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BPS M5 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE Course Outline (3 Weeks) BPS M5-CO April, 2017 Version: B Giesecke & Devrient America, Inc. Page 1 of 29 Course Outline (3 Weeks) TRAINING MATERIALS: BPS M5 Course OUTLINE for distribution BPS M5 Training Manual BPS M5 Technical Diagrams BPS M5 Training Supplement (USB) Laptop with windows XP or Windows 7 Hyper terminal or serial emulation program USB stick (32GB preferable) I. LESSON: WEEK 1 / DAY 1 II. TOPIC: Introduction and Getting to know the BPS M5. Complete Overview of the system including available processing operations. Menu options for user, supervisor, and service roles. Service items available for supervisor and service. III. TRAINING OBJECTIVES: Upon completion of this day of the course, the successful student should be able to: Be familiar with the supporting documentation and supplemental training available for the BPS M5 product. Understand safety issues when operating and servicing the BPS M5. Be familiar with optional and external equipment available for the BPS M5 Become familiar with BPS M5 Processing Operation procedures Understand the different modes of processing operations. Be familiar with User, Supervisor, Service and Administrator menu options for each role. Understand the method used to code the different models of the BPS M5 product. Understand the various omponents used to operate and control the system. Understand the functional components that comprise the Basis Module. Be familiar with configurations that will be used during training Learn how to configure, modify, and operate the System set-up

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Page 1: Course Outline (3 Weeks) · BPS M5 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE Course Outline (3 Weeks) BPS M5-CO April, 2017 Version: B Giesecke & Devrient America, Inc. Page

BPS M5 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE

Course Outline (3 Weeks) BPS M5-CO April, 2017 Version: B Giesecke & Devrient America, Inc. Page 1 of 29

Course Outline (3 Weeks) TRAINING MATERIALS: BPS M5 Course OUTLINE for distribution BPS M5 Training Manual BPS M5 Technical Diagrams BPS M5 Training Supplement (USB) Laptop with windows XP or Windows 7 Hyper terminal or serial emulation program USB stick (32GB preferable)

I. LESSON: WEEK 1 / DAY 1

II. TOPIC: Introduction and Getting to know the BPS M5. Complete Overview of the system including available processing operations. Menu options for user, supervisor, and service roles. Service items available for supervisor and service.

III. TRAINING OBJECTIVES: Upon completion of this day of the course, the successful student should be able to: • Be familiar with the supporting documentation and supplemental training available for the BPS

M5 product.

• Understand safety issues when operating and servicing the BPS M5.

• Be familiar with optional and external equipment available for the BPS M5

• Become familiar with BPS M5 Processing Operation procedures

• Understand the different modes of processing operations.

• Be familiar with User, Supervisor, Service and Administrator menu options for each role.

• Understand the method used to code the different models of the BPS M5 product.

• Understand the various omponents used to operate and control the system.

• Understand the functional components that comprise the Basis Module.

• Be familiar with configurations that will be used during training

• Learn how to configure, modify, and operate the System set-up

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BPS M5 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE

Course Outline (3 Weeks) BPS M5-CO April, 2017 Version: B Giesecke & Devrient America, Inc. Page 2 of 29

IV. INSTRUCTIONAL TASKS: A. Review the outline for the BPS M5 Training Program

B. Identify the overall course goal, and the general course objectives.

C. Distribute the Training Manual and Technical Diagrams.

D. Distribute BPS M5 DVD.

E. Identify the main sections in the Customer Documents

1. Operating Manual

2. Site and Facility Requirements

3. NotaScan Sensors

F. Identify the main sections in the Service Documents

1. Maintenance Manual

2. Repair Manual

3. Adjustment Procedures

4. Technical Diagrams

5. Software Installation

6. Software Tools

7. Control Center Documentation

8. BDC Control Instructions

9. DustoVac Dust Removal

10. LVM-S.2

11. Frequency Drive Converter

G. Identify the main sections in the Technical Documents

1. Quick Procedures

H. Identify the main sections in the Training Documents

1. Training Manual

2. Training Handouts

I. Terms and Abbreviations

J. Safety

K. External equipment - printer, reconciliation PC, server PC, et cetera.

L. Describe the method used to code the different models of the BPS M5

M. Identify the following:

1. the Input Module

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2. the Operating Module

3. the Delivery Module(s)

4. the Shredder Module, Audit stacker, and the Fail-Safe pocket

5. the Pneumatic Unit

N. Identify how to power on/off the Pneumatic Unit.

O. Components used to operate and control the system (at the Machine)

1. the Emergency Stop buttons

2. the Drive Slow buttons

3. the various Function buttons

4. the Screen, keyboard, keypad, and mouse

5. the Chip card reader

6. the Main switch

7. the Bander Safety button (ZHT)

8. the I/O keyboards in the Delivery Module(s)

9. the Band Advance buttons

P. Overview of Window XP, the Oracle databases, and the Banknote Processing

software.

Q. System Users:

1. SYSTEM ADMINISTRATOR (sysadmin)

2. SUPERVISOR

3. SERVICE (the Field Engineer)

4. OPERATOR

R. Identify and describe the following terms:

1. Meta Section

2. Shift

3. Parameter

4. Accounting Unit

S. Manner in which rejects are handled

T. Describe Header card processing.

U. Procedure to process banknotes

1. Logging on,

2. Opening a section, and

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3. Selecting an operating parameter.

V. Serial processing, parallel processing, and continuous feed processing.

W. Identify two configurations that will be used fairly extensively during training

1. one for Blanks

2. one for Currency

X. Run a shift, and demonstrate the process of configuring the BPS M5.

Y. Proper procedures for "shutting down"

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I. LESSON: WEEK 1 / DAY 2

II. TOPIC: Main menu software operations. Software tools available including function and operations.

III. TRAINING OBJECTIVES: Upon completion of this day of the course, the successful student should be able to: • Be familiar with the Administration utility.

• Become familiar with the Configuration Tool.

• Understand the Event Viewer.

• Be familiar with the Banknote Viewer.

• Understand the Event Viewer.

• Be familiar with the System Administration Tool

• Be familiar with the Basic User Interface (BUI) Tool

• Understand the DB Memory Manager

• Understand the DB Access

IV. INSTRUCTIONAL TASKS:

Review of the material covered to date with a Question and Answer session.

Overview of Software Operations from the Main Menu:

1. Administration

2. Configuration Tool

3. Banknote Viewer

4. DB Memory Manager

5. System Administration

6. BUI Tool

A. Administration

1. Administrator Card Acess Version

2. User Rights

3. Administration Functions

4. Writing user data

5. Displaying Data on the Chip Card

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B. Configuration Tool

1. Creating a stacking mode

2. Bander Format

3. Sensor Menu Items

4. Service Menu

5. Sychrozing new data with a database

C. Banknote Viewer

1. Selecting Bankote properties

2. Defining Display Details

3. Displaying Special Banknote Data sets

D. Event Viewer

1. Requesting the Operation logs

2. Requesting the Machine logs

3. Windows XP logs

E. Banknote Viewer

1. Selecting Bankote properties

2. Defining Display Details

3. Displaying Special Banknote Data sets

F. System Administration

1. Changing the Administrator password

2. Chaning the G&D user password

3. Settng the System time and date

G. BUI Tool

1. Country Settings

2. Language properties

H. DB Memory Manager

1. Settings for Automatic Data Removal

2. Memory Usage allocation

3. Data removeal

4. Deleting unreferenced names

5. Deleting unreferenced history

I. DB Access

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1. Data Base fundamentals

2. Importing data

3. Exporting data

4. Viewing tables

5. Editing tables

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II. LESSON TITLE: Week 1 / Day 3

III. TRAINING OBJECTIVES:

Review of the material covered to date with a Question and Answer session.

Machine PC:

1. Interfaces

2. List of Hardware Compnents

3. Layout of the MPC

4. Hardware Connections

5. MPC Housing

6. Com Adapter

7. Power Supply

8. Housing Fan

A. Motherboard / CPU Board

1. JILI DVI Adapter

B. Interfaces of the CPU

1. Serial Port Com 1

2. Serial Port Com 2

3. eSATA

4. USB

5. Ethernet Connector 1 (Ether 1)

6. Ethernet connector 2/3 (Ether 2/3)

7. VGA Interface

8. PS/2

9. MPC Housing

C. Memory

D. PCI-Riser Card

E. Can Card/board

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F. MPC Software

G. Basic Principles of Installation

1. Dual Drive Installation with Internal Recovery

2. Dual Drive Installation with External Recovery

3. Single Drive Instalatin with Enhanced Recovery

H. Installation Tools and Installation Options

1. Creating a Bootable USB Stick

2. Preparing a notebook for Network Installation

3. Quickstart from DVD

4. Boot ON Lan configuration

5. Information about the Server Connection

I. Error Messages during Installation

J. Data Structrue Conventions

1. Hotfix structure

K. Full Image Installation

1. Starting the Installation environment

2. Booting from the USB Stick

3. Starting the Installation with the Image Installation Utility (IIU)

4. Continuing an Internal Recovery Installation

5. Continuing an External Recovery Installtion

L. Release and Hotfix Installtion

1. Initialization

2. Directly form the Image Installer Manager

3. From the BPS application

4. Hotfix installation

5. Release installation

M. Recovery

1. Internal Recovery Installation

2. External Recovery Installation

3. MPC Housing

N. Customer Backups

1. Basic Principles

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2. Backup

3. Restore

4. Full Restore

5. Fast Restore

6. Integrity Checks aftter Restore

O. System Startup

P. System Shutdown

Q. Security Levels

R. Access to the Media Archive

S. Image Conversion

T. Printer Installation

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II. LESSON TITLE: Week 1 / Day 4

III. TRAINING OBJECTIVES:

Review of the material covered to date with a Question and Answer session.

Maintenance of the Software Installation

1. Manual Activation of System Functions

A. Bios Configuration

1. Resetting the BIOS to Default Configuration

B. Administrator access

C. Autostart Applications

D. Typical Processing Times

E. Information on IP configurations

F. Version Concept

G. Image Installer Log files

H. USB Installation Modes

I. Anticopying Protection

J. Bios Update

K. Sensor computer System

1. Sensor sytem Achitecture

2. Measurement of analog signals

3. Digitizing analog signals

4. Calculation of properties

5. Building a sort class

N. Sensor PC application

O. Interfaces between components

P. SCS Interfaces

Q. NetworkEthernet Switch

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R. SCS Backplane

S. SAP-PPC-BE

1. Removal/Installation

T. SAP-IPS

1. Removal/Installation

U. External Interfaces

V. External Interfaces of the SCS

W. Machine Interface

X. External Interfaces of the SPC Software

Y. File Interface

Z. External Interfaces.

AA. Components in the MPC used with the sensors:

1. the Sensor Measurement Processor (SMP)

2. the Sensor Integration Controller (SIC)

3. the Image Processing Unit (IPS)

4. the Sensor Algorithm Processor (SAP)

BB. Hardware Components

CC. Sensor Measurement Units

DD. SAP-PPC Basis Board

EE. Software Components

FF. Real-time Software (SRT) for SAP-PPCApplications

GG. Basic Software for the Application

HH. The Programmable Sensor Logic

II. Framework Application

JJ. Sensor Interfaces

KK. Algorithms

LL. Maintenance and Error Diagnosis

MM. Sensor PC.

NN. Architecture

OO. System Structure

PP. Teamwork and Interaction

QQ. Sensor Configuration and Adaptation

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1. adap

2. config

3. eval

4. logs

5. Opmodes

6. progs

7. sorts

8. temp

9. trigger

SS. PC Interface Response

TT. Real-time Interface Response

UU. NOTASCAN IMAGE (NSC2)

VV. Technical Data

WW. Centering Elements

XX. NSC2 Installation/Removal

YY. Sensor Pairig

ZZ. Taking a Reading of the Operating Hours of the NotaScan Image (NSC2)

AAA. Sensor Cleaning

1. Cleaning the expansion card in the NotaScan Profile sensor(DIS).

BBB. IPS/NSC2 Configurations

CCC. Sensors

1. the NotaScan sensor

2. the Thickness sensor

3. the M Feature Detector (MFD) sensor (a.k.a. the USD sensor)

4. the Magnetic sensor

5. the Fluorescence / Phosphorescence sensor

6. the Conductivity sensor

7. the Limpness sensor

DDD. Sensor Error logging

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BPS M5 FIELD ENGINEER - TRAINING PROGRAM

I. LESSON TITLE: Week 2 / Day 1

II. TRAINING OBJECTIVES:

Review of the material covered to date with a Question and Answer session.

Complete Machine

A. Electronic signal generating and/or control components:

1. IPPD photodetectors and Reflective photodetectors (RLS)

2. Two operating modes for reflective photodetectors (light and dark actuated)

3. Reed switches , micro switches, and push-button switches

4. DC motors and Stepper motors

5. Pneumatic actuators (5/2 way and 2/2 way solenoid valves)

B. Real Time Control – Distributed Controller System

C. Module controllers locations and functions:

1. the Singler Module Controller (SMC)

2. the Sensor Transport Controller (STC)

3. the Gate Photodetector Controller (GPC)

4. the Bander Printer Controller (BPC)Controller

D. Describe the method used to name the GPC and BPC

E. Module Controllers. WOM. LEDs. Reset and Service Buttons

F. Basis Hardware MDCNG3

1. Communication/CAN bus

2. Serial Interface RS232

G. Optional Extension Boards

1. WOM

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2. DSP3NG

3. MCM3

4. BPI3

H. BPS Field bus

I. Software Arhitecture of the Real Time Control

1. Boot-Software / Firmware

2. Module Addressing

J. Status Display of the Main Board

1. MDC fuses

2. Switch Groups

3. Reset and Service Buttons

K. Photodetectors, switches, motors, and actuators in the Input Module

L. Photodetectors, switches, motors, and actuators in the Operating Module

M. Photodetectors, switches, motors, and actuators in the Delivery Module(s)

N. Uninteruptible Power Supply (UPS)

O. Motor Controller (FCU)

P. Power Control Unit (PCU)

Q. Gate positioning and feedback

Input Module

A. The Large Continuous Feeder (LCF):

1. LCF electrical components

2. Feeder Plate (FEPL)

3. Feeder Rake (FERA)

4. Sliding Door

5. LCF Stepper Motors

6. LCF Manual Input

7. LCF Feeding Process

8. LCF Singling Modes

9. LCF Gate Modes

B. Banknote Singler

1. Singler Construction

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2. Singling Principles

3. Singling Theory

4. Singler Quality Adjustment Tool

5. Banknote Density Camera

a. Components

b. Description

c. Operation

d. Calibration

e. Troubleshooting

C. Pneumatic Unit and its effect on banknote singling.

D. Pneumatic gauges monitoring the air supply system

E. Components used to feed banknotes into the system (tiger valves)

F. Banknote Transport

1. Flat Belts

2. Roundbelts

3. Toothed Belts

G. Input Module Flatbelt System

1. Adjusting Belt Tension

2. Pnuematic Tensioner

3. Adjustment options

H. Review the techniques used for running blanks through the system, and have the

students run the system using blanks.

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I. LESSON TITLE: Week 2 / Day 2

II. TRAINING OBJECTIVES:

Review of the material covered to date with a Question and Answer session.

Air Supply System LVM.S-2:

1. LVM.S-2 Description

2. Conditions for Operation

3. Focus Control Unit

A. LVM.S-2 Operation

1. Boge Concept

B. Checking System Functionality

1. Service menu display

2. Date/time setting

3. Version information

C. Parameter Setting

D. Tan (Display) Test

E. Warning and Fault messages

F. Compressed Air Dryer (DR 8-2)

G. Oil/Water Seperator (OWAMAT)

H. Condensate Drain (Bekomat 31)

I. LVM.S-2 Maintenance and Service

1. Compressor Sevice

2. Reciever/Tank Service

3. Cyclone Filter

4. Filter Mats

5. Owamat Service

6. Bekomat Testing and Service

Operator Module:

R. Interface Controls

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1. Touch Screen

2. On Screen Display

3. Chip Card Reader

4. Keyboard

5. keypad

6. Mouse

S. Operater Panel Removal/Installtion

T. Hardware components connected to the USB Hub

U. Reject Stacker

Security Systems:

A. Protective Covers

B. Doors, Flap Doors, and Activated Doors

C. Fail Safe Compartment

D. Machine Safety System (MSS)

1. MSS Units

2. Door Circuit

3. E-stop Circuit

4. Principles of MSS Door

5. Principles of MSS E-Stop

6. Troubleshooting MSS

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I. LESSON TITLE: Week 2 / Day 3

II. TRAINING OBJECTIVES:

Review of the material covered to date with a Question and Answer session.

Electrical Power Supply and Control

A. Power Control Unit (PCU) junction box

B. Power control elements

1. Circuit breakers

2. Service switch

3. Transport on Hour Meter

C. Voltage distribution between individual electrical components

1. Signals to and from the Power Control Unit (PCU)

D. Frequency Converter Unit (FCU)

1. Installation/wiring

2. Intregal keypad

3. Viewing and editing parameters

4. Parameter Organization

5. Steps occurring upon transport start/run

6. Steps occurring upon transport jam clearing

7. Steps occurring when the LVM.S-2 is active

E. The Uninteruptable Power Supply (UPS)

1. Power Supply Unit

2. Battery box

F. Sensor Computer System (SCS) power

Delivery Module:

A. Operating Controls in the Delivery Module

B. Stacker

C. Bander

1. Banding Process

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D. Package Delivery

1. Extracting process

2. Package pushing

E. Large Delivery Module

F. Coupling Module

G. Fail-Safe Compartment

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BPS M5 FIELD ENGINEER - TRAINING PROGRAM

I. LESSON TITLE: Week 2 / Day 4

II. TRAINING OBJECTIVES:

Review of the material covered to date with a Question and Answer session.

Adjustment procedures:

Mechanical Adjustments:

1. Pnuematic belt tensioner

2. Belt tensioning values

3. Gate vanes

4. Guide plates

5. Air Conducting Plate

6. Singler Drum and Retarding Block

7. Stripper

8. Sensor Comb and Belt guide

9. Belt Re-routing

10. Presser

11. Band Folding Slider

12. Band Print Head

13. Stacker Collecting Plate

Electrical Adjustments:

1. Mirror Reflective Photodetectors

2. Reject gate monitoring

3. MDC Addressing

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4. Flap door proximity switches

5. Reflective PDs (Void1 and Void2)

6. SI0 signal

7. Sensor Swiveling Plate Proximity Switches

8. Magnetic Switches

9. Motor Protection Switch

10. FCU

11. Proximity Switches

Adjustments using software

1. Checking the machines Run-Time

2. Stackers (synchronization)

provide an overview of the Control and Synchronization Signals.

3. Stacker Adjustment

Pnuematic Adjustments:

1. Flap Door air adjustments

2. Compressed Air Adjustments

3. Cylinder end position adjustments

4. Pnuematic Cylinder Movement Times

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Course Outline (3 Weeks) BPS M5-CO April, 2017 Version: B Giesecke & Devrient America, Inc. Page 23 of 29

I. LESSON TITLE: Week 2 / Day 5

II. TRAINING OBJECTIVES:

Review of the material covered to date with a Question and Answer session.

Maintenance procedures:

A. 8 hour maintenance interval

1. Cleaning the transport section

2. Cleaning the Singler Area

3. Cleaning Sensors outside the swiveling plate area

B. 40 hour maintenance interval

1. Checking Input module Round Belts

2. Air Filtration System

3. Cleaning Photo Detectors

C. 500 hour maintenance interval

1. Checking Spiral Stacker Discs

2. Checking the Singler Rotor

3. Cleaning the Retard Block

4. Checking the round belts

5. Checking the Flat Belt

6. Checking the Toothed Belts’

7. Checking Banknote Gates

8. Checking Banding operation

9. Checking warning lables

10. Cleaning the back area of the machine

11. Cleaning Fan Filters

12. Checking Air Conducting Plate

13. Checking the Safety Equipment

14. Checking the transport drive rollers

15. Checking the band printing

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D. 1000 hour maintenance interval

1. Checking the pneumatic flap door

2. Checking airlines and hoses

3. Checking the battery connections

4. Checking the presser fork

5. Checking tooth belts

6. Replace round belts

7. Cleaning the valves on the Singler and Retarding system

E. 2000 hour maintenance interval

1. Taking a reading of the NotaScan Image (NSC2)

F. 6000 hour maintenance interval

1. Changing the Air Conducting Plate filter

2. Replace Lithium batteries

3. Replace rechargeable batteries

Control Center Operations: (TBD)

BPS Connect Casino

G. Use BPS Connect Casino to process rejects.

H. Demonstrate through Documentation how to set up the BPS Connect Casion for BPS

M5. (BPS Connect Casino Installation Manual)

I. Configuring TCP/IP Protocols of the BPS Connect Casino Server

J. Demonstrate through Documentation how to set up BPS M5 for BPS Connect Casino.

(BPS Connect Casino Installation Manual)

K. Demonstrate how to install the Zebra printer

L. Demonstrate how to change the Zebra printer paper roll

M. Demonstrate how to change the Zebra printer print ribbon

N. Demonstrate how to change the Zebra printer print head

O. Demonstrate how to change the Zebra printer cutter.

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Course Outline (3 Weeks) BPS M5-CO April, 2017 Version: B Giesecke & Devrient America, Inc. Page 25 of 29

I. LESSON: Week 3 / Day 1

II. TRAINING OBJECTIVES:

Review of the material covered to date with a Question and Answer session.

TECHNICAL DIAGRAMS, provide an overview of the electrical drawings

A. COMPLETE MACHINE

1. Pnuematic Module Connnections

2. Main Switch Connections

3. CAN cabling

4. Fuse (UPS) Assignment

5. Sensor Power Supply Fuses (SSV)

6. Batteries and the Battery cut-off switch

7. Connection Diagram UPS

8. MDCNF Assignment diagram

9. Plug Connections MDCNF-WOM

10. MDCNF Power Supply circuit diagram

11. MDCNF Digital Output circuit diagram

12. NDCNF Digital Input circuit diagram

13. NDCNF Analog Input circuit diagram

14. Schematic diagram PCU

B. INPUT MODULE

1. Cable connections

2. External I/O interface

3. SMC Connectin Diagram

4. SMC MCM Assigment Diagram

5. SMC DSP Assignment Diagram

6. MSS-MESS Processing Unit

7. Data Conections between Machine PC and Operating area

8. Input Module Pnuematic Diagram

C. Operating Module

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1. STC Connection Diagram

2. Cable Connections

3. STC Plug Assignments

4. FU Schematic Diagram

D. Delivery Modue

1. LDM Cable Connections

2. 4DM Delivery Module Connections

3. GPC Connection Diagram

4. BPC Connection Diagram

5. BPC Input/Output Signals

6. BPI Assignment Diagram

7. BPC BPI Input/Output Signals

8. MSS Unit BAND Assignment Diagram

9. Delivery Module Pnuematic Diagram

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I. LESSON: Week 3 / Day 2

II. TOPIC: TROUBLESHOOTING

III. TRAINING OBJECTIVES:

A. Review

B. E-TEST

C. BDC TROUBLESHOOTING

D. Set up the system with problems for troubleshooting, and have the students

troubleshoot the problems.

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I. LESSON: Week 3 / Day 3

II. TOPIC: TROUBLESHOOTING CONTINUES

IV. TRAINING OBJECTIVES:

E. Review

F. E-TEST

G. BDC TROUBLESHOOTING

H. Set up the system with problems for troubleshooting, and have the students

troubleshoot the problems.

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BPS M5 FIELD ENGINEER TRAINING PROGRAM COURSE OUTLINE

Course Outline (3 Weeks) BPS M5-CO April, 2017 Version: B Giesecke & Devrient America, Inc. Page 29 of 29

I. LESSON: Week 2 / Day 4

II. TOPIC: Course completion, final review, critique and graduation.

III. TRAINING OBJECTIVES:

A. Review

B. Final Test

C. Practical Test

D. Training Critique

E. Graduation

F. Departure and flights.