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Sistema de Recaudo Control e Información y
Servicio al Usuario Proyect
Maintenance and Repair Manual
(Heavy)
Automatic Recharger
CB-EDR-HM-00-V1.0
Copyright ⓒ LG CNS
It is forbidden to copy and distribute on certain or whole part of this content without precedent approval of LG CNS
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Bogota SIRCI Project User Requirement Definition
Document Prepared by: Reviewed by: Approved by:
Maintenance and
Repair Manual (Heavy)
CB-EDR-HM-00-V1.0
Automatic
Recharger
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Bogota SIRCI Project User Requirement Definition
Document History
Previous
Version
Present
Document
Date Numeral Changes Type
CB-EDR-HM-00-V1.0
Automatic
Recharger
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Table Of Contents
1. AUTOMATIC RECHARGER EQUIPMENT STRUCTURE ....................................... １
1.1 Overview ............................................................................................................... １
1.2 External / Internal Structure and Main Module .................................................. １
1.2.1 External Structure ............................................................................................. １
1.2.2 Main Module Structure I .................................................................................... ２
1.2.3 Internal Structure .............................................................................................. ３
1.2.4 Main Module Structure II ................................................................................... ４
2. ERROR HANDLING ................................................................................................. ６
2.1.1 Supply of the power (1/3) .................................................................................. ６
2.1.2 Power Supply (2/3) ........................................................................................... ７
2.1.3 Power Supply (3/3) ........................................................................................... ８
2.1.4 USB Trouble (1/2) ............................................................................................. ９
2.1.5 USB Trouble (2/2) ......................................................................................... １０
2.1.6 LCD Screen Trouble (1/2) ............................................................................. １１
2.1.7 LCD Screen Trouble (2/2) ............................................................................. １２
2.1.8 Keypad Trouble (1/2) .................................................................................... １３
2.1.9 Keypad Trouble (2/3) .................................................................................... １４
2.1.10 Keypad Trouble (3/3) .................................................................................. １５
2.1.11 RTC Trouble (1/2) ....................................................................................... １６
2.1.12 RTC Trouble (2/2) ....................................................................................... １７
2.1.13 Bill Module Trouble (1/3) ............................................................................. １８
2.1.14 Bill Module Trouble (2/3) ............................................................................. １９
2.1.15 Bill Module Trouble (3/3) ............................................................................. ２０
2.1.16 Printer Trouble (1/2) .................................................................................... ２１
2.1.17 Printer Trouble (2/3) .................................................................................... ２２
2.1.18 Printer Trouble (3/3) .................................................................................... ２３
3. DEVICE MAINTENANCE ..................................................................................... ２４
3.1 Automatic Recharger ...................................................................................... ２４
3.1.1 Outline .......................................................................................................... ２４
3.1.2 Structure ....................................................................................................... ２４
3.1.3 Specification ................................................................................................. ２５
3.1.4 Replacement Method .................................................................................... ３１
3.1.5 Connector Specification ................................................................................ ３８
3.2 Maintenance Flow chart .................................................................................. ５０
4. AUTOMATIC RECHARGER INSTALLATION AND UPDATE ............................ ５１
4.1 Automatic Recharger Installation ................................................................... ５１
4.1.1 Procedure ..................................................................................................... ５１
4.1.2 Device Registration ....................................................................................... ５２
4.1.2.1 Power ON ....................................................................................................... ５２
4.1.2.2 SAM Card Mounting ....................................................................................... ５３
4.1.2.3 USB Mounting Method .................................................................................... ５４
CB-EDR-HM-00-V1.0
Automatic
Recharger
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5. AUTOMATIC RECHARGER HEAVY MAINTENANCE ....................................... ５５
5.1 CPU Board ........................................................................................................ ５５
5.1.1 CPU BOARD Specification ........................................................................... ５５
5.1.1.1 CPU Board Specification ................................................................................ ５５
5.1.1.2 CPU Board Block Diagram ............................................................................. ５５
5.1.1.3 CPU Board Check point .................................................................................. ５６
5.1.2 Sub BOARD Specification ............................................................................ ５７
5.1.2.1 Sub Main Board Specification ......................................................................... ５７
5.1.2.2 Sub Main Board Block Diagram ...................................................................... ５７
5.1.2.3 Sub Main Check point ..................................................................................... ５８
CB-EDR-HM-00-V1.0
Automatic
Recharger
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1. Automatic Recharger Equipment Structure
1.1 Overview
The Automatic Recharger is recharged the transit card.
1.2 External / Internal Structure and Main Module
1.2.1 External Structure
390mm (W)
[Automatic Recharger]
440mm (D)
1500mm (H)
CB-EDR-HM-00-V1.0 Automatic Recharger
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Bogota SIRCI Project User Requirement Definition
)
)
)
Division 내 용
Size
440mm(D) x 1500mm(H) x 390mm(W)
Material BASE PLATE(SUS), Exterior (STEEL, Painted_SLIVER)
1.2.2 Main Module Structure I
390mm (W)
1
2
3
Automatic Recharger
440mm (D)
1500mm (H)
Name Explanation
1) 4.3’ LCD Display of operation information
2) RFID Antenna
3) Bill Module
ISO14443 Type A, 13.56MHz card recognition and
charging
6 varieties of colombia bill
Insert each 1 bill
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1.2.3 Internal Structure
CPU, SUB,
LCD Board
RF Antenna
Keypad
Printer
SMPS
Bill Module
Batter
Power Panel
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1.2.4 Main Module Structure II
1) Printer Module
Print daily closing , accounting statement.
2) RFID Antenna
13.56MHz RF Card
ISO 14443 Type A
3) CPU Board
Control all attached equipment of Automatic Recharger and transfer data to main server.
CPU
- S3C2440(ARM9 Core) : 400MHz
Memory
- SDRAM : 128MByte
- Nor : 8MByte
- Nand : 512Myte
RF Module
- RC531( Type A)
4) Sub Main Board
Control I/O communicating CPU Board.
Exterior PORT
- Ethernet : 1
- USB : 1
- RS -232 : 5
SAM
- Socket 4EA(SIM Type)
Sound
- SW Codec controal
- Speaker : 5W * 1
5) I/O Board
Control I/O communicating CPU Board and Sub Main Board.
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6) Bill Module
: Recognize 6 varieties of Colombian Bill.
7) SMPS
: AC 110V, DC24V, DC12V
8) Battery
: Operate for 2 minute by using SMPS sub power.
9) Power Panel
: Input AC120V, output AC120V
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2. Error Handling
2.1.1 Supply of the power (1/3)
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2.1.2 Power Supply (2/3)
Output Voltage
AC 110V
Check
<Power Panel>
Output Voltage
DC12V Check
<SMPS>
Output Voltage
DC12V Check
<Connecter Board>
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p
p
p
p
2.1.3 Power Supply (3/3)
Fuse(F1) Check
U3 Out
U5 Out
U2 Out
ut 5V Check
ut 5V Check
ut 8V Check
U28 Output 3.3V
U1 Output 5V Check
U4 Out
ut 3.3V Check
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(
2.1.4 USB Trouble (1/2)
Cannot update USB
Check USB Memory
PASS
Check USB file system
FAT32 is not
PASS
Check CPU board USB
PASS
Check USB power
FAIL
FAIL
FAIL
FAIL
- Replace USB Memory stick
- Format USB by FAT file system
- Replace CPU PCB
- Replace SUB Main PCB
PASS
FAIL
Check USB Cable
- Replace USB Cable
PASS
No trouble
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2.1.5 USB Trouble (2/2)
Check of U21 USB
Controller
Check USB Power
Pin No. 1 5V
Check USB Cable
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2.1.6 LCD Screen Trouble (1/2)
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2.1.7 LCD Screen Trouble (2/2)
Check LCD Data &
Power Line (Sub Main)
Check LCD Data &
Power Line (LCD B/D)
Check LCD FFC Cable
Check LCD Board
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Check LCD
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2.1.8 Keypad Trouble (1/2)
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2.1.9 Keypad Trouble (2/3)
Check CPU Board
Key Data Line
& Power Line
Check FFC
Check SUB Board Key
Data Line & Power
Line
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2.1.10 Keypad Trouble (3/3)
Check I/O
Check I/O Board
Key Data Line &
Power Line
Check Keypad
Cable
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Check Keypad
Key Data Line &
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2.1.11 RTC Trouble (1/2)
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2.1.12 RTC Trouble (2/2)
Check RTC Battery
Check RTC IC
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2.1.13 Bill Module Trouble (1/3)
Bill Module Trouble
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2.1.14 Bill Module Trouble (2/3)
Check Bill Module
Check Data Cable
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2.1.15 Bill Module Trouble (3/3)
Check I/O Board
Data line
Check I/O Connecter
Check UART Chip
(U10)
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2.1.16 Printer Trouble (1/2)
Printer Trouble
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2.1.17 Printer Trouble (2/3)
Check Printer
Check Data Cable
Check I/O Board
Data line
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2.1.18 Printer Trouble (3/3)
Check I/O Connecter
Check UART Chip
(U10, U18)
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y
3. Device Maintenance
3.1 Automatic Recharger
3.1.1 Outline
3.1.2 Structure
CPU, SUB,
LCD Board
Speaker
Antenna
Keypad
Printer
SMPS
Bill Module
Batter
Power Panel
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3.1.3 Specification
1) CPU Specification
EXT_UART
USB
Controller IC
CPU Board is the core board and plays main program also control the
communication of module.
ETHERNET
RC531
S3C2440
SDRAM
CPU
- S3C2440(ARM9 Core) : 400MHz
Memory
- SDRAM : 128MByte
- Nor : 8MByte
- Nand : 512Myte
RF Module
- RC531 (Type A)
EXT_UART
- SB16C554A
USB Controller
- UBI9033
NAND FLASH
NOR FLASH
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ETHERNET
- W5100 (WIZNET)
2) SUB Main Board Specification
Communicate with CPU Board and control various I/O device.
AC97 Codec
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POWER PART
RS-232
SIM Slot
Debug
Exterior PORT
- Ethernet : 1
- USB : 1
- RS -232 : 5
: Printer 1, Bill Module1, RFID Reader1, Debug 1, Spare Port 1
SAM
- Socket 4EA(SIM Type)
-
Sound
- SW Codec control
- Speaker : 5W * 1
Input Power
- DC12V Input from I/O Board
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r
er
r
3) I/O Board Specification
Communicate with CPU Board, Sub main board and control I/O device.
Senor Connecte
I/O Connecte
KEYPAD Connect
Inside Lamp Connecter
Printer Connecter
Power Part
Bill Module Connecter
RFID Module Connecter
Spare RS-232 Connecter
Antenna LED Connecter
Sub Main Power Connecter
4) Antenna Board Specification
Recognize card connecting CPU Board RC531.
5) Keypad Specification
Power Signal Connecter
Main Power Connecter
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Transfer entered Key value through I/O Board to CPU Board.
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6) SMPS and Battery Specification
- SMPS : Supplied power from Power Panel and output DC 12/24V.
- Battery : 140W(Max) for 2minute.
7) Power Panel Specification
- Supply power from outside power.
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3.1.4 Replacement Method
1) CPU Board Separation
① Unfasten the screw which is fixed to Sub Main Bracket and let down it.
② Remove 40Ping FFC cable which is connecting LCD Board and let it down in
direction of arrow.
③ Remove 30Pin FFC cable and Antenna Cable which is connecting Sub Main Board.
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④ Unfasten fixed screw which is connecting Sub Main Board and separate Sub
Main Board.
2) Sub Main Board Separation
① Unfasten fixed screw which is connecting Sub Main Bracket and separate
Sub main Board.
② Separate Connector which is connecting Sub Main Board.
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3) I/O Board Separation
① Unfasten fixed screw connecting I/O Cover and separate in direction of arrow.
② Remove connector connecting I/O Board.
③ Unfasten fixed screw which is connecting I/O Board and separate it.
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4) KEYPAD Board Separation
① Remove Connector which is connecting.
② Separate fixed screw which is connecting KEYAPAD and separate KEYPAD.
-
5) PRINTER Separation
① Separate Connector which is connecting Printer.
② Unfasten fixed screw which is
Connected to exterior mechanism
and separate it.
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6) BILL MODUEL Separation
① Pull Silver Bar of Bill Module up and separate it in the direction of red arrow.
② Hold the bottom of Bill Module PCB and pull forward.
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7) SMPS 및 BATTERY Separation
① Separate Connector which is connecting SMPS and Battery.
② Unfasten fixed screw which is connecting to exterior and pull forward.
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8) POWER PANEL Separation
Separate the fixed screw which is connected device.
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3.1.5 Connector Specification
1) USB2.0 Cable
CON '1’
(USB2.0)
Color
1 1
CON '2’
(Sub Board J13)
2 2
3 3
4 4
2) Speaker Cable
CON '1’
'(Sub Board J11,J12)
1 WHITE 1
Color
CON '2’'
(66SF03N-
5W 4ohm)
2 BLACK 2
3) Inside Lamp Cable
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CON '1'
(Connecter Board J3)
Color
CON '2'
(INSIDE LAMP)
1 12V 2
2 GND 1
4) Main Door_SW Cable
CON '1'
(Main Door_SW)
1 BLACK 3
2 RED 2
3 WHITE 1
Color
CON '2'
(Connecter
Board_J4)
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5) SUB DOOR, CASH BOX S/W Cable
CON '1'
(SUB Door_SW)
Color
CON '2'
(Connecter
Board_J6)
COM BLACK 2
N. O WHITE 1
CON '3'
(CASH BOX_SW)
Color
CON '4'
(Connecter
Board_J9)
COM BLACK 2
N. O WHITE 1
6) MAIN IF Cable
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CON '1'
(SUB Board_J25)
Color
CON '2'
(Connecter
Board_J1)
1 1
2 2
…. ….
39 39
40 40
7) Main Serial Cable
CON '1'
(SUB Board_J16)
Color
CON '3'
(Connecter
Board_J7)
1 1
2 2
CON '2'
(SUB Board_J16)
Color
CON '3'
(Connecter
Board_J7)
1 3
2 4
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8) Main Power Cable
CON '1'
(Connector Board_J17)
Color
CON '2'
(Sub Board_J3)
1 1
2 2
3 3
4 4
5 5
6 6
9) Antenna Cable
CON '1'
(CPU Board_J23)
Color
(Antenna Board_J1)
1 RED 1
2 WHITE 2
3 BLACK 3
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CON '2'
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10) Antenna LED Cable
CON '1'
(LED Board)
Color
(Connecter Board_J12)
CON '2'
1 WHITE 1
6 BLACK 2
11) KEYPAD Cable
CON '1'
(KEYPAD Board)
Color
(Connecter Board_J2)
CON '2'
1 1
2 2
… …
29 29
30 30
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12) Printer Cable
CON '1'
(Connector Board J8)
Color
CON '2'
(PRINTER_PWR)
1 RED 1
3 BLACK 2
CON '1'
(Connector Board J8)
Color
CON '2'
(PRINTER_PWR)
4 BLACK 5
5 ORANGE 2
6 YELLOW 3
7 GREEN 6
9 BLUE 8
10 PINK 7
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13) BILL RFID READER Cable
CON '1'
(Connector Board J10)
Color
CON '2'
(BILL RFID)
1 RED 1
2 BLACK 2
3 BLUE 3
4 WHITE 4
14) BILL Module Cable
CON '1'
(Connector Board J5)
Color
1 BLACK 5
2 WHITE 11
3 BLACK 7
7 RED 6
8 GREEN 12
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CON '2'
(BILL Module)
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15) LAN Cable
CON '1'
(RJ-45)
Color
CON '2'
(RJ-45)
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
16) Power Signal Cable
CON '1'
(Connector Board J11)
Color
CON '2'
(SMPS SIGNAL)
1 RED 1
2 BLACK 2
3 BLUE 3
4 WHITE 4
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17) Power Input Cable
CON '1'
(Connector Board J19)
Color
CON '2'
(Sub Main)
1 BLACK 1
2 BLACK 2
3 BLACK 3
4 BLACK 4
5 BLACK 5
6 BLACK 6
7 RED 7
8 RED 8
9 WHITE 9
10 WHITE 10
11 WHITE 11
12 WHITE 12
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18) AC Input Cable
CON '1'
(SMPS AC IN)
Color
CON '2'
(POWER_AC OUT)
1 BROWN L
2
Greenish
yellow
F. G
3 BLUE AC_N
19) Battery Cable
CON '1'
(SMPS BATT_OUT)
Color
1 RED VCC
2 BLACK GND
20) RFID Cable
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CON '2'
(BATTERY)
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CON '1'
(SMPS BATT_OUT)
Color
CON '2'
(BATTERY)
1
2
3
4
21) FREME Ground
Red 1
Red 2
BLACK 7
BLACK 8
BLUE 3
BLUE 4
WHITE 5
WHITE 6
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3.2 Maintenance Flow chart
Error
Check ERROR CODE
Device maintenance
and replacement due to
MANUAL
Conduct
TEST
OK
NO
Repair complete
1) Tool : Screwdriver, Tester
2) Notice
- Check each part of the adjustment value for every 12months or in a tim
ely
manner.
Receive replacement
parts
Check maintenance
referral and ERROR CODE
Device repair due to
MANUAL
Conduct
TEST
NO
OK
Repair complete
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)
3) Detail check items
Inspection cycle
No Items
1
month
3months 6months 12months
Remarks
1 Power/Voltage Check
2 Operation of Printer
3 Operation of KEYPAD
4 Check of LCD Operation
5 Check of SMPS Operation
6 Check of BATTERY Operation
7 Check of BILL MODULE Operation
8 Check of POWER panel Operation
4. Automatic Recharger Installation and update
4.1 Automatic Recharger Installation
4.1.1 Procedure
No Division Contents
1
Device
registration
… … … …
1) Power ON
2) SAM Mounting Method
USB Mounting Method
3
비고
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4.1.2 Device Registration
4.1.2.1 Power ON
2
1
2
3
① Power Panel Power S/W ON
② SMPS Power S/W ON, Battery S/W ON
③ Sub Main Board S/W ON
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4.1.2.2 SAM Card Mounting
<Picture 1> <Picture 2>
① Push the SAM slot like Picture 1 and lift the cover in direction of the arrow like
picture
<Picture 3> <Picture 4>
② Combine the SAM card like picture 3 and push and fix SAM Slot in direction of the
arrow like picture 4.
③ Insert the rest of 3 slots using same method.
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4.1.2.3 USB Mounting Method
① Turn off the module
② Insert USB to USB PORT and power on
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y
5. Automatic Recharger Heavy Maintenance
5.1 CPU Board
5.1.1 CPU BOARD Specification
5.1.1.1 CPU Board Specification
CPU Board : Main board of the attended recharger and operate main program so that
control all of module communication and function.
Division Specification Remarks
CPU
Memory
RF Module ISO 14443 Type A
S3C24440
SDRAM : 128MByte
Nor Flash : 8MByte
Nand Flash : 512 MB
te
5.1.1.2 CPU Board Block Diagram
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5.1.1.3 CPU Board Check point
- KEYPAD
M_#KEY_IRQ1
KEY_5.0V
C116
100nF
C-1608
3_I
2_I
1
2
3
4
5
6
U107
74HC14D
SOIC14(P1.27-W7.0)\74HC14D
1A
VCC
1Y
2A
2Y
3A
3Y
GND74Y
14
13
6A
12
6Y
11
5A
10
5Y
9
4A
8
3
2
Test Point
M_#KEY_IRQ1
1
1K
5K
CORRECTION
7
4
2
0
8
5
10K
MENU
KIND
6
9
CANCEL
PAYMENT
REFUND
OK
TP100
TP101
TP102
TP104
TP103
TP105
TP112
TP110
TP108
TP106
TP109
TP107
M5.0V
TP118
TP116
TP114
TP120
TP119
TP117
TP115
TP1133TP111
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
21
21
22
22
23
23
24
24
25
25
26
26
27
27
28
28
29
29
30
30
DST520-030
DST520-030
① Circuit description
: Invert input signal and send it to CPU.
(Check other signal’s frame is same as others or not.)
② Waveform measurements
J100
31
31
32
32
<Normal key input waveform>
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5.1.2 Sub BOARD Specification
5.1.2.1 Sub Main Board Specification
- Communicated with CPU Board and control I/O.
riticle Specification Remarks
CPU S3C24440
SDRAM : 128MByte
Memory
RF Module ISO 14443 Type A
5.1.2.2 Sub Main Board Block Diagram
Nor Flash : 8MByte
Nand Flash : 512 MB
te
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5.1.2.3 Sub Main Check point
- RS-232
VDD_3.3V
U9
C-1005
C-1005
1
C1+
3
C1-
4
C2+
5
C2-
11
T1IN
10
T2IN
12
R1OUT
9
R2OUT
15
GND
C36 100nF
C37 100nF
DBG_TX[3]
CUSTOM_TX[3]
DBG_RX[3]
CUSTOM_RX[3]
DBG_TX
DBG_RX
R86 100R R-1005
R89 100R R-1005
R92 100R R-1005
R94 100R R-1005
VCC
T1OUT
T2OUT
R1IN
R2IN
16
2
V+
6
V-
14
7
13
8
C38 100nF
C39 100nF
C40 100nF
R87 1K R-1005
R93 1K R-1005
SP3232EY
TSSOP16
TX Test Point
C-1005
C-1005
C-1005
R91 1K R-1005
R95 1K R-1005
RX Test Point
VDD_3.3V
12
TC3
10uF/16V
TC-3216-A
R88 100R R-1005
R90 100R R-1005
CPU DEBUGER
2
3
1
J7
TSH-3813
STEREO-JACK-SH381D-PA9T-A
③ Circuit description
: Change UART signal into RS -232 signal
④ Waveform measurements
< Normal TX waveform >
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< Normal TX waveform >
- SIM Part (Clock)
SAM5.0VSAM5.0V
Y1
4
VCC
C47
100nF
C-1608
C86
100nF
C-1608
2
1 2
1 2
GND
3.6864MHz(SCO-105)
Y3
4
VCC
2
GND
3.6864MHz(SCO-105)
① Circuit description
: Circuit that supply the stable Clock to allow SIM Card to operate.
OUT
OUT
R124
1K
3
SAM5.0VSAM5.0V
3
R-1608
R201
1K
R-1608
R1003 0R R-1608
SIM_CLK1
R1002
Z_0R
R-1608
SIM_CLK2
Test Point
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② Waveform measurements
<Normal Clock Wavement>
- SIM Part (Signal)
SIM_PWR_ON1_5V
SIM_RESET_ON1_5V
SAM5.0V
R129 1K
SIM_CLK1
SIM_RX1_A
SIM_TX1_A
R-1608
Q1
SI2301DS(SOT-23)
R125
1
10K
R-1608
R134 100R
R136 100R R-1608
D4
SD103B(SOD123)
32
R-1608
R126
10K
12
1
2 3
Test Point
ZD1
Z_L16513
2
3
1
Q3
Z_MMBT3904(SOT-23)
R127
1K
R-1608
R128
1K
R-1608
C50
30pF
C-1608
C48
100nF
C-1608
SM1
GND
1
VCC
2
RST
CLK3FU1
7
SIO
9
S1
DRC017S
C51
Z_10pF
SIM SOCKET #1
C-1608
GND
VPP
FU2
5
6
4
8
10
S2
① Circuit description
: Circuit that realize to recognize SIM CARD
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② Waveform measurements
<Waveform when normally recognize SIM CARD>
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FCC Statement
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions:
(1) This device may not cause harmful interference. and
(2) This device must accept any interference received, including interference that may cause
undesired operation.
Any changes or modifications to the equipment not expressly approved by the party responsibl e for
compliance could void the user's authority to operate the equipment.
Note: This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation.
This equipment generates, uses and can radiate radio frequency energy and, if not installed and used
in accordance with the instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation. If this
equipment does cause harmful interference to radio or television reception, which can be determined
by turning the equipment off and on, the user is encouraged to try to correct the interference by one or
more of the following measures:
—Reorient or relocate the receiving antenna.
—Increase the separation between the equipment and receiver.
—Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
—Consult the dealer or an experienced radio/TV technician for help.
.
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