zeus - cassida pro · • the zeus interfaces with many printers, and has customizable options for...

CassidaPRO Zeus: Service Manual 2018 Cassida Corporation. All rights reserved.

Rev: 09/05/2018

cassidapro.com/partner/

Zeus2-POCKET CURRENCY

DISCRIMINATOR

SERVICE MANUAL· Specifications

· Assembly· Procedures

· Troubleshooting· Quality Testing

· Parts Information


Rev: 09/05/2018


1. OVERVIEW1.1. Introduction from Cassida USA1.2. Cross Section Side View Diagram1.3. Specifications1.4. Communication Ports / Pin-Outs

1.4.1. Serial/RS2321.4.2. RJ111.4.3. RJ451.4.4. USB-A1.4.5. USB-C

1.5. Accessories1.6. Required Tools for Disassembly 1.7. Definitions and Terms1.8. Main PBA Connector Detail 1.9. Mecha PBA Connector Detail1.10. Circuit Block Diagram

2. QUALITY CONTROL TESTING2.1. Software Version Check and Update2.2. Sensor and Mechanical Check2.3. Currency and Function Check

3. PROCEDURES3.1. Battery Replacement3.2. Dust Cover Tension Adjustment 3.3. Re-aligning ADF Rollers3.4. Dust Cover Hook Replacement 3.5. Connecting Remote Display 3.6. CIS Calibration 3.7. Hopper Sensor Calibration 3.8. Double Sensor Calibration 3.9. Adjustments after PBA Replacement

4. DISASSEMBLY4.1. Side Covers (Left / Right)4.2. Assembly Bank Note Guide 4.3. Assembly Hopper and Top Panel4.4. Upper Door 4.5. Fly Wheel4.6. Encoder Disk4.7. Assembly Lower Guide4.8. Assembly Power Supply4.9. Main Motor 4.10. Assembly Reject Pocket 4.11. Dust Cover 4.12. Assembly Guide CIS Upper4.13. Assembly Guide CIS Lower 4.14. Assembly Stacker 4.15. PBA Replacement

4.16. Roller Replacement 4.17. Guide Reject Pocket Replacement

5. TROUBLESHOOTING GUIDE5.1. PS Sensor Errors5.2. Read/ID Errors5.3. ID Errors5.4. “ReStartRecognitionAPP” Error5.5. Upgrading (When EMERGENCY Screen is displayed) 5.6. Settings (Reset after Power Down/ Start-up Issues)

6. SERVICE MENU GUIDE6.1. Starting Test Menu6.2. Diagnosis6.3. Program Update6.4. Adjustments6.5. Backup and Restore6.6. Reports Clear6.7. Statistics Report6.8. Log Data6.9. Data Download6.10. Software Version

APPENDIX I: Spare Parts List

APPENDIX II: Error Codes/Messages

APPENDIX III: Contact Information

APPENDIX IV: Return Merchandise Authorization

APPENDIX V: Notices

This service manual is confidential and exclusively for the use of current Cassida PRO Series partners and their technicians. This manual shall not be shared with outside sources including but not limited to end users, competitors, social media, or marketing channels. No part of this document shall be reproduced in whole or in part without written permission from Cassida Corporation.

TABLE OF CONTENTS


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OVERVIEW

INTRODUCTION FROM CASSIDA USA

Thank you for partnering with Cassida PRO to sell and service the industry leading counterfeit detection equipment. Cassida PRO is proud to provide the best in class recognition and detection and dedicated service to our partners. Please visit our partner page listed below for the most up to date software, manuals, and information regarding our PRO Series products.

http://cassidapro.com/partner/

In addition, should you need further assistance including tech-to-tech troubleshooting, parts ordering, or general inquiries, please call our service center at:

1-888-800-0303(Option 1)(Option 1)

The following nomenclature will be used to show shortcuts and menu navigation throughout the service menu:

[#] Denotes the number key to press to access the menu option

-> Denotes the next number in the sequence to reach the final menu

All shortcut keys given are assuming that the technician has already opened the service menu. The headings given are the default options set on the product as it is shipped. Actions will be printed in bold text.

1.

1.1.

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CROSS SECTION SIDE VIEW DIAGRAM

1. Hopper Sensor2. PS1 Sensor3. Upper Cover4. Back Light5. Magnetic Sensor6. PS2 Sensor

7. Lower Cover8. Dust Drawer9. Image Sensor10. Reject Sensor11. Diverter12. Stacker Sensor

Receiver/Reflector SensorEmitter

1.2.

9

10

11

12

12

3

456

7

8

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MODEL CASSIDA PRO Zeus

COUNTING SPEED 800/1000 Bill/Min

HOPPER CAPACITY 500+ Notes

REJECT CAPACITY 100 Bills

STACKER CAPACITY 200 Bills

DETECTION METHODS MG, Full-Line UV, Double-Sided IR, High Definition Color CIS, Color Spectrum Analysis

BILL SIZE RANGE 4.7” x 2.4” - 7.1” x 3.5”(120 x 60mm to 180 x 90 mm)

POWER SUPPLY 100-240V/50-60Hz

WEIGHT 16.84 lbs (7.6 kg)

DIMENSIONS 10.8” W x 9.8” D x 12”H(276*250*305 mm)

FUNCTIONS INCLUDED Mix Mode

Sort Mode

Count Mode

Face Mode

Orientation Mode

Value Sort Mode

Add Feature

Strap Feature (by denomination, by count, by custom)

OPTIONAL FEATURES: Bar Code Mode

Bar Code + Cash Mode

Serial Capture Mode

SPECIFICATIONS 1.3.

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CONNECTIVITY / PORTS

RS-232 - SERIAL CONNECTION

1) CONNECTION WITH A PC

• Connection to a PC for remote printing is possible by using the serial port on the back of the discriminator. An RS232 male – RS232 female cable may be used to directly connect to a serial port on a PC. An RS232 male – USB-A converter cable may also be used to connect the discriminator serial port to a PC USB port. Both cables are available at most electronic retailers

Example of RS232 male - USB-A converter cable:

Communication data format:

This is available in the ZEUS Protocol Manual. If you need this information, please contact [email protected].

1.4.

1.4.1.

1. AC2. Serial Port (Printing)

NULL MODEM3. RJ12 (Remote Display)4. RJ45 (Network PortGND)5. USB-B (PC Connection Port)6. USB-A (Programming Update and

Export Port)

AC

Serial Port

RJ12

RJ45

USB-B

USB-A

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RS-232 - SERIAL CONNECTION

2) CONNECTION WITH A PRINTER

• The Zeus interfaces with many printers, and has customizable options for the serial portdata output setup. Due to the large variety of supported devices, the below pin-outis given for the Rx, Tx, and GND pins. All other pins are not connected (NC). Customcables may be created or ordered using the below pin-out.

The RS232 Port Pin-out is as follows:

1. NC2. Tx (Zeus -> Printer)3. Rx (Printer -> Zeus)4. NC5. GND6. NC7. NC8. NC9. NC

• You may also elect to use a standard RS232 cable, which requires a Null Modemadapter (female to male converter) at the end of RS232 male – RS232 female cable.Null modem adapters are available from most electronics retailers.

Example of RS232 female to male converter:

RJ11

1) CONNECTION WITH A CUSTOMER DISPLAY (remote display)Required cable: RJ11 to RJ11 cable

2) CONNECTION WITH A PCRequired cable: RJ11 to RS232 female (RS232 PC Port)• The RJ11 to RS232 female cable is a custom cable.• Please contact Cassida PRO for pricing and availability.

1.4.1.

1.4.2.

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RJ45 (LAN)

1) CONNECTION WITH A PCRequired cable: LAN Cable (LAN PC Port)• Communication data format: TBD. API manual available upon request.

USB-A

1) CONNECTION FOR USB EXTERNAL STORAGEConnection for USB external storage• USB memory file system must FAT32 format.

USB-B

1) CONNECTION WITH A PCRequired cable: USB-B – USB-A (USB-A PC Port)• Communication data format: API manual available upon request. • Requires Windows Driver (linux-cdc-acm.inf) which can be provided by

Cassida PRO Tech Support upon request.

Example of USB-B – USB-A cable:

1.4.3.

1.4.4.

1.4.5.

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ACCESSORIES

· Extended Bill Guides · External Display · Universal Cash Handling Thermal Printer · Cassida Air Duster · CleanBill Pro Cleaning Cards · CleanPro Cleaning Swabs

*Please contact Cassida PRO for pricing and availability of the items above.

REQUIRED TOOLS FOR SERVICE AND DISASSEMBLY

#2 Screwdriver (+)

2.5mm Screwdriver (-)

2mm and 2.5mm Hex key(Allen Key)

5.5mm, 7mm, and 13mm Wrench (Span-ner)

Tweezers

Long/Needle Nose Pliers

100mm Cable Ties

Angle Cutters

1.5.

1.6.

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DEFINITIONS AND TERMS

• ADF ROLLER: Automatic Document Feeder Roller - located in hopper area,responsible for feeding bills into unit

• Hopper: Either the top or back of the currency counter unit, where stacks of currencyare placed for feeding

• Reject Pocket: Location where rejected and suspect bills are passed to during sortand count operations

• Stacker: Area where currency is passed during sorting or counting upon meeting thesort or detection criteria

• CIS: Contact Imaging Sensor - image sensors almost in direct contact with the object tobe scanned. CIS is widely used in optical identification technology.

• UV Sensor: Ultraviolet Sensor - Sensors used to verify luminescence or fluorescencecounterfeit features in certain currencies

• IR Sensor: Infrared Sensor - Sensors used to verify IR ink counterfeit features (eithertransmissive or reflective) in certain currencies

• MG Sensor: Magnetic Sensor - Sensors that use magnetic fields to verify counterfeitfeatures in certain currencies

• Double: A misfeed error where two banknotes pass through the unit at the same time,or the unit detects a discrepancy in thickness of banknote

• Chain: A misfeed error where two banknotes pass through the unit too closely afterone another, so that the unit cannot differentiate the two bills

1.7.

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MECHA PBA CONNECTOR DETAIL 1.9.

MAIN PBA CONNECTOR DETAIL 1.8.

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CIRCUIT BLOCK DIAGRAM 1.10.

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QUALITY CONTROL TESTING

When servicing units or attempting to diagnose issues, the service engineer may test the machines according to the procedures described below. This report summarizes what should be checked and how. The following tests are suggested to be performed as a first pass to check overall unit health. These checks are similar to the Cassida PRO in-house QC process and cover the majority of the functions and diagnostic features provided by the Zeus.

SOFTWARE VERSION CHECK AND UPDATE

To check the software version on the unit:

1) Enter the Service Menu -> [9] S/W Version

2) The first line on this screen will tell you the software version in date code, plusthe product index in parentheses. Standard software for the Zeus is (1); anythingelse is a custom release.

To update the software on the unit:

3) Connect a USB external storage device (formatted as FAT32) to back of unit’sUSB-A port loaded with the latest software found at cassidapro.com/partner

4) Go into Service Menu -> [2] Program Update

5) Select the desired software file either by pressing the associated number on thekeypad, or using the up and down arrows and pressing [SET] key.

6) The screen will prompt you to verify you want to continue. Press the [YES]key to proceed. DO NOT TURN OFF UNIT WHILE UPDATING.

7) After update is complete, enter the Service Menu -> [4] Backup & Restore.Make sure there are no bills in the Stacker pocket.

8) Select [4] Rebuild Software. There will be a prompt to continue. This optionpushes the newly loaded software to the auxiliary hardware and initializes andsyncs all internal components. Failure to perform this step may result in improperoperation.

9) After screen returns to Main Menu, enter the Service Menu -> [4] Backup &Restore again.

10) Select [3] Factory Default Setting. There will a prompt to continue. Unit will goback to Main Menu when finished.

NOTE: If you do not perform steps 8 to 10, the unit will not recognize some features and you will experience unusual errors or side effects.

2.

2.1.

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SENSOR AND MECHANICAL CHECKS

NOTE: as of this edition of the service manual, each sensor test in the Diagnosis -> Sensor Detail menu will change color from white to BLUE to indicate test was performed and passed. If an error is detected by the Zeus, the failed sensor will display in RED. These colors will be reset once the menu is exited.

SENSOR TEST

This test quickly checks the health of various mechanical parts and sensors.

1) Enter Service Menu -> [1] Diagnosis -> [7] Sensor Detail

2) Check Main Motor by pressing [1] FW or [3] BW (Forwards and Backwards, respectively), then stop the motor by pressing [2] 3) Check the Diverter by pressing [4] Rejector and then [5] Stacker several times back and forth. An audible ‘click’ should be heard when the solenoid engages.

4) Check the Wing Motor by pressing [7] Wing and then press [7] again to stop the motor.

5) Check the Power Supply Fan by pressing [8] Fan and then press [8] again to stop the fan.

6) Check the Dust Cover. Open Dust Cover (gently press center tab downward until clear cover locks in place) then press [9] to close. Repeat several times. To adjust the tension, see procedure [3.2 Dust Cover Tension Adjustment]

7) Check ADF (pickup position sensor). Figure 2 below shows the correct alignment of pickup roller and ADF roller. When B position of ADF rubber starts showing, the position A of pickup rubber is better if it is on highest position. And when position of A is at right position, ADF value in sensor detail menu becomes ‘1’. Check this value while turning the pickup roller.

2.2.

[Fig. 1]

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2.2.SENSOR AND MECHANICAL CHECKS

8) Notes will slip and may cause feed errors and jamming.• Manually turn the Pickup Roller (it does not matter in which direction) until

you can barely see the white section of the ADF Roller. You should be able to see just one of the white “gear” teeth on this section exposed from the front.

• The ADF Roller (back roller with a white urethane teeth section) and Pickup Roller (front roller with a black teeth section) are both located on the top of the unit, as part of the hopper. The rollers must be aligned such that a banknote will touch one of the roller teeth from either roller at any point in time. Otherwise, the banknote may feed incorrectly, slip, or feed askew. There should only be 5 to 7 teeth showing from the front side. If there are 8 or more teeth visible, or you do not see any teeth, the rollers need to be realigned.

9) Upper Door (PS1 Sensor) • Open the upper door and check the value of L and R.• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.

10) Lower Door (PS2 Sensor)• Open the upper door and check the value of L and R.• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.

11) Double Sensor

• Open the upper door and check the value of L and R.• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.• With the door closed, the values of L and R should be around 2000. Any

value above 1000 will still operate correctly in most cases.• With the door open, the values of L and R should both be 4095.

12) Hopper (Hopper Sensor)• Open the upper door and check the value of L and R.• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.• With no obstructions, the value of Hopper should be ‘0’ and Diff should be

< 100• Cover the hopper sensor and the value should change to Hopper ‘1’ and

Diff to >1000.

13) Rejector (Reject Pocket Sensor)• Open the upper door and check the value of L and R.• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.• With no obstructions, the value of the reject sensor should be ‘0’ and Diff

should be >1000.• Cover the reject sensor and the value should change to Rejector ‘1’ and

Diff to <100

14) Stacker (Stacker Pocket Sensor)• Open the upper door and check the value of L and R.

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KEYPAD TEST

1) Go into Service Menu -> [1] Diagnosis -> [8] Keypad Test

2) Press every key until ZEUS displays “Keypad Press Test: OK” and the [EXIT] key becomes available. Press [EXIT] to return to the service menu.

• If the door is open, L and R should be ‘1’, otherwise should be ‘0’.• With no obstructions, the value of the stacker sensor should be ‘0’ and Diff

should be >1000.• Cover the stacker sensor and the value should change to Stacker ‘1’ and

Diff to <100

SENSOR AND MECHANICAL CHECKS 2.2.

[Fig. 2]

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CURRENCY AND FUNCTION CHECKS

MIX MODE (BASIC CURRENCY RECOGNITION)• Run a stack of same-denomination bills, split evenly into the 4 possible orientations

(ex. face to the right, face to the left, back to the right, back to the left). Do thisfor each denomination, from $1 to $100. The amount of bills used depends onavailability, but Cassida recommends testing with a large quantity of bills (100 perdenomination).

FUNCTION MODE TESTSNOTE: Use 2 bills of each denomination (14 bills total) to perform the following mode tests.

1) Sort2) Count3) Face4) Orientation5) VALUSORTTM

PRINT FUNCTION• After performing any of the currency tests, the Menu hotkey will become Print.

Connect a thermal printer to the serial port in the back of the unit. Press the Printhotkey, and the summary will be printed. Check to make sure the currency (i.e.USD), date, and time are correct.

DETAILED SENSOR INFORMATIONSCANNING QUALITY TESTNOTE: This test checks feeding quality, image quality, RGB histograms, and position, MG, IR, UV sensors. Enter the Service Menu -> [1] Diagnosis ->[5] Scanning Quality

• Count 10 to 30 notes. The display will show double sensor output first. Graphicalinformation is assigned to numeric keys. Press each number repeatedly to scrollthrough the values and tolerances of each sensor individually

[1] Double sensor output[2] Magnetic sensor output[3] Position sensor output[4] Scanned image[5] CIS shading waveforms

The [0] and [8] keys are commonly used to enlarge the screen (Key [0]) or to reduce the screen (Key [8]). The [ADD] and [STRAP] keys are used to scroll the display left or right.

• In every display, the assigned numeric key itself acts like a next/previous key. Forexample: Display the Magnetic sensor output by pressing Key [3], then the key[3] is used to show ‘display for all Magnetic sensors’ -> ‘display for Left Magneticsensor’ -> ‘display for Center Magnetic sensor’ -> etc.

1) Check Double Sensor• Select this display by pressing in Service Menu -> [1] Diagnosis -> [5]

2.3.

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Scanning Quality -> [1] DBL. An example of passing double sensors is displayed below:

2.3.

Normal - The waveform above was acquired after counting three $1 bills.• In this waveform, you should check ‘DbL’ (Red) and ‘DbR’ (Blue) signals to

ensure there are three swings with similar depth resulting from counting the 3 notes.

Abnormal - If there is no signal check related parts · Double Sensor, · Harnesses · Mecha board

2) Check Magnetic Sensors• Select this display by pressing in Service Menu -> [1] Diagnosis -> [5]

Scanning Quality -> [2] MG. An example of passing sensors for three $1 notes is displayed below:

In this menu, you may check the magnetic head signals for scanned notes. ‘dbR’(Blue) shows the note is passing the magnetic sensors. There are three channels of magnetic sensors, MHL(Left), MHC(Center), and MHR(Right).

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When you press Key [2] you will then see each magnetic head individually. Below is an example of the MHL on a passing sensor.

2.3.

In this test, you should confirm whether magnetic sensor output is within range, and falls within the expected detection envelope for each note scanned.

Abnormal - If the signal seems flat, out of range, or outside of the scan envelop check:

· Magnetic Sensors· Mecha PBA· Cable Connections

3) Check Position Sensors and Main motor• Select this display by pressing in Service Menu -> [1] Diagnosis -> [5]

Scanning Quality -> [3]Position Sensors. The below image shows a passing scan and position.

• Default screen pictured below:

This graph displays adf encoder (light blue), ps1L (blue) and ps2L (blue in lower position), ps1R (red) and ps2R (red in lower position), npm (yellow) signals.

In Fig. 6, the machine’s counting speed is plotted along the vertical axis called NPM (Notes Per Minute), and horizontal axis shows times. The teal square wave is the signal from the encoder used to determine physical position of the ADF rollers. The red and blue pulses for each PS1 and PS2 sensor are the sensed position of the note in the bill transport path.

[Fig. 6]

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Normal - The signal (yellow) varies but is approximately 1000 npm on average. The teal square wave is uniform except for the first and last pulses which will be longer.

Abnormal - If it cannot reach the 1,000 npm level, uneven encoder spacing, or misaligned PS1 and PS2 pulses check:• The holes of the encoder wheel to assure they are not blocked or bent• Encoder Board and (PBA_ENCODER)• Mecha Board (PBA_MECHA)• A loose Drive Belt can also cause the bills to not count at the 1,000 npm

level.• PS1 or PS2 reflectors may be cracked due to foreign objects passed

through bill transport path• Wiring may be loose or damaged

CURRENCY AND FUNCTION CHECKS 2.3.

4) Check Image Sensor• Select this window by pressing Service Menu -> [1] Diagnosis -> [5] Scanning

Quality -> [4]Images. An example of a passing scan is displayed below. Note that only one bill may be displayed at a time. It is suggested to use a high denomination to verify that enhanced security features are available for viewing.

This menu allows you to check the actual images acquired by the CIS image sensor, UV, and IR full line scanning images, and back light source. Ensure that each quadrant has an image, and that no repetitive artifacts are visible in the display of each separate image.

Abnormal - If repetitive noise, colored bars, or missing images are noted check:

· CIS sensor flat ribbon cable for damage· Cable connections to MAIN board· CIS sensor for debris, dirt, damage, or cracking· UV/IR emitters for debris, dirt, damage, or cracking· Calibration waveforms

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5) Check CIS shading waveforms• Select this display by pressing in Service Menu -> [1] Diagnosis -> [5]

Scanning Quality -> [5]CIS Pixels. An example of a passing CIS RGBwaveform level is given below:

In this menu, the CIS’s RGB shading waveforms are displayed. Every photocell in the CIS has different sensitivity and different exposure to the light source. To compensate for non-linear sensitivity, the system saves a reference waveform from a white plate, or calibration sheet. If a photocell is defective, the shading waveform will show discontinuities as shown below:

If this occurs, clean the surface of the CIS and calibrate the CIS again. If the waveform is still the same following cleaning and calibration, the CIS should be replaced.

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If you press the [5] key again,the shading waveform of UV & IR transmitted illumination will be displayed as shown below for a passing sensor:


If the waveform doesn’t look similar to Fig. 10, clean the IR/UV bar and attempt a calibration. If discontinuities are still present, replace the IR/UV bar.

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BATTERY REPLACEMENT - CR2302 BUTTON CELL

1. With the unit facing front, remove the left side cover (Reference Section 4.1.). On the Mecha Board, locate the battery behind the serial port and RJ11 port (marked J25 on PCB).

2. Gently bend the clip to reach the battery, then slide battery out3. Insert new battery into slot, ensuring clip is returned to position

3.1.

PROCEDURES 3.

DUST COVER TENSION ADJUSTMENT

HOW TO ADJUST THE TENSION OF THE DUST COVER

1. With the unit facing front, remove the right side cover. Turn the power on and enter the Service Menu -> [1] Diagnosis -> [7] Sensor Detail.

2. Engage the dust cover release solenoid by pressing [9] key.3. Ensure screws 1 and 2 are snug, but not overly tight. Loosen screw 2

slightly, if necessary.4. Open dust cover and close it by pressing [9].5. If the dust cover closes too hard, fast, and/or it bounces and stays open,

adjust the tension by tapping the spring (3) downward. If the dust cover closes too slowly or does not close completely, adjust the tension by adjusting the spring (4) upward.

6. Repeat step 3 and 4 until the dust cover operates properly. Optimum adjustment is when the dust cover makes a clear contact and a soft noise against bottom of the reject pocket.

7. Tighten screws while holding tensioner in position and verify proper dust cover operation.

3.2.

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DUST COVER HOOK REPLACEMENT

1. Turn the power off and remove right side cover.2. Loosen screw (1).3. Remove pin (3).4. Remove hook (2) and replace module from the hook shaft.5. Re-install the pin (3). Check the movement of the two parts. The hook should move

freely.6. Tighten the screw (1)7. Turn on the power and go into Service Menu ->[1] Diagnosis ->[7] Sensor Detail.

You can close the dust cover by pressing [9] key. If necessary, adjust the tension[3.2 .Dust Cover Tension Adjustment]

3.3.

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CONNECTING REMOTE DISPLAY

Please refer to picture below.

3.4.

RJ11 (ZEUS) <-> MAIN (Display)

LINK (1st Display) <-> MAIN (2nd Display)

LINK MAIN LINK MAIN

1ST DISPLAY 2ND DISPLAY

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DISASSEMBLY 4.

DISASSEMBLE COVER_SIDE_L/COVER_SIDE_R(Side Covers - LEFT/RIGHT)

1) Loosen 4 screws (M3x10 tap)


3) Loosen 4 screws (M3x6)

4.1.

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DISASSEMBLE ASSEMBLY_BANKNOTE_GUIDE (Assembly Bank Note Guide - Top Panel)


4.2.

DISASSEMBLE ASSEMBLY_OP (Assembly Hopper and Top Panel)

1) Loosen 1 screw (M3x6 SEMS) and remove FRONT_GND_1WAY wire

2) Spread wings outward and then pull out towards you

3) Pull up the connector cover and remove the harness (FRONT_TO_MAIN_FFC).

4.3.

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DISASSEMBLE UPPER DOOR (Upper Door - Rear Panel)

1) Open the Lower Door

2) Open the Upper Door

3) Loosen 4 screws (M3x6) and remove the upper door

4.4.

DISASSEMBLE FLY_WHEEL (Fly Wheel - Right Side Panel)

1) Loosen 1 screw (SET SCREW M4x8) with Allen key

2) Remove the flywheel

4.5.

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DISASSEMBLE ASSEMBLY_GUIDE_LOWER (Assembly Lower Guide - Lower Door and Assembly)

1) Loosen links

2) Loosen 2 screws (M3x7) until the ASSEMBLY_GUIDE_LOWER drops down. Then turn the screws about 1 turn more.

3) Take out the clips holding the supports in place

4) Guide the harness (PS2_HARNESS_1WAY) into the interior and pull the ASSEMBLY_GUIDE_LOWER toward you and downward at the same time.

4.7.

DISASSEMBLE ENCODER_DISK (Encoder Disk - Right Side Panel)


2) Remove c-clip (6 ), then remove ENCODER_DISK

4.6.

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DISASSEMBLE ASSEMBLY_GUIDE_LOWER (Assembly Lower Guide - Lower Door and Assembly)

4.7.

DISASSEMBLE ASSY_SMPS(Assembly Power Supply)

1) Loosen 2 screws(M3x6) and remove the ASSY_COVER_REAR


3) Take out the power cable (ASSY_SMPS_HARNESS)

4) Take out the ASSY_SMPS handling the power cable carefully.

4.8.

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DISASSEMBLE ASSEMBLY_SMPS(Assembly Power Supply)

4.8.

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DISASSEMBLE ASSY_MAIN_MOTOR (Main Motor)

1) Loosen 3 screws (M3x6 SEMS)

4.9.

DISASSEMBLE ASSEMBLY_REJECT_POCKET(Assembly Reject Pocket)


2) Pull up and slide out the ASSEMBLY_REJECT_POCKET.

4.10.

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DISASSEMBLE DUST_COVER(Dust Cover)

1) Loosen the 4 screws that hold the PBA_MECHA in place (M3x6 SEMS)

2) Lift the PBA_MECHA slightly up and remove c-clip (6 ) and the circular Left Hinge (HINGE_L_DUST_COVER)

3) Loosen 1 screw (M3x6 SEMS) and remove the Solenoid and the Hook (HOOK_DUST_COVER)

4) Loosen 1 screw (M3x8 SEMS) and remove the Dust Cover Ratchet (RATCHET_DUST_COVER)

5) Loosen 1 Nut (M8) with spanner #13 (M8) and #5.5 (M3). Remove the circular Right Hinge (HINGE_R_DUST_COVER)

6) Remove COVER_STACKER_LOWER by pressing the tabs on its sides and pulling it outward.

7) Take out DUST_COVER, squeezing the sides lightly if necessary.

4.11.

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DISASSEMBLE DUST_COVER(Dust Cover)

4.11.

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DISASSEMBLE ASSEMBLY_GUIDE_CIS_UPPER(Assembly Guide CIS Upper)

1) Remove upper door (see SECTION 4.4)

2) Unplug all cable harnesses from PBA_MAIN

3) Loosen 1 screw (M3x6 SEMS) and remove the encoder sensor

4) Carefully cut the tie-wraps and remove tie-wraps from shaft

5) Remove 2 c-clips (5 ) and remove the shaft

6) Take out ASSEMBLY_GUIDE_CIS_UPPER

4.12.

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DISASSEMBLE ASSEMBLY_GUIDE_CIS_LOWER(Assembly Guide CIS Lower)

1) Remove Encoder Disk (ENCODER_DISK) (see SECTION 4.6)

2) Remove c-clip (6 ) and remove the ASSEMBLY_PULLEY_1WAY_36S3M and PULLEY_FEED_32S3M

3) Loosen 2 screws (M3x6 SEMS) and remove the HOLDER_CIS

4) Loosen 2 screws (M3x6 SEMS) and remove the HOLDER_CIS on the opposite side

5) Remove CIS while supporting its harness with tweezers

6) Remove c-clip (6 ) and remove PULLEY_ADF_42S3M and PULLEY_ADF_16S3M

7) Loosen 4 screws (M3x6 tap) on both sides

4.13.

DISASSEMBLE ASSEMBLY_GUIDE_CIS_UPPER(Assembly Guide CIS Upper)

4.12.

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DISASSEMBLE ASSEMBLY_GUIDE_CIS_LOWER(Assembly Guide CIS Lower)

4.13.

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DISASSEMBLE ASSEMBLY_STACKER(Assembly Stacker)

1) Disconnect the wing motor harness and the STACKER_HARNESS_1WAY

2) Disassemble PBA_MECHA and turn it down, disconnecting any harnesses attached toPBA_MECHA as necessary to reach screws behind board

3) Loosen 2 screws (M3x6 tap) on Left Side

4) Loosen 2 screws (M3x6 tap) on Right Side

4.14.

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PBA REPLACEMENT 4.15.

NO. PBA REQUIRED DISASSEMBLE PROCESS

1 ASSEMBLY_PBA_LED_BAR 4-4

2 PBA_DB_L 4-4

3 PBA_DB_R 4-4

4 PBA_ENCODER 4-1 (COVER_SIDE_R)

5 PBA_FRONT 4-1, 4-2, 2-3, 3-2(1)

6 PBA_HOPPER 4-1, 4-2, 4-3

7 PBA_MAIN 4-1 (COVER_SIDE_L), 3-2(2)

8 PBA_MECHA 4-1 (COVER_SIDE_L), 3-2(3)

9 PBA_PS1_LEFT 4-4

10 PBA_PS1_RIGHT 4-4

11 PBA_PS2 4-1, 4-7

12 PBA_REJECT 4-1, 4-2, 4-3

13 PBA_SMPS 4-1 (COVER_SIDE_L), 4-8

14 PBA_POS_SEN 4-1 (COVER_SIDE_R)

15 PBA_STACKER 4-1, 4-11

614

5

12

1513

7

8

11

4

2,3

9,10

1

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PBA_FRONT — HOPPER SENSOR CALIBRATIONWhen PBA-FRONT is replaced, Hopper sensor should be calibrated

1. Prepare a small sheet like a name card and attach black tape on it.2. Go into Test Menu -> [1. Diagnosis] -> [7. Sensor Detail]3. Place the sheet on the hopper4. Adjust the variable resistor confirming the hopper diff is 3,000 to 4,000

ranges.

PBA_MAIN — CIS CALIBRATIONWhen the PBM_MAIN is replaced, the CIS sensor should be calibrated. (CIS should be calibrated too when it is replaced with the new one.)

1. Go into Test Menu -> [3. Adjustment] -> [5. CIS Calibration (R)2. Open the Upper door and attach the shading sheet referring to the below

figure.3. Align the shading sheet to A and B sides. This sheet can be attached due to

magnetic.4. Close the Upper door tightly and press [YES] to start calibration.5. Open the Upper door and remove the shading sheet.6. Close the Upper door tightly and go into [6. CIS calibration (T)] and press

[YES].

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PBA_MECHA — DOUBLE SENSOR CALIBRATIONWhen the PBA_MECHA is replaced, Double sensors should be calibrated.

1. Go into Test Menu -> [1. Diagnosis] -> [7. Sensor Detail]2. Adjust the variable resisters confirming the double level is in 2000 ~ 3500

ranges.3. Open the Upper door and check the double levels. They should be 4095. If

not, repeat Step 2.

VR1(Right)

VR2(Left)


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ROLLER REPLACEMENT 4.16

NO. ROLLER REQUIRED DISASSEMBLE PROCESS

1 ASSEMBLY_ADF 4-1~4-6, 4-12, 4-13

2 ASSEMBLY_PICKUP (ROLLER_PICKUP) 4-1, 4-2, 4-3

3 ASSEMBLY_REVERSE_ROLLER 4-1, 4-2, 4-3

4 ROLLER_F_PINCH 4-1, 4-2

5 ROLLER_TIGHTENER 4-1

6 ROLLER_EXIT_PINCH 4-1, 4-7

7 FEED_PINCH_ROLLER (BEARING) 4-1, 4-7

8 ASSEMBLY_EXIT_ROLLER 4-1, 4-4, 4-5, 4-6, 4-12, 4-13

9 ASSEMBLY_FEED_ROLLER 4-1, 4-4, 4-5, 4-6, 4-12, 4-13

10 ROLLER_R_FINCH 4-1, 4-2

11 RUBBER_PICKUP No Need

32

65

7

4

111

8 9

10

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REPLACEMENT GUIDE_REJECT_POCKET(Reject Pocket Film)

1) Disassemble according to 2-1, 2-2, 2-3, and 2-9

2) Loosen 4 screws (M3x6 SEMS) on both sides

3) Tilt up the ASSY_REJECT_PLATE


4.17.

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TROUBLESHOOTING GUIDE 5.

PS SENSOR ERRORS

Symptom and Reason: “CHECK PS1” or “CHECK PS2” is displayed after power on. This error is caused by PS1 and PS2 sensor problem and may be due to various reasons including debris on the sensors and reflectors, cracked reflectors, damaged sensors, damaged cables, poor or damage connectors, or MECHA/MAIN board issues.

5.1.

Causes and Solution: To isolate the failing component it is recommended to test the below steps in the given order:

1. Check the sensors in Service menuA.) Enter Service menu -> [1] Diagnosis -> [7] Sensor DetailB.) Check ‘Upper Door’ (PS1) and ‘Lower Door’ (PS2)C.) ‘1’ means the door is open. If all the doors are closed but the level is ‘1’,

then the sensor is not working.

[Fig. 1]

[Fig. 2]

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PS SENSOR ERRORS

2. Check level of the sensorsA.) Confirm the harness is properly connected

5.1.

3. Diagnose PBA_MECHA and Check the Sensor Voltage LevelA. In Service menu -> [1] Diagnosis -> [7] Sensor Detail, press [1] to run the

main motor and if the main motor starts running, then press [2] key to stopB. Check the voltage level of the PS1 or/and PS2 sensor with DVM. Please

refer to the points below.

PS1 Connector PS2 Connector

PS1 RPS1 LPS1 RPS1 L

C.) Normal levels:i. Door open: < 1V (typically < 0.5V)ii. Door closed: > 4.0V (typically 4.5~4.8V)

D.) Abnormal levelsi. Door open: > 2.7Vii. Door closed: < 3.2V

[Fig. 3]

[Fig. 4]

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In the case of lower than expected voltages, 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: Section 3.1 PBA replacement

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

PS SENSOR ERRORS 5.1.

READ/ID ERRORS

Symptom and Reason: All bills are rejected as READ/ID ERROR.

Worn bills may be rejected as READ ERROR, but if all notes are rejected as READ ERROR it is likely that the system failed to capture an image of notes from the CIS.

Causes and Solution: Perform the below steps to isolate the failing component from the following list: CIS sensor, LED bar (UV back light) and Main board.

1. If LED bar (UV back light) is defective it is likely for the unit to reject all the notes as ‘SUSPECT IR. [Fig. 5] shows the scanner output when the LED bar is defective. IR T and UVT images are all black.

5.2.

A.) Power off unit and dischargeB.) Check the harness between CIS and MAIN boardC.) Take out the harness, marked 1 in [Fig. 5], from the connector and reinsert

it.D.) Power on unitE.) Check the images in the Service Menu -> [1] Diagnosis -> [5] Scanning

Quality -> [4] Scanned Image.F.) If all the images are correctly received from the CIS sensor as in [Fig. 2],

then test the machine with additional bills.

[Fig. 1]

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READ/ID ERRORS 5.2.

2. If CIS is defective then in Service Menu -> [1] Diagnosis -> [5] Scanning Quality -> [4] Scanned Image the image may looks similar to [Fig. 3] below. In this case replace the CIS sensor.

3. CIS or Main board issues may manifest (as shown above A.) Power off unitB.) Connect a new CIS to the MAIN boardC.) Place the CIS on a table or flat surface with a bill between the CIS and the

table.D.) Turn on the power and go into the Service Menu -> [1] Diagnosis -> [5]

Scanning Quality -> [4] Scanned Image E.) Count a bill. The machine reads an image from the new CIS on the table

rather than the CIS in the machine F.) If the image looks like [Fig. 1] with an abnormal colored image of RGB

and IR R then it means the MAIN board is functioning correctlyi.) Replace the CIS which is currently installed in the machine

G.) Otherwise if the image looks like [Fig. 4]ii.) Replace the PBA_MAIN board

H.) Calibrate CIS (R) and CIS (T) once unit is reassembled

[Fig. 2]

[Fig. 3]

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READ/ID ERRORS 5.2.

ID ERRORS (by IR Light Source Problem)

Symptom and Reason: If the IR light source is malfunctioning frequent or constant ID ERROR bill rejection may occur. [Fig. 1] has green lines in the background caused by improper IR illumination while [Fig. 2] is displaying correctly. In tandem, attempting a calibration will likely fail.

5.3.

[Fig. 4]

[Fig. 5]

[Fig. 1]

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ID ERRORS (by IR Light Source Problem) 5.3.

Causes and Solution:

1. Poor connections to the harness between the UV light source and Mecha PBAA.) Reseat the connectorsB.) Re-calibrate

[Fig. 2]

[Fig. 3]

[Fig. 4]

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ID ERRORS (by IR Light Source Problem) 5.3.

2.) Check the harness connectorsA.) Gently pull on each wire in the connector. All wires should be securely

clipped into the plastic connectorB.) If a wire connector is not clipped into the connector, then it looks like the

below picture.

GOOD BAD

[Fig. 5]

[Fig. 6]

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“ReStartRecognitionAPP” ERROR

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

5.4.

Causes and Solution:

1. To isolate the failing component, perform the troubleshooting in following order:A.) Power off unit and dischargeB.) Check the harness between MAIN and MECHAC.) Disconnect and reconnect the wire harness [Fig. 5].D.) Power on unit and check if error has been resolved

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

A.) Insert external storage media formatted to FAT32 file systemB.) Service Menu -> [4] Backup and Restore -> [1] BackupC.) Save settingsD.) Power off unit and dischargeE.) Replace the MAIN boardF.) Power on unit and check if error has been resolvedG.) If the problem is solved, restore sensor settings from the backup created in

step #2.H.) To restore, in Service Menu -> [4] Backup and Restore -> [2] Restore

3. If step #2 does resolve the error:A.) Power off unit and dischargeB.) Replace the Main board with the original boardC.) Replace the Mecha board.D.) Power on unit and check if error has resolvedE.) Adjust Double level

[Fig. 7]

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“ReStartRecognitionAPP” ERROR 5.4.

UPGRADING (When EMERGENCY screen is displayed)

1. After upgrading software, if the file has been corrupted or the transfer failed, thefollowing error may be displayed. After initialization, an emergency or failuremessage will splash to the main screen

5.5.

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

[Fig. 8]

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UPGRADING (When EMERGENCY screen is displayed)

3. Press and hold the left hand [C] & [START] buttons followed by [STRAP] and enter password 0806.

4. Go to [2] PROGRAM UPDATE and upgrade again

5.5.

SETTINGS(Reset after Power Down/Start-up Issues)

May be caused by a depleted battery. Some symptoms from battery issues:• User settings reset after shutting unit down• Incorrect date or date reset to 1970 after shutdown• Occasional need to power cycle unit several times to start up unit• All modes reset back to default

5.6.

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SERVICE MENU GUIDE

STARTING TEST MENU

1. Press [1] + [2] keys together, and press [3] key while keeping the two keys pressed.2. The unit will prompt the user for a password.3. Input password “0806” then press [ENTER].4. Select a test menu item by pressing a numeric key or using [UP]/[DOWN] and

[SET] key

DIAGNOSISThis menu contains quick access to diagnosis tools, and special options the technician may enable or disable the end user from viewing.

[1] Diagnosis -> [1] Special Settings• This menu contains options that the technician may decide on a per customer basis

to enable or disable. If the options are disabled, the end user will not have visibility or access to the affected setting.

[1] Suspect Detail ON• If this option is ON, the end user will be able to view the detailed

reason for rejection on suspect notes. This includes the fail category, such as SUSPECT IR, SUSPECT MG, and SUSPECT UV. In many cases the end user does not need this level of detail and only needs to know whether or not the note is suspect. To disable this option, press [1] -> Suspect Detail OFF

[2] ValuSortTM ON• If this option is on, the user will be able to view and use the ValuSortTM

option in the MODE menu from the main screen. If a user does not want to view or use this option, disable ValuSortTM mode by pressing [2] -> ValueSortTM OFF

[3] Dust Cover Menu OFF• In many cases, the end user has no desire to use the optional dust

cover which is disabled by default. In the case that the end user prefers to use the dust cover, the technician may enable the dust cover

6.

6.2.

6.1.

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menu option by pressing [3] Dust Cover Menu ON. Setting this option to ON will enable the dust cover option [8] on the main menu, and the end user will not be able view or change the operation of the dust cover.

NOTE: Setting [3] -> Dust Cover Menu ON does not enable the dust cover. This only allows the technician or end user access to the dust cover menu from the main screen.

[4] Barcode ON• This is an optional feature for unlocked units and is grayed out by

default on main releases. Enabling this option enables use of Barcode mode which is used for scanning and reading bar coded tickets. Refer to the user manual for information on how to use bar code mode if enabled.

[5] Zero Count at Strap OFF• This option sets the system to reset the count each time a strap is

completed. To enable this feature, press [5] -> Zero Count at Strap ON

[2] Selector • This allows manual control of the position of the selector solenoid which is the

diverter that controls where scanned bills pass. Use this option to manually test the functionality of the diverter and solenoid.

[1] To the Reject• This sets the diverter to the reject pocket.

[2] To the Stacker• This sets the diverter to the stacker.

[3] CIS LED• This allows manual control of the CIS LED.

[1] OFF• This turns off illumination from the CIS LED bar.

[2] ON • This turns on illumination from the CIS LED bar. This may be used to

visually identify problems with non-uniformities in the CIS illumination panel. Open the upper door on the backside of the unit to view the CIS illumination. Check for inconsistencies, unlit portions, or blinking/wavering light. Use this in conjunction with scanning and calibration graphs to check proper operation of the CIS sensor.

DIAGNOSIS 6.2.

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[4] LED• This allows manual control of the CIS LED.

[1] OFF• This turns off illumination from the front panel LED bar.

[2] ON• This turns on illumination from the front panel LED bar. Use this menu

option to diagnose illumination issues with the front LED.

[5] Scanning Quality• This allows the technician to view detailed information from the Zeus’ on-board

sensors and to help diagnose scanning issues. It is suggested that the technicianruns 2 or 3 high denomination bills ($50’s or $100’s) once this option has beenselected to view detailed scanning results such as security thread, watermark etc. Inmost of the following screens, use the [8] key to zoom into a curve, the [0] key tozoom out, and the [ADD] and [STRAP] keys to pan left and right along a zoomedcurve.

NOTE: To exit this menu, press the top unmarked key closest to the display.

[1] Double Sensor Detail• Pressing [1] repeatedly in this menu allows the technician to view

each double sensor output independently. Each ‘pulse’ is one bill thathas been scanned. Check to ensure that the sensor data matches theenvelope, and that the normalized curve (YELLOW on LEFT doublesensor, TEAL on RIGHT double sensor) does not exceed the boundinglines.

[2] Magnetic Sensor Detail• Pressing [2] repeatedly in this menu allows the technician to view

each double sensor output independently. Each ‘pulse’ is one scannedbill. Ensure that the magnetic sensor levels are around the sampleamplitude, and that the width of the pulses is within the envelope(BLUE line) for each bill. If no signal is noted, or abnormal spikesare noted, this points to an issue with the magnetic sensors. MHL isthe LEFT sensor, MHC is the CENTER sensor, and MHR is the rightmagnetic sensor.

[3] Position and Speed Details• Pressing [3] displays the position sensor input, and the average notes

per minute. Each pair of PS1 and PS2 sensors should have similarpulse locations. PS2 pulses should appear after PS1 pulses, to theright. The X-axis is time in seconds. NPM default is 1000 notes perminute. The graphs are displayed in the same order as the key givenon screen:• ADF - TEAL - Position of the rollers as given by the encoder

wheel. This graph should be a well formed square wave withlonger pulses at the start and end of the graph for when the rollers

DIAGNOSIS 6.2.

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are speeding up and slowing down. • PS1L - BLUE - Left upper position sensor. This is the first

position sensor along the bill path that notes when a bill has been passed towards the CIS.

• PS1R - RED - Right upper position sensor. Paired with the left sensor above, this is the second location sensor in the upper path.

• PS2L - BLUE - Left lower position sensor. This detects the location of a note after it has passed the CIS sensor.

• PS2R - RED - Right lower position sensor. This is paired with the left lower sensor at the end of the bill transport path.

• NPM - YELLOW - Notes Per Minute graph. This is the average number of notes per minute passed through the unit. Note that this is truly an average, as the Zeus unit will vary speeds to minimize motor effort while maintaining a constant average number of notes per minute.

[4] Scanned Images• Pressing [4] displays the captured image from the last bill through the

transport path. Using newer series bills or high denomination bills, the technician is able to view the security features of the bill and diagnose CIS, IR, and UV sensor errors. The first screen displays 4 quadrants: • RGB - Color image captured by the CIS sensor. Irregularities

in this image are indicative of CIS pixel issues or possible sensor problems. Inspect the ribbon cable for damage, the sensor for debris or cracks, or the main board for rendering issues.

• IR R - Reflected Infrared Scan Image. This image will show IR stripes. If the image is dark or missing, this points to an issue with the IR illumination bar, the cable to the IR illuminator, or the main board.

• IR T - Transmitted Infrared Scan Image. This is a through-scan image of the note that will clearly display watermarks, security threads, and other IR features. If this image is dark or missing, this points to an IR illuminator issue, flat cable issue, or main board problem.

• UV T - Transmitted Ultraviolet Image. This is usually the darkest of the captured image. Use this to view watermarks, security thread, and UV features. If this image is dark or missing, inspect the UV illuminator bar for cracking, debris, damage to the cable, or the main board for rendering issues. Pressing [4] repeatedly will show higher resolution images of each scanning technique, and a histogram of the color/shading captured. Use the histogram to check for low or abnormal responses.

[5] UV, IR and RGB Detail• Pressing [5] will cycle through the detailed UV, IR, and RGB

throughput information.• RGB IR - This image displays the per-pixel values of each

portion of the full illumination bar. Note any flat areas, or

DIAGNOSIS 6.2.

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abnormal spikes which indicate issues with the CIS bar. Each color’s graph should mimic the others regardless of shape. The IR illumination graph should be similar, but of lower amplitude.

• IRT and UVT - This image displays the scanning quality of the IR and UV sensors. In general, the IR waveform should be ‘U’ shaped with a relatively flat bottom. The UV waveform (BRIGHT BLUE) should be relatively flat. Both waveforms should be free of spikes or 0 values between the vertical bounding lines.

[6] CPU S/N• This menu provides the unit’s CPU IDs (CPU0 and CPU1) and

detailed information about the unit. This information is stored on the main board of the unit. Cassida may request this information if the technician or end user needs to unlock the Zeus for extra software features.

[7] Sensor Detail• This menu option provides a simple and fast way to troubleshoot the

hardware in the Zeus. This is the first menu suggested to diagnose possible hardware issues, which allows the technician to exercise most components of the unit. By pressing the marked number numbers on the display, the technician can test each component independently. For every component that passes the default range tests built into the software, the menu option will turn BLUE. If a sensor fails, or is out of range, the value will turn RED.

1. Main Motor Forward2. Main Motor STOP3. Main Motor Reverse4. Toggle Selector Position to Reject Pocket5. Toggle Selector Position to the Stacker6. Unused7. Toggle Wing Motor On/Off8. Toggle Power Supply Fan9. Close Dust Cover

The technician may then check the remainder of the sensors by:• Opening Upper Door/Opening Lower Door• Verify 2000 < Double Level < 3000• Cover Hopper Sensor• Cover Reject Pocket Sensor• Cover Stacker Senor

[8] Keypad Test• This menu allows the technician to verify that all buttons on the front

panel of the unit are functioning correctly. In order to exit this menu, the user must press EVERY button on the front panel and ensure it has been selected. Use this to diagnose issues with the keypad, [C], or [START/STOP] keys.

DIAGNOSIS 6.2.

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Use this menu to update the Zeus’ software following the below steps:• Copy upgrade software from http://www.cassidapro.com/

partner page to a USB memory stick (FAT32 format)• Insert the USB memory stick into the Zeus• Select [2] Program Update• Ensure the new software is highlighted using [UP]/[DOWN]

keys and press [SET]• The Zeus will load the software and reboot.

NEVER TURN OFF POWER OR REMOVE THE USB DEVICE BEFORE SOFTWARE UPDATE HAS FULLY COMPLETED AT THE RISK OF PERMANENT DAMAGE TO THE UNIT.

ADJUSTMENTSUse this menu to modulate hardware levels and calibrate the CIS sensor.

[3] Adjustment ->[1] Wing Motor Duty• Use the arrow keys to modulate the duty cycle of the wing motor. This may be used

to synchronize an off-timing on the wing motor. A higher duty cycle translates to a higher speed, and a lower duty cycle translates to a lower speed.

[2] Hopper Threshold• Use the arrow keys to change the sensor threshold of the hopper sensor. The

technician may view the high value by covering the hopper sensor to ensure that the difference value is greater than the assigned threshold. Modulate the threshold value to ensure that the difference value when the sensor is covered is greater than the assigned threshold.

[3] Stacker Threshold• Use the arrow keys to change the sensor threshold of the stacker sensor. The

technician may view the low value by covering the stacker sensor to ensure that the difference value is less than the assigned threshold. Modulate the threshold value to ensure that the difference value when the sensor is covered is less than the assigned threshold.

[4] Reject Threshold• Use the arrow keys to change the sensor threshold of the reject sensor. The

technician may view the low value by covering the reject sensor to ensure that the difference value is less than the assigned threshold. Modulate the threshold value to ensure that the difference value when the sensor is covered is less than the assigned threshold.

[5] CIS Calibration (Reflected)• The CIS calibration should be done any time CIS replacement, main board

replacement, or extensive repair work is performed. In order to run this calibration, the Cassida PRO specific shading sheet must be used. Affix the magnetic side of the

PROGRAM UPDATE 6.3.

6.4.

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shading sheet just below the reflectors in the upper door ensuring that the edges of the sheet are aligned in the center of the door. Close the door firmly until a ‘click’ is heard from the latch engaging. Proceed to run the CIS (R) calibration by selecting [YES]. For a passing calibration, the RGB values of the sensor will be displayed and the background will be BLACK. For a failed calibration, the RGB graphs will be uneven with low spots or spikes, and the background will be PURPLE with <N.G.> displayed in the center. This is usually due to improper placement of the calibration sheet.

[6] CIS Calibration (Transmitted)• Ensure no material is blocking the CIS sensor and the IR/UV illumination bar. Do

not use a shading sheet for this calibration. Select [YES] to calibrate. The IR curveshould be ‘U’ shaped with a relatively flat bottom. No spikes or 0 values should bepresent. The UV waveform (LIGHT BLUE) should be relatively flat around the samerange as the bottom of the IR ‘U’ shape with no spikes or 0 values.

[7] Currency• The default software comes with only one currency available: USD. Users or VARs

may request additional currency scanning at a nominal fee. Use this menu to selectthe unit’s default currency on an unlocked unit with custom software

BACKUP AND RESTOREThis menu provides options to the technician to backup current unit settings, rebuild software, and to reset all settings back to the factory default settings.

[4] Backup and Restore ->[1] Backup• Technicians are encouraged to use this operation before performing any major

changes to a unit. By running the backup, all user settings, test menu settings,and calibrations will be saved to an external storage medium. Insert a FAT32formatted external storage device into the USB port on the backside of the unit.Select [YES] to save current unit settings to the storage media. A new directorywill be created in the base folder of the storage media with a name following theformat ‘ _YYMMDDhhmmss’ where Y is year, M is month, and D is day, h is hour,m is minute, and s is second. This format is used to ensure that no settings file isoverwritten, but does not contain any information about what unit the backup filewas created for. If the technician plans on saving the backup file for multiple units,it is suggested that a new directory is created with the serial number of the unit asthe directory name.

[2] Restore• To restore saved settings, insert the FAT32 formatted storage device into the USB

port on the backside of the unit. In order for the Zeus to detect saved settings file,the desired directory must be placed in the base folder of the external storagemedia. The unit will detect all settings files stored in the root directory, ensurethat the correct settings are selected using the [UP]/[DOWN] arrow keys beforeloading. Press the [SET] key to load the selected file.

ADJUSTMENTS 6.4.

6.5.

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NOTE: Loading settings from a different tool can cause major malfunctions and destroy the unit. Ensure that the settings being loaded were originally captured from the same unit.

[3] Factory Default Set• Selecting this option resets all unit settings to the default as shipped from Cassida.

This option will reset ALL user menu and test menu settings.

[4] Software Rebuild Selecting this option performs a software rebuild. Every time the main software is updated, the technician must perform a software rebuild. The purpose of performing this step is to reinitialize all auxiliary hardware. When software is loaded, it is pushed to the main board, but does not reinitialize mechanical components, or update the MECHA board software. By performing a rebuild, all hardware is synchronized and reinitialized to ensure all components and controllers operate together.

REPORTS CLEAR• Selecting this option will clear all reports saved on the Zeus. This will remove all saved

usage data from the daily, weekly, and monthly reporting. Press [YES] to clear all saved report data. The unit will reinitialize after clearing the reports.

STATISTICS REPORT• This menu contains access to the unit’s log data which include scanning errors, total

bills scanned, and other usage statistics.

[6] Statistics Report -> [1] Statistics Report

• Selecting this option opens the statistic report for viewing. Scroll through the report by using the [UP]/[DOWN] arrow keys, or press [PRINT] to have the report print on a receipt for ease of viewing. This report may be used to view detailed information about cumulative bills scanned, rejects by reject type, sensor or motor errors, and time between maintenance intervals. This information may be used to diagnose non-repeatable or marginal issues as well as provide information about how frequently a user operates each unit. It is suggested that the technician uses the TOTAL COUNTS to judge an appropriate maintenance interval based on duty cycle.

[2] Statistics Reset• Selecting this option will clear all of the current statistics data. This will also clear all

detailed log data from section [7] Log Data . Some technicians choose to perform the reset on each maintenance interval to determine usage between visits. Other technicians prefer to never clear the data to keep a unit lifetime statistics.

LOG DATA• Technicians may view this detailed report to access all operations that the unit has been

through. This includes settings changes, run times, power-ons, initializations, software

BACKUP AND RESTORE 6.5.

6.6.

6.7.

6.8.

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loads, etc. This highly detailed report is intentionally verbose and may be used to detect user change issues. For example: A unit is reported to be passing counterfeits. When the technician arrives on site, all counterfeits are being properly rejected and the technician is unable to replicate the issue. The technician then checks the detailed log data and notes that 3 days prior, a user disabled counterfeit detection, and 1 day prior a user re-enabled counterfeit detection. In this case, the technician is able to instruct the users about the exact failure reason and determine that the user is at fault for this issue.

DATA DOWNLOAD• This function collects data for software development. It requires an external USB

storage device formatted to FAT32. There are two separate menu items, allowing the collection of data for both genuine notes and fake notes. Zeus creates both a [GENUINE] and a [FAKE] folder on the storage media. The collected data is saved to the appropriate folder automatically based on the code and type of note designated below. Once these data have been collected, send the scanned files to [email protected]

WARNING: Never remove the USB memory stick from the Zeus while downloading data. It will cause corrupted data. Wait for the Zeus screen to display “READY!” or after completely exiting from the service menu prior to removing the external storage device.

[8] Data Download -> [1] Bank Note• For each orientation of a banknote, a designation code must be input to ensure

the correct data collection and output format. Refer the below image to determine the code for the note being collected. The first digit of the code determines the denomination of the bill being scanned. The second digit refers to the orientation of the bill.

• Input the proper code and press [ENTER] before collecting data. The unit will beep and the filed “CURRENT CODE” will be updated with the user input code.

6.8.LOG DATA

6.9.

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• Place notes on the hopper. The Zeus will count the bills and collect data. The data is stored in an internal buffer and copied to the USB external storage media automatically. If the internal buffer capacity reaches its limit, the Zeus will display “Waiting” and stop collecting data. It will resume collecting data automatically when the buffer gets enough free space.

• Do not remove the USB storage medium while downloading or buffering state.• Collect data at least 12 times for each genuine note, 3 times per orientation:

• Once at the left side of the hopper• Once at the center of the hopper• Once at the right side of the hopper

[2] Fake NoteNOTE: This menu is only for collecting data on fake bills. Never attempt to collect data with a genuine bank note. Place the fake notes on the hopper, the Zeus will count them and collect data. Proceed using the same steps as outlined above for the fake note. Ensure the code is correct, and that the bill being scanned is actually a suspect note.

SOFTWARE VERSION• This menu option provides the technician with information about the Zeus’ internal

hardware and software configuration. This screen may be used to determine the currently installed software version, UI version, hardware revisions, and datapack library revisions per currency.

1-2 Selector• Test the diverter by changing the direction to the stacker or the reject pocket.

1-3 CIS LED• Turn on/off the CIS LED and back light LED. Repeatedly press [2] to check the LEDs in

this order:1. Back light 2. Blue CIS3. Red CIS 4. UV CIS5. Green CIS

6.9.DATA DOWNLOAD

6.10.

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1-4 LED• Turn on/off the other LEDs of the indicator, PS1, PS2, stacker and reject.1-5 Scanning Quality• Check the scanning quality by observing various graphs and images. After running

several bills, the following sensor outputs should be checked. The graphs or images areassigned to the numeric keys:

• [1] key: Double sensor output• [2] key: Magnetic sensor output• [3] key: Position sensor output• [4] key: Scanned image• [5] key: CIS shading waveforms

To magnify or reduce the graph, the [8] and [0] keys are used. Press [0] to magnify.Press [8] to reduce. [ADD] and [STRAP] keys are used to scroll the graph. These keys are not available for some graphs:

1. Double Sensor Output• The graph is toggled whenever the [1] key is pressed; Double Sensor Left -> Double

Sensor Right -> Double Sensor All ->

“1051” and “1069” means the sensor output level for one note for Left and Right respectively. If a double-note is fed, the output signal level will drop below the one-note level.

2. Magnetic Sensor Output• The graph is toggled whenever the [2] key is pressed; Left -> Center -> Right -> ALL.

The picture immediately above on the right is magnified and scrolled properly from theoriginal magnetic sensors’ output waveform.

SOFTWARE VERSION 6.10.

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3. Position Sensor Output

4. Scanned Image• You can check 4 different images; Color (RGB), Reflective IR, Transmissive IR and

Transmissive UV. To check images one-by-one, repeatedly press the [4] key.

5. CIS shading waveforms

• To see the CIS shading waveforms, press the [5] key. The graph is toggled between the waveform of RGB and the waveform of IR and UV whenever the [5] key is pressed

RGB Waveforms IR&UV Waveforms

NOTE: To exit from these graph windows, press the [F1] key (marked in the photo at theleft) or press [C] to exit completely from the test menu.

1-6 CPU S/N• This function reports CPU serial numbers. This may be required for specific software

updates or upgrades.


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1-7 Sensor Detail• This menu allows you can check motor, separator, wing motor and sensors all on a

single screen. When a test completes successfully, the color turns blue. If the color of the DOUBLE LEVEL turns red, check the sensor.

Press the numeric keys to test mechanisms:[1] Main Motor forward rotation[2] Main Motor STOP[3] Main Motor backward rotation[4] Separator to the reject[5] Separator to the stacker[7] Wing on/off (toggle)[8] Fan on/off (toggle)[9] Dust Cover on

The definition of the sensors’ status is:ADF: 1 (Pickup Roller Position Normal) Upper/Lower Door L, R: 0 (closed), 1(opened)For other sensors’ output, please refer to “3. ADJUSTMENT”.

1-8 Keypad Test• Press every key until the screen displays “Keypad Press Test: OK.”


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RECOMMENDED SPARE PARTS APX 1

PART PART CODE QTY PART NAME PICTURE

1 1A10001A 1 ASSY_FAN

2 1A10002A 1 ASSY_MAIN_MOTOR

3 1A10003A 1 ASSY_WING_MOTOR

4 1A10005A 1 ASSY_SOLENOID_10ms

5 1E08001A 1 MOT_TO_MEC_FFC

6 1E08002A 1 CIS_TO_MAIN_FFC

7 1E08003A 1 FRONT_TO_MAIN_FFC

8 1E08004A 1 DOUBLE_HARNESS_2WAY

9 1E08005A 1 PS2_HARNESS_1WAY

10 1E08006A 1 PS1_HARNESS_2WAY

11 1E08007A 1 STACKER_HARNESS_1WAY

12 1E08008A 1 REJECT_HARNESS_1WAY

13 1E08009A 1 POS_SENSOR_HARNESS_1WAY

14 1E08010A 1 ENCODER_HARNESS_1WAY

15 1E08014A 1 SMPS_HARNESS_1WAY

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16 1E08017A 1 LED_HARNESS_1WAY

17 1E08018A 1 HOPPER_HARNESS_1WAY

18 1E08019A 1 SERIAL_HARNESS_1WAY

19 1E08020A 1 FRONT_GND_1WAY

20 1E09501A 1 PBA_MAIN

21 1E09502A 1 PBA_MECHA

22 1E09503A 1 PBA_FRONT

23 1E09504A 1 PBA_STACKER

24 1E09505A 1 PBA_POS_SEN

25 1E09506A 1 PBA_REJECT

26 1E09507A 1 PBA_PS2

27 1E09508A 1 PBA_PS1_LEFT

28 1E09509A 1 PBA_PS1_RIGHT

29 1E09510A 1 1E09510A

30 1E09511A 1 PBA_DB_L

31 1E09512A 1 PBA_DB_R

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32 1E09513A 1 PBA_ENCODER

33 1E09517A 1 SMPS

34 1E10001A 1 LCD_240X320_2.8_80_I/F

35 1E10002A 1 CIS

36 1E20003A 1 MR_HEADER_60mm

37 1E20004A 1 MR_HEADER_30mm_L

38 1E20005A 1 MR_HEADER_30mm_R

39 1M10006A 1 DUST_DRAWER

40 1A20035A 1 DB_SENSING_MODULE

41 1M10035A 1 SUPPORTER_STACK_WHEEL(To assemble stacking wheelmodule)

42 1M10038A 1 SWING_SELECTOR

43 1M20011A 1 CLIP_MG_HEAD (To assemble HG head)

44 1M20014A 2 BRACKET_MG(To assemble magnetics)

45 1M30001A 2 ROLLER_R_PINCH

46 1M30002A 2 ROLLER_EXIT_PINCH

47 1M30003A 2 ROLLER_F_PINCH

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48 1M30005A 1 ASSY_ADF

49 1M30006A 1 ASSY_FEED_ROLLER

50 1M30007A 1 ASSY_EXIT_ROLLER

51 1M30008A 1 ASSY_REVERSE_ROLLER

52 1M40018A 1 ASSY_CLUTCH

53 1M70006A 2 MG_30(Magnetic)

54 1M70007A 1 MG_63(Magnetic)

55 1M70010A 3 BRUSH_ANTISTATIC

56 1M70011A 3 BRUSH_REJECT

57 1M70012A 2 GUIDE_REJECT_POCKET

58 1M70013A 1 ENCODER_DISK

59 1M80001A 1 TIMING_BELT_171



62 1M80004A 2 BEARING_F688

63 1M80005A 1 BEARING_688

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64 1M80007A 1 BEARING_696

65 1M80008A 2 FEED_PINCH(BEARING_626)

66 1M80036A 1 SNAP_RIVET (To assemble hopper sensor PBA)

67 1S20002A 1 ASSY_COVER_SOLENOID_24V

68 1M30009A 4 URETHANE_PICKUP

69 1A20020A 1 ASSY_LIGHTING_MODULE

70 1A20026A 1 ASSY_PULLEY_1WAY_36S3M

71 1O10008A 1 SHADING_SHEET

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ERROR CODES/MESSAGES APX 1I

ERROR MESSAGE REJECT REASON CHECK

ID ERROR Unknown Currency CIS/LED Bar

DIFF Different Denomination ---

CHAIN Bills fed too close to each other Feeding Mechanism

DOUBLE Two or more bills passed togetherFeed Gap, Double

Sensors, Deformed/Taped Note

HALF Half Bill detected Ps1/Ps2, Torn Or Deformed Note

SKEW Bills were skewedFeed Mechanism,

Improper Loading Of Notes In Hopper

SRL MISMATCH Serial numbers of the bill did not match ADC (Main Board)

NO SRL No serial number found on the bill Face of bill

ERROR MESSAGE SOLUTION

JAM1 Open upper door and remove bill(s) from path

JAM2 Open lower door and remove bill(s) from path

FEED ERROR Remove Bills from Hopper. Adjust Feeding Mechanism

MOTOR ERROR Make sure path is clear and all belts are connected properly. Test Motor in both directions using the Service Menu

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ERROR CODES/MESSAGES APX 1I

ERROR MESSAGE SOLUTION

DIVERTER ERROR Check for jammed bills or debris around the diverter. Test diverter using the Service Menu

UPPER DOOR OPEN Close upper door

LOWER DOOR OPEN Close lower door

CLEAR STACKER Remove bills from Stacker

CLEAR REJECT Remove bills from Reject Pocket

CLEAR HOPPER Remove bills from Hopper

CHECK PS1Clear track / check upper door. Use DVM to check Voltage Level.

Inspect reflectors for physical damage and cracking.

CHECK PS2Clear track / check upper door. Use DVM to check Voltage Level.

Inspect reflectors for physical damage and cracking.

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CONTACT INFORMATION

ADDRESSCASSIDA CORPORATION

11035 Technology Place Mailing: Suite 500 | Deliveries: Suite 200

San Diego, CA 92127

PHONEToll Free: 888-800-0303

[email protected]

WEBSITEwww.cassidapro.com/partner

RETURN MERCHANDISE AUTHORIZATION

In order to begin the process of a return (and repair or exchange), Cassida PRO Tech Support requires the following information before unit is sent to Cassida:

• Model and Serial Number of Unit• Customer or Company Name• Phone• Email • Return Shipping Address• Issue with unit

NOTICES

NOTICES Check these sections for important notices about your product.

GENERAL PRODUCT SAFETY INSTRUCTIONSWhen using this unit, basic safety precautions should always be observed, including the following:

• Read this manual before operation.• Do not use this unit in areas where it may be exposed to water or any other

liquids. • Make certain the unit is installed on a flat surface.• Do not use in areas exposed to high temperature, humidity or smoke. • For indoor use only. • Store and operate the unit in a well ventilated environment, and away from direct

sunlight, high intensity lighting and magnetic fields that could interfere withsuspect bill sensors.

• Do not touch moving parts during operation. • Keep foreign objects -paper clips, staples, etc. - away from moving parts or from

falling into the unit.• Operate using a surge suppressor or power conditioner. When not in operation

for extended periods of time, disconnect the power cord from the wall unit. • Prior to and during cleaning, unplug the unit from the wall. Follow the cleaning

instructions and maintainance schedule contained in this manual. • In the event of incorrect operation or care of the unit, the manufacturer is not

APX III

APX IV

APX V

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responsible for damage caused to the unit or the operator or technician. Cassida is not liable for damages resulting from use of the unit for purposes other than for the intended purpose without prior written consent from Cassida. Modifications made to the unit by persons other than Cassida or its authorized contractor/subcontractor is strictly prohibited. Any damages resulting from the unauthorized modification of the unit are not the responsibility of Cassida.

• Contact your authorized Cassida PRO technician, distributor or salesrepresentative for tchnical assistance.

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