LG CNS KSCCCBR400A AUTOMATIC RECHARGER User Manual Manual
LG CNS CO., LTD. AUTOMATIC RECHARGER Manual
LG CNS >
Users Manual
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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Document Prepared by: Reviewed by: Approved by:
Maintenance and
Repair Manual (Heavy)
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Document History
Previous
Version Present
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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
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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
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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
[Automatic Recharger]
390mm (W) 440mm (D)
1500mm (H)
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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
Automatic Recharger
Name Explanation
1) 4.3’ LCD Display of operation information
2) RFID Antenna ISO14443 Type A, 13.56MHz card recognition and
charging
3) Bill Module 6 varieties of colombia bill
Insert each 1 bill
1
)
2
)
3
)
390mm (W) 440mm (D)
1500mm (H)
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1.2.3 Internal Structure
Bill Module
Batter
y
Power Panel
RF Antenna
Keypad
Printer
SMPS
CPU, SUB,
LCD Board
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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)
<Power Panel>
<SMPS>
<Connecter Board>
Output Voltage
AC 110V
Check
Output Voltage
DC12V Check
Output Voltage
DC12V Check
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2.1.3 Power Supply (3/3)
Fuse
(
F1
)
Check
U3 Out
p
ut 5V Check
U5 Out
p
ut 5V Check
U2 Out
p
ut 8V Check
U28 Output 3.3V
Check
U1 Out
p
ut 5V Check
U4 Out
p
ut 3.3V Check
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2.1.4 USB Trouble (1/2)
Cannot update USB
- Replace USB Memory stick
Check USB Memory
from PC
FAIL
Check USB file system
(
FAT32 is not
FAIL
PASS
- Format USB by FAT file system
PASS
Check CPU board USB
host controller IC(U12)
FAIL
- Replace CPU PCB
PASS
Check USB power
PASS
- Replace SUB Main PCB
FAIL
No trouble
PASS
Check USB Cable - Replace USB Cable
FAIL
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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
Check LCD Board
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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
Cable
Check SUB Board Key
Data Line & Power
Line
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2.1.10 Keypad Trouble (3/3)
Check I/O
Connector Cable
Check I/O Board
Key Data Line &
Power Line
Check Keypad
Cable
Check Keypad
Key Data Line &
Power 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 UART Chip
(U10)
Check I/O Connecter
Check I/O Board
Data line
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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 I/O Board
Data line
Check Data Cable
Check Printer
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2.1.18 Printer Trouble (3/3)
Check UART Chip
(U10, U18)
Check I/O Connecter
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3. Device Maintenance
3.1 Automatic Recharger
3.1.1 Outline
3.1.2 Structure
Bill Module
Batter
y
Power Panel
Antenna
Keypad
Printer
SMPS
CPU, SUB,
LCD Board
Speaker
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3.1.3 Specification
1) CPU Specification
CPU Board is the core board and plays main program also control the
communication of module.
CPU
- S3C2440(ARM9 Core) : 400MHz
Memory
- SDRAM : 128MByte
- Nor : 8MByte
- Nand : 512Myte
RF Module
- RC531 (Type A)
EXT_UART
- SB16C554A
USB Controller
- UBI9033
EXT
_
UART
USB
Controller IC
S3C2440
RC531
ETHERNET
NAND FLASH
NOR FLASH
SDRAM
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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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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
SIM Slot
RS-232
POWER PART
Power
Debug
USB
Ethernet
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3) I/O Board Specification
Communicate with CPU Board, Sub main board and control I/O device.
4) Antenna Board Specification
Recognize card connecting CPU Board RC531.
5) Keypad Specification
I/O Connecte
r
KEYPAD
Co
nn
ec
t
er
Senor Connecte
r
Power Part
Inside Lamp Connecter
Printer Connecter
Bill Module Connecter
RFID Module Connecter
Spare RS-232 Connecter
Antenna LED Connecter
Sub Main Power Connecter
Main Power Connecter
Power Signal 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 CON '2’
(Sub Board J13)
1 1
2 2
3 3
4 4
2) Speaker Cable
CON '1’
'(Sub Board J11,J12) Color CON '2’'
(66SF03N-
5W 4ohm)
1 WHITE 1
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) Color CON '2'
(Connecter
Board_J4)
1 BLACK 3
2 RED 2
3 WHITE 1
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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 CON '2'
(Antenna Board_J1)
1 RED 1
2 WHITE 2
3 BLACK 3
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10) Antenna LED Cable
CON '1'
(LED Board) Color CON '2'
(Connecter Board_J12)
1 WHITE 1
6 BLACK 2
11) KEYPAD Cable
CON '1'
(KEYPAD Board) Color CON '2'
(Connecter Board_J2)
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 CON '2'
(BILL Module)
1 BLACK 5
2 WHITE 11
3 BLACK 7
7 RED 6
8 GREEN 12
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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 CON '2'
(BATTERY)
1 RED VCC
2 BLACK GND
20) RFID Cable
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CON '1'
(SMPS BATT_OUT) Color CON '2'
(BATTERY)
1 Red 1
Red 2
2 BLACK 7
BLACK 8
3 BLUE 3
BLUE 4
4 WHITE 5
WHITE 6
21) FREME Ground
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3.2 Maintenance Flow chart
1) Tool : Screwdriver, Tester
2) Notice
- Check each part of the adjustment value for every 12months or in a tim
ely
manner.
Conduct
TEST
Erro
r
Check ERROR CODE
Device maintenance
and replacement due to
MANUAL
Repair complete
OK NO
Conduct
TEST
Receive replacement
parts
Check maintenance
referral and ERROR CODE
Device repair due to
MANUAL
Repair complete
OK NO
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3) Detail check items
No Items Inspection c
y
cle Remarks
1
month 3months 6months 12months
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 비고
1
Device
registration
1) Power ON
2) SAM Mounting Method
3
)
USB Mountin
g
Method
… … … …
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4.1.2 Device Registration
4.1.2.1 Power ON
① Power Panel Power S/W ON
② SMPS Power S/W ON, Battery S/W ON
③ Sub Main Board S/W ON
1
2
2
3
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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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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
S3C24440
Memory SDRAM : 128MByte
Nor Flash : 8MByte
Nand Flash : 512 MB
y
te
RF Module ISO 14443 Type A
5.1.1.2 CPU Board Block Diagram
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5.1.1.3 CPU Board Check point
- KEYPAD
TP100
TP103
TP102
TP101
2
7
2
U107
74HC14D
SOIC14(P1.27-W7.0)\74HC14D
1A
1
1Y
2
2A
3
2Y
4
3A
5
3Y
6
GND
74Y 8
4A 9
5Y 10
5A 11
6Y 12
6A 13
VCC 14
KEY_5.0V
C116
100nF
C-1608
MENU
M_#KEY_IRQ1
4
10K
CORRECTION
5K
TP119
TP118
J100
DST520-030
DST520-030
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 31 31
32 32
M5.0V
3_I
2_I
1K
TP116
TP117
KIND
REFUND
CANCEL
6
9
8
0
OK
5
M_#KEY_IRQ1
1
TP115
TP114
TP112
TP113
3
TP111
TP110
PAYMENT
TP108
TP109
TP120
TP107
TP106
TP104
TP105
3
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
<Normal key input waveform>
Test Point
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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.
A
riticle Specification Remarks
CPU S3C24440
Memory SDRAM : 128MByte
Nor Flash : 8MByte
Nand Flash : 512 MB
y
te
RF Module ISO 14443 Type A
5.1.2.2 Sub Main Board Block Diagram
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5.1.2.3 Sub Main Check point
- RS-232
③ Circuit description
: Change UART signal into RS -232 signal
④ Waveform measurements
< Normal TX waveform >
CUSTOM_RX[3]
VDD_3.3V
TC3
10uF/16V
TC-3216-A
12
CUSTOM_TX[3]
VDD_3.3V
R91 1K R-1005 R88 100R R-1005
R95 1K R-1005
R90 100R R-1005
C39 100nF
C-1005
CPU DEBUGER
DBG_TX[3] DBG_TX
DBG_RX[3] DBG_RX
J7
TSH-3813
STEREO-JACK-SH381D-PA9T-A
2
3
1
C37 100nF
C-1005
C38 100nF
C-1005
R86 100R R-1005
R92 100R R-1005
R87 1K R-1005
C36 100nF
C-1005
R93 1K R-1005
U9
SP3232EY
TSSOP16
C1+
1
C1-
3
C2+
4
C2-
5
T1IN
11
T2IN
10
R1OUT
12
R2OUT
9
GND
15
T1OUT 14
T2OUT 7
R1IN 13
R2IN 8
VCC 16
V- 6
V+ 2
R89 100R R-1005
R94 100R R-1005
C40 100nF
C-1005
TX Test Point
RX Test Point
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< Normal TX waveform >
- SIM Part (Clock)
SAM5.0VSAM5.0V
SIM_CLK2
R201
1K
R-1608
C86
100nF
C-1608
1 2
Y3
3.6864MHz(SCO-105)
VCC
4
OUT 3
GND
2
SAM5.0VSAM5.0V
C47
100nF
C-1608
1 2
SIM_CLK1
Y1
3.6864MHz(SCO-105)
VCC
4
OUT 3
GND
2
R124
1K
R-1608
R1002
Z_0R
R-1608
R1003 0R R-1608
① Circuit description
: Circuit that supply the stable Clock to allow SIM Card to operate.
Test Point
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② Waveform measurements
<Normal Clock Wavement>
- SIM Part (Signal)
GND
R125
10K
R-1608
C50
30pF
C-1608
R136 100R R-1608
Q3
Z_MMBT3904(SOT-23)
1
2 3
C48
100nF
C-1608
R129 1K
R-1608
R126
10K
D4
SD103B(SOD123)
12
R127
1K
R-1608
Q1
SI2301DS(SOT-23)
1
32
R128
1K
R-1608
31
2
ZD1
Z_L16513
SIM_PWR_ON1_5V
SAM5.0V
SIM_RX1_A
SIM SOCKET #1
SIM_RESET_ON1_5V
SIM_TX1_A
R134 100R
R-1608
SIM_CLK1
SM1
DRC017S
VCC
1
RST
2
CLK
3FU1 4
GND 5
VPP 6
SIO
7FU2 8
S1
9S2 10
C51
Z_10pF
C-1608
① Circuit description
: Circuit that realize to recognize SIM CARD
Test Point
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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 responsible 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.
.