HARDWARE TRAINING

ATM - First Level Maintenance

PT.DIEBOLD INDONESIA
German Center 1st Floor
Jl. Kapt. Subijanto Dj. Blok COA No.1
BSD-Tengerang

( Office :021-531 532 01

( Call Center : 021-531 531 81
Materi Training
1. OPTEVA SERIES TERMINAL
2. TOP CHASSIS MODULES
- LCD
- Card Reader
- Thermal Printer
- CPU
- TCM
- EPP
- Power & USB Hub

3. BOTTOM CHASSIS MODULES

- Lock Combinations
- Power Supply
- Cassettes
- AFD Modules
- CCA AFD

4. Opeteva Service Diagnostics

 OPTEVA Series Terminal
520 510 500
Front Load / Real Load Lobby Front Load Lobby Front Load Lobby
 TOP CHASSIS - Switches

Switch Maintenance & Power

Opteva 500 / 510 FL

Switch Maintenance & Power

Opteva 520 FL
 TOP CHASSIS - LCD
Two-color status LED located on display interface CCA
Colors are green & yellow
Visible through ventilation holes in CCA cover
Used for troubleshooting
Reference section 2 in the consumer display on-site
service manual
• 15 inch / 10 inch diagonal LCD panel
– Thin Film Transistor (TFT) active matrix technology
• Backlight module
– Two lamps (LCD)
– Seven lamps (SLVD)
• Inverter CCA
– Provides power for the fluorescent lamps
– One in LCD module
– Three in SLVD module
 The Sunlight Viewable Display
LCD Consumer
Display Only Parts
1- Touch Screen
2- 15” LCD Display
4- Fan Kit
6- Inverter CCA
8- Backlight Lamps
 The Sunlight Viewable Display
Inside T2° Outside
Vandal
Inverter glass

T1°
Fan

TFT
Neon
LCD
Array

Lamp brightness sensor External brightness

Thermal sensor sensor
 TOP CHASSIS - LCD
1 Fascia cabling bracket
2 Monitor support bracket
3 DVI cable connector access holes
4 Consumer monitor cables
5 Monitor retainer bracket
6 Monitor retainer bracket mounting hardware
7 Fascia cabling bracket mounting hardware
 TOP CHASSIS - LCD
• There are three CCAs in the service display

1. Inverter DC to AC CCA
2. DCC/DC Power CCA
3. Receiver CCA

1 Four screws and washers

2 Air Filter CoverFan Support
 TOP CHASSIS - LCD
• Sunlight Viewable Display Module
– LCD panel +50º F to +140º F temperature range
– Display brightness 1500 cd
– Power consumption 75 W
• Consumer Display Module
– Operating temperature +50º F to +140 F
– Display brightness 200 cd
– Power consumption 30 W
• Service Display
– Brightness 150 cd
LCD Diagnostics
LCD Diagnostics
 TOP CHASSIS - Card Reader
• Sankyo, low cost, high reliability R/W
• Read/Write
• Tracks 1-2-3
• High & low coercivity cards
• Bi-directional reader
• 24vdc Supply Voltage
• USB Interface to Processor
• Retained Card Bin
• Secure
• Non-Secure
• Digital Decoding Capability
• Head wear detection
• Chip Station
 TOP CHASSIS - Card Reader
• PM performed on routine service calls
– Remove & clean with compressed air
– Clean read/write heads with alcohol cards
• SPINS part
– Clean rollers with alcohol and/or alcohol cards
– Perform only approved, necessary adjustments as listed in the
Motorized Card Reader/Writer Service Manual
– Replace module if necessary
TOP CHASSIS - Card Reader

There are very limited replaceable parts for

the Motorized Card R/W

Replaceable parts include:

• Timing Belt
• Motor Assembly
• Outer Bezel Assembly
TOP CHASSIS - Card Reader
DIAGNOSTICS- Card Reader
DIAGNOSTICS- Card Reader
DIAGNOSTICS- Card Reader
DIAGNOSTICS- Card Reader
DIAGNOSTICS- Card Reader
DIAGNOSTICS- Card Reader
TOP CHASSIS - Thermal Printer
• Print Mechanism
– 80 mm Thermal
– Two color printing
– Black/Red
– Mounted to
Transport
 TOP CHASSIS - Thermal Printer
Print Mechanism
–Compact / Lightweight
–Dual CCA’s
–Integral Cutter
–Platen Stepper Motor
–TOF or Blank Paper
–Printed side down
–Dot density
203 DPI
–Print speed
150 mm / second (6 inches)
 TOP CHASSIS - Thermal Printer

Print Mechanism
–Two CCA’s control
–The printer
–Transport Stepper Motor
–Communications
-and-
–Generate local voltages from 24v
supply
–Monitor Printer Sensors
 TOP CHASSIS - Thermal Printer
Print Mechanism
– Bi-directional Transport Stepper Motor
– Self-aligning Integrated Fascia Interface Funnel
– USB Communications
– Auto Load
– Retract Bin
 TOP CHASSIS - Thermal Printer
Print Mechanism
– Contained within the Print Engine
– TOF Sensor
– Paper-out Switch
– Printer Open Switch
– Cutter Home Sensor

TOF Sensor Printer Open Switch

 TOP CHASSIS - Thermal Printer
Two Paper Low Positions
– 2 Position Paper Low Sensor
– Transport Exit Sensor
– Floating Integrated Fascia
Funnel
– Auto-load Entry Guide

Transport
Exit Sensor
 TOP CHASSIS - Thermal Printer
– Cutter drive mechanism
– Cutter blades
– Cutter position detection
switch

Cutter Position Detection Switch

 TOP CHASSIS - Thermal Printer
Part of printer base
Capacity
– 60 forms of same length
– 25 forms of various length
Maximum retracted form length
– Six inches
Retract Gate

Retract Gate
 TOP CHASSIS - Thermal Printer
Rolled paper
– 254 mm (10 inches)
Paper low sensor
– Two position settings
– Modulated infrared light

Two Paper Low

Positions
 TOP CHASSIS - Thermal Printer
Print Mechanism
Controller CCA Daughter CCA
Print Head
– Supports power conversion Interconnect
from 24 VDC input to local
voltages
– USB communication
Controls
– Printing and Cutting
– Presenting and Retracting
– Purging and status
information

Power USB Port Form Feed Switch

 TOP CHASSIS - Thermal Printer
Three Controller CCA LED’s
– Green Power LED Power LED
– Red Paper Roll End LED
– Off – Normal
– On – Near end detected
– Blinking - Self-test standby
state
– Red Error LED
– On – Off-line
– Off – Normal
– Blinking - Error

Error LED Paper Roll End LED

 TOP CHASSIS - Thermal Printer
Transport Exit and Lead-through
Daughter CCA Paper-low Sensors Indicator
Controls
– Transport Motor
– Lead-through Indicator
Accepts inputs from
– Roll Near End or Paper-low
Sensor
– Transport Exit Sensor

Controller CCA Transport Motor

Interconnect
 TOP CHASSIS - Thermal Printer
Transport Motor
Transport Belts / Shafts
Transport Retract Gate / Idler Roller
Transport Bezel
Transport Exit Sensor
 TOP CHASSIS - Thermal Printer
No adjustments required for
the printer or the
transport
Printer Mechanism
Transport Assembly
Printer Control CCA
Daughter CCA
Paper Low Sensor
Thermal Printer Diagnostics
Thermal Printer Diagnostics
 TOP CHASSIS - CPU
• DVI
• Combined Digital and Analog signals
• DVI-D
• Digital signal only DVI

DVI-D
 TOP CHASSIS - CPU
• The Motherboard
– Based on 845G Chipset
– Pentium 4 Processor
• μPGA478 socket
– System Bus speed of 400/533
MHz
– ATX Form Factor
• ECP - Extended Capabilities Port
• EPP – Enhanced Parallel Port
• FWH – Firmware Hub
• GMCH – Graphics & Memory
Controller Hub
• ICH4 – I/O Controller Hub w/AHA
Bus
• PLC – Platform LAN Connect
• S3 – Suspend-to-RAM (Sleep
State)
• SPD – Serial Presence Detect
• WfM – Wired for Management
 TOP CHASSIS – DVI Card
• Restricted access to
– BIOS Setup
• Supervisor password required
– Alternate Boot Media Menu
• ATM password required
• Press F12 during POST
• Two (2) ways to clear passwords
– Using a valid password and then setting no password
– Configuration of jumper J9H2
• Set 2 to 3
• PCI Secondary Digital Display
Card
– Secondary Digital Video
Interface
• DVI Digital Port
• Optional Operator Display
VGA Port
 TOP CHASSIS – ABC Card
• High Side Communication Card
– Serial Communication
– Supports Diebold High Side Communications LED
– Used with Agilis Base Communication
• ABC
– Supports wide array of protocols
– LED connected to RTS signal
 TOP CHASSIS - TCM
• Jumper
Blocks
Item Description Reference
Designator
1 BIOS Setup J9H2
Configuration
Jumper Block
2 Front Panel Audio J8A1
Connector Jumper
Block

• Battery type
– Maintenance-free sealed Lead-Acid Leak proof
– 8 hour typical recharge time
– 3-6 year life expectancy
 TOP CHASSIS - CPU

Backenridge Denver
 TOP CHASSIS – USB & Power HUB
USB HUB 4 or 7 Ports

POWER HUB 12 Ports (24VDC)

 TOP CHASSIS – EPP4/5

• EPP4 Supports various Algorithms:

– DES
– 3DES
– MAC
– Various PIN block formats
• The Encrypting PIN Pad Four (EPP4) consists of a base secure module with hardened
keypad and a country specific legend set.
• The secure module is available with either a large or a small keyboard.
 TOP CHASSIS – EPP4/5
– 16 key stainless steel keyboard
– Tamper resistant case PIN Description Direction
– Microprocessor with DES and RSA engine
1 Not Connected
– Battery-backed RAM
2 -USB Signal
– Designed to replace the standard keyboard
and the EPP2 3 +USM Signal
– The EPP4 is available in Two Sizes 4 Common Ground
– EPP4 is a self-powered device.
– Requires voltage between 10.8 and 26.4
– The connector is a USB type B receptacle according to
the USB 1.1 specification.
– The connector has a top entry (perpendicular to the
PCB).
– The pin layout and connector details are:
TOP CHASSIS – EPP4/5
 TOP CHASSIS – EPP4/5
Power connector
USB connector
To Function keyboards

Db 9 connector

Beeper and LEDs

TOP CHASSIS – EPP4/5 Diagnostics
TOP CHASSIS – EPP4/5 Diagnostics
TOP CHASSIS – EPP4/5 Diagnostics
TOP CHASSIS – TCM
USB HUB

TCM

Power Supply
TOP CHASSIS – TCM

Processor shelf

Housing
TOP CHASSIS – TCM

TCM CCA

DC Distribution

USB Hub
TOP CHASSIS – TCM
TOP CHASSIS – TCM
TOP CHASSIS – TCM Diagnostics
TOP CHASSIS – TCM Diagnostics
BOTTOM CHASSIS – Power Supply

OutPut Connectors
J1, J2, J3 ------ + 48 Volt
(Pin 1&2 --- 48 Volt)
(Pin 3&4 --- Return)

J4, J5 ------ 24 Volt

(Pin 1 --- 24 Volt)
(Pin 2 --- Return)
BOTTOM CHASSIS – AFD Modules
 BOTTOM CHASSIS – AFD Modules
• Front Load or Rear Load Presenter
Type Dispenser
• Up to 5 Feed Channels (Picker
Modules)
• 2 types of Cassettes
– Convenient
– Tamper Indicating
• Picks, Stacks, and Transports Media
to Consumer
• Retracted Media is placed in a
Partitioned Divert/Retract Cassette

1 Transport Module
2 Stacker Module
3 CCA
4 Picker Modules (1-5)
BOTTOM CHASSIS – AFD Modules
BOTTOM CHASSIS – AFD Modules
Transport

Left side – top view

Right side – top view

Left side – bottom view

BOTTOM CHASSIS – AFD Modules
Stacker

Left Side view

Right Side view

BOTTOM CHASSIS – AFD Modules
Stacker

Beveled end plate

Rollers
BOTTOM CHASSIS – AFD Modules

Stacker

Divert/Retract Cassette
Latch pin

Divert/Retract Cassette
Present switch
BOTTOM CHASSIS – AFD Modules

Partition follower
 BOTTOM CHASSIS – AFD Modules
Standby Position

Partition
follower Divert Door
Tampak Tampak
dari Luar Luar

Partition
Drive Link Divert Door
Tampak Tampak
dari Dalam
Dalam
 BOTTOM CHASSIS – AFD Modules
Penanganan problem First Level Maintenance :
1. Adjust Stop Bill sesuai dengan Uang yang digunakan dengan
melihat posisi berhentinya Push Plate (no. 1,3,4 & 5)
2. Divert Tambour Door harus terbuka jika sudah masuk dispenser (no. 6)
3. Perhatikan pergerakan Push Plate ketika dispenser berfunfsi (no. 2 & 3)

2 3

4
5
6
BOTTOM CHASSIS – AFD Modules
Picker

Keyboard matrix
assembly with integrated
Non-adjustable
double detect assembly

Feed wheel assembly

BOTTOM CHASSIS – AFD Modules
Picker

Feed wheel frame finger with

bearing

Feed wheel stepper motor

Module release tabs

Feed wheel frame finger with

bearing
BOTTOM CHASSIS – AFD Cassette
Cassettes
– Large cassette capacity at (340mm) 13.38 inches
Max. 2800 lembar
– Locking or non-locking options for both high and low security needs

Tampak belakang
 BOTTOM CHASSIS – AFD Cassette
Cassette Button Configurations

MP LB SB D2 D1 D0

H2 H1 H0

Basic Configuration Button Denom

D2 0 D1 0 D0 0 Denom

0 0 1 A

0 1 0 B

0 1 1 C

1 0 0 D

1 0 1 E

1 1 0 F

1 1 1 G

1 = Button YES
0 = Button NO
BOTTOM CHASSIS – AFD Cassette

Upper Rail

Akibat Pemasangan Upper rail salah !!!

BOTTOM CHASSIS – AFD Cassette
Divert/Retract Cassette

Lid with partition

Tambour door

Body
BOTTOM CHASSIS – AFD Cassette

Divert/Retract Cassette

1 Mylar divider
2 Partition
3 Partition drive link
4 Partition lock assy.
5 Partition ramp
 BOTTOM CHASSIS – CCA AFD
–Dispenser Control CCA
– Mounted on side of dispenser
– Contains control circuitry and
firmware
–Firmware
– Controls dispense operations
– Reads currency cassette information
– Contains routines to handle:
• communications
• mispicks
• come-alongs
• short notes
• double notes
• long notes
• motor drive pulse sequence
commands
 BOTTOM CHASSIS – CCA AFD
CCA
1 J1 Stacker brushless DC Motor
2 Fuse F1 and associated LED
3 J2 Stacker Sensor Harness
4 J3 Transport Sensor Harness
5 Status LED’s
6 S1 remain in boot load
7 S2 reset
8 J20 (reserved)
9 Picker 1-5 Stepper Motor
10 Picker 1-5 keyboard cable
11 J13 Stacker Cam Motor
12 J10 Stacker Push Plate Motor
13 Fuse F2 and associated LED
14 J5 USB
15 J4 Power and associated LED
BOTTOM CHASSIS – AFD Re-asembly
BOTTOM CHASSIS – AFD Re-asembly
BOTTOM CHASSIS – AFD Re-asembly
BOTTOM CHASSIS – AFD Re-asembly
BOTTOM CHASSIS – AFD Re-asembly
BOTTOM CHASSIS – AFD Re-asembly
BOTTOM CHASSIS – AFD Re-asembly
BOTTOM CHASSIS – AFD Re-asembly
PM/CM Analisa Diagnostics LOG
THANK YOU