1250hs Service Manual

1250HS Model
Banknote Counting Machine

Service Manual
TP01313012 Rev. 00
E De La Rue 2000
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.
3. 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, Technical
Memorandum are used. These are not numbered.
3.1 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 inserted in the section provided at the rear of
the manual as a 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 inserted in the section provided at the rear of
the manual as a reference. The remainder of the Technical
Bulletin can then be destroyed.
3.2 Machine Modification

On receipt of a Technical Bulletin or Technical Memorandum which
does not entail a Service Manual amendment but is a modification to
a machine, the following actions should be taken:
D This is issued for reference only. The modification will be carried
out on machines built in the factory.
D It is important therefore that the complete Technical
Bulletin/Technical Memorandum should be kept by the Service
Engineer as a local reference. This enables Service Engineers to
differentiate between machines of differing build standards.
These Technical Bulletins/Technical Memoranda are to be
inserted in the Section at the rear of the Service Manual.
3.3 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.
1250HS Prelims
May 2000 Page 1
3.4 Record of Amendments
Records of Amendments should not be inserted on any page other
than an Amendment Record Sheet.
3.5 Page Replacements

Care must be taken that any page replacements issued in Technical
Bulletins/Technical Memoranda contain all previously issued changes.
Prelims 1250HS
Page 2 May 2000
4. SAFETY WARNING
THIS MACHINE IS A CLASS 1, 3 – WIRE EARTHED PRODUCT, AND REQUIRES

THE EARTH CONNECTION TO MAINTAIN CONTINUING SAFETY OF
OPERATION.
WARNING : FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, FUSES

MUST BE REPLACED WITH THOSE OF THE SAME TYPE AND SAME RATING.
1250HS Prelims
May 2000 Page 3
RECORD OF AMENDMENTS
TECHNICAL DATE
BRIEF DESCRIPTION
BULLETIN No. AMENDED
Prelims 1250HS
Page 4 May 2000
RECORD OF AMENDMENTS
TECHNICAL DATE
BRIEF DESCRIPTION
BULLETIN No. AMENDED
1250HS Prelims
May 2000 Page 5
CONTENTS
Title Page
Duty of Confidence
Technical Bulletins and Memoranda
Safety Warning
Record of Amendments
Contents (this page)
Preface/Spare Parts
Health and Safety

Section 1 General Description
Section 2 Operating Instructions
Section 3 Mechanical Description
Section 4 Electrical Description
Section 5 Maintenance
Section 6 Diagnostics
Section 7 Settings and Adjustments
Section 8 Removal, Overhaul and Replacement
Appendix 1 Band Stamper Unit
Appendix 2 Pedestal Unit
Appendix 3 Technical Bulletins/Memoranda
Prelims 1250HS
Page 6 May 2000
5. PREFACE
This Technical Manual contains technical information for use by
Engineers in order to perform Servicing and Maintenance of the
1250HS Banknote Counting Machine.
6. SPARE PARTS
When ordering spare parts, it will be necessary to give the PART
NUMBER and DESCRIPTION as quoted in the illustrated parts list.
If no part number is quoted, then the ITEM NUMBER, DESCRIPTION

and KEY TO FIGURE? is to be given.
It will prove to be helpful if the DESCRIPTION as written in the

appropriate KEY TO FIGURE? is quoted on all orders for spare parts.
IMPORTANT – THE FOLLOWING SECTION ON SAFETY MUST BE UNDER-

STOOD AND STRICTLY ADHERED TO BY ALL SERVICING AND OPERATING
PERSONNEL.
7. HEALTH AND SAFETY

7.1 High Voltage
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.
7.2 High Energy

All servicing personnel are warned of the dangers of arcing and burns
from high energy components such as contained in the power supply
unit (PSU).
7.3 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.
All items of clothing such as ties, loose overalls and long hanging
jewellery should be removed. Long hair should be tied up.
7.4 Cabling And Power

Do not use the colour of cables as an indication of their voltage or
polarity.
Always use a test meter to check that the terminals are not live before
touching.
1250HS Prelims
May 2000 Page 7
7.5 Static Sensitive 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.
7.6 Effects of Electromagnetic Fields

The function of this machine may be affected by the use of
equipment, close to the machine, which is capable of emitting high
electromagnetic fields, e.g. mobile phones, security transmitters.
7.7 Solvents
All fluids used for cleaning purposes must be non – toxic and must
comply with the relevant COSHH and Health And Safety regulations.
Note: Wherever these symbols appear throughout this manual

reference should be made to Paragraph 7 ( Health & Safety ).
Prelims 1250HS
Page 8 May 2000
Section 1
General Description
1250HS Section 1
May 2000 Page 1
CONTENTS
Para. Page
1. INTRODUCTION 3
2. MAIN SPECIFICATIONS 3
Illustrations
Figure 1 1250HS General View 4
Figure 2 1250HS Machine with Pedestal 5
Section 1 1250HS
Page 2 May 2000
1. INTRODUCTION
The 1250HS Note Counter is a stand–alone table top counter which is
microprocessor controlled and contains a vacuum operated verify,
batch and count note system. The main function of the machine is to
count banded banknotes, however, documents of similar and suitable
parameters may also be counted. A general view of the machine is
shown in Figure 1.
A pedestal mounted version of the 1250HS machine is also available,

as shown in Figure 2.
2. MAIN SPECIFICATIONS
Electrical
Voltage 98 – 264V a.c.
(110–240V a.c. nominal)
50/60Hz.
Mean Power 350W max
LCD Display 10 digits
Mechanical
Weight – desktop 20kg
Weight – pedestal 36kg
Dimensions Height 285mm
Width 345mm
Depth 430mm
Dimensions Height 965mm
(pedestal) Width 555mm
Depth 570mm
Document Size Range Min 100mm x 50mm
Max 200mm x 100mm
Document Thickness 0.06mm to 0.18mm
Banknote Capacity 150 notes
Count Speed From 25 to 40 notes per second
Acoustic noise level at 80dBA – desktop, no shutters
speed 4 74 dBA – desktop, with shutters
Environmental
Operational Use
Temperature +10°C to +35°C
Relative Humidity 30% to 80% RH
(without condensation
Barometric Pressure 650mBar to 1100mBar (equival-
ent to 3000m above sea level to
sea level high pressure)
Storage
Temperature –10°C to +50°C
1250HS Section 1
May 2000 Page 3
Figure 1. 1250HS General View
Section 1 1250HS
Page 4 May 2000
Figure 2. 1250HS Machine with Pedestal
1250HS Section 1
May 2000 Page 5
Section 2
Operating Instructions
1250HS Section 2
May 2000 Page 1
user guide
1250HS
Banknote counting / verifying machine
contents
Safety information 2
Introduction
Overview of machine 3
1250HS Controls 4
1250HS Display 4
Setting up 5
Basic operating functions

Verify Mode 6
Batch Mode 8
Count Mode 9
Accumulative Totals 10
Speed 11
Advanced operating functions

Verify Value Mode 12
Batch Value Mode 15
Count Value Mode 17
Accumulative totals 18
Supervisor functions
Machine configuration 19
Data Recovery 19
Restoring Factory Defaults 19
Shutter Operation 20
Alarm Operation 20
Band Stamping Operation 20
Printer Operation 21
Remote Display 22
Information
Display messages 23
Maintenance
Specification 24
Routine maintenance 25
Revision 1
1250HS user guide
Declaration of conformity
Manufacturer & responsible person Details of product
De La Rue
Walton Road, Farlington
Portsmouth, Hampshire PO6 1TJ Banknote counter Model types
Telephone: +44 (0)23 9238 3161
Fax: +44 (0)23 9232 5822 1250HS
This product conforms to the essential requirements of:
Electromagnetic compatibility Directive 89/336/EEC

Amended by 92/31/EEC
Low voltage electrical equipment (safety) Directive 73/23/EEC

Amended 93/68/EEC
and is supported by the following applicable standards

EN 55 022
EN 50 082-1
EN 60 950
EN 29001 (ISO 9001)
Tony Robinson Quality Manager.

Authorised signatory on behalf of the responsible person
Warning
This machine has been designed for optimum
safety for users. For your added protection
please follow these guidelines.
Voltages above 42V are potentially dangerous.
Always keep fingers away from moving
feedplate and spindles.
Always handle mains-supplied equipment
with caution.
Never open the machine when it is plugged in.
Do not cover air vents at rear with notes.
Always keep loose clothing, jewellery and hair
out of the feed area when operating the
machine.
Lift the machine from the base only.
Care when lifting >25kg etc.
Reference: TP05313012 - ISS1

2
Revision 1
Introduction
overview of machine
The 1250HS is a high speed

machine for verifying and
5 counting bundles of banknotes.
3 It has been designed to be easy
to use and maintain as well as
safe and reliable.
15
1 4 6 7 8
11 12
16
10 13 14
1 On / off switch 10 Filter bowl

2 Reset switch 11 Remote display (RS232 only)
3 Control panel 12 CMS/Printer (RS232 only)
4 Note counting area 13 Mains socket -
Disconnect from the mains supply to isolate
5 Adjustable note stop position the machine for maintainence.
6 Feedplate 14 Optional pedestal unit
7 Clamp arm 15 Spindles (count mechanism) Air / Dust
filter (Ref Page 25)
8 Shutter mechanism (if fitted)
9 Table top unit lifting point 16 Air vents - Do not cover
Revision 1
Introduction
1250HS controls
5 4 3 2 1
6 7 8 9 10 11 12
1 Start/stop
2 Value press to count notes by value
3 Numeric keypad
4 Total displays total of notes counted
5 LCD display
6 Verify check notes against pre-set number
7 Batch counts bundles of required size
8 Count counts unknown quantity
9 Auto enables/disables automatic start
10 Clear clears totals
11 Feed open opens feedplate to release notes
12 Speed sets throughput speed, press to step through pre-set speeds
3 2
4 5 6 7 8 9 10
1 Batch display displays batch/verify quantity

2 Bar visible when counting by number of notes / invisible when value
counting
3 Count display displays the count
4 Verify visible in verify mode
5* CMS visible if on-line to PC
6* Shutter visible if shutter is enabled
7* Remote display visible if a remote display is enabled
8 Autostart visible if automatic start is on
9* Printer visible if on-line to printer
10 * Bandstamper visible if Bandstamper is on
* The function of these keys and corresponding symbols are dependant on the feature being fitted.
4
Revision 1
Introduction
setting up
The 1250HS must be installed on a flat and

level surface.
An office desk, or pedestal unit (available
as an option) are suitable.
Note: If the pedestal unit is used, the
machine must be fixed using the bolts
and fixing points provided.
1
The notes should be prepared prior to
counting in the machine.
Square up the bottom (short edge) of the
bundle and position the band (if used)
90mm away from the edge to be counted.
Used banknotes should be fanned
through to eliminate any damage along
the short edge of the notes. Torn or
folded banknotes should be removed or
unfolded.
New banknotes should be fanned to
separate any notes which may be
sticking together.
2
The note stop adjuster should be
adjusted to the correct position for the
Note Adjust notes being counted.
For good quality notes the note stop may
Feedplate be moved forward.
For poor quality notes the note stop
should move backwards.
switching
Connect the mains lead to the socket at
the rear of the machine.
Plug the machine’s power lead into a
mains socket and switch on the mains
on
supply. Ensure that the counting
mechanism is free from obstructions prior
to switching on.
Press the On/Off button to switch the
machine on (this button is pressed again
to turn the machine off).
The machine will power up and complete
a self test routine showing 1250HS on the
LCD display.
The machine will then be ready to
operate in the last chosen mode of
operation.
Revision 1
verify mode
1
To verify the quantity of notes in a bundle
against a preset number, press the
VERIFY key.
2
The count bar will be displayed and the #
symbol will show.
The three small digits show the preset
bundle size that the machine will be
verifying.
Press the VERIFY key repeatedly to
choose a bundle size from the preset
sizes saved in the memory of the
machine.
If a different bundle size is required type
in the size using the numeric keypad.
This bundle size will be stored in the
memory of the machine.
The bundle size can be up to a maximum
of 150 notes.
3
Insert the bundle of notes into the note
counting area of the machine ensuring
that it is gently pushed against the note
stop at the rear of the feedplate.
If Autostart is selected, the machine will
begin counting the notes. If Autostart is
not selected, press START to begin
counting.
If a shutter is fitted and enabled it will
close before the machine begins
counting.
Revision 1
verify mode
4
If the number of notes counted is the
same as the pre-set bundle size, the
feedplate opens and the Verify total is
added to the ACCUMULATIVE VERIFY
TOTAL. The bundle can be removed and
the next bundle processed.
If the number of notes counted is not the
same as the pre-set bundle size or an
abort occurs, the feedplate will remain
closed and the notes cannot be removed.
The display will flash showing incorrect
verification.
5
The notes can be removed by pressing
the RESET or FEED OPEN key.
The bundle has not been added to the
ACCUMULATIVE VERIFY TOTAL.
Pressing the START / STOP key during
the counting operation will stop the
machine on the bundle that it is counting.
Pressing RESET will open the feedplate.
The bundle being counted will not be
TOTALS.
The bundle must be recounted.
Revision 1
batch mode
1
To create smaller batches of notes from a
larger bundle, press the BATCH key,
(example: 2 batches of 50 notes from a
bundle of 100 notes).
The count bar -- will be displayed.

The 3 small digits show the pre-set
bundle size that the machine will be
creating. Press the BATCH key
repeatedly to choose a batch size from
the pre-set sizes saved in the memory of
the machine. If a different batch size is
required, type in the size using the
numeric keypad.
This batch size will be stored in the
memory of the machine.
2
Insert the bundle of notes into the note
counting area of the machine, ensuring
that it is pushed gently against the note
counting.
counting.
3
When the number of notes counted is the
same as the chosen batch size, the count
number is added to the ACCUMULATIVE
BATCH TOTAL and the feedplate
remains closed so that the notes can be
clipped together to make a smaller
bundle. Press START to make up
another batch or FEED OPEN to remove
the notes from the machine.
4
If there were insufficient notes to create
the batch size required or an abort
occurs, the machine will flash an error on
the display.
The notes maybe removed by pressing
the RESET or FEED OPEN key. The
bundle total will not be added to the
ACCUMULATIVE BATCH TOTAL.
Revision 1
count mode
1
To count the remainder of a bundle of
notes after a batching operation or to
count a random number of notes (loose
or banded), press the COUNT key.
The count bar -- will be displayed and

the three small digits will show to
indicate COUNT mode.
2
Insert the notes into the note counting
area of the machine ensuring that they
are pushed gently against the note stop
at the rear of the feedplate.
counting.
counting.
3
When the notes have been counted, the
feedplate will open and the display will
show the count total. This will be added to
the ACCUMULATIVE COUNT TOTAL.
Counting after a Batching Operation
1
When counting a random number of
notes after a batching operation, the
feedplate will be closed. Press the
COUNT key to enter the COUNT mode.
Press the START key to count the
remainder of the notes. The TOTAL will
be added to the ACCUMULATIVE
COUNT TOTAL and not the BATCH
TOTAL.
If the count is successful, the feedplate
will open and the notes can be removed.
Revision 1
accumulative totals
1
Each mode of operation has its own
ACCUMULATIVE TOTAL.
In VERIFY mode, pressing the TOTAL
key will show the number of notes
then counted in VERIFY mode since the total
was last cleared.
In BATCH mode, pressing the TOTAL
counted in BATCH mode since the total
was last cleared.
then In COUNT mode, pressing the TOTAL
counted in COUNT mode since the total
was last cleared.
then These totals are called, ACCUMULATIVE
VERIFY, BATCH and COUNT TOTALS.
2
To clear any of the totals, press the
TOTAL key to display the TOTAL for that
mode of operation, then press the
+ TOTAL + CLEAR key. This will clear the

TOTAL shown and leave the others
unaffected.
accumulative totals in value mode
1
When the machine is counting by note
VALUE, there is a TOTAL for each mode
of operation, VERIFY VALUE TOTAL,
BATCH VALUE TOTAL and COUNT
VALUE TOTAL.
When the TOTAL key is pressed it will

show the TOTAL for that mode of
operation since it was last cleared.
Press TOTAL + CLEAR to reset that

+ TOTAL to zero.
10
Revision 1
variable speed
The fastest machine speed is 40 notes per second,

however, you may wish to reduce the speed when
counting very poor quality notes.
Select the speed by pressing the SPEED key.
Press this key repeatedly to step through the pre-set
speeds;
Lowest speed 24 notes per second *
Highest speed 40 notes per second *
* Speeds are approximate.
11
Revision 1
1250HS value modes
In one of the VALUE modes, the 1250HS

will count information by the VALUE of
the note bundle.
verify value mode
1
To verify the value of a bundle of notes
against a pre-set value, press the
VERIFY key, followed by the VALUE
key.
The display will show the # symbol.
2
Verify Value, Autostart OFF.
Insert the notes into the note counting
area of the machine ensuring that they
are pushed back gently against the note
The display will show U...nnn, asking the

user to enter the total bundle value to be
verified.
Enter the total value using the numeric
keypad and press START to accept.
3
The display will show d...nnn, asking the
user to enter the denomination of the
notes in the bundle.
Enter the denomination using the numeric
keypad.
Press START to begin counting.
12
Revision 1
1250HS value modes
verify value mode
4
Verify Value, Autostart ON.
When the notes are placed on the
feedplate, the machine will automatically
verify using the previous verification total
and denomination value.
5
In order to change values, press START
before the notes are placed on the
feedplate.
The display will show U...nnn to allow the

total bundle value to be verified to be
entered using the numeric keypad.
Press START to accept.
6
The display will show d...nnn asking the
keypad.
Place the notes onto the feedplate to
begin counting.
13
Revision 1
1250HS value modes
verify value mode
7
If the value of notes counted is the same
as the expected bundle value, the
feedplate opens and the VERIFY VALUE
TOTAL is added to the ACCUMULATIVE
VERIFY VALUE TOTAL.
The bundle can be removed and the next
bundle processed.
8
If the value of the notes counted is not the
same as the preset bundle value, or an
abort occurs, the feedplate will remain
closed and the notes cannot be removed.
The display will flash showing the
incorrect verification.
The notes can only be removed by

pressing the RESET or FEED OPEN
key. The count display will show zero
and the bundle will not have been added
to the ACCUMULATIVE display.
9
Pressing the START /STOP key during
the counting operation will stop the
machine on the bundle it is counting.
Pressing RESET will open the feedplate

and the bundle being counted will not be
VALUE TOTALS.
The bundle must be recounted.
10
If a fraction is required, when the display
shows d....nnn, press VALUE before
. entering a denomination
Press START key to begin counting.
14
Revision 1
1250HS value modes
batch value mode
1
To separate a batch of a particular value
from a larger value bundle of notes, press
the BATCH key followed by the VALUE
key.
The highest denomination of notes to be

counted is placed on the feedplate.
Autostart is OFF.
A ‘b’ symbol appears on the left hand

side of the display.
The value of the batch size to be

separated can be entered using the
numeric keypad.
Press the START key to accept.
2
The display shows d...nnn for the user to
enter the denomination value of the notes
to be counted.
The denomination value is entered from
the numeric keypad.
Press START to accept and begin
preparing the batch of notes.
3
If the batch is completed, the display will
count to the BATCH VALUE required.The
batch of notes can be clipped together.
Press START to prepare another batch
of the same value, or FEED OPEN to
remove the batch.
15
Revision 1
1250HS value modes
batch value mode
4
If there were insufficient notes to create
the batch size required or an abort
occurs, the machine will flash an error on
the display.
The notes maybe removed by pressing

the RESET or FEED OPEN key. The
bundle total will not be added to the
ACCUMULATIVE BATCH TOTAL.
5
Verify batch, Autostart On.
When notes are placed on the machine it
will automatically count using the
previous batch settings.
To change batch values press START
prior to loading the notes.
Enter the batch value required.
Press START to accept.
Enter the denomination and then load the
notes.
6
. entering a denomination
16
Revision 1
1250HS value modes
count value mode
1
To count the remainder of a bundle of
notes, or by note value after a batching
operation, or to count a random value of
notes (loose or banded), press the
COUNT key followed by the VALUE key.
2
Count Value, Autostart OFF.
Insert the notes into the Note Counting
area of the machine ensuring that it is
pushed gently against the note stop at the
rear of the feedplate.

notes to be counted.
keypad.
Press START to begin counting.
3
Count Value, Autostart ON.
When the notes are placed on the
feedplate, the machine will automatically
count using the previous denomination
value.
In order to change the values, press
START before the notes are placed on to
the feedplate.
keypad.
Place the notes on to the feedplate to
begin counting.
close before the machine begins to count.
17
Revision 1
1250HS value modes
count value mode
4
When the notes have been counted, the
feedplate will open and the display will
show the COUNT TOTAL.
This will be added to the
ACCUMULATIVE COUNT VALUE
TOTAL.
5
. entering a denomination.
accumulative totals
1
The value modes each have their own
ACCUMULATIVE TOTAL.
In each mode, pressing the TOTAL key
will show the TOTAL for that mode since
it was last cleared.
+ Press TOTAL + CLEAR to zero the

TOTAL for that mode.
All other modes will be unaffected.
18
Revision 1
Supervisor Modes
machine configuration
1
This operation allows you to save your
own set-up configuration in the memory,
e.g verify bundle sizes, speed, totals etc.
Set the machine to the preferred
+ configuration.
Press TOTAL and 0 to save the preferred
configuration.
data recovery
1
In the event of a power failure, the mode
operation and the ACCUMULATIVE
TOTALS are saved in the memory of the
machine.
At any time, the data can be retrieved by
+ pressing TOTAL and VALUE keys.
The machine will then operate in the
mode of operation last stored in the
memory by the user.
factory defaults
1
At any time, it is possible to restore the
factory defaults from the memory of the
machine.
+ This can be done by pressing TOTAL
and AUTO.
19
Revision 1
Supervisor modes
shutter operation (if fitted)
1
The auto-closing shutter can be turned
+ OFF or ON by pressing TOTAL and 1 to
switch between the two modes.
When the shutter is on, the symbol
is shown on the display.
A hard link within the machine disables
the ON/OFF function when removed.
This is for applications where the shutter
must be permanently ON.
This option is not available on counters in
the USA.
alarm operation
1
The machine has an alarm which takes
the form of an audible beep. This will
indicate any errors such as incorrect
verification, failure to complete a batch or
failure to pick a note.
The alarm can be turned ON/OFF by
+
pressing TOTAL and 2.
The beep sounds once on switch OFF
and twice on switch ON.
bandstamper operation (if fitted)
1
The unit which stamps an ‘OK’ symbol on
the band around a note bundle can be
turned OFF or ON by pressing TOTAL
+ and 4 to switch between the two modes.
When the bandstamper is ON, the
symbol is shown in the display.
The stamp should only operate when 100
notes are verified.
2
Replacing the Ink.
Press TOTAL and 8 to close the
+ feedplate.
Switch the machine OFF.
Replace the bandstamper cartridge.
Switch the machine ON.
20
Revision 1
Supervisor mode
remote printer operation
1
Rear of Machine RS232 only
The 1250HS is designed to drive a
Citizen CBM 910 type printer which plugs
into the port on the rear of the machine.
The printer plugs into the rear of the

machine.
Remote display CMS / Printer
The remote printer can be turned OFF or

ON by pressing TOTAL and 5 to switch
between the two modes.
When the printer is ON, the symbol
is shown on the display.
21
Revision 1
Supervisor mode
remote customer display
1
RS232 only
Rear of Machine
The 1250HS is designed to drive a
remote customer display available as an
accessary from De La Rue. When the
display is plugged into the port at the rear
of the 1250HS it is automatically
activated.
The display must be connected before
the machine is switched on.
Remote display CMS / Printer Plug into remote display port as shown.
2
When the display is activated, the remote
display symbol is shown on the
machine display.
+ Press TOTAL and 3 to turn ON and OFF.

The remote customer display shows the
results of the completed counts which
can be added to the ACCUMULATIVE
TOTALS in the memory of the machine.
3 Note Quantity The display shows the information for

completed bundlle counts by number of
notes or by value of notes.
# #
Note Value
4
Pressing the TOTAL key in any mode will
send ACCUMULATIVE TOTALS to the
remote display.
5
The display shows the information for
completed bundle counts by number of
notes, or by value of notes.
22
Revision 1
Information
display messages
display reason solution
Hardware Error Switch off the machine and turn the

machine on again. If the problem
persists turn off the machine and contact
your agent’s service engineer.
Software Error Switch off the machine and turn the

machine on again. If the problem
persists turn off the machine and contact
your agent’s service engineer.
Operation Error Press the RESET switch. If the problem

persists, check that the correct operation
sequence is being used.
Details are in the relevant pages of this
user guide.
23
Revision 1
Maintainence
specification
Dimensions Height Width Depth

Desktop 285mm 345mm 430mm
Pedestal 965mm 345mm 365mm
Weight
Desktop 20kg
Pedestal 36kg
Document size range 100mm x 50mm minimum

200mm x 100mm maximum
Document thickness 0.06mm to 0.18mm
Acoustic noise level

at speed 4
Desktop no shutters 80 dBA
Desktop with shutters 74 dBA
Banknote capacity 150 notes
LCD display 10 digits
Count speed 24 to 40 notes per second variable
Power supply 110V 50/60 HZ

120V 60 HZ
230V 50/60 HZ
Nominal
Dependant on machine variant.
Power consumption 350W max.
Operational Use
Temperature +10°C to + 35°C
Relative Humidity 30% to 80% RH (without
condensation)
Barometric Pressure 650mBar to 1100mBar
(Equivalent to 3000M above sea
level to sea level high pressure)
Storage
Temperature +10°C to + 50°C
24
Revision 1
Maintainence
routine maintainence
CAUTION
Switch off the machine and disconnect it from the
mains prior to routine maintainence.
Spindle Filters
At regular intervals the spindle filters will need
cleaning.
Main Filter Bowl
At regular intervals the main filter will need cleaning.
Shutters
Clean track for auto-closing shutter.
Mains socket
Disconnect from the mains supply to isolate the
machine for maintainence.
Twist Fit
Filter
Element
Spindle Cap
Transparent
Filter Bowl
Filter Element
Spindle
Head
25
Revision 1
Section 3
Mechanical Description
1250HS Section 3
May 2000 Page 1
CONTENTS
Para. Page
1. INTRODUCTION 3
2. BASE ASSEMBLY 3
3. COVERS 3
4. FEED PLATE AND DAMPER 4
5. FEED PLATE GEARBOX ASSEMBLY 4
6. NOTE STOP AND BATCHING ARM 4
7. VACUUM SYSTEM 4
8. SPINDLE ASSEMBLY 5
9. SPINDLE DRIVE ASSEMBLY 5
10. PEDESTAL 5
11. OPTIONS 5
11.1 Shutters 5
11.2 Band Stamper Unit 5
Section 3 1250HS
Page 2 May 2000
1. INTRODUCTION
The 1250HS is a flat bed note counter using suction spindles to move
and count notes in bundles. Mechanically the machine can be broken
down into the following assemblies:
D Base Assembly
D Covers
D Electronics and sensors
D Feed Plate and Damper
D Feed Plate Gear Box Assembly
D Note Stop and Batching Arm
D Vacuum System
D Spindle Assembly
D Spindle Drive Assembly
D Pedestal Assembly
2. BASE ASSEMBLY
The base comprises a pressed steel chassis onto which each
component is mounted. The front part of the chassis is common to all
builds whilst the rear of the chassis is dependent on the machine
variant. For table top versions the rear chassis comprises a rear
pump mount and electronic mains inlet filter mount. The pedestal
version consists of a simpler mount for the rear electrical inlet filter
and pneumatic filter.
The front chassis includes a centre wall which provides rigidity to the
unit and separates the pump from the spindles, as well as supporting
the shutters and top box.
3. COVERS
Under normal operating conditions the machine is almost completely
enclosed by covers. The covers protect the operator from moving
parts and reduce the machine noise level. The main covers are of
rigid polycarbonate ABS mouldings which are fitted over the chassis:
D Rear cover – variants for table top and pedestal machines.
D Front cover – common to all variants and incorporates the reset
button and spring.
D Inner cover – covers all the front workings of the machine.
D ‘Flower pot’ – covers the spindles and provides some dust
extraction and channelling through to the base of the machine.
D Spindle cover – a disk over the spindle housing retained by a
centre cap. This cover incorporates fan blades to assist in dust
removal.
D Base cover – the base cover is secured to the chassis and there
are two variants; table top and pedestal.
1250HS Section 3
May 2000 Page 3
4. FEED PLATE AND DAMPER
Notes are placed and supported on a mirror polished plate which is
mounted on the damper assembly. In the rest position, the feed plate
is open. On operation, the plate moves towards the spindles and
closes against a clamping ‘tail fin’ (the force is obtained from a torsion
spring in the assembly). The clamped assembly then rests against
the spindles but with free motion constrained by the damper, and a
small drive force made by a separate tension spring.
On completion of a count, the clamp arm assembly is opened by the

action of the link from the feed plate gearbox. The tail fin rotates out
of the way and the notes are free to be removed.
The damper operation is critical to accurate counting as it prevents

feed plate bounce. The damper consists of a fluid base in which a
rotary fluted piston can rotate. The piston is mounted on a shaft
which runs in bearings in the top and bottom components of the
damper assembly. The damper is filled with silicone fluid on assembly
and is sealed for life.
5. FEED PLATE GEARBOX ASSEMBLY

The feed plate gearbox assembly provides the drive to open the feed
plate. The assembly consists of a zinc casting on which is mounted a
DC brushless motor. The motor drives a worm through a V pulley/belt
combination and the worm in turn drives a worm wheel on a shaft
which turns the cam and operates the link to the feed plate. A
microswitch is used to sense the position of the cam.
6. NOTE STOP AND BATCHING ARM

When a bundle of notes is placed on the feed plate, it is butted up
against a note stop. The note stop is a plastic assembly, which
provides the ability to adjust for note condition if necessary. The
position of the note stop provides the datum for locating the notes on
the spindles.
The batching arm, mounted on the chassis mid wall, is driven by a

solenoid and is used to retain notes in batching mode. The arm
operates temporarily to hold the non counted notes against the pack
whilst the counted notes are clipped or marked by the operator.
7. VACUUM SYSTEM
Notes are sucked onto the spindles by vacuum derived from an AC
driven pump. Air is sucked through the spindle heads via a small filter
in each spindle and then through the vacuum ports in the rotating
spindle housing. The air is then passed through the main filter
assembly before it goes into the vacuum pump.
Exhaust air is blown on the note pack through the riffler where it is
used to assist in note separation.
The spindle and main filters must be cleaned on a regular basis. The
spindle filters are removed by pulling off the green caps on top of each
spindle. The main filter is removed by releasing the locking ring
above the filter.
Section 3 1250HS
Page 4 May 2000
8. SPINDLE ASSEMBLY
The spindle assembly consists of five spindles mounted on a rotating
housing. The spindles have small gears at their bases and these
mesh into a fixed gear in the spindle base to form a sun and planet
arrangement. The gears rotate in a set pattern in order to present a
flat edge to the note stack and then suck and turn the note before
releasing it so that it is collected by the back of the next spindle, which
is in turn collecting the next note.
Air is sucked through the housing from the spindles, it is switched as
the spindles rotate as ports are opened and closed.
The presence of a note causes a drop in pressure in the vacuum
circuit. The drop is sensed by a vacuum sensor mounted on the I/O
board which is linked by a small pipe from the base of the spindle
assembly.
9. SPINDLE DRIVE ASSEMBLY

The spindle housing is rotated by a timing belt driven by a DC
brushless motor. The drive is via a reduction gear. The spindle drive
motor and the feedplate gear box motor are identical and are
therefore interchangeable.
10. PEDESTAL
The pedestal unit is a stand alone floor mounted unit which is
mounted on castors, situated under the main cabinet.
The vacuum pump is situated in the base of the unit and is accessed
via a service panel. The main filters are still accessible in the top of
the machine.
11. OPTIONS
The following options are available:
D Shutters (fitted as standard on UL approved counters).
D Band Stamper
11.1 Shutters
Sliding covers which close over the counter mechanism during
operation. The shutters can be factory fitted or installed later at a
service centre. The shutters consist of two PVC windows which slide
on rails at the top end and a brush strip at their lower end.
The drive for the shutters is from 2 toothed belts operating over
different pulley diameters in order to give differential movement.
Motive power is from a stepper motor driving one of the pulleys. The
belt over the larger pulleys is continuous whilst the belt over the small
pulleys is cut and the ends are clamped into the shutter carrier with a
shutter belt clamp.
11.2 Band Stamper Unit

The unit stamps an ‘OK’ symbol on the band around a note bundle.
The unit can be turned OFF or ON by pressing TOTAL and 4 to switch
between the two modes. When the unit is ON, the symbol ‘*’ is shown
on the display.
1250HS Section 3
May 2000 Page 5
Section 4
Electrical Description
1250HS Section 4
May 2000 Page 1
CONTENTS
Para. Page
1. INTRODUCTION 3
2. ELECTRONICS AND SENSORS 3
3. CONTROL BOARD 3
3.1 Interconnections 4
4. I/O BOARD 5
4.2 I/O PCB Link Positions 7
5. DAUGHTER BOARD 7
6. HALL EFFECT BOARD 8

7. POWER SUPPLY UNIT 8

Illustrations
Figure 1 1250HS Interconnection Diagram 11
Figure 2 Cable Routing Diagram 12
Section 4 1250HS
Page 2 May 2000
1. INTRODUCTION
The 1250HS electrical system is based around a single
microprocessor system with the electronics distributed over 4 printed
circuit boards. The Control Board and I/O Board form the main part of
the control system. The Hall Effect Board provides spindle speed
sensing and the Daughter Board provides a connection to the outside
world for an optional remote display, remote printer and to a PC for
data collection. An interconnection diagram is shown in Figure 1.
2. ELECTRONICS AND SENSORS

The electronics system comprises:
D A control board mounted in the top box and connected to the
membrane keypad and the RJ11 output ports. This board
contains the control microprocessor.
D An I/O board sited in the front base of the unit which is

connected to all switches and the vacuum sensor.
D A Hall Effect board mounted in the ‘flower pot’ which accepts

signals from 5 magnets fixed into the spindle housing.
D An RJ11 daughter board mounted in the back of the top box

which holds two RJ11 sockets to provide external display and
printer options.
D A membrane keypad in the top box providing user interface to

the machine.
D A switched mode power supply unit with a single input voltage

range of 98 to 264VAC. The PSU is identical to that used on
2600 and 2700 machines and is therefore interchangeable.
D A mains socket and IEC filter located in the rear of the machine.
3. CONTROL BOARD
The Control Board is located in the top box directly behind the key
panel and contains the single chip microprocessor that controls the
complete machine. The board also contains non volatile memory to
store user configurations and the user interface (LCD and connector
to the membrane push buttons).
1250HS Section 4
May 2000 Page 3
3.1 Interconnections
The following tables list the connection details from the Control Board.
Control Board P1 – I/O Board Interface

Pin No Remarks
1 5V
2 Not Connected
3 Reset Button
4 30V
5 MC2
6 Not Connected
7 Vacuum Head Pulse
8 0V
9 ISB–Clock
10 ISB–Data
Control Board P2 – Membrane
Pin No Remarks
1 Column 1
2 Column 2
3 Column 3
4 Column 4
5 Column 5
6 Column 6
7 Column 7
8 Column 8
9 Row 1
10 Row 2
11 Row 3
Section 4 1250HS
Page 4 May 2000
Control Board P3 – Daughter Board Interface
Pin No Remarks
1 Not Connected
2 RX
3 RTS
4 TX
5 CTS
6 DTR
7 10V (10mA)
8 0V
4. I/O BOARD
The I/O Board is located in the base of the machine towards the front
and contains all the machine interfaces, including the drivers for the
low voltage motors and solenoids, a logic level output to the vacuum
pump solid state switch, inputs from the machine sensors and
switches, and the vacuum sensor.
The following tables list the connection details from the I/O Board.
I/O Board P1 – Control Board Interface

Pin No Remarks
1 5V
2 Not Connected
3 Not Connected
4 30V
5 Hall Effect Output
6 Not Connected
7 Spindle Motor Pulse
8 0V
9 ISB–Clock
10 ISB–Data
1250HS Section 4
May 2000 Page 5
I/O Board P2 – Machine Interface
Pin No Remarks
1 30V (To Batching Solenoid)
2 5V (To Microswitches)
3 Stamping Solenoid
4 Batching Solenoid
5 5V (To Hall Effect Board and Solid State Relay, pin 3)
6 Shutter Open Switch
7 Hall Effect Board Output
8 Feedplate Switch
9 0V (To Hall Effect Board)
10 30V (To Stamping Solenoid)
11 Solid State Relay, pin 4
12 UL Shutter Interlock Switch
13 UL Shutter Interlock Switch
14 Shutter Closed Switch
15 Reset Switch
16 Note Present Switch
I/O Board P3 and P4 – Feed Plate Motor and Spindle Motor

Pin No Remarks
1 Coil A – to Motor pin 8
2 Hall 1 – to Motor pin 7
5 Coil B – to Motor pin 4
6 Coil C – to Motor pin 3
7 5V – to Motor pin 2
8 0V – to Motor pin 1
Section 4 1250HS
Page 6 May 2000
I/O Board P5 – Shutter Motor
Pin No Remarks
1 Phase 1a
2 Phase 1b
3 Phase 2a
4 Phase 2b
5 30V
6 30V
I/O Board P6 – Thermistor

Pin No Remarks
1 30V (from Switched Mode PSU)
2 0V (from Switched Mode PSU)
3 Thermistor
4 0V (to Thermistor)
4.2 I/O PCB Link Positions

Links LK1 and LK2 set the default shutter operation, dependent on the
build of the counter.
Build LK1 & LK2 Shutter Operation

UL Build Counter Not Fitted Always Enabled
CE Build Counter Fitted May Be Disabled
Note: Both links should always be in the same state. There must
never be only one link fitted.
5. DAUGHTER BOARD
The daughter board is mounted at the back of the top box and
provides access for optional externally connected peripheral devices.
The board contains two connectors (P2 and P3) to allow the
connection of an external display, a printer or a PC running CMS
software. Connection to the Control board is via connector P1 and an
8 way ribbon cable.
The following table lists the connection details from the Daughter
Board.
1250HS Section 4
May 2000 Page 7
Daughter Board P1 – Control Board Interface
Pin No Remarks
1 Not Connected
2 RX
3 RTS
4 TX
5 CTS
6 DTR
7 10V (10mA)
8 0V
6. HALL EFFECT BOARD

The Hall Effect board contains a sensor for detecting the magnets
housed in the spindle assembly. The board is mounted inside the
spindle housing diametrically opposite to the point of note picking.
Connection to the I/O board is via connector P1 and a 3 way
cableform.
The following table lists the connection details from the Hall Effect
Board.
Hall Effect Board P1 – Machine Interface

Pin No Remarks
1 5V
2 0V
3 Sensor Output
7. POWER SUPPLY UNIT

The PSU is a switch–mode unit with a single input voltage range of 98
to 264VAC. It provides a semi–regulated output on PL2 of 30VDC
+/–10%.
The following tables list the connector details to the Power Supply
Unit.
PSU PL1 – Mains Input

Pin No Remarks
1 AC Mains
3 AC Mains
Section 4 1250HS
Page 8 May 2000
PSU PL2 – DC Power Output
Pin No Remarks
1 +30V
2 0V
3 0V
4 +30V
WARNING
There are voltages present on the power supply which are potentially very
hazardous. Be very careful around this unit if the machine is stripped for
servicing and connected to the mains.
8. PRINTER CABLE
DLR Part No. 2606007201
Counter PC
(6 way FCC–68 Plug) (25 way D Type Socket)
From To
pin 1 pin 7
pin 2 pin 2
pin 3 pin 3
pin 6 pin 20
9. CMS CABLE
DLR Part No. 2606004002
Counter PC
(6 way FCC–68 Plug) (9 way D Type Socket)
From To
pin 1 pin 5
pin 2 pin 3
pin 3 pin 2
pin 5 pins 8, 4, 6
pin 6 pin 7
1250HS Section 4
May 2000 Page 9
KEY TO FIGURE 1
ITEM DESCRIPTION PART NO QTY
1 SWITCH MICRO 0.1A 250V AC NO (see Section 8, Figure 14) 02520335 3
2 SOCKET IEC 2 FUSES RFI FILTER 02541178 1
3 CBLFM – MOTOR FB06133901 2
4 PCBP RJ11 DAUGHTER BOARD (see Section 8, Figure 18) FB09127703 1
5 PCBP HALL EFFECT SWITCH ASSY (see Section 8, Figure 4) FB09127802 1
6 KIT CONTROL BOARD (see Section 8, Figure 18) FB04501101 1
7 PCBP I/O BOARD (see Section 8, Figure 4) FB09128004 1
8 MOTOR BRUSHLESS 30V DC 51W 1P (see Section 8, Figure 14) 02510155 2
9 RELAY SST 10A 28V AC LINE (see Section 8, Figure 17) 02530059 1
10 PSU MEANWELL 150C FUSE 30V 2A (see Section 8, Figure 4) 02620415 1
11 SWITCH PUSH 2 POLE 8A 250V (see Section 8, Figure 17) 02680384 1
12 CABLEFORM INTERBOARD FB06133601 1
13 CABLEFORM LOW VOLTAGE FB06133501 1
14 SWITCH MICRO 0.1A 250V AC NO (see Section 8, Figure 17) 02520335 1
15 SOLENOID 30V 1.5A (see Section 8, Figure 12) 02530099 1
16 COOLING FAN ASSEMBLY (see Section 8, Figure 22) FB02000301 1
17 SHUTTER – MICROSWITCH PLATE ASSY FB02001001 1
Section 4 1250HS
Page 10 May 2000
May 2000
1250HS Switched Mode
IEC/Filter Assembly On/Off Switch 11 Stamping
PSU
Solenoid
2
L P1 1 PL1 10
Live L
16 Batching
Neutral N P2 2 PL2 15
N Solenoid
1 2 3 4
Earth
13 Fan
E
Main 1 Shutter Open
Earth Switch
Stud
30V 0V Shutter
2 3 8 P6 17 Closed Switch
P3
9
Solid + Notes Present
Feed Plate Motor 14
State 3 Switch
Relay P2
– 8
Feedplate
P4 I/O Board 1 Switch
1 4
Spindle Motor 1 Reset Switch
3 Pressure
Sensor
P5
Run P1
Hall
Capacitor 5 4 3 2 1 Shutter Motor
P1 Effect
7 12
Board
Daughter Board
P1 5
P2
P1 P3 Control Board P2
Vacuum Pump
4 6
P3
Section 4
Page 11
Figure 1. 1250HS Interconnection Diagram

Page 12
Section 4
Cableform – Shutter Motor

FB06000401
Cableform – Interboard
FB06133601
Cableform – Motor
Cableform – Motor
FB06133901
May 2000
FB06133901
1250HS
Figure 2. 1250HS Cable Routing Diagram – sheet 1

May 2000
1250HS
Cableform – Mains Desktop

FB06133801
Section 4
Page 13

Page 14
Section 4
Cableform – Low Voltage

May 2000
FB06133504
1250HS

Section 5
Maintenance
1250HS Section 5
May 2000 Page 1
CONTENTS
Para. Page
1. GENERAL 3
2. PRECAUTIONS 3
3. FIRST LINE MAINTENANCE 3

3.1 Clean the Spindle Filters 3
3.2 Clean the Main Filter 4
3.3 Operational Checks 4
3.4 Cleaning and Inspection 4
3.5 Pump Motor 5
3.6 Vacuum and Pressure Relief Valves 6
3.7 Vacuum Pump Wiring 6
Illustrations
Figure 1 Vacuum Pump End Plate 5
Figure 2 Carbon Blade Width 6
Figure 3 Vacuum Pump Wiring 7
Section 5 1250HS
Page 2 May 2000
1. GENERAL
It is essential that maintenance be carried out on the 1250HS
machine on a regular basis in order to achieve efficient operation with
minimal breakdown periods.
This section is designed to achieve this aim, by dividing the

maintenance and servicing required into varying levels. Each level is
dependent upon the technical capability of involved personnel and
technical content of the level concerned.
Maintenance is also covered by a preventive maintenance schedule

on a WEEKLY and SIX MONTHLY basis. The schedule provides for
regular inspection, and rectification where necessary, covering
designated areas of the machine during the period of six months
usage. This schedule is subject to variation when environmental
conditions such as dust, humidity or note condition may necessitate
more regular service intervals.
2. PRECAUTIONS
Extreme care must be taken when working on the machine with the
covers removed and the machine running, some low voltage circuits
are exposed. Running the machine without the top cover should be
kept to a minimum as the cooling efficiency is greatly reduced. When
rotating the machine about its rear base (i.e. to service the filter), the
mains lead should be removed to prevent damage to the mains
socket.
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 the microprocessor device.
3. FIRST LINE MAINTENANCE

The following maintenance procedures should be carried out by the
service engineer at the prescribed time intervals.
3.1 Clean the Spindle Filters (Section 8 Figure 9)

Clean the five spindle filters using the following procedure:
a. Unplug the machine from the mains supply.
b. Secure each spindle in turn (by hand) and remove the spindle
caps (item 5).
c. Remove and clean the filters (item 3).
d. Reassemble the components in the reverse order.
1250HS Section 5
May 2000 Page 3
3.2 Clean the Main Filter (Section 8 Figure 16)
Clean the main filter as follows:
a. Unplug the machine from the mains supply.
b. Remove the transparent bowl (item 10) by releasing the locking

ring above the filter.
c. Wash the bowl in warm soapy water, rinse and dry thoroughly.
d. Inspect the ‘O’ ring (item 7) for wear, splits or cracks and replace
if necessary. The ‘O’ should be secured to the bowl using Loctite
415 (Part No. 00340401) or equivalent.
e. Remove the filter element (item 5) and clean.
f. To reassemble the main filter reverse the above procedure.
3.3 Operational Checks

Prior to removing the main cover, carry out the following:
a. Inspect the feed assembly for damage, looseness and
smoothness of operation when counting. Check the separator
spring condition and clamp arm adjustment. Any adjustment
required should be carried out in accordance with the procedures
detailed in Section 7 of this manual.
b. Check the LCD displays and keypad are fully functional, using
diagnostic mode 3.
c. Check the reset button and mains switch for damage or

stickiness of operation.
d. Check the counting head spindles for bearing and gear wear,
surface damage, and fouling with the inner cover.
e. Check the vacuum settings – diagnostic mode 2.
f. Record the machine count total.
g. Check the operation of the auto start switch.
3.4 Cleaning and Inspection

The following points should be noted when cleaning the machine.
D Oilite Bearings. Excessive use of an aerosol or liquid cleaner is
not recommended, especially on or near the feed assembly or
shutter rail as they have oilite bearings fitted. The use of a
solvent could cause loss of lubricant resulting in rapid
deterioration of the bearings.
D Solvents. Extreme care must be exercised when using solvents.

They must not be used on or near plastic materials.
Carry out the following cleaning and inspection routines:–

a. Clean the machine of all excess dirt and accumulated dust using
a soft brush and vacuum cleaner.
Section 5 1250HS
Page 4 May 2000
b. Check that all plug–in electronic components, IC’s, plugs and
sockets etc, are fully inserted into their respective positions.
c. Check all belts for wear, i.e. no cracks, nicks or kinks.
3.5 Pump Motor (Section 8, Figure 17)

The pump has a long life expectancy and therefore dismantling should
seldom become necessary. However, the carbon blades may
eventually wear out, leading to a complete loss of vacuum. At the
routine service, the carbon blades should be inspected for wear. The
minimum width permissible for correct functioning of the pump is
13mm (see Figure 2).
Noting the blade width during each routine service will enable the
service engineer to assess the rate of wear and thus determine
whether or not the blade needs replacing before the next routine
service.
To inspect the carbon blades proceed as follows:

a. Remove the rear cover and filter assembly.
b. Unscrew and remove the four nuts and ease off the end plate to
expose the rotor and carbon blades. The end plate should only
be cleaned using either air pressure or a dry cloth as certain
fluids or mechanical abrasion will remove the special film on the
inside surface.
End Plate
Figure 1. Vacuum Pump End Plate

c. Remove and clean the carbon blades. Blow clean the rotor slots
and housing of all excess carbon dust. Measure the width of
each blade and record the narrowest. If any blade is less than
13mm then all blades must be replaced. If it is envisaged that
the blade will wear to 13mm before the next routine service then
all blades must be replaced.
d. Replace the blades and ensure that the round edges contact the
housing and that they are free to drop in their slots as the rotor is
turned.
1250HS Section 5
May 2000 Page 5
Carbon Blade
02310472
13mm (min)
Figure 2. Carbon Blade Width

e. Check that the non return valve is free to move and is not
cracked or perished.
f. To re–assemble and replace the pump motor, reverse the above

procedure.
g. Check the vacuum level and pressure as detailed in Section 6.
3.6 Vacuum and Pressure Relief Valves

(Section 8, Figure 16)
Inspect the valve ball for deposits and check for leakage due to poor
seating down. If necessary remove and clean the ball. Clean the
valve body and seat using a soft brush and cleaning solvent. On
completion, push the ball inwards (by finger tip) and check that is
reseats correctly.
3.7 Vacuum Pump Wiring

Two versions of the pump are in existence. One has the thermal trip
mounted on the outside of the pump whilst the other has a thermal trip
built integral to the pump itself. Both types are interchangeable,
however the wiring differs slightly for each (see Figure 3).
Section 5 1250HS
Page 6 May 2000
External Thermal Trip
Thermal Trip
2 4 White
Relay female connector

White
Red Orange
male connector
1 3
Chassis Bulkhead
To I/O PCB
Internal Thermal Trip
2 4 Orange
Relay
Red
1 3
Chassis Bulkhead
To I/O PCB
Figure 3. Vacuum Pump Wiring
1250HS Section 5
May 2000 Page 7
Section 6
Diagnostics
1250HS Section 6
May 2000 Page 1
CONTENTS
Para. Page
1. INTRODUCTION 3
2. SERVICE DIAGNOSTICS 3
2.1 Diagnostic 0 – Check Sum 4
2.2 Diagnostic 1 – Sensor Check 4
2.3 Diagnostic 2 – Vacuum Level Display 5
2.4 Diagnostic 3 – Display and Keyboard Test 5
2.5 Diagnostic 4 – Timed Feed Arm Test 5
2.6 Diagnostic 5 – Batch Arm Test 5
2.7 Diagnostic 6 – Timed Shutter Test 5
2.8 Diagnostic 7 – Remote Display Test 6
2.9 Diagnostic 8 – Spindle Start Delay 6
2.10 Diagnostic 10 – Serial Port Settings Adjustment 6
2.11 Diagnostic 11 – Printer Port Settings Adjustment 7
2.12 Diagnostic 13 – Cycling the Machine 8
2.13 Diagnostic 14 – Initialise the NOVRAM 8
2.14 Diagnostic 15 – Spindle Speed Calibration 8
2.15 Diagnostic 45 – Display Background Totals 9
2.16 Diagnostic 92 – Note Drop Point 9
3. PRODUCTION DIAGNOSTICS 9
4. ERROR CODES 9
4.1 Program Errors 9
4.2 Hardware Errors 9
4.3 User Errors 10
Illustrations
Figure 1 1250HS Control Panel 3
Section 6 1250HS
Page 2 May 2000
1. INTRODUCTION
The 1250HS has a diagnostic facility for checking the operation of the
component parts of the machine. The facility is used to set up the
vacuum and pressure relief valves as well as analysing the dynamic
performance of the 1250HS.
The 1250HS offers two levels of diagnostics:

D Field Service
D Production
Four hidden switches are located on the facia (refer to Figure 1). The
two on the right are designated H1 and H2, H1 being the upper key.
The hidden switches on the left are designated H3 and H4, H3 being
the upper key.
H3 H1
H4 H2
Figure 1. 1250HS Control Panel
A number of error codes are also displayed to assist with fault

diagnosis.
2. SERVICE DIAGNOSTICS
Pressing hidden switches H1 and H2 simultaneously allows entry to
the Service Diagnostic Mode.
In all diagnostic modes, pressing the VERIFY key once returns the
machine to the diagnostic select mode, allowing another diagnostic
function to be selected. Pressing the VERIFY key whilst in the select
mode causes a machine reset, returning it to normal operation.
On entry into machine diagnostics, the following is shown on the

count display:
‘xx–xx’ – software version/revision for
one second
‘Dn 1’ – diagnostics mode 1
The machine is now in the diagnostic select mode. To select a

particular diagnostic mode press the numeric keys for the required
number. Alternatively, the available modes can be incremented or
decremented through using the H1 and H2 keys respectively.
The START key is used to enter the diagnostic mode selected and the
VERIFY key is used to exit from the diagnostic mode.
1250HS Section 6
May 2000 Page 3
2.1 Diagnostic 0 – Check Sum
Diagnostic mode 0 allows a check sum operation to be carried out. If
a fault is detected the message ‘FAIL’ is displayed. If no fault is
detected the firmware version number and revision level is displayed.
‘xx–xx’ – software version/revision.
2.2 Diagnostic 1 – Sensor Check

On entry into diagnostic mode 1, seven bars are displayed in the
‘Count’ area of the display. Each bar is in either an upper or lower
position to reflect the status of various sensors and switches. Bar 1 is
the left most bar with bar 7 being the furthest to the right. The bars
represent the status of the various sensors as follows:
Bar 1 – Shows the status of the RESET switch.

Down when the switch is pressed.
Bar 2 – Shows the status of the Note Stop switch.

Down when notes are present or the switch is activated.
Bar 3 – Shows the status of the Feed Arm switch.

Down when the feed arm is closed.
Bar 4 – Shows the status of the Shutter Open switch.

Up when the shutter is fully open.
Bar 5 – Shows the status of the Shutter Closed switch.

Up when the shutter is fully closed.
Bar 6 – Shows the position of the spindle position Hall Effect

sensor. The bar pulses down 5 times during one full
revolution of the spindles.
Bar 7 – Shows the status of the Spindle Motors internal Hall

Effect sensor. The bar pulses up and down as the
spindle head is rotated.
Whilst in diagnostic mode 1 the following operations can be carried

out:
Pressing numeric key 1 closes the shutters. A further press of key 1

opens the shutters. This process can be repeated indefinitely.
Pressing numeric key 0 closes the Feed Arm. A further press of key
0 opens the Feed Arm. This process can be repeated indefinitely.
On exit of this diagnostic mode the Feed Arm and Shutters are
opened.
Note: The spindle motor is prevented from operating in this
diagnostic mode.
Section 6 1250HS
Page 4 May 2000
2.3 Diagnostic 2 – Vacuum Level Display
Entry into diagnostic mode 2 displays an accurate ‘real time’
measurement of the Vacuum Level. The vacuum pump can be
toggled on and off using the START/STOP key.
On entry into diagnostic mode 2 the pump is switched on. On exit of

diagnostic mode 2 the pump is switched off.
2.4 Diagnostic 3 – Display and Keyboard Test

Entry into diagnostic mode 3 causes the display to show all segments
and symbols. If a numeric key is pressed the display clears and the
corresponding number is displayed. If any other key (apart from
VERIFY) is pressed, a code is displayed which represents the key
pressed.
Press the VERIFY key to exit this diagnostic mode.
2.5 Diagnostic 4 – Timed Feed Arm Test

Entry into diagnostic mode 4 allows the operation of the feed arm to
be timed. Pressing the START/STOP key closes the feed arm. The
operation is timed and the result should fall within an upper and lower
limit which results in ‘PASS’ being displayed for a successful result. If
the feed arm fails to operate within the timing limit then the display
shows ‘FAIL’.
Pressing the START/STOP key a second time results in a similar

timing being carried out for the open operation, with the relevant
message being displayed depending on the results of the operation.
The process of opening and closing the feed arm can be repeated
indefinitely.
On exit of the diagnostic mode the feed arm is returned to the open
position.
2.6 Diagnostic 5 – Batch Arm Test

Entry into diagnostic mode 5 allows the batch arm to be tested.
Pressing the START/STOP key activates the Batch Arm for 300mS.
A 500mS delay is initiated before the batch arm can be operated
again.
2.7 Diagnostic 6 – Timed Shutter Test

Entry into diagnostic mode 6 allows the operation of the shutters to be
timed. Pressing the START/STOP key closes the shutters. The
operation is timed and the result should fall within an upper and lower
limit which results in ‘PASS’ being displayed for a successful result. If
the shutter fails to operate within the timing limits then the display
shows ‘FAIL’.
Pressing the START/STOP key a second time results in a similar

timing being carried out for the open operation, with the relevant
message being displayed depending on the results of the operation.
The process of opening and closing the shutter can be repeated
indefinitely.
On exit of the diagnostic mode the shutter is returned to the open

position.
1250HS Section 6
May 2000 Page 5
2.8 Diagnostic 7 – Remote Display Test
Entry into diagnostic mode 7 allows the remote display to be tested.
The remote display shows the internal software revision, followed by a
full digit count up from 0 to 9. This check will highlight any defective
digits. Finally, the remote display’s internal oscillator frequency test is
invoked. If the frequency is correct the remote display will show
‘PASS’. If the frequency is incorrect the display will show ‘FAIL’.
2.9 Diagnostic 8 – Spindle Start Delay

Diagnostic mode 8 allows selection of the delay between the feed arm
closing and the spindles starting to move.
The selectable delays are 0, 0.4 or 0.8 seconds. The default after
initialising the NOVRAM (diagnostic 14) is 0 seconds. Pressing the
BATCH key repeatedly scrolls through the delay options.
Press the VERIFY key to exit this diagnostic mode.
2.10 Diagnostic 10 – Serial Port Settings Adjustment

Diagnostic mode 10 is used to change the RS232 interface
configuration parameters for CMS operation and includes Baud Rate,
Poll Rate, Stop Bits, Parity Mode and Data Bits selection.
Entry into diagnostic mode 10 causes the baud rate selection to be

displayed. The sequence for programming the RS232 configuration
parameters is as follows:
a. Baud Rate Selection

The display shows the current baud rate with BAU indicated on
the RHS e.g. 9600 bAU.
The baud rate options are 1200, 2400, 4800, 9600 and 19200
where 9600 is the factory default.
Pressing the BATCH key repeatedly scrolls through the baud
rate options on the display. The START key is used to enter the
selected baud rate into NOVRAM. The display then moves on to
the poll rate selection.
b. Poll Rate Selection

The display shows the current poll rate with POL indicated on the
RHS e.g. 10 POL. The Poll Rate is set in the range 100mS to
2.5 seconds and is displayed in multiples of 100mS (i.e. 1
second = 10 on the display) and the factory default is 1 second.
The numerical keypad is used to change the poll rate on the
display and the START key is used to enter the selected poll rate
into NOVRAM The display then moves on to the number of stop
bits selection.
c. Number of Stop Bits Selection

The display shows the current number of stop bits with StP
indicated on the RHS e.g. 1 StP. The number of stop bits can be
set to either 1 or 2, where the factory default is 1 stop bit.
Pressing either the 1 or 2 numerical key changes the number of
stop bits on the display. The START key is used to enter the
selected number of stop bits into NOVRAM. The display then
moves on to the parity mode selection.
Section 6 1250HS
Page 6 May 2000
d. Parity Mode Selection
The display shows the current parity mode with PAr indicated on
the RHS e.g. EvEn PAr. The parity mode options are NonE, odd
and EvEn, where the factory default is EvEn parity. Pressing the
BATCH key repeatedly scrolls through the parity mode options.
The START key is used to enter the selected parity mode into
NOVRAM. The display will then move on to the number of data
bits selection.
e. Number of Data Bits Selection

The display shows the current number of data bits with dAt
indicated on the RHS e.g. 7 dAt. The number of data bits can be
set to either 7 or 8, where the factory default is 7 data bits.
data bits on the display. The START key is used to enter the
selected number of data bits into NOVRAM. The display will
then return to the baud rate selection.
The VERIFY key can be pressed at any time to exit diagnostic
10, but an option that has been altered on the display will only be
entered in NOVRAM by first pressing the START key.
2.11 Diagnostic 11 – Printer Port Settings Adjustment

Diagnostic mode 11 is used to change the printer interface
configuration parameters for printer operation and includes Baud
Rate, Stop Bits, Parity Mode and Data Bits Selection. On entering
this mode the baud rate selection is displayed. The sequence for
programming the printer configuration is as follows:
a. Baud Rate Selection

The display shows the current baud rate with BAU indicated on
the RHS e.g. 9600 bAU.
The baud rate options are 1200, 2400, 4800, 9600 and 19200,
where 9600 is the factory default.
Pressing the BATCH key repeatedly scrolls through the baud
rate options on the display. The START key is used to enter the
selected baud rate into NOVRAM. The display then moves on to
the Stop Bits selection.
b. Number of Stop Bits Selection

The display shows the current number of stop bits with StP
indicated on the RHS e.g. 1 StP. The number of stop bits can be
set to either 1 or 2, where the factory default is 1 stop bit.
stop bits on the display. The START key is used to enter the
selected number of stop bits into NOVRAM. The display then
moves on to the parity mode selection.
c. Parity Mode Selection

The display shows the current parity mode with PAr indicated on
the RHS e.g. EvEn PAr. The parity mode options are NonE, odd
and EvEn, where the factory default is EvEn parity. Pressing the
BATCH key repeatedly scrolls through the parity mode options.
The START key is used to enter the selected parity mode into
NOVRAM. The display will then move on to the number of data
bits selection.
1250HS Section 6
May 2000 Page 7
d. Number of Data Bits Selection
The display shows the current number of data bits with dAt
indicated on the RHS e.g. 7 dAt. The number of data bits can be
set to either 7 or 8, where the factory default is 7 data bits.
data bits on the display. The START key is used to enter the
selected number of data bits into NOVRAM. The display will
then return to the baud rate selection.
The VERIFY key can be pressed at any time to exit diagnostic
11, but an option that has been altered on the display will only be
entered in NOVRAM by first pressing the START key.
2.12 Diagnostic 13 – Cycling the Machine

Diagnostic mode 13 cycles the machine as if batching notes,
continuously. It is not intended for heavy use, which would result in
rapid wear occurring. Each action in the cycle is timed to ensure that
it is completed within specified limits.
If any action fails to comply with the specification the machine is

stopped and an error message is displayed.
The process can be continued by pressing the RESET key. To exit

the process press the VERIFY key. If the process is continued using
the RESET key the machine operations should be reset to their start
positions prior to continuing the cycling routine.
The vacuum pump is not activated in this diagnostic mode.
On exit from this mode the machine should be returned to its normal
start–up positions.
2.13 Diagnostic 14 – Initialise the NOVRAM

Entry into diagnostic mode 14 sets the non–volatile memory to the
default values. To reset the NOVRAM to the default values press the
START key; the display shows ‘SEt’. Press the START key a second
time and the display shows ‘donE’ when the operation is complete.
If the machine is unable to set the NOVRAM the display shows ‘FAIL’.
2.14 Diagnostic 15 – Spindle Speed Calibration

Entry into diagnostic mode 15 allows the spindle speed calibration to
be carried out. To initiate the test, press the START key. If the key is
pressed whilst the test is in progress the test will be halted. If the
machine is fitted with shutters they will close prior to the spindle motor
starting.
The machine cycles through all speeds. Each speed is checked to

see if it can be attained within a time limit. If all speeds are achieved
the display shows ‘Pass’, otherwise ‘Fail’ is displayed along with the
speed at which the failure occurred.
A minimum unloaded speed equivalent to 45 notes per second must

be achieved.
Section 6 1250HS
Page 8 May 2000
2.15 Diagnostic 45 – Display Background Totals
Entry into diagnostic mode 45 displays the background totals stored in
NOVRAM. The START key is used to scroll through the following
totals:
1 Total number of count cycles (machine life).
2 Total number of power ups.
3 Total number of error occurrences for each error type
since last service.
4 Total number of count cycles since last service.
Pressing the CLEAR key after cycling through all totals will clear totals
3 and 4 above.
Note: Totals 1 and 2 can only be cleared in production diagnostic
mode 14.
2.16 Diagnostic 92 – Note Drop Point

Entry into diagnostic mode 92 allows the setting and checking of the
note drop point of the spindle head. Refer to Section 7 of this manual
for setting instructions.
3. PRODUCTION DIAGNOSTICS
Pressing hidden switches H3 and H4 simultaneously will cause the
display to show ‘P.I.N.’. Entry of the correct PIN number will put the
machine into the Production Diagnostic Mode. This level of
diagnostics is identical to the Service Diagnostics apart from
diagnostic mode 14. Diagnostic mode 14 should only be carried out if
installing a new PCB.
4. ERROR CODES
Error codes are displayed to aid fault diagnosis and fall under three
categories: Program Errors, Hardware Errors and User Errors. To
clear an error message press the RESET switch.
4.1 Program Errors

P120 An attempt has been made to clear a fixed verify size.
P129 The verify size was not set before a clear operation was
requested.
P130 Internal checksum failure. Replace microprocessor.
4.2 Hardware Errors

H131 Feed Arm took too long to close.
H132 Feed Arm took too long to open.
H133 Shutters took too long to close.
H134 Shutters took too long to open.
1250HS Section 6
May 2000 Page 9
4.3 User Errors
U146 The machine has attempted to count over its maximum
limit (>250).
U147 Reset button pressed while feed arm is moving.
U148 Start/Stop button pressed whilst machine counting.
U149 Reset pressed whilst machine counting.
Section 6 1250HS
Page 10 May 2000
Section 7
Settings and Adjustments
1250HS Section 7
May 2000 Page 1
CONTENTS
Para. Page
1. INTRODUCTION 3
2. MECHANICAL SETTINGS 3
2.1 Vacuum Settings 3
2.2 Tail Clamp and Feed Plate Adjustment 3
2.3 Shutter Belt Fitting and Tensioning 4
2.4 Spindle Alignment 5
2.5 Spindle Timing 5
2.6 Spindle Speed 7
2.7 Tension Spring 8
2.8 I/O PCB Link Positions 8
Illustrations
Figure 1 Tail Clamp and Feed Plate Adjustment 4
Figure 2 Spindle Alignment 5
Figure 3 Backstop Adjuster 6
Figure 4 Centre Spindle Fixing Screw 6
Figure 5 Picked Note Drop Point 7
Figure 6 Tension Spring 8
Section 7 1250HS
Page 2 May 2000
1. INTRODUCTION
The following settings and adjustments are defined for the mechanical
functions of the machine.
2. MECHANICAL SETTINGS
2.1 Vacuum Settings

To set the vacuum level in the system carry out the following
procedure:
a. Enter diagnostic mode 2 (refer to Section 6 of this manual) and

press the START key. The vacuum pump is switched on and the
display shows the instantaneous reading of the vacuum seen at
the head.
Note: To simulate a note, the suction holes in the head should be

totally covered (if tape is used then any residue must be carefully
cleaned).
b. With the holes in each head covered, slowly rotate the spindle
assembly by hand and note the maximum vacuum reading.
c. Set the vacuum level to 200 units. The minimum permissible

reading on any spindle is 190 units. If any spindle fails to reach
the minimum level replace the head assembly.
d. The general level of vacuum is adjusted by means of the small

valve on the filter manifold in the rear of the unit (to access
remove the rear cover). As the valve is screwed down the
vacuum level increases and vice versa.
e. If thick or plastic notes are being counted, it is recommended

that the vacuum be increased (maximum is approximately 240
units).
f. If porous notes are being counted the vacuum can be lowered to

150 – 160 units on each head.
2.2 Tail Clamp and Feed Plate Adjustment

To adjust the tail clamp and feed plate carry out the following
procedure:
a. Remove the inner cover.
b. Refit the feedplate. Run the head using diagnostic mode 4.

Rotate the head by hand so that each suction spindle in turn
provides a deflection at x of 1mm or that it just touches the
facing plate (refer to Figure 1).
c. Adjustment is by means of the screw on the clamp arm

assembly (Section 8, Figure 6, item 8).
1250HS Section 7
May 2000 Page 3
Kiss Point
x
Figure 1. Tail Clamp and Feed Plate Adjustment
2.3 Shutter Belt Fitting and Tensioning

The shutters are moved by two belts; the longer belt is a standard belt
and the shorter belt is made by cutting down a long belt and clamping
the ends under the shutter carrier. To fit and tension the belts carry
out the following procedure:
a. Fit the long belt in the shutter belt clamp. Tension the belt by
sliding the shutter idler shaft in its slot in the back wall of the
base.
b. Cut and offer up the second belt and lay it over the idler pulley.
Mark off the excess length.
c. Slacken the idler pulley shaft and remove the belt from the
pulley. Remove the shutter shaft and carriers.
d. Fit the lengths of belt into the carrier and clamp the screws.
Refit the carriers and shaft.
e. Locate both belts but leave the shutter idler pulley loose.
f. Carefully slide the shutter carriers so that both are at the right
hand end of their travel. Check that the shutter microswitch
operates (listen for a click).
g. Slightly tension the belts and carefully tighten the shutter idler
shaft.
h. Fit the shutters and carefully move them by hand (always move
the leading shutter) and check that the microswitches at each
end are operated. If the microswitches do not operate, either
slacken the shutter idler pulley shaft and move one of the belts to
correct the fault or loosen the microswitch securing nut,
re–position the microswitch and then re–tighten the nut.
Section 7 1250HS
Page 4 May 2000
2.4 Spindle Alignment
The spindles must be aligned accurately to ensure pick accuracy and
efficiency. Alignment is achieved by means of a jig plate which is
used to locate the spindle heads (Figure 2). Locate the Spindle
Heads into the Timing Jig (part number T1200130). The centre
spindle has two ports or slots cut into the shaft. Align the narrower of
the two ports in the direction of the arrow in Figure 2. Carefully locate
the base on the spindle head assembly.
Figure 2. Spindle Alignment
2.5 Spindle Timing

The exact point where a note is dropped is critical to the operation of
the machine. The timing is adjusted by means of an arm which locks
the centre spindle. The arm is located in the base of the spindle unit
and is clamped by a screw which is accessed by removing the inner
cover and flower pot. On later build machines, access to the timing
arm clamp screw is from the underside of the machine. To set the
note drop point proceed as follows:
a. With the inner cover fitted move the backstop adjuster to the
extreme right (see Figure 3). Enter diagnostic 92.
b. Place mint test notes carefully against the note stop, ensuring
the bundle is evenly stacked.
c. Press the green ‘stop/start’ button – the feed plate will close and
the vacuum is activated.
d. Rotate the spindles to pick notes manually VERY SLOWLY and
adjust the centre spindle from the underside of the machine by
moving the timing arm to achieve the drop point setting indicates
in Figure 5.
e. Tighten the centre spindle adjuster arm and recheck the drop
position for all spindles.
f. Exit this diagnostic routine.
1250HS Section 7
May 2000 Page 5
Adjuster
Figure 3. Backstop Adjuster
Fixing
screw
Figure 4. Centre Spindle Fixing Screw
Section 7 1250HS
Page 6 May 2000
(see below)
Figure 5. Picked Note Drop Point
2.6 Spindle Speed

The spindle speed can be selected from between 24 and 40 notes
per second. The speed self calibrates during operation of the
machine. If the machine is taken into a new environment, or on initial
set up, or after diagnostic 14 has been carried out, it will be necessary
to run a speed calibration in accordance with diagnostic mode 15
(refer to Section 6 of this manual).
1250HS Section 7
May 2000 Page 7
2.7 Tension Spring
Tension spring adjustment is carried out by locating the end of the
tension spring on one of the six securing features located below the
spindle motor. Moving the spring towards the front of the machine
increases the tension, thus providing more force to the feed
mechanism. The factory/optimum setting is position 3 (see Figure 6).
Figure 6. Tension Spring
2.8 I/O PCB Link Positions

Links LK1 and LK2 set the default shutter operation, dependent on the
build of the counter.
Build LK1 & LK2 Shutter Operation

UL Build Counter Not Fitted Always Enabled
CE Build Counter Fitted May Be Disabled
Note: Both links should always be in the same state. There must
never be only one link fitted.
Section 7 1250HS
Page 8 May 2000
Section 8
Removal, Overhaul & Replacement
1250HS Section 8
May 2000 Page 1
CONTENTS
Para. Page
1. INTRODUCTION 4
2. TOOLS REQUIRED 4
3. COVERS AND SHUTTERS 4
4. SPINDLE DRIVE ASSEMBLY 5
5. FEED GEARBOX AND DAMPER ASSEMBLIES 5
6. FEED GEARBOX ASSEMBLY 6
7. DAMPER ASSEMBLY/FEED ARM ASSEMBLY 6
8. POWER SUPPLY UNIT 6
9. NOTE ADJUSTER AND RIFFLER 7
10. SPINDLE ASSEMBLY REMOVAL 7
11. SPINDLE ASSEMBLY REPLACEMENT 9
12. MAINS SWITCH 10
13. VACUUM PUMP ASSEMBLY 10
Illustrations
Figure 1 Spindle Head Alignment 9
Figure 2 1250HS General View – Tabletop 13
Figure 3 1250HS Basic Kit 15
Figure 4 Base Unit Assembly 19
Section 8 1250HS
Page 2 May 2000
CONTENTS (continued)
Illustrations
Figure 5 Damper and Feed Arm Assembly 21
Figure 6 Damper and Feed Arm Sub Assembly 23
Figure 7 Feed Plate Sub Assembly 24
Figure 8 Note Stop Assembly 25
Figure 9 Spindle Head Assembly 27
Figure 10 Housing Assembly 29
Figure 11 Spindle Drive Assembly 31
Figure 12 Solenoid/Batch Link Assembly 32
Figure 13 Riffler Assembly 33
Figure 14 Gearbox Assembly 35
Figure 15 Gearbox Sub Assembly 37
Figure 16 Filter Unit 39
Figure 17 Vacuum Pump Assembly 41
Figure 18 Top Box Assembly 43
Figure 19 Shutter Kit 45
Figure 20 Shutter Inner Drive Assembly 46
Figure 21 Shutter Outer Drive Assembly 47
Figure 22 Cooling Fan Assembly 49
1250HS Section 8
May 2000 Page 3
1. INTRODUCTION
This section describes the removal, overhaul and replacement
procedures for the main assemblies of the 1250HS machine. The
mains supply must be removed prior to any removal/replacement
procedure.
2. TOOLS REQUIRED
The following tools are required to carry out the removal/replacement
procedure:
D 2mm ball ended allen key
D 7mm spanner
D 8mm spanner
D 10mm spanner
D Circlip pliers (internal and external)
D Long nosed pliers
D No 1 posidrive screwdriver
D No 2 posidrive screwdriver
D Small flatbladed screwdriver
D Hide or rubber mallet
D Head timing jig (Part No. T1200109)
D Bearing pullers
3. COVERS AND SHUTTERS

Before removing any of the machine covers, disconnect the machine
from the mains supply and remove the mains connector.
Undo the two screws securing the rear cover. Press down on the top
middle of the cover to release the clip features and then slide the
cover backwards.
Remove the top box by undoing the two screws securing it to the
machine frame. Slide the box upwards and to the right so that it can
be taken off its location features.
Remove the two screws from both sides of the front cover. Lift off the
front cover by manoeuvring it upwards and forwards.
Unclip the shutters (if fitted) from their carrier blocks, taking care not
to damage the clip features or scratch the shutters when storing them.
The machine may be run with the covers off for diagnostic purposes;
all safety procedures must be observed. However, the shutter
mechanism will not operate correctly without the shutters, as the
weight of these is required to activate the corresponding micro
switches.
Using a 3mm Allen key, release the feed plate. The screw for this is
located through the small hole in the centre of the feed plate.
Align the slotted hole in the base of the inner cover with the tail clamp
by rotating the feed plate drive pulleys.
Remove the two screws from the front of the cover and the single
screw from the rear. Whilst easing the batching arm back, lift off the
inner cover.
Section 8 1250HS
Page 4 May 2000
Care should be taken not to damage the rubber friction grip at the rear
of the tail clamp.
If required for diagnostic purposes, the feed plate can be refitted and
the machine run without covers.
Undo and remove the two 3mm screws that secure the shutter runner
at the front of the chassis.
The runners require regular cleaning. The brushes slide into the
runners and should be replaced if showing signs of excessive wear.
Note that the longer brush is situated at the rear and both are pushed
to the right hand end of the runner.
If the top box is not going to be required, it is advisable to disconnect

the cable from the I/O PCB at this stage.
4. SPINDLE DRIVE ASSEMBLY

To remove the spindle drive assembly proceed as follows:
Unhook the feedplate drive spring from below the spindle motor and
disconnect the motor control cable from the spindle motor.
Remove the two screws from the base of the spindle motor mounting
bracket.
Disengage the spindle drive gear from the drive belt and lift out the
spindle drive assembly.
Remove the spindle drive gear by undoing the 5mm hex screw in its
centre.
Remove the spindle motor from its mounting by unscrewing the three
screws from underneath.
Release the spindle drive pinion from the shaft by loosening the grub
screws. This allows the drive pinion to be pulled from the shaft.
When reassembling secure the grub screws with Loctite 222.
5. FEED GEARBOX AND DAMPER ASSEMBLIES

To simplify the procedure it is easier to remove the feed plate gearbox
and damper assembly as one complete assembly. Proceed as
follows:
Remove the mains switch extension by removing the locking clip.

Slide to the right, off the switch. Pull forward and rotate 90 degrees
and then pull fully out.
Disconnect the cables from the reset and feed cam microswitch.
Disconnect the cable from the feed motor.
1250HS Section 8
May 2000 Page 5
Undo and remove the three screws from the base of the gearbox
assembly and the three screws from the base of the damper
assembly. Lift out the gearbox and damper assemblies as one
complete unit.
Remove the circlip securing the two link arms to the base of the clamp
arm. Remove the screw from the damper end of the bridge support.
This enables the two assemblies to be separated.
6. FEED GEARBOX ASSEMBLY

The only field serviceable items on this assembly are the motor and
the drive belt.
To replace the feed motor remove the three screws securing it to it’s
mounting. Note that this motor is identical to that used to drive the
spindle assembly and that therefore they are interchangeable.
To remove the feed pulley, loosen the two grub screws that secure it
to the motor shaft.
Remove the drive belt by removing the top screw and the screw to the
right hand side. Loosen the remaining screw enough to allow the
motor to swivel round. Drop the motor to release the tension on the
drive belt and slide the belt off.
Replacement of the gears or associated bearings in this assembly

should only be carried out at an approved repair centre.
7. DAMPER ASSEMBLY/FEED ARM ASSEMBLY

This assembly has a limited number of serviceable parts. The two
springs associated with the assembly require periodic replacement
and are removed by unclipping them from the base of the tail clamp.
To replace the tail clamp unscrew the linkage from the base of the tail
clamp and then pull the tail clamp from its pivot. Care should be
taken not to lose the tail clamp bush.
Pull the rubber friction grip out from the tail clamp and inspect. If the
friction grip shows signs of wear it should be replaced.
8. POWER SUPPLY UNIT

Servicing on the power supply unit is limited to fuse replacement only.
If the PSU is diagnosed defective it should be replaced as a complete
assembly. Before any procedure is carried out the mains power
supply must be removed from the machine. To remove the PSU
proceed as follows:
Remove the screws securing the power supply cover and fan and lift
off the cover.
Remove connectors CN1 and CN2 from the power supply PCB.
Loosen the three PCB standoffs and lift out the power supply.
Section 8 1250HS
Page 6 May 2000
Removing the PSU allows access to the run capacitor. To replace the
run capacitor remove the two connections from its top and undo and
remove the nut underneath.
The mains inlet and vacuum pump relay are situated behind the small
cover to the rear of the PSU and are accessed by removing the two
screws at the bottom of the cover and lifting off the cover.
To replace the mains connector disconnect the cables and remove the
two securing screws.
To replace the pump relay disconnect the cables and remove the two
securing screws.
9. NOTE ADJUSTER AND RIFFLER

Unclip the circlip from the right hand end of the adjuster slide rail.
Slide the adjuster rail over to release the note adjuster.
Using a long 3mm ball ended Allen key, undo the screw from the base
of the riffler assembly. Access to this screw is via a cut out in the
casting.
Disconnect the 8mm diameter riffler pipe from the vacuum pump.
Remove the riffler assembly whilst feeding the riffler pipe through the
machine.
Remove the riffler spring by undoing the screw accessed through the
hole in the plastic cover.
Re–assemble the riffler assembly but do not fit it to the machine.

When replacing the riffler spring, the bend at the end should point
upwards with the crease in line with the edge of the plastic riffler plate.
With the riffler removed, slide the rear note stop forward and off it’s
two locating posts.
To remove the auto start microswitch disconnect the two cables

connected to it and remove the M3 nyloc nut. The polarity of these
cables is not important.
On re–assembly check that the microswitch actuator arm is positioned

behind the plastic lug on the switch plate.
10. SPINDLE ASSEMBLY REMOVAL

Due to the fit of the bearings in the spindle head assembly, the
assembly should not be serviced in the field. If a fault is diagnosed
with the bearings or spindles then the complete assembly should be
replaced. The faulty unit should be returned to the factory or an
approved distributor where bearing presses and pullers are available.
To remove the spindle assembly proceed as follows:
Disconnect the link at the base of the batch arm and turn the batch
arm to provide access to the spindle assembly.
When the link is released the solenoid assembly can be easily

dismantled or replaced.
1250HS Section 8
May 2000 Page 7
Disconnect the cable from the Hall Effect sensor.
Remove the three screws securing the spindle cover and lift off the
cover.
Remove the spindle drive belt.
Disconnect the 6mm spindle vacuum pipe from the filter assembly.
Unscrew the three spindle assembly mountings from the base using
a 3mm Allen key. Care should be taken not to damage the six rubber
mounting pads.
Disconnect the vacuum pipe from the spindle assembly to the vacuum
sensor. The vacuum sensor is mounted on the I/O PCB. The lower
connector on the switch is used for measuring vacuum levels.
Remove the spindle assembly from the machine taking care to guide
the 6mm vacuum pipe through the hole in the rear panel.
Invert the head assembly.
Remove the timing adjuster screw using a 4mm Allen key.
Using a size 1 pozi screwdriver remove the two screws that secure
the timing adjuster arm. Lift off the adjuster arm.
Remove the base from the spindle assembly.
With the aid of circlip pliers remove the circlips from the spindle gears.
Lift off the spindle gears and slide out the pins from the spindle shafts.
Push out the spindle shafts from the spindle head assembly.
Carefully remove the centre cap and top cover.
Remove the upper spindle bearings.
Pull the lower bearing from the spindle head assembly.
Remove the centre spindle by releasing the circlip and then remove
the upper and lower bearings.
Check all bearings for wear or damage. All bearings should be

replaced at the same time i.e. if one needs replacing then all must be
replaced .
Note: If the head assembly has a brass centre spindle and either the
centre spindle (item 14, Figure 10) or the spindle housing (item 15,
Figure 10) require replacement, then a complete new Spindle
Assembly (head) must be installed. No spare components are
available for this type of head.
Section 8 1250HS
Page 8 May 2000
11. SPINDLE ASSEMBLY REPLACEMENT
On replacement care must be taken to ensure that all
spindles/bearings are seated correctly. To replace the spindle
assembly proceed as follows:
Re–fit the lower bearing to the centre spindle.
Fit the centre spindle into the centre hole of the spindle housing (the
spindle should be inserted from the lower side of the housing).
Fit the centre spindle top bearing. Press the bearing home and fit the
circlip.
Refit all remaining bearings. Locate the top cover to the housing and
then refit the spindles.
Refit pins, gears and circlips to the five spindles. The spindles must
be aligned accurately to ensure pick accuracy and efficiency.
Alignment is achieved by means of a jig plate which is used to locate
the spindle heads (Figure 1). Locate the Spindle Heads into the
Timing Jig (part number T1200109).
The centre spindle has two ports or slots cut into the shaft. Align the
narrower of the two ports in the direction of the arrow in Figure 1.
Figure 1. Spindle Alignment
Ensure the two ‘O’ rings fitted to the spindle housing base are in good
condition – replace as required.
Locate the spindle housing base on the spindle assembly as shown in

Figure 1. Secure the timing adjuster arm in position using two M3
countersunk screws.
1250HS Section 8
May 2000 Page 9
Loosely fit the timing adjuster locking screw; this is tightened once the
timing has been set.
Remove the timing jig. Slowly rotate the spindle assembly to ensure
that spindles are not binding and that the assembly rotates freely.
Carefully refit the centre spindle cap. Refit the five filters and caps to
the spindles.
12. MAINS SWITCH

To remove the mains switch proceed as follows:
Pull out the wire clip that secures the switch extender arm to the
mains switch.
Disconnect the extender arm from the switch by moving it towards the
spindle assembly. To disconnect from the switch pull the extender
arm forward to clear the chassis. Rotate 90° and slide out.
Undo and remove the two screws that secure the mains switch in
position.
Remove the mains inlet cover by releasing the two securing screws.
On the vacuum pump relay, disconnect the red wire from terminal 3
and the white wire from terminal 4.
Manoeuvre the switch out of the machine. Make a note of the

connector positions and then disconnect the four connectors.
To replace the switch assembly reverse the above procedure.
13. VACUUM PUMP ASSEMBLY

To remove the vacuum pump assembly proceed as follows:
Remove the note adjuster and riffler assembly as detailed in

paragraph 9.
Pull out the wire clip that secures the switch extender arm to the
mains switch.
Disconnect the extender arm from the switch by moving it towards the
spindle assembly and then remove the extender arm.
Disconnect the spindle vacuum pipe from the main filter.
Disconnect the exhaust/riffler pipe from the vacuum pump.
Using a 3mm allem key, undo and remove the four screws that secure
the pump mounting tray to the rear of the main chassis.
Undo and remove the four screws that secure the pump chassis to
the base.
Disconnect the mains cable to the PSU at connector CN1.
Section 8 1250HS
Page 10 May 2000
Disconnect the two wires from the run filter.
Disconnect the earth lead from the main chassis.
Lift the vacuum pump chassis at the back and pull it backwards to
separate it from the main assembly, taking care not to damage the
wires connected to the PSU.
Disconnect the cable between the pump and the mains relay.
Undo and remove the four nuts securing the pump to its resiliant
mounts and then lift out the vacuum pump.
For vane replacement refer to Section 5, paragraph 3.5.
To replace the vacuum pump assembly reverse the above procedure.
1250HS Section 8
May 2000 Page 11
KEY TO FIGURE 2
1 SCREW M4 x 16 PAN POZI MS ZCEP 00460231 2
2 SCREW M4 x 16 CSK POZI MS ZCEP 00460841 4
4 FRONT COVER ASSY FB02001101 1
5 COVER – REAR (DESKTOP) FB14124502 1
6 RETAINER CLIP FOR DIA 010 SHFT 02420163 1
7 SPRING – RESET BUTTON FB43134001 1
8 SPACER PLN M4 x 10 LNG 8OD TAPPED 02460141 1
9 RESET BUTTON FB14128802 1
Section 8 1250HS
Page 12 May 2000
May 2000
1250HS
9 Detail A
2 4
4
6 see detail A
5 1
2
Section 8
Page 13
Figure 2. 1250HS General View – Tabletop (FT12570101)

KEY TO FIGURE 3
1 SCREW M4 X 8 PAN POZI MS ZCEP 00460228 2
2 WASHER M4 FORMA MS ZCEP 00460305 2
4 SCREW PLASTITE 4MM X 8MM LG PAN 02461076 10
5 BASE UNIT ASSEMBLY (see Figure 4) FB01140601 1
6 1250HS FRONT COVER ASSY FB02001101 1
7 1250HS TOPBOX ASSY (see Figure 18) FB02001201 1
8 FEED PLATE SUB–ASSEMBLY (see Figure 7) FB02136501 1
9 1250 COMMON PACKING KIT FB03001301 1
10 BUTTON – SW EXT. FB14130501 1
11 CLIP – ON/OFF SWITCH FB42134901 1
Section 8 1250HS
Page 14 May 2000
May 2000
1250HS
8
7
11
10
Detail A
1 2
2 2
12
see detail A
5 4
10
Section 8
6
Page 15
3
4
Figure 3. 1250 Basic Kit (FB03002001)

This page deliberatley left blank
Section 8 1250HS
Page 16 May 2000
KEY TO FIGURE 4
1 LABEL BLK SAD 00390542 1
2 CIRCLIP EXT SHAFT 4.5 00420106 3
9 NUT PLN HEX M4 00460405 1
10 NUT NYLOC M4 00461502 2
11 WASHER M4 INT SHAKEPROOF 00462052 2
12 SCREW STAP M4 x 8 PAN POZI 00462910 1
13 SCREW M4 X 12 BUT HD HTS BLU 00463796 3
14 LABEL WARNING 01001533 1
15 LABEL -- BOOK 19 X 19 02390233 1
16 SPRING EXT SS WIRE D6.35 x 69.85 02430374 1
17 SCREW STAP No. 6 X 1/4 FLAN POZI 02460007 1
18 WASHER M4 EXT FAN DISC MS ZCEP 02460255 1
20 PCB STANDOFF LENGTH 6.3 02461079 6
21 BUSH INSULATING 3/6 02490249 2
22 PSU MEANWELL 150 C FUSE 30V 2A 02620415 1
23 BELT TIMING T5 X 420 X 10WD 02280534 1
24 SPINDLE HEAD ASSEMBLY (see Figure 9) FB01117901 1
25 COOLING FAN ASSY (see Figure 22) FB02000301 1
26 FEEDPLATE GEARBOX ASSEMBLY (see Figure 14) FB02116801 1
27 NOTE STOP ASSEMBLY (see Figure 8) FB02122102 1
28 SPINDLE DRIVE ASSEMBLY (see Figure 11) FB02125901 1
29 RIFFLER ASSEMBLY (see Figure 13) FB02126301 1
30 BRACE -- DAMPER/GEARBOX FB02134801 1
31 SOLENOID/BATCH LINK ASSY (see Figure 12) FB02136001 1
32 DAMPER AND FEED ARM ASSEMBLY (see Figure 6) FB02138101 1
33 PCB HALL EFFECT SWITCH ASSY FB09127803 1
34 PCB I/O BOARD FB09128005 1
35 BASE -- GENERIC ASSEMBLY FB12124003 1
1250HS Section 8
May 2000 Page 17
KEY TO FIGURE 4 (continued)
36 ADJUSTER – NOTE STOP FB14121501 1
37 COVER INNER FB14125101 1
38 COVER – MOUNTING FB14125202 1
39 BATCH ARM FB14126701 1
40 COVER – PSU (PLASTITE) FB14138701 1
41 POST – NOTE STOP MOUNT FB20121401 2
42 SHAFT NOTE STOP ADJUSTER FB20128101 1
43 FIXING BRACE FB21124201 2
44 SHUTTER RAIL MACHINED FB22134201 1
Section 8 1250HS
Page 18 May 2000
15
25
37 13
3
12
33
A_1
38 4 7
3 3
43 30
2
24 6 7
3 3
A_1
2 4 7
29
A_6
3 32 8 16
2 A_1
36
14
4
1 9 18
41 10
40
42 2
17
A_6
2
11 20 A_6
27
3
5 22
A_16
4 26 4 7
A_6
3 A_9 2 2
A_26
A_6
35
A_6
4 11 20 34 39 21
3 A_6
2
A_6
31
23
41 10
19
2 28 4 44
2
Figure 4. Base Unit Assembly (FB01140601)
1250HS Section 8
May 2000 Page 19
KEY TO FIGURE 5
1 GREASE BRG MTS 1000 00754025 1
4 SCREW STAP NO4 X 5/16 PAN POZI 00461409 1
5 SPRING EXT SSWIRE D7 x 35LG 02430375 1
6 SCREW STAP NO6 X 1/2 PAN POZI 02460522 2
7 TAIL CLAMP ASSEMBLY FB02120101 1
8 DAMPER AND FEED ARM SUB ASSY (see Figure 6) FB02120701 1
9 LINK, FEED ARM SUB ASSEMBLY FB02123701 1
10 LINK – TAIL CLAMP FB16111401 1
11 COVER – CLAMP ARM FB16134701 1
Section 8 1250HS
Page 20 May 2000
7
4
11
5
9
10 2
8 6
2
Figure 5. Damper and Feed Arm Assembly (FB02138101)
1250HS Section 8
May 2000 Page 21
KEY TO FIGURE 6
2 DAMPER ASSEMBLY FB02120601 1
3 FEED ARM ASSEMBLY FB02122701 1
4 CLAMP ARM ASSEMBLY FB02122801 1
5 COLLET – DAMPER SHAFT FB20105501 1
6 SPRING–NOTE CLAMP FB43105901 1
8 SCREW M5 X 20 HEX MS ZCEP 00462724 1
9 NUT PLN HEX M5 MS ZPL CP 00460406 1
Section 8 1250HS
Page 22 May 2000
1
7 4
8
2
Figure 6. Damper and Feed Arm Sub Assembly (FB02120701)
1250HS Section 8
May 2000 Page 23
KEY TO FIGURE 7
1 SCREW M5 X 12 BUT SKT HTS BLU 00463799 1
2 FACING – FEED PLATE FB14123001 1
3 FEED PLATE FB16122901 1
Section A–A
1
A
Figure 7. Feed Plate Sub–Assembly (FB02136501)
Section 8 1250HS
Page 24 May 2000
KEY TO FIGURE 8
3 NUT NYLOC M3 00461501 1
4 SWITCH MICRO 0.1A 250VAC NO 02520334 1
5 LEVER – AUTO START FB14119601 1
6 NOTE STOP FB14126402 1
2 3
1 6
Figure 8. Note Stop Assembly (FB02122102)
1250HS Section 8
May 2000 Page 25
KEY TO FIGURE 9
2 SCREW M4 X 10 CAP SKT HTS BLKOX 00462410 1
3 SEALANT LOCTITE 5331 00751015 A/R
4 BARBED FITTING 1/16 NYLON 02310435 1
5 O RING 16.0 OD 1.0 D NITRILE 02450085 2
6 HOUSING ASSEMBLY (see Figure 10) FB01137302 1
7 FILTER ASSY – SUCTION SPINDLE FB02110501 5
8 ARM – SPINDLE HEAD FB10102102 1
9 CAP – SPINDLE MKII FB14118001 5
10 MOUNTING PAD FB14128901 6
11 CAP – SPINDLE CENTRE FB14131001 1
12 MACHINED BASE – SPINDLE UNIT FB21101704 1
13 PIPE SUCTION CENTRE FB31133401 1
14 FIT PUSH 90DG 6ID HOZE 1/8BSP 00310361 1
Section 8 1250HS
Page 26 May 2000
6
5
7 11
5
14 3
12
13
10
6
1 5
2
15
2 2
Figure 9. Spindle Head Assembly (FB01117901)
1250HS Section 8
May 2000 Page 27
KEY TO FIGURE 10
1 ADHESIVE LOCTITE 415 50GM 00750018 A/R
3 CIRCLIP EXT SHAFT 10SER1400 02420027 6
4 PIN DOWEL SS D3 x 23LG 02480080 5
5 BEARING BALL ID17 OD35 02490105 1
6 BRG BALL 10ID x 19OD x 7WD 2 SHIELD 02490219 5
7 BEARING 6000 2BRS 02490244 1
8 BEARING BALL 12ID x 28OD x 8WD 02490246 5
9 MAGNET 10DIA x 4 LG 02520339 5
10 SPINDLE – SUCTION FB10117604 5
11 GEAR – SPINDLE DRIVE FB14101601 5
12 COVER – SPINDLES FB14125301 1
13 RETAINER – SPINDLE UNIT FB16101901 1
14 CENTRE SPINDLE – SPINDLE HEAD FB20101403 1
15 SPINDLE HOUSING (M/C EXTRUSION) FB21123304 1
Section 8 1250HS
Page 28 May 2000
10
5
12
3 8
5
15
1 9
5
14 6
5
5
4
5
11
5
3 13
2
5
Figure 10. Housing Assembly (FB01137302)
1250HS Section 8
May 2000 Page 29
KEY TO FIGURE 11
2 WASHER – SHAKEPROOF M3 00462072 3
3 SCREW M3 X 3 GRUB SKT HTS BLU 00462101 2
4 SCREW M8 X 20 SKT SHOULDER HTS 02461057 1
5 MOTOR BRUSHLESS 30V DC 51W 1P 02510155 1
6 GEAR/PULLEY & BEARINGS ASSY FB02132902 1
7 BRACKET – SPINDLE DRIVE FB10126202 1
8 PINION – SPINDLE DRIVE FB20120501 1
9 ADHESIVE LOCTITE 222 00340409 A/R
Section 8 1250HS
Page 30 May 2000
5
9 3 8
2 7
6
10 2 1
3 3
Figure 11. Spindle Drive Assembly (FB02125901)
1250HS Section 8
May 2000 Page 31
KEY TO FIGURE 12
1 CONNECTOR MULTY 2 PIN 00541461 1
2 TERMINAL (120) 00541471 2
3 PIN SPIROL 1/8¨ x 3/4¨ 02480073 1
4 SOLENOID 30V 1.5AMP 02530099 1
5 LINK – BATCH ARM FB14127601 1
110± 5
2 1
2
Pin to be
equally spaced
4
3
5
Figure 12. Solenoid/Batch Link Assy (FB02136001)
Section 8 1250HS
Page 32 May 2000
KEY TO FIGURE 13
1 RIFFLER ASSEMBLY FB02126301 1
2 FIT PUSH 90DG. 8ID HOZE 1/8 BSP 02310436 1
1 2 8
Note : Item 1 includes items 2 and 8.
Figure 13. Riffler Assembly (FB02126301)
1250HS Section 8
May 2000 Page 33
KEY TO FIGURE 14
1 CLIP RETENTION 11 DIA 20 WIDE 00420154 1
5 WASHER M4 PLN FM C MS ZCEP 00460315 1
6 SCREW M3 x 3 GRUB SKT HTS BLU 00462101 2
7 PIN DOWEL SS D2.5 12LG 02480069 1
8 MOTOR BRUSHLESS 30VDC 51W 1P 02510155 1
10 BELT VEE COGGED SECTION 5 x 260L 02280532 1
11 CAM – FEED PLATE ASSEMBLY FB02123501 1
12 GEARBOX SUB ASSEMBLY (see Figure 15) FB02134102 1
13 VEE PULLEY – MOTOR FB20119402 1
14 VEE PULLEY – WORM FB20119503 1
16 ADHESIVE LOCTITE 222 00340409 A/R
Section 8 1250HS
Page 34 May 2000
Note position of
motor connector
9
2
2 15 6 16
3 3
2
13
3 10 4
2
11
14
5
7
12
Figure 14. Gearbox Assembly (FB02116801)
1250HS Section 8
May 2000 Page 35
KEY TO FIGURE 15
1 CIRCLIP EXT SHAFT 10SER1400 02420027 4
2 CIRCLIP INTERNAL FOR 35MM BORE 02461072 1
3 BEARING BALL ID17 OD35 02490105 1
4 BEARING BALL 10ID x 22OD x 6WD 02490245 3
5 WORM GEAR/SHAFT ASSY FB02119201 1
6 GEARBOX HOUSING FB10117001 1
7 WORM – FEEDPLATE GEARBOX FB20117102 1
Section 8 1250HS
Page 36 May 2000
7
4
3
3
1
4
2
Figure 15. Gearbox Sub–Assembly (FB02134101)
1250HS Section 8
May 2000 Page 37
KEY TO FIGURE 16
1 FIT PUSH 90DG 6ID HOZE 1/8 BSP 00310361 1
3 WASHER, M4 CRINKLE 00460505 4
4 BALL STEEL 8D CORROSION RESIST 00492402 1
5 FILTER AIR 40 MICRON ELEMENT 02310474 1
6 FIT PUSH STRAIGHT 1/8BSP ID8 02310463 1
7 SPRING – COMPRESSION ID10 10LG 02430389 1
8 O RING 36.27ID 1.78 D NITRILE 02450076 1
9 MOUNTING – FILTER FB14126501 1
10 LOCKRING – FILTER FB14126801 1
11 BOWL – FILTER FB14126901 1
12 ADJUSTER – RELIEF VALVE FB20129301 1
13 HOUSING – FILTER FB22126601 1
14 SPRING – PRESSURE RELIEF LOWER FB43135502 1
Section 8 1250HS
Page 38 May 2000
1 15
12
2
4
7
3
4
4
14
13
6 15
5
10
11
Figure 16. Filter Unit (FB01137401)
1250HS Section 8
May 2000 Page 39
KEY TO FIGURE 17
1 LABEL BLK SAD VYN E CONN 12 X 12 00390521 1
10 WASHER M6 CNKL CU BE 00460507 8
11 SCREW M3 X 8 CSK MS ZCEP 00460830 2
12 NUT NYLOC M3 MS ZPL 00461501 2
13 WASHER M4 SFTY SPNG STL 00462073 6
15 SCREW STAP M4 X 8 PAN POZI 00462910 1
16 LABEL WARNING MAINS 25MM 01001533 2
17 FIT PUSH 90DG 8ID HOZE 1/8BSP 02310436 2
18 PUMP VACUUM – 230V 50/60HZ +10% –15% 02310441 1
PUMP VACUUM – 115V 60HZ ±10% 02310444 1
PUMP VACUUM – 127V 60HZ ±10% 02310445 1
19 MOUNTING ANTI–VIBRATION 02410468 4
21 RELAY SST 10A 280V AC LINE 02530059 1
22 SOCKET IEC 2 FUSES FRI FILTER 02541178 1
23 FUSE 3A 15 ANT SURGE CERAMIC 02570068 1
24 SWITCH PUSH 2 POLE 8A 250V 02680384 1
25 FILTER UNIT (see Figure 16) FB01137401 1
26 CHASSIS PUMP FB12127503 1
27 COVER – MAINS (TT) FB16130801 1
28 HOSE PUMP/RIFFLER FB31128401 1
29 HOSE MANIFOLD PUMP FB31128501 1
30 HOSE SPINDLE MANIFOLD FB31133201 1
32 CAPACITOR (RUN FILTER) 4µF 230V 02630481 1
CAPACITOR (RUN FILTER) 16µF 115/127V 02630482 1
Section 8 1250HS
Page 40 May 2000
May 2000
1250HS
17 31
2 16
18
9 3 21
16 22
2 2
15 11 12
2 2
27
19
1
4
2 25
29
3
3
32
26
24
5 8
20
10 8 7
8 2
7 30
2 2 6 13
8
2 2 28
14 13 4
23 4 4 4
Section 8
Page 41
Figure 17. Vacuum Pump Assembly (FB03000601)

KEY TO FIGURE 18
5 NUT NYLOC M3 00461501 1
7 TOP BOX FRONT FB01137701 1
8 CHASSIS -- TOP BOX FB12131401 1
9 COVER -- REAR (TOP BOX) FB14130101 1
10 PCBP RJ11 DAUGHTER BOARD FB09127703 1
11 1250HS PCB KIT (CONTROL BOARD) FB045001302 1
12 SELF ADHESIVE LABEL RS232 02390230 2
Section 8 1250HS
Page 42 May 2000
1 4 5
Detail A
10
12
8 11
2
7 9
3 6
2 4
4
4
See Detail A
1 2 4
4 4 4
Figure 18. Top Box Assembly (FB02001201)
1250HS Section 8
May 2000 Page 43
KEY TO FIGURE 19
2 CIRCLIP EXT SHAFT 7 00420108 1
9 PIN DOWEL PLL 2.5 X 16LG GRADE 1 00480918 1
10 BEARING DRY 3/16ID 1/4OD 3/8LG 02490251 1
11 MOTOR 30 OHM FB06000401 1
13 SHUTTER – INNER DRIVE ASSY (see Figure 20) FB02136701 1
14 SHUTTER – OUTER DRIVE ASSY (see Figure 21) FB02136801 1
15 PULLEY – SHUTTER D/A FB04125501 2
16 SHUTTER – INNER FB14130201 1
17 SHUTTER – OUTER FB14130301 1
18 SHAFT – SHUTTERS FB21136602 1
19 SHAFT – PULLEY FB22132201 1
20 BRUSH – LONG FB41135101 1
21 BRUSH – SHORT FB41135201 1
22 SPRING COMPRESSION 44.45 X 4.57 02430410 1
23 SHUTTER – MICROSWITCH PLATE ASSY. FB02001001 1
Section 8 1250HS
Page 44 May 2000
May 2000
1250HS
11 9 4 5
2 2
22 18
23 6 8
2 2
15
12 6 8 3
13 2 2 2
14
19 5 7
1 15 10
20
16
17
21
Section 8
Page 45
Figure 19. Shutter Kit (FB03000501)

KEY TO FIGURE 20
1 SCREW M4 X 8 CSK POZI MS ZCEP 00460838 2
2 BEARING PLAIN 8ID 10OD 10LG 02490252 2
3 BELT TIMING T2 x 600 02280556 1
4 CLAMP – MSWITCH TRIP FB22132501 1
5 CARRIER – INNER SHUTTER FB22136201 1
2
2
3
4
1
2
Figure 20. Shutter Inner Drive Assembly (FB02136701)
Section 8 1250HS
Page 46 May 2000
KEY TO FIGURE 21
2 BEARING PLAIN 8ID 10OD 10LG 02490252 2
3 BELT TIMING T2 x 600 02280556 1
4 CLAMP – SHUTTER BELT FB22132601 1
5 CARRIER – OUTER SHUTTER FB22136301 1
2
2
3
4
1
2
Figure 21. Shutter Outer Drive Assembly (FB02136801)
1250HS Section 8
May 2000 Page 47
KEY TO FIGURE 22
2 NUT NYLOC M3 00461501 2
3 FAN INCLUDING RESISTOR MOD FB02000401 1
4 MOUNTING BKT – COOLING FAN FB16000101 1
Section 8 1250HS
Page 48 May 2000
2
2
3
1
2
Figure 22. Cooling Fan Assembly (FB02000301)
1250HS Section 8
May 2000 Page 49
Appendix 1
Band Stamper Unit
1250HS Appendix 1
May 2000 Page 1
CONTENTS
Para. Page
1. INTRODUCTION 3
Illustrations
Figure 1 Band Stamper Kit 5
Appendix 1 1250HS
Page 2 May 2000
1. INTRODUCTION
The band stamper unit stamps an ‘OK’ symbol on the band around a
note bundle. The unit is turned ON or OFF by pressing TOTAL and 4
to switch between the two modes. When the unit is ON, the * symbol
is shown on the display. The stamp only operates when 100 notes
are verified.
The band stamper unit is located on the damper and feed arm
assembly.
1250HS Appendix 1
May 2000 Page 3
KEY TO FIGURE 1
1 PACK OF 12 PRE–INKED SLUGS 02350309 1
2 CIRCLIP EXTERNAL ID 4.7 02461104 1
3 SOLENOID – BAND STAMPER FB02138401 1
4 FRICTION GRIP – TAIL CLAMP FB14127001 1
5 BODY – BAND STAMPER FB14129401 1
6 COVER – BAND STAMPER FB14129501 1
7 ACTUATOR – BAND STAMPER FB14129601 1
8 CARRIER – STAMP FB14129801 1
9 SPACER – STAMP SOLENOID FB14138301 1
10 SPRING – BAND STAMPER FB43136101 1
Appendix 1 1250HS
Page 4 May 2000
2
8
4
3 9
10
Figure 1. 1250 Band Stamper Kit (FB03000401)
1250HS Appendix 1
May 2000 Page 5
Appendix 2
Pedestal Unit
1250HS Appendix 2
May 2000 Page 1
CONTENTS
Para. Page
1. INTRODUCTION 3
Illustrations
Figure 1 General Assembly – Pedestal 5
Figure 2 1250HS Pedestal Kit 7
Figure 3 1250HS Pedestal Voltage Kit 9
Appendix 2 1250HS
Page 2 May 2000
1. INTRODUCTION
The pedestal version of the 1250HS machine is similar to the table top
version discussed in the main part of the manual. The majority of
descriptions can be applied to the pedestal version with minor
differences. These differences are highlighted in this appendix.
1250HS Appendix 2
May 2000 Page 3
KEY TO FIGURE 1
1 1250HS BASIC KIT (see Section 8, Figure 3) FB03002001 1
2 1250 PEDESTAL KIT (see Figure 2) FB03002201 1
3 1250 BANDSTAMPER KIT (see Appendix 1, Figure 1) FB03000401 1
4 SHUTTER KIT (see Section 8, Figure 19) FB03000501 1
5 1250 VOLTAGE KIT 220V 50HZ (PED) (see Figure 3) FB03001001 1
6 CONNECTOR SHNT 2WY 1RW 02540045 2
Appendix 2 1250HS
Page 4 May 2000
Figure 1. General Assembly – Pedestal (FT120801)
1250HS Appendix 2
May 2000 Page 5
KEY TO FIGURE 2
3 LABEL SERIAL NUMBER – 1250HS FB04001201 1
5 SCREW M5 X 16 HEX MS ZCEP 00462723 16
7 CASTOR UNBRAKED D50 TWIN WHEEL 02280555 4
8 PAWL LATCH DZUS DP140S 02410437 1
9 PEDESTAL – FABRICATED FB12132001 1
10 COVER – REAR (PED) FB14124601 1
11 COVER – BASE (PED) FB14124801 1
Appendix 2 1250HS
Page 6 May 2000
3
10 1
2
11
4
4
9
7 2 5 6 12
4 16 16 16 16
Figure 2. 1250 Pedestal Kit (FB03002201)
1250HS Appendix 2
May 2000 Page 7
KEY TO FIGURE 3
1 SCREW M3 X 6 PAN POZI 00460218 2
7 WASHER M4 CRINKLE 00460505 2
8 WASHER M6 CNKL CU BE 00460507 8
9 SCREW M3 X 8 CSK POZI MS ZCEP 00460830 2
10 NUT NYLOC M3 00461501 2
11 WASHER M4 SFTY SPNG STL 00462073 2
12 SCREW STAP M4 X 8 PAN POZI 00462910 3
13 PUMP VACUUM ASSY – 230V 50/60HZ +10% – 15% 02310441 1
PUMP VACUUM ASSY – 115V 60HZ 10% 02310444 1
PUMP VACUUM ASSY – 127V 60HZ 10% 02310445 1
14 PUSH FIT STRAIGHT 1/8 BSP ID8 02310463 2
15 MOUNTING ANTI–VIBRATION 02410468 4
17 RELAY SST 10A 280V AC LINE 02530059 1
18 SOCKET IEC 2 FUSES FRI FILTER 02541178 1
19 FUSE 3A15 ANT SURGE CERAMIC 02570068 1
20 SWITCH PUSH 2 POLE 8A 250V 02680384 1
21 FILTER UNIT FB01137401 1
22 CHASSIS – REAR (PED) FB12131501 1
23 MAINS COVER – PED FB16130901 1
24 HOSE MANIFOLD (PED) FB31133001 1
25 HOSE PUMP RIFFLER (PED) FB31133101 1
26 HOSE SPINDLE MANIFOLD (PED) FB31133301 1
27 SEALANT LOCTITE 5331 00751015 1
28 CAPACITOR (RUN FILTER) 4µF 230V 02630481 1
CAPACITOR (RUN FILTER) 16µF 115/127V 02630482 1
Appendix 2 1250HS
Page 8 May 2000
7 2
2 2
23 12
9
17
18 9 10
2 2
11 4
2 2
28 16
9
16
4
21 2
9
20
6 1
2 2 19 22
26
24
25
14 27
2
13
3 15
8 4
8 5
8 8
Figure 3. 1250 Pedestal Voltage Kit (FB03001001)
1250HS Appendix 2
May 2000 Page 9
Appendix 3
1. TECHNICAL BULLETINS/MEMORANDA
1.1 Introduction
This appendix is reserved for the insertion of Technical
Bulletin/Memoranda title pages, in accordance with the instructions
given at the front of this manual.
1250HS Appendix 3
May 2000 Page 1

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1250HS Model

Banknote Counting Machine

Walton Road, Farlington

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

3.1 Service Manual Amendment

3.2 Machine Modification

3.3 Master Copies

3.5 Page Replacements

THIS MACHINE IS A CLASS 1, 3 – WIRE EARTHED PRODUCT, AND REQUIRES

WARNING : FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, FUSES

Technical Bulletins and Memoranda

Contents (this page)

Health and Safety

Section 2 Operating Instructions

Section 3 Mechanical Description

Section 4 Electrical Description

Section 7 Settings and Adjustments

Section 8 Removal, Overhaul and Replacement

Appendix 1 Band Stamper Unit

Appendix 2 Pedestal Unit

Appendix 3 Technical Bulletins/Memoranda

If no part number is quoted, then the ITEM NUMBER, DESCRIPTION

It will prove to be helpful if the DESCRIPTION as written in the

IMPORTANT – THE FOLLOWING SECTION ON SAFETY MUST BE UNDER-

7. HEALTH AND SAFETY

Wall isolating switchgear must be installed in accordance with local

7.2 High Energy

7.3 Moving Parts

7.4 Cabling And Power

7.6 Effects of Electromagnetic Fields

Note: Wherever these symbols appear throughout this manual

Figure 1 1250HS General View 4

Figure 2 1250HS Machine with Pedestal 5

A pedestal mounted version of the 1250HS machine is also available,

Basic operating functions

Advanced operating functions

This product conforms to the essential requirements of:

Electromagnetic compatibility Directive 89/336/EEC

Low voltage electrical equipment (safety) Directive 73/23/EEC

and is supported by the following applicable standards

Tony Robinson Quality Manager.

Reference: TP05313012 - ISS1

The 1250HS is a high speed

1 On / off switch 10 Filter bowl

1 Batch display displays batch/verify quantity

The 1250HS must be installed on a flat and

The count bar -- will be displayed.

The count bar -- will be displayed and

Counting after a Batching Operation

+ TOTAL + CLEAR key. This will clear the

accumulative totals in value mode

When the TOTAL key is pressed it will

Press TOTAL + CLEAR to reset that

The fastest machine speed is 40 notes per second,

1250HS value modes

In one of the VALUE modes, the 1250HS

verify value mode

The display will show U...nnn, asking the

1250HS value modes

verify value mode

The display will show U...nnn to allow the

Press START to accept.

1250HS value modes