Mars CashFlow 560 Applications Design Guide
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23174 G3 142922044
CashFlow 560 changegiver Applications Design Guide
Published by :
Mars Electronics International
Eskdale Road
Winnersh Triangle
Wokingham, Berkshire RG41 5AQ
United Kingdom
For information on translations in your country, please write to the Technical Communications
Manager at the above address.
CashFlow560 changegiver Applications Design Guide
©, Mars, Inc., 1996.
All rights reserved.
Except as permitted under the relevant local legislation, no part of this publication may be
copied, transmitted, transcribed, or distributed in any form or by any means, or stored in a
database or retrieval system, or translated into any language (natural or computer), without the
prior written permission of Mars Electronics International.
Mars, CashFlow and the Mars Electronics International device are registered trademarks.
©, Mars, Inc., 1996.
Mars Electronics reserves the right to change the product or the product specifications at any
time. While every effort has been made to ensure that the information in this publication is
accurate, Mars Electronics disclaims any liability for any direct or indirect losses (howsoever
caused) arising out of use or reliance on this information.
This document does not necessarily imply product availability.
Part Number : 142922044
This Edition ( March 1996) Printed in the United Kingdom.
ii ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
SAFETY.......................................................................................1
OVERVIEW.................................................................................2
PRODUCT OPERATION..........................................................5
GENERAL.............................................................................5
ELECTRO-MECHANICAL PRODUCT ........................5
SERIAL INTERFACE PRODUCTS..............................5
COIN ACCEPTANCE, ROUTING & RETURN ...................13
ACCEPTOR MODULE.................................................6
ACCEPT GATE MODULE ...........................................7
SEPARATOR ...............................................................7
CONTROL BOARD......................................................7
SPINE..........................................................................7
TRANSFORMER ASSEMBLY.....................................8
KEYPAD.......................................................................8
DISPENSER................................................................8
COIN STORAGE CASSETTE .....................................8
COIN ACCEPTANCE.................................................13
COIN ROUTING ........................................................14
CHANGE PAYBACK..................................................15
TUBE SENSOR USAGE............................................16
TABLE OF CONTENTS
Tube Combinations.............................................9
Exact Change Equation....................................10
Using Exact Change Inhibit ..............................12
Global Coin Inhibit ............................................14
Use of Tubes ....................................................15
Best Change Calculation..................................15
Full sensors ......................................................16
Coin cassette removal detection.......................17
Full sensor error detection................................18
Coin count re-calibration...................................18
Low sensor error detection...............................18
©, Mars, Inc., 1996. iii
CashFlow 560 changegiver Applications Design Guide
PRODUCT INTERFACES......................................................21
ELECTRICAL INTERFACES..............................................22
ELECTRO MECHANICAL INTERFACE ............................25
EXACT CHANGE OUTPUT.......................................25
CREDIT RELAY DRIVE.............................................25
SAFETY LINE............................................................25
PRICE LINE COMMON.............................................25
PRICE LINE OUTPUTS.............................................25
MACHINE INTERFACE......................................................26
SINGLE / MULTI VEND .............................................27
SENSE INPUT TIMING .............................................27
VEND START ............................................................27
VEND FINISHED.......................................................28
BLOCKER RESET.....................................................28
DELAYED BLOCKER RESET ...................................29
BLOCKER HOLD RESET..........................................30
ESCROW ACCEPT...................................................31
PRICE SENSE / BLOCKER / ESCROW ACCEPT /
VEND START/ INHIBIT INPUTS................................32
Coin count re-calibration...................................19
Home sensors...................................................20
EXTERNAL CREDIT DISPLAY ..........................................33
DISPLAYING CREDIT ...............................................33
CANCELLING CREDIT..............................................33
DISPLAYING VEND PRICE.......................................34
DISPLAYING PRICE TEACH CREDIT......................34
DISPLAYING FLOAT VALUE.....................................34
POWER ON INDICATOR...........................................34
DISPLAYING TUBE VALUE ......................................34
VOLTAGE RANGES ..................................................35
POWER CONSUMPTION / RATING.........................35
TERMINAL CONNECTOR..................................................35
MAN MACHINE INTERFACES ..........................................36
KEYPAD.....................................................................36
LED Usage .......................................................37
Manual Coin Dispense......................................37
Automatic Tube Float (Float Up).......................38
iv ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
INTERNAL DIAGNOSTICS & ERROR HANDLING ..........41
HOST MACHINE PROBLEMS ..................................41
COIN HANDLING PROBLEMS .................................43
ON-BOARD EEPROM PROBLEMS..........................44
AUDIT FEM PROBLEMS...........................................46
HOST INTELLIGENT INTERFACE(HI2) ERRORS ...46
MISCELLANEOUS ERRORS....................................47
VIA MARS
KEY FUNCTIONS......................................................49
USING THE TERMINAL............................................50
VISUAL AUDIT..........................................................52
DIAGNOSING TERMINAL PROBLEMS ...................64
Float Down Mode..............................................39
Resetting Tube Counts.....................................39
Price Teach ......................................................39
Homing the Dispensers ....................................40
Displaying Tube Value......................................40
Host Inhibited....................................................41
Removal of Blocker...........................................41
Blocker Return..................................................42
Cashbox Full.....................................................42
Bad Replies Received ......................................42
No Response....................................................43
Full Sensor Failure............................................43
Post Gate Strobe (PGS) Failure.......................43
Tube Cassette Removal...................................43
Home Sensor Failure........................................44
Motor Failure / Jam...........................................44
Incorrect Configuration vsn. No........................44
EEPROM Corruption ........................................45
Write Timeout ...................................................45
Audit not initialised............................................46
Audit FEM corrupt.............................................46
Audit removed ..................................................46
HI2 Error...........................................................46
Acceptor Initialising Error..................................47
ROUTE ALPHA 250 TERMINAL...................48
Visual Audit Interrogation..................................52
Testing the Terminal.........................................65
©, Mars, Inc., 1996. v
CashFlow 560 changegiver Applications Design Guide
ENVIRONMENTAL PERFORMANCE.................................66
TEMPERATURE RANGE...................................................66
HUMIDITY...........................................................................66
VIBRATION.........................................................................66
INSTALLATION ..................................................................66
TRANSPORTATION...........................................................67
LIQUIDS..............................................................................67
VOLTAGE ...........................................................................68
VOLTAGE TRANSIENTS ...................................................68
SAFETY CLASSIFICATIONS...............................................69
CLASSIFICATION ..............................................................69
PARTITIONS.......................................................................69
SAFETY INSULATION .......................................................70
ENERGY STORAGE..........................................................70
FLAMMABILITY.................................................................70
ELECTRO-MECHANICAL AND MAINS INPUT RATINGS71
MECHANICAL PARTS.......................................................71
COMPATIBILITY......................................................................72
BILL VALIDATOR INTERFACE .........................................74
MARS ELECTRONICS INTERNATIONAL OFFICES .....78
INDEX.........................................................................................79
APPENDIX ................................................................................84
INTERFACE DRAWING .....................................................84
vi ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
SAFETY
International & National Standards
Conformance
When installed and operated according to the
instructions for the particular unit, CashFlow
products are designed to meet the applicable
Safety and Electro Mechanical Conformance
standards for any country in which they are used.
CashFlow
construction. No safety earth connection is
necessary or provided.
560 products are of class II
560
Dangerous Environments
Do not operate in the presence of flammable
gases, fumes or water.
Disposal of Product
Do not dispose of any parts of this product by
incineration.
Rated Operating Voltage
The rated voltage is indicated on a clear see
through label above the changegiver keypad.
Always operate the changegiver from the type of
power source indicated on the label.
Warning: before removing or replacing modules
SWITCH OFF or ISOLATE the ELECTRICITY
SUPPLY to the host machine
THIS MANUAL IS PROVIDED FOR USE ONLY BY PERSONNEL
TRAINED TO UNDERTAKE ELECTRICAL INSTALLATION
©, Mars, Inc., 1996. 1
CashFlow 560 changegiver Applications Design Guide
OVERVIEW
The CashFlow 560 range of changegivers have been designed to
address a wide range of market needs and are compatible with the
majority of modern vending machines. They are plug compatible
replacements for the previous MS1600, ME1600 and ME1900
series of changegivers. The flexible approach allows easy matching
of modules for all types of applications. They are designed to work
with a wide range of coinsets and can be upgraded to accept new
coins. There are four change tubes and field selection of the coins
to be stored in them is possible. On the front of the changegiver is a
keypad which is used to dispense coins and re-configure some
aspects of the changer. All CashFlow
up of several modules;
• Control board
• Spine
• Transformer
• Keypad
• Dispenser
• Acceptor
• Separator
• Coin Storage Cassette
560 changegivers are made
Control Board
Spine
Dispenser
Back Cover
Transformer
Keypad
Acceptor
Separator
Coin Storage Cassette
Exploded View of the CashFlow Changegiver
2 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
The basic functionality of all changegivers is to:
The following function is appropriate for electro-mechanical 4-price
product only:
The following functions are appropriate for electro-mechanical 4price, Executive and BDV product only:
• Accept payment
• Signal the payment available to the machine (credit
output)
• Monitor the product request inputs (sense inputs)
• Return un-used change
• Monitor the machine inhibited condition (blocker)
• Enable the appropriate price line output (if the vend is
authorised)
• Deduct the vend price from the credit available
• Indicate to the host machine the exact change
condition
The product options currently available are;
• CashFlow
mechanical changegiver
N.B. A credit display for use with the above variant can be provided.
• CashFlow
electronic Protocol A serial interface
• CashFlow
BDV serial interface
• CashFlow
MDB serial interface
560 - 4 price - A four price electro-
560 - Executive - changegiver with an
560 - BDV - changegiver with an electronic
560 - MDB - changegiver with an electronic
©, Mars, Inc., 1996. 3
CashFlow 560 changegiver Applications Design Guide
With the use of the Mars Route Alpha 250 terminal you can also
re-configure certain operational aspects of the changegiver. This
includes inhibiting coins, changing from single to multi vend etc..
®
The CashFlow
be supplied with an audit fuction extension module (FEM) fitted, or
this can be supplied for fitting at a later date.
The FEM allows for reports to be supplied either via a hand-held
Mars
These reports can include:
Audit 920 printer, or down-loaded via a terminal to a P.C..
560 electro-mechanical and Executive products can
• Value of cash manually filled
• Value of cash retained in the changegiver
• Value of cash sales
• Value of token sales
• Value of cash taken by the machine
• Value of cash to cashbox
• Value of cash dispensed as change
The process of obtaining data is detailed in the section of this book
concerned with the Mars
For further details of audit installation please refer to the Mars
900 Installation Guide, part number 143451999.
Additional information on the audit FEM and the Mars
printer can be obtained from your MEI regional office.
Route Alpha 250 terminal.
®
Audit
Audit 920
4 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
PRODUCT OPERATION
GENERAL
ELECTRO-MECHANICAL PRODUCT
When a coin is entered through the electro-mechanical changegiver
there are several conditions that are electronically checked.
After coins have been accepted and a product selection button is
pressed a sense current flows through the changegivers sense
circuit. The sense current is not sufficient to energise the relay, but
enough for the changegiver to detect. When the changegiver
detects that a product selection button has been pressed the
changegiver looks up the price associated with the selection. If
sufficient credit exists the changegiver turns the price line output on.
This disconnects the safety line from price line common and
connects the price line output to price line common. The vend motor
relay within the vending machine is then energised, turning the vend
motor on and closing a switch across the selection button.
When the vend cycle begins the blocker signal indicates to the
changegiver that a vend has started. The price of the vend is
deducted and the changegiver waits for the vend to finish. The price
line output is turned off when the changegiver considers the vend to
have finished.
Unused credit may be returned after the vend has finished either
automatically if in single vend mode, or by customer demand if it is
in multi vend mode, or after a pre-determined time in multi-vend
option setting, depending on how the changegiver has been set up.
SERIAL INTERFACE PRODUCTS
Dependent on which version of product is being used , when coins
or cashless card are inserted the value involved will be shown on the
display, if used. The host machine’s VMC communicates all
functions as required with the changegiver and any other
peripherals, such as an audit unit or cashless payment system, that
are being used.
The VMC in the host machine produces signals to the changegiver
(excluding MDB product) indicating when a vend is to be made, and
the value of the vend required. The changegiver will then ascertain
if sufficient credit is available to cover the cost of the vend. If the
changegiver is set to “No Overpay” it will confirm that any remaining
coin credit that would result from the vend can be returned before
authorising the vend.
©, Mars, Inc., 1996. 5
CashFlow 560 changegiver Applications Design Guide
If the vend is allowed the cost will be deducted from the credit prior
to authorising the VMC to start the vend. Should the vend fail, this
credit will be re-instated.
ACCEPTOR MODULE
There are some functions of the acceptor module which are
common across the whole CashFlow
include coin discrimination, control and communication.
When a coin is put through the acceptor module it’s validity is
determined by measuring certain parameters. It also looks at the
coin type status to define whether the payment is a valid coin or
token, or an invalid coin. Finally, the inhibit status is checked. If the
coin is not inhibited, then it will be accepted, the accept gate
opened, and the coin routed to either a tube or cashbox. The
acceptor module is made up of the discriminator, back cover and the
accept gate.
The discriminator comprises a flight deck and lid which together
form the coin control and flight path. On the inside of the flight deck
lid there is a mechanical device incorporated near the coin entry
point. This device is known as the coin deflector and is used to bring
coins under control as they enter the product
product range. These
Flight Deck
Coin Deflector
Reject
Route
Acceptor Module
A hinge at the top right hand side of the flight deck allows coupling
of the lid via an intermediate component, known as the lid arm. This
allows the lid to locate accurately to the flight deck independently of
the hinge. The lid also maintains a parallel coin throat by being
Accept
Route
Flight Deck
Lid
Coin Path
Accept Gate
Module
6 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
spaced from the deck on three bosses which locate the lid squarely
to the deck.
The design of the lid arm hinge area allows the lid to open to 180
degrees relative to the deck. The opening is restricted to just over
100 degrees by the back cover to prevent the lid possibly fouling
other parts.
The action of the hinge spring allows the lid to remain open when
past about 100 deg. and will snap shut when closed to about 60
degrees although the lid will need to be pressed to ensure that it is
correctly seated against the deck. The acceptor module connects to
the control board via a 10 way ribbon cable.
On the front of the acceptor module there is a six way socket. This
is for use with a Mars
hand held and, when connected to the acceptor, allows some of the
operational aspects of the changegiver to be altered.
Route Alpha 250 terminal. The terminal is
ACCEPT GATE MODULE
The accept gate module contains a solenoid operated gate, optical
coin strobes and coin routing components. Coins that are correctly
discriminated are routed to the accept exit by energising the accept
gate. Coins that are rejected are routed to the reject exit.
SEPARATOR
The separator separates the coins into different routes, either to the
coin storage tubes or the cashbox. It contains a solenoid bank and,
at the bottom, a top level sensor assembly which is used to avoid
tube overflow.
CONTROL BOARD
This is the main PCB which controls the way in which the
changegiver operates. There are several different control boards,
but basically these are the 4 price for electromechanical machines,
and the Executive, MDB and BDV for electronic machines.
SPINE
The spine provides the housing for all of the other modules. On the
rear of the spine are the three standard keyhole fixing points for
fitting the changegiver into a machine.
©, Mars, Inc., 1996. 7
CashFlow 560 changegiver Applications Design Guide
TRANSFORMER ASSEMBLY
The transformer assembly is housed behind the keypad cover. To
gain access to the transformer there is a screw located under the top
flap of the keypad cover. Once this screw has been removed the
keypad cover will lift off and the transformer is accessible. The
transformer connects to the control board via two looms and is
available in 24V, 100V, 120V, 220V, and 240V options.
Note: On CashFlow
transformer is replaced by a reservoir capacitor.
KEYPAD
The keypad is used to float or dispense coins and to re-configure
some aspects of the way in which the changegiver works.
DISPENSER
The dispenser is held in the spine by two clips, one on each side. It
connects to the control board via a loom. It contains four dispense
arms which, when operational, dispense coins from each of the four
storage tubes. The dispenser also contains low level sensors which
detect when the coin tubes are low on coins. It is possible to
dispense coins from more than one tube at the same time.
560 BDV and MDB changegivers the
COIN STORAGE CASSETTE
The coin storage cassette clips to the front of the changegiver and
contains four independent coin storage tubes. There are thirteen
different sizes of tube, each numbered from 0 - 7. These cover most
sizes of coins that you should want to route to coin tubes.
N.B. Some have a suffix of “.5” (i.e. 2.5), and dimensions range from
0 which has the largest bore and 7 with the smallest bore. Each tube
has a designator fitted at the bottom. The size of the designator
fitted is dependant upon the thickness of the coin. There are eight
different sizes of designator each lettered from A - H.
The front cover is marked A,B,C,D to indicate the position of the
fitted tube, as shown below. Coins of the following sizes can fit into
each of the positions:
• Coin diameters from 15.0 to 26.0 mm in position A
• Coin diameters from 18.6 to 32.5 mm in position B
• Coin diameters from 15.0 to 29.2 mm in position C
• Coin diameters from 18.6 to 29.2 mm in position D
8 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
Tube Combinations
Tube Position A Position B Position C Position D
0
1
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
✘✔✘✘
✘✔✘✘
✘✔✔✔
✘✔✔✔
✘✔✔✔
✔✔✔✔
✔✔✔✔
✔✔✔✔
✔✔✔✘
✔✔✔✘
✔✘✔✘
✔✘✔✘
✔✘✔✘
COIN SIZES FOR EACH TUBE
Tube No Part No
0 101812001 31.01 32.50
1 140164001 29.21 31.00
2 101825001 26.91 29.20
2.5 169494001 26.01 26.90
3 101838001 24.51 26.00
3.5 169509001 23.21 24.50
4 101841001 21.61 23.20
4.5 169512001 20.76 21.60
5 101854001 19.51 20.75
Min Coin
Diameter
Max Coin
Diameter
5.5 169525001 18.61 19.50
©, Mars, Inc., 1996. 9
CashFlow 560 changegiver Applications Design Guide
Tube No Part No
6 101867001 18.11 18.60
6.5 169538001 16.70 18.10
7 101870001 15.00 16.69
Although there are different sizes of tubes and designators
available, not every tube can be fitted into every position in the
cassette.
There are prisms located at the top of each tube which, when
combined with the optos on the separator form the top level sensor.
The top level sensors are used to indicate when a tube is full. When
a tube is full any further coins are routed to the cashbox.
The cassette can be automatically filled by feeding coins through
the product, or manually filled by removing the cassette from the
changegiver.
Min Coin
Diameter
Max Coin
Diameter
On the front of the cassette are float indicators which you can
position manually by sliding up and down.
Exact Change Equation
When the changegiver, other than MDB product, detects that the
quantity of coins in a coin tube is below the low-level sensor, a
signal is sent to the vending machine to switch on the exact change
light (ECL) so as not to risk short-changing a customer.
Setting the exact change equation ensures that the optimum
combinations of change coins are always dispensed, by using
coins from alternative tubes to make up the change required, and
that the ECL is on for the minimum time possible.
An explanation of the process used to determine the optimum coins
for change can be found later under the heading of Best Change
Calculation.
Two exact change equations can be set using Route Alpha 250
terminal, addresses 236 and 237. The tubes A, B, C and D are
coded 1, 2, 4 and 8
Address 236 = exact change equation, part 1 - offers the first option
to use change coins from nominated tubes .
10 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
Address 237 = exact change equation, part 2 - sets a second
selection of change tubes.
Address 383 can also be used, with BDV product only, to give an
additional early warning setting, (in conjunction with addresses
271-274), and trigger the ECL to come on at an earlier point when
the coin count in a selected tube becomes low coded 1, 2, 4, and 8.
1p 2p 5p 10p
Low-level sensor
Tube
AB D
12 48Code
C
EXAMPLE: A four-tube changegiver contains 1p, 2p, 5p and 10p
coins, and the vend price is 16p.
If 20p is inserted, the optimum change payout will be from tubes A
and B. Therefore address 236 - exact change equation, part 1must be set to 3 (using code 1 + code 2 to equal 3). This setting will
ensure that the ECL comes on when tubes A and B become low.
If 50p is inserted, the optimum change payout will be from tubes A,
B AND D. Thus address 237 - exact change, equation part 2- must
be set to 11( using codes 1 + 2 + 8 to equal 11. This setting will
ensure that the ECL comes on when tubes A, B and C become low.
Setting both addresses 236 and 237 will cause the ECL to come on
when tubes A and B, or tubes A, B and C become low.
If the vending machine becomes inhibited (blocked) this is signalled
to the changegiver by the blocker signal. During the inhibited state,
coin acceptance is disabled. This condition may occur because
there are no products left in the machine, or the machine has
developed a fault.
©, Mars, Inc., 1996. 11
CashFlow 560 changegiver Applications Design Guide
Using Exact Change Inhibit
When the machine is in exact change mode, selected coins can be
inhibited, other than with MDB product.
Setting the exact change inhibit option will stop a specified coin or
coins being accepted when the exact change light is on. It is usual
to inhibit the highest value coin(s) to minimise the risk of the
customer being short-changed.
When the coin level rises again above the low count, the ECL is
turned off, and the inhibit option switched off so that the previously
inhibited coins are accepted.
The coin set for the unit is divided into three exact change groups,
in which each coin has a code. The groups are associated with
addresses 232, 233 or 234. Set the range value of the addresses to
the code of the coin you want to inhibit. Add the codes together to
inhibit more than one coin at a time in each group.
Addresses 232 - coins 1 - 4 using codes 1, 2, 4 and 8
Addresses 233 - coins 5 - 8 using codes 1, 2, 4 and 8
Addresses 234 - coins 9 - 12 using codes 1, 2, 4 and 8
12 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
COIN ACCEPTANCE, ROUTING & RETURN
The changegiver has a standard coin entry and exit chuting. Coin
return via a reject lever is also standard. The coin acceptance, and
the routing used on coin acceptance, are dependant on:
• The set up of various configuration items in the
changegiver EEPROM
• Other changegiver conditions which will alter while the
changegiver is in operation
As a result of this, both coin acceptance and coin routing are
dynamic, i.e. changing in time as the state of the changegiver alters.
The dependencies are detailed in the following sections.
COIN ACCEPTANCE
The acceptance of each coin is determined primarily by the set up
of default inhibits in the EEPROM. This specifies which coins should
always be inhibited (i.e. rejected). In addition to these defaults, extra
inhibits will be imposed depending on the following conditions:
In normal mode with the overpay inhibit flag set:
• Coins which are not dynamically routed to the tubes will
be inhibited and rejected if their value, plus the existing
coin credit, cannot be returned due to lack of correct
change coins
• Coins which would take the total system credit over the
maximum allowed credit are inhibited
• Vend tokens are inhibited if the total system credit is
not zero
In normal mode with the overpay inhibit flag clear:
The Vending Machine Contoller (VMC) overules this in the MDB
product
• If use exact change has been signalled, the exact
change inhibits are imposed
• Coins which would take the total system credit over the
maximum allowed credit are inhibited
• Vend tokens are inhibited if the total system credit is
not zero
In float mode:
• All coins which are not dynamically routed to the tubes
will be inhibited
In price teach mode:
• Coins which would take the total system credit over the
maximum allowed credit are inhibited
• Vend tokens are inhibited
©, Mars, Inc., 1996. 13
CashFlow 560 changegiver Applications Design Guide
Global Coin Inhibit
In addition to the individual coin inhibits described above, a global
coin inhibit can be imposed. This will inhibit all coin acceptance
regardless of any other conditions. A global inhibit is imposed when:
• Manually dispensing coins either from the key pad or
the terminal
• Returning credit
• A vend is in progress (VMC function on MDB)
• A price is on the display due to a product selection
being made with insufficient credit. (When in price
display mode). (Not on MDB)
• Value of tube contents is on the display. (Not MDB)
• Any bits in the EEPROM error register are set, apart
from code 5
• A free vend token has been accepted
• An executive type vending machine has indicated that
it requires a free vend
• The host machine has indicated it is inhibited
• The cashbox error code or if the protocol A error code
is set
• The blocker signal is not present
COIN ROUTING
The coin routing used is determined in the EEPROM. If a tube is not
®
fitted this is indicated as 00 on the Mars
display. In addition, there are conditions which prevent coin routing
to a tube even when it does store the coin. These are any of the
following:
• The tube full sensor reads covered (or has failed its
self-test, if test enabled on acceptor)
• There was a fatal dispenser error on that tube
• The tube counts held in changegiver RAM are equal
to, or greater than, the maximum level for that tube.
The routes, determined by all the above criteria, are the dynamic
routes. Before a coin can be routed it must first be accepted. If a coin
is rejected none of the above applies.
Route Alpha 250 terminal
14 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
CHANGE PAYBACK
In general the changegiver will attempt to return any coin credit to
the consumer, in the best possible coin mix. However, this simple
statement requires clarification.
Use of Tubes
• The changegiver will only attempt to use tubes which
are shown as fitted, and have not been disabled by the
occurrence of sensor or dispenser faults
• If a tube is fitted and is not disabled, it will be allowed to
be used for change payback only if its tube counts are
above the safe count value at the start of the change
payback sequence
• The changegiver will not function if the coin storage
cassette is not fitted
Best Change Calculation
Once the tubes that can be used have been determined the best
coin mix to pay back the change is calculated. Best coin mix is
defined as the first of the following found to be possible:
• Correct change paid with minimum number of coins
• Correct change paid with non-optimal coin mix
• Closest change paid with minimum number of coins
• Closest change paid with non-optimal coin mix
• No change paid
Once the best coin mix has been determined the dispensers will
start to pay the change out. The software will drive as many motors
as possible at once to expedite the change payback. (Not MDB)
Should either of the following occur the dispense sequence will be
suspended once each motor has got to its home position:
• The tube has run out of coins while coins are still
required. This could occur if the low level sensor/s go
from covered to uncovered, causing a tube count
recalibration, which reduced the number of coins held
in the tube. (Not MDB)
• A dispenser error is detected (stall, etc.)
The software will then re-compute the best coin mix to pay back the
credit still remaining and re-start the dispensers with this new coin
mix. The above will be repeated until all the change which can be
dispensed has been paid.
©, Mars, Inc., 1996. 15
CashFlow 560 changegiver Applications Design Guide
TUBE SENSOR USAGE
This section describes the operation of the tube sensors in more
detail. The sensor operation significantly affects the users
perception of how the changegiver appears to operate.
Each tube has associated with it three sensors:
• The full level sensor (opto sensor)
• The low level sensor (opto sensor)
• The tube dispenser home position sensor (reed switch)
Full sensors
Effect on coin routing
The changegiver cannot read the tube full sensors directly, but must
request their status from the acceptor module. The acceptor module
then performs a self-test of the full sensors. The acceptor module
reports both the reading of the sensor, covered or uncovered, and
the outcome of the self-test, OK or failed.
The changegiver will perform the following actions, on a tube-bytube basis, based on the self-test results and the sensor reading:
Self-Test
Result
OK Un-covered
OK Covered
Sensor
Reading
Changegiver Action
This is the normally expected
result. The changegiver will clear a
full sensor error, if flagged. It does
not take any further direct action.
However the routes may be
updated if the tube counts have got
to their maximum level
This is a fault condition, as the
maximum level a tube should reach
is 3 coins from full. The
changegiver will signal a full level
sensor error. If the low level sensor
is reading covered then there is a
good chance that the tube is really
full, so the changegiver will
recalibrate the tube counts to the
pre-programmed Full Number.
16 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
Self-Test
Result
Sensor
Reading
Changegiver Action
This condition cannot occur, as the
acceptor will always assume any
Failed Un-covered
Failed Covered
failed sensors are covered, and will
act as if this is so.
This is a fault condition, due to the
failure of the acceptor module’s
sensor self-test (opto was seen on
with the LED being off). The
changegiver will signal a full level
sensor error. It will ignore the
reported reading, and continue to
use the last (good) reading before
the failure. The routing will be
updated. The tube is still used for
dispense. If all 4 main tube sensors
are reported as failed, then the
cassette is assume to be removed,
and a cassette out error will be
flagged.
Note that sunlight, or other intense
light source can affect the sensor
self-test, causing it to fail. Thus the
changegiver will inhibit the self-test
feature when float or price teach
mode is entered. When this mode
of operation is selected, the selftest result will always be OK.
Coin cassette removal detection
If the coin storage cassette is removed, all the tube full sensors on
the tubes will read covered. Should the changegiver detect this all
tubes full condition, it will flag a cassette removed error and will
indicate a changegiver error on the error LED. No change payback
will be attempted from the tubes. Manual dispensing from the tubes
will still be allowed, but the tube counts will not be decremented.
Coins will still be accepted but routed to the cashbox.
The error will be cleared as soon as a coin is accepted or a dispense
©, Mars, Inc., 1996. 17
CashFlow 560 changegiver Applications Design Guide
attempted with the coin cassette back in place. Note that if all tubes
really have overfilled to cover the sensors then a cassette removed
error will be indicated, but will clear once the tube level drops.
Full sensor error detection
The changegiver will detect full sensor errors on dispensing from a
tube if coin storage cassette removal has not been detected. The
appropriate full sensor error register will be set and a changegiver
error will be indicated on the error LED. Since the sensor reads full
the tube will no longer be routed to, but no other action will be taken,
i.e. the tube will still be dispensed from.
The full sensors are read on initialisation, acceptance and
dispensing coins. Full sensor errors relating to a tube are cleared
whenever a full sensor reads uncovered. Note that this means that
if more than 1 coin covers the full sensor, the full error for that tube
will initially be set on dispensing from that tube, but it will be cleared
again as soon as the sensor becomes uncovered.
Coin count re-calibration
When accepting coins, the full sensors will be used for re-calibrating
the number of coins in the tubes. For any given coin type the number
of coins that it takes to cover the full sensor can vary due to
variations in coin thickness. For this reason the tube counts for a
tube will be set to be their full re-calibration number only if:
• The sensor status has changed
• The result of the sensor self test was good
• A coin cassette error has not been detected
• The recorded tube counts are more than 9 from their
expected level:
Low sensor error detection
The low sensor is checked at the following times:
• On power-up
• Before beginning any dispensing, either manual
dispensing or credit return
• Immediately after every coin is paid out
• One second after a coin is accepted
The status of the low level sensors will be held in non-volatile
memory, thus preserving this information for the next power-up.
18 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
Coin count re-calibration
Low level recalibration is intelligent in its handling of tube storage
cassette removal and replacement. The main assumption made is
that the tube storage cassette is not removed during a change return
operation. The following table gives the details of the low sensor
operation.
A tolerance of +/-one coin is applied to the tube counts before
recalibration on low level sensors is done. This reflects the fact that
due to the variables, both electrical and mechanical, it is unlikely that
the number of coins in a tube will always be the same.
Thus, if the tube counts are within one of their expected level , no
recalibration will occur when the low sensor goes from covered to
uncovered.
©, Mars, Inc., 1996. 19
CashFlow 560 changegiver Applications Design Guide
The following table gives a brief summary of the low sensor
operation.
Read at Status Action
Power-up
Coin
acceptance
Prior to
dispense
During
dispense
Reset tube
counts
UNCOVERED
COVERED
UNCOVERED
COVERED
UNCOVERED
COVERED
UNCOVERED
COVERED
UNCOVERED
COVERED
If required reset of tube counts to 0
If required reset of tube counts
to tube float level
If required reset of tube counts
to tube low count
If required reset of tube counts
to tube loat level
If required reset of tube counts
to tube low count
If required reset of tube counts
to tube float level
If required reset of tube counts
to tube low count 1
None
If required reset of tube counts
to tube safe count
If required reset of tube counts
to tube float level
UNCOVERED
Exit Float
Mode
COVERED
Home sensors
The function of the home sensors is to signal that the dispenser
arms are in the correct parked position before an attempt to
dispense coins from the coin storage cassette is made. Should this
fault have occured then an error signal will appear on the (red) error
LED on the keypad, which will flash on and off.
To remedy this the coin storage cassette should be removed and
then pressing the (yellow) mode key twice. This will drive the
dispense arm solenoids and and all 4 of the dispense arms will be
parked in the correct position in sequence.
20 ©, Mars, Inc., 1996.
If required reset of tube counts
to tube low count
If required reset of tube counts
to tube float level
CashFlow 560 changegiver Applications Design Guide
PRODUCT INTERFACES
The external interfaces to the changegiver product can be divided
into two groups and are explained in the following pages.
• Electrical interfaces: includes looms to interface host
machine with 4-price, Executive, BDV and MDB
versions, connectors and power supplies.
• Man machine interfaces: includes keypad, terminal and
credit display.
These are described in the following sections.
Mechanical Interface Drawings showing the space envolope,
mounting detail, reject mechanism clearance detail and coin routing
are at the end of the book in the Appendix.
The current product types available are;
• CashFlow
electromechanical changegiver
A credit display can be provided, if required, for use with the above
variant.
• CashFlow
electronic Protocol A serial interface
• CashFlow
BDV serial interface
• CashFlow
MDB serial interface
560 - 4 price - A four price
560 - Executive - changegiver with an
560 - BDV - changegiver with an electronic
560 - MDB - changegiver with an electronic
©, Mars, Inc., 1996. 21
CashFlow 560 changegiver Applications Design Guide
ELECTRICAL INTERFACES
The diagram below illustrates the external electrical interfaces and
options for the CashFlow
Facility For
External
Cashbox
Full Sensor
Input
Optional
Credit
Display
560.
Machine
Credit Relay
Drive
Serial
Comms
*
Machine +
Optional
Credit
RelayRelay
Optional Serial
CashFlow 560 - 4 Price
Relay
†
Comms
Power
Adaptor
Loom
Option
Connector
(remote)
CashFlow 560 - Executive
Option
Connector
(remote)
CashFlow 560 - BDV / MDB
Serial
Comms
Power and
Comms
NOTE: The machine and serial communications loom are
connected together within the changegiver for the CashFlow
560-
BDV and MDB products.
22 ©, Mars, Inc., 1996.
CashFlow 560 changegiver Applications Design Guide
The mains electro-mechanical interface circuit diagram for
CashFlow 560 4 Price is shown below.
Line
Neutral
Exact Change
Price Line Common
Price Sense 1
Price Sense 2
Price Sense 3
Price Sense 4
Price Line 1
Price Line 2
Price Line 3
Price Line 4
Safety
Machine Interface
Connections
Escrow Accept
Neutral
Host Interface for CashFlow 560 4 Price
©, Mars, Inc., 1996. 23
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