Upper Control Card Repair Manual

Copyright ©Diebold, Incorporated

TM-000545-001B PD 7336
January 2015

CONFIDENTIAL - Trade Secret Material

Only Diebold and entities granted an express written license by Diebold may possess or use this
material. Unauthorized possession or use is illegal and is punishable by fine and/or imprisonment.

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Document History
Document Number Date Remarks
TM-000545-001A 12/2014 Original edition
TM-000545-001B 1/2015 Corrected part number in Table 8-1

Section 1
Introduction

1.1 Audience

This service manual is intended for technicians trained to service the Upper Control Card (UCC) as part of
the terminal alarm system.

1.2 Information Covered in this Manual

This manual provides service information for the UCC. This manual also describes the following
information about the UCC:

• Functional requirements
• Communications capability
• Physical characteristics
• Electrical characteristics
• Embedded software
• On-board memory capacities
• USB interface
• Maintenance
• Troubleshooting
• Component pin out illustrations
Section 2
Upper Control Card Functional Requirements

2.1 UCC Functionality

The UCC provides input and output connections for the following:

• Upper chassis intrusion switches

• USB connections
• UCC inputs
• UCC outputs
• Signage port
• LED status indicators
• Board mounted sensors
• Service interface

2.1.1 Upper Chassis Intrusion Switches

The upper chassis is provided with two intrusion switches (primary and secondary) ports. The switch
circuits are normally closed (N.C.). These circuits will open when the fascia is opened (primary) or the
upper chassis rear access door is open (secondary). The signals are processed at the Upper Control
Card (UCC) and routed via the switch panel mount to the Lower Control Card (LCC) and the Alarm Out
interface cable.

2.1.2 USB Connections

The following USB connections are provided on the UCC:

• A USB B connection to the ATM processor platform.

• Two service USB ports for key board and external media device.
• One service USB port for ValiTech token service tool identification and authorization.
• Six ATM internally facing USB ports for:
o Upper chassis hub
o Safe hub
o OSI
o K61 microcontroller
o Spare ports for additional devices

Provide the ability to disable individual USB ports by command. May be accomplished by disabling
enumeration or disabling USB power, VBUS.

2.1.3 UCC Inputs

The UCC input features are as follows:

• Provide locking power connector that includes discrete lines connected to the ATM power switch
which will be connected directly to the ATM AC/DC module.
• Provide Upper Chassis Intrusion alarming capabilities by:
o Provide connection for safe door open/close monitoring used in maintenance operations
o Provide a door open/close port for primary entry, entry indicated by high logic
o Provide a door open/close port for secondary entry, entry indicated by high logic
• Provide four spare contacts for 5 VDC logic input as follows:
o IN1, J23 is allocated to equipment tray 1 closure switch
o IN2, J24, is allocated to equipment tray 2 closure switch in terminals with two equipment
trays in the upper chassis
o IN3, J25 is not allocated
o IN4, J26 is not allocated
• Provide (2) inputs for external sensor boards powered by the UCC.

2.1.4 UCC Outputs

The output UCC features are as follows:

• Provide two contacts in the power connector for the power switch signal from the UCC input
section.
• Provide a lock solenoid connection port.
• Provide signage output port used to activate signage light.
• Provide connector for remote status indicators, to include out of service, in service and supplies
low indicators.
• Provide four spare output contacts for 24 VDC output.

2.1.5 Signage Port

The signage port has the following electrical characteristics:

• Minimum voltage rating of 30 VDC.

• Operating voltage of 24 VDC.
• Maximum sinking current 100% on time of 1.2 amps.
• A typical drive greater than or equal to 0.8 amp @ 24 VDC.

2.1.6 LED Status Indicators

UCC Power and Alarm status LEDs are as follows:

• Terminal shutdown with alarms still active, weekend mode. GREEN blink rate of one per second
while in weekend mode and six per second indication to release MOM switch.
 • AC present in terminal indicated by GREEN LED controlled by AC/DC module.
• UCC board happy lights to indicate normal operation of UCC as follows:
o GREEN LED indicates U-controller is operating properly
o YELLOW LED indicates the terminal needs service
o RED LED indicate the U-controller is not operating correctly
• GREEN LED continuous for microcontroller operating.
• A BLUE LED on each USB port to indicate VBUS present.
• A GREEN LED on each USB port to indicate USB port enumeration.

2.1.7 Service Interface

UCC and cover will be used for the primary service entry into the ATM and provide the following:

• Contacts for a rocker power switch.

• Contacts for a momentary action maintenance switch.
• Contacts for a momentary action idle power switch to power off terminal functions as a power
savings mode for weekend operations.
• USB ports as defined in Section 2.1.2.
• All indicator LEDs will be visible with the UCC cover installed.

2.1.8 Board Mounted Sensors

The following UCC sensors are installed:

• An ambient temperature sensor with an accuracy of +/- 2 degrees centigrade reported to Agilis
Module Interface (AMI) by an unsolicited message.
• A tilt sensor to monitor ATM mounting angle. A solicited message is generated and
communicated to the LCC via AMI when the UCC detects a 10 degree change in angle from the
last INIT value of the ATM.

2.2 Upper Control Card (UCC) USB Communications Capability

2.2.1 General Requirements

The UCC USB will:

• Be configured using the Agilis Configuration Utility (ACU).

• Allow provisioning as defined in the Module Provisioning Infrastructure Software Requirements
Specification (SRS).
• Utilize a message format in accordance with the Light Weight Communication Bus document set.
• Support SPEAR 2.0 communications protocol.
• Provide nonvolatile storage space for Authorization codes for the terminal.
• Provide nonvolatile storage space for a module pairing table.
2.2.2 USB Communications Overview

The UCC USB hub will:

• Attach to the host PC platform.

• Attach to third-party USB device(s).
• Use the Diebold modules device driver (DBDUSB) for USB device communication.
• Use a VID/PID as designated by Diebold's internal pool of available IDs.

2.2.3 Messaging

UCC shall generate the following USB event status messages and send as unsolicited messages to AMI
and forwarded by AMI to the listed device as follows:

• Service Door Open - AMI.

• Service Door Closed - AMI.
• Fascia Door Open - AMI.
• Fascia Door Closed - AMI.
• Maintenance Switch Activated - AMI.
• Authorized Access Granted - AMI and LCC.
• Terminal Tilt Alarm, exceeding alarm limit - AMI and LCC.
• Lock Solenoid Engaged - AMI.
• Event status change for attached devices - AMI and LCC.
• Environmental status (temperature/tilt) - sent in response to any AMI received message.

2.2.4 Data Logging

The UCC will maintain and store all time stamped log files (two megabytes of nonvolatile memory
available) that are accessible as an AMI solicited message and includes the following:

• Sensor events.
• USB events.
• System events.
• Error status.

The UCC also provides access to AMI to module pairing table by access request message.

2.3 Physical Characteristics

The UCC CCA is assembled as a module that includes the cover, switches and labels.

2.3.1 Board Mounted Connectors and Switches

The UCC circuit card assembly provides connectivity via twenty-six (26) board mounted Connectors and
two (2) operator switches. Refer to Table 2-1 for Connector pin information. See Figure 2-1 for locations
on the UCC.

Table 2-1 UCC Connectors and Switches

Connector
Number Description Pin
J1 Power connector, 8 circuit Pin 1 - 24V RETURN
Pin 2 - SW OFF
Pin 3 - AC/DC GOOD
Pin 4 - LED RETURN
Pin 5 - +24V
Pin 6 - SW ON
Pin 7 - NC
Pin 8 - AC LED
J2 Door ports, 3 circuit Pin 1 - SECONDARY DOOR
Pin 2 - PRIMARY DOOR
Pin 3 - +5VDC
J3 RSI output, 5 circuit Pin 1 - IN SERVICE LED
Pin 2 - SUPPLIES LOW LED
Pin 3 - OUT OF SERVICE LED
Pin 4 - RETURN
Pin 5 - 24V
J4 Signage control, 3 circuit Pin 1 - SIGNAGE CONTROL
Pin 2 - RETURN
Pin 3 - 24VDC
J5 Door ports, 6 circuit Pin 1 - UCI PRI N.O.
Pin 2 - UCI PRI N.C.
Pin 3 - UCI SEC N.O.
Pin 4 - UCI SEC COM
Pin 5 - SAFE_DOOR N.O.
Pin 6- SAFE_DOOR_COM
J6 Tamper resistant switches, 7 circuit Pin 1 - 5V
Pin 2 - SW_SP10_SS_SCLK
Pin 3 - SW_SP10_SS_MOSI
Pin 4 - SW_SP10_SS_MISO
Pin 5 - SW_SP10_SS_PRIMARY
Pin 6 -
SW_SP10_SS_SECONDARY
Pin 7 - RETURN
J7 USB_B connector, circuit Pin 1 - VBUS
Pin 2 - DM
Pin 3 - DP
Pin 4 - GND
J8 Safe hub/Top Hat hub, USB_A_dual connector, Pin A1 - VBUS
8 circuit Pin A2 - DM
Pin A3 - DP
Pin A4 - GND
Pin B1 - VBUS
Pin B2 - DM
Pin B3 - DP
Pin B4 - GND
J9 OSI/Camera USB_A_dual connector, 8 circuit Pin A1 - VBUS
Pin A2 - DM
Pin A3 - DP
Pin A4 - GND
Pin B1 - VBUS
Pin B2 - DM
Pin B3 - DP
Pin B4 - GND
J10 Spare/Entry Keypad USB_A_dual connector, 8 Pin A1 - VBUS
circuit Pin A2 - DM
Pin A3 - DP
Pin A4 - GND
Pin B1 - VBUS
Pin B2 - DM
Pin B3 - DP
Pin B4 - GND
J11 Keyboard/DVD USB_A_dual connector, 8 circuit Pin A1 - VBUS
Pin A2 - DM
Pin A3 - DP
Pin A4 - GND
Pin B1 - VBUS
Pin B2 - DM
Pin B3 - DP
Pin B4 - GND
J12 Valitech, USB_A, 4 circuit Pin 1 - VBUS
Pin 2 - DM
Pin 3 - DP
 Pin 4 - GND
J13 Terminal power switch, 4 circuit Pin 1 - SW_ON_LOOP
Pin 2 - LED RETURN
Pin 3 - SW OFF
Pin 4 - GND
J14 Idle mode switch, 3 circuit Pin 1 - SWITCH_ON_LOOP
Pin 2 - N.C.
Pin 3 - SW_ON_LOOP
J15 Maintenance switch, 2 circuit Pin 1 - MAINT_SW
Pin 2 - GND
J16 Not used
J17 RS232 port, 6 circuit Pin 1 - UART2_TXD
Pin 2 - UART2_RTS
Pin 3 - 3.3V
Pin 4 - UART2_RXD
Pin 5 - UART2_CTS
Pin 6 - GND
J18 Spare outputs, 3 circuit Pin 1 - SPARE_OUT
Pin 2 - GND
Pin 3 - 24V
J19 Spare outputs, 3 circuit Pin 1 - SPARE_OUT
Pin 2 - GND
Pin 3 - 24V
J20 Spare outputs, 3 circuit Pin 1 - SPARE_OUT
Pin 2 - GND
Pin 3 - 24V
J21 Spare outputs, 3 circuit Pin 1 - SPARE_OUT
Pin 2 - GND
Pin 3 - 24V
J22 Solenoid drive, 3 circuit Pin 1 - SPARE_SOLENOID
Pin 2 - GND
Pin 3 - 24V
J23 Spare inputs, 3 circuit Pin 1 - 5V
Pin 2 - SPARE_IN1
J24 Spare inputs, 3 circuit Pin 1 - 5V
Pin 2 - SPARE_IN2
J25 Spare inputs, 3 circuit Pin 1 - 5V
Pin 2 - SPARE_IN3
J26 Spare inputs, 3 circuit Pin 1 - 5V
 Pin 2 - SPARE_IN4
S1 Reset switch

Figure 2-1 Upper Control Card (UCC) Connectors

1 UCC CCA 16 Connector J21

2 Connector J12 17 Connector J5
3 Connector J11 18 Connector J26
4 Connector J15 19 Connector J25
5 Connector J14 20 Connector J24
6 Connector J13 21 Connector J1
7 Connector J23 22 Connector J9
8 Connector J4 23 Connector J8
9 Connector J18 24 Connector J10
10 Connector J3 25 Connector J7
11 Connector J19 26 Connector J17
12 Connector J6 27 Connector J16 (not used)
13 Connector J20 28 Reset switch S1
14 Connector J22 29 Switch S2 (not installed)
15 Connector J2

2.3.2 Operating Environment

The UCC will operate under the following conditions:

• Temperature 0° C to 60° C
o Max rate of change 10° C per hour
o
• Humidity 5 to 95% RH (non-condensing)
o Max rate of change 10% per hour
o High absolute humidity (32g/kg dry air; maximum wet bulb 35° C)
o Low absolute humidity (1g/kg dry air)

2.4 Electrical Characteristics

The UCC has the following electrical characteristics:

• Operate the terminal(s) from the 24 VDC supply voltage, with an acceptable input voltage range
of 21.6 volts to 26.4 volts
• Consume up to 10 watts of power.
• Customer supplied systems and sensors using UCC connections are to be self powered.

Section 3
Embedded Software
UCC uses the Freescale Kinetis K-61 chip set using Green Hills Multi firmware tools to provide the
following:

• A means to remotely update the embedded software

• A means of uniquely identifying itself. The module must report the following information:
o Unique serial number
o Diebold coordinated product identifier
o Current version of the embedded software build
 o Current hardware revision level
• Enable service diagnostics
• A means to remotely access and exercise the module and view the status data
• Retain metric parameters during power outages
• Perform a self-test by command
• Remotely react to a reset command

Section 4
UCC Maintenance
The UCC requires no adjustments or maintenance. Verify the following status LEDs:

• Status indicator - HAPPY (D31)

NOTE
If HAPPY green LED (D31) is not flashing or the red LED is energized, press the RESET
switch S1 on the UCC to reset the board.
o Green LED when microprocessor is operating properly
o Red LED if microcontroller does not configure the output line or set the output as a high
o Yellow LED is for operational warning
• HAPPY yellow LED (D39) provides warning status
• +24V Power available green LED (D35,D36) energized
• +3.3V Power available green LED (D3, D4,D5,D6,D7,D8,D9,D12,D20,D21,D22,D23,D24)
energized
• USB status indicator blue LED (D10,D11,D13,D14.D15,D16,D17,D18,D19,D25,D26)
• Alarm (maintenance switch) status green LED (D37)
o Solid when operational
o Blinking at constant rate when entering terminal and action is required to validate service

Section 5
UCC Troubleshooting
Twenty-nine (29) light emitting diodes (LEDs) are mounted on the UCC and used to identify various
system status conditions. See Figure 5-1 and refer to Section 4.

Figure 5-1 Upper Control Card LED Indicator Locations

 Table 5-1 LED Indicator Locations
LED
Item Number LED Color Indication
1 D20 Green 3.3VDC inlet power
2 D18 Blue UCC VBUS23
3 D23 Green USB_LED22
4 D19 Blue UCC VBUS_K61
5 D24 Green USB_LED23
6 D25 Blue UCC VBUS21
7 D21 Green USB_LED24
8 D26 Blue UCC VBUS22
9 D22 Green USB_LED21
10 D37 Green Main switch LED steady green = normal operation/blinking green (after
pressing) = starts a timed required input code to prevent activation of alarm.
11 D36 Green Idle mode switch LED
12 D35 Green AC LED
13 D31 Green/Red HAPPY light LED flashing green = operating/steady red = non-operating
14 D39 Yellow HAPPY light (warning)
15 D6 Green USB_LED3
16 D17 Blue UCC VBUS4
17 D5 Green USB_LED2
18 D16 Blue UCC VBUS3
19 D4 Green USB_LED1
20 D10 Blue UCC VBUS2
21 D3 Green USB_LED5
22 D11 Blue UCC VBUS1
23 D8 Green USB_LED6
24 D15 Blue UCC VBUS6
25 D7 Green USB_LED4
26 D14 Blue UCC VBUS5
27 D13 Blue 5V input power
28 D9 Green USB_LED7
29 D12 Green 3.3VDC inlet power

Use Table 5-2 to troubleshoot the UCC CCA.

Table 5-2 UCC Troubleshooting

Corrective
Type of problem Problem Probable cause action
Power UCC AC AC power outage Check for AC
power power available
failure • Terminal AC power is not available
• AC IN power cable fault

UCC No +24V power available, D35, D36, and D37 LEDs Replace cable
24VDC OFF Replace power
power switch
failure • DC power cable fault
• Power switch fault Replace 400W
AC/DC power
• 400W AC/DC power supply fault supply

UCC 5VDC No 5VDC power available, D12 LED OFF Replace UCC
power
failure
 UCC No 5VDC power available, any one of the following Replace UCC
3.3VDC LEDs are OFF D3,D4,D5,D6, D7,D8,
power D9,D20,D21,D22,D23,D24
failure
Communications USB hub USB cable faults Connect or
(7-port or 4- replace USB
port) signal cable
loss
UCC not functioning, any one of the following LEDs Attempt to reset
are OFF UCC code by
D10,D11,D13,D14,D15,D16,D17,D18,D19,D25,D26 pressing the
RESET button
on the UCC. If
this does not
correct the
problem, then
replace the UCC
USB bus fault Troubleshoot
USB hubs
HAPPY UCC fault Attempt to reset
Light status UCC code by
green LED pressing the
stops RESET button
flashing and on the UCC. If
yellow this does not
and/or red correct the
LED is problem, then
energized replace the UCC

Section 6
Diagnostics
Diagnostics for this module are handled through the terminal-resident Diebold Service Application (DSA)
software. There are no on-board diagnostics available for any of the alarm option components.

Section 7
Removing and Replacing the UCC
Refer to the appropriate terminal module removal and replacement manual for instructions.

Section 8
Parts
Field-replaceable parts are listed in this section.

CAUTION

The certifications received from various entities, for example: Canadian Standards Association
(CSA), Technischer Überwachungs Verein America (TUV) and Underwriters Laboratory (UL), are
based on the use of Diebold approved parts. Accordingly, Diebold strongly suggests that only
Diebold approved parts be used as replacement parts. Failure to do so may adversely impact the
reliability and safety of the equipment.

NOTE

• The Restriction of Hazardous Substances (RoHS) directive regulates the use of certain
materials in electrical and electronic equipment placed in the European Economic Area
(EEA) market starting July 1, 2006. Some parts listed in this document have both RoHS
compliant and RoHS noncompliant part numbers.
• RoHS compliant parts can be used in any equipment regardless of the equipment's
location or placed-in-market date.
• RoHS noncompliant parts can only be used in equipment located outside the EEA market
or in equipment placed in the EEA market before July 1, 2006.
Table 8-1 Upper Control Card (UCC) CCA
Item Diebold Part Number Description
Refer to Figure 8-1
[1]
1 49-246708-000E UCC, CCA
[1]
This part number is for the CCA only. To order the field replaceable assembly, use 49-254764-000A

Figure 8-1 Upper Control Card (UCC) CCA

1 CCA
2 Mounting screw hole location
3 Mounting screw hole location
4 Mounting screw hole location

Section 9
Wiring Diagrams for UCC CCA
See appropriate terminal cabling manuals for information on DC power, USB and logic cabling
connections.

GLOSSARY
ACU

Agilis Configuration Utility

AMI

Agilis Module Interface

CSA

Canadian Standards Association

CCA

Circuit card assembly

DBDUSB

Diebold modules device driver

DSA

Diebold Service Application

LCC

Lower control card

SRS

Software Requirements Specification

TUV

Technischer Überwachungs Verein America

UCC

Upper Control Card

UL

Underwriters Laboratory