Cale CWT Compact: Change Dispensing Error - Technical... | terminalfaults.org

Technical Background:

The change dispensing mechanism relies on 24V DC solenoids activating coin hoppers. An embedded controller regulates dispensing time based on transaction data. Optical encoders provide feedback on coin dispensing rotation, feeding back to the controller. Dispensing accuracy is affected by solenoid actuation speed, optical encoder signal integrity, and coin hopper calibration. Environmental factors such as temperature (-40C) can affect solenoid response time and optical sensor accuracy. A CAN bus manages communication between the main controller and the change dispenser.

Symptoms:

The Cale CWT Compact terminal is dispensing incorrect change amounts during transactions. This includes dispensing too little change, too much change, or no change at all.

Possible Causes:

1. Coin Hopper Jam: Foreign objects or deformed coins obstructing the dispensing mechanism.
2. Solenoid Failure: Degraded solenoid performance due to wear, corrosion, or electrical faults (open circuit or short circuit).
3. Optical Encoder Malfunction: Contamination (dust, debris) or physical damage to the optical encoder, resulting in inaccurate coin count feedback.
4. Communication Error: CAN bus communication errors between the main controller and the change dispenser.
5. Low Voltage: Insufficient 24V DC power supply voltage affecting solenoid actuation.
6. Calibration Error: Incorrect calibration settings within the terminal's software, leading to inaccurate dispensing calculations.

Solution:

1

Initiate a terminal reboot. Monitor the diagnostic logs for any error codes related to the change dispenser or communication errors.
2

Access the terminal's diagnostic menu and run the coin dispensing test. Observe if the correct number of coins is dispensed for each denomination.
3

Audit the coin levels in each hopper, ensuring adequate coin supply.
4

Check for any physical obstructions or foreign objects within the coin dispensing area using a flashlight.
5

Clean the optical encoder using compressed air to remove dust and debris.
6

Inspect the wiring harness connecting the change dispenser to the main controller for loose connections or damaged wires.
7

Verify the 24V DC power supply voltage to the change dispenser using a multimeter. Ensure it is within the specified tolerance.

Safety Warning:

The Cale CWT Compact operates on 24V DC power. While this is low voltage, Lockout/Tagout (LOTO) procedures are MANDATORY before performing any maintenance or troubleshooting. Disconnect the power supply before any work. Be cautious of sharp edges or moving parts within the dispensing mechanism. Always wear appropriate PPE (Personal Protective Equipment), including safety glasses and gloves.

Prevention:

Regularly clean the coin dispensing area to prevent coin hopper jams and optical encoder contamination. Implement a preventative maintenance schedule to inspect and clean the terminal's internal components. Apply cable strain relief to all wiring harnesses to prevent loose connections due to vibration or environmental factors.

Expert Tip:

Check the diagnostic logs immediately after a dispensing error. Often, specific error codes (e.g., 'Hopper Timeout', 'Encoder Fault') point directly to the failing component. Also, use an external CAN bus analyzer to monitor the communication between the main controller and the coin dispenser. Intermittent communication issues can be difficult to diagnose otherwise.

Frequently Asked Questions

•What is the typical lifespan of the solenoids in the CWT Compact?

Solenoid lifespan varies based on usage and environmental conditions. Expect 500,000 to 1,000,000 cycles under normal conditions. Extreme temperatures and frequent use will reduce lifespan.

•How often should the optical encoders be cleaned?

Optical encoders should be cleaned every 3 months in high-dust environments, and every 6 months in cleaner environments. Use compressed air only. Do NOT use solvents.

•What is the recommended CAN bus termination resistance for the CWT Compact network?

The CAN bus requires a 120-ohm termination resistor at each end of the bus. Verify the presence and integrity of these resistors during troubleshooting.

Cale CWT Compact: Change Dispensing Error - Technical Analysis

Technical Background:

Symptoms:

Possible Causes:

Solution:

Safety Warning:

Prevention:

Expert Tip:

Frequently Asked Questions

•What is the typical lifespan of the solenoids in the CWT Compact?

•How often should the optical encoders be cleaned?

•What is the recommended CAN bus termination resistance for the CWT Compact network?

Related questions

Technical Background:

Symptoms:

Possible Causes:

Solution:

Safety Warning:

Prevention:

Expert Tip: