BPS C4 FIELD ENGINEER TRAINING PROGRAM

COURSE OUTLINE

Course Outline (5 Day)

I. LESSON: DAY 1

II. REQUIRED TRAINING MATERIALS:

• BPS C4 Training Manual

• BPS C4 CBT
• Laptop with windows XP or Windows 7
• Hyper terminal or serial emulation program
• USB stick (2GB preferable)

III. TOPIC: Introduction and Getting to know the BPS C4. User, Supervisor, and
Service role operations. Menu items available for the supervisor and service
technician. BPS C4 OMOCO Configurations, Configuring Thresholds, reporting and
Operating Disturbances with proper Jam Recovery. Reject investigations.

IV. OBJECTIVES: Upon completion of this day of the course, the successful student
should be able to:

• Understand the differences between the BPS200 and BPS C4 product

• Understand Hardware Differences and Enhancements
• Understand Software Differences and Enhancements
• Learn how to configure, modify, and operate the System set-up
• Become familiar with BPS C4 operating procedures
• Understand User, Supervisor, and Service Operations
• Become familiar with the available Menu options
• Determine/set up the basic customer data for the system
• Be familiar with available processing modes.
• Make changes to the currency and denominations already configured in the system.
• Configure customer report settings to determine which reports are issued and at
what time intervals.
• Edit and configure sorting modes to determine how banknotes are to be sorted by
the system.
• Configure stacking modes to determine the outcome of the sorting decisions.
• Configure the operating mode to determine the organization, type, and procedures
used for banknote processing.
• Change/edit sorting thresholds so that the thresholds may be adapted for specific
banknote qualities.
• Change or switch between adaptions configured in the system.
• Enable or Disable Mechanical and Authentication Thresholds.
• Configure Mechanical and Authentication Thresholds for processing.
• Be able to view and analyze rejects through the GUI menu and SEP via Banknote
Viewer.

Course Outline (5 Day)

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COURSE OUTLINE

• Determine how transport events are summarized into reject reasons and to select
which reject reasons are displayed.
• Understand the importance of Jam Recovery and perform proper Jam Recoveries to
ensure count validity.

V. INSTRUCTIONAL TASKS:

• Distribute the following documentation: the BPS C4 - TRAINING MANUAL AND the BPS
C4 - CBT.
• Identify the Operating manual and Service manual.
• Identify the main sections in the BPS C4 - TRAINING MANUAL
• Using BPS C4 – CBT, describe (in general) the information within each of the
following sections:
• Spares @ More interactive parts catalog
• Computer Based Training
• Service DVD and respective sections
• Customer Documents
• Service Documents
• Technical Information
• Engineering Information
• Identify and describe the more important Terms and Abbreviations associated with
the BPS C4.
• Describe and discuss safety issues of which all personnel must be aware when
operating the system. (BPS C4 Service Manual - Chapter 1)
• Identify and describe the external/optional equipment that can be attached to the
BPS C4, including the printer, Bar Code Scanner, server PC, Header Card Creator,
5th Stacker and Singler Air Assist.
• Identify and describe the general functional units comprising the BPS C4, include
emphasis on and history of:
1. Operating Unit Map 2
2. 3 Phase Motor and Frequency Unit
3. Spring loaded tensioners
4. Fast Ethernet Switch
5. Back Cover, Front Cover, and Connection Plug Sheet
6. Power Source Line Conditioning Filter
7. USB Hub assembly
8. Rocker Motor Connector

• At the BPS C4, identify the main components that comprise the Basis Module,
Standard Delivery Module, Large Delivery Module and describe their functions.
• Explain the different modes of processing available on the BPS C4 (Operating
Manual chapter 6)
• Show User menu items available and explain their function. (Operating Manual
chapter 5)
• Show Supervisor menu items available and explain their function.
• Show Service menu items available and explain their functions.
• Explain menu item icons and shortcuts.

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• Explain each item in the BPS C4 Install/Set up training handout. (Operating Manual
Chapter 8)
• Explain available processing modes. (Operating Manual Chapter 6)
• Identify and describe the OMOCO menu settings used to establish the following:
1. Starting OMOCO (Operating Manual Chapter 11)
2. Selecting the Operating Mode (Operating Manual Chapter 11)
3. Searching for Operating Modes (Operating Manual Chapter 11)
4. Printing Operating Mode Reports (Operating Manual Chapter 11)
5. Creating Operating Modes (Operating Manual Chapter 11)
6. Deleting Operating Modes (Operating Manual Chapter 11)
• Identify and describe the Threshold possibilities available on the system, which
include:
1. ATM
2. FIT
3. Unfit
4. Special
• Identify and describe the procedure for changing thresholds including
1. Activating Authentication Features (Operating Manual Chapter 8)
2. Changing Automatic Report Settings (Operating Manual Chapter 8)
3. Repeat the printing or sending of reports (Operating Manual Chapter 8)
• Explain the effects of threshold adjustments on sorting outcomes.
• Identify, compare, and contrast the various Reports and the Logs generated by the
BPS C4. (Operating Manual A3 and Service Notes)
• Describe the manner in which currency processing is performed by the use of header
cards.
• Have each student assume the role and responsibilities of the SV and the OP
configure the BPS C4 for BN processing and process currency through it, including
the use of header cards.
• Have the students observe the flow of currency through the system during
processing, and lead them in the correct recovery steps from jam conditions during
processing. (Operating Manual chapter 7)

Course Outline (5 Day)

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I. LESSON TITLE: Day 2

I. TOPIC: Suction Air Singler Assist System. Windows CE Specialties with the use
of the USB Service Stick, Software updating of the Windows CE image and BPS C4
Application Software, Configuration Tool.

II. OBJECTIVES: Upon completion of this day of the course, the successful student
should be able to:

1. Be familiar with Suction Air Singler Assist System.

2. Understand maintenance required for the Suction Air Singler Assist System.
3. Be able to access the file structure of the BPS C4.
4. Understand how to make a Boot/Service stick.
5. Be able to locate specific files and know what partitions where the different parts of
the software reside.
6. Understand Database functions.
7. Demonstrate familiarity with interaction of the different files and their function within
the software.
8. Demonstrate how to update or install the BPS C4 Windows CE image.
9. Demonstrate how to update or install the BPS C4 Application Software.
10. Demonstrate how to update or install an Adaptation.
11. Understand how to utilize the Configuration Tool, its function and purpose.
12. Demonstrate how to access the database and create/Append a BPS C4 database.
13. Demonstrate the ability to pull standard Log files as required for troubleshooting
purposes.

III. INSTRUCTIONAL TASKS:

• Conduct a review of the material covered to date in conjunction with a Question and
Answer session.
• Demonstrate how to make a Boot/Service Stick and have each student test theirs on
the machine. (QP C4-16 How to make a Service Stick)
• Have the students take turns accessing different functions of the Service dialog box.
• Have the students become familiar with the different partitions of the Flash File
System. (C4 Software Components Map training handout.)
• Explain each partition in the Flash File System and the files functions which they
contain.
• Define what an adaptation is. The demands, requirements and different parts
necessary for proper configuration of the BPS C4.
• Explain the purpose of the Configuration Tool.
• Have the students configure the machine to working order (by deleting the DB).
• Explain the BPS Software components used to ensure full functionality of the
product.
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• Use questions and answers with the students as they follow written procedure to
install the BPS C4 Application software. (Use SB _001b)
• Have the students perform a complete Windows CE image install with BPS C4
Application Software. (QP C4-17)
• Explain the importance of having known good software components and have the
students gather components on their Boot/Service stick.

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I. LESSON TITLE: Day 3

TOPIC: Header Card Creator. DEG Reconciliation. DEG Reconciliation

installation/ setup. BPS C4 Installation/ setup. Header Card Creator
installation/ setup. Troubleshooting DEG and HCC problems. Header
Card Zebra printer maintenance.

OBJECTIVES: Upon completion of this day of the course, the successful student should
be able to:

1. Be able to completely install, setup, and commission a BPS C4. (practical test)
2. Understand Various Troubleshooting tools.
3. Gather and interpret various types of information derived from data analysis.
4. Review and understand all the Quick Procedures available for the C4
5. Review and understand all the Technical Bulletins available for the C4.
6. Successfully pass the BPS C4 Final Test. (written test)

INSTRUCTIONAL TASKS:

• Conduct a review of the material covered to date in conjunction with a Question and
Answer session.
• Discuss Header Card Creator and DEG Reconciler.
• Use the DEG Reconciler to process rejects. (Recon Path.doc)
• Demonstrate through Documentation how to set up the DEG for BPS C4. (DEG
Manuals)
• Demonstrate through Documentation how to set up BPS C4 for DEG. (DEG
Manuals)
• Demonstrate through Documentation how to operate the Header Card Creator. (HCC
Manuals)
• Explain the Header Card Creator product (HCC Operating Manual)
• Allow students to use the Header Card Creator to Align and Print a Header Card.
• Allow students to Install and configure a Zebra Printer setting all print settings
• Demonstrate how to install and set up the Header Card Creator Program
• Demonstrate how to install the Zebra printer
• Demonstrate how to change the Zebra printer paper roll
• Demonstrate how to change the Zebra printer print ribbon
• Demonstrate how to change the Zebra printer print head
• Demonstrate how to change the Zebra printer cutter.

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I. LESSON TITLE: Day 4

II. TOPIC: Troubleshooting machine problems, Troubleshooting Sensor problems,

Troubleshooting Camera and Header Card problems, Camera adjustment, Data
Analysis.

III. OBJECTIVES: Upon completion of this day of the course, the successful student
should be able to:

• Be familiar with different types of Sensor Data.

• Be familiar with Analyzing PPC Status Display.
• Be familiar with Analyzing MDC4 Status Display.
• Understand how to use the special tools to perform signal measurements.
• Know how to verify voltage and troubleshoot the Power Supply Unit.
• Understand touch screen faults.
• Be familiar with the different programs and connection options.
• Be familiar with FTP and LAN connections.
• Know how to access the Loader Menu and install Sensor Software manually.
• Be familiar with the component testing program.
• Know how to adjust and calibrate the camera.
• Be familiar with how to perform a quick test on the camera.

IV. INSTRUCTIONAL TASKS:

• Conduct a review of the material covered to date in conjunction with a Question and
Answer session.
• Discuss programs and connections options. (Service Manual 13.1.1)
• Review establishing serial communication (Service Manual 13.1.2) and Hyper-
terminal (13.1.4), Shell Commands (13.1.4.1), and Capturing Text (13.1.4.2)
• Review FTP and establishing a LAN connection. (Service Manual 13.1.3)
• Review the Loader menu (13.1.5) and Installing Software (13.1.6)
• Review Component Test (aka Service Tool 14.1.7)
• Explain and use MDC_PP
• Review Data Analysis (Service Manual 13.2) including:
• Analyzing PPC Status Displays (13.2.1)
• Analyzing MDC4 Status Displays (13.2.2)
• Signal Measurement on Plugs (13.2.3)
• Review Error Senarios (Service Manual 13.3) including:
• Verifying Voltage on the Power Supply Unit (13.3.1)
• Increased Start-up time (13.3.2)
• High Reject and/or Jam Rate (13.3.3)
• All Banknotes are rejected (13.3.4)
• Touch Screen Faults (13.4.5)
• Explain the Camera Calibration process.
• Demonstrate how to perform camera mechanical alignment.
• Demonstrate how to perform the camera focus adjustment.
• Demonstrate how to perform quick camera test with a video monitor.
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I. LESSON TITLE: Day 5

II. TOPIC: BPS C4 installation, set up and commissioning. Review maintenance.

Review of available Quick Procedures and Technical Bulletins. Practical and Final
Test.

I. OBJECTIVES: Upon completion of this day of the course, the successful student
should be able to:
• Review and understand all required maintenance for the C4.
• Review and understand all the Quick Procedures available for the C4
• Review and understand all the Technical Bulletins available for the C4.
• Successfully pass the BPS C4 Final Test. (written test)
• Successfully pass the BPS C4 Practical Test (performance test)

II. INSTRUCTIONAL TASKS:

• Conduct a review of the material covered to date in conjunction with a Question and
Answer session.
• Review all the required maintenance for the C4.
• Review all the Quick Procedures available for the C4.
• Review all the Technical Bulletins available for the C4.
• Prepare the BPS C4 as delivered from Germany. Allow students to complete the
practical test according to the practical test requirements.
• Allow the students to Set up the BPS C4.
• Allow the students to build a DEG.
• Have the students install a Zebra printer and print a header card for processing.
• Allow the students to configure an OMOCO according to the Practical test
specifications.
• Have the student’s process 100 notes of each currency.
• Have the students Reconcile 1 note of each currency

**Take the Final Test and Present Certificates**

Course Outline (5 Day)

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