Cobra Service Manual

Cobra® Banknote Sorting Machine
Service Manual
TP01311011 Rev 05 en
November 2009
Cobra® is a registered trademark of De La Rue International Limited.
© 2009 De La Rue International Ltd.
Jays Close, Viables

Basingstoke, Hampshire RG22 4BS, UK
Telephone: +44 1256 605000
Telefax: +44 1256 605004
www.delarue.com
Cobra® Banknote Sorting Machine Service Manual

Proprietary Rights Notice All Rights Reserved. This material contains items of technical information, advice, know-
how, drawings, designs, and specifications that embody substantial creative efforts and con-
fidential information, ideas, and expressions, all of which remain the valuable properties and
trade secrets of De La Rue International Limited. This duty of confidence also entails that
this material shall not be disclosed to a third party, or reproduced or transmitted in any form
or by any means, electronic, mechanical, or otherwise, including photocopying and record-
ing, or in connection with any information storage or retrieval system, without written con-
sent of De La Rue International Ltd.
The above duty of confidence also entails a prohibition of reproduction of this text without
specific authority, in writing, from De La Rue.
Manual Updates Look online for updates to this or other manuals at www.askdelarue.com. This website con-
tains additional resources, including Technical Bulletins produced by De La Rue. The web-
site requires a user ID and password. If you do not have access to this website, you can
apply by sending an e-mail to askdelarue@uk.delarue.com and completing a form.
Environmental and Safety De La Rue recognizes that care for the environment is a central business concern. De La
Notice Compliance Rue is dedicated to operating in a manner that protects the environment and prevents pollu-
tion.
In keeping with De La Rue’s commitment to compliance with all applicable laws and regula-
tions, the equipment you have purchased is compliant with the member state’s enactment of
the ROHS (2002/95/EC) and WEEE (2002/96/EC) directives. If you have any concerns on
how to dispose of electrical and electronic parts from your De La Rue equipment in compli-
ance with your country’s regulations, please do not hesitate to contact your regional De La
Rue office.
FCC Compliance This equipment generates, uses, and can radiate radio-frequency energy that can cause
interference to radio communication if not installed and used in accordance with the instruc-
tion manual. This equipment has been tested and found to comply with the limits for a Class
A computing device pursuant to Subpart J of Part 15 of FCC Rules, which provide reasona-
ble protection against such interference when operated in a commercial environment.
Equipment operation in a residential area is likely to cause interference, in which case the
user, at his own expense, is required to take necessary measures to correct such interfer-
ence.
CE Compliance This equipment conforms to essential CE requirements for electromagnetic compatibility,

radiated electromagnetic fields, and electrostatic discharge. Any installation practices, modi-
fications, or maintenance procedures that are not performed in accordance with or do not
meet the approval of De La Rue Cash Systems requirements nullify the CE certification on
this product.
Trademarks MS-DOS®, Windows® 95, Windows® 98, Windows NT®, and Windows® for Workgroups
are registered trademarks of Microsoft Corporation. Other product names mentioned herein
are for identification purposes only and can be tradenames, trademarks, or registered
trademarks of their respective companies.
TP01311011 Rev 05 November 2009 Preliminary-i

Revision History
Revision History
Rev Level Issue Date Technical Writer

03 October 2007 LJT
05 September 2009 LJT
Associated Publications
Operation, configuration and troubleshooting instruction are covered in a
series of publications appertaining to the Cobra Note Sorter. In addition
to this User Guide, the following publications are available:
 Graphical Control Consol Diagnostics Guide 440-0163-002
 Cobra Quick Reference Guide TP05311013
 Cobra Service Manual TP01311011
 Cobra Detector Manual TP09311011
 Cobra Site Planning Manual TP04511001
List Of Abbreviations
EMC: Electro-Magnetic Compatibility
PCB: Printed Circuit Board
SSD: Static Sensitive Devices
FSM: Four Stacker Module
TSDM: Twin Stacker Destruction Module
ACDP: Automatic Commercial Deposit Processing
DSM: Desktop Shredder Module
Preliminary-ii Cobra® Banknote Sorting Machine Service Manual

Safety Issues
Safety Issues
THE FOLLOWING SECTION ON SAFETY MUST BE UNDERSTOOD
AND STRICTLY ADHERED TO BY ALL SERVICING AND OPERATING
PERSONNEL.
Warning: This equipment may be connected to an uninterruptible power
supply - see Section 5 of Supervisor Guide. To avoid shock hazard make
sure the unit is completely isolated before removing covers.
High Voltage: If single/three phase power is supplied to the machine,

exercise caution when working in areas where mains power is present as,
hazardous voltages will exist.
Wall isolating switchgear must be installed in accordance with local
regulations and standards, and be capable of being either disconnected
or locked in the off position.
High Energy: All servicing personnel are warned of the dangers of

arcing and burns from high-energy components such as the batteries and
power supply unit (PSU).
Weight: Care must be taken when lifting items weighing 20 kg or over

during refitting. The fitting of such items should be regarded as a two-
person task.
Moving Parts: Extreme care must be taken by all servicing personnel

when working near moving machine parts. This is especially important
when covers are open or removed and safety interlock circuits
overridden. On no account should the machine be operated, with the
covers removed, in the presence of operating staff.
Under certain fault conditions it is possible for motors to start. When
working on motor circuits of motor driven parts when the cover interlocks
are overridden, always ensure that an emergency stop switch is pressed
in.
Emergency stop switches, which cannot be overridden, are provided
which will either stop the machine if it is running or prevent it from starting.
These switches are of the red push type with yellow escutcheon plates.
Additionally, all covers that are operator accessible are protected by
safety interlock switches to ensure that the machine will not run when the
covers are open.
All items of clothing such as ties, loose overalls and long hanging
jewellery should be removed. Long hair should be tied up.
Cutting Blades: Certain mechanisms and heads contain sharp-edged
blades. Exercise caution when working in these areas.
Light Emissions: The safety precautions for detectors which emit UV

light or lasers must be followed in accordance with the instructions in the
relevant detector manuals.
TP01311011 Rev 05 November 2009 Preliminary-iii

Safety Issues
Cabling and Power: Do not use the colour of cables as an indication of

their voltage or polarity. Always use the wire number in conjunction with
the wiring schedules.
Always use a test meter to check that the terminals are not live before
touching.
SSD Devices: Normal precautions concerning the handling of MOS

components are applicable in order to minimise the risk of damage to
these devices by STATIC ELECTRICAL DISCHARGE. This entails
avoiding contact with the pins of these devices and ensuring that when
they are removed from a PCB, the pins are strapped together with
conductive tape, or placed on a suitably earthed metal plate, thus
ensuring that ALL pins remain at the same potential. Any external
clothing, overalls, etc., manufactured of NYLON or a similar material must
not be worn as they are capable of reaching extremely high voltage
potentials caused by friction during normal wear. These precautions are
especially necessary in respect of microprocessor devices.
EMC (Electro-Magnetic Compatibility): In accordance with the

European EMC Directive (see CE declaration of conformity) this product
is fitted with EMC countermeasures. These countermeasures include
components like metallic machine covers, mains filters, ferrites, screened
enclosures, critical earthing arrangements, screened cables and critical
wiring. It is important that all these components critical to EMC
performance remain as fitted by the factory. Only Service personnel
trained by De La Rue are permitted to service the machine.
Solvents: All fluids used for cleaning purposes must be non-toxic and
must comply with the relevant COSHH and Health And Safety
regulations.
Pneumatics: Before attempting any maintenance or servicing on the

pneumatics system ensure that the air supply is removed. Should it be
necessary to carry out any fault finding on the machine while the
pneumatics are functioning, extreme caution should be exercised.
Preliminary-iv Cobra® Banknote Sorting Machine Service Manual

Safety Issues
Safety Symbols The following symbols can help prevent injury to the Operator.
It is advisable to be aware of what these symbols represent:
Primary Symbol Description Secondary Symbol
Danger, High Voltage

Potentially lethal voltages are present. Use extreme care
in any of these areas. Turn power off before servicing
(two possible symbols).
Danger, UV Light, Do Not Look Directly at Light

Fluorescent and phosphorescent detectors contain UV
light. Use discretion and care when working around these
detectors.
Warning, Crushing Hazard

These areas can cause crushing. Use extreme care in
any of these areas. Turn power off before servicing.
Warning, Equipment Starts and Stops Automatically

Keep hands clear whenever equipment is under power.
Warning, Hot Surface

These areas are extremely hot and can cause burns if
touched (two possible symbols).
Warning, Laser Light

Do not look directly into laser beam.
Aperture Warning
Keep hands and objects clear when equipment is under
power.
Pinch Point Warning

Keep hands and objects clear when equipment is
running.
Ear Protection Advisory

Wear ear protection to avoid damage to hearing.
TP01311011 Rev 05 November 2009 Preliminary-v

Site Requirements
Site Requirements
It is recommended that a suitable table be made available to hold the

weight of the Cobra machine 120kg (264lb) and expansion module 63kg
(139lb).
Note: The machine is only to be relocated by an approved installer with
the correct lifting tools.
Connection Points
Preliminary-vi Cobra® Banknote Sorting Machine Service Manual

Connection Points
This page is intentionally left blank.
TP01311011 Rev 05 November 2009 Preliminary-vii

Connection Points
Preliminary-viii Cobra® Banknote Sorting Machine Service Manual

Table of Contents
Table of Contents
Chapter 1 System Description
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.1.2 ACDP Separator Recognition Feature . . . . . . . . . . . . . . . 1-5
1.1.3 Cobra Feature Summary . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.4 Machine Relocation . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.1.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.2 GCC PC, Screen, and Key Pad . . . . . . . . . . . . . . . 1-9
1.2.2 Removal and Replacement . . . . . . . . . . . . . . . . . . . . . 1-10
1.2.2.2 Key Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.2.2.3 Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.3 Mother Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.1 Mother Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.2 Safety Control Logic . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.4 Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.4.1 Node LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.4.2 Software Download . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.5 Motor Controllers . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1.5.1 Motor Controller Inputs . . . . . . . . . . . . . . . . . . . . . . . 1-25
1.5.2 Motor Controller Outputs . . . . . . . . . . . . . . . . . . . . . . 1-25
1.5.3 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.5.4 Motor Controller Programming . . . . . . . . . . . . . . . . . . . 1-26
1.5.4.1 Parts Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.5.4.2 Program Hardware Installation . . . . . . . . . . . . . . . . . . . . 1-27
1.5.4.3 Motor Controller Programming . . . . . . . . . . . . . . . . . . . . 1-28
1.5.4.4 Program Software Installation . . . . . . . . . . . . . . . . . . . . . 1-29
1.5.4.5 Parameter Values for Cobra Feeder and Transport . . . . . . . . . 1-29
1.5.5 Motor Controller Replacement . . . . . . . . . . . . . . . . . . . 1-30
1.5.6 Fault-Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.6 Fault-Finding Guide . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.7 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . 1-32
TP01311011 Rev 05 November 2009 TOC-i

Table of Contents
Chapter 2 Friction Feeder
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Settings and Adjustments . . . . . . . . . . . . . . . . . . 2-2

2.2.1 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.2 Feed Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.3 Stripper Wheel, O-Ring, and Nudger Timing . . . . . . . . . . . 2-4
2.2.4 Note Feed Sensor Vane Timing . . . . . . . . . . . . . . . . . . 2-6
2.2.5 Feeder Motor Drive Belt Tension . . . . . . . . . . . . . . . . . 2-7
2.2.6 Contra Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.7 Note Pick Belt Tension . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.8 Note Feed Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.9 Outer Note Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.10 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3 Removal and Replacement . . . . . . . . . . . . . . . . . . 2-10
2.3.1 Stripper Wheel Removal and Replacement . . . . . . . . . . . 2-10
2.3.2 Note Entry Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.3 Contra Roller Removal . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.4 Contra Roller Replacement . . . . . . . . . . . . . . . . . . . . . 2-13
2.5 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . 2-14

2.5.1 Operator Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.6 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . 2-15
2.6.1 Friction Feeder Kit (400-3000-401) . . . . . . . . . . . . . . . . . 2-15
2.6.2 Feeder Motor Assembly (550-2010-501) . . . . . . . . . . . . . 2-19
2.6.3 O-Ring Drive (550-2009-302) . . . . . . . . . . . . . . . . . . . . 2-20
2.6.4 Stripper Wheel Assembly (550-2007-103) . . . . . . . . . . . . 2-21
2.6.5 Nudger Assembly - Single (550-2006-701) . . . . . . . . . . . . 2-22
2.6.6 Nudger Assembly - Friction Feeder (550-2006-601) . . . . . . . 2-23
2.6.7 Contra Roller Adjust Assembly (400-2002-401) . . . . . . . . . 2-24
2.6.8 Pinch Assembly - Feeder (400-2009-101) . . . . . . . . . . . . . 2-25
2.6.9 Stand-off 36T Pulley Assembly (400-2009-801) . . . . . . . . . 2-26
2.6.10 Stand-off Pulley O-Ring Assembly (400-2012-202) . . . . . . . 2-26
2.6.11 Stand-off Pulley 2MR Assembly (400-2012-502) . . . . . . . . . 2-27
2.6.12 Stand-off Pulley 2MR FL FR Assembly (400-2012-702) . . . . . 2-27
2.6.13 Feeder Side Plate Assembly (400-2015-501) . . . . . . . . . . . 2-28
2.6.14 Feed Tray Assembly (400-2006-601) . . . . . . . . . . . . . . . 2-29
2.6.15 Feeder Back-Plate Motor ASSY (400-2057-801) . . . . . . . . . 2-30
TOC-ii Cobra® Banknote Sorting Machine Service Manual

Table of Contents
Chapter 3 Transport
3.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.1 Settings and Adjustments . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2.1 Sensors TSB Through TSI and TSK . . . . . . . . . . . . . . . . . 3-4
3.2.2.2 Sensor TSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.2.3 Sensors LOA Through LOJ . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3 Transport System . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.1 Mark 1 Modification to Allow Expansion . . . . . . . . . . . . . 3-7
3.3.2.2 Semi-Stretch Transport Belts . . . . . . . . . . . . . . . . . . . . . 3-19
3.3.2.3 Transport Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.3.2.4 Limpness Detector Roller . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.3.3.2 Semi-Stretch Transport Belts . . . . . . . . . . . . . . . . . . . . . 3-20
3.4 Stackers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.5 Diverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.6 Transport Drive System . . . . . . . . . . . . . . . . . . . . 3-27
3.7 Timing Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.7.3 Electrical Interconnections . . . . . . . . . . . . . . . . . . . . . 3-31
3.8 Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.9 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.9.1.1 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.9.1.2 Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.9.1.3 Rear Cover Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.9.2.2 Side Cover Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.9.2.3 Rear Cover Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.11 Sensor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
TP01311011 Rev 05 November 2009 TOC-iii

Table of Contents

3.12.1 CIS SDA Transport Kit . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.12.2 Mark I Transport Belt Path . . . . . . . . . . . . . . . . . . . . . 3-42
3.12.3 Front Roller Assemblies Kit (400-3000-204) . . . . . . . . . . . 3-47
3.12.4 Mark II Transport Belt Paths . . . . . . . . . . . . . . . . . . . . 3-49
3.12.4.1 Mark II Common Rollers (400-3002-501) . . . . . . . . . . . . . . 3-51
3.12.4.2 Zone 1 Belt Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.12.4.4 Zone 2 Belt Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.12.4.5 Variant 2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.12.4.6 Variant 2C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3.12.4.7 Variant 2D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.12.4.8 Variant 2E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
3.12.4.9 Variant 2F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.12.4.10 Variant 2G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3.12.4.11 Zone 3 Belt Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.12.5 Sub-Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . 3-84
3.12.5.1 Capstan and Stacker Assemblies (400-3000-103) . . . . . . . . . 3-84
3.12.5.2 Capstan/Stacker Wheel Lower Assembly (400-4002-301) . . . . . 3-85
3.12.5.3 Capstan/Stacker Wheel Upper Assembly (400-4002-401) . . . . . 3-86
3.12.5.4 Caspstan Assembly (400-2000-803) . . . . . . . . . . . . . . . . . 3-87
3.12.5.5 Capstan/Handwheel Assembly (400-2008-103) . . . . . . . . . . 3-88
3.12.5.6 50” Diameter-Crowned Standoff Assembly (400-2001-201) . . . . 3-89
3.12.5.10 25” Diameter-Div Standoff Assembly (400-2005-202) . . . . . . . 3-91
3.12.5.11 Limpness Roller Standoff Assembly (400-2009-901) . . . . . . . . 3-91
3.12.5.12 16” Diameter Twin Individual Inboard Standoff Assembly 
(400-2014-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
3.12.5.13 16” Diameter Twin Standoff Assembly (400-2017-601) . . . . . . 3-92
3.12.5.14 16” Diameter Twin Individual Inboard Standoff Assembly
(400-2017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.12.5.15 25” Diameter Twin Individual Inboard Standoff Assembly
(400-2017-801) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.12.5.16 25” Diameter Double Standoff Assembly (400-2018-101) . . . . . 3-94
3.12.5.17 16/17.4” Diameter Double Standoff Assembly (400-2018-402) . . 3-94
3.12.5.18 50” Diameter Outboard Standoff Assembly (400-2018-501) . . . . 3-95
3.12.5.19 16” Diameter Twin Double Standoff Assembly (400-2026-201) . . 3-95
3.12.5.20 Limpness Roller Standoff Assembly (400-2026-301) . . . . . . . . 3-96
3.12.5.21 20” Diameter Central Roller Standoff Assembly (400-2033-602) . 3-96
3.12.5.22 22” Diameter Plastic Roller Standoff D/A (400-2040-801) . . . . . 3-97
3.12.5.23 22” Diameter Plastic Double IND Standoff D/A (400-2040-901) . . 3-97
3.12.5.24 25” Diameter Plastic Roller Standoff D/A (400-2041-001) . . . . . 3-98
3.12.5.25 Magnetic Housing Bearing Assembly (400-2041-201) . . . . . . . 3-98
3.12.5.26 22” Diameter Plastic Double-Linked Standoff D/A (400-2041-502) 3-99
3.12.5.27 22” Diameter Plastic INBRD Standoff D/A (400-2041-601) . . . . 3-99
3.12.5.28 Plastic Double Roller Standoff D/A (400-2043-201) . . . . . . . . 3-100
3.12.5.29 Stacker Entry Roller Bracket Assembly (400-2016-703) . . . . . . 3-101
3.12.5.30 Pivot Roller Offset Assembly (400-2025-401) . . . . . . . . . . . . 3-103
TOC-iv Cobra® Banknote Sorting Machine Service Manual

Table of Contents
Chapter 4 Power
4.1 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Safety Interface Circuits . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.3 Communications Interface . . . . . . . . . . . . . . . . . . . . . 4-6
4.1.4 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.1.4.2 Power Systems and Power Distribution in an Integrated System . 4-9
4.2 Settings and Adjustments . . . . . . . . . . . . . . . . . . 4-13
4.3 Removal and Replacement . . . . . . . . . . . . . . . . . . 4-14
4.3.1 Power Supply Tray . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.3.2 Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.4 Wiring Schedules . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.5 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.5.1 MDU Mains Bus (400-6007-801) . . . . . . . . . . . . . . . . . . . 4-18
4.5.2 MDU Neutral Bus (400-6007-901) . . . . . . . . . . . . . . . . . . 4-19
4.5.3 MDU Contactor (400-6008-001) . . . . . . . . . . . . . . . . . . . 4-20
4.5.4 MDU Relay Control (400-6008-101) . . . . . . . . . . . . . . . . . 4-21
4.5.5 MDU Shredder Power (400-6008-201) . . . . . . . . . . . . . . . 4-22
4.5.6 MDU IEC Outlet Power Cable (400-6008-301) . . . . . . . . . . . 4-23
4.5.7 Cobra Hybrid Safety (400-6008-401) . . . . . . . . . . . . . . . . 4-24
Chapter 5 Preventative Maintenance
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Dust and Dirt Removal . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Maintenance Routines . . . . . . . . . . . . . . . . . . . . . 5-4

5.3.2 Weekly Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.3 Semi-Annual Routines . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.4 Annual Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 Estimate of Annual Service Times . . . . . . . . . . . . . 5-7
5.5 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . 5-8
5.6 Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6.1 Attaching an External Drive to GCC . . . . . . . . . . . . . . . . 5-11
TP01311011 Rev 05 November 2009 TOC-v

Table of Contents
Chapter 6 Four-Pocket Extension
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.2.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.2 Attachment and Alignment . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.3 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.3.2 Control and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3 Mother Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.1 Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.2 Safety Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4 Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5 Motor Controllers . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.7 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.8 Transport System . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.8.1 Settings, Removal, and Replacement . . . . . . . . . . . . . . . 6-12
6.8.2 Belt Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.8.3 Transport Drive System . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.9 Stackers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.9.1 Settings and Adjustments . . . . . . . . . . . . . . . . . . . . . 6-18
6.11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.13 Ancillary Motherboard Connections . . . . . . . . . . . 6-26
Chapter 7 ACDP Separator Recognition Feature
7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.2.1 Barcode Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.1.1 Barcode Reader Front-End Detector Card . . . . . . . . . . . . . 7-5
7.2.1.2 Barcode Reader Decoder/Controller . . . . . . . . . . . . . . . . . 7-6
7.2.2 Magnetic-Stripe Detector . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2.2.1 MR Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2.2.2 Magnetic-Stripe Detector Front-End Amplifier Card . . . . . . . . 7-9
7.2.2.3 Magnetic-Stripe Detector . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.3.1 Parts Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.4 Setup/Adjustment and Calibration . . . . . . . . . . . . 7-26
TOC-vi Cobra® Banknote Sorting Machine Service Manual

Table of Contents
7.4.1 Mechanical Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

7.4.1.2 Magnetic Detector Setup . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.4.2 Electrical Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7.4.2.2 Magnetic-Stripe Detector . . . . . . . . . . . . . . . . . . . . . . . 7-34
7.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.6 System Requirements . . . . . . . . . . . . . . . . . . . . . 7-36
7.6.2 Node Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.6.3 System Software . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.7 System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7.7.2 Barcode Reader Checks . . . . . . . . . . . . . . . . . . . . . . . 7-37
7.8 Wiring Schedules . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7.8.1 Barcode Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7.8.1.2 Barcode Reader Decoder/Controller Card . . . . . . . . . . . . . . 7-39
7.8.2 BCR/Magnetic-Stripe Detector Interconnection . . . . . . . . . 7-40
7.8.3 Magnetic-Stripe Detector . . . . . . . . . . . . . . . . . . . . . . 7-41
7.8.3.2 Magnetic-Stripe Detector Card . . . . . . . . . . . . . . . . . . . . 7-41
7.9 Magnetic Stripe Detectors: Improving Calibration and
Functionality 7-43
7.9.1 Updating the Magnetic Strip PCB with Firmware Kit (FK100307/02)
7-43
7.9.2 Magnetic Stripe Detector Setup . . . . . . . . . . . . . . . . . . 7-44
7.9.3 Magnetic Head Adjustment with Firmware Kit FK100307/02 . . 7-45
7.9.3.1 Testing Magnetic Head Adjustments . . . . . . . . . . . . . . . . . 7-45
Chapter 8 Quick Deposit Processing (QDP) Usage
8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 QDP Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.2.1 Machine Configuration . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.2.2 Process Configuration . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.2.3 Process Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.3 OutSort Pockets . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
TP01311011 Rev 05 November 2009 TOC-vii

Table of Contents
TOC-viii Cobra® Banknote Sorting Machine Service Manual

Chapter 1
System Description
Topic Page Number
1.1 - Overview 1-2
1.2 - GCC PC, Screen, and Key Pad 1-9
1.3 - Mother Board 1-13
1.4 - Nodes 1-20
1.5 - Motor Controllers 1-25
1.6 - Fault-Finding Guide 1-31
1.7 - Illustrated Parts List 1-32

1.1 Overview System Description
1.1 Overview
The De La Rue Cobra® product incorporates elements of proven and

leading-edge technologies used in the existing 3700 and 6000 series sort-
ers. The machines are highly engineered to provide heavy-duty, high-
authenticity banknote sorting in single and multiple denominations.
This document is reissued to incorporate information with appropriate
references regarding two 6000 modules that can now interface with the
Cobra system: the Four-Stacker Module (FSM) and the Two-Stacker
Destruction Module (TSDM).
One or both of these modules can appear in sites that require banding,
post packaging, banknote destruction, or some combination of these
applications.
This reissue also includes information regarding the separator recognition
feature that enables Automated Commercial Deposit Processing (ACDP),
an enhancement to throughput using batch processing.
1.1.1 Cobra Product Range
The Cobra 4004 (Figure 1-1) is a stand-alone Detector/Cull Module

(DCM) that can connect to a maximum of 10 Four-Pocket Module (4PM)
extension modules (see Figure 1-2 on Page 1-3).
The DCM and the 4PM extension modules have four output pockets, pro-
viding a maximum of 44 output pockets. The DCM contains one cull
pocket for rejected notes.
Note: Rates and capacities depend on note size, quality, and process.
Figure 1-1 Cobra 4004 (DCM)
Automatic Backplate 21-cm (8.3-inch)

Adjustment- Continuous Colour Graphic
Feed, Friction Hopper LCD Screen
Feeder Rate= Maximum 12
Notes/Second
Feeder Capacity= 1000
Notes
Four Output
Pockets-
Capacity 200
Notes Power Switch
Cover Handle
Stacked Cull/
Overrun Pocket
Capacity 100
Notes

System Description 1.1 Overview
Figure 1-2 Cobra Four-Pocket Extension Module
Output Pockets (4)

Overrun Pocket
Cover Handle
The basic Cobra 4004 expands to accommodate more complex sorting

requirements by adding extension modules, whether Cobra four-pocket
extensions or 6000 FSM/TSDM modules.
Table 1-1 lists the product codes for different configurations.
Table 1-1 Cobra Product Options

Product Codes Description
Cobra 4004 Detector/Cull Module (DCM)
Cobra 4008 DCM + one 4PM
Cobra 4012 DCM + two 4PMs
Cobra 4016 DCM + three 4PMs
Cobra 4020 DCM + four 4PMs
DCM + one FSM + optional Post Packaging
Option 1
Unit Delivery Subsystem (PPUDS)
Option 2 DCM + one TSDM
Option 3 DCM + one FSM + one TSDM
Option 4 DCM + one 4PM + one FSM
Option 5 DCM + one 4PM + one TSDM
Option 6 DCM + DSM
A Cobra line-up consisting entirely of Cobra DCM and extension modules

rests on one or more tables, as needed. In options 1 through 5, the desk
butts up to either the FSM (options 1, 3, 4) or the TSDM (options 2 and 5)
and the Cobra DCM and extension module rest on the desk.
TP01311011 Rev 05 November 2009 1-3

The PPUDS consists of the following:

 Downfeeds located by the banders in the FSM/TSDM modules to
deliver banded notes to a conveyor system
 Conveyor system located at the front bottom of the FSM/TSDM to
deliver banded notes to the PPU
 The Universal Bundling System (UBS) developed by Marden Edwards
or a 5000 PPU to package multiple sets of banded notes (usually sets
of 5 or 10) into larger bundles
The 4004 contains all the detectors and the control unit, both of which
control the path followed by each note: either to the cull pocket or to the
appropriate output pocket in the 4004 or the 4PM extension module.
The left side of the 4004 has an exit path that needs to align with the input
path on the right side of the adjacent 4PM. Additional 4PMs chain
together to the left in the same way.
The Cobra DCM can also be connected to the Desktop Shredder Module
Figure 1-3 shows the Cobra 4008, consisting of a 4004 with one 4PM
extension module.
Figure 1-3 Cobra 4008- 4PM Extension Module to the left of the DCM
Figure 1-4 shows a Cobra 4004 with an FSM and a TSDM.
Figure 1-4 Cobra 4004 with 6000 Units
A. 4004 With 6000 FSM B. 4004 With 6000 TSDM
1-4 Cobra® Banknote Sorting Machine Service Manual

Upgrades to the Cobra product include the Mark II version, which features
belt layouts to increase flexibility in customer applications and in handling
different note types.
Besides the belt layout, no other differences exist among the Cobra ver-
sions. Refer to 3.12.2 on Page 3-42 for belt layout information.
Section 6.11 on Page 6-21 has information on maintaining extension
modules.
1.1.2 ACDP Separator Recognition Feature
The separator recognition feature enables a Cobra site to process

batches from multiple sources that are merged as a continuous input
stream to enhance maximum machine throughput.
As a part of note preparation, an operator inserts special separator cards
to delimit each batch.
Then, as the operator feeds the prepared note batches into the feeder,
the separator recognition feature recognizes the separator cards and
reads the unique identification barcode.
The control system can then separately track and account each batch.
Thus, the Cobra can now perform Automated Commercial Deposit
Processing (ACDP) functions.
The separator recognition feature consists of two subsystems: a mag-
netic stripe detector and a barcode reader. Each operates independ-
ently of the other, but both are required to provide appropriate signals to
the Unicorn control system.
The separator card has a pattern of stripes printed with magnetic ink to
serve as the recognition feature. A unique barcode printed on the separa-
tor card then identifies each batch. After the magnetic detector recognises
the magnetic pattern, the barcode reader reads the barcode and sends
the identity to the system software.
Separator cards are of two types: header and trailer. The header cards
mark the beginning of a batch whereas the trailer cards identify the end of
the batch. Both cards have printed stripes of magnetic ink, with similar but
distinctly different patterns, on one face of the card.
In addition, header cards have barcodes and numeric text representing
the barcode on the reverse face.
To distinguish header cards from trailer cards, the trailer cards have a
printed yellow area on each end of the reverse face of the card.
Figure 1-5 on Page 1-6 illustrates the front and back of both the header
and trailer cards.
TP01311011 Rev 05 November 2009 1-5

Figure 1-5 Typical Header/ Trailer Separator Cards for ACDP
123456
123456
Q
Barcode Area Q1
2
Header
Separator
Card
123456
123456
Q
Q1 Barcode Area
2
Side A Side B
Note: Not to scale.
Trailer
Separator
Card
Chapter 7 provides further details on the ACDP separator recognition 

feature.
1.1.3 Cobra Feature Summary
The Cobra product consists of the following:

Detector Cull Module  Detector/Cull Module (4004):
 Four output pockets that loose-stack a maximum of 200 notes each
 One cull (or reject pocket) that loose-stacks a maximum of
100 notes
 Overrun box
If not equipped with additional 4PM extension modules, the DCM
module has an overrun box in which to deposit notes following an
output incident.
If equipped with an FSM or TSDM, the last module (FSM/TSDM)
contains an overrun box in which to deposit notes following an out-
put incident.
 Note feeder:
 One friction note feeder with a 1000-note capacity hopper to support
continuous feeding. The feeder can handle note batches that
exceed normal capacity without causing problems or stopping the
system.
 After the operator selects the type of process to run, the feeder
backplate automatically adjusts to the largest note size.
 After the machine starts, the feeder mechanism synchronises with
the output pocket stacker wheel tines.
 User interface
 The machine uses a 21 cm (8.3 inch) flat LCD screen that supports
colour graphics and a wide viewing angle. The LCD screen can be
an optional touch screen.
 The user interface, running under Windows®, shows a colour repre-
sentation of the machine. The display shows the selected note proc-
ess type and denomination type. As the machine runs, the output

pocket graphics show the number of sorted notes, enabling the

operator to monitor the number of notes entering the output pockets.
 Just like a computer keyboard, the operator key pad moves freely.
Therefore, the operator can put it to one side to make space for
other work.
 Transport:
 A system of belts transports notes from the feeder mechanism, past
the detectors, and into the output pockets.
 The machine uses short-edge note feeding.
 The transport mechanism drives both note transport belts, ensuring
that slippage does not occur.
 The transport belts, woven together in a continuous loop, are strong
and robust.
 CAN bus control system
The 6000-based computer system handles the information from the
detectors, keeps track of the notes, and routes the notes to the
appropriate pocket. The computer system also keeps a record for
reporting and accounting.
 Interfaces:
 LAN/WAN (TCP/IP) connection
 Standard RS-232C serial port
 Parallel printer interface
 Batch card separator recognition feature:
 Enables batch processing from multiple sources
 Recognizes special batch separator cards and reads the unique
identification code assigned to each
 Uses a pattern of magnetic stripes rather than hole-pattern recogni-
tion in a document ear as used in the 6000 separator
 Identifies batches through bar code reading (Cobra and 6000)
Four-Pocket Extension  Four-pocket extension module (4PM):
Module
 Each module has four output pockets that loose stack a maximum of
200 notes each.
 The last extension module has the overrun box in which to deposit
notes following an output incident.
Optional 6000 Modules  Optional 6000 output modules (FSM or TSDM):
 Each output pocket can stack loose-fill notes or can have banders
for note bundling. When equipped with banders, the output pockets
can also have downfeeds to deliver the bundled notes to a PPUDS.
 The TSDM, equipped with a shredder, permits note destruction for
heavily soiled or unfit notes.
TP01311011 Rev 05 November 2009 1-7

1.1.4 Machine Relocation
As a desktop banknote sorter, the machine is designed to be carried by

four people. A trolley is recommended for transportation.
However, when lifting the machine to a desk top, use the T bars provided
with the machine. Refer to the Site Planning Manual, TP04511001.
1.1.5 Maintenance
Cobra design allows service engineers to access the main Printed Circuit
Boards (PCBs) from the top of the machine with the cover raised. Such
access allows service engineers to install upgrades without
disassembling the machine.
The service engineer can carry out all routine Cobra maintenance at the
front of the machine, minimising disruption and machine downtime.
Cobra machine design also enables easy access. The side covers use
quick release fasteners and the LCD screen mounts on hinges so that the
operator can move it out of the way to clean the detectors.
The hinged screen mounting also enables a ninety-degree viewing angle
to service engineers when working at one end of the machine.
Another goal achieved in the Cobra design is the reduction in the amount
of note dust generated during sorting. Most note dust is trapped at the
first detector (the thickness detector). Dust collects in the base tray, which
minimises the amount of dust carried through the machine.
For full system resilience, Cobra machines can incorporate a power-fail
backup device. The Uninterruptible Power Supply (UPS) is external to the
machine.
The remainder of this chapter addresses the following:
 GCC personal computer, screen,  Motor controllers
and key pad
 Mother board  Fault-finding guide
 Nodes  Illustrated parts list

System Description 1.2 GCC PC, Screen, and Key Pad
1.2 GCC PC, Screen, and Key Pad
1.2.1 Interconnections
Table 1-2 shows the cable wiring between the LCD and the PC. For
information on the display assembly, Part Number 400-3000-501, refer to
Section 1.2.2 on Page 1-10.
Table 1-2 LCD Screen to PC Interconnections

Description Pin Description
G4 (Green Pixel Data 4) 1 2 G3 (Green Pixel Data 3)
G2 (Green Pixel Data 2) 3 4 G5 (Green Pixel Data 5)
B5 (Blue Pixel Data 5) 5 6 B4 (Blue Pixel Data 4)
B3 (Blue Pixel Data 3) 7 8 B2 (Blue Pixel Data 2)
B1 (Blue Pixel Data 1) 9 10 G1 (Green Pixel Data 1)
G0 (Green Pixel Data 0) 11 12
No Connection (NC) 13 14 B0 (Blue Pixel Data 0)
NC 15 16 NC
Gnd (Ground) 17 18 SCLK (Shift Clock)
Gnd (Ground) 19 20 NC
Gnd (Ground) 21 22 NC
ENAB (Compound Synch) 23 24 CGnd (Chassis Ground)
NC 25 26 NC
NC 27 28 +12v (+12v Supply)
+12v (+12v Supply) 29 30 +12v (+12v Supply)
Vcc * (5v/3v3 Supply) 31 32 Vcc * (5v/3v3 Supply)
R0 (Red Pixel Data 0) 33 34 Gnd (Ground)
NC 35 36 Gnd (Ground)
NC 37 38 NC
R1 (Red Pixel Data 1) 39 40 NC
R2 (Red Pixel Data 2) 41 42 R4 (Red Pixel Data 4)
R3 (Red Pixel Data 3) 43 44 R5 (Red Pixel Data 5)
The keyboard uses a standard keyboard cable between the key pad and
the PC.
TP01311011 Rev 05 November 2009 1-9

1.2 GCC PC, Screen, and Key Pad System Description
1.2.2 Removal and Replacement
1.2.2.1 Screen
Caution! The screen assembly wiring is very delicate and can

easily be damaged. Carry out all work on the screen with the
screen assembly removed from the machine.
Warning! High voltages exist on the inverter board and on the
display itself. Do not dismantle any part of the screen assembly
with the machine powered on.
Use Procedure 1-1 to remove/replace the screen.
Procedure 1-1 Removing/Replacing the Screen

Screen Removal 1. Switch power to the machine off.
2. Lift the front cover of the machine up.
3. Unclip the screen on the right-hand side and swing it forward.
4. Go to the rear of the machine and unplug the screen cable from the
rear of the computer.
5. Go to the front of the machine and pull the screen cable through the
front panel.
6. Unscrew bolts A (see Figure 1-6 on Page 1-10) to remove the
screen assembly from the hinge and lift it away.
7. Do one of the following:
Note: An inverter mounted on the rear of the metalwork behind the black
plastic cover powers the screen.
A. Unscrew Bolts B (see Figure 1-6) and remove the black plastic
cover to gain access to the inverter.
Figure 1-6 Rear of Screen
Screen Replacement B. Reverse Steps 1 – 6 to replace the screen.

System Description 1.2 GCC PC, Screen, and Key Pad
1.2.2.2 Key Pad
The key pad (see Figure 1-7 on Page 1-11) is a free-standing unit that
uses a single cable to connect to the Cobra DCM.
Use Procedure 1-2 to remove/replace the key pad.
Procedure 1-2 Removing/Replacing the Key Pad

1. Switch power to the machine off.
2. Unplug the key pad and remove it from the machine.
3. To replace the key pad, verify that power is off and plug the new key
pad into the machine.
Figure 1-7 Key Pad
1.2.2.3 Computer
The rear of the machine houses the GCC PC computer (see Figure 1-8
on Page 1-12). Use Procedure 1-3 to remove the PC.
Procedure 1-3 Removing the GCC Computer

Removal 1. Switch power to the machine off.
2. After noting their orientations and positions, remove all the 

connectors from the rear of the computer.
3. Remove the power wires from the left side of the PC, noting the
position of each wire to ease replacement.
4. Remove the ‘P’ clips securing the wiring harnesses to the sides of
the PC.
5. Remove the four bolts securing the computer to the framework.
6. Withdraw the computer.

Replacement 7. Reverse Steps 1 – 6 to replace the computer.
Figure 1-8 on Page 1-12 shows the PC (Part Number 0265 0059), which
has a 25-conductor, D-type connector to interface to the display assembly
(Part Number 400 3000 501). The external appearance of the Industrial
PC (Part Number 400 3003 101) introduced to manufacturing in July,
2002, is the same as the one shown, except that the 25-conductor, D-type
display interface is removed. The display interface is through the standard
super VGA connection shown.
TP01311011 Rev 05 November 2009 1-11

1.2 GCC PC, Screen, and Key Pad System Description
Figure 1-8 GCC PC Location
Display Interface Plug for Display

Display Interface Plug for Display
(Part Number 400 3000 501)
(Part Number 400 3003 101)

System Description 1.3 Mother Board
1.3 Mother Board
The mother board provides interconnections for the following:

 CAN bus connections between the nodes and the GCC PC
 Connections from the nodes to the sensors, motor controllers, and
diverters
 Connection between Node B and the detector processor
 Connections among the detector processor, detector interface, and the
detector controller
 Connections between the detector interface and the detectors
 Safety control circuit
 Low-voltage distribution
The mother board location is in the machine rear on the centre shelf.
1.3.1 Mother Board Layout
Figure 1-9 on Page 1-14 and Figure 1-10 on Page 1-15 show the layout
of the PCB. Table 1-3 through Table 1-5 on Page 1-17 show the J
connectors and the pin functions. Table 1-6 on Page 1-18 presents the
fuses and Table 1-7 on Page 1-18 lists the LEDs for the mother board.
Table 1-3 Detector Mother Board Connections
J Pins
Detector ID
Conn 1 2 3 4 5 6 7 8 9 10 11 12 13
1 Thickness – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V
10 H&T – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V
11 Spare – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V
12 Audio/Limp – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V
13 Twin Mag – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V
14 Gross Soil – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V
15 Central Mag – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V
16 UV – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V
17 Metal Thread – 0V 0V 0V 0V – 5V 5V – – 15V – – –15V

Pattern Pattern Pattern
21 Pattern – 0V 0V 0V 0V Ready 5V 5V Signal Trigger 15V – – –15V
TP01311011 Rev 05 November 2009 1-13

1.3 Mother Board System Description
Figure 1-9 Mother Board, Left Hand

Figure 1-10 Mother Board, Right Hand
TP01311011 Rev 05 November 2009 1-15

Table 1-4 Ancillary Mother Board Connections

J Conn Pins
ID
Conn To 1 2 3 4 5 6 7 8 9 10 11 12 13
2 Key Lock – 0V 0V 0V 0V 5v – – 15V – – –15V
Printer/ Prnt/
22 Config
– 0V 0V RxD TxD CTS RTS 5v 5v
Confg
15V – –15V –
Diverter
23 05 DV D Node B Node B Node B Node B 5V 0V 42V 0V – – – – –
Diverter
24 02
DV A Node B Node B Node B Node B 5V 0V 42V 0V – – – – –
Diverter
28 03
DV E Node B Node B Node B Node B 5V 0V 42V 0V – – – – –
Diverter
29 04 DV B Node B Node B Node B Node B 5V 0V 42V 0V – – – – –
Diverter
30 06
– Node B Node B Node B Node B 5V 0V 42V 0V – – – – –
Diverter
31 01
DV F Node B Node B Node B Node B 5V 0V 42V 0V – – – – –
Pockets QI, C,
34 3, 4 Full D 5V F15 Node C 5V F15 Node C 5V F15 Node C – – – – – – –
Barcode Serial Chas-

35 Reader 1
15V RxC TxC 5V F15 0V 0V RTSC CTSC –15V
sis
– – –
Pockets
QI, A,
36 1, 2, Cull B, E 5V F15 Node B 5V F15 Node B 5V F15 Node B – – – – – – –
Full
Feeder
39 Motor
MTB Node C Node C Node C Node C Node C Node C Node C Node C 5V F15 0V nu – –
Trans-
40 port MTA Node B Node B Node B Node B Node B Node B Node B Node B 5V F15 0V nu nu –
Motor
Back-
41 plate MTC Node C Node C Node C Node C – – – – – – – – –
Motor
S Motor
43 1 NU Node B Node B Node B Node B – – – – – – – – –
Track
58 Clock – Clk @2.5v 5V F15 0V See further notes under TP section.
Trans-
port
65 Motor MCA 0V 42v 42v 0V – – – – – – – – –
Control
Feeder
66 Motor MCB 0V 42v 42v 0V – – – – – – – – –
Control
48V 24V 24V
68/100 Fans – UnS UnS UnS 0V – – – – – – – – –
Lo Rem
69 Mag
– – 42v – 0V – – – – – – – – –
24V 24V
73 5000 Soil – 0V
UnS UnS
0V – – – – – – – – –
79 H/Lamp – – 12V – 0V – – – – – – – – –
Power
102 Fail – – 0V – 0V – – 0V – – 0V – 0V –
GCC
Serial
103 Shut- 2 15V RxB TxB 5V F15 0V 0V RTSB CTSB –15V Earth – – –
down
200 Speaker – LS1+ LS1– LS2+ LS2– – – – – – – – – –
Serial
201 NU 3 15V RxB TxB 5V F15 0V 0V RTSB CTSB –15V Earth – – –

Table 1-5 Track Sensor Mother Board Connections

J Sensor Pins
Conn Type Description ID 1 2 3 4 5 6 7 8
New Note
26 Sensor TSB Node B (9b) 0V Node B (10a) 12V Node B (9c) 0V Node B (10b) 12V
Update
32 Sensor 2 TSC Node B (12a) 0V Node B (12c) 12V Node B (12b) 0V Node B (13a) 12V
Update
33 Sensor 3 TSJ Node B (10c) 0V Node B (11b) 12V Node B (11a) 0V Node B (11c) 12V
Stacker Count
37 Sensor 4 TSE Node B (16a) 0V Node B (16c) 12V Node B (16b) 0V Node B (17a) 12V
Stacker Count
38 Sensor 2 TSD Node B (13b) 0V Node B (14a) 12V Node B (13c) 0V Node B (14b) 12V
Track
Stacker Count
42 Sensor 3 TSG Node C (12a) 0V Node C (12c) 12V Node C (12b) 0V Node C (13a) 12V
Update
47 Sensor 1 TSK Node C (9b) 0V Node C (10a) 12V Node C (9c) 0V Node C (10b) 12V
Stacker Count
48 Sensor 5 TSF Node C (10c) 0V Node C (11b) 12V Node C (11a) 0V Node C (11c) 12V
Cull Stacker
53 Count Sensor TSH Node C (13b) 0V Node C (14a) 12V Node C (13c) 0V Node C (14b) 12V
Note Fed
54 Sensor TSA Node C (16a) 0V Node C (16c) 12V Node C (16b) 0V Node C (17a) 12V
Cull Sensor
44 Note present LOF Node B (17b) 0V Node B (18a) 12V Node B (17c) 0V Node B (18b) 12V
Stacker 2 
45 Flyer/Present LOB+LOG Node B (18c) 0V Node B (19b) 12V Node B (19a) 0V Node B (19c) 12V
Stacker 4 
46 Flyer/Present LOC+LOH Node B (20a) 0V Node B (20c) 12V Node B (20b) 0V Node B (21a) 12V
Pocket
Feeder Hopper
55 Notes Present LOA Node C (17b) 0V Node C (18a) 12V Node C (17c) 0V Node C (18b) 12V
Stacker 5 
56 Flyer/Present LOD+LOI Node C (18c) 0V Node C (19b) 12V Node C (19a) 0V Node C (19c) 12V
Stacker 3 
57 Flyer/Present LOE+LOJ Node C (20a) 0V Node C (20c) 12V Node C (20b) 0V Node C (21a) 12V
TP01311011 Rev 05 November 2009 1-17

Table 1-6 Mother Board Fuses

Fuse From To Test Point
F1 42V Switched Diverter +42V – –

F2 42V Switched J66 (2,3) – J66 (2,3)
F3 48V Unswitched J67 48V Fused TP8
F4 42V Switched J69 (2) – J69 (2)
F5 24V Unswitched J73 (2,3) – J73 (2,3)
F6 12V J79 (2) – J79 (2)
F7 5V Detector 1 – TP19
F8 5V Diverter – TP20
F9 12V Vision – TP21
F10 –12V Vision – TP22
F11 5V Vision – TP23
F12 12V GCC – TP24
F13 –12V GCC – TP25
F14 5V GCC – TP26
F15 5V – – TP27
F16 5V D Cont Extension Port – TP6
– Transclock (U5) Node C (30a) Node B (30a) TP7
Table 1-7 Mother Board LEDs

LED Voltage or From
15 Covers Closed
16 +48V Unswitched
17 +15V
18 +12V
19 +24V
20 –15V
21 –12V
22 +42V Switched
23 +5V
26 Emergency Stop OK
27 Override
28 SCR Enable
30 J102 (9, 11) Power Fail PSU

1.3.2 Safety Control Logic
The Cobra DCM contains the safety control logic on the mother board.
Figure 1-11 shows the circuit and links for the Cobra 4004. The following
are key features:
 Connectors J75, J81, J78, and J203 are interconnections to other
modules.
 J82 connects to the cover interlock switch.
 J101 connects to the 48V PSU and inhibits the output.
 J87 is not used.
Figure 1-11 Safety Control Logic
Section 4.1.2 on Page 4-3 provides more detailed information on the

safety circuits.
TP01311011 Rev 05 November 2009 1-19

1.4 Nodes System Description
1.4 Nodes
The Cobra 4004 has three nodes on the CAN bus:

 Node 1 (A) – the Operator node (GCC PC)
 Nodes 2 (B) and 3 (C) – node boards that interface the Cobra 4004
subsystems to the PC (Figure 1-12).
Node boards 2 and 3 plug into the mother board (see Figure 1-12). Each
node board interface to the CAN serial bus provides the following:
 Six track-/pocket-sensor, low-current interfaces (node sensors A – F)
 Two track-/pocket-sensor, high-/low-current interfaces (node sensors
G – H)
 Three diverter interfaces (div/opto A – C)
 Three lamp-driver interfaces (lamp driver A – C)
 One DC motor drive interface
 One stepper motor interface
 One direct I/O port
 Two serial ports (serial comms A, B)
Figure 1-12 Node Board Locations
Node 3 (NDC) Detector Interface

Node 2 (NDB) Detector Processor
Figure 1-13 on Page 1-21 shows the location of the machine sensors
and diverters.

System Description 1.4 Nodes
Figure 1-13 Sensor, Diverter, and Lamp Locations
DV F
(if equipped) DV B TS E DV A TS D QI A TS C
QI B
LO B/G TS H
LO C/H
DV E
TS G
LO A
DV D
TS F
QI C
LO F
LO E/J
LO D/I
QI D
TS B TS I TS K
TS A
(At Rear of Machine on Stripper Wheel Shaft)
1.4.1 Node LEDs
Table 1-8 lists the various node LED indications. The software loaded to
the nodes depends on the node location (Node 2 or 3) as shown in
Table 1-9 on Page 1-22. A node change requires a download for correct
operation. Also, swapping nodes with each other or replacing one with a
spare requires a download.
Table 1-8 LED Indications

LED OK LED Updates LED Assignment Description
On During Process Selection LO Long-Range Opto Sensor
On During Process Selection TS Track Sensor
Toggle Continuous TRK CLK/CAN BUS (Green) –
Off Continuous TRK CLK/CAN BUS (Red) –
Off Continuous HALT Detector Processor Running
TP01311011 Rev 05 November 2009 1-21

Table 1-9 Node LEDs

LED Node 2 (NDB) Node 3 (NDC)
Green LOC LOH (NS8) LOE LOJ (NS16)
Green LOB LOG (NS7) LOD LOI (NS15)
Green LOF (NS6) LOA (NS14)
Green TSE (NS5) TSA (NSA13)
Green TSD (NS4) TSH (NS12)
Green TSC (NS3) TSG (NS11)
Green TSJ (NS2) TSF (NS10)
Green TSB (NS1) TSK (NS9)
Status Light – –
Always 0 – –
Node ID 2 3
Red TRK CLK TRK CLK

Green TRK CLK TRK CLK
Red Can Bus Can Bus
Green Can Bus Can Bus
Green SW2 SW2

Green SW1 SW1
Red HALT HALT
Green 5V 5V
Green SYNCH SYNCH

System Description 1.4 Nodes
1.4.2 Software Download
By configuration, Node B monitors CAN bus activity and terminates the

Cobra control system if it detects an error. The node configuration occurs
when the software downloads to the node; thus, a forced software
download is necessary when replacing Node B.
Use Procedure 1-4 to force a software download.
Procedure 1-4 Forcing a Software Download to a Node

1. Logout and close the GCC.
2. Launch the DSU (Database Setup Utility) from the Windows Start
menu.
3. Select View\Control System Globals from the menu bar.
4. Select the node and change the Force Download field from False
to True.
5. Close the Database Setup Utility.
6. Launch Cal Setup from the Windows Start menu.
TP01311011 Rev 05 November 2009 1-23

Use Procedure 1-5 to remove and replace the node boards.
Procedure 1-5 Removing/Replacing the Node Boards

Removal 1. Switch off mains power to the machine.
2. Open the front cover.
3. Remove the cover protecting the printed circuit boards from the top
of the framework.
4. Remove the node boards.
Replacement 5. Reverse Steps 1 through 4 to replace the node boards.

System Description 1.5 Motor Controllers
1.5 Motor Controllers
Two motor controllers are located at the rear of the Cobra machine: one
controls the feeder motor and the other controls the main transport.
Each motor controller attaches to a node printed circuit board that
provides the necessary control for the transport system.
Because Ashurst Logistic Electronics makes the unit, it is also known as
the ALE controller. Each ALE motor controller can control three motor
applications:
 Stacker wheel drive (in 6000 module only, if required)
 Module transport drive
 Feeder drive
All motors are brushless DC motors to provide accurate control.
The motor controller receives a frequency signal from the appropriate
node to control motor speed: the faster the frequency, the faster the
speed.
1.5.1 Motor Controller Inputs
Disable: Disables the motor and can reset controller in conjunction with
speed
Reset: Resets controller and disables motor.
Motors Disable: Ensures motor is turned off.
Power In: 42V and 5V.
Speed: The frequency signal to control speed.
Direction: clockwise or counter-clockwise
Feedback: An encoder to feedback speed and position information
Comms in: Download information to configure the controller.
1.5.2 Motor Controller Outputs
Drive OK: Status of the controller sent to the node.

Comms Out: Passes on data to the next controller.
TP01311011 Rev 05 November 2009 1-25

1.5 Motor Controllers System Description
1.5.3 Status Indicators
Four LED indicators are visible on the motor controller (see Table 1-10).
Table 1-10 Motor Controller Status LEDs

LED Functions
3 Enabled Motor controller enabled

3 O O 4 4 5V 5V present
1 Remote OK The down-stream motor controller is OK
1 O O 2 2 Local OK The motor controller is OK
Motor controllers on the Cobra machine do not connect in a daisy chain.

Therefore, the Remote OK indicator has no meaning. During normal
operation, all LEDs except the Remote OK indicator are lit.
1.5.4 Motor Controller Programming
Motor controllers require configuration to define whether the controlled

motor drives function for a transport/stacker wheel or the feeder.
The control system sends configuration parameters to the controller
through the controller serial communications port.
A software application called MTERM111 downloads the configuration
parameters to the controller through a special adapter required to convert
the PC communications port from and RS-232 type to an RS-422 type.
The software application allows configuration using buttons to allow one-
press programming, eliminating the need to remember or code any
values and control characters.
However, the application can still give detailed communications control to
the controller whenever required. The converter uses a 9-conductor, D-
type connector to connect to the PC.
1.5.4.1 Parts Required
Table 1-11 lists the parts required to program from an external PC.
Table 1-11 Parts to Program a Controller From an External PC

Part Number Description Comments
Programming cable
550 6013 202 –
form
The use of other programming cable forms (for example,
Converter power incorporating the Greenwich Instruments GW232 converter)
400 6006 501
cable form is possible, but the user is responsible for verifying that
power and wiring are correct.
Controller shorting
550 6003 101 The link is already installed in the controller on the machine.
link

Table 1-11 Parts to Program a Controller From an External PC (Continued)

N/A Mterm111.exe Programming application installed on a PC.
File containing the correct parameter data sets installed on
N/A Mterm111.ini
the PC.
Table 1-12 lists additional items required to copy the application to the
Cobra GCC PC for local operation.
Table 1-12 Additional Parts to Program a Controller From the GCC PC

Description Comments
QWERTY keyboard The Cobra key pad does not have keys for all the required characters.
Mouse To click on program buttons in the application.
Floppy drive Only used whenever the program requires installation.
1.5.4.2 Program Hardware Installation
Use Procedure 1-6 to install the programming hardware.
Procedure 1-6 Installing the Programming Hardware

1. Remove power to the machine (power off):
2. Wire the converter power cable form +ve wire (red on

400 6006 501) to Pin 8 (VDC) on the converter.
3. Wire the converter power cable form –ve wire (black on
400 6006 501) to Pin 7 (GND) on the converter.
4. On the Cobra, insert the converter power cable form connector into
any note sensor port (NS1 – NS16) on the Cobra mother board. If all
are in use, temporarily unplug one.
5. Insert the 9-conductor, D-type connector (part of the converter) on
the programming cable form into COM1 or COM2 on the PC.
If the PC is the Cobra operator PC, COM1 is on the rear panel
above the keyboard connector and COM2 is on the side next to the
power terminals. If the machine system communications ports are in
use, temporarily remove the connector in use.
Procedure 1-6 continued on the next page...

Procedure 1-6 continued from the previous page:
6. Insert the 26-conductor HDD-type connector on the other end of the
programming cable form into the controller 26-conductor, HDD-type
plug.
7. Verify that the controller shorting link (blanking plug) is inserted into
the controller 26-conductor, HDD-type socket.
TP01311011 Rev 05 November 2009 1-27

1.5.4.3 Motor Controller Programming
Use Procedure 1-7 to program the motor controllers.
Procedure 1-7 Programming the Motor Controllers

1. After installing the hardware, power the machine up.
2. Start the GCC with the cover locks not operated (that is, with covers
closed) to activate the +42V supply to the controllers.
3. Start the Mterm111.exe application.
The MotBas Terminal Program Version 1.11 (De La Rue) start-up
screen appears.
If the application does not start, refer to Procedure 1-8 on
Page 1-29.
4. After the application screen appears, click Setup Port in the 
program pull-down menus and verify the communication port
settings:
Baud rate 9,600 bits/sec

Data bits 8
Stop bits 1
Echo Off
Parity Even
Select COM1 or COM2
Comms port
(the port into which the converter plugs)
Flow control None
DTR On
RTS On
5. Initialise the controller and verify that it responds by typing {A}

(enter all the characters, including the braces).
The screen displays {B}.
6. Press one of the marked buttons for the desired controller type to
program.
The controller responds by echoing the characters sent and the pro-
gram displays them.
7. Look at the first three characters returned to verify successful
programming.
Each must read {B}.
The remainder of the list of returned characters represents the pro-
gramming instructions.

1.5.4.4 Program Software Installation
The Cobra First-Line Maintenance Service training course supplies the

software application.
Use Procedure 1-8 to install the application on an external PC or the
Cobra GCC PC.
Procedure 1-8 Installing the Software Program

1. Create a folder called MTERM on the c:\ drive and copy the
Mterm111.exe file into it.
2. Copy the following files into the c:\windows\system folder (or
c:\winnt\system if using Windows NT):
 Filedlg.vbx  Pdqcomm2.vbx  Vbrun300.dll
3. Copy the file labeled Mterm111.ini into the c:\windows folder (or
c:\winnt if using Windows NT).
4. If required, create a short-cut to Mterm111.exe.
1.5.4.5 Parameter Values for Cobra Feeder and Transport
With the correct version of the Mterm111.ini file, a range of programmed

buttons are available on screen.
When you press one of these buttons, the system sends all the motor
controller parameters to the controller. Table 1-13 lists the values sent.
Table 1-13 Motor Controller Parameters

Parameter Short Name Feeder Transport
Controller address – A A
Proportional gain KP 800 5000
Velocity gain KV 4000 10000
Feed forward gain KF 4000 0
Integral gain KI 0 0
Gearing/direction GR 4096 1474
Motor type MT 0 0
Feedback type FT 001200 000600
PWM type PT 0 0
Maximum current MI 0 0
Demand acceleration limit DA 18000 1024
Feedback acceleration limit FA 18000 1024
Output shutdown type OT 0 1
Note: If the Mterm111.ini file is not available, you can send individual
parameters to the controller. You must enter the commands literally, as
seen, observing correct bracket type and case.
Use Procedure 1-9 on Page 1-30 to manually send parameters.
TP01311011 Rev 05 November 2009 1-29

Procedure 1-9 Manually Sending Motor Controller Parameters

1. Unless programming has already been performed, you must first
enter {A} to initialise the controller for communications.
If “!”appears, the controller has a communications error.
While observing the following warning, remove, then reapply power
to the controller to recover.
Warning! To prevent possible damage to controller electronics, do
not remove the controller power cable while the Cobra is powered on.
2. Enter the general command:
2.1 Type axx, where a = controller address (usually set to “a“) and
xx = identifier code for the desired parameter.(see Table 1-13)
2.2 Follow the identifier code with the data to set a parameter. For
example, the proportional gain of the feeder motor control key
is aKP+5000. Enter all characters exactly as shown.
3. Read the data from the controller to check each setting:
For example, enter akp, then enter ?.
Each time you press ?, the next character in the parameter displays
until the full reply is sent.
1.5.5 Motor Controller Replacement
The standard Cobra sorter uses two motor controllers: one drives the
transport motor while the other drives the feeder motor. The controllers
are located under the central partition in the rear of the machine. Refer to
Section 3.7.3 on Page 3-31 for the main transport electrical
interconnections and part numbers.
Note: The internal fuse fitted to the controller is a 12.5-amp slow-blow
5 x 20 mm fuse (Part Number 0257 0093) in the Cobra application.
1.5.6 Fault-Finding
When running up the relevant motor or running the motor in Cobra

diagnostics control, viewing the status of the motor controller on a set of
indicators located within the controller housing is possible. Table 1-14
shows the LED indication for normal running.
Table 1-14 Motor Controller Diagnostic LEDs

LED Illuminated Status Comment
1 When “On”: Temperature above 90 degrees C. Verify that
O Off
Red Temperature limit reached motors and belts are not too tight.
2 Too much current.Check that the motors and
O Off When “On”: Overloadn belts are not too tight.
Red
3
O On Voltage OK Correct voltage (20 – 60V)
Green
4
O On Healthy Software running
Green
5
O Off Saturation Off when running
Green

System Description 1.6 Fault-Finding Guide
1.6 Fault-Finding Guide
The following presents some common problems and provides steps for a
possible solution to each problem.
Windows NT or XP Does Not Possible Solutions:
Start
1. Check that mains power is turned on.
2. Check that the machine single-phase supply is turned on.
3. Check the input power at the power supply or at TP8.
GCC Application Does not Possible Solutions:
Start
1. Manually reset the nodes.
2. Try logging out of/into Windows NT if MSDE service has started.
Cannot Logout of the GCC Possible Solutions:
Application
1. If performing a manual batch, verify that all batches are complete
and that the feeder is empty. Press the Batch key.
2. Clear any faults logged in the Incident page.
3. Verify that the transport has fully run down.

Note: As a last resort whenever these procedures fail, send a Clocksync
message from the CAN Spy application to terminate the GCC application.
Do the following from within the CAN Spy application:
3.1 Select the Options tab.
3.2 Select the Send option.
3.3 Tab to the Actual Message to send box.
3.4 Delete anything currently in this box and type 768.
3.5 Tab to press Send and press ENTER.
3.6 Minimise the application.
The GCC application closes with a system error.
4. Proceed with the recovery action that appears on screen.
After you complete the recovery, you should be able to log out of the
GCC application.
TP01311011 Rev 05 November 2009 1-31

1.7 Illustrated Parts List System Description
1.7 Illustrated Parts List
Table 1-15 provides a key to figures contained within this chapter.
Table 1-15 Key to Figures in this Chapter

Item Description Part No Qty
Figure 1-6 on Page 1-10 Display Assembly 400 3003 101 (Note) 1
Figure 1-7 on Page 1-11 Key pad Assy 400 2011 401 1
Figure 1-8 on Page 1-12 PC, Industrial, 5V, ±12V 0265 0687 (Note) 1
Figure 1-9 on Page 1-14;
Figure 1-10 on Page 1-15
PCB Back plane (Mother board) 400 9500 204 1
Figure 1-12 on Page 1-20 PCB Acorn Node Board 400 9500 509 2
Figure 1-12 on Page 1-20 PCBP MK3 Proc 370 9534 706 1
Figure 1-12 on Page 1-20 PCBP Enhanced Detector I/F 370 9530 702 1
Figure 1-12 on Page 1-20 Kit-SL Corr PCB (if pattern equipped) 370 4015 103 1
Note: An alternative display and industrial PC was introduced to 

manufacturing during July and August 2002.
You can recognise older-style components by the 25-conductor, D-type
connector linking them together (see Figure 1-8 on Page 1-12).
The new display assembly is compatible with the older PC, but the new
PC is not compatible with the older display assembly. The old part
numbers are as follows:
 400 3000 501 Display assembly

 0265 0059 PC, industrial
 500 3011 603 Detector Controller Printed Circuit Board (PCB)
 400 9534 707 MK4 Detector Processor PCB Kit
Note 1: The quantities of detector controller PCBs is dependent upon

the number of detectors.
Note 2: Can Bus Terminator - 550-6006-002

System Description 1.7 Illustrated Parts List
1.7.1 Other Useful Parts and Numbers
Table 1-16 provides a list to other useful parts and numbers.
Table 1-16 Other Useful Parts and Numbers

Part Number Description
3106003302 3700 Data Capture Cable
02410548 Gas Struts
01004778 DLR Test Notes
3214103201 Nudger Inserts Feeder
02280130 O-Rings (O-Ring DD50.40IDx3.35) Feeder
02280710 CIS Drive Belt MKII
02280311 Thickness Drive belt MKII new
02620732 New XP PC with USB
02530131 Relay 220/240v 10A (Omron Type) LY2
02530134 Relay 110/120v 10A (Omron Type) LY2
02520397 Roller Ball Switch Main Inspection Cover
02310522 Filters Dust (Fans)
4002010305 DLR Cover main Inspection Logo
4039000701 Label Set Cobra
TP01311011 Rev 05 November 2009 1-33

1.7 Illustrated Parts List System Description
NOTES:

Chapter 2
Friction Feeder
Topic Page Number
2.1 - Overview 2-2
2.2 - Settings and Adjustments 2-2
2.3 - Removal and Replacement 2-10
2.5 - Routine Maintenance 2-14

2.1 Overview Friction Feeder
2.1 Overview
The feeder feeds notes singly from the bottom of the stack in the feed
hopper to the transport belt system.
The system consists of a:
 Separator wheel
 Nudgers
 Stripper wheel
Sensors indicate when a note has entered the feeder and when the feed
hopper is empty. When a sensor detects the presence of notes in the
hopper, the feeder mechanism and the transport system starts.
The nudgers and O-ring wheel together move the lowest notes to the
peeler wheel and contra roller, which separate off a single note and feed it
to the transport system.
The feeder back plate automatically adjusts for the size of the
denomination when the denomination is chosen during process/
denomination setup.
The module can also feed and recognize separators to indicate batches,
as required by the operators.
2.2 Settings and Adjustments
2.2.1 Initial Checks
Before proceeding with the setting and adjustment routines, carry out the
maintenance routines detailed in “Routine Maintenance” on Page 2-14.
The following routines establish a working feeder that operates at its
optimum performance.
Further minor adjustments can be required to compensate for differences
in world currency conditions.
This section addresses the following settings and adjustments:
 Feedplate
 Stripper wheel, O-ring, and nudger timing
 Note feed sensor vane timing
 Feeder motor drive belt tension
 Contra roller
 Note pick belt tension
 Note feed ramp
 Outer note guide
 Electrical

Friction Feeder 2.2 Settings and Adjustments
2.2.2 Feed Plate
Use Procedure 2-1 to set the feed plate.
Procedure 2-1 Setting the Feed Plate

1. Remove the adjustable feeder backplate (Figure 13, item 43).
2. Loosen the three securing screws shown in Figure 2-1.
Figure 2-1 Feed Plate Position
3. Move the feed plate to the position indicated in Figure 2-1, which
shows the position of the plate relative to the nudger wheels.
Note: Make certain that the top of the feed tray is level with the top of the
initial drive belt (see Figure 2-13 on Page 2-17, item 18).
4. Tighten the securing screws.
TP01311011 Rev 05 November 2009 2-3

2.2 Settings and Adjustments Friction Feeder
2.2.3 Stripper Wheel, O-Ring, and Nudger Timing
The following procedures assume that the toothed belts and pulleys are
assembled to the note feeder shafts such that the three nudger rollers,
the stripper wheel, and the O-rings can turn simultaneously.
Procedure sets the timing positions of the stripper wheel and the two
trailing nudgers relative to the O-ring nudger, which is held at a home
position during the setting of each of the other wheels. Figure 2-2 shows
the wheel positions wheels.
Figure 2-2 O-Ring and Nudger Wheel Timing
Procedure 2-2 Setting Up the Stripper Wheel, O-Ring, and Nudger Timing
Setting the O-Ring Nudger 1. Turn the shaft of the O-ring (leading) nudger counter-clockwise such
Shaft to Datum (Home) that the O-rings are just flush with the outside diameter of the O-ring
Position nudger.
Timing Position Check 2. Verify that with the O-ring nudger at its datum or home position, the
leading edge of the stripper wheel insert is about to enter the gap
between the stripper wheel and the separation (contra) wheel.
Adjustment 3. Do the following if adjustment is necessary:
A. Remove the pick-point sensing disc (on the rear of the stripper
wheel shaft at the rear of the feeder) by removing the two 3-mm
hex bolts. To remove the disc, also remove the Hall-effect sensor
at the same time. Two 3-mm screws and a nut plate hold the 
sensor to the bracket.
B. Hold the O-ring nudger shaft in its datum/home position using a 
13-mm wrench on the flats near the rear of the shaft assembly.
Hold the shaft in this position for Steps C through E.

C. Loosen the transtorque nut on the rear of the stripper wheel shaft
with a 16-mm wrench.
D. Rotate the stripper wheel so that the leading edge of the stripper
wheel insert just enters the gap between the stripper wheel and
the separation (contra) wheel.
E. Tighten the transtorque nut.
4. Repeat Steps 1 and 2 to check the position of the stripper wheel 

timing relative to the O-ring nudger shaft and Step 3 to make minor
adjustments as necessary.
Centre Nudger Shaft Timing 5. Perform Step 1 to set the O-ring nudger to its datum position. Then
Check set the leading edge of the nudger insert to a point that is 19 mm
from the right-hand edge of the feed tray cutout (see Figure 2-3).
Figure 2-3 Nudger Timin
14 mm
19 mm

A. Hold the O-ring nudger shaft in its datum position using a 13-mm
wrench on the flats near the rear of the shaft assembly. Hold the
shaft in this position for Steps B through D.
B. Loosen the transtorque nut on the rear of the centre nudger shaft
C. Rotate the nudger wheel so that the leading edge of the insert is
set to a point that is 19 mm from the right-hand edge of the feed
tray cutout.
D. Tighten the transtorque nut.
7. Repeat Step 5 to check the position of the centre nudger wheel 

Trailing Nudger Shaft Timing 8. Perform Step 1 to set the O-ring nudger to its datum position. Then
Check set the leading edge of the nudger insert to a point that is 14 mm
from the right-hand edge of the feed tray cutout (see Figure 2-3 on
Page 2-5).
TP01311011 Rev 05 November 2009 2-5

A. Hold the O-ring nudger shaft in its datum position using a 13-mm
wrench on the flats near the rear of the shaft assembly. Hold the
shaft in this position for Steps B through D.
B. Loosen the transtorque nut on the rear of the trailing nudger shaft
C. Rotate the nudger wheel so that the leading edge of the insert is
set to a point that is 14 mm from the right-hand edge of the feed
tray cutout.
D. Tighten the transtorque nut.
10. Repeat Step 8 to check the position of the trailing nudger wheel 
Note: These settings are satisfactory for a majority of currencies and 
conditions. However, if some hesitancy in feeding distressed notes occurs
while test notes and other currency notes feed satisfactorily and all other
settings are correct, retarding the stripper wheel by one tooth with respect
to the nudger rollers (that is, rotate the stripper wheel clockwise by one
tooth of the timing pulley) is permissible, but only as a last resort.
2.2.4 Note Feed Sensor Vane Timing
Verify that the feeder is at its datum point: turn the shaft of the O-ring
(leading) nudger counter-clockwise such that the O-rings are just flush
with the outside diameter of the O-ring nudger. Then verify that the timing
vane position is as shown in Figure 2-4.
Figure 2-4 Timing Vane

2.2.5 Feeder Motor Drive Belt Tension
Use Procedure 2-3 to set the feeder motor drive belt tension.
Procedure 2-3 Setting the Feeder Motor Drive Belt Tension

1. Position the motor and drive belt in the general position shown in
Figure 2-5. Attach with the bolts, but do not tighten them.
Figure 2-5 Feeder Motor
Feeder Motor
2. Rotate the motor housing assembly to remove any belt slack. Turn
the feeder mechanism while applying tension to the belt to ensure
that the belt teeth engage the pulley grooves.
Note: Be careful to not put the belt under tension in the next step.
3. Tighten the motor securing bolts to a recommended torque of 1 Nm
after just removing the belt slack.
2.2.6 Contra Roller
Use Procedure 2-4 to set the contra roller gap.
Procedure 2-4 Setting the Contra Roller Gap

1. Use a screwdriver to push the gap-adjusting screw against its
spring. Turn the screw counter-clockwise to open the gap between
the contra roller and the stripper wheel (see Figure 2-6 on
Page 2-8) to maximum gap.
2. Loosen the two bolts securing the contra roller bearing housing to
the back plate. The hole in the contra roller provides access to the
bolts.
3. Place a 0.15-mm feeler gauge between the contra roller and the
stripper wheel and adjust the gap.
4. Tighten the bolts.
Note: In the next step, place a 0.1-mm feeler gauge between the contra
roller and the stripper wheel and adjust the gap so that the gauge can just
be moved in a direction perpendicular to a line joining the centre of the two
wheels.
TP01311011 Rev 05 November 2009 2-7

5. Use a screwdriver to push the gap-adjusting screw against its

spring. Adjust the gap between the contra roller and the stripper
wheel to 0.1 mm.
If feeding is slow and erratic, the gap is possibly be too small. Adjust
the spring-loaded gap-adjusting screw until the gap is satisfactory.
Figure 2-6 Contra Roller and Adjustment

2.2.7 Note Pick Belt Tension
Use Procedure 2-5 to set the note pick belt tension.
Procedure 2-5 Setting the Note Pick Belt Tension

1. Loosen the bolt that secures the tension wheel support standoff.
2. Use a wrench to rotate the standoff until the belt slack is just taken
up. Do not tension the belt.
3. Re-tighten the bolt.
2.2.8 Note Feed Ramp
To set the note feed ramp position, loosen the thumbscrew and adjust the
ramp position to give optimum feed performance.
2.2.9 Outer Note Guide
To set the outer note guide position, position the note guide to suit the
width of notes being processed.
2.2.10 Electrical
The Cobra 4004 feeder requires no electrical setup. However, diagnostic

routines exist to check the feeder operation. Refer to the Graphic Control
Consol Diagnostics Guide (440-0163-001) for more information.
TP01311011 Rev 05 November 2009 2-9

2.3 Removal and Replacement Friction Feeder
2.3 Removal and Replacement
2.3.1 Stripper Wheel Removal and Replacement
Warning! Metal objects, such as staples, can easily damage

the stripper.
With practice, you can replace the stripper wheel reasonably quickly.
Use Procedure 2-6 to remove the stripper wheel.
Procedure 2-6 Removing and Replacing the Stripper Wheel

Removal 1. Release the screws shown in Figure 2-7 to remove the front feeder
plate. attention to the belts when removing the feeder plate.
Figure 2-7 Front Feeder Plate
Screw
Feeder Plate
Screws
2. Remove the belts shown in Figure 2-8 and Figure 2-9 on

Page 2-11.
Figure 2-8 View Below Feeder

Friction Feeder 2.3 Removal and Replacement
Figure 2-9 Feeder Belts
3. Remove the M3 screw and special washer retaining the outer pulley
on the O-ring nudger shaft and withdraw the pulley.
4. Remove the M3 screw retaining the stripper wheel and withdraw the
pulley.
Replacement 5. Reverse the above procedure, taking care to orient the outer pulley
on the O-ring nudger shaft in the same sense as the inner pulley,
and to orient the stripper wheel correctly on the shaft. The stripper
wheel and shaft design determines that you can assemble the wheel
correctly or 180° out of phase. Figure 2-10 shows the correct
orientation.
Figure 2-10 Stripper Wheel Mechanism
TP01311011 Rev 05 November 2009 2-11

2.3 Removal and Replacement Friction Feeder
6. Verify central alignment of the stripper wheel with the feed plate, as
shown in Figure 2-11. If the alignment is incorrect, check the feed
plate or the stripper wheel as required.
Figure 2-11 Feed Plate and Stripper Wheel
2.3.2 Note Entry Guide
Use Procedure 2-7 to replace the note guide.
Procedure 2-7 Removing and Replacing the Note Guide

1. Remove the two securing nuts.
2. Lift off the shim assembly and extract the Melinex guide.
3. To replace the note guide shim, fit a new Melinex guide and re-
assemble to the machine, reversing the above procedure.
2.3.3 Contra Roller Removal
Use Procedure 2-8 to remove the contra roller.
Procedure 2-8 Removing the Contra Roller

1. Using a screwdriver, push the gap-adjusting screw against its spring
and open the gap between the contra roller and the stripper wheel to
the maximum (see Figure 2-6 on Page 2-8).
2. Loosen the two bolts that secure the bearing housing to the back
plate and move the contra wheel away from the stripper wheel. The
hole in the contra roller gives access to the bolts.
3. Unscrew the grub screws that secure the contra roller to the shaft
and remove the contra roller.

Friction Feeder 2.3 Removal and Replacement
2.3.4 Contra Roller Replacement
Procedure 2-9 Replacing the Contra Roller

1. Affix the contra roller to the shaft.
2. Move the bearing housing such that a gap of approximately 0.5 mm

is between the contra roller and the stripper wheel surface.
3. Lightly tighten the bearing housing bolts.
4. Move the contra roller so that it aligns symmetrically with the groove
in the stripper wheel pick surface (see Figure 2-12).
Figure 2-12 Contra Roller Alignment
Contra Roller
Stripper Wheel
5. Secure the contra roller to the shaft by tightening the grub screws to
a recommended torque of 0.25 Nm.
6. Use Procedure 2-4 on Page 2-7 to set the contra roller gap.
TP01311011 Rev 05 November 2009 2-13

2.4 Fault-Finding Guide Friction Feeder
Use Feeder diagnostics to test the feeder module and to find a fault in the
feeder. For more detailed information, refer to the Graphic Control Consol
Diagnostics Guide (440-0163-00X).
Table 2-1 provides a check list to help in isolating faults.
Table 2-1 Fault Isolation Guide

Stream Poor Damaged High
Possible Correction
Feeds Feeding Notes Cull Rate
    Incorrect contra roller/stripper wheel gap

–    Feeder backplate not in correct position
–  – – Incorrectly adjusted/damaged Melinex guide
–  –  Incorrect timing of stripper wheel and nudgers
–  – – Incorrect pick point sensor/stripper wheel orientation
  – – Worn separator (contra)/nudger wheels
–  – – Dirty/defective note feed sensor
–  – – Pick point sensor defective
2.5 Routine Maintenance
2.5.1 Operator Activity
Perform the following on a monthly basis:

1. Verify that no debris is behind the feeder back plate.
2. Verify that the rubber parts to the nudgers, stripper wheel, 
separation (contra) roller, and pinch rollers are in good condition and
clean, as necessary, with cleaning fluid (Part Number 0234 0172).
3. Verify that the O-ring belts to the feeder rollers are in good condition.
4. Clean the note feed/separator sensor.

Friction Feeder 2.6 Illustrated Parts List
2.6.1 Friction Feeder Kit (400-3000-401)

Table 2-2 Friction Feeder Kit (400-3000-401)
Item Part No. Description Qty
1 0046 0305 WASHER M4 FORMA MS ZCEP 22

3 0046 0405 NUT PLN HEX M4 MS ZPL CP 10
4 0046 2072 WASHER M3 SFTY SPNG STL 6
7 0046 2405 SCREW M3 X 8 CAP SKT HTS BLKOX 6
13 0046 3794 SCREW M4 X 8 BUT HD HTS BLU 1
14 0046 3799 SCREW M5 X 12 BUT SKT HTS BLU 3
15 0046 4408 SCREW M4 X 12 CSK SKT HTS BLKOX 1
17 0228 0130 BELT DR 50.4 I/D X 3.5 SECTN 2
18 0228 0593 BELT GT 2MR 192 2
19 0228 0594 BELT HTD 174-3M-9 2
20 0228 0595 BELT HTD 180-3M-9 1
21 0228 0596 BELT HTD 168-3M-9 1
22 0228 0597 BELT HTD 210-3M-9 1
24 320 2350 701 ACTUATOR ARM D/A 1
25 400 2002 101 NUT PLATE / RACK DA – CONTRA ROLLER 1
26 400 2002 401 CONTRA ROLLER ADJUST ASSY 1
27 400 2005 801 HOUSING BEARING FEED ASSY 1
28 400 2006 003 PLATE, FEEDER, RIGHT HAND SIDE 1
29 400 2006 601 TRAY FEED ASSY 1
30 400 2006 803 FRONTPLATE D/A, FEEDER 1
31 400 2009 101 PINCH ASSY – FEEDER 1
32 400 2009 801 STANDOFF 36T PULLEY ASSY 1
33 400 2010 701 SENSOR MOUNTING ASSEMBLY 1
34 400 2012 202 STANDOFF PULLEY O-RING ASSY 2
TP01311011 Rev 05 November 2009 2-15

2.6 Illustrated Parts List Friction Feeder
Table 2-2 Friction Feeder Kit (400-3000-401) (Continued)

35 400 2012 502 STANDOFF PULLEY 2MR ASSY 2

36 400 2012 702 STANDOFF PULLEY 2MR FL FR ASSY 2
37 400 2015 501 COVER FEEDER LH ASSY 1
38 400 2015 601 OPTO SENSOR ASSY 1
39 400 2015 701 OPTO EMITTER ASSY 1
40 400 2019 501 PLATE, CLAMP D/A 1
41 401 6000 302 PLATE STIFFNESS, CONTRA – ROLLER 1
42 401 6001 302 PLATE, FEEDER TOP 1
43 401 6003 201 BACKPLATE, ADJUSTABLE, FEEDER 1
44 402 0004 401 PLATE, SUPPORT, BACKPLATE – FEEDER 1
45 402 0010 701 SPACER, FEEDER MOTOR 1
46 402 0010 801 SPACER, ADJ BACKPLATE MTR – FDR 1
47 402 0010 901 STANDOFF, SPRING POST – FEEDER 1
48 402 0011 402 STANDOFF – FRONT PLATE MOUNTING 2
49 402 7000 101 GEAR, 66 TOOTH MOD 1 1
50 550 2006 601 NUDGER ASSY, FRICTION FEEDER 1
51 550 2006 701 NUDGER ASSY, SINGLE 1
52 550 2007 103 STRIPPER WHEEL ASSEMBLY 1
53 550 2009 302 O-RING DRIVE 1
54 550 2009 703 MOTOR ASSEMBLY 1
55 550 2010 501 FEEDER MOTOR ASSEMBLY 1
56 552 0068 201 SHAFT, GUIDE – ADJ BACKPLATE 1
57 552 0068 301 BLOCK GUIDE – ADJ BACKPLATE

Figure 2-13 Friction Feeder Kit (400-3000-401)
TP01311011 Rev 05 November 2009 2-17

Figure 2-14 Friction Feeder Kit (400-3000-401) <T09R>

2.6.2 Feeder Motor Assembly (550-2010-501)

Table 2-3 Feeder Motor Assembly (550-2010-501)
Item Part No Description Qty

12 0247 0083 GROMMET OPEN 6.4 ID X 14.3 OD 1
19 0262 0541 ENCODER 360 LINE PLUS INDEX 1
20 0262 0543 LEAD ENCODER DP TYPE 1
21 551 6000 702 PLATE, MTG, STACKER ENCODER 1
23 552 0009 401 INSERT, GROMMET, ENCODER MTG 1
24 552 0012 002 SPACER, STACKER ENCODER 1
Figure 2-15 Feeder Motor Assembly (550-2010-501)
TP01311011 Rev 05 November 2009 2-19

2.6.3 O-Ring Drive (550-2009-302)

Table 2-4 O-Ring Drive (550-2009-302)

4 0048 0722 PIN SPL HVYDY 2 X 12LG 1
5 0242 0020 CLIP RTG INT FTG TYPE 26MM BORE 1
6 0249 0055 BEARING BALL 10 ID 26 OD 8 WD 1
7 0249 0153 BEARING BALL 8 ID 22 OD 7 THK 1
8 321 4106 203 PULLEY – O-RING CAM LH 1
9 552 0033 502 SHAFT, O-RING DRIVE 1
10 552 0035 502 HOUSING, BEARING, O-ring DRIVE 1
11 552 0037 002 SHIELD 1
12 552 0037 302 WASHER, 15 OD, 3.3 ID, 2 THK 1
13 552 0038 802 SHAFT, O-RING DRIVE 1
15 552 0046 002 WASHER, LOCTION, O RING DRIVE 1
16 552 0046 202 SLEEVE, O RING DRIVE – FEEDER 1
17 552 7001 702 PULLEY 3MR 30T, DOUBLE WIDTH 1
19 552 0044 403 PULLEY, ‘0’ RING CAM LH – MODIFIED 1
Figure 2-16 O-Ring Drive (550-2009-302)

2.6.4 Stripper Wheel Assembly (550-2007-103)

Table 2-5 Stripper Wheel Assembly (550-2007-103)

6 0228 0343 COUPLING TRANTORQUE ID 8 OD 19 1
8 0249 0098 BEARING BALL 2 SHIELD 2
9 400 2003 002 WHEEL, STRIPPER ASSEMBLY 1
10 550 2031 001 VANE ASSY – FEEDER 1
11 552 0035 604 HOUSING, STRIPPER BRG – FEEDER 1
12 552 0081 202 SHAFT, STRIPPER WHEEL 1
13 552 7001 304 PULLEY 3M 30T 1
Figure 2-17 Stripper Wheel Assembly (550-2007-103)
TP01311011 Rev 05 November 2009 2-21

2.6.5 Nudger Assembly - Single (550-2006-701)

Table 2-6 Nudger Assembly - Single (550-2006-701)

2 0228 0343 COUPLING TRANSTORQUE ID 8 OD 19 1
4 0249 0055 BEARING BAALL 10 ID 26 OD 8 WD 2
5 321 4103 201 INSERT NUDGER 1
6 551 4000 402 NUDGER 1
7 552 0031 502 HOUSING, BEARING, NUDGER ASSY. 1
8 552 0035 402 SHAFT, SINGLE NUDGER 1
9 552 7001 902 PULLEY 3M 30T 1
Figure 2-18 Nudger Assembly - Single (550-2006-701)

2.6.6 Nudger Assembly - Friction Feeder (550-2006-601)

Table 2-7 Nudger Assembly - Friction Feeder (550-2006-601)
1 0046 0337 WASHER M4 PLN FM A MS Z/BLK 1

3 0228 0343 COUPLING TRANSTORQUE ID 8 OD 19 1
6 321 4103 201 INSERT NUDGER 2
7 551 4000 302 NUDGER 1
8 552 0030 202 HOUSING, BEARING, DOUBLE NUDGER 1
9 552 0035 202 SHAFT, DOUBLE NUDGER 1
10 552 7001 802 PULLEY 3M 36T/30T 3
Figure 2-19 Nudger Assembly - Friction Feeder (550-2006-601)
TP01311011 Rev 05 November 2009 2-23

2.6.7 Contra Roller Adjust Assembly (400-2002-401)

Table 2-8 Contra Roller Adjust Assembly (400-2002-401)
1 0028 8622 CLUTCH ROLLER 14 OD X 8 ID 1

2 0242 0174 CIRCLIP INT DIA 16 THIN PROFILE 1
4 0042 0107 CIRCLIP EXT SHAFT 6 1
6 0046 2105 SCREW M4 X 5 GRUB SKT HTS BLU CUP PT 2
7 0243 0432 SPRING COMP 7.62 OD 0.56 WD LC-022D-7 1
8 0246 1181 WASHER, PRELOAD DIA 16 1
10 400 2002 301 HOUSING DA, CONRA ROLLER 1
11 400 2002 501 GEAR ASSY, 16 TOOTH – CONTRA ADJ 1
12 402 0001 602 CAM, CONTRA ROLLER ADJUSTER 1
13 402 0014 001 STOP, SCREW 1
14 550 2033 301 CONTRA ROLLER, FEEDER 1
15 552 0075 202 SHAFT – CONTRA 1
Figure 2-20 Contra Roller Adjust Assembly (400-2002-401)

2.6.8 Pinch Assembly - Feeder (400-2009-101)

Table 2-9 Pinch Assembly - Feeder (400-2009-101)

4 320 2306 501 TYRE ASSEMBLY 2
6 322 0392 202 SCREW SHOULDER 2
7 552 0033 402 SPACER SHIELD 2
8 400 2008 901 ARM, PINCH D/A – FEEDER 1
10 400 2009 001 ARM, PINCH D/A – FEEDER 1
11 402 0007 101 SPACER, INNER, PINCH, FEEDER 1
12 402 0007 202 SPACER, PINCH ARM – FEEDER 2
13 500 2039 601 ROLLER CROWNED, DBL SHIELDED DA 1
14 554 3000 802 TORSION SPRING, FEEDER TENSIONER 2
Figure 2-21 Pinch Assembly - Feeder (400-2009-101)
TP01311011 Rev 05 November 2009 2-25

2.6.9 Stand-off 36T Pulley Assembly (400-2009-801)

Table 2-10 Stand-off 36T Pulley Assembly (400-2009-801)
1 00462073 WASHER M4 SFTY SPNG STL 1

2 02460473 SCREW M4 X 70 CAP SKT HTS BLKOX 1
3 4020007601 STANDOFF, PULLEY ECC – FEEDER 1
4 4020007701 WASHER, BEARING CLAMP, M4 1
5 5502010602 PULLEY, 36T D/A 1
Figure 2-22 Stand-off 36T Pulley Assembly (400-2009-801)
2.6.10 Stand-off Pulley O-Ring Assembly (400-2012-202)

Table 2-11 Stand-off Pulley O-Ring Assembly (400-2012-202)
1 400 2012 102 PULLEY O-RING D/A – FEEDER 1

2 402 0008 802 STANDOFF PULLEY – FEEDER 1
3 402 0008 901 SHIELD, PULLEY – FEEDER 1
4 402 0014 201 SCREW, SPECIAL – CSK SKT M5 X 55 1
Figure 2-23 Stand-off Pulley O-Ring Assembly (400-2012-202)

2.6.11 Stand-off Pulley 2MR Assembly (400-2012-502)

Table 2-12 Stand-off Pulley 2MR Assembly (400-2012-502)
1 400 2012 602 PULLEY 2MR 30 TEETH ASSY 1

4 402 0014 201 SCREW, SPECIAL – CSK SKT M5 X 55 1
Figure 2-24 Stand-off Pulley 2MR Assembly (400-2012-502)
2.6.12 Stand-off Pulley 2MR FL FR Assembly (400-2012-702)

Table 2-13 Stand-off Pulley 2MR FL FR Assembly (400-2012-702)
1 400 2012 401 PULLEY 2MR 30 TEETH FL ASSY 1

Figure 2-25 Stand-off Pulley 2MR FL FR Assembly (400-2012-702)
TP01311011 Rev 05 November 2009 2-27

2.6.13 Feeder Side Plate Assembly (400-2015-501)

Table 2-14 Feeder Side Plate Assembly (400-2015-501)
Item Description Part No Qty
1 0046 0304 WASHER M3 FOMA MS ZCEP 2

2 0046 0405 NUT PLN HEX M4 ZPL CP 2
5 0046 2409 SCREW M3X10 CAP SKT HTS BLKOX 2
6 320 2390 301 OPTO SENSOR-BDR 1
7 400 2006 503 PLATE, FEEDER SIDE PLATE LH 1
8 400 2008 401 NOTE GUIDE – FEEDER 1
9 401 6001 702 PLATE, NOTE GUIDE – FEEDER 1
10 401 6001 801 CLAMP, NOTE GUIDE – FEEDER 1
Figure 2-26 Feeder Side Plate Assembly (400-2015-501)

2.6.14 Feed Tray Assembly (400-2006-601)

Table 2-15 Feed Tray Assembly (400-2006-601)
Item Description Part No. Qty

4 0046 2404 SCREW M4X 6 CAP SKT HTS BLKOX 2
5 0046 4401 SCREW M3X 8 CSK SKT HTS BLKOX 3
6 024 10215 KNOB KNURLED M4X10LG ML BLACK 1
7 400 2006 703 TRAY, FEED D/A 1
8 400 2013 501 NOTE GUIDE ASSY - FEEDER 1
9 550 2044 702 BRKT D/A - SKI RAMP 1
10 550 6014 401 CBLFM EMITTER FEED TRAY 1
11 551 2004 101 SKI RAMP - FEEDER 1
12 552 0096 902 GUIDE NOTE WIDTH 1
Figure 2-27 Feed Tray Assembly (400-2006-601)
Exploded View
Isometric View
Exploded View
TP01311011 Rev 05 November 2009 2-29

2.6.15 Feeder Back-Plate Motor ASSY (400-2057-801)
Table 2-16 Feeder Back-Plate Motor ASSY (4002057801)

Item Part Number Description Quantity
1 02461310 Washer M3 SFTY ST STL 4
2 02461311 Washer M4 SFTY ST STL 1
3 02461318 Screw M3x10 CAP SKT ST STL 4
4 02461321 Screw M4x6 CAP SKT ST STL 1
5 02490469 Tolerance Ring 5x8 LG 1
6 4020051501 Leadscrew, Adjust Backplate FEEDER 1
7 4020051604 Sleeve, Adjust Backplate FEEDER 1
8 4020051701 Housing, Adjust Backplate FEEDER 1
9 5506006401 Motor, Stepper ASSY - SANYO DEN 1
Figure 2-28 Feeder Back-Plate Motor ASSY (400-2057-801)

NOTES:
TP01311011 Rev 05 November 2009 2-31

NOTES:

Chapter 3
Transport
Topic Page Number
3.1 - Transport 3-2
3.2 - Sensors 3-3
3.3 - Transport System 3-7
3.4 - Stackers 3-21
3.5 - Diverters 3-24
3.6 - Transport Drive System 3-27
3.7 - Timing Vanes 3-29

3.8 - Safety Controls 3-32
3.9 - Covers 3-33
3.11 - Sensor Parts List 3-37

3.1 Transport Transport
3.1 Transport
3.1.1 Overview
The transport subsystem consists of several sections that are driven by a

single motor and motor controller. A digital signal drives the motor
controller. The motor speed is directly proportional to the digital signal
frequency.
When the transport starts, the motor speed ramps up gradually and, when
the transport stops under normal conditions, the speed ramps down.
When the transport stops in response to a jam, the motor speed ramps
down more rapidly to cause the transport to stop as rapidly as possible.
A revised belt path, introduced in July/August of 2002 and known as
Mark II, consists of three configurable zone segments and a standard belt
kit.
Section 3.12 on Page 3-38 describes both Mark I and II belt paths. The
Illustrated Parts List section now includes lists of roller and belt kits for
belt variants 2E, 2F, and 2G as well as standoff assemblies that apply to
these variants.
In addition to a fault-finding guide, a sensor parts list, and an illustrated
parts list, the remainder of this section provides procedures to set/adjust
and remove/replace the following:
 Sensors  Transport drive system
 Transport system  Timing vanes
 Stackers  Safety controls
 Diverters  Covers

Transport 3.2 Sensors
3.2 Sensors
The system automatically calibrates the sensors each time the machine is
switched on, but the service engineer can also calibrate the sensors using
diagnostics functions (refer to Graphical Control Console Diagnostics
Guide, 440-0163-001 or TP01311012). When the measured drive current
becomes too high, the diagnostics function indicates that the optical
devices need cleaning or changing.
3.2.1 Settings and Adjustments
The sensor elements have no specific mechanical or electrical

adjustments because electrical drive to the light emitters is automatically
adjusted to maximise the sensor operational reliability.
TP01311011 Rev 05 November 2009 3-3

3.2 Sensors Transport
Figure 3-1 shows the location of all the sensors on the Cobra 4004.
Figure 3-1 Location of Sensors, Diverters, and Lamps
DV F
(If Equipped) DV B TS E DV A TS D QI A TS C
QI B
LO B/G
TS H
LO C/H
DV E
TS G
DV D LO A
TS F
QI C
LO F
LO E/J
LO D/I
QI D TS B TS I TS K
TS A
(At Rear of Machine on Stripper Wheel Shaft)
3.2.2.1 Sensors TSB Through TSI and TSK
The following provides removal and replacement procedures for sensors

TSB through TSI and TSK.
Removal Use Procedure 3-1 to remove sensors TSB through TSI and TSK.
Procedure 3-1 Removing Sensors TSB – TSI and TSK

1. Remove the associated guides and circuit boards shown in
Table 3-1 on Page 3-5.
2. Remove the connectors from the rear of the sensor.
3. Remove the single bolt securing the sensor to the backplate.
4. Remove the sensor from the front of the machine.

Transport 3.2 Sensors
Replacement Use Procedure 3-2 to replace sensors TSB through TSI and TSK.
Table 3-1 Guide and Circuit Board Removal

Circuit Board
Sensor Guide Removal
Removal
TSB None –
TSC None –
TSD Upper and lower guides (Pocket 1) Yes
TSE Upper and lower guides (Pocket 2) Yes
TSF Upper and lower guides (Pocket 3) –
TSG Upper and lower guides (Pocket 4) –
TSH Upper and lower guides (Cull Pocket) –
TSK Lower entry guide for thickness detector Yes (on emitter)
Procedure 3-2 Replacing Sensors TSB – TSI and TSK

1. Locate the sensor on the backplate and fasten to friction tightness
with the single bolt.
2. Align the sensor such that the belt passes midway between the
arms and perpendicular to the sensor light source and detector path.
3. Tighten the locating bolt.
4. Replace the connectors at the rear of the sensor.
5. Replace any guides and circuit boards removed for access.
3.2.2.2 Sensor TSA
Removal Sensor TSA is a Hall-effect sensor attached to the timing disk on the rear
of the stripper wheel shaft. Use Procedure 3-3 to remove sensor TSA.
Procedure 3-3 Removing Sensor TSA

1. Unbolt the two 3-mm hex bolts on the rear of the stripper wheel shaft
(at the rear of the feeder) to remove the pick-point sensing disc.
2. Remove the two screws and a nut plate to remove sensor TSA from
the bracket. Remove the timing disc and the Hall-effect sensor
together.
TP01311011 Rev 05 November 2009 3-5

3.2 Sensors Transport
Replacement Use Procedure 3-4 to replace sensor TSA.
Procedure 3-4 Replacing Sensor TSA

1. Re-assemble the pick-point sensing disc and sensor, verifying that
the disc has correct orientation with the stripper wheel (see
Figure 3-2).
Figure 3-2 Stripper Wheel Mechanism
2. Verify that an equal gap, back and front, exists between the sense
vane and sensor.
3.2.2.3 Sensors LOA Through LOJ
Sensors LOA – LOJ are sensors in which the light source is mounted
remotely from the detector, such as across a stacker pocket or the cull
pocket.
Use Procedure 3-5 to remove a light source or detector for sensors LOA
– LOJ.
Procedure 3-5 Removing/Replacing Sensors LOA – LOJ

1. Carefully unplug the connector from the light source or detector.
2. Unscrew the device from the mounting and withdraw the device.
3. Reverse the steps to replace a sensor light source or detector.

Transport 3.3 Transport System
3.3 Transport System
The original Cobra 4000 series (Mark 1) used a fixed transport belt path.
The Mark II variant provides configurable belt paths to accommodate a
wider range of note types and customer applications.
Section 3.12 on Page 3-38 shows the belts and pulleys for both Mark I
and Mark II machines. The note in Figure 3-30 shows how to identify the
Mark variant of a machine.
Recent developments in the Cobra product allow a Cobra 4004 (DCM) or
a Four-Pocket Extension (4PM) module to mate up with a 6000 Four-
Stacker Module (FSM), a Two-Stacker Destruction Module (TSDM), or
variants of the two: Two-Stacker Module (TSM) and Destruction Module
(DM).
To accommodate the new development, Mark 1 machines require an exit
path that allows connection to a 4PM or a 6000 output module.
3.3.1 Mark 1 Modification to Allow Expansion
The following information describes the upgrade of a Mark 1 Cobra 4004

to enable it to couple to a 4PM extension module or a 6000 output module
(FSM/TSDM).
To determine whether a 4004 machine requires the upgrade, check the
front top left-hand corner of the machine back plane. If a diverter is
present (see Figure 3-3), the machine does not require an upgrade.
Figure 3-3 Upper Left Corner of Back Plane Showing Presence of Diverter
Diverter
Note: The mother board status must upgrade to status 04. Older 4004
machines that upgrade with the addition of a 4PM could require modifica-
tions to the 4PM mother board. (see Section 4.1.1 on Page 4-2)
Table 3-2 on Page 3-8 lists the parts required for Kit Number 400-3006-
101.
TP01311011 Rev 05 November 2009 3-7

3.3 Transport System Transport
Table 3-2 Kit No 400-3006-101

1 0046 0305 Washer M4 FORMA MS ZCEP 8

4 0046 0405 Nut PLN Hex M4 MS ZPL CP 1
5 0046 1571 Nut SCLH M3 #2 SHNK Carb STL 2
6 0046 1575 Nut SCLH M4 #2 SHNK Carb ST 3
7 0046 1579 Nut SCLH M5 #2 SHNK Carb STL 2
8 0246 1310 Washer M3 SFTY ST STL 2
12 0246 1317 Screw M3X 8 Cap SKT ST STL 4
13 0246 1322 Screw M4X 8 Cap SKT ST STL 6
14 0246 1334 Screw M5X10 Cap SKT ST STL 8
16 0246 1335 Screw M5X16 Cap SKT STSTL 2
19 0046 3761 Stud SCLH M4X12 MS ZCEP 1
20 0246 1367 Screw M3X 8 CSK SKT ST STL 2
21 0246 1375 Screw M6X16 CSK SKT ST STL 3
22 0246 1361 Screw M4X10 BUT SKT ST STL 1
23 0228 0607 Belt Flat, S/ELAS, FIT LG 958 mm MAN LG 930 mm 1
24 0228 0680 Belt Flat, SS, FIT LGH 216 MAN LGH 213 12 WD 0.45 THK 1
25 0241 0548 AS Strut 100 mm Stroke 280N 'Stop & Stay' 2
26 0246 0255 Washer M4 Ext Fan Disc MS ZCEP 1
27 0246 1243 Spacer PCB Blind FXG Push IN 4.8LG 3
29 0254 1347 IEC Socket 10A Shuttered Panel MNT 1
30 321 6168 101 Washer M3 Special 2
31 400 2002 002 Diverter Assy - LH 1
32 400 2010 304 Cover, Main Inspection 1
33 400 2015 201 Roller, Crowned D/A - 16 DIA 9
34 400 2018 701 Track Sensor Assembly 1
35 400 2029 201 Cover, LH End Assy - 4PM 1
36 400 4006 701 Mods TO MK1 Bkplt to Accept 4PM 0

Table 3-2 Kit No 400-3006-101 (Continued)

37 400 6007 001 CBLFM -Exit Track Upgrade Kit 1
38 400 9500 103 PCBP BI - Directional Diverter 1
39 401 6009 201 Guide, UPR Exit-ADPT PLT 1
40 401 6009 301 Guide, LWR Exit-ADPT PLT 1
41 401 6012 401 Guide Diverter Entry-UPR TRK LH 1
42 402 0000 901 Shield - 16 DIA Roller 9
43 402 0007 401 Stop, Eccentric Diverter O/travel 1
44 402 0024 601 Plate, Adaptor -4PM 1
45 402 0024 801 Standoff 16 DIA RLR -ADPT PLT 9
46 402 0024 901 Standoff, 25 DIA RLR -ADPT PLT 2
47 402 0025 001 Spacer, 16DIA RLR -ADPT PLT 9
48 402 0025 301 Bracket, Adaptor - LWR RLR 1
49 402 0030 401 JIG 1 - MK1 BKPLT Update for 4PM 1
50 402 0030 501 JIG 2 - MK1 BKPLT Update for 4PM 1
51 403 9000 701 Label Set - Cobra 1
52 500 2003 802 Roller Crowned D/A 2
53 552 0088 601 Shield, Roller Cull Belt Rtrn 4
54 400 2014 804 Bracket Rear Cover Upper 1
55 400 6008 501 Cable form Interlock Override Switch 1
Caution! Always double check before drilling or cutting

because you may not be able to correct errors, resulting in the
need for a new backplate assembly.
Warning! Protect the machine components from debris; use a
vacuum cleaner to remove any shavings as they are produced.
This upgrade to a Mark 1 DCM enables the 4004 to expand to a 4008 or
larger Cobra machine or to couple to a 6000 module by adding an exit
port that interfaces with the entry port of a 4PM extension module or 6000
module. To do so involves adding a diverter and transport track sensor,
exchanging the left-hand cover, and performing other modifications.
Use Procedure 3-6 to modify a Mark1 Cobra 4004.
Procedure 3-6 Modifying a Cobra DCM to Accept a Four-Pocket Module

1. Verify that machine power is off before attempting this modification.
2. Remove the main inspection cover assembly from the machine at

the hinge arms. Refer to Section 3.9 on Page 3-33.
3. Remove the left-hand side cover from the machine.
4. Modify the machine backplate assembly to take the additional

diverter assembly, transport track, and cable form routing. Drawing
400 4006 701 provides detailed changes. The end result appears in
Figure 3-4 on Page 3-10.
TP01311011 Rev 05 November 2009 3-9

Figure 3-4 Modifying a Cobra DCM To Accept a Four-Pocket Module (400 4006
701)

5. Remove the transport roller assemblies from the front top left-hand
side of the machine backplate assembly so that you can mount jig 1
(Item 49) as in Figure 3-6 on Page 3-12, View V, Detail X.
6. Modify the backplate assembly as described in Notes relating to jig
1 (see Figure 3-4 on Page 3-10).
Figure 3-5 Modified Backplate Assembly- Part 1
M5 PSMs
M5 PSMs
TP01311011 Rev 05 November 2009 3-11

3.3
Notes relating to Jig 1:
3-12
1. Remove M6 PSM nut from backplate at Position A.
2. Clamp jig to backplate at Position B using M6 x 12 long cap skt screw, PN 0046 2417, (radial
location is via stud at Position C).
3. Pilot drill 5 off holes Ø3 at Positions D and E.
4. Create cutout in backplate as per shaded area shown using profiled cutout in jig as template.
5. Remove jig and enlarge holes/fit PSM nuts as follows:
Transport System
a) 3 D holes Ø5.40/5.48 and fit M4 PSM nuts, PN 0046 1575, with heads on reverse face; that
is, toward inside of machine.
Figure 3-6
b) 2 E holes Ø6.35/6.43 and fit M5 PSM nuts, PN 0046 1579, with heads on reverse face; that
Jig 1 and Notes
Transport

7. Using jig 2 (Item 50) in Figure 3-7 on Page 3-13, modify the side of
the backplate assembly as described in Notes relating to jig 2.
Figure 3-7 Jig 2 and Notes
Notes relating to Jig 2:

6. Drill backplate Ø4.75/4.83 at Position F to dimensions shown and fit M3 PSM nut, PN 0046 1571, with head on reverse face; that
7. Clamp jig to backplate at Position F (ensuring that lower edge of jig is horizontal) using M3 x 8 long cap skt screw, PN 0046 2405.
8. Drill 1 off hole Ø3 at Position G.
9. Remove jig and enlarge hole G to Ø4.75/4.83. Fit M3 PSM nut, PN 0046 1571, with head on reverse face; that is, toward inside of
machine.
10. Fully clamp jig to backplate at Positions F and G using M3 x 8 long cap skt screws, PN 0046 2405.
11. Create cutout in backplate as per shaded area shown using profiled cutout in jig as a template.
12. Pilot drill 1 off hole Ø3 at Position H.
13. Remove jig and enlarge hole H to Ø3.96/4.04. Fit M4 x 12 long PSM Stud, PN 0046 3761, with stud pointing toward inside of
machine; that is, flush on external surface of backplate.
TP01311011 Rev 05 November 2009 3-13

8. Drill and slot the five holes as described in The remaining features
required (see Figure 3-8 on Page 3-14).
9. For assembly, refer to Figure 3-9 on Page 3-14.
10. Attach the new track sensor assembly (Item 34) to the backplate
assembly with M4 button screw (Item 22) and plain washer (Item 1).
Figure 3-8 Remaining Features
The remaining features required:

14. Drill 1 off hole Ø20 to dimensions
shown (top left of Figure 3-6 on
Page 3-12).
15. Cut 4 off slots in backplate base tray as
per details W and Z.
Figure 3-9 Exit Track Assembly
Track Sensor Diverter

Assembly
16-mm Roller Adapter Plate

Assembly
25-mm Roller
Assembly
Spacer Under
Cap Head
Screw

11. Use the cable form upgrade kit (Item 37) to connect the sensor
cable form to connector J33 on the mother board PCB (refer to
Figure 1-9 on Page 1-14 and Table 1-5 on Page 1-17.
12. Attach the TSJE connector to the bottom connector of the track 
sensor and the TSJS connector to the top.
13. Assemble a 25-mm roller assembly as shown in Figure 3-10.
 Attach it onto the adapter plate (Item 44) with an M6 countersunk

bolt (Item 21).
 Attach the plate onto the machine backplate assembly with two each
Items 14, 2, and 10.
Figure 3-10 25-mm Roller Assembly
14. Assemble the nine 16-mm roller standoff assemblies as shown in

Figure 3-11 on Page 3-15 and attach them to the adapter plate
(Item 44).
Figure 3-11 16-mm Roller Assembly
TP01311011 Rev 05 November 2009 3-15

15. Attach the upper and lower note guides (Items 39 and 40) using four
each Items 13,1, and 9 to the adapter plate (Item 44).
16. Attach the diverter (Item 31) using two each Items 12, 30, and 8.
 Attach the diverter stop (Item 43) using Items 18 and 8.

 Attach the diverter guide (Item 41) using Items 13, 1, and 9.
 Attach the diverter board (Item 38) using the PCB spacer (Item 27)
to the underside of the backplate assembly top plate.
 Connect the cable form from the diverter board to connector J31 on
the mother board PCB using the cable form upgrade kit (Item 37);
refer to Figure 1-10 on Page 1-15 and Table 1-4 on Page 1-16.
17. Remove the 25-mm roller standoff shown in Figure 3-12 on
Page 3-16 and bolt on the bracket adapter (Item 48).

Assemble a 25-mm roller assembly and attach it to the bracket
adapter using item 17 with Items 14, 2, and 10.
Figure 3-12 Standoff Roller Assembly
Remove Standoff
From Here and
Attach Bracket
Adapter With
New Standoff
Assembly
18. Re-route the top transport belt and adjust the tensioner as described
in Section 3.3.2 on Page 3-19.
19. Replace the left-hand stretch belt with the 958-mm long belt (Item
23) and add the 216-mm long belt (Item 24); refer to Figure 3-35 on
Page 3-50, Items 1 and 5 (the Mark 2 common belt path).
Note: Place the belts with the shiny side to the note.
20. Use Items 20 to connect the IEC Socket (Item 29) to the cutout
shown in Detail Y, Note 11, Figure 3-7 on Page 3-13.
21. Using the cable form upgrade kit (Item 37), connect the two-core
mains cable and earth lead as shown below.

22. Connect the other end of the mains cable to the terminal block
located between the machine backplate and the power supply units:
wire black to black (live) and white to white (neutral). The earth lead
Using the cable form upgrade kit (Item 37), connect the cable form
marked BRKR to the BRKR connector on the back plane board.
23. Connect other end to the unused AUX connections on the mains
power switch. (The switch is under the black plastic housing.) Route
the cable in the trunking.
24. Attach the side cover (Item 35).
25. Transfer the pocket windows, ‘T’ section and handle, from the old
cover to the new cover (Item 32).
26. Place new labels (Item 51) to the cover.
27. Attach the new main inspection cover.
28. Replace the gas springs with Item 25 because the new cover is
lighter and requires a lower-force spring; refer to Section 3.9 on
Page 3-33.
29. Remove the right-hand rear cover mounting bracket (as viewed from
rear) and replace it with Item 54.

Mount the interlock override switch (Item 55) to the bracket (Item 54)
and route the cable neatly to the mother board as shown in
Figure 3-13 on Page 3-18.
30. Replace the rear cover and adjust the mounting bracket as required.

Verify that the interlock override switch pushes back into the inner
position when the cover is replaced. The switch overrides the safety
interlock system when positioned in the centre of its travel.
31. Check the electrical circuit to verify that all the new connections are
secure.
 Disconnect the machine from the mains supply.
 Switch the mains switch on.
TP01311011 Rev 05 November 2009 3-17

Figure 3-13 Interlock Override Switch Assembled to the Cobra
32. Check the resistance between the chassis and the mains connector
and between the mains terminals with a DVM set to Ohms.
33. Live or neutral to chassis should be greater than 200 Meg Ohms.
Live to neutral should be greater than 30 Meg Ohms.
34. Place the machine in the customer-specified location (refer to the
Site Survey section in the Site Planning Manual (TP04511001) for
space information.

Connect the 4-pocket module as described in Procedure 6-1 on
Page 6-4.
35. Upgrade the machine database to configure the software to 
recognise the 4PM.
36. Test the system functionality.

3.3.2.1 Non-Stretch Transport Belts
The gap setting between the two dynamic tensioner rollers must be 8 –
10 mm (0.31 – 0.39 inches) as shown in Figure 3-14. To set the gap for
non-stretch transport belts (0.8 mm/0.03 inches thick), adjust the
appropriate static tensioner (loosen and slide along the slotted hole in the
backplate). Remember to tighten the static tensioner after setting the gap.
Note: Refer to Section 3.12 on Page 3-38 for the capstan location.
Figure 3-14 Dynamic Tensioner Setting
3.3.2.2 Semi-Stretch Transport Belts
The semi-stretch transport belts (0.5 mm/0.02 inches thick) have no

settings.
3.3.2.3 Transport Rollers
The transport rollers have no required adjustments.
TP01311011 Rev 05 November 2009 3-19

3.3.2.4 Limpness Detector Roller
Use Procedure 3-7 to set the limpness detector roller.
Procedure 3-7 Setting the Limpness Detector Roller

1. Loosen the reaction roller support mounting bolt and slide the
assembly on the backplate to achieve a 2 mm ±0.1 mm (0.08 inches
±0.004 inches) gap between the limpness roller and the reaction
roller (see Figure 3-15).
2. Verify that the reaction roller is perpendicular to the backplate.
Adjust the shim thickness if required.
Figure 3-15 Limpness Detector Roller Setting
3.3.3.1 Non-Stretch Transport Belts
Use Procedure 3-8 to remove a 0.8-mm (0.03 inches) thick non-stretch

transport belt.
Procedure 3-8 Removing a Non-Stretch Transport Belt

1. Loosen the static belt tensioner to prevent damage to the belt.
2. Remove the belt.
3. When replacing, fit the non-stretch transport belts such that the
smooth side is in contact with the note path.
4. See Section 3.3.3.2 to adjust the position of the static tensioner
after correctly fitting the belt.
3.3.3.2 Semi-Stretch Transport Belts
Simply pull a 0.5-mm (0.02-inches) thick semi-stretch transport belt off the
rollers to remove it. When replacing the belt, fit the belt around the
appropriate rollers. Always use a non-flanged roller for the final belt
placement to prevent over stretching the belt.

Transport 3.4 Stackers
3.4 Stackers
Each stacker wheel requires adjustment to a defined position setting in

relation to the stacker position sensor. The stacker position sensor is a
Hall-type sensor that outputs a signal each time a tine passes the note
entry guides. A green LED located at the machine top left front
(Figure 3-16) indicates the signal from the stacker position sensor. The
correct stacker wheel positions in relation to the stacker position sensor
depend on the note pitch and the stacker output position.
Figure 3-16 Cobra Stackers
Stacker Position Indicator Stacker Wheel 4 Stacker Wheel 2 Hand Wheel
ø 26.500 ø 26.000
ROLLER OD
29.100
ø 28.000
Stacker Wheel 5 Stacker Wheel 3 Stacker Wheel 1
To determine the note pitch, divide the transport speed (millimetres/

second) by the note feed speed (notes/second). The pitch is given in
millimetres. In a standard machine, the transport speed is 2,400 mm/sec,
the feed speed is 10 notes/sec, and the note pitch is 240 mm. Table 3-3
shows the settings for the different note pitch options.
Use Procedure 3-9 to set the stacker wheels. The procedure involves
manually positioning the transport until the stacker position indicator
comes on. Use this position as a reference point to adjust Stacker Wheel
2. While using Table 3-3 as a guide for further manual adjustments to the
transport, adjust Stacker Wheels 4, 5, 3 and 1 (cull pocket).
TP01311011 Rev 05 November 2009 3-21

3.4 Stackers Transport
Table 3-3 Output Stacker Hand-Wheel Setting

Stacker Drive Note Output Stacker a
Pulley Pitch
Grooves (mm) 2 4 5 3 1 (Cull)
20 b 240.0 0 0 35 35 13
21 228.6 0 3 43 46 27
22 218.2 0 6 50 4 39
24 200.0 0 10 16 26 13
26 184.6 0 14 30 44 35
a. Hand wheel increments counter-clockwise from stacker index position.
b. Shaded row indicates standard 10 notes/second with note pitch of 240 mm.
Procedure 3-9 Setting the Stacker Wheels

Note: In the next step, do not select a process or the diagnostic menus.
1. Power up the machine.
2. Turn the transport hand wheel knob counter-clockwise until the
stacker position sensor indicator (see Figure 3-16 on Page 3-21)
comes on.
3. Set Stacker Wheel 2 as follows while the transport is in this position.
Note: When choosing a tine to set a stacker wheel, do not use a tine that
looks bent or deformed. Replace damaged tines at the earliest opportunity.
4. Loosen the centre bolt and rotate the stacker wheel until the tip of a
tine aligns to the line of note entry. This position is 1 – 2 mm (0.04
0.08 inches) above the surface of the lower stacker entry guide (see
Figure 3-17 on Page 3-22).
Figure 3-17 Stacker Wheel Index Position
1-2mm
5. Retighten the central bolt to a torque of 1.65 – 2.0 Nm when the

stacker wheel is in the correct position.
6. Go to Stacker Wheel 4.

Transport 3.4 Stackers
 Refer to Table 3-3 for the setting of the hand wheel position for this
output stacker. Use the row corresponding to the drive pulley
grooves and note pitch in use.
 Rotate the hand wheel counter-clockwise by the stated number of
divisions marked on the brass ring mounted behind the hand wheel
knob.
7. Repeat Step 3 to adjust the stacker wheel and Step 6 to proceed to
Stacker Wheels 5, then 3 and 1 (the cull pocket), in order.

Use Procedure 3-10 to remove/replace a stacker wheel.
Procedure 3-10 Removing/Replacing a Stacker Wheel

1. Remove the two bolts securing the detector/lamp mounting bracket
to the backplate (see Figure 3-18).
Figure 3-18 Typical Stacker Pocket
2. Remove the two bolts securing the detector/lamp mounting bracket

to the pocket base plate.
3. Pull the detector/lamp mounting bracket away from the stacker
assembly.
4. Remove the stacker wheel mounting bolt.
5. Remove the stacker wheel.
6. Reverse the above procedure to replace a stacker wheel.
7. Use Procedure 3-9 on Page 3-22 to reset the stacker wheel timing.
TP01311011 Rev 05 November 2009 3-23

3.5 Diverters Transport
3.5 Diverters
The diverter requires two settings whenever the diverter motor assembly
is first installed or is replaced during service. After setting, the diverter
usually does not need subsequent adjustment. The settings are as
follows:
 Diverter blade alignment
 Over-travel stop position
Use Procedure 3-11 to align the diverter blade.
Procedure 3-11 Aligning the Diverter Blade

Diverter Blade Alignment 1. Power up the machine and log onto the operating system.
2. Select the diagnostic mode and enter the Diverter Diagnostics

page. Refer to Graphical Control Console Diagnostics Guide,
TP01311012, for more information.
3. Select the diverter to be adjusted.
4. Set the diverter to the Pass position (that is, in line with the belt
path).
5. Select Setup (toggle F11).
The diverter moves down to the datum stop and comes back to the
Pass position.
6. Check that the blade position is in line with the transport belt path,
as shown in Figure 3-19 on Page 3-25.
 If no adjustment is required, go to Step 7.
Note: Do not use the diverter blade to rotate the motor in the next step.
 If adjustment is required:
 Loosen the two motor mounting screws ('X' on Figure 3-19 on
Page 3-25) and rotate the motor assembly until the blade is in line
with the transport belt.

Transport 3.5 Diverters
Figure 3-19 Diverter Setting
Note: This is diverter 4 in the pass position, as viewed from the machine front.
 Re-tighten the screws when the setting is correct.

Over-Travel Stop Position 7. Loosen the screw that mounts the diverter over-travel stop and
position the over-travel stop such that it allows the diverter blade to
move upwards by the maximum amount.
8. Using the Diagnostic menu, move the diverter to the Divert position
(F8).
9. Position the diverter over-travel stop to give 0.5-mm clearance
between the stop and the diverter blade.
10. Tighten the over-travel stop mounting screw.
11. Toggle the diverter a few times to check for smooth operation.

The setting is now complete.
TP01311011 Rev 05 November 2009 3-25

3.5 Diverters Transport
Remove and replace the diverter as a complete assembly. Use

Procedure 3-12 to remove/replace a diverter assembly:
Procedure 3-12 Removing/Replacing a Diverter Assembly

1. Unplug the motor cable from the rear of the machine.
2. Remove the two bolts securing the diverter assembly to the 

backplate.
Recommendation: Remove the circuit boards when 
withdrawing the diverter units for the upper two stacker pockets.
3. Remove the diverter assembly from the rear of the machine, through
the hole and slot in the backplate.
4. Reverse the above procedure to replace a diverter assembly.
5. Use Procedure 3-11 on Page 3-24 to set the diverter mechanical

position.
3.5.3 Electrical Interconnections

Figure 3-20 shows the electrical connections for the diverter.
Figure 3-20 Diverter Electrical Connections
Diverter Interface PCB

Diverter
Diverter Connector
on the motherboard
Table 3-4 Diverter Electrical Connections

1 400 9500 103 PCBP Diverter Interface 1

2a 400 2002 002 Diverter Assembly LH 1
2b 400 2001 802 Diverter Assembly RH 1
The upper belt path in the Cobra DCM and in the 4-pocket extension
module uses Item 2a (left-hand diverter). The lower belt path in the Cobra
DCM uses Item 2b (right-hand diverter) only.

Transport 3.6 Transport Drive System
3.6 Transport Drive System
The transport drive system consists of the drive electronics to the DC

transport motor mounted on Node B board and a series of pulleys and
belts. Figure 3-21 shows the system.
Figure 3-21 Transport Drive System (Viewed from Machine Rear)
The transport system only requires you to set the belt tensions. Each belt
passes around at least one idler pulley that mounts on an eccentric cam.
Turn these idlers to set the proper tension.
Use Procedure 3-13 to adjust the belt tension.
Procedure 3-13 Adjusting Transporter Belt Tension

1. Loosen the tension idler (if more than one tension idler exists in the
belt run, loosen all) and fit the belt over the pulleys.
2. Rotate the tension idler(s) just enough to remove the slackness from
the belt and lightly tighten.
3. Rotate the pulley system to allow the belt teeth to engage with the
grooves in the pulleys.
This action causes the belt to become slack.
4. Remove the slack from the belt by further rotating the tension
idler(s). It is important that the belt is just taut. The belt must not be
tensioned, because this shortens the bearing life and damages the
backplate. A small amount of slack is acceptable provided that the
belt cannot jump grooves on the pulley.
5. Tighten tension idlers to the recommended torque of 6.2 – 7.5 Nm.
TP01311011 Rev 05 November 2009 3-27

3.6 Transport Drive System Transport

Use Procedure 3-14 to remove a transport belt.
Procedure 3-14 Removing/Replacing a Transport Belt

1. Loosen the belt tension.
2. Lift the belt off the pulleys.

Note: To remove a belt from a pulley, you may need to remove one or
more other belts that share the same pulley shafts. Use Steps 1 and 2 for
each belt.
3. Reverse the procedure to replace a transport belt.
4. Use Procedure 3-13 to apply tension to all replaced belts.
Table 3-5 and Table 3-6 list the belts and pulleys, respectively, used in
the transport system.
Table 3-5 Transport Drive Belts

Belt Design Length
Part No Description
(Figure 3-21) (mm)
T-1 0228 0673 3M HTD Double-sided 585

T-2 0228 0689 3M HTD Single-sided 1,863
T-3 0228 0311 3M HTD Double-sided 945
T-5 0228 0676 3M HTD Single-sided 357
Table 3-6 Transport Pulleys

Pulley Desig PN Inner
Pulley Desc (Inner/Outer)
(Figure 3-21) PN Outer
402 0002 701 Spacer
A
402 7000 501 42T-3M
402 7000 501 42T-3M
B
402 7000 501 42T–3M
402 7000 401 36T-5M
C
402 7000 501 42T-3M
402 7000 401 36T-5M
D
402 7004 101 20T-3M
402 7000 301 21T-5M
E
402 7000 501 42T-3M
F 402 7001 101 19T-3M
G 402 7001 001 34T-3M
20T-5M
H 402 7001 401
96T-3M

Transport 3.7 Timing Vanes
3.7 Timing Vanes
A Hall-effect sensor measures the transport system speed using metal

timing vanes mounted on pulley H (see Figure 3-21 on Page 3-27).
Use Procedure 3-15 to set/adjust the timing vanes.
Procedure 3-15 Setting/Adjusting the Timing Vanes

1. Adjust the sensor distance from the backplate to ensure that the
sensor disc is not in contact with either side wall of the sensor slot.
2. Adjust the radial position of the sensor so that the clearance
between the circumference of the sensor disc and the bottom of the
sensor slot is 0.2 – 1.8 mm (see Figure 3-22).
Figure 3-22 Timing Vane Setting
Timing Sensor
0.2 – 1.8 mm
Drive Pulley with

Timing Vanes
Backplate Ensure That the Disk Does

Not Contact the Sensor
TP01311011 Rev 05 November 2009 3-29

3.7 Timing Vanes Transport
Use Procedure 3-16 to remove/replace a sensor.
Procedure 3-16 Removing/Replacing a Sensor

1. Power the machine off.
2. Disconnect the sensor from the Hall-effect interface circuit board.
3. Remove the Hall-effect sensor and mounting bracket.
4. Remove the sensor from the mounting bracket.
5. Reverse Steps 2 through 4 to reassemble the sensor.
6. Use Procedure 3-15 on Page 3-29 to adjust the mechanical 

position of the diverter.
Use Procedure 3-17 to replace a timing vane.
Procedure 3-17 Replacing a Timing Vane

1. Use Procedure 3-16 to remove the Hall-effect sensor.
2. Remove the three bolts securing the disc to the pulley assembly.
3. Reverse Steps 1 and 2 to reassemble the vane.
4. Use Procedure 3-15 on Page 3-29 to adjust the sensor.

Transport 3.7 Timing Vanes
3.7.3 Electrical Interconnections
Figure 3-23 shows the electrical connections between the transport

motor and the Hall-effect sensor. Table 3-7 identifies the parts shown in
Figure 3-23.
Table 3-7 Transport Motor and Hall-Effect Sensor Connections (400-2062-601)

1 400 6001 703 MAIN DRIVE MOTOR 1

2 400 9500 601 PCBP HALL-EFFECT 1
3 0252 0404 SENSOR HALL-EFFECT 1
4 400 4001 402 MOTOR CONTROLLER 1
5 402 7000 903 Pulley Drive Motor 1
6 0228 0293 Clamp Transtorque 1
Figure 3-23 Transport Motor and Hall-Effect Sensor Connections
1
5
3 2
DC Motor 1 J40
(motherboard)
Transport Clock
(motherboard)
4
J58
J65
42V
Power
TP01311011 Rev 05 November 2009 3-31

3.8 Safety Controls Transport
3.8 Safety Controls
3.8.1 General Description
The Cobra 4004 safety control system consists of the following:

 A cover switch, which has an override for engineering access
 An Emergency Stop button, if specified by the customer. The Emer-
gency Stop button stops machine operation even when the cover
switch override is active.
The circuitry that controls the safety system resides on the mother board
and, when triggered, provides an inhibit signal for the 48V motor and fan
power supply. Refer to Section 1.3.2 on Page 1-19.
Use Procedure 3-18 to set the position of the cover switch.
Procedure 3-18 Setting/Adjusting the Cover Switch

1. Loosen the two bolts that secure the switch to the mounting bracket
and the two bolts that secure the mounting bracket to the framework
to friction tightness (see Figure 3-24).
Figure 3-24 Cover Switch
Hinge Mounting Bolts Switch Mounting Bolts
Cover Switch
2. Adjust the switch position such that the cover hinge metal work
operates reliably and releases the switch actuator when the lid is
opened and closed.
3. Tighten all bolts.

Transport 3.9 Covers
Access to the cover switch is from the rear of the machine. The cover
switch location is inside the framework on the upper left-hand wall as
viewed from the rear. Two bolts that pass through the switch body and
mounting bracket into a tapped plate secure the switch.
The hinge metalwork pushing against the switch plunger operates the
switch as the lid is closed.
Use Procedure 3-19 to remove the cover switch.
Procedure 3-19 Removing the Cover Switch

1. Remove the two bolts securing the switch to the mounting bracket.
Take care not to lose the tapped plate.
2. Remove the self-tapping screw securing the switch cover and open
the cover.
3. Loosen the screws that connect the two wires to the switch and
remove the wires.
4. Loosen the cable gland on the switch.
5. Remove the wiring from the switch body.
6. Reverse the procedure to replace the switch.
7. Use Procedure 3-18 to adjust the switch position.
3.9 Covers
The machine covers consist of the following:

 A front cover panel that hinges upwards to reveal the note transport
system located on the front of the machine backplate
 A left and right side cover panels
 A back cover panel
Cover Panel Fasteners A pair of hinge mechanisms at the cover panel top left and right sides
secure the front cover panel.
Two locating pegs secured to the side cover panels fit into receptacles
near the base on the machine frame. A single 1/4-turn fastener at the
panel top secures each side cover panel.
Securing the rear cover panel is similar in manner to the side cover
panels: two locating pegs fit into receptacles near the base of the
machine, but two 1/4-turn fasteners at the panel top secure the cover
panel.
TP01311011 Rev 05 November 2009 3-33

3.9 Covers Transport
The applicable cover panel adjustments are such to make the cover
panels fit close to the machine and flush with each other.
3.9.1.1 Front Cover
Use Procedure 3-20 to adjust the front cover panel position.
Procedure 3-20 Adjusting the Front Cover Panel Position

1. Loosen the bolts securing the front cover panel to the hinges.
2. Loosen the two bolts on each side of the machine securing the
hinge to the framework (see Figure 3-25).
Figure 3-25 Cobra Hinge Mounting
Hinge Mounting Bolts
3. Move the cover to the required position.
4. Tighten all bolts.

Transport 3.9 Covers
3.9.1.2 Side Covers
The side cover panel settings and adjustments are made in two stages.
The first adjustment ensures that the side cover panel is correctly
positioned on the frame. The second adjustment ensures that the 1/4-turn
fastener lines up correctly with its receptacle.
Use Procedure 3-21 to align the side cover panels to the machine frame.
Procedure 3-21 Aligning the Side Cover Panels

1. Lift up the machine front cover panel.
2. Turn the 1/4-turn fastener to unfasten the side cover panel.
3. Pull the top slightly away from the machine and lift the cover panel
to remove it.
Procedure 3-21 continued on the next page...
Procedure 3-21 continued from the previous page:
4. Loosen the four bolts that secure each of the two receptacles to the
machine framework.
5. Move the receptacles to the required positions.
6. Tighten the four bolts on each receptacle.
7. Check that the panel fits correctly and make further minor 
Use Procedure 3-22 to check the fastener alignment.
Procedure 3-22 Checking Side Cover Panel Fastener Alignment

1. Locate the pegs in the receptacles.
2. Push the cover panel top toward the machine and note any 
positional inaccuracy between the 1/4-turn fastener and the 
receptacle.
3. If misalignment exists, remove the cover panel from the machine.
4. Loosen the bolts securing the fastener receptacle and move the
receptacle to the required position.
5. Tighten the screws and attach the cover panel.
3.9.1.3 Rear Cover Panel
Adjustments to the rear cover panel are very similar to those for the side
cover panels. Follow a similar procedure, but note the following 
differences:
 Adjust the position of the two pegs on the back cover panel itself.
Adjust the two pegs in conjunction with their associated receptacle.
 The back cover panel has two 1/4-turn fasteners on the top. Align each
fastener with its respective receptacle.
TP01311011 Rev 05 November 2009 3-35

3.9 Covers Transport
3.9.2.1 Front Cover Panel
The following procedure requires two people. Use Procedure 3-23 to

remove/replace the front panel.
Procedure 3-23 Removing/Replacing the Front Cover Panel

1. Lift the front cover panel.
2. With a second person to support one end of the front cover panel,
remove on the same end the bolts that secure the cover panel to the
hinge.
3. With the second person remaining at that end, move to the opposite
end and support the cover panel while removing the corresponding
bolts on that end.
4. Lift the cover panel away from the machine.
5. Reverse the procedure to replace the front cover panel.
3.9.2.2 Side Cover Panels
Use Procedure 3-24 to remove/replace a side cover panel.
Procedure 3-24 Removing/Replacing a Side Cover Panel

1. Open the front cover panel.
2. Unfasten the 1/4-turn fastener at the top centre of a side cover

panel.
3. Pull the top of the cover panel away from the machine while
simultaneously lifting the cover panel upward and away from the
machine.
4. Replace the side cover panel:
4.1 Insert the pegs into the corresponding receptacles.

4.2 Push the cover panel top toward the machine.
5. Fasten the 1/4-turn fastener to secure the cover panel.
3.9.2.3 Rear Cover Panel
Use Procedure 3-25 to remove/replace the rear cover panel.
Procedure 3-25 Removing/Replacing the Rear Cover Panel

1. Unfasten the two 1/4-turn fasteners at the top centre of the rear
cover panel.
2. Pull the top of the cover panel away from the machine while 
simultaneously lifting the cover panel upward and away from the
machine.
3. Replace the rear cover panel:
3.1 Insert the pegs into the corresponding receptacles.

3.2 Push the cover panel top toward the machine.
4. Fasten the two 1/4-turn fasteners to secure the cover panel.

Transport 3.10 Fault-Finding Guide

You can use Transport Diagnostics to test the transport system and to
find a fault on the transport system. Refer to Graphical Control Console
Diagnostics Guide (440-0163-00X or TP01311012).
Table 3-8 provides a check list to help in isolating faults.
Table 3-8 Fault Isolation Guide

Xport Fails Poor Xport Damaged
Possible Problem
to Run Stacking Jams Notes
 – – – Motor Controller problem. Check indicators.
Motor encoder problem. Check the motor encoder for
 – – – proper connection and determine whether the motor shaft
is broken.
–    Notes not stacked correctly in feeder
–    Notes in feeder are badly damaged
Debris (staples, rubber bands, part notes, paper clips, and
–   
so on) in feeder, transport path, or stackers
–    Guides (metal or Melinex) may be out of alignment
–    Diverter problem. Check diverters using Diagnostics.
–    Stacker splines may be damaged
Stacker wheel speed problem. Check stacker wheel 
–  – –
calibration.
–  – – Anti-static brushes may be worn or damaged
– –  – Detector head positions not at home position
– –  – Belts may be damaged
– –  – Sensor problem. Check, clean, and calibrate all sensors.
3.11 Sensor Parts List
Table 3-9 lists the sensors and their part numbers.
Table 3-9 Sensor Parts List

Location Part No. Sensor Description Qty
Update and Count Sensors 400 2018 701 Track Sensor Assembly 9
Base of Output Pockets 400 9500 401 PCB BIN Sensor Transmitter 5
Side of All Output Pockets 400 9500 401 PCB BIN Sensor Transmitter 4
Upper Side of Output Pockets 400 9501 101 PCB BIN Sensor Receiver 2
Lower Side of Output Pockets 400 9500 301 PCB BIN Sensor Receiver 2
Top of Cull Pocket (Stacker 1) 400 9501 201 PCB Bin Sensor Receiver, Single 1
Backplate of Output Pockets 310 9531 404 PCB Bin Sensor Receiver 4
TP01311011 Rev 05 November 2009 3-37

3.12 Illustrated Parts List Transport

This chapter provides parts list and descriptions for the CIS SDA Trans-
port Kit, and the belt/roller assemblies for Mark 1 and Mark 2 machines.
3.12.1 CIS SDA Transport Kit
Table 3-10 CIS SDA Transport Kit Illustrated Parts

Item Part Number Description Qty
1 00425103 P-CLIP Cable DIA 4.4 FIX 4.3D 1
2 00460305 WASHER M4 FORMA MS ZCEP 7
3 00460306 WASHER M5 FORMA MS ZCEP 2
4 00460405 NUT PLN HEX M4 MS ZCEP 1
5 00461101 Spacer PLN 4.0 ID 3.2LG 6.3 OD 3
6 00750002 Adhesive Loctite 222 4
7 02280311-SDA Belt TMG HTD 3mm D/S 945 LG 9WD 1
8 02280710 Belt TMG HTD 420 LG 3mm 6WD 1
9 02280720 Belt FLAT, SS FIT LG 290 MAN LG 285 12WD 0.45THK 1
10 02461258 Pillar, HEX Nylon 15LG / M4 FML/M 2
11 02461311 WASHER M$ SFTY ST STL 6
12 02461323 SCREW M4x10 CAP SKT ST STL 2
15 4002001303 Standoff 16 DIA CRN RLR ASSY 4
16 4002001502 Standoff 25 DIA CRN RLR ASSY 2
17 4002002803 Idler, 42T - 3M ASSY - Inner LVL 4
18 4002021701 Idler Flat D/A CIS 1
19 4002022202 Pulley 50D Drive D/A 1
20 4002023502 Pulley Idler D/A CIS 1
21 4002027901 Bracket ASSY - STKR Entry Roller 1
22 4002028001 Guide LWR Entry D/A SSHT CIS 1
23 4002031702 Plate Clamp M4 D/A 1
24 4002063602 Kit, Magnet ASSY 1
25 4002068001 Belt Carrier SDA D/A NO 1 1
26 4002068101 Belt Carrier SDA D/A NO 2 1
27 4002095001 Pulley 19T CIS Belt Drive D/A 2
28 4006007502 CBLFM LVDT EXT CIS 1
29 4016027502 Plate POSN Belt Carrier 1
30 4020050101 Plate 42T Idler MTG 1
31 4027000305 Pulley, Drive 21T - 3M 1

Transport 3.12 Illustrated Parts List
Figure 3-26 CIS Transport Kit (Front View)
TP01311011 Rev 05 November 2009 3-39

Figure 3-27 CIS Transport Kit (Rear View #1)

TP01311011 Rev 05 November 2009 3-41

3.12.2 Mark I Transport Belt Path

The Mark I transport has a fixed belt path; the introduction of the Mark II
belt path provided more detection configuration and belt routing options.
Table 3-11 shows the part numbers for each of the Mark I transport belts
shown in Figures 3-30 through 3-33.
Figure 3-30 on Page 3-43 shows the location of the major sub-assem-
blies used in the Mark I belt path.
Table 3-11 Mark I Transport Belts

Belt Ref Figure Part No Length (mm)
G 3-30, 3-32 0228 0635 180

H 3-32 0228 0680 216
B
3-32
D 0228 0685 415
P 3-33
E 3-30
0228 0683 460
M 3-32
I
3-32 0228 0681 522
L
F 3-32 0228 0686 775

O 3-33 0228 0608 832
J 0228 0682 860
3-32
C 0228 0687 1300
N 0228 0446 1790
Q 3-33 0228 0444 1991
K 0228 0677 2210
A 3-30 0228 0454 3110

Note 1: The slot angle indicates that the machine has a Mark I transport belt layout (compare with Figure 3-35 on Page 3-50).
Transport
Belt A
0228 0454
Figure 3-30
TP01311011 Rev 05 November 2009

Note 1
Mark I Belt Path – Belts A, E, and G
Note 2: Belt G fits around the three right-hand rollers shown in this Belt G Belt E
figure. Compare this same section area in Figure 3-8 on Page 3-14. 0228 0635 0228 0683
3-43
Figure 3-31 Mark I Belt Path – Belts B, C, D, F, H, I, J, L, and M
0228 0687
Belt C
0228 0685
Belt D
0228 0685
Belt B
0228 0686
Belt F
0228 0683
Belt M
28.000
ø
26.000
ø
0228 0635
26.500
ø
ROLLER OD
Belt G
0228 0680
Belt H
0228 0681
0228 0681
Belt I
Belt L
0228 0682
Belt J

Figure 3-32 Mark I Belt Path – Belts K, N, and Q
0228 0444
Belt Q
0228 0446
Belt N
0228 0677
Belt K
TP01311011 Rev 05 November 2009 3-45

Figure 3-33 Mark I Belt Path – Belts O and P
0228 0685
Belt P
0228 0608
Belt O
29.100
28.000
ø
26.000
ø
26.500
ø
ROLLER OD

3.12.3 Front Roller Assemblies Kit (400-3000-204)
Table 3-12 Kit, Front Roller Assemblies – 400 3000 204

1 400 2001 201 STANDOFF 50 DIA CRN RLR ASSY 7

3 400 2001 401 STANDOFF 16 DIA CRN RLR/POST ASSY 4
4 400 2001 501 STANDOFF, 25 DIA CRN RLR ASSY 38
5 400 2005 202 STANDOFF, 25 DIA DIV RLR ASSY 5
6 400 2009 901 STANDOFF, LIMPNESS RLR ASSY 1
7 400 2014 001 STANDOFF ASSY, 16 DIA RLR INBD 2
8 400 2017 601 STANDOFF ASSY, 16 DIA TWIN IND. OBD. 3
9 400 2017 701 STANDOFF ASSY, 16 DIA TWIN IND. INBD. 3
10 400 2017 801 STANDOFF ASSY, 25 DIA TWIN IND. INBD. 2
11 400 2018 101 STANDOFF ASSY, 25 DIA DBL COMB. RLR 2
12 400 2018 402 STANDOFF ASSY, 16/17.4 DIA COMB RLR 1
13 400 2018 501 STANDOFF ASSY, 50 DIA ROLLER OUTBD. 1
TP01311011 Rev 05 November 2009 3-47

Figure 3-34 Kit, Front Roller Assemblies – 400 3000 204

3.12.4 Mark II Transport Belt Paths

The Mark II belt path is configurable to accommodate customer detector
packages and process requirements. The following zones contain the
configurable belt path groups:
 Zone 1 – lower right-hand side
 Zone 2 – central right-hand side
 Zone 3 – upper right-hand side
Table 3-13 shows these zones and the common belts and rollers used in
all machine configurations. Each zone can have several configurations.
For example, six variants exist for Zone 2: kits 2A through 2G.
Table 3-13 Mark II Common Belt Paths – 400 3005 501

1 0228 0607 BELT FLAT S/ELAS FIT LG 958 MAN LG 930 1

4 0228 0677 BELT FLAT 2210 LG 12 WIDE 1
5 0228 0680 BELT FLAT SS FIT LGH 216 MAN LGH 213 1
TP01311011 Rev 05 November 2009 3-49

Figure 3-35 Mark II Common Belt Paths – 400 3005 501
Note

3.12.4.1 Mark II Common Rollers (400-3002-501)
Table 3-14 Mark II Common Rollers – 400 3002 501


3 400 2001 402 STANDOFF 16 DIA CRN RLR/POST ASSY 3
5 400 2005 202 STANDOFF 25 DIA DIV RLR ASSY 6
6 400 2017 602 STANDOFF 16 DIA TWIN IND OBD 3
7 400 2018 403 STANDOFF 16/17.4 DIA COMB RLR 1
8 400 2018 501 STANDOFF 50 DIA RLR OU 1
SKELETON BACKPLATE 4-POCKET DESK
9 – 1
SORTER
TP01311011 Rev 05 November 2009 3-51

Figure 3-36 Mark II Common Rollers (400-3002-5001)

3.12.4.2 Zone 1 Belt Path
Figures 3-37 and 3-38 show the belt layout and the roller kit for Zone 1,
which currently has no alternative options.
3.12.4.3 Roller and Belts 1A (400-3007-001)
Table 3-15 Kit Roller and Belts 1A – 400 3007 001

1 0228 0444 BELT FLAT NON-STRETCH 1991G 1

2 0228 0685 BELT FLAT SS FIT LGH415 MAN 1
3 400 3007 101 KIT ROLLERS 1A 1
Figure 3-37 Kit Roller and Belts 1A – (400-3007-001)
TP01311011 Rev 05 November 2009 3-53

Roller and Belts 1A (400-3007-

101)
Table 3-16 Kit Rollers 1A – 400 3007 101


Figure 3-38 Kit Rollers 1A – 400 3007 101

Zone 2 layout options contain a primary belt path (2A) and several varia-
tions from the primary path. Subsequent sections contain drawings and
parts lists identifying each available variant for this zone (2B through 2G).
Primary Belt Path 2A Figures 3-39 and 3-40 illustrate the primary belt layout and roller kit for
Zone 2.
Table 3-17 2A (Primary) Roller Kit and Belts – 400 3005 902
1 0228 0455 BELT FLAT SEMI-ELAST C 532LG 1
2 0228 0611 BELT FLAT S/ELAS FIT 347LG 1
4 0228 0705 BELT FLAT SS FIT LGH 193LG 1
6 0241 0541 FOOT, PUSH ON 1
7 400 2016 703 BRACKET ASSY – STKR ENTRY ROLLER 1
8 400 3004 502 KIT ROLLERS 2A 1
9 401 6008 001 ARM SUPPORT – SSHT RLLR 1
Figure 3-39 2A (Primary) Roller Kit and Belts – 400 3005 902
TP01311011 Rev 05 November 2009 3-55

2A Roller Kit (400-3004-502)
Table 3-18 2A Roller Kit – 400 3004 502


2 400 2014 001 STANDOFF ASSY 16 DIA RLR INBD 8
3 400 2017 701 STANDOFF ASSY 16 DIA TWIN IND 2
4 400 2026 201 STANDOFF ASSY 16 DIA TWIN COMB 1
Figure 3-40 2A Roller Kit – 400 3004 502

3.12.4.5 Variant 2B
Table 3-19 2B Roller Kit and Belts – 400 3006 601

1 0228 0635 BELT FLAT S/ELAS FIT LGH183 1

7 400 3004 201 KIT ROLLER VARIANT 2B 1
Figure 3-41 2B Roller Kit and Belts – 400 3006 601
TP01311011 Rev 05 November 2009 3-57

2B Roller Kit (400-3004-201)
Table 3-20 2B Roller Kit – 400 3004 201


Figure 3-42 2B Roller Kit – 400 3004 201

3.12.4.6 Variant 2C
Table 3-21 2C Roller Kit and Belts – 400 3007 701

1 0228 0455 BELT FLAT S/ELAS 542LG FITTED 1

5 400 3007 801 KIT ROLLERS 2C 1
Figure 3-43 2C Roller Kit and Belts – 400 3007 701
TP01311011 Rev 05 November 2009 3-59

Table 3-22 2C Roller Kit – 400 3007 801


Figure 3-44 2C Roller Kit – 400 3007 801
Note: This Kit Reflects the Differences to

the Standard Kit 40030045XX

3.12.4.7 Variant 2D
Table 3-23 2D Roller Kit and Belts – 400 3008 001


3 0228 0683 BELT FLAT SS FIT LGH460 1
7 400 3007 901 KIT ROLLER VARIANT 2D 1
Figure 3-45 2D Roller Kit and Belts – 400 3008 001
TP01311011 Rev 05 November 2009 3-61

Table 3-24 2D Roller Kit – 400 3007 901


Figure 3-46 2D Roller Kit – 400 3007 901
Note: This Kit Reflects the Differences to

the Standard Kit 40030045XX

3.12.4.8 Variant 2E
Table 3-25 2E Kit Rollers and Belts – 400 3009 701

0228 0617
1 BELT FLAT S/ELAS FIT LG 600 MAN LG 582 1
4003 0097
0228 0680
2 BELT FLAT SS FIT LGH 216 MAN LG 213 12 WD 0.45 THK 1
4003 0097
0228 0680
3 BELT FLAT SS FIT LGH 216 MAN LGH 213 12 WD 0.45 THK 1
4003 0097_2
0228 0681
4003 0097
0228 0685
4003 0097
6 400 3009 801 KIT ROLLERS VARIANT 2E 1
7 401 6022 701 GUIDE, TOP RIGHT CORNER 1
8 402 0040 001 GUIDE, TOP RIGHT CORNER 2 1
Figure 3-47 2E Kit Rollers and Belts – 400 3009 701
TP01311011 Rev 05 November 2009 3-63

Table 3-26 2E Kit Rollers – 400 3009 801


3 400 2040 602 PLATE CARRIER MAG D/A 1
4 400 2040 801 STOFF D/A 22 PLASTIC RLLR 4
5 400 2040 901 STOFF D/A DIA 22 PLASTIC DBL IND 1
6 400 2041 001 STOFF D/A DIA 25 PLASTIC RLLR 1
7 400 2041 201 HOUSING BEARING ASST MAG 1
8 400 2041 401 PLATE CARRIER MAG LWR D/A 1
9 400 2041 502 STOFF D/A 22 PLASTIC DBL LNKD 1
10 400 2041 601 STOFF D/A 22 PLASTIC INBRD 2
11 400 2043 101 STOFF D/A 25 PLASTIC INBRD 1
12 402 0038 401 DRILL JIG MAG 1
13 402 0039 701 DRILL JIG MAG UPPER 1
14 402 0039 801 SPACER, PLASTIC RLLR STOFF 1
Figure 3-48 2E Kit Rollers – 400 3009 801

3.12.4.9 Variant 2F
Table 3-27 2F Kit Roller and Belts – 400 3009 901

0228 0605
1 BELT FLAT S/ELAS FIT LG 290 MM MAN LG 282 MM 1
4003 0099_1
0228 0605
2 BELT FLAT SS FIT LGH 290 MAN LG 282 12 WD 0.45 THK 1
4003 0099_2
0228 0680
4003 0099_2
0228 0680
4 BELT FLAT SS FIT LGH 216 MAN LGH 213 MM 12 WD 0.45 THK 1
4003 0099_3
0228 0683
5 BELT FLAT SS FIT LGH 460 MM MAN LGH 451 12 WD 0.45 THK 1
4003 0099
0228 0685
4003 0099
0228 0719
7 BELT FLAT SS FIT LGH 375 MM MAN LGH 368 12 WD 0.45 THK 1
4003 0099_2
8 400 3010 002 KIT ROLLERS VARIANT 2F 1
Figure 3-49 2F Kit Roller and Belts – 400 3009 901
TP01311011 Rev 05 November 2009 3-65

Table 3-28 2F Kit Rollers – 400 3010 002


3 400 2033 602 STOFF ASSY, 20 DIA RLR CENTRAL 1
8 400 2041 201 HOUSING BEARING ASSY MAG 1
10 400 2041 502 STOFF D/A DIA 22 PLASTIC DBL LNKD 2
11 400 2043 201 STOFF D/A PL RLLR DBL 1
12 402 0038 401 DRILL JIG MAG 1
Figure 3-50 2F Kit Rollers –400 3010 002

3.12.4.10 Variant 2G
Table 3-29 2G Kit Rollers and Belts – 400 3010 101

0228 0611
1 BELT FLAT S/ELAS FIT LG 357 MM MAN LG 347 MM 1
4003 0101
0228 0617
2 BELT FLAT S/ELAS FIT LG 600 MAN LG 582 1
4003 0101
0228 0680
3 BELT FLAT SS FIT LGH 216 LG 213 12 WD 0.45 THK 1
4003 0101
0228 0680
4003 0101_2
0228 0681
4003 0101
0228 0685
4003 0101
7 400 3010 201 KIT ROLLERS VARIANT 2G 1
Figure 3-51 2G Kit Rollers and Belts – 400 3010 101
TP01311011 Rev 05 November 2009 3-67

Table 3-30 2G Kit Rollers – 400 3010 201


3 400 2016 703 BRACKET ASSY – STKR ENTRY ROLLER 1
4 400 2026 201 STOFF ASSY, 16 DIA TWIN COMB 1
9 400 2041 201 HOUSING BEARING ASSY MAG 1
11 400 2041 502 STOFF D/A DIA 22 PLASTIC DBL LNKD 1
12 400 2041 601 STOFF D/A DIA 22 PLASTIC INBRD 3
13 402 0038 401 DRILL JIG MAG 1
Figure 3-52 2G Kit Rollers – 400 3010 201

Zone 3 has several optional layouts: a primary belt path (3A) and several
variations from the primary path. Subsequent sections contain drawings
and parts lists that identify each available variant for this zone (variants
3B through 3F).
Primary Belt Path 3A Figures 3-53 and 3-54 show the primary belt layout for Zone 3.
Table 3-31 3A Kit Rollers and Belts – 400 3006 002

1 0228 0510 BELT FLAT NON-STRETCH 2860LG 1

4 0228 0707 BELT FLAT SS FIT LGH785LG 1
5 400 2025 401 PIVOT ROLLER OFFSET ASSY 3
6 400 3005 302 KIT ROLLER VARIANT 3A 1
TP01311011 Rev 05 November 2009 3-69

Figure 3-53 3A Kit Rollers and Belts – 400 3006 002

Table 3-32 3A Kit Rollers – 400 3005 302


5 400 2026 301 STANDOFF LIMPNESS RLR ASSY 1
Figure 3-54 3A Kit Rollers – 400 3005 302
TP01311011 Rev 05 November 2009 3-71

Variant 3B
Table 3-33 3B Kit Rollers and Belts – 400 3007 201

1 0228 0604 BELT FLAT S/ELAS FIT LG522MM 1

6 400 2034 101 PIVOT ROLLER ASSY – CENTRAL 1

Figure 3-55 3B Kit Rollers and Belts – 400 3007 201
TP01311011 Rev 05 November 2009 3-73

Table 3-34 3B Kit Rollers – 400 3004 901


6 400 2033 601 STANDOFF ASSY 20 DIA RLR CENTRAL 1
Figure 3-56 3B Kit Rollers – 400 3004 901

Variant 3C
Table 3-35 3C Kit Rollers and Belts – 400 3007 301

1 0228 0607 BELT FLAT S/ELAS FIT MAN LG930 1

BELT FLAT NON-STRETCH BLK 2785 LONG 12
2 0228 0658 1
WIDE
BELT FLAT SS FIT LGH1240MAN LGH1215
3 0228 0679 1
12WD 0.45THK
TP01311011 Rev 05 November 2009 3-75

Figure 3-57 3C Kit Rollers and Belts – 400 3007 301

Table 3-36 3C Kit Rollers – 400 3004 301


Figure 3-58 3C Kit Rollers – 400 3004 301
Variant 3D
Table 3-37 3D Kit Rollers and Belts – 400 3007 401


3 0228 0707 BELT FLAT SS FIT LGH785LG 1
4 0228 0715 BELT FLAT SS FIT 360LG 1
6 400 3004 801 KIT ROLLER VARIANT 3D 1
TP01311011 Rev 05 November 2009 3-77

Figure 3-59 3D Kit Rollers and Belts – 400 3007 401

Table 3-38 3D Kit Rollers – 400 3004 801


Figure 3-60 3D Kit Rollers – 400 3004 801
Variant 3E
Table 3-39 3E Kit Rollers and Belts – 400 3007 501


2 0228 0617 BELT FLAT S/ELAS FIT LG600MM MAN LG 582MM 1
6 400 2034 101 PIVOT ROLLER ASSY – CENTRAL 1
7 400 3005 001 KIT ROLLER VARIANT 3E 1
TP01311011 Rev 05 November 2009 3-79

Figure 3-61 3E Kit Rollers and Belts – 400 3007 501

Table 3-40 3E Kit Rollers – 403 0005 001


6 400 2033 601 STANDOFF ASSY 20 DIA RLR CENTRAL 1
Figure 3-62 3E Kit Rollers – 400 3005 001
Variant 3F
Table 3-41 3F Kit Rollers and Belts – 400 3007 601

1 0228 0658 BELT FLAT NON-STRETCH BLK 2785 LONG 12 WIDE 1

2 0228 0687 BELT FLAT SS FIT LGH1300MM 1
3 0228 0714 BELT FLAT SS FIT LGH945MM 1
5 4003 0046 01 KIT ROLLER VARIANT 3F 1
TP01311011 Rev 05 November 2009 3-81

Figure 3-63 3F Kit Rollers and Belts – 400 3007 601

Table 3-42 3F Kit Rollers – 400 3004 601


Figure 3-64 3F Kit Rollers – 400 3004 601
TP01311011 Rev 05 November 2009 3-83

3.12.5 Sub-Assembly Drawings
3.12.5.1 Capstan and Stacker Assemblies (400-3000-103)
Table 3-43 Kit, Capstan, and Stacker Assemblies – 400 3000 103
1 400 2001 902 HOUSING, BEARING-CAPSTAN ASSY 5

2 400 2008 103 CAPSTAN/HANDWHEEL ASSY 1
3 400 2000 803 CAPSTAN ASSY 3
Figure 3-65 Kit, Capstan, and Stacker Assemblies – 400 3000 103

3.12.5.2 Capstan/Stacker Wheel Lower Assembly (400-4002-301)
Table 3-44 Capstan/stacker Wheel Lower Assembly – 400 4002 301


3 0246 1263 SCREW M4 X 20 BUT HD BLKOX 3
5 400 2017 201 DISC, STACKER WHEEL D/A 1
6 401 6005 601 DISC, STACKER WHEEL 1
7 402 0011 901 WHEEL, STACKER (LOWER) – MACHINED 1
8 402 0013 801 SPACER – 8,1 ID X 10,7 OD X 15 LG 1
9 502 0124 501 WASHER CLAMP, CHAMFERED 1
Figure 3-66 Capstan/stacker Wheel Lower Assembly – 400 4002 301
TP01311011 Rev 05 November 2009 3-85

3.12.5.3 Capstan/Stacker Wheel Upper Assembly (400-4002-401)
Table 3-45 Capstan/Stacker Wheel Upper Assembly – 400 4002 401


3 0246 1263 SCREW M4 X 20 BUT HD BLKOX 3
5 400 2017 201 DISC, STACKER WHEEL D/A 1
6 401 6005 601 DISC, STACKER WHEEL 1
7 402 0012 001 WHEEL, STACKER (UPPER) – MACHINED 1
8 402 0013 801 SPACER – 8,1 ID X 10,7 OD X 15 LG 1
9 502 0124 501 WASHER CLAMP, CHAMFERED 1
Figure 3-67 Capstan/Stacker Wheel Upper Assembly – 400 4002 401

3.12.5.4 Caspstan Assembly (400-2000-803)
Table 3-46 Capstan Assembly – 400 2000 803


3 0048 0737 PIN SPL HVYDY 2 X 16 LG 1
4 400 2000 902 ARM, TENSION D/A – CAPSTAN 1
5 400 2001 902 HOUSING, BEARING – CAPSTAN ASSY 1
6 400 2015 201 ROLLER, CROWNED D/A – 16 DIA 1
7 402 0000 302 PULLEY, CAPSTAN 1
8 402 0000 501 SHAFT, TENSION ROLLER 1
9 402 0000 901 SHIELD – 16 DIA. ROLLER 1
10 501 4000 701 SHIELD DIA 25 ROLLER 1
11 501 4000 801 CAP, DIA 16/25 ROLLER 1
12 502 0124 501 WASHER CLAMP, CHAMFERED
Note: Capstan Spring P/N 4043000301
Figure 3-68 Capstan Assembly – 400 2000 803
TP01311011 Rev 05 November 2009 3-87

3.12.5.5 Capstan/Handwheel Assembly (400-2008-103)
Table 3-47 Capstan/Handwheel Assembly – 400 2008 103


3 400 2000 902 ARM, TENSION D/A – CAPSTAN 1
4 400 2008 202 HOUSING, BRG ASSY – CAPSTAN HANDWHEEL 1
6 402 0000 302 PULLEY, CAPSTAN 1
7 402 0000 501 SHAFT, TENSION ROLLER 1
8 402 0000 901 SHIELD – 16 DIA ROLLER 1
9 402 0005 802 HANDWHEEL, MODIFIED – CAPSTAN 1
10 402 0005 901 WASHER, CLAMP – CAPSTAN HANDWHEEL 1
11 501 4000 801 CAP, DIA 16/25 ROLLER 1
Note: Capstan Spring P/N 4043000301
Figure 3-69 Capstan/Handwheel Assembly – 400 2008 103

3.12.5.6 50” Diameter-Crowned Standoff Assembly (400-2001-201)
Table 3-48 Standoff Assembly, 50 Diameter Crowned – 400 2001 201

1 0246 0429 SCREW M6 X 75 SKT CAP GRADE 12.9 1

2 400 2001 101 ROLLER, 50 DIA CRN DBL SHIELDED D/A 1
3 402 0001 201 STANDOFF, 25 AND 50 DIA ROLLER 1
Figure 3-70 Standoff Assembly, 50 Diameter Crowned – 400 2001 201


4 402 0000 701 STANDOFF 16 DIA RLR – TRPT 1
TP01311011 Rev 05 November 2009 3-89



5 402 0001 001 POST, SCREW – 16 DIA RLR ASSY 1


2 402 0001 201 STANDOFF, 25 AND 50 DIA ROLLER 1
3 500 2039 601 ROLLER CROWNED. DBL SHIELDED DA 1

3.12.5.10 25” Diameter-Div Standoff Assembly (400-2005-202)
Table 3-52 Standoff Assembly, 25 Diameter Div – 400 2005 202

1 0046 2429 SCREW M6 X 20 SKT CAP HD FTS BLACK 1

2 402 0003 602 STANDOFF, 25 DIA DIV ROLLER 1
3 500 2003 802 ROLLER CROWNED D/A 1
4 552 0088 601 SHIELD, ROLLER CULL BELT RTRN 2
Figure 3-74 Standoff Assembly, 25 Diameter Div – 400 2005 202
3.12.5.11 Limpness Roller Standoff Assembly (400-2009-901)
Table 3-53 Standoff Assembly, Limpness Roller – 400 2009 901

1 0246 0386 SCREW M6 X 80 SKT CAP HD FTS BLACK 1

2 402 0008 601 STANDOFF, ROLLER LIMPNESS 1
4 501 4000 801 CAP, DIA 16/25 ROLLER 1
5 550 2017 001 CRACKLE ROLLER D/A 1
Figure 3-75 Standoff Assembly, Limpness Roller – 400 2009 901
TP01311011 Rev 05 November 2009 3-91

3.12.5.12 16” Diameter Twin Individual Inboard Standoff Assembly (400-2014-001)
Table 3-54 Standoff Assy, 16 Diameter Twin Individual Inboard – 400 2014 001
5 402 0012 601 STANDOFF 16 DIA TWIN IND. INBD. 1
Figure 3-76 Standoff Assy, 16 Diameter Twin Individual Inboard – 400 2014 001
3.12.5.13 16” Diameter Twin Standoff Assembly (400-2017-601)
Table 3-55 Standoff Assembly, 16 Diameter Twin – 400 2017 601

6 402 0012 501 SPACER – BEARING DIA 16 ROLLER 1
Figure 3-77 Standoff Assembly, 16 Diameter Twin – 400 2017 601

3.12.5.14 16” Diameter Twin Individual Inboard Standoff Assembly (400-2017)

3 400 2015 201 ROLLER, CROWNED D/A — 16 DIA 2
4 402 0000 901 SHIELD — 16 DIA. ROLLER 1
5 402 0012 601 STANDOFF 16 DIA TWIN IND. INBD. 1
6 402 0012 701 SPACER — BEARING DIA 16 ROLLER 1
3.12.5.15 25” Diameter Twin Individual Inboard Standoff Assembly (400-2017-801)

2 402 0012 801 STANDOFF, 25 DIA TWIN IND. INBD 1
3 402 0012 901 SPACER, BRG – DBL/TWIN 25 DIA RLR 1
4 500 2039 601 ROLLER CROWNED, DBL SHIELDED DA 2
TP01311011 Rev 05 November 2009 3-93

3.12.5.16 25” Diameter Double Standoff Assembly (400-2018-101)
Table 3-58 Standoff Assembly, 25 Diameter Double – 400 2018 101


2 400 2018 001 ROLLER ASSY – 25 DIA DOUBLE 1
3 402 0012 801 STANDOFF, 25 DIA TWIN IND. INBD. 1
Figure 3-80 Standoff Assembly, 25 Diameter Double – 400 2018 101
3.12.5.17 16/17.4” Diameter Double Standoff Assembly (400-2018-402)
Table 3-59 Standoff Assembly, 16/17.4 Diameter Double – 400 2018 402

3 400 2018 302 ROLLER D/A – 16/17.4 DIA DOUBLE 1
Figure 3-81 Standoff Assembly, 16/17.4 Diameter Double – 400 2018 402

3.12.5.18 50” Diameter Outboard Standoff Assembly (400-2018-501)
Table 3-60 Standoff Assembly, 50 Diameter Outboard – 400 2018 501


2 400 2001 101 ROLLER, 50 DIA CRN DBL SHIELDED D/A 1
3 402 0013 201 STANDOFF, 50 DIA ROLLER OUTBD. 1
Figure 3-82 Standoff Assembly, 50 Diameter Outboard – 400 2018 501
3.12.5.19 16” Diameter Twin Double Standoff Assembly (400-2026-201)
Table 3-61 Standoff Assembly, 16 Diameter Twin Double – 400 2026 201

3 400 2026 501 ROLLER D/A – 16 DIA DOUBLE 1
5 402 0012 601 STANDOFF, 16 DIA TWIN IND INBD 1
Figure 3-83 Standoff Assembly, 16 Diameter Twin Double – 400 2026 201
TP01311011 Rev 05 November 2009 3-95

3.12.5.20 Limpness Roller Standoff Assembly (400-2026-301)
Table 3-62 Standoff Assembly, Limpness Roller – 400 2026 301

1 0246 0386 SCREW M6X80 SKT CAP HD HTS BLAC 1

2 400 2027 701 CRACKLE ROLLER D/A 1
3 402 0008 601 STANDOFF, ROLLER LIMPNESS 1
5 501 4000 801 CAP, DIA 16/25 ROLLER 1
Figure 3-84 Standoff Assembly, Limpness Roller – 400 2026 301
3.12.5.21 20” Diameter Central Roller Standoff Assembly (400-2033-602)
Table 3-63 Standoff Assembly, 20 Diameter Central Roller – 400 2033 602
1 0246 1312 WASHER M5 SFTY ST STL 1

2 0246 1344 SCREW M5 x 75 CAP SKT ST STL 1
3 400 2024 701 ROLLER 20 DIA D/A SOIL 1
Figure 3-85 Standoff Assembly, 20 Diameter Central Roller – 400 2033 602

3.12.5.22 22” Diameter Plastic Roller Standoff D/A (400-2040-801)
Table 3-64 Standoff D/A Diameter 22 Plastic Roller – 400 2040 801
1 0046 1752 WASHER M4 x 9 x 0.8 NYLON 1

2 0245 0067 O-RING 7.1 I/D x 1.6D NITRILE 1
3 0246 0206 SCREW M4 x 10 LG CH SLD NYN 1
4 0249 0526 BEARING PLASTIC 81D 220D 14THK 1
5 402 0037 601 STANDOFF 22 DIAM PLASTIC ROLLER 1
Figure 3-86 Standoff D/A Diameter 22 Plastic Roller – 400 2040 801
3.12.5.23 22” Diameter Plastic Double IND Standoff D/A (400-2040-901)
Table 3-65 Standoff D/A Diameter 22 Plastic Double IND – 400 2040 901
1 0046 1752 WASHER M4 x 9 x 0.8 NYLON 1

4 0249 0526 BEARING PLASTIC 81D 220D 14THK 2
5 402 0037 801 STANDOFF 22 DIAM ROLLER DBL 1
6 402 0037 901 SPACER PLASTIC ROLLERS 1
Figure 3-87 Standoff D/A Diameter 22 Plastic Double IND – 400 2040 901
TP01311011 Rev 05 November 2009 3-97

3.12.5.24 25” Diameter Plastic Roller Standoff D/A (400-2041-001)
Table 3-66 Standoff D/A Diameter 25 Plastic Roller – 400 2041 001
1 0046 1752 WASHER M4 x 9 x 0.8 NYLON 1

4 0249 0527 ROLLER SARNA P3702 DIA 25 1
5 402 0037 601 STANDOFF 22 DIAM PLASTIC ROLLER 1
Figure 3-88 Standoff D/A Diameter 25 Plastic Roller – 4002 0410 01
3.12.5.25 Magnetic Housing Bearing Assembly (400-2041-201)
Table 3-67 Housing Bearing Assembly, Magnetic – 400 2041 201

1 0246 1231 PRE-LOAD WASHER EPL12 1

2 0246 1311 WASHER M4 SFTY ST STL 1
3 0246 1361 SCREW M4 x 10 BUT SKT ST STL GRA2-70 1
4 0249 0153 BEARING, BALL 81D 220D 7 THK 2
5 402 0001 901 SHIELD, BEARING 1
6 402 0028 201 HOUSING, AUX CAPSTAN BRG 1
7 402 0038 001 SHAFT, AUX CAPSTAN 1
8 402 0038 101 SPACER NON MAG SHAFT 1
9 402 0038 201 ROLLER DIAM 16 NON MAG 1
10 0U20 1521 WASHER (1110 STOCK) 1

Figure 3-89 Housing Bearing Assembly, Magnetic – 400 2041 201
3.12.5.26 22” Diameter Plastic Double-Linked Standoff D/A (400-2041-502)
Table 3-68 Standoff D/A Diameter 22 Plastic Double Linked – 400 2041 502
1 0046 1752 WASHER M4 x 9 x 0.8 NYLON 1

4 0249 0531 ROLLER SARNA 22 OD DOUBLE 1
5 402 0037 801 STANDOFF 22 DIAM RLLR DBL 1
Figure 3-90 Standoff D/A Diameter 22 Plastic Double Linked – 400 2041 502
3.12.5.27 22” Diameter Plastic INBRD Standoff D/A (400-2041-601)
Table 3-69 Standoff D/A Diameter 22 Plastic INBRD – 400 2041

601
1 0046 1752 WASHER M4 x 9 x 0.8 NYLON 1

4 0249 0526 BEARING PLASTIC 81D 220D 14 THK 1
5 402 0038 301 STANDOFF 22 DIAM PLASTIC RLLR I/B 1
TP01311011 Rev 05 November 2009 3-99

Figure 3-91 Standoff D/A Diameter 22 Plastic INBRD – 400 2041 601
3.12.5.28 Plastic Double Roller Standoff D/A (400-2043-201)
Table 3-70 Standoff D/A Plastic Roller Double – 400 2043 201
1 0046 1752 WASHER M4 x 9 x 0.8 NYLON 1

4 0249 0526 BEARING PLASTIC 81D 220D 14 THK 1
5 402 2043 301 PLASTIC RLLR AND SLEEVE D/A 1
6 402 0037 801 STANDOFF 22 DIAM RLLR DBL 1
7 402 0037 901 SPACER PLASTIC ROLLERS 1
Figure 3-92 Standoff D/A Plastic Roller Double – 400 2043 201

3.12.5.29 Stacker Entry Roller Bracket Assembly (400-2016-703)
Table 3-71 Bracket Assembly, Stacker Entry Roller – 400 2016 703
1 0042 0106 CLIP EXT SHAFT 4.5 2

5 0046 2427 SCREW M4X20 CAP SKT 1
6 0046 2428 SCREW M5X20 CAP SKT 1
7 0100 2468 BEARING-BALL 6ID 12OD 4WD 2
8 400 2015 201 ROLLER, CROWNED D/A 16DIA 1
9 400 2016 503 BRACKET DA, ROLLER FIXED 1
10 400 2016 603 BRACKET DA, ROLLER MVG 1
11 401 4002 001 TYRE – STKR ENTRY ROLLER 1
12 402 0000 901 SHIELD 16 DIA ROLLER 2
13 402 0011 602 PIN ROLLER BRACKET 1
14 402 0015 101 BUSH STKR ENTRY ROLLER 2
15 402 0022 201 MOUNT TYRE STKR ENTRY RLR 2
16 0243 0435 SPRING TORSION 76.8NM 1
TP01311011 Rev 05 November 2009 3-101

Figure 3-93 Bracket Assembly, Stacker Entry Roller – 400 2016 703

3.12.5.30 Pivot Roller Offset Assembly (400-2025-401)
Table 3-72 Pivot Roller Offset Assembly – 400 2025 401

1 0042 0106 CIRCLIP EXT SHAFT 4.5 2

4 0100 2468 BEARING – BALL 61D 120D 4WD 2
5 400 2025 001 BRACKET DA, ROLLER MVG 1
6 401 6009 501 MTG ROLLER PIVOT 1
7 402 0015 102 BUSH STKR ENTRY ROLLER 2
8 402 0022 201 MOUNT, TYRE STKR ENTRY RLR 2
9 402 0025 401 TYRE, PIVOT ARM 1
10 402 0030 601 PIN ROLLER BRACKET 1
Figure 3-94 Pivot Roller Offset Assembly – 400 2025 401
TP01311011 Rev 05 November 2009 3-103

NOTES:

NOTES:
TP01311011 Rev 05 November 2009 3-105


Chapter 4
Power
Topic Page Number
4.1 - Power 4-2
4.2 - Settings and Adjustments 4-13
4.3 - Removal and Replacement 4-14
4.4 - Wiring Schedules 4-15

4.1 Power Power
4.1 Power
4.1.1 Overview
This section describes the Cobra AC/DC power systems, internal power
distribution, and fuses.
The Cobra AC/DC power systems and internal power distribution have
two configurations:
 Standard Cobra setup - For use with other Cobra four-pocket exten-
sions
 Modified setup - Accommodates Cobra line-up integration with 6000
modules, such as:
 The Four-Stacker Module (FSM)
 The Two-Stacker Destruction Module (TSDM).
Variants of the FSM and TSDM:
 Two-Stacker Module (TSM)
 Destruction Module (DM), which can be part of the hybrid config-
uration.
The integration of the 6000 modules (FSM, TSDM) enables a Cobra site
to band stacks of banknotes and, when required, to destroy those bank-
notes determined unfit for continued circulation.
The 6000 modules can be equipped with downfeeds that deliver banded
banknotes to a conveyor that runs the length of the bander sections.
The conveyor delivers the banknotes to a 5000 PPU or to a Universal
Bundling System for post-packaging (that is, to combine 5 or 10 banded
stacks into larger bundles).
The Cobra and 6000 modules are essentially independent, yet they
interconnect with each other through three well-defined electrical
systems:
 Safety interface circuits
 Communications interface (CAN bus)
 Power
Refer to the following manuals for additional information on the safety
interlocks, CAN bus interconnections, and power:
 Cobra Site Planning Manual - TP04511001
 FSM/TSDM Service Manual - TP01511002
 DSM Service Manual - TP01511021

Power 4.1 Power
4.1.2 Safety Interface Circuits
The safety interface protects the operator from rotating or moving parts.
Both the Cobra and 6000 have similar concepts that provide the following:
Open Cover Protection  Whenever an operator cover is open, the motors and actuators stop
operating in the module containing the open cover while other modules
whose covers remain closed are not affected. However, in this sce-
nario, the software stops all motors, thus stopping the machine.
Emergency Stop Buttons  Whenever an emergency stop button, located in various places within
(6000 Modules Only) the machine modules, is active, all motors and actuators in the entire
machine stop regardless of which button is active.
Override Switches  Whenever an override switch is active, all protection against open 
covers is overridden throughout the machine. This allows the machine
to run normally with the covers open and does not affect the action of
the emergency stop buttons.
 A single switch provides the override function. You cannot operate the
switch without removing a tool-released cover. The override switch is
active for all machine operator covers. When you replace the protec-
tive cover, the override condition automatically cancels.
Shredder Protection  Where a site is equipped with a shredder, the cutting head chamber
has protection just as with an open cover. However, unlike the open
cover protection, the override switch cannot disable the cutting head
protection.
 In all cases, protection consists of preventing power from reaching the
actuators.
All the above protection functionality applies in the 6000 whereas the
Cobra does not have emergency stop buttons or cover override switches.
Provision is made for them, however, because the integrated Cobra/6000
hybrid machines require all the above protection functionality.
The table supporting the Cobra permits the addition of an emergency stop
button and the Cobra is equipped with an override switch that resets
when the rear cover closes.
The Cobra back plane performs the 6000 Detector/Cull Module (DCM)
function of terminating the safety loop.
Figure 4-1 on Page 4-5 shows details of the safety scheme requirement
and displays relevant Cobra back plane circuitry and the 6000 DC box to
illustrate the requirements for connecting the two systems together.
The Cobra back plane and 6000 DC Box already have the required
functionality, provided the shown safety cable interconnects the Cobra
and 6000 modules.
The safety cable passes from Safety Out on the Cobra mother board to
Safety In on the 6000 module DC box.
The loop must terminate as on 6000 with a shorting plug in the Safety
Out connector in the last module and with a shorting plug in the Safety In
connector on the Cobra back plane.
Note: The Cobra back plane must be status ‘04’ or later.
TP01311011 Rev 05 November 2009 4-3

4.1 Power Power
The system safety interface signals consist of the following:

 E Stop Out
The E Stop Out signal passes emergency stop button signals to the
next module after passing through any emergency stop buttons in the
module.
 E Stop Return
The E Stop Return signal is the last output from all emergency stop
buttons that passes back through all modules, allowing access to the E
Stop Return signal throughout the system. The E Stop Return signal
ensures that the module motor systems become disabled when any
stop button is active. If no stop button is active, this signal is at 48V.
 Breaker
The Breaker signal passes to all modules to indicate that the machine
isolator is on and helps distinguish between a mains failure and an
intentional power off. When the machine isolator is on, the signal is at
48V. The Breaker signal also ensures that 6000 module batteries are
isolated from the Cobra when the machine isolator switch is off.
 Override
The Override signal passes to all modules to indicate when the
machine cover override switch is on. When the machine cover override
switch is on, the Override signal is at 48V. Override prevents the cover
switches from turning off the module motor systems.
 System 0V
The System 0V connection completes the 0V return back to the first
Cobra module.

Power
Safety Out (J76) Safety In Safety Out

Safety In (J203) Breaker
1
1 1 1 1 1 1
48V Override
Figure 4-1
S 0V E Stop Out
Mains Breaker
Breaker (J75) Breaker
(Closed if Mains On) 1 0V D E Stop RTN
Override
System 0V

E Stop Out E Stop 1 S 0V
E Stop Return E Stop Switch 2
Override (J78) (Or Link) 4
O/R Switch (or Link)
1 E Stop 2
E Stop Switch 2
6000 Interlock System
(Or Link) 4
SCR Enable Cover 1
Cover Switch Cover (J82) 1
(Closed if Cover Closed) E Stop Inactive
1 3
Override On 5
Cover Closed 9
Cover 2 48V 48V
E Stop (J81) 1
E Stop Switch (or Link)
1 3 Batt En
5 48V 48V
48V 9 Batt En
SCR (J87) Cover 3 48V 48V Batt OK
1
1
48V Covers
3
S 0V S 0V I/P Breaker
5
Override
9 48V
Covers Enable
0V D Batt In
0V D Inhibits (J101)
Override E Stop Battery
K1-1 1
S 0V
S 0V Relay
48V
0V D S 0V 0V D E Stop Driver
S 0V K1-2 Batt Out
S 0V S 0V K2-1 48V
0V D K1 K2
0V D Enable Safety
K2-2 S 0V S 0V Relay
0V D
Driver
0V D 0V D 0V D Enable All Contacts 1 1
SW 48V
NC Gen I/O1 Gen I/O2 6000 DC Box
Node Interface (J27) Cover Override Breaker Cobra Motherboard
Status
+24V Module
Integrated System Safety Interface
Inhibit
–24V
Node To Machine
Motor Systems
+24V Module
Inhibit
–24V
Node
42V Actuator Supply
Module 1 Module 2
4.1
4-5
Power
4.1 Power Power
4.1.3 Communications Interface
The communications among modules in a Cobra/6000 system occur over

the communications interface, which is the Controller Area Network
(CAN) bus.
Similarity of architecture and performance in the Cobra and 6000 systems
enables the distributed control systems to connect directly together using
a standard CAN cable without any modification.
The Cobra operator personal computer becomes the system Graphical
Control Console (GCC) and 6000 end modules connect as though
connected to a 6000 DCM.
The communications interface between a Cobra system and the FSM/
TSDM modules requires connecting the CAN Out connector on the
Cobra back plane to the CAN In connector on the first 6000 node using a
standard CAN cable of suitable length.
Recommendation: Use optically isolated CAN nodes where
possible.
4.1.4 Power
4.1.4.1 Power Systems and Power Distribution in a Cobra System
AC Input The Cobra machine AC input (see Figure 4-2) is a universal supply that
accepts single-phase 120/240 Vac. Both the live and neutral inputs, which
are fused, are applied to the two power supply units and the UV lamp
controller (see Figure 4-3 on Page 4-7).
Figure 4-2 Cobra Mains Input Wiring
Power Switch
Fuses
Mains Input Connector
In a standard Cobra installation, the 120/240 Vac mains is derived from a

normal site outlet through an Uninterruptible Power Supply (UPS), if
installed.

Power 4.1 Power
DC Power Supplies The Cobra machine is equipped with the two DC power supplies identified
in Figure 4-3. Both units mount on a tray on the bottom shelf of the
machine on the right-hand side, as viewed from the machine rear.
Figure 4-3 Power Supply Tray
UV Lamp Controller
A B Multiple-Voltage PSU
Note: The 42 Vdc PSU is behind the multiple-voltage PSU.
The Power Supply Unit (PSU) near the machine rear is a 400-Watt supply
that provides +5V, ±12V, ±15V, and 48V. The 48V powers fans and
safety interlock circuits. The 48V supply is derived from wiring the +24V
and the –24V supplies in series and referencing the negative end of the
combined supplies to the system 0V.
The PSU near the machine front is a 600-Watt supply that provides 42V
for the transport, feeder, and diverter motors. The 42V supply is derived in
a similar manner using the +21V and –21V supplies.
Internal Power Distribution Figure 4-4 on Page 4-8 shows the internal power distribution of the
Cobra system.
Fuses Table 4-1 on Page 4-8 lists the fuses that mount on the mother board.
TP01311011 Rev 05 November 2009 4-7

4.1 Power Power
Figure 4-4 Internal Power Distribution - Cobra
UV Lamp
Driver
Mains
Input
+5V
System CPU +12V
–12V
+5V +5V
Vision CPU +12V +12V
–12V –12V
+15V
Mother Power
Transport Motor +42V –15V
Board Supplies
Feeder Motor +42V +42V
Low Rem Mag +42V +48V
+24V
Soil Detector +42V 0V
H/Lamp +42V
+48V
Fans
+48V
Table 4-1 Mother Board Fuses

Designation Power Rail Rating (Amps) Description
F1 42V 3.75 Diverter supply

F2 42V 2.5 Feeder motor supply
F3 48V 2.5 Safety interlocks
F4 42V 0.5 Low rem mag
F5 24V 0.5 Soil detector
F6 +12V 2.5 H/lamp
F7 5V 8 Detectors
F8 5V 4 Diverters
F9 +12V 4 On board
F10 –12V 0.5 On board
F11 5V 8 On board
F12 +12V 4 On board
F13 -12V 0.5 On board
F14 5V 8 On board
F15 5V 2.5 On board

Power 4.1 Power
4.1.4.2 Power Systems and Power Distribution in an Integrated System
Cobra AC input, DC power supplies, internal power distribution, and

fusing remain the same in a Cobra/6000 hybrid configuration.
However, an integrated Cobra/6000 site requires 400 Vac, three-phase
power at 50/60 Hz.
Because the Cobra uses single-phase power of 120/240 Vac and the
6000 requires three-phase power of 400 Vac, an integrated Cobra/6000
application must accommodate the differing power systems.
The following compares the Cobra and 6000 power systems (see
Table 4-2).
Table 4-2 Cobra Versus 6000 Power Systems

Function Cobra 6000
Input Voltage Cobra is a dual-voltage system (120/240 Vac). 6000 is a 400-Vac line system only.
Cobra can function as a stand-alone unit. As a The 6000 is always a multi-module
stand-alone unit, Cobra receives power machine. 6000 modules draw power
Power
directly from normal site outlets through a from an AC mains power distribution
Derivation
mains on/off switch built into the Cobra base unit (Power Supply C or PSC) in the
unit. Detector/Cull Module (DCM).
The Cobra DCM makes no provision to distrib- An on/off breaker in PSC isolates
ute power to additional modules. However, a power from the machine. Thus, the
single on/off point is maintained by passing AC breaker functions as a single power
mains from one module to the next to power switch point regardless of the number
Power Isolation an isolator relay in the downstream modules. of modules in a line-up.
With each module connected in this manner,
the on/off switch in the base unit isolates the
whole machine regardless of the number of
modules in the line-up.
Cobra has no internal mains failure protection 6000 modules have built-in mains fail-
and must receive power through a proprietary ure protection through the use of 42V
Mains Failure
Uninterruptible Power Supply (UPS) in the batteries that directly support the
Protection
mains input line to maintain data and system module 48V power rail.
integrity.
Based on a comparison of the two power systems, integrating 6000 mod-

ules into a Cobra site requires adding a Mains Distribution Unit (MDU) as
the power interface.
The MDU, which is very much like the PSC that resides in the 6000 DCM,
fulfils the 6000 module power requirements in the absence of the DCM
while simultaneously meeting the power requirements for Cobra.
Thus, the MDU resolves the various Cobra/6000 incompatibilities: power
switching and distribution to the modules.
Each Cobra module retains its UPS unit to separately protect AC mains
from failure. The 6000 modules retain their internal batteries to protect AC
mains from failure.
To further accommodate Cobra/6000 differences, the table that supports
the Cobra DCM and any Cobra 4PM extension modules also houses the
MDU and UPS units in an external cabinet that bolts to the table. In terms
of supplying power, the Cobra units together with the supporting table and
its cabinet function as the 6000 DCM in a 6000 configuration.
TP01311011 Rev 05 November 2009 4-9

4.1 Power Power
Figure 4-5 shows a rear view of the table and the cabinet housing the
MDU and UPS units in an integrated Cobra/6000 system.
Figure 4-5 UPS and MDU in Integrated Cobra/6000 Application
A. Mains Distribution Unit B. Uninterruptible Power Supply
Sites that do not have 400 Vac power require a voltage-boost transformer
or auto transformer.
Figure 4-6 shows a block diagram of the AC power distribution in an inte-
grated Cobra system with 6000 modules.
The MDU connects directly to the site supply through the site isolator
switch and provides a master isolator switch.
Normally, the master isolator switch remains on to allow the Cobra UPS
units to charge.
However, this switch can be used to isolate the MDU, whenever required.
Warning! The UPS continues to produce single-phase mains
voltages even with the master isolator switch off.
The Cobra on/off switch, also referred to as the machine isolator, powers
the whole machine so that the operator has a familiar and clear means of
powering up.
When Cobra modules connect to the MDU (through their UPS units, if
installed), the DCM and 4PM extension modules have AC mains present
at their mains input sockets.
When the machine isolator switch is on, the Cobra DCM energises and
provides AC mains at its power outlet to switch power to the 4PM exten-
sion module in accordance with the normal Cobra switch-on procedure.
With the DCM module energised, the power outlet in the 4PM extension
module, in turn, energises a power transfer relay in the MDU.
Only when the power transfer relay energises does power connect to the
remaining sockets on the MDU and on to the 6000 modules.
The one exception is single-phase output 4, which also requires that the
Cobra transport be running (if this option is installed). Output 4 powers
detector pumps or other auxiliary equipment.

Power
Cobra DCM Cobra 4PM FSM TSDM/TSM

Figure 4-6
Machine
Isolator Mains In Mains Out Mains In Mains Out

TSDM/
Cable 3 Cable 5 Cable 6 Shredder
FSM Control TSDM/TSM
DC Box Box DC Box
UPS UPS
Cable 2 Cable 4 Cable 7 Cable 8 Cable 9
230 Vac, 230 Vac, 230 Vac, 230 Vac, 230 Vac, 230 Vac, 230 Vac, 400 Vac, Track Clock
10 Amps 10 Amps 100 VA 10 Amps 10 Amps 10 Amps 4 Amps 20 Amps 6-Wire RJ11
Cobra Expansion Relay Output 1 Output 2 Output 3 Output 4 Shredder

Output Output Control In 3 1 2 L3 In 3-
L1 In L2 In Output
Site
Isolator Pump
3- Controller
400 Vac, Power (Optional)
25 Amps, Master
Transfer
50/60 Hz Isolator
Relay
Cable 1
Mains Distribution Unit
Power Distribution in an Integrated Cobra/6000 Application
4.1
4-11
Power
4.1 Power Power
The 230 Vac mains to the Cobra DCM is derived from a single phase on
the left-most AC outlet in the MDU when viewed from the rear.
A second phase provides 230 Vac to the Cobra 4PM extension module
(Expansion Output).
The power transfer relay must receive 230 Vac from the DCM unit mains
out (in a 4004 configuration) or the 4PM expansion module mains out (in
a 4008 configuration) to enable power to the 6000 modules.
The desk on which the Cobra system rests provides cable manage-
ment for the additional cables required to power an integrated Cobra/
6000 system. (see Table 4-3)
Table 4-3 Cables Required to Power an Integrated Cobra/6000 System

Cable # Description
Cable 1 Three-phase power in routes directly from the site supply to the MDU.
MDU Cobra Output to the Cobra UPS power in (desk cable management
Cable 2
system)
Cobra UPS power out to the Cobra DCM mains in passes through a hole in
Cable 3
the desk – (desk cable management system)
MDU 4PM Expansion Output to the expansion UPS power in – (desk cable
Cable 4
management system)
Expansion UPS power out to Cobra 4PM expansion module mains in –
Cable 5
(desk cable management system)
Cobra DCM mains out (if no expansion unit) or Cobra 4PM expansion mod-
Cable 6 ule mains out (if equipped) to MDU Relay Control In passes through a hole
in the desk – (desk cable management system)
MDU Output 1 to 6000 module 1 (FSM or TSDM) – interface to 6000 power
Cable 7
trunking
MDU Output 2 to 6000 module 2 (TSDM when FSM is present) – interface
Cable 8
to 6000 power trunking
MDU Shredder Output to TSDM shredder – interface to 6000 power trunk-
Cable 9
ing

Power 4.2 Settings and Adjustments
4.2 Settings and Adjustments
Use the potentiometers shown in Figure 4-7 to adjust the power supplies
and set them in accordance with the values shown in Table 4-4 on
Page 4-14. Verify that all units are installed on the machine with power
applied before making any adjustments.
Figure 4-7 Power Supply Unit Front Panels
Notes Note 1: Because all measurements reference the system 0V, make the
measurements at the input terminals on the mother board rather than at
the supply. Silk screening on the mother board identify the connections.
Note 2: Verify that the sense lines are connected before adjusting the
+5V supply.
Note 3: Set the two elements of each supply to the same voltage when
adjusting the 48V and the 42V supplies:
 While measuring across the negative supply half (–24V/–21V), set the
supply to the nominal voltage.
 While measuring across the combined supply, set the overall voltage
(48V/42V) using the adjustment potentiometer for the positive half of
the supply.
Note 4: Do not adjust the unmarked adjustment on the 21V PSU (Part
Read! Number 0262 0661), which is for setting the ‘module-good’ signal.
TP01311011 Rev 05 November 2009 4-13

4.3 Removal and Replacement Power
Table 4-4 Power Supply Settings

Test Point
Nominal
(0V on TP9 – Supply Tolerance Notes
Voltage
TP18)
TP19, TP20,
TP23, TP26, 5V +5.15V ±0.01V –ve rail referenced to system 0V
TP27
TP21
+12V +12.00V ±0.1V –ve rail referenced to system 0V
TP24
TP22,
–12V –12.00V ±0.1V +ve rail referenced to system 0V
TP25
J72 +15V +15.00V ±0.1V –ve rail referenced to system 0V
J77 –15V –15.00V ±0.1V +ve rail referenced to system 0V
The two supplies connect in series to provide a
+24V +24.00V ±0.2V 48V ±0.4V supply. The most negative terminal 
TP8 (48V)
–24V –24.00V ±0.2V connects to system 0V.
The two supplies connect in series to provide a
+21V +21.00V ±0.2V
J63 (42V) 42V ±0.4V supply. The most negative terminal
–21V –21.00V ±0.2V connects to system 0V.
4.3 Removal and Replacement
Remove the power supply tray from the machine to remove either power
supply unit.
4.3.1 Power Supply Tray
Use Procedure 4-1 to remove the power supply tray.

Warning! Because this action requires access to the rear of the
machine, only authorised personnel should perform the proce-
dure. Verify that power to the machine is off: isolate the DCM and
any four-pocket modules from the uninterruptible power supplies
that connect to the mains power supply.
Procedure 4-1 Removing/Replacing the Power Supply Tray

Power Supply Tray Removal 1. Remove power from the machine.
2. Unplug the mains connectors from the right-hand side of both PSUs.
3. Unplug the output connectors from the left-hand side of both PSUs,
noting their positions.
4. Remove the bolt securing the ‘P’clip to the front PSU (B in
Figure 4-3 on Page 4-7).
5. Remove the bolts (A in Figure 4-3 on Page 4-7) and move the
cable support plate away from the working area.
6. Remove the four bolts (two at each end) securing the power supply
tray to the machine base plate.
7. Lift the power supply tray clear of the machine.
Power Supply Tray 8. Reverse the procedure steps to replace the power supply tray.
Replacement

Power 4.4 Wiring Schedules
4.3.2 Power Supply Units
Use Procedure 4-2 to remove a power supply unit:
Procedure 4-2 Removing/Replacing a Power Supply Unit

PSU Removal 1. Remove the power supply tray as detailed in Procedure 4-1.
2. Remove the screws securing the PSU to the tray and remove the
PSU.
PSU Replacement 3. Reverse the procedure steps to replace the PSU.
4.4 Wiring Schedules
Table 4-5 through Table 5 on Page 4-24 present the wiring schedules for
the Cobra/6000 hybrid AC distribution system, which includes the MDU.
Table 4-5 MDU Mains Bus 400 6007 801

Wire Length
Cable AWG/Type Colour From To Description
No (mm)
1 190 CB4-1 CB8-1 L3
2 165 CB8-1 CB7-5 L3
3 150 CB7-5 RL-6T3 L3
1 4 12/UL1015 Brown 190 CB5-1 CB7-1 L1
5 170 CB7-3 RL4T2 L2
6 180 CB6-1 CB7-3 L2
7 165 CB7-1 RL-2T1 L1
Table 4-6 MDU Neutral Bus 400 6007 901

Wire Length
Cable AWG/Type Colour From To Description
No (mm)
8 260 CB1-8 CB2-3
9 125 CB2-3 CB3-3
10 125 CB3-3 CB4-3
1 11 12/UL1015 Blue 125 CB4-3 CB5-3 Neutral
12 125 CB5-3 CB6-3
13 125 CB6-3 CB8-3
14 150 CB8-3 CB7-7
TP01311011 Rev 05 November 2009 4-15

4.4 Wiring Schedules Power
Table 4-7 MDU Mains Contactor 400 6008 001

Wire Length
Cable AWG/Type Colour From To Desc
No (mm)
1 540 CB1-2 RL-1L1 L1
2 540 CB1-4 RL-3L2 L2
1 3 12/UL1015 Brown 540 CB1-6 RL-4L3 L3
4 360 CB1-2 CB2-1 L1 (Unswitched)
5 360 CB1-4 CB3-1 L2 (Unswitched)
Table 4-8 MDU Relay Control 400 6008 101

Wire Length
No (mm)
1 Brown 140 CON8-L RL-A1 Live
1 2 16/UL1015 Blue 160 CON8-N RL-A2 Neutral
3 Grn/Yel 175 CON8-E Chassis Gnd
Table 4-9 MDU Shredder Power 400 6008 201

Wire Length
No (mm)
1 170 CB7-2 CON7-L1 L1
2 Brown 160 CB7-4 CON7-L2 L2
1 3 12/UL1015 150 CB7-6 CON7-L3 L3
4 Blue 140 CB7-8 CON7-N Neutral
5 Grn/Yel 170 Chassis CON7-Gnd Earth
Table 4-10 MDU IEC Outlet Power Cable 400 6008 301
Wire Length
No (mm)
1 Grn/Yel IEC-E Chassis Earth
16/UL1017
1 2 Blue 110 IEC-N CB*-4 Neutral
3 16/UL1015 Brown IEC-L CB*-2 Line
Table 4-11 Cobra Hybrid Safety Circuit 400 6008 401

Wire Length
No (mm)
1 Black PL1-1 SK1-1 Breaker
2 White PL1-3 SK1-2 Override
26/6C
3 Red PL1-6 SK1-3 E-Stop Out
SCRN
1 4 Green 1450 PL1-7 SK1-4 E-Stop Rtn
5 Blue PL1-9 SK1-6 System 0V
PL1
6 Drain Wire Bare Conn N/C Screen
Shell

Power 4.5 Illustrated Parts List
Table 4-12 is a parts list for the Cobra power supplies.

Table 4-13 lists components that make up the MDU as well as some of
the interconnection between the Cobra and the 6000 modules.
The MDU is part of the TLN Mark 2 Jersey Build kit (PN 400T 0054 02).
Tables 4-14 through 5 are parts lists for the various MDU buses and
cables.
Table 4-12 Cobra Parts List

Part Number Description
0262 0690 Uninterrupt Power Supply, 1400 VA, 120 Vac, 50/60 Hz a
0262 0691 Uninterrupt Power Supply, 1400 VA, 240 Vac, 50/60 Hz b
0262 0661 Power Supply 21V/21V 15A 600W
0262 0662 Power Supply 5V 60A/12V 8A, 24V/24V 0.5A 400W
0266 7451 IEC Plug 10A Flanged 6.3 mm Tabs, Panel Mount
0100 2835 Fuse 6A25 6.3 x 32 SB cer
a. Cobra uses either UPS (120/240 Vac)
b. Required for a Cobra/6000 hybrid configuration
Table 4-13 MDU AC Distribution and Communications

Part Number Description Qty
400-6007-801 Mains Distribution Unit Mains Bus (Table 4-5) 1
400-6007-901 CBLFM – MDU Neutral Bus (Table 4-6) 1
400-6008-001 CBLFM – MDU Mains Contactor (Table 4-7) 1
400-6008-101 CBLFM – MDU Relay Control (Table 4-8) 1
400-6008-201 CBLFM – MDU Shredder Power (Table 4-9) 1
400-6008-301 CBLFM – MDU IEC Outlet Power Cable (Table 4-10) 1
400-6008-401 CBLFM – MDU Cobra Hybrid Safety (Table 4-11) 1
0262 0580 CAN Bus Cable – 2 Meter (RJ-45) 1
0259 0679 190 CY, 5-Core, 6.0 mm2, 18.9 mm OD, 600V 1
0259 0525 Mains Cable, IEC CE22 Extension, 2 Meter a, b 3

0254 1373 IEC Cordset, Plug/Skt, 240V, 1 Meter 1
0262 0691 Uninterrupt Power Supply, 1400 VA, 240 Vac 2 1
a. These quantities apply to a hybrid system consisting of one Cobra 4004 and one
FSM or TSDM. If Cobra connects to both FSM and TSDM, the site requires an 
additional mains cable (0259 0525).
b. When the Cobra has an extension module (4PM), the site requires an additional
UPS and two additional mains cables (0259 0525).
TP01311011 Rev 05 November 2009 4-17

4.5 Illustrated Parts List Power
4.5.1 MDU Mains Bus (400-6007-801)
Table 4-14 MDU Mains Bus (400-6007-801)

1 0256 7499 Bootlace Ferrule 4.0 mm Sq Orange 3

2 0256 7536 Crimp Ferrule Yellow Twin Entry 6mm Cable 4
3 0256 7537 Termination Fork Tongue 4 Yellow 3
4 0259 0612 Wire 4.0 mm Sq UL1015 Brown 12 AWG 1210 mm
5 0047 0401 Tywrap 92/102 Long 4
6 0239 0188 Ident Label WML Series 1
7 0059 0271 Sleeve Ident PVC 4.0 ID x 5 Lg Brown 2
8 0059 0272 Sleeve Ident PVC 4.0 ID x 5 Lg Red 2
9 0059 0273 Sleeve Ident PVC 4.0 ID x 5 Lg Orange 2
10 0059 0274 Sleeve Ident PVC 4.0 ID x 5 Lg Yellow 2
11 0059 0275 Sleeve Ident PVC 4.0 ID x 5 Lg Green 2
12 0059 0276 Sleeve Ident PVC 4.0 ID x 5 Lg Blue 2
13 0059 0277 Sleeve Ident PVC 4.0 ID x 5 Lg Violet 2
Figure 4-8 MDU Mains Bus (400-6007-801)

4.5.2 MDU Neutral Bus (400-6007-901)
Table 4-15 MDU Neutral Bus (400-6007-901)


3 0259 0610 Wire 4.0 mm Sq UL1015 Blue 12AWG 1.035 m
9 0059 0278 Sleeve Ident PVC 4.0 ID x 5 Lg Gray 2
10 0059 0279 Sleeve Ident PVC 4.0 ID x 5 Lg White 2
11 0059 0280 Sleeve Ident PVC 4.0 ID x 5 Lg Black 2
Figure 4-9 MDU Neutral Bus (400-6007-901)
TP01311011 Rev 05 November 2009 4-19

4.5.3 MDU Contactor (400-6008-001)
Table 4-16 MDU Contactor (400-6008-001)


3 0256 7537 Termination Fork Tongue 4 Yellow 3
4 0259 0612 Wire 4.0 mm Sq UL1015 Brown 12AWG 2.4 m
5 0047 0401 Tywrap 92/102 Lg 6
11 0059 0275 Sleeve Ident PVC 4.0 ID x 5 Lg Green 2
Figure 4-10 MDU Contactor (400-6008-001)

4.5.4 MDU Relay Control (400-6008-101)
Table 4-17 MDU Relay Control (400-6008-101)

1 0056 0308 Termination Ring-T M4 Blue Insulated 1

2 0100 1664 Termn Pshn Crimp 1.5 – 2.5 mm 3
Crimp Spade Blue Vinyl M3 14 – 16 AWG
3 0256 7524 2
Ins Flared
4 0047 0401 Tywrap 92/102 Lg 1
6 0259 0617 Wire 1.5 mm Sq UL1015 Grn/Yel 16 AWG 0.18 m
7 0259 0618 Wire 1.5 mm Sq UL1015 Blue 16 AWG 0.16 m
8 0259 0600 Wire 1.5 mm Sq UL1015 Brown 16 AWG 0.14 m
Figure 4-11 MDU Relay Control (400-6008-101)
TP01311011 Rev 05 November 2009 4-21

4.5.5 MDU Shredder Power (400-6008-201)
Table 4-18 MDU Shredder Power (400-6008-201)


2 0256 7501 Bootlace Ferrule 4.0 mm Sq Non Ins 5
3 0256 7509 Termination Ring 4 mm Yellow 1
4 0047 0401 Tywrap 92/102 Lg 1
Figure 4-12 MDU Shredder Power (400-6008-201)

4.5.6 MDU IEC Outlet Power Cable (400-6008-301)
Table 4-19 MDU IEC Outlet Power Cable (400-6008-301)

1 0056 0308 Termination Ring-T M4 Blue Insulated 1

2 0100 1664 Termn Pshn 1.5 – 2.5 mm 3
3 0256 7482 Bootlace Ferrule 1.5 mm Sq Black 2
8 0047 0401 Tywrap 92/102 Lg 1
Figure 4-13 MDU IEC Outlet Power Cable (400-6008-301)
TP01311011 Rev 05 November 2009 4-23

4.5.7 Cobra Hybrid Safety (400-6008-401)
Table 5 Cobra Hybrid Safety (400-6008-401)

1 0254 1195 Connector, Crimp Type 8 Way 1

2 0254 7472 9-Way D Plug Crimp Style Conn 1
3 0256 0201 Contact Crimp 26/24 AWG CT SKT 5
4 0262 0592 Pillar D-Type Male/Female 2
5 0259 0278 Cable, 6-Core Scnd 24 AWG UL/CSA 1.45 m
6 0259 0569 Sleeve, Heat shrink 3:1 Ratio 0.04 m
8 0256 1224 Pin Crimp 24 – 28 AWG D-Type 1
9 0254 0882 Conn RFI Hood Die-cast Metal 1
Figure 4-14 Cobra Hybrid Safety (400-6008-401)

NOTES:
TP01311011 Rev 05 November 2009 4-25

NOTES:

Chapter 5
Preventative Maintenance
Topic Page Number
5.1 - Introduction 5-2
5.2 - Dust and Dirt Removal 5-3
5.3 - Maintenance Routines 5-4
5.4 - Estimate of Annual Service Times 5-7
5.5 - Corrective Maintenance 5-8
5.6 - Backups 5-9

5.1 Introduction Preventative Maintenance
5.1 Introduction
Read and comply with the Safety Issues information in the preliminary
Read! section of this service manual before attempting any preventive main-
tenance tasks.
The performance of regular maintenance on the Cobra 4000 series

machines is essential to achieving efficient operation with minimal break-
down periods.
This section divides the required maintenance and servicing tasks into
various levels of technical ability and content.
Equally important as the performance of all maintenance tasks as recom-
mended, is the maintenance of up-to-date service records
Where possible, maintenance periods break down into daily, weekly,
semi-annual, and annual periods.
Because local conditions vary, adjust maintenance schedules accord-
ingly.
For example, constant processing of very dirty currency requires more
frequent cleaning of the machine and filters.
Normal precautions concerning the handling of MOS components are
applicable to minimise the risk of damage to these devices by static elec-
trical discharge.
Avoid contact with the device pins and ensure that the pins are strapped
together with conductive tape or placed on a suitably earthed metal plate
when removing them from a PCB, thus ensuring that all pins remain at
the same potential.
Do not wear any external clothing, overalls, and so on, manufactured of
nylon or similar materials because they are capable of reaching extremely
high-voltage potentials through friction during normal wear.
Some maintenance routines require access to the inside of the
Read! machine. In these instances, only authorised personnel should per-
form these routines.

Preventative Maintenance 5.2 Dust and Dirt Removal
5.2 Dust and Dirt Removal
Do not use compressed air to clean the system because this action forces
dust into bearings and increases the risk of foreign objects shorting
electrical items.
Instead, use a vacuum cleaner, suitable soft brushes, lint-free cloths, non-
toxic cleaning solvent, and cotton swab sticks to clean dirt and dust from
the machine.
TP01311011 Rev 05 November 2009 5-3

5.3 Maintenance Routines Preventative Maintenance
5.3 Maintenance Routines
5.3.1 Daily Routines
Upon completion of the daily routines (Table 5-1), report to the service
provider for correction any damage to the transport belts, feeder wheels,
or other parts of the system.
Table 5-1 Daily Maintenance Routines

Time
Routine Action
(Minutes)
Clean dust from the transport with a vacuum cleaner and
D1 10
brush. Clean optical sensors with a lint-free cloth and solvent.
Inspect the transport highway and remove any pieces of torn
D2 5
notes, paper clips and staples.
Note: Times for daily routines are for each unit.
5.3.2 Weekly Routines
Perform the weekly routines listed in Table 5-2, in conjunction with the
daily routines.
Table 5-2 Weekly Maintenance Routines

Time
Routine Action
(Minutes)
Inspect the transport rollers for dirt and ink build up. Remove
W1 5
with a lint-free cloth and solvent.
Clean screen using an appropriate proprietary computer screen
W2 2
cleaner and soft cloth.
Backup. Backups are only required in following circumstances:
 After changes to the database.
W3 10
 Whenever historical records are considered critical.
See Section 5.6 on Page 5-9.
W4 With machine turned off, remove and clean rear fan filters. 2
W5 Complete Thickness Calibration Check 15
Note: Times for weekly routines are for each unit.

Preventative Maintenance 5.3 Maintenance Routines
5.3.3 Semi-Annual Routines
An accredited Cash Systems service engineer is to complete the

technical actions listed below.
The times shown are for the inspection of the unit and any mandatory
component changes; repairing any deficiencies found during the
inspection require additional time (see Section 5.5 on Page 5-8).
The assumption is that spare parts are available on site to complete the
work.
Perform the semi-annual maintenance routines in Table 5-3.
Table 5-3 Semi-Annual Maintenance Routines

Time (Minutes)
Routine Action DCM
4PM
(4004)
Confirm that the cover interlock and the emergency stop switch (if
6M1 3 3
equipped) operate correctly.
Confirm that each cooling fan is operational; replace filters as appropri-
6M2 2 2
ate.
6M3 Clean all transport sensors and check operation. 5 5
Inspect all belts for wear and damage. Check for free movement of
6M4 15 15
hinged guide assemblies and pulleys.
Check all cover hinges for free movement and wear. Check gas struts for
6M5 5 5
leaks and correct cover support.
6M6 Check blade condition and operation in diverter assemblies. 5 5
6M7 Check condition and proper operation of stacking wheels. 5 5
6M8 Clean all detectors and calibrate to the relevant calibration specification. 30 N/A
Check the general cleanliness of the machine and take appropriate
6M9 10 10
action.
6M10 Confirm that power supply voltages are within the service limits. 10 10
Check all wiring and earth connections, in particular, for security and con-
6M11 5 5
tinuity.
Replace feeder stripper wheel, separation roller, front nudgers, nudger
6M12 40 N/A
rubbers, and O-rings.
6M13 Check the alignment of the four-pocket extension and DCMs. 5 5
TP01311011 Rev 05 November 2009 5-5

5.3 Maintenance Routines Preventative Maintenance
5.3.4 Annual Routines
An accredited De La Rue service engineer should perform the following

annual maintenance routines in conjunction with the semi-annual
routines.
Table 5-4 Annual Maintenance Routines

Time (Minutes)
Routine Action DCM
4PM
(4004)
A1 Replace all note transport belts. 120 100
Check all rollers for stiffness or lack of smoothness and replace
A2 30 20
as necessary.

Preventative Maintenance 5.4 Estimate of Annual Service Times
5.4 Estimate of Annual Service Times
The actual time spent in maintaining the Cobra depends greatly on the
number of four-pocket extension modules (Table 1-1 on Page 1-3), the
environment, and customer usage.
Use Table 5-5 as a guideline to estimate the service times for a Cobra
4004 used 7 hours/day, 5 days/week, and 50 weeks/year.
Table 5-5 Annual Service Times Estimates

Time
Routine Qty/Yr
Cobra 4004 Cobra 4016a
Semi-Annual 2 4 hr 30 min 11 hr 30 min

Annual 1 2 hr 30 min 8 hr 30 min
Total 3 7 hr 20 hr
a. Cobra 4016 consists of a Detector/Cull Module and three four-pocket extension mod-
ules.
TP01311011 Rev 05 November 2009 5-7

5.5 Corrective Maintenance Preventative Maintenance
5.5 Corrective Maintenance
An estimate of the number of corrective maintenance events for each

year is four for each unit, with an average correction time of one hour.
The correction time assumes that any required spare parts are available
to the on-site engineer.
Complete the preventative maintenance inspections as part of corrective
maintenance to reduce the potential downtime experienced by the cus-
tomer.

Preventative Maintenance 5.6 Backups
5.6 Backups
What Can Damage a The following can damage a database:

Database?
 The unlikely event of a hard-disk failure
 Site voltage supply problem
 Mistakes made in the database
Recommendation: Use a well-maintained UPS to supply the
machine to prevent voltage-related problems. Where records are
of paramount importance, consider other options.
Before making any planned changes to a database, make a copy of the
databases in case the database changes are incorrectly entered and the
database becomes unrecoverable.
Why Back Up? Because you can use a backup to restore the last saved working
database and records therein.
Make a backup as regularly as required, bearing in mind that all data,
from the last backup until the error, is lost unless you consider other
options.
Backing Up Use Procedure 5-1 to back up and recover the database.
Note: The numbered steps occur on-site. The lettered steps occur off-
site at the technical support facility.
Procedure 5-1 Backing Up and Recovering a Database

Local Site-Backup Activity 1. Use the Full Database Backup command in the Database
Maintenance page of the GCC user interface to make regular
backups of the machine database. Refer to Figure 5-1.
Figure 5-1 Database Maintenance to Create Backups
Location of Backup
TP01311011 Rev 05 November 2009 5-9

5.6 Backups Preventative Maintenance
2. Make database copies in the backup directory (c:\backup_1).
3. Move the files with the .bak extension to an external recording

medium and archive them using a method that identifies the backup
date. Moving the file empties the folder, making it available for the
next backup.
Requirement to Recover the 4. Move the file in the Full Database Backup location to an external
Database recording medium or locate the last working database backup, if
stored externally.
5. Send the latest backup to De La Rue Technical Support.
When Technical Support returns the recovered data, go to Step 6.
Technical Support Recovery Technical Support uses MSSQL7 and the Enterprise Manager tool to
Activity recover the data from the backup sent from the local site:
A. Stop the MSSQL7 service.
B. Copy a blank database to c:\Program Files\Unicorn\Databases.
C. Start the MSSQL7 service.
D. Open the Enterprise Manager and restore the database from the
backup sent from the site. Refer to Figure 5-2.
Figure 5-2 Enterprise Manager to Restore Databases
E. Close the Enterprise Manager.

F. Stop the MSSQL7 service.
G. Copy the following to a device suitable for loading data onto the cus-
tomer’s machine:
 c:\Program Files\Unicorn\Databases\Unicorn_log.ldf
 c:\Program Files\Unicorn\Databases\Unicorn_data.mdf
H. Send the device to the site so that the local site can reinstall the data-
base onto the machine.

Local Site Recovery Activity 6. Close the GCC.
7. Stop the MSDE service.
8. Copy the following to a backup folder:
9. Copy the following from the device sent from Technical Support:
10. Start MSDE.
11. Restart GCC.
5.6.1 Attaching an External Drive to GCC
Use Procedure 5-2 to attach an external drive to the GCC.
Procedure 5-2 Attaching an External Drive to the GCC

1. Power the machine off.
2. Connect the external drive to the correct connector on the GCC

using the ribbon cable supplied with the drive.
Connect the ribbon cable with the marked wire (wire 1) uppermost
(Figure 5-3).
Note: A floppy drive does not require a twisted ribbon cable.
Figure 5-3 CD and Floppy Drive Connectors
CD and Floppy Drive Connectors

(Pin 1 at Top When Cutaway to
the Left)
0 12
5 0
Voltages
Retaining Clip
Power Connectors for the Drives
Warning: Verify that the power

connector is located the correct
way round.
TP01311011 Rev 05 November 2009 5-11

3. Connect the DLR power cable to the drive and the socket on the
GCC.
4. Do one of the following:
A. If the machine recognises the external drive, go to the next step.
B. If the machine does not recognise the external drive:
B.1 Power the machine down, then power the machine up

again.
B.2 Press DEL on the key pad after the memory check has com-
pleted. This gives you access to the BIOS.
5. In BIOS, check the following:
5.1 The floppy drive is set as drive a: (if connecting a floppy drive).
5.2 The primary slave drive (directly under the primary hard drive)
is set as AUTO.
Note: If AUTO is not an option or the machine does not recognise the CD
drive, set the primary slave drive as a CD drive.
6. Save and exit.
Part numbers for the CD-RW and floppy drives are as follows:
 CD-RW drive kit 0262 0686
 Floppy drive kit 0262 0685
Note: Newer PCs come equipped with two (2) USB slots, allowing data
extraction via the GCC PC.

NOTES:
TP01311011 Rev 05 November 2009 5-13

NOTES:

Chapter 6
Four-Pocket Extension
Topic Page Number
6.1 - Introduction 6-2
6.2 - Installation 6-3
6.3 - Mother Board 6-7
6.4 - Nodes 6-8
6.5 - Motor Controllers 6-9
6.6 - Sensors 6-10
6.7 - Power 6-11

6.8 - Transport System 6-12
6.9 - Stackers 6-17
6.11 - Maintenance 6-21
6.13 - Ancillary Motherboard Connections 6-26

6.1 Introduction Four-Pocket Extension
6.1 Introduction
The Four-Pocket Module (4PM) extension appears singly or in multiples

to provide a range of stacker options for the customer.
The 4PM extension module derives its design from the Cobra Detector/
Cull Module (DCM) unit (4004) and uses the following identical
components:
 Power supply  Node
 Diverter  Stacker assembly
 Drive motors  Motor controller
 Sensors  Mother board (see Section 6.3 on Page 6-7)
The four-pocket extension module contains four output pockets in a body
modified from the design of the DCM. All culled notes are directed to the
cull pocket in the DCM.
However, following an incident in note routing through the four-pocket
extension modules, the notes route to an overrun box connected to the
final module.
The DCM contains all detectors and the detection system control, which
determines the path that each note follows: either to the cull pocket or to
the appropriate output pocket in the DCM or in an extension module.
Each unit has its own mains power supply cable. Three control cables
connect the extension modules to the DCM.
Metal brackets attached at the base and top of the adjacent sides hold the
units together.
Read this section of the service manual in conjunction with the other sec-
tions.

Four-Pocket Extension 6.2 Installation
6.2 Installation
The four-pocket extension module sits on a recommended extension

desk (PN 0202 0003) or a heavy-duty bench to the left of the DCM
(Figure 6-1).
A standard desk (PN 0202 0004) supports the DCM. Refer to the Cobra
Site Planning Manual, TP04511001.
Figure 6-1 Cobra 4008 – One Four-Pocket Extension and the DCM
6.2.1 Preparation
Before attaching a four-pocket extension module to a Cobra system,

observe the following precautions:
 Verify that the Cobra system is mounted in the position where it is to be
used.
 Verify that the desk has sufficient area to mount the four-pocket exten-
sion module. A recommended standard desk (PN 0202 0004) supports
the DCM while an extension desk (PN 0202 0003) supports each 4PM
module.
 Verify that the desk/work-surface is able to bear the weight of the com-
bined system.
 In the event that the four-pocket extension module mounts on a sepa-
rate work surface, adjust the height of the work surface such that it is
within 0.5 mm (0.02 inches) of the surface supporting the Cobra sys-
tem.
 When separate work surfaces are used, attach them together using tie
bars or other suitable brackets.
 Verify that the flatness of the combined work surfaces for the entire
system is within 1 mm (0.04 inches) over its entire length.
 Verify that the work surfaces are level to within 1 degree of the true
horizontal plane.
TP01311011 Rev 05 November 2009 6-3

6.2 Installation Four-Pocket Extension
 Verify that a suitable mains power distribution is available which allows

all modules to receive power through separate power sockets.
6.2.2 Attachment and Alignment
Two internal front and rear tie brackets and three cable forms
mechanically fasten a 4PM extension module to an adjacent unit or units,
as shown in Figure 6-2. Additional 4PM extension modules connect in
similar manner to the left.
The note path of each module exits on the left-hand side and must
accurately align with the input path on the right-hand side of the next
module to the left.
Figure 6-2 Alignment and Clamping Brackets (Right-Hand View)
CAN Bus and Safety Connections
Power-On Sense
Mounting Brackets
Note: The side covers between the modules remain in place.

Use Procedure 6-1 to attach and align an extension module to the DCM.
Procedure 6-1 Attaching and Aligning a Cobra Extension

1. Connect the mains power, power-on sense, CAN bus, and safety
circuit connections observing the following notes:
Note: 1: Mains input power for each Cobra module is from on-site wall
sockets or, preferably, from the output of each module’s UPS.
For Cobra-only sites: the UPS input power comes directly from the
on-site wall sockets. However, in a Cobra/6000 hybrid configuration,
the UPS input power comes from the MDU Cobra and Expansion
Outputs.
Note: 2: Power-on sense: Mains-Out from upstream modules to the
Mains In-downstream modules; that is, from the 4004 to succeeding 4PMs.
Note: 3: The CAN bus originates in the DCM PC and goes to J49 of the
4004. The CAN bus then daisy-chains to succeeding extension modules
(out on J50 to J49 of the next downstream module).

Four-Pocket Extension 6.2 Installation
2. Align the two backplates so that the vertical faces are in dress
alignment.
3. Set the 34 mm +0.5 mm gap between the backplates at the front
and tighten the front bracket.
4. Set the 34 mm +0.5 mm gap between the backplates from the rear
and tighten the rear brackets; re check the backplate alignment.
34 mm ± 0.5 mm
Transport Interface
Note: The bracket screw-locating holes on the module right-hand side

allow forward/backward movement. The bracket screw-locating holes on
the module left-hand side allow left-to-right movement. Remove the plastic
cover to the power contacts to adjust the rear bracket.
5. Adjust the height of the transport interface plate so that the belt path
is straight.
6. Repeat the steps in Procedure 6-1 for each Cobra extension
module.
Overrun Box The left-most 4PM, if installed, has an overrun box to eject notes from the
transport system during jam recovery. The overrun box mounts on the
4PM frame as shown. Connect the overrun box sensor plug to J55 on the
4PM mother board (Figure 6-3 on Page 6-7).
Mounting Bolts
TP01311011 Rev 05 November 2009 6-5

6.2 Installation Four-Pocket Extension
6.2.3 Cables
6.2.3.1 Power
Each module must have an independent mains power supply. The power
rating for each four-pocket extension module is 1,300 Watts.
6.2.3.2 Control and Safety
Three cables connect the 4PM extension modules to the DCM or to an

adjacent extension module:
 Controller Area Network (CAN) bus cable
 Power-on sense cable – to sense when the DCM has mains power
applied (refer to Power on Page 6-11
 Machine safety interlock cable – cover open
Each cable terminates in the final extension module.

Four-Pocket Extension 6.3 Mother Board
6.3 Mother Board
The mother board is identical to that of the DCM except that the extension
mother board has no connections to any detector plugs and detector
controller connectors (refer to Figure 1-9 on Page 1-14 and Figure 1-10
on Page 1-15 in Chapter 1).
6.3.1 Interconnections
The mother board provides interconnections for the following:

 The CAN bus connections between the nodes and GCC PC in the
DCM
 Connections from the nodes, sensors, motor controllers, and diverters
 Safety control circuit
 Low-voltage distribution
 Connector for CAN bus terminating resistor.
The mother board is located in the upper rear section of the machine.
Section 1.3.1 on Page 1-13, gives interconnection and fuse details.
Note: The CAN bus, safety interlock, and power-on signal cables must
terminate in the leftmost 4PM extension module.
Also refer to Section 1.3.1 on Page 1-13.
Figure 6-3 shows the connections between two adjacent modules.
Figure 6-3 Electrical Connections for the Cobra
Rear View of Cobra Line-up
6.3.2 Safety Control
Safety control circuit connections are in the middle of the mother board
(Figure 6-4). Also refer to Section 1.3.2 on Page 1-19, and to Section
4.1.2 on Page 4-3.
TP01311011 Rev 05 November 2009 6-7

6.4
6-8
6.4
Nodes
Nodes
Safety In (J203) Safety In (J203) Safety Out (J76)

Safety Out (J76)
Figure 6-4
1 1 1 1 1 1
48V 48V
0V D 0V D
S 0V S 0V S 0V S 0V
Mains Breaker Breaker Breaker
(Closed If Mains On) Breaker Override Breaker Override
1
(J75) E Stop Out 1 1
(J75) E Stop Out
E Stop Return E Stop Return
S 0V S 0V
O/R Switch (Or Link)
Override Override
1 (J78) 1 1 (J78)
SCR Enabled SCR Enabled
Cover Switch E Stop Inactive E Stop Inactive
(Closed If Cover Closed) Cover Cover
Override On (J82) Override On
1 (J82) Cover Switch 1
48V Cover Closed (Closed If 48V Cover Closed
Cover Closed)
E Stop Switch (Or Link)
E Stop E Stop
1 (J81) 1 (J81)
E Stop Switch
48V (or link) 48V
SCR (J87) SCR (J87)
1 1
48V 48V
Covers Covers
0V D 0V D 0V D 0V D
Override Inhibits (J101) Override Inhibits (J101)
S 0V K1-1 1 48V K1-1 1
48V S 0V
Safety Control Logic
0V D S 0V 0V D E Stop K1-2 0V D S 0V 0V D E Stop K1-2

S 0V S 0V
K2-1 K2-1
S 0V S 0V 0V D 0V D
Enable K1 K2 Enable K1 K2
0V D S 0V K2-2 0V D S 0V S 0V K2-2
0V D 0V D
Enable 0V D Enable
0V D 0V D 0V D All Contacts NC 0V D 0V D 0V D All Contacts NC
Node interface (J27) Cover Override Breaker Cobra Motherboard Node Cover Override Breaker Cobra Motherboard
Interface
Status (J27) Status
+24V Module +24V Module
Inhibit Inhibit
–24V –24V
Refer to Section 1.4 on Page 1-20.
Node To Machine Node To Machine

Motor Systems Motor Systems
+24V Module +24V Module
Inhibit Inhibit
–24V –24V
42V Actuator Supply 42V Actuator Supply

Module 1 Module 2

Four-Pocket Extension
Four-Pocket Extension 6.5 Motor Controllers
6.5 Motor Controllers
Refer to Section 1.5 on Page 1-25. Each 4PM extension module has one
installed motor controller to drive the transport. The parameter settings for
this controller are the same as those for the transport motor controller in
the DCM.
TP01311011 Rev 05 November 2009 6-9

6.6 Sensors Four-Pocket Extension
6.6 Sensors
The 4PM extension module uses the same sensors as the Cobra DCM.
Figure 6-5 shows the locations of the sensors listed in Table 6-1. For
procedures for removal and replacement, refer to Section 3.2.2 on
Page 3-4.
Table 6-1 Sensor Parts List

Refer to Figure 6-5 Description Part Number
Diverter Diverter assembly – LH 400 2002 002
Update Sensor Track sensor assembly 400 2018 701
Count Sensor Track sensor assembly 400 2018 701
PCB BIN sensor receiver 310 9531 404
Stacker Contents Sensor
PCB BIN sensor transmitter 400 9500 401
– Upper Stackers
– Lower Stackers
Figure 6-5 Locations of Sensors, Diverters, and Lamps

Four-Pocket Extension 6.7 Power
6.7 Power
The DCM and each 4PM extension module connects individually to the
mains supply.
A power-on cable between each module confirms that the upstream
module has mains power and energises a relay in the module
(Figure 6-6).
Mains power must be available at the module mains socket and the
power-on sense socket to power the power supplies within the module.
Figure 6-6 Module Power
Module Power
Distribution
PSU 1
Mains Live
Socket PSU 2
Mains power for
Neutral
module Fuses
Relay
Power-on Live
sense socket
Power-on from
Neutral
previous module
Power-on to next
module
Refer to Chapter 4, for details on power distribution within the module.
TP01311011 Rev 05 November 2009 6-11

6.8 Transport System Four-Pocket Extension
6.8 Transport System
Notes arrive through the right-hand side of the 4PM extension module
(Figure 6-7 on Page 6-13) from a corresponding exit in the left-hand side
of the adjacent unit.
Additional 4PM extension modules chain in like fashion to the left.
6.8.1 Settings, Removal, and Replacement
The settings and adjustments on the 4PM extension module are generally
the same as those on the DCM.
Refer to Chapter 3, Transports, for settings, removal, and replacement
details on the following:
 Stackers
Note: Each 4PM extension module has its own stacker position
sensor. Figure 6-7 on Page 6-13 and Figure 6-8 on Page 6-14 show
the adjustment handwheel.
 Diverters
 Transport drive system
 Safety control
 Covers
6.8.2 Belt Paths
Table 6-2 lists and Figures 6-7 and 6-8 show the transport belts for
delivering banknotes.
Table 6-2 Transport Belts

Belt Ref Figure Length (mm) Part Number
A 216 0228 0680

B 6-7 2320 0228 0409
C 2320 0228 0409
D 1438 0228 0691
E 6-8 860 0228 0682
F 860 0228 0682

Four-Pocket Extension 6.8 Transport System
Figure 6-7 Transport Belts A, B, and C
Hand
Wheel
TP01311011 Rev 05 November 2009 6-13

Figure 6-8 Transport Belts D, E, and F
Hand
Wheel
6.8.3 Transport Drive System
Tables 6-3 and 6-4 list the designated drive belts and pulleys,
respectively, that appear in Figures 6-9 and 6-10, which show the four-
pocket extension module transport drive system.
Chapter 3, Transports, describes the settings, adjustments, and proce-
dures for removal and replacement.
Table 6-3 Transport Drive Belts

Length
Belt Ref Fig Description Part Number
(mm)
G 882 Belt, Timing, HTD, 9 mm Wide 0228 0692

H 6-9 420 Belt, Timing, HTD, 9 mm Wide 0228 0637
I 804 Belt, Timing, HTD 0228 0633
J 357 Belt, Timing, HTD, 9 mm Wide 0228 0676
K 6-10 1135 Belt, Timing, HTD, 9 mm Wide 0228 0690
L 945 9 mm Wide, Double Sided 0228 0311

Four-Pocket Extension 6.8 Transport System
Table 6-4 Transport Pulleys
Pulley Inner Outer

Fig
Ref Description Part Number Description Part Number
A – – Pulley 42T – 3M 402 7000 502

B Pulley 42T – 3M 402 7000 502 Pulley 42T – 3M 402 7000 502
6-13
C Pulley 36T – 5M 402 7000 402 Pulley 36T – 5M 400 4002 701
E Pulley 36T – 5M 402 7000 402 Pulley 20T – 3M 402 7001 402
Note: The four-pocket extension modules must use the same stacker
drive pulley as the DCM to which they connect.
Figure 6-9 Outer Drive Belts G, H, and I
TP01311011 Rev 05 November 2009 6-15

Figure 6-10 Inner Drive Belts J, K, and L

Four-Pocket Extension 6.9 Stackers
6.9 Stackers
Each stacker wheel requires adjustment to a defined position setting in

relation to the stacker position sensor. The stacker position sensor is a
Hall-type sensor that outputs a signal each time a tine passes the note
entry guides.
A green LED located at the machine top right front (Figure 6-11)
indicates the signal from the stacker position sensor.
The correct stacker wheel positions in relation to the stacker position
sensor depend on the note pitch and the stacker output position
Figure 6-11 Four-Pocket Extension Module Stackers.
Output 8 Output 6
Location of Stacker
Position Indicator
Output 6
Center Bolt
Output 9
Output 7
To determine the note pitch, divide the transport speed (millimetres/sec-

ond) by the note feed speed (notes/second).
The pitch is given in millimeters. In a standard machine, the transport
speed is 2,400 mm/sec, the feed speed is 10 notes/sec, and the note
pitch is 240 mm.
Table 6-5 on Page 6-18 lists the settings for various note pitch options.
TP01311011 Rev 05 November 2009 6-17

6.9 Stackers Four-Pocket Extension
Table 6-5 Output Stacker Handwheel Setting
Stacker Drive Pulley Output Stacker a, b

Note Pitch (mm)
Grooves
6/10 8/12 9/13 7/11
20 c 240.0 0 17 37 19
21 228.6 0 20 45 25
22 218.2 0 23 0 30
24 200.0 0 27 18 39
26 184.6 0 31 32 2
a. Handwheel increments counter-clockwise from stacker index position.
b. Cobra 4008 = Stackers 6 – 9; Cobra 4012 = Stackers 10 – 13.
c. Shaded row indicates standard 10 notes/second with note pitch of 240 mm.
Use Procedure 6-2 to set the stacker wheels. The procedure involves
manually positioning the transport until the stacker position indicator
comes on.
Use this position as a reference point to adjust Stacker Wheel 6.
Using Table 6-5 on Page 6-18 as a guide, adjust Stacker Wheels 8, 9,
and 7 (cull pocket).
Procedure 6-2 Setting the Stacker Wheels

Note: In the next step, do not select a process or the diagnostic menus.
1. Power up the machine.
2. Turn the transport manual knob counter-clockwise until the stacker

position sensor indicator (Figure 6-11 on Page 6-17) comes on.
3. Set Stacker Wheel 6 (Cobra 4008) or 10 (Cobra 4012) as follows
while the transport is in this position.
Note: When choosing a tine to set a stacker wheel, do not use a tine that
looks bent or deformed. Replace damaged tines at the earliest opportunity.
3.1 Loosen the centre bolt and rotate the stacker wheel until the tip
of a tine aligns to the line of note entry. This position is 1 –

Four-Pocket Extension 6.9 Stackers
2 mm (0.04 – 0.08 inches) above the surface of the lower

stacker entry guide (Figure 6-12).
Figure 6-12 Stacker Wheel Index Position
1 – 2 mm
3.2 Retighten the central bolt to a torque of 1.65 – 2.0 Nm when

the stacker wheel is in the correct position.
4. Go to Stacker Wheel 8 (or 12).
4.1 Refer to Table 6-5 for the setting of the hand wheel position for
this output stacker. Use the row corresponding to the drive pul-
ley grooves and note pitch in use.
4.2 Rotate the hand wheel counter-clockwise by the stated
number of divisions marked on the brass ring mounted behind
the hand wheel knob.
5. Repeat Step 3 to adjust the stacker wheel and Step 4 to proceed to
Stacker Wheels 9 (or 13) and 7 (or 11).
TP01311011 Rev 05 November 2009 6-19

6.10 Fault-Finding Guide Four-Pocket Extension
Refer to the following sections:

 Section 1.6 on Page 1-31
 Section 3.10 on Page 3-37

Four-Pocket Extension 6.11 Maintenance
6.11 Maintenance
Chapter 5 contains preventive maintenance routines.
TP01311011 Rev 05 November 2009 6-21

6.12 Illustrated Parts List Four-Pocket Extension
Table 6-6 lists the belt and pulley parts lists included earlier in this
section. Figures 6-13 through 6-15 show the front roller and stand-off
assemblies, outer drive belts, and capstan and stacker assemblies used
in the four-pocket extension.
Table 6-6 Index to Belt and Pulley Parts Lists

Parts List Reference Page
Sensors Table 6-1 6-10
Transport belts Table 6-2 6-12
Transport drive belts Table 6-3 6-14
Transport drive pulleys Table 6-4 6-15
Table 6-7 Key to Front Roller and Standoff Assemblies

Inner Outer
Item
Description Part Number Description Part Number
A Spacer 400 4002 701 Pulley 42T – 3M 402 7000 502

B Pulley 42T – 3M 402 7000 502 Pulley 42T – 3M 402 7000 502
C Pulley 36T – 5M 402 7000 402 Spacer 400 4002 701
D Idler 24T – 3M 400 2004 402 Idler 96T – 3M 400 2004 402
E Pulley 36T .5M 402 7000 402 Pulley 20T – 3M 402 7001 402
F Idler 72T – 3M 400 2004 802 Idler 21T – 3M 400 2004 802
H Idler 42T – 3M 400 2003 102 – –
I – – Idler 42T – 3M 400 2003 102
J Flanged Idler D/A 400 2023 801 – –
K – – Flanged Idler D/A 400 2023 801
Table 6-8 Key to Outer Drive Belts

Part
Item Description Qty
Number
G Belt, Timing, HTD, 9 mm Wide 0228 0692 1

H Belt, Timing, HTD, 9 mm Wide 0228 0637 1
I Belt, Timing, HTD 0228 0633 1

Four-Pocket Extension 6.12 Illustrated Parts List
Figure 6-13 Front Roller and Standoff Assemblies
TP01311011 Rev 05 November 2009 6-23

6.12 Illustrated Parts List Four-Pocket Extension
Figure 6-14 Outer Drive Belts

Four-Pocket Extension 6.12 Illustrated Parts List
Table 6-9 Key to Capstan and Stacker Assemblies

Figure Detail
Item Part Number Description
(Chapter 3)
1 400 2001 201 Stand-Off, 50 mm Diameter Crown Roller Assembly Figure 3-70 on
Page 3-89
Page 3-89
3 400 2001 401 Stand-Off, 16 mm Diameter Crown Roller Post Assembly Figure 3-72 on
Page 3-90
Page 3-90
5 400 2005 202 Stand-Off, 25 mm Diameter Div Roller Assembly Figure 3-73 on
Page 3-90
6 400 2001 902 Stacker Housing Bearing Capstan Assembly Figure 3-66 on
Page 3-85
7 400 2008 103 Capstan/Handwheel Assembly Figure 3-69 on
Page 3-88
8 400 2000 803 Capstan Assembly Figure 3-65 on
Page 3-84
9 400 2016 703 Bracket Assembly – Stacker Entry Roller Figure 3-93 on
Page 3-102
Figure 6-15 Capstan and Stacker Assemblies
TP01311011 Rev 05 November 2009 6-25

6.13 Ancillary Motherboard Connections Four-Pocket Extension
6.13 Ancillary Motherboard Connections
Table 6-10 FSM1 Ancillary Motherboard Connections
J Conn PINS
ID
Conn To 1 2 3 4 5 6 7 8 9 10
Diverter Node
23 DVD Node D Node D Node D 5V 0V 42V 0V - -
08 D
Diverter Node
24 DVA Node D Node D Node D 5V 0V 42V 0V - -
06 D
Diverter Node
28 DVE Node D Node D Node D 5V 0V 42V 0V - -
07 D
Diverter Node
29 DVB Node D Node D Node D 5V 0V 42V 0V - -
09 D
Update Node Node D Node Node
33 Sensor 4 TSX D(10c) 0V (11b) 12V D(11a) 0V D(11c) 12V - -
Pockets QI, Node Node

34 5V F15 Node E 5V F15 5V F15 - - - -
Full 7,9 C,D E E
Pockets Qi, Node Node
35 5V F15 Node D 5V F15 5V F15 - - - -
Full 6,8 A,B D D
Stacker Node Node Node
37 TSE 0V 12V 0V 12V - -
Count 8 D(16a) D(16c) D(16b)
Stacker Node Node Node Node
38 TSD 0V 12V 0V 12V - -
Count 6 D(13b) D(14a) D(13c) D(14b)
Trans- Node Node Node Node 5V
40 port MTA Node D Node D Node D Node D 0V
D D D D F15
Motor
42 TSG 0V 12V 0V 12V - -
Count 7 E(12a) E(12c) E(12b) E(13a)
Stacker LOB Node D Node Node Node
45 6 Fly/ 0V 12V 0V 12V
LOG (18c) D(19b) D(19a) D(19c)
Pres
Stacker LOC Node Node Node Node
46 8 Fly/ 0V 12V 0V 12V
LOH D(20a) D(20c) D(20b) D(21a)
Pres
48 TSF 0V 12V 0V 12V - -
Count 9 E(10c) E(11b) E(11a) E(11c)
Stacker LOD Node Node Node Node
56 9 Fly/ 0V 12V 0V 12V
LOI E(18c) E(19b) E(19a) E(19c)
Pres
Stacker LOE Node Node Node Node
57 7 Fly/ 0V 12V 0V 12V
LOJ E(20a) E(20c) E(20b) E(21a)
Pres
Track
58 - CLK @2.5V 5V F15 0V - - - - - -
Clock
Trans-
65 port MCB 0V 42V 42V 0V - - - - - -
Control
68/ 24V
Fans - 48V UnS 24V UnS 0V - - - - - -
100 UnS
24V
78 Override - 0V 24V UnS 0V - - - - - -
UnS

Four-Pocket Extension 6.13 Ancillary Motherboard Connections
NOTES:
TP01311011 Rev 05 November 2009 6-27

6.13 Ancillary Motherboard Connections Four-Pocket Extension
NOTES:

Chapter 7
ACDP Separator Recognition Feature
Topic Page Number
7.1 - Overview 7-2
7.2 - Operation 7-5
7.3 - Installation 7-12
7.4 - Setup/Adjustment and Calibration 7-26
7.5 - Specifications 7-35
7.6 - System Requirements 7-36
7.7 - System Checks 7-37
7.8 - Wiring Schedules 7-38

7.9 - Magnetic Stripe Detectors: Improving Calibration
and Functionality 7-43
7.1 Overview ACDP Separator Recognition Feature
7.1 Overview
The separator recognition feature enables a Cobra site to perform

Automated Commercial Deposit Processing (ACDP).
That is, the Cobra process batches from multiple sources that are merged
as a continuous input stream to enhance maximum machine throughput.
As a part of note preparation, an operator inserts special separator cards
to delimit each batch.
Then, as the operator feeds the prepared note batches into the feeder,
the separator recognition feature recognizes the separator cards and
reads the unique identification bar code.
The control system can then separately track and account each batch.
Separator Components The separator recognition feature consists of two subsystems
(Figure 7-1): a barcode reader and a magnetic-stripe detector.
Each operates independently of the other, but both are required to pro-
vide appropriate signals to the Unicorn control system.
The header separator card has a pattern of stripes printed with magnetic
ink to serve as the recognition feature and a unique barcode printed on
the card to identify each batch.
After the magnetic detector recognises the magnetic header pattern, the
barcode reader reads the barcode and sends the identity to the system
software.
When the magnetic detector recognizes the magnetic trailer pattern, it
signals the end of the batch to the control system. 1.1.2 on Page 1-5
describes the separator card types.
Figure 7-1 Block Diagram of Separator Recognition Components
Machine
Back Plane
Laser Cobra
Motherboard
P1 Serial 3 Cobra Node
Photo Barcode Reader P2 Signal, Barcode Reader Power,

Power, Decoder/ Serial UART
Diode Head Card P3 Controller P4
Control Intfce
P5
15V,
0V
Direction of Comms, Node
Note Travel Power CPU
Barcode
P6 Reader
(Opto)
Magnetic P7 Signal, Magnetic
MR Separator Opto
Detector Stripe
Sensor Power P8 P9 Pattern Iso
Head Card Detector
Note Path
Note: P1 through P9 are arbitrary designations used for descriptive purposes only.

ACDP Separator Recognition Feature 7.1 Overview
Component Location The magnetic-stripe detector and barcode reader decoder/controller

cards reside in the machine lower rear compartment under the shelf
above the operator PC.
As shown in Figure 7-2, the cards mount side by side in a space allow-
ance of 80 mm by 180 mm (about 3 by 5 inches).
Note: Because the cards are underneath the shelf, Figure 7-2 shows
the solder side of the circuit boards and all components shown are on the
component side.
Figure 7-2 View of the Separator Circuit Boards in Cobra
Cobra Back Plate
Barcode
Data to
System
LEDs, Links,
Test Points Barcode
Reader Card
Barcode Head
Inter-Circuit
Board
Connectors
Magnetic
Detector Data
to System
LEDs, Links,
Test Points Magnetic Stripe
Detector Card
Magnetic
Head
Cobra Rear Cover
The magnetic-stripe detector uses a Magneto-Resistive (MR) head to

capture magnetic signals.
The detector processes these signals into digital waveforms representing
the width and spacing of the magnetic stripes on the document.
An optical port on the Cobra mother board interfaces the detector with the
node CPU, connecting to TPU 15 through an opto-isolator on the node.
The signals then pass to the sorter control system for pattern recognition.
Header (marker for batch start) and trailer (marker for batch end) docu-
ments have different stripe patterns, thus enabling the control system to
recognize the start and finish of a batch.
The small size of the magnetic-stripe sensor enables placement close to
the feed point.
Early recognition of a batch separator allows the operator to stop the
feeder before the next batch starts.
TP01311011 Rev 05 November 2009 7-3

7.1 Overview ACDP Separator Recognition Feature
The barcode reader, which is based on those in current use in the 5000
and 6000 systems, is able to read a variety of barcode symbologies in
common use and sends its read results to the control system.
The detector front end contains a laser and photo detector with a local
amplifier and digitizer. The photo detector converts the light reflected from
the bars on the note into a stream of binary signals.
Because space at the head is limited, the amplifier required to minimize
noise resides on a compact printed circuit board near the head while the
main decoding functions are remote from the head.
The barcode reader communicates with Node C, Serial B, through Serial
Port 3 on the mother board.
Serial Port 3 on the Cobra mother board provides 15V to both subsys-
tems.

ACDP Separator Recognition Feature 7.2 Operation
7.2 Operation
This section describes the operation of the barcode reader and magnetic-
stripe detector subsystems.
7.2.1 Barcode Reader
The barcode reader subsystem reads a variety of barcode symbologies in

common use and sends the result to the control system.
The Cobra application uses interleaved 2-of-5 and Code 39 symbologies.
Barcodes consist of printed black bars on a separator document. Narrow
barcode sizes range from 0.5 through 1.5 mm (0.02 through 0.06 inches).
A fixed laser and a photo diode head placed in the machine transport
read the bars. The laser is a red, Class II unit able to focus to a spot of at
least 250 m (0.0098 inches).
The focused laser spot falls on the separator document and the photo
diode converts the reflected light into an electrical signal as the separator
passes the head.
Barcode Reader Components The barcode reader subsystem consists of the following:
 Front-end detector card
 Decoder/controller card
7.2.1.1 Barcode Reader Front-End Detector Card
Figure 7-3 illustrates a block diagram of the barcode reader front-end

detector card.
Figure 7-3 Barcode Reader Front-End Detector Card
Note To Barcode Reader

Decoder/Controller
Photo
Amplifier Digitiser Barcode Out
Diode
Analog Out
Laser On
P Capsel
2
Peak
Detector Digipot Control
Power In (15V)
P1 BCR Front-End Card

La
se
Note: P1 and P2 are arbitrary

r
Em
designations used for descriptive

it t
er
purposes only.
The front-end detector consists of the laser, photo diode, and a local
amplifier/digitizer. The amplifier/digitizer converts the light reflected from
the document and picked up by the photo diode into a stream of binary
signals representing the width and spacing of the barcode elements.
The front-end card attaches to the side of the photo detector integrating
chamber. The photo diode, which is soldered directly to the board, has a
spacer to set its height from the circuit board and its position in the cham-
ber hole.
TP01311011 Rev 05 November 2009 7-5

7.2 Operation ACDP Separator Recognition Feature
Amplifier/Digitizer The amplifier/digitizer on the circuit board does the following:

 The amplifier converts the photo diode signal into a 0 – 5 Volt analog
signal that feeds the peak detector and the digitizer circuits. The ampli-
fier output eventually passes to the decoder/controller circuit board,
which, after calibration, controls the amplifier gain to suit signals
received from the photo diode.
 The signal peak detector uses signals from the amplifier to provide an
adjustable digitizing threshold output under control of the decoder/con-
troller board. The decoder/controller board also sets the peak detector
time constant based on document speed.
 The signal digitizer compares the analog light pattern signals output
from the amplifier to the threshold level output from the peak detector
and passes the result to the decoder/controller board. The decoder/
controller board can then adjust the threshold level to suit the meas-
ured signal amplitude. The digitised barcode signal output is a TTL-
compatible waveform.
Laser The front-end card also provides a connection to the laser that not only
provides power, but also enables laser on/off control. The decoder/con-
troller board supplies the laser on/off control line (logic 0) to the laser.
When the interface cable is removed, the laser is off.
A Capsel line from the decoder/controller selects either of two peak
detector time constants intended for different machine speeds. When
Capsel is logic high, the larger time constant is enabled.
7.2.1.2 Barcode Reader Decoder/Controller
The barcode reader decoder/controller (Figure 7-4) analyses the binary

data from the front-end detector card and outputs a serial data message if
the input data corresponds to valid barcode data.
Figure 7-4 Barcode Reader Decoder/Controller Card
To
Barcode Reader Barcode Reader Decoder/Controller
Front-End Card
Barcode
Barcode In
Decoder
Analog In
Laser On P
Capsel 3
Serial
Digipot Control Processor Serial Interface
Interface
Power Out (15V) P To Serial 3 on
4 Motherboard
Power In (15V)
Power
P5
Power Out (15V) Serial

Communications
To Magnetic Stripe Detector

Note: P3 through P5 are arbitrary designations used for descriptive purposes only.

Decoder/Controller Functions The decoder/controller provides the following:

 Barcode decoding, a complex function performed by a proprietary chip
that receives the digitised signal from the head and transmits valid bar-
code data over the decoder/controller serial port on its TxD pin to the
machine system control.
 Control functions, provided by a Programmable Interrupt Controller
(PIC) processor, which has the same design as the 5000/6000 read-
ers. The following are the control functions:
 Enable/disable the barcode laser
 Calibrate the amplifier gain and digitising threshold:
 Store the calibrated values in EEPROM (non-volatile memory)
 Load the calibrated values into the control devices (processors)
 Switch the peak detector time constants in the front-end card
 Switch the serial transmission source among the decoder integrated
circuit, the barcode controller processor, and the magnetic-stripe
detector controller processor
 Switch the RTS sources among the decoder integrated circuit, the
barcode controller processor, and the magnetic-stripe detector
controller processor
 Switch between two barcode signal sources (Head 1/Head 2)
 Enable scanner sync from a ‘note present’ signal (not used)
 Drive an LED to aid calibration
 Serial RS-232 connection to the machine control system through the
Serial 3 port on the mother board
 Power supplies (15V from the machine) to drive the barcode reader
(front-end card and laser) and the magnetic-stripe detector functions
Serial Communications Serial RS-232 ports serves as the interface from barcode reader systems
Interface to machine control systems. Machine control systems simultaneously
supply serial data to barcode readers, the on-board PIC processor, and
the magnetic-stripe detector controller, enabling each to receive mes-
sages of interest. All share the transmit line, which the control system
selects for the required device to communicate back. The interface uses
the Clear to Send (CTS) line and provides a link option to select CTS from
the port, or connect it to 0V. CTS connects to all serial data sources.
The following describes the communications parameters for all devices:
 Data rate: 9,600 bps
 Data bits: 7
 Stop bits: 1
 Parity: Even
 RTS: Transmitting end controls output. Logic low requests data
transmission.
 CTS: Input to the transmitting end. Logic low grants transmission.
Barcode Reader Power The Cobra supplies 15V to power the separator system. Power (12V)
can also come through the barcode reader/decoder serial port connection
at some point in the future. The barcode reader/decoder card then distrib-
utes all voltages for the separator system.
TP01311011 Rev 05 November 2009 7-7

7.2.2 Magnetic-Stripe Detector
The magnetic-stripe detector consists of the following:

 Magneto-Resistive (MR) sensor
 Front-end amplifier card
 Magnetic-stripe detector
7.2.2.1 MR Sensor
The MR sensor detects the edges of the magnetic stripes that are on the
magnetically encoded separators described in 1.1.2 on Page 1-5. The
MR sensor is a differential type consisting of a pair of offset MR elements.
The element offset does not exceed 0.75 mm (0.03 inches).
When the magnetic separator recognition stripes pass the sensor head,
the detector processes the resulting signals into binary pulses that repre-
sent the time the stripes are under the head.
The machine control system uses this information to determine the width
and spacing of the stripes.
Figure 7-5 shows typical signal characteristics. Each negative pulse rep-
resents the front edge of a stripe while each positive pulse represents the
back edge.
The top trace shows an output from the MR sensor when groups of three
magnetic stripes of about 6 mm (0.24 inches) pass under the head. The
lower trace shows the resultant binary output from the detector.
Figure 7-5 Typical Signals From a Magneto-Resistive Sensor
The small signals from the MR sensor require local amplification to mini-
mise noise. Because of limited space at the detector head, a front-end
amplifier card is provided at the head while the main functions of mag-
netic-stripe detection occur remotely from the head.
The separators usually have magnetic stripes printed on one side only
and this side is most often presented to the magnetic detector. However,
the sensor can read the magnetic-stripe pattern if the separators are fed
with the wrong face to the detector.

7.2.2.2 Magnetic-Stripe Detector Front-End Amplifier Card
Figure 7-6 illustrates a block diagram of the front-end amplifier card.
Figure 7-6 Magnetic-stripe Detector Front-End Amplifier Card
Stripe Detector Front-End Card
Power Power In (15V)
MR P To Magnetic
Sensor 7 Stripe Detector
Fixed
Gain Head Signal Out
Amp
Note: P7 is an arbitrary designation used for descriptive purposes only.
The front-end amplifier card has a linear analog amplifier with fixed gain
that is set to produce an output voltage of approximately 1V peak-to-peak
when a separator card is under the head under normal machine condi-
tions.
The card receives 15V power from the machine through the magnetic-
stripe detector card. An on-board power supply provides a low-noise 5V
supply to power the front-end card.
7.2.2.3 Magnetic-Stripe Detector
Figure 7-7 illustrates a block diagram of the magnetic-stripe detector

card.
Figure 7-7 Magnetic-Stripe Detector Card
To Barcode Reader
Decoder/Controller
Serial
Power In (15V)
Communications
P6
Non-
Test and
Volatile
Status
Power to Head (15V) Memory
To Mag Detector P To
Front-End Card Motherboard
8
Variable P
Head Signal In A/D Processor Separator Pattern
Gain Amp 9
Magnetic Stripe Detector
Note: P6, P8, and P9 are arbitrary designations used for descriptive purposes only.
TP01311011 Rev 05 November 2009 7-9

The magnetic-stripe detector consists of an AC-coupled variable gain

analog amplifier that feeds into a PIC processor containing an integral
analog-to-digital (A/D) converter.
The amplifier input is the 1V peak-to-peak signal from the head card. The
amplifier offsets its output to +2.5V, enabling it to feed a 0 – 5V signal to
the A/D converter.
A PIC-controlled digipot in the Op-Amp feedback enables setting the
amplifier gain range from 1 through 10.
The processor samples the analog data and runs an algorithm to find the
magnetic-stripe transitions. The processor then sets/resets a separator
pattern output to indicate the state changes.
The separator pattern output polarity is such that a logic 0 indicates tran-
sition to a magnetic stripe while a logic 1 indicates the transition from a
stripe. Therefore, the quiescent output is a logic 1 (refer to Figure 7-5 on
Page 7-8).
The processor samples the signal at variable rates (40 through
150 seconds per sample) and applies the algorithm to the data at the
fastest rate.
The PIC applies a simple digital filter based on averaging a fixed number
of samples.
Because the averaging period must be related to the wanted signal
period, the PIC must know the machine speed to select the sample rate.
The data and its associated data message pass through the serial port
associated with the barcode reader.
The PIC processor contains a Universal Asynchronous Receiver/Trans-
mitter (UART) to form a bi-directional serial port with Tx, Rx, RTS, and
CTS lines.
These lines, which output at TTL levels (+5V, 0V), interface to the bar-
code reader decoder/controller circuit, which in turn combines the data
and passes it to the machine control system.
The receive data to the PIC processor is common to all three serial
devices (magnetic-stripe detector, barcode decoder, and the barcode
processor) in the separator system, which simultaneously receive the
messages.
The Cobra control system requests data for transmission and the barcode
reader decoder/controller is responsible for switching the correct transmit-
ter to the transmit line.
The transmission parameters for the magnetic-stripe detector serial port
are the same as for the serial port on the barcode reader decoder/control-
ler.
The magnetic-stripe detector circuit board has a 1-K bit, serial access
EEPROM that serves as Non-Volatile Memory (NVM) to retain calibration
levels and machine speed data when power is off. PIC I/O lines drive the
memory.

The circuit board also has the following test and status circuitry:
 Two PIC-driven LEDs to indicate status conditions (including calibra-
tion)
 5V LED driven from the local 5V supply
 A PIC-driven D/A converter that can output internal signal levels, such
as the following:
 Pre- and post-processed analog signals
 Threshold values
 Calibration settings
The D/A is a parallel data type that is able to respond to data supplied at
the maximum PIC sampling rate.
The PIC reads two links to configure which data is output from the D/A
converter, such as test points on:
 Analog signal in
 Analog signal to the PIC
 Digital stripe pattern out
 D/A converter output
The circuit board receives power from its +5V supply and 15V derived
from the barcode reader decoder/controller circuit board.
TP01311011 Rev 05 November 2009 7-11

7.3 Installation ACDP Separator Recognition Feature
7.3 Installation
The following information updates a Cobra machine to incorporate the

magnetic-stripe and barcode reader detectors for the ACDP separator
recognition feature.
7.3.1 Parts Required
ACDP Separator Recognition Table 7-1 lists the parts of the ACDP Separator Recognition kit.
Kit
Table 7-1 Separator Recognition Kit

Item Description Part Number Qty
1a Cable form 400 6009 301 1
2b Cable form Magnetic Decoder to System 400 6008 701 1

3 Drill Jig Backplate 401 6023 402 1
4 M4 PSM 0046 1575 2
5 Grommet Strip 3 mm 0047 0604 70 mm
6 Barcode Assembly 400 2047 201 1
7 – – –
8 Washer M4 Sfty SS 0246 1311 4
9 Front plate D/A FDR 400 2006 805 1
10 Head Assembly Magnetic-stripe Detector 400 2047 301 1
11 Screw M3 x 8 Skt Cap SS 0246 1317 5
12 Washer Plain M3 Form A MS ZPL 0046 0304 8
13 Washer Sfty M3 SS 0246 1310 9
14 – – –
15 Restraint Magnetic-stripe Guide 402 0045 601 1
16 Magnetic-stripe Guide Shim 400 2041 701 1
17 Clamp Plate 401 6022 801 1
18 Bracket Guide Mounting Magnetic Stripe 400 2042 801 1
20 Thumb Screw 400 2047 501 1
21 Anti-Static Brush 372 0038 101 1
22 Bracket Anti-Static Brush 400 2042 702 1
23 P-Clip N x 2 0042 5105 2
24 Drill Jig Partition 401 6023 701 1
25 Assembly PCBs 400 2047 401 1
26 Spacer PLN ID4.4 OD8.8 LG15.8 0046 1872 3
27 Screw M3 x 25 BUT 0246 1295 3
28 Nut M3 0046 0404 4

ACDP Separator Recognition Feature 7.3 Installation
Table 7-1 Separator Recognition Kit (Continued)

Item Description Part Number Qty
29 P-Clip 0042 5111 3
32 Cable form Barcode Decoder to System 400 6008 901 1
33 Cable form Separator Magnetic Head 400 6008 601 1
34 Washer M4 Form A MS ZPL 0046 0305 3
35 Screw M4 x 10 BUT SS 0246 1361 2
36 Screw M4 x 10 CAP SS 0246 1323 3
a. This cable form is required with the S1-04 mother board.
b. This cable form is required with the S1-05 mother board.
Do the following:
1. Verify that all parts identified in the kit are available.
2. Read Section 7.4 on Page 7-26 before performing this modification.
3. Refer to Figure 7-8 for the separator system interconnections.
Figure 7-8 Separator Recognition System Interconnections
Note Path MS DET

J208
Mag Det Head Mag Stripe Cableform
MR Cableform
Card J1 J1 Detector J4 4006 0087 01
Sensor 4006 0086 01
4009 5017 XY 4009 5018 XY See Note
J2
Cobra
Direction of Cableform Motherboard
Note Travel 4006 0090 01 4009 5002 05
J1 Serial 3
J201
BCR Head BCR Decoder/
Photo Cableform Cableform
Card J2 J5 Controller J9
Diode 4006 0088 01 4006 0089 01
4009 5020 XY 4009 5021 XY
J1
Printed Circuit Board
Laser Machine Mounting Plate
Back Plane
Note: Cable form 400 6009 301 required for S1-04 motherboard
Tools Required
 2 x M6 x 10 full-thread bolts  3-mm diameter twist drill
 Power drill  12-mm diameter twist drill
 5.4-mm diameter twist drill  Flat file
 3.5-mm diameter twist drill (or stub twist drill to improve power drill
access)
TP01311011 Rev 05 November 2009 7-13

Special Tools You also need the following special tools If you must update the node:
 Fine point precision soldering iron  Magnifying glass
 Fine solder  Earthing kit
 Solder sucker  Good lighting
Software To fully accomplish the upgrade, you need software issue Global 9 or
higher.
Use Procedure 7-1 to apply the ACDP upgrade to an existing Cobra
machine.
Procedure 7-1 Applying the ACDP Upgrade

1. Power the Cobra machine down and remove the power supply.
2. Remove the rear cover.
3. Check the status of the mother board.

3a If the status is S1-04, the upgrade requires cable form Item 1.
3b If the status is S1-05 or greater, the upgrade requires cable
form Item 2.
Recommendation: Where required in the following step, per-
form attempted upgrades to node circuit boards under full work-
shop conditions and facilities.
4. Check the status of the node boards in position 3.
Circuit boards 4009 5005 status 04 (or below) require an update to
make them compatible with the separator recognition operation.
Note: After a node is modified, the node remains interchangeable with
other nodes. If desired or as needed, modify any spare nodes to allow their
use in position 3.
Circuit Board Modification For all status 04 or below circuit boards, carry out the following mod-
ification:
4.1 Connect a 28 – 26 AWG wire between Pin 2 (U69) and
Pin 129 (U91) as follows. See Figure 7-9.
 Solder the wire to R247 as shown to connect to Pin 129
(U91).
 After removing solder from TP75 and TP39, use the result-
ing holes to feed the linking wire between Pin 2 (U69) and
R247.
4.2 After modifying the node, use indelible ink to mark it as Si.

Figure 7-9 Modifications applied to Node Circuit Board (04 or Below)
TP39
R247
U91
Added Wire
U69
TP75
Alternatively, request a modified node circuit board through Spares

Administration, Basingstoke.
Equipping the Barcode 5. Open the front cover and, using Figure 7-10 on Page 7-16 as a
Reader guide, remove the designated three rollers, lower guide, and
transport belt.
Then attach the drill jig (Item 3) using the two M6 x 10 full-thread
bolts.
TP01311011 Rev 05 November 2009 7-15

Figure 7-10 Backplate Position to Mount the Barcode Reader
Remove Rollers and Lower Guide
Remove Transport Belt
A. Backplate Before Attaching Barcode Reader
Position of Drill Jig

401 6023 402
Increase These 3-mm Diameter

Holes to 12-mm Diameter and Increase These
Use File to Remove Material to 3-mm Diameter
Form a Slot Holes to 5.4 mm
B. Perpendicular View on Backplate Front Face

(Adjacent to Feeder) Showing Drill Jig Position.

Caution! A mains cable runs behind the backplate and could

be damaged when drilling holes in the following step. Exercise
care and verify that it is not damaged during the drilling process.
6. While using the drill jig as a guide, drill 4 x 3 mm holes as shown in
Figure 7-10 on Page 7-16. Then do the following:
6.1 Remove the drill jig.
6.2 Enlarge two of the 3-mm diameter holes to a diameter of
12 mm.
6.3 Using a small file, remove the material between the two
12-mm diameter holes to form a slot.
6.4 Enlarge the other two holes to 5.4 mm diameter.
6.5 Attach two PSMs (Item 4) to the two 5.4-mm diameter holes on
the rear side of the backplate.
6.6 Use an M4 bolt and washers to pull the PSMs into the back-
plate.
Note: Because drill access is restricted in the next step, drilling the hole at
an angle is acceptable.
7. Refer to Figure 7-11 to mark the position of the hole at the given
dimensions and drill a 3.5-mm diameter hole in the base tray.
Figure 7-11 Hole for P-Clip in Base Tray
8. Remove all metal debris using a vacuum cleaner.
9. Insert the grommet strip (Item 5) into the slot (length of 59 mm).
10. Reassemble the 25-mm roller standoff assemblies, lower guide, and
transport belt.
11. Attach the barcode assembly (Item 6) using the M4 x 10 bolts (Item
36) and washers (Item 8). Then do the following:
11.1 Align the barcode reader note guides parallel to the note path
as shown in Figure 7-12.
TP01311011 Rev 05 November 2009 7-17

Figure 7-12 Barcode Reader Installed into Cobra
Verify That the Barcode Assembly Does Not Touch This Roller
Assembly
11.2 Inspect the barcode assembly to verify that it does not touch
the leading lower roller assembly.
11.3 Adjust, as necessary, by bending the mounting bracket.
12. Remove the lower tractor belt standoff from the feeder front plate
(refer to Figure 7-13 on Page 7-18).
Figure 7-13 View of Feeder Front Plate with Equipped Mag-Stripe Detector
Magnetic-Stripe Detector
Pressure Shim Assembly
Positions of Tractor Belt and O-Ring

Belt Standoffs
Anti-Static Brush
Assembly
Assembly

12.1 Take the O-ring belt off its left-hand pulley.
12.2 Remove the feeder front plate.
12.3 Remove the remaining two standoffs from the feeder front
plate and assemble them to the new front plate D/A (Item 9).
Note: Do not over tighten the tractor belt in the next step.
Read!
13. Assemble the new feeder front plate to the machine and replace the
tractor belt and O-ring belt. Apply tension to the tractor belt such that
it is just tight.
14. Attach the magnetic-stripe head assembly (Item 10) to the feeder
front plate D/A using two M4 bolts (Item 35), plain washers (Item
34), and safety washers (Item 8).
15. Refer to Procedure 7-3 on Page 7-30 to adjust the position of the
magnetic-stripe head assembly.
16. Refer to Figure 7-14 when assembling the magnetic-stripe restraint
guide (Item 15), pressure shim (Item 16), and clamp plate (Item 17)
to the bracket (Item 18) using screws (Item 19) and safety washers
(Item 13).
16.1 Align the stripe guide shim such that it is parallel to the mount-
ing bracket at a distance of 42 mm.
16.2 Also align the restraint guide shim such that it lies centrally
over the stripe guide shim.
16.3 Attach this assembly to the feeder front plate using the thumb-
screw (Item 20).
Figure 7-14 Pressure Shim Assembly
Magnetic
Magnetic-Stripe
Stripe Guide Shim
Restraint Guide Shim
Clamp Plate
Mounting Bracket
Thumb Screw
Feeder Front Plate
42 mm
TP01311011 Rev 05 November 2009 7-19

17. Refer to Figure 7-15 on Page 7-20 when assembling the anti-static
brush (Item 21) to the mounting bracket (Item 22) using two each of
screws (Item 11), plain washers (Item 12), and safety washers (Item
13).
17.1 Attach this assembly to the feeder front plate using two each of
screws (Item 19) and safety washers (Item 13).
17.2 Position the brush such that it is just touching the tractor belt
as shown in Figure 7-13 on Page 7-18 and described in
Procedure 7-5 on Page 7-32.
Figure 7-15 Anti-Static Brush Assembly
Anti-Static Brush
Mounting Bracket
M3 x 8 Screws
Feeder Front Plate

M3 x 6 Screws

18. Route cables from the barcode and magnetic-stripe detectors

through the slot in the backplate as shown in Figure 7-16.
P-clip the magnetic-stripe wire to the following:
 Feeder front plate as shown in Figure 7-13 using a p-clip (Item

23), M3 x 8 screw (Item 11), and washer (Item 12)
 Base tray using a p-clip (Item 23), screw (Item 30), washer
(Item 12), and nut (Item 28).
Note: The p-clip on the feeder front plate on new machines has a dedi-
cated position. However, on some early upgrades, this position is not
present. Therefore, mount the p-clip on the left-hand feed plate attaching
screw as shown in Figure 7-13. This requires enlarging the hole in the p-
clip.
Figure 7-16 Barcode and Magnetic-Stripe Detector Wire Routes
P-Clip the Magnetic-Stripe

Detector to the Base Tray
TP01311011 Rev 05 November 2009 7-21

19. At the rear of the machine, remove the detector front-end circuit
boards from the top left of the partition.
Caution! In the next step, take care to not drill through cables
on the underside of the partition.
20. Refer to Figure 7-17 to attach the drilling jig (Item 24) to the partition
using M4 screws and drill three 3.5-mm holes in the positions
indicated.
20.1 Remove any cables and p-clips, as needed, to position the
drilling jig.
20.2 Remove all metal debris using a vacuum cleaner.
20.3 Replace the cables and p-clips.
Figure 7-17 Partition Drill Jig
Drill Jig (4016 0237 01) Position

Jig Location Hole Position for Mark 2 Belt Path
Drill Holes (3.5 mm Diameter)
Jig Location Hole Position for Mark 1 Belt Path

21. Refer to Figure 7-18 while removing the barcode and the magnetic-
stripe circuit boards from the mounting plate in assembly Item 25.
Note: In new Cobra builds, the circuit board assembly is quickly detacha-
ble from the partition.
21.1 Assemble the mounting plate to the partition underside using
spacers (Item 26), M3 x 25 BUT screws (Item 27), washers
(Items 12 and 13), and nuts (Item 28).
21.2 Reassemble the barcode and magnetic-stripe circuit boards to
the mounting plate.
Figure 7-18 Printed Circuit Board Assembly
Spacers, Screws,
Washers, and Nuts
Assembly Printed
Circuit Boards
Magnetic-Stripe
Printed Circuit
Barcode Printed Board
Circuit Board
Rear View of Machine
22. Attach the magnetic-stripe detector cable form (Item 33) to the
magnetic detector head card. (The barcode detector assembly
includes this cable form.)
TP01311011 Rev 05 November 2009 7-23

23. Route the barcode cable form and magnetic-stripe cable form
through the p-clips (Item 29) shown in Figure 7-19.
Figure 7-19 View Looking at Left-Hand Rear Side of Motor Controller
Position and Attach P Clip Using M3 x 10

Cap Head Screw and M3 PLN Washer
(DLR C.S. Numbers 0042 5111,
0246 1323, and 0046 0305, respectively)
Position P Clip (DLR C.S. # 0042 5111)

and Replace Existing Feeder Motor
Attaching Screw With M4 x 16 Cap Head
Screw (DLR C.S. # 0246 1325)
23.1 Attach the upper p-clip to the backplate with a screw (Item 30)
and washer (Item 12).
23.2 Use the motor securing screw to attach the lower p-clip.
Replace the screw with a longer screw (Item 31).
23.3 Verify that the cables are clear of belts and pulleys.

24. Refer to Figure 7-20 to route the barcode and magnetic-stripe cable
forms through the p-clip (Item 29) on the partition using an M4 x 10
screw (Item 36) and washer (Item 35). The p-clip position is
optional.
Figure 7-20 Top View of Partition With P-Clip Position on Underside
Position of P-Clip, Attaching M4 x 10 Cap Head

Screw, and M4 PLN Washer (DLR C.S. #
0042 5111, 0246 1323, and 0046 0305,
Respectively
25. Use cable form (Item 32) to connect J9 of the barcode circuit board
to Serial 3 port J201 on the mother board. Route the cable form
neatly in the trunking component.
26. Use cable form (Item 2) to connect the magnetic-stripe circuit board
to J208 on the mother board (status 05) labelled MS_DET.
If the mother board status is 04:
26.1 Use cable form (Item 1) to connect to J204 at the Pin1 end.
26.2 Plug J204 into J208 (MS_DET) and connect the socket
marked CTRL_SYS to J4 of the magnetic-stripe circuit board.
26.3 Route the cable form neatly in the trunking component.
27. Reassemble the detector front-end circuit boards as required.
28. To set up barcode and magnetic-stripe systems, use these

procedures:
 Adjusting the Laser Focus on Page 7-28
 Adjusting the Magnetic Head on Page 7-30
 Loading Factory Default Values on Page 7-33
 Calibrating Head 2 on Page 7-33
 Calibrating the Magnetic-Stripe Detector on Page 7-34
29. Switch the machine on and perform the system checks. Refer to
Section 7.7 on Page 7-37.
30. Replace rear cover.
TP01311011 Rev 05 November 2009 7-25

7.4 Setup/Adjustment and Calibration ACDP Separator Recognition Feature
7.4 Setup/Adjustment and Calibration
This section covers mechanical and electrical setup, as well as calibration

of the separator recognition subsystems. The provided information sets
and confirms subsystem operation.
The information also assumes the separator recognition subsystems are
complete and fully installed in the Cobra system.
The one exception is in the barcode reader laser adjustment.
The setup information applies only to Cobra applications.
7.4.1 Mechanical Setup
7.4.1.1 Barcode Reader Setup
Front-End Detector Card The barcode reader front-end detector card (400 9502 0XX) has no setup
Configuration Links links.
Detector/Controller For normal operation, set the barcode reader detector/controller
Configuration Links (400 9502 1XX) links as shown in Table 7-2. The links can have different
settings during calibration.
Table 7-2 Barcode Reader Decoder/Controller Configuration Links

Link Normal Setting Function
BTC (Barcode Time Constant) – Sets the time constant for the adaptive dig-
J2 In itising threshold on the front-end card. The link in selects the slower time
constant.
J3 Out CAL
These links are used together during
J4 Out DIAG calibration.
RST – Used during calibration to (See Procedures 7-6 and 7-7.)
J6 Out
reset the PIC.
CTS-EXT – Sets CTS to come
J7 Out from an off-board source. If J7 and J8 define the CTS source.
installed, J8 must not be installed. Inserting both links together is illegal.
CTS-INT – If J7 is not installed, Barcode chip is programmed to ignore
J8 Out inserting J8 sets CTS ‘low’. CTS.
Removing J8 sets CTS ‘high’.
BUZ (Buzzer) – A buzzer can connect to J10.
J10 Out
Do not equip with a shorting link.

ACDP Separator Recognition Feature 7.4 Setup/Adjustment and Calibration
Figure 7-21 shows the view from rear of machine.

The barcode reader coder/controller board (400 9002 1XX) is the left-
hand circuit board of the separator recognition system.
Figure 7-21 LED and Jumpers on Barcode Reader Decoder/Controller
LEDs Jumpers
J2 J3 J4 J6 J7 J8
CTS-INT
OK CTS-EXT
RST
DIAG
CAL
BTC
Barcode Reader Laser The barcode laser requires adjustment to ensure that the beam is
Adjustment focused at the correct distance and, more importantly, to ensure that the
spot of light on the note is as small as possible.
In the event that the laser, as supplied, has been pre-focused, all that is
necessary is to confirm the correct setting.
Adjustment Preparation Note: The adjustment must occur with the laser out of the machine
housing.
1. If the laser is already attached to the machine, remove the laser
housing, along with its bracket, from the machine backplate to gain
the necessary access:

To remove the laser from the housing, loosen the four Allen-head
screws from the laser clamp and gently pull the laser body out. 

Make sure to retain the O ring; verify that it is not trapped in the laser
guide tube.
2. Screw the lens in or out to focus the laser to achieve the smallest spot
possible on a reference surface when the laser body tube is
29 0.5 mm (1.14 inches) from the surface. 

The focused spot should be less than 250 microns (0.00098 inches)
in diameter.
Procedure 7-2 on Page 7-28 offers a technique that can be useful in
adjusting the laser.
TP01311011 Rev 05 November 2009 7-27

Procedure 7-2 Adjusting the Laser Focus

1. Screw the lens to its outer limit using the tool supplied with the laser.
2. Position the laser body against a fixed reference.
3. While using a black reference surface (the spot is more easily seen
when the surface is black), line up the spot to reflect from the
surface and slide the surface toward and away from the laser.
4. Measure the distance at which the reflected spot is smallest and
brightest.
When the distance is less than 29 mm (1.14 inches), screw the lens
in. When the distance is greater than 29 mm, screw the lens out.
Laser
Body
Reference Surface 29 mm
Note: In the next step, take care to not get the compound on the lens or
the laser body. The compound requires about 30 minutes to set to obtain
handling strength.
5. When you have completed the adjustment, lock the lens in position
using a suitable thread locking adhesive (recommended: Loctite
Screwlock 222). Refer to De La Rue spec ES0100-120-00, Method
Number 9).
6. After the Loctite has hardened, insert the laser into its housing,
pushing it fully home before tightening the four clamp screws.
7. Attach the housing to the machine.
Warning! Although the laser is a red, Class II unit not consid-
ered dangerous to the eye, it is still very bright and you should not
look at it directly. Be aware that if the laser is screwed in too far,
the laser is capable of producing a narrow parallel beam visible
even at long distances.
Barcode Head Guide The barcode head guide requires adjustment to ensure that notes are
Adjustment guided over the laser head without snag points.
You can make adjustments to the barcode head guide while it is off the
machine (preferable) or on (possible).
Loosen the two screws on the laser housing to adjust the guide. Make the
adjustment as shown in Figure 7-22 on Page 7-29, which shows a rear
view, as though the housing were off the machine.
Adjust the guide such that the guide is flush  0.25 mm (0.0098 inches)
with the top of the small triangular projection on the housing along the
whole width of the guide.

Figure 7-22 Barcode Head Guide
Straight Edge Guide
Laser
Housing
Adjustment
Laser
Bracket
Loosen Guide
Screws
Laser
7.4.1.2 Magnetic Detector Setup
Front-End Card Configuration The magnetic detector front-end card (400 9501 7XX) has no setup links.
Links
Magnetic-Stripe Detector For normal operation, set the magnetic-stripe detector (400 9501 8XX)
Setup links as shown in Table 7-3. The links can have different settings during
calibration.
Table 7-3 Magnetic-Stripe Detector Configuration Links

Link Normal Setting Function
J3 Out Reset – Provides hard reset of PIC

J5 Out SL1
These links, which are software controlled, are for
J6 Out Mode2
engineering use.
J7 Out Mode1
J8 Out CAL – Requests calibration mode
The magnetic-stripe detector has the following LEDs:
Table 7-4 Magnetic-Stripe Detector LED Indicators

LED Function
Used during the calibration process. See discussion in
D2 Calibration gain set
Procedure 7-8 on Page 7-34 for use.
D3
Engineering use No user functions
D4
D5 5V OK Must be on for normal operation
TP01311011 Rev 05 November 2009 7-29

Figure 7-23 shows the view from the rear of machine. The magnetic-
stripe detector board (400 9001 8XX) is the right-hand circuit board of the
separator recognition system.
Figure 7-23 LEDS and Jumpers on Magnetic-Stripe Detector Card
LEDs Jumpers
J3 J5 J6 J7 J8
D5 D4 D3 D2
CAL
Mode 1
5V OK Gain OK Mode 2
SL1
Reset
Magnetic Head Adjustment The magnetic head must be in reliable, even contact with notes, yet must
not obstruct or cause jams.
Use Procedure 7-3 to adjust the magnetic head position.
Procedure 7-3 Adjusting the Magnetic Head

1. Verify that the top face of the magnetic sensor is flush with the top
face of the feed tray (lay a straight edge over both surfaces).
2. Tighten the two screws indicated in Figure 7-24 to clamp the
magnetic sensor circuit board mounting bracket.
Figure 7-24 Magnetic Head

Magnetic Head Guide A mylar guide helps keep the notes in contact with the sensor.
Retaining Plate Adjustment
The magnetic head guide retaining plate prevents the mylar guide from
being pushed away from the sensor head surface when a stiff note or
separator document passes over the sensor.
The mylar guide fits under the retaining plate.
Use Procedure 7-4 to adjust the magnetic head guide retaining plate.
Procedure 7-4 Adjusting the Magnetic Head Guide Retaining Plate

1. Insert the retaining plate between the pinch assembly outer arm and
the plain external washer.
2. Adjust the retaining plate to achieve a dimension of 2.5  0.2 mm
between the magnetic guide retaining plate and the magnetic
sensor circuit board mounting bracket (Figure 7-25), making sure
that the adjacent faces are parallel.
Figure 7-25 Magnetic Guide Retaining Plate
TP01311011 Rev 05 November 2009 7-31

3. Tighten the pinch assembly attaching screw, making sure to

maintain the setting dimension between the retaining plate and the
magnetic sensor circuit board mounting bracket.
Anti-Static Brush Adjustment The Cobra machine belts are susceptible to a static charge buildup that
can cause the notes to stack incorrectly in the pockets and also interfere
with the sensitive magnetic head sensor.
Therefore, an anti-static brush is attached to help reduce/eliminate the
static charge buildup.
Use Procedure 7-5 to adjust the anti-static brush.
Procedure 7-5 Adjusting the Anti-Static Brush

1. Adjust the brush such that the tips of the bristles are just in contact
with the outside of the toothed belt (Figure 7-26).
Figure 7-26 Anti-Static Brush

7.4.2 Electrical Setup
7.4.2.1 Barcode Reader
The control circuit on the barcode reader/controller card (400 9502 1XX)
has three links (DIAG, RESET, and CAL) to enable calibrating the
barcode reader heads.
Calibration sets the analog gain and the digitising threshold of the
barcode reader function to suit the separator documents in
use.Calibration first involves loading the factory default values, then
calibrating the barcode reader head.
Load Factory Defaults Use Procedure 7-6 to load the EEPROM with default values from PIC
memory.
Procedure 7-6 Loading Factory Default Values

1. Remove links J6 (RST), J4 (DIAG), and J3 (CAL).
2. Apply power to the machine.
3. Short link J4 (DIAG), then link J3 (CAL).
4. Momentarily short link J6 (RST).

The LED should blink (on, then off) and remain off for 1 second.
Then the LED continually flashes twice as a signal to remove the
links.
5. Remove link J3 (CAL), then link J4 (DIAG).
The LED flashes three times, indicating the EEPROM is now tested.
5a If the LED now flashes, the EEPROM has an error.
5b If the LED remains on, the factory default values have suc-
cessfully loaded.
Calibrate Barcode Reader The barcode reader has two heads: Head 1 (transmissive) and Head 2
Head (reflective). As used in the Cobra application, the barcode reader uses
Head 2 only.
Use Procedure 7-7 to calibrate barcode reader Head 2.
Procedure 7-7 Calibrating Head 2

1. Place a separator in the head gap in such a manner that the laser
lights a blank part of it.
2. Remove links J6 (RST), J4 (DIAG), and J3 (CAL).
3. Apply power to the machine.
4. Short link J3 (CAL).
5. Momentarily short link J6 (RST).

The LED goes off for 1 second, then flashes twice to signal it is in
the Calibrate Head 2 mode. After a 1-second delay, either of the fol-
lowing occurs:
5a If the LED flashes twice continually, an error has occurred.
5b If the LED remains ON, head 2 has successfully calibrated.
After calibration, the measured values are automatically stored in the on-
board flash memory.
TP01311011 Rev 05 November 2009 7-33

7.4.2.2 Magnetic-Stripe Detector
The circuit board provides the on-board processor with reset and
calibrate links and a status LED to assist in gain calibration.
Calibration seeks to optimize the amplification of signals received from
the magneto-resistive sensor. This ensures that the separator monitoring
function detects all separator documents.
Use Procedure 7-8 to calibrate the magnetic-stripe detector.
Procedure 7-8 Calibrating the Magnetic-Stripe Detector

1. Apply power to the separator detection hardware.
The 5V OK LED (D5) lights.
2. Insert link J8 (Calibration) and verify that all other links are removed.
3. Insert and remove link J3 (Reset).

The magnetic-stripe detector boots up and, with J8 in place, enters
the calibration mode. The on-board PIC sets the gain to minimum
and prepares to sample and record the largest and smallest values
it sees.
4. Feed a quantity of separator documents through the machine so
that the stripe detector can assess the signal quality from the read
head.
The exact quantity of separator documents is not critical, but they
must represent the separator documents to be used.
5. Remove calibration link J8.
5a If LED D2 (Gain OK) does not light after a short delay, insert
link J8 (Calibration) and repeat Steps 4 and 5 until D2 lights.
5b If LED D2 (Gain OK) lights after a short delay, the stripe detec-
tor stores the gain because it is calibrated. Go to the next step.
6. Momentarily insert link J3 (Reset).
The magnetic-stripe detector boots up and is now ready to detect
magnetic stripes on separator documents.

ACDP Separator Recognition Feature 7.5 Specifications
7.5 Specifications
The following provides various specifications on the separator recognition

components.
Table 7-5 Separator Recognition Components

Barcode Reader Front-End Detector
The front-end card receives ±15V power from the machine through the barcode reader
decoder/controller. On-board regulators provide the internal power requirements (+5V,
0V, –5V) and 5V at 55 mA for the laser.
Power The ±15V load requirements are:
 +15V is less than 75
 mA–15V is less than 10 mA
Card Dimensions The maximum card dimensions are approximately 50 by 30 mm (2.0 by 1.2 inches).
Digipot A Dallas DS1267 digipot controls the amplifier gain and digitizer threshold level using a
three-wire serial data interface from the decoder/controller board.
Barcode Reader Decoder/Controller

The barcode reader/decoder card requires +5V at 120 mA and supplies +5V at 75 mA to
the magnetic detector derived from the +15V supply through an on-board regulator.The
card also supplies ±15V to the magnetic detector and the barcode reader front-end cards.
Power The total load on the ±15V power, including the load of the 5V supply, is as follows:
 +15V is less than 290
 mA –15V is less than 25 mA
Card Dimensions The circuit board dimensions are approximately 80 by 90mm (3.1 by 3.5 inches.
Serial Interface Driver The serial interface driver chip is a MAX232-type that generates its own ±V from the 5V
supply.
A proprietary decoder chip (Agilent HBCR2211) provides the barcode reader function.
Decoder Chip
The decoder chip has an associated RAM and latch and its circuitry is just like those on
5000/6000 barcode readers. The HBCR2211 handbook provides a full description of the
device and its operation.
Programmable Interrupt The PIC is a 16c711, 18-pin, SOIC running at 4 MHz.
Controller
MR Sensor Head
The MR sensor head is a Murata BS05 C1HFAA or BS05C1HGCA that mounts directly
on the front-end amplifier card.
Magnetic-Stripe Detector Front-End Amplifier
Dimensions The front-end card dimensions are approximately 50 by 30 mm (2.0 by 1.2 inches).
The magnetic-stripe detector card receives ±15V power from the machine through the
barcode reader decoder/controller.
The power requirements are as follows:
Power  +5V is less than 75
 mA +15V is less than 20 mA (including power supplied to the front-end card)
 15V is less than 10 mA
Dimensions The circuit board dimensions are approximately 80 by 90 mm (3.2 by 3.5 inches).
TP01311011 Rev 05 November 2009 7-35

7.6 System Requirements ACDP Separator Recognition Feature
7.6 System Requirements
7.6.1 Back Plane Printed Circuit Board
A standard kit build requires mother board back plane printed circuit
board (400 9500 205). Circuit board 4009 5002 04 requires a special
cable form (400 6009 301) to enable connection to the separator system.
A separator recognition system cannot possibly connect to any back
plane issue earlier than 04.
7.6.2 Node Card
A standard build also requires node card 400 9500 505 or later. Use of
node card issue 04 (or earlier) requires a salvage.
7.6.3 System Software
The Graphical Control Console PC requires installation of software

release Global 9 or later to enable use of the separator recognition
system.

ACDP Separator Recognition Feature 7.7 System Checks
7.7 System Checks
7.7.1 Magnetic Detector Checks
In a batching mode, feed header separators followed by trailer

separators.
Check that the screen acknowledges that a batch starts when the header
is fed and that a batch completes when the trailer is fed.
This confirms that the magnetic pattern recognition is operational.
7.7.2 Barcode Reader Checks
Enter the barcode diagnostic mode and turn the laser on/off.
Successful on/off operation verifies the serial communications link to the
reader with its cabling/power connections and much of the reader circuit
board operation.
In a batching mode, feed header separators followed by trailer separators
just as in the magnetic detector checks.
Verify that the barcode number on the header document appears in the
batch table in the reconciliation page.
TP01311011 Rev 05 November 2009 7-37

7.8 Wiring Schedules ACDP Separator Recognition Feature
7.8 Wiring Schedules
The following tables provide pinout information for the various

connections in the separator system. Each table identifies the applicable
PX and JX connectors. PX is an arbitrary designation for descriptive
purposes only as shown in Figures 7-1, 7-3, 7-4, 7-6, and 7-7. Figure 7-8
provides the JX connector of each unit.
7.8.1 Barcode Reader
7.8.1.1 Barcode Reader Front-End Detector Card
The barcode reader front-end detector card interfaces with the laser and
the decoder/controller card.
Table 7-6 lists pinout information for the 4-conductor CT-type connector
to the laser. This interface powers the laser when the ‘laser on’ signal is
asserted and the interlock pins on the laser connector make contact.
Table 7-6 Front-End Detector to the Laser (P1/J1)
Pin Function
1 Laser 5V
2 Interlock 1
3 Interlock 2
4 Laser 0V
Table 7-7 lists pinout information for the 15-conductor CT-type connector
to the decoder/controller card. Cable form 400 6008 801 connects the
front-end detector to the decoder/controller card.
Table 7-7 Front-End Detector to the Decoder/Controller Card (P2/J2)
Pin Function
1 Barcode Signal Out
2 +15V
3 0V
4 –15V
5 Laser On
6 Digipot RST
7 Digipot CLK
8 Digipot DQ
9 CAPSEL control
10 0V
11 Barcode Analog Out
12 No Connection (N/C)
13 N/C
14 N/C
15 Chassis

ACDP Separator Recognition Feature 7.8 Wiring Schedules
7.8.1.2 Barcode Reader Decoder/Controller Card
The barcode reader decoder/controller card interfaces with the front-end

detector card, the mother board (control system), and the magnetic-stripe
detector.
The decoder/controller connects to the front-end head card over a 15-
conductor CT-type connector using the pinouts. (seeTable 7-8) Cable
form 400 6008 801 connects the decoder/controller card to the front-end
detector.
Table 7-8 Decoder/Controller Card to Front-End Detector (P3/J5)
Pin Function
1 Head 2 Barcode Signal In

2 +15V
3 0V
4 –15V
5 Laser On
6 Digipot RST
7 Digipot CLK
8 Digipot DQ
9 CAPSEL control
10 0V
11 Head 2 Barcode Analog In
12 Head 1 Barcode Analog In
13 NP
14 Head 1 Barcode Signal In
15 Chassis
The decoder/controller connects to the machine control system over a 9-

conductor D-type plug connector using the pinouts shown in Table 7-9.
Cable form 400 6008 901 connects the decoder/controller card to the
machine control system.
Table 7-9 Decoder/Controller to Machine Control System (P4/J9)
Pin Function
1 +15V
2 Serial Tx (output from barcode system)
3 Serial Rx (input to barcode system)
4 N/C
5 0V
6 0V
7 /CTS input
8 /RTS output
9 –15V
TP01311011 Rev 05 November 2009 7-39

7.8.2 BCR/Magnetic-Stripe Detector Interconnection
The decoder/controller interfaces with the magnetic-stripe detector over a

12-conductor CT-type connector using the pinouts shown in Tables 7-10
and 7-11.
The magnetic-stripe detector receives power and serial communications
from the barcode reader.
These connectors are at the card-to-card interface to shorten the wire
lengths and to enable combining the cards without rerouting.
Cable form 400 6009 001 interconnects the two cards.
Table 7-10 BCR to Magnetic-Stripe Detector (P5/J1)

Pin Function
1 +15V output
2 Serial Tx (output from magnetic detector)
3 Serial Rx (input to magnetic detector)
4 5V (from local regulator)
5 0V
6 0V
7 /CTS input
8 /RTS output
9 –15V output
10 N/C
11 N/C
12 Chassis
Table 7-11 Magnetic-Stripe Detector to BCR (P6/J2)

Pin Function
1 +15V input
2 Serial Tx (output from magnetic detector)
3 Serial Rx (input to magnetic detector)
4 5V input
5 0V
6 0V
7 /CTS input
8 /RTS output
9 –15V input
10 N/C
11 N/C
12 Chassis

ACDP Separator Recognition Feature 7.8 Wiring Schedules
7.8.3 Magnetic-Stripe Detector
7.8.3.1 Detector Front-End Amplifier Card
The detector front-end amplifier card interfaces with the magnetic-stripe

detector over a 6-conductor CT-type connector using the pinouts shown
in Table 7-12.
Cable form 400 6008 601 connects the front-end amplifier card to the
magnetic-stripe detector.
Table 7-12 Front-End Amplifier to Magnetic-Stripe Detector (P7/J1)

Pin Function
1 +15V
2 0V
3 –15V
4 0V
5 MR head (signal out)
6 Chassis
7.8.3.2 Magnetic-Stripe Detector Card
The magnetic-stripe detector card interfaces with the front-end amplifier

over a 6-conductor CT-type connector using the pinouts shown in
Table 7-13.
Cable form 400 6008 601 connects the magnetic-stripe detector to the
front-end amplifier card.
Table 7-13 Magnetic-Stripe Detector to Front-End Amplifier (P8/J1)

Pin Function
1 +15V
2 0V
3 –15V
4 0V
5 MR head (signal In)
6 Chassis
TP01311011 Rev 05 November 2009 7-41

The magnetic-stripe detector card also interfaces to the machine control

system over an 8-conductor CT-type connector using the pinouts shown
in Table 7-14.
Cable form 400 6008 701 connects the magnetic-stripe detector to the
machine control system.
Table 7-14 Magnetic-Stripe Detector to Machine Control System (P9/J4)

Pin Function
1 5V from control system

2 Opto anode (supply)
3 Opto cathode (stripe signal)
4 0V
5 N/C
6 Chassis
7 N/C
8 N/C
The mother board uses a 4-conductor CT-type connector to connect to

the magnetic detector. Table 7-15 shows the pinout information.
Table 7-15 Mother Board to Magnetic Detector Pinout Information

Pin Function
1 5V from control system

2 Opto anode
3 Opto cathode (stripe signal)
4 0V
Note 1: The separator recognition system cannot use early mother

boards (Status 02 or lower).
Note 2: Status 03 or 04 mother boards do not have a dedicated con-
nector for the magnetic detector. 

Therefore, plug the connector from the magnetic detector into OPTO1 on
the mother board. 

This is a 15-conductor plug requiring either an interface cable or a modifi-
cation to the normal cable for use on these mother boards. Use cable
form 400 6009 301 in this application.

ACDP Separator Recognition Feature 7.9 Magnetic Stripe Detectors: Improving Calibration and Functionality
7.9 Magnetic Stripe Detectors: Improving Calibration and Functionality
7.9.1 Updating the Magnetic Strip PCB with Firmware Kit (FK100307/02)
Updating the Magnetic Stripe PCB firmware improves the calibration

and functionality of the Magnetic Stripe Detector.
Use Procedure 7-9 to replace the firmware on the Magnetic Stripe PCB.
Procedure 7-9 Fitting Firmware Kit (FK100307/02) to the Magnetic Stripe PCB
1. Disconnect all power to the Cobra sorter.
2. Disconnect cables J1, J2, and J4 from the Magnetic Stripe PCB.
3. Remove the M3 hex screws (4) from the Magnetic Stripe PCB.
4. Remove the Magnetic Stripe PCB.
5. Place the Magnetic Stripe PCB on a flat surface.
6. Remove the Peripheral Interface Controller (PIC) labeled

FK100307/01 from U4, using a PLCC extraction tool.
7. Install PIC FK100307/02 onto U4.
8. Replace the Magnetic Stripe PCB
9. Replace the M3 hex screws (4) to the Magnetic Stripe PCB
10. Reconnect cables J1, J2, and J4 to the Magnetic Stripe PCB
11. Reconnect power to the Cobra Sorter
Figure 7-27 Magnetic Stripe PCB
TP01311011 Rev 05 November 2009 7-43

7.9 Magnetic Stripe Detectors: Improving Calibration and Functionality ACDP Separator Recognition Feature
7.9.2 Magnetic Stripe Detector Setup
Figure 7-28 illustrates the rear-view of the Cobra sorter. The Magnetic
Stripe Detector circuit board (400-900-18XX) sits upon the right-hand side
of the Separator Recognition System
Figure 7-28 LEDs and Jumpers on the Magnetic Stripe Detector Card
For normal operation, set the magnetic stripe detector (4009 5018 XX)
links as shown in Table 7-16. The links have different settings during
calibration.
Table 7-16 Magnetic Stripe Detector Configuration Links

Normal
Link Function Description
Setting
J3 Out Reset Provides a hard reset of the PIC
J5 Out SL1
These links, which are software controlled, are reserved for
J6 Out Mode 2
engineering use only.
J7 Out Mode 1
J8 Out Cal Requests Calibration Mode
The magnetic stripe detector has the following LEDs:
Table 7-17 Magnetic Stripe LED Indicators

LED Function Description
Used during the calibration process. See Calibration notes
D2 Calibration Gain Set
for use.
D3
Engineering Use No User Functions
D4
D5 5V OK Must be on for normal operation

ACDP Separator Recognition Feature 7.9 Magnetic Stripe Detectors: Improving Calibration and Functionality
7.9.3 Magnetic Head Adjustment with Firmware Kit FK100307/02
The magnetic head must be set to give continuous contact with

separators. However, the magnetic head must not obstruct notes, or
cause jams.
Use Procedure 7-10 to adjust the mechanical magnetic head position.
Procedure 7-10 Calibrating the Magnetic Stripe Detector with Firmware kit
FK100307/02
1. Apply power to the Separator Detection hardware.
The 5V LED (D5) illuminates.
2. Insert link J8 (Calibration)
3. Verify that all other links are removed.
4. Momentarily insert and remove link J3 (Reset).

The Magnetic Stripe Detector boots up and, with J8 in place, enters
Calibration Mode. LED D2 illuminates and blinks twice. The on-
board PIC sets the gain to minimum and prepares to sample and
record the largest and smallest values it detects.
5. Select Category Sequence Process
So that the Mag Stripe Detector can assess the signal quality form the
read head:
6. Feed a quantity of separator documents through the machine
Note: The exact quantity of separator documents is not critical, but must
be at least between 50 and 100. They must represent the separator docu-
ments to be used.
Once the correct gain is achieved, LED D2 begins to blink continuously.
7. Remove calibration link J8.
8. Momentarily insert link J3 (Reset)

LED D2 blinks twice, indicating that the PIC has downloaded the
gain setting.
The magnetic stripe detector boots up and is now ready to detect
magnetic stripes on separator documents.
7.9.3.1 Testing Magnetic Head Adjustments
Use Procedure 7-11 to test Magnetic Head Adjustments
Procedure 7-11 Testing Magnetic Head Adjustments

1. Select a process that uses separators.
2. Feed a number of batches, using header and trailer cards, to start

and stop the batches (25 recommended)
Note: It is not necessary to feed cash.
3. Use the Magnetic Stripe diagnostic to confirm that the Magnetic
Stripe Detector is functioning correctly, and that both leading, and
trailing codes are consistently recognised, in both the normal, and
reverse positions.
TP01311011 Rev 05 November 2009 7-45

7.9 Magnetic Stripe Detectors: Improving Calibration and Functionality ACDP Separator Recognition Feature
NOTES:

Chapter 8
Quick Deposit Processing (QDP)

Usage
Topic Page Number
8.1 - Overview 8-2
8.2 - QDP Set Up 8-5
8.2.1 - Machine Configuration 8-5
8.2.2 - Process Configuration 8-5
8.2.3 - Process Parameters 8-6
8.3 - OutSort Pockets 8-7

8.1 Overview Quick Deposit Processing (QDP) Usage
8.1 Overview
Quick Deposit Processing is a methodology that improves customers’

productivity. It is an enhancement to the current Automated Commercial
Deposit Processing (ACDP) process and greatly reduces the volume of
documents that need to be processed at the reject entry workstation.
This translates directly into potential FTE savings in the cash centre. This
Marketing Release is designed to allow De La Rue sales staff to fully
explain the benefits to end-users.
To understand QDP and its advantages it is first necessary to understand
ACDP. The diagram below shows the ACDP process applied to a
customer that processes 30,000 retail deposits per day with an average
size of 200 banknotes. They run a two-pass process.
In the first pass the header card is read by the sorter to open the batch
before being sent to the reject pocket. The banknotes are then processed
and some are rejected – in this case 1% of the total.
Finally the trailer card is processed to close the batch and is also sent to
the reject pocket.
Next, the contents of the reject pocket are re-fed in a second pass. The
header card is again read to open the batch before being rejected. The
subsequent banknotes are re-processed - this time the reject rate is
assumed to be 20%.
Finally the trailer card closes the batch and is routed to the reject pocket.
The result is that although only 12,000 banknotes remain in the reject
pocket after a second pass, they are accompanied by 60,000 header and
trailer cards, making 72,000 documents in total.
Figure 8-1 ACDP
6,000,000 banknotes 1st batch: 1% reject rate 72,000 documents, 72 kg weight

30,000 batches of 200 notes each =60,000 notes+60,000 PCDs 30,000 batches need to be checked
60,000 header & trailer cards (PCDs) 2nd batch: 20% reject rate for 12,000 rejected notes
=12,000 notes+60,000 PCDs

Quick Deposit Processing (QDP) Usage 8.1 Overview
How QDP is different It still assumes a two-pass process as with ACDP, except this time the
trailer is fed first. This opens the batch before being sent to the reject
pocket. The notes are then processed as before with the same 1% reject
rate. The header closes the batch and is sent to the reject pocket.
The big difference is in the second pass.
This time, the trailer opens the batch but rather than being rejected is out-
sorted to a pre-assigned pocket. When the header card is seen, two
things can happen.
If there are no rejected notes between the trailer and the header it will be
out-sorted. If banknotes in that batch are rejected the header will also be
sent to the reject pocket.
The removal of all trailer cards and some header cards from the reject
pocket means that with QDP the work at the reject entry station is greatly
reduced.
In the example illustrated in Figure 8-2, 12,000 rejected notes plus a
maximum of 12,000 header cards (assuming a worst case of 1 reject per
batch) would remain in the reject pocket, a total of 24,000 documents in
contrast to 72,000 documents with ACDP.
Since 1000 documents weigh approximately 1kg, this also represents a
considerable reduction in the manual effort required to move the rejects to
the reject entry area of the cash centre.
Figure 8-2 QDP Process Example
6,000,000 banknotes 1st batch: 1% reject rate Max 24,000 documents, 24 kg

30,000 batches of 200 notes each =60,000 notes+60,000 PCDs weight
60,000 header & trailer cards (PCDs) 2nd batch: 20% reject rate Only batches with rejected notes
=12,000 notes+60,000 PCDs need to be checked
QDP is a method to reduce the effort in manual processing of cull pocket

documents. It is aimed mainly for high volume sites as a ‘second pass’
process.
For the basic method of QDP see Procedure 8-1 on Page 8-4.
TP01311011 Rev 05 November 2009 8-3

8.1 Overview Quick Deposit Processing (QDP) Usage
Procedure 8-1 Method for operation of quick deposit processing:

1. First pass process utilises batches with leading and trailing
separators as normal, configured so that the identifying separator is
at the end of the batch.
2. The second pass process (QDP Process) then reprocesses the
output of the cull pocket.
a) A significant percentage of originally culled notes will be success-
fully identified on this second pass
b) All leading separators (IE those without a barcode identifier) are
OutSorted to a nominated pocket.
c) Trailing separators for any batches that have no culls in this sec-
ond pass are OutSorted to a nominated pocket (this may be the
same or a different pocket to the leading separators).
d) Trailing separators for any batches which do have a cull in the sec-
ond pass are culled.
e) The Separator OutSort pockets are not accounting pockets, and
can be emptied at any point without error.
The result is that the cull stack after the second pass is significantly
smaller than the original cull stack, resulting in a significant saving in
manual processing of the cull stack.

Quick Deposit Processing (QDP) Usage 8.2 QDP Set Up
8.2 QDP Set Up
8.2.1 Machine Configuration
The machine should be configured for barcode recognition on the trailing

separator.
8.2.2 Process Configuration
The process should have an operational setting set to use QDP (see
Figure 8-3).
Figure 8-3 Operational Setting
Check this box to

enable QDP for this
operational setting
Set batch mode to

Leading and Trailing
continuous
Category groups should be set up as normal, with additional groups for

the leading and trailing separators.
These should contain the categories ‘CullLeadingSeparator’ and
‘CullTrailingSeparator’ respectively.
TP01311011 Rev 05 November 2009 8-5

8.2 QDP Set Up Quick Deposit Processing (QDP) Usage
Figure 8-4 Logical Destinations
The logical
destinations for the
OutSort pockets need
to have the Separator
OutSort checkbox
ticked.
This checkbox will

only be enabled if the
operational setting is
set to use QDP.
If the Category Group selected does not contain ‘CullLeadingSeparator’

or ‘CullTrailingSeparator’, or if it contains any other category, then the
user will be presented with an error message when they try to set the
checkbox, and it will automatically clear.
The bundle size should be adjusted to account for the greater thickness of
separators in the pockets.
The Use QDP and Separator OutSort checkboxes can be viewed on the
Logical Destination and Operational Settings tabs, but may not be edited
there.
8.2.3 Process Parameters
The process parameters for the stacker contents component,

ContentsPocketCapacity (242) should be set to match the chosen bundle
size.

Quick Deposit Processing (QDP) Usage 8.3 OutSort Pockets
8.3 OutSort Pockets
Logical destinations which are set as OutSort pockets will be treated in

the following manner.
1. Pocket contents will not be counted towards batch totals
2. Pocket contents will be counted with respect to pocket capacity and
cause the feeder to pause and stop when they become full.
3. Pockets contents can be removed as required, causing pocket count
to return to zero without error.
TP01311011 Rev 05 November 2009 8-7

8.3 OutSort Pockets Quick Deposit Processing (QDP) Usage
NOTES:

List of Procedures
List of Procedures

1-1 Removing/Replacing the Screen . . . . . . . . . . . . . . . . . . . 1-10
1-2 Removing/Replacing the Key Pad . . . . . . . . . . . . . . . . . . 1-11
1-3 Removing the GCC Computer . . . . . . . . . . . . . . . . . . . . 1-11
1-4 Forcing a Software Download to a Node . . . . . . . . . . . . . . . 1-23
1-5 Removing/Replacing the Node Boards . . . . . . . . . . . . . . . . 1-24
1-6 Installing the Programming Hardware . . . . . . . . . . . . . . . . 1-27
1-7 Programming the Motor Controllers . . . . . . . . . . . . . . . . . 1-28
1-8 Installing the Software Program . . . . . . . . . . . . . . . . . . . . 1-29
1-9 Manually Sending Motor Controller Parameters . . . . . . . . . . . 1-30

2-1 Setting the Feed Plate . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-2 Setting Up the Stripper Wheel, O-Ring, and Nudger Timing . . . . 2-4
2-3 Setting the Feeder Motor Drive Belt Tension . . . . . . . . . . . . 2-7
2-4 Setting the Contra Roller Gap . . . . . . . . . . . . . . . . . . . . . 2-7
2-5 Setting the Note Pick Belt Tension . . . . . . . . . . . . . . . . . . 2-9
2-6 Removing and Replacing the Stripper Wheel . . . . . . . . . . . . 2-10
2-7 Removing and Replacing the Note Guide . . . . . . . . . . . . . . 2-12
2-8 Removing the Contra Roller . . . . . . . . . . . . . . . . . . . . . . 2-12
2-9 Replacing the Contra Roller . . . . . . . . . . . . . . . . . . . . . . 2-13
Chapter 3 Transport
3-1 Removing Sensors TSB – TSI and TSK . . . . . . . . . . . . . . . 3-4
3-2 Replacing Sensors TSB – TSI and TSK . . . . . . . . . . . . . . . 3-5
3-3 Removing Sensor TSA . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-4 Replacing Sensor TSA . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-5 Removing/Replacing Sensors LOA – LOJ . . . . . . . . . . . . . . 3-6
3-6 Modifying a Cobra DCM to Accept a Four-Pocket Module . . . . . 3-9
3-7 Setting the Limpness Detector Roller . . . . . . . . . . . . . . . . . 3-20
3-8 Removing a Non-Stretch Transport Belt . . . . . . . . . . . . . . . 3-20
3-9 Setting the Stacker Wheels . . . . . . . . . . . . . . . . . . . . . . 3-22
3-10 Removing/Replacing a Stacker Wheel . . . . . . . . . . . . . . . . 3-23
3-11 Aligning the Diverter Blade . . . . . . . . . . . . . . . . . . . . . . 3-24
3-12 Removing/Replacing a Diverter Assembly . . . . . . . . . . . . . . 3-26
3-13 Adjusting Transporter Belt Tension . . . . . . . . . . . . . . . . . . 3-27
3-14 Removing/Replacing a Transport Belt . . . . . . . . . . . . . . . . 3-28
3-15 Setting/Adjusting the Timing Vanes . . . . . . . . . . . . . . . . . 3-29
3-16 Removing/Replacing a Sensor . . . . . . . . . . . . . . . . . . . . 3-30
3-17 Replacing a Timing Vane . . . . . . . . . . . . . . . . . . . . . . . 3-30
TP01311011 Rev 05 November 2009 LOP-i

List of Procedures
3-18 Setting/Adjusting the Cover Switch . . . . . . . . . . . . . . . . . 3-32

3-19 Removing the Cover Switch . . . . . . . . . . . . . . . . . . . . . 3-33
3-20 Adjusting the Front Cover Panel Position . . . . . . . . . . . . . . 3-34
3-21 Aligning the Side Cover Panels . . . . . . . . . . . . . . . . . . . 3-35
3-22 Checking Side Cover Panel Fastener Alignment . . . . . . . . . . 3-35
3-23 Removing/Replacing the Front Cover Panel . . . . . . . . . . . . 3-36
3-24 Removing/Replacing a Side Cover Panel . . . . . . . . . . . . . . 3-36
3-25 Removing/Replacing the Rear Cover Panel . . . . . . . . . . . . . 3-36
Chapter 4 Power
4-1 Removing/Replacing the Power Supply Tray . . . . . . . . . . . . 4-14
4-2 Removing/Replacing a Power Supply Unit . . . . . . . . . . . . . 4-15

5-1 Backing Up and Recovering a Database . . . . . . . . . . . . . . 5-9
5-2 Attaching an External Drive to the GCC . . . . . . . . . . . . . . . 5-11

6-1 Attaching and Aligning a Cobra Extension . . . . . . . . . . . . . 6-4
6-2 Setting the Stacker Wheels . . . . . . . . . . . . . . . . . . . . . . 6-18

7-1 Applying the ACDP Upgrade . . . . . . . . . . . . . . . . . . . . . 7-14
7-2 Adjusting the Laser Focus . . . . . . . . . . . . . . . . . . . . . . 7-28
7-3 Adjusting the Magnetic Head . . . . . . . . . . . . . . . . . . . . . 7-30
7-4 Adjusting the Magnetic Head Guide Retaining Plate . . . . . . . . 7-31
7-5 Adjusting the Anti-Static Brush . . . . . . . . . . . . . . . . . . . . 7-32
7-6 Loading Factory Default Values . . . . . . . . . . . . . . . . . . . 7-33
7-7 Calibrating Head 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7-8 Calibrating the Magnetic-Stripe Detector . . . . . . . . . . . . . . 7-34
7-9 Fitting Firmware Kit (FK100307/02) to the Magnetic Stripe PCB . 7-43
7-10 Calibrating the Magnetic Stripe Detector with Firmware kit FK100307/02
7-45
7-11 Testing Magnetic Head Adjustments . . . . . . . . . . . . . . . . . 7-45

8-1 Method for operation of quick deposit processing: . . . . . . . . . 8-4
LOP-ii Cobra® Banknote Sorting Machine Service Manual

List of Tables
List of Tables

1-1 Cobra Product Options . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-2 LCD Screen to PC Interconnections . . . . . . . . . . . . . . . . . 1-9
1-3 Detector Mother Board Connections . . . . . . . . . . . . . . . . . 1-13
1-4 Ancillary Mother Board Connections . . . . . . . . . . . . . . . . . 1-16
1-5 Track Sensor Mother Board Connections . . . . . . . . . . . . . . 1-17
1-6 Mother Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-7 Mother Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-8 LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1-9 Node LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-10 Motor Controller Status LEDs . . . . . . . . . . . . . . . . . . . . . 1-26
1-11 Parts to Program a Controller From an External PC . . . . . . . . 1-26
1-12 Additional Parts to Program a Controller From the GCC PC . . . . 1-27
1-13 Motor Controller Parameters . . . . . . . . . . . . . . . . . . . . . 1-29
1-14 Motor Controller Diagnostic LEDs . . . . . . . . . . . . . . . . . . 1-30
1-15 Key to Figures in this Chapter . . . . . . . . . . . . . . . . . . . . . 1-32
1-16 Other Useful Parts and Numbers . . . . . . . . . . . . . . . . . . . 1-33

2-1 Fault Isolation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-2 Friction Feeder Kit (400-3000-401) . . . . . . . . . . . . . . . . . . 2-15
2-3 Feeder Motor Assembly (550-2010-501) . . . . . . . . . . . . . . . 2-19
2-4 O-Ring Drive (550-2009-302) . . . . . . . . . . . . . . . . . . . . . 2-20
2-5 Stripper Wheel Assembly (550-2007-103) . . . . . . . . . . . . . . 2-21
2-6 Nudger Assembly - Single (550-2006-701) . . . . . . . . . . . . . 2-22
2-7 Nudger Assembly - Friction Feeder (550-2006-601) . . . . . . . . 2-23
2-8 Contra Roller Adjust Assembly (400-2002-401) . . . . . . . . . . . 2-24
2-9 Pinch Assembly - Feeder (400-2009-101) . . . . . . . . . . . . . . 2-25
2-10 Stand-off 36T Pulley Assembly (400-2009-801) . . . . . . . . . . . 2-26
2-11 Stand-off Pulley O-Ring Assembly (400-2012-202) . . . . . . . . . 2-26
2-12 Stand-off Pulley 2MR Assembly (400-2012-502) . . . . . . . . . . 2-27
2-13 Stand-off Pulley 2MR FL FR Assembly (400-2012-702) . . . . . . 2-27
2-14 Feeder Side Plate Assembly (400-2015-501) . . . . . . . . . . . . 2-28
2-15 Feed Tray Assembly (400-2006-601) . . . . . . . . . . . . . . . . 2-29
2-16 Feeder Back-Plate Motor ASSY (4002057801) . . . . . . . . . . . 2-30
TP01311011 Rev 05 November 2009 LOT-i

List of Tables
Chapter 3 Transport
3-1 Guide and Circuit Board Removal . . . . . . . . . . . . . . . . . . 3-5
3-2 Kit No 400-3006-101 . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-3 Output Stacker Hand-Wheel Setting . . . . . . . . . . . . . . . . . 3-22
3-4 Diverter Electrical Connections . . . . . . . . . . . . . . . . . . . . 3-26
3-5 Transport Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-6 Transport Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-7 Transport Motor and Hall-Effect Sensor Connections 
(400-2062-601) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-8 Fault Isolation Guide . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-9 Sensor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-11 Mark I Transport Belts . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3-12 Kit, Front Roller Assemblies – 400 3000 204 . . . . . . . . . . . . 3-47
3-13 Mark II Common Belt Paths – 400 3005 501 . . . . . . . . . . . . 3-49
3-14 Mark II Common Rollers – 400 3002 501 . . . . . . . . . . . . . . 3-51
3-15 Kit Roller and Belts 1A – 400 3007 001 . . . . . . . . . . . . . . . 3-53
3-16 Kit Rollers 1A – 400 3007 101 . . . . . . . . . . . . . . . . . . . . 3-54
3-17 2A (Primary) Roller Kit and Belts – 400 3005 902 . . . . . . . . . 3-55
3-18 2A Roller Kit – 400 3004 502 . . . . . . . . . . . . . . . . . . . . . 3-56
3-19 2B Roller Kit and Belts – 400 3006 601 . . . . . . . . . . . . . . . 3-57
3-20 2B Roller Kit – 400 3004 201 . . . . . . . . . . . . . . . . . . . . . 3-58
3-21 2C Roller Kit and Belts – 400 3007 701 . . . . . . . . . . . . . . . 3-59
3-22 2C Roller Kit – 400 3007 801 . . . . . . . . . . . . . . . . . . . . . 3-60
3-23 2D Roller Kit and Belts – 400 3008 001 . . . . . . . . . . . . . . . 3-61
3-24 2D Roller Kit – 400 3007 901 . . . . . . . . . . . . . . . . . . . . . 3-62
3-25 2E Kit Rollers and Belts – 400 3009 701 . . . . . . . . . . . . . . 3-63
3-26 2E Kit Rollers – 400 3009 801 . . . . . . . . . . . . . . . . . . . . 3-64
3-27 2F Kit Roller and Belts – 400 3009 901 . . . . . . . . . . . . . . . 3-65
3-28 2F Kit Rollers – 400 3010 002 . . . . . . . . . . . . . . . . . . . . 3-66
3-29 2G Kit Rollers and Belts – 400 3010 101 . . . . . . . . . . . . . . 3-67
3-30 2G Kit Rollers – 400 3010 201 . . . . . . . . . . . . . . . . . . . . 3-68
3-31 3A Kit Rollers and Belts – 400 3006 002 . . . . . . . . . . . . . . 3-69
3-32 3A Kit Rollers – 400 3005 302 . . . . . . . . . . . . . . . . . . . . 3-71
3-33 3B Kit Rollers and Belts – 400 3007 201 . . . . . . . . . . . . . . 3-72
3-34 3B Kit Rollers – 400 3004 901 . . . . . . . . . . . . . . . . . . . . 3-74
3-35 3C Kit Rollers and Belts – 400 3007 301 . . . . . . . . . . . . . . 3-75
3-36 3C Kit Rollers – 400 3004 301 . . . . . . . . . . . . . . . . . . . . 3-77
3-37 3D Kit Rollers and Belts – 400 3007 401 . . . . . . . . . . . . . . 3-77
3-38 3D Kit Rollers – 400 3004 801 . . . . . . . . . . . . . . . . . . . . 3-79
3-39 3E Kit Rollers and Belts – 400 3007 501 . . . . . . . . . . . . . . 3-79
3-40 3E Kit Rollers – 403 0005 001 . . . . . . . . . . . . . . . . . . . . 3-81
3-41 3F Kit Rollers and Belts – 400 3007 601 . . . . . . . . . . . . . . 3-81
3-42 3F Kit Rollers – 400 3004 601 . . . . . . . . . . . . . . . . . . . . 3-83
3-43 Kit, Capstan, and Stacker Assemblies – 400 3000 103 . . . . . . 3-84
3-44 Capstan/stacker Wheel Lower Assembly – 400 4002 301 . . . . . 3-85
3-45 Capstan/Stacker Wheel Upper Assembly – 400 4002 401 . . . . . 3-86
3-46 Capstan Assembly – 400 2000 803 . . . . . . . . . . . . . . . . . 3-87
3-47 Capstan/Handwheel Assembly – 400 2008 103 . . . . . . . . . . 3-88
LOT-ii Cobra® Banknote Sorting Machine Service Manual

List of Tables
3-48 Standoff Assembly, 50 Diameter Crowned – 400 2001 201 . . . . 3-89

3-52 Standoff Assembly, 25 Diameter Div – 400 2005 202 . . . . . . . . 3-91
3-53 Standoff Assembly, Limpness Roller – 400 2009 901 . . . . . . . . 3-91
3-54 Standoff Assy, 16 Diameter Twin Individual Inboard – 400 2014 001 3-92
3-55 Standoff Assembly, 16 Diameter Twin – 400 2017 601 . . . . . . . 3-92
3-58 Standoff Assembly, 25 Diameter Double – 400 2018 101 . . . . . 3-94
3-59 Standoff Assembly, 16/17.4 Diameter Double – 400 2018 402 . . 3-94
3-60 Standoff Assembly, 50 Diameter Outboard – 400 2018 501 . . . . 3-95
3-61 Standoff Assembly, 16 Diameter Twin Double – 400 2026 201 . . 3-95
3-63 Standoff Assembly, 20 Diameter Central Roller – 400 2033 602 . . 3-96
3-64 Standoff D/A Diameter 22 Plastic Roller – 400 2040 801 . . . . . . 3-97
3-65 Standoff D/A Diameter 22 Plastic Double IND – 400 2040 901 . . 3-97
3-67 Housing Bearing Assembly, Magnetic – 400 2041 201 . . . . . . . 3-98
3-68 Standoff D/A Diameter 22 Plastic Double Linked – 400 2041 502 . 3-99
3-69 Standoff D/A Diameter 22 Plastic INBRD – 400 2041 601 . . . . . 3-99
3-70 Standoff D/A Plastic Roller Double – 400 2043 201 . . . . . . . . . 3-100
3-71 Bracket Assembly, Stacker Entry Roller – 400 2016 703 . . . . . . 3-101
3-72 Pivot Roller Offset Assembly – 400 2025 401 . . . . . . . . . . . . 3-103
Chapter 4 Power
4-1 Mother Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-2 Cobra Versus 6000 Power Systems . . . . . . . . . . . . . . . . . 4-9
4-3 Cables Required to Power an Integrated Cobra/6000 System . . . 4-12
4-4 Power Supply Settings . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-5 MDU Mains Bus 400 6007 801 . . . . . . . . . . . . . . . . . . . . 4-15
4-6 MDU Neutral Bus 400 6007 901 . . . . . . . . . . . . . . . . . . . 4-15
4-7 MDU Mains Contactor 400 6008 001 . . . . . . . . . . . . . . . . . 4-16
4-8 MDU Relay Control 400 6008 101 . . . . . . . . . . . . . . . . . . 4-16
4-9 MDU Shredder Power 400 6008 201 . . . . . . . . . . . . . . . . . 4-16
4-10 MDU IEC Outlet Power Cable 400 6008 301 . . . . . . . . . . . . 4-16
4-11 Cobra Hybrid Safety Circuit 400 6008 401 . . . . . . . . . . . . . . 4-16
4-12 Cobra Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-13 MDU AC Distribution and Communications . . . . . . . . . . . . . 4-17
4-14 MDU Mains Bus (400-6007-801) . . . . . . . . . . . . . . . . . . . 4-18
4-15 MDU Neutral Bus (400-6007-901) . . . . . . . . . . . . . . . . . . 4-19
4-16 MDU Contactor (400-6008-001) . . . . . . . . . . . . . . . . . . . 4-20
4-17 MDU Relay Control (400-6008-101) . . . . . . . . . . . . . . . . . 4-21
4-18 MDU Shredder Power (400-6008-201) . . . . . . . . . . . . . . . . 4-22
4-19 MDU IEC Outlet Power Cable (400-6008-301) . . . . . . . . . . . 4-23
TP01311011 Rev 05 November 2009 LOT-iii

List of Tables

5-1 Daily Maintenance Routines . . . . . . . . . . . . . . . . . . . . . 5-4
5-2 Weekly Maintenance Routines . . . . . . . . . . . . . . . . . . . . 5-4
5-3 Semi-Annual Maintenance Routines . . . . . . . . . . . . . . . . . 5-5
5-4 Annual Maintenance Routines . . . . . . . . . . . . . . . . . . . . 5-6
5-5 Annual Service Times Estimates . . . . . . . . . . . . . . . . . . . 5-7

6-1 Sensor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-2 Transport Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-3 Transport Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-4 Transport Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-5 Output Stacker Handwheel Setting . . . . . . . . . . . . . . . . . 6-18
6-6 Index to Belt and Pulley Parts Lists . . . . . . . . . . . . . . . . . 6-22
6-7 Key to Front Roller and Standoff Assemblies . . . . . . . . . . . . 6-22
6-8 Key to Outer Drive Belts . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-9 Key to Capstan and Stacker Assemblies . . . . . . . . . . . . . . 6-25
6-10 FSM1 Ancillary Motherboard Connections . . . . . . . . . . . . . 6-26

7-1 Separator Recognition Kit . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-2 Barcode Reader Decoder/Controller Configuration Links . . . . . 7-26
7-3 Magnetic-Stripe Detector Configuration Links . . . . . . . . . . . . 7-29
7-4 Magnetic-Stripe Detector LED Indicators . . . . . . . . . . . . . . 7-29
7-5 Separator Recognition Components . . . . . . . . . . . . . . . . . 7-35
7-6 Front-End Detector to the Laser (P1/J1) . . . . . . . . . . . . . . . 7-38
7-7 Front-End Detector to the Decoder/Controller Card (P2/J2) . . . . 7-38
7-8 Decoder/Controller Card to Front-End Detector (P3/J5) . . . . . . 7-39
7-9 Decoder/Controller to Machine Control System (P4/J9) . . . . . . 7-39
7-10 BCR to Magnetic-Stripe Detector (P5/J1) . . . . . . . . . . . . . . 7-40
7-11 Magnetic-Stripe Detector to BCR (P6/J2) . . . . . . . . . . . . . . 7-40
7-12 Front-End Amplifier to Magnetic-Stripe Detector (P7/J1) . . . . . . 7-41
7-13 Magnetic-Stripe Detector to Front-End Amplifier (P8/J1) . . . . . . 7-41
7-14 Magnetic-Stripe Detector to Machine Control System (P9/J4) . . . 7-42
7-15 Mother Board to Magnetic Detector Pinout Information . . . . . . 7-42
7-16 Magnetic Stripe Detector Configuration Links . . . . . . . . . . . . 7-44
7-17 Magnetic Stripe LED Indicators . . . . . . . . . . . . . . . . . . . 7-44
NONE
LOT-iv Cobra® Banknote Sorting Machine Service Manual

List of Figures
List of Figures
1-1 Cobra 4004 (DCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Cobra Four-Pocket Extension Module . . . . . . . . . . . . . . . . 1-3
1-3 Cobra 4008- 4PM Extension Module to the left of the DCM. . . . . 1-4
1-4 Cobra 4004 with 6000 Units . . . . . . . . . . . . . . . . . . . . . . 1-4
1-5 Typical Header/ Trailer Separator Cards for ACDP . . . . . . . . . 1-6
1-6 Rear of Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-7 Key Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-8 GCC PC Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-9 Mother Board, Left Hand . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-10 Mother Board, Right Hand . . . . . . . . . . . . . . . . . . . . . . . 1-15
1-11 Safety Control Logic . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1-12 Node Board Locations . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-13 Sensor, Diverter, and Lamp Locations . . . . . . . . . . . . . . . . 1-21

2-1 Feed Plate Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-2 O-Ring and Nudger Wheel Timing . . . . . . . . . . . . . . . . . . 2-4
2-3 Nudger Timin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-4 Timing Vane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-5 Feeder Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-6 Contra Roller and Adjustment . . . . . . . . . . . . . . . . . . . . . 2-8
2-7 Front Feeder Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-8 View Below Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-9 Feeder Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-10 Stripper Wheel Mechanism . . . . . . . . . . . . . . . . . . . . . . 2-11
2-11 Feed Plate and Stripper Wheel . . . . . . . . . . . . . . . . . . . . 2-12
2-12 Contra Roller Alignment . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-13 Friction Feeder Kit (400-3000-401) . . . . . . . . . . . . . . . . . . 2-17
2-14 Friction Feeder Kit (400-3000-401) <T09R> . . . . . . . . . . . . . 2-18
2-15 Feeder Motor Assembly (550-2010-501) . . . . . . . . . . . . . . . 2-19
2-16 O-Ring Drive (550-2009-302) . . . . . . . . . . . . . . . . . . . . . 2-20
2-17 Stripper Wheel Assembly (550-2007-103) . . . . . . . . . . . . . . 2-21
2-18 Nudger Assembly - Single (550-2006-701) . . . . . . . . . . . . . 2-22
2-19 Nudger Assembly - Friction Feeder (550-2006-601) . . . . . . . . 2-23
2-20 Contra Roller Adjust Assembly (400-2002-401) . . . . . . . . . . . 2-24
2-21 Pinch Assembly - Feeder (400-2009-101) . . . . . . . . . . . . . . 2-25
2-22 Stand-off 36T Pulley Assembly (400-2009-801) . . . . . . . . . . . 2-26
2-23 Stand-off Pulley O-Ring Assembly (400-2012-202) . . . . . . . . . 2-26
2-24 Stand-off Pulley 2MR Assembly (400-2012-502) . . . . . . . . . . 2-27
2-25 Stand-off Pulley 2MR FL FR Assembly (400-2012-702) . . . . . . 2-27
2-26 Feeder Side Plate Assembly (400-2015-501) . . . . . . . . . . . . 2-28
2-27 Feed Tray Assembly (400-2006-601) . . . . . . . . . . . . . . . . 2-29
2-28 Feeder Back-Plate Motor ASSY (400-2057-801) . . . . . . . . . . 2-30
TP01311011 Rev 05 November 2009 LOF-i

List of Figures
Chapter 3 Transport
3-1 Location of Sensors, Diverters, and Lamps . . . . . . . . . . . . . 3-4
3-2 Stripper Wheel Mechanism . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 Upper Left Corner of Back Plane Showing Presence of Diverter . 3-7
3-4 Modifying a Cobra DCM To Accept a Four-Pocket Module 
(400 4006 701) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-5 Modified Backplate Assembly- Part 1 . . . . . . . . . . . . . . . . 3-11
3-6 Jig 1 and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-7 Jig 2 and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-8 Remaining Features . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-9 Exit Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-10 25-mm Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-11 16-mm Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-12 Standoff Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-13 Interlock Override Switch Assembled to the Cobra . . . . . . . . . 3-18
3-14 Dynamic Tensioner Setting . . . . . . . . . . . . . . . . . . . . . . 3-19
3-15 Limpness Detector Roller Setting . . . . . . . . . . . . . . . . . . 3-20
3-16 Cobra Stackers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-17 Stacker Wheel Index Position . . . . . . . . . . . . . . . . . . . . 3-22
3-18 Typical Stacker Pocket . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-19 Diverter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-20 Diverter Electrical Connections . . . . . . . . . . . . . . . . . . . . 3-26
3-21 Transport Drive System (Viewed from Machine Rear) . . . . . . . 3-27
3-22 Timing Vane Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-23 Transport Motor and Hall-Effect Sensor Connections . . . . . . . 3-31
3-24 Cover Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-25 Cobra Hinge Mounting . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-26 CIS Transport Kit (Front View) . . . . . . . . . . . . . . . . . . . . 3-39
3-27 CIS Transport Kit (Rear View #1) . . . . . . . . . . . . . . . . . . 3-40
3-30 Mark I Belt Path – Belts A, E, and G . . . . . . . . . . . . . . . . . 3-43
3-31 Mark I Belt Path – Belts B, C, D, F, H, I, J, L, and M . . . . . . . . 3-44
3-32 Mark I Belt Path – Belts K, N, and Q . . . . . . . . . . . . . . . . . 3-45
3-33 Mark I Belt Path – Belts O and P . . . . . . . . . . . . . . . . . . . 3-46
3-34 Kit, Front Roller Assemblies – 400 3000 204 . . . . . . . . . . . . 3-48
3-35 Mark II Common Belt Paths – 400 3005 501 . . . . . . . . . . . . 3-50
3-36 Mark II Common Rollers (400-3002-5001) . . . . . . . . . . . . . 3-52
3-37 Kit Roller and Belts 1A – (400-3007-001) . . . . . . . . . . . . . . 3-53
3-38 Kit Rollers 1A – 400 3007 101 . . . . . . . . . . . . . . . . . . . . 3-54
3-39 2A (Primary) Roller Kit and Belts – 400 3005 902 . . . . . . . . . 3-55
3-40 2A Roller Kit – 400 3004 502 . . . . . . . . . . . . . . . . . . . . . 3-56
3-41 2B Roller Kit and Belts – 400 3006 601 . . . . . . . . . . . . . . . 3-57
3-42 2B Roller Kit – 400 3004 201 . . . . . . . . . . . . . . . . . . . . . 3-58
3-43 2C Roller Kit and Belts – 400 3007 701 . . . . . . . . . . . . . . . 3-59
LOF-ii Cobra® Banknote Sorting Machine Service Manual

List of Figures
3-44 2C Roller Kit – 400 3007 801 . . . . . . . . . . . . . . . . . . . . . 3-60

3-45 2D Roller Kit and Belts – 400 3008 001 . . . . . . . . . . . . . . . 3-61
3-46 2D Roller Kit – 400 3007 901 . . . . . . . . . . . . . . . . . . . . . 3-62
3-47 2E Kit Rollers and Belts – 400 3009 701 . . . . . . . . . . . . . . . 3-63
3-48 2E Kit Rollers – 400 3009 801 . . . . . . . . . . . . . . . . . . . . 3-64
3-49 2F Kit Roller and Belts – 400 3009 901 . . . . . . . . . . . . . . . 3-65
3-50 2F Kit Rollers –400 3010 002 . . . . . . . . . . . . . . . . . . . . . 3-66
3-51 2G Kit Rollers and Belts – 400 3010 101 . . . . . . . . . . . . . . . 3-67
3-52 2G Kit Rollers – 400 3010 201 . . . . . . . . . . . . . . . . . . . . 3-68
3-53 3A Kit Rollers and Belts – 400 3006 002 . . . . . . . . . . . . . . . 3-70
3-54 3A Kit Rollers – 400 3005 302 . . . . . . . . . . . . . . . . . . . . 3-71
3-55 3B Kit Rollers and Belts – 400 3007 201 . . . . . . . . . . . . . . . 3-73
3-56 3B Kit Rollers – 400 3004 901 . . . . . . . . . . . . . . . . . . . . 3-74
3-57 3C Kit Rollers and Belts – 400 3007 301 . . . . . . . . . . . . . . . 3-76
3-58 3C Kit Rollers – 400 3004 301 . . . . . . . . . . . . . . . . . . . . 3-77
3-59 3D Kit Rollers and Belts – 400 3007 401 . . . . . . . . . . . . . . . 3-78
3-60 3D Kit Rollers – 400 3004 801 . . . . . . . . . . . . . . . . . . . . 3-79
3-61 3E Kit Rollers and Belts – 400 3007 501 . . . . . . . . . . . . . . . 3-80
3-62 3E Kit Rollers – 400 3005 001 . . . . . . . . . . . . . . . . . . . . 3-81
3-63 3F Kit Rollers and Belts – 400 3007 601 . . . . . . . . . . . . . . . 3-82
3-64 3F Kit Rollers – 400 3004 601 . . . . . . . . . . . . . . . . . . . . 3-83
3-65 Kit, Capstan, and Stacker Assemblies – 400 3000 103 . . . . . . . 3-84
3-66 Capstan/stacker Wheel Lower Assembly – 400 4002 301 . . . . . 3-85
3-67 Capstan/Stacker Wheel Upper Assembly – 400 4002 401 . . . . . 3-86
3-68 Capstan Assembly – 400 2000 803 . . . . . . . . . . . . . . . . . 3-87
3-69 Capstan/Handwheel Assembly – 400 2008 103 . . . . . . . . . . . 3-88
3-74 Standoff Assembly, 25 Diameter Div – 400 2005 202 . . . . . . . 3-91
3-75 Standoff Assembly, Limpness Roller – 400 2009 901 . . . . . . . 3-91
3-77 Standoff Assembly, 16 Diameter Twin – 400 2017 601 . . . . . . . 3-92
3-80 Standoff Assembly, 25 Diameter Double – 400 2018 101 . . . . . 3-94
3-81 Standoff Assembly, 16/17.4 Diameter Double – 400 2018 402 . . 3-94
3-82 Standoff Assembly, 50 Diameter Outboard – 400 2018 501 . . . . 3-95
3-83 Standoff Assembly, 16 Diameter Twin Double – 400 2026 201 . . 3-95
3-85 Standoff Assembly, 20 Diameter Central Roller – 400 2033 602 . 3-96
3-87 Standoff D/A Diameter 22 Plastic Double IND – 400 2040 901 . . 3-97
TP01311011 Rev 05 November 2009 LOF-iii

List of Figures
3-89 Housing Bearing Assembly, Magnetic – 400 2041 201 . . . . . . 3-99

3-90 Standoff D/A Diameter 22 Plastic Double Linked – 400 2041 502 3-99
3-91 Standoff D/A Diameter 22 Plastic INBRD – 400 2041 601 . . . . 3-100
3-92 Standoff D/A Plastic Roller Double – 400 2043 201 . . . . . . . . 3-100
3-93 Bracket Assembly, Stacker Entry Roller – 400 2016 703 . . . . . 3-102
3-94 Pivot Roller Offset Assembly – 400 2025 401 . . . . . . . . . . . . 3-103
Chapter 4 Power
4-1 Integrated System Safety Interface . . . . . . . . . . . . . . . . . 4-5
4-2 Cobra Mains Input Wiring . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 Power Supply Tray . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4 Internal Power Distribution - Cobra . . . . . . . . . . . . . . . . . 4-8
4-5 UPS and MDU in Integrated Cobra/6000 Application . . . . . . . . 4-10
4-6 Power Distribution in an Integrated Cobra/6000 Application . . . . 4-11
4-7 Power Supply Unit Front Panels . . . . . . . . . . . . . . . . . . . 4-13
4-8 MDU Mains Bus (400-6007-801) . . . . . . . . . . . . . . . . . . . 4-18
4-9 MDU Neutral Bus (400-6007-901) . . . . . . . . . . . . . . . . . . 4-19
4-10 MDU Contactor (400-6008-001) . . . . . . . . . . . . . . . . . . . 4-20
4-11 MDU Relay Control (400-6008-101) . . . . . . . . . . . . . . . . . 4-21
4-12 MDU Shredder Power (400-6008-201) . . . . . . . . . . . . . . . 4-22
4-13 MDU IEC Outlet Power Cable (400-6008-301) . . . . . . . . . . . 4-23
4-14 Cobra Hybrid Safety (400-6008-401) . . . . . . . . . . . . . . . . 4-24

5-1 Database Maintenance to Create Backups . . . . . . . . . . . . 5-9
5-2 Enterprise Manager to Restore Databases . . . . . . . . . . . . . 5-10
5-3 CD and Floppy Drive Connectors . . . . . . . . . . . . . . . . . . 5-11

6-1 Cobra 4008 – One Four-Pocket Extension and the DCM . . . . . 6-3
6-2 Alignment and Clamping Brackets (Right-Hand View) . . . . . . . 6-4
6-3 Electrical Connections for the Cobra . . . . . . . . . . . . . . . . . 6-7
6-4 Safety Control Logic . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-5 Locations of Sensors, Diverters, and Lamps . . . . . . . . . . . . 6-10
6-6 Module Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6-7 Transport Belts A, B, and C . . . . . . . . . . . . . . . . . . . . . . 6-13
6-8 Transport Belts D, E, and F . . . . . . . . . . . . . . . . . . . . . . 6-14
6-9 Outer Drive Belts G, H, and I . . . . . . . . . . . . . . . . . . . . . 6-15
6-10 Inner Drive Belts J, K, and L . . . . . . . . . . . . . . . . . . . . . 6-16
6-11 Four-Pocket Extension Module Stackers. . . . . . . . . . . . . . . 6-17
6-12 Stacker Wheel Index Position . . . . . . . . . . . . . . . . . . . . 6-19
6-13 Front Roller and Standoff Assemblies . . . . . . . . . . . . . . . . 6-23
6-14 Outer Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6-15 Capstan and Stacker Assemblies . . . . . . . . . . . . . . . . . . 6-25
LOF-iv Cobra® Banknote Sorting Machine Service Manual

List of Figures

7-1 Block Diagram of Separator Recognition Components . . . . . . . 7-2
7-2 View of the Separator Circuit Boards in Cobra . . . . . . . . . . . 7-3
7-3 Barcode Reader Front-End Detector Card . . . . . . . . . . . . . . 7-5
7-4 Barcode Reader Decoder/Controller Card . . . . . . . . . . . . . . 7-6
7-5 Typical Signals From a Magneto-Resistive Sensor . . . . . . . . . 7-8
7-6 Magnetic-stripe Detector Front-End Amplifier Card . . . . . . . . . 7-9
7-7 Magnetic-Stripe Detector Card . . . . . . . . . . . . . . . . . . . . 7-9
7-8 Separator Recognition System Interconnections . . . . . . . . . . 7-13
7-9 Modifications applied to Node Circuit Board (04 or Below) . . . . . 7-15
7-10 Backplate Position to Mount the Barcode Reader . . . . . . . . . . 7-16
7-11 Hole for P-Clip in Base Tray . . . . . . . . . . . . . . . . . . . . . . 7-17
7-12 Barcode Reader Installed into Cobra . . . . . . . . . . . . . . . . . 7-18
7-13 View of Feeder Front Plate with Equipped Mag-Stripe Detector . . 7-18
7-14 Pressure Shim Assembly . . . . . . . . . . . . . . . . . . . . . . . 7-19
7-15 Anti-Static Brush Assembly . . . . . . . . . . . . . . . . . . . . . . 7-20
7-16 Barcode and Magnetic-Stripe Detector Wire Routes . . . . . . . . 7-21
7-17 Partition Drill Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-18 Printed Circuit Board Assembly . . . . . . . . . . . . . . . . . . . . 7-23
7-19 View Looking at Left-Hand Rear Side of Motor Controller . . . . . 7-24
7-20 Top View of Partition With P-Clip Position on Underside . . . . . . 7-25
7-21 LED and Jumpers on Barcode Reader Decoder/Controller . . . . . 7-27
7-22 Barcode Head Guide . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7-23 LEDS and Jumpers on Magnetic-Stripe Detector Card . . . . . . . 7-30
7-24 Magnetic Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-25 Magnetic Guide Retaining Plate . . . . . . . . . . . . . . . . . . . 7-31
7-26 Anti-Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7-27 Magnetic Stripe PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
7-28 LEDs and Jumpers on the Magnetic Stripe Detector Card . . . . . 7-44

8-1 ACDP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2 QDP Process Example . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-3 Operational Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8-4 Logical Destinations . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
TP01311011 Rev 05 November 2009 LOF-v

List of Figures
NOTES:
LOF-vi Cobra® Banknote Sorting Machine Service Manual

Cobra Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Cobra Service Manual

Uploaded by

Copyright:

Available Formats

Cobra® Banknote Sorting Machine

© 2009 De La Rue International Ltd.

Jays Close, Viables

Cobra® Banknote Sorting Machine Service Manual

CE Compliance This equipment conforms to essential CE requirements for electromagnetic compatibility,

TP01311011 Rev 05 November 2009 Preliminary-i

Rev Level Issue Date Technical Writer

Preliminary-ii Cobra® Banknote Sorting Machine Service Manual

High Voltage: If single/three phase power is supplied to the machine,

High Energy: All servicing personnel are warned of the dangers of

Weight: Care must be taken when lifting items weighing 20 kg or over

Moving Parts: Extreme care must be taken by all servicing personnel

Light Emissions: The safety precautions for detectors which emit UV

TP01311011 Rev 05 November 2009 Preliminary-iii

Cabling and Power: Do not use the colour of cables as an indication of

SSD Devices: Normal precautions concerning the handling of MOS

EMC (Electro-Magnetic Compatibility): In accordance with the

Pneumatics: Before attempting any maintenance or servicing on the

Preliminary-iv Cobra® Banknote Sorting Machine Service Manual

Primary Symbol Description Secondary Symbol

Danger, High Voltage

Danger, UV Light, Do Not Look Directly at Light

Warning, Crushing Hazard

Warning, Equipment Starts and Stops Automatically

Warning, Hot Surface

Warning, Laser Light

Pinch Point Warning

Ear Protection Advisory

TP01311011 Rev 05 November 2009 Preliminary-v

It is recommended that a suitable table be made available to hold the

Preliminary-vi Cobra® Banknote Sorting Machine Service Manual

This page is intentionally left blank.

TP01311011 Rev 05 November 2009 Preliminary-vii

This page is intentionally left blank.

Preliminary-viii Cobra® Banknote Sorting Machine Service Manual

Chapter 1 System Description

1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

TP01311011 Rev 05 November 2009 TOC-i

Chapter 2 Friction Feeder

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Settings and Adjustments . . . . . . . . . . . . . . . . . . 2-2

2.5 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . 2-14

TOC-ii Cobra® Banknote Sorting Machine Service Manual

3.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

TP01311011 Rev 05 November 2009 TOC-iii

3.12 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . 3-38

TOC-iv Cobra® Banknote Sorting Machine Service Manual

4.1 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Chapter 5 Preventative Maintenance

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 Dust and Dirt Removal . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Maintenance Routines . . . . . . . . . . . . . . . . . . . . . 5-4

5.5 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . 5-8

5.6 Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

TP01311011 Rev 05 November 2009 TOC-v

Chapter 6 Four-Pocket Extension

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5 Motor Controllers . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6.7 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.8 Transport System . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6.12 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . 6-22