6100xe Service Manual

Self-Service
Systems
ProCash 6100xe
Service Manual
Questions and suggestions
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regarding this manual?
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giving the order number of this manual
in your message:
Address:
WINCOR NIXDORF International GmbH
Handbuchredaktion BD PSD 43
33094 Paderborn
Germany
Fax: +49 (0) 52 51 693-62 09
E-mail: manuals.hardware@wincor-nixdorf.com
ProCash 6100xe - Service Manual 01750143767 A

ProCash 6100xe
Service Manual
Edition August 2008

Copyright © Information and trademarks
© WINCOR NIXDORF International GmbH 2008
All rights, including rights of translation and

rights of reproduction by reprinting, copying
or similar methods, even of parts, are
reserved.
Any violations give rise to a claim for
damages.
All rights, including rights created by patent

grants or registration of a utility model or
design, are reserved. Delivery subject to
availability; right of technical modifications
reserved.
All names of hardware and software

products mentioned in this manual are
trade names and/or trademarks of their
respective manufacturers.
This manual was

produced using paper
treated with chlorine-free
bleach
ProCash 6100xe - Service Manual 01750143767 A

I Contents..…………....………...….........
1 Introduction.........................................
(Safety Precautions, Technical data)
2 Product description...….....................
3 Service Manual...….............................
4 Troubleshooting…..............................
5 Operator Panel…………………...........
6 Removal/Installation of Components
II Index………………………….................
01750143767 A ProCash 6100xe - Service Manual 0-1

0-2 ProCash 6100xe - Service Manual 01750143767 A
Contents
Introduction ...................................................................................................1-1
Symbols used in this manual ..........................................................................1-1
Important safety precautions...........................................................................1-2
General power interrupt ..................................................................................1-4
Description of the device ................................................................................1-4
Structure of the manual...................................................................................1-5
Outline .......................................................................................................1-5
Supplementary documentation ..................................................................1-5
Technical data.................................................................................................1-6
Electrical characteristics of the supply network.........................................1-6
Device conditions ......................................................................................1-7
Installation specifications...........................................................................1-8
Environmental conditions ..........................................................................1-9
Climatic environmental conditions in acc. with EN 60721....................1-9
Mechanical environmental conditions in accordance
with EN 60721.....................................................................................1-9
Noise emission in accordance with EN 27779 ...................................1-10
Compliance with standards and certifications .........................................1-11
Standards met ....................................................................................1-11
Conformity..........................................................................................1-11
Notes concerning radio interference suppression
and electrical safety ...........................................................................1-11
UL 291................................................................................................1-12
FCC rules and Canadian Standard ICES - 003 .................................1-12
Certification for data transmission......................................................1-12
Environmental protection ..............................................................................1-13
Environmentally and recycling-friendly product development .................1-13
Saving energy..........................................................................................1-13
Disposing of used consumables..............................................................1-13
Labels on plastic case parts ....................................................................1-13
Returning, recycling and disposing of used units and consumables.......1-14
Product Description......................................................................................2-1
Meanings of the designations used ................................................................2-1
Mechanical structure.......................................................................................2-2
Photosensor positions ....................................................................................2-3
01750143767 A ProCash 6100xe - Service Manual I-I

Contents
Electronic modules .........................................................................................2-5

Boards ............................................................................................................2-6
Controller board.........................................................................................2-6
Feeder board .............................................................................................2-7
Feeder ............................................................................................................2-8
Pressor ......................................................................................................2-8
Pre-feeding................................................................................................2-8
Feeding .....................................................................................................2-9
Double feeding sensor ..............................................................................2-9
Vertical movement...................................................................................2-10
Horizontal transport .................................................................................2-12
Note reader RS15.........................................................................................2-14
Introduction and description ....................................................................2-14
General information.................................................................................2-17
Standard sensors ....................................................................................2-17
Banknote processing...............................................................................2-18
Special characteristics ............................................................................2-18
Mechanical adjustments..........................................................................2-18
Cleaning the note validator module.........................................................2-20
Horizontal movement ....................................................................................2-28
SHIFT mechanism ........................................................................................2-29
Crosspoint.....................................................................................................2-31
Banknote transport .......................................................................................2-33
Intermediate transport...................................................................................2-34
Drum cassette module (cassettes) ...............................................................2-35
Cassette electronic board........................................................................2-39
High-Level reply codes .................................................................................2-41
Alarm wiring ..................................................................................................2-44
Function 'System locked 3'......................................................................2-44
Alarm cable .............................................................................................2-44
Alarm loop ...............................................................................................2-45
Cable assignment plan EMA ...................................................................2-46
Alarm board .............................................................................................2-47
Service Manual..............................................................................................3-1
Checks and adjustments of cassettes ............................................................3-2
Checks and adjustments of the feeder ...........................................................3-7
Photosensor adjustment............................................................................3-8
Pressor adjustment ...................................................................................3-9
Transport check.......................................................................................3-10
Motor speed check ..................................................................................3-11
Checking the thickness measuring station ..............................................3-12
I-II ProCash 6100xe - Service Manual 01750143767 A

Contents
Feeding motor margins verification .........................................................3-14

Controller ......................................................................................................3-15
Banknote scanner check ..............................................................................3-17
Banknote scanner speed adjustment ......................................................3-17
Description of the banknote code ............................................................3-19
Updates.........................................................................................................3-20
Firmware updating ...................................................................................3-20
Note references updating ........................................................................3-23
Troubleshooting............................................................................................4-1
Test programs.................................................................................................4-1
'Stand alone' test .......................................................................................4-1
Online test .................................................................................................4-2
Intervention procedure ....................................................................................4-7
Power on sequence...................................................................................4-7
OPEN command........................................................................................4-9
Extended Status ......................................................................................4-10
Error log...................................................................................................4-14
High-level reply codes .............................................................................4-24
Error codes – feeder................................................................................4-31
Error codes – controller ...........................................................................4-34
Error codes – banknote scanner .............................................................4-39
Error codes – drum modules ...................................................................4-42
Operator Panel ..............................................................................................5-1

Messages........................................................................................................5-2
Removal / Installation of Components ........................................................6-1

Device overview..............................................................................................6-1
Overall view ...............................................................................................6-1
Customer panel .........................................................................................6-2
Front door open .........................................................................................6-3
Safe door open ..........................................................................................6-4
Pull-out unit pulled out and open ...............................................................6-5
Opening / closing the device...........................................................................6-6
Pulling out / pushing in the upper transport ...............................................6-6
Opening / closing the feeder......................................................................6-6
Opening / closing the feeder cover............................................................6-7
Opening / closing the front door ................................................................6-8
Device with deposit boxes....................................................................6-8
Device without deposit boxes...............................................................6-8
Opening / closing the pull-out unit .............................................................6-9
01750143767 A ProCash 6100xe - Service Manual I-III

Contents
Removing / inserting the drum modules ..................................................6-10

Upper transport cover ...................................................................................6-13
Feeder cover.................................................................................................6-14
Control panel cover.......................................................................................6-16
Control panel ................................................................................................6-17
Controller cover ............................................................................................6-18
Feeder - movable part...................................................................................6-19
Feeder - fixed part ........................................................................................6-20
Banknote scanner.........................................................................................6-22
Deflector station............................................................................................6-23
Feeder controller...........................................................................................6-24
Main controller ..............................................................................................6-24
Power supply unit .........................................................................................6-25
Upper transport.............................................................................................6-26
Pull-out unit...................................................................................................6-27
Intermediate transport...................................................................................6-29
Fan................................................................................................................6-30
Converting the drum modules.......................................................................6-31
Converting from right (B, D, F, H) to left (A, C, E, G) .............................6-31
Converting from left (A, C, E, G) to right (B, D, F, H) .............................6-32
Conversion of ProCash 6000xe to ProCash 6100xe..............................6-33
I-IV ProCash 6100xe - Service Manual 01750143767 A

Abbreviations
C
CE Communauté Européenne (European Community) Declaration of
Conformity
D
DT Data Transmission
E
EC European Community
EEC European Economic Community
EMA Intruder alarm system
EMC Electromagnetic Compatibility
EN European standard
I
IEC International Electrotechnical Commission
T
TCK Thickness
01750143767 A ProCash 6100xe - Service Manual I-V

Abbreviations
I-VI ProCash 6100xe - Service Manual 01750143767 A

Introduction
This service manual has been compiled for authorized service personnel only.
The operating and installation instructions should also be read since certain
details are only described in these instructions.
Symbols used in this manual

 Text following a dash represents an item in a list.
" " Text in quotation marks refers to other chapters or sections in this
document.
 Text following this symbol describes actions to be performed in the

specified order.
Text following this symbol should be given special attention in order to
avoid damage and injury.
i Text following this symbol contains general information to facilitate use

of the device and help avoid operating errors.

Important safety precautions Introduction
Important safety precautions

Please read the following notes carefully before doing any work on the
device.
This device complies with the relevant safety regulations for information
processing equipment.
 When moving the device from a cold to a warm environment, do not
operate it for at least two hours to prevent possible damage caused by
condensation.
 Only use the original packaging material to transport the device.
 Observe the warning and information labels on the device.
 The device is equipped with a safety-tested power cable which must be
connected only to a suitable grounded outlet.
 Always hold the plug when removing the power cable. Never pull the cable
itself.
 Install cables in such a way that they will not be stepped on or tripped over
or damaged or crushed in any way.
 Have damaged cables replaced immediately.
 Make sure that there is always free access to the sockets used or to the
electrical circuit-breakers of the house installation.
 In case of an emergency (e. g. damaged cabinets, controls or power
cables, foreign objects and liquids in the device) observe the following
instructions:

Introduction Important safety precautions
Deactivate the device immediately by:

Switching off the automatic circuit-breaker or removing the fuse inset
from the fuse holder in the distribution box of the building installation;
Disconnecting the plug connector of the power supply cable from the
grounded socket in the building installation;
 During a thunderstorm, data transmission lines may not be connected or
disconnected.
 Always keep the device's vents free from obstruction to ensure proper air
circulation and to prevent malfunctions resulting from overheating.
 Only use accessories and extension components which have been
approved by us. Nonobservance can result in damage to the system or
violations of regulations concerning safety, radio interference and
ergonomical requirements.
 Note that there are only safety extra-low voltage circuits (SELV circuits) if
you want to feed voltage from an external source into prepared cables to
install additional electronics (e. g. EMA connection).
 Only use cleaning agents approved by WINCOR NIXDORF International
GmbH for cleaning and maintenance (see chapter "Maintenance and
Service").
Repair work may only be carried out by authorized personnel.

Unauthorized opening of the device or repair work carried out
improperly could result in considerable danger to the user.
In case of noncompliance, WINCOR NIXDORF International GmbH
excludes all liability.

General power interrupt Introduction
General power interrupt

i A general power interrupt has the following effects:
– All currently running transactions are immediately aborted.
– Banknotes remain in the transport paths. They are transported to
the reject tray after the device is switched on.
 Switch off the device at the power switch.
 To ensure that the entire device is disconnected from power, you must also
pull the plug of the power cable from the wall outlet or interrupt the power
supply in the distributor box of the building by switching off the circuit-
breaker or by removing the fuse.
Description of the device

The automated teller safe ProCash 6100xe makes it possible with its closed
money cycle to dispense cash that has been deposited before.
Two people can work on this ATS at the same time.

Introduction Structure of the manual
Structure of the manual
Outline
The chapter "Introduction" describes the important safety precautions. It also
gives an overview of the possible functions of the ProCash 6100xe.
The features are also described in the chapter "Introduction" in the section
"Technical data".
The chapter "Product Description" describes how the ProCash 6100xe
functions.
This is followed by the chapter "Service Manual" which contains all information
required for service on the ProCash 6100xe.
The chapter "Troubleshooting" describes the procedure for finding and treating
faults that may occur.
The chapter "Operator Panel" describes the operator panel and provides a list
of messages which may appear on its LC display during regular operation.
The next chapter "Removal / Installation of Components" provides detailed
information on how to remove and install each component.
Supplementary documentation
For the operation and installation of the device, separate manuals are
available in several languages.
These manuals can be ordered from our print partner. They are also available
in the intranet.
Usually the manufacturers' original manuals for OEM components are included
in the shipment. They may contain more detailed information.

Technical data Introduction
Technical data
Electrical characteristics of the supply network

Line voltage range: 110 - 120 V 220 - 240 V
Rated frequency: 50/60 Hz 50/60 Hz
Network type: TN (network with PE TN (network with PE
conductor) conductor)
Permissible voltage
tolerance range: - 10 % to + 5 % - 10 % to + 5 %
Permissible tolerance for
rated frequency: ±1% ±1%

Introduction Technical data
Device conditions
110 - 120 V 220 - 240 V
Idle mode Operation Idle Operation
(max.) mode (max.)
System without heating
Rated current 260 mA 2.8 A 130 mA 1.7 A
consumption:
Apparent power 30 VA 300 VA 30 VA 300 VA
consumption:
Active power: 25 W 260 W 25 W 260 W
Power factor: 0.81 0.86 0.81 0.86
Leakage current: 0.31 mA 0.31 mA

Protection class: I I
Fuse: 10 A slow fuse or 16 A 10 A slow fuse or 16 A
automatic circuit- automatic circuit-
breaker breaker
Power supply connection: Country-specific safety Country-specific safety
plug plug
Degree of protection acc.
to EN 60529: IP 20 IP 20

Installation specifications
Dimen-
sions: UL safe with UL safe without CEN III safe CEN III safe
deposit deposit with deposit without deposit
cassettes cassettes cassettes cassettes
Height: 775 mm 775 mm 790 mm 790 mm

(30.51") (30.51") (31.1") (31.1")
Width: 500 mm 500 mm 500 mm 500 mm
(19.69") (19.69") (19.69") (19.69")
Depth: 885 mm 850 mm 885 mm 850 mm
(34.84") (33.46") (34.84") (33.46")
Operation
and
maintenan- 1.45 m2 1.45 m2 1.45 m2 1.45 m2
ce space: (15.60 ft²) (15.60 ft²) (15.60 ft²) (15.60 ft²)
Device approx. approx. approx. approx.

weight: 340 kg 340 kg 400 kg 400 kg
(749.6 lb) (749.6 lb) (881.8 lb) (881.8 lb)
Surface approx. approx. approx. approx.

load: 7.54 kN/m2 7.85 kN/m2 8.87 kN/m2 9.24 kN/m2
(1.09 lbf/inch²) (1.14 lbf/inch²) (1.29 lbf/inch²) (1.34 lbf/inch²)
i For detailed information concerning the dimensions please refer to the

chapter "Planning the Installation", section "Device dimensions" in the
installation guide.

Environmental conditions
Climatic environmental conditions in acc. with EN 60721
Class Ambient temperature Relative

humidity
% r.h.
°C (°F)
Operation (indoors): 3K2 + 15 to + 35* (+ 59 to + 95*) 10 to 75
Limit range of
operation (indoors): ** 3K3 + 5 to + 40 (+ 41 to + 104) 5 to 85
Transport: 2K2 - 25 to + 60 (- 13 to + 140) 15 to 98
Storage: 1K2 + 5 to + 40 (+ 41 to + 104) 5 to 85
* The temperature value of + 35 °C (+ 95 °F) deviates from the value of

the standard (+ 32 °C (+ 104 °F)).
** In the limit range the device may only be operated for a short period of
time.
Mechanical environmental conditions in accordance with

EN 60721
Class Remarks
Operation 3M2 Building with minimum external vibration
Transport (in 2M2 All types of commercial vehicles and trailers
original packing) as well as rail and air transport
Storage (in 1M3 Noticeable vibration and shocks, e.g. by
original packing) machines or passing vehicles

Noise emission in accordance with EN 27779

Noise values acc. to ISO 9296 Idle mode Operation
***
Sound power level LWAd 6.5 B 6.7 B
Workplace-related sound pressure level LpAm 44 dB 50 dB
(at adjacent workplace)
*** typical operating cycle

Compliance with standards and certifications
Standards met
Safety standards:
IEC 950 EN 60950 CSA C22.2-950 UL 1950 UL 291
EMV-Standards:
EN 55022 / B EN 55024 FCC CFR 47, part 15, subpart B, class A

ICES-003
Conformity
The CE mark of conformity attached to the product or its package indicates
that the product complies with the requirements of the following EC directives:
 EMC Directive 2004/108/EC
 Low Voltage Directive 2006/95/EC
The corresponding statement of compliance has been issued by:
Heinz-Nixdorf-Ring 1
33106 Paderborn
Germany
Notes concerning radio interference suppression and

electrical safety
All other devices connected to this product must comply with the EMC
Directive 89/336/EEC including amending directive 93/68/EEC (as of
7/20/2009 EMC Directive 2004/108/EC) and the Low Voltage Directive
73/23/EEC including amending directive 93/68/EEC (as of 1/16/2007 Low
Voltage Directive 2006/95/EC).

UL 291
In order to meet guideline UL 291, ensure the following during installation:
 The unit must be connected to a grounded receptacle.
 For a free-standing installation the security container of the ATM shall be
anchored in accordance with this instruction, either using the listed
anchoring devices or using similar devices. Each anchoring device shall
withstand a 22,000 pound (97,861 N) vertical or horizontal force applied in
an attempt to remove the security container from its location.
If the free-standing installation is inside a building and the anchoring devices
cannot be secured to the building structure, the unit shall be attached to a
steel plate at least 4 feet by 8 feet by ½ inch thick (1.22 m by 2.44 m by 12.7
mm thick) or an equivalent structure so as to restrict the removal of the teller
machine from the building. The release mechanism of the attachment devices
shall only be accessible when the door of the security container is open.
FCC rules and Canadian Standard ICES - 003

NOTE: This equipment has been tested and found to comply with the limits for
a Class A digital device, pursuant to Part 15 of the FCC rules and Canadian
Standard ICES - 003. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operating in a
commercial environment. The equipment generates, uses and can radiate high
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference
at his own expense.
Certification for data transmission

The certification number or CE mark of the data transmission module (if
present) is attached directly to the DT card or to the housing of the system
unit.

Introduction Environmental protection
Environmental protection
Environmentally and recycling-friendly product

development
This product has been designed according to our corporate guideline
'Environmentally and recycling-friendly product development'.
This means that crucial criteria such as long life, choice of material and its
labeling, emissions, packaging, ease of disassembly and recyclability have
been taken into account. This saves resources and relieves the strain on the
environment.
Saving energy
Please switch on devices that need not be constantly running only when they
are actually needed. They should also be turned off when they are not needed
for longer periods of time.
Disposing of used consumables

Dispose of consumables, batteries and cleaning and maintenance materials
according to national regulations (where relevant complying with vendor
specifications).
Labels on plastic case parts

Please do not stick any labels on plastic case parts since that would make
recycling more difficult.

Environmental protection Introduction
Returning, recycling and disposing of used units

and consumables
Further information regarding the return and recycling of used
units and consumables can be obtained from your local branch
office or from our Environmental Protection section (Referat
Umweltschutz):
Tel.: +49 (0) 52 51 693-67 07
Fax: +49 (0) 52 51 693-77 67 07
E-Mail: mailto:referat.umweltschutz@wincor-nixdorf.com

Product Description
This section describes how the ProCash 6100xe functions.
Meanings of the designations used

LS Photosensor
Input Notes Input Notes
Feeder Feeder
F_Input Input photosensor
Thickness sensor Photosensor for thickness measurement
Note reader Note reader
Alignment sensor Alignment photosensor
Note_In Sensor Banknote input photosensor
F_out Banknote output photosensor
F_Reject Photosensor for rejected banknotes
Rejected Notes Rejected Notes
F-shift Photosensor F-shift
Upper Track Upper transport system
Left Output Left Output
Right Output Right Output
Cross Point Area Crosspoint
Fcash Safe input photosensor
Fout Banknote output photosensor
Fin Input photosensor
Safe Safe
F_Sort Photosensor sort inquiry

Mechanical structure Product Description
Mechanical structure
The figure below shows the mechanical structure of the ProCash 6100xe.
B R R
A
R L R
L
L
L
D R R
C
R R
L
L
L
L
F R R
E
R R
L
L
L
H R R
G
R R
L
L
L

Product Description Photosensor positions
Photosensor positions
The figure below shows the photosensor positions of the ProCash 6100xe.

Photosensor positions Product Description
Transport path of banknotes

Input notes Feeder
F_Input Thickness measurement

Alignment sensors
Photo Alin.
(Fshift left&right)
Note scanner
Upper
R L track
F_out Note in sensor
Rejected
notes F-shift
F_Reject/Output
FCNTX
Fendh
Crosspoint
FINQ
Fout
Fcash
Fin
Safe

Product Description Electronic modules
Electronic modules
The ProCash 6100xe consists of the following modules:
Top section
 Feeder,
 Banknote scanner
 Horizontal transport,
 SHIFT mechanism,
 Power supply,
 Motherboard,
 Operator panel.
Safe section
 Intermediate transport,
 Safe transport mechanism,
 Drum modules.
B R R
A
R R
L
L
L
D R R
C
R R
L
L
L
L
F R R
E
R R
L
L
L
H R R
G
R R
L
L
L

Boards Product Description
Boards
Controller board
The controller board is shown in the following illustration. The connectors have
the following function:
J21
J18
J24
J14
J10 J20
J5 J4
J2 J8 +
J11
J23
J13
CM14.8 Controller J9
J12 J7
J15 J16
J22 J19 J3
J17
J1 Currently not used J13 Currently not used

J2 Signal to CM14SAFE-8 J14 Currently not used
J3 Photosensor connection to J15 RS232 connection
SHIFT mechanism J16 RS232 connection
J4 Voltage to CM14SAFE-8 J17 Display connection
J5 Photosensor connection cash J18 Currently not used
J6 Currently not used J19 Service cable connection
J7 Currently not used J20 Currently not used
J8 Note scanner connection J21 USB connection
J9 Feeder connection J22 Connection from
J10 Currently not used power supply
J11 Extension J23 Currently not used
J12 Currently not used J24 Horizontal motor connection

Product Description Boards
Feeder board
The feeder board is shown in the following illustration. The connectors have
J1
CM14 Feeder J9
J2 J3
J1 Signal from controller J3 Connection to the fixed part of

J2 Connection to the movable the feeder
part of the feeder J4 Connection to the fixed part of
the feeder

Feeder Product Description
Feeder
Pressor
At the start of the feeding procedure, the 'F_Input' photosensor situated at the
feeder entrance controls the presence of the banknotes. If the indicator is
positive, the pressor electromagnet presses the bundle of notes against the
pre-feeder rollers.
If the 'F_Input' sensor does not detect any banknotes, the machine replies with
the message 'No input note'.
Pre-feeding
At this stage, the motor which controls the pre-feeder and feeder shaft is
activated. In the first phase of rotation, the pre-feeder shaft brings the pre-
feeder rubber sectors into contact with the bottom banknote and pushes it
towards the feeder entrance (between the feeder disc and the alignment
rollers).

Product Description Feeder
Feeding
In the second phase of rotation, the feeder shaft takes the banknotes arriving
from the pre-feeder stage with the rubber feeding tongues and separates each
of them from the deposited bundle. While each note is being checked by the
thickness sensor, the others are held back by the rejection belts.
Double feeding sensor

The note is then passed through two rollers, which check it for thickness and
immediately recognize double thickness, misfeeding or unaligned notes. If
feeding is not correct, the rejection procedure is activated and the bottom
alignment mechanism switched to the reject position.

Vertical movement
The note is conveyed by the feeding belts, which, along with the feeding
tongues, extract the note from the bundle.

The note is brought onto the vertical track. Its movement is controlled by the
electromagnet which pushes the belts against the note on the frontal part of
the track.
The note is pulled by the belts towards the alignment mechanism until it is fully
aligned.
If the alignment mechanism is activated by the reject solenoid, the note
continues vertically until it is deposited in the reject tray.

Horizontal transport
The feeder photosensors at the base of the stop-point control the alignment of
the note with the aid of the horizontal stopping system. Via the thickness
sensor, the feeder also monitors the time it takes the note to cross the
thickness control area.
The alignment photosensors monitor the time taken to reach the alignment
bar. If these parameters are in line with the reference figures, the vertical
electromagnet is deactivated and the horizontal one is activated, with the
result that pressure on the vertical belts is removed and the horizontal feeder
rollers are activated.
The note then moves towards the feeder exit.
If the alignment mechanism is activated by the reject solenoid, the note
continues vertically until it is deposited in the reject tray.
If the controller encounters any anomalies at the feeding stage, the respective
solenoid diverts the note towards the reject tray.

If the reject solenoid activates the stop mechanism, the note continues moving
vertically and is deposited in the reject tray.
As the note reaches the feeder exit, the photosensor FOUT checks the timing
of transit. If all is well, a new feeding cycle starts.

Note reader RS15 Product Description
Note reader RS15

The scanner receives the notes from the feeder and passes them in front of
sensors which read the information that is necessary to determine the
denomination and direction of the notes.
Introduction and description
This module recognizes passing banknotes and sends the result to the
controller via a serial interface. Depending on the results of the note validator,
the CM 24 controller transports the banknotes to the corresponding cassettes
in the safe or to the output tray. The module can simultaneously recognize up
to 32 denominations.
The scanning unit has been developed with full image technology and contains
Compact Image Sensors (CIS). They enable the scanning of images on the
front and rear of the passing banknotes. In addition to the optical sensors, a

Product Description Note reader RS15
number of magnet-sensitive sensors and an infrared sensor are used to

recognize the magnetic pattern and infrared characteristics on each banknote.
The optical and magnetic sensors are used for the classification and testing of
the passing banknotes. Moreover, UV sensors can be used to identify matt
images on the front and rear of the banknotes.
The unit also contains a thickness sensor, which identifies unusual
thicknesses on the passing banknotes (if two banknotes have been drawn
inside simultaneously or if banknotes are stuck together).
1 Magneto-resistive array sensor 3 UV Dullness sensor

2 OPTICAL sensors (CIS with 4 Ultrasonic TAPE sensor
GR/IR and RD)
The figure displays the position of the various sensors in the device.

Sensor Function
MAG sensor Checks the magnetic information
IMAGE sensor Checks the image information
UV sensor Checks the UV information
TCK/TAPE sensor Checks the thickness (TCK) and recognizes banknotes
which are stuck together (tape sensor)
Input sensor Input photosensor

General information
Working direction Narrow side first (one direction)
Processable banknote format Width: 58 mm – 85 mm (2.28" – 3.35")
Length: 120 mm – 185 mm (4.72" – 7.28")
Thickness: 0.07 mm – 0.12 mm
(0.0028" – 0.0047")
Path width 100 mm (3.94")
Max. displacement (FW +/-10°
adjustable)
Transport speed 1 to 2 min/s
Feed rate (throughput) max. 10 bn/s
Communication interface RS232C and USB 2.0
Power supply 22V to 40V I ≤ 1A
Operating temperature +10 / +40°C (+50 / +104 °F)
Relative humidity max. 80%
Dimensions (W/L/H) 180 x 230 x 110 (7.09" x 9.06" x 4.33")
Standard sensors
Thickness sensors 1 (mechanical)
Full image display / Infrared CIS 2 x 108 mm (A6)
spectral sensor
UV sensor 1 – point sensor
Full image magnetic sensors Magneto-resistive sensor line
Additional sensor interface High speed SCI (serial communication
interface)

Banknote processing
Banknote recognition Visible image GR+RD both sides
Authenticity test IR, magnetic map and thread, UV
Quality tests (optional) Soiling/limpness, banknotes with bent
corners, folds, holes, cut off or missing
pieces, tears (if it changes the image), large
marks, dimensional test
Thickness processing Vertical recognition of stuck + double
banknotes
Number of denominations Max. 32 + 32 banknote channels
Banknote classification 4 categories according to ECB art. 6
specification
Special characteristics
Traceability according to art. 6 / Banknote fingerprint recognition and
section 36 (ECB requirements) reading via USB port
Module update Remote download firmware and currency
data via RS232C cable
(*) All technical data is subject to modifications at any time
Mechanical adjustments
The photosensors have their own setting value that is saved when the device
runs through its last test cycle. When a photosensor is replaced, this setting
therefore has to be repeated immediately on the photosensors using the tool
software test.

Description of connections
1 USB connection 2 Alim. + data connection

Cleaning the note validator module

The note validator is equipped with highly-developed sensors, which have to
be maintained at regular intervals to ensure correct operation.
During the diagnostics phase it is possible for the scanner to send an error
message if cleaning is required.
The reading frequency 'Preventive Maintenance (PM)' depends on numerous
factors:
 Work load of the device
 Banknote type
 Condition of the banknotes
We recommend you to always carry out 'Preventive Maintenance (PM)' during

device maintenance and at least twice a year.
'Preventive Maintenance (PM)' is carried out as follows:
1. Scanner status
2. FW and configuration test
3. Sensor test prior to cleaning
4. Cleaning process
 Optical
 Active rollers
 Passive rollers
 UV sensor & contrast
 Magnetic contrast rollers
 Final cleaning with compressed air
5. Sensor test after cleaning
6. Final test
The following pages provide a detailed description of 'Preventive Maintenance
(PM)'.

General information
The majority of reading sensors are automatically adjusted each time they are
switched on or even for each payment to compensate for the working
conditions (soiling, temperature, etc.).
This means that the scanner module does not display an error status; the
capacities of its sensors are within the accepted limits.
The only two sensors which cannot provide complete feedback with regard to
their working statuses are the two image scanners. If a point on the protective
glass of the image scanner is dirty, the image of the banknote will display a
black line at the corresponding position. In this case, the scanner will only
increase the reject rate. An error or error classification cannot be allocated to a
soiled sensor.
Scanner status
When carrying out scanner maintenance, at first check whether the module
answers with 'Unit Ready (40)'. If the scanner displays an error status, please
refer to the diagnostics chapter in the service manual.
FW and configuration test
Check whether all FW, configuration and working parameters as well as the
banknote data files have been adapted to the currently released and
distributed versions.
i The release for OPT sensor data is usually different from scanner to
scanner. Do not observe this information.
Sensor check prior to cleaning
Check the sensor of the recognition unit with the available tool.
Save the measured data to compare them with the values after cleaning.

Cleaning the optical sensors
1 Optical sensor
Clean the optical sensors (1) (front &

rear) using a cleaning cloth and a
glass cleaning agent without
ammonia.
A cleaning kit with damp and dry cloths can be ordered via the spare parts list.

Cleaning the active rollers
1 - 4 Active rollers
Place a cloth (1) (damp and soaked

with cleaning agent) into the scanner.

Hold the cloth and move all the active

rollers by turning the drive (1).
 Repeat this procedure with a dry cloth.

Cleaning the passive rollers
1 Passive rollers
These rollers press the banknotes onto the active rollers. Soiling does not
affect their functionality.
Clean these rollers using cleaning
cloths to remove excessive dirt from
the rollers.

UV sensor
Clean the UV sensor using cleaning

cloths and a glass cleaning agent.
UV contrast
Clean the UV contrast using cleaning

cloths and a glass cleaning agent.

Contrast roller of the magnetic sensor
1 Magnetic sensor
 Remove dirt/dust using a brush.
 Finally clean the sensor with compressed air.
Sensor check after cleaning
Check once more whether the parameters of all sensors are within the limit,
and compare the value with the value saved before.
Test the unit with authentic banknotes.

Horizontal movement Product Description
Horizontal movement
The note is moved towards the device. This lets it change from a horizontal
movement to a vertical movement and move towards the safe or the output
tray.
At the end of the horizontal stage a photosensor monitors the passage of the
note. It also activates the SHIFT command when the note is positioned
correctly at the top of the vertical track.
The scanner module must recognize the note before it has completely left the
SHIFT photosensor otherwise the note will not be accepted and it will be
deposited in the output tray.
Banknote photosensor
(FSHIFT)
Vertical transport path

Product Description SHIFT mechanism
SHIFT mechanism
SHIFT uses a balancing mechanism controlled by a solenoid to change from
horizontal note movement to vertical note movement.
When the equalizer is in the rest position the horizontal rollers press against
the belt coming from the horizontal transport block, resulting in traction for the
note placed between the moving belt and the rollers.
When the SHIFT solenoid is activated it detaches the horizontal transport

rollers and at the same time places the two vertical transport rollers against the
vertical shaft rollers which are in constant rotation.

SHIFT mechanism Product Description
Due to constant pressure from the vertical movement rollers the note that is
freed from the belt can only move in a vertical direction towards the deflector
which then sends it towards the safe or diverts it to the side compartments.

Product Description Crosspoint
Crosspoint
The crosspoint block is made up of a series of deflectors mounted on a slide.
The solenoid can place it in two different working positions:
 1.: Center - the banknote is transported towards the safe,
 2.: Right - the note is transported to the reject tray.
The slide of the crosspoint is controlled by a solenoid. The note is moved
towards the safe when the solenoid is in rest position and the crosspoint is in
the central position.
When the solenoid is activated, the crosspoint is positioned on one side and
the crosspoint deflectors convey the note to the output tray.
During a cash-out procedure the notes coming out of the safe are diverted by
the deflector to the output tray.
In this case diversion of the note comes from underneath to the selected side.
The central deflectors guide the note from SHIFT to the safe.
The right or left deflectors guide the note from the SHIFT solenoid to the
output tray and from the safe to the output tray.

Crosspoint Product Description

Product Description Banknote transport
Banknote transport
The note that has been diverted by the crosspoint deflectors is pulled along by
two sets of belts towards the stacker wheels which put the bundle in the output
tray.
A set of photosensors monitors the movement of the note from the diverters to
the stacker.
In the stacking compartment another set of sensors records when the bundle
of notes has been withdrawn by the operator.

Intermediate transport Product Description
Intermediate transport
The photosensor mounted above the entrance slot controls movement of the
note into the safe.
The intermediate transport is located on the ceiling of the safe and, with the
aid of a set of motorized rollers, it moves the note below or above depending
on whether a deposit or withdrawal operation is being carried out.
Intermediate transport for UL safes Intermediate transport for a Strongbox'
Intermediate transport for CEN safes
Once it enters the safe the note is moved along rollers to its specific cassette.
The transport rollers are attached to the cassettes and driven by the main
motor located in the safe.
Cassette A Cassette B
Motorized rollers

Product Description Drum cassette module (cassettes)
Drum cassette module (cassettes)

The cassettes are mounted in pairs on movable trays.
Each cassette ensures movement of the note via a series of rollers which are
matched with those of the opposite cassette.
A solenoid on the target cassette activates the positioning of a diverter which
intercepts the note along the vertical track and forces it to turn into the target
cassette.
The input photosensor detects the presence of the note and starts off the
'Pinch Roller' command. The pinch rollers open up to accept the note and
close once the note has gone beyond the conveying roller.
E
E
E
E
E
E
R
R
R
R
R
The drum that rewinds the notes is activated and moves the note along the two
mylar belts lining it up with the other notes which have been arranged in spiral
fashion.
The last note in will be the first one out.

Drum cassette module (cassettes) Product Description
The note is moved out by inverting the rotation of the conveying rollers that are
powered by the motor on the rear panel inside the safe.
The cassette that has been selected for output activates the diverter and the
rewinding coils which start the unrolling of the drum containing the notes.

The notes are separated from the drum by two skimming blades and conveyed
towards the exit. The photosensors control the timing of the transit.
E
E
R
R
MYLAR TAPES
A
A input
output
B B
side for tape detection

black part of the tape at the

fixing coiled hub beginning of the tape spool
Photo Full
black part of the tape out
tape spool
from the tape spool
fixing coiled hub
Photo Empty
black part of the tape out

from the tape spool
fixing coiled hub Photo Full
black part of the tape at the

tape spool beginning of the tape spool
fixing coiled hub
Photo Empty

Cassette electronic board

The figure shows the electronic board of the cassette C500.
The connectors are used as shown below:
U7 J4 U12
U2 U11
U1 U3
X1
J2 U8 U5 U4
C500 J8 J5 J9
J2 Currently not used

J4 Connection of photosensors and magnets
J5 Connection of CMLOW board
J8 Connection of first STEP_DRV board
J9 Connection of second STEP_DRV board

The figure below shows the electronic board of cassette C500 (STEP_DRV).
The connectors are used as shown below:
J2 or J3 J1
STEP_DRV Board
J1 Connection of motor
J2 or J3 Connection of C500 board

Product Description High-Level reply codes
High-Level reply codes

The ProCash 6100xe controller firmware responds to each host command by
issuing a specific feedback code which corresponds to the status of the
ProCash 6100xe.
The area is given for every reply code.
The next two tables show the reply codes relating to general conditions and
operating conditions of the ProCash 6100xe.
General conditions
Code Description Area
00 Boot mode Controller
01 OK
02 Software error Controller
03 Syntax error Software
04 Context error Software
Operating conditions
05 Cover open Upper cover
06 Safe open Safe door
07 Feeder open Feeder
08 Unlock cassette Cassette trays
09 Note in right output Right output tray
10 Note in left output Left output tray
11 Note in front output Reject output feeder
12 No input note Feeder
13 Denomination full Cassettes
14 Denomination empty Cassettes

High-Level reply codes Product Description
The next table shows the reply codes relating to operating errors.
Operating errors
15 Misfeeding Feeder
16 Feeder jam Feeder
17 Jam in recognition unit Banknote scanner
18 Upper track jam Upper transport path
19 Crosspoint jam Crosspoint
20 Lower track jam Safe
21 Output track jam Output area
22 Jam in cassette A Cassette A
23 Jam in cassette B Cassette B
24 Jam in cassette C Cassette C
25 Jam in cassette D Cassette D
26 Jam in cassette E Cassette E
27 Jam in cassette F Cassette F
28 Jam in cassette G Cassette G
29 Jam in cassette H Cassette H
40 Note has not reached cassette A Safe
41 Note has not reached cassette B Safe
42 Note has not reached cassette C Safe
43 Note has not reached cassette D Safe
44 Note has not reached cassette E Safe
45 Note has not reached cassette F Safe
46 Note has not reached cassette G Safe
47 Note has not reached cassette H Safe
49 Note overflow Banknote scanner
50 Count error All

Product Description High-Level reply codes
The next table shows the reply codes relating to hardware failures. Some
various warning messages that may came either from the journal or from the
application software as a consequence of incongruent commands are shown
in the table after that.
Hardware failures
30 Out of service All
31 Deposit Out of service Feeder - Banknote scanner
32 - 39 Cassette Out of service Cassettes
48 Internal communication error All
Various
64 Note on feeder input Feeder
65 Wrong key All / controller
66 No cassettes present All
67 Wrong side All
68 Req. over limit Withdrawal command
69 Cassette not present
70 Cassette's note ID not empty
71 Note ID not present
72 No journal E. journal
73 Record not present E. journal
95 Statistic record All (Error log only)
97 Safe door was open All (Error log only)
98 Lock All (Error log only)
99 Power OFF All

Alarm wiring Product Description
Alarm wiring
Function 'System locked 3'

Function 'System locked 3' is a safety function.
While function 'System locked 3' is active it is not possible to carry
transactions at the system.
An activated function 'System locked 3' can have the following reasons:
 Power supply at the lock is missing,
 via alarm function (depending on the configuration )
Unit Blocked cable to 12 V
FlipFlop function via safe key
Alarm cable
The alarm cable is either a 5-wire or a 34-wire cable. The individual wires have
red / blue Power supply for the lock:
red = 12 V / blue = ground
black Unit Blocked cable
if connected with 12 volt, no cash in or cash dispensing
transactions are possible and the lock cannot be opened
pink / grey or Robbery contact
pink / violet Is opened for 1-3 seconds in the case of an alarm.
all others Robbery components, e.g.
– vibration detector,
– breakaway sensor,
– additional door contacts, etc.

Product Description Alarm wiring
Alarm loop
1 2 3
1 Bridge 3 Relay in switch box

2 Alarm relay
Bridge
If necessary, it is possible to remove the bridge (1) and replace it via an alarm
resistance.
Application alarm
The application alarm is triggered via the customer software.

The alarm relay (2) is opened on the alarm board via a SW command.
Lock alarm
The lock alarm is triggered via the lock.

By entering the combination + 1 a relay is opened in the switch box (3).

Cable assignment plan EMA

Product Description Alarm wiring
Alarm board
Distributor board
1 Jumper of Unit Block configuration
i The unit blocking function is selected by mounting the jumpers.

The function is activated using the safe key.


Service Manual
This chapter provides all information that is needed to service the ProCash
6100xe correctly.

Checks and adjustments of cassettes Service Manual
Checks and adjustments of cassettes

Photosensor adjustment
The voltage of the photosensors FOTIN and FOTOUT can be adjusted for
cassettes from T.L.06 on.
Proceed as follows to do this:
 Select the 'Modules Test' menu and then 'Cassettes (In/Out)'.
 Select the menu item 'Command' in the 'Modules Test' menu.

Service Manual Checks and adjustments of cassettes
 Select 'Photo. Adj.' at the center of the screen.

 Wait approximately 2 seconds.
 Verify that the strength of 'Foto IN Current' and 'Foto OUT Current' is
between 2 and 150.
 Check whether the cassette status (see left screen side) is 40 or 05 or 04.
This adjustment should be carried out without any external light

i interference (it should be done with the cassette inside the safe and
with the cassette empty).

The following pages describe the programs that are used to test the correct
functioning of the modules.
Cassette test
 Select the 'Modules Test' menu and then 'Cassettes (In/Out)'.
 Select the menu item 'Command' in the 'Modules Test' menu.
With the cassette test you can verify the correct functioning of the main
components of the cassette itself.
The left-hand side of the screenshot below shows the status of each sensor of
the cassette. Press the 'Start' button to see the variation of the photosensor

Service Manual Checks and adjustments of cassettes
each time that a banknote is cashed (in or out). Pressing 'Stop' causes the
program to store the situation at that moment.
By installing the cassette outside the safe using the extension cable that is
included in the Service Kit it is easy to verify a possible problem in the cassette
by executing the commands shown at the center of the screen, i.e. you can
check the correct functioning of pinch rollers, sorter, etc.

Furthermore, by covering and uncovering the photosensor it is easy to check

their functionality, as shown on the left of the screen. You can also check
internal transport mechanisms by simulating the withdrawal of some notes.

Service Manual Checks and adjustments of the feeder
Checks and adjustments of the feeder

The verifications and the adjustments described below should be done every
time that one of the components of the feeder (front part, back part, electronic
board) is replaced.
To execute the verifications or the adjustment, use the diagnostic program.
 Select from the 'Modules Test' menu 'Feeder Test' and then 'Adjustment'.
General CM24 Windows Test rel. xxx X

User Commands Tools Modules Test RS 232 Exam Data Exit Service Config
Select "Modules Test"

then "Feeder Test"
Feeder test X
Commands
Commands Adjustment Exit
Select "Adjustment"

Checks and adjustments of the feeder Service Manual
Photosensor adjustment
Feeder Adjustment X
Feeder Status 40 Pressor Mechanical Adj Refresh Exit
Serial Number Pressor test Transparent Help
*********** Change 0947 Travel Step
M Up current Thickness Mechanical Adj

Click with All
the mouse M Down current
on "All" Fotin 0250 40
Thickness Gain Adjust
FShiftr 0054 40 Transport Adjust
( Use 100 notes for test )
FShiftl 0100 40 483 Strobe test per
0054 1/2 Thickness
Fotoalin 0026 40 0018 Velocity Value 0098 normal Value
Fout 0032 40 306 Strobe marg per
0145 1.6v Thicness val
Thickness photo sample Feed motor test Feed Motor Margin

0000 Viscous torque
Foto Spess 1
Stop Read 0000 Minimum torque
Foto Spess 2 0000 Start-stop torque
DEVICE ( 1 ) - Correctly Executed
 Select 'All'.
 Verify that the reported value is between 0002 and 0254.
 If this condition is not satisfied, replace, in sequence, the electronic board,
the back part of the feeder and the front part of the feeder.
 Perform an adjustment after every replacement.

Pressor adjustment
Feeder Adjustment X

Click with the All
mouse on Down current
M
Pressor Test Fotin 0250 40

0054 1/2 Thickness

0000 Viscous torque
Foto Spess 1
 Select 'Pressor test'.

 Verify that the reported values are within the following range:
 Travel Step: between 0900 and 1199
 Up current: L or M
 Down current: L or M
 If this condition is not satisfied, replace, in sequence, the electronic board
and the front part of the feeder.
 After each replacement check the photosensor values.

Transport check
Feeder Adjustment X

All
M Down current
Fotin 0250 40
Click with FShiftl 0100 40 483 Strobe test per

0054 1/2 Thickness
mouse on
Fotoalin 0026 40 0018
Transport Velocity Value 0098 normal Value
Adjust

0000 Viscous torque
Foto Spess 1
 Select 'Transport Adjust'.

 Strobe test: between 447 and 575
 Velocity Value: between 002 and 254
 Strobe marg.: between 060 and 400
 If this condition is not satisfied, replace, in sequence, the electronic board,
the back part of the feeder and the front part of the feeder.

Motor speed check

Feeder Adjustment X

All
M Down current
Fotin 0250 40
0054 1/2 Thickness

Click with
mouse on ( Use 100 notes for test )
Feed motor 0000 Viscous torque
Foto Spess 1
Test Stop Read 0000 Minimum torque
 Select 'Feed motor test'.

 Viscous torque: between 002 and 254
 Start-stop torque: between 002 and 254

Checking the thickness measuring station

Feeder Adjustment X

All
M Down current
Fotin 0250 40
Select 'Thickness FShiftl 0100 40 483 Strobe test per

Gain Adjust' 0054 1/2 Thickness

0000 Viscous torque
Foto Spess 1
Adjustment of operating point
 Select 'Thickness Gain Adjust'.

 1/2 Thickness: between 002 and 254
 normal Value: between 002 and 254
 1.6v Thickness val: between 002 and 254

Mechanical verification of thickness sensor
 Place 100 banknotes in the feeder input tray.
 Feed the banknotes by using the 'Thickness Gain Adjust' command.


Feeding motor margins verification
Feeder Adjustment X

All
M Down current
Fotin 0250 40
0054 1/2 Thickness

Click with 0000 Viscous torque
Foto Spess 1
mouse on Stop Read 0000 Minimum torque
Feed Motor
Margin
 Place 100 banknotes in the feeder input tray.
 Feed them by clicking on 'Feed Motor Margin'.
 Verify that the value 'Minimum torque' is between 002 and 254.


Service Manual Controller
Controller
The verifications and the adjustments described below should be performed
every time the controller board or one of the photosensors in the upper
transport mechanism (Fshift, Finq, Fcash, Fcnt, Fendv or Fout) or the
horizontal transport motor are replaced.
To execute the verifications or the adjustment, use the diagnostic program.
 From the menu 'Modules Test' select the 'Controller Test' and then menu
item 'Adjust'.

Controller Service Manual
Horizontal transport photosensors and motor adjustment
 Select 'Adjust All'.
 Wait a few seconds, click on 'ReadValue'.
 Verify that the reported values are between 002 and 254.
If this condition is not satisfied, replace the controller board.

Service Manual Banknote scanner check
Banknote scanner check
Banknote scanner speed adjustment

This operation should be done whenever the banknote scanner is replaced.
Use the test program to adjust the speed of the banknote scanner module.
 Select the menu item 'Identifier' under 'Modules Test', and in the next
window select ’System Check' – 'Set Default Parameters'.

Banknote scanner check Service Manual
 Confirm the next message with 'Yes' and wait until the adjustment is
finished.
i After that, the system must necessarily be switched off and switched
on again!

Service Manual Banknote scanner check
Description of the banknote code
C U V S
Currency code
(two first characters of ISO code)
Value code
Note type
Value coding
A=1 F = 25 K = 1000 P = 50,000 U = 500,000

B=2 G = 50 L = 2,000 Q = 100,000 V = 1,000,000
C=5 H = 100 M = 5,000 R = 250 W = 2,000,000
D = 10 I = 200 N = 10,000 S = 20,000 X = 5,000,000
E = 20 J = 500 O = 20,000 T = 250,000 Y = 10,000,000
Currency code
Country Code Country Code Country Code

Europe EUR Iceland ISK Slovakia SKK
Argentina ARS Ireland EIP Russia RUR
Brazil BRL Israel ILS Saudi Arabia SAR
Canada CAD Japan JPY South Africa ZAR
China RMB Kuwait KWD South Korea KRW
Cyprus CYP Malaysia MYR Switzerland CHF
Croatia CRD Mexico MXP Taiwan TWD
England GBP New NZD Turkey TRL
Zealand
Finland FIM Norway NOK USA USD
Hong Kong HKD Oman OMR Venezuela VEB
Hungary HUF Poland PLZ
Examples
 'USDA' means 10 US $, note type A

 'EUFN' means 25 Euro, note type N

Updates Service Manual
Updates
Firmware updating
The firmware of all modules that are part of the ProCash 6100xe is stored in
flash EPROM so it can be updated by a download operation.
 To update the firmware use the test program. Open the session and, from
the 'User Commands' menu, click on 'Download', and then on 'Module
Firmware'.
Reader Update
Module Firmware

Service Manual Updates
 Enter the password.
 Select the required option.

 Click on 'Find' and, using standard Windows commands, select the file
(.hex) that you want to download. confirm the operation by clicking
'Download'.

Note references updating

To update note references, use the diagnostics program.
 Select 'Download' from the 'User Command' menu and then 'Reader
Update'.

 Enter the password.

The marked area shows the presently installed reference values of 'Bank 0' or
'Bank 1'.

The bank chosen for the installation is always marked by a green rectangle.
 Select the reference file'xxx.hex' by clicking 'Find' and then 'Download'.

Troubleshooting
Test programs
'Stand alone' test

 Switch on the machine and verify the correct execution of the self
diagnosis.
The following parts should be activated in sequence:
 Upper and lower vertical transports
 Horizontal and vertical upper transports
 Recycling cassettes should execute the 'preset' operation
 Feeder module executes self diagnosis
At the end, 'SYSTEM OK' or 'UNIT READY' should appear on the LC display.
 If it doesn't, please proceed as described in the section "Power on
sequence".

Test programs Troubleshooting
Online test
 Connect the machine to the host system (computer) and activate the
diagnostic 'CM Tool'.
 Select 'Open' in the 'User Commands' menu and verify that no errors are
shown. In case errors are shown proceed as described in the section
'OPEN command'.

Troubleshooting Test programs
 Select 'Extended Status' from the 'User Command' menu.

 Verify that the settings are as shown in the figure below.
 If the settings are different, proceed as described in the section 'Extended

Status'.

Troubleshooting Test programs
 Select 'Setup' from the 'User Command' menu.

 Verify that the banknote reader and the drum modules are correctly
configured (for example see following figure).
 Place some notes in the input tray and select 'Deposit' in the 'User
Commands' menu.
 Verify that the operation is correctly executed and that the cash status of
the cassettes is coherent with the number of deposited banknotes.
 Withdraw the same number of deposited banknotes and verify that the
cash status of all cassettes is set to 0.
 Change operator side and execute the same operations (deposit and
withdrawal) again.

Troubleshooting Intervention procedure
Intervention procedure
At the moment of intervention engineers may find the ProCash 6100xe in two
different states.
 The device is in error status.
 The machine is running.
In case 2 engineers should look at the error log in order to see what caused
the defect (see section "Error Log").
Power on sequence
In case 1 the procedure is as follows:
 Look at the complete machine to see that there are no evident anomalous
conditions (jammed notes, loose screws, etc.).
 Switch on the ProCash 6100xe and verify that the power-on self-diagnosis
is correctly executed. The following table shows the sequence of the self
tests and the actions to be taken in case that these operations are not
correctly executed.

Intervention procedure Troubleshooting
Step Description Remedy

1 Upper and lower  Check that the feeder, the upper cover
vertical transports are and the safe door are closed.
activated.
 Check that the device has the correct
main voltage and that the fuses are
not blown.
 In the diagnostic program execute the
'OPEN' command and eliminate the
reported error (see section "OPEN
command").
2 Vertical and horizontal  Check the motors and the
upper transports are connections.
activated.
3 The 8 drum modules  Execute the 'Extended Status'
perform the preset command of the diagnostic program
operation. and check that the cassette has not
Note: If a cassette is been switched off (see section
empty, the motor is "Extended status").
activated once. If the  In case that the cassette is in error
cassette contains condition, proceed as described in the
banknotes, the motor is section "High-level reply codes".
activated twice.
4 The feeder executes a  Execute the 'Extended Status'
self-diagnosis. command in the diagnostic program
(see section "Extended status").
 If the feeder is in an error condition,
please proceed as described in the
section "High-level reply codes".
5 The ProCash 6100xe  Wait for the end of the second self-
terminates its self- diagnosis cycle.
diagnosis phase. Self-
 Execute the 'OPEN' command in the
diagnosis will not start
diagnostic program (see section
again and the LCD
"OPEN command").
shows 'System OK' or
'Unit Ready'.

OPEN command
The following flowchart details the error conditions that may occur during
execution of the OPEN command. The meaning and suggested action are
given for each error.
Error code Description Remedy
03 Syntax error Verify that the command sequence sent to
the machine is correct and try again the
operation.
04 Context error – Wait until the self-diagnostics are
completed and re-send the command.
– Verify that there is no working session
already open on the other RS232
interface.
65 Wrong key – The used password is not correct.
– All cassettes are disconnected or
switched off.
66 No cassette No cassettes are activated for the registered
activated operator.
Change the operator, re-send the OPEN
command and check the set-up.
67 Wrong side The operator on the other side is already
registered.
To change the operator first execute the
CLOSE command, then register the desired
operator using the OPEN command.
104 Protocol error It is not possible to communicate with the
device.
Check the RS232 connections (cables,
connectors), change the RS232 interface,
use a different cable to connect the PC,
make sure the relevant COM port of the PCs
is consistent with the software set-up, and
check the baud rate (9,600 bits/sec, 8 bits,
no parity, 1 stop bit).
If the problem persists, replace the controller
board.

Extended Status
Using the 'Extended Status' command you can look up detailed information
regarding the status of every module.
This command puts in evidence both the primary condition of error (high level
reply code), and the detailed information regarding the status of the module
that is in error condition (low level reply code).
The command can also be sent in error conditions since no previous OPEN
command is required.
No status code is returned for missing modules.

This figure shows the report of the 'Extended Status' command when no
anomalies are present. In this case three status messages are possible:
 40 = Unit ready
 05 = Cassette empty
 04 = Cassette full
Extended Status Left Side
REPLY CODE : Device (1) Correctly Executed Refresh Exit
MODULE STATUS DESCRIPTION
Feeder (40) Unit ready

Controller (40) Unit ready
Identifier (40) Unit ready
Cassette A (40) {or (05)} Unit ready {or Cassette empty}
Cassette B (40) {or (05)} Unit ready {or Cassette empty}
Cassette C (40) {or (05)} Unit ready {or Cassette empty}
Cassette D (40) {or (05)} Unit ready {or Cassette empty}
Cassette E (40) {or (05)} Unit ready {or Cassette empty}
Cassette F (40) {or (05)} Unit ready {or Cassette empty}
Cassette G (40) {or (05)} Unit ready {or Cassette empty}
Cassette H (40) {or (05)} Unit ready {or Cassette empty}
Clicking with the mouse it is possible to obtain detailed information

regarding the status of the module (low level reply code and related description)

This table shows the report of the Extended Status command when anomalies
are found. In this case there are two cassettes called A (the second one is
installed in place of cassette B, e.g. because the original cassette B was
defective and it has been replaced with an other one previously called A).
Cassette H has been switched off by software (because of an anomaly inside
the cassette itself).
Extended Status Left Side
REPLY CODE : Device (1) Correctly Executed Refresh Exit
MODULE STATUS DESCRIPTION
Feeder (40) Unit ready

Controller (40) Unit ready
Identifier (40) Unit ready
Cassette C (40) {or (05)} Unit ready {or Cassette empty}
Cassette D (40) {or (05)} Unit ready {or Cassette empty}
Cassette E (40) {or (05)} Unit ready {or Cassette empty}
Cassette F (40) {or (05)} Unit ready {or Cassette empty}
Cassette G (40) {or (05)} Unit ready {or Cassette empty}
Cassette H 00 Disabled
Clicking with the mouse it is possible to obtain detailed information

regarding the status of the module (low level reply code and related description)
To solve the first problem it should be sufficient to run the 'Assign Cassette'
command (cassette must be empty, then check the setup (see chapter
"Service Manual", section "Check and adjustments of banknote scanner –
Banknote scanner – setup").

Before solving the second problem, make sure drum module H is switched on.
To do so, first select the 'Tool' menu in the test program, then select 'Device
test'. Click on the relevant cassette button.
Then test the drum module by filling and emptying it twice.

Error log
The error log lists errors that have occurred to the unit during the deposit or
withdrawal operation. Analyzing the error log is the only way to understand
how the ProCash 6100xe is running.
When intervening, the first thing engineers should do is to check this
information.
You should first save the error log. To do this press the 'Save Error Log' button
CM14 S.N.: 00xxx Data : 03/23/02
Client : YYYYYYYYY Site :
Module Version Release Den Num

Controller 0903 3.00
Feeder B012 4.00
Note read B500 1.10
Cassette A A002 2.10 ESKT 0
Cassette B A002 2.10 ESMT 0
Cassette C A002 2.10 ESNU 0
Cassette D A002 2.10 ESNU 0
Cassette E A002 2.10 ESNU 0
Cassette F A002 2.10 ESNU 0
Cassette G A002 2.10 ESNU 0
Cassette H A002 2.10 ESNU 0
Error Log X
Init Error Log Config Exit
Insert error/s
Save Error Log Read Log to read
Last Error 42 Analysis

Uploading Error num 42
Record Life Operation Pending Errors

Type Num Number Rec Off RC 1 2 3 4 5 6 7 8 9 A B
5 42 72801 O O 99 00 00 00 00 00 23 03 16 24 00 00
Device ( 1 ) - Correctly Executed

The screen shown below will appear. Click 'Find' to select the destination
directory of the file and its name. It is very important to fill all fields shown:
serial number of the device, place and customer.

Looking at the example given below you can see that, in the case of an error,
the high-lighted row indicates the High-Level Reply Code (RC) of the error
itself and the Low-Level Reply Codes of all the modules at the moment of the
error.
Error Log X
Insert error/s
Last Error 1-42

Analysis
Record Life Operation Cassette Status

Type Num Number Side Type RC Feed Cntr Idn A B C D E F G H
1 26 71200 L W 23 40 40 40 40 1A 40 05 05 05 05 05
4 27 1 - B 00 00 01 01 00 01 00 00 00 00 00 00
2 28 71200 P P 23 40 40 40 40 1A 40 05 05 05 05 05
5 29 71200 O O 99 23 08 06 00 00 00 00 00 00 00 00
5 30 72801 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 31 73201 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 32 73736 O O 99 00 00 00 00 00 00 00 00 00 00 00
1 33 74265 R D 16 18 40 40 40 40 40 05 05 05 05 05
3 34 818 + A 75 75 01 74 74 00 00 00 00 00 00 00
Error condition High level Low level reply codes

in withdrawal reply code of all the modules

The high-lighted row shows an entry into the error log when the ProCash
6100xe is switched off (High Level reply code =99). All high level codes
available at the time of switch-off will be saved. This means that, in the
presence of HL RC=99, all the following numbers (pending 1, 2 and 3) do not
mean the status (Low level reply codes) of the modules but are a queue of
High-Level reply codes coming from the device.
The date and time are saved, too.
Error Log X
Insert error/s
Last Error 1-42 Analysis

Record Life Operation Pending Errors

Type Num Number Rec Off RC 1 2 3 4 5 6 7 8 9 A B
1 26 71200 L W 33 40 40 40 40 1A 40 05 05 05 05 05
4 27 1 - B 00 00 01 01 00 01 00 00 00 00 00 00
2 28 71200 P P 23 40 40 40 40 1A 40 05 05 05 05 05
5 29 71200 O O 99 23 08 06 00 00 23 03 16 24 00 00
5 30 72801 O O 99 00 00 00 00 00 23 03 17 18 00 00
5 31 73201 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 32 73736 O O 99 00 00 00 00 00 00 00 00 00 00 00
1 33 74265 R D 16 18 40 40 40 40 40 05 05 05 05 05
3 34 818 + A 75 75 01 74 74 00 00 00 00 00 00 00
Switch-off row Date and time

High level reply codes

The 'enhanced error line' makes error analysis easier. The meaning of each
column of this new row is shown below. All values are expressed in
hexadecimal. The example shows an error that happened during the deposit
phase.
Error Log X
Insert error/s
Last Error 1-42

Analysis
Record Withdrawal Operation Photo count Cassette Counter

Type Num time Delta Dep Photo Feed Shift Count Cash A B C D E F G H
1 26 71200 L W 33 40 40 40 40 1A 40 05 05 05 05 05
4 27 1 - B 00 00 01 01 00 01 00 00 00 00 00 00
2 28 71200 P P 23 40 40 40 40 1A 40 05 05 05 05 05
5 29 71200 O O 99 23 08 06 00 00 00 00 00 00 00 00
5 30 72801 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 31 73201 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 32 73736 O O 99 00 00 00 00 00 00 00 00 00 00 00
1 33 74265 R D 16 18 40 40 40 40 40 05 05 05 05 05
3 34 16:04 818 + A 75 75 01 74 74 00 00 00 00 00 00 00
BN Counted by:
Error extension row Cassette H
(deposit phase) Cassette G
Cassette F
Error time
Cassette E
Cassette D
Cassette C
Cassette B
Cassette A
A B C
FCASH
A= Counted banknotes (in withdrawal) since last switch-off FCNTX
B= Deposit operation FSHIFT
C= Status of the photosensors FEEDER

When an error happens during a deposit operation a hexadecimal value is

output in the 'Op Id' column. This value includes the code of the status (dark or
light) of the photosensors FINQ, FSHIFT, FENDH and FCASH at the time of
the error.
The table shows the status of photosensors in relation to the hexadecimal
value.
Value Photosensor status

Hex. FINQ FSHIFT
0
1
2
3
4
5
6
7
Photosensor light (not covered)

Photosensor dark (covered)

An extension error row has also been added for errors that happen during
withdrawal operations. The meaning of each column in this new row is given in
the figure below. All values are expressed in hexadecimal.
Error Log X
Insert error/s
Last Error 1-42

Analysis
Record Withdrawal Operation Photo count Cassette Counter

Type Num time Delta Dep Photo Feed Shift Count Cash A B C D E F G H
1 26 71200 L W 33 40 40 40 40 1A 40 05 05 05 05 05
4 27 16:04 1 - B 00 00 01 01 00 01 00 00 00 00 00 00
2 28 71200 P P 23 40 40 40 40 1A 40 05 05 05 05 05
5 29 71200 O O 99 23 08 06 00 00 00 00 00 00 00 00
5 30 72801 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 31 73201 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 32 73736 O O 99 00 00 00 00 00 00 00 00 00 00 00
1 33 74265 R D 16 18 40 40 40 40 40 05 05 05 05 05
3 34 818 + A 75 75 01 74 74 00 00 00 00 00 00 00
BN Counted by:
Withdrawal extension Cassette H
error row Cassette G
Cassette F
Cassette E
Error time
Cassette D
Cassette C
Cassette B
Cassette A
A B C
FCASH
A= Counted banknotes (in withdrawal) since last switch-off FCNTX
Withdrawal operation FSHIFT
B=
C= Cassette in use at the error time FEEDER

If the cause of an error is not eliminated by the operator it will be shown again.
In this case the relevant record will be marked with the letters P P, meaning it
is not a real error but a consequence of a previous situation.
Error Log X
Insert error/s
Last Error 1-42

Analysis
Record Life Operation Cassette Status

Type Num Number Side Type RC Feed Cntr Idn A B C D E F G H
1 26 71200 L W 23 40 40 40 40 1A 40 05 05 05 05 05
4 27 1 - B 00 00 01 01 00 01 00 00 00 00 00 00
2 28 71200 P P 23 40 40 40 40 1A 40 05 05 05 05 05
5 29 71200 O O 99 23 08 06 00 00 00 00 00 00 00 00
5 30 72801 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 31 73201 O O 99 00 00 00 00 00 00 00 00 00 00 00
5 32 73736 O O 99 00 00 00 00 00 00 00 00 00 00 00
1 33 74265 R D 16 18 40 40 40 40 40 05 05 05 05 05
3 34 818 + A 75 75 01 74 74 00 00 00 00 00 00 00
Duplicated error condition

of record number 23

By clicking on the 'Analysis' button you can get the global situation of the
errors that happened since the last initialization of the error log.
Each error is described in full and the Low Level Code and the number of
errors are displayed. By clicking on the Low Level button, you can see the
possible corrective actions that can be taken.
With 'Save on File', the program will generate a text file stating the error
statistics.
CM24 Error Log Analysis X
Exit
Input Note 160653 Total Errors 19 rate 1/ 8455
Errors in upper area 13 rate 1/ 12357 Save on file
Errors in safe area 2 rate 1/ 80326
CM24 ( 16) - Feeder Jam rate 1/ 17850
16 Feeder Jam 9
LL Code Description Num Rate
17 Reader Jam 1
18 Upper Track 1
19 Cross Point 3 Reject op. failed -note stuck 4
49 Overflow 0 26
21 Output Track 0
20 Lower Track 1 Hor. Time out 2 -Fout too long 2
19
22 Cass. A Jam 1
23 Cass. B Jam 0
24 Cass. C Jam 0 Note stuck on thickness sensor 1
25 Cass. D Jam 0 21
26 Cass. E Jam 0
27 Cass. F Jam 0 Reject op. failed -note inside 1
28 Cass. G Jam 0 25
29 Cass. H Jam 0
40 Cass. A Miss 0
41 Cass. B Miss 0
42 Cass. C Miss 0
Device (1) Correctly Executed
Clicking on this button, the statistic

of the situations happened on the machine
will be stored inside a text file

The figure shows an example of the statistics file.
+=====================================================+
| CM24 STATISTIC |
+================================+=====+====+=========+
| error code and description | Num | % | rate |
|--------------------------------+-----+----+---------|
| TOTAL ERRORS DETECTED | 19| - | 160653|
| ERRORS DETECTED IN UPPER AREA | 13| 68| 12357|
| ERRORS DETECTED IN SAFE AREA | 2| 11| 80326|
+===+============+=====+=======+===+=========================================+
| HL| Description |Num |freq | LL| Description |Num | % |
|Err| | |1/Bnk n|Err| | | |
+===+-------------+----+-------+---+-------------------------------+----+----|
| 16|Feeder Jam | 9| 17850| 26| Reject op. failed -note stuck | 4| 44|
+===+-------------+----+ | 19| Hor.Time out 2 -Fout too long | 2| 22|
| | 21| Note stuck on thickness sensor| 1| 11|
| | 25| Reject op. failed -note inside| 1| 11|
| | 18| Hor.Time out 1 -Fshift -->Fout| 1| 11|
+===+-------------+----+-------+---+-------------------------------+----+----|
| 17|Reader Jam | 1| 160653| 20| Lenght measure under 100 mm | 1| 100|
+===+-------------+----+-------+---+-------------------------------+----+----|
| 19|Cross Point | 3| 53551| 17| Note not arrived on FCASH | 2| 67|
+===+-------------+----+ | 11| Note stuck in the Fshift area | 1| 33|
+===+-------------+----+-------+---+-------------------------------+----+----|
| 20|Lower Track | 1| 160653| 27| Time out from cass.to FCASH | 1| 100|
+===+-------------+----+-------+---+-------------------------------+----+----|
| 22|Cass. A Jam | 1| 160653| 1D| Notes overlapping under FOTOUT| 1| 100|
+===+-------------+----+-------+---+-------------------------------+----+----|
| 29|Count Error | 4| 40163| 19| Not expected note on FCASH | 4| 100|
+-------+---+-------------------------------+----+----|

High-level reply codes

These are errors at power-on or during normal operations.
The following table shows the error or warning conditions that may happen at
power-on or during normal operation of the machine.
For each error/warning the table indicates the area that generates it, and gives
an explanation and the suggested action to take.
Code Description Area Cause and action taken
00 Boot mode Controller Device in download mode. Firmware
can be replaced via RS232.
01 OK
02 SW error Controller Flash memory CRC error on the
controller board (CICOM).
Replace the flash memory.
03 Syntax error SW Syntax error in the host command.
Check the command sequence.
04 Context error SW The requested command cannot be
executed.
05 Cover open Upper The upper cover is open (forced
cover condition after any error in the upper
mechanical track). Check the micro
block (20211).
06 Safe open Safe door The safe door is open. Check the
sensor.
07 Feeder open Feeder The feeder is open (forced condition
after a feeder jam error). Check the
feeder position or the micro switch on
CAB 0502-01.
08 Cassette Cassette One of the cassette trays is open
unlocked trays (forced condition after any error in the
safe area). Check the position of each
tray and if necessary the CAB-0562
block.
09 Note on right Right Notes detected in the right output tray.
output output If necessary check the FOUTR
photosensor on CAB-0554.


10 Note on left Left output Notes detected in the left output tray. If
output necessary check the FOUTR
photosensor on CAB-0554.
11 Note on front Reject Notes detected on the reject tray of the
output output feeder. Check the reject photosensor
feeder on CAB-0565.
12 No input note Feeder No input notes detected on the feeder
input slot after a deposit command.
Check the input note photosensor on
CAB_0563.
13 Denomination Cassettes All cassettes programmed with the
full specified denomination are full. If not
true, check the FEND photosensor
(CAB-0528) or the condition of the
Mylar tape used to carry the notes in
the cassettes.
14 Denomination Cassettes All cassettes programmed with the
empty specified denomination are empty. If
not true, check the FEND photosensor
(CAB-0528) or the condition of the
Mylar tape used to carry the notes in
the cassettes. Also check the counter
of the cassettes.
15 Misfeeding Feeder The thickness sensor has not detected
any input note after 4 feeding cycles.
Check the input note position and
repeat the command. If the error
persists, verify the adjustments
described in the feeder
documentation, with reference to the
thickness sensor and the feeding
block.


16 Feeder jam Feeder An error has been detected during the
feeding cycle. The 'Feeder Open'
condition is activated.
Possible causes:
Input jam – the note transition time
under the thickness sensors is too
long (note entered crooked).
Vertical jam - the note transition time
from the thickness sensor to the
vertical alignment sensors is too long
(note delayed in the vertical path).
Horizontal jam – the note transition
time on the horizontal path exceeds
the limits.
Open the feeder, remove the notes,
close it and restart.
If the error occurs too many times and
the notes are in good condition check
the feeder adjustments in the specific
documentation.
17 Jam in Banknote The note is jammed inside the unit or
banknote scanner its transition time exceeds the limits.
scanner The 'Cover Open' status is activated.
Open the note scanner, remove the
jammed note, check the conditions of
the internal surfaces, close it and
restart. If necessary check the
description in the note scanner
documentation.


18 Upper track Upper track The note has not reached the F-SHIFT
jam sensor within the specified time. More
than two notes have been detected in
the path. The 'Cover Open' status is
activated. Open the upper cover,
remove the jammed notes, close it,
wait for the cleaning procedure, collect
the notes conveyed to the output tray
and restart. If necessary check the
adjustment of the upper transport
system.
19 Crosspoint jam Crosspoint The note transition time on the F_Shift
sensor is too long. The note does not
reach the destination path in time. The
'Cover Open' status is activated. Same
procedure as above.
20 Lower track Safe During a deposit operation an
jam imbalance has been detected between
the number of notes in a specific
cassette and the number of 'diverted'
commands directed to the same
cassette. During a withdrawal
operation the number of notes in the
path is not correct or the note
transition time exceeds the limit. The
'Cassette Unlocked' status is
activated.
Power off the ProCash 6100, open the
safe, open the cassette trays and
check all the note paths. If necessary
remove the cassettes and check the
note position. Remove the jammed
notes, also check the safe input block
and restart. This type of error can be
caused by damaged notes. If there is
no obvious cause, check the rules
described in the cassette and safe
interior documentation.


21 Output track Output area The note transition time from FCASH
jam to FOUTx exceeds the limits. The
'Cover Open' status is activated. Open
the cover and lift the two frames over
the crosspoint area. Remove the
jammed notes, check for any visible
obstructions, close and restart. Also
check that the notes are not torn or do
not have holes. If necessary check the
FCASH, FCNTx photosensors and the
crosspoint rules.
22 - Jam in Cassette A The cassette photosensors detected a
29 cassette A to to H wrong transition time. The 'Cassette
H Unlocked' status is activated. Power
off the ProCash 6100xe, open the safe
and the tray with the cassette causing
the error. Check and remove the
jammed notes. If necessary check the
cassette adjustment. When one or
more notes are manually removed
from the cassette the cassette note
counter will be wrong.
30 Out of service All If one of the operating errors of the
previous table is not eliminated by the
operator and the subsequent cleaning
procedure the ProCash 6100xe goes
out of service. The same can occur at
power-on time if one of the modules
does not respond or is not working. To
understand the problem you can run
the 'Extended Status' command or
Transparent mode. To exit this status,
power off the ProCash 6100xe.
31 Deposit out of Feeder The feeder or the note scanner is not
service banknote working. It is possible to withdraw the
scanner cash anyway.


32-39 Cassettes A to Cassettes One of the cassettes does not respond
H out of A-H to the 485 line. Check the connections
service and, if necessary, replace the
electronic board of the cassette in
question.
40 - Missing note in Cassettes The number of 'Sorter Off' operations
47 cassettes A-H directed to the cassette is greater than
A to H the number of notes arriving in the
cassette. The note can be at the
bottom of the safe or in a different
cassette. Check and undo the latest
operation.
48 Internal All RS 485 internal serial error.
communication
error
49 Note overflow Banknote The note scanner does not define a
scanner target for the note in transit within the
limit. The 'Cover Open' status is
activated. Open the cover, check the
notes in the path, close and restart.
50 Count error All At the end of a withdrawal operation
the delivered notes do not match the
requested ones. Redeposit the notes
and repeat the withdrawal command.
This error can occur when the notes
are torn or have holes.
64 Note on feeder Feeder Note left on the feeder input tray at the
input end of a deposit command.
65 Wrong key All/contr. The key code used is wrong.
66 No cassette All There are no cassettes enabled with
present reference to the operator side used.
67 Wrong side All The operator side used in the
command is not correct.
68 Req. over limit Withdraw. The number of requested notes
(withdrawal command) exceeds 200.
69 Cassette not The cassette is not present.
present


70 Cass. / The cassette or denomination is not
denomination empty.
id not empty
71 N.id not
present
72 No journal E. journal The optional electronic journal kit is
not present or not working.
73 Record not E. journal The journal record is not present in the
pres. specific range.
74 Wrong All Loaded firmware not compatible.
firmware
80 Information on All Only used in the error log to save
module's information on the module's hardware.
hardware
81 Information All Only used in the error log to save
module's information on the module's software.
software
82 Information All Only used in the error log to save
'Sorter Off' information on 'Missing note in
cassette'.
83 Self cleaning All Only used in the error log to represent
is enabled a 'Self cleaning' entry.
94 Error during All Only used in the error log to save
recovery errors which occur during the recovery
phase phase.
95 Statistic record All Only used in the error log to save the
statistics at power-off.
96 Service log All Only used in the error log to save the
data defined in the associated
command.
97 'Safe door All Only used in the error log to save the
open' log 'safe door open' conditions.
98 Lock All Device lock for the period of time
defined in the associated command (5
to 30 minutes).
99 Power OFF All Only used in the error log to save the
processes in the turned-off state.

Error codes – feeder

This table shows all error codes relating to the feeder module (High level
codes 15 or 16).
The section "Error analysis" describes the LL reply codes by means of
flowcharts that explain how the machine works and why the error conditions
occur.
Hex Description Possible cause
Code
01 Idle mode
02 Syntax error Wrong command
03 Jam Reject aborted
04 The notes in the input tray – Note stack not positioned
cannot be fed. properly in input tray.
– The separating mechanism
does not function properly.
06 – 0F Reserve
10 Feeder motor out of operation
11 E2PROM faulty
12 Reserve
13 Reserve
14 Thickness measuring sensor
out of operation
15 The speed of the main motor is – The vertical drive belts are too
too high. tight.
– The speed of the main motor
has not been adjusted
properly.
– The main motor does not
function properly.
16 Internal RAM error Memory error.
17 The pressor does not return to The pressure motor is faulty or
its start position within the has not been adjusted properly.
prescribed time.
18 Reserve


Code
19 Note positioned over FOUT for – Note is damaged.
too long – The horizontal transport
mechanism does not function
properly.
– The main motor does not
function properly.
– The horizontal upper transport
unit does not function properly.
1A Jam 11 No input note
1B Jam 12 No note in front input
1C Jam 13 Flash error
1D Jam 14 The measured thickness value
for a single banknote is not within
the tolerance range.
1E Jam 15 The measured thickness value
for a double banknote is not
within the tolerance range.
1F Jam 16 'Fallin' photosensor covered
20 Feeder open – The operator has not closed
the feeder properly.
– The microswitch which
controls the closing of the
feeder does not function
properly.
21 Note blocked under thickness – Note is damaged.
sensor – The area of the thickness
sensor is blocked.
– The vertical transport does not
have enough power.
22 The right alignment sensor is – The reject mechanism does
dark before the cash-in not function properly.
procedure begins. – The right alignment sensor


Code
23 The left alignment sensor is – The reject mechanism does
dark before the cash-in not function properly.
procedure begins. – The left alignment sensor does
not function properly.
24 The FOUT photosensor is dark – The reject mechanism does
before the cash-in procedure not function properly.
begins. – FOUT does not function
properly.
25 The reject procedure has failed, – Note is damaged.
the note did not cover the – The vertical transport does not
alignment sensors within the have enough power.
prescribed time.
26 The reject procedure has failed, – Note is damaged.
the note stops after covering – The vertical transport does not
the alignment sensors. have enough power.
– The reject mechanism does
27 – 2F Reserve
30 Warn 02 - Photosensors do not – Photosensors are dirty
supply enough current. – Photosensors are not ok.
– The board of the feeder does
31 Warn 03 - Photosensors supply – Photosensors are dirty
too much current. – Photosensors are not ok.
– The board of the feeder does
32 - 37 Reserve
38 External RAM error
39 Initialization test failed
3A – 3F Reserve
40 OK Command properly executed.
41 Busy

Error codes – controller

This table shows all error codes relating to the controller.
The following pages in the section "Error analysis" describe the LL reply codes
by means of flowcharts that explain how the machine works and why the error
conditions occur.
Code
00 Reserve
01 Not ready Internal error on controller board
02 Flash error Flash CRC error
03 Entry error Setup error
04 RAM error RAM without timer
05 Note lies under – Note is damaged (holes).
FSHIFT photosensor – FSHIFT photosensor is faulty or soiled
without having a (please clean it).
destination. – Note scanner has not communicated
destination to controller.
– Controller has not communicated
destination properly.
06 Note lies under – Note is damaged (holes).
FCASH photosensor – FCASH photosensor is faulty or soiled
without having a (please clean it).
destination. – Controller has not communicated
destination properly.
07 - Reserve
09
0A Time-out during – Note is damaged.
transport from feeder – Feeder counted one note too many.
to FSHIFT. – FSHIFT photosensor does not function
properly or is soiled (please clean it).
– The horizontal upper transport unit does


Code
0B Too many notes in the – Note is damaged.
upper track – Feeder counted one note too many.
– FSHIFT photosensor does not function
– The horizontal upper transport motor does
0C FSHIFT counts more – Note is damaged (holes).
notes than feeder – Feeder counted one note too few.
– FSHIFT photosensor is faulty or soiled
(please clean it).
0D – Reserve
0F
10 One note stops under – Note is damaged.
FINQ photosensor – FINQ photosensor does not function
during recovery time. properly or is soiled (please clean it).
– SHIFT unit does not function properly.
– SHIFT area not free (blocked by jammed
note).
11 Note stops under – Note is damaged.
FSHIFT photosensor. – FSHIFT photosensor does not function
– The horizontal upper transport unit does
FCNTX photosensor – FCNTX photosensor does not function
(cash-in procedure). properly or is soiled (please clean it).
– The vertical upper transport unit does not
function properly.
13 Time-out during – Note is damaged.
banknote transport – FCNTX photosensor does not function
from FINQ to FCNTX properly or is soiled (please clean it).
(cash-in procedure). – SHIFT unit does not function properly.
– The vertical upper transport unit does not
function properly.


Code
14 The note does not – Note is damaged.
reach the FINQ – FINQ photosensor does not function
photosensor within properly or is soiled (please clean it).
the prescribed time. – SHIFT unit does not function properly.
– The horizontal/vertical upper transport unit
15 Note was not – FENDH photosensor does not function
deflected by the properly or is soiled (please clean it).
SHIFT mechanism – SHIFT unit does not function properly.
and covers the
FENDH photosensor.
16 MDE jam 1 Home position command for MDE motor was
not successful.
17 Note moving in the – Note is damaged.
direction of the safe – FCASH photosensor does not function
does not reach the properly or is soiled (please clean it).
FCASH photosensor – The intermediate transport does not
in the predefined function properly.
period of time.
– The transport in the safe does not function
properly.
FCASH photosensor – FCASH photosensor does not function
(cash-in procedure). properly or is soiled (please clean it).
– The intermediate transport does not
function properly.
properly.
FCASH photosensor – FCASH photosensor does not function
(cash-out procedure). properly or is soiled (please clean it).
function properly.
properly.
– The drum module used does not function
properly.


Code
19 Unexpected note at Unexpected note at FCASH (cash-out
FCASH procedure)
1A Time-out during – Note is damaged.
banknote transport – FCNTX photosensor does not function
from FCASH to properly or is soiled (please clean it).
FCNTX (cash-out – SHIFT unit does not function properly.
procedure).
– The upper transport unit does not function
properly.
1B Note stops under – Note is damaged.
FCNTX photosensor – FCNTX photosensor does not function
(cash-out procedure). properly or is soiled (please clean it).
– The upper transport unit does not function
properly.
– The drum module used does not function
properly.
1C, Reserve
1D
1E Note does not reach – Note is damaged.
target drum module – The intermediate transport does not
(drum module A) function properly.
properly.
– The sorter in cassette A does not function
properly.
1F Note does not reach – Note is damaged.
(drum module B) function properly.
properly.
– The sorter in cassette A or B does not
function properly.


Code
20 Note does not reach – Note is damaged.
(drum module C) function properly.
properly.
– The sorter in cassette A, B or C does not
function properly.
(drum module D) function properly.
properly.
– The sorter in cassette A, B, C or D does not
function properly.
(drum module E) function properly.
properly.
– The sorter in cassette A, B, C, D or E does
(drum module F) function properly.
properly.
– The sorter in cassette A, B, C, D, E or F
(drum module G) function properly.
properly.
– The sorter in cassette A, B, C, D, E, F or G


Code
(drum module H) function properly.
properly.
– The sorter in cassette A, B, C, D, E, F, G or
H does not function properly.
26 Too many notes in the – Note is damaged.
lower transport path – FCASH photosensor does not function
function properly.
properly.
27 Time-out during – Note is damaged.
banknote transport – FCASH photosensor does not function
from drum module to properly or is soiled (please clean it).
FCASH. – The intermediate transport does not
function properly.
properly.
40 OK
41 Busy
Error codes – banknote scanner

This table shows all error code relating to the scanner module.
The following pages in the section "Error analysis" describe the LL reply codes
by means of flowcharts that explain how the machine works and why the error
conditions occur.
Hex Name Description
Code
01 Reserve


Code
03 Serial timeout error Timeout during data reception
04 Download error Wrong CRC / adress or defective
.hex-file
05 - 06 No longer used
07 DSP timeout error DSP timeout
08 DSP BUSY DSP still busy
09 IMG error Image memory error
0A DSP SPT error SPT Download error
0B Reserve
0C DXL error DSP defective link to FGPA
0D - 0E Reserve
0F Reference error The 'bank' references are not valid
10 RAM error RAM memory test failed
11 Reserve
12 Flash-EPROM Flash-EPROM write error
programming error
13 - 14 Reserve
15 Input photosensor Input photosensor error
16 OPT error OPT photosensor error
17 UV error UV calibration failed
18 SYM error CIS symmetry error
19 Reserve
1A Overrun HQ error Banknotes too close
1B Overrun HH error Banknotes too close
1C DSP programming error DSP booting process failed
1D Voltage error Power supply problems
1E Reserve
1F Reference error No references may be loaded on DSP
20 Reserve
21 Note is too long. Jam – Banknote length more than 160
mm or banknote stopped
22 Reserve
23 FPGA programming error FPGA booting process failed


Code
24 - 25 Reserve
26 HCK error Checksum error of host firmware
27 DCK error Checksum error of DSP firmware
28 FCK error Checksum error of FPGA firmware
29 SCK error Checksum error of SPT firmware
2A Reference error Checksum error of references
2B Reserve
2C SPD error Speed error
2D - 2E Reserve
2F TAP error TAPE photosensor error
30 TLK error Connection with TAPE photosensor
failed
31 MLK error Connection with MAG photosensor
failed
32 MAG error MAG photosensor error
33 STB error System strobe error
34 USB timeout error USB connection failed
35 - 3F Reserve
40 OK Module is ok
41 Busy

Error codes – drum modules

This table shows all error codes relating to the cassette modules.
The low-level message is also given for each error. That makes it easier to
identify the origin of the problem. The following pages in the section "Error
analysis" describe the LL reply codes by means of flowcharts that explain how
the machine works and why the error conditions occur.
Code
01 Idle mode After a reset
03 Jam 0 Basic jam
04 drum module full
05 drum module empty
06 The address of the cassette does – The cassette has not been
not match the physical position. allocated any address following
its replacement.
– Electronic board of cassette is
faulty.
07 Jam 1 Cancellation
08– Reserve
0F
10 EEPROM error EEPROM is faulty.
11 Sorter out of service – Mechanical problem.
– Electronic board of cassette is
faulty.
12 Cassette with wrong address Electronic board is faulty.
(different from A ÷ H)
13 The note counter setting of the Electronic board is faulty.
cassette is too high.
14 The parameter setting for the note Electronic board is faulty.
height is too high.
15 The self-diagnostics upon power- – Mechanical problem.
on have not been terminated – Electronic board is faulty.
correctly.
16 RAM error Electronic board is faulty.


Code
17 Flash error
18 FOTIN photosensor is dark before – FOTIN photosensor is dirty.
a cash-out procedure begins. – FOTIN photosensor is not ok.
– Mechanical problem.
19 FOTOUT photosensor is dark – FOTOUT photosensor is dirty.
before a cash-out procedure – FOTOUT photosensor is not
begins. ok.
1A Note stops before FOTIN – FOTIN photosensor is not ok.
photosensor is covered (cash-out – Mechanical problem.
procedure).
1B Note stops before FOTOUT – FOTOUT photosensor is not
photosensor is covered (cash-out ok.
procedure). – Mechanical problem.
1C Note stops under FOTIN – FOTIN photosensor is not ok.
photosensor (cash-out – Mechanical problem.
procedure).
1D Note stops under FOTOUT – FOTOUT photosensor is not
photosensor (cash-out ok.
1E Password not saved. Electronic board is faulty.
1F Reserve
20 Note stops before FOTOUT – FOTOUT photosensor is not
photosensor is covered (cash-in ok.
21 Note stops under FOTOUT – FOTOUT photosensor is not
photosensor (cash-in procedure). ok.
22 Reserve
23 Note stops before FOTIN – FOTIN photosensor is not ok.
photosensor is covered (cash-in – Mechanical problem.
procedure).
24 Note stops under FOTIN – FOTIN photosensor is not ok.
photosensor (cash-in procedure). – Mechanical problem.
25-27 Reserve


Code
28 Time-out during feed. – EMPTY photosensor is dirty or
not ok.
– Mylar stripe is not wound on
roller properly.
29 Time-out during 'initial position' – EMPTY photosensor is dirty or
procedure. not ok.
– Mylar stripe is not wound on
roller properly.
2A Time-out during 'Reverse-Home' – FULL photosensor is dirty or
procedure. not ok.
2B FOTOUT remains dark at the end – FOTOUT photosensor is dirty
of preset operation or not ok.
2C FOTIN remains dark at the end of – FOTIN photosensor is dirty or
preset operation not ok.
2D FOTOUT remains dark at the end – FOTOUT photosensor is dirty
of 'Home' operation. or not ok.
2E FOTOUT remains light at the end – FOTOUT photosensor is dirty
of cash-out operation or not ok.
2F FOTIN remains light at the end of – FOTIN photosensor is dirty or
cash-out operation not ok.
30 More than 10 notes inserted after – Electronic board of cassette is
the 'Full' status faulty.
– Controller board is faulty.
31 Cassette was recognized as full – Electronic board of cassette is
without the relevant marker being faulty.
defined.


Code
32 Note stops under FOTOUT – FOTOUT photosensor is not
photosensor (feed / home position ok.
33 Jam 16 Timeout during recognition
process – reverse home position
command
34-37 Reserve
38 Current strength at trimmer0 – FOTIN and FOTOUT
reached minimum value. photosensors are dirty or not
ok.
39 Current strength at trimmer0 – FOTIN and FOTOUT
reached maximum value. photosensors are dirty or not
ok.
3A Current strength at trimmer1 – FOTIN and FOTOUT
reached minimum value. photosensors are dirty or not
ok.
3B Current strength at trimmer1 – FOTIN and FOTOUT
reached maximum value. photosensors are dirty or not
ok.
3C Jam 21 Loaded firmware is not
compatible.
3E Warning Note clearance is too low
40 OK Operation has been properly
completed.
41 Busy


Operator Panel
View of the operator panel
Left Operator LED Right Operator LED
Menu Skip
UNIT READY
Esc LEFT OPERATOR Enter
Display
KEYS
The operator panel consists of the following:

 Two green LEDs that show the selected operator side during a deposit or
withdrawal operation.
 Liquid crystal display (LCD) that shows all operating errors or error
conditions of the machine at all times (online level).
 Four keys to access local functions (local mode level) that make the
following features available:
 Extended diagnostic features to be activated by the operator only with
phone support by an engineer.
It is possible to access the features in the local mode session by pressing the
'Menu' key. The 'Enter', 'Skip' and 'Esc' keys are used to change the selection
and to access all functions nested inside each feature. Pressing the 'Menu'
key at every point will take you back to the online level.

Messages Operator Panel
Messages
The following tables show all possible messages that can be shown on the
LCD of the operator panel during normal operation of the machine (online
level). Suggested action by the operator is given for each message.
Messages in English
Messages on the operator display

Text 1 Text 2 Text 3
00 RECOVERY PHASE 00 PLEASE 00 RECOVERY
WAIT PHASE
01 UNIT READY
UNIT READY UNIT READY
LEFT SIDE RIGHT SIDE
DEPOSIT WITHDRAWAL
LEFT SIDE RIGHT SIDE
02 SW ERROR SW ERROR
03 SYNTAX ERROR SYNTAX ERROR
04 CONTEXT ERROR CONTEXT ERROR
05 COVER OPEN CHECK UPPER
COVER
06 SAFE OPEN CLOSE SAFE DOOR
07 FEEDER OPEN CLOSE FEEDER
08 CASSETTE CHECK CASSETTE
UNLOCK TRAY POSITION
09 BANKNOTE ON RIGHT PICK UP NOTE ON
OUTPUT RIGHT EXIT SLOT
10 BANKNOTE ON LEFT PICK UP NOTE ON
OUTPUT LEFT EXIT SLOT
11 REJECT SLOT PICK UP NOTE ON
FRONT EXIT SLOT
12 NO INPUT BANKNOTE PLACE BANKNOTE ON
FEEDER INPUT
13 DENOMINATION FULL 13 DENOMINATION
FULL
14 DENOMINATION EMPTY 14 DENOMINATION

Operator Panel Messages

EMPTY
15 MISSFEEDING CHECK NOTE ON
FEEDER INPUT BAY
16 FEEDER JAM OPEN FEEDER AND
REMOVE BANKNOTE
17 READER JAM OPEN READER AND
REMOVE BANKNOTE
18 UPPER TRACK JAM OPEN UPPER COVER
AND CLEAR JAM
19 CROSS POINT JAM OPEN UPPER COVER
AND CLEAR JAM
19 CROSS POINT JAM OPEN UPPER COVER
AND CLEAR JAM
20 LOWER TRACK JAM OPEN SAFE &
CLEAR CASS. A JAM
21 OUTPUT TRACK JAM OPEN UPPER COVER
AND CLEAR JAM
22 CASSETTE A JAM OPEN SAFE &
CLEAR JAM
23 CASSETTE B JAM OPEN SAFE &
CLEAR JAM
24 CASSETTE C JAM OPEN SAFE &
CLEAR JAM
25 CASSETTE D JAM OPEN SAFE &
CLEAR JAM
26 CASSETTE E JAM OPEN SAFE &
CLEAR JAM
27 CASSETTE F JAM OPEN SAFE &
CLEAR JAM
28 CASSETTE G JAM OPEN SAFE &
CLEAR JAM


29 CASSETTE H JAM OPEN SAFE &
CLEAR JAM
30 UNIT OUT OF SERVICE OFF&ON IF STILL
30 CALL SERVICE
31 DEPOSIT OUT OF OFF&ON IF STILL
SERVICE 31 CALL SERVICE
32 CASSETTE A OUT OF OFF&ON IF STILL
33 CASSETTE B OUT OF OFF&ON IF STILL
34 CASSETTE C OUT OF OFF&ON IF STILL
35 CASSETTE D OUT OF OFF&ON IF STILL
36 CASSETTE E OUT OF OFF&ON IF STILL
37 CASSETTE F OUT OF OFF&ON IF STILL
38 CASSETTE G OUT OF OFF&ON IF STILL
39 CASSETTE H OUT OF OFF&ON IF STILL
40 MISSING NOTE ON OPEN SAFE & CHECK
CASSETTE A TRACK TO CASS.
CASSETTE B TRACK TO CASS.
CASSETTE C TRACK TO CASS.
CASSETTE D TRACK TO CASS.
CASSETTE E TRACK TO CASS.
CASSETTE F TRACK TO CASS.

Operator Panel Messages

CASSETTE G TRACK TO CASS.
CASSETTE H TRACK TO CASS.
48 INTERNAL ERROR OFF&ON IF STILL
31 CALL SERVICE
49 BANKNOTE OVERFLOW OPEN UPPER COVER
AND CLEAR JAM
50 DEPOSIT COUNT UNDO DEPOSIT CHECK
ERROR BANKNOTES


Removal / Installation of Components
Device overview
Overall view
1 Customer panel 5 Lock of front door

2 Grip for pulling out 6 Front door handle
the upper transport 7 Deposit input (right)
3 Power switch 8 Deposit input (left)
4 Lock of front door 9 Front door

Device overview Removal / Installation of Components
Customer panel
1 Release lever for feeder cover

2 Cash input tray
3 Operator display
4 Reject / cash output tray
5 Release lever for feeder

Removal / Installation of Components Device overview
Front door open
1 Safe door 4 Key lock of safe

2 Electronic number combination 5 Deposit box (right)
lock 6 Deposit box (left)
3 Knob to open the safe 7 Front door

Device overview Removal / Installation of Components
Safe door open
1 Pull-out unit 3 Front door

2 Safe door

Removal / Installation of Components Device overview
Pull-out unit pulled out and open
1 Movable part of the pull-out unit 6 Drum module D

2 Fixed part of the pull-out unit 7 Drum module E
3 Drum module A 8 Drum module F
4 Drum module B 9 Drum module G
5 Drum module C 10 Drum module H

Opening / closing the device Removal / Installation of Components
Opening / closing the device

Switch the device off at the mains switch before you work in the safe
section.
Pulling out / pushing in the upper transport

Pulling it out:
Grasping the gripping edge (1), pull
out the upper transport as far as
possible.
Pushing it in:
Grasping the gripping edge (1), push
the upper transport into the device as
far as possible.
Opening / closing the feeder

Opening it:
Push one or both levers in the
direction of the arrow (1). Take hold of
the feeder at the back (2) and tilt it
forward.
Closing it:
Take hold of the feeder at the side of
the upper part and tilt it back until it
locks into position.

Removal / Installation of Components Opening / closing the device
Opening / closing the feeder cover
 Open the feeder (see section "Opening / closing the feeder").

Opening it:
Pull the release lever for the feeder
cover (1) upwards and raise the cover
in the direction shown by the arrow.
Closing it:
Tilt the cover back until it locks into
place.

Opening / closing the front door
i The front door may only be opened and closed when the upper
transport is in position.
Device with deposit boxes

Opening it:
Insert the keys in the locks of the front
door (1). Turn the keys 90 degrees to
the right and open the front door by
the lever (2).
Closing it:
Close the front cover by the handle
(2), turn the keys 90 degrees to the
left and remove the keys from the
lock.
Device without deposit boxes
 To open it: Open the front door by the lever (2).
 To close it: Close the front cover by the handle (2) as far as possible.

Opening / closing the pull-out unit

section.
 Open the safe (see section "Opening / closing the safe" in the operating
manual of ProCash 6100xe).
Opening it:
Pull the handle upwards at the green
point (1) and pull the pull-out unit out
of the device as far as possible by the
handle.
Press the green release lever (1)

downwards and swing the movable
part of the pull-out unit as far as
possible to the left.
Closing it:
Swing the movable part of the pull-out
unit back until it locks into position.
Push the pull-out unit in the device
until the latching mechanism locks into
position.

Removing / inserting the drum modules

section.
 Open the pull-out unit (see section "Opening / closing the pull-out unit").
i The drum modules must be replaced in their original positions.
Release the corresponding drum

module.
Movable part of the pull-out unit:

Turn the appropriate release lever (1)
to (4) clockwise through 90 degrees.
(1) Drum module A

(2) Drum module C
(3) Drum module E
(4) Drum module G

Fixed part of the pull-out unit:

Press the appropriate release lever (1)
to (4) into the device.
(1) Drum module B

(2) Drum module D
(3) Drum module F
(4) Drum module H
Take hold of the drum module by the

base (see figure) and pull it out as far
as possible.

Push the securing plates (1) outwards

as far as possible (see arrows) and
remove the drum module.
Reinstall it by following the same steps in reverse order.
When inserting the drum module make sure that the Mylar film is taut.
If the film is slack, it could be damaged when the drum module is
placed in the mounting.

Removal / Installation of Components Upper transport cover
Upper transport cover

 Pull out the upper transport (see section "Opening / closing the device").
Left cover
Remove the screw (1) on the base of

the left cover.
Remove the screw (1).

Pull the left cover (2) towards the front
of the device (see arrow) and remove
it.
Reinstall it by following the same steps

in reverse order.

Feeder cover Removal / Installation of Components
Feeder cover
 Remove the right cover of the upper transport and the controller cover (see
sections "Upper transport cover" and "Controller cover").
Right cover
Pull the cover (2) upwards (see arrow)

and remove it.

in reverse order.
Left cover
Pull the cover (2) upwards (see arrow)

and remove it.

in reverse order.

Removal / Installation of Components Feeder cover
Upper cover
Remove screw (1) on the right and left

side.
Pull the cover (2) upwards and remove

it.
Remove screws (1) and (2).
Remove the covers (3) and (4)

upwards.
Reinstall them by following the same

steps in reverse order.

Control panel cover Removal / Installation of Components
Control panel cover

 Remove the feeder cover (see section "Feeder cover").
Remove the screw (1) and the bolt (2)

each on the left and on the right side.
Take hold of the cover (3) at the top

and tilt it forward.
Detach connector (1).
Remove the control panel cover (2)

upwards.

in reverse order.

Removal / Installation of Components Control panel
Control panel
 Remove the control panel cover (see section "Control panel cover").
Remove screws (1) to (4).
Remove the control panel (5) from the

cover.

in reverse order.

Controller cover Removal / Installation of Components
Controller cover
Remove the screw and the threaded
plate (1).
Make sure the threaded plate

i does not fall into the device.
Lower the cover (2).
Remove screws (1) and (2).
Remove the controller cover (3).

in reverse order.

Removal / Installation of Components Feeder - movable part
Feeder - movable part

 Remove the feeder cover (see section "Feeder cover").
 Remove the upper transport cover (see section "Upper transport cover").
Detach connectors (1) and (2) from the

controller.
Open the cable clamp (3) and pull the
cable out of the cable clamp.
Remove the retainer ring (1) and

detach the shock absorber (2)
sidewards.

Feeder - fixed part Removal / Installation of Components
Press the lock (1) upwards on the left

and right (e.g. with a ballpoint pen).
Remove the movable part of the
feeder upwards.

in reverse order.
Feeder - fixed part

 Remove the movable part of the feeder (see section "Feeder - movable
part").
Loosen the release levers (1) and (2)

on the left and right side.
Move the locking lever up.
 Remove the controller cover (see section "Controller cover").

Removal / Installation of Components Feeder - fixed part

controller.
Remove the cable from the cable

clamp (1).
Disconnect the timing belt (2) from the
gearwheel and place it on the tab (3).
Remove the fixed part of the feeder
upwards.

in reverse order.

Banknote scanner Removal / Installation of Components
Banknote scanner
Detach the plastic ring (1) from the

gearwheel on the bottom side.
Turn the green wheel (1) until the

timing belt disengages.
Remove screw (1) with the

corresponding nut.
Remove screw (2).
Disconnect the plug (3).
Remove the banknote scanner
upwards.

in reverse order.

Removal / Installation of Components Deflector station
Deflector station
Disconnect the plug connection (1).

Release the screw (2) and change the
position of the locking lever.
Remove the deflector station (4)
upwards from the device.

in reverse order.

Feeder controller Removal / Installation of Components
Feeder controller
Disconnect all cables from the

controller (1).
Remove the clearance bolts (2) and
(3) and the screws (4) and (5).
Remove the controller (1).

in reverse order.
Main controller
Disconnect all cables from the main

controller (1).
Remove screws (2) to (6).
Remove the main controller (1).

in reverse order.

Removal / Installation of Components Power supply unit
Power supply unit


power supply unit (4).
Push the power supply unit (4) slightly

to the rear and remove it upwards.

in reverse order.
When mounting the power supply unit, make sure that the tabs are
positioned correctly below the power supply unit.

Upper transport Removal / Installation of Components
Upper transport
 Remove the banknote scanner, the feeder, the deflector station and the
controller.
Loosen the fastening screws of the

V.24 connector (1) and (2) and remove
the V.24 connector.
 Remove all connectors on the upper transport, or disconnect all plug

connections with the upper transport if you have not already done so.
Remove the cable (1) from the cable

clips.
Release the screw (2) and push the

locking lever (3) towards the center of
the device (see arrow).
 Lift the upper transport slightly at the front and pull it forward from the rail.
Reinstall it by following the same steps in reverse order. As you do so, note
the following installation instruction!

Removal / Installation of Components Pull-out unit
Installation instruction
Following installation of the upper

transport, ensure that the lock (1) is
again pushed up to the stop (see
arrow) and the screw (2) tightened.
Pull-out unit
 Remove all drum modules (see section "Opening / closing the device").
Disconnect the ribbon cables (1) and

(2) at the rear of the pull-out unit.

Pull-out unit Removal / Installation of Components
Press the locking bar (1) on the

movable part of the pull-out unit and,
at the same time, turn the hand knob
(2) anti-clockwise.
Repeat this procedure with all pull-out

units.
 Close the pull-out unit and push it back into the safe as far as possible.
Remove the two stop screws (1) and
(2).
Pull the pull-out unit (3) out of the safe.

in reverse order.
When installing a new pull-out unit

make sure that the bracket is attached
to position (1) (CEN safe) or position
(2) (UL safe) depending on the safe
type.
After installing the pull-out unit, make sure that the stop screws are
replaced and tightened!

Removal / Installation of Components Intermediate transport
Intermediate transport
 Remove the pull-out unit (see section "Pull-out unit").
Remove screws (1) to (3) countersunk
into the safe housing and ...
... remove the right transport rail (1) in

the safe.
Disconnect the plug (1) on the

intermediate transport (6).
Remove the countersunk screws (2) to
(5).
Remove the intermediate transport (6)
downwards from the safe.

in reverse order.

Fan Removal / Installation of Components
Fan
 Remove the pull-out unit (see section "Pull-out unit").
Disconnect the plug (1) on the

backplane and remove the cable from
the cable holder (2).
Remove screws (3) and (4) and
remove the fan.

in reverse order.

Removal / Installation of Components Converting the drum modules
Converting the drum modules
Converting from right (B, D, F, H) to left

(A, C, E, G)
Loosen the locking screw (1) and
remove the drive gear (2).
Remove the retaining rings (3) and (4)

and pull off the green knobs (5) and
(6).
Position the knobs (1) and (2) on the

axles (3) and (4). Make sure the letter
'L' (left) is on the visible side of the
knobs.
Secure the knobs with the retainer

rings.
i The drive gear is no longer
required.

Converting the drum modules Removal / Installation of Components
Make sure that the lock is in its

i lower position on both sides (in
the figure screw (1) is placed
through the upper hole of the
lock).
Converting from left (A, C, E, G) to right

(B, D, F, H)
Remove the retaining rings (1) and (2)
and pull off the green knobs (3) and
(4).
Position the knobs (1) and (2) on the

axles (3) and (4).
Make sure the letter 'R' (right) is on the
visible side of the knobs.
Secure the knobs with the retainer
rings.
Place the drive gear (5) on the bolt (6)
as far as possible and secure the drive
gear with the locking screw.

Push the locking mechanism up and

tighten screw (1) again.
Conversion of ProCash 6000xe to

ProCash 6100xe
Detach the connector (1) and remove
the two cable ties (2) and (3).

Remove the retaining ring (3) and pull

off the mounting roller.
Unscrew the connector with the
screws ((1) and (2)).
Replace the mounting roller onto the

axle (1).
Fasten the connector at points (1) and

(2).
Plug the connector (3) in.

Fasten the bracket at points (1) and

(2).
Turn the drum module so that the

bottom side points upwards.
Fasten the clamps (1) and (2) tight as

shown here.
Make sure that the lock is in its

i lower position on both sides (in
the figure screw (1) is placed
through the upper hole of the
lock).


Index
B H
Banknote scanner 2-14 High-level reply codes 4-24
Banknote transport 2-33 High-Level reply codes 2-41
Horizontal transport 2-28
C
I
Cassettes 2-35
Checks and adjustments of Important safety precautions 1-2
cassettes 3-2 Intermediate transport 2-34
Checks and adjustments of the Intervention procedure 4-7
feeder 3-7
Controller 3-15 M
Crosspoint 2-31
Manual (structure) 1-5
D Mechanical structure 2-2
Description of the device 1-4 O

Drum cassette module 2-35
OPEN command 4-9
E Operator Panel 5-1
Electronic modules 2-5 P

Error codes 4-34
Photosensor positions 2-3
Error codes – banknote scanner
4-39 R
Error codes – drum modules 4-42
Error codes – feeder 4-31 Removal / Installation of
Components
Error log check 4-14 Banknote scanner 6-22
Extended Status 4-10 Control panel 6-17
Control panel cover 6-16
F Controller cover 6-18
Converting the drum
Feeder 2-8 modules 6-31
01750143767 A ProCash 6100xe - Service Manual II-1

Index
Deflector station 6-23 S

Device overview 6-1
Fan 6-30 Shift mechanism 2-29
Feeder - fixed part 6-20 SHIFT mechanism 2-29
Feeder - movable part 6-19 Stand alone test 4-1
Feeder controller 6-24
Structure of the manual 1-5
Feeder cover 6-14
Intermediate transport 6-29
Main controller 6-24 T
Opening / closing the device Technical data 1-6
6-6
Power supply unit 6-25 Test programs 4-1
Pull-out unit 6-27 Troubleshooting 0-1
Upper transport 6-26
Upper transport cover 6-13 U
Repair (Service Manual) 3-1
Updates 3-20
II-2 ProCash 6100xe - Service Manual 01750143767 A

Notes
01750143767 A ProCash 6100xe - Service Manual

Published by
33094 Paderborn
Germany
Order No.: 01750143767 A 1 GB

6100xe Service Manual

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ProCash 6100xe - Service Manual 01750143767 A

Edition August 2008

© WINCOR NIXDORF International GmbH 2008

All rights, including rights of translation and

All rights, including rights created by patent

All names of hardware and software

This manual was

ProCash 6100xe - Service Manual 01750143767 A

01750143767 A ProCash 6100xe - Service Manual 0-1

01750143767 A ProCash 6100xe - Service Manual I-I

Electronic modules .........................................................................................2-5

I-II ProCash 6100xe - Service Manual 01750143767 A

Feeding motor margins verification .........................................................3-14

Operator Panel ..............................................................................................5-1

Removal / Installation of Components ........................................................6-1

01750143767 A ProCash 6100xe - Service Manual I-III

Removing / inserting the drum modules ..................................................6-10

I-IV ProCash 6100xe - Service Manual 01750143767 A

01750143767 A ProCash 6100xe - Service Manual I-V

I-VI ProCash 6100xe - Service Manual 01750143767 A

Symbols used in this manual

 Text following this symbol describes actions to be performed in the

i Text following this symbol contains general information to facilitate use

01750143767 A ProCash 6100xe - Service Manual 1-1

Important safety precautions

1-2 ProCash 6100xe - Service Manual 01750143767 A

Deactivate the device immediately by:

Repair work may only be carried out by authorized personnel.

01750143767 A ProCash 6100xe - Service Manual 1-3

General power interrupt

 Switch off the device at the power switch.

Description of the device

1-4 ProCash 6100xe - Service Manual 01750143767 A

Structure of the manual

01750143767 A ProCash 6100xe - Service Manual 1-5

Electrical characteristics of the supply network

1-6 ProCash 6100xe - Service Manual 01750143767 A

Leakage current: 0.31 mA 0.31 mA

01750143767 A ProCash 6100xe - Service Manual 1-7

Height: 775 mm 775 mm 790 mm 790 mm

Device approx. approx. approx. approx.

Surface approx. approx. approx. approx.

i For detailed information concerning the dimensions please refer to the

1-8 ProCash 6100xe - Service Manual 01750143767 A

Climatic environmental conditions in acc. with EN 60721

Class Ambient temperature Relative

* The temperature value of + 35 °C (+ 95 °F) deviates from the value of

Mechanical environmental conditions in accordance with

01750143767 A ProCash 6100xe - Service Manual 1-9

Noise emission in accordance with EN 27779

*** typical operating cycle

1-10 ProCash 6100xe - Service Manual 01750143767 A

Compliance with standards and certifications

EN 55022 / B EN 55024 FCC CFR 47, part 15, subpart B, class A

Notes concerning radio interference suppression and

01750143767 A ProCash 6100xe - Service Manual 1-11

FCC rules and Canadian Standard ICES - 003

Certification for data transmission

1-12 ProCash 6100xe - Service Manual 01750143767 A