COBRADET

Cobra
Banknote Sorting Machine

Detector Manual
TP09311011 Rev 00
E De La Rue 2001
Walton Road, Farlington

Portsmouth, Hampshire PO6 1TJ.
Telephone: 023 9238 3161
Telefax: 023 9232 5822
www.delarue.com
All items of technical information, advice, know–how, drawings,

designs, specifications and other items communicated in this
document are confidential and remain the property of De La Rue and
shall not be disclosed to a third party without the written consent of De
La Rue.
The above duty of confidence also entails a prohibition of reproduction

of this text without specific authority, in writing, from De La Rue.
1. TECHNICAL BULLETINS AND MEMORANDA
Technical Bulletins are numbered consecutively and Customers of a
product will receive all Technical Bulletins. To prevent confusion,
when a modification is not applicable to all machines (for example a
modification to a 220Volts 50Hz machine may not be relevant to a
115Volts 60Hz machine), Technical Memorandum are used. These
are not numbered.
1.1 Service Manual Amendment

On receipt of a Technical Bulletin or Technical Memorandum which
entails a Service Manual amendment, the following actions should be
taken:
a. Where the Amendment is a page replacement:
D The relevant page is to be inserted in the Manual and the old

page(s) removed. Manual custodians are advised to file the old
pages for future reference.
D The Record of Amendments page is to be completed with the

Technical Bulletin number (not required for a Technical
Memorandum), a brief description of the Technical
Bulletin/Technical Memorandum and the date.
D The Technical Bulletin/Technical Memorandum Title page should

then be filed for future reference. The remainder of the Technical
Bulletin can then be destroyed.
b. Where the Amendment is NOT a page replacement:
D The relevant page is to be amended in the manual and the

margin next to the amendment annotated with the Technical
Bulletin number and date or the Technical Memorandum date.
D The Record of Amendments page is to be completed with the

Technical Bulletin number (not required for a Technical
Memorandum), a brief description and the date.
D The Technical Bulletin/Technical Memorandum Title page should

then be filed for future reference. The remainder of the Technical
Bulletin can then be destroyed.
1.2 Machine Modification

It is recommended that separate Technical Bulletin and Technical
Memorandum files are kept on each machine site as a reference for
all modifications issued. The full copy of the Technical Bulletin and
Technical Memorandum should be filed.
This record will therefore show all machine modifications, whether

implemented in the factory prior to machine installation, or those
carried out on site.
1.3 Master Copies

A master copy of all Technical Bulletins/Technical Memoranda should
be retained by the Service Manager to be used as a reference if
required.
6000 Prelims
May 2001 Page 1
1.4 Record of Amendments
Records of Amendments should not be inserted on any page other
than an Amendment Record Sheet.
1.5 Page Replacements

Care must be taken that any page replacements issued in Technical
Bulletins/Technical Memoranda contain all previously issued changes.
Prelims 6000
Page 2 May 2001
RECORD OF AMENDMENTS
TECHNICAL DATE
BRIEF DESCRIPTION
BULLETIN No. AMENDED
6000 Prelims
May 2001 Page 3
RECORD OF AMENDMENTS
TECHNICAL DATE
BRIEF DESCRIPTION
BULLETIN No. AMENDED
Prelims 6000
Page 4 May 2001
CONTENTS
Title Page
Duty of Confidence
Technical Bulletins and Memoranda
Record of Amendments
Contents (this page)
Health and Safety
Maintaining CE Compliance
Section 1 General Detector Information
Section 2 Thickness Detector
Section 3 Solid State Holes & Tears
Section 4 Vision Detector
Section 5 Optical Pattern Detector
Section 6 UV Bright Detector
Section 7 Limpness Detector
Section 8 Soil Detector
Section 9 Twin Magnetic Ink Detector
Section 10 Infa–Red Detector
6000 Prelims
May 2001 Page 5
IMPORTANT – THE FOLLOWING SECTION ON SAFETY MUST BE UNDER-
STOOD AND STRICTLY ADHERED TO BY ALL SERVICING AND OPERATING
PERSONNEL.
2. HEALTH AND SAFETY

2.1 High Voltage
If single / three phase power is supplied to the machine, exercise
caution when working in areas where mains power is present as
hazardous voltages will exist.
Wall isolating switchgear must be installed in accordance with local

regulations and standards, and be capable of being either
disconnected or locked in the off position.
2.2 High Energy

All servicing personnel are warned of the dangers of arcing and burns
from high energy components such as the batteries and power supply
unit (PSU).
2.3 Weight
Care must be taken when lifting items weighing 20kg or over during
refitting. The fitting of such items should be regarded as a two person
task.
2.4 Moving Parts

Extreme care must be taken by all servicing personnel when working
near moving machine parts. This is especially important when covers
are open or removed and safety interlock circuits over–ridden. On no
account should the machine be operated, with the covers removed, in
the presence of the customers operating staff.
Under certain fault conditions it is possible for motors to start. When

working on motor circuits or motor driven parts when the cover
interlocks are over–ridden, always ensure that an emergency stop
switch is pressed in.
Emergency stop switches, which cannot be over–ridden, are provided

which will either stop the machine if it is running or prevent it from
starting. These switches are of the red push type with yellow
escutcheon plates.
Additionally, all covers that are operator accessible are protected by

safety interlock switches to ensure that the machine will not run when
the covers are open.
All items of clothing such as ties, loose overalls and long hanging
jewellery should be removed. Long hair should be tied up.
2.5 Cutting Blades

Certain mechanisms and heads contain sharp–edged blades. Apply
caution when working in these areas.
Prelims 6000
Page 6 May 2001
2.6 Light Emissions
The safety precautions for detectors which emit U.V. light or lasers
must be followed in accordance with the instructions in the relevant
detector manuals.
2.7 Cabling And Power

Do not use the colour of cables as an indication of their voltage or
polarity, Always use the wire number in conjunction with the wiring
schedules.
Always use a test meter to check that the terminals are not live before
touching.
2.8 SSD Devices

Normal precautions concerning the handling of MOS components are
applicable in order to minimise the risk of damage to these devices by
STATIC ELECTRICAL DISCHARGE. This entails avoiding contact
with the pins of these devices and ensuring that when they are
removed from a pcb, the pins are strapped together with conductive
tape, or placed on a suitably earthed metal plate, thus ensuring that
ALL pins remain at the same potential. Any external clothing,
overalls, etc., manufactured of NYLON or a similar material, must not
be worn as they are capable of reaching extremely high voltage
potentials caused by friction during normal wear. These precautions
are especially necessary in respect of microprocessor devices.
2.9 EMC
Various parts of the machine, particularly those items supplied by
mains power, but also including PCB’s, contactors, etc. are housed in
EMC (Electro–Magnetic Compatibility) shielded boxes. The machine
external covers also form part of a general EMC shield. To comply
with EMC regulations, it is important that these shields and covers are
always fitted and secure when the machine is in operation.
2.10 Solvents
All fluids used for cleaning purposes must be non – toxic and must
comply with the relevant COSHH and Health And Safety regulations.
2.11 Pneumatics
Before attempting any maintenance or servicing on the pneumatics
system ensure that the air supply is removed. Should it be necessary
to carry out any fault finding on the machine while the pneumatics are
functioning, extreme caution should be exercised.
Note: Wherever these symbols appear throughout this manual

reference should be made to Paragraph 2 ( Health & Safety ).
6000 Prelims
May 2001 Page 7
3. MAINTAINING CE COMPLIANCE
Any installation practices, modifications or maintenance procedures
carried out which are not in accordance with the requirements of, or
approved by De La Rue Cash Systems, will nullify the CE
certification of this product and could lead to prosecution.
Prelims 6000
Page 8 May 2001
Section 1
___________________________
General Detector Information
4000 Section 1
May 2001 Page 1
CONTENTS
Para Page
1. INTRODUCTION 4
1.1 Note Authentication and Assessment System 4
______________________________________________
2. DESCRIPTION 6
2.1 Detector Interface Board 6
______________________________________________
3. MAINTENANCE 6
______________________________________________
4. FAULT DIAGNOSIS 8
4.1 Error Messages 8
4.2 Preliminary 8
4.3 Test For Transport System Integrity 8
______________________________________________
5. DETECTOR SYSTEM DIAGNOSTICS - GENERAL 9
5.1 Introduction 9
5.2 General Protocol Details 10
5.3 Access Code 12
______________________________________________
6. DETECTOR SYSTEM DIAGNOSTICS -
FUNCTION 1 ‘CONFIGURATION’ 14
6.1 Option 1 ‘Load Configuration’ 14
6.2 Option 2 ‘List Configuration’ 14
6.3 Option 3 ‘Edit Configuration’ 15
______________________________________________
FUNCTION 2 ‘SYSTEM DIAGNOSTICS’ 23
7.1 Option 11 ‘Display Status’ 23
7.2 Option 12 ‘View Memory’ 25
7.3 Option 13 ‘Change Memory’ 25
7.4 Option 21 ‘Show Engineer’s Log’ 25
7.5 Option 22 ‘Test a Function’ 26
7.6 Option 23 ‘Print truth Table’ 26
7.7 Option 24 ‘Show 1mm Counter’ 26
7.8 Option 31 ‘Configurator Contents’ 26
7.9 Option 32 ‘Configurator Details’ 26
7.10 Option 33 ‘Configurator Self Test’ 26
7.11 Option 34 ‘Configuration Verify’ 26
7.12 Option 41 ‘RAM Test’ 26
7.13 Option 42 ‘EPROM Checksum Test’ 26
7.14 Option 00 ‘End’ 26
______________________________________________
Section 1 4000
Page 2 May 2001
CONTENTS (continued)
Para Page
FUNTION 3 ‘DETECTOR DIAGNOSTICS’ 31
8.1 Option 11 ‘List Detector Names’ 31
8.2 Option 12 ‘List Trace Measure Codes’ 31
8.3 Option 13 ‘List Cull Text Codes’ 31
8.4 Option 14 ‘List Error Codes’ 31
8.5 Option 21 ‘Show Algorithm Data’ 32
8.6 Option 22 ‘List Algorithm Text Codes’ 32
8.7 Option 23 ‘Show DAC Settings’ 32
8.8 Option 24 ‘Show Audio Calibration’ 32
8.9 Option 31 ‘Detector Controller’ 33
8.10 Option 00 ‘End’ 36
______________________________________________
FUNCTION 4 ‘TRACE DATA’ 39
9.1 Trace System General Details 39
9.2 Option 11 ‘Examine Note Trace Data’ 40
9.3 Option 12 ‘Examine Histogram Trace Data’ 42
9.4 Option 13 ‘Examine Trace Measure Table’ 42
9.5 Option 21 ‘Set Note Trace Conditions’ 45
9.6 Option 22 ‘Set Up Histogram Trace’ 46
______________________________________________
Tables
Table 1 Trace Measure Data 43
______________________________________________
Illustrations
Figure 1 Detector Interface Board Block Diagram 7
______________________________________________
Figure 2 Detector System Diagnostics Flow Chart 13
______________________________________________
Figure 3 Configuration Flow Chart 21
______________________________________________
Figure 4 System Diagnostics Flow Chart 27
______________________________________________
Figure 5 Detector Processor Decision Process 29
______________________________________________
Figure 6 Detector Diagnostics Flow Chart 37
______________________________________________
Figure 7 Trace Data Flow Chart 47
______________________________________________
4000 Section 1
May 2001 Page 3
1. INTRODUCTION
Information applicable to all note authentication and assessment
detectors is given in this Section, and information applicable to a
specific detector only is given in the corresponding sections which
follow.
1.1 Note Authentication and Assessment System

General
The note authentication and assessment system employs a range of
detectors that sense the features and quality of each note. The detector
microprocessor determines from the detector responses, from a store
of note specifications and from the operator’s requirements, to which
pocket each note is diverted.
Detectors
The standard range of detectors comprise the following.
a) Thickness (Doubles) detector, by which multiple notes are detected,

together with the length of each fold and tape.
b) Solid state holes-and-tears detector, by which holes,open tears and

missing corners in notes are detected, together with the length of
each note.
c) Limpness detector, by which the audio condition of each note is

measured.
Notes that are too close together or are overlapping, and notes that are
of incorrect length, are passed to the cull pocket. The condition levels
at which notes are segregated, and the output batch quantities are pre-
set in software but may be reset by the operator.
Each detector is interfaced by a common Interface Board to the detector
processor.
Operation
Once the operating process is selected, the detector processor passes
to the detector interface the decision parameters applicable to both the
process selected and the type and location of the detectors interfaced.
Whilst notes are being transported, the processor passes to the

interface the timing and position details of each note. These details
enable the detector head signals to be sampled whilst the note is
passing through the head, and sampled repeatedly for every millimetre
of transport movement. For each detector the note signature so
obtained, together with the detector decision parameters, enables a
discrete decision to be made and forwarded by the interface to the
detector processor.
The detector processor collates the discrete decisions arising from all
detectors in order to obtain for each note a composite decision. This is
compared with the appropriate process truth table in order to make the
note routeing decision, which is passed on to the transport processor.
Section 1 4000
Page 4 May 2001
Parameter Adjustment
Whilst the operator can adjust fitness parameters at the keyboard, the
Site Engineer can adjust decision parameters, including truth tables,
after entering the appropriate pass code. These adjustments can be
carried out only when the machine is in the standby mode.
Following any access to the configurable data, the detector issue level
held in the detector processor is automatically updated.
Upon request, the following data can be printed out:
l Process information
l Detector truth tables
l Detector settings
l Configuration change history
Self Check
Upon switch-on of the machine, change of process and at certain other
times, the machine checks that all aspects of the interface and
associated detector heads are fully functional. Any malfunction is
reported through the intercommunication system to inform the operator
or Engineer. If a printer is fitted a diagnostic print-out can be obtained
if any check fails.
Detector Processor
The detector and transport processors are identical with only firmware
differences. The detector processor is responsible for the following:
l Holding a permanent record of the detector operating routine.
l Holding a semi-permanent record of detector calibration parame-
ters, which are amended automatically to off-set variations.
l Holding a semi-permanent record of the Customer’s detector pack-
age layout and operational requirements.
l Holding a semi-permanent record of the Establishment’s note char-
acteristics, which can be amended by the Service Engineer.
l Holding a current record of the findings of the detector interrogation.
l Maintaining the detector configuration table for use by itself, by the
detector interface, and by the transport processor.
l Supporting the operation of each detector.
l Providing the combined findings of all detectors with a destination
code.
l Monitoring the performances of itself and the detector interface.
l Supporting the keyboard manipulation of configuration data, whilst
enforcing multi-level access by operator and Engineer, and logging
in a History file in non-volatile memory those changes that affect the
machine’s security arrangements.
l Decoding the process selection and priming the detectors
accordingly.
l Supporting the security key arrangement to ensure configuration
integrity.
4000 Section 1
May 2001 Page 5
2. DESCRIPTION
2.1 Detector Interface Board

The detector interface board receives from the detector processor the
decision threshold levels for the various detectors, and converts these
from digital to analogue form. It also receives the detector analogue
outputs, and compares these with the corresponding threshold levels.
The result of the comparison for each detector is forwarded to the
detector processor. A block diagram of the detector interface board is
shown in Figure 1.
3. MAINTENANCE
It is necessary to carry out the routine transport adjustments first, as
the transport must function correctly before the detectors can be cor-
rectly set. If a detector requires re-adjustment at another time then it is
at least necessary to ensure that the transport (flat) belts adjustment is
correct first.
To complete some of the detector adjustments it may be necessary to

override the cover interlock safety to run the machine with the Cobra
main inspection cover open..
Before carrying out any maintenance procedures the section on Health

and Safety, located in the preliminary pages of this manual, must be
read
Section 1 4000
Page 6 May 2001
Figure 1 Detector Interface Board - Block Diagram
4000 Section 1
May 2001 Page 7
4. FAULT DIAGNOSIS
4.1 Error Messages

Some machine-reported error messages can be used in investigating
detector faults. Error numbers 1 to 25 and 41 to 56 inclusive indicate a
fault with the detector processor board. If such an error is repeatedly
reported and cannot be cleared by any other means, for example
switching the machine off and on, replace the board by a spare.
Error number 34 indicates that the detector is not ready. This indication
may be caused by a disengagement of a connector of the detector sys-
tem. (Refer to the block diagram in the corresponding detector section).
4.2 Preliminary
The performance of the detectors is affected by the performance of the
note transport system. Therefore, before investigating specific detector
faults, it is necessary to check for proper operation of the note transport
system. This check is described under the following heading.
Ensure that, if any part of the detector system is renewed, the Setting
Up procedure of the corresoponding Appendix is subsequently carried
out.
4.3 To Test For Cobra 4004 Transport System Integrity

Before any diagnostic work is carried out on the detector, it must be es-
tablished that the note transport system is working properly. To do this,
carry out the following checks.
Cleanliness
Check that all transport sensors and the detector are clean. If any item
is found to be excessively dirty, then remind the supervisor or operator
of the importance of thorough daily cleaning.
Note Feeder
Check that the note feeder adjustments are correct. Observe whether
the feeder gives any multiple feeds. Multiple feeds can be identified by
counting the number of notes in the cull pocket and comparing the count
with the number of notes in the transport trace (diagnostic function 09
in the diagnostics menu, set up to trace culls only).
If the number of multiple feeds is excessive, check whether the notes

are badly degraded, poorly prepared, or incorrectly loaded into the hop-
per. If they are not, check that the separator roller and ’O’ rings are
clean. Check that all parts are correctly fitted, undamaged and not ex-
cessively worn.
Note Transport
Visually check the condition of the note transport belts. Check the set-
ting of the belt tensions at each of the drive capstans.
Ensure all rollers move freely.
Culls
Use the transport note trace to determine whether the transport
processor is culling the notes. Use the detector processor note trace to
determine whether the detector processor is culling the notes. If either
Section 1 4000
Page 8 May 2001
processor is initiating the culls then investigate and correct with
appropriate action against the cull reason.
If the cull rate is still excessive, investigate specific detector faults.
Service Report
This should include a statement verifying that the test for system
integrity is completed and include also details of all corrective actions
taken.

GENERAL
5.1 Introduction
The detector processor supports a user interface, via the Cobra 4004
keyboard and display. This section details the detector processor func-
tions available through keyboard operation to the operator,
supervisor and engineer, and provides a guidance as to their usage.
A summary of the detector system diagnostics is given in the flow chart
of Figure 2.
Detector Processor Direct Communications

When the detector processor diagnostics are accessed, control of the
user interface is effectively handed over to the detector processor
(direct communications). The functions that require direct
communications are as follows.
a) Request change to condition sort level (diagnostics utility)
b) Set up condition sort pointers (set up utility)
c) Detector processor diagnostics
Functions (a) and (c) are specifically selected from within the machine
diagnostic environment. Function (b) is transparent to the operator and
is entered via a supervisor configuration screen.
4000 Section 1
May 2001 Page 9
5.2 General Protocol Details
As far as is possible, certain protocols have been adopted throughout
all keyboard and display activities.
In those instances where comprehensive prompting is not possible due

to limited screen size the following conventions are adopted.
a) ‘->’ (right cursor key) - use of this key is generally reserved for
stepping on to the next phase of an operation (e.g. display next
block of memory).
b) ‘<-’ (left cursor key) - where the operation permits, use of this key
steps back to the previous phase of an operation (e.g. display
previous block of memory).
c) ‘I<-’ - Cancelling numeric input or abort key.
d) The screen is sometimes frozen to allow it to be examined before

being overwritten. The bottom right hand corner of the display will
show the prompt ‘->’, indicating that the right cursor key is required
to continue.
e) Prompts for numeric input expect, by default, decimal numbers. If

hexadecimal input is required a full QWERTY keyboard is required.
Screen or Printer Selection

Where appropriate, the operator has the option to output data either to
the printer or the screen. Where this is the case (for example listing a
configuration table), the operator is presented with the following menu.
Output to screen only 0
Output to printer 1
Enter an option- -
Typing ‘0’ - will list the data to the screen.

Typing ‘1’ - will list the data to the printer.
The data is ‘’printed’’ to a file and the user is prompted to enter a filena-
me and select a folder to save data in, using Windows NT functions, it
is possible to print or view the data.
Text Input
Where text input is required, the operator is presented with the following
information.
!”£$%&’()*+,-./0123456789:;<=>?@
ABCDEFGHIJKLMNOPQRSTUVWXYZ[ ] _’
abcdefghijklmnopqrstuvwxyz
END
Text is entered by positioning the cursor under the required character
and pressing ‘ENTER’. Cursor movement is achieved by using the
cursor control keys. As each character is added to the string it is
displayed at the bottom left of the screen. Pressing ‘CLEAR’ will cause
the most recently entered character to be cancelled from the string.
Once the required text string has been entered, moving the cursor
under the word ‘END’ and pressing ‘ENTER’ will terminate the entry.
Where text strings are limited to a specified number of characters (as
Section 1 4000
Page 10 May 2001
stacker titles), the text entry will be automatically terminated when the
required number of characters have been entered.
Bit Mask Create or Modify

In certain applications the operator is required to create or modify a bit
mask. Where this is required the operator is presented with the follow-
ing information, for example.
Detector number ? _
000000FF
00000000000000000000000011111111
END ->
The masks are in binary format, each bit of the mask having a
ignificance appropriate to its application. Individual bits may be toggled
on and off by entering their bit number. Bit numbers may be referenced
to 0 or 1 depending on the application.
In the above example detectors 1 to 8 are enabled, 9 to 32 disabled.
Condition Sort Level Change - Diagnostics Utility

This utility enables the operator to adjust ALL of the sensitivity pointers
referenced by the current process.
Fault Reporting
Normal fault reporting is controlled by the transport processor. Fault
codes 1000 to 40999 have been reserved for detector and detector
processor faults. The first two digits of the error code refers to the of-
fending detector (for example: 1xxx = detector 1, 12xxx= detector 12).
Error codes which begin with 40xxx refer to the detector processor itself.
The remaining three digits represent the actual error code logged.
During detector diagnostics, however, detector faults logged will auto-

matically invoke the fault reporting menu. For example:
Det. Proc. faults menu
Explain a fault 1
Clear displayed fault 2
Print error log entries 3
Exit 0
Detector 3 fault code 31
Option 1 will allow access to a fault explanation routine which will

prompt the operator for the detector number and the fault code, using
the currently reported fault details as default.
Option 2 will delete the currently displayed fault and report on the next
most recent fault logged. A fault code of 0 implies no more faults
logged.
Option 3 will print a complete list of all faults logged, together with its ex-
planation.
Option 0 will return the operator to the routine from which the faults
menu was called.
4000 Section 1
May 2001 Page 11
5.3 Detector Processor Menu.
This is the top level of the detector processor diagnostics routines and
is entered after the access authority has been established. After
selection the operator is presented with the following menu, refer to fig-
ure 2.
Section 1 4000
Page 12 May 2001
DETECTOR SYSTEM
DIAGNOSTICS ACCESS
AUTHORITY 0
1 2 3 4 0
Configuration System Detector Trace Data END

Diagnostics Diagnostics
see Figure 3 see Figure 4 see Figure 6 see Figure 8
Figure 2 Detector System Diagnostics Flow Chart
4000 Section 1
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FUNCTION 1 ‘CONFIGURATION’
Access authority required: 0
This function presents a further options menu giving access to the

different aspects of the configuration environment. On selection of this
function the following menu will be displayed.
Configuration menu (level 1)

Load configuration 1: List configuration 2
Edit configuration 3: Not used 4
Ascii table 5: End 0
A summary of the configuration function is given in the flow chart of

Figure 3.
6.1 Option 1 ‘Load Configuration’
This option will force the loading of the configuration file from the
configuration EPROM. Any configuration data held in the system
memory will be overwritten. A warning message is displayed first;
pressing ‘ENTER’ carries out the option whereas pressing ‘CLEAR’
aborts the operation.
6.2 Option 2 ‘List Configuration’
This option presents a further sub-menu which enables the operator to

list-print various tables of the configuration file. The menu offered to the
operator is split into two separate pages, movement between them be-
ing achieved by using the right and left cursor keys.
Page 1:
Configuration list menu (lev. 2)
Master table 1: History 2
Processes 3: Notes 4
Detectors 5: Transport 6
Proc. titles 7: End 0
change menu ->
Page 2:
Configuration list menu (lev. 2)
Complete list 1: Cond. ptrs 2
Note base tbl. 3: End 0
<- change menu
On selection of the required listing option the operator is first given the
choice to list all of the defined data tables, or select a specific table for
listing. The operator is then prompted to select either the display or the
printer for output.
Section 1 4000
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6.3 Option 3 ‘Edit Configuration’
This option presents a further sub-menu which enables the operator to

make changes to the various configuration data tables. On selection of
a particular option the operator will be presented with a specialised edit
menu, enabling changes to be made to the selected data table type.
The ‘edit configuration’ menu offered to the operator is split into two
separate pages, movement between them being achieved by using the
right and left cursor keys.
Page 1:
Configuration edit menu (lev. 2)
Create config. 1: Master tbl. 2
Process data 3: Note data 4
Detector data 5: Transp. data 6
Proc. titles 7: End 0
change menu ->
Page 2:
Configuration edit menu (lev. 2)
Edit title 1: Cond. ptrs. 2
Note base data 3: End 0
<- change menu
Option 1 page 1 ‘Create Configuration’

DO NOT SELECT THIS OPTION, otherwise the detector processor will
stop working.
Option 2 page 1 ‘Master Table’

This option enables the operator to change the variables that are held
in the configuration file master table. On selection the operator is
presented with the following menu.
Master table edit (level 3)
List table 1: Schd. per. 2
Note tasks 3: Speed 4
Supervisor code 5: Eng. code 6
Mod. Det. mask 7: Add lang. 8
End 0
Option 1 - ‘List table’ - this option enables the master table to be listed
to either the display or the printer.
Option 2 - ‘Scheduler pd’ - modify nominal transport movement be-

tween scheduler interrupts (scheduler period).
Option 3 - ‘Note tasks’ - modify maximum number of notes which may

be concurrently processed by the detector processor.
Option 4 - ‘Speed’ - modify the nominal transport speed for the machine
as known by the detector processor.
Option 5 - ‘Supervisor code’ - modify the supervisor access code.
Option 6 - ‘Eng. code’ - modify the engineer’s access code.
4000 Section 1
May 2001 Page 15
Option 7 - ‘Mod. Det. mask’ - modify the machine detector mask.
Setting a bit in the mask to zero will switch the corresponding detector
off for ALL processes.
Option 8 - ‘Add language’ - DO NOT USE THIS OPTION.
Option 0 - ‘End’ - selecting this option will return the operator to the
‘Configuration edit menu (level 2)’.
Option 3, page 1 ‘Process Data’

This option enables the process data tables to be edited or created.
On selection, the following options menu is displayed.
Process table menu (level 3)
List table(s) 1: Add process 2
Add note 3: Add T.P. ref 4
Add title rf. 5: Mod. Det. mask 6
Find table 7: Mod. Note Dest.8
Mod cond. ptr. 9: End 0
Each option prompts the user for the data required to implement the
edit.
Option 1 ‘List table(s)’ - this option will enable all or specific process
data tables to be listed to either the display or the printer. If the CLEAR
key is pressed whilst displaying these tables, it will take the operator
back to the previous level.
Option 2 ‘Add process’ - this option will create a new process data table
if the user supplied process identity is unique.
Option 3 ‘Add note’ - option to add a new note number to a given

process data table. The operator will also be required to supply the
destination for each of the grades for this note.
Option 4 ‘Add T.P.ref’ - change the reference to a transport data table.

The new transport data table reference will only be accepted if the
process table already exists.
Option 5 ‘Add title ref’ - change the reference to the process title table.
The new title reference will only be accepted if the process table already
exists.
Option 6 ‘Mod. Det.mask’ - modify the detector mask for the given
process. Setting a bit in the mask to zero, will switch the corresponding
detector off.
Option 7 ‘Find table’ - find the address for the given process data table.
If the process table cannot be found then an address of 0 will be
displayed.
Option 8 ‘Mod note dest.’ - modify a note’s destination for the various
grades, for the process and note selected.
Option 9 ‘Mod. cond. ptr’ - modify the condition pointer mask which
defines which, if any, of the sensitivity pointers are to be automatically
offered to the operator at process selection. Setting a bit in the mask to
zero will disable the corresponding pointer for operator adjustment.
Section 1 4000
Page 16 May 2001
Option 0 ‘End’ - selecting this option will return the operator to the
Option 4, page 1 ‘Note Data’

This option enables the note data tables to be edited or created.
Note data table menu (level 3)
List table(s) 1: Add note 2
Add detector 3: Find table 4
Note size 5: Mod. data sort 6
End 0
Each option prompts the user for the data required to implement the
edit.
Option 1 ‘List table(s)’ - this option will enable all or specific note data
tables to be listed to either the display or the printer.
Option 2 ‘Add note’ - this option will create a new note data table if the
user supplied note identity is unique.
Option 3 ‘Add detector’ - add a new detector reference to a note data

table. The new detector reference will only be accepted if it is valid (is
between 1 and 32) and the detector data table already exists in the
configuration.
Option 4 ‘Find table’ - find the address for the given note data table. If
the note table cannot be found then an address of 0 will be displayed.
Option 5 ‘Note size’ - change the default note size. This note size
applies only to note tables whose configured dimensions, length or
width, is zero. This option does not make any changes to the
configuration file, but simply changes the default values held by the
detector processor.
Option 6 ‘Mod. data sort’ - modify the data reduction type for each grade
of a note. This enables the operator to change the data reduction to
either AND, OR, NAND or NOR data sort.
Option 5, page 1 ‘Detector Data’

This option enables the detector data tables to be edited or created.
Detector data table menu (level 3)
List table(s) 1: Add det. 2
Add crit. 3: Edit param 4
Find table 5: Det. name 6
Det. position 7: Det. read time 8
End 0
Option 1 ‘List table(s)’ - this option will enable all or specific detector
data tables to be listed to either the display or the printer.
Option 2 ‘Add detector’ - this option will create a new detector data table
if the user supplied detector identity is valid (1 to 32) and unique.
4000 Section 1
May 2001 Page 17
Option 3 ‘Add criterion’ - add a new detector criterion to a detector table
entry. The new criterion will only be created if the identity is unique
within the context of the detector chosen.
Option 4 ‘Edit param’ - edit the parameters of a given detector or

criterion entry.
Option 5 ‘Find table’ - find the address for the given detector data table.
If the detector table cannot be found then an address of 0 will be
displayed.
Option 6 ‘Detector name’ - change the 4 characters used to describe the

detector’s name or function.
Option 7 ‘Det. position’ - modify the detector position. The detector

position should be measured with respect to the transport track
sensor B.
Option 8 ‘Det. read time’ - modify the time at which the detector
processor will read the results from a detector. If this time is set to zero,
the detector processor will calculate a read time based on the detector
position and the note length.
Option 6, page 1 ‘Transport Data’

This option enables the transport data tables to be edited or created.
Transport table menu (level 3)
List table(s) 1: Add table 2
Find table 3: Edit table 4
Add stacker 5: End 0
Option 1 ‘List table(s)’ - this option will enable all or specific transport
processor data tables to be listed to either the display or the printer.
Option 2 ‘Add table’ - this option will create a new transport data table if
the user supplied identity is unique.
Option 3 ‘Find table’ - find the address for the given transport data table.
If the transport cannot be found then an address of 0 will be displayed.
Option 4 ‘Edit table’ - this enables the user to modify a stacker data
entry for a given transport processor data table.
Option 5 ‘Add stacker’ - create a new stacker entry into a given transport
data table. The new stacker number must be unique within the
specified transport data table and must be in the range 1 to 15.
Section 1 4000
Page 18 May 2001
Option 7, page 1 ‘Process Titles’
This option enables the process title data tables to be edited or created.
Process title menu (level 3)
Find table 3: Edit title 4
End 0
Option 1 ‘List table(s)’ - this option will enable all or specific process title
Option 2 ‘Add table’ - this option will create a new process title data table
if the user supplied identity is unique. The user will be required to enter
a new title string for each language defined in the master table.
Option 3 ‘Find table’ - find the address for the given title data table. If
the title table cannot be found then an address of 0 will be displayed.
Option 4 ‘Edit title’ - This option is not used by Cobra machine.
Option 1, page 2 ‘Edit title’

This option is not used by Cobra machine.
Option 2, page 2 ‘Condition Pts’

This option enables the condition pointer data tables to be edited or
created. On selection, the following options menu is displayed.
Condition sort data menu (level 3)
Find table 3: Edit pointer 4
Add pointer 5: End 0
Option 1 ‘List table(s)’ - this option will enable all or specific condition
pointer data tables to be listed to either the display or the printer.
Option 2 ‘Add table’ - this option will create a new condition pointer data
table if the table identity is unique.
Option 3 ‘Find table’ - find the address for the given condition pointer
data table. If the condition pointer table cannot be found then an
address or 0 will be displayed.
Option 4 ‘Edit pointer’ - option to change the parameters of a given

pointer within a specified condition pointer table.
Option 5 ‘Add pointer’ - add a pointer to a given condition pointer table.

The pointer will only be added if the identity is unique within the context
of the selected table.
4000 Section 1
May 2001 Page 19
Option 3, page 2 ’Note Base Data’
This option enables the note base data tables to be edited or created.
Note base data menu (level 3)
List tbls. 1: Add table 2
Find table 3: Mod note offset 4
Edit text 5: End 0
Option 1 ‘List table(s)’ - this option will enable all or specific note base
Option 2 ‘Add table’ - this option will create a new note base data table
if the table identity is unique.
Option 3 ‘Find table’ - find the address for the given note base data
table. If the note base table cannot be found then an address of 0 will
be displayed.
Option 4 ‘Mod note offset’ - modify the value of the note base offset.
Option 5 ‘Edit table text’ - This option is not used by Cobra machine.
Option 0 ‘End’
Selecting this option will return the operator to the ‘Configuration menu
(level 1)’.
Option 4 ‘Not Used’

This option is not used by the Cobra machine.
Option 5 ‘Ascii Table’
This option merely provides an ASCII-to-hexadecimal look-up table.
Option 0 ‘End’
Selecting this option will return the operator to the ‘Detector Processor
menu (level 0)’.
Section 1 4000
Page 20 May 2001
CONFIGURATION
Access Authority 0
1 2 3 4 5 0
Load List Edit Save ASCII Code End

Configuration Configuration Configuration Configuration
Access 0 0 3 0
Authority
Page 2
Page 1 3 Page 2
1 2 3 4 5 6 7 0 1 2 3 0
Master History Processes Notes Detectors Transport Process End Edit Condition Note Base End
Table Titles Table Pointers Data
Page 2
Page 2 1 2 3 4 5 0
1 2 3 0 List Add Find Mod Edit End
Tables Table Tables Note Table
Complete Condition Note End Offset Text
List Pointer Base Page 2
Table 1 2 3 4 5 0
List Add Find Edit Add End

Tables Tables Tables Pointer Pointer
1 2 3 4 5 6 7 0
Create Master Process Note Detector Transport Process
Configuration Table Data Data Data Data End
Titles
Page 1 Page 1
1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 0 1 2 3 4 5 0
List Note List

Add End Tables Add Note End List Find End
Tables Tasks Engineer Detector Tables Add
Code Language Size Table Stacker
Scheduler Speed Mod Add TP
Period Modify Add Note Find Edit
Table Data Sort Table
Supervisor Det Mask Table
Code
Page 1
1 2 3 4 5 6 7 8 0 1 2 3 4 0
1 2 3 4 5 6 7 8 9 0
List Add Note Add List Add Detector End List End
Tables Title Find Mod End Tables Find Tables Find
Table Cond Ptr Criterion Table Position
Ref Table
Mod
Add Add TP Mod Det Note Add Table Edit Title
Process Ref Mask Add Edit Detector Detector
Dest Detector Parameters Name Read Time
Figure 3 Configuration Flow Chart
4000 Detectors Section 1

May 2001 Page 21
Section 1 4000 Detectors
Page 22 May 2001
FUNCTION 2 ‘SYSTEM DIAGNOSTICS’
This function provides access to the system diagnostic routines

provided for detector-processor orientated test and monitoring
functions. The options provided are split into several menu pages,
movement between them being achieved by using the right and left
cursor keys.
Page 1:
Sys. diagnostics 1 (level 1)
Display status 11
View memory 12
Change memory 13
End 00
change menu ->
Page 2:
Show engineer’s log 21
Test a function 22
Print truth table 23
Show 1mm counter 24
End 00
<- change menu ->
Page 3:
Configurator contents 31
Configurator details 32
Configurator self test 33
Configuration verify 34
End 00
<- change menu ->
Page 4:
RAM test 41
EPROM checksum test 42
End 00
<- change menu
Selection of the required option is made by entering the two- digit option
numbers from any page. A summary of the system diagnostics is given
in the flow chart of Figure 4.
7.1 Option 11 ‘Display Status’

This option provides a list of miscellaneous software data. This facility

is primarily intended for use during software development. This list can
be output to the display or to the printer.
4000 Section 1
May 2001 Page 23
The following data is currently listed.
ramstrt : start address of data (ram) segment

_edata : end address of allocated ram
conbase : start address of configuration
authptr : address of note truth tables
Time_map : start address of scheduler timing map
ntask1 : start address of first note task
&datumt1 : address of datum time primary buffer
&datumt2 : address of datum time secondary buffer
trctb1 : address of trace table master table
histb1 : address of histogram data table
freeram : next free address in ram
lastram : ram top address
Procedure cksm addr : address of procedure checksum
Config cksm addr : configuration length (checksum)
Process code : current process code
Denomination code : current denomination code
Status flags : detector processor status flags
Run time error flags : run time error status
Fitness det mask : detectors used for grade 1 to 15
Auth. det mask : detectors used for grade 0
Det. reply ram strt : start of circular ram for detector bit replies
Det. reply ram pntr : pointer to circular ram
Control task table : address of table containing control tasks
Control table size : current number of tasks in control table
Cross ref table : address of detector cross reference table
Det. config. store : start address of criteria store for all
detectors
Det. results store : start address of results store for all
detectors
Bytes reserved for stack : stack allocation
Bytes required by stack : number of bytes used by the stack
Scheduler’s per second : number of level 2 interrupts/second
Send result time : send result time for selected process
Sensor B position : position of sensor B (mm) from sensor A
Sensor C position : position of sensor C (mm) from sensor A
Sensor E position : position of sensor E (mm) from sensor A
Slip at C : average slip (mm) at C
Slip at E : average slip (mm) at E
Data reduction time(max) : current max. data reduction time (mm)
Note trace time (max) : current max. note tracing time (mm)
Thickness exe.time (max) : current max. thickness execution time (mm)
H&T exe.time (max) : current max. holes + tears exection time (mm)
Length exe.time (max) : current max. length execution time (mm)
UVB exe. time (max) : current max. UV execution time (mm)
Twin mag exe. time (max) : current max. mag. execution time (mm)
Met. Thd.exe.time (max) : current max. metal thread execution time (mm)
Section 1 4000
Page 24 May 2001
7.2 Option 12 ‘View Memory’
This option enables the operator to list the detector processor system
memory, to either the printer or the display.
If output to the printer has been selected, the operator is prompted for
a start and end address of the memory area of interest.
If output to the display has been selected the operator is prompted for
a start address only. The first 6 words, starting from the address
specified, are then output to the screen. The operator then has the
following options.
-> = display next 6 locations
<- = display previous 6 locations
CLEAR = end operation
In both cases (printer or display) the data is presented in hexadecimal,

decimal and ASCII formats.
7.3 Option 13 ‘Change Memory’

Access authority required : 3
This option enables the operator to modify the contents of the detector
processor system memory. After selecting the required address, the
operator is presented with the following menu (for example address
20088 has been chosen).
20088 18762 494A IJ

‘ENTER’ to change data
‘CLEAR’ to end
Pressing ‘ENTER’ will enable the operator to modify the contents of the
address shown. The new data must be entered in hexadecimal format.
Pressing ‘->’ will increment the address to the next word.
Pressing ‘<-’ will decrement the address to the previous word.
Pressing ‘CLEAR’ will end the operation.
7.4 Option 21 ‘Show Engineer’s Log’

This option enables the contents of the engineer’s log to be listed to

either the display or the printer. The engineer’s log is a list of certain
system faults which result from illegal conditions being detected in the
software or hardware. Each entry consists of 22 long words and reflects
the contents of the processor stack at the time of the error routine being
called.
This data is primarily intended for the use of DLR engineering

personnel in tracing the history and origins of fault conditions which may
prove difficult to isolate by any other means.
4000 Section 1
May 2001 Page 25
7.5 Option 22 ‘Test a Function’
This option enables a software function to be tested. It is intended for

use as a software development tool.
7.6 Option 23 ‘Print Truth Table’

This option is not available in this version of the machine.
7.7 Option 24 ‘Show 1mm Counter’

This option displays the count value contained in the 1mm counter
maintained by the detector processor. The Cobra transport system pro-
vides the clock signal which is synchronised each time the machine is
started.
7.8 Option 31 ‘Configurator Contents’

7.9 Option 32 ‘Configurator Details’

This option is not applicable to the Cobra note sorter.
7.10 Option 33 ‘Configurator Self Test’

This option is not applicable to the Cobra note sorter.
7.11 Option 34 ‘Configuration Verify’

7.12 Option 41 ‘RAM Test’

This option performs a non destructive test on the detector processor

RAM. The start address of each 16k bytes block of memory is displayed
as it is tested. Success or failure is reported as appropriate.
7.13 Option 42 ‘EPROM Checksum Test’

This option performs a checksum test on the detector processor

program EPROM. The actual EPROM checksum and the calculated
checksum are displayed together with a success or failure message.
Any difference in the two checksum values implies EPROM failure.
7.14 Option 00 ‘End’

menu (level 0)’.
Section 1 4000
Page 26 May 2001
SYSTEM DIAGNOSTICS
ACCESS AUTHORITY 0
para 7.1 7.2 7.3
11 12 13
Page 1 Change
Display View
Status Memory Memory
Access
Authority 0 0 3
para 7.4 7.5 7.6 7.7

21 22 23 24
Page 2
Show Engineers Test a Function Print Truth Table 1mm
Log Counter
Access
Authority 0 0 0 0
para 7.8 7.9 7.10 7.11

31 32 33 34
Page 3 Configurator Not Used

Configurator Configuration
Contents Details Verify
Access
Authority 0 0 0
para 7.12 7.13

41 42 00
EPROM
Page 4 END
RAM Test Check Sum
Test
Access
Authority 0 0
Figure 4 System Diagnostics Flow Chart
4000 Section 1
May 2001 Page 27
This page deliberately left blank
Section 1 4000
Page 28 May 2001
Start
Fail Fail Fail Fail

Pass
Note 1 Grade Grade Grade Grade Grade
0 1 2 3 15 Ungraded
Fail
Pass Pass Pass Pass
Cull Dest (1) Dest (2) Dest (15)
Fail Fail Fail Fail

Pass
0 1 2 3 15 Ungraded
Pass Pass Pass Pass

Fail
Fail Fail Fail Fail

Pass
0 1 2 3 15 Ungraded
Fail Pass Pass Pass Pass

Pass
Grade
Note 1 1
Fail
Pass
Note 2 Grade
1
Fail
Pass
Note 3 Grade
1
Fail
Unclassified
Figure 5 Detector Processor Decision Process

May 2001 Page 29
Page 30 May 2001
FUNCTION 3 ‘DETECTOR DIAGNOSTICS’
This function provides access to the detector diagnostic routines

provided for monitoring functions. The options provided are split into
two menu pages, movement between them being achieved by using the
right and left cursor keys.
Page 1
Det. Diagnostics 1 level 1)
List detector names 11
List trace measure codes 12
List cull text codes 13
List error codes 14
End 00
Change menu ->
Page 2
Det. Diagnostics 2 (level 1)
Show algorithm data 21
List algorithm text codes 22
Show DAC settings 23
Show audio calibration 24
End 00
<- change menu
Page 3
Det. Diagnostics 3 (level 1)
Detector Controller 31
Selection of the required option is made by entering the two- digit option
numbers from any page. A summary of the detector diagnostics is
given in the flow chart of Figure 6.
8.1 Option 11 ‘List Detector Names’

This option will provide a list of all detector numbers declared in the con-
figuration file together with the detector names.
8.2 Option 12 ‘List Trace Measure Codes’

8.3 Option 13 ‘List Cull Text Codes’

8.4 Option 14 ‘List Error Codes’

4000 Section 1
May 2001 Page 31
8.5 Option 21 ‘Show Algorithm Data’
Access authority required:0
This option enables the operator to determine how a particular detector

system has been configured for the current selected process. Detector
systems may be configured in one of two ways, the method of configu-
ration being determined by the type of detector.
Type 0 (e.g Soil, Holes-and-Tears)

Each of the detector systems is configured to perform certain process
dependent tasks (algorithms). Each detector system task consists of an
algorithm number plus a list of associated algorithm parameters. The
algorithm number defines the type of operation (e.g soil or tape). The
parameters are numerical constants which are accessed during the
execution of the algorithm. The significance and number of the
parameters is dependent upon the algorithm to which they relate.
The detector system produces a true or false reply, for each algorithm
and parameter combination. Each reply occupies a single bit in the
reply word associated with the detector in question. The significance of
each bit is determined by the time order in which the detector
configuration is performed. The first algorithm result is associated with
the least significant bit.
Type 1 (e.g Pattern)

For this type of detector, the system is simply sent a series of informa-
tion words that define a mode of operation. The detector reply is a 6 bit
code word that indicates the result of the operation. In the case of the
pattern detector the information words sent define the pattern sets
which are to be used. The reply word indicates the best pattern found
for a given note.
This utility allows the detector system algorithm data to be examined.

The data is presented in the time sequence observed during detector
configuration. It is therefore an essential tool in detector reply
interpretation.
8.6 Option 22 ‘List Algorithm Text Codes’

8.7 Option 23 ‘Show DAC Settings’

The detector system has 8 hardware D to A converters which are used

to set various detector thresholds (e.g doubles threshold). The contents
of the DAC’s (8 bit) are displayed when this option is selected.
8.8 Option 24 ‘Show Audio Calibration’

This option provides information on the calibration documents used to

set up the audio gain on the Limpness detector. This information is
used in the Limpness setting up procedure.
Section 1 4000
Page 32 May 2001
8.9 Option 31 ‘Detector Controller’
Option 11 ‘Controller Self Test’
This option enables a detector controller to be selected to perform its

self test diagnostic routine. On selection the operator is prompted to
enter the detector number in question. The results of the self test are
displayed on the screen. If the controller logs any faults, the fault report
menu is automatically presented.
Option 12 ‘Load Controller Errors’
Access authority required 0
This option enables any errors logged by the specified detector

controller to be displayed via the fault reporting menu.
Option 13 ‘Test Controller Comms’
This option enables the specified detector controller to detector

processor interface to be tested. The following tests are performed:
a) Test output FIFO - checks the operation of the control lines on the
detector processor output FIFO.
b) Test input FIFO - checks the operation of the control lines on the
detector processor input FIFO.
c) Communication loop check - detector processor transmits the

nibbles O - F, each of which is echoed by the controller. The
transmit/receive sequence is displayed as it occurs.
Option 14 ‘Controller Echo Test’
This option enables the operator to send a single 16 bit data word to a
detector controller. On selection the operator is prompted for the
controller number, the data word to be sent and the allowed timeout.
The detector controller response is displayed on the screen.
Note: The data word sent to the controller will only be echoed if it is a
valid function code. This option may cause several errors to be logged
depending on the data word sent.
Option 21 ‘Show Algorithm Data’
This option enables the operator to determine how a particular detector

controller has been configured for the current selected process.
Detector controllers may be configured in one of two ways. The method
of configuration is determined by the type of detector.
4000 Section 1
May 2001 Page 33
Type 0 (e.g. Soil, Holes and Tears).
Each of the detector controllers is configured to perform certain process
dependent tasks (algorithms). Each detector controller task consists of
an algorithm number plus a list of associated algorithm parameters.
The algorithm number defines the type of operation (e.g.soil, tape etc.)
The parameters are numerical constants which are accessed during the
execution of the algorithm. The significance and number of the param-
eters is dependent upon the algorithm to which they are associated.
The detector controller produces a true/false reply, for each algorithm/

parameter combination. Each reply occupies a single bit in the reply
word associated with the detector in question. The significance of each
bit is determined by the chronological order in which the detector
configuration is performed. The first algorithm result is associated with
the least significant bit.
Type 1 (e.g. pattern)

For this type of detector, the controller is simply sent a series of
information words that define a mode of operation. The detector reply
is a 14 bit code word that reflects the result of the operation (in the case
of the pattern detector the information words sent define the pattern sets
to be used. The reply word reflects the best pattern found for a given
note).
This utility allows the detector controller algorithm data to be examined.

The data is presented in the chronological sequence observed during
detector configuration. It is therefore an essential tool in detector reply
interpretation.
Option 22 ‘Reset ALL Controllers’
This option will force all detector controllers to perform a hard reset.
Any valuable data held by the detector controllers will be lost.
This option will also reset some of the detector processor hardware, as
a result the transport processor will log a detector processor communi-
cations fault and terminate the direct communications mode. Such ac-
tion will not corrupt data in the detector processor, which should recover
fully.
Option 23 ‘Controller Memory’
The memory contents of the detector controller specified are displayed.

The address from which memory examination is to commence is
requested, and may be any valid address within the memory map of the
detector controller concerned.
This function is very often used in the setting up of detectors, and allows
the sampled response from a detector for the last note traced, to be
displayed. For detailed information refer to the relevant detector service
manual. The response can be displayed as numerical data or as
graphical data.
Section 1 4000
Page 34 May 2001
The numerical format is byte orientated, with an address and 8 bytes of
data per line. Use of the right and left arrows allow the address to be
incremented and decremented respectively.
In graphical format, the memory contents are displayed horizontally, an

asterix representing the value of a location contents by its displacement
from the left margin. For printer display the Engineer is requested to
provide a scale factor.
Option 24 ‘Select Data Capture Mode’
This option enables a detector controller to be specified for data

capture. The detector controller selected must have an emulator
connected, with emulator RAM enabled at address 20000.
Option 31 ‘Show Engineer’s Log’
This option enables a detector controller’s engineer’s log to be

examined. The engineer’s log is a list of certain system faults which
result from illegal conditions being detected in the software/hardware.
Each entry consists of 22 long words and reflects the contents of the
processor stack at the time of the error routine being called.
If output to the printer is selected, the operator is requested for the

number of logs that are to be printed.
If output to the screen has been selected, data is output from the
engineer’s log start address and is formatted as an address followed by
8 data bytes. The operator then has the following options:
-> = display next 48 bytes
<- = display previous 48 bytes
DELETE = end operation
Option 32 ‘Set Controller Comms Log’
This option enables all communications between a detector controller

and the detector processor to be traced. On selection the operator is
prompted for the detector controller number and the communications
‘trace end’ word. All communications between the selected controller
and the detector processor are then logged until the ‘trace end’ word is
sent. The default ‘trace end’ communication word offered is the error
function code.
Option 33 ‘Show Controller Comms Log’
This option enables the controller’s communications log to be

examined. Each line of output is formatted as a suffix showing direction
of communication, the four individual nibbles which make up the word
communication and the decoded word. Tx implies data from detector
processor to detector controller, Rx implies the reverse.
4000 Section 1
May 2001 Page 35
Option 34 ‘Controller A/D Conversion’
This option enables a specified detector controller A/D conversion

results to be continuously displayed. Data is displayed for both channel
1 and 2 in decimal and hexadecimal formats. A counter showing the
number of conversions performed is also displayed to give an idea of
the conversion rate (approximately 3 per second).
Option 41 ‘List Trace Measure Codes’
This option will list all valid trace measure codes, together with the
associated text to either the screen or the printer.
Option 42 ‘List Algorithm Text Codes’
This option will list all valid algorithm codes together with the associated
text to either the screen or the printer.
Option 43 ’List Cull Text Codes’
This option will list all valid cull codes, together with the associated text
to either the screen or the printer.
Option 44 ‘List Error Codes’
This option will list all valid error codes, together with the associated text
(long and short) to either the screen or the printer.
Option 51 ‘List Detector Names’
This option will provide a list of all detector numbers declared in the
configuration file together with the detector name.
8.10 Option 00 ‘End’

menu (level 0)’.
Section 1 4000
Page 36 May 2001
DETECTOR DIAGNOSTICS
Access Authority 0
Page 1 Page 2 Page 3
11 12 13 14 21 22 23 24 31 0
List Detector List Trace List Cull List Error Show List Show DAC Show Audio Detector End
Names Measure Text Codes Codes Algorithm Algorithm Settings Calibration Controller
Codes Data Text Codes
Access
Authority3 0 0 0 0 0 0 0
Page 1 Page 2 Page 3 Page 4

11 12 13 14 21 22 23 24 31 32 33 34 41 42 43 44 51 00
Controller Test Show Controller Show Show List Trace List
Controller List Cull
Self Test Algorithm Memory Engineers Controller Measure Text Codes Detector End
Comms Data Log Comms Log Codes Names
0 Load 0 0 0 Select Data 0 Set 0 Controller 0 List 0 List Error 3

Controller Controller Reset All Capture Controller A/D Algorithm Code
Errors Echo Test Controllers Mode Comms Log Conversion Text Codes
0 0 0 0 0 0 0 0
Figure 6 Detector Diagnostics Flow Chart

May 2001 Page 37
Page 38 May 2001
FUNCTION 4 ‘TRACE DATA’
This function provides access to the detector processor data trace

routines. Specifically the trace facilities allow for the logging of data
associated with notes being fed. The detector system trace facilities are
presented on two pages, movement between them being achieved by
using the right and left cursor keys. The first page is concerned with
viewing trace data, the second with setting conditions for the trace
system.
Page 1
Data trace menu (level 1)
Examine note trace data 11
Examine histogram trace data 12
Examine trace measure table 13
End 00
Change menu ->
Page 2
Data trace menu 2 (level 1)
Set note trace conditions 21
Set up histogram trace 22
End 00
<- change menu
A summary of the trace data system is given in the flow chart of

Figure 7.
9.1 Trace System General Details

The trace system, by default, logs all detector replies for all notes fed.
Each detector reply comprises two 16-bit words. The first word is the
bit-wise reply to the algorithm results. The second word is reserved for
passing a measure code from the detector for tracing by the detector
processor. The most significant bit of the reply data is reserved for
detector culling. If this bit is set the note concerned is culled, the
remainder of the reply is given over to a cull reason code. In addition to
logging the detector replies, the following data is logged.
l note datum time
l note value (monetary value - for value balancing)
l note destination
l destination reason flags
The destination reason flags are used to store miscellaneous data

about conditions which have contributed to a note’s final destination.
The significance of the bits is as follows.
0 Data reduction over-run - detector processor ran out of time
whilst result calculation was in progress.
1 Detector cull - a detector cull bit was set.
4000 Section 1
May 2001 Page 39
2 Feed stop request bit pending - the detector processor had
requested a feed stop and was waiting for the transport to
comply.
3 Suspect - the note concerned was routed to a stacker
declared as a suspect stacker.
4 Transport processor cull - the transport processor culled the
note before it reached sensor E.
In addition to the normal note-by-note trace, a frequency histogram of

traced measures is available. From this data the distribution of a
population with respect to a particular measured attribute may be
examined.
It should be noted that the trace buffer is cleared at each feed start and
at process selection.
9.2 Option 11 ‘Examine Note Trace Data’

This option enables the operator to display either all entries in the trace
buffer or only those with a specific destination.
After selecting which notes are to be displayed the following menu is

displayed, for example.
Note 0 Datum time 20642
Destination 0 Note value 0000
Culled by detector 1
Det. reply data = ENTER exit = CLEAR
Change note <- -> Truth = DOWN
Note - defines the note position within the trace buffer. Note 0 is the
latest note to be traced, with subsequent notes numbered -1, -2, -3 and
so on. The operator is always presented with the latest note first.
Selection of other notes in the trace buffer is made using the ‘<-’ and
‘->’ cursor keys (less and more recent respectively).
Datum time - this is the note’s datum time with respect to sensor A. It
may be used to cross refer detector processor trace data with transport
processor trace data.
Destination - this defines the note destination as supplied to the

transport processor. Note - this may not correspond with the note’s final
destination, if for example the transport decides to cull the note or use
an alternative stacker.
Note value - the note’s monetary value is displayed as a hexadecimal

number representing the mantissa and exponent (one byte each).
The third and fourth lines are reserved to explain the destination reason
flags. These lines will be blank if no destination reason flags are set.
Section 1 4000
Page 40 May 2001
Pressing ‘ENTER’ enables the detector replies and measures for the
current note to be examined. The data is formatted as follows.
do1 do2 do3 do4

PATT UV THIK HOLE
reply (HEX) 0004 0000 0000 0008
(DEC) 4 0 0 0
meas (HEX) 0001 0000 0000 0096
1 0 0 150
A detector entry of ‘xxxx’ implies that the corresponding detector is not

used for the selected process. Typing ‘->’ will scroll on to a second page
of detector reply, if there are more than four detectors in the system, or
return to the note selection level.
‘DOWN’ (shift keys) enables the truth tables results to be examined.

This option functions in the same manner as the ‘Show truth table’
option under system diagnostics, except that the result of each
algorithm is shown. For example:
Note number: 6002
Grade: 3
Reduction AND, fail
Destination 2
d01........1111.0 PATT
d02.........1.0.0 THIK
The detector replies that are required to categorise a note for this grade
are listed as a bitwise representation of the detector response. Each bit
of a reply is the result of a single criterion. A “.” in any position implies
that the reply associated with that position is of no significance. A ‘1’ in
any position implies that the algorithm associated with that position
passed the required test, a ‘0’ implies a failure. The overall result for the
note or grade being examined is displayed after the data reduction type.
The detector processor decision process is shown in Figure 5.
If a printed copy of the note trace data has been requested, the number
of trace entries to be output is requested. The print-out shows the most
recent note entry in the buffer at the top of the list. Each note trace entry
is formatted to occupy four lines on the print-out. Only those detectors
in use are included in the list. A typical note entry will be listed as
follows.
d01 d02 d03 d04

PATT UV THIK HOLE datum flag dest value
Reply (HEX 0001 0000 0002 0003 32398 0000 2 0000
(DEC) 1 0 2 3
Meas (HEX) 0000 0000 0000 0096
(DEC) 0 0 0 150
4000 Section 1
May 2001 Page 41
9.3 Option 12 ‘Examine Histogram Trace Data’
This option enables the detector histogram data to be displayed. The
histogram must previously have been defined, using the ’set up
histogram trace’ option (paragraph 9.6). A histogram display begins
with a data table. For example:
5 detector number
22 trace measure number
1000 notes traced
1 under range
0 over range
138 histogram median
The trace measure number reflects the selected measure which the
detector has been returning for tracing. The under and over range
numbers define the total number of notes that were outside the defined
range of the histogram. The histogram median corresponds to that
measure which effectively splits the population into two equal totals.
The option of clearing down the accumulated histogram data (e.g. after
each run) is offered.
The histogram itself is displayed as follows.

135 0 0%
136 15 1% *
137 45 6% ****
138 200 26% ********************
139 240 50% ************************
140 210 71% *********************
141 160 87% ****************
142 100 97% **********
143 20 99% **
144
145 9 100% *
146
147
In the first column is displayed the measure value. The second column
represents the number of entries for the associated measure value.
The third column depicts the percentage of the total number of notes
traced has so far been plotted, including the current row. Finally a visual
bar chart representation of the number of notes falling into each
measured category is displayed. The number of stars in each column
is scaled according to the requirements of the most populated category.
9.4 Option 13 ‘Examine Trace Measure Table’

This option displays the trace measure table which holds all the trace
measures from all the detectors but only for the last note fed. The ‘<-’
and ‘->’ cursor keys are used to scroll through the table and the ‘CLEAR’
key is used to exit from the table. The trace numbers are displayed in
the LH column. Table 1 lists some of the basic trace measures currently
implemented.
Section 1 4000
Page 42 May 2001
TABLE 1 : TRACE MEASURE DATA
Measure Description Measure Page No.
No.
THICKNESS
(not used) 1 page 1
doubles channel 1 count 2
doubles channel 2 count 3
thickness prime error 4
HOLES AND TEARS

note length (h+t) 5
h+t prime error 6
U.V. BRIGHT
UV Bright count 7 page 2
MAG INK
mag ink count 8
MAG THREAD
thread 1 start 9
thread 1 end 10
thread 2 start 11
thread 1 centre 12
METAL THREAD
thread 1 start 13 page 3
thread 1 end 14
thread 2 start 15
thread 1 centre 16
ITALIAN MAG INK for 100K

Italy mag ink window samples 17
Italy mag ink other samples 18
Italy mag ink first sample 19 page 4
LENGTH
note length 20
length prime error 21
Inboard singles average 23 page 4
(cont.)
Inboard doubles average 24
4000 Section 1
May 2001 Page 43
TABLE 1 : TRACE MEASURE DATA (continued)
No.
Outboard singles average 25
Outboard doubles average 26
Result for thick setup 27 page 5
Metal thread thread 1 start 28
Metal thread thread 1 end 29
Metal thread thread 2 start 30
Metal thread thread 1 centre 31
l.e. miss. corner size 32
t.e. miss. corner size 33 page 6
Hole type 34
Diamond hole size 35
MRTA thread position 36
ENHANCED THICKNESS DETECTOR

Peak no-note level CH1 37
Peak no-note level CH2 38
Note level CH1 39 page 7
Note level CH2 40
Rolling average level CH1 41
Rolling average level CH2 42
pk/pk no-note noise CH1 43
pk/pk no-note noise CH2 44
Computed singles threshold CH1 45 page 8
Computed singles threshold CH2 46
Computed doubles threshold CH1 47
Computed doubles threshold CH2 48
Leading cornerfold size 49
Trailing cornerfold size 50
Tape size 51 page 9
Cross tape size 52
Gap increase CH1 53
Gap increase CH2 54
Twin mag. ink count 55
H&T average lamp ref. level 56
H&T nominal width measure 57 page 10
H&T length of missing leading corner 58
H&T length of missing trailing corner 59
Section 1 4000
Page 44 May 2001
TABLE 1 : TRACE MEASURE DATA (continued)
No.
H&T leading corner threshold 60
H&T trailing corner threshold 61
H&T mm of screw adjustment 62
SURF detector reply 63 page 11
9.5 Option 21 ‘Set Note Trace Conditions’

This option enables the operator to define which type of notes to be
traced. Selection of this option leads the operator through three
sub-menus. Each sub-menu offers the option to specify one or more
conditions for a note to be traced.
menu 1
Destination ? -
0006
0000000000000110
End ->
This menu enables the operator to define a bit mask corresponding to

those destinations whose notes are to be traced. The cull is denoted as
stacker 0 and occupies the least significant bit in the mask. The bit
mask as shown would trace only those notes whose destination was
stacker 1 or 2.
menu 2
Red’n over run 1: Detector cull 2
Feed stop req 3: Suspect 4
Transport cull 5: -
08
01000
End ->
This menu enables the operator to define which type(s) of note is to be

traced. For example, the bit mask as shown would trace suspect notes
only.
menu 3
Detector number 3
Trace measure number? 0
This menu enables the operator to define the trace measure number for
each detector configured for the currently selected process. This
measure will be returned by the detector as part of its reply. It will be
traced, both in the note trace buffer and in the histogram for this detector
(if defined). Typing ‘ENTER’ without changing the trace measure
number or ‘->’ will move the display on to the next detector number.
4000 Section 1
May 2001 Page 45
9.6 Option 22 ‘Set Up Histogram Trace’
This option enables the operator to define the structure of a detector
measure histogram. The operator is prompted to enter the following
information.
1. Detector number
2. Minimum measure value to be traced
3. Maximum measure to be traced
4. Resolution of the histogram (difference between
adjacent histogram columns)
5. Detector trace measure number to be traced
Section 1 4000
Page 46 May 2001
TRACE DATA ı
AUTHORITY 0ı
Page 1ı Page 2ı
11ı 12ı 13ı 21ı 22ı 00ı
Examine Nota ı Examine ı Examine Trace ı Set Note Trace ı Set Up ı ENDı
Trace Dataı Histogram ı Measure Dataı Conditionsı Histogram ı
Trace Dataı Traceı
0ı 0ı 0ı 0ı 0ı
Access ı
Authorityı
Figure 7 Trace Data Flow Chart
4000 Section 1
May 2001 Page 47
Section 1 4000
Page 48 May 2001
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Figure 1 Thickness Detector
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LVDT Armature
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LVDT
LVDT Armature
bearing assembly
Sensor roller
Direction of travel
Reference roller
Banknote
Figure 2 Essential Elements of the Detector Head
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SIGNALS
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SK3 SK4
PL3 PL4
SCHEDULE 8 Front-end board
PL1 PL2
SCHEDULE C SK1 SK1 SCHEDULE
Outboard LVDT Inboard LVDT
START TRACKING
SCHEDULE 1
SK1
J1
Detector
processor J4
PL17 SK17
Power supply
J5
Detector interface
board Mother/distribution
board
Figure 3 General Block Diagram
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Figure 4 Functional Block Diagram
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i=áåâI=ihNI=Åçåíêçäë=íÜÉ=~Åíáçå=çÑ=ÄçíÜ=çÑÑëÉí=Åçåíêçä=ÅáêÅìáíë=~ë=ÑçääçïëW
~F ihN=áå=qê~Åâ=éçëáíáçåW==íÜÉ=aÉíÉÅíçê=mêçÅÉëëçê=Åçåíêçäë=íÜÉ=ÅáêÅìáí=
ïÜÉå=~å=çÑÑëÉí=~ÇàìëíãÉåí=áë=Å~êêáÉÇ=çìíI=Äó=áëëìáåÖ=~=Lpqôq=
qo^`hfkd=éìäëÉ=EçåÉJëÜçí=ãçÇÉFK
ÄF ihN=oÉãçîÉÇW==íÜÉ=çÑÑëÉí=Åçåíêçä=ÅáêÅìáí=áë=Åçåíáåìçìëäó=~ÅíáîÉ=
EÑêÉÉJêìå=ãçÇÉFK
ÅF ihN=få=kl=qo^`h=éçëáíáçåW==íÜÉ=çÑÑëÉí=Åçåíêçä=ÅáêÅìáí=áë=Çáë~ÄäÉÇK
aìêáåÖ=åçêã~ä=çéÉê~íáçåI=~=Lpqôq=qo^`hfkd=Åçãã~åÇ=áë=áëëìÉÇ=çå=
É~ÅÜ=ÑÉÉÇëí~êí=Äó=íÜÉ=aÉíÉÅíçê=mêçÅÉëëçêK==fÑ=íÜÉêÉ=áë=~åó=ÇêáÑí=áå=íÜÉ=
åçJåçíÉ =äÉîÉä=ÇìêáåÖ=êìååáåÖI=ÅáêÅìáíêó=çå=íÜÉ=aÉíÉÅíçê=fåíÉêÑ~ÅÉ=Äç~êÇ=
ã~áåí~áåë=íÜÉ=çÑÑëÉí=~í=HNKMs==íÜÉêÉ~ÑíÉêK
qÜÉ=éêáã~êó=ìëÉ=çÑ=íÜÉ=iba=~êê~óë=çå=íÜÉ=cêçåíJÉåÇ=Äç~êÇ=áë=íç=áåÇáÅ~íÉ=
ïÜÉå=é~Ç=êÉéä~ÅÉãÉåí=áë=åÉÅÉëë~êóK==^ë=íÜÉ=é~Çë=ïÉ~êI=íÜÉ= åçJåçíÉ ==
äÉîÉä=êÉÇìÅÉë=~åÇ=áë=ÅçãéÉåë~íÉÇ=Ñçê=Äó=áåÅêÉ~ëÉÇ=çÑÑëÉí=ÅçåíêçäK==tÜÉå=
~ää=íÜÉ=iba ë=~êÉ=lk=EÅçêêÉëéçåÇáåÖ=íç=íÜÉ=ã~ñáãìã=äáãáí=çÑ=çÑÑëÉí=
ÅçåíêçäFI=íÜÉ=é~Çë=ãìëí=ÄÉ=êÉéä~ÅÉÇK
^=ëÉÅçåÇ~êó=ìëÉ=çÑ=íÜÉ=iba=~êê~óë=áë=~ë=~=Çá~ÖåçëíáÅ=íççäK==táíÜ=ihN=
êÉãçîÉÇ=EÑêÉÉJêìå=ãçÇÉFI=~=Çáëéä~ÅÉãÉåí=çÑ=íÜÉ=êçääÉêë=ïáää=Å~ìëÉ=~=
ÅÜ~åÖÉ=áå=íÜÉ=iba=~êê~ó=ëí~íÉK==^=ÅÜ~åÖÉ=çÑ=íÜÉ=ip_=EiÉ~ëí=páÖåáÑáÅ~åí=
_áíF=çåäó=ÅçêêÉëéçåÇë=íç=~ééêçñáã~íÉäó=MKMNãã=ÅÜ~åÖÉK
fÑ=ÄçíÜ=isaq ë=~êÉ=ÅçååÉÅíÉÇ=íç=íÜÉ=Ñêçåí=ÉåÇ=Äç~êÇI=~=Lobâv=ëáÖå~ä=
áë=ÖÉåÉê~íÉÇ=Äó=íÜÉ=cêçåíJÉåÇ=Äç~êÇ=~åÇ=é~ëëÉÇ=íç=íÜÉ=aÉíÉÅíçê=
mêçÅÉëëçêK==fÑ=íÜÉ=Lobâv=ëáÖå~ä=áë=ãáëëáåÖI=íÜÉ=aÉíÉÅíçê=mêçÅÉëëçê=
áëëìÉë=~= èb`h=aq =ãÉëë~ÖÉK=== aq =áë=íÜÉ=ëóëíÉã ë=~ÄÄêÉîá~íáçå=Ñçê=
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OKQ táêáåÖ=pÅÜÉÇìäÉë
pÅÜÉÇìäÉ=_=J=qÜáÅâåÉëë=aÉíÉÅíçê=`~ÄäÉ
táêÉ=åç `çäçìê cêçã qç cìåÅíáçå
N _êçïå phN=L=NM phP=L=R HNRs
O oÉÇ phN=L=S phP=L=P H=Rs
P lê~åÖÉ phN=L=NN phQ=L=P èO=ef
Q vÉääçï phN=L=NO phQ=L=Q èO=il
R dêÉÉå phN=L=NQ phQ=L=R Lpqôq=qo^`hfkd
S _äìÉ phN=L=R phQ=L=S Lobâv
T sáçäÉí phN=L=NP phP=L=S JNRs
U dêÉó= phN=L=V phQ=L=O èN=il
V tÜáíÉ phN=L=U phQ=L=N èN=ef
NM _ä~Åâ phN=L=P phP=L=O Ms
NN Ää~Åâ pòbbk phN=L=N aê~áå
m~ÖÉ=U j~ó=OMMN
pÅÜÉÇìäÉ=`=J=isaq=iÉ~Ç=`~ÄäÉë
N oÉÇLvÉääçï phqN=L=N isaq lëÅK=Eéêáã~êóF
O oÉÇ phqN=L=O isaq isaq=ëáÖK=EëÉÅçåÇ~êóF
P _äìÉ phqN=L=P isaq `ÉåíêÉ=í~é=EëÉÅçåÇ~êóF
Q _ä~Åâ phqN=L=Q isaq Lisaq=ëáÖK=EëÉÅçåÇ~êóF
R _ä~ÅâLvÉääçï phqN=L=R isaq Llp`K=Eéêáã~êóF
S dêÉÉå= phqN=L=S isaq `ÉåíêÉ=í~é=EëÉÅçåÇ~êóF
T dêÉó= phqN=L=T phqN=L=U Lobâv=ifkh
pÅÜÉÇìäÉ=f=J=gN=jçíÜÉêÄç~êÇ=`çååÉÅíáçåë
gN qç cìåÅíáçå
N
R pâP=L=OQ`
U pâP=L=OP`
V pâP=L=OO`
NM miNT=L=V
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NO pâP=L=OM`
NP miNT=L=U
NQ pâQ=L=NS_
j~ó=OMMN m~ÖÉ=V
PK c^riq=cfkafkd=drfab
fÑ=~=Ñ~ìäí=áë=ëìëéÉÅíÉÇ=áå=íÜÉ=qÜáÅâåÉëë=aÉíÉÅíçêI=Ñáêëí=îÉêáÑó=íÜ~í=íÜÉ=Ñ~ìäí=
áë=êÉéÉ~í~ÄäÉ=~åÇ=áë=~=ÇÉíÉÅíçê=Ñ~ìäíI=åçí=~=íê~åëéçêí=Ñ~ìäíK==fÑ=íÜÉ=Ñ~ìäí=áë=
êÉéÉ~í~ÄäÉI=Å~êêó=çìí=íÜÉ=áåáíá~ä=ÅÜÉÅâë=ÇÉí~áäÉÇ=áå=q~ÄäÉ=NK==fÑ=íÜÉ=Ñ~ìäí=
éÉêëáëíëI=Ñçääçï=íÜÉ=Çá~ÖåçëíáÅ=Ñäçï=ÅÜ~êí=áå=cáÖìêÉ=RK
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íçê=ÇêáîÉ=ÄÉäíI=~åÇ=~Çàìëí=áÑ=åÉÅÉëë~êóK
isaq=~êã~íìêÉ=ÇçÉë=åçí=ãçîÉ=ÑêÉÉäó=áå= ^Çàìëí=íÜÉ=éçëáíáçåáåÖ=çÑ=íÜÉ=~êã~íìêÉ=áÑ=
isaq=ÄçêÉK éçëëáÄäÉK==líÜÉêïáëÉ=êÉåÉï=íÜÉ=~êã~íìêÉ=
~åÇ=íÜÉ=isaqK
isaq=~êã~íìêÉ=ÄÉ~êáåÖ=é~Ç=áë=ïçêå=çìí= oÉåÉï=íÜÉ=~êã~íìêÉ=ÄÉ~êáåÖ=é~Çë=çÑ=ÄçíÜ=
EÜáÖÜ=iba=ÅçìåíFK isaq ëK
cêçåíJÉåÇ=Äç~êÇ=áë=åçí=ÅçååÉÅíÉÇ=íç=íÜÉ= j~âÉ=éçëáíáîÉ=ÅçååÉÅíáçåë=Ñêçã=íÜÉ=cêçåíJ
jçíÜÉêLÇáëíêáÄìíáçå=Äç~êÇK ÉåÇ=Äç~êÇ=íç=íÜÉ=jçíÜÉêLÇáëíêáÄìíáçå=
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Ö~é=áë=ÅäçëÉÇ ÖìáÇÉK
PKN qÉëí=mçáåíë
qÜÉ=íÉëí=éçáåíë=ïÜáÅÜ=éêçîáÇÉ=~å=~áÇ=íç=ëÉêîáÅáåÖ=~êÉ=ÖáîÉå=áå=q~ÄäÉ=OW
q~ÄäÉ=OW=qÉëí=mçáåíë
qÉëí=éçáåí qÉëí=éçáåí cìåÅíáçå
E`Ü~ååÉä=NF E`Ü~ååÉä=OF
qmON qmU mêÉJ~ãé=~åÇ=ÑáäíÉê=çìíéìí
qmPV qmQN ^å~äçÖìÉ=ÅçìåíÉê=çÑÑëÉí
qmOM qmT ^å~äçÖìÉ=çÑ=åçíÉ=íÜáÅâåÉëë
qmN qmN Ms
m~ÖÉ=NM j~ó=OMMN
START
Repeat Setting-up
procedure
Temporarilly remove LK1 and

Yes Is Fault No observe Front-end board LED's.
repaired? Move upper roller by winding a note
through the transport
END
Yes Any change in LED

readings?
No
Yes Is upper roller

moveable?
Yes No
Is LVDT armature free to
move in bore?
Check condition of
No suspension rollers
and renew if
necessary
Renew armature
and LVDT if
necessary
No
Is fault repaired?
Yes
Is fault repaired?
Yes
No
START
Renew Front-end
board
START
Yes
Is fault repaired? START
No
Renew Interface board, and

then Detector processor board.
Consult Technical Services if
Fault persists.
Figure 5 Fault Diagnostic Routine
j~ó=OMMN m~ÖÉ=NN
QK pbqqfkdp=^ka=âgrpqjbkqp
pÉííáåÖë=~åÇ=~ÇàìëíãÉåíë=~êÉ=ÇÉëÅêáÄÉÇ=Ñçê=íÜÉ=ÑçääçïáåÖ
l fåÄç~êÇ=~åÇ=çìíÄç~êÇ=åçíÉ=Éåíêó=ÖìáÇÉë
l båíêó=êçääÉêë
l ^ãéäáÑáÉê=Ö~áå
l pÉåëçê=êçääÉê=Ö~é
l isaq=Åçáä=éçëáíáçå
QKN ^ãéäáÑáÉê=d~áå=~åÇ=pÉåëçê=oçääÉê=d~é
Note: If any part of the procedures described in paragraphs 3.6 or 3.7

fails, set the links, amplifier adjusters and roller gaps in accordance with
the instructions in paragraph 3.8. On completion repeat the procedures
described in paragraphs 3.6 and 3.7.
mêÉé~êÉ=íÜÉ=`çÄê~=QMMQ=íç=Å~äáÄê~íÉ=íÜÉ=qÜáÅâåÉëë=aÉíÉÅíçê=~ë=ÑçääçïëK
~F mêçÖê~ã=íÜÉ=`çÄê~=QMMQ=Ñçê=qÜáÅâåÉëë=Å~äáÄê~íáçå=éêçÅÉëë=PPQT==
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ÄF båíÉê=íÜÉ=íÜáÅâåÉëë=î~äìÉë=çÑ=íÜÉ=`~äáÄê~íáçå=qÉëí=kçíÉ=Em~êí=kçK=
PTPVNNPNMNF=ìëáåÖ=aÉíÉÅíçê=aá~ÖåçëíáÅ=ÑìåÅíáçå=cUK
ÅF lêáÉåí~íÉ=íÜÉ=`~äáÄê~íáçå=qÉëí=kçíÉ=ëç=íÜ~í=áí=ïáää=ÑÉÉÇ=áåíç=íÜÉ=`çÄê~=
QMMQ=ÖêÉó=EëáåÖäÉ=íÜáÅâåÉëëF=ÉåÇ=ÑáêëíK==rëÉ=qÜáÅâåÉëë=Å~äáÄê~íáçå=
éêçÅÉëë=PPQT=íç=ÑÉÉÇ=íÜÉ=åçíÉ=íÜêçìÖÜ=íÜÉ=íÜáÅâåÉëë=ÇÉíÉÅíçêK
ÇF lÄëÉêîÉ=íÜÉ=Çáëéä~ó=~åÇ=åçíÉ=íÜÉ=êÉëìäíK==qÜÉ=ÑçääçïáåÖ=Éñ~ãéäÉ=áë=
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Figure 6 Example of Calibration Result Screen
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P qçí~ä=ÇçìÄäÉë=Åçìåí=èO=EåçåJÅçåíáÖìçìëF=EããF
Q mêáãáåÖ=Éêêçê=EëÉÉ=kçíÉ=NF
PT mÉ~â=åçJåçíÉ=äÉîÉä=èN
PU mÉ~â=åçJåçíÉ=äÉîÉä=èO
PV ^Åíì~ä=åçíÉ=äÉîÉä=èN
QM ^Åíì~ä=åçíÉ=äÉîÉä=èO
QN oçääáåÖ=~îÉê~ÖÉ=äÉîÉä=èN
QO oçääáåÖ=~îÉê~ÖÉ=äÉîÉä=èO
QP mâJmâ= êìåJçìí =èN=EëÉÉ=åçíÉ=OF
QQ mâJmâ= êìåJçìí =èO=EëÉÉ=åçíÉ=OF
QR `çãéìíÉÇ=ëáåÖäÉë=íÜêÉëÜçäÇ=èN
QS `çãéìíÉÇ=ëáåÖäÉë=íÜêÉëÜçäÇ=èO
QT `çãéìíÉÇ=ÇçìÄäÉë=íÜêÉëÜçäÇ=èN
QU `çãéìíÉÇ=ÇçìÄäÉë=íÜêÉëÜçäÇ=èO
QV iÉ~ÇáåÖ=ÅçêåÉê=ÑçäÇ=ëáòÉ=EããF
RM qê~áäáåÖ=ÅçêåÉê=ÑçäÇ=ëáòÉ=EããF
RN q~éÉ=ëáòÉ=EããF
RO `êçëë=í~éÉ=ëáòÉ=EããF
RP d~é=áåÅêÉ~ëÉ=èN=EëÉÉ=åçíÉ=OF
RQ d~é=áåÅêÉ~ëÉ=èO=EëÉÉ=åçíÉ=OF
Note: 1.The priming error is the difference between the detected note
leading edge position and the position based on priming. This error is
a signed byte, e.g 2 =+2, 1 = +1, FF = -1, FE = -2 etc
A positive priming error means that the actual note position is late with
respect to the priming. Should the priming error exceed +12, the note
is culled (8000 or 8001) and no trace measures are recorded.
Note: 2. To convert to microns, divide by 0.64.
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Section 4
___________________________
Vision Detector

May 2001 Page 1
CONTENTS
Para Page
1. BRIEF DESCRIPTION 4
______________________________________________
2. PRINCIPLES OF OPERATION 5
2.1 Structure 5
2.2 Detector Head 6
2.3 ISA Interface Card 7
2.4 PC Card 7
2.5 System PSU 7
______________________________________________
3. FAULT-FINDING GUIDE 8
______________________________________________
4. SETTINGS AND ADJUSTMENTS 8
4.1 Adding/Replacing a Captured Note Image 8
4.2 Masking Out 9
4.3 To Add a Note 10
4.4 Links, Switches, Connectors & Configuration 10
4.5 Pattern Controller PCB 10
4.6 VISION System 11
______________________________________________
5. ROUTINE MAINTENANCE 16
5.1 Operator Undertaking 16
5.2 Service Engineer Undertaking 16
5.3 Service Engineer Undertaking (calibration) 17
5.4 Off-site Service 23
______________________________________________
6. REMOVAL AND REPLACEMENT 23
6.1 Detector Head 23
6.2 Vision PC 24
______________________________________________
7. ILLUSTRATED PARTS LIST 25
______________________________________________
Tables
Table 1 Fault Finding Guide 8
______________________________________________
Table 2 Result Codes 20
______________________________________________

Page 2 May 2001
Illustrations
Figure 1 Vision Detector in Cobra 4004 Chassis 4
______________________________________________
Figure 2 Vision System - Block Diagram 5
______________________________________________
Figure 3 Vision Detector Head 6
______________________________________________
Figure 4 Pattern Controller Configuration 10
______________________________________________
Figure 5 Note Images Captured Before & After Calibration 17
______________________________________________
Figure 6 VISION Captured Image of Calibration Document 18
______________________________________________
Figure 7 Code 0x000/0x400 Calibration Successful 21
______________________________________________
Figure 8 Code 0x0001/0x4001 - Minimum Amplitude
Error Detected 21
______________________________________________
Figure 9 Code 0x0002/0x4002 - Maximum Amplitude
Error detected 22
______________________________________________
Figure 10 Code 0x0003/0x4003 - Maximum Deviation
Error Detected 22
______________________________________________
Figure 11 Vision Head Location 23
______________________________________________
Figure 12 Vision PC 24
______________________________________________
Figure 13 Vision Detector 25
______________________________________________

May 2001 Page 3
1. BRIEF DESCRIPTION
Vision Detector
Figure 1 Vision Detector in Cobra 4004 Chassis
The Vision detector is designed to provide a range of note detection

functions. The standard functions are; sorting by denomination, facing
and orientation and out–sorting suspect/un–recognized notes. Vision
utilises the visible reflected light from an illuminated banknote to build a
two dimensional image of the document. This image is processed and
compared with a range of pre–captured ‘sample’ notes held in the
Vision system database to provide a ‘best match’ answer as to the type
of document passing under the detector head.
The ‘best match’ figure is a value representing features which correlate

between the live note and the database image. If this value does not
exceed a pre–determined threshold then no match is found and the
note is culled.
Additional detection functions are available after appropriate hardware

and software changes. The additional functions are graffiti detection,
and a range of detection specifically intended for newly printed pre–
issue documents. The range includes accurate print position detection,
missing and smudged print detection, serial number positional
detection, and visual thread positional detection.
The additional positional functions are achieved by performing

searches of the captured image for correlation with reference
templates. Graffiti, missing and smudge print detection is achieved by
comparing the captured image to reference images. These additional
functions are normally performed at reduced pixel resolution, due to
processing time restrictions.

Page 4 May 2001
2. PRINCIPLES OF OPERATION
2.1 Structure
The Vision detector comprises five main hardware elements:
l Head CCD Array PCB
l Head Motherboard
l ISA Interface Card
l PC Card
l System PSU
A block diagram of the Vision system is shown in Figure 2 which shows

the elements of the Vision system and their relationship to the DLRS
Pattern Card running the Third Party Detector (TPD) interface
algorithm.
The Vision detector is isolated from the system into which it is integrated
by means of optical isolation for the Note Present and Transport Clock
interface signals. The detector also has a separate floating DC power
supply.
The Vision detector comprises the following main assemblies:
l Detector Head
l PC Chassis
Figure 2 Vision System - Block Diagram

May 2001 Page 5
2.2 Detector Head
The Detector Head comprises:
l A machined enclosure, length 192.95mm (219.95 including connec-

tor at rear), width 113.2mm, height 96mm (see Figure 2).
l A line scan CCD array plus interface electronics together with its
mounting system, adjustment mechanisms and lens assembly.
l A light source.
l An optical prism.
l An optical filter.
Figure 3 Vision Detector Head
a) Enclosure
The enclosure is painted black to minimise internal reflected light
and is sealed to provide dust–proofing. Separate electrical
connections are provided for:
Head power – circular multi-pole connector
CCD data – 50-way SCSI2 connector
b) CCD Array
The CCD array comprises a linear group of photo–diodes or
sensing elements. Each photo–diode produces a charge
proportional to the light incident upon it.
c) Visible Light Source

The light source uses 2 miniature 12 volt Halogen lamps wired in
parallel. The 12V supply for the lamps is provided by the PC switch
mode PSU and distributed via the ISA card fitted to the Vision
system PC chassis.
The lamps are fitted immediately above the glass prism and are
focused onto the nominal centre line of the sensing elements of the
CCD array.

Page 6 May 2001
d) Optical Prism
The optical prism is a conduit for the light illuminating the passing
banknote. The prism also carries the light reflected from the
document.
e) Head Motherboard
The head motherboard provides an interface to the CCD array and
an A/D converter which digitises the CCD information captured for
transmission to the system ISA interface card. The head mother-
board communicates with the ISA interface card through the 50 way
SCSI2 connector.
2.3 ISA Interface Card

The ISA Interface card buffers the data from the Head. The card also
interfaces to the PC via the ISA bus.
Communication with the Head is via a 50-way SCSI 2 connector. Data

transfer to the PC card is over the ISA bus at 8MHz.
2.4 PC Card
The PC card is a complete PC system with serial and parallel I/O, VGA
output and disk interfaces. The applications software uses the data
from the ISA Interface card. All software runs under Windows 95
operating system.
The PC has one serial port (COM2) dedicated to the Third Party
Detector interface, which is a conduit for detection setup instructions to
the PC and for detection results in the other direction. A higher
specification PC card is required for the additional detection functions
listed in paragraph 1.
2.5 System PSU

One 150W switch mode PSU provides DC power for all the Vision
system components. The input is 85–135V/180–265V AC and the
output produced is ±5V and ±12V.

May 2001 Page 7
3. FAULT-FINDING GUIDE
Table 1: Fault Finding Guide
Sorter Fault name Description Possible causes
Fault
Code
X067 TPDE_TIMEOUT VISION did not supply 1. VISION RS232 connection to

an expected status sorter disconnected.
message.
X068 TPDE_NO_RESULT VISION did not supply 1. VISION RS232 connection to
an expected note sorter disconnected.
result. 2. Pattern controller expecting
VISION response too early
(Calculate P26 parameter in
VISION criteria).
All other faults must be referred, in the first instance, to the DLR service
department. Detector Processor faults (those formatted X9XX) are not
covered here.
4. SETTINGS AND ADJUSTMENTS
4.1 Adding/Replacing a Captured Note Image

Important note : After capturing or recapturing notes, all files with
extensions ‘.nfl’, ‘.512’ and ‘.bdb’, together with the ‘BNoteDAQ.ini’ file
should be sent to: The Pattern Capture Dept, De La Rue Ltd,
Walton Road, Portsmouth:
The ‘BNoteDAQ.ini’ file is found in the windows directory, the other files
are in the ‘country’ directory in c:/databases.
To add a note to the pattern set:
Note: The configurator will require a change for the machine to be able
to recognise and process the note. The new note must be evaluated for
any features that other detectors will be expected to detect.
a) Connect a PS2 keyboard and mouse to the VISION computer.
b) Connect a VGA monitor to the VISION computer.
c) Power up the host machine and VISION.
d) Close down BnoteDaq (cntrl C).
e) In order to recover from any possible problems carry out the

following:
Use Windows Explorer to create a directory in C:\databases\ ***
called Old (where *** = the country directory)
Go to the country directory and click the right mouse button to select
all of the files. Hold down the mouse button and place the pointer
above the directory called old and release the mouse button.

Page 8 May 2001
Several options are available; select Copy. Duplicate files are
added to the new directory.
If there is a problem, recovery can be made by repeating copying
the files from the Old directory back into the country directory.
f) Open the VISION test program (on screen Icon).
g) Enter E0 process on the host machine.
h) Select the GO button on the tool bar in the Vision test program.
i) Feed the note through the host machine in face A.
j) Confirm that the captured image of the note does not have any
irregularities or defects and that there are green lines on all four
edges. Also check that it is possible to zoom in and out of the image
using the mouse buttons.
k) Save the file (all text in bold must be entered as shown).

The path should take the format C:\databases\***\****
where *** = the country directory (find name using Windows
Explorer)
and **** = description of the captured note
value_description_date or issue number_face
ie 10_poundUK_99_front
The term _back or _front must be used at the end,
for example C:\databases\England\10_poundUK_99_front
l) Repeat with face C of the note (back).
m) Minimise the test program window.
4.2 Masking Out

‘Masking out’ enables areas of the note to be ignored by the Vision
detector. This reduces the impact of areas that change from one note
to another (serial numbers, signatures etc).
To mask areas out proceed as follows:
a) Open the TEST program.
b) Select f the FILE menu and go to the file to be masked and open it.
Use the mouse buttons to zoom in and out of the note image.
c) Select MR from the top menu bar.
d) Place the mouse pointer over the area to be masked and hold down
the left mouse button whilst dragging over the area to be masked
(the area will go purple, although some areas may look as though
they have been missed).
To unmask areas use the right mouse button.
e) When the desired result is achieved, save the file and forward a
copy of the file to the Pattern Capture Department.

May 2001 Page 9
4.3 To Add a Note
If it is intended to add a note to the Vision detector, the request is
processed by Walton Road and the files will be returned along with an
updated configurator. The addition of a note to the configurator will
require a configurator rewrite.
If the note has not been evaluated before (security features, sort levels)
then DLR Walton Road will need to evaluate it; unless it is purely for out-
sorting on its pattern.
On receipt of the files, they should be copied to the correct directories

and the new configurator can be installed.
4.4 Links, Switches, Connectors & Configuration

Both the Pattern Controller PCB and the VISION detector require con-
figuration. This is done when the system is set up/commissioned on a
banknote sorting machine. Some of the settings are dependant upon
machine fitment, these are described below.
In addition, some of the connections on the VISION detector are

used solely in the process of capturing images for database crea-
tion and for fault finding on the system.
4.5 Pattern Controller PCB

Refer to Figure 4 for correct configuration of the Pattern Controller,
when used with the VISION detector:

Page 10 May 2001
K1 Left hand = 1Mbit PROM, Right hand = 2 or 4 Mbit PROM
K2, LK3, LK5, LK6 Does not need to be fitted
K4, LK8, LK12,-15 Set links to left hand position
K7 Set links to right hand position
K9, LK10 Ensure these links are set for the appropriate machine
SW1, SW2 Board address, set to suit configurated address of detector
U22,U23, U33, U38 No devices fitted
Figure 4 Pattern Controller Configuration
4.6 Vision System

There are no links/switches on any VISION system PCBs that are used
in the setting up of the detector.
All settings are made either by mechanical adjustment of the head itself,
or by parameters within the ‘BNoteDAQ.ini’ file in the c:\WINDOWS
directory of the VISION system PC. A description of the function of the
‘BNoteDAQ.ini’ file parameters is made below:

May 2001 Page 11
Parameter Name Default Function Comments
Setting
ExpositionTime – Synchronises VISION Typical settings:–

scan rate with the linear 1.85m/s (3700) = 196
transport speed of the 2.4m/s (3200) = 130
sorting machine. 2.4m/s (Cobra) = 130
If set incorrectly the grey 5.3m/s (6000) = 23
scale & processed images 7.2m/s (5000) = 1
will appear to be different
lengths
Blacklevel – Image intensity threshold Will need to be set lower for darker
for: images i.e. (darker notes/ faster
a. Initiation of image transport)
capture.
Typical setting:–
b. Finding note edges
Bank of England / 6000 = 40.
against background.
Ensure that note edges are being
found correctly, but also that
premature triggering does not occur.
DSPregister – Configures operation 8 Bit test value with functions as fol-
lows:–
mode of detector head. Bits 0..2 set output from head.
This setting need only be Bit 3 selects head input.
changed for testing Bit 4 selects o/p blanking.
purposes. Bits 5..7 set non–classification functions
– keep set to 0.
Bit # Setting Function
0..2 0 Entire ADC scale
1 1:2 ADC scale
2 1:4 ADC scale
3 ‘Saw tooth’ output
4 ‘10101010’ output
5 ‘01010101’ output
6 High Z output
7 ROM image
3 0 CCD Array
1 Digi–pot o/p
4 0 Blanks output
1 Normal output
Normal setting = 16.

Page 12 May 2001
Setting
– Sets the number of blank/ Fixed settings:–

BLANKregister isolation pixels to ignore at Reticon array = 5.
the start of each scan. Dalsa array = 10.
CoarseGain – Sets analog system gain Gain setting should be made to use
entire dynamic range of VISION system
at the front end of the o/p where
head. Coarse adjustment possible. Darker notes/higher transport
speeds will require higher settings.
Typical settings:–
Bank of England / 6000 = 90.
Vietnam / 3700 = 195.
FineGain – As above, but fine Typical setting = 128.
adjustment.
1clock – Size in millimetres of one 5xxx approx. = 0.5
Transport Clock cycle. 37xx/32xx/6000 approx. = 1.0
Direction – Direction of note travel Typical settings:–
relative to head and CCD Fitting Setting
array orientation. 3700 l/h (Dalsa) –1
3700 r/h (Dalsa) 1
3200 r/h (Dalsa) 1
6000 l/h (Reticon/PerkinElmer –1
5000 r/h (Reticon/PerkinElmer) –1
Cobra (Reticon/PerkinElmer) --1
Cobra (Dalsa) 1
CheckNotePresent – Use/Don’t use external Settings:–
0 – Only use internal threshold test to
note priming signal. initiate capture of note image.
1 (normal setting) – Use note prime
signal + internal
threshold test to initiate image
capture.
NotePresentLevel – Sets polarity of ‘Note 0 – Asserted low.

1 – Asserted high.
present’ signal.
GhostNoteDelay_m – Max. distance after ‘Note Mechanism to overcome
‘invisible’ batch separators/other media
m Present’ asserted with no causing ‘No/late note response’ from
note image capture VISION detector.
initiated before ‘timeout’ &
Typical setting = 20.
responding
‘Not Recognised’.
Dbpath – Directory on VISION Typical setting =‘C:\Databases’.
system PC containing
Database info.

May 2001 Page 13
Setting
Dbnumber –1 VISION database number. Examples:–

Dbnumber=2 would force
selection of file BN0002.bdb as the
database.
Dbnumber=–1 (default) forces
VISION to use the database
selected in the sorter
configuration.
12Distance 10 Sets minimum permissible Typical setting = 5.
separation between first &
second note match
contenders.
If their scores come within
this threshold the note will
be reported as
‘Not Recognised: 12 distance’.
The purpose of this

mechanism is to reduce
the probability of
crossovers occurring.
TraceResults – Enables/Disables note Typical settings:–
result information being TraceResults = 1 (Enabled).
saved to disk. If enabled, TraceResults = 0 (Disabled).
results are saved from Example filename:–
memory to disk (VISION Csi19990914.csv
applications s/w directory)
(Note data recorded on the
at FEED STOP/when
14/09/99).
exiting from the VISION
applications program.
The data is saved in
‘Comma Separated Value’
file format. This is readily
imported into most
spreadsheet packages.
The filename contains the
date & is in the following
format :–
Csi<yyyy><mm><dd>.csv
EnableAllNotes 0 Enabled – Makes all notes Typical settings:–
in the database live. EnableAllNotes = 1 (Enabled)
Disabled – Only note EnableAllNotes = 0 (Disabled).
numbers specified by the
banknote sorting machine
are live.

Page 14 May 2001
Setting
LogFile – Destination of VISION Examples:–

system operational dia- LogFile=
logue. This information CONOUT$ sends all messages to
can be sent to the console the console (DOS window).
or to a file for system diag- LogFile=
nostic purposes. C:\Diagnostic\Dialog. txt sends all
messages to the specified file/ direc-
tory for later analysis.
FirstThreshold – Highest pattern match Typical Setting = 970.
score above this threshold Changes to this parameter are NOT
leads to note recommended and are
classification. possible ONLY after a thorough
assessment of the live currency per-
formance against the VISION data-
base.
SecondThreshold – If no pattern match scores Typical Setting = 960.
fall above the First Changes to this setting are NOT
Threshold then the recommended and are possible
highest pattern match ONLY after a thorough
score between the First & assessment of the live currency per-
Second Threshold also formance against the VISION data-
passing the Graffiti test base.
(below) leads to
classification.
GraffitiForSecond – ‘Graffiti’ as measured by Typical Setting = 60.
Threshold the VISION detector must
be below this threshold, if
a note is to be ‘recog-
nised’ when note recogni-
tion score is between First
& Second Threshold.
Note: All other parameters within the ‘BNoteDAQ.ini’ file either do not
concern the operation of the classification system or are not intended to
be altered within the current system specification. No attempt should be
made to change these.

May 2001 Page 15
5. ROUTINE MAINTENANCE
5.1 Operator Undertaking

The following daily checks should be carried out by the operator:
a) Clean off any dirt/dust from the external optical faces of the
detector.
b) Visually inspect the external surfaces of the detector head, prism

and associated guiding, in particular the Melinex, for mechanical
damage. Replace any defective or worn Melinex as required.
c) Check that the lamps are illuminated by inspecting the external

optical face as indicated on Figure 3. Replace any lamps that are
defective. Replace lamps every 2000 hours.
5.2 Service Engineer Undertaking

The following six-monthly checks should be performed by the Service
Engineer:
a) Visually inspect the external surfaces of the detector head, prism

and associated guides, in particular the Melinex, for mechanical
damage. Replace any defective or worn Melinex as required.
b) Check that all lamps are illuminated by inspecting the external

optical face as indicated on Figure 3. Replace any lamps that are
defective. To replace a lamp remove the head from the back-plate.
Undo and withdraw two screws and remove the heatsink. Access
to the lamps can be gained through the apertures.
Note: Care should be taken when replacing lamps as they may still be
hot. The lamps should be handled with a clean cotton cloth, and only
after they have been allowed to cool down. The fitment of the lamps are
similar to that of a plug and socket. Firm gentle force on he lamps will
remove or replace them.
c) Perform the calibration procedure as detailed in paragraph 5.3.
d) Check the belts for correct tension. Replace any belts that are worn
or damaged.
e) Inspect the condition of all cables and connectors.
f) Clean the external optical face of the detector.

Page 16 May 2001
5.3 Service Engineer Undertaking (calibration)
Note: This calibration routine is only required when Vision is used for
functions in addition to Note Classification i.e graffiti.
The purpose of the calibration procedure is as follows:
a) To set the system gain, such that a note of fixed reflectivity will upon
capture, produce an image of a specified amplitude.
b) To normalise the output of the detector head, such that the effects
of an uneven illumination profile and of note presentation due to the
main transport belt and O–rings, are removed.
To achieve the above requires the feeding and image capture of a cali-
bration document. This image is then processed and a correction factor
for each used pixel of the detectors line scan array is calculated. These
coefficients are then stored on the VISION system PC and downloaded
to the head at process selection time. To facilitate this calibration proc-
ess, the ‘head FPGA software’ fitted to the head motherboard in position
U9, should be V1.14 or later.
Figure 5 illustrates the effect that this process has on a typical captured
image.
Figure 5 Note Images Captured Before (left) & After (right) Calibration
(for illustrative purposes only)
When calibration is required

The VISION detector should be calibrated:
a) As part of routine maintenance, once per 8 weeks.
b) If a VISION detector head has been re–fitted for any reason e.g.
after repair, Firmware upgrade etc.
c) A new VISION detector head has been fitted.
d) Either or both halogen lamps in the VISION detector head have
been replaced.
e) If either the main transport belt or any of the VISION detector
assembly O–rings have been changed or renewed. Ensure that
the head is set up so that the O–rings do not mark the prism
surface. If a mark is observed it can be removed with a soft, lint
free cloth.

May 2001 Page 17
Note: If a replacement transport belt has white identification marks on
it that would be positioned against the detectors prism glass, then these
marks should be masked by writing over in black permanent marker
pen. Allow the ink to dry before use.
Items required
The following items are required to carry out the calibration procedure:
a) A supply of the VISION calibration document (DLR part number
02390250). If the document becomes damaged or marked and
cannot be cleaned, it must be replaced. It is recommended that
several calibration documents are kept available.
b) Cleaning materials – a dry, lint free soft cloth to clean the VISION
detector head prism, and an alcohol based cleaning fluid and cloth
or towel for cleaning the feeder Stripper wheel and Contra roller.
Procedure
To calibrate the VISION detector proceed as follows:
a) Obtain a VISION detector calibration document (DLR part number
02390250). With the exception of the diagonal line on one face,
this document should be free from defect, marks, stains, scratches
etc. The purpose of this document is to present a uniformly
reflective surface to the VISION detector as any mark or damage
will degrade the effectiveness of the calibration process. The
typical appearance of the calibration document post–capture by
the VISION detector is shown in Figure 6.
Note: This image is for information purposes only and cannot be ob-
served in normal operation.
To observe the image:
i. Connect Monitor, keyboard and Mouse to vision PC.
ii. Close BnoteDaq.exe using Ctrl C.
iii. Start Test.exe
iv. Click on scanner.
v. Click Re Read Image.
Figure 6 VISION Captured Image of the Calibration Document

Page 18 May 2001
b) Using a soft lint free cloth, clean the prism of the VISION detector
head to be calibrated.
c) Using cleaning fluid and a cloth or towel, clean the feeder surfaces
that will come into contact with the document and are liable to mark
it e.g. contra–roller. Ensure that both are dry when cleaning is
finished.
d) Adjust the feeder so that the centre–line of the calibration
document is in line with the centre–line of the transport belt.
e) Ensure that the BNote DAQ program is open on the Vision PC.
f) Select the appropriate VISION calibration process and
denomination:
i. Upper head – Process number = d63. Denomination = d63.
ii. Lower head – Process number = d64. Denomination = d64.
g) Place the calibration document in the feeder. Facing of the
document should be such that the black diagonal line is not on the
side that is presented to the detectors prism. When the calibration
document is fed, check that the long edges of the document are
contained within the width of the detector prism.
h) Press the ‘START’ key and ensure that the document feeds with
the minimum amount of skew.
i) Re–feed the note until it enters the PASS pocket. Note that the
document is always routed to the CULL pocket on the first feed.
If, after 5 re–feeds the note has still not entered the PASS pocket,
refer to Table 2. If the calibration document becomes marked on
any pass then clean it before the next pass, (a pencil eraser can be
used).
Similarly, if it becomes damaged then it must be replaced before
re–feeding.
j) End the calibration process and enter a sorting process that uses
the VISION detector to confirm that it is performing correctly.
Results
The calibration algorithm can return one of the result codes listed in
Table 2, after having processed the image of the calibration document.
If required, these can be examined in the Detector Processor trace data
buffer.

May 2001 Page 19
Table 2: Result Codes
Calibration Meaning Possible Causes Corrective Action
Result
Code
0x8000/ Calibration note culled by transport / VISION If not the first pass – Check the Transport
0xc000 detector. Note that on the first pass, the Damage to the system diagnostics for
document is always sent to the CULL pocket document/ Poor CULL reason and
by the VISION detector. This is due to the feed. remedy.
time required to perform the calibration
algorithm – the Nth pass result is returned on
the N+1th feed of the document.
0x0000 Passed Calibration. In this instance the document will be routed to the pass pocket.
0x4000/
0x0001/ Image breached the Minimum Amplitude Lamp failure. Check/replace lamps.
0x4001 threshold. In this instance the document will
be routed to the fail pocket. The
minimum amplitude threshold prevents too
small a dynamic range being used in the note
image.
Dirt on prism. Check/clean prism.
Dirt on/damaged Check/clean/ replace
calibration docu- calibration
document.
ment.
Wrong calibration Check/replace
document. calibration
document.
Poor presentation Check note guiding
of note. (o–rings etc.) and
renew if
necessary.
Edge of calibration Check/adjust
document not within feeding position.
detector prism.
Gain set too low. Check/increase gain.
0x0002/ Image breached the Maximum Amplitude System gain set too Check/reduce gain.
0x4002 threshold. In this instance the document will high.
be routed to the fail pocket. The
maximum amplitude threshold prevents
possible image saturation and consequent
non–linear effects after normalisation.
Aperture open too Check/close down
wide. aperture.
0x0003/ Image breached the Maximum Deviation One lamp failed. Check/replace lamps.
0x4003 threshold. In this instance the document will
be routed to the fail pocket.
Dirt on prism. Check/clean prism.
Dirt on/damaged Check/clean/ replace
calibration docu- calibration
document.
ment.
Wrong calibration Check/replace
document. calibration
document.
Bad rotational/ verti- Check & adjust on a
cal alignment of the setting up jig (off site).
array.

Page 20 May 2001
The following Figures show examples of ‘Lupa’ single line scans that
would qualify for the categories described in Table 2. It is not
necessary to enter ‘Lupa’ program, Figures 7 to 10 show reflected light
conditions that may affect calibration.
Figure 7 Code 0x000/0x4000 Calibration Successful
Figure 8 Code 0x0001/0x4001 – Minimum Amplitude Error Detected

May 2001 Page 21
Figure 9 Code 0x0002/0x4002 – Maximum Amplitude Error Detected
Figure 10 Code 0x0003/0x4003 – Maximum Deviation Error Detected

Page 22 May 2001
5.4 Off–site Service
Internal servicing of the detector head is carried out off–site due to the
sensitive nature of the internal CCD array and the possible contamina-
tion of any internal optical surfaces. The following tasks should be
performed by a qualified service engineer:
a) Inspect the condition of all PCBs, cable-forms and connectors.
b) Check all the internal and external optical faces of the detector.
c) Check and replace lamps as required.
d) Check that the Vision system is setup correctly in accordance with

the production setup and test procedure. Replacement units are set
up on a jig prior to shipment.
6. REMOVAL AND REPLACEMENT
6.1 Detector Head
Note: Disconnect power from machine whilst removing or filting

detector head
Fixing
bolts
Figure 11 Vision Head Location
To remove the Vision Head proceed as follows:
a) Remove the three bolts (Figure 11) securing the Detector Head to
the back plate.
b) Remove the plug from the base of the unit.
c) Remove the ribbon cable and connector from the side of the unit.
d) Lift the detector head away from the back plate.
e) To replace the Vision Head, reverse the above procedure. Line up

the optical head with the transport belts before finally tightening the
fixing bolts.

May 2001 Page 23
6.2 Vision PC
Figure 12 Vision PC
To remove the Vision PC proceed as follows:
a) Remove the four cables and connectors from the rear of the PC.
b) Remove the power supply cables from the side of the PC.
c) Unfasten all ‘P’-clips securing cables to the metalwork of the PC.
d) Loosen the four bolts securing the PC to the base plate
e) Lift the PC out of the machine.
f) To replace the Vision PC, reverse the above procedure.

Page 24 May 2001
7. ILLUSTRATED PARTS LIST
Part number Description
370204101 Guide - Melinex Assembly
02580056 2 x Lamp Quartz Hal 12v 10w

l6415
4004000601 RH Vision Head & PC
5003063101 Kit PCBP detector Controller
Lamp Quartz
Guide
Melinex Assembly
RH Vision Head
Figure 13 Vision Detector

May 2001 Page 25
Page 26 May 2001
Section 5
___________________________
Optical Pattern Detector

May 2001 Page 1
CONTENTS
Para Page
______________________________________________
______________________________________________
3. FAULT FINDING GUIDE 7
3.2 Preliminary 7
3.3 To Test For Transport Integrity 7
3.4 Fault Finding Procedure 8
3.5 Error CODES 8
3.6 To Mask Out All Detectors Except Optical Pattern 9
3.7 To Detect Note Profile 11
3.8 Detector Reply Codes 12
______________________________________________
4.1 Mechanical Settings 13
4.2 Electrical Settings 14
4.3 Head Amaplifier Board 14
4.4 Optical Trigger Board 15
______________________________________________
5.1 Daily Routine Maintenance By Operator 16
5.2 6 Monthly Maintenance By Service Engineer 16
______________________________________________
6.1 Detector Head Lens 17
______________________________________________
______________________________________________

Page 2 May 2001
Illustrations
Figure 1 Optical Pattern Det. General Block Diagram 5
______________________________________________
Figure 2 Optical Pattern Det. Detailed Block Diagram6
______________________________________________
Figure 3 Fault Diagnostic Flowchart 10
______________________________________________
Figure 4 Example Pattern & Trigger Waveform 11
______________________________________________
Figure 5 Test Document 14
______________________________________________
Figure 6 Pattern Detector Head 18
______________________________________________
Figure 7 Light Path 19
______________________________________________
Figure 8 Melinex Guide Setting 209
______________________________________________
Figure 9 Head Components 21
______________________________________________
Figure 10 Head Assembly 21
______________________________________________
Figure 11 Pattern Head Setting 22
______________________________________________

May 2001 Page 3
The Optical Pattern Detector discriminates the reflective patterns from
banknotes as they pass through the detector.
Light from an optical ‘fishtail’ shines on the banknote as it passes the
detector head and creates a reflection of varying magnitude, deter-
mined by the pattern on the note. This reflected light is converted into
a current output by a photo-diode fitted to the optical fibre termination
on top of the detector head.
The current output from the photo diode is converted into an analogue
voltage, which is then filtered on the Reflective Head Amplifier board.
The filtered outpu is then sampled on the Sliding Correlator board.
As the banknote approaches the detector, two photo-transistors (in the
Trigger Block beneath the detector) detect the leading edge and provide
the Sliding Correlator with a trigger signal. The Sliding Correlator uses
this signal to determine the accurate position of the note.
A block diagram of the detector system is shown in Figure 1. A more
detailed block diagram of the system is shown in Figure 2.
The current output from the photo-diode is applied to the Head amplifier
board via pins 1 & 2 of PL2. The signal is converted to a negative
voltage and amplified by the pre-amplifier U1, the gain of which is set by
RV2. A positive d.c. level, also applied to the pre-amplifier input, can be
adjusted by RV1 to offset the signal and prevent saturation occurring.
The output of the pre-amplifier is fed to an analogue to digital converter
on the Sliding Correlator board via a low-pass filter. The analogue input
voltage, representing the note pattern, is sampled and correlated with
stored references for nominal note alignment positions, and for a
number of ‘slide’ positions either side of the nominal. The advantage of
this technique is such that for any pattern mis-registration, or small
positional inaccuracy, automatic compensation is efficiently achieved.
The Optical Trigger board comprises two identical channels, and
therefore only one is described with references to the second in
parentheses, ( ). Light emission from the detector head causes the
photo-transistor to conduct, and it’s output go high. The high voltage
threshold level is set by RV1 (RV2), and applied to the non-inverting
input of U1/1 (U1/2). The output of U1/1 (U1/2) is also high and is
applied to PL1 pin 1.
When a note passes the detector head, the level of light received by the
photo-transistor is greatly reduced, causing it to conduct less. This
reduces the voltage level to U1/1 (U1/2), and switches the output of U1/
1 (U1/2) to low.
The negative-going output from U1/1 (U1/2) changes the high level on
PL1 pin 1 to a low and becomes the TRIGGER signal on the Sliding
Correlator board. The leading edge of the note informs the Correlator
that a note is present at the detector head.
The high level (no note) at the input of U1/1 (U1/2) is also used to
provide an input to U1/3 (U1/4). The output of this device is high and
provides a trigger READY signal (active high).
The READY signal will go low if a note remains under the detector head
for longer than expected, if the diodes are obscured, or if the lamp fails.

Page 4 May 2001
Head Photodiode Trigger Sensor
SK3
Head Amplifier Board Optical Trigger Board
SK1 SK2
SCHEDULE 3
SCHEDULE 12
SCHEDULE 5
SK12
J21
J3
Sliding Correlator Board
Buffer and Source

Select Circuit Power Supply Unit
PL17 SK17
Detector Processor Board

J4
Mother/Distribution Board
Figure 1 Optical Pattern Detector - General Block Diagram

May 2001 Page 5
Figure 2 Optical Pattern Detector - Detailed Block Diagram

Page 6 May 2001
3. FAULT FINDING GUIDE
3.1 Error Messages

A ‘Check DA detector’ error message indicates that the detector is not
ready. This message can occur if there is a fault with the Auto-Trigger
unit.
3.2 Preliminary
transport system. Therefore, before investigating specific detector
faults, it is necessary to check for correct operation of the transport
system, as described in paragraph 3.3.
Ensure that, if any part of the detector system is renewed, the

adjustment procedure described in paragraphs 4.1 and 4.2 is
subsequently carried out.
3.3 To Test For Transport Integrity

Before any diagnostic work is carried out on the detector, it must be
established that the transport system is working correctly. To do this
carry out the following checks.
Cleanliness
Check that all transport sensors, and the detector are clean. If any item
is found to be dirty, then remind the supervisor or operator of the
importance of thorough daily cleaning.
Transport clock
Using the Transport diagnostic program, check that both the voltage
and the speed of the transport clock are satisfactory.
If the transport clock fails this test, check that the area around the
transport sensor and timing disc is clear, and that the timing sensor is
oriented correctly before deciding to renew parts.
Note feeder
Check that the Note Feeder adjustments are correct. Observe whether
the feeder gives any multiple feeds. These can be identified by counting
the number of notes in the Cull pocket, and comparing the count with
the number of notes in the transport trace (Diagnostic function 09 in the
Diagnostics menu – set up to trace culls only).

are badly degraded, poorly prepared, or incorrectly loaded into the
hopper. If they are not, check that the separator roller and nudger
rubbers are clean. Check that all parts are correctly fitted, undamaged
and not excessively worn.
Belt slip
Use the Transport diagnostic to check that the slip is within
specification. Check whether the detector processor slip log shows any
anomalies. If there are no signs of anomalies, but the slip is greater
than specified limits, then check belt tensions, condition and
cleanliness. Detector and sensor positions should not be changed.

May 2001 Page 7
Culls
Use the Transport Node trace to determine if the transport processor is
culling the notes, and the Detector Processor Note trace to determine if
the detector processor is culling the notes. If either processor is
initiating the culls, then investigate the culling reason and correct the
problem – but not if the detector initiates the cull.
If the cull rate is still excessive, investigate specific detector faults.
Service report
This should include a statement verifying that the test for system
integrity is completed, and also details of all corrective actions taken.
3.4 Fault Finding Procedure

If the fault persists, proceed as follows:
a) Carry out the full maintenance checks as detailed in paragraph 5.2.

This may identify errors in the following areas:
i. Mechanical
ii. Light source input
iii. Sound connection of boards and connectors
iv. System set-up
b) Check that the power supply to the Head Amplifier board is in

accordance with paragraph 4.2.
c) Some machine-reported error messages indicate a fault with the

pattern system, see paragraph 3.5.
d) If these steps fail to identify the fault, follow the diagnostic flowchart
of Figure 3.
3.5 Error Codes

The system reports the occurrence of internal errors, as listed below:
Error Error Type Action

Code
40306 Unable to find pattern set Push Sliding Correlator
PCB firmly home.
Replace Sliding
Correlator PCB

Page 8 May 2001
3.6 To Mask Out All Detectors Except The Optical
Pattern Detector
a) Select the Diagnostics Menu
b) Select Detector System Engineers Function
c) Enter the Engineer’s Access Code.
d) If the Detector Number of the Optical Pattern Detector is not known:
i. Select Detector Diagnostics
ii. Select List Detector Names
iii. Note the number for the Optical Pattern Detector, and Exit.
e) Select Configuration
f) Select Edit Config (Edit configuration)
g) Select Process Data
h) Select Mod. Det. Mask (Modify Detector Mask)
i) Enter the Process Table Idendity (Process number currently being

used).
j) The second row of 1’s and 0’s represents the state of each detector,
enabled (1) or disabled (0), Detector 1 first on the right hand side.
Note the current form of this detector mask so that it can be
re-established later. To disable an enabled detector, and vice-
versa, enter the detector number. Ensure that the Optical Pattern
Detector is the only detector enabled.
k) Return to the Accounting menu.
l) Select and re-run the Set-up menu.
The machine is now ready to run with all detectors masked out, except
the Optical Pattern Detector.
When the setting up of the detector has been completed, re-establish

the original detector mask.

May 2001 Page 9
Check for presence
START of Trigger and Note
profile (see para 3.7)
Replace Auto
Trigger assembly Is Trigger
and set up Auto present?
Trigger board No
Yes
Is Note Profile Yes Replace Sliding

present? Correlator board
No
Replace and set

up Reflective
Head Amplifier
board
If not already done, replace

sliding correlator board. If Is fault
fault persists, contact cleared?
Technical Services. No
Yes
END
Figure 3 Fault Diagnostic Flowchart

Page 10 May 2001
3.7 To Detect Note Profile
The following waveforms may be monitored:
Waveform Monitor on Board At point
Pattern waveform Reflective Head Amplifier Board TP1
Trigger pulse Optical Trigger Board PL1 pin

1
Example waveforms are shown in Figure 4.
Figure 4 Example Pattern and Trigger Waveforms

May 2001 Page 11
3.8 Detector Reply Codes
The detector reply codes which may be viewed from the Diagnostics
menu are:
Detector Name : Operator = DA

Engineer = PATT
The specific Detector Replies from the Pattern Detector will depend
upon the pattern set installed, and the notes being fed. The replies can
only be checked by referring to the pattern set installed. Each face and
orientation of each denomination/issue of note is assigned a pattern
code number.
The pattern detector can cull notes if it cannot classify the note. In this
instance a “pattern suspect” code of 3F (hexadecimal) is returned.
Note: The detector can only output a pattern code relevant to the
patterns in the pattern set. Therefore whether the Detector Reply
matches that of the correct denomination in the pattern set can only be
checked by referring to the installed pattern set itself.

Page 12 May 2001
The following procedures define the mechanical and electrical settings
and adjustments necessary to achieve optimum performance of the
Optical Pattern Detector.
4.1 Mechanical Settings

There should be no need to re-adjust the detector head (see Figure 6)
once it has been set correctly. However, if any component parts of the
detector head are replaced, then set the head up as follows:
a) Remove the retaining circlip, the M6 crinkle washer and the plain
washer from the end of the pivot arm, and place to one side.
b) Slacken the two M3x5 set screws in the detector head and withdraw
the pivot pin from the support bracket, taking care with the nylon
washer.
c) Assemble the head, using new components as appropriate (see

Figures 9 & 10) but do not tighten the set screws.
d) When the head is assembled (see Figure 10) squeeze the faces X
and Y together until the nylon washer is held tight between the inner
faces of the head and support bracket. Tighten the two set screws
to lock the head to the pivot pin. Replace the two M6 washers and
the circlip, renewing as necessary.
The following procedure ensures the correct setting of the Pattern De-
tector head in relation to the transport belt, and must be carried out be-
fore attempting any electrical setting or adjustment.
a) Check that the detector head is at 90º to the machine backplate (see
Figure 11).
b) The gap between the head and the belt should be zero, i.e. with the
transport running, the belt should just contact the head without
being deflected.
c) To obtain the Head set position, slacken the latch and support
bracket securing screws to friction tightness, and position the
components accordingly. Tighten the screws on completion.
d) Check that the Melinex guide is parallel to the Head at the point
where they make contact. To adjust the guide, loosen to friction
tightness, the two adjustment screws and the clamp screw (see
Figure 8). Tighten the screws on completion.
e) Run the transport system to ensure the notes lie flat when passing
beneath the head.

May 2001 Page 13
4.2 Electrical Settings
The following procedures must be carried out whenever the following
components are replaced or adjusted:
lLight source
lOptical fibre light pipes
lPattern detector head
Take EXTREME CARE when replacing or removing the diode housing.
Before attempting to adjust any settings on the Head Amplifier or

Optical Trigger boards, check that the power supplies to the Sliding
Correlator and Head Amplifier boards are as follows:
Board Measure voltage between: Voltage
Sliding Correlator U1 pin 16 with respect to U1 pin 8 +5V
Head Amplifier U1 pin 4 with respect to TP2 +5V
U1 pin 11 with respect to TP2 -5V
4.3 Head Amplifier Board

In order to set up the Head Amplifier board, it is necessary to prepare a
test document as follows:
a) Cut a piece of Polyart 2 (DLRS 01001589) to the dimensions of the

WIDEST note in the relevant currecny.
Approx 12mm
dimensions of the widest note

relevant to the given currency
Cut the document to the
Black drafting
Polyart 2
tape (matt)
(DLRS 01001589)
(DLRS 02340016)
Figure 5 Test Document

Page 14 May 2001
b) Place a strip of matt black drafting tape (DLRS 02340016) on one
face of the test document (see Figure 5)
c) Use a Cobra Spray Brush to ensure that the light emitting surface of
the head is clean of dirt and ink.
To set up the Head Amplifier board:
a) Connect a digital voltmeter between TP1 and TP2 (0V). TP2 is

nearest to the potentiometers.
b) Manually wind the test document through the transport until the
black area is directly beneath the head.
c) Adjust RV1 (Offset) to achieve a voltage of 0.13V ±30mV.
d) Manually wind the test document through the transport until a white
area is directly beneath the head.
e) Adjust RV2 (Gain) to achieve a voltage of 2.38V ±30mV.
f) NOTE that RV1 and RV2 interact with each other, and therefore
continued fine adjustment of both may be necessary to achieve the
above voltages.
4.4 Optical Trigger Board

To set up the Optical Trigger board proceed as follows:
a) Remove any document that is beneath the head.
b) Connect a digital voltmeter between TP1 and TP3 (0V).
c) Adjust RV1 to give a positive voltage of between 7.5V and 8.0V.
d) Disconnect the DVM from TP1 and connect it to TP2.
e) Adjust RV2 to give a positive voltage of between 7.5V and 8.0V.

May 2001 Page 15
5.1 Daily Routine Maintenance By Operator

The operator should perform the following routine maintenance on a
daily basis:
a) Clean dirt and ink from the pattern head lens
b) Clean debris and dust from the trigger optical sensors
c) Inspect the Melinex note guide, and renew if damaged (see

Figure 10).
5.2 6-Monthly Maintenance By Service Engineer

The Maintenance Engineer should perform the following routine
maintenance on a 6-monthly basis:
a) Visually inspect the Pattern Head, Melinex note guide and Trigger
assembly for mechanical damage. Renew defective parts.
b) Check the lamp source and light pipes. Renew the lamp.
c) Check the belts for correct tension. Renew if they are worn or
damaged.
d) Inspect the condition of all boards, cableforms and connectors.

Renew or repair defective items.
e) Clean the Pattern Head and the Trigger sensors.
f) Ensure the system is set up as described in paragraph 4

Page 16 May 2001
6.1 Detector Head Lens

If the lens on the underside of the detector head should become
displaced, then a repair may be effected with Kit Number 02360198 as
follows:
a) Remove all remnants of the old lens.
b) Place 320 grit abrasive paper on a flat surface.
c) Hold the optical face of the pattern head squarely on the paper and
rub back and forth until the surface is even in appearance.
d) Repeat the above step with 600 grit paper.
e) Wipe off all residue with a damp cloth.
f) Wet the felt pad with water and place on a flat surface.
g) Apply half the contents of the polish sachet evenly to the felt pad.
h) Rub the optical face along the felt pad until high lustre is achieved
evenly along the face (add more polish if necessary).
i) Clean off any residue with a damp cloth.
j) The surface is now ready for the new lens.
k) Empty the contents of both syringes into the mixing cup and mix
thoroughly.
l) Apply a layer of epoxy to the newly polished face of the Pattern

Head.
m) Position the lens onto the Pattern Head, apply pressure to remove
air bubbles, and hold in position using elastic bands.
n) Wipe off excess epoxy and cure at 20º for 24 hours.

May 2001 Page 17
Figure 6 Pattern Detector Head

Page 18 May 2001
Figure 7 Light Path

May 2001 Page 19
Figure 8 Melinex Guide Setting

Page 20 May 2001
Pattern
Head
Mounting
Block
Pattern
Sub-Plate
Set Screws
Pivot Pin
Circlip Nylon ‘O’ Ring
Washer
Figure 9 Head Components
Face X
Face Y
Figure 10 Head Assembly

May 2001 Page 21
Zero Gap
Pattern
Head
Locking
Clip
90 ° Transport
Belt
Mounting
Block
90°
Figure 11 Pattern Head Setting

Page 22 May 2001
02580048 Lamp Halogen 12v 20w
3106003503 CBLFM Photo Diode assy
3202309501 Pattern Head assy
TBA Note Guide
3704015103 Kit - SL CORR PCB
BB02306702 PCB Optical Trigger

May 2001 Page 23
Page 24 May 2001
Section 6
___________________________
UV Bright Detector

May 2001 Page 1
CONTENTS
Para Page
____ _________________________________________
2.1 UV Bright Detection 4
2.2 Test Points 5
2.3 Wiring Schedules 5
______________________________________________
3.2 To Mask Out All Detectors Except UV Detector 9
3.3 How To Set Up UV Trace Measure 10
3.4 How To View Trace Measure Table 11
______________________________________________
4.1 Mechanical Settings 12
4.2 Electrical Settings 12
______________________________________________
5.1 Detector Head Removal 14
5.2 Detector Head Replacement 14
______________________________________________
______________________________________________
Tables
Table 1 Test Points 5
______________________________________________
Table 2 LED Status 9
______________________________________________
Illustrations
Figure 1 UV Bright Detector 3
______________________________________________
Figure 2 Elements of the Detector Head 3
______________________________________________
Figure 3 General Block Diagram 4
______________________________________________
Figure 4 Detector System - Detailed Block Diagram 7
______________________________________________
Figure 5 Fault Diagnostic Routine 8
______________________________________________

Page 2 May 2001
Figure 1 U.V. Bright Detector
The U.V. Bright detector identifies banknotes that give abnormally high
fluorescent responses to ultra-violet light.
TO U.V. BRIGHT BOARD
REFERENCE
PHOTO-DIODE
SENSING
PHOTO-DIODE
UV PASS
FILTER
BLUE PASS
FILTER
U.V. Tube
Direction of Travel
Banknote
Figure 2 Elements of the Detector Head

May 2001 Page 3
Figure 2 shows a functional block diagram of the U.V. Bright Detector
board. The banknote passes in front of an ultra-violet light source, and
the resultant blue fluorescence is sensed by the adjacent photo-diode,
which is shielded from the direct rays of the light source.
A second photo-diode monitors the intensity of the light source. The

output signals from the two photo-diodes are processed and then indi-
cate the degree of fluorescence of each banknote.
The detector system comprises:
l The photo-diodes of the detector head
l The U.V. Lamp of the detector head
l The U.V. Bright board of the detector head
l The U.V. Lamp Driver assembly
l A part of the detector interface board.
The location of the detector system components, together with the

identification of the associated connectors and wiring schedules, are
shown in the general block diagram of Figure 3.
UV Bright Board UV Lamp Board
SK2 SK1 SCHEDULE 32
SCHEDULE 27
SK5 SCHEDULE 5
J16
Detector Interface J5 PL17 SK1 UV Lamp Driver

Board Power Supply Unit Transform Board
Mother / Distribution
UV Lamp Driver Assembly
MAINS
2.1 U.V. Bright Detection

A more detailed block diagram of the system is shown in Figure 4.
From the a.c. mains supply at the terminal block, a constant current
supply for the U.V. lamp is derived on the U.V. Lamp Driver board of the
U.V. Lamp Driver assembly, by a rectifier and current sink TR1. This
supply is routed through pins 3 and 4 of the board and pins 1 and 4 of
the U.V. Lamp board of the detector head, and thence to the lamp.
Lamp starter components are on the U.V. Lamp board.

Page 4 May 2001
The output of the lamp sensor is routed through PL1 pins 3 and 4 of the
U.V. Bright board to pre-amplifier U1, filter U2, buffer/comparator U3
and thence to the green LED2. The comparator reference is fixed, but
the pre-amplifier gain is pre-set by potentiometer RV2. When the lamp
intensity exceeds the lowest useful level, as determined by RV2, LED2
is energised and a U.V. Bright Ready signal is asserted. This signal is
routed through PL2 pin4 of the board and J16 pin 5 of the Mother/distri-
bution board to buffer U5 of the Detector Interface board.
The output of the fluorescence sensor is similarly processed through

another channel of the same devices, but the pre-amplifier gain is fixed,
and the comparator reference is a fraction of the processed lamp sensor
signal, determined by RV1. When the intensity of fluorescence exceeds
a level determined by RV1, the red LED1 is energised and the U.V.B.
signal is asserted. This signal is routed to buffer U7 of the Detector
Interface board.
2.2 Test Points

A summary of the test points included to assist servicing is shown in
Table 1.
Table 1: Test Points
Test point of Test point of Function

lamp sensor fluorescence
sensor channel
channel
TP2 TP2 Signal return level (0 volt)
TP1 TP3 Pre-amplifier output
TP4 - Preset comparator reference
- TP5 Buffer output
2.3 Wiring Schedules
Schedule 27 - UV Bright Detector Cable
Wire no. Colour From To Function
1 Brown SK2 / 2 J16 / 7 + 5V
2 Red SK2 / 1 J16 /6 + 5V
3 Green SK2 / 6 J16 /4 0V
4 Blue SK2 / 4 J16 /5 UVB READY
5 White SK2 / 3 J16 /8 UVB
6 Black SK2 / 5 J16 /3 0V
7 Black Screen J16 /1 Drain

May 2001 Page 5
Schedule 32 - UV Lamp Driver Cable
Wire no. Colour From To Function
1 Brown SK1 / 1 CN2 / 1
2 Blue SK1 / 4 CN2 / 4
Schedule 5 - J16 (Motherboard) Connections
J16 pin To Function
1 OV
2 0V
3 0V
4 0V
5 SK3 / 24b UVB READY
6 +5V
7 +5V
8 SK3 / 23b UVB INPUT
9 SK3 / 22b SPARE INPUT
10 PL17 / 9 +15V
11
12
13 PL17 / 8 -15V
14

Page 6 May 2001
Figure 4 UV Bright Detector System - Detailed Block Diagram

May 2001 Page 7
START
Is Detector Yes
Ready?
No
Is Fault Yes
Repaired?
Place photyocopy
No
or writing paper Carry out setting-
under detector up procedure END
head
Check UV Bright
board power
supply
Is fluorescence
seen on note
Is Fault Yes
Repaired?
Check UV Lamp
Driver board
output No
(330V dc off-load) END
Renew UV Bright
board
Is output No
available?
Yes
Is Fault Yes
Repaired?
Renew UV Lamp Renew UV Lamp
board Driver board No
END
Renew Detector Head.

Consult Technical
Is Fault No
Services if fault persists
Repaired?
Yes
END

Page 8 May 2001
3.1 Fault-Finding Procedure

If a fault exists, proceed as follows:
a) Remove the three screws securing the head cover and remove the
cover.
b) Check all connections between the detector head and the Mother/
distribution board and the U.V. Lamp Drive board.
c) Run the machine without any notes in the transport, and observe
the state of the red and green LED’s on the U.V. Bright board.
Table 2 shows the action to take in response to the LED status.
Table 2: LED Status
RED LED1 GREEN LED2 Action to take
OFF ON System functional (but may need to be made

more sensitive), see paragraph 4.
ON ON Sensitivity too high. RV1 needs adjusting clock-

wise to de-sensitise. Check and re-adjust circuit
as described in paragraph 4.
OFF U.V. Lamp circuit not functioning, or lamp

unserviceable. This will give a Check DU
Detector message when trying to feed-start.
d) Follow the fault diagnosis routine of Figure 5.
e) Re-fit and re-secure the detector head cover.
3.2 To Mask Out All Detectors Except The U.V. Bright

Detector
a) Select the Diagnostics Menu
b) Select Detector System Engineers Function
d) If the Detector Number of the U.V. Bright Detector is not known:
i. Select Detector Diagnostics
ii. Select List Detector Names
iii. Note the number for the U.V. Bright Detector, and Exit.
e) Select Configuration
f) Select Edit Config (Edit configuration)
g) Select Process Data
h) Select Mod. Det. Mask (Modify Detector Mask)

May 2001 Page 9
i) Enter the Process Table Idendity (Process number currently being
used).
enabled (1) or disabled (0), detector 1 is first on the right hand side.
Note the current form of this detector mask so that it can be re-
established later. To disable an enabled detector, and vice-versa,
enter the detector number. Ensure that the U.V. Bright Detector is
the only detector enabled.
the U.V. Bright Detector.

3.3 How To Set Up U.V. Trace Measure

To set up the trace measures proceed as follows:
a) Select Detector Systems Engineers Functions : 02.
b) Enter the 4-digit access code.
c) Select Trace Data : 04.
d) Press SHIFT and > to page forward.
e) Select Set Note Trace Conditions : 21.
f) The display then prompts Destination? This provides the facility to

be selective about which pockets notes are traced into – the default
is All.
g) Press SHIFT and > to move forward.
h) The display then requests which category of note is to be traced –

default is All.
i) Press SHIFT and > to move forward.
j) The display shows the detector number and prompts Trace

Measure Number? – Select a specific trace measure shown below,
and press Enter.
Quantity (units of mms) Trace measure number

UV bright count (non-contiguous) * 7
k) The display re-prompts with the same question to confirm the trace
measure – Press Enter again.
*This is the total number of mm samples – along the length of the note
– that were above the UV Bright threshold (as set by RV1). Note that if
a UV pointer (Sort Levels menu) is available, this will be scaled in
‘percentage of note length’. Remember therefore to convert the pointer
setting to actual measurements when assessing trace measure results.

Page 10 May 2001
3.4 How To View Trace Measure Table
The function described is a ‘single-shot’ facility, and permits the viewing
of all detector trace measures for the last note fed.
To view the trace measures p0roceed as follows:
a) Select Detector Systems Engineers Functions : 02.
b) Enter the 4-digit access code.
c) Select Trace Data : 04.
d) Select Examine Trace Measure Table : 13.
e) The display then requests if screen or printer output is required.

Enter 0 for screen, or 1 for printer.
f) The start of the Trace Measure table is displayed. Use the following
keys to view the required trace measure:
Press SHIFT and > to page forward.
Press SHIFT and < to page backward.
Press CLEAR to exit.

The detector reply codes which may be viewed from the Diagnostics
menu are:
Detector Name : Operator = DU
Engineer = UV
This detector has a simple Yes/No response depending upon whether

it detects a U.V. Bright note or not. The Detector Reply is a 4-digit hex
reply, of which the right-hand digit is the most relevant. The possible
replies are:
Note is
UV Dull (Good note) UV Bright (Note culled)
0000 (Hex) 0 (Dec) 0001 (Hex) 1 (Dec)

May 2001 Page 11
In order to carry out the following procedures, the following items are
required:
l A digital voltmeter (DVM)
l A trimpot adjuster
l 250 genuine (U.V. dull) banknotes for each denomination that the
machine will sort.
l A photocopy of one banknote for each denomination of the above

banknotes (alternatively a sheet of photocopy or plain writing paper
cut to banknote size).
4.1 Mechanical Settings

Check that the detector head housing (front end) is separated from the
transport belt by 3±1mm. To adjust the separation proceed as follows:
cover.
b) Loosen the two screws holding the head assembly, to friction

tightness.
c) Move the head assembly to achieve the required separation.
d) Re-tighten the two securing screws holding the head assembly.
Do not replace the cover at this stage as access is required for the
electrical adjustments.
4.2 Electrical Settings

WARNING
HIGH VOLTAGE D.C. (330V) IS PRESENT AT THE LAMP
DRIVER BOARD OUTPUT, AND AT THE LAMP BOARD
INPUT.
The electrical settings are made on the U.V. Bright board. To perform
the electrical set-up proceed as follows:
a) 1If the head cover is not already removed, remove the three screws
securing the cover, and remove the cover to expose the board.
b) Power up the Cobra 4004, and ensure that the U.V. lamp is ON.
c) Allow the U.V. Bright Detector a period of 2 minutes to warm up

before proceeding.
d) Connect the DVM to TP1 and TP2 (0 Volt) and check for a reading
of 1.6V ±0.1V. Adjust RV2 if necessary to satisfy the check.
e) Follow the instructions in paragraph 3.2 to mask out all detectors

except the U.V. Bright detector.

Page 12 May 2001
f) Select a process which utilises the U.V. Bright detector. The aim of
this setting-up procedure is to set the U.V. threshold safely above
the ‘brightest’ genuine denomination. Care should be taken not to
bias this threshold too high in order to accept notes that have been
contaminated by a U.V. bright substance – such as washing
powder.
g) The U.V. threshold is controlled by RV1. A clockwise adjustment

increases the threshold voltage (at TP4) and thus de-sensitises the
system.
h) To achieve an initial setting, manually wind a genuine denomination

under the head. Ensure that there is no obvious visible
fluorescence.
i) Take care to shield the U.V. detector when the front cover is open,
since the red LED can easily be turned on by stray light, and adjust
RV1 until the red LED just goes OFF.
j) Close the front cover.
k) Run 250 notes of one denomination through the machine.
l) If any notes are rejected, re-adjust RV1 half a turn clockwise, and
repeat the run. If a small number of notes are repeatedly rejected,
manually hold them under the U.V. detector head to check for an
obvious denomination – if such notes are found, remove them from
the pack.
m) Repeat the above two steps for each denomination.
n) Run a photocopy of each denomination and ensure that all are

rejected.
o) If any detectors were masked out, then mask them back in.
p) Re-fit and re-secure the head cover.

May 2001 Page 13
5.1 Detector Head Removal

To remove the detector head proceed as follows:
cover.
b) Disconnect the connector SK2 from the U.V. Bright board, and the
connector SK1 from the U.V. Lamp board.
c) Support the Detector Head assembly, and remove the two screws
securing the assembly to the machine back-plate. Withdraw the
assembly.
5.2 Detector Head Replacement

To replace the detector head proceed as follows:
a) Position the detector Head assembly on the machine back-plate.
b) Loosely secure the assembly to the back-plate by the two screws.
c) Connect SK2 to PL2 on the U.V. Bright board.
d) Connect SK1 with PL1 on the U.V. Lamp board.
e) Carry out the mechanical adjustments as described in

paragraph 4.1.

Page 14 May 2001
01003520 Photodiode BPW21
01003860 Photodiode OSD 1.5
3709533402 PCB UV Lamp
BB09530302 PCB UV Bright
Figure 6 UV Detector

May 2001 Page 15
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START
Repeat setting-up
instructions
Is fault
repaired YES END
?
NO
Plug spare microphone

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observe signal level
Replace
Any change in
microphone YES
signal level
assembly
NO
Is fault repaired Change front-end

END YES NO
? board
Replace Detector Interface and

the Detector Processor board. Is fault repaired
NO YES END
Consult 'Technical Services' if ?
fault persists.
Figure 4 Fault Diagnosis Procedure
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Section 8
___________________________
Soil Detector

May 2001 Page 1
CONTENTS
Para Page
______________________________________________
2.1 Reference Tile 5
2.2 Detector Head 5
2.3 Front-end Board 6
2.4 Detector Controller Board 6
2.5 Soft Start Lamp Supply Board 6
______________________________________________
______________________________________________
4.1 General 12
4.2 Preliminary Checks 12
4.3 Reference Tile 14
4.5 Front-end Board 15
4.7 To Mask Out All Detectors Except Soil 16
______________________________________________
5.1 6 Monthly Maintenance By Service Engineer 17
______________________________________________
6.1 Reference Tile Assembly 18
______________________________________________
______________________________________________
Tables
Table 1 Detector Reply Codes 16
______________________________________________

Page 2 May 2001
Illustrations
Figure 1 Upper and Lower Soil Detectors 4
______________________________________________
Figure 2 System Block Diagram 5
______________________________________________
Figure 3 Soft Start Lamp Supply Board 7
______________________________________________
Figure 4 Fault Diagnosis Routine 11
______________________________________________
Figure 5 Front End Board - Position of Controls 13
______________________________________________
Figure 6 Soil Detector 19
______________________________________________

May 2001 Page 3
Figure 1 Upper and Lower Soil Detectors
A soil detector determines the ‘soiled’ status of a banknote and,

according to a threshold set by the machine operator, decides whether
the note is fit or unfit for re-use. The ‘soiled’ state is determined by a
measurement of the amount of light reflected from the banknote.
The detector calibrates itself at frequent intervals by the use of a

reference tile, which is viewed by the detector head between each
banknote as they pass. This tile is positioned so that it is wiped by the
notes as they travel along the transport, and is thus assumed to have
constant reflectivity, subject to cleaning by the operator at appropriate
intervals.
On Cobra 4004 machines, soil detectors usually occur as an upper and

a lower unit which monitor both sides of the banknote, and are mounted
near the upper right hand corner of the back plate. They are mounted
on standoff pillars so that they monitor the banknotes outboard of the
standard transport belts.
The soil detectors are shown in Figure 1, and the principal components
are shown in the block diagram in Figure 2.

Page 4 May 2001
Detector controller
Soft start lamp

Front-end Board
supply board
Head
Detector Interface J5 J14 SK14
Board Power Supply Unit
Light
TILE
Figure 2 System Block Diagram
2.1 Reference Tile

The Reference tile is a white ceramic tile that is uniform and stable in its
degree of reflectivity. The tile is kept clean, on a short term basis, by
the wiping action of notes travelling across its surface. The tile should
be positioned correctly, relative to the transport belts, to allow this to
happen. To avoid a significant build-up of greasy dirt on the surface of
the tile, the tile should be cleaned daily.
2.2 Detector Head

The head is mounted on two standoffs opposite the Reference tile. It is
a dust-sealed assembly, and apart from routine lamp replacement, it is
not field serviceable under any circumstances.
The head comprises:
l A precisely aligned tungsten halogen lamp
l A lens to focus the lamp light onto the banknote
l Glass filter windows to allow light to leave and enter the head
l Two photo-diodes to receive light reflected from the banknote
l Two amplifiers to boost the diode signals before transmission to the

Front-end Board

May 2001 Page 5
The signal produced is substantially unaffected by normal variations of
the banknote position from its nominal position, provided that the head
is set in the operating position according to the adjustment procedure.
2.3 Front-end Board

The front-end board is mounted behind the right-hand side cover, and
its functions are:
l Checking that the outputs from the head are within an acceptable
range.
l Calibrating the system on command from the detector controller.
l Sharing the process of analogue to digital conversion with the de-

tector controller.
2.4 Detector Controller Board

The detector controller board is mounted in the rear of the cabinet, and
is responsible for:
l Triggering the front-end board processes
l Sharing the process of analogue to digital conversion with the front-

end board
l Running the software algorithms that determine the soil state of the
note
l Communicating with the rest of the machine via the detector proc-
essor board
2.5 Soft Start Lamp Supply Board

The soft start lamp supply board provides individual 4-volt supplies for
the upper and lower soil heads.

Page 6 May 2001
Soft start lamp supply board
Figure 3 Soft Start Lamp Supply Board
Schedule 1 - Detector Head to Front End Board

Colour From To Description
Blue PL2 / 1 PSD01 / 1 - 15V
Green PL2 / 6 PSD01 / 2 + 15V
Black PL2 / 3 PSD01 / 3 0V
Red PL2 / 4 PSD01 / 6 SIG.1
Yellow PL2 / 5 PSD01 / 9 SIG.2
White
SCREEN PL2 / 2 SCREEN
Schedule 2 - Detector Head to Soft Start Lamp Supply Board

Grey PL2 / 1 PL1 / 3 + 4V
Grey PL2 / 2 PL1 / 2 0V
Grey PL4 / 1 PL1 / 3 + 4V
Grey PL4 / 2 PL1 / 2 0V

May 2001 Page 7
Schedule 3 - PSU to Soft Start Lamp Supply Board
Grey PSU / 1 PL1 / 1 +5V
Grey PSU / 2 PL1 / 2 COMMON (+5V)
Grey PSU / 3 PL1 / 3 COMMON (+12V)
Grey PSU / 4 PL1 / 4 +12V
Schedule 4 - Detector Controller to Lower Calibration Board (signals)

64-way connector pin 1 20-way connector pin 1 CONTROL1
64-way connector pin 2 20-way connector pin 2
64-way connector pin 3 20-way connector pin 3 /CONTROL
64-way connector pin 4 20-way connector pin 4 COMPL.1
64-way connector pin 9 20-way connector pin 9 /START
64-way connector pin 10 20-way connector pin 10 CAL.1
64-way connector pin 11 20-way connector pin 11 /INCREMENT
64-way connector pin 12 20-way connector pin 12 COUNTERS
64-way connector pin 13 20-way connector pin 13 /CAL
64-way connector pin 14 20-way connector pin 14 COMPL.
64-way connector pin 15 20-way connector pin 15 /DETECTOR
64-way connector pin 16 20-way connector pin 16 VALID

Page 8 May 2001
Schedule 5 - Detector Controller to Upper calibration Board (signals)
64-way connector pin 25 20-way connector pin 9 /START
64-way connector pin 26 20-way connector pin 10 CAL.1
64-way connector pin 27 20-way connector pin 11 /INCREMENT
64-way connector pin 28 20-way connector pin 12 COUNTERS
64-way connector pin 29 20-way connector pin 13 /CAL
64-way connector pin 30 20-way connector pin 14 COMPL.
64-way connector pin 31 20-way connector pin 15 /DETECTOR
64-way connector pin 32 20-way connector pin 16 VALID
Schedule 6 - Detector Controller to Calibration Boards (supplies)

64-way connector pin 49 16-way connector pin 1 - 15V
64-way connector pin 54 16-way connector pin 6 + 15V
64-way connector pin 59 16-way connector pin 11 + 5V
64-way connector pin 61 16-way connector pin 13 0VA
64-way connector pin 63 16-way connector pin 15 0VD

May 2001 Page 9
This procedure assumes that the particular detector exhibiting a fault
has already been identified. Some machine-reported error messages
can be used to investigate soil detector faults.
The performance of the soil detector is affected by the performance of

the note transport system. Therefore, before investigating specific
detector faults, carry out the usual tests for transport system integrity as
detailed in the main manual sections.
If the problem persists, follow the diagnostic routine detailed in Figure 4.

Page 10 May 2001
START
Check condition
and adjustment of
major components
Is fault
repaired
?
Replace Detector
Controller board
Is fault
Yes repaired
?
No
Replace Front-
end board
Is fault
Yes repaired
?
No
Was head
replaced Yes
?
No
Replace detector
head
Is fault
Yes repaired No
?
END
Consult
’Technical Services’
Figure 4 Fault Diagnosis Routine

May 2001 Page 11
4.1 General
Two soil detectors are normally fitted, with one detector head above the
note path, and one detector head below, so that both sides of a
banknote are viewed.
Adjustment is necessary if any of the following is disturbed:
l The position of the reference tile holder
l The detector head
l The front-end board is replaced
As the adjustments for the two detector heads and the two front-end
boards are identical, the following procedure describes the setting up of
one system only. When adjusting both systems, they may be adjusted
together at each step.
Adjustments to RV1 and RV2 of the front-end board are intended to set
the system close to the centre of its operating range of voltages. This
operating range is very wide, and is intended to cover all subsequent
variations between lamps, lamp ageing effects, and the effects of dust
build-up on the heads during normal use.
4.2 Preliminary Checks

Ensure that the following electrical connections are made:
a) Between the controller board and the front-end board
b) Between the front-end board and the detector head
c) Between the power supply and the soft-start lamp supply board
d) Between the soft-start lamp supply board and the detector head
Ensure that the Reference tile opposite the Detector head, and all
windows on the Detector head, are clean, dust-free and undamaged.
If necessary, clean them with a SLIGHTLY DAMP clean cloth.
The following tools are necessary, in order to carry out the electrical
adjustments:
l A Digital voltmeter (DVM)
l A trimpot adjuster
The location of test points and adjustment potentiometers is shown in

Figure 5.

Page 12 May 2001
Figure 5 Front-end Board - Positions Of Controls

May 2001 Page 13
4.3 Reference Tile
To set the position of the white reference tile proceed as follows:
a) Loosen to friction tightness, the two mounting bolts that secure the
tile’s mounting bracket to the back plate.
b) Move the bracket, so that the white reference tile is in the plane of
the contacting faces of the transport drive.
c) Tighten the mounting bolts.
4.4 Detector Head

To set up the Detector head proceed as follows:
a) Check that the face of the Detector head is approximately 14 mm

distant from the contacting faces of the transport belts. If necessary
adjust the position as follows:
i. Loosen the two standoffs, to friction tightness
ii. Re-position the Detector head to the required position.
iii. Re-tighten the mounting bolts.
b) Ensure that the illumination area (filament image and halo) is fully
within the glazed area of the tile. If necessary, move the tile as
described in paragraph 4.3.
c) Place a strip of masking tape onto the back plate, so that the
distance from the head to the reference tile may be marked during
the course of this procedure.
d) Loosen to friction tightness the two standoff pillars.
e) Close the machine front cover. Measure the voltage between test
points TP23 and TP1 on the front-end board. Adjust the position of
the head in relation to the reference tile, whilst maintaining the face
of the head parallel to the tile, and re-measure the voltage between
TP23 and TP1.
f) Repeat the above step to find the position of the head which gives
the maximum voltage.
g) Mark the position of the head on the masking tape.
h) Repeat steps e to g but measuring the voltage between TP2 and

TP1.
i) Set the detector head mid-way between the marks.
j) Tighten the securing bolts and remove the masking tape.
k) Look at the image of the filament on the reference tile, and if it is

abnormally bright, or dim, then it is advisable to change the lamp so
that a more ‘normal’ image is obtained.

Page 14 May 2001
l) If a new lamp is not available, then providing it was possible to set
the Detector up successfully, it should perform satisfactorily, though
a reduced life may result.
m) If the lamp is changed then:
i. Re-calibrate the Detector by repeating steps c to j.
ii. Ensure that any dirt dislodged from other parts of the machine
is cleaned off the faces of the head and tile.
4.5 Front-end Board

The setting-up of the front-end board involves setting its input to an
optimum level. To set the input to the front-end board to an optimum
level proceed as follows:
a) Close the machine front cover.
b) Set RV1 and RV2 (see Figure 5) to the fully clockwise position
(minimum gain).
c) Disconnect the connector from PL1 on the soft start lamp supply
board to remove power from the lamp.
d) Ensure that the shorting links between pins 1 & 2 of LK2 and LK3
are in position.
e) Select a machine process that uses the soil detector, and initiate a
calibration cycle, by making the machine start to feed banknotes.
f) Press the STOP key on the keyboard to stop the machine.

If the procedure is to be successful, no more calibration cycles
should be initiated, and power to the front-end board must not be
interrupted until this procedure is completed.
g) Check that pins 4 to 13 of devices U1 and U2 are at CMOS logic-

low levels (less than 5V for a 15V supply).
h) Connect the connector to PL1 on the soft start lamp supply board to
restore power to the lamp.
i) Wait for five minutes to allow the lamp to stabilise.
j) Connect the negative lead of the DVM to TP23 (0V), and the
positive lead to pin 7 of device U3.
k) With the machine cover still closed, adjust RV1 anticlockwise to

achieve a voltage of 13.0V ±0.2V.
It is possible, but not very likely, that RV1 will run out of adjustment
or for U3 to saturate before the desired target of 13V is reached.
If RV1 has run out of adjustment, then leave it at its maximum
setting. If it appears that the output is saturating, then the position
of RV1 may be estimated as follows:
If, for example, saturation occurs at 12.5V, and RV1 has been
turned by half a turn between 12V and 12.5V, then turn RV1 by
a further half turn to reach the estimated position. The final
reading must never be less than 11.5V.

May 2001 Page 15
l) Move the positive DVM lead to U1 pin 8. Repeat step k but adjust
RV2 instead of RV1. Setting up is now complete.

The following details the Detector Reply codes that may be seen from
the Optical Soil detectors via the Diagnostic menu.
The detector is split into an upper and a lower soil detector with both
parts having a unique Detector name and Reply.
UPPER LOWER
Detector Names : Operator = DS1 = DS2
Engineer = SOLU = SOLL
Both detectors have a simple Go/No go reply, being a 4-digit

hexadecimal number, where the right hand digit is the most significant.
Table 1: Detector Reply Codes
Reply SOLU SOLL
Note is unfit Hex 0000/4000 0000/4000

Dec 0/0 0/0
Note is fit Hex 0001/4001 0001/4001

Dec 1/1 1/1
The reason why the machine displays either 0000 or 4000 is that bit 14
is toggled between notes.
4.7 To Mask Out All Detectors Except The Soil Detector
a) Select the Diagnostics Menu.
b) Select Detector System Engineers Function.
d) If the Detector Number of the Soil Detector is not known:
i. Select Detector Diagnostics.
ii. Select List Detector Names.
iii. Note the number for the Soil Detector, and Exit.
e) Select Configuration.
f) Select Edit Config (Edit configuration).
g) Select Process Data.
h) Select Mod. Det. Mask (Modify Detector Mask).
i) Enter the Process Table Identity (Process number currently being

used).

Page 16 May 2001
enabled (1) or disabled (0), Detector 1 is first on the right hand side.
enter the detector number. Ensure that the Soil Detector is the only
detector enabled.
the Soil Detector.

5.1 6-Monthly Maintenance By Service Engineer

The Maintenance Engineer should perform the following routine main-
tenance on a 6-monthly basis:
a) Thoroughly clean the detector and surrounding area of the

machine.
b) Carefully inspect the reference tile. Renew the tile assembly if there
are scratches, chips, cracks, or there is discolouration.
c) Inspect the windows on the face of the head without removing the
head from the machine. Renew the head is any of the windows are
cracked, chipped or loose. Light scratching of the windows is
tolerable provided that the patch of illumination on the tile is free of
excessive distortion and colouration.
Note: The head is not field serviceable under any circumstances.
d) Replace the lamp in the head by a new, unused lamp. At the same
time, ensure that there is no dirt preventing the lamp assembly from
seating properly in the head.
e) If either the tile or the head is renewed, carry out the full setting-up
procedure described in paragraph 4.

May 2001 Page 17
6.1 Reference Tile Assembly

To remove the reference tile assembly proceed as follows:
a) Remove the two bolts securing the assembly to the back plate.
b) Remove the assembly from the machine.
c) To replace the reference tile assembly reverse the above

procedure.
d) Carry out the full setting-up procedure described in paragraph 4.
6.2 Detector Head

To remove the detector head assembly proceed as follows:
a) Disconnect the cable from the detector head at the front end board.
b) Remove the two bolts securing the assembly to the standoffs.
c) Remove the assembly from the machine, taking carel to pass the
cable through the holes in the metalwork.
d) To replace the detector head assembly reverse the above

procedure.
e) Carry out the full setting-up procedure described in paragraph 4.

Page 18 May 2001
3706008202 2000Hr Life lamp
2xBB02313102 Soil Detector Head Assembly
3209546201 PCBP Soil Detector
3709531002 PCBP Slow Start PSU 4v
2000Hr
Life Lamp
Soil Detector
Head Assembly
Figure 6 Soil Detector

May 2001 Page 19
Section 9
___________________________
Twin Magnetic Ink Detector

May 2001 Page 1
CONTENTS
Para Page
______________________________________________
2.1 Detector System 5
2.2 Magnetic Ink Detection 5
2.3 Magnetic Thread Detection 6
2.4 Test Points 6
______________________________________________
3.2 Preliminary 9
3.3 Transport System Integrity 9
______________________________________________
4. SETTINGS AND ADJUSTMents 13
4.1 Mechanical Adjustments 13
4.2 Electrical Adjustments 14
4.3 To Mask Out All Detectors Except Twin Mag. Ink 17
______________________________________________
______________________________________________
______________________________________________
Tables
Table 1 Detector Test Points 6
______________________________________________
Table 2 Detector Reply Codes (mag ink) 12
______________________________________________
Table 3 Detector Reply Codes (mag thread) 12
______________________________________________

Page 2 May 2001
Illustrations
Figure 1 Twin Magnetic Ink Detector 4
______________________________________________
Figure 2 Permanent Magnet 5
______________________________________________
Figure 3 Twin Mag. Ink - General Block Diagram 6
______________________________________________
Figure 4 Twin Mag. Ink - Detailed Block Diagram 7
______________________________________________
Figure 5 Fault Diagnostic Routine 11
______________________________________________
Figure 6 Location of Detector Heads 13
______________________________________________
Figure 7 Location of Test Points & Potentiometers 15
______________________________________________
Figure 8 Magnetic Head Detector 19
______________________________________________

May 2001 Page 3
Twin Magnetic Ink Detector
Figure 1 Twin Magnetic Ink Detector
The Twin Magnetic Ink detector authenticates banknotes with both

magnetic ink features and machine-readable thread.
On its path around the note transport system, the banknote passes a
permanent magnet mounted near the lower right-hand corner of the
transport (see Figure 2), and the magnetic features of the note retain
some magnetism.
When the note passes the twin heads of the detector (see Figure 1), the
level of magnetism on the banknote is measured.
The amplitude of the detected signal reflects the level of magnetism on

the banknote, and in general, two levels of amplitude are detected along
the length of a banknote. The lower level signal results from the lower
level of magnetism detected in the magnetic ink used on the banknote,
and the higher amplitude results from the magnetic thread. The
resulting signals are processed, and passed to the detector processor
for separate analysis.

Page 4 May 2001
Permanent
Magnet
Figure 2 Permanent Magnet
2.1 Detector System

The detector system comprises:
lA pair of permanent magnets in a magnet housing.
lA twin magnetic head assembly, which includes a detector board.
lPart of the Detector interface board.
lThe control signal generation part of the Detector processor board.
A block diagram of the system is shown in Figure 3.
2.2 Magnetic Ink Detection

A detailed block diagram of the detector system is shown in Figure 4.
Low going pulses on the LOW MAG output indicates magnetic ink
detected. A /READY function is derived from the zero-volt return on the
Detector board, and routed to buffer U5 of the Detector interface board.

May 2001 Page 5
Front-end Board
SCHEDULE 30
Detector Head 1 Detector Head 2
SCHEDULE 8
SK 13
J13
Detector Interface J5 PL17 SK17

Board Power Supply Unit
Figure 3 Twin Magnetic Ink Detector – General Block Diagram
2.3 Magnetic Thread Detection

The action is the same as that for magnetic ink detection, except that
the threshold reference is higher, and is set by RV2. A low going pulse
on the HIGH MAG output indicates that a magnetic thread has been
detected.
2.4 Test Points

Table 1: Detector Test Points
Mag. Thread Mag. Ink Function
Test Point Test Point
TP3 TP3 Pre-amplified Head signal (+ve
going and clamped to zero volts)
TP5 TP4 Pre-set threshold reference
TP6 TP7 Logic 1 output for magnetisation
below threshold reference
0V2 0V2 Signal return (0V)

Page 6 May 2001
Figure 4 Twin Magnetic Ink Detector - Detailed Block Diagram

May 2001 Page 7
Twin Magnetic Ink Detector Cable

Wire No Colour From To Function
1 Brown Pin 3 SK8 / 9 HIGH MAG
2 Red Pin 1 SK8 / 6 + 5V
3 Green Pin 4 SK8 / 14 IMM CLOCK
4 Blue Pin 6 SK8 / 5 /READY
5 White Pin 2 SK8 / 8 LOW MAG
6 Black Pin 5 SK8 / 3 0V
Black Screen SK8 / 1 DRAIN
J13 Mother/Distribution Board Connections

From To Function
J13 / 1 0V
J13 / 2 0V
J13 / 3 0V
J13 / 4 0V
J13 / 5 SK3 / 11A I/O 27
J13 / 6 + 5V
J13 / 7 + 5V
J13 / 8 SK3 / 10A I/O 28
J13 / 9 SK3 / 9A I/O 29
J13 / 10 SK3 / 9 + 15V
J13 / 11 SK3 / 14A DET. OUT 11
J13 / 12 SK3 / 16A DET. OUT 12
J13 / 13 SK3 / 8 - 15V
J13 / 14 SK3 / 6A I/O 32

Page 8 May 2001
3.1 Error Messages

A ‘Check DY’ message may be caused by a disconnection of one of the
connectors in the twin magnetic Ink detector system.
3.2 Preliminary
transport system. Therefore, before investigating specific detector
faults, it is necessary to check for correct operation of the note transport
system.
Ensure that, if any part of the detector system is renewed, adjustment

procedures of paragraphs 4.1 and 4.2 are carried out.
3.3 Transport System Integrity

Before any diagnostic work is carried out on the detector, it must be
established that the note transport system is working correctly. To do
this carry out the following procedures:
Cleanliness
Check that all transport sensors and detectors are clean. If any item is
found to be excessively dirty, remind the supervisor and operator of the
importance of thorough daily cleaning.
Transport clock
Using the transport diagnostic, check that both the voltage and speed
of the transport clock are satisfactory.
If the transport clock fails the above test, check that the area around the
timing sensor, and timing disc is clear, and that the timing sensor is
orientated correctly before deciding to renew parts.
Note feeder
Check that the note feeder adjustments are correct. Observe whether
the feeder gives any multiple feeds. Multiple feeds can be identified by
counting the number of notes in the cull pocket, and comparing the
count with the number of notes in the transport trace (Diagnostic
function 09, set up to trace culls only).

are badly degraded, poorly prepared, or incorrectly loaded into the
hopper. If they are not, check that the contra roller and nudgers are
clean. Check that all parts are correctly fitted, undamaged and not
excessively worn.
Belt slip
Use the transport diagnostic to check that the slip is within specification.
Check whether the detector processor slip log shows any anomalies. If
there are no signs of anomalies, but the slip is greater than the allowed
limits, then check belt tensions, condition and cleanliness. Detector and
sensor positions should not be changed.

May 2001 Page 9
Culls
Use the transport note trace to determine whether the transport
processor is culling the notes. Use the detector processor note trace to
determine whether the detector processor is culling the notes. If either
processor is initiating the culls, then investigate and correct the
appropriate action against the cull reason, but not if the detector initiated
the cull.
If the cull rate is still excessive, investigate specific faults.
Service report
The service report should include a statement verifying that the test for
system integrity is completed. The report should also include details of
all corrective actions taken.
3.4 Fault Finding Procedure

If a fault persists proceed as follows:
a) Check all connections between the detector heads and the Mother/
Distribution Board.
b) Follow the Diagnostic routine of Figure 5.

Page 10 May 2001
Is Ink feature or Thread Replace Detector Interface
START Yes
displayed ? Board
No
Is magnet assembly intact ? No
Renew magnet assembly
Yes
Adjust magnet assembly
Yes Is fault cleared ?
No
Replace Detector Board and

adjust
Replace Detector Heads

and adjust Head assembly
No
Contact
Technical Services
END

May 2001 Page 11
The following details the detector reply codes that may be seen from the
twin magnetic ink detectors via the diagnostic menu.
Magnetic ink detection only
Detector Name : Operator =DY
Engineer = MAGI or MAG
This detector has a simple Go/No go reply, being a 4-digit hexadecimal

number, depending upon whether the required amount of magnetic ink,
in one area of the note, was detected or not.
Table 2: Detector Reply Codes (magnetic ink)
Reply MAG
Note is unfit Hex 0000

Dec 0
Note is fit Hex 0001

Dec 1
Magnetic thread detection only

The detector name associated with this detector is as for the magnetic
ink detector. When used in this way, the detector looks for a magnetic
thread in three areas of the note, as follows:
a) Where it expects a thread of a faced and oriented note
b) Where it expects a thread of a faced and un-oriented note
c) An area of note bounded by the extremes of a & b.
If the detector finds a magnetic thread in any of the above areas of note,
then it sets the reply as detailed in Table 3.
Table 3: Detector Reply Codes (magnetic thread)

Detector Reply
Binary Hex. Result
No thread found anywhere 000 0000 CULL
Thread found in area a 001 0001 VALID
Thread found in area b 010 0002 VALID
Thread found in areas a & b 011 0003 CULL
Too much magnetic signal detected 100 0004 CULL

Page 12 May 2001
In order to carry out the adjustment procedure, the following items are
required:
l A test pack of banknotes with the magnetic ink feature and magnetic
thread for each denomination that the machine is required to
process.
l A pack of banknotes without the magnetic ink feature and without a

magnetic thread.
l A trimpot adjuster.
l A dual-beam oscilloscope – although this is not essential, it does

provide a useful check on correct operation.
4.1 Mechanical Adjustments

If any components are disturbed, then re-assemble/adjust as necessary
to achieve the following:
Magnetic head assembly
a) The heads must be in line with each other, and perpendicular to the
back plate.
b) The heads should be positioned 2.0 mm each side of the belt,

unless specified otherwise to read specific features.
c) The PCB bracket should be positioned such that the heads are in
the same plane as the note transport system, and such that a ban-
knote just contacts the face of the heads, without distorting, as it
passes.
2.0 mm
2.0 mm
DETECTOR HEAD DETECTOR HEAD
MOUNTING BRACKET
TRANSPORT BELTS
Figure 6 Location Of Detector Heads

May 2001 Page 13
Lower guide
d) The melinex guide should be set such that it lays flat against the
face of the heads. The point of contact should be just prior to the
heads’ centre line.
Magnet assembly
e) The face of the magnet should be 1.5mm to 2.0 mm away from the
lower surface of the nearest belt.
4.2 Electrical Adjustments

All electrical adjustments are made on the detector board. The detector
board is housed in a die-cast box located behind the right-hand side
cover of the machine.
To gain access to the detector board, remove the cover of the die-cast
box. The location of test points and adjustment potentiometers is
shown in Figure 7.
In order to simplify the following procedures, orientate all the notes in

each test pack, that have a magnetic ink feature, the same way.
In the following procedure, those steps that involve the use of an oscil-
loscope are marked with an asterisk, ‘ ’.
*
To set up the twin magnetic ink detector proceed as follows:
a) Mask out all the detectors except the twin magnetic ink detector,
see paragraph 4.3.
b) Set the sensitivity of both the oscilloscope beams to 5 volts per

*
division, and the sweep rate to 20 milliseconds per division.
c) Connect beam 1 probe to J13 pin 11, and the signal return clip to
*
TP1. Pin 11 gives a negative-going pulse as the leading edge of a
note passes under the head, and a positive-going pulse as the
trailing edge passes under the head.
d) Set the oscilloscope to trigger on beam 1 and connect Beam 2

*
probe to TP7
e) Set RV1 and RV2 to mid-positions.

Page 14 May 2001
Figure 7 Location of Test Points and Potentiometers

May 2001 Page 15
Magnetic ink features
f) Select an appropriate process (counting rather than sorting), and a

denomination of test notes with a magnetic ink feature, that is most
similar in size to the notes without the magnetic ink feature.
g) Feed the selected pack of test notes, orientated appropriately

through the machine. Adjust RV1 just sufficiently for notes to be no
longer culled. Check on the oscilloscope that the magnetic ink
*
features are displayed, and are correctly related to the leading and
trailing edges of the notes.
h) Feed the pack of notes without the magnetic ink feature, and check
that all the notes are culled. Check on the oscilloscope that the
*
magnetic ink features are not displayed.
i) Re-feed the pack of test notes fed at step g, using a different, but
allowable orientation. Check that no notes are culled. If necessary
re-adjust RV1 just sufficiently to satisfy the check.
j) Repeat step i for each remaining allowable orientation, if any, of the

pack.
k) Select the denomination of the next unfed pack of notes.
l) Feed that pack of test notes, orientated appropriately through the

machine. If necessary re-adjust RV1 just sufficiently to satisfy the
check.
m) Repeat step l for each remaining allowable orientation, if any, of the

pack.
n) Repeat steps k, l & m for the remaining packs of notes.
Magnetic thread features
o) Select an appropriate process (counting rather than sorting), and a

denomination of test notes with a magnetic thread feature, that is
most similar in size to the notes without the magnetic thread feature.
p) Feed the selected pack of test notes, orientated appropriately

through the machine. Adjust RV2 just sufficiently for notes to be no
longer culled. Check on the oscilloscope that the magnetic thread
*
features are displayed, and are correctly related to the leading and
trailing edges of the notes.
q) Feed the pack of notes without the magnetic thread feature, and
check that all the notes are culled. Check on the oscilloscope that
*
the magnetic thread features are not displayed.
r) Re-feed the pack of test notes fed at step p, using a different, but
allowable orientation. Check that no notes are culled. If necessary
re-adjust RV2 just sufficiently to satisfy the check.
s) Repeat step r for each remaining allowable orientation, if any, of the

pack.

Page 16 May 2001
t) Select the denomination of the next unfed pack of notes.
u) Feed that pack of test notes, orientated appropriately through the

machine. If necessary re-adjust RV2 just sufficiently to satisfy the
check.
v) Repeat step u for each remaining allowable orientation, if any, of the

pack.
w) Repeat steps t, u & v for the remaining packs of notes.
4.3 To Mask Out All Detectors Except The Twin Magnetic

Ink Detector
a) Select the Diagnostics Menu.
b) Select Detector System Engineers Function.
d) If the Detector Number of the Twin Magnetic Ink Detector is not

known:
i. Select Detector Diagnostics.
ii. Select List Detector Names.
iii. Note the number for the Twin Magnetic Ink Detector, and Exit.
e) Select Configuration.
f) Select Edit Config (Edit configuration).
g) Select Process Data.
h) Select Mod. Det. Mask (Modify Detector Mask).
i) Enter the Process Table Identity (Process number currently being

used).
enabled (1) or disabled (0), Detector 1 is first on the right hand side.
enter the detector number. Ensure that the Twin Magnetic Ink
Detector is the only detector enabled.
the Twin Magnetic Ink Detector.


May 2001 Page 17
To remove the detector head assembly proceed as follows:
a) Unplug the detector head cable at the connector behind the back
plate.
b) Remove the two bolts securing the head bracket to the back plate
c) Lift the assembly away from the machine.
d) To replace the head assembly reverse the above procedure.
e) Carry out the full setting up procedure described in paragraph 4.

Page 18 May 2001
01002972 Magnetic Head
3702003104 Note Guide D/A Twin Mag
BB09531202 PCBP Mag Thread Detector
99981987 Magnet
Magnetic Head
Note Guide D/A -

Twin Mag
Figure 8 Magnetic Head Detector

May 2001 Page 19
Page 20 May 2001
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ÉåÇ=Äç~êÇK
ÄF cçääçï=íÜÉ=aá~ÖåçëíáÅ=êçìíáåÉ=çÑ=cáÖìêÉ=QK
Check
START Detector
Controller Memory
Is Note
profile detected
?
Yes
Repeat setting-up
procedure
No
Is fault
Yes repaired
?
No
Replace
front-end board
Is fault
Yes repaired
?
No
Replace
Detector head
assembly
Is fault
Yes repaired
?
No
Replace
Detector controller board.
If fault persists contact
Technical Services.
END
Figure 4 Fault diagnostic procedure
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l qêáãéçí=~ÇàìëíÉê
l oìäÉê
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ïáåÇçïI=íÜÉ=áääìãáå~íáçå=ëçìêÅÉëI=~åÇ=íÜÉ=êÉÑÉêÉåÅÉ=íáäÉ=~êÉ=ÑêÉÉ=Ñêçã=
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Figure 5 Part of Front-end Board Showing LK2
`~äáÄê~íáçå
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Note: It is possible that during this routine, LED A, which was OFF,
turns ON. It is not necessary to re-adjust RV2a as the setting will still
be within specification.
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Note: It is possible that during this routine, LED A, which was OFF,
turns ON. It is not necessary to re-adjust RV2b as the setting will still
be within specification.
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Cobra

Banknote Sorting Machine

Walton Road, Farlington

All items of technical information, advice, know–how, drawings,

The above duty of confidence also entails a prohibition of reproduction

1.1 Service Manual Amendment

D The relevant page is to be inserted in the Manual and the old

D The Record of Amendments page is to be completed with the

D The Technical Bulletin/Technical Memorandum Title page should

b. Where the Amendment is NOT a page replacement:

D The relevant page is to be amended in the manual and the

D The Record of Amendments page is to be completed with the

D The Technical Bulletin/Technical Memorandum Title page should

1.2 Machine Modification

This record will therefore show all machine modifications, whether

1.3 Master Copies

1.5 Page Replacements

Technical Bulletins and Memoranda

Contents (this page)

Health and Safety

Section 2 Thickness Detector

Section 3 Solid State Holes & Tears

Section 4 Vision Detector

Section 5 Optical Pattern Detector

Section 6 UV Bright Detector

Section 7 Limpness Detector

Section 8 Soil Detector

Section 9 Twin Magnetic Ink Detector

Section 10 Infa–Red Detector

2. HEALTH AND SAFETY

Wall isolating switchgear must be installed in accordance with local

2.2 High Energy

2.4 Moving Parts

Under certain fault conditions it is possible for motors to start. When

Emergency stop switches, which cannot be over–ridden, are provided

Additionally, all covers that are operator accessible are protected by

2.5 Cutting Blades

2.7 Cabling And Power

2.8 SSD Devices

Note: Wherever these symbols appear throughout this manual

1.1 Note Authentication and Assessment System

a) Thickness (Doubles) detector, by which multiple notes are detected,

b) Solid state holes-and-tears detector, by which holes,open tears and

c) Limpness detector, by which the audio condition of each note is

Whilst notes are being transported, the processor passes to the

l Detector truth tables

l Configuration change history

2.1 Detector Interface Board

To complete some of the detector adjustments it may be necessary to

Before carrying out any maintenance procedures the section on Health

4.1 Error Messages

4.3 To Test For Cobra 4004 Transport System Integrity

If the number of multiple feeds is excessive, check whether the notes

If the cull rate is still excessive, investigate specific detector faults.

5. DETECTOR SYSTEM DIAGNOSTICS -

Detector Processor Direct Communications

a) Request change to condition sort level (diagnostics utility)

b) Set up condition sort pointers (set up utility)

c) Detector processor diagnostics

In those instances where comprehensive prompting is not possible due

c) ‘I<-’ - Cancelling numeric input or abort key.

d) The screen is sometimes frozen to allow it to be examined before

e) Prompts for numeric input expect, by default, decimal numbers. If