Money Counting Machine Problems: Complete Troubleshooting Guide (2025)

Money counting machines process billions of dirhams daily across banks, retail stores, and businesses throughout the UAE. Yet 73% of companies experience counting errors or machine malfunctions that cost an average of AED 8,800 annually in operational delays and miscounts.

This comprehensive guide covers 12 common problems, brand-specific solutions, and expert maintenance strategies to keep your cash counting operations running smoothly.

Quick Problem Diagnostic Tool

Is your money counting machine:

❌ Miscounting bills? →
❌ Jamming frequently? →
❌ Overheating? →
❌ Rejecting good bills? →
❌ Showing error codes? →

Still unsure? Use our complete diagnostic checklist below.

The 12 Most Common Money Counting Machine Problems

1. Miscounting and Inaccurate Counts

Problem: Machine consistently gives wrong counts, missing bills, or adding extras

Miscounting and inaccurate counts occur when the machine fails to detect or separate bills correctly, leading to discrepancies in totals. This can result from dirty sensors, worn-out rollers, or jammed notes, ultimately affecting cash accuracy and trust in the device.

Symptoms:

Count differs when rechecked manually
Inconsistent results with same bill stack
Missing 1-3 bills per hundred counted

Root Causes:

Dirty optical sensors (78% of cases)
Worn counting rollers (15% of cases)
Improper bill alignment (7% of cases)

Brand-Specific Solutions:

Cassida Models (DB-360, C900, Tiger):

Remove front panel and locate dual CIS sensors
Use Cassida cleaning cards (Part #: CC-100) monthly
Check roller tension – should require 2-3 pounds pressure to stop

Glory Models (GFS-120, GFS-220N):

Access sensor cleaning mode via Menu → Maintenance → Clean
Run 5 cleaning cards through automatic cycle
Calibrate using Glory’s built-in calibration sequence

MIRAGE Models (SY-200, SY-100):

Power off and access sensor compartment via side panel
Clean sensors with lint-free cloth and 70% isopropyl alcohol
Check feed roller alignment and clean with alcohol-dampened cloth
Recalibrate using Menu → Settings → Calibration with fresh UAE dirham notes

Step-by-Step Fix:

Power down machine completely (unplug for 30 seconds)
Open sensor access panel (consult manual for location)
Clean sensors with lint-free cloth and alcohol
Test rollers for proper grip and alignment
Run calibration with 50 mixed denomination bills
Verify accuracy with test batches

Prevention: Clean sensors weekly for high-use environments, monthly for moderate use. Check out How to clean cash counting machine.

2. Frequent Bill Jamming

Problem: Bills get stuck during counting, stopping the process.

This common issue can be caused by dirty or misaligned rollers, worn-out feed belts, or inconsistent bill sizes. Frequent jamming not only disrupts workflow but can also lead to machine damage if not addressed promptly.

Jam Frequency Analysis:

1-2 jams/day: Normal wear, basic maintenance needed
3-5 jams/day: Moderate issue, immediate attention required
6+ jams/day: Critical problem, professional service recommended

Common Jam Locations:

Feed roller area (45% of jams)
Counting sensor chamber (30% of jams)
Output stacker (25% of jams)

Immediate Solutions:

For Feed Roller Jams:

Turn off machine immediately
Remove jammed bills gently (never force)
Check for torn pieces inside mechanism
Clean rollers with alcohol-dampened cloth

For Sensor Chamber Jams:

Open chamber access door
Remove bills without touching sensors
Inspect for foreign objects or debris
Test door closure mechanism

For Output Stacker Jams:

Clear output area completely
Check stacker alignment guides
Ensure proper bill exit angle
Test with small batch (10-20 bills)

Advanced Troubleshooting:

Cassida Machines:

Check “Jam Detection” sensitivity in settings menu
Adjust to “Medium” for mixed condition dirham notes
Replace feed rollers every 500,000 notes counted

Glory Machines:

Use “Gentle Mode” for older dirham notes
Check belt tension indicator (should show green)
Clean transport path monthly with compressed air

MIRAGE Machines:

SY-200: Use “Precision Mode” for mixed condition notes
SY-100: Adjust speed settings for optimal accuracy
Both models: Clean sensor areas weekly due to UAE dust conditions

Preventive Measures:

Sort dirham notes by condition before counting
Remove damaged notes (tears, tape, excessive wear)
Keep humidity between 40-60% to prevent static
Store notes in climate-controlled environment

3. Machine Overheating and Shutdowns

Problem: Machine shuts down unexpectedly during operation.

Overheating can result from prolonged use without proper ventilation, dust-clogged fans, or internal component strain. This not only interrupts counting tasks but may also shorten the machine’s lifespan if not resolved.

Warning Signs:

Fan running continuously at high speed
Hot air exhaust from vents
Slower counting speed before shutdown
“OVERHEAT” error message

Cooling Solutions for:

High-Volume Environments (Banks, Exchange Houses, Large Retailers):

Install dedicated AC vent 2 feet from machine
Use external cooling fans during peak hours in UAE summer
Schedule 15-minute breaks every 2 hours
Consider upgrading to heavy-duty models for extreme temperatures

Standard Office Environment:

Ensure 6-inch clearance on all vented sides
Avoid direct sunlight (especially important in UAE climate)
Clean internal fans monthly due to dust conditions
Use during cooler parts of day when possible

Quick Cooling Protocol:

Stop counting immediately when overheating detected
Power down and unplug for minimum 30 minutes
Check vents for dust blockage while cooling
Clean internal fans with compressed air
Restart with reduced batch sizes

Long-term Solutions:

Upgrade to models with better thermal management
Install room temperature monitoring
Create scheduled maintenance calendar
Train staff on proper cool-down procedures

4. Excessive Bill Rejection

Problem: Machine rejects legitimate bills, slowing operations.

This often happens due to dirty sensors, outdated software, or overly sensitive counterfeit detection settings. It disrupts workflow and can frustrate users by requiring repeated manual checks of valid currency.

Rejection Rate Benchmarks:

0-2%: Normal operation
3-5%: Moderate concern, adjustment needed
6%+: Serious problem requiring immediate attention

Rejection Reasons by Frequency:

Counterfeit detection too sensitive (40%)
Worn or damaged bills (25%)
Incorrect denominations mixed (20%)
Foreign currency accidentally included (10%)
Machine calibration drift (5%)

Sensitivity Adjustment Guide:

For UV Detection Issues:

Lower UV sensitivity by 10-15%
Test with known genuine aged bills
Avoid fluorescent lighting interference

For Magnetic Detection Problems:

Reduce MG sensitivity for older UAE dirham notes
Check for magnetic interference nearby
Clean magnetic sensors monthly

For Size Detection Errors:

Recalibrate with fresh dirham notes from UAE Central Bank
Check for paper debris in size sensors
Adjust tolerance settings incrementally

Brand-Specific Calibration:

Cassida Models:

Menu → Settings → Detection → Sensitivity
Reduce each detection type by 1 level
Test with 100 mixed bills
Fine-tune based on results

Glory Models:

Service Menu (hold Clear + Set for 5 seconds)
Navigate to Authentication Settings
Adjust threshold values down 5-10 points
Save and test configuration with UAE dirham notes

MIRAGE Models:

Menu → Settings → Detection → Sensitivity
Lower UV and MG sensitivity by 1-2 levels for SY-200
For SY-100: Adjust counterfeit detection to “Standard” mode
Test with aged UAE dirham notes to verify acceptance

5. Display Errors and System Malfunctions

Problem: Screen shows error codes, freezes, or displays incorrect information.

These issues can stem from software glitches, loose internal connections, or power fluctuations. They hinder usability, make troubleshooting difficult, and may signal deeper hardware or firmware problems.

Common Error Codes and Solutions:

E01 – Sensor Error:

Clean all optical sensors
Check sensor cable connections
Restart machine and recalibrate

E02 – Motor Malfunction:

Check for mechanical obstructions
Lubricate motor bearings (qualified technician only)
Verify power supply voltage

E03 – Memory Error:

Power cycle machine completely
Reset to factory defaults
Contact manufacturer if persists

E04 – Communication Error:

Check all internal cable connections
Update firmware if available
Professional diagnostic required

Display Troubleshooting Steps:

Document error code and when it occurs
Power cycle – off for 60 seconds minimum
Check connections – power, display cables
Test in safe mode if available
Reset to defaults as last resort
Contact support with error log

6. Counterfeit Detection Failures

Problem: Machine fails to detect counterfeit dirham notes or flags genuine UAE currency.

This can occur due to outdated counterfeit detection technology, dirty sensors, or improper calibration. Such failures compromise security and trust, increasing the risk of financial loss or operational delays.

Detection Technology Comparison:

UV Detection: 85% accuracy for basic counterfeits
Magnetic Detection: 95% accuracy for advanced fakes
Infrared Detection: 98% accuracy when properly calibrated
Combined Detection: 99.7% accuracy (recommended)

Calibration Best Practices:

Use freshly issued dirham notes for calibration
Include various denominations (5, 10, 20, 50, 100, 200, 500, 1000 AED)
Perform monthly calibration updates
Document all calibration sessions

When to Upgrade Detection:

Counterfeit attempts increase in your area of UAE
New security features added to UAE dirham currency
Detection accuracy drops below 98%
UAE Central Bank regulatory requirements change

7. Unusual Noise During Operation

Problem: Machine produces loud, grinding, or irregular sounds.

This may indicate internal wear, debris buildup, or mechanical misalignment. Ignoring these sounds can lead to bigger malfunctions, reduced efficiency, and costly repairs over time.

Sound Diagnosis:

Grinding noise: Worn bearings or gears
Squealing: Belt tension issues
Clicking: Loose components
Whirring: Fan imbalance or obstruction

Noise Level Standards:

Normal operation: 55-65 dB
Concerning level: 66-75 dB
Immediate service needed: 76+ dB

Safe Noise Reduction:

Clean and lubricate accessible moving parts
Tighten visible loose components
Check belt alignment and tension
Replace worn rubber feet/dampeners

Professional Service Required:

Internal gear replacement
Motor bearing service
Belt and pulley alignment
Internal component balancing

8. Speed and Performance Issues

Problem: Machine counts significantly slower than specifications.

This slowdown can result from dirty internal components, outdated firmware, or worn-out motors. Reduced speed hampers productivity and may signal the need for cleaning, maintenance, or part replacement.

Performance Benchmarks:

High-end models: 1,000-1,500 notes/minute
Mid-range models: 600-1,000 notes/minute
Budget models: 300-600 notes/minute

Speed Optimization:

Clean all sensors for optimal detection
Use consistent dirham note quality to reduce stops
Proper note alignment prevents re-feeds
Regular maintenance keeps mechanisms smooth
Appropriate batch sizes prevent overloading

When Slow Speed Indicates Problems:

30%+ reduction from normal speed
Inconsistent counting rhythm
Frequent stops and starts
Unusual mechanical sounds

9. Power and Electrical Issues

Problem: Machine won’t turn on, random shutoffs, or electrical faults.

These problems often arise from faulty power cords, unstable power supply, internal wiring issues, or damaged circuit boards. Such electrical failures can completely halt operations and require prompt technical attention to avoid further damage.

Electrical Troubleshooting:

Check power source – test outlet with other device
Inspect power cord – look for damage or loose connections
Verify voltage requirements – some machines need specific voltage
Test internal fuses – replace if blown (check manual first)

Power Quality Requirements:

Voltage stability: ±5% of rated voltage
Clean power: Use surge protector or UPS
Proper grounding: Essential for sensitive electronics
Adequate amperage: Check machine specifications

Electrical Safety:

Never operate with damaged cords
Ensure proper electrical grounding
Use appropriate circuit breakers
Schedule electrical system inspection annually

10. Software and Firmware Problems

Problem: Outdated software causing compatibility or performance issues.

When the machine’s software or firmware is not updated regularly, it can lead to errors, slowdowns, or inability to recognize new bill designs. Keeping software current is essential to maintain accuracy, security, and optimal performance.

Update Process:

Check current version in system settings
Download updates from manufacturer website only
Backup settings before updating
Follow update instructions exactly
Test all functions after update

Common Software Issues:

Slow response to button presses
Incorrect UAE dirham recognition
Feature malfunctions
Compatibility with new dirham note designs

11. Environmental Damage

Problem: Dust, humidity, or temperature affecting performance.

Exposure to dusty environments, high humidity, or extreme temperatures can degrade internal components, clog sensors, and cause malfunctions. Proper placement and regular cleaning are crucial to protect the machine and ensure reliable operation.

Environmental Standards for UAE Climate:

Temperature: 18-26°C (ideal for UAE indoor environments)
Humidity: 40-60% relative humidity (challenging in UAE)
Dust level: Minimal – extremely important due to UAE sand/dust
Vibration: Stable surface, minimal external vibration

Protection Strategies for UAE Environment:

Use dust covers when not in operation (essential in UAE)
Install air filtration in counting areas
Monitor and control humidity levels with dehumidifiers
Provide stable, vibration-free surface
Consider sealed environment for high-dust areas

12. Mechanical Wear and Component Failure

Problem: Internal components wearing out from normal use.

Over time, parts like rollers, belts, and sensors can degrade due to continuous operation, leading to decreased accuracy and frequent breakdowns. Regular maintenance and timely replacement of worn components are vital to keep the machine running smoothly.

Component Lifespan Expectations:

Counting rollers: 500,000-1,000,000 dirham notes
Sensors: 2-3 years with proper maintenance
Motors: 5-7 years under normal use
Belts and gears: 3-5 years depending on usage

Preventive Replacement Schedule:

High-use (>10,000 dirham notes/day): Every 6 months inspection
Medium-use (1,000-10,000 dirham notes/day): Annual inspection
Low-use (<1,000 dirham notes/day): Bi-annual inspection

Brand-Specific Maintenance Guides for Money counters

Cassida Money Counters

Monthly Maintenance:

Clean sensors with Cassida cleaning cards
Check roller condition and alignment
Update detection databases for UAE dirham security features
Test all denominations (5-1000 AED)

Annual Service:

Replace counting rollers
Calibrate all detection systems for UAE currency
Update firmware
Professional internal cleaning (important due to UAE dust)

Glory Cash Counting Machines

Weekly Tasks:

Run automatic cleaning cycle
Check belt tension indicators
Clear any error logs
Test emergency stop functions with UAE dirham notes

Quarterly Service:

Replace feed rollers if needed
Calibrate detection sensitivity for UAE currency
Check motor performance
Update software

MIRAGE Note Counting Machines

Bi-weekly Maintenance:

Clean external sensors (more frequent due to UAE dust)
Check power connections and stability
Test counting accuracy with UAE dirham notes
Clear dust from vents (critical in UAE environment)
Inspect feed mechanism for wear

Semi-annual Service:

Professional internal cleaning (essential due to UAE climate)
Replace worn feed rollers if needed
Firmware updates and calibration
Comprehensive testing with all UAE denominations
Check counterfeit detection accuracy

MIRAGE-Specific Tips:

SY-200: Features advanced UV/MG detection – calibrate monthly for UAE dirham security features
SY-100: Budget-friendly model – increase cleaning frequency in high-dust environments
Both models: Use gentle cleaning solutions to avoid damaging sensitive components

Cost Analysis: Repair vs. Replacement

When to Repair Money counting machines

You should consider repairing the machine if it is less than three years old, the cost of repair is less than 40% of the replacement cost, parts are readily available, and the expected downtime for repair is acceptable.

Common Repair Costs in UAE:

Sensor cleaning: AED 180-370
Roller replacement: AED 550-1,100
Display repair: AED 740-1,480
Motor replacement: AED 1,100-2,200

When to Replace Money Counting machines

It’s best to replace the machine if it is over five years old, the repair cost exceeds 50% of the replacement value, multiple systems are failing at once, or the technology is outdated and no longer meets the security standards required for printing UAE dirhams.

Replacement Budget Planning in UAE:

Budget models: AED 740-1,850
Professional models: AED 2,950-7,400
High-end commercial: AED 9,250-18,500
Bank-grade systems: AED 18,500+

Need a new unit? Check out our currency counting machines tailored to UAE conditions.

Professional Service Directory

When to Call a Technician

Immediate professional service needed for:

Internal component replacement
Electrical system problems
Firmware corruption
Warranty-covered issues

Emergency Troubleshooting Checklist

When your machine stops working:

☐ Step 1: Power cycle completely (off 60 seconds)
☐ Step 2: Check for obvious obstructions or jams
☐ Step 3: Verify power source and connections
☐ Step 4: Note any error codes or unusual sounds
☐ Step 5: Try with small batch of perfect UAE dirham notes
☐ Step 6: Check environmental conditions (especially important in UAE)
☐ Step 7: Review recent changes or maintenance
☐ Step 8: Contact manufacturer support or UAE distributor if needed

Conclusion

Money counting machine problems are typically preventable through regular maintenance and proper operation. The key to maintaining peak performance is understanding your specific machine’s needs, following manufacturer guidelines, and addressing issues promptly before they become costly repairs.

Remember the golden rules:

Clean regularly and thoroughly
Use quality bills when possible
Monitor performance metrics
Schedule preventive maintenance
Know when to call professionals

By following this comprehensive guide, you can maximize your machine’s lifespan, maintain counting accuracy, and minimize operational disruptions. Regular attention to these details will save both time and money while ensuring reliable cash handling operations.

Need personalized help with your specific machine model? Contact our certified technicians or use our online diagnostic tool for immediate assistance.