dimensions....................................................................................... 12.8-8
EMC .................................................................................................................. 12.8-9
ESD ................................................................................................................... 12.8-9
Acoustic Noise Emission .................................................................................. 12.8-9
FUNCTIONAL DESCRIPTION .............................................................................. 12.8-10
MECHANICAL DESCRIPTION ............................................................................. 12.8-10

PATH OF NOTES ............................................................................................... 12.8-10
Forming the Stack ........................................................................................... 12.8-10
Present ............................................................................................................. 12.8-11
Purge................................................................................................................ 12.8-12
Sensors ............................................................................................................ 12.8-13
PICK MODULE .................................................................................................. 12.8-14
NCR CONFIDENTIAL AND PROPRIETARY

Use pursuant to Company Instructions
12.8-i MAY 2003

PRESENTER MODULE ..................................................................................... 12.8-15

Linear Variable Displacement Transducer (LVDT) ....................................... 12.8-15
Main Timing Disk ........................................................................................... 12.8-16
Flicker Shaft, Anti-Static Brush, and Deflectors............................................. 12.8-17
Bill Alignment Assembly................................................................................ 12.8-17
Note Clamp ..................................................................................................... 12.8-19
Presenter Transport ......................................................................................... 12.8-21
Presenter Timing Disk..................................................................................... 12.8-23
Transport Sensors ............................................................................................ 12.8-24
Exit Sensor ...................................................................................................... 12.8-25
Shutter Assembly ............................................................................................ 12.8-26
Purge Bin Location Components .................................................................... 12.8-26
Purge Transport ............................................................................................... 12.8-27
Purge Sensor.................................................................................................... 12.8-27
Main Motor and Vacuum Pump...................................................................... 12.8-27
Motor Control Circuit...................................................................................... 12.8-28
ELECTRICAL DESCRIPTION ............................................................................... 12.8-28
CURRENCY DISPENSER CONTROL BOARD ................................................... 12.8-29

VOLTAGE AND CURRENT ............................................................................. 12.8-31
COMPATIBILITY............................................................................................... 12.8-31
DISPENSER SECURITY SWITCH ................................................................... 12.8-31
SCHEMATIC DESCRIPTION............................................................................ 12.8-31
INTEL386TM EX EMBEDDED MICROCONTROLLER ................................ 12.8-31
Clock and Power Management Unit ............................................................... 12.8-32
Chip Select Unit .............................................................................................. 12.8-32
Parallel I/O Unit .............................................................................................. 12.8-35
Asynchronous Serial I/O Unit ......................................................................... 12.8-37
Interrupt Control Unit...................................................................................... 12.8-37
Timer/Counter Unit ......................................................................................... 12.8-38
Watchdog Timer Unit...................................................................................... 12.8-39
DMA and Bus Arbiter Unit ............................................................................. 12.8-40
Synchronous Serial I/O Unit ........................................................................... 12.8-40
Refresh Control Unit ....................................................................................... 12.8-41
JTAG-Compliant Test-Logic Unit .................................................................. 12.8-41
EXTERNAL PERIPHERALS ............................................................................. 12.8-42
CPLDs ............................................................................................................. 12.8-42
Programmable Interval Timer ......................................................................... 12.8-43
USB Interface.................................................................................................. 12.8-43
Configuration Switches ................................................................................... 12.8-43
Diagnostic LEDs ............................................................................................. 12.8-43
Memory Requirements.................................................................................... 12.8-43
Clock and COMCLK ...................................................................................... 12.8-44
A/D Converter ................................................................................................. 12.8-44
COMMUNICATIONS INTERFACE.................................................................. 12.8-46
SDC Interface.................................................................................................. 12.8-46
RS-232 Interface ............................................................................................. 12.8-46
RS-232 Diagnostics Interface.......................................................................... 12.8-46
OPERATION OF TRANSPORT SENSOR LEDS ............................................. 12.8-47
OPERATION OF TSEN5 AND TSEN2 LEDS/PHOTO-SENSORS ................. 12.8-47
MAIN TRANSPORT TIMING DISK ................................................................. 12.8-47

MAY 2003 12.8-ii

STEPPER MOTOR OPERATION ...................................................................... 12.8-47

Stepper Motor Speed ....................................................................................... 12.8-48
Stepper Motor Characteristics......................................................................... 12.8-48
PICK MODULE PRESENT IDENTIFICATION ............................................... 12.8-48
SECURITY SHUTTER OPERATION ............................................................... 12.8-48
SPLIT PURGE BIN ............................................................................................. 12.8-49
HARDWARE RESET CONTROL ..................................................................... 12.8-49
Watchdog Signal ............................................................................................. 12.8-49
Reset Control Lines......................................................................................... 12.8-49
AC MOTOR......................................................................................................... 12.8-50
CONNECTOR ASSIGNMENT ............................................................................... 12.8-50

Power Interface ............................................................................................... 12.8-50
SDC Interface.................................................................................................. 12.8-51
RS-232 Communications Interface ................................................................. 12.8-51
RS-232 Diagnostic Interface ........................................................................... 12.8-51
Transport LEDs and Sensors........................................................................... 12.8-52
On-Board Shutter ............................................................................................ 12.8-52
Pick Modules................................................................................................... 12.8-53
Note Thickness Sensor / LVDT ...................................................................... 12.8-53
Stepper Motors ................................................................................................ 12.8-53
RDI Interface................................................................................................... 12.8-54
Intelligent Cassette Interface ........................................................................... 12.8-54
Universal Serial Bus (USB) Interface ............................................................. 12.8-54
Stepper Motor Sensors .................................................................................... 12.8-55
JTAG Interface ................................................................................................ 12.8-55
Split Purge Bin Interface ................................................................................. 12.8-55
SINGLE PICK INTERFACE BOARD .................................................................... 12.8-56

PERSONAS 86 CURRENCY DISPENSER ....................................................... 12.8-56
NEW INTERIOR DISPENSER AND P87 DISPENSER ................................... 12.8-56
DOUBLE PICK INTERFACE BOARD .................................................................. 12.8-56
TRANSPORT AND TIMING SENSORS AND LEDS ........................................... 12.8-57

LINEAR VARIABLE DISPLACEMENT TRANSDUCER (LVDT) ................ 12.8-57
Bill Detection Voltage Waveforms ................................................................. 12.8-59
FIRMWARE DESCRIPTION .................................................................................. 12.8-61

PERIPHERAL CONTROL INTERFACE........................................................... 12.8-62
Diagnostics Switch Pack (P86 and NID Currency Dispenser
Control Boards) ............................................................................................... 12.8-62
SDC Command Switch Pack........................................................................... 12.8-62
SDC INTERFACES............................................................................................. 12.8-63
SDC Secondary Communications Interface.................................................... 12.8-63
SDC NVRAM Interface .................................................................................. 12.8-63
HOST SYSTEM INTERFACE ........................................................................... 12.8-64
DEVICE CONTROL INTERFACE .................................................................... 12.8-64
INTELLIGENT CONTAINERS INTERFACE .................................................. 12.8-64
TAMPER INDICATE SERVICE ........................................................................ 12.8-64
HARDWARE INTERFACE................................................................................ 12.8-65
NODE CONTROL APPLICATION (NCA) INTERFACE ................................ 12.8-65

12.8-iii MAY 2003

FIRMWARE COMMANDS................................................................................ 12.8-65

I/O Commands ................................................................................................ 12.8-65
Diagnostic Commands .................................................................................... 12.8-66
Dispense Enable Switch .................................................................................. 12.8-67
Tamper Indicating Commands ........................................................................ 12.8-67
POWER-UP/SYSTEM RESET INITIALIZATION ........................................... 12.8-67
Firmware Initialization .................................................................................... 12.8-67
Bill Width and Singularity Learning ............................................................... 12.8-67
Device Initialization ........................................................................................ 12.8-68
VIRTUAL CASSETTE TYPES .......................................................................... 12.8-68
BILL SINGULARITY ......................................................................................... 12.8-68
LVDT (SINGULARITY DETECTION) CIRCUIT SELF CALIBRATION...... 12.8-69
BILL PRESENTATION ORDER ....................................................................... 12.8-69
CASSETTE IDENTIFICATION ......................................................................... 12.8-70
INTELLIGENT CASSETTE SECURITY (ICS) ................................................ 12.8-71
LEVEL 0 .............................................................................................................. 12.8-71
LEVEL 1 .............................................................................................................. 12.8-71
FIRMWARE MAP .............................................................................................. 12.8-71
ERROR RECOVERY.......................................................................................... 12.8-72
Error Reporting ............................................................................................... 12.8-72
Error Recovery Procedures ............................................................................. 12.8-73
Error Thresholding .......................................................................................... 12.8-77
STATE OF HEALTH (SOH) ................................................................................... 12.8-78

UPDATING STATE OF HEALTH..................................................................... 12.8-78
DEFINITION OF MODULES NVRAM............................................................. 12.8-79
Terminal Management Subsystems (TMS)..................................................... 12.8-79
Module History Area....................................................................................... 12.8-79
State Of Health Updating ................................................................................ 12.8-79
THE DISPENSE OPERATION ............................................................................... 12.8-80
SERVICE AIDS ....................................................................................................... 12.8-85
CURRENCY EVALUATION QUALIFICATION PROCEDURE......................... 12.8-85

CALIBRATING THE DISPENSER ................................................................... 12.8-85
ESTABLISHING SINGULARITY AND SIZE .................................................. 12.8-87
Calculation of Reject Rate............................................................................... 12.8-91
ERROR MESSAGES .......................................................................................... 12.8-91
Dispenser Clear Transport Error ..................................................................... 12.8-91
Change Parameter Errors ................................................................................ 12.8-92
Learn Parameter Errors ................................................................................... 12.8-92
ELECTRICAL AND MECHANICAL ADJUSTMENTS ....................................... 12.8-94

DRIVE BELT TENSION .................................................................................... 12.8-94
P86/P87 Drive Belt Arrangement. .................................................................. 12.8-94
NID Front Access Drive Belt Arrangement .................................................... 12.8-95
REMOVING THE ELECTRONICS BOX (P86/P87)......................................... 12.8-95
REMOVING THE CONTROL BOARD .......................................................... 12.8-100
P86/P87 Dispenser ........................................................................................ 12.8-100
New Interior Dispenser ................................................................................. 12.8-102

MAY 2003 12.8-iv

REMOVING THE MAIN MOTOR (NID) ....................................................... 12.8-103

Front Access NID.......................................................................................... 12.8-103
REMOVING THE LVDT.................................................................................. 12.8-104
P86/P87 Dispenser ........................................................................................ 12.8-104
Front Access NID.......................................................................................... 12.8-105
ELECTRONIC VERIFICATION OF LVDT .................................................... 12.8-106
PICK MODULE TIMING ................................................................................. 12.8-106
LEVEL 0 DIAGNOSTIC TESTING...................................................................... 12.8-107

P86 AND NID CURRENCY DISPENSER CONTROL BOARDS ................. 12.8-107
SWITCHES AND LEDs INTERFACE............................................................. 12.8-107
MODE OPTION ................................................................................................ 12.8-107
ON-BOARD SWITCH SETTINGS .................................................................. 12.8-107
TEST SEQUENCES .......................................................................................... 12.8-108
TEST DESCRIPTIONS ..................................................................................... 12.8-108
TEST ROUTER ................................................................................................. 12.8-108
TEST 01H - MICROCONTROLLER CONFIDENCE AND EPROM
SUMCHECK ..................................................................................................... 12.8-109
TEST 02H - SRAM DATA ............................................................................... 12.8-110
TEST 03H - SRAM ADDRESS ........................................................................ 12.8-110
TEST 04H - ALL RAM DATA ......................................................................... 12.8-111
LEVEL 1 DIAGNOSTIC TESTS........................................................................... 12.8-112

DIAGNOSTICS TEST MENUS ....................................................................... 12.8-112
CLEAR.......................................................................................................... 12.8-112
SET NOTES .................................................................................................. 12.8-112
STACK.......................................................................................................... 12.8-112
PRESENT...................................................................................................... 12.8-113
DISPENSE .................................................................................................... 12.8-113
MAIN MOTOR............................................................................................. 12.8-113
SELF TEST ................................................................................................... 12.8-113
EXIT SHUTTER........................................................................................... 12.8-113
SENSOR/SWITCH STATUS ....................................................................... 12.8-113
PRESENTER BILL DRIVE ......................................................................... 12.8-113
LEARN BILL PARAMETERS .................................................................... 12.8-113
PRESENTER CLAMP.................................................................................. 12.8-114
PICK VALVE ............................................................................................... 12.8-114
SDC TURNAROUND .................................................................................. 12.8-114
RUN-TO-RUN .............................................................................................. 12.8-114
Gulp Feed Detector Switch ........................................................................... 12.8-114
M_STATUS AND M_DATA............................................................................ 12.8-115
Actual to Virtual Cassette Mapping .............................................................. 12.8-115
CURRENCY DISPENSER TI........................................................................... 12.8-116
Diagnostics Test Menu.................................................................................. 12.8-116
TAMPER INDICATION .............................................................................. 12.8-116

12.8-v MAY 2003

LEVEL 3 DIAGNOSTICS ..................................................................................... 12.8-117

S_DATA ............................................................................................................ 12.8-117
TALLIES ........................................................................................................... 12.8-117
Transaction Tallies ........................................................................................ 12.8-117
TMS Interface Support Area Tallies ............................................................. 12.8-118
STRAPPING........................................................................................................... 12.8-119
P86/NID CURRENCY DISPENSER CONTROL BOARDS .......................... 12.8-119
PREVENTIVE MAINTENANCE ......................................................................... 12.8-120

P86 PRESENTER .............................................................................................. 12.8-120
P87 PRESENTER .............................................................................................. 12.8-121
ELECTRONICS BOX (P86 AND P87) ............................................................ 12.8-122
NID FRONT ACCESS PRESENTER ............................................................... 12.8-122
PM PROCEDURES ........................................................................................... 12.8-123
CURRENCY/MEDIA CONTAINERS ............................................................. 12.8-123
PICK MODULES .............................................................................................. 12.8-123
Suction Cups ................................................................................................. 12.8-124
PRESENTER ASSEMBLY ............................................................................... 12.8-125
SHUTTER ASSEMBLIES ................................................................................ 12.8-125
LUBRICATION ..................................................................................................... 12.8-126

LUBRICANT TYPE.......................................................................................... 12.8-126
GENERAL INSTRUCTIONS ........................................................................... 12.8-126
Presenter Assembly ....................................................................................... 12.8-127
Pick Module .................................................................................................. 12.8-127
INTERNAL CABLES ............................................................................................ 12.8-128

DISPENSER MAIN MOTOR (P86 AND P87) ................................................ 12.8-128
DISPENSER MAIN MOTOR (NID) ................................................................ 12.8-128
P86 AND P87 DISPENSERS INTERCONNECTION DIAGRAM ................. 12.8-129
P86 AND P87 PRESENTERS CABLING (SHEET 1 OF 3) ............................ 12.8-130
NEW INTERIOR DISPENSER INTERCONNECTION DIAGRAM.............. 12.8-133
NID FRONT ACCESS PRESENTER CABLING (SHEET 1 OF 4) ................ 12.8-134
ASSEMBLY AND SCHEMATIC DIAGRAMS ................................................... 12.8-138

MAY 2003 12.8-vi

Contents
Chapter 12.8
Bill Alignment Dispensers
INTRODUCTION
This chapter describes NCR currency dispensers that form the stack of bills
using the bill alignment mechanism in place of the stacker wheel of the 56XX
Dispenser. These dispensers are:
The Personas 86 Currency Dispenser introduced in the NCR Personas 86
ATM
The Front Access New Interior Dispenser (NID) introduced in the NCR
Personas 77 ATM
The Personas 87 Currency Dispenser (short-nosed version of the P86
using the NID Control Board).
NOTE: 1. The stacker wheel type of currency dispenser used in some early
P86 ATMs is described in Appendix A of Chapter 12.6.
NOTE: 2. Differences between dispenser types are pointed out in the text.
AREAS OF CHANGE
The major areas of change between the Bill Alignment type dispensers and
other dispensers in the NCR range are:
Mechanical changes:
Reduced height presenter module 100 mm (4 in.) less in height than
the presenter in the 56XX dispenser
New bill alignment mechanism replaces the stacker wheel
Main motor and control board fastened to detachable assembly (P86
dispenser only)
Aria pick modules introduced on P86 dispenser.
Electrical:
The bill alignment dispenser is made in 115 V and 230 V main motor
variants with the NID additionally built in a 100 V version for Japan
New dispenser control printed circuit board (P86 and later NID type)
New Linear Variable Displacement Transducer (LVDT) with on-pcb
coils
LEDs and sensors are permanently attached to the harness
No pre-LVDT sensor
No gulp feed detection or low temperature detection.

12.8-1 MAY 2003

Software:
Changes to control new electronics.
PICK MODULES
The Bill Alignment Dispenser can use the Aria or the 56XX single and double
pick modules. Aria pick modules are described in Chapter 12.9. Refer to
Chapter 12.6 for the description of the 56XX type.
NOTE: 1. Where there is a mixture of Aria and 56XX type pick modules,
then the Aria type must always be put to the lower positions.
NOTE: 2. The Aria single and double pick modules were designed originally
for the Personas 86 Currency Dispenser but are interchangeable with the
56XX Enhanced Currency dispenser pick modules. They can not, however,
be used with the H-8010-56XX-XX-08 and H-8010-56XX-XX-08 (IE)
presenters. The Personas 86, 87, and NID presenters can not be used with
earlier versions of the currency dispenser.
SINGLE AND DUAL CONFIGURATION (P86)
The Personas 86 is available in either single cash dispenser configuration or, if

running on an NT platform, dual cash dispenser configuration. A single,
4-high dispenser can be configured to recognize up to seven different
denominations of currency, one from each possible cassette type. It is limited
to dispensing four denominations because of the maximum number of
cassettes it can hold. In the dual dispenser, the second dispenser may be
configured with a further seven denominations against the seven cassette
types giving a total of 14 denominations but again limited to dispensing eight
at any one time because of the physical maximum number of cassettes (2 x 4-
high).

MAY 2003 12.8-2

GENERAL DESCRIPTION
Bill alignment dispensers present a bunch of up to 40 bills in up to four
denominations of currency to the cardholder. A detect and purge system
controls the movement of currency along the transport. Misfed or damaged
currency is bunched and driven into a purge bin. The option is available, via
application commands, to retract currency presented to the cardholder but not
taken, to the purge bin.
OPERATIONAL ENVIRONMENT
The dispenser operates as an intelligent module under the control of its own
onboard microprocessor. It communicates with the ATM central processing
unit over the SDC serial bus. Dispenser device control firmware, resident in
the dispenser memory, interfaces to the ATM transaction control and
diagnostic programs.
VARIANTS
The variants of the currency dispenser are designated as follows:
115 V or 230 V Electronics Box (P86 and P87)
100 V, 115 V, 230 V versions (NID)
2, 3, and 4 Standard Width Cassettes*
2, 3, and 4 Standard Width, Tamper Indicating Cassettes*
2, 3, and 4 Position, No Cassettes*
Open Purge Bin
Latchfast Purge Bin.
NOTE: * The P86 dispenser and the NID are only available in 2, 3 and 4
high variants.
CONTAINERS
Currency Cassette
1
3 2
5 4
7 6
A
B
1 C
D
2 E
F
G
3
4
5
6
7 A
B
C
D
E
F
G
Currency in the dispenser is contained within currency cassettes, and these

are used to transport currency to and from the ATM. The cassettes are
provided in the following optional levels of security:

12.8-3 MAY 2003

Standard currency cassette (now obsolete):

Latchfast
Tamper indicating (mechanical).
Wide currency cassettes (replaces obsolete standard width cassette):
Standard Security variant
Tamper indicating variant
Cash Security variants:
Intelligent Cash Security (ICS) variant
ATM Cash Security variant.
The dispenser is capable of using all the currency cassettes developed for
5070/80/81/84/85/88 ATMs.
NOTE: A full description of the currency cassette is given in Chapter 12.2.
Purge Bin
Rejected currency is diverted to the purge bin in the dispenser. The purge bin
is provided in the following optional levels of security:
Latchfast plastic bin (shown in the illustration above)
Open.

MAY 2003 12.8-4

SECURITY
Three levels of security are available in respect to the physical security of the
currency:
Standard security
Tamper indicating with mechanical devices
Cash Security variants:
Intelligent Cash Security (ICS) variant
ATM Cash Security variant.
Standard Security
The currency cassettes and purge bin remain seal-fast secure when the ATM
is opened. Latch-fast security provides a level of security where access to the
currency can not be achieved without using a simple tool.
Tamper Indicating
Tamper-indicating security prevents access to the currency in the currency
cassettes and dispenser transport by using seal-fast containers and covers.
Tamper indicating on the currency cassettes is by multi-shot mechanical
containers.
NOTE: Mechanical indicators are not available on the purge bin. A dispenser
ordered with mechanical TI is supplied with a standard latch-fast purge
bin with a sealable door lock.
Cash Security
There are two types of Cash Security currency cassettes: the Intelligent Cash
Security (ICS) cassette and the ATM Cash Security cassette. Both are
designed to fit into a security system that injects a marking ink onto the
currency within the cassette if the ATM is attacked. The currency is
permanently stained and therefore no longer of any use. Because of this, it is
very important that the correct procedures be observed when handling this
type of cassette.

12.8-5 MAY 2003

SPECIFICATIONS
Currency Dimensions
Currency Length
Currency
Width
Cassette Body
Width
1
3 2
5 4
7 6
A
B
1 C
D
2 E
F
G
3
4
5
6
7 A
B
C
D
E
F
G
The dispenser is capable of dispensing new or used currency of the following

dimensions:
Width:
Minimum 62 mm (2.44 in.)
Maximum 95 mm (3.74 in.).
Length:
Minimum 120 mm (4.72 in.)
Maximum 178 mm (7.01 in.).
Test Media
Size
The following requirements for paper, used as test media (bills) is provided for
information only. The size of test media that can be used in the dispenser is as
follows:
Length: (Standard Plastic Cassette):
Minimum - 120 mm (4.72 in.)
Maximum - 170 mm (6.70 in.).
Length: (Wide Plastic Cassette):
Maximum - 172 mm (6.78 in.).
Length (Wide Aluminium Cassette):
Maximum - 178 mm (6.78 in.).
Width (All cassettes):
Maximum - 95 mm (3.74 in.).
Width and Length tolerance 2mm.

MAY 2003 12.8-6

Thickness, including inking:

Minimum - 0.06 mm (0.002 in.)
Maximum - 0.26 mm (0.010 in.).
Thickness of intaglio inking:
Minimum - 0.00 mm (0.00 in.)
Maximum - 0.075 mm (0.003 in.).
Bill thickness tolerance 10%.
Material
The paper used for producing the test media (bills) must have the following
characteristics:
Paper Weight = 65 to 95 g/m2
Thickness (excluding ink) = 0.06 to 0.185 mm
Bendtsen roughness = 200 to 1200 ml/min.
Taber stiffness (machined direction) = 1.2 to 4.0 (cross direction) = 0.8 to
2.4
Bendtsen porosity = maximum 150 ml/min.
Single tear (machine direction) = minimum 230 mN (cross direction) =
minimum 270 mN
Contrast ratio opacity (including inking) - 79 to 93%
NOTE: The process of manufacturing paper aligns the majority of fibres in

the direction the paper passes through the rollers this is known as the
machined direction. The direction perpendicular to this is known as the
cross direction.
Intaglio Ink
The requirements for Intaglio inking are to prevent any keying effects where
the patterns on adjacent bills are such that they interlock inhibiting
separation when sliding one bill across the width of the adjacent bill.
Therefore certain geometric patterns on the paper are either authorized or
not.
Unauthorized Patterns -
A series of parallel lines greater than 30 degrees from the vertical. The
longest edge of the bill is defined as the horizontal
A series of concentric circles.
Authorized Patterns -
Cross hatching of lines to produce a diamond pattern
A series of intersecting circles.

12.8-7 MAY 2003

Power Requirements
The power requirements of the bill alignment dispenser are:
Direct current:
+5 V 5% 2.5 A
+12 V 10% 0.5 A
-12 V 10% 0.1 A
+24 V 10% 3.5 A.
Alternating current:
100 Vac, 3.0 A r.m.s., 5.0 A surge (NID only)
115 Vac, 5.5 A r.m.s., 20.0 A surge
230 Vac, 3.0 A r.m.s., 10.0 A surge.
Weight
The weights of the component parts of the dispenser are:
P86 Dispenser:
Basic unit (2 double pick modules + presenter) = 40.7 kg (89.73 lb.)
Presenter unit = 21.3 kg (46.96 lb.)
P87 Dispenser:
New Interior Dispenser (Front and Rear Access):
Single pick module = 6.3 kg (13.9 lb.)
Double pick module = 9.7 kg (21.38 lb.)
Currency cassette empty = 3.2 kg (7.05 lb.)
Currency cassette full = 6.0 kg (13.2 lb.)
Purge bin empty = 1.0 kg (2.2046 lb.)
Purge bin full = 1.3 kg (2.9 lb.).
Dispenser Dimensions
The dimensions of the dispenser with four pick modules (excluding ATM
interface requirements) are:
P86 Dispenser:
Width = 300 mm (11.81 in.)
Height = 700 mm (27.56 in.)
Depth = 831 mm (32.72 in.).
P87 Dispenser:
Width = 300 mm (11.81 in.)
Height = 700 mm (27.56 in.)
Depth = 650 mm (25.59 in.).
New Interior Dispenser (Front Access):
Width = 300 mm (11.81 in.)
Height = 780 mm (30.95 in.)
Depth = 650 mm (25.59 in.).

MAY 2003 12.8-8

EMC
The Bill Alignment Currency Dispenser as a stand-alone unit must meet the
following specifications:
FCC CFR47 part 15
EN 55022 Class A
When installed, the dispenser shall not prevent the ATM from achieving
FCC and CE Class A radiated and conducted limits with the following
margins:
Radiated Emission Margin = 4dB V/m
Conducted Emission Margin = 20dB V (QP)
ESD
The Bill Alignment Currency Dispenser complies with the following
specification when installed in an NCR ATM:
IEC 1000-4-2 with the following test levels
Air Discharge 8kV
Contact Discharge 4kV
Acoustic Noise Emission

Maximum noise emission levels shall be within CES 2-10-02 Category 2, and
further NCR Dundee limits, when operating within the parent ATM:
Sound Power:
65 dBA Idle
68 dBA Operating
Sound Pressure:
65 dBA Operating.

12.8-9 MAY 2003

FUNCTIONAL DESCRIPTION
The following sections describe the operation of the dispensers mechanical,
electrical/electronic, and firmware components under the headings:
Mechanical Description
Electrical Description
Firmware Description
MECHANICAL DESCRIPTION
The P86 Dispenser, the P87 Dispenser, and the New Interior Dispenser in the
P77 ATM are built with two, three, or four pick modules suspended below the
presenter module.
In the following description, the components are described in the order
they are encountered by notes passing through the dispenser.
PATH OF NOTES
The path of notes through the presenter is shown in the following diagrams:
Forming the Stack

Notes enter the presenter from the pick modules, pass the LVDT and are
projected against the bill stop gate of the bill alignment mechanism by the
flicker shaft fingers. They then fall on to the top off the note clamp transport
where they form a stack.
P86
P87

MAY 2003 12.8-10

NID Front Access
Present
The note clamp transport is lifted up so that the note stack is held against the
underside of the top set of presenter transport belts. The belts are driven and
the stack of notes is moved out to the facia exit slot where it is held for the
cardholder.
P86
P87

12.8-11 MAY 2003

NID Front Access
Purge
If the stack is not taken by the cardholder, or a mispick has been detected,
then the presenter transport is driven in reverse and the stack of notes is
moved into the purge bin.
P86
P87

MAY 2003 12.8-12

NID Front Access
Sensors
The position of the sensors that detect the movement of notes is shown in the
diagrams below:
P86
NOTE: Early P86 dispensers have a single sensor in the position T3. Later
models have two sensors T3 and T3A arranged across the width of the
transport as in the P87 and NID (see the section, Transport Sensors).
P87

12.8-13 MAY 2003

NID Front Access
PICK MODULE
The P86, P87, and NID Currency Dispensers may be configured with two,
three, or four pick modules hanging vertically below the presenter module.
Pick position number 1 is immediately below the presenter, number 2 is
below number 1, number 3 below number 2, and 4 below 3.
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. On some P86 dispensers the single pick module may be of the 56XX
type (described in Chapter 12.6) and on later P86 and all P87 and New
Interior Dispensers both single and double pick modules will be Aria type
(described in Chapter 12.9).
NOTE: Where there is a mixture of Aria and 56XX type pick modules, then
the Aria type must always be put to the lower positions.

MAY 2003 12.8-14

PRESENTER MODULE
The presenter module has the following functions:
stack up to 40 bills and present the stack to the cardholder
detect when the stack of bills is taken
control the exit shutter behind the ATM facia or an optional on-board
shutter
provide a housing for the purge bin
drive damaged, mispicked, or not-taken currency into the purge bin
detect when the purge bin is full
drive, through gearing, all the pick modules
detect the movement of bills through the transport
create the timing signal for the measurement of bill singularity
supply the pick vacuum to all the pick modules.
The components of the presenter which achieve these functions are:
linear variable displacement transducer (LVDT)
main timing disk
flicker shaft
bill alignment assembly and bill stop gate
note clamp, clamp arm, clamp motor, stack sensor
presenter transport and motor
presenter timing disk
transport sensors
exit sensor
shutter assembly
purge bin location components
purge transport
purge sensor
main motor and vacuum pump
vacuum pump and tubing
motor control circuit on the dispenser control board.
The following sections describe these components.
Linear Variable Displacement Transducer (LVDT)
Bills passed up from the pick modules enter the presenter via the LVDT
transport. This short transport is the only one in the presenter that is driven

12.8-15 MAY 2003

by the main motor and is linked via a gear train to the first pick module
transport.
The LVDT is a sensing device, situated in the transport just before the
flicker shaft, which gives an electrical output proportional to the displacement
of two movable roller assemblies caused by bills passing between them and
fixed reference rollers. The rollers are attached to ferrite cores which project
through sensing coils printed on a pcb. The output from the coils is digitized,
integrated, and is compared to the expected value (held in memory) for the
currency being dispensed. In this way torn, folded, or multiple bills are
detected. Refer to the Electrical Description section for a more detailed
description of the LVDT.
NOTE: There is no Pre-LVDT sensor on the bill alignment presenters. The

timing of the calculation is carried out by the LVDT itself.
Main Timing Disk

The main timing disk pulley is driven by toothed belt from the main motor.
Thirty-six 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 flicker shaft and as a
reference in the measurement of bill width. The interval between the
interrupts represents a distance travelled by the bill of approximately 1 mm.
P86/P87

MAY 2003 12.8-16

NID Front Access
Flicker Shaft, Anti-Static Brush, and Deflectors
The plastic fingers on the flicker shaft impart an extra impetus to the notes as
they leave the LVDT transport so that they are projected against the bill stop
gate of the bill alignment assembly. On the NID this action is augmented by a
second flicker shaft assembly with short flicker fingers. The longer flicker
fingers also drag the notes into the stack against plastic guides attached to the
LVDT transport.
Just as the notes leave the LVDT transport they pass through an anti-
static brush to remove any electric charge that would hinder them forming
into a stack. Above the anti-static brush two plastic note deflectors are clipped
between tie bars so that they brush across the upper surface of the note and
provide a light downward pressure to keep the trailing edge of the notes down
and aid the action of the flicker fingers.
Bill Alignment Assembly

The bill stop gate of the bill alignment assembly hangs down into the path of
the notes as they are flicked out of the LVDT transport. Notes strike the gate,
bounce back from it, and fall down on to the top of the note clamp transport
where they are dragged into a stack by the action of the flicker fingers.
The neat formation of the stack of notes depends upon the bounce given to
the notes by the gate which, in turn, depends on the position of the gate. The
gate hangs from a belt transport driven by a stepper motor controlled by the

12.8-17 MAY 2003

dispenser firmware. The position for the width of notes being dispensed is
calculated by the firmware from the note width stored in the dispenser bill
configuration procedure. During a transaction, if the width of notes to be
dispensed varies, the gate is moved to the new position before the next size is
dispensed. The recommended method of forming the stack is from the smallest
bills first, getting progressively larger, so that the bill alignment mechanism
moves out to accommodate each larger size. The zero reference position of the
bill alignment mechanism is sensed by the stack sensor which is interrupted
by a flag on the bill stop gate when the mechanism has been driven fully
forward. This is done at the start of every dispense and the gate is driven from
there to its calculated position.
When the stack of notes is completed, the gate is driven back slightly
towards the rear of the dispenser to clear the stack and the note clamp
transport is then raised. If the stack has been formed successfully, the notes
will be driven forwards by the presenter transport belts to be taken by the
cardholder. If, however, a fault has been detected, the notes will be driven to
the purge bin. To achieve this, the presenter transport drives the stack
forward until its trailing edge just passes the stack sensor. then the bill
alignment mechanism is driven towards the rear of the dispenser. This action
causes the bill stop gate to be lifted out of the presenter belt transport by the
action of passing over ramps attached to the side frames of the presenter. The
mechanism is sensed fully back and up by a second flag on the bill stop gate
interrupting the beam of the rear bill alignment sensor. The bill alignment
mechanism remains in this position during the purge cycle. The presenter
transport is then driven rearward to deliver the stack to the purge bin.
The following illustrations show the bill alignment assembly in the P86/
P87 and NID front access dispensers.
P86/P87

MAY 2003 12.8-18

NID Front Access
Note Clamp
The note clamp transport is a tray assembly that is raised and lowered by
semicircular cams (a single cam on earlier dispenser models) driven by a
stepper motor via a gear train. The transport consists of a set of three belts
held between two shafts at either end of the metal tray. One of the shafts is
driven by the presenter transport stepper motor via a toothed belt and the
other shaft is an idler. The transport belts run on crown pulleys on the shafts.
Also fixed to the clamp tray is the plastic stack tray. When the note clamp
transport is in the down position this stack tray is higher than the transport
belts so that the notes can stack on its top surface. As the transport is lifted by
the action of the cams the idler shaft lifts in elongated holes in the stack tray
so that the belts are lifted up above the surface of the stack tray and lift the
stack of notes from it. In this way, when the notes are driven by the presenter
transport they are not impeded by rubbing across the stack tray. Part of the
stack tray is shaped to project beyond the drive shaft to provide a support for
notes when being purged into the purge bin.
In its down position, the note clamp transport sits within a metal bracket,

12.8-19 MAY 2003

attached between the presenter side frames, that has vertical plates to
prevent notes from falling off the sides of the note clamp transport. Fingers on
the bill stop gate hang down through the slots in the stack tray to prevent any
notes from falling off the rear of the note clamp transport.
The note clamp transport is sensed in its up and down position by two
sensors that are interrupted by a flag on the shaft attached to the clamp
lifting cams. On the NID there is provision to add a third sensor that detects
the clamp transport in a mid-raised position. This is for future development in
dispensing small media. The stack of notes is sensed by the same sensor that
detects the forward position of the bill alignment assembly. The sensor looks
down through a hole in the tray of the clamp transport to an LED attached to
the metal bracket that provides the vertical side plates.

MAY 2003 12.8-20

Presenter Transport
P86
P87

12.8-21 MAY 2003

NID Front Access
The presenter transport consists of an upper set of three belts bearing against
a lower set of three belts, both sets driven by a stepper motor via toothed belts
at the left hand side of the dispenser. The transport belts pass across crown
pulleys on the drive and tension shafts. The lower set of belts runs from the
exit of the dispenser to just above the LVDT transport and the upper set runs
from the exit and extends over the note clamp transport.
Just after the note alignment mechanism backs away from the stack of
notes, the note clamp transport is raised by the rotation of the semicircular
cam. The clamp is lifted so that its belts press against the underside of the top
set of presenter transport belts and the note stack is held between both sets of
belts. The stepper motor then drives the presenter transport (and also through
a gearwheel the belts on the note clamp transport) so that the stack of notes is
moved to the exit held between the upper and lower presenter transport belts.
The toggle shaft at the exit compensates for different thicknesses of stack and
permits the stack to be pulled from the dispenser by the cardholder.
In the front access NID the transport belts pass around a large diameter
drum so that the stack of notes is turned through 180 degrees and then driven
to the exit above the purge bin. The NID has a nodding nose arrangement and
may optionally have an on-board shutter.

MAY 2003 12.8-22

Presenter Timing Disk

An opto-electronic sensor controls the time that the presenter stepper motor
has to be powered to drive the transport and stop it with the bills projecting
from the exit slot. The sensor beam is chopped by the segments on a timing
disk attached to the presenter transport drive shaft to produce interrupts
equivalent to travel of the stack of 1.6 mm on the P86/P87 and 1.5 mm on the
NID.
The illustration below shows the P86/P87 presenter timing disk.

12.8-23 MAY 2003

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. See the illustrations below and
also the diagrams in the section Path of Notes.
The photograph of the NID dispenser shows T3 and T3A arranged across
the width of the transport. These sensors and their respective LEDs are wired
in series and have been introduced to improve detection of certain world
currencies that have a transparent section as part of the bill design. The
single T3 of the P86 dispenser (shown below) was fitted to early models and
has now been replaced by the double sensor T3/T3A.
P86

MAY 2003 12.8-24

P87
NID Front Access
Exit Sensor
The last sensor on the transport is the exit sensor T5 which sees the stack in
the present position and detects when it is taken by the cardholder.

12.8-25 MAY 2003

Shutter Assembly
The dispenser control board incorporates the circuits to control a remote (facia
mounted) or on-board shutter. Refer to Chapter 12.3 for information on facia
mounted shutters.
The on-board shutter is an option on the New Interior Dispenser only. It is
opened via linkage by a solenoid. The open and closed positions of the shutter
are reported to the control board by an opto-electronic sensor that has its
beam interrupted by the solenoid linkage.
A second solenoid (the security solenoid) wired in parallel with the shutter
solenoid, moves linkage that locks the shutter in the closed position.
Purge Bin Location Components

The purge bin is held in the presenter 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 is operated by the inserted purge bin to
inform the electronics system that the bin is in place.
When a latchfast purge bin is installed, a keyplate enters holes in the top
front of a latchfast purge bin and pushes the truck door up into the top. The

MAY 2003 12.8-26

rear door of the latchfast purge bin is secured by a sealable latch.
Purge Transport
The purge transport consists upper and lower foam roller shafts driven via
toothed gears from the presenter transport and upper and lower plastic
guides. The extended portion of the note stack tray forms the lower note
support guides and an upper set of plastic guides is attached between the
drive shaft of the upper presenter transport belts and the upper foam roller
shaft.
On a purge, either due to a mispick being detected or the stack of notes not
being taken by the cardholder, the direction of the stepper motor driving the
presenter transport is reversed, (the bill alignment mechanism having been
previously driven to its rearmost and up position), thus moving the stack into
the note guides which direct the notes from the belts in between upper and
lower foam roll shafts. A friction clutch arrangement makes sure that the
foam roll shafts only drive when the presenter motor is reversed and the notes
are driven in the direction of the purge bin. The foam rollers complete the task
of pushing notes into the bin.
Purge Sensor
The movement of the stack into the purge bin is detected by a sensor and LED
that look across the path of the notes at the foam rollers. This sensor also
detects a bin overfill condition.
Main Motor and Vacuum Pump

The main motor drives the LVDT transport and all pick modules via toothed
timing belts. It also drives the vacuum pump to provide a vacuum to the pick
line via 6 mm bore tubing. A vacuum reservoir is located near the pump to
improve the system vacuum, and an air filter in the tubing above the first pick
module protects the pump from damage caused by ingress of grit particles.
On the P86 and P87 dispensers the motor and pump assembly is located

12.8-27 MAY 2003

in a separate electronic box assembly that also houses the dispenser control
board. This box is attached below the start of the long projecting nose of the
dispenser and is supplied in 230 V and 115 V versions.
On the front access NID the motor and vacuum pump are located at the
rear of the presenter next to the LVDT transport.
Motor Control Circuit

The motor control circuits are located on the dispenser control board. These
circuits include: the drive circuits for the main motor, the presenter transport
motor, the bill alignment motor, and the clamp motor.
ELECTRICAL DESCRIPTION
The components referred to in this section are those that achieve the control of
the dispenser either by converting firmware commands into electrical signals
or by sensing an event in the dispenser and producing an equivalent electrical
response. The components are:
currency dispenser control board
single pick interface board
double pick interface board
transport and timing sensors and LEDs
clamp up and down sensors
bill alignment forward and up sensors
main timing disk sensor
presenter timing disk sensor
pick timing sensor
the linear variable displacement transducer (LVDT)

MAY 2003 12.8-28

CURRENCY DISPENSER CONTROL BOARD

The following illustrations show the P86 Currency Dispenser and the NID
Control Boards. The NID Control Board is backwards compatible with the P86
type and is also used on the P87 dispenser.
The Universal Serial Bus connector J10 is removed from the NID board
and provision is made for a Split Purge Bin Interface to be developed. The
main visible difference is in the position of the Flex Authorization Switch,
which is at the top of the P86 board and at the right-hand side of the NID
board. The following description applies to both boards with the differences
pointed out in the text.
NOTE: Connector J3 is populated only on boards fitted to OEM dispensers.

12.8-29 MAY 2003

NOTE: Connector J3 is populated only on boards fitted to OEM dispensers.
The Currency Dispenser Control Board controls the operation of the

currency dispenser and monitors the currency path through the dispenser. It
is an intelligent board, responsible for collating all sensor information and
operating the individual pick modules, the presenter, the ac motor and stepper
motors, and also communicating commands and responses to the ATM core
processor.
The Currency Dispenser Control Board is a mixed technology pcb
employing both Surface Mount Technology (SMT) and Plated Through Hole
(PTH) components.
The functions of the Currency Dispenser Control Board can be
summarized as follows:
1. To co-ordinate operation of the currency dispenser transport hardware
including all motors, sensors, and actuators.
2. To process instructions from and provide responses to the ATM core elec-
tronics via either an SDC or (for OEM) an RS-232 interface.
3. To provide a power and logic interface to the associated single and double

MAY 2003 12.8-30

pick modules.
4. To provide a power and logic interface for future intelligent cassette and
purge bin modules.
VOLTAGE AND CURRENT

The Currency Dispenser Control Board requires the following voltages and
currents:
+5 V 0.25 V @ 2.5 A (max)
+12 V 1.2 V @ 0.5 A (max)
-12 V 1.2 V @ 0.1 A (max)
+24 V 2.4 V @ 3.5 A (max)
COMPATIBILITY
The SDC variant of the Currency Dispenser Control Board is designed for
operation in NCR P86 and New Interior Currency Dispensers. The RS-232
variant of the Currency Dispenser Control Board is designed for operation in
dispensers that are OEM models.
DISPENSER SECURITY SWITCH

Switch SW1 on the Currency Dispenser Control Board (sheet 8 of the control
board schematic diagrams) is used to authorize running level 1 diagnostic
tests: STACK, PRESENT, and DISPENSE. Refer to the section, Level 1
Diagnostic Tests.
SCHEMATIC DESCRIPTION
The sheet numbers referred to in the following text apply to the schematic
diagrams in the Currency Dispenser Schematic Diagrams section of this
chapter.
INTEL386TM EX EMBEDDED MICROCONTROLLER

The Currency Dispenser Control Board hardware is based around the Intel
Embedded 80386 microcontroller (80386EXTC) (sheet 3). This device is fully
specified in the Intel documentation:
Datasheet - Intel386TM EX Embedded Microprocessor
Intel386TM EX Embedded Microprocessor Users Manual.
The Intel386EXTC embedded processor is a highly integrated, 32-bit fully
static processor optimized for embedded applications. The device has a 16-bit
external data bus and a 26-bit external address bus. The microprocessor
integrates many commonly used DOS-type peripherals and a 32-bit
programming architecture compatible with the large software base of Intel386
processors.
The microprocessor has the following features:
Operating Frequency 33 MHz
Supply Voltage 4.5 V - 5.5 V
Packaging, 144-pin Thin Quad Flat Pack (TQFP)
Full 32-bit internal architecture:
8-, 16-, 32- bit, data types
Eight general purpose 32-bit registers.

12.8-31 MAY 2003

High performance 16-bit data bus:

Two clock bus cycles
address pipelining.
Integrated memory management unit:
virtual memory support
optional on-chip paging
Four levels of hardware enforced protection.
Large uniform address space:
64-megabyte physical
64-terabyte virtual
4-gigabyte maximum segment size.
Integrated peripheral functions:
Clock and Power Management Unit
Chip-select Unit
Parallel I/O Unit
Asynchronous Serial I/O Unit
Interrupt Control Unit
Timer/Counter Unit
Watchdog Timer Unit
DMA and Bus Arbiter Unit
Synchronous Serial I/O Unit
Refresh Control Unit
JTAG-compliant Test-logic Unit.
Clock and Power Management Unit

The clock generation unit includes a divide-by-two counter, a programmable
divider for generating a pre-scaled clock (PSCLK), and a divide-by-two
counter for generating baud-rate clock inputs and reset circuitry. The CLK2
input provides the fundamental timing for the chip. It is divided by two
internally to generate a 50% duty cycle Phase 1 (PH1) and Phase 2 (PH2) for
the core and integrated peripherals. for power management, separate clocks
are routed to the core (PH1C/PH2C) and the peripheral modules (PH1P/
PH2P). to help synchronize with external devices, the PH1P clock is provided
on the CLKOUT output pin.
The Intel386EXTC is supplied with a 66 MHz clock which is divided by
two internally to give the operation frequency for the device.
Two power management modes are provided for flexible power saving
options. During Idle mode the clocks to the CPU are frozen in a known state.
(PH1C low and PH2C high), while the clocks to the peripherals continue to
toggle. In Powerdown mode the clocks to both core and peripherals are frozen
in a known state (PH1C low and PH2C high). The bus interface unit will not
offer any DMA, DRAM refresh, or HOLD requests in Powerdown mode
because the clocks to the entire device are frozen.
Chip Select Unit

The Chip-Select Unit (CSU) decodes bus cycle address and status information
and enables the appropriate chip selects. The individual chip-selects become
valid in the same bus state as the address and become inactive when, either a
new address is selected or the current bus cycle is complete. The CSU is
divided into eight separate chip-select regions, each of which can enable one of

MAY 2003 12.8-32

the eight chip-select pins. Each chip-select region can be mapped into memory
or I/O space. A memory mapped chip-select region can start on any 2(n+1) Kbyte
address location (where n= 0 - 15, depending upon the mask register). The size
of the region is also dependent upon the mask used.
Chip selects generated by the CSU can be connected directly to the chip-
enable inputs of external memory and I/O devices. If a particular device or
address region does not require a chip-enable signal, a chip-select region can
be programmed to enable only termination of accesses to that region. A chip-
select region can also be programmed to generate a chip-enable signal and
terminate accesses to that region.
The CSU provides eight signals, or channels, allowing direct access to, up
to eight devices or address regions. each channel can be configured to operate
in either 16-bit or 8-bit bus mode, generate up to 31 wait states, and either
terminate a bus cycle automatically or wait for an external ready signal. Each
chip-select channel consists of address and mask registers and an output
signal. The address and mask registers define memory or I/O address blocks
for each channel. When the processor accesses a channels address block, the
CSU activates the channels output signal. Chip-select channels are not
activated during interrupt acknowledge cycles and halt and shutdown cycles.
The chip-select signals are allocated as follows:
Chip-Select Signal Function

CS0b PORT_ENb Enables latch to allow data to be written.
Enables latch to allow data to be read.
CS1b EN_LEDSb Enables latch to write data to LEDs.
Enables latch to read configuration switches.
CS2b A2Db Reads ADC output.
CS3b - Configured as bit 3 of Port 2, TXD.
CS4b - Configured as bit 4 of Port 2, RXD.
CS5b EN_TIMER_USBb Enables access to 82C54 Interval timer registers and USB
interface device registers.
CS6b RAM_CSb Enables SRAM
UCSb UCSb Enables EPROM
The signal PORT_ENb is further decoded in the decode CPLD (sheet 10)
on the Currency Dispenser Control Board to generate the signals:
PORT_MSB_RDb, PORT_LSB_RDb, PORT_MSB_WR, PORT_LSB_WR.
The signal PORT_LSB_WR (sheet 6) writes the following signals from the
lower 8 bits of the data bus to peripherals:
Data Bit Signal Function

0 RCODE0 Analogue multiplexer code 0
5 S0 Pick Module select ID0
6 S1 Pick Module Select ID1
7 NULL_NTS Strain Gauge Null
NULL_LVDT

12.8-33 MAY 2003

The signal PORT_MSB_WR (sheet 6) latches the following signals from

the upper 8-bits of the data bus to peripherals:

8 EN_CLAMPb Clamp motor enable 0 = on
9 EN_PRESb Presenter motor enable 0 = on
10 EN_ALIGNb Align motor enable 0 = on
11 DIR Clamp/Presenter/Align motor direction
12 SELECT_TDISK Select main timing disk or presenter timing disk
0 = Main timing disk
1 = Presenter timing disk
13 ICS_SELb Intelligent module serial comms select.
0 = Cassettes selected for serial comms
1 = Purge bin selected for serial comms
14 SHUT_ONb Control shutter motor or solenoid 0 = on
15 AC_MOTOR_ONb Main transport motor enable. 0 = enable
The signal PORT_LSB_RDb (sheet 8) reads in the following signals on to

the lower 8 bits of the data bus:

0 CAS_TEMPb Cassette temperature. 0 = low temperature
1 CAS_ID1b Cassette ID 1
4 CAS_ID4b Cassette ID 4. 0 = present
5 CASLOWb Cassette contents low. 0 = low
6 NULL_OK Strain gauge (LVDT) healthy
7 AD2_COMPb A/D conversion complete. 0 = complete
The signal PORT_MSB_RDb (sheet 8) reads in the following signals on to

the upper 8 bits of the data bus:

8 CONF1 Module configuration line 1
9 CONF2 Module configuration line 2
10 FLEX_AUTHb Flex disk authorization. 0 = authorized
11 PURGE_INb Purge bin present sensor. 0 = present
12 GULP (P86) Gulp feed sensor. 1 = gulp feed
CLK_CONFIG (NID) Reserved on NID, reads as high (1)
13 SHUT_LOCK Shutter locked. 1 = locked
14 SHUT_OPEN Shutter open. 1 = open
15 Reserved Reads as high (1).

MAY 2003 12.8-34

The chip-select signals EN_LEDSb, A2Db (P86 only), and RAM_CSb are
further decoded in the decode CPLD (sheet 10) with the RDb, WRb, BLEb, and
BHEb signals from the processor. This generates the following signals:
Chip Select Signal CPLD Output Signal

EN_LEDSb LEDS_WRb
LEDS_RDb
A2Db A2D-RDb (P86 only)
RAM_CSb SRAM_WEb
SRAM_OEb
Chip_select signal EN_TIMER_USBb (sheet 10) is decoded with address

line A5 to generate signals EN_USb (P86 only) and EN-TIMERb.
The chip-select signals access the following areas of memory or I/O space:
Chip Select Mem I/O Address
CS0b I/O 0000H - 0001H 16-bit

CS1b I/O 0002H 8-bit LEDs
I/O 0003H 8-bit Switches
CS2b I/O 0004H - 0005H 8-bit
CS3b - Configured as bit 3 of Port 2, TXD
CS4b - Configured as bit 4 of Port 2, RXD
CS5b I/O 0040H - 0043H 8-bit Interval Timer registers
0060H - 007FH 8-bit USB device registers (P86
only)
CS6b Mem 000H - 3FFFFH 16-bit SRAM
UCSb Mem 03FE0000 - 03FFFFFF 8-bit EPROM at start-up (NID
only)
Parallel I/O Unit

The 386 EX microprocessor has three 8-bit general-purpose I/O ports. All port
pins are bi-directional, with TTL level inputs and CMOS-level outputs. All
pins have, both a standard operating mode and a peripheral mode (a
multiplexed function), and have similar sets of control registers located in I/O
address space.
Each port has three control registers and a status register.
Port Control Register (PnCFG) (n = 1 - 3)

Port Control Register (PnCFG) selects whether an I/O port or a peripheral is
connected to the pin.
Port Direction Register (PnDIR) (n = 1 - 3)

Port Direction Register (PnDIR) enables or disables the three-state output
driver. The pin is configured as a high impedance input, an open-drain output
(requires external pull-up resistor) or a complementary output.
Port Data Latch (PnLTC) (n = 1 - 3)

Each bit of the Port Data Latch (PnLTC) register contains data to be driven on
to a corresponding pin which is in I/O mode.
NOTE: Reading this register returns the value in the register not the state of
the pin.

12.8-35 MAY 2003

Port Pin State (PnPIN) (n = 1 - 3) - Read Only

The Port Pin State (PnPIN) register returns the current state of the pin.
The registers are accessible in expanded I/O space and are located at the
following addresses:
P1CFG F820H P1DIR F864H P1LTC F862H P1PIN F860H

P2CFG F822H P2DIR F86CH P2LTC F86CH P2PIN F868H
P3CFG F824H P3DIR F874H P3LTC F872H P3PIN F870H
The I/O ports are configured as follows:
Port 1 Configuration
Port Signal Function
P1.0 - Configured as DCD0b of SIO
P1.1 - Configured as RTS0b of SIO
P1.2 - Configured as DTR0b of SIO
P1.3 - Configured as DSR0b of SIO
P1.4 - Configured as RI0b of SIO
P1.5 TX_EN TX enable as SDC SPECIFICATION
P1.6 LVDT_GAINb Selects LVDT gain (0 = low gain, 1 = normal gain)
P1.7 A2D_CONVERTb Initiates A/D conversion
Port 1, bits 5, 6, and 7 are configured as complementary outputs.
P2.0 - Configured as CS0b of CSU, PORT_ENb
P2.1 - Configured as CS1b of CSU, EN_LEDSb
P2.2 - Configured as CS2b of CSU, A2Db
P2.3 TXD Transmit serial data to Remote Diagnostics Interface (RDI)
or Intelligent Cassette Interface (ICS).
P2.4 RXD Receive serial data from RDI or ICS.
P2.5 - Configured as RXD0 of SIO
P2.6 - Configured as TXD0 of SIO
P2.7 - Configured as CTS0b of SIO
P3.0 LEDON Transport LEDs enable line. 1 = on
P3.1 MOTOR_CLOCK Clock for stepper motor drive circuits.
P3.2 - Configured as INT0 of ICU, PRES_TDISK
P3.3 - Configured as INT1 of ICU, MAIN_TDISK
P3.4 (P86) GATE_0 Input to 82C54 Programmable Interval Timer, Counter 0
enables/disables counting.
P3.4 (NID) SPLITb Split purge bin solenoid enable. 0 = on.
P3.5 (P86) GATE_1 Input to 82C54 Programmable Interval Timer, Counter 1
enables/disables counting.
P3.5 (NID) ENABLE_PULSEb Enable solenoid pulsing. 0 = on.
P3.6 (P86) - Configured as INT6 of ICU, EXT_TIMER0
P3.6 (NID) PICK_ON Enable Pick 1=on.
P3.7 - Configured as INT7 of ICU, EXT_TIMER1

MAY 2003 12.8-36

Asynchronous Serial I/O Unit

The Intel386 EX microprocessors asynchronous Serial I/O (SIO) unit is a
Universal Asynchronous Receiver/Transmitter (UART). It is functionally
equivalent to the National Semiconductor NS16450 and INS8250. The
Intel386 EX embedded processor contains two full-duplex, asynchronous
serial channels.
The SIO unit converts serial data characters received from a peripheral
device or modem to parallel data and converts parallel data characters
received from the CPU, to serial data. The CPU can read the status of the
serial port at any time during its operation. This status information includes
the type and condition of the transfer operations being performed and any
errors (parity, framing, overrun, or break interrupt).
Each SIO channel contains a baud-rate generator, transmitter, receiver,
and modem control unit. the baud-rate generator can be clocked by either, the
internal serial clock (SERCLK) signal, or the COMCLK pin. The transmitter
and receiver contain shift registers and buffers. Data to be transmitted is
written to the transmit buffer. The buffers contents are transferred to the
transmit shift register and shifted out via the transmit data pin (TXDn). Data
received is shifted in via the receive data pin (RXDn). When a data byte is
received, the contents of the receive shift register are transferred to the
receive buffer. the modem control logic provides interfacing for the
handshaking signals between an SIO channel and a modem or data set.
In addition to the transmit and receive channels, each SIO can generate
an interrupt or a request (or both) to the DM A unit. An interrupt can be
generated when an error has occurred in the receive channel (for instance,
when the transmit channel is ready to transmit another character, when the
receive channel is full, or when a change has occurred in any of the modem
control signals). A DMA request may be issued at any time a channels receive
buffer is full or its transmit buffer is empty. This allows the SIO to run at
higher speeds for more efficient processing of serial data.
The Currency Dispenser Control Board uses both SIO channels. The first
channel is used to provide an SDC or RS-232 communications interface with
the dispenser and the second channel provides a diagnostics interface. See the
Communications Interface section.
Interrupt Control Unit

The Interrupt Control Unit (ICU) contains two 8259A modules configured as
master and slave. The modules are similar to the industry-standard 8259A
architecture. The ICU directly supports up to ten external and eight internal
interrupts.
The master 82C59A has seven interrupt sources and a slave 82C59A
connected to its IR signals. The slave has nine interrupt sources connected to
its IR signals (two sources are multiplexed into IR1). The interrupts can be
globally or individually enabled or disabled. The master can receive multiple
interrupt requests at once and it can also receive a request while the core is
already processing another interrupt. The master uses a programmable
priority structure which determines the order in which to process multiple
interrupt requests and which requests can interrupt the processing of other
requests.
When the master receives an interrupt request, it checks to see that the
interrupt is enabled and determines its priority. If the interrupt is enabled
and has sufficient priority, the master sends the request to the core. This

12.8-37 MAY 2003

causes the core to initiate an interrupt acknowledge cycle.

The Currency Dispenser Control Board interrupts are as follows:

INT0 PRES_TDISK Interrupt from presenter motor timing disk.
INT1 MAIN_TDISK Interrupt from main motor timing disk
INT2 - Configured as bit 4 of Port 3, GATE_0
INT3 - Configured as bit 5 of Port 3, GATE_1
INT4 SHUTTER_INTb Interrupt from dispenser shutter.
INT5 USB_INTb Interrupt from external USB interface.
Not used on NID board. Read as high (1).
INT6 EXT_TIMER0 Interrupt from 82C54, Programmable Interval Timer, counter
0
INT7 EXT_TIMER1 Interrupt from 82C54, Programmable Interval Timer, counter
1
INT8 - Configured as bit 1 of Port 3. MOTOR_CLOCK
INT9 - Configured as bit 0 of Port 3, LEDON.
NOTE: External timers are used only for de-bug using special board
populations.
Timer/Counter Unit
The Timer/Counter Unit (TCU) has the same basic functionality as the
industry standard 82C54 counter/timer. The TCU contains control logic and
three independent 16-bit down-counters, which can be driven by a prescaled
value of the processor clock or by an external clock. Each counter is capable of
handling clock inputs up to 8MHz. The counters contain two count formats
(binary and BCD) and six different operating modes, two of which are periodic.
Both hardware and software triggered modes exist, providing for internal or
external control. The counters output signals can appear at device pins,
generate interrupt requests, and initiate DMA transactions.
The TCU counters each have two input signals and one output signal:
CLKINn
Each counters clock input signal (CLKINn) can be connected to either the
internal prescaled clock signal (PSCLK) or to the external timer clock pin
(TMRCLKn). This allows the use of either a prescaled value of the processors
internal clock or an external clock to drive each counter. The maximum
CLKINn frequency, whether connected internally or externally, is 8 MHz.
GATEn
Each counter has a gate input signal (GATEn). This signal provides counter
operation control. Depending on the mode of operation of the counter, a high
level on a counters GATEn signal enables or resumes counting and a low level
disables or suspends counting. In other modes, a rising edge on GATEn loads a
new count value. Each counters GATEn signal can be independently
connected to either Vcc or the external timer gate pin (TMRGATEn).
Alternatively, each counters GATEn signal can be driven high or low through
register bits.

MAY 2003 12.8-38

OUTn
Each counter has an output signal (OUTn). This signal can be independently
connected to an external timer clock output pin (TMROUTn). OUT0, OUT1,
and OUT2 are routed to the interrupt control unit. OUT1 is also routed to
DMA channel 0, and OUT2 is routed to DMA channel 1. The OUTn signals
can, therefore, drive external devices, generate interrupt requests, and
initiate DMA transactions, or combinations of the three.
Counter Operating Modes

Each counter operates independently. Six different counting modes are
available and two count formats: binary (16 bits) or BCD (4 decades). In each
operating mode it is possible to program the counter with an initial count and
to change this value during operation. The count and status of each counter
can be determined without disturbing its current operation.
Timer Signal Signal Function

TMRCLK0 - Configured as INT4, SHUTTER_INTb
TMRGATE0 - Configured as INT5, USB_INTb
TMROUT0 - Configured as bit 0 of Port 3, LEDON
TMRCLK1 - Configured as INT6, EXT_TIMER0
TMRGATE1 - Configured as INT7, EXT_TIMER1
TMROUT1 Configured as bit 1 of Port 3, MOTOR_CLOCK
TMRCLK2 COUNT_TDISK Counts pulses from either the main motor timing disk or the
presenter motor timing disk.
TMRGATE2 - unused (tied high)
TMROUT2 - unused (tied high)
Watchdog Timer Unit

The Watchdog Timer (WDT) unit consists of a 32-bit down-counter that
decrements every PH1P cycle, allowing up to 4.3 billion count intervals. the
WDTOUT pin is driven high for sixteen CLK2 cycles when the down-counter
reaches zero (the WDT times out). The WDTOUT signal can be used to reset
the chip, to request an interrupt, or to indicate to the user that a ready-hang
situation has occurred. The down-counter can also be updated with a user-
defined 32-bit reload value under certain conditions. Alternatively the WDT
unit can be used as a bus monitor or as a general purpose timer.
The Currency Dispenser Control Board processor uses the WDT in
Watchdog mode. Watchdog mode protects systems from software upsets. The
system software must reload the down-counter at regular intervals. If it fails
to do so, the timer expires and asserts WDTOUT. For example, the watchdog
times out if the software goes into an endless loop. The WDTOUT signal is
used in conjunction with signals RDIRESb, RDIRES2b, POWER_RESb, and
RESET-INb to reset the processor using the RESET pin. these signals also
place data latches into a high impedance state. Hardware reset control of the
Currency Dispenser Control Board is further specified in the section
Hardware Reset Control.

12.8-39 MAY 2003

DMA and Bus Arbiter Unit
DMA Controller
The DMA controller improves the system performance by allowing external or
internal peripherals to transfer information directly to or from the system. It
contains two identical channels. Within the operation of the individual
channels several different data transfer modes are available. These modes can
be combined in various configurations to provide a versatile DMA controller
with a feature set beyond that of the 8237 DMA family, however, it can be
configured to be used in an 8237-like mode. Each channel can transfer data
between any combination of memory and I/O with any combination (8 or 16
bits) of data path widths. An internal temporary register that can disassemble
or assemble to or from either an aligned or a non-aligned destination or
source, optimizes bus bandwidth.
The Currency Dispenser Control Board does not use external DMA
requests.
Bus Arbiter
The Bus Arbiter, a part of the DMA controller, services bus control requests
from the two DMA channels, an external device, and the refresh control unit.
the DMA channels interface with the bus arbiter through its DMA channel
request signals (DREQn) and its DMA channel acknowledge signals
(DMAACKn#). Other external bus masters interface with the bus arbiter
through similar request and acknowledge signals, the HOLD and HOLDA
signals respectively. The refresh control unit gains bus control through an
internal refresh request. The REFRESH# status pin indicates that the
Refresh Control Unit has gained bus control and that a valid refresh cycle is
being executed. Refresh requests always have the highest priority, while the
priority structure of the other three requests is configurable.
Synchronous Serial I/O Unit

The Synchronous Serial I/O Unit (SSIO) provides for simultaneous, bi-
directional communications. It consists of a transmit channel, a receive
channel, and a dedicated baud-rate generator. The transmit and receive
channels can be operated independently (with different clocks) to provide non-
lockstep, full-duplex communications. Either channel can originate the
clocking signal (Master Mode) or receive an externally generated clocking
signal (Slave Mode). With a maximum clock input of CLK2/4 to the baud-rate
generator, the SSIO can deliver a baud rate of up to 8.25 Mbits per second
with a processor clock of 33 MHz. Each channel is double buffered and the two
channels share the baud-rate generator and a multiply-by-two transmit and
receive clock. The SSIO supports 16-bit serial communications with
independently enabled transmit and receive functions and gated interrupt
outputs to the interrupt controller.
The Intel386 EX processor is configured to use both channels of the
asynchronous Serial I/O (SIO) unit, hence the SSIO is not used.

MAY 2003 12.8-40

Refresh Control Unit

The Refresh Control Unit (RCU) simplifies the interface between the
processor and a Dynamic Random Access Memory (DRAM) device by
providing a way to generate periodic refresh requests and refresh addresses.
These refresh requests and addresses can then be used by an external DRAM
controller to generate the appropriate DRAM signals and addresses needed to
perform refresh operations. The RCU can be used in conjunction with the
Chip-select Unit to generate chip-select signals for DRAM regions. These
signals can be used by the external DRAM controller to initiate refresh cycles.
The RCU can also be used when interfacing to pseudo-static random access
memory (PSRAM). This type of memory has an interface similar to static
random access memory (SRAM), but requires a periodic refresh similar to
DRAM.
The Currency Dispenser Control Board is populated with SRAM, hence
the RCU is not used.
JTAG-Compliant Test-Logic Unit

The JTAG Test-logic Unit provides access to the device pins and to a number
of other testable areas on the device. It is fully compliant with the IEEE1149.1
standard and thus interfaces with five dedicated pins: TRST#, TCK, TMS,
TDI, and TDO. It contains the Test Access Port (TAP) finite-state machine, a
4-bit instruction register, a 32-bit identification register, and a single-bit
bypass register. The test logic unit also contains the necessary logic to
generate clock and control signals for the Boundary Scan chain. Because the
test logic unit has its own clock and reset signals, it can operate autonomously.
While the rest of the microprocessor is Reset or Powerdown, the JTAG unit
can read or write various register chains.
The JTAG signals are routed to two CPLDs on the Currency Dispenser
Control Board in a chain. The Motor Control CPLD is the first device in the
chain, followed by the Decode CPLD. The processor is the last device in the
chain. The JTAG interface allows in-system programming of the CPLDs.
These devices are programmed using JEDEC (Joint Electron Device
Engineering Council) files. The processor, however, requires a BSDL
(Boundary Scan DEscription Language) file and is bypassed during the
programming sequence. A connector interface is provided to the JTAG signals.

12.8-41 MAY 2003

EXTERNAL PERIPHERALS
The following peripherals interface to the INtel386EX embedded
microprocessor:
CPLDs
Decode CPLD
Motor Control CPLD
Programmable Interval Timer
USB Interface
Configuration Switches
Diagnostic LEDs
SRAM
EPROM
Clock and COMSCLOCK
COMCLOCK (P86 only)
A/D Converter.
CPLDs
The Currency Dispenser Control Board is populated with two CPLDs
(Complex Programmable Logic Devices).
The output of both CPLDs may be tristated by pulling the relevant pin
high (TRISTATE1 and TRISTATE2). The JTAG interface on both devices has
been used to allow in-system programming (ISP). The Motor Control CPLD
and the Decode CPLD are the first and second devices in the chain. The JTAG
signals are brought out to a 10-way header which is not normally populated.
Decode CPLD
The Decode CPLD (sheet 10) performs the following functions:
Decodes the chip select signals from the processor to address latches and
peripheral devices
Selects whether the main timing disk output signal (MAIN_TDISK) or the
presenter timing disk output signal (PRES_TDISK) is input to the proces-
sor (COUNT_TDISK)
Decodes signals to address multiplexers (RCODE3 - RCODE4)
Selects between SDC and RS-232 communications interface
On the NID Control Board the following clock signals are generated from
the 66 MHz (MASTER_CLOCK) input:
6 MHz clock for SDC timing
375 kHz clock for the 80C54 Programmable Interval Timer
46.88 kHz clock for the stepper motor chopper circuit
180 Hz clock for solenoid pulsing.
Motor Control CPLD

The Motor Control CPLD (sheet 15) performs the following functions:
Generates signals to drive three stepper motors from incoming clock and
enable signals
Generates signal to pulse the LED associated with transport sensor 5
(TLED)
Generates interrupt signal (SHUTTER_INTb) from signals SHUT_LOCK
and SHUT_OPEN
Enables 180 Hz solenoid pulsing clock (NID board only).

MAY 2003 12.8-42

Programmable Interval Timer

In addition to the TCU in the Intel386 EX processor, an 82C54 Programmable
Interval Timer (PIT) is also provided (sheet 10). This device provides three
timers, two of which are used on the P86 Currency Dispenser Control Board.
Both timer clocks are supplied with a 375 KHz clock, and timer outputs
EXT_TIMER0 and EXT_TIMER1 are connected to interrupts INT6 and INT7
respectively, of the Intel386 EX processor.
The PIT registers are accessed through addresses 0040H - 0043H.
USB Interface
Provision is made on the Currency Dispenser Control Board for a USB
interface to be implemented by a connector with address, data, and control
signals for a USB controller device. The USB interface can be accessed
through addresses 0060H - 007FH.
NOTE: The USB controller is not provided on the board.
Configuration Switches
Eight configuration switches (sheet 5) are provided for configuration use and
Extended Level 0 Diagnostics. The switches are I/O addresses and have a base
address of 0003H. The switches are configured as an input.
The data byte is returned as follows:
Data Bit Switch Number

8 1
9 2
10 3
11 4
12 5
13 6
14 7
7 8
Switch closed = 1
Switch open = 0
Diagnostic LEDs
Eight LEDs (sheet 7) are provided to display Extended Level 0 Diagnostics
information during start-up. The LEDs are I/O addressed and have a base
address of 0002H. Data bits 0 to 7 are mapped to LEDs 1 to 8 respectively.
Memory Requirements
SRAM
The Currency Dispenser Control Board is populated with 512 KBytes of
SRAM (sheet 4). this is implemented as a single 256 K x 16 (4 Mbit) device.
The SRAM is battery backed by a 3.6 V battery because information such as
configuration data and state of health reports must be stored when the
dispenser experiences a power fail or is powered down. The SRAM is a low
powered device with a maximum data retention current of 15 A max. and
data retention voltage of 2 V min. The SRAM support circuit consists of a
MAX691 integrated circuit using a UL approved battery with two protection
diodes. The SRAM can be accessed over the address range 0000H - 3FFFFH.

12.8-43 MAY 2003

EPROM
A 128 or 256 x 8 EPROM (sheet 4) provides code space on the Currency
Dispenser Control Board. At start up, the EPROM can be accessed at address
03FE0000H (P86), 03FC000H (NID), as the processor fetches the first
instruction from address 03FFFFF0H after reset. The device is accessed using
the chip select signal UCSb from the Intel 386EX processor. The device is
relocated after start-up. As the EPROM is an 8-bit device, the BS8b signal
dynamically changes the default 16-bit bus cycle to an 8-bit bus cycle. This is
configured by connecting BS8b to the upper chip select signal UCSb.
The device is one-time programmable.
NOTE: Provision is made for a 256K x 8 EPROM by means of a board

population option.
Clock and COMCLK

The 386 EX Embedded Microprocessor is supplied with an external 66 MHz
clock (sheet 3). This clock is connected to the CLK2 input. It is divided by 2
internally to generate a 50% duty cycle, Phase 1 and Phase 2. the core and
integrated peripherals are, therefore, supplied with a 33 MHz clock signal.
The COMCLK signal (sheet 3) is connected to an external 12 MHz clock.
COMCLK is an alternative clock source for the asynchronous serial ports. It is
used to generate a data rate of 187.5 KBits/s for the SDC communications
interfaces.
On the NID Control Board a 6 MHz COMCLK generated internal to the
Decode PLD may be used as an alternative population option to the 12 MHz
oscillator.
A/D Converter
An analogue to digital converter is used to process (read) the voltage level
selected by each of the three input multiplexers (sheet 9). The three
multiplexers are selected by writing a value to I/O address 0000H. Each of the
24 voltage sources input to the multiplexers may be selected using five data
lines (RCODE0-4). RCODE0-2 select one of the eight signals applied to each
multiplexer and RCODE3 and RCODE4 are used to select one of the
multiplexers.
The multiplexer inputs are assigned as follows:
Multiplexer
Data (RCODE4-0) Function
Source
00000B PICK_SEN1 Pick sensor 1
00100B INTERLOCK Interlock voltage sensor
00101B TSEN_5 Transport sensor 5
01000B TSEN_7 Transport sensor 7 (Not used)
01001B TSEN_6 Transport sensor 6 (Not used)
01100B CLAMP_UP Clamp up sensor

MAY 2003 12.8-44

Multiplexer
Data (RCODE4-0) Function
Source
01101B CLAMP_DOWN Clamp down sensor
01110B ALIGN_HOME Align home sensor
01111B ALIGN_DOWN Align down sensor
10000B (P86) BENCHTESTb Unused
10000B (NID) SPLIT_SEN1 Split purge bin position 1
10001B (P86) INPUT17 Unused
10001B (NID) SPLIT_SEN2 Split purge bin position 2
10010B INPUT18 Unused
10101B INPUT19 Unused
10100B NTS1 LVDT1 (or Strain1) output voltage
10101B NTS2 LVDT2 (or Strain2) output voltage
10110B 80H_REF A/D Converter self test value 80H
10111B 00H_REF A/D converter self test value 00H
The analogue to digital conversion is started by activating the signal

A2D_CONVERTb (Port 1 bit 7). Data is latched to the output of the converter
and can be read by accessing I/O address 0004H. Signal A2D_COMPb from
the converter indicates that the conversion is complete. This signal can be
read at I/O address 0000H, data bit 7.
The A/D converter operates in standalone mode and data is valid
approximately 600 nsecs after signal A2D_CONVERTb returns to its inactive
state (high). The reference voltage to the A/D converter is approximately
2.45 V.
A/D Converter Self Test

Reference input signals, 00H_REF and 80H_REF, of approximately 0.0 V and
2.5 V respectively, can be selected from the multiplexer inputs to test the A/D
converter. This allows the integrity of the A/D converter to be tested during
Extended Level 0 Diagnostics as follows:
Select 80H_REF by writing 10110B to address 0000H (This selects a volt-
age of approximately 2.5 V for conversion).
Wait 10 S.
Initiate A/D conversion.
Wait 7 S
Read conversion data at address 0004H.
A valid value returned lies in the range 78H to 88H.
Select 00H_REF by writing 10111B to address 0000H (This selects a volt-
age of approximately 0 V for conversion).
Wait 10 S.
Initiate A/D conversion.
Wait 7 S.
Read conversion data at address 0004H.
A valid value returned lies in the range 00H to 03H.

12.8-45 MAY 2003

Processing Multiplexer Inputs

The table below describes how the input signals to the multiplexers are
processed:
Input Signal Description

TSEN1-7 (P86) The reading obtained when the sensors are clear is saved in memory. The sen-
TSEN1-5 (NID) sors are then monitored and the new readings obtained compared with those
stored. When a note blocks the sensor, the reading obtained is reduced. The
clear value stored in memory should be regularly updated to account for small
changes due to, for example, build up of dirt, voltage fluctuations and so on.
PICK1-4 Processed in the same way as TSEN.
NTS1-2 The reading obtained relates to the deflection of the LVDT rollers.
INTERLOCK The input is used to determine if the 24 V interlock is open or closed.
Reading > 80H indicates interlock closed, 24 V present.
Reading <= 80 H indicates interlock open, 24 V disabled.
CLAMP-UP Reading > 40H indicates clamp is in the up position.
Reading <= 40H indicates clamp is not in the up position.
CLAMP-DOWN Reading > 40H indicates clamp is in the down position.
Reading <= 40H indicates clamp is not in the down position.
CLAMP_MID Reading > 40H indicates clamp is in the mid position.
(NID only) Reading <= 40H indicates clamp is not in the mid position.
ALIGN-HOME Processed as CLAMP_UP.
ALIGN-DOWN Processed as CLAMP_DOWN.
XX_REF Used during A/D converter self test.
BENCHTESTb Used to test the A/D converter by inputting 0 or 1 via jumper selection.
COMMUNICATIONS INTERFACE
The Currency Dispenser Control Board provides either an SDC or an RS-232
communications interface. That is, the board may be built with one or other of
these interfaces. An RS-232 diagnostic interface is also provided for debug
purposes only.
SDC Interface
Data connection to the SDC serial bus is provided using one of the SIO
channels in the Intel386 EX processor and RS-485/RS-422 transceivers
(sheet 5). The first SIO channel is used to provide transmit and receive signals
for SDC and the SDC reset signal is used to reset the processor.
The connector for this interface is populated only on the SDC version of
the Currency Dispenser Control Board.
RS-232 Interface
The RS-232 Interface is provided by the first channel of the SIO Unit and an
RS-232 transceiver (sheet 5).
The connector for this interface is populated only on the RS-232 version of
the Currency Dispenser Control Board.
RS-232 Diagnostics Interface

The RS-232 Diagnostics Interface is provided by the second channel of the SIO
and an RS-232 transceiver. This interface is provided for debug purposes only
and the associated connector is not normally populated.

MAY 2003 12.8-46

OPERATION OF TRANSPORT SENSOR LEDS

In order to increase the life of the transport sensor LEDs, the LEDs are only
turned on during a dispenser operation. the signal LEDON (active high) is
used to enable the LED drive transistors (sheet 11). The transport sensors will
be in a fully operational state 100 S after the LEDs are turned on. The
transport sensors will be fully inoperative 100 S after being disabled.
OPERATION OF TSEN5 AND TSEN2 LEDS/PHOTO-SENSORS

Transport sensor TSEN5 is the exit sensor and can be affected by sunlight. To
overcome this problem, the associated LED, TLED5 is pulsed with high
current to provide high intensity pulses of infra-red well above the ambient
level coming from the sunlight.
Transport sensor TSEN2 is the transport sensor mounted in the area of
the clamp mechanism of the currency dispenser. The distance between the
LED and sensor is significantly greater than that between the other transport
LED/sensor pairs. To overcome this problem, the associated LED, TLED2, is
pulsed with high current to provide high intensity pulses of infra-red.
For both LED/photosensor pairs the LED is pulsed as follows:
ON period 250 S +5%/-0%

OFF period 750 S +5%/-0%
The photo-sensor circuitry of TSEN5 uses high pass filters to further

negate ambient light, and a peak detector to provide steady TSEN5 signal and
TSEN2 signals (sheet 14).
MAIN TRANSPORT TIMING DISK

The output of the main transport timing disk comparator (MAIN_TDISK) and
the output of the presenter motor timing disk comparator (PRES_TDISK) are
both provided as interrupts to the processor (INT0 and INT1). The number of
timing disk pulses is also counted by processors internal timer unit
(TMRCLK2). The main timing disk signal (MAIN_TDISK) is multiplexed in
the Decode CPLD (sheet 10) with the output of the presenter timing disk
comparator (PRES_TDISK) (sheet 12). MAIN_TDISK is selected when signal
SELECT_TDISK is low. PRES_TDISK is selected when signal SELECT-
TDISK is high. Signal SELECT_TDISK is generated by the processor.
STEPPER MOTOR OPERATION

Control is provided to operate three stepper motors (sheet 15) on the p86
Currency Dispenser. These are the Presenter. Clamp, and Align motors. Only
one motor may be operated at any one time. The stepper motors are controlled
by the clock (MOTOR_CLOCK), direction (DIR) and enable (EN_PRESb,
EN_CLAMPb, EN_ALIGNb) signals from the Intel386EX processor. These
signals are encoded in the Motor Control PLD to provide correct signals for
the motor driver ICs.
NOTE: The RS-232 version of the Currency Dispenser Control Board is

populated to drive the two stepper motors found in 4G currency
dispensers.

12.8-47 MAY 2003

Stepper Motor Speed

The Currency Dispenser stepper motors are driven at the following speeds:
Presenter Motor
Minimum Speed = 450 Hz
Maximum Speed = 1600 Hz
The presenter motor speed is ramped from minimum to maximum speed
in 660 msecs. The speed is incremented by 57.5 Hz every 33 msecs.
Clamp Motor
Speed = 800 Hz
Align Motor
Speed = 500 Hz
Stepper Motor Characteristics

The presenter and clamp motors are operated in Full Step bipolar drive mode.
In a bipolar drive, the current in each of the two phases of the motor is
reversed every second step, and the two phases are driven with a 90O phase
difference. Current sense resistors are included in the ground returns of the
stepper motor windings to derive a voltage which is compared to a reference
level by a voltage comparator. This limits the current in the motor windings.
Additionally, a chopper circuit (frequency set to - 46.875 kHz) is included in
the drive to all motors.
The currents supplied to each motor are as follows:
Presenter Motor - 3.2 A
Clamp Motor - 0.8 A
Align Motor - 0.8 A
NOTE: The current levels flowing through the stepper motor windings
necessitate a pcb constructed with a separate power ground plane, with a
connection to the logic ground plane at the power connector.
PICK MODULE PRESENT IDENTIFICATION

In order to determine if one (or more) non-intelligent (standard) pick modules
is connected to the Currency Dispenser, the following steps are taken:
Select currency cassettes for serial communications, ICS_SELb is set high
by writing a 1 to address 0000H, bit 13
Set pick module identity code S0 and S1, write value address 0000H, bits
5 and 6
Read Intel386 EX processor, port 4, bit 2
if data is high, module is present
if data is low, module is not present.
SECURITY SHUTTER OPERATION

The P86 Currency Dispenser has a security shutter fitted in front of the
module (at the currency exit) - refer to Chapter 12.3. This shutter is operated
by a motor driven from a separate driver board controlled by the currency

MAY 2003 12.8-48

dispenser via the SDC power interface. Sensors mounted on the shutter driver
board detect when the shutter is open and closed. The motor is turned on
when the signal SHUT_ONb is set low.
The New Interior Dispenser may optionally be fitted with an on-board
shutter opened by a solenoid that operates when signal SHUT_ONb is set low.
In addition when signal ENABLE_PULSEb is set low, the solenoid will be
pulsed on/off at 180 Hz, with a 50% duty cycle.
The device control firmware is not aware of which type of shutter is
implemented.
For both types, the shutter open and closed sensors are read as follows:
SHUT_LOCK active (high) Shutter in locked position

SHUT_OPEN active (high) Shutter in open position
If the shutter is locked or open then an interrupt (SHUTTER_INTb) is

generated.
SPLIT PURGE BIN

Provision is made on the NID Control Board to control a split purge bin with a
solenoid operated movable deflector that diverts bills into either of two
sections. This is a possible future development and is not described at this
time.
HARDWARE RESET CONTROL

Two reset control lines enter the control board via the Remote Diagnostics
Interface (RDI). These are as follows:
Signal Description
RDIRESb When set low holds the Intel 386 EX microprocessor in reset.
RDIRES2b When set low places the outputs of the D-type latches on the data bus into a high
impedance state. These devices latch data from the data bus to peripherals (For
example, LEDs).
Watchdog Signal
The signal WATCH_ON from the Watchdog Timer Unit is used to reset the
processor after a specified period of processor inactivity. It is also used to reset
output latches and generate a disable signal which is fed to the pick interface
units.
Reset Control Lines

Two additional active low reset control lines exist on the Currency Dispenser
Control Board, these are as follows:
Signal Description
POWER_RESb Generated from the MAXIM691 battery controller IC and set low when the +5 V
supply on board falls below 4.7 V. This signal resets the Intel386 EX Micropro-
cessor. The data latches are set in a high impedance state.
RESET_INb Set low by control signal from the SDC interface. This signal resets the Intel386
EX Microprocessor. The data latches are set in a high impedance state.
All bidirectional and output signals except TDO are forced into a high
impedance state using the FLTb pin. If this signal is active then an emulator

12.8-49 MAY 2003

may be fitted with the processor present.

The TRSTb signal resets the TAP controller in the JTAG-compliant Test-
logic unit in the processor. The unit must be reset on power up using the
TRSTb signal. this is achieved by connecting the inverted reset signal
(RES_CON) to the TRSTb pin.
AC MOTOR
The ac motor is used to drive the pick units and is controlled by the Currency
Dispenser Control Board. It is switched on by writing a 0 to bit 15 of the I/O
address 0000H and turned off by writing a 1 to this bit.
CONNECTOR ASSIGNMENT
Power Interface
The Currency Dispenser Control Board is powered directly from the ATM
power supply via the 16-way right-angled header J1. Provision is made on the
connector to control the motorized shutter interface board. The shutter signals
are as follows:
Signal Description
SHUT_OPEN High = shutter open
SHUT_LOCK High = shutter locked
SHUT_ONb Low = shutter motor on
The pinout of connector J1 is as follows:
+5 V 9 1 GND
+12 V 10 2 GND
-12 V 11 3 GND
+24 V 12 4 GND
GND 13 5 SHUT_LOCK
SHUT_ONb 14 6 GND
GND 15 7 SHUT_OPEN
+24V_INT 16 8 FRAME_GND

MAY 2003 12.8-50

SDC Interface
The SDC Interface connector (J2) is a 10-way right angle latched header with
the pinout shown below. The SDC primary is located in the core of the ATM.
N/C 1 2 N/C
DATA_P 3 4 DATA_N
RESET_P 5 6 RESET_N
N/C 7 8 N/C
SIG_REF 9 10 N/C
RS-232 Communications Interface

The RS-232 Communications Interface connector (J3) is a 9-way right-angled
D-type with the following pinout:
GND 5 9 RS232_RI0
RS232_DTR0 4 8 RS232_CTS0
RS232_TXD0 3 7 RS232_RTS0
RS232_RXD0 2 6 RS232_DSR0
RS232_CD0 1
RS-232 Diagnostic Interface

Connector J19 (P86), J17 (NID), provides the RS-232 diagnostic interface for
the Currency Dispenser Control Board. It is a 10-way vertical header with the
following pinout:
RS232_CD1 1 2 RS232_DSR1
RS232_RXD1 3 4 RS232_RTS1
RS232_TXD1 5 6 RS232_CTS1
RS232_DTR1 7 8 RS232_RI1
GND 9 10 N/C

12.8-51 MAY 2003

Transport LEDs and Sensors

On the P86 Control Board two connectors (J8 and J7) provide the interface to
transport LEDs and sensors. On the NID board only connector J8 is necessary
and connector J7 is used for the on-board shutter assembly.
Connector J8 carries the signals to transport LEDs and sensors 1 to 5, and
also provides interfaces to the purge bin and ac motor. This connector is a 24-
way right-angle header with the following pinout:
AC_MOTOR_ONb 1 2 +5 V
TSEN1 3 4 T1LED_POS
TSEN1_POS 5 6 T1LED
TSEN2 7 8 T2LED_POS
TSEN2_POS 9 10 T2LED
TSEN3 11 12 T3LED_POS1
TSEN4 15 16 T4LED_POS
TSEN5 19 20 T5LED_POS
GND 23 24 PURGE_INb
Connector J7 on the P86 board provides an interface to transport LEDs

and sensors 6 and 7. This is an 8-way right angle header with the following
pinout:
TSEN6 1 2 T6LED_POS
TSEN6_POS 3 4 T6LED
TSEN7 5 6 T7LED_POS
TSEN7_POS 7 8 T7LED
On-Board Shutter
Connector J7 on the NID board provides the interface to the on-board shutter
assembly solenoid and sensors. This is an 8-way right angle header with the
following pinout:
GND 1 2 OPEN_LED_POS
GND 3 4 GND
LOCK_LED_POS 5 6 SHUT_LOCK
SHUT_OPEN 7 8 GND

MAY 2003 12.8-52

Pick Modules
Connector J4 provides the interface to the currency dispenser pick modules. It
is a 40-way right-angle latched header connector with the following pinout:
CAS_ID1b 1 2 GND
CAS_ID2b 3 4 GND
CAS_ID3b 5 6 GND
CAS_ID4b 7 8 GND
CAS_TEMPb 9 10 GND
CASLOWb 11 12 GND
(No connection on NID) GULPb 13 14 LEDON_PICK
GND 15 16 GND
S0 17 18 S1
DISABLEb 19 20 COILENb
PICK 21 22 PSEN1
PSEN2 23 24 PSEN3
PSEN4 25 26 PICK_TXD
PICK_RXD 27 28 GND
GND 29 30 +12 V
+5 V 31 32 +5 V
GND 33 34 GND
GND 35 36 GND
+24 V 37 38 +24 V
+24 V 39 40 +24 V
Note Thickness Sensor / LVDT

The Note Thickness sensor (NTS) or LVDT is connected to 10-way right angled
latch header connector J9. The pinout is as follows:
+5 V 1 2 GND
STRAIN_REF 3 4 NTS_1
NTS_2 5 6 NULL_NTS
NULL_OK 7 8 N/C
LVDT_GAIN_SELb 9 10 N/C
Stepper Motors
Connector J13 provides the interface to the three stepper motors used in the
currency dispenser. This is a 12-way right-angled header with the following
pinout:
PRES_A_POS 7 1 PRES_B_POS
PRES_C_POS 8 2 PRES_D_POS
CLAMP_A_POS 9 3 CLAMP_B_POS
CLAMP_C_POS 10 4 CLAMP_D_POS
ALIGN_A_POS 11 5 ALIGN_B_POS
ALIGN_C_POS 12 6 ALIGN_D_POS

12.8-53 MAY 2003

RDI Interface
The RDI interface is provided by 20-way vertical header connector J12 with
the following pinout:
+5 V 1 2 RDIRESb
SW0 3 4 RDIRES2b
SW1 5 6 LED1
SW2 7 8 LED2
SW3 9 10 N/C
SW4 11 12 LED3
SW5 13 14 LED4
SW6 15 16 PICK_RXD
SW7 17 18 TXD
GND 19 20 GND
Intelligent Cassette Interface

10-way right-angle header connector J11 provides the interface to the
intelligent cassette module. The connector has the following pinout:
+24 V 1 2 +24 V
GND 3 4 GND
+5 V 5 6 GND
ICS_TXD 7 8 ICS_RXD
GND 9 10 N/C
Universal Serial Bus (USB) Interface

The P86 board has a 26-way vertical header connector J10 which provides a
USB interface. This connector is not on the NID board. The connector has the
following pinout:
D0 1 2 BLEb
D1 3 4 A1
D2 5 6 A2
D3 7 8 A3
D4 9 10 A4
D5 11 12 +5 V
D6 13 14 +5 V
D7 15 16 +5 V
EN_USBb 17 18 GND
RDb 19 20 GND
WRb 21 22 GND
USB_INTb 23 24 GND
RES_CONb 25 26 GND

MAY 2003 12.8-54

Stepper Motor Sensors

4-way right-angle header J5 and 24-way right angle header J6 provide the
interface to the stepper motor sensors. The connector pinouts are as follows:
J5 Pinout
P86 Pinout NID Pinout

ALIGN_DOWN_LED 1 CLAMP_MID_LED
GND 2 GND
+5V_ALIGN_DOWN 3 +5V_MID_SEN
ALIGN_DOWN 4 CLAMP_MID
J6 Pinout
CLAMP_UP_LED 1 2 ALIGN_LED
GND 3 4 GND
+5V_CLAMP_UP 5 6 +5V_ALIGN_HOME
CLAMP_UP 7 8 ALIGN_HOME
CLAMP_DOWN_LED 9 10 PRES_TD_LED
GND 11 12 GND
+5V_CLAMP_DOWN 13 14 +5V_PRES_TDISK
CLAMP_DOWN 15 16 PRES_TDISK
CONF1 17 18 MAIN_TD_LED
GND 19 20 GND
CONF2 21 22 +5V_MAIN_TDISK
GND 23 24 MAIN_TDISK
JTAG Interface
Connector J15 provides the JTAG interface to the Intel386 EX microprocessor
and CPLDs. This is a 10-way vertical header connector with the following
pinout:
+5V 1 2 TCK
GND 3 4 TDI
GND 5 6 TDO_2
GND 7 8 TMS
N/C 9 10 TRSTb
Split Purge Bin Interface

Connector J10 on the NID board provides the interface to the split purge bin (future
development).

12.8-55 MAY 2003

SINGLE PICK INTERFACE BOARD

PERSONAS 86 CURRENCY DISPENSER
The single pick modules used on the early Personas 86 Currency Dispensers
are the same as those used on the 56XX Enhanced Currency Dispenser and
use the same single pick interface board. The description of this board appears
in Chapter 12.6 of this manual and is not repeated here.
NOTE: The GULP- and TEMP1 signals that may be generated by the 56XX
pick module are still passed via Aria pick modules to the P86 dispenser
control board, where they are recognized and acted upon.
Later P86 dispensers use the Aria single pick module described in
Chapter 12.9 of this manual.
NEW INTERIOR DISPENSER AND P87 DISPENSER

Single pick modules used on the NID and P87 dispenser are all of the Aria
type which uses the same single pick interface board as 56XX pick modules.
Aria pick modules and interface boards are described in Chapter 12.9 of this
manual.
56XX type pick modules can also be fitted to both dispensers, however, in
this case, the GULP- and TEMP1 signals will have no effect on dispenser
operation because these signals are not used by the NID control board.
DOUBLE PICK INTERFACE BOARD

The Aria double pick module is used on P86, P87, and the NID. The Double
Pick Interface board in the Aria double pick module is the same board as that
used in the 56XX Enhanced Currency Dispenser. The board acts as an
interface between the actuators and sensors in the Currency Dispenser
Double Pick Module and the Currency Dispenser Control Board. Aria pick
modules and interface boards are described in Chapter 12.9 of this manual.

MAY 2003 12.8-56

TRANSPORT AND TIMING SENSORS AND LEDS

Infra-red radiation detecting sensors are used throughout the dispenser to
detect the movement of currency, the movement of mechanical assemblies, and
to produce timing pulses. The sensors consist of an infra-red emitting LED
transmitting across a gap to a phototransistor detector. In the presenter
timing, note clamp up, mid, and down sensors, and the bill align up sensor, the
LED and phototransistor are housed in one U-shaped plastic assembly. In the
transport sensors, the phototransistors and LEDs are in separate assemblies
wired into the harness and fastened above and below the transport. Most of
the transport sensors and LEDs operate in the same way and have identical
circuits.
All sensor power supplies are brought to the sensor assemblies from the
control board or the pick interface board via the electrical harness. Signals
from the sensors return to these boards via the harness. Refer to the section
Internal Cables for diagrams of the connections to the sensors.
Sensor signals are passed to the control board for processing. Their
analogue voltage value is converted to a digital value and compared to a
reference clear value held in memory.
LINEAR VARIABLE DISPLACEMENT TRANSDUCER (LVDT)
The LVDT multiple bill detector is capable of detecting single, double and
triple bills, folded, taped, overlapping bills (drag-outs), and soiled bills. The
LVDT assembly is carried on a bracket fastened between the side frames of
the presenter.
Two metal wheels are attached to plastic blocks mounted on flat metal
springs. The springs push the wheels down so that they bear on the top of
wheels of the same diameter fastened to a gear driven shaft in the transport.
Bills passing between the two sets of wheels push the LVDT wheels upwards.
This movement is transmitted to ferrite cores attached to the plastic blocks.
These cores pass through holes in the centre of coils printed on the LVDT pcb
and the coils convert the core movement into a voltage output. As a bill passes
between the rollers the voltages vary according to the thickness of the bill. An
analogue to digital converter transforms the levels obtained into digital
information.

12.8-57 MAY 2003

Before bills are picked at the start of a dispense operation a sample

reading is made of the roller movement for two complete revolutions of the
LVDT wheels. This is equivalent to one bill pitch (approximately 179.8 mm).
Any movement is due to the eccentricity of the rollers and dirt

accumulation on the roller surfaces. A voltage reading is taken on each
interrupt from the main timing disk. The LVDT coils are read alternately. The
main timing disk output also determines when the revolutions have been
performed. The overall sample reading is obtained by integrating the varying
voltage as shown in the following section. This reading is stored by the
dispenser microprocessor. Bills are then picked.
A sudden rise in the monitored voltage waveform from the LVDT shows
that a bill has arrived at the rollers and starts a picked bill reading. Again
the varying voltage resulting from the roller deflection is integrated for one
bill pitch. This reading, with a bill present, is stored, and the sample reading
taken earlier is subtracted leaving a reading which represents the cross-
sectional area (CSA) of the bill.
The reading for CSA obtained is compared to a table representing single,
double, and triple bills. An example table for $10 test bills is shown below.
Number of Bills Nominal Reading (Hex) Reading Band (Hex)

Single 61 4D to 74
Double C2 B0 to EC
Triple 123 120 to 168
The table provides distinct bands for each type of bill and has safety
margins between each type to eliminate the danger of passing a double as a
single. The sensing rollers are designed to perform one complete revolution for
each pick operation. Because a sample reading is taken at the start of each
dispense, dirt build up on the rollers does not affect the accuracy of the
detection system.

MAY 2003 12.8-58

Bill Detection Voltage Waveforms

The following diagrams show examples of the voltage waveforms obtained for
normal and faulty pick conditions. The integration period is from t0 to t1 (one
bill pitch). Voltages given are approximate only.
Initial Sample
The initial sample is made without bills passing and produces a signal similar
to a sine wave with a peak to peak value of approximately 0.5 V.
Single Bill
A single bill lifts the waveform by about 0.5 V to 1.0 V. The bill cross sectional
area is found by subtracting the initial sample from the sample with the
raised waveform.

12.8-59 MAY 2003

Folded Single Bill
A folded single bill produces a stepped shape on top of the original waveform.
Double Bill
A double bill lifts the waveform by 1 V as shown above.
Drag Out
A drag out of two bills would produce the stepped shape shown. The highest
point being where the bills overlap.

MAY 2003 12.8-60

FIRMWARE DESCRIPTION
The following description of the firmware is not complete but introduces only
the topics thought necessary for an understanding of dispenser operation.
The P86 Currency Dispenser Device Firmware provides device control,
including full error recovery procedures, for the NCR Personas 86 Currency
Dispenser, the Personas 87 Currency Dispenser, and the New Interior
Dispenser in the SDC peripheral environment.
The firmware interface provides dispensing of up to four different
currency denominations with a single dispenser and up to eight
denominations with dual dispensers. It accepts, executes, and returns status
information in response to device control commands from the next level
process.
The firmware operates under control of the VxWorks real time kernel by
soliciting commands from the SDC Secondary software and sending solicited
and unsolicited responses to the SDC secondary for transmission to the host
system.
The P86 Currency Dispenser firmware will operate as a dual
implementation module, that is, it can be a PROM based, or a Programmable
Serial Distributed Control (SDC) secondary based peripheral. The mode of
operation is determined at run time. The firmware is PROM based by default,
but it will accept a new driver on receiving a Write Module Memory command.
This allows enhancements to be made to the device control firmware.
The P86 Currency Dispenser firmware can be configured as one of up to
eight dispensers in the operational environment. The purpose of this is to
allow up to eight dispensers to be present in a self-service terminal.
The dispenser firmware is plug compatible with previous releases of the
SDC 56XX Currency Dispenser firmware; there are no new T_CODE,
M_STATUS, SOH modules or message IDs. Some additional M_DATA values
have been added to indicate faults within new dispenser mechanisms.
SDC Link
SDC Communications Firmware
Currency Dispenser Service Dispenser TI Service
Command/Response Command/Response
Execution Main Task Execution TI Task
Bill Map Interrupt Server
Dispenser Control Firmware

12.8-61 MAY 2003

The SDC Currency Dispenser Device firmware has eight interfaces:

Peripheral Control Interface
SDC Interfaces
Host System Interface
Device Control Interface
Intelligent Containers Interface
Tamper Indicate Service
Hardware Interface
Node Control Application Interface.
PERIPHERAL CONTROL INTERFACE

The peripheral control interface allows initialization of the currency dispenser
control hardware to be carried out at module reset/power up. It supports the
reporting of the hardware environment to the host system by interrogating
the switch pack for configuration information.
Diagnostics Switch Pack (P86 and NID Currency Dispenser Control Boards)
SDC Command Switch Pack

The SDC Command switch pack on the currency dispenser control board
selects the mode of operation of the board as defined below:
Mode SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1

Normal 0 0 X X X X X X
Burn-in/ Replica 0 1 X X X X X X
Level 0 Diagnostics 1 X X X X X X X
NOTE: 0 = Switch OFF/OPEN, 1 = Switch ON/CLOSED, X = dont care.

Switch 8 (SW8) on the switchpack corresponds to the most significant bit.
Module Class Variant

In normal mode (SW8=0, SW7=0) the switches SW6 to SW4 are used to define
the module class variant. There is only one module class variant for the

MAY 2003 12.8-62

dispenser and so the switches should be set to zero. The switch settings are
not checked by the firmware.
Link Address
The P86 dispenser firmware can be configured as one of up to eight dispensers
in the operational environment. In normal and burn-in/replica mode, switches
SW3 to SW1 are used to select the link address where the currency dispenser
resides in the SDC system (normal link address = 9). Switches SW6 to SW4
again select the currency dispenser type. Link addresses range from 64 to 71.
SW3 SW2 SW1 Link Address Dispenser Service Names

Normal (Burn-in)
0 0 0 9 (64) CURRENCY_DISPENSER_01, DISP_TI_SERVICE_01
: : : : to
Level 0 Diagnostics Mode

Level 0 diagnostics mode is selected by SW8 set to 1. Tests for the SDC node
on the control board are described in Chapter 2.3.
Default Setting
The default switch settings selected on the switch pack for shipping should be
the Normal Mode, with all switches SW1 to SW3 set to 0.
SDC INTERFACES
SDC Secondary Communications Interface

All communication with the host system takes place across the SDC link. This
provides the facility to receive commands from the host and transmit solicited
and unsolicited responses to the host.
SDC NVRAM Interface

The SDC secondary RAM interface firmware (NVRAM I/F) provides a
consistent interface between all SDC secondary nodes and the resident
NVRAM and to firmware responsible for state of health (SOH). The NVRAM
I/F is further divided into two main functional interfaces, the system manager
interface and the peripheral firmware interface.
System Manager Interface

The system manager interface is the part of the SDC secondary interface
which provides the following status information on the SDC secondary node:
Summarized module SOH
Component SOH
Secondary tally/tally threshold information/update
Secondary module/component history
SOH state change information.

12.8-63 MAY 2003

Peripheral Firmware Interface

The peripheral firmware interface allows the peripheral firmware access to
the control board NVRAM and provides the following facilities:
Tally update and thresholding
State of health access
NVRAM initialization.
The SDC NVRAM provides nine procedures for use by the peripheral
firmware to access that area of NVRAM used to store module status
information.
The procedures are as follows:
Initialize NVRAM
Update count
Reset count
Report count
SOH update
SOH report
Add to history area
System escape.
A response is received to each of these procedures, indicating either that
the command has been actioned successfully or that the NVRAM area for this
module ID does not exist.
HOST SYSTEM INTERFACE

The host system interface allows the host system to send commands to the
currency dispenser device firmware service. The currency dispenser device
firmware service responds with transaction maintenance and tally
information.
The tally information returned with every solicited or unsolicited response
has the format TALLY_NUMBER, TALLY_INCREMENT_VALUE. Only the
values of those tallies which are non zero are returned. Once this information
has been sent by the currency dispenser device firmware, all the transaction
tallies are zeroed.
DEVICE CONTROL INTERFACE

The currency dispenser device firmware is in two parts: the Command
firmware and the Execution firmware. The device control interface allows the
currency dispenser device command firmware to control the operations of the
dispenser via the execution firmware. It allows the command firmware to
issue commands to, and receive responses from, the execution firmware.
INTELLIGENT CONTAINERS INTERFACE

The intelligent containers interface allows the firmware to interrogate the
intelligent containers on-module NVRAM, to obtain the modules State Of
Health and cash management information.
TAMPER INDICATE SERVICE

The tamper indicate service responds to the dispenser device firmware with
container information when any container is removed or inserted.

MAY 2003 12.8-64

HARDWARE INTERFACE
The hardware interface provides control and status information for the
currency dispenser via memory mapped I/O.
NODE CONTROL APPLICATION (NCA) INTERFACE

This interface allows the currency dispenser to report the services it supports
to the NCA.
FIRMWARE COMMANDS
The P86 currency dispenser device firmware is designed to be fully compatible
with the 5084 currency dispenser so that applications can be fully migrated by
adding migration layers. 5070 and 5081 applications cannot be migrated
without source code changes since the T_CODES returned for these
applications are incompatible with the 5084 and 56XX. In addition the 56XX
device firmware supports an intelligent application. The intelligent
application has commands to increase the functions of the dispenser. It
monitors the dispenser, reporting via the NVRAM interface and it provides
cash management when intelligent cassettes are installed.
I/O Commands
The device firmware controls the delivery of bills from the currency cassettes
to the cardholder. This is a two stage operation consisting of picking bills from
the selected currency cassettes and stacking them in the currency handling
mechanism (STACK command), then presenting them to the cardholder
(PRESENT command). Bills may be cleared from the currency handling
mechanism into the purged bills area by using the CLEAR or
CHECK_IF_BILLS_LEFT commands. Alternatively, bills can be delivered to
the cardholder using the DISPENSE command which stacks and then
presents bills as a one stage operation. Once DISPENSE is initiated, the
transaction can not be voided.
NOTE: The maximum number of bills that can be stacked in one stack or
dispense operation is 40. The valid range is 1 - 40 and, when not given, the
maximum value will default to 40.
The following table describes the I/O commands that give compatibility
with the 5084 dispenser.
Command Purpose
STACK Picks bills and stacks them in currency handler.
PRESENT Presents bills to cardholder.
CLEAR Sends bills from currency handler to purge bin.
DISPENSE Picks bills and presents them to cardholder in one operation.
SELF_TEST Tests the operation of the dispenser.
RETURN_CASSETTE_ STATUS Determines the cassette types present and the state (full,
low, empty, or fatal) of the cassettes and purge bin.
SET_BILL_SIZES Permits dynamic configuration of the bill width parameter for
each cassette type.
READ_DISPENSE_ COUNTS Permits the next level process to access the bills dispensed
to the cardholder during the last dispense operation counts
maintained by the firmware.
CLEAR_DISPENSE_ COUNTS Resets the counts of bills dispensed during the last transac-
tion to zero.

12.8-65 MAY 2003

Command Purpose
SET_BILL_ SINGULARITIES Permits the next level process to configure the bill singulari-
ties for each cassette type to enable multiple bill detection.
(Replaces the SET_BILL_OPACITIES command of the
5084).
SET_BILL_ PRESENTATION_ORDER Permits the next level process to configure the order in
which dispensed bills are stacked for presentation to the
cardholder.
READ_CONFIGURED_ PARAME- Allows the next level process to read back the bill width
TERS parameters, bill singularities and bill presentation order cur-
rently configured.
REQUEST_ AUTHORIZATION_ MODE These two commands are provided to achieve compatibility
AUTHORIZED_DISK_CHECK with the 5084 dispenser. The commands always respond
with a status of NORMAL security.
RESET Provided for compatibility with the 5084.
Commands which provide the enhanced functions of the 56XX currency

dispenser are described in the following table:
Command Purpose
RETRACT_BILLS Drives the bills back from the present position to the purge
bin or just to the stack position (half retract). Used if the
cardholder fails to remove the bills during a timeout set by
the application.
READ_VIRTUAL_ CASSETTE_TYPES Permits the next level process to find the current relation-
ship of virtual to physical cassette types stored by the
device.
LEARN_BILL_ PARAMETERS Makes it possible to learn the bill width and singularity
parameters for a particular cassette type.
EXIT_SHUTTER_ TEST Makes it possible to test the exit shutter.
DISABLE_CASSETTE_ POSITION Prevents the dispenser attempting to pick from one or more
specified cassette positions.
CHECK_IF_BILLS_LEFT Determines if bills have been left in the transport from a pre-
vious command. Performs the same operations as the
CLEAR command except that the transaction code indicates
if bills were seen entering the purge bin. The
CHECK_IF_BILLS_LEFT command is used after a DIS-
PENSE or PRESENT that resulted in an UNKNOWN
PRESENT condition.
ENABLE_CASSETTE_ POSITION Enables cassette positions previously disabled by the
DISABLE_ CASSETTE_POSITION command.
ENABLE_EXTENDED_CASSETTE_ID Enables the firmware to recognise the extended cassette
types 5, 6, and 7.
SET_VIRTUAL_RELATIONSHIP Allows the virtual to physical relationship of cassette types
to be set.
DISABLE_EXTENDED_CASSETTE_ Disables recognition of extended cassette types 5, 6, and 7.
ID
REPORT_EXTENDED_CASSETTES Reports if the extended cassette types 5, 6, and 7, have
been enabled.
Error recovery is performed on all I/O commands.
Diagnostic Commands
Several diagnostic commands are provided. The commands, DIAG_CLEAR,
DIAG_DISPENSE, DIAG_STACK, DIAG_PRESENT, DIAG_SELF_TEST, and
DIAG_EXIT_SHUTTER_TEST are similar to the I/O commands CLEAR,
DISPENSE, STACK, PRESENT, SELF_TEST, and EXIT_SHUTTER_TEST

MAY 2003 12.8-66

respectively, except that no error recovery is performed. The

REPORT_TALLY_MNEMONICS command permits the next level process to
gain access to the tally mnemonics of the transaction tallies for the currency
dispenser.
In addition, further diagnostic commands are provided to permit fault
diagnosis to a lower level. These commands are:
MAIN_MOTOR_TEST
PRESENTER_BILL_MOTOR_TEST
SENSOR_TEST
PRESENTER_CLAMP_TEST
PICK_VALVE_TEST.
After each of the above diagnostic tests the controlling program should
send a CLEAR command to clear any currency from the dispenser.
The RESET command is provided to allow initialization of the firmware.
Dispense Enable Switch

The position of the dispense enable switch, on the dispenser control board, can
be read with the SENSOR_TEST command. This allows the next level process
to ensure that diagnostic dispense operations can only be performed by
authorized personnel, by determining that the switch has been operated after
entry to diagnostics.
Tamper Indicating Commands

The tamper indicate (TI) service permits an application to receive information
on the removal or insertion of containers by sending unsolicited responses on
these events. This service is initially disabled. The RESET command
initializes the TI firmware and disables TI reporting.
TI reporting is enabled by the ENABLE_TI_REPORTING COMMAND,
and disabled by the DISABLE_TI_REPORTING command. The current state
of TI reporting is found by issuing a READ_TI_STATUS command.
POWER-UP/SYSTEM RESET INITIALIZATION
Firmware Initialization
The RESET message can be sent at any time and is provided for migration
purposes only.
When the currency dispenser has been out of service due to a fault
condition then, following service of the device, the State Of Health for the
device must be reset.
It is necessary to configure the bill widths and bill singularities using
SET_BILL_WIDTHS and SET_BILL_SINGULARITIES commands on
installation and when new bill types are introduced into the dispenser. If this
is not done then the bill width values are set to the default (66mm) and the
singularity is set to 0FFH. An attempt to stack bills will result in an
M_STATUS of PARAMS_NOT_CONFIGURED.
Bill Width and Singularity Learning

The LEARN_BILL_PARAMETERS command enables new bills to be
calibrated for width and singularity.

12.8-67 MAY 2003

Device Initialization
The CLEAR or CHECK_IF_BILLS_LEFT I/O commands puts the dispenser
into a known state where the transport is clear of currency and in a ready
state to accept further I/O commands. A CLEAR, DIAG_CLEAR, or
CHECK_IF_BILLS_LEFT command must be issued after every power-up and
when the dispenser is returned to service after a fault condition is corrected.
VIRTUAL CASSETTE TYPES

The following terms apply to this section:
Physical Cassette Refers to the type of cassette defined by the setting of magnets on the side of
the cassette. Once set, this is fixed, and will be the same wherever the cas-
sette is used.
Virtual Cassette Refers to one of four fields in a command/response to/from the dispenser
firmware. Each virtual cassette type must be mapped onto a physical cas-
sette type. This mapping is set in various commands to the dispenser.
The concept of a virtual cassette type is introduced to allow a simple

application interface for intelligent cassettes and cassettes with extended
cassette IDs. this provides a range of cassette types from 1 - 255 instead of
simply 1 - 4.
The application sends commands specifying the number of bills to stack
from each virtual cassette type and receives response status information
(severity, RS_DATA, RC_DATA) relating to these virtual cassette types. A
translation from virtual to physical cassette type is performed within the
currency dispenser device software, thus enabling many different cassette
types to be handled. The virtual to physical cassette type relationship is set up
by the application, through parameters in the command data of all bill picking
commands. This relationship remains set within the dispenser until another
bill picking command is successfully actioned.
While bills are in the transport or at the present position, the virtual to
physical relationship can not be changed. This makes sure that when these
bills are taken by the cardholder or put into the purge bin that the response
information uses the same relationship as when the bills were picked.
The current virtual to physical relationship is stored through a power-
down and is read by the application on power-up before a CLEAR command is
issued. The READ_VIRTUAL_CASSETTE_TYPES command achieves this.
Virtual cassette types 1 to 4 map on to physical cassette types 1 to 4. The
application can use the RETURN_CASSETTE_STATUS command to
determine the physical cassette types installed after replenishment or power-
up to set up the virtual type command data. The response data fields S_DATA,
RS_DATA, and RC-DATA always return virtual cassette based information to
the application.
BILL SINGULARITY
The term singularity describes the parameters used by dispensers to
recognize a single bill. Because the P86 currency dispenser uses the LVDT to
determine whether the picked bill is single, singularity is a measure of the
cross-sectional area of the bill. (Refer to the description of the LVDT in the
section Electrical Description.)
The bill singularity values are configured through commands and are held
in the processors NVRAM on the P86 Control Board. The P86 dispenser

MAY 2003 12.8-68

firmware uses the bill size parameters to verify bill width of the currency
being stacked. If, on power-up or system reset, the parameters in the
execution processors NVRAM are found to be corrupted, then, bill widths are
set to 66mm (U.S. dollar size) and the singularities are set to 0FFH. These can
be set at any time using the SET_BILL_SIZES and
SET_BILL_SINGULARITIES commands.
The singularity thresholds are kept for each cassette type. These are
compared with the singularities measured by the LVDT to determine whether
a bill is single, multiple, folded, or torn. This is used for invalid bill detection
and rejection.
LVDT (SINGULARITY DETECTION) CIRCUIT SELF CALIBRATION

Each dispenser maintains an LVDT circuit compensation factor in NVRAM to
provide accurate calibration of the LVDT circuit. This factor is calculated and
adjusted by the firmware at run-time as bills are picked, thus providing
dynamic self calibration. On initial installation of a dispenser or when the
control board NVRAM is re-initialized, the compensation factor is set to 80H,
representing a nominal value of 1.
As bills are picked from each cassette, the average of the actual good bill
singularities will be measured across between 255 and 295 bills, depending
upon the number of bill picked during the last operation. The average is then
divided by the reference singularity of the bills being picked, to generate a
new compensation value. This is not done during the command
LEARN_BILL_PARAMETERS.
The compensation factor is stored as a byte in NVRAM with an initial
value of 80H. Adjustment will be limited to 25% (that is, 60H to 0A0H). This
value is returned in the Diagnostic Sensor Test response message.
Bill singularity is determined by comparing the actual singularity
multiplied by the compensation factor, to the reference singularity value for
the bill.
NOTE: 1. Although rejection of bills is always guaranteed, until at least 255

bills have been dispensed, multiple bills may not be accurately counted.
NOTE: 2. Bill singularity learning should not be attempted on a dispenser

which has not had time to adjust its compensation factor, as incorrect
results will be obtained.
NOTE: 3. The bill singularity parameters for the dispenser will be the same
as for the SDC 56XX Dispenser for the same type of notes.
BILL PRESENTATION ORDER

Bill presentation order parameters are held in firmware. The cassette type
bill presentation order specifies the order in which bills are stacked to be
presented to the cardholder. This is completely configurable, allowing, for
instance, the largest (or highest denomination) bills to be at the bottom of the
bundle presented to the cardholder and the smallest (or lowest denomination)
bills to the top.
The default bill presentation order for the 56XX enhanced currency
dispenser is:
Top of bundle - highest cassette type bills

12.8-69 MAY 2003

Second in bundle - second highest cassette type bills

Third in bundle - third highest cassette type bills
Bottom of bundle - lowest cassette type bills.
The recommended maximum number of bills in a stack is 40. In most
countries the dispenser firmware is set to this limit.
CASSETTE IDENTIFICATION
Cassettes of any type can be placed in any pick module. The dispenser
identifies each cassette by the interaction of magnets on 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 S3 S4 (handle end)
0 0 1 1 Cassette type 1
Extended cassette types are identified in the following way:
Magnet present (switch contacts made) = 0

Magnet absent (switch contacts open) = 1
Extended cassette types are not recognized until the ENABLE-
EXTENDED_CASSETTE_ID command has been successfully performed.
Switches S2, S3, S4, show Cassette Type
When a cassette is inserted into the dispenser a two minute timer is

started. If the magnet configuration changes to denote a new or invalid
cassette type during that period, and remains in that state for more than a 1/2
second, this new type is accepted for the cassette. Once the two minute timer
has expired, the current state of the inserted cassette is fixed until it is
physically removed. The removal of a cassette before the two minute timer has
expired will override the timer.
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. For example, assuming the
following configuration:
Pick Module Cassette Type
Top #1
Second #3
Third #1
Bottom #2
A STACK request from cassette type #1 causes bills to be picked from the
cassette in the uppermost pick module until it is out of bills or a pick failure
occurs then picking commences from the cassette type #1 in the third pick
module. Low media is not flagged until all cassettes of the same type are
indicating low media.

MAY 2003 12.8-70

INTELLIGENT CASSETTE SECURITY (ICS)

An ICS Control Module alarms board may be fitted to provide additional
cassette security. This alarms board is used in conjunction with ink cartridges
attached to the currency cassettes. If the correct handling procedures are not
followed, the cash within all the cassettes will have ink injected into it and be
rendered useless. The aim is to discourage theft of the cassettes.
The current implementation is a basic system that simply monitors for the
alarm line being set. Implementation of an intelligent cash security system is
a possible future development.
There are two levels for intelligent cash security, level 0 and level 1.
LEVEL 0
ICS Level 0 involves hardware only, a latching mechanism is attached to the
cassette to increase its security.
LEVEL 1
With ICS Level 1 an alarms board is connected to the dispenser control board
via the intelligent cassette connector J11. This switches the signal on the TXD
line straight through to the RXD line during normal operation. Where an
alarm state is detected, the RXD line will be held low. At the start of execution
of any command that drives the motors (stack, present, clear, purge, motor
test, pick valve test, bill learn, bill present), the state of the alarms board is
checked. This is done by setting TXD high and checking that RXD is high,
then setting TXD low and checking that RXD is low. If either of these
conditions is not true, an M_STATUS of 33 (pick interface communications
failure) will be reported in the solicited response. The SOH for all cassettes
and the purge bin will then be set to Removed.
NOTE: In normal mode, to operate with the firmware that services ICS
mode, a turnaround plug must be fitted to the cassette connector. This has
the TXD and RXD pins (7 and 8) connected together to ensure that the
alarm state is never reported.
The alarm state can only be cleared in the hardware with a full power off
and on.
FIRMWARE MAP
Bills are tracked throughout the transport by the execution firmware, which
monitors the sensors and maintains a map of the position of bills. In this way
bill jams and mispicks can be pinpointed and appropriate error recovery
taken. Error recovery is performed on faults detected during the STACK
command.

12.8-71 MAY 2003

ERROR RECOVERY
The firmware provides automatic error recovery on all I/O commands and
limited recovery on some diagnostic commands. Diagnostic recovery is limited
to the following:
Retrying DIAG_STACK and DIAG_DISPENSE up to four times when bill
verification errors occur.
Performing retries on all internal communications failures for all com-
mands. Retries for communications failures are performed up to three
times and, if they are unsuccessful a comms fail is reported.
The presenter and main transports in the dispenser are monitored by
timing wheels. As either transport is driven, its timing wheel rotates at the
same speed and generates interrupts at equidistant intervals. This facility is
used by the transport and bill mapping. On receipt of an interrupt, the current
position of the bills in the transport is compared with the expected position. In
this way, the map monitors the movement of bills in the transport as well as
detecting sensor faults, bill jams, and timing wheel faults. This can help in the
evaluation of the success of error recovery procedures.
In addition, the main transport includes the LVDT to detect any bad bills
and the main transport map helps keep count of any detected bad bills.
Error Reporting
Errors are reported in two ways:
Via NVRAM interface
Via SDC NCA interface.
NVRAM Interface
The currency dispenser has up to 14 logical sub-modules, each of which has an
associated area of NVRAM on the control board containing SOH module
status information. These sub-modules are:
Control board (also provides central logging and history files)
Pick module 1 (top)
Pick module 2
Pick module 3
Pick module 4 (bottom)
Standard cassette position 1 (top)
Standard cassette position 2
Standard cassette position 3
Standard cassette position 4 (bottom)
Standard purge bin (purged bills container)
Presenter transport
Exit shutter
Suction cups
System (required by node control application).
The sub-modules can have one of three architectures:
module with its own personal NVRAM
module using non-personal NVRAM
module with no NVRAM.
After any firmware command is performed, any change in the SOH of any

MAY 2003 12.8-72

of the sub-modules is reported by the UPDATE_STATE_OF_HEALTH

command. This command allows data to be sent describing the cause of the
fault for the particular sub-module.
Tallies are maintained for the currency dispenser to indicate how often
various components have been used. These tallies are updated by the
command firmware, via the NVRAM interface.
Thresholds are held for some of these tallies so that when a tally reaches a
certain value, the response to the command firmware from the NVRAM
interface indicates that the threshold for that tally has been met. The SOH for
the relevant sub-module is then updated.
SDC Secondary Communications Interface

Any errors found can be reported through the maintenance and severity fields
in the responses to commands and in unsolicited response messages from the
device driver interface.
Error Recovery Procedures

This section describes the error recovery procedures for various faults.
Sensor Clear When It Should Be Blocked

All transport sensors are tested statically before bill movement is attempted.
If any sensor has failed clear then this will be reported as a sensor fault and a
dispense is not attempted. When bill movement is attempted the sensors are
monitored to check that bills reach them within defined times. If a sensor fails
to detect bills when expected then a bill jam is reported indicating that the
sensor failed to go blocked. Error recovery consists of clearing the transport of
bills except in a present operation where the fault is at the exit sensor. In this
case the present operation will be completed because it is too late to clear the
bills (unknown present status is reported). If this fault persists after two
further consecutive dispenser operations then a fatal condition will be
reported.
Sensor Blocked When It Should Be Clear

If a sensor on one of the pick modules fails to clear, then a bill jam is reported.
The state of health data indicates which sensor needs to be inspected.
Overfill is detected if the purge bin overfill sensor fails to clear.
If any presenter transport sensor is blocked at the start of a PRESENT,
the bills are purged.
NOTE: The error condition where a bill is seen at a pick sensor when no bill
should be seen there, is covered by the error recovery defined in the
section Pick Sensor Fail Clear and Invalid Pick Interrupt.
Presenter Clamp or Clamp Sensor Failure

If the presenter clamp fails, two presenter clamp test operations are
performed. If either succeeds, the operation continues, otherwise it stops.
Bill Alignment Mechanism or Bill Alignment Sensor Failure

If the bill alignment mechanism fails, two bill alignment test operations are
performed. If this succeeds, the operation will continue, otherwise it will stop.

12.8-73 MAY 2003

Container Not Installed

If during STACK, LEARN_BILL_PARAMETERS, DISPENSE,
DIAG_DISPENSE, or DIAG_STACK, a cassette to be picked from is not
installed, the operation is rejected with a status of cassette not installed. If
during STACK, PRESENT, DISPENSE, SELF_TEST, DIAG_DISPENSE,
DIAG_SELF_TEST, LEARN_BILL_PARAMETERS, DIAG_STACK,
DIAG_PRESENT, the purge bin is not installed, the command is rejected with
a status of purge bin not installed.
An attempt is made to clear any bills in the transport to the purge bin.
Cassette Empty
If more than one cassette of the same type is installed, an attempt is made to
dispense from the other cassettes when one becomes empty or unusable. All
cassettes of the same type are picked until each one is empty before empty
cassette is reported in the RS_DATA.
If the correct amount of bills is not dispensed then the bills are cleared to
the purge bin.
Pick Failure
A pick failure occurs when a bill can not be picked when the cassette is not
reporting low. If a low has previously been reported, then the pick failure
means that the cassette is now empty
Like Cassette Empty, if more than one cassette of the same type is
installed, an attempt will be made to dispense from the other cassettes when
one goes fatal. If the correct amount of bills is not dispensed then the bills are
cleared to the purge bin.
Whenever a pick attempt fails then pick fail recovery is invoked. If the bill
cannot be picked after a pick fail recovery, a pick failure is reported.
Pick fail recovery attempts to pick from a cassette of the same type in a
lower pick module until either,
(a) The pick attempt succeeds, in which case picking continues from that
cassette for the rest of the transaction.
or
(b) There are no more cassettes of the same type in a lower module. In this
case the pick valves are disabled and the motor is run for 1.2 seconds (to
recover the vacuum). All subsequent picking is attempted from the topmost
healthy cassette of the required type. Up to three more pick attempts, with
vacuum recovery run prior to each pick attempt, are tried, before failing the
transaction with pick fail status.
NOTE: If the consecutive mispick count for a cassette is non-zero, the

vacuum recovery defined in step (b) will be done before attempting to pick
from the cassette.
Bill Verification Errors

If multiple bills, underlength bills, overlength bills, torn or folded bills are
detected, all bills will be purged and up to three retries will be attempted to
pick the bills. If the fourth attempt fails, the response to the command will
indicate too many rejects.

MAY 2003 12.8-74

Main Transport Motor Failure/Timing Disk Fails

If the timing wheel does not generate interrupts (and the interlock is not
disconnected) at the start of an operation then the main motor has failed.
There will be three attempts to start the motor. If these are successful then
the operation will continue. Otherwise the device is inoperative.
If the number of interrupts indicates that the wheel is too slow, an attempt
will be made to clear the bills to the purge bin and the event will be reported.
Presenter Transport Disk Fails

If the wheel stops generating interrupts, then the wheel has failed. If the bills
have not reached the cardholder then the bills will be cleared from the
transport.
If no interrupts are being generated at the start of an operation and the
bills are not seen to move then the presenter motor has failed.
Exit Sensor Blocked Initially

If the exit sensor is blocked initially on an operation (other than CLEAR,
DIAG_CLEAR, CHECK_IF_BILLS_LEFT, or RETRACT) following a
successful present operation, then error recovery is not attempted and a
NOT_TAKEN is reported with a severity of SUSPEND.
Exit Shutter Jam

During a present operation the bills are stopped when the leading edge of the
bundle is detected under the exit sensor. The bills are retracted slightly before
an attempt is made to open the shutter. If the shutter does not fully open on
the first attempt (there are no shutter retries on a present operation), the bills
are immediately purged. Three shutter recovery attempts are made at the end
of the error recovery procedure. If the shutter does not operate properly on the
retries, a SUSPEND severity is reported.
If the bundle disappears from the transport while attempting to move the
bundle to the purge bin, it is assumed that the cardholder has removed the
bills. This will be reported as a GOOD dispense, and error recovery is not
performed.
If the bills are successfully removed to the purge bin, and bills are not
unexpectedly seen at the exit sensor, a BAD dispense (T-CODE 2) is reported
and error recovery is performed as normal. If bills are unexpectedly seen at
the exit sensor, bills are not successfully moved to the purge bin, or bills are
jammed near the exit area, then an unknown dispense (T-CODE 3) is reported
and no error recovery is performed until the start of the next command. In
both of these cases a shutter jammed closed M-STATUS will be reported.
If the exit shutter is jammed open before an operation (other than
CLEAR, DIAG_CLEAR, CHECK_IF_BILLS_LEFT, or RETRACT), up to three
retries are attempted to close the shutter. If this is unsuccessful, any bills
stacked are purged, and shutter jammed open is reported. If the shutter
opens during a present or pre-present operation, it will stop immediately, and
an attempt will be made to move the bills to the pre-purge position. The
operation will then proceed in the same way as described above for the shutter
not fully opening on the present command.

12.8-75 MAY 2003

Status NOT_TAKEN Returned

If a NOT_TAKEN status is returned in response to the command following a
PRESENT or DISPENSE command, a RETRACT_BILLS command can be
issued. This will cause the bills to be withdrawn into the purge bin.
If the exit sensor is blocked initially on any operation (other than a
CLEAR, CHECK_IF_BILLS_LEFT, or RETRACT_BILLS) following a
successful PRESENT or DISPENSE command, then error recovery is not
attempted, and a severity of SUSPEND is returned.
Severity of SUSPEND Returned

When a severity of SUSPEND is reported the next command received must be
a CLEAR, CHECK_IF_BILLS_LEFT, or a RETRACT_BILLS otherwise the
command is rejected with a status of NOT_CLEARED/NOT_TAKEN.
Error on Move Bill Alignment Mechanism to Present Position after STACK

If no error is reported on the STACK command, then the presenter clamp
mechanism is moved to the present position in anticipation of a PRESENT
command. If any error occurs during this operation, no error recovery takes
place at this time and the error is reported on the PRESENT command. Error
recovery is performed on the PRESENT operation, which will continue if the
error recovery succeeds, other wise the PRESENT will not be performed and
bills will be purged.
Error On Move Clamp To Present Position After STACK

If no error is reported on the STACK command then the presenter clamp is
moved to the present position in anticipation of a PRESENT command. If any
error occurs during this operation, no error recovery takes place at this time
and the error is reported on the PRESENT command. Error recovery is
performed on the PRESENT operation which continues if the error recovery
succeeds, otherwise the PRESENT will not be performed and bills will be
purged.
Purge Bin Overfill Sensor Blocked

If the overfill sensor is blocked at the end of an operation then the motor is
run for an additional 3 seconds in an attempt to clear the fault. If this fails,
overfill is reported.
Self Test Command

The recovery procedure is to clear bills from the transport into the purge bin.
The device severity (S_DATA.byte 0) is set to FATAL for all errors
(recovered or not) except pick failure and cassette empty or too many
rejects. These faults affect only the cassette on which the fault occurs and
cause the appropriate cassette severity field to be set to fatal when all
cassettes of that type are affected.
Unable to Update NVRAM

In the event of being unable to update the SOH, the next response message
will contain an M_STATUS of CANNOT_ACCESS_NVRAM and the device is
marked as FATAL.

MAY 2003 12.8-76

Interlock Broken
If an interlock fault is generated and cleared by closing the safe door, then
error recovery is performed at the start of the next DISPENSE, SELF_TEST,
STACK, EXIT_SHUTTER_TEST, or LEARN_BILL_PARAMETER command.
Performing a CLEAR before these commands removes the need for error
recovery.
Pick Sensor Fail Clear and Invalid Pick Interrupt

Most of the errors reported as Pick Sensor Fail Clear, or Invalid Pick
Interrupt, are caused by bad media and are treated like rejects. All bills
already picked are purged. The operation is retried up to three times.
NOTE: Retries on these failures are only done in STACK and DISPENSE. If
the failure occurs in SELF_TEST or BILL_LEARN there is no retry.
Error Thresholding
If the error recovery procedure is unsuccessful the device is set inoperative by
S_DATA byte 0 (severity of whole device) = FATAL, for all errors except exit
shutter jammed open where SUSPEND is used for the initial detection, and
FATAL is set if the condition persists after error recovery following the
SUSPEND timeout.
If the error recovery procedure is successful then the S_DATA field byte 0
is set as follows on all faults except too many rejects, pick failure, out of
bills, and cassette not installed.
First occurrence of fault - ROUTINE
Second consecutive occurrence - WARNING
Third consecutive occurrence - FATAL.
Too many rejects, pick failure, out of bills, and cassette not installed
affect only the cassette on which the fault occurs therefore the appropriate
S_DATA field is set for these errors.
The severity of each virtual cassette type is generated from a set of counts
maintained by the firmware for each cassette installed in the dispenser.
There are error counts with limits for both bill rejects (bad bills) and pick
failures (mispicks).
Mispick failure limit = 12
Reject failure limit = 20.
The corresponding virtual cassette type severity is generated from the
total number of pick failure attempts (mispicks) or reject attempts on the
installed cassettes of that type.
Pick failure:
More than four mispicks left = ROUTINE
Equal to or less than four mispicks left = WARNING
No mispicks left = FATAL.
Rejects:
More than five rejects left = ROUTINE
Equal to or less than five rejects left = WARNING
No rejects left = FATAL.
That is, if there are two cassettes of the same type installed, then the error

12.8-77 MAY 2003

limit for rejects will be 40, and a ROUTINE response will be returned while
the consecutive reject count is less than 35.
Cassette not installed, Out of bills, Bundle Too Thick, Parameters
Not Configured, and Cassette Disabled, cause the appropriate cassette
severity to be set to FATAL on the first occurrence of the fault.
On SELF_TEST and DIAG_SELF_TEST commands, another set of
thresholds are used in conjunction with those mentioned above:
Mispick limit = 8
Rejects limit = 4.
If either of these thresholds or the thresholds above are reached then the
cassette is marked FATAL. This ensures problem cassettes are identified by a
single SELF_TEST operation.
STATE OF HEALTH (SOH)

NCR P86/P87 and NID Currency Dispensers have up to 14 logical sub-
modules. Each sub-module has an area of NVRAM containing SOH module
status information. This NVRAM is on the control board. The sub-modules
are:
Dispenser Control board (also provides central error logging and history
files)
Pick module 1 (top pick module)
Pick module 2 (2nd pick module)
Pick module 3 (3rd pick module)
Pick module 4 (bottom pick module)
Standard Cassette pos 1 (cassette held in top position)
Standard Cassette pos 2 (cassette held in 2nd position)
Standard Cassette pos 3 (cassette held in 3rd position)
Standard Cassette pos 4 (cassette held in bottom position)
Standard Purge bin (purged bills container)
Presenter transport
Exit shutter
Suction cups
System (required by Node Control Application).
The sub-modules can have one of three architectures:
Module with its own personal NVRAM
Module using non-personal NVRAM
Module with no NVRAM.
UPDATING STATE OF HEALTH

The State of Health (SOH) of each module is updated where there is an
irrecoverable fault on the dispenser, the lifetime of a component reaches its
threshold, or the severity of an error has reached the inbuilt threshold.
When an out-of-service device has been serviced, then the State Of Health
reset to HEALTHY is detected, and all internal error flags are reset, returning
the device into service.

MAY 2003 12.8-78

DEFINITION OF MODULES NVRAM

The use of the Modules NVRAM is defined in this section. This includes
details of the information which is stored in the TMS Interface Area, TMS
Support Area, Module Error Log and Module History Area.
Terminal Management Subsystems (TMS)
TMS Interface Area

The TMS Interface Area stores information about modules which is to be
transmitted to the Module Control Program.
TMS Support Area

The TMS Support Area is used by the driver to decide when a State of Health
change should take place by referring to tallies and thresholds.
Module History Area

The Module History Area holds information about the history of the module. It
is updated at rework centres or after preventive maintenance has been carried
out.
NOTE: All the modules are recorded in the Dispenser Control board history
area.
State Of Health Updating

The SOH of the cassettes and purge bin is updated by diagnostic and I/O
commands. The SOH of all other modules is updated only by I/O commands.
Diagnostic commands which attempt to pick bills will be inhibited if either
the SOH of the cassette to be picked from or the SOH of the purge bin is not
HEALTHY. Diagnostic commands are not inhibited by any other module being
unhealthy.
The SOH of the presenter will be set automatically to HEALTHY when
the safe door is closed, if the SOH was previously unhealthy due to an
interlock broken fault.

12.8-79 MAY 2003

THE DISPENSE OPERATION

The following description of a dispense operation explains the interaction
between the firmware and the mechanical and electrical components of the
dispenser. The illustrations below shows the sensors that detect the
movement of notes through the P86, P87, and front access NID presenters:
NOTE: The P87 illustrations are not repeated in this section because they
are similar to the P86.
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 presenter as far as the flicker
shaft. It also drives the pump which supplies the vacuum to all pick modules.
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 and the
LVDT takes its reference reading. The bill alignment mechanism is driven
forward by its own stepper motor until it is seen by the stack sensor T2. This
provides a reference position for the firmware and from there the bill
alignment mechanism is driven back to the position suited to the known width
of notes to be dispensed. If, during a transaction, notes of different widths are
to be dispensed, small notes increasing to large, then the bill alignment
mechanism will be driven to each new position before the next size of notes is
picked from the cassette.
When the firmware identifies the cassette, it sends a signal to energize the

MAY 2003 12.8-80

solenoid valve on the specific pick module and this extends the vacuum
through to the suction cups on that pick arm. The solenoid signal is ANDed
with the output from the sensor on the pick arm timing disk and it is the
resultant output which is used to operate the solenoid. The first note in the
cassette attaches to the suction cups and is lifted past the spring fingers on
the note guides and across the note separator brushes in the cassette, into
position above the D wheels in the pick module transport. The vacuum
solenoid is de-energized so that the vacuum is vented to atmosphere and the
note is released and gripped between the D wheels and pinch wheels on the
shaft above.
Just at the start of the pick module transport, the picked note passes
between the LED and sensor device of the pick sensor. This infra-red sensor
monitors the size of the picked note and the measurement obtained by it is
compared to the note size values held in the execution processors NVRAM. A
mismatch causes the firmware to reject the note to the purge bin.
The note is turned into the vertical transport of the pick module by the
curved shape of plastic skid plates. The note is pressed against these skid
plates by the transport belts and is driven up either to a higher pick module or
to the presenter module.
In the presenter the notes are supported by driven belts and pass between
the rollers of the Linear Variable Displacement Transducer (LVDT). They are
then flicked out of the LVDT transport by the fingers of the flicker shaft, so
that they strike the bill alignment gate and fall on top of the note clamp
transport forming a stack between the side plates of the note stop bracket. The
fingers of the flicker shaft aid the formation of the stack by acting to drag the
notes against plastic guides attached to the LVDT transport.
The illustrations below shows the note path in the presenter up to the
formation of the stack:

12.8-81 MAY 2003

When the stack of notes is complete, the bill alignment mechanism is

driven back to a position where the clamp transport can be raised. The clamp
motor is started and drives the cam to lift the note clamp transport so that the
note stack is held against the upper belts of the presenter transport and is in a
position where it can be detected by the stack sensor. The raised position of
the note clamp transport also means that the extended ends of the stack tray
form a support for the stack into the purge bin if the notes are rejected.
The stack sensor is then interrogated by firmware and should report
blocked, indicating the presence of the stack. If the stack is successful and
the stack sensor is blocked (that is, bills are present in the stack position) then
the firmware moves the bills to the transport sensor two positions before the
exit sensor (the pre-present sensor, T3). This movement helps to speed the
overall transaction time.
Depending upon the information fed to the firmware by the sensors, the
present operation can now be carried out or rejected. If the stack operation has
been successful, the PRESENT command opens the exit shutter and the
present motor drives the transport forward and then stops with the stack held
in the present position, from where the cardholder can grip the currency and
pull it from the end of the dispenser. The movement of the stack along the
transport is monitored by infra-red sensors. One sensor, at the end of the
transport (the exit sensor) looks at the stack in the present position. The
following illustrations show the path of the notes to the present position

MAY 2003 12.8-82

If a fault has occurred in stacking then, once the note clamp tray has been
raised, the presenter transport is driven forward until the trailing edge of the
stack of notes just clears the stack sensor when it is stopped. The bill
alignment mechanism is driven fully back so that its gate is lifted clear of the
transport by ramp surfaces attached to both side frames of the dispenser. The
presenter transport is then driven in reverse by the present motor until the
note stack is pushed into the purge bin. An infra-red sensor and LED monitors
the purge transport and also acts as the purge bin overfill sensor.
If the cardholder fails to take the stack of currency from the exit slot, the
presenter transport can be reversed to drive the stack back to the purge bin
(after first raising the bill alignment mechanism) as shown in the following
illustrations.

12.8-83 MAY 2003

When the exit sensor is detected clear of bills, the shutter is closed and the
clamp is returned to the home (down) position ready for the next dispense
operation.

MAY 2003 12.8-84

SERVICE AIDS
The following sections contain information relevant to the servicing and
operating procedures of the dispenser assembly.
CURRENCY EVALUATION QUALIFICATION PROCEDURE

NOTE: The P86, P87, and NID Currency Dispensers are calibrated in the
same way as the other dispensers in the 58XX and 56XX ranges of ATMs
and singularity values previously calculated for these are valid for the
P86, P87, and NID.
When the first P86, P87, or NID dispenser is received in each country the local
Field Engineering organization must establish the singularity values for each
type of currency to be dispensed. These singularity values must then be
entered to every ATM dispensing that currency, upon initial installation or
whenever the dispenser control board or the LVDT has been changed or
repaired.
The currency evaluation qualification procedure can only be performed on
a calibrated dispenser. Attempting the procedure on an uncalibrated or
incorrectly calibrated dispenser will give incorrect results.
CALIBRATING THE DISPENSER

NOTE: Dispensers are shipped pre-calibrated by the manufacturing plant.
Calibration is required if the LVDT or control board are replaced or
NVRAM is corrupted.
The dispenser maintains an internal compensation factor in NVRAM on
the dispenser control board. This compensation factor allows for differences
that exist between the singularities calculated by different LVDT assemblies
because of mechanical tolerances. The dispenser adjusts the LVDT
compensation factor automatically as bills of a known singularity value are
dispensed. While bills are dispensed the actual average of good single bill
singularities is measured over 255 bills. This average is compared to the
singularity figure typed in at installation time and the compensation factor is
adjusted accordingly. Initially the compensation factor is set to 80H
(equivalent to 1.00) and this is changed automatically by the dispenser and
updated every 255 bills.
To achieve dispenser calibration at least 255 bills of a known singularity
must be dispensed. This may be local currency or test media.
The following procedure describes how to calibrate a dispenser on a
terminal running on the OS/2 platform using TERMINAL UTILITIES. If
configuring dual dispensers you will use the SYSTEM APPLICATION on NT
and should refer, for details to the NCR publication, B006-6167-A000, Self-
Service Platform Software, Personas (PLATFORM For Windows NT), System
Application User Guide.
You will require to use level 1 diagnostic tests to dispense cash and for this
reason you need to insert the field engineers diagnostic disk (Product ID
D539-0003-0000) in the flex disk drive.
The procedure is as follows:

12.8-85 MAY 2003

1. Prepare a cassette to accept the test currency. See Chapter 12.2 for the
method of adjusting cassettes to currency size
2. Set the cassette magnets to indicate cassette type 1. See Chapter 12.2 for
this setting
3. Load the test currency into the cassette
4. Insert the cassette into the dispenser
5. Put the ATM into supervisor mode
6. Select the TERMINAL UTILITIES option on the ATM opening menu
7. Select the CONFIGURATION option on the utilities menu
8. Select the DISPENSER BILL CONFIG option on the CONFIGURATION
menu and check that the following menu appears:
9. Select CHANGE and respond to the prompt screens which appear.
10. Enter the provided bill size parameter for Type 1

MAY 2003 12.8-86

11. Press the Enter key to accept the bill size for types 2, 3, and 4
12. Enter the provided singularity figure for Type 1

13. Press the Enter key to accept the singularity values for types 2, 3, and 4
14. Press the Enter key to accept the presentation order and check that you
are returned to the DISPENSER BILL CONFIGURATION screen
15. If you wish to continue by configuring types 5, 6 and 7 select the
EXTENDED option and repeat steps 9 to 14 above.
16. Select the CONFIG MENU activator
17. Answer Yes (1) to the prompt to return to the CONFIGURATION menu
18. Select UTILITIES MENU to return to the utilities menu
19. Select the MAINTENANCE/DIAGNOSTICS option on the UTILITIES
menu
20. Operate the dispenser security switch
NOTE: The dispenser security switch (SW1 on the dispenser control board)
is a toggle action switch which can be left in either position during normal
dispenser operation.
21. Select the CONTROL MENU activator from the diagnostics menu
22. Select CASH ENABLE to ON
23. Select CURRENCY DISPENSER on the DIAGNOSTICS menu
24. At the CURRENCY DISPENSER menu select the SET NOTES option
25. Set the number of bills to be picked, from cassette type 1, to 40. Set the
remaining types to 0 (zero)
26. Select the LOOP activator at the CURRENCY DISPENSER menu
27. Select the DISPENSE test at the CURRENCY DISPENSER menu and
permit the loop count to go at least as far as 7.
The dispenser is now calibrated and you can evaluate the currency to be
dispensed as described in the next section.
ESTABLISHING SINGULARITY AND SIZE

In this procedure you have to cause the ATM to calculate the singularity and
size of 40 dispensed bills five times for each currency you wish to evaluate.
Due to the nature of the currency the singularity calculated may vary for each
attempt. Add the five figures and take the average (divide by five and round to
the nearest whole number) and the answers are the singularity and size
values you enter to the ATM and to all ATMs using the same currency.
To achieve a good singularity figure the currency loaded for this procedure
should comprise of new bills. Load the currency so that the same side of each

12.8-87 MAY 2003

bill is facing the truck door of the cassette. Put the bills into the cassette in 50
bill bunches, alternately right way up and upside-down (see the illustration
below). This makes sure that variations in inking are allowed for.
The singularity procedure is as follows:

1. Prepare cassettes to accept the denominations of currency you will nor-
mally be dispensing from the ATMs. See Chapter 12.2 for the method of
adjusting cassettes to currency size
2. Set the cassette magnets to indicate cassette types 1, 2, 3 and 4 as
required. See Chapter 12.2 for this setting
3. Load at least 200 bills of each denomination of the currency into the cas-
settes
4. Insert the cassettes into the dispenser
5. Put the ATM into supervisor mode
6. Select the TERMINAL UTILITIES option on the ATM opening menu
7. Select the CONFIGURATION option on the UTILITIES menu
8. Select the DISPENSER BILL CONFIG option on the CONFIGURATION
menu and check that the following menu appears:

MAY 2003 12.8-88

9. Select LEARN and respond to the prompt screens which appear
10. Select SET BILLS to change the number of bills to be dispensed during
the learn
NOTE: The menus only show the cassette types present in the ATM.
11. Select the cassette type or ALL to change the number of bills to be dis-
pensed
12. Enter the number of bills you want to dispense

13. When you have made all the changes you want, select LEARN MENU to

12.8-89 MAY 2003

return to the LEARN BILL PARAMETERS menu
NOTE: * The menu now displays the number of bills you have selected for
each cassette.
14. Select the cassette type to learn from, or select ALL if you are measuring
currency in all the cassette types displayed
15. When the dispenser stops select BILL CONFIG to return to the DIS-
PENSER BILL CONFIGURATION menu
16. Make a note of the singularity and size figures on the screen against the
cassette type selected or all cassette types if applicable
17. Empty the purge bin as necessary
18. Repeat steps 9 to 17 until you have five readings of singularity and size for
each cassette type loaded
19. Add each set of five figures and divide the total by five to obtain an aver-
age singularity and size for each cassette type
20. Select CHANGE at the DISPENSER BILL CONFIGURATION menu and
respond to the prompt screens which appear
21. Press Enter to accept any parameters you are not changing
22. Enter the calculated bill size and singularity figures for the cassette types
23. Select the CONFIG menu activator
24. Answer Yes (1) to the prompt to configure the new parameters and return
to the CONFIGURATION menu
25. Select UTILITIES menu to return to the UTILITIES menu.

MAY 2003 12.8-90

The procedure is now complete. From the UTILITIES menu you can now
enter level 1 diagnostics and dispense notes to test the validity of the
singularity values. A minimum of one cassette full of used notes and one
cassette full of new notes of each denomination should be dispensed. New
notes must be loaded with alternate packs right way up and then upside
down. Bowed notes must be loaded with the bow towards the note pusher.
A reject rate less than 1.5% must be achieved when dispensing an average
of 2.5 bills per transaction. If the reject rate is greater than this the
singularity and size values should be recalculated.
Calculation of Reject Rate

The reject rate is calculated using the following formula. The numbers for
rejected bills and total bills picked are taken from tallies.
Total Number of Rejected Bills

Reject Rate = x 100%
Total Bills Picked + Total Number of Rejected Bills
ERROR MESSAGES
Errors occurring during bill configuration procedures result in the error
messages described below.
Dispenser Clear Transport Error

When the DISPENSER BILL CONFIG option is selected from the
CONFIGURATION menu a CLEAR command is sent to clear the transport of
any bills. If the clear operation fails then the error screen shown below is
displayed. You return to the CONFIGURATION menu by selecting the
CONFIG MENU activator.

12.8-91 MAY 2003

Change Parameter Errors

The currency parameters are checked for errors as they are entered. If an
error is detected then an error message is displayed in the position indicated
in the following illustration:
The message is shown for two seconds and then you are prompted to enter
the new parameter value again. Once all the parameter values have been
changed and checked, the main dispenser screen reappears with the new
parameter values. If a mistake becomes apparent at this point then the user
can select CHANGE again.
The dispenser parameter error messages are as follows:
ERROR - VALID RANGE XX - XXX - Parameter value is outside the per-
missible range. This applies to bill sizes and singularity values
DUPLICATE VALUE IN SEQUENCE - A duplicate value has been
entered in the presentation order
ERROR - INVALID SEQUENCE - The user has input fewer than four val-
ues for the presentation order.
Learn Parameter Errors
Cassette Errors During Learn

If an attempt to learn the parameters from a particular cassette type fails
then, providing the error is not fatal, the operation will be tried repeatedly
until successful, or a fatal error occurs. Should a fatal error occur then the
error screen shown below appears, and, after 5 seconds, you are returned to
the LEARN menu.

MAY 2003 12.8-92

Dispenser Error During Learn

The following screen appears if a fatal dispenser error occurs while learning
parameters from the dispenser. Any changes made up to this point can not be
written to the dispenser therefore you are returned to the CONFIGURATION
menu via the CONFIG MENU activator:
Dispenser Read/Write Errors

If, while communicating with the dispenser, an error occurs which is not fatal,
then the operation is tried repeatedly until it is successful or until a fatal error
occurs. When a fatal error is encountered then a DISPENSER COMMS
ERROR screen showing one of the following messages is displayed. The
CONFIG MENU activator on the screen returns you to the configuration
menu.
UNABLE TO READ PARAMETERS - A fatal error has occurred while
reading data from the dispenser. Unable to read the currently configured
dispenser parameters so can not continue with configuration.
CONFIGURATION NOT COMPLETED - Fatal error while writing data to
the dispenser. The configuration data is written to the dispenser NVRAM
using three separate dispenser calls. One sets the new bill sizes, one sets
the new singularity values and the third sets the new presentation order.
Because the data is split into three parts, if this type of error occurs then
the dispenser configuration is incomplete.

12.8-93 MAY 2003

ELECTRICAL AND MECHANICAL ADJUSTMENTS

This section describes the adjustments for the Personas 86, Personas 87, and
New Interior Currency Dispensers.
DRIVE BELT TENSION

Proceed as follows to adjust the tension of the drive belt from the main motor
to the intermediate pulley. Refer to the illustrations following the procedure
for each type of dispenser
1. Check for a deflection of 2.0 mm (0.08 in.) when a force of 1.0 N (0.21 lb.) is
applied to the mid span of the drive belt.
2. If the tension is wrong, loosen the four motor mounting screws.
3. Move the main motor to adjust the belt tension.
4. Tighten the screws and check the tension again.
5. Repeat the adjustment until the correct tension is achieved.
P86/P87 Drive Belt Arrangement.

MAY 2003 12.8-94

NID Front Access Drive Belt Arrangement
REMOVING THE ELECTRONICS BOX (P86/P87)

On the Personas 86 and 87 Currency Dispensers the electronics box contains
the main motor and pump assembly, solid state relay, and motor run capacitor.
It also provides a mounting place for the dispenser control board. Its removal
gives access to these components and also to the LVDT assembly.

12.8-95 MAY 2003

Remove the electronics box as follows:
1. Disconnect the cable at the bottom left-hand side of the control board.
Check that the connector is labelled with its control board connector num-
ber.
2. Push out the cable ties holding the harness to the top and left-hand side of
the control board cover.
3. Loosen the two screws on the left-hand side of the control board cover.

MAY 2003 12.8-96

4. Unscrew and remove the screw at the bottom right-hand side of the con-
trol board cover.
5. Remove the control board cover from the electronics box.
6. Push out the cable ties holding the dispenser harness on to the electronics
box.
7. Disconnect the cables from the lower right-hand side of the electronics
box.
8. Disconnect the remaining cables from the control board. Check that each
connector is labelled with its control board connector number.
9. Unscrew and remove the two screws securing the green turning wheel in
position.
10. Remove the green turning wheel from the presenter drive wheel and then
ease off the timing belt.
11. Remove the two plastic rivets securing the timing disk sensor in position.
Move the sensor clear of the timing disk.

12.8-97 MAY 2003

12. Loosen the four main motor mounting screws and ease the timing belt off
the rear of the timing disk gear towards the presenter side frame.
13. Lift the timing belt over the timing disk.
14. At the upper left-hand side of the electronics box remove the screw attach-
ing the earth strap to the presenter.

MAY 2003 12.8-98

15. Remove the air hose from the pump.
16. Remove the two top screws (1 each side) holding the electronics box to the
presenter.
17. Remove the two bottom screws holding the electronics box to the pick mod-
ule.

12.8-99 MAY 2003

18. Lift the electronics box to release its hooks from the presenter tie shaft
and lift it clear of the dispenser.
Fitting the replacement electronics box is a reversal of the removal
procedure.
REMOVING THE CONTROL BOARD
P86/P87 Dispenser
Remove the control board as follows:

1. Loosen the two screws on the left-hand side of the control board cover.
2. Disconnect the cable at the bottom left-hand side of the control board.
Check that the connector is labelled with its control board connector num-
ber.

MAY 2003 12.8-100

3. Unscrew and remove the screw on the bottom right-hand side securing the
control board cover to the electronics box.
4. Remove the control board cover from the electronics box.
5. Push out the cable ties holding the dispenser harness on to the electronics
box.
6. Disconnect the remaining cables from the control board. Check that each
connector is labelled with its control board connector number.
7. Unscrew and remove the screws securing the heat sink to the left-hand
side of the electronics box.

12.8-101 MAY 2003

8. Unscrew and remove the four screws securing the control board to the
electronics box and then remove the control board.
Fitting the replacement Control Board is a reversal of the removal
procedure.
New Interior Dispenser

On the New Interior Dispenser the control board is attached to its mounting
plate by six Pozidrive screws into stand-offs and a further two screws through
the heat sinks, as shown in the illustration below:
The control board mounting plate is hung in slots in the presenter side
frames and fastened by a screw at each side in the positions indicated in the
illustration below:

MAY 2003 12.8-102

REMOVING THE MAIN MOTOR (NID)

For the P86/P87 procedure, see the section Removing the Electronics Box.
Front Access NID

Proceed as follows to remove the main motor from the front access NID:
1. Remove the cable guard (3 screws) at the left-hand side of the dispenser
and let it hang free.
2. Remove two connectors from the SSR assembly and then the 4 screws (two
at each side) and remove the assembly.
3. Remove the green handwheel (2 screws).
4. Remove the circlip and retaining washer and slip off the timing belt
between the handwheel and main motor shaft.
5. Remove the plastic rivets holding the timing disk sensor and move the
sensor clear of the timing disk.
6. Slacken the four screws holding the main motor to the side frame.
7. Ease the timing belt off the timing disk gear towards the presenter side
frame.
8. Remove the timing disk from its shaft and lift the timing belt off the main
motor pulley.
9. Remove four motor screws, slackened in step 6, and lift the motor out of
the slot in the side frame.
10. Disconnect the vacuum hose from the pump.

12.8-103 MAY 2003

REMOVING THE LVDT
P86/P87 Dispenser
In the P86/P87 dispensers the LVDT assembly is attached between the side
frames of the presenter by two screws at either side. To remove the LVDT
proceed as follows:
NOTE: There is no field adjustment on this LVDT version.
1. Make sure you have access to both sides of the dispenser.

2. Remove the electronics box as described in the procedure given earlier in
this chapter.
3. Remove the four screws attaching the LVDT assembly to the presenter
side frames - two at either end.
4. Slide the LVDT forward out via the space vacated by the electronics box,
taking care not to trap any wires.
Fitting the replacement LVDT is a reversal of the removal procedure.

MAY 2003 12.8-104

Front Access NID

Remove the LVDT assembly from the Front Access NID as follows:
1. Remove the main motor.

2. Remove the LVDT shield (2 screws in presenter side frames at both sides).
3. Remove the circlips inside and outside of the right-hand side frame, on the
drive shaft of the LVDT upper belt transport.
4. Slide the shaft out of the presenter right-hand side frame so that the ten-
sion is removed from the transport belts.
5. Remove the screws from the LVDT assembly (2 screws in the presenter
side frames at both sides).
6. Ease the LVDT assembly out between the belts.

12.8-105 MAY 2003

ELECTRONIC VERIFICATION OF LVDT

The following procedure verifies the LVDT adjustment:
1. Clear NVRAM
2. Load a cassette with currency of a known singularity value.
3. Put size and singularity values of the test currency into NVRAM.
4. Dispense 1000 bills.
5. Perform the Level 1 Diagnostics Sensor/Switch Status test.
6. Check that the LVDT calibration ratio returned in the last byte of
M_DATA is 80H 12.5% (that is, between 70H and 90H).
NOTE: Values outside the range given above indicate that further
investigation of the LVDT may be necessary
PICK MODULE TIMING

The Personas 86, Personas 87, and New Interior dispensers do not require any
timing relationship to be set between the action of the pick modules and the
presenter. The pick module to pick module relationship does, however, still
require to be set. The adjustment procedures are described in Chapter 12.9.

MAY 2003 12.8-106

LEVEL 0 DIAGNOSTIC TESTING

P86 AND NID CURRENCY DISPENSER CONTROL BOARDS
The following paragraphs describe the unique features of the on-board level 0
tests on the Dispenser Control board.
SWITCHES AND LEDs INTERFACE

On the Personas 86/New Interior Dispenser Control board the switches at
location U17 and LEDs D1, D2, D3, and D4 are used to select and report on
the diagnostic tests on the pcb components.
MODE OPTION
Switch SW8 (of set U17) is used to determine which method of testing is to be
used. If SW8 is OFF then diagnostics are performed in start-up mode. If SW8
is ON then diagnostics are run in Test Mode (that is, either selected or run-to-
run tests).
ON-BOARD SWITCH SETTINGS

The on-board switch settings are as shown in the following table:
Test Mode SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1
Start-up 0 X X X X X X X
Run To Run 1 SW7 SW6 0 0 0 0 0
Selected 1 SW7 SW6 0 <---------TEST ID---------->
0 = Switch OFF/OPEN
1 = Switch ON/CLOSED
X = Dont Care
SW7 - Loop Option:

OFF = Run test sequence once
ON = Run test sequence indefinitely (according to error option)

12.8-107 MAY 2003

SW6 - Error Option (valid only if SW7 is ON)

OFF = Halt on error
ON = Continue on error.
NOTE: Switch 8 (SW8) on the switchpack corresponds to the most

significant bit.
LEDs
While a test is being executed its test number is displayed on LEDs D1 - D3.
LEDs D4 - D8 are OFF.
For example:
LED D8 D7 D6 D5 D4 D3 D2 D1
0 0 0 0 0 <-----Test ID------>
NOTE: LED D4 is always ON if an error code is being displayed.
TEST SEQUENCES
Test No.
Test Description Start-Up Run-To-Run Selected
Hex
01 Micro-Controller Confidence and X X X
EPROM Sum Test
02 SRAM Data Test X X X
03 SRAM Address Test X X X
04 All RAM Data Test X
TEST DESCRIPTIONS
The following subsections define each test in turn. Each subsection identifies
the switch settings which cause the test to be executed.
TEST ROUTER
Purpose
The Test Router controls the way in which the Level 0 Diagnostics executes.
Description
The L0 switches are read and the appropriate test or test sequence executed.
Test Selection
Switch Number SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1
X X X X X X X X

MAY 2003 12.8-108

Test Results
LED Status
00 Start-up Passed
0D Bad Switch Setting
0E CPU Quick Check Failed
Notes
The error codes displayed by the router do not flash.
If the LEDs indicate 0FH then the MCU is probably held in a RESET
state.
TEST 01H - MICROCONTROLLER CONFIDENCE AND EPROM SUM-

CHECK
Purpose
To test the Micro-Controller, MCU and check that the contents of the EPROM
is valid.
Description
The following functions are performed:
Check the required MCU commands, flags and registers needed to per-
form a sumcheck on the EPROM
Perform EPROM sumcheck.
Test Selection
Run-To-Run 1 SW7 SW6 0 0 0 0 0
Selected 1 SW7 SW6 0 0 0 0 1
Test Results
LED Status
00H Pass code
08H MCU ALU fault
0DH EPROM sumcheck fail
Notes
On power up the LEDs should be 0FH. If LEDs stay at 0FH the MCU is
probably held in a RESET state.
The top two bytes of EPROM are reserved for L0 diagnostics. The
checksum value is stored here.

12.8-109 MAY 2003

TEST 02H - SRAM DATA
Purpose
To test all SRAM not allocated as non-volatile RAM (NVRAM).
Description
The following sequence is executed:
1. SRAM data area boundaries are calculated.
2. First two bytes of SRAM under test checked for any faults external to
SRAM.
3. A one is rotated through each byte in SRAM under test to check for inter-
nal SRAM faults.
Test Selection
Test Results
LED Status
00H Pass code
08H Internal data error in SRAM.
0AH External data fault on SRAM
Notes
The board is populated with only one SRAM.
TEST 03H - SRAM ADDRESS
Purpose
To check that there are no hard faults on memory not allocated as NVRAM.
Description
The following sequence is executed:
1. Write 00H to all SRAM under test and verify.
2. Write 0FFH to Byte 0 of SRAM under test and verify.
3. Read back from locations given by enabling one and only one address line.
These are the diagonal addresses (1,2,4,8...). If an address line fails to all
of SRAM under test the data read back is 0FFH. If an address fails inter-
nally to one bit of SRAM, then the data read back is neither 00H or 0FFH.
Test Selection

MAY 2003 12.8-110

Test Results
LED Status
00H Pass code
08H Data error while verifying 00H write
09H Data error while verifying 0FFH write - at address 0000H
0AH SRAM address bus error
0EH Chip select fault
Notes
If board is populated with only one SRAM then error codes refer to upper or
lower half of memory.
TEST 04H - ALL RAM DATA
CAUTION
This test will destroy any data stored within RAM area allo-
cated as NVRAM.
Purpose
This test has the same purpose as Test 02H except that all populated RAM is
tested.
Description
As per Test 02H except that Step 1 is missed and all populated RAM is tested.
Test Selection
Test Results
LED Status
00H Pass code
08H Internal data fault in SRAM.
0AH External data fault on lower SRAM

12.8-111 MAY 2003

LEVEL 1 DIAGNOSTIC TESTS

DIAGNOSTICS TEST MENUS
The currency dispenser diagnostics test menus are as follows:
Looping is allowed on certain tests.
CLEAR
The Clear test drives any bills left in the transport, into the purged bills area.
SET NOTES
The Set Notes test allows you to set the number of notes (bills) to be picked,
from each cassette type present. If the combined maximum number of notes is
greater than 40 the test fails and displays Invalid number of notes. You are
then prompted to Set notes for cassette X.
A default of five bills is picked if no number is entered.
STACK
The Stack test picks a number of bills, from each cassette type, and stacks
them for presentation.
A default of five bills is picked, from each cassette type, unless changed
using the Set Notes option.
NOTE: This test is not offered unless there has been a change of state of the
dispenser security switch after entry to diagnostics, and the Cash
Enable option on the control menu is set ON.

MAY 2003 12.8-112

PRESENT
The Present test moves previously stacked bills to the exit slot for removal.
DISPENSE
The Dispense test performs the Stack and Present tests in a single operation.
A default of five bills is picked, from each cassette type, unless changed
using the Set Notes option.
MAIN MOTOR
The Main Motor test tests the pick/stack transport drive motor.
SELF TEST
The Self Test test picks one bill from each pick module, with a cassette
installed, and moves the bills into the purge bin. The exit shutter is then
exercised.
EXIT SHUTTER
The Exit Shutter test checks the exit shutter sensors while the shutter is open
and again when it is shut.
SENSOR/SWITCH STATUS
The Sensor/Switch Status test determines the state of all sensors/switches
and reports them as M_DATA.
PRESENTER BILL DRIVE

The Presenter Bill Drive test activates the presenter bill drive at two speeds,
fast and slow, in both the forward and reverse directions.
LEARN BILL PARAMETERS

The Learn Bill Parameters test instructs the firmware to learn the bill
parameters. The test is only offered for configured cassettes. Forty bills are
picked from a selected cassette, inspected for width and singularity, and then
deposited in the purge bin.
The bill width and singularity is returned as T_DATA.

12.8-113 MAY 2003

PRESENTER CLAMP
The Presenter Clamp test exercises and monitors the presenter clamp and the
bill alignment mechanism. The mechanisms are monitored by their own home
sensors. Before the clamp test is performed the bill alignment mechanism will
be moved to the home position if required.
The clamp test initially checks the position of the presenter clamp. If it is
not at home, it is driven until it reaches home. When it is in the home position,
it is driven to the present position and then driven back to home. Failure in
any of these operations is reported.
The bill alignment test initially checks the position of the bill alignment
mechanism. If it is not at home, the mechanism is driven until it reaches
home. When it is in the home position, it is driven to the smallest bill position
and then driven back to home. Failure in any of these operations is reported.
The outcome of the test is returned as M_DATA.
PICK VALVE
The Pick valve test energizes the main motor and the pick valve of the pick
module, in the selected position, for a period of 10 seconds.
NOTE: 1. No feedback is provided for this test. You have to manually confirm
the operation of the valve.
NOTE: 2. All currency cassettes must be removed from the dispenser for this
test to run.
SDC TURNAROUND
The SDC Turnaround test carries out a turnaround test between the SDC
service and the module.
RUN-TO-RUN
The Run-To-Run test automatically performs the following tests, in sequence:
Clear
Sensor/Switch status
Presenter clamp
Presenter bill drive
Self Test
Exit shutter
Dispense (only if the security switch has been operated, refer to Dis-
pense).
Clear.
Gulp Feed Detector Switch

On any 56XX pick modules fitted to the P86 dispenser, check the action of the
gulp feed detector switch by triggering the switch during a CLEAR test. The
dispenser should stop instantaneously.
NOTE: On the New Interior Dispenser, the P87 Dispenser, or on a P86

Dispenser fitted with a NID control board, Gulp Feed Detect is not
supported and triggering the switch on a 56XX Pick Module will have no
effect.

MAY 2003 12.8-114

M_STATUS AND M_DATA

The M_STATUS codes and M_DATA returned for the currency dispenser are
listed in the NCR publication, B006-6273-A000 56xx/Personas Self-Service
Financial Terminals Diagnostic Status Code Notebook.
Actual to Virtual Cassette Mapping

Error codes returned by a Self Test or Dispense test are mapped to the virtual
type (VT) of the cassette. This section enables you to determine which cassette
type has returned which code.
The following algorithm is used by both Sysapp (Aptra) and Terminal
Utilities (S4i):
1. Map codes returned by physical cassette types 1 to 4, into the correspond-
ing virtual type.
2. Map physical extended types 5 to 7 into the unused virtual type entries in
ascending order.
3. Set any unused virtual type slots to their physical types.
The following examples explain how the error codes can be traced to the
correct cassette position in the dispenser.
Example 1
Step 1 Byte 0 1 2 3
VT 1 2 3 4
Physical
1 2 Note: In this example two cassettes are
Position Type Type 1. To achieve a code for each
Type 1 run the test with one removed
1 5 in turn.
2 1
3 2
4 1 Byte 0 1 2 3
Step 2
VT 1 2 3 4
Physical
1 2 5
Position Type
1 5
2 1
3 2
4 1
Step 3 Byte 0 1 2 3
VT 1 2 3 4
Physical
1 2 5 4
Position Type
1 5
2 1
3 2
4 1

12.8-115 MAY 2003

Example 2
Step 1 Byte 0 1 2 3
VT 1 2 3 4
Physical
3 4
Position Type
1 3
2 4
3 6
4 7 Byte 0 1 2 3
Step 2
VT 1 2 3 4
Physical
6 7 3 4
Position Type
1 3
2 4
3 6
4 7
Step 3 - No further mapping required. All fields filled by steps 1 and 2.
CURRENCY DISPENSER TI
Diagnostics Test Menu

The currency dispenser TI diagnostics test menu is as follows:
TAMPER INDICATION
The Tamper Indication test displays the status of the dispenser tamper
indicator as M_DATA.

MAY 2003 12.8-116

LEVEL 3 DIAGNOSTICS
S_DATA
The S_DATA returned for the currency dispenser are:
S_DATA Meaning
00 GOOD (No error).
01 ROUTINE (Minor fault).
02 WARNING (May require attention).
03 SUSPEND (Possible customer tampering).
04 FATAL (Requires immediate attention).
TALLIES
The tallies recorded for the currency dispenser are:
Transaction Tallies
Tally Description
PKFAIL 1 Pick attempt failure. A dispense attempt reported a pick failure on virtual cassette
number 1. This tally is not incremented if the cassette low media sensor is acti-
vated.
PKFAIL 2 As PKFAIL 1 for virtual cassette number 2.
SIZEERR1 Bill size errors. A dispense attempt was not successful because at least one
undersize, oversize or extra bill was detected from virtual cassette number 1.
SIZEERR2 As SIZEERR1 for virtual cassette number 2.
DOUBLE1 Double bill errors. A dispense attempt was not successful because at least one
double bill was detected from virtual cassette number 1.
DOUBLE2 As DOUBLE1 for virtual cassette number 2.
REJECT1 Bills picked from virtual cassette number 1 and purged due to bill verification
errors. This count does not include good bills picked and purged during dispense
by position.
REJECT2 As REJECT1 for virtual cassette number 2.
PICKED 1 Bills picked and successfully stacked from virtual cassette number 1 or success-
fully diverted during dispense by position.
PICKED 2 As PICKED 1 for virtual cassette number 2.
DISP OPS Dispense, dispense by position or clear main transport operations attempted.
TRANSEN Dispenser transport sensor fault or transport jam. A dispense or zero dispense
attempt was not successful because a fault was detected on one of the dis-
penser transport sensors:
The fault may have occurred for a number of reasons:
- Sensor blocked initially (jam or sensor fault).
- Bill not seen under sensor at correct time (jam or sensor fault)
- Bill did not clear sensor at correct time (jam or sensor fault)

12.8-117 MAY 2003

Tally Description
- Main motor timing disk failure (jam or sensor fault).
COMMINIT Reserved
COMMRET Reserved
COMMFAIL Reserved
RES 5070 Reserved for H-8010-5070-XX-08 currency dispenser.
EXITSHUT Exit shutter faults detected. The conditions causing this tally to be incremented
are:
- Exit shutter sensors indicate that shutter failed to open during a present opera-
tion
- Exit shutter sensors indicate that shutter is not closed on initiation of a dis-
pense, dispense by position, clear dispense, purge, or present operation
- EXIT_SHUTTER_TEST or DIAG_SHUTTER_TEST failed.
PRES OPS Present operations attempted.
PRSTROPS Other presenter operations attempted, for example, clamp or purge.
PRSTRJAM Presenter mechanism was not in the correct position or jammed during a dis-
pense, dispense by position, clear dispense, purge or present operation.
PRES_ERR Reserved
EXITSENS Reserved
PRESDISK Presenter timing disk failed to operate correctly.
PRESJAM Presenter bill jam was detected:
- Presenter transport sensors failed to block/clear while tracking bills
- Sensors failed static on/off test
- Sensors blocked initially on present or at end of purge.
TMS Interface Support Area Tallies

The tallies held in TMS NVRAM on the Personas 86 and NID Currency
Dispenser Control boards can be read using the Rework Diagnostics Tool.

MAY 2003 12.8-118

STRAPPING
P86/NID CURRENCY DISPENSER CONTROL BOARDS
The strapping associated with the P86 and NID Currency Dispenser Control
board has the following default position:
First Dispenser, SDC command switch pack (U17) - set switches 1 to 8 to
off for normal running
Second Dispenser, SDC command switch pack (U17) - set switch 1 to on
and switches 2 to 8 to off for normal running.

12.8-119 MAY 2003

PREVENTIVE MAINTENANCE
The following tables list the part numbers of the parts and assemblies that
should come under examination during preventive maintenance checks.
P86 PRESENTER
Item No. on
Drawing
Part No. Quantity Description Comments
445-0670055
Rev. A
5 445-0582160 5 Snap fit bearing
7 445-0665196 1 Note clamp assy.
8 445-0654953 1 Foam roll shaft assy.
22 009-0018425 3 Transport belt (lower)
23 009-0018426 3 Transport belt (upper)
30 445-0646519 5 Transport top belt (flat)
33 445-0663149 1 Fly guides assy.
34 445-0663266 1 Flicker shaft assy.
39 445-0656780 1 Purge bin support assy.
44 445-0643781 2 Pulley - 16T
45 009-0012944 2 Drive belt (bill align.)
47 445-0657073 1 Bill alignment assy.
56 445-0587806 3 Drive gear 36T/5 wide
58 445-0638120 4 Gear/pulley - 36T/24G
59 445-0611654 1 Gear - 36T (18, 0 wide)
61 445-0587795 1 Gear/pulley 36T/44G
62 445-0630747 1 Drive gear 48T/5 wide
63 445-0609571 5 Drive or idle gear 36T
64 445-0630722 1 Double gear - 24T/48T
65 445-0645767 1 Gear - 36T/clutch
66 445-0646454 2 Gear - 26T/5 wide (idler)
67 445-0653071 1 Drive gear - 15T/clutch
68 445-0616448 1 Pulley - 24T
69 009-0012943 1 Synchronous belt
70 009-0005208 1 Synchronous belt 6 wide X 3, OP
X318PLth.
X408PLth.
87 445-0612449 1 Air filter assy.
88 445-0669862 1 Uni-harness
94 445-0663270 1 Anti-static brush (top)
95 445-0663271 1 Anti-static brush (bottom) R.H.
96 445-0663272 1 Anti-static brush (bottom) L.H.

MAY 2003 12.8-120

P87 PRESENTER
Item No. on
Drawing
Part No. Quantity Description Comments
445-0669860
Rev. A
5 445-0582160 5 Snap fit bearing
7 445-0665196 1 Note clamp assy.
22 009-0018430 3 Transport belt (lower)
23 009-0018431 3 Transport belt (upper)
30 445-0646519 5 Transport top belt (flat)
33 445-0663149 1 Fly guides assy.
34 445-0663266 1 Flicker shaft assy.
39 445-0656780 1 Purge bin support assy.
44 445-0643781 2 Pulley - 16T
45 009-0012944 2 Drive belt (bill align.)
56 445-0587806 3 Drive gear 36T/5 wide
58 445-0638120 4 Gear/pulley - 36T/24G
59 445-0611654 1 Gear - 36T (18, 0 wide)
61 445-0587795 1 Gear/pulley 36T/44G
62 445-0630747 1 Drive gear 48T/5 wide
63 445-0609571 5 Drive or idle gear 36T
64 445-0630722 1 Double gear - 24T/48T
65 445-0645767 1 Gear - 36T/clutch
66 445-0646454 2 Gear - 26T/5 wide (idler)
67 445-0653071 1 Drive gear - 15T/clutch
68 445-0616448 1 Pulley - 24T
69 009-0012943 1 Synchronous belt
X318PLth.
X408PLth.
87 445-0612449 1 Air filter assy.
88 445-0669862 1 Uni-harness
95 445-0663271 1 Anti-static brush (bottom) R.H.
96 445-0663272 1 Anti-static brush (bottom) L.H.

12.8-121 MAY 2003

ELECTRONICS BOX (P86 AND P87)
Item No. on Quantity

Drawing Part No. (Double Description Comments
445-0670170 Pick)
15 445-0670114 1 AC harness
NID FRONT ACCESS PRESENTER
Item No. on
Drawing Part No. Quantity Description Comments
445-0657600
3 445-0664109 1 Fly guide assy.
6 445-0667192 1 Exit assy.
8 445-0587796 1 Pulley - 42T/18T
11 445-0615814 1 Pivot assy.
12 445-0642547 1 Nose tension shaft assy.
17 445-0656050 1 Purge flicker assy.
21 445-0657839 1 Note clamp assy.
29 445-0664203 1 Stack flickers assy.
36 445-0587791 1 Gear - idler 42T/BRG
37 445-0587795 1 Gear/pulley - 36T/44G
38 445-0587806 2 Gear - drive 36T/ 5 wide
39 445-0609571 4 Gear - 36T drive or idle
40 445-0616448 1 Pulley - 24G
41 445-0630722 2 Gear - double 24T/48T
42 445-0630747 3 Gear - drive 48T/5 wide
43 445-0633190 1 Gear - 26T/10 wide
44 445-0633963 2 Gear - 36T/10 wide
45 445-0638120 6 Gear/Pulley - 36T/24G
46 445-0645767 1 Gear - 36T/clutch
47 445-0646454 5 Gear - 26T idler
48 445-0653071 1 Gear - 15T/clutch
49 445-0658226 2 Gear - 26T/5 wide (drive)
50 445-0667934 1 Gear - 24T/5 wide (drive)
51 445-0643781 2 Pulley - 16T
52 009-0005026 1 Belt - synchronous
58 3MR-384-09 5 Belt - synchronous

MAY 2003 12.8-122

Item No. on
Drawing Part No. Quantity Description Comments
445-0657600
60 009-0016561 3 Belt - inner transport
61 009-0016562 3 Belt - outer transport
62 009-0016563 2 Belt - drum transport
63 445-0658240 1 Vacuum reservoir
65 445-0612679 1 Air filter
66 445-0667194 1 Tube - vacuum (700mm)
68 445-0668825 1 Harness - LVDT
69 445-0663427 1 Harness - NID F/A
70 009-0018392 2 Bearing - polymer flanged
72 445-0582160 12 Bearing - snap fit
79 445-0646989 1 Anti-static brush (bottom)
80 445-0647248 1 Anti-static brush (bottom)
PM PROCEDURES
At each service call the Customer 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 and the air filter in the vacuum
line.
NOTE: Vacuum the dust from all areas of the currency dispenser.
CURRENCY/MEDIA CONTAINERS
Clean the purge bin and all cassettes (including spare cassettes) both
inside and out.
NOTE: Pay particular attention to the front door of the cassette.
PICK MODULES
Check that the reed switch housing is not cracked (replace if necessary)
NOTE: A note low condition may not be identified if the reed switch housing
is damaged.
Inspect the pick lines for broken nozzles. Replace the pick line if broken,
cracked or bent
Check and replace suction cups if necessary. Read the Suction Cups sec-
tion following
Check alignment and clean all pick sensors/LEDs
Inspect the dispenser for worn or broken gears. Replace gears where nec-
essary. 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
Swap pick module orientation to prolong gear life (for example, on a 4 high
dispenser the top and bottom modules should exchange places, as should

12.8-123 MAY 2003

the middle two modules)

Lubricate the pick modules and check their mechanical adjustment; refer
to the LUBRICATION section in this chapter.
Ensure pick modules are properly timed.
Suction Cups
State of Health Systems

Replace suction cups when the SOH Replace Soon message appears. The
threshold is 103 000 bills.
Non SOH Systems

The following information is provided as a guide to formulating replacement
schedules for individual ATMs:
Lower usage ATMs (150 dispense operations daily, 1 bill per pick module
per operation); replace suction cups annually
Medium usage ATMs (250 dispense operations daily, 2 bill per pick module
per operation); replace suction cups every six months
Higher usage ATMs (350 dispense operations daily, 3 bill per pick module
per operation); replace suction cups every three months.

MAY 2003 12.8-124

PRESENTER ASSEMBLY
Look to see if the air filter above the top pick module is contaminated with
dust, and replace it if it is (Part No. 445-0612449).
NOTE: Annual replacement of the filter is recommended. When you disturb

the air filter some dust will drop down the tubing to the lowest pick
module. Disconnect the tube from the lowest pick solenoid and clean the
dust from the tube and solenoid.
Measure the vacuum above and below the in-line air filter. The minimum
acceptable vacuum is 19 in. Hg /650 mbar. Both readings must be identi-
cal; replace the air filter if the two readings are not the same
Strip and clean the pump if the vacuum level is low
NOTE: To maximise ATM availability, the pump should be replaced and the
original pump should be taken to a repair centre.
Lubricate the presenter.
SHUTTER ASSEMBLIES
For dispensers controlling facia mounted shutters, make sure both dispenser
and depository shutters are aligned and run freely.
On the NID, check the operation of the on-board shutter.

12.8-125 MAY 2003

LUBRICATION
This section describes the lubrication of the currency dispenser during
component replacement.
LUBRICANT TYPE
The following lubricants are recommended:
Lubricant Type
A No.2 General Purpose Oil
B Synthetic Lubricating Grease (009-0004618 = 100gm containers)
For No.2 General Purpose Oil any one of the following lubricants can be
used:
Shell Oil Co. Donax T-6
Mobil Oil Co. Mobile ATF 220
Exxon Oil Co. ATF or Esso ATF.
GENERAL INSTRUCTIONS
The following general instructions must be observed:
1. 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 detail.
3. Avoid excessive lubrication. Apply only that amount which will provide a
thin coating on the entire bearing area or surface, unless otherwise speci-
fied.
4. All parts to be lubricated must be free from dust, corrosion and metal
chips.
5. Lubricate bearing areas and surfaces during assembly, unless conditions
caused by subsequent handling are detrimental (for example, accumula-
tion of chips, grit, and so on) to the proper operation of the part. In those
cases lubrication should be applied after assembly.
6. Apply lubricants using the most convenient method when none is speci-
fied, that is by brushing, dipping, or oil can. Spraying is not recommended.
7. Lubricate all spring hooks and spring studs with lubricant B.
8. Working clipped or riveted assemblies should not be lubricated before riv-
eting but only after all processes, handling, or storage involving exposure
to dirt or serious atmospheric contamination are past.
9. 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.
10. Lubricants can cause serious deterioration of rubber. Avoid contamination
of drive belts and drive rolls.
CAUTION
Make sure that no lubricant spills on to the teeth of

gears as this may impair their performance.

MAY 2003 12.8-126

Presenter Assembly
Lubricate as follows:
Transport assemblies:
All bronze bearings - with A
Rollers (before assembly) - with A
Cam arms, rolls retained by riveted studs - with A
Twin-track cam, raceways, bore, cam roll and roll pivot stud - with B
Gears turning on stationary stud, on the stud, in the bore - with B
Toggle, pivot - with A.
All plastic bearings (before assembly) - with A.
Pick Module
Lubricate as follows:
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.

12.8-127 MAY 2003

INTERNAL CABLES
The diagrams in this section are the schematics of the internal cables of the
Currency Dispenser. Refer to Chapter 12.9 for Aria pick module internal
cables.
DISPENSER MAIN MOTOR (P86 AND P87)
AC Jumper
J1
NEUTRAL 1 42 1
V
V
V
Main Motor
Filter*
LIVE 2 31 1 SSR SSR 2 2
V
V
V
V
V
3
V
GROUND 3 Jumper V V
V
1 2
V Motor Run
Frame Capacitor
Ground 1
SSR J1
1 4 SSR
V
V
2 3 SSR
V
V
Frame Frame
V
V
Ground 2 Ground 3
* The filter is present only on OEM dispenser models
DISPENSER MAIN MOTOR (NID)
DISP AC
J1 Motor Jumper
P1 J1
1 NEUTRAL 33 4 2 1
V
V
V
V
V
LIVE
Filter* Main Motor
2 11 2
V
3 1 1 SSR SSR 2
V
V
V
V
V
V V
GROUND 3
3 22 Jumper
V
V V
V
1 2
V Motor Run
Frame Capacitor
Ground 1
SSR J1
1 3 SSR
V
2 4 SSR
V
* The filter is present only on OEM dispenser models

MAY 2003 12.8-128

P86 AND P87 DISPENSERS INTERCONNECTION DIAGRAM
AC Interlock Main
SSR P5 Motor
Sensors: Exit, Transport Sensors 3, 3A, 4,

Purge Overfill, Stack.
UNI
DC J8
J1 LEDs: Exit, Transport LEDs 3, 3A, 4, Purge
M1 Overfill, Stack.
Purge Bin Present Switch
J1 Motorized Shutter Control Board
SDC Bus J2
Clamp Motor
J13 Align Motor

Dispenser Control Board
Present Motor
Timing Disks - Main, Present, Clamp Sensors,

J6
Up, Down, Align Home, P87 Configuration Loop
J9 Note Thickness Sensor/LVDT
Pick Sensor
Pick LED
J4 J1 Double J5 Solenoid Valve
Pick Pick Arm Timing
Interface Disk
J4 To Lower Pick
Module I/F (P1)

12.8-129 MAY 2003

P86 AND P87 PRESENTERS CABLING (SHEET 1 OF 3)
J8 P1
AC MOT ON (WHITE) 2
1
V V V V V V V
V V
+5 V (BLACK) SSR
2 1
TSEN1 (GREEN) G T1
V V
3
TSEN1+ (WHITE)
5 W SENSOR
T1LED+ (RED)
4 R
V V
T1LED (BLACK) T1 LED
6 B
TSEN2 (GREEN)
7 G T2
V V
TSEN2+ (WHITE)
W SENSOR
V V V V V
9
T2LED+ (RED)
8 R
V V
10 B
11 TSEN3 (GREEN)
G T3
V V
13 W SENSOR
LINK1 (GREEN) G T3A
V V
TSEN3+ (WHITE)
W SENSOR
12 T3LED+ (RED)
R T3
V V
V V
14 B LED
LINK2 (BLACK) R T3A
V V
T3LED (BLACK)
B LED
TSEN4 (GREEN)
V V V V V V V V V V
15 G T4
V V
TSEN4+ (WHITE)
17 W SENSOR
TLED4+ (RED)
16 R
V V
TLED4 (BLACK) T4 LED
18 B
T5SEN (GREEN)
19
V V
G T5
T5SEN+ (WHITE)
21 W SENSOR
T5LED+ (RED)
20 R
V V

22 B
GND
23 C Purge Bin
V V
PURGE INb
24 NO Microswitch

MAY 2003 12.8-130

J13
PRES A+
4
V V V V
V V V V
7
PRES C+
8 3 Presenter
1 PRES B+ Motor
2
PRES D+

2 1
9 CLAMP A+ 1
V V V V
V V V V
10 CLAMP C+ 2 Clamp
3 CLAMP B+ 3 Motor
4 CLAMP D+ 4
ALIGN A+ 1
V V V V
V V V V
11
12 ALIGN C+ 2 Align
5 ALIGN B+ 3 Motor
ALIGN D+
6 4
J6
CLAMP UP LED (RED)
R
V V V V V V V V V V V V V V V V V V V V V V
V V V V
1
GND (BLACK) Clamp
3 B
+5 V (WHITE) Up
5 W Sensor
CLAMP UP (GREEN)
7 G
CLAMP DOWN (RED)
9 R
V V V V
GND (BLACK) Clamp

11 B
+5 V (WHITE) Down
13 W Sensor
15 CLAMP DOWN (GREEN)
G
ALIGN LED (RED) V V V V
2 R
GND (BLACK)
4 B Align
+5 V (WHITE) Home
6 W
ALIGN HOME (GREEN)
8 G
PRES TDISK (RED)
10 R
V V V V
GND (BLACK)
12 B Timing
+5 V (WHITE) Disk
14 W
PRES TDISK (GREEN)
16 G
MAIN TD LED (RED)
18
V V V V
R
GND (BLACK) Main
20 B
+5 V (WHITE) Timing
22 W Disk
MAIN TDISK (GREEN)
24 G
19 CONFIG 1a P87_J1 P87_P1
17
CONFIG 1b
Link Open = P86

Link Closed = P87

12.8-131 MAY 2003

J4 J1
CAS ID1-
40C
V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V
1
2 GND
39
CAS ID2- 38
3
GND 37
4
CAS ID3-
5 36
6 GND
35
CAS ID4-
7 34
GND
8 33
CAS TEMP-
9 32
GND
10 31
CASLOW-
11 30
12 GND
29
13 GULP-
28
LEDON_PICK
14 27
Pick Interface Board

GND 26
15
GND
16 25
S0
17 24
S1
18 23
DISABLE-
19 22
COILEN-
20 21
PICK
21 20
PSEN1
22 19
PSEN2
23 18
PSEN3
24 17
PSEN4
25 16
PICKTXD
26 15
27 PICK RXD
14
GND
28 13
29 GND
12
+12 V
30 11
+5 V
31 10
+5 V
32 9
GND
33 8
GND
34 7
35 GND
6
36 GND
5
+24 V
37 4
+24 V
38 3
+24 V
39 2
+24 V
40 1

MAY 2003 12.8-132

NEW INTERIOR DISPENSER INTERCONNECTION DIAGRAM
AC Interlock Main
SSR P5 Motor
Sensors: Exit, Transport Sensors 3, 3A, 4,

Purge Overfill, Stack.
UNI
DC J8
J1 LEDs: Exit, Transport LEDs 3, 3A, 4, Purge
M1 Overfill, Stack.
Purge Bin Present Switch
J1 Motorized Shutter Control Board
SDC Bus J2
Clamp Motor
J13 Align Motor

Present Motor
Timing Disks - Main, Present, Clamp Sensors,

J6
Up, Down, Align Home
J9 Note Thickness Sensor/LVDT
Pick Sensor
Pick LED
J4 J1 Double J5 Solenoid Valve
Pick Pick Arm Timing
Interface Disk
J4 To Lower Pick
Module I/F (P1)
J7 Shutter Open and Locked Sensors and LEDs
J5 Clamp Mid Sensor and LED
J14 Shutter Open and Locked Solenoids

12.8-133 MAY 2003

NID FRONT ACCESS PRESENTER CABLING (SHEET 1 OF 4)
J8 P1
AC MOT ON (WHITE) 2
1
V V V V V V V
V V
+5 V (BLACK) SSR
2 1
TSEN1 (GREEN) G T1
V V
3
TSEN1+ (WHITE)
5 W SENSOR
T1LED+ (RED)
4 R
V V
6 B
TSEN2 (GREEN)
7 G T2
V V
TSEN2+ (WHITE)
W SENSOR
V V V V V
9
T2LED+ (RED)
8 R
V V
10 B
11 TSEN3 (GREEN)
G T3
V V
13 W SENSOR
LINK1 (GREEN) G T3A
V V
TSEN3+ (WHITE) W SENSOR

12 T3LED+ (RED)
R T3
V V
V V
14 B LED
LINK2 (BLACK) R T3A
V V
T3LED (BLACK) B LED
TSEN4 (GREEN)
V V V V V V V V V V
15 V V G T4
TSEN4+ (WHITE)
17 W SENSOR
TLED4+ (RED)
16 R
V V
TLED4 (BLACK) T4 LED
18 B
T5SEN (GREEN)
19
V V
G T5
T5SEN+ (WHITE)
21 W SENSOR
T5LED+ (RED)
20 R
V V
22 B
GND
23 C Purge Bin
V V
PURGE INb
24 NO Microswitch

MAY 2003 12.8-134


J13
PRES A+
4
V V V V
V V V V
7
PRES C+
8 3 Presenter
1 PRES B+ Motor
2
PRES D+
2 1
CLAMP A+ 1
V V V V
9
V V V V
10 CLAMP C+ 2 Clamp
3 CLAMP B+ 3 Motor
4 CLAMP D+ 4
ALIGN A+ 1
V V V V
V V V V
11
12 ALIGN C+ 2 Align
ALIGN B+ 3 Motor
5
ALIGN D+
6 4
J7
OPEN_LED_POS (RED)
SHUT_OPEN
V V V V
3
V V V V V V V V
2
GND (BLACK)
1 4
SHUT_OPEN (WHITE)
7 1
GND (GREEN) 2
8
LOCK_LED_POS (RED)
V V V V
5 3
SHUT_LOCK
GND (BLACK) 4
3
SHUT_LOCK (WHITE)
6 1
GND (GREEN)
4 2
J5
CLAMP_MID_LED (RED)
3
V V V V
V V V V
1
CLAMP_MID
GND (BLACK)
2 4
+5V (WHITE)
3 1
CLAMP_MID (GREEN)
4 2

12.8-135 MAY 2003

J6
CLAMP UP LED (RED)
R
V V V V V V V V V V V V V V V V V V V V V V V V
V V V V
1
GND (BLACK) Clamp
3 B
+5 V (WHITE) Up
5 W Sensor
CLAMP UP (GREEN)
7 G
CLAMP DOWN (RED)
9 R
V V V V
GND (BLACK) Clamp
11 B
+5 V (WHITE) Down
13 W Sensor
15 CLAMP DOWN (GREEN)
G
ALIGN LED (RED)
V V V V
2 R
GND (BLACK)
4 B Align
+5 V (WHITE) Home
6 W
ALIGN HOME (GREEN)
8 G
PRES TDISK (RED)

10 V V V V R
GND (BLACK)
12 B Timing
+5 V (WHITE) Disk
14 W
PRES TDISK (GREEN)
16 G
MAIN TD LED (RED)
18
V V V V
R
GND (BLACK) Main
20 B
+5 V (WHITE) Timing
22 W Disk
MAIN TDISK (GREEN)
24 G
CONFIG 1
23
21
19
17
J14
24V_INT (Black)
2 1
V V V V
V V
OPEN_SHUTTERb (White) SHUTT1

4 2
1 24V_INT (Black)
1
V V
3 SHUTT2
OPEN_SHUTTERb (White)
2

MAY 2003 12.8-136

J4 J1
CAS ID1- 40C
1
2 GND
39
3 CAS ID2- 38
GND 37
4
CAS ID3-
5 36
6 GND
35
CAS ID4-
7 34
8 GND
33
CAS TEMP-
9 32
GND
10 31
CASLOW-
11 30
12 GND
29
13 GULP- 28
LEDON_PICK
14 27
Pick Interface Board

GND 26
15
GND
16 25
17 S0 24
S1 23
18
19 DISABLE- 22
COILEN-
20 21
PICK
21 20
PSEN1
22 19
PSEN2
23 18
PSEN3
24 17
PSEN4
25 16
PICKTXD
26 15
27 PICK RXD
14
GND
28 13
29 GND
12
+12 V
30 11
+5 V
31 10
+5 V
32 9
GND
33 8
GND
34 7
35 GND
6
GND
36 5
+24 V
37 4
+24 V
38 3
+24 V
39 2
+24 V
40 1

12.8-137 MAY 2003

ASSEMBLY AND SCHEMATIC DIAGRAMS

The following pages contain the assembly and schematic diagrams for the
electronic components of the dispenser listed below:
P86 Dispenser Control Board
Assembly Front View (445-0653529)
Assembly Rear View (445-0653529)
Schematic Diagram (Sheets 1 to 19) (445-0653534)
New Interior Dispenser Control Board
Assembly Front View (445-0668249)
Assembly Rear View (445-0668249)
Schematic Diagram (Sheets 1 to 19) (445-0668251).

MAY 2003 12.8-138

P86 Dispenser Control Board Assembly Front View

12.8-139 MAY 2003

P86 Dispenser Control Board Assembly Rear View

MAY 2003 12.8-140

P86 Dispenser Control Board Schematic Diagram (Sheet 1 of 19)

12.8-141 MAY 2003


MAY 2003 12.8-142


12.8-143 MAY 2003


MAY 2003 12.8-144


12.8-145 MAY 2003


MAY 2003 12.8-146


12.8-147 MAY 2003


MAY 2003 12.8-148


12.8-149 MAY 2003


MAY 2003 12.8-150


12.8-151 MAY 2003


MAY 2003 12.8-152


12.8-153 MAY 2003


MAY 2003 12.8-154


12.8-155 MAY 2003


MAY 2003 12.8-156


12.8-157 MAY 2003


MAY 2003 12.8-158

P86 Dispenser Control Board Schematic Diagram (Sheet 19 of 19

12.8-159 MAY 2003

NID Control Board Assembly Front View

MAY 2003 12.8-160

NID Control Board Assembly Rear View

12.8-161 MAY 2003

NID Control Board Schematic Diagram (Sheet 1 of 19)

MAY 2003 12.8-162


12.8-163 MAY 2003


MAY 2003 12.8-164


12.8-165 MAY 2003


MAY 2003 12.8-166


12.8-167 MAY 2003


MAY 2003 12.8-168


12.8-169 MAY 2003


MAY 2003 12.8-170


12.8-171 MAY 2003


MAY 2003 12.8-172


12.8-173 MAY 2003


MAY 2003 12.8-174


12.8-175 MAY 2003


MAY 2003 12.8-176


12.8-177 MAY 2003


MAY 2003 12.8-178


12.8-179 MAY 2003


MAY 2003 12.8-180

Bill Alignment Dispenser

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BILL ALIGNMENT DISPENSERS

Bill Alignment Dispensers

INTRODUCTION ...................................................................................................... 12.8-1

GENERAL DESCRIPTION ....................................................................................... 12.8-3

FUNCTIONAL DESCRIPTION .............................................................................. 12.8-10

MECHANICAL DESCRIPTION ............................................................................. 12.8-10

NCR CONFIDENTIAL AND PROPRIETARY

12.8-i MAY 2003

PRESENTER MODULE ..................................................................................... 12.8-15

ELECTRICAL DESCRIPTION ............................................................................... 12.8-28

CURRENCY DISPENSER CONTROL BOARD ................................................... 12.8-29

NCR CONFIDENTIAL AND PROPRIETARY

MAY 2003 12.8-ii

STEPPER MOTOR OPERATION ...................................................................... 12.8-47

CONNECTOR ASSIGNMENT ............................................................................... 12.8-50

SINGLE PICK INTERFACE BOARD .................................................................... 12.8-56

DOUBLE PICK INTERFACE BOARD .................................................................. 12.8-56

TRANSPORT AND TIMING SENSORS AND LEDS ........................................... 12.8-57

FIRMWARE DESCRIPTION .................................................................................. 12.8-61

NCR CONFIDENTIAL AND PROPRIETARY

12.8-iii MAY 2003

FIRMWARE COMMANDS................................................................................ 12.8-65

STATE OF HEALTH (SOH) ................................................................................... 12.8-78

THE DISPENSE OPERATION ............................................................................... 12.8-80

SERVICE AIDS ....................................................................................................... 12.8-85

CURRENCY EVALUATION QUALIFICATION PROCEDURE......................... 12.8-85

ELECTRICAL AND MECHANICAL ADJUSTMENTS ....................................... 12.8-94

NCR CONFIDENTIAL AND PROPRIETARY

MAY 2003 12.8-iv

REMOVING THE MAIN MOTOR (NID) ....................................................... 12.8-103

LEVEL 0 DIAGNOSTIC TESTING...................................................................... 12.8-107

LEVEL 1 DIAGNOSTIC TESTS........................................................................... 12.8-112

NCR CONFIDENTIAL AND PROPRIETARY

12.8-v MAY 2003

LEVEL 3 DIAGNOSTICS ..................................................................................... 12.8-117

PREVENTIVE MAINTENANCE ......................................................................... 12.8-120

LUBRICATION ..................................................................................................... 12.8-126

INTERNAL CABLES ............................................................................................ 12.8-128

ASSEMBLY AND SCHEMATIC DIAGRAMS ................................................... 12.8-138

NCR CONFIDENTIAL AND PROPRIETARY

MAY 2003 12.8-vi

Bill Alignment Dispensers

NCR CONFIDENTIAL AND PROPRIETARY

12.8-1 MAY 2003

SINGLE AND DUAL CONFIGURATION (P86)

The Personas 86 is available in either single cash dispenser configuration or, if

NCR CONFIDENTIAL AND PROPRIETARY

MAY 2003 12.8-2

Currency in the dispenser is contained within currency cassettes, and these

NCR CONFIDENTIAL AND PROPRIETARY

12.8-3 MAY 2003

Standard currency cassette (now obsolete):

NOTE: A full description of the currency cassette is given in Chapter 12.2.

NCR CONFIDENTIAL AND PROPRIETARY

MAY 2003 12.8-4

NCR CONFIDENTIAL AND PROPRIETARY

12.8-5 MAY 2003

The dispenser is capable of dispensing new or used currency of the following

NCR CONFIDENTIAL AND PROPRIETARY

MAY 2003 12.8-6

Thickness, including inking:

NOTE: The process of manufacturing paper aligns the majority of fibres in

NCR CONFIDENTIAL AND PROPRIETARY

12.8-7 MAY 2003