Afd 2.0

1.1 Active Dispenser AFD 2.
0
1.1.1 Introduction
The Active Dispense is a presenter type dispenser. It picks currency or other dispensable media from
dispense cassettes, stacks the media, and transports the stack of media to the consumer through a slot in
the fascia of the terminal. It can present media, retract and dump it if not taken. There is a Front Load and
Rear Load Active Dispense modules. Front Load and Rear Load Transports have short and long versions.
The cassette options include
 convenient or Secure currency cassettes
 convenient, Secure, or Bin divert cassettes
To gain full access to the module, a blue latch is used.
AFD 2.0
1.1.2 Main Parts

Following table shows the main parts of the dispenser.
Cash Out Cassette
RRC Cassette without lock
RR Cassette with Lock
Transport Module
Stacker Module
This SOP is for IPL’s Engineers benefit ONLY, not for distribution, Sale, or reproduction. Page 2 of 61
AFD 2.0
Picker Module
AFD Dispenser’s Controller
Dispenser unlock Module
AFD 2.0
Over All View
AFD 2.0
1.1.3 Function Principle of Dispenser

1.1.3.1 Picking and stacking
Firmware reads the cassette coding. Feed Modules pick the requested number of notes from cassettes.
Retract/reject routines may occur. Largest banknotes picked first, smallest last. Notes placed in the Stacker
Module, into the tray. Stacker sensor counts the number of arriving notes, FW compares it with the number
of picked notes.
1.1.3.2 Present
Well prepared notes in the Stacker Tray are presented by Host command through the Transport Module.
Notes are considered as vulnerable from this point.
1.1.3.3 Restore
After a successful Present operation, the Transport and Stacker Module returns to idle position, which is
Stacking.
1.1.3.4 Retract
If customer does not remove (all) notes after timeout and represent attempts, the notes are retracted
behind the shutter, then placed into the Retract compartment of the Reject/Retract cassette.
1.1.3.5 Reject
During Picking sequence, if the dimensions, or number of picked notes is not OK even after a
Restack/Recovery attempt, notes are Rejected and placed into the Divert compartment of the
Reject/Retract cassette.
1.1.3.6 Dump
Host can decide to dump the note stack in the Stacker Tray any time. It is placed into the Divert compartment
of the Reject/Retract cassette.
1.1.3.7 Divert
During dispenser self-tests and diagnostic tests, the module picks some single notes from the Feed Modules
and places them into the Divert compartment of the Reject/Retract cassette.
1.1.4 Modules of AFD Dispenser
Following are the basic modules of the AFD Dispenser.
1. Stacker Module
2. Picker Module
3. Transport Module
4. Cash out cassette
5. RR cassette
1.1.5 Stacker Module
1.1.5.1 Functions of Stacker Module
Following are the functions of the stacker module.
 The stacker arranges the picked media into a neat stack and lifts the stack into the transport.
 The stacker module also holds the Reject/Retract Cassette.
AFD 2.0
 If commanded so, the Stacker Module opens and closes the exit shutter, performs single or bundle
divert and dump operations.
 The Stacker Module includes motors for driving:
1. Transport Belts
2. Stacker Cam
3. Transport Push Plate
4. All 3 motors are stepper motors
1.1.5.2 Functions of Stacker Cam
Following are the five functions which are performed by the stacker cam.
 Opens and closes divert door
 Raises and lowers the money tray
 Latches and unlatches the exit shutter’s security lock
 Opens and closes exit shutter
 Operates the reject/retract compartment partition divider
1.1.5.3 Main Parts of the Stacker module

Below pictures shows the main parts of the stacker module.
AFD 2.0
AFD 2.0
1.1.5.4 Stacker Removal & Replacement

1.1.5.4.1 Removal
Following are the steps to remove the stacker.
 Remove the transport
 Disconnect the stacker sensor cable (J2).
 Disconnect the motor cable connector (J1). Compress the connector lock latch, then pull the connector
up.
 If present, disconnect the dock switch cable (J62).
 If present, remove the screw that secures the stacker to the first picker channel.
 Release the stacker latch springs, then slide the stacker toward yourself and lift up the stacker to
remove it.
1.1.5.4.2 Replacement
Following are the steps to replace the stacker.
 To replace the stacker, reverse the removal procedure
 Make sure that connector J1, J2, J62 are properly seated
 Make sure all sensors on the transport and stacker are clean and unblocked.
 After the stacker is replaced, the stacker sensor emitter is new and must be manually recalibrated. Refer
to recalibrate the sensor.
AFD 2.0
1.1.5.5 Removing the Stacker Sub-Assembly

 Removing and replacing the divert door and stacking tray do not require removing the stacker sub-
assembly first from the dispenser.
 Removing the replacing the other components of the stacker sub-assembly require that the stacker has
been removed from the dispenser.
 Following pictures shows the stacker Sub-Assembly.
AFD 2.0
1.1.5.6 AFD Stacker ’s Cabling

Following image shows the cabling of the stacker.
AFD 2.0
1.1.5.7 Cam Removal and Replacement

Following is the procedure for removal and replacement of the Cam.
 Remove the 138-tooth cam timing belt.
 Rotate the cam counterclockwise so that the partition drive link notch is at the 5 o'clock position
 Remove the partition follower assembly.
 Remove the cam screw and washer.
 Remove the cam from the pin.
 Make sure that the arrow on the gate actuator aligns with the notch in the frame (gate closed position)
 Verify that the gate actuator cam roller and the transport cam roller are in the cam groove and the cam
vain is in the sensor.
 Position the cam with the partition drive link notch at 5 o'clock.
AFD 2.0
 After assembly, rotate the cam to verify that the tray raises before the gate actuator moves to the gate
open position.
1.1.5.8 Stacker Check Points

Following image shows the points which should be while the preventive maintenance of the stacker. At every PM,
Stacker Cam should be removed and cam and the below mentioned parts should be checked.
AFD 2.0
1.1.5.9 Note Stop Adjustment

 Use the small screw drive & push the pin & adjust the note stop position at 4 as shown in the image
below.
 Push in the note stop locking pin before moving the note stop to the desired position as shown in the
image below.
AFD 2.0
1.1.5.10 Paddle Wheel Removal & Replacement

1.1.5.10.1 Removal
Following is the procedure to remove the Paddle Wheel.
 Remove the combination gear, paddle wheel shaft, and motor pulleys.
 Remove the timing belt if it hasn't already come off with the pulleys, please see below picture.
 Remove the E-ring and bearing from the non-cam side of the paddle wheel shaft.
 Rotate the shaft and pull the paddle wheel shaft gently outward and upward into the bearing relief hole
for easy removal from the frame.
 Pull the paddle wheels to remove them from the shaft.
 Please note that there is a groove in the shaft for each paddle wheel. A corresponding ridge inside the
paddle wheel hub engages the shaft to keep it in place.
1.1.5.10.2 Replacing of Paddle Wheel Shaft
Following are the steps to replace paddle wheel shaft.
 Lift the latch and slide the 20-groove pulley off of the shaft.
 Remove the bearing.
 Remove the E-ring.
 To replace the paddle wheels and the paddle wheel shaft, reverse the removal procedure.
1.1.5.11 Sensor Recalibration
The transport and stacker sensors must be calibrated if any of the following sub-assembly are replaced.
1. Transport sub-assembly
2. Stacker sub-assembly
3. Control CCA
 Please note that the sensors must be clean and unblocked before the sensors are calibrated.
AFD 2.0
1.1.5.12 Transport and Stacker Sub-Assembly Connector

The below image shows the properly seated and improperly seated connector.
1.1.6 Front –Load Transport Module

1.1.6.1 Main Parts
 The transport is mounted on top of the stacker. The transport moves the stack of dispensable media
through the exit shutter on the fascia to the consumer.
 The stacker first lifts the media into the transport path. The push plate and belts move the media to the
front of the transport until it blocks the exit sensor. The push plate stops, the gate opens, and the belts
push the stack of media through the opening to the consumer. The transport holds the media in this
position until the consumer removes it. If the consumer does not remove the media, the transport can
retract the media. The media can be held in escrow or deposited into the retract compartment of the
divert/retract cassette.
AFD 2.0
 Following images shows the basic components of the transport module.
AFD 2.0
AFD 2.0
1.1.6.2 Removal & Replacement of transport Module

1.1.6.2.1 Removal
Following is the procedure to remove the transport module.
 Remove the divert cassette, if present.
 Remove the control CCA cover.
 Position the cam so that the stacker tray is in the full down position and the divert tray is over the
stacker tray.
 Remove the transport connector from J3 on the CCA. Un-route the cable from the stacker features.
 Whenever removing or installing the lower shaft (transport), use EXTREME CAUTION not to stretch the
belts any more than necessary.
 Remove the lower transport shaft assembly by releasing the right side from its recess in the frame.
 Once free, remove the left side from the bearing hold to remove the tension on the semi-stretch
transport drive belts.
 Move the divert door into a neutral position.
 For the front load only, unscrew the standoff that secures the gate drive flip gear, then remove the
gear. The gear is used to correct the timing.
 Remove the four mounting screws (M3x6) that secure the transport.
 Push the transport from the back to loosen the stacker-to-transport push plate timing belt.
 Remove the transport-to-stacker inter-module timing belt and the stacker-to-transport push plate
timing belt.
 Lift the transport at the front and back and remove it.
1.1.6.2.2 Replacement
 To replace the transport sub –assembly, reverse the removal procedure and verify the following
alignments.
1. The stacker tray is in the full down position with the divert tray over the stacker tray.
2. The divert cassette is not present in the sub-assembly.
AFD 2.0
3. The edge of the transport frame rests in the groove of the divert door.
4. The transport mounting holes are on the outside of the stacker.
5. Make sure that the stacker frame locating boss is set in the slots in the transport.
6. Make sure that index marks on the gate drive flip gear align with the arrows on the rack gears.
7. Make sure that connector J3 is properly seated.
1.1.6.3 Transport & Stacker Alignment
Below image shows the correct and incorrect Transport to Stacker Alignment.
1.1.7 Feed / Picker Module

1.1.7.1 Main Parts
Following images shows the basic components of Feed/Picker Module.
AFD 2.0
The stripper wheel shaft is clutched so that it only rotates in one direction. The stripper wheel is a high
friction rubber wheel that prevents more than one bank note being dispensed by the feed wheels. The
wheel is mounted on the end of the stripper wheel shaft and is pressed against the center feed wheel by
the media cassette with a preset force. If the feed wheels pick more than one note from the stack, the extra
notes will be held back (stripped) by the non-rotating stripper wheel.
AFD 2.0
A fender covers the stripper wheel to prevent damage to the media by the stripper wheel. The take-away
wheel shaft can rotate freely in both directions. The rubber take-away wheel provides friction to drive the
note once it is past the stripper wheel. The take-away wheel is mounted on the end of the take-away shaft
and is pressed against the center feed wheel by the media cassette with a preset force. Once the raised
drive sections of the feed wheels lose contact with the picked note, the take-away wheel forces the note
against the recessed rubber section of the center feed wheel, supplying the friction to drive the note past
the stripper wheel.
1.1.7.2 Take Away Wheel
1.1.7.3 Take-Away spring

The take-away springs have small, bi-directional rollers that help the outside feed wheels drive the note
out of the feed channel. They are spring loaded against the two outside feed wheels and operate on the
same principal as the take-away wheel. When the note enters between the take-away springs and the feed
wheels, the force of the take-away springs against the feed wheels provides the friction for the feed wheels
to drive the note out of the feed channel. The take-away springs are not field-replaceable.
1.1.7.4 Functions of the Picker Module

Following are the functions of the picker module.
 Reads the cassette coding.
 Pick media from the cassette.
AFD 2.0
 Count and grade the media.
1.1.7.5 Classification of Notes

1.1.7.5.1 Mispicks:
The failure of the feed wheel cam to pick a single note from the media stack in the cassette in one rotation
of the feed wheel.
1.1.7.5.2 Come Along:
An undesired second note that is in the same cycle as a desired note and is restacked. This can be caused
by worn stripper, take away or feed wheels.
1.1.7.5.3 Short:
A note that is detected by the double detect system as less than half the regular note height (e.g. A
lengthwise folded bill)
1.1.7.5.4 Single:
A good desired note of proper height and thickness.
1.1.7.5.5 Long:
A note that is measured at least half an inch higher than normal.
1.1.7.5.6 Early Doubles:
Two overlapped notes that are restacked.
1.1.7.5.7 Late Doubles:
Two significantly shingled notes that are restacked.
1.1.7.5.8 Late Tape:
A note that has a wrinkle or tape towards the end of the note causing the note profile to look thick. It is still
dispensed
1.1.7.5.9 Actions and Notes:
When we look at the Actions and Notes for Mispicks, Actions = the number of mispicks. In other words how
many times the feed wheel turned to pick up the note. Notes= the number of notes that had a mispick.
Example1: If there are 4 mispick Actions on 1 Note, it means the Feed Wheel rotated 4 times to extract the
1 note.
Example2: If there are 8 mispick Actions on 3 Notes, it means that the Feed Wheel rotated 8 times to get 3
notes out.
AFD 2.0
1.1.7.6 Removal and Installation of Picker Module

1.1.7.6.1 Picker Sub-assembly One and Two
Following is the procedure to remove and install the Picker Sub-Assembly one and two.
 Remove all cassettes if any are present.
 Remove the control CCA.
 Whenever removing or installing the lower shaft (transport), use EXTREME CAUTION not to stretch the
belts any more than necessary.
 Remove the lower transport shaft assembly by releasing the right side from its recess in the frame.
 Remove the left side from the bearing hole to remove tension on the semi-stretch vertical transport
drive belts.
 Set the shaft assembly aside in a safe place and secure the vertical timing belts to prevent damage to
them.
 Remove the screw that secures the stacker to the first picker channel, if present. Release the stacker
latch springs and slide the stacker and transport unit toward the rear.
 Remove the screw(s) attached to the picker that you want to remove.
 Remove the transport and stacker from the picker stack.
 Remove the picker motor cable and the keyboard cable. Save them to be used on the replacement sub-
assembly.
 On the picker you want to remove, release the latch springs and slide the sub-assembly toward yourself
to disengage it from the pins in the sub-assembly below it, then lift the sub-assembly from the stack.
1.1.7.7 Picker Sub-assembly Three and Four
The following steps describe how to remove pickers three and four without removing the CCA, the
transport, or the stacker.
 Remove the lower TPR shaft assembly by releasing the right side from its recess in the frame.
 Remove the left side from the bearing hole to remove tension on the semi-stretch vertical transport
drive belts.
 Set the shaft assembly aside in a safe place and secure the vertical timing belts to prevent damage to
them.
 Disconnect the keyboard cables [AFD 2.0 version]) for pickers three and four from the CCA and remove
the cables from the cable route dressing.
 Disconnect the motor cables [AFD 2.0 version]) for pickers three and four then remove them from the
cable route dressing.
 Remove the screw(s) attached to the picker that you want to remove.
 On the picker above the one you want to remove, release the latch springs and slide the subassembly
toward the back to disengage it from the pins in the sub-assembly below it.
 Lift the picker (s) with stacker, CCA, and transport from the stack.
AFD 2.0
 On the picker you want to remove, release the latch springs and slide the sub-assembly toward the back
to disengage it from the pins in the sub-assembly below it, then lift the sub-assembly from the stack.
1.1.7.8 Replacement of Picker module

 If required, attach a motor cable and keyboard cable to the picker before assembling the picker
stack.
 Assemble the picker stack. Make sure that the picker guides and pins are properly engaged.
 If removed separately, attach and secure the transport and stacker assemblies.
 Route the motor cables for pickers one and two as shown in above picture.
 Attach the control CCA.
 Connect the motor cables from pickers one and two to the CCA.
 Route and connect the motor cables from pickers three and four. Start with the sub-assembly that
is farthest from the CCA.
 Route and connect the keyboard cables. Start with the sub-assembly that is farthest from the CCA.
 Install the vertical timing belts and the lower transport drive shaft assembly. Make sure that the
belts are not twisted and are centered on the crown rollers.
 Install the CCA cover. Make sure that no cables are pinched behind the cover.
AFD 2.0
1.1.7.9 Feed Wheel Replacement Guidelines

 The Feed Wheel used in Active Dispenser module is the non-aggressive Feed Wheel. P/N: 49-
204018-000D
 The PM Kit 49-267135-000A contains a Feed Wheel, a Fender, a Stripper Wheel and a Take-away
Wheel.
 The maximum shelf time of the Feed Wheel assembly is 18 months. For maximum performance,
install the Feed Wheel maximum after 18 months of its manufacturing date.
 The manufacturing date is indicated on the part's box, or on the side of the wheel.
 If not worn out, just dirty  clean with soapy water
 If visibly worn  replace Feed Wheel
 Use for maximum 400.000 notes dispensed
AFD 2.0
1.1.7.10 Feed Wheel Alignment

 After Feed Motor and/or motor coupling replacement, the Feed Wheel position should be aligned
 Feed Wheel alignment check should be performed in case of feed problems.
 Below image shows the procedure for feed wheel alignment.
AFD 2.0
1.1.7.11 Physical Observation to find the problematic parts in feed module:

Following images shows the parts when they are in correct state and when they are in incorrect state.
Feed Wheels
AFD 2.0
AFD 2.0
AFD 2.0
AFD 2.0
1.1.8 Media/Currency Cassette Types
1.1.8.1 Reject/Retract Cassette Types

Below image shows the types of the reject bin
AFD 2.0
1.1.8.2 Main Parts of COC:

Following are the images which shows the basic components of the COC.
AFD 2.0
1.1.8.3 Cassettes Denomination & button settings 500:

Following is the procedure for the cassette and button settings for 500 denomination.
Denomination: 500 PKR
Dimensions: 147 x 65 mm
 Please gently remove the coding buttons from the lower row of the cassette’s backside with a plier.
(Remove the 3 buttons from CC, CC7, and CC4 positions)
 Using the removed buttons, push one of them in to the H2 position as indicated with green below.
 Leave the denomination button (D1) in its place.
 Make sure that you have a button in the parity position (MP)
1.1.8.4 Side Guide & Upper Rail settings for PKR 500:
Following is the procedure for side guide and upper rail settings for PKR 500.
 Inside the cassette lower section (body), check the Lower Side Guide settings. It should be in position
9 on the left (odd) side, and 10 on the right (even) side.
 In the top (lid) of the cassette, please check the Upper Rail configuration. It should be the Upper Rail
Config-6, as indicated on the below drawing.
AFD 2.0
 It means that that rail number 49-024317-000A must be clipped together with 49-024321-000A
spacer and 49-023320-000A cap. You can see these part numbers written on the rails!
 This is the way how these 3 rails (rail & spacer &cap) should be hooked together:
1.1.8.4.1 Configuring the Upper Rail
Rails must be installed in the lid of the cassette so that it will be configured correctly for the height of the
media to be dispensed.
1.1.8.4.2 Upper Rail – Removal
Following is the procedure to remove the upper rail.
 Open the cassette lid until it lies flat on the work surface.
 At each of the two rail locks, use a flat blade screwdriver (or similar object) to lift and hold the rail
flange above the rail lock. Slide the rail until it is past the rail lock and disengages from the eight rail
latches, then remove the rail from the lid.
 Repeat Step 2 for the remaining rail.
AFD 2.0
1 Rail hook
2 Rail lock
3 Rail mounting slot
1.1.8.4.3 Upper Rail - Replacement
 If the rail for your media requires a cap or a spacer or both, assemble the required parts (Figure 3-
3). Make sure that the hook in the cap engages the rail correctly, then press the parts together until
they are fully seated.
Figure 3-3 Rail, Spacer, and Cap Assembly

1 Cap
2 Spacer
3 Rail
AFD 2.0
 Position the rail (or rail assembly) with the ramp toward the front of the cassette and the rail flange
mounting notches and mounting slots against the rail latches in the lid.
 Attach the rail to the rail latches nearest a rail lock as follows:
a) Place your fingers on both sides of a rail mounting slot that is beside a rail lock.
b) Press the rail firmly against the lid and slide the rail (or rail assembly) onto the rail latches.
 Repeat Step 4 for the slot beside the second rail lock.
 Make sure that all eight rail latches fully engage the flanges of the rail (Figure 3-4).
 Repeat Step 2 through Step 6 for the remaining rail.
Figure 3-4 Upper Rail (or rail assembly) Installed correctly in the Cassette Lid
1 Spacer
2 Cap
3 Rail
4 Rail hook
Following is the procedure for the cassette and button settings for 1000 denomination
 Leave the denomination buttons (D1 and D0) in their place.
 Make sure that you DO NOT have a button in the parity position (MP)
AFD 2.0
1.1.8.6 Side Guide & Upper Rail settings for PKR 1000:
Following is the procedure for side guide and upper rail settings for PKR 1000.
5 8
AFD 2.0
 This is the way how these 3 rails (rail & spacer &cap) should be hooked together.
1.1.8.6.2 Upper Rail - Removal
flange above the rail lock (Figure 3-2). Slide the rail until it is past the rail lock and disengages from
the eight rail latches, then remove the rail from the lid.
Figure 3-2 Rail Flange Lock
1 Rail hook
2 Rail lock
AFD 2.0

1 Cap
2 Spacer
3 Rail
AFD 2.0
1 Spacer
2 Cap
3 Rail
4 Rail hook
Following is the procedure for the cassette and button settings for 5000 denomination
 Leave the denomination button (D2) in its place.
 Make sure that you have a button in the parity position (MP)
AFD 2.0
1.1.8.8 4.0.8 Side Guide & Upper Rail settings for PKR 5000:
3 6
 This is the way how these 3 rails (rail+spacer+cap) should be hooked together:
AFD 2.0

1.1.8.8.2 Upper Rail - Removal
flange above the rail lock (Figure 3-2). Slide the rail until it is past the rail lock and disengages from
the eight rail latches, then remove the rail from the lid.
Figure 3-2 Rail Flange Lock
1 Rail hook
2 Rail lock
AFD 2.0

1 Cap
2 Spacer
3 Rail
1 Spacer
AFD 2.0
2 Cap
3 Rail
4 Rail hook
1.1.8.9 Cassette Coding – Currency Coding
Insert coding buttons into the indicated positions.
 Insert one button into CC position
 Insert one button into CC0 and one button into CC1 positions
 Insert one button into D1 position
 Since these add up to 4, you must insert a button into MP, to make the parity odd
 Note Stop settings for all COCs is 4
AFD 2.0
 You must also insert button(s) into D position(s) according to the denomination code.
 Then count all buttons (excluding the Media Low). The number of buttons must be uneven (odd).
To ensure odd parity, you may need to insert a button in the MP position.
1.1.8.10 Cash Loading Instructions
Following instructions should be kept in mind while cash loading.
 While loading new currency, the edges of the notes should be fanned along both edges multiple
times in both direction. Another alternative is to run the currency through the counter or sorting
machine. Make sure that none of the currency is stuck together.
 When the lid is fully opened on the diebold cassettes, it provides the proper loading angle for the
currency. By loading with the lid fully open notes will automatically be provided with a loading angle
that provides superior picking performance. No loading tray is required, it is built into the design of
the cassette.
 Currency loaded under the stack or notes folded from the below side can cause dispenser error. So
make sure that currency is not folded or the notes are not under the stack of the other notes.
 Make sure that the notes are not sticking out from the sides, top or bottom.
 While loading new currency in the form of 100 banknotes bundle, Please make sure that each
bundle is opposite in orientation with the neighboring bundle
 Do not load severely bent currency

 If you must load new currency with the fit currency in the same cassette, then make sure that all the fit
currency is placed in front of the cassettes towards the lid hinge and new currency is placed in the back.
AFD 2.0
1.1.8.11 Floor Extension Spring Forces

 Take reading when floor extension is flush with floor
AFD 2.0
Floor Extension Spring Forces
1.1.8.12 Tensioner Replacement

 Move the keypad cover starting on one end and working your way down
AFD 2.0
 If cassette slips out from the Picker Module too easy, replace the latch tensioner. If keypad cover is
worn, replace that too.
1.1.8.13 Media Low Actuator:
AFD 2.0
1.1.8.14 Cassettes Check Points:

Following images shows the points which should be checked while preventive maintenance.
AFD 2.0
AFD 2.0
1.1.8.15 Divert Cassette:
There are two types of reject is coming with AFD dispenser:

Open Reject cassette
 Open cassette without lock & retract compartment
 RR cassette with lock & retract compartment
AFD 2.0
1.1.9 Circuit Card Assembly CCA:
1.1.9.1 Main CCA Function Principle:

CCA – Circuit Card Assembly
 It controls dispenser operations drives motors and receives signals from sensors
 7 stepper motors in the 4-high Active Dispense module:
1. 4 picker motors
2. Push Plate motor
3. Cam motor
4. Transport motor
 It contains the dispenser firmware which determines the different routines for picking, transporting,
presenting, retracting, rejecting notes and also recovery routines
If you replace the Active Dispense control CCA, then you must reset the Active Dispense communication. If
the Active Dispense control CCA is replaced, the sensors must be manually recalibrated
1.1.9.2 Firmware:
 There are typically, two layers of firmware: boot loader and primary.
 The firmware controls the dispenser operations including the dispenser routines to handle USB
communications, mispicks, come-along, short notes, doubles, long notes, as well as the motor drive
pulse sequence commands.
 The firmware also reads the currency cassette information to perform and complete a dispense
operation
 Primary firmware can be flashed (updated) from ATM software
 Every time the AMI is started, it compares the FW file on HDD with the FW of the module. If different
versions, the file will be downloaded on the CCA, depending on the FW upgrade rule setting in ACU.
AFD 2.0
1.1.9.3 Secure Communication:

 A Trusted Platform Module (TPM) is a specialized chip that is installed on the PC motherboard for
the purpose of hardware authentication. It stores keys, digital certificates and passwords.
 To meet PCI requirements that any new devices handling cash must use secure communication.
 SPEAR: Secure Protocol for Encryption and Authentication using RSA
 After PC motherboard replacement, Active Dispense CCA replacement and software changes the
secure communication must be re-established
1.1.9.4 CCA Connections Identification:

Following image shows the connection details of CCA.
AFD 2.0
1.1.9.5 CCA LEDs:

Following image shows the status LED present on CCA.
1.1.9.6 LEDs Status:
AFD 2.0
1.1.9.7 Processor LEDs:
AFD 2.0
1.1.9.8 Sensors Status LEDs:
D16 – Divert cassette present

ON=Cassette present, OFF=Cassette absent
D18 – Exit gate (shutter)
ON=Gate closed, OFF=Gate open
D19 – Cam upper sensor
ON=Not blocking sensor, OFF=Blocking sensor
D20 – Can lower sensor
ON=Not blocking sensor, OFF=Blocking sensor
D21 – Exit sensor
ON=Sensor blocked, OFF=Sensor not blocked
D22 – Stacker sensor
ON=Sensor blocked, OFF=Sensor not blocked
D134 – Docking switch
ON=Switch open, OFF=Switched closed
AFD 2.0
1.1.9.9 Removal & Replacement:

 Disconnect all the cables and remove the two screws as shown in the image below.
 It controls dispenser operations drives motors and receives signals from sensors
 If you replace the Active Dispense control CCA, then you must reset the Active Dispense
communication.
 If the Active Dispense control CCA is replaced, the sensors must be manually recalibrated
 Primary firmware can be flashed (updated) from ATM software
 After PC motherboard replacement, Active Dispense CCA replacement and software changes the
secure communication must be re-established
1.1.10 Guidelines for Preventive Maintenance
Following tasks should be performed while preventive maintenance of the AFD dispenser 2.0
1. Perform all PM task listed in Picker, Stacker and Transport Module sections
2. Check the vertical belts. If you see any cracks or cuts on one of them, replace all 3 of the belts
3. Vacuum all accumulated dust from the AFD module
4. Check the AFD cable retractor, USB and Power cabling for proper routing and connection
5. Check all cabling inside safe. They may interfere with the AFD module vertical section
6. Check the horizontal position of the AFD against the fascia. Adjust if necessary.
1.1.10.1 Stacker Module:

1. Remove stacker cam belt and cam
2. Check cam rollers clean all parts below the cam
3. Check all moving parts. Replace if necessary
4. Apply a thin layer of grease to all moving parts, use white grease
5. Check cam itself. If found scratches, replace CAM
6. Check divert door and its operation
7. Check exit shutter actuator arm position and gear alignment check gate smooth operation
8. Replace paddle wheels
9. Check note stop position, adjust if necessary
AFD 2.0
10. Check stacker belts and transport guides condition

11. Clean stacker sensor
12. Check reject/retract cassette, cassette present switch
13. Check stacker docking latch and cables
14. Don’t use alcohol for rubber parts
15. Use soap water type chemical to clean rubber parts.
1.1.10.2 Feed Module:

1. Remove strip wheel, take-away wheel, feed wheel assembly
2. Vacuum all dust from the feed module
3. clean the 4-brown roller on the platen springs
4. Check the cassette opening pin. Replace if broken or damaged
5. Check the smooth and correct clutch operation of the stripper pivot block
6. Check the condition of the stripper wheel, take-away wheel and feed wheel. If worn, replace
them. If not worn, just dirty, greasy, clean them with soapy water solution.
7. Check the snap latch pin’s condition. If worn, replace it
8. Check the backside of the feed module, check the note guides
1.1.10.3 Transport Module:
1. Apply a small amount of grease into push plate tracks
2. Clean the dust and dirt from the exit shutter gate
3. Apply a small amount of grease between the shutter gate and the fascia plate corners
1.1.10.4 Cassettes:
1. Try removing the cassette without pushing the blue button. If cassette slips out, replace the snap
latch pin is feed module and the cassette keyboard cover
2. Remove all banknotes from the cassette and check the push plate for smooth operation
3. Check the floor extension spring forces. Adjust if necessary
4. Check the cassette tambour door. If it is severely damaged, replace the cassette
5. Check the correct closing of the cassette lid. Replace cassette if cannot close
AFD 2.0
1.2 AFD 2.0 Errors

Dispenser’s error codes can be viewed from EJ & T/SOP. Following table shows different error codes and
their description.
Error Codes Description

AFD0C106 Cassette 1 Empty
AFD0C107 Feed wheel stuck from Cassette 1
Proximity prob has become unusable since last calibration (Cassette 1),
AFD0C119 replace feed module
AFD0C120 Unsolicited note detected from Cassette 1
AFD0C121 Thick Notes detected from Cassette 1
AFD0C122 Thin Notes detected from Cassette 1
AFD0C123 Short Notes detected from Cassette 1
AFD0C124 Tall Notes detected from Cassette 1
AFD0C125 Pick failure detected from Cassette 1
AFD0C126 Proximity prob End of Life of Cassette 1, replace feed module
AFD0C226 Proximity prob End Of Life of Cassette 2, replace feed module
AFD 2.0

AFD0CA04 Proximity prob Interrupt Failure, replace feed module
AFD0CA05 Motor Mux Failure
AFD0CA10 Motor Interrupt Failure
AFD0DE04 Dispense Timeout
AFD0CO17 Module is Offline
AFD0DE04 Dispense Timeout
AFD0DE05 Count Mismatch. Notes picked not equal notes stacked
AFD0DE06 Dispense by cassette from cassette that is not present
AFD0DE08 Dispense by denomination from denomination that is not present
AFD0DE10 Dump Failure after dispense failure
AFD0DE13 Unidentified (wrong) cassette code
AFD0DE19 Cassettes shuffled, must query configuration
AFD0DS01 Docking Switch Open
AFD0EX01 Exit sensor blocked when dispense command sent
AFD0FD12 Trap Detected
AFD0RB06 Money taken during operation
AFD0RJ01 Divert Door Can’t move to dispense position
AFD0RJ02 Divert Door Can’t move to reject/divert position
AFD0RJ03 Divert Cassette Full
AFD0RJ06 Divert/Retract Cassette Missing
AFD0RJ07 Divert Door won't move
AFD0RM10 RAM Error
AFD0SE01 SPEAR has not been established
AFD0SE02 SPEAR mode mismatch
AFD0SE03 SPEAR platform fault
AFD0SE04 Platform integrity: Authorization required
AFD 2.0
AFD0SE05 Platform integrity: See SSTC Dashboard

Security key generation is in progress, this is for informational purposes
AFD0SE13 only
AFD0SE18 Module is Unpaired
AFD0SH01 Exit shutter won't close
AFD0SH02 Exit shutter won't open
AFD0SH07 Exit shutter won't move
AFD0ST01 Stack Sensor blocked when dispense command sent
AFD0ST04 Stacker Sensor Extra Notes
AFD0ST05 Stacker Sensor Dirty
AFD0ST07 Money tray won't move
AFD0ST08 Stacker Sensor Blocked
AFD0ST09 Stacker Sensor Failed
AFD0ST26 Stacker Sensor at End of Life
AFD0TP04 Dispense Transport Jam
AFD0TP07 No forward drive (During Present to Exit)
AFD0TP08 Stalled
AFD0XS07 Exit Sensor Jam
AFD0XS08 Exit Sensor Blocked
AFD0XS09 Exit Sensor Stuck Open/Clear
AFD0XS26 Exit Sensor at End Of Life
Software problem. Pull a 1T and open a TI. DSA is not seeing a specific EFC
AFD0ZZ99 but the module is reporting that it is not in an OK state.
Software problem. Pull a 1T and open a TI. DSA is not seeing a specific EFC
AFD0XS26 but the module is reporting that it is not in an OK state.

Afd 2.0

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1.1 Active Dispenser AFD 2.

1.1.2 Main Parts

Cash Out Cassette

RRC Cassette without lock

RR Cassette with Lock

AFD Dispenser’s Controller

Dispenser unlock Module

Over All View

1.1.3 Function Principle of Dispenser

1.1.5.3 Main Parts of the Stacker module

1.1.5.4 Stacker Removal & Replacement

1.1.5.5 Removing the Stacker Sub-Assembly

1.1.5.6 AFD Stacker ’s Cabling

1.1.5.7 Cam Removal and Replacement

1.1.5.8 Stacker Check Points

1.1.5.9 Note Stop Adjustment

1.1.5.10 Paddle Wheel Removal & Replacement

1.1.5.12 Transport and Stacker Sub-Assembly Connector

1.1.6 Front –Load Transport Module

 Following images shows the basic components of the transport module.

1.1.6.2 Removal & Replacement of transport Module

1.1.7 Feed / Picker Module

1.1.7.2 Take Away Wheel

1.1.7.3 Take-Away spring

1.1.7.4 Functions of the Picker Module

 Count and grade the media.

1.1.7.5 Classification of Notes

1.1.7.6 Removal and Installation of Picker Module

1.1.7.8 Replacement of Picker module

1.1.7.9 Feed Wheel Replacement Guidelines

1.1.7.10 Feed Wheel Alignment

 Below image shows the procedure for feed wheel alignment.

1.1.7.11 Physical Observation to find the problematic parts in feed module:

1.1.8 Media/Currency Cassette Types

1.1.8.1 Reject/Retract Cassette Types

1.1.8.2 Main Parts of COC:

1.1.8.3 Cassettes Denomination & button settings 500:

Figure 3-3 Rail, Spacer, and Cap Assembly

3 Rail mounting slot

1.1.8.8.1 Configuring the Upper Rail

1.1.8.8.3 Upper Rail - Replacement

 Do not load severely bent currency

1.1.8.11 Floor Extension Spring Forces

Floor Extension Spring Forces

1.1.8.12 Tensioner Replacement

1.1.8.13 Media Low Actuator:

1.1.8.14 Cassettes Check Points:

1.1.8.15 Divert Cassette:

There are two types of reject is coming with AFD dispenser:

1.1.9 Circuit Card Assembly CCA:

1.1.9.1 Main CCA Function Principle:

1.1.9.3 Secure Communication:

1.1.9.4 CCA Connections Identification:

1.1.9.5 CCA LEDs:

1.1.9.6 LEDs Status:

1.1.9.7 Processor LEDs:

1.1.9.8 Sensors Status LEDs:

D16 – Divert cassette present

1.1.9.9 Removal & Replacement:

1.1.10.1 Stacker Module:

10. Check stacker belts and transport guides condition

1.1.10.2 Feed Module:

1.2 AFD 2.0 Errors