Zeus 2-Pocket Currency Discriminator

Troubleshooting Guide

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ZEUS TROUBLESHOOTING GUIDE

TABLE OF CONTENTS

PS sensor errors 2

Read errors 5

ID errors 8

ReStartRecognitionAPP error 12

EMERGENCY error in software update 14

Note: This Troubleshooting guide is excerpted from the Zeus Service Manual.

This service manual is confidential and exclusively for the use of Cassida Pro Series partners and their technicians and should not be shared with

outside sources. No part of this document can be reproduce in whole or in part without written permission from Cassida Corporation.

© 2016 Cassida Corporation. All rights reserved. Revision date: 6/16/2016

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PS Sensor Problem (Updated 4/28/2016)

Symptom and Reason

“CHECK PS1” or “CHECK PS2” is displayed after power on.

This error can be caused by PS1 and PS2 sensor problem.

[Fig. 1]

Causes and Solution

To debug what part exactly failed, we recommend to test by following order.

1. Check the sensors in test menu • Go into test menu -> [1] -> [7] (Sensor Detail) • Check ‘Upper Door’ (PS1) and ‘Lower Door’ (PS2) • ‘1’ means the door is open. If all the doors are closed but the level is ‘1’, then the sensor is not working.

[Fig. 2]

2. Check level of the sensors • Confirm the harness is properly connected.

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[Fig. 3]

3. Check the sensor level

• In ‘Sensor Detail’ menu, press [1] key to run the main motor and if the main motor starts running, then press [2] key to stop • Check the voltage level of the PS1 or/and PS2 sensor with DVM. Please refer to the points in Fig. 4.

[Fig. 4]

• Normal level Door open: < 1V (typically < 0.5V) Door closed: > 4.0V (typically 4.5~4.8V)

• Abnormal level Door open: >2.7V

Door closed: <3.2V

In this case, check for dust on the surface of the sensor assembly or between cap and sensor surface and

clean the sensor. Check the level again.If the level is still out of normal level, replace the sensor referring to:

Zeus Service Manual: page 24, Section 3.1 PBA replacement

4. If sensor levels are correct, replace the PBA_MECHA Board.

PS2 Connector

PS1 Connector

PS2 R

PS2 L

PS1 R

PS1 L

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READ ERROR problem (Updated 3/17/2016) Symptom and Reason

All bills are rejected as READ ERROR. Worn bills can be rejected as READ ERROR, but if all notes are rejected as READ ERROR, it means that the system failed to get the image of notes from the scanner (CIS sensor). Causes and Solution

1. Bad LED Bar

This problem is related to the CIS sensor, LED bar (UV backlight) and Main board.

If the LED bar (UV backlight) is defective, then it is likely to reject all the notes as “IR SUSPECT”. [Fig. 1] shows the scanner output when the LED bar is defective. IR T and UV T images are all black.

[Fig. 1]

To debug exactly which part failed, we recommend testing in the following order. The entire procedure should be done in power off condition:

2. Check the harness between CIS and MAIN board

A bad connection can cause this problem. Take out the harness, marked 1 in [Fig. 5], from the connector and

reinsert it. Check the images in the test menu -> [1] -> [5] (Scanning quality) -> [4] (Scanned image). If all the

images are correctly received from the CIS sensor as in [Fig. 2], then test the machine with additional bills.

[Fig. 2]

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3. Check the image

If step #1 does not work, then in test menu -> [1] -> [5] -> [4] (Scanned Image), count a bill and check the image.

If the image looks like [Fig. 3], the CIS should be replaced.

[Fig. 3]

If the image looks like [Fig. 4], the CIS or MAIN board is defective. (We assume the LED bar is working without

any problem). To identify the defective part, turn off the power and connect a new CIS to the MAIN board. Place

the CIS on a table or flat surface with a bill between the CIS and the table. Turn on the power and go into the

test menu again (Test menu -> [1] -> [5] -> [4]). Count a bill. The machine reads an image from the new CIS on

the table rather than the CIS in the machine. If the image looks like [Fig. 1] but with some strange but not all

black image of RGB and IR R then it means the MAIN board is OK. You should replace the CIS which is currently

installed in the machine. Otherwise if the image looks like [Fig. 4], you should replace the MAIN board.

[Fig. 4]

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4. After replacement

If you replace CIS or Main board, you should calibrate CIS sensor in test menu. Please refer to section 3-2 Adjustment after

PBA replacement / 2. PBA_MAIN on page 33.

[Fig. 5]

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ID ERROR by IR light source problem (Updated 3/17/2016)

Symptom and Reason If there is something wrong with the IR light source, it can cause ID ERROR bill rejection. If you compare the two pictures below, the first one has green lines in the background. It was caused by bad IR illumination. You can see these pictures in reject detail view -> press [IMG] button. Also, if you try to calibrate CIS(T) in the test menu, the calibration will probably fail.

Bad

Normal

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Causes and Solution

Check the harness between the UV light source and Mecha PBA.

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Check the harness connectors by gently pulling on each wire. All wires should be securely clipped into the plastic

connector.

If a wire connector is not clipped into the connector, then it looks like the below picture.

Bad

Good

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ReStartRecognitionAPP problem (Updated 3/17/2016)

Symptom and Reason

“ReStartRecognitionApp” appears when the communication between MAIN board and MECHA board failed.

Display of “ReStartRecognitionApp”

Causes and Solution

To debug what part exactly failed, we recommend testing in the following order. All the checks should be done with the

power off:

1. Check the harness between MAIN and MECHA Disconnect and reconnect the wire harness (see figure 1).

2. Backup If step #1 does not correct the problem, backup all sensor settings so they can be restored after the main board is

replaced.

To backup, in test menu -> [4] -> [1] (Backup)

3. Replace MAIN Replace the MAIN board and test the machine again. If the problem is solved, restore sensor settings from the

backup created in step #2.

To restore, in test menu -> [4] -> [2] (Restore)

4. Replace MECHA If the step #3 does not work, then replace the Main board with the original one and replace the Mecha board. Test

the machine again. If the problem is solved, then adjust Double level according to the Zeus Service Manual. Please

refer to pages 25 and 26, under the headings: Adjustment after PBA replacement / 3. PBA_MECHA.

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[Fig. 1]

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How to upgrade when you get an EMERGENCY screen (Updated 4/29/2016)

1) After upgrading with NONE_******.tbk

2) Emergency screen pops up – NEVER press the [EXIT] button

3) Press [C]&[START] + [BATCH], when the Emergency screen pops up. And enter password 0806.

4) Go to PROGRAM UPDATE and upgrade again.