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NCR 5635 Service Manual

Spray currency dispenser
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NCR 5635
Spray Currency Dispenser
Service Manual
B006-6280-A000
April 2002
NCR — CONFIDENTIAL AND PROPRIETARY
Use pursuant to Company Instructions

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Summary of Contents for NCR 5635

  • Page 1 NCR 5635 Spray Currency Dispenser Service Manual B006-6280-A000 April 2002 NCR — CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions...
  • Page 2 NCR, therefore, reserves the right to change specifications without prior notice. All features, functions, and operations described herein may not be marketed by NCR in all parts of the world. In some instances, photographs are of equipment prototypes. Therefore, before using this document, consult with your NCR representative or NCR office for information that is applicable and current.
  • Page 3 A prescrites dans le Réglement sur le brouillage radioélectrique édicté par le ministère des Communications du Canada. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 4 If this equipment does cause interference, which can be determined by turning the equipment off and on, the user is encouraged to consult an NCR service representative immediately. Caution NCR Corporation is not responsible for any radio or television...
  • Page 5 Revision Record Date Page Description of Change April First issue of manual. 2002 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 5635 Spray Currency Dispenser Service Manual...
  • Page 6 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 5635 Spray Currency Dispenser Service Manual...

  • Page 7: About This Manual

    Preface Preface This manual contains the information required to maintain Purpose the 5635 Currency Dispenser. It includes a functional description of the dispenser, adjustment procedures, calibration procedures, internal cabling, connector pinouts, strapping details, power requirements, and mechanical installation in the host.

  • Page 8: Related Information Products

    Related Information dispenser are: Products NCR 5635 Spray Currency Dispenser - Owner’s Guide (B006-6279- A000). Aimed at the person who will be responsible for the day to day running of the dispenser, this book describes the replenishment tasks of loading currency cassettes and clearing jams.

  • Page 9: Table Of Contents

    Dispenser Motor and Transport ........... 1-16 Main Timing Disk................1-16 Linear Variable Displacement Transducer (LVDT)....1-16 Divert Gate ..................1-17 Exit Sensor ..................1-17 Control Board..................1-18 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 10 Cassette Identification Code ............4-2 Currency Dimensions Adjustment ..........4-6 Currency Width Adjustment............4-17 Matching Cassette Bodies And Lids..........4-25 Note Low Sensing Adjustment ............ 4-25 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 11 Pick Module..................4-49 Cleaning ....................4-50 Replacement Instructions..............4-51 Replacing the Control Board............4-51 Replacing the 5635 Spray Presenter ..........4-53 Replacing a 5635 Dispenser Pick Module ........4-54 Configuration ..................4-55 RS232 Comms.................. 4-55 Bill Singularity ................4-55 Connector Pin-outs................4-56 AC Connector..................
  • Page 12 Reject Bin ..................A-1 EMC....................A-2 Power Requirements............... A-2 Acoustic Noise ................. A-3 Weight....................A-3 Dimensions..................A-3 Environment ..................A-4 Index ....................Index-1 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 13: Dispenser Functional Description

    Dispenser Motor and Transport 1-16 Main Timing Disk 1-16 Linear Variable Displacement Transducer (LVDT) 1-16 Divert Gate 1-17 Exit Sensor 1-17 Control Board 1-18 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 14 Table of Contents Dispenser Functional Description Firmware Description 1-20 Dispense Operation 1-22 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 15: Introduction

    Dispenser Functional Description Introduction Introduction The 5635 Spray Currency Dispenser dispenser is designed to take currency bills from a secure storage, check them, and present them to the cardholder. The term spray is used to describe the way that the dispenser presents the bills in a continuous stream, or spray, rather than bunching them together and presenting the bills as a single bundle.
  • Page 16 Misfed or faulty currency is diverted into a purge bin. The path of notes through the dispenser is shown in the following diagram. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 17: Currency Containers

    Currency Cassettes three parts: the lid, the body and the base. There are two types of cassette used with the 5635 dispenser; Standard and Tamper Indicating. The Tamper Indicating cassette has a counting mechanism in the base that counts the number of times the cassette is inserted into the dispenser up to a maximum of six.
  • Page 18 (4.72in) (3.74in) (6.77in) The illustration below shows an open currency cassette looking from the rear (handle) end towards the front (truck door) end. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 19 More than one cassette of a particular type can be installed. The dispenser treats all cassettes with the same type as one logical cassette. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 20 The external shape of the base forms rails which slide into the cassette guides in the pick module. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 21 Removal of the cassette from the dispenser automatically closes and latches the front door and the interior of the cassette can only be reached by opening the top access lid. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 22: Purge Bin

    If a fault is detected during a dispense (say, double or damaged bills) then the reject gate is operated to deflect the bills into the purge bin. There are two types of bin in the 5635 dispenser: Standard Latch fast.
  • Page 23 Currency is removed from the latch fast purge bin through a door that can be sealed. A microswitch in the presenter informs the firmware that the latchfast bin is in place. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 24: Pick Modules

    Hold a currency cassette Cassette guides and latch mechanism Identify the inserted cassette Cassette identity sensors Open the front of the cassette Pick module keyplate NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 1-10 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 25: Currency Cassette Guides And Latch

    For each pick cycle one bill is picked and fed into the transport mechanism. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 1-11...

  • Page 26: Pick Mechanism Operation

    “Adjustments” section of Chapter 4. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 1-12 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 27 The bill is taken up between the pick and pressure wheels and fed into the transport section. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 1-13...

  • Page 28: Pick Sensor

    ± ± 50 or 200 50 bills are left. The vertical transport of the pick modules on the 5635 dispenser Pick Module consists of three belts stretched between an upper driven shaft and a Transport lower idler shaft. Smooth plastic skid plates project between the centre belt and the two outer belts.

  • Page 29: Presenter

    The spray presenter houses the following assemblies: Dispenser motor and transport section Main timing disk Linear Variable Displacement Transducer Exit sensor Divert gate Purge bin. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 1-15...

  • Page 30: Dispenser Motor And Transport

    2 mm. The term “singularity” describes the parameters used by the Linear Variable dispenser to recognize a single currency bill. In the 5635 dispenser Displacement the detection of singularity of the currency is related to the cross- Transducer (LVDT) sectional area of the bills.

  • Page 31: Divert Gate

    Dispenser Functional Description Presenter The LVDT is situated in the 5635 presenter transport. It gives an electrical output proportional to the displacement of a movable roller assembly caused by bills passing between it and a fixed reference roller. The movable roller is attached to a ferrite core which projects through a sensing coil printed on a pcb.

  • Page 32: Control Board

    The EPROM contains Level 0 diagnostics and executable code. The SRAM contains variables, buffers and other data. SRAM is battery backed. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 1-18 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 33 3 to 8 way decoder. The mapped devices consist of buffers used to interface to various Sensors, Comms Control hardware, diagnostic switches and user switches. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 1-19...

  • Page 34: Firmware Description

    The firmware provides the facility to deliver currency from the cassettes to the cardholder. This is a single stage operation that picks bills from the selected cassette and delivers them to the cardholder. The 5635 Dispenser supports the following command set: Command Comments...
  • Page 35 Get Bill Sizes Reports the bill size parameter values by cassette to the application Sensor Test Reads the state of all sensors and switches on the 5635 dispenser. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 36: Dispense Operation

    The transport motor is switched on and the pick solenoid of the selected cassette is energized to provide vacuum to the pick mechanism suction cups. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 1-22 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 37 The process of picking bills is repeated until the bill count of good bills at the LVDT equals the dispense command bill count. A status message is transmitted to the PC core. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 1-23...
  • Page 38 Dispenser Functional Description Dispense Operation NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 1-24 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 39 Left Side Mounting Locations Right Side Mounting Locations Power Requirements/Connections AC Power DC Power Power Connections Interface Connection Electrical Connections Electrical Characteristics of Interfaces NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 40 Table of Contents Installation NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 41: Mounting Dispenser

    Locations diagram: Note The height of a single pick unit is 137mm (5.4in.). NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 42 The illustration below shows the locations of the holes in the left- hand pallet mounting feet. These feet are suitable for supporting the dispenser on a retractable tray as is done in the NCR EasyPoint 55 terminal. Note The width of the dispenser between the outer surfaces of the side plates is 225.075 millimetres (8.9in.) and to the outer edge of the...

  • Page 43: Right Side Mounting Locations

    Mounting Dispenser The locations of the right-hand side 6.8mm (0.27in.) dia. mounting Right Side holes are shown in the following illustration. Mounting Locations NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 44 Note The width of the dispenser between the outer surfaces of the side plates is 225.075 millimetres (8.9in.) and to the outer edge of the mounting feet is 330 millimetres (13in.). NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 45: Power Requirements/Connections

    +5V ± 5% 1.5A +24V ± 5% 2A +24V The required connector type is as follows: Housing = Molex 39-01-2165 Crimp = 39-00-0059 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 46: Power Connections

    Installation Power Requirements/Connections The AC and DC power connections to the dispenser are shown on Power Connections the following illustration. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 47: Interface Connection

    Installation Interface Connection Interface Connection The dispenser interface connector is a 25-way male D-type connector on the control board. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 48: Electrical Connections

    The connector configuration for this interface is as follows: Pin 1 SCRN Cable screen Pin 2 Transmitted data, FROM the dispenser Pin 3 Received data, TO the dispenser NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 49: Electrical Characteristics Of Interfaces

    The logic level interfaces are designed to use the standard TTL voltage thresholds (High, greater than 2V; Low, less than 0.8V). NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 50 Note: If the handshake circuits are not used (CTSL and RTSL), then the standard LSTTL devices are capable of driving the interface. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 2-10 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 51 Preparation of Currency Emptying the Currency Purge Bin 3-10 Standard Currency Purge Bin 3-10 Latch Fast Currency Purge Bin 3-11 Clearing Currency Dispenser Jams 3-13 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 52: Operating Instructions

    Table of Contents Operating Instructions NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 53: Preparation Of Currency

    New or uncirculated currency should be separated (fanned) out several times before loading into the cassette. Any notes considered unacceptable should be removed. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 54 Lift the latch up a small amount. Pull the top of the latch towards you then hinge it down. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 55 Raise the lid and, applying slight pressure at the front of the lid to help disengage the tags, remove the lid from the cassette base. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 56 Operating Instructions Replenishing the Currency Cassettes Lift the pusher arms and move the pusher to the rearmost position by pushing against the pusher. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 57 Align the edges of the bills in both planes by holding a bundle loosely between the fingers and thumbs of both hands and tapping lightly on a flat surface, then tapping the bill ends. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 58 Note: When loading the cassette, alternate packs/bundles of 100 bills as shown, and make sure that any bowed bills are loaded with the bow towards the pusher. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 59 The currency should remain between the front support and the pusher in an upright position, neatly stacked between the cassette guides. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 60 11 Lift the latch up and forward until it hooks on to the lid latch block. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 61 14 Firmly push the full cassette into the terminal until the cassette latch clicks into place. 15 Repeat Steps 1 to 14 for all cassettes which require to be replenished. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 62: Emptying The Currency Purge Bin

    If the purge note area is fitted with a flap, lift the flap and remove Standard Currency the currency from the note tray Purge Bin NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 3-10 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 63: Latch Fast Currency Purge Bin

    Remove any lock or seal from the bin. Lift the ring and turn it counterclockwise. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 3-11...
  • Page 64 Note: Damaged or poor quality currency must not be re-cycled in the cassette for dispensing. It should be removed from the terminal and, to maintain accurate accounting, replaced with better quality currency. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 3-12 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 65: Clearing Currency Dispenser Jams

    Reach inside the space vacated by the cassette and remove any jammed bills. Push the cassette back into the terminal until the cassette latch clicks into place. Proceed to Step 5. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 3-13...
  • Page 66 Once the bills have been removed from the main transport, make sure that the transport belts are still located on top of the pulleys NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 3-14 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 67: Maintenance Instructions

    4-25 Currency Singularity 4-27 Singularity 4-27 Internal Compensation Factor 4-27 Condition of Currency 4-27 Calibrating the Dispenser 4-28 Establishing Singularity and Size 4-29 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 68 Adjustments 4-36 Pick Module Timing 4-36 Separating the Pick Units of the Aria Double Pick Module 4-38 Internal Timing of 5635 (Aria-Type) Pick Modules 4-39 Aria Double Pick Module Pick Unit Relationship 4-41 Assembling Aria Pick Modules to the Presenter...
  • Page 69 Replacing a 5635 Dispenser Pick Module 4-54 Configuration 4-55 RS232 Comms 4-55 Bill Singularity 4-55 Connector Pin-outs 4-56 AC Connector 4-56 RS232 Connector 4-56 DC Connector 4-57 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 70 Table of Contents Maintenance Instructions NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 71 These adjustments are described in this section and include the following: Cassette identification code Cassette currency dimensions adjustment Currency singularity adjustment. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 72: Cassette Adjustments

    D: Alphas for denoting additional cassette identification types or, for same use as B. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 73 The cassette has space in the NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 74 More than one cassette of a particular type can be installed. The dispenser treats all cassettes with the same type as one logical cassette. Selection order is from the uppermost pick module downwards. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 75 Note 2. The bar above or below the X indicates whether the magnet should be placed in the housing with the marked end up or down respectively. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 76: Currency Dimensions Adjustment

    “Currency Length Guide Codes and E Spacer Settings.” The codes correspond to markings on the floor of the currency com- partment, on the note guides themselves, and on the E spacers. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 77 The note guides in the body of the cassette bear against spacer blocks known as E spacers. There are two types of E spacers: Segment Type Note Adjustment Spacer Fixed Size Note Adjustment Spacer. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 78 Fixed Size Note Adjustment Spacer The fixed size spacer provides the same function as the Segment Type spacers described above, however, the fixed spacers must be NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 79 The procedure and example given after the code tables should make this clear. Currency Length Guide Codes and E Spacer Setting Currency Length Note Guide E Spacer L.H. (4.72) (4.76) NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 80 (5.44) (5.48) (5.52) (5.56) (5.60) (5.64( (5.68) (5.72) (5.76) (5.80) (5.83) (5.87) (5.90) (5.94) (5.98) (6.02) (6.06) (6.10) (6.14) (6.18) (6.22) (6.26) NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-10 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 81 Check that the triangular parts on the note guides point to the numbers on the floor of the cassette corresponding to the note guide codes. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-11...
  • Page 82 E9 for the right hand guide. Move the pusher fully forward. Unscrew and remove the screws and flat washers securing the note guides to the cassette floor. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-12 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 83 Take care not to damage or bend the spring fingers. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-13...
  • Page 84 Use a sharp knife to cut the spacer just above the number 11 so that you are left with a spacer that has the letter E and segments up to number 9. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-14 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 85 3 and the right hand guide (A) should also be pointing at the number 3. Refer to the following figure for an example of the right-hand guide. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-15...
  • Page 86 Maintenance Instructions Cassette Adjustments 14 Replace the flat washers and screws in the base of the cassette. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-16 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 87: Currency Width Adjustment

    Each Yellow spacer is also attached to the lid note guides by a cross headed screw - see the following illustrations. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-17...
  • Page 88 Maintenance Instructions Cassette Adjustments NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-18 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 89 E spacer to E10. Put the spacers on a work surface so that you can read the letters and numbers embossed on their sides. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-19...
  • Page 90 12 Install the four new Yellow spacers by pressing the legs of the spacer together and pushing them into the apertures in the cassette lid. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-20 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 91 Each Yellow spacer is also clipped in to the lid note guides - see the following illustrations. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-21...
  • Page 92 Determine the width of the new currency. Read the spacer codes for that currency width from the “Currency Width Spacer Codes” table. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-22 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 93 Clip the lid note guides to the yellow spacers on the lid (make sure the cut outs on the note guides are facing out). NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-23...
  • Page 94 (2.91) (2.95) (2.99) (3.03) (3.07) (3.11) (3.15) (3.12) (3.23) (3.27) (3.31) (3.35) (3.39) (3.43) (3.46) (3.50) (3.54) (3.58) (3.62) (3.66) (3.70) (3.74) NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-24 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 95: Matching Cassette Bodies And Lids

    75 note setting. If the pips are set towards the handle of the cassette then it is set for the 200 note setting. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-25...
  • Page 96 Turn the block around so that the pips face the opposite way then insert the block back into the pusher. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-26 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 97: Currency Singularity

    The term “singularity” describes the parameters used by the Singularity dispenser to recognize a single currency bill. In the 5635 dispenser the LVDT determines whether a picked currency item is single by measuring the cross sectional area of the item. This measurement is compared with a threshold value held in NVRAM to determine whether a bill is single, multiple, folded, or torn.

  • Page 98: Calibrating The Dispenser

    NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-28 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 99: Establishing Singularity And Size

    NVRAM. The normalised figures you have obtained, using the above procedure on a calibrated dispenser, may be set into any other 5635 dispenser running the same currency, without the need for further calibration or calculation.

  • Page 100: Diagnostic Tests

    If a fault is found the indication cycles until power is removed from the board. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-30 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 101: Start-Up Tests

    MCU ALU fault MCU RAM fault MCU timer fault MCU interrupt control register fault MCU serial control register fault EPROM sumcheck fail NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-31...
  • Page 102 Lower SRAM address bus error in lower 8 lines BA 0 - 7 Lower SRAM address bus error in upper 8 lines BA 8 - 15 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-32 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 103: Manual Tests

    LED D12 is then flashed the number of times equivalent to the status code. Status Status Code Passed Internal data error in lower SRAM NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-33...
  • Page 104 Lower SRAM address bus error in lower 8 lines BA 0 - 7 Lower SRAM address bus error in upper 8 lines BA 8 - 15 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-34 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 105 Upper SRAM address bus error in lower 8 lines BA 0 - 7 Upper SRAM address bus error in upper 8 lines BA 8 - 15 Chip select fault NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-35...

  • Page 106: Adjustments

    The adjustments to the dispenser are the Pick Module timing and the Dispenser Motor drive belt tension. Pick modules on the 5635 Dispenser are known as the Aria pick Pick Module Timing modules. The gear trains of the Aria pick modules lock them together in a fixed timing relationship so that the timing must be set as the dispenser is assembled as described in the following sections.
  • Page 107 The NVRAM must be cleared to de-configure the removed pick modules. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-37...
  • Page 108 Separating the Pick Units of the Aria Double Pick Module To adjust a double pick module you must first isolate the gear trains of the two pick units by removing the timing belt (NCR part number 445-0587791) shown in the following figure.
  • Page 109 Take off and retain the 26T idler gear (NCR part number 445- 0633190) directly below the pick line (left side of the module...
  • Page 110 Replace the idler gear removed in step 2. Be careful not to dislodge the setting. On a double pick module carry out steps 1 to 6 on the lower pick unit. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-40 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 111 Assembling Aria Pick Modules to the Presenter Once the pick modules have been prepared, as in the previous procedures, the pick modules can be assembled with a 5635 spray presenter to produce the complete currency dispenser. There are no timing adjustments to the spray presenter.
  • Page 112 Check that the timing mark is aligned. Timing mark 1 should be in line with the timing sensor body. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-42 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 113 3 timing mark on the cluster timing disk lines up with the timing sensor body. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-43...
  • Page 114 Check that all the timing marks are aligned. Timing marks 1 , 2 , 3, and 4 should be in line with their respective timing sensor bodies. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-44 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 115: Dispenser Motor Drive Belt Tension

    (0.12in) for a force of 3 Newtons (306g or 10.8oz.) applied at mid-span. Maintaining this adjustment, tighten the transport motor mounting screws. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-45...

  • Page 116: Preventive Maintenance

    Medium usage ATMs (250 dispense operations daily, 2 bill per pick module per operation); replace suction cups every six months NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-46 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 117: Currency/Media Containers

    Currency/Media (including spare cassettes) both inside and out (See “Cleaning”). Containers Note: Pay particular attention to the front door of the cassette. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-47...

  • Page 118: Lubrication

    In those cases lubrication should be applied after assembly. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-48 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 119: Spray Module

    Pick line, bearing faces - with B Pick line hub bearing surface - with B Plastic bearings (before assembly) - with A Cassette latch stud - with B. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-49...

  • Page 120: Cleaning

    Clean the cassette with a cloth dampened with water. For stubborn marks and grease try a clean cloth dampened with isopropyl alcohol. Do not use any other cleaning agents or abrasives. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-50 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 121: Replacement Instructions

    After fitting a new control board, refer to the “Configuration” section later in the chapter to set up the new board. It is also necessary to re-set the currency singularity. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual 4-51...
  • Page 122 Maintenance Instructions Replacement Instructions The 5635 dispenser board is secured by 4 screws A and is behind a metal panel, itself secured by 4 screws B : The following table and illustration indicate the purpose and position of each connector on the 5635 dispenser control board.

  • Page 123: Replacing The 5635 Spray Presenter

    Maintenance Instructions Replacement Instructions Pin-out details for these connectors are at the end of the chapter. Proceed as follows to remove the spray presenter from the 5635 Replacing the 5635 dispenser: Spray Presenter Switch off the terminal power. Disconnect the terminal cable from the dispenser control board power connector J3 and Comms connector J1.

  • Page 124: Replacing A 5635 Dispenser Pick Module

    Maintenance Instructions Replacement Instructions Fit the new spray presenter. Pick modules on the 5635 dispenser are latched together and are Replacing a 5635 known as Aria pick modules. Dispenser Pick As necessary, release the four latches securing the pick module to...

  • Page 125: Configuration

    The items requiring configuration are the RS232 comms settings and bill opacity or singularity. To select RS232 comms and baud rate, set the DIP switches (U23 on RS232 Comms the 5635 control board), SW1-SW8 as follows: Switch no. Setting where 0 = up and 1 = down.

  • Page 126: Connector Pin-Outs

    The RS232 connector is a 25-way D-type male connector, J1 on the RS232 Connector 5635 dispenser control board. XRES COMM_ID1 COMM_ID0 COMM_S1 COMM_S0 LRTS LCTS LTXD LRXD NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-56 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 127: Dc Connector

    Maintenance Instructions Connector Pin-outs The dc connector is a 7-way header connector (J3 on the 5635 DC Connector dispenser control board). +24V (Interlocked) NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 128 Maintenance Instructions Connector Pin-outs NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions 4-58 NCR 5635 Spray Currency Dispenser Service Manual...

  • Page 129: Currency

    Table of Contents Specifications Appendix A Specifications Currency Currency Cassettes Reject Bin Conducted and Radiated Emissions Harmonics and Flicker Emissions Radiated Immunity Power Requirements Acoustic Noise Weight Dimensions Environment NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions...
  • Page 130 Table of Contents Specifications NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions...
  • Page 131 This corresponds to approximately 2260 new or 1580 used U.S. dollars. The reject bin can hold 50 bills. Reject Bin NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR Spray 5635 Currency Dispenser Service Manual...

  • Page 132: Emc

    +5V ± 5% @ 1.5A Requirements +24V ± 10% @ 4.0A AC Power: 115VAC 5.5A RMS 20.2A surge 230VAC 3.0A RMS 10.0 A surge. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR Spray 5635 Currency Dispenser Service Manual...

  • Page 133: Acoustic Noise

    Dimensions for the location of the dispenser securing holes are given in Chapter 2. Note The height and depth dimensions above exclude any interfacing requirements to the ATM. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR Spray 5635 Currency Dispenser Service Manual...

  • Page 134: Environment

    Note: After power down in extreme conditions, it will be necessary to allow a period for the module to return within operating limits. NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR Spray 5635 Currency Dispenser Service Manual...

  • Page 135: Index

    Currency Dispenser 3-13 Command set, firmware 1-20 Compensation factor 4-27 Configuration Spray Dispenser 4-55 Connector DC, Currency Dispenser 4-57 RS232, Currency Dispenser 4-56 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual Index-1...
  • Page 136 Timing on the 5635 Dispenser 4-36 Pick Modules Function of components 1-10 Pick Module Keyplate 1-11 Replacement Instructions 4-51 Replacing a 5635 Dispenser Pick Module 4-54 Replacing the 5635 Spray Presenter 4-53 Replacing the Control Board 4-51 Currency Length Adjustment 4-6...
  • Page 137 Environment A-4 Establishing Singularity and Size 4-29 Exit Sensor 1-17 Firmware Description 1-20 Fixed size spacers Cassette Lid 4-21 Functional Description 1-1 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual Index-3...
  • Page 138 Fixed Size 4-21 Segment Type 4-17 Note Guides 4-7 Note Low Sensing Adjustment 4-25 NVRAM Clear 4-33 Path of notes 1-2 Pick Modules NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions Index-4 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 139 Configuration 4-55 Establishing 4-29 Size Establishing currency 4-29 Spacer Codes Currency Width 4-24 Spacers 4-17 Cassette Lid 4-17 Specifications Dispenser A-1 EMC A-2 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions NCR 5635 Spray Currency Dispenser Service Manual Index-5...
  • Page 140 Tamper Indicating Cassette 1-3 Test notes 4-27 Timing 5635 Pick Modules 4-36 Aria Pick Modules 4-36 Timing Disk Description 1-16 Transport, Dispenser 1-16 Weight A-3 NCR - CONFIDENTIAL AND PROPRIETARY Use pursuant to Company Instructions Index-6 NCR 5635 Spray Currency Dispenser Service Manual...
  • Page 141 NCR 5635 Spray Currency Dispenser Service Manual Number: B006-6280-A000 Date: April 2002 NCR welcomes your feedback on this publication. Your comments can be of great value in helping us improve our information products. You may send your comments to us electronically. See over for details.
  • Page 142 Thank you for your evaluation of this publication. Fold the form where indicated, tape (please do not staple), affix stamp and drop in the mail. F 8763-0695 Fold Affix Postage Stamp Here NCR Financial Solutions Ltd. Information Solutions Feedback Kingsway West Dundee Scotland DD2 3XX...

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