BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE
COURSE OUTLINE (5 DAYS) TRAINING MATERIALS:
I. I.
II. IV.
1.
BPS 200 Course OUTLINE for distribution
2.
BPS 200 Training Manual
3.
BPS 200 Service DVD
4.
Laptop with windows XP or Windows 7
5.
Hyper terminal or serial emulation program
6.
Crossover Cable
LESSON: DAY 1 TOPIC: Introduction and Getting to know the BPS 200. Complete Overview of the system including available processing operations. Menu options for user, supervisor, and service roles. Service items available. TRAINING OBJECTIVES: Be familiar with basic operator duties and maintenance. Be familiar with System Operation To become familiar with software loading and the troubleshooting tools available INSTRUCTIONAL TASKS:
—Operation: Overview, Operation of the System, Operator Maintenance Overview
BPS 200--A Revolution for Banknote Sorting Applications Banknote Processing Systems from G&D System Approach BPS 200 Machine Configurations BM, SDM, LDM, FSE Important Applications Standard Sensor Functions Standard Sensor Functions (in one housing): Sensor System—distribution of measurement functions in sensor unit Important Options Important Sensor Options BPS 200—Graphic User Interface (GUI)
Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 1 of 9
BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE
Site and Facility Requirements
Operating the System
Operator Training –Service Bulletin 9, Revision: C Cleaning Intervals
Operator Maintenance—Machine Technician Training
Remove operating panel screen/display Remove Operating Panel screen/ display—replace all as one unit Adjust stepper motor Remove rocker tray liners and wearing plate Replace friction band Replace or rotate turning skids
Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 2 of 9
BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE I.
LESSON: DAY 2
II.
TOPIC:
Basis Module Hardware component service and replacement.
III. TRAINING OBJECTIVES:
Know the Basis Module hardware components. Be familiar with Basis Module hardware component replacement.
IV. INSTRUCTIONAL TASKS:
DAY 2—Hardware: Machine Components, Documentation, Maintenance Overview
Connectors Discuss connectors—rear panel BPS 200 singler Singler—step motor is eccentric cam on bearing Rocker trays—old style vs. new style Rocker trays—old style: front rocker tray, back rocker tray, 2 rocker tray liners Rocker trays for current machine Retard assembly Retard assy—review parts of assy as noted Replacement of turning skids---operator maintenance as shown yesterday Round belt transport with and without optional sensors BPS 200 Sensors
− Standard sensor housing; belt-free transport system
Distribution of measurement functions in the sensor unit
− SIL (LEFA); Fluorescence/Phosphorescence sensor; Transmission sensor; US thickness
sensor; Magnet sensor; Optional soil sensor Sensor specifications Circuit diagram of the electrical components Sensor self test
Servicing the Machine
service plug setup of the Service Manual: parts list parts replacement adjustment
Hardware Components—removal
Sensor unit Remove sensor
− thickness sensor felt--replace/clean felts from back − window with adhesive frame—when replace PD lamp Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 3 of 9
BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE − clean sensor rollers with alcohol
Limpness sensor remove limpness sensor
− clean or replace microphone felts − can replace all 3 shafts separately
Round and friction belts remove round and friction belts Stepper motor remove stepper motor Delivery modules
− stacker assy, collecting plate, toothed belts, retaining ring & stacking wheel − remove stacker assy, collecting plate, toothed belts, retaining ring & stacking wheel
Rear delivery unit/compartment
− transport shafts, flat belts, gate drives & gate vane − remove transport shafts, flat belts, gate drives & gate vane
Flat Belts
− roller stations, baffle plates, drive pulley Flat Belts—the number of long flat belts corresponds to the number of delivery modules. − Roller Stations—use a ruler for the adjustment (approx. 0.8 mm) as follows: − Baffle Plates—Insert a new baffle plate including bearing as well as washer and tighten. − Remove the drive pulley with two cup springs.
Coupling remove coupling 3-17—ask dave shilling if this needs to be taught Reject Area
− Drive roller, stacking wheel, stepper motor, reject cover
Reject Area
− − − −
Drive Roller—pull the drive roller out of the front side of the machine. Stacking Wheel—pull the stacking wheel off the axle. Stepper Motor—pull the stepper motor with axle out to the rear. Reject Cover Operating Controls Operating Controls
− Remove the operating unit circuit board with cover. − remove the pneumatic spring when the tension is released − Remove the micro-switch; it must be adjusted and then tested.
Controller
− MDC 4 circuit board, PPC circuit board
Controller
− MDC 4 Circuit Board—remove the MDC 4, switch on the machine and test the function. − PPC Circuit Board—remove the PPC. Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 4 of 9
BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE I.
LESSON: DAY 3
II.
TOPIC:
Finish machine assembly. Adjustments, calibration, troubleshooting tools,
III. TRAINING OBJECTIVES:
Know the Delivery Module hardware components. Be familiar with Delivery hardware component replacement. Be familiar with application software loading. Be familiar with sensor software loading. Be familiar with the troubleshooting tools available
IV. INSTRUCTIONAL TASKS:
DAY 3—Hardware: Maintenance, Adjustments and Calibrations Finish reassembling machine Adjustments
Check limpness sensor with wear-measurement gauge Adjust rocker tray Change stepper motor settings Readjust singler gap--SB# 12 Adjust top short edge transport Adjustment procedure for the lifting solenoid in the idle position (anchor retracted) Adjustment procedure for the lifting solenoid in the working position (anchor extended, pinch roller on the stop for the belt mounting for the round belts)
Calibrations
Set up hyperterminal window SB# 3 Calibrate fluorescence sensor 9-17 Calibrate limpness sensor 9-16
Troubleshooting tools
Connect through internet explorer
− reject statistics/reasons; Change service language; check for breakdown of sensor functions; remote control service—map only, test all parts from this screen
Load software
Boot loader menu Connect thru internet explorer
− reject statistics/reasons; Change service language; check for breakdown of sensor functions; remote control service—map only, test all parts from this screen Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 5 of 9
BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE
FTP (file transfer protocal)
− Through LAN connection − FFS—install new files and test (through ftp)
Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 6 of 9
BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE I.
LESSON: DAY 4
II.
TOPIC:
Software tools, error diagnosis.
III. TRAINING OBJECTIVES:
Be familiar with MAP software components Be familiar with the software architecture Be familiar with Basis Module hardware component replacement. Know the available error diagnostic utilities and programs.
IV. INSTRUCTIONAL TASKS:
DAY 4—Software: Software Tools Overview
BPS 200 data processing/controlling System components/interfaces Memory layout MAP software components Software architecture The file system of DV-Application Banknote sorting Process controlling Configuration—operation modes Accounts Operation with internet technology Operation with multi language Reporting/report generator Data interface Service tool Additional tool—OMOCO (Opmode Configuration) Adaptation tool—BPS 200 Configuration Tool
Error Diagnosis The following utilities and programs are available for the error diagnosis. MDC Diag diagnosis program Displays on the MDC4 Displays in the PPC computer board Test Photo Detectors—call MDC Diag to test the photo detectors. Test MDC4 Test PPC OMOCO Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 7 of 9
BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE
I.
LESSON: DAY 5
II.
TOPIC:
Technical Bulletins and Service Bulletins. Final Review
III. TRAINING OBJECTIVES:
Be familiar with BPS 200 Technical Bulletins. Be familiar with BPS 200 Service Bulletins. Be familiar with using the error code database. Know how to obtain various types of sensor data.
IV. INSTRUCTIONAL TASKS:
DAY 5—Software: Service Bulletins Setup of Service PC for diagnostics SB# 1
IP Addresses, Subnet Mask, Ipconfig, Ping, Network Setup under NT, Hyperterminal
Setting up an RAS Server SB# 2
Server Setup Client Setup (only for Service Locations) Establishing a connection Starting a RAS Server Dialing in from a Client Testing the connection
How to record data on a BPS 200 SEP SB# 3
Serial Connection LAN Connection
How to capture a core dump after a SEP hang-up SB# 4 Testing the BPS 200 Data Interface SB# 6
Setup of your laptop Logging Getting your own IP-address Set automatic report Set host IP-address Disable the automatic reports
How to obtain reports in electronic form SB# 7
Software Release dependent directory SW Release Directory Operator Reports, Operator data transmission Supervisor Reports
Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 8 of 9
BPS 200 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE
Uploading report files
BN Properties, Reject Reasons and Fit/Unfit Reasons in SW Release V2.0 SB# 8
Attached to this document you will find a list of all BN properties which is based on the SEP – shell (hyperterminal program connected to the SEP) command PropObj - 1,1
Service relevant Aspects of Release 2.70 SB# 13
Discuss new features of software release 2.70 if time permits
BPS 200 Error Codes SB# 14
Structure of the BPS 200 Error Codes
− Address of reporting device − Main Error Code − Optional Error Code
Error Code Database SW Requirements Query Window Message Window Export Import
How to get Sensor self test Data SB# 16
Preparation Recording the Results
− − − − − − −
Transmission sensor (TMS) Thickness sensor (DIS) Fluorescence sensor (FPS) Magnetic sensor (MAG) Limpness sensor (LPS) Conductivity sensor (LEFA) High Level Soil sensor (SFS)
**Take the Final Test and Present Certificates**
Course Outline (5 Days) June, 2013 Giesecke & Devrient America, Inc.
BPS 200-CO Version: A Page 9 of 9