FLOWBIRD CWT Compact S4 Touch Instruction Manual

CWT Compact S4 Touch
Installation &
Maintenance Manual

Page 2CWT Compact S4 Touch Installation & Maintenance Manual for CWT 1.0-0Issue 3
CWT Compact S4 Touch Installation & Maintenance Manual
Issue 3,
Published: 2020-01-14.
© 2020 Cale Access AB. All rights reserved. Flowbird reserves all proprietary rights relating to the contents of this
document. Flowbird reserves all rights over usage, reproduction, representation, marketing, translation, adaptation or
modification, and generally all rights over present and future utilisation by any means, for any purpose and in any
territory, throughout the period of protection. All use of the contents of this document requires the prior written
permission of Flowbird. Flowbird reserves the right to change data, drawings and descriptions without prior notice.
Certain characteristics may vary according to customer requirements and do not represent a commitment by
Flowbird.
Flowbird
Headoffice 100 avenue de Suffren,
75015 Paris - France
Box 1031
164 21 KISTA, Sweden
Sweden office
Website:
Product Website:
Support www.calegroup.se/en/support.
www.calegroup.se
www.flowbird.group

Page 3CWT Compact S4 Touch Installation & Maintenance Manual for CWT 1.0-0Issue 3
Table of Contents
Table of content
1. Aprovals 6
2. Introduction 6
2.1 About this Manual ............................................................................................. 6
2.2 Available formats ............................................................................................... 7
2.3 List of major changes ........................................................................................ 7
2.4 Target audience ................................................................................................ 7
2.5 Structure of this book ........................................................................................ 7
2.6 References ....................................................................................................... 8
2.7 Terminology ...................................................................................................... 8
3. Safety 10
3.1 High voltage .................................................................................................... 10
3.2 Batteries .......................................................................................................... 11
3.2.1 Back-Up battery holder on CPU board ........................................................... 11
3.2.2 Short-circuit risk .............................................................................................. 12
3.2.3 Caustic acid .................................................................................................... 12
3.2.4 Risk of explosion ............................................................................................. 12
3.2.5 Disposal .......................................................................................................... 13
3.3 LCD display .................................................................................................... 13
3.4 Heavy lifting .................................................................................................... 13
3.5 Risk of tipping ................................................................................................. 13
3.6 ESD protection ................................................................................................ 14
4. Product description 15
4.1 Means of payment .......................................................................................... 16
4.1.1 Coin system .................................................................................................... 17
4.1.1.1 Anti-pin module ........................................................................................... 18
4.1.1.2 Coin verifier ................................................................................................ 21
4.1.1.3 Escrow ....................................................................................................... 23
4.1.1.4 Coin handling board ................................................................................... 24
4.1.1.5 Coin box ..................................................................................................... 25
4.2 Card readers ................................................................................................... 26
4.3 Touch enabled Colour display ........................................................................ 27
4.4 Data communication ....................................................................................... 28
4.5 Print system .................................................................................................... 28
4.5.1 GeBe GTP4672 Thermal printer ..................................................................... 29
4.5.1.1 Sensors ...................................................................................................... 31
4.5.1.2 Printer mounting ......................................................................................... 32
4.5.1.3 Paper supply .............................................................................................. 33
4.5.2 Preprinting on printer media ............................................................................ 33
4.5.3 Black mark location ......................................................................................... 34

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Table of Contents
4.6 The service menu ........................................................................................... 35
4.7 Mechanical design .......................................................................................... 35
4.7.1 General ........................................................................................................... 35
4.7.2 Product label ................................................................................................... 36
4.7.3 Inside the cabinet ............................................................................................ 36
4.7.4 Inside the pedestal .......................................................................................... 38
4.7.4.1 COIN BOX Vault ......................................................................................... 39
4.7.5 Door locks ....................................................................................................... 40
4.7.5.1 Mechanical locks ........................................................................................ 40
4.7.5.2 Electronic locks .......................................................................................... 41
4.7.5.3 Door-open sensors ..................................................................................... 43
4.7.6 Heating system ............................................................................................... 44
4.8 Power supply .................................................................................................. 44
4.8.1 Power control .................................................................................................. 44
4.8.2 Battery charging by solar power ..................................................................... 45
4.8.3 Battery charging by mains power .................................................................... 46
4.9 Administrative tools ......................................................................................... 46
4.10 CWT Compact interconnections ..................................................................... 47
4.11 CPU board version 0501-E0150 Rev I ............................................................ 47
4.12 Terminal measurements ................................................................................. 51
5. Installation 51
5.1 Site preparations ............................................................................................. 51
5.1.1 Minimal site dimensions & Mounting holes ..................................................... 51
5.1.2 Solar power positioning ................................................................................... 52
5.1.3 Placing the terminal on an existing concrete foundation ................................. 53
5.1.4 Pouring a new concrete foundation ................................................................ 54
5.1.5 Power supply .................................................................................................. 55
5.2 Installing the terminal ...................................................................................... 56
5.2.1 Mounting the pedestal in its foundation .......................................................... 56
5.2.2 Mounting the cabinet on top of the pedestal ................................................... 57
5.2.3 Installing the battery ........................................................................................ 57
5.2.4 Connecting to the mains power grid ................................................................ 58
5.2.5 Installing a modem .......................................................................................... 58
5.2.6 Loading paper in a GeBe printer ..................................................................... 61
5.2.7 Installing the coin box ...................................................................................... 62
5.3 Program loading .............................................................................................. 62
5.4 Changing the settings of the terminal ............................................................. 63
6. Daily operation 63
6.1 Changing and emptying the coin box .............................................................. 63
6.2 Paper refill ....................................................................................................... 65
7. Preventive maintenance 65

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Table of Contents
7.1 Batteries .......................................................................................................... 65
7.2 GeBe Printer GTP4672 .................................................................................. 67
7.2.1 Print head ........................................................................................................ 67
7.2.2 Cleaning .......................................................................................................... 70
7.2.3 Testing ............................................................................................................ 71
7.3 Coin handling unit ........................................................................................... 71
7.4 Card readers ................................................................................................... 72
7.4.1 Chip-card reader ............................................................................................. 72
7.4.2 Hybrid card reader .......................................................................................... 72
7.5 Display module ............................................................................................... 73
7.6 Cabinet door display window .......................................................................... 73
7.7 Cabinet ........................................................................................................... 73
7.8 Solar panel ...................................................................................................... 74
8. Corrective maintenance 74
8.1 Lead battery replacement ............................................................................... 75
8.2 CPU board lithium cell replacement ................................................................ 75
8.3 Printer replacement ......................................................................................... 76
8.4 Coin unit replacement ..................................................................................... 76
8.5 Coin verifier replacement ................................................................................ 77
8.6 Card reader replacement ................................................................................ 78
8.7 Display Module replacement ........................................................................... 78
8.7.1 Connecting the display to the CPU board ....................................................... 80
8.8 Cabinet & pedestal ......................................................................................... 81
8.8.1 Cabinet & pedestal door replacement ............................................................. 81
8.8.2 E-lock replacement ......................................................................................... 82
9. Changing the CWT Compact software and firmware 84
10. Appendix 85
10.1 CWTC S4 Touch door .................................................................................... 85
10.2 CWTC S4 Touch Display Panel ..................................................................... 85
10.3 CWTC S4 Touch Display unit ......................................................................... 86
87Keyword Index

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Aprovals
1 Aprovals
PCI Data Security Standard (PCI DSS), Level 1.
A set of comprehensive requirements for enhancing payment account data
security. Developed by the founding payment brands of the PCI Security
Standards Council, including American Express, Discover Financial Services, JCB
International, MasterCard Worldwide and Visa Inc. Inc. International, to help
facilitate the broad adoption of consistent data security measures on a global
basis. This is a multifaceted security standard that includes requirements for
security management, policies, procedures, network architecture, software design
and other critical protective measures. This comprehensive standard is intended
to help organizations proactively protect customer account data.
EN 12414 - Vehicle parking control equipment – Pay and display ticket
machines – Technical and functional requirements.
Flowbird has the IP 33 approved
EN 14450 - Secure storage units. Requirements, classification and
methods of test for resistance to burglary.
Secure safe cabinets. The CWT Compact is tested according to this standard with
very good result, but a pay and display terminal cannot be certified to this
standard due to the requirements of the standard. Test documentation is available
from Flowbird.
FCC part 15 (2006) Subpart B, class B
ADA, DDA and Article 11
CE
2 Introduction
2.1 About this Manual
This Manual describe the Installation and Maintenance of your CWT Compact
terminal, model S4 Touch.
All available functions are described in the manual without specifically mentioning
which functions are implemented as standard and which of them that is optional.
Some of the figures show optional items.

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Introduction
2.2 Available formats
The handbook is available in the following formats:
· Adobe Acrobat Reader (PDF)
· WebHelp (HTML)
· WebHelp with viewer for Windows (.EXE)
Flowbird distributors can download them from the Partner Area of our website
www.calegroup.se. We recommend that you visit the web site regularly to ensure
that you have the latest version of the handbook.
Keep previous issues of the manual because Flowbird cannot guarantee that new
issues will include information on older versions of the CWT Compact products.
2.3 List of major changes
The list below contains major changes since the last released versions.
Page
Change
Issue
Initial draft
1
Terminal measurements
Updated terminal measures to
inches
2
CPU board version 0501-E0150 Rev
I
Added Com port information
3
2.4 Target audience
This manual is intended primarily for personnel who plan and carry out the
installation and maintenance of the CWT Compact terminals in the field.
This document is focused on the CWT Compact S4 Touch.
2.5 Structure of this book
The structure of this document is outlined below.
· Introduction introduces this document itself, as well as to WebOffice in
terms of a system overview and general functions.
· Safety describes the risks when working with the terminal
· Product presentation describes the product and its use
51
47
6
10
15

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Introduction
· Installation describes how to best install the terminal
· Operation describes how to operate the terminal on a daily base
· Preventive maintenance describes the maintenance you can do to keep the
terminal working fault free
· Corrective Maintenance describes how to fix problems.
· changing the CWT Compact software and firmware describe the process of
upgrading the terminal to the latest software
· The Appendix Contains 3 exploded view drawings depicting:
oThe CWTC S4 Touch door
oThe CWTC S4 Touch Display Panel
oThe CWTC S4 Touch Display unit
2.6 References
1. CWT Software Configuration Handbook (0400-T0232). This document also
describes the service menu AVR and program updating procedures,
information that may be required during installation and maintenance.
2. Exploded view drawings for each model
3. CWT User Interface Design Handbook
4. CWT 104 & Compact Installation & Maintenance
5. User guide CCC
6. CWTC OS Update for CPU board version 0501-E0150.docx
7. Mounting of Top Hat
2.7 Terminology
Term
Meaning
AVR
The AVR is an 8-bit RISC single chip micro controller. The AVR
uses on-chip flash memory for program storage. See more
about AVR updates in the CWT Software Configuration
Handbook.
WebOffice
an internet based back office system from Flowbird
CWT
Common term for all Cale WebTerminal models (CWT 2110,
CWT 2115, CWT 2120, CWT Compact Classic, CWT 104,
CWT 104 S, CWT Compact all models).
CWTC S4 Touch
A CWT Compact terminal with a touch screen display and
wake up button. The display is tilted inwards.
ESD
Electro Static Discharge
51
63
65
74
84
85
85
85
86

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Introduction
Firmware
Firmware is a computer program that is embedded in a
hardware device, for example a micro controller. Firmware is
somewhere between hardware and software. Like software, it is
a computer program which is executed by a computer. But it is
also an intimate and vital part of a piece of hardware and has
little meaning outside of that particular hardware.
GPRS
General Packet Radio Service is a mobile data service available
to users of GSM (see below) based mobile phones and
modems. GPRS is packet-switched meaning that multiple users
share the same transmission channel, only transmitting when
they have data to send. Thus, the total available bandwidth can
be immediately dedicated to users who are actually sending at
any given moment, providing higher utilization where users only
send or receive data intermittently. Usually, GPRS data are
billed per kilobytes of information transferred.
GSM
The Global System for Mobile communications is the most
popular standard for mobile phones in the world. It includes
packet data capabilities by means of GPRS (see above).
LAN
Local Area Network
Magstripe
Short for Magnetic stripe
PCB
Printed Circuit Board – A thin board with electrical wires
"printed" onto the board, connecting the central processor to
other components on the board. Some examples of PCBs
include motherboards, RAM chips, and network interface
cards.
RFID
Radio Frequency Identification – An automatic
identification method, relying on storing and remotely retrieving
data using devices called RFID tags or transponders. An RFID
tag is an object that can be applied to or incorporated into a
product, animal, or person for the purpose of identification
using radio waves. Most RFID tags contain at least two parts.
One is an integrated circuit for storing and processing
information, modulating and demodulating an RF signal. The
second is an antenna for receiving and transmitting the signal.
Residual-current device
(RCD)
Also known as a ground fault circuit interrupter (GFCI), ground
fault interrupter (GFI) or an appliance leakage current
interrupter (ALCI). In Australia, they are sometimes known as
"safety switches". The device disconnects a circuit whenever it
detects that the electric current is not balanced between the live
and the neutral conductors. Such an imbalance is sometimes
caused by current leakage through the body of a person who is
grounded and accidentally touching the energized part of the
circuit.
TFT
TFT-LCD (Thin Film Transistor-Liquid Crystal Display) is a
variant of Liquid Crystal Display (LCD) which uses Thin-Film
Transistor (TFT) technology to improve image quality. TFT LCD
is one type of active matrix LCD, though it is usually
synonymous with LCD.

Page 10CWT Compact S4 Touch Installation & Maintenance Manual for CWT 1.0-0Issue 3
Introduction
Wi-Fi
Short for Wireless Fidelity, a wireless technology brand owned
by the Wi-Fi Alliance intended to improve the interoperability of
wireless local area network products based on the IEEE 802.11
standards.
3 Safety
This manual uses the labels listed below to indicate specific type of risks that you
will encounter during certain procedures:
Danger:
Danger means that an accident may occur if the safety precautions are not
followed. This type of accident is likely to be fatal to human beings.
Warning:
Warning means that an accident may occur if the safety precautions are not
followed. This type of accident may be fatal or cause severe injuries to human
beings or may create essential damage to the product.
Caution:
an accident could occur if safety instructions are not followed. This type of
accident may cause injury to people or may create damage to the product.
Caution:
ESD-sensitive component. Follow procedures for ESD protection. See section
ESD protection .
3.1 High voltage
Danger:
Contact with live components of equipment powered by high-voltage current can
be life-threatening. Also, bear in mind that moist components may conduct
electricity although they possess insulating properties when dry.
Some parts inside the pedestal and in the heating system inside the cabinet are
live with hazardous voltage even when the terminal is switched OFF.
Before working on components that conduct high-voltage electricity:
Turn OFF the power supply. Unscrew or switch OFF the fuse if there is one.
Make sure that the equipment is not exposed to moisture while you are working.
14

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Safety
Follow all applicable local worker safety regulations.
3.2 Batteries
3.2.1 Back-Up battery holder on CPU board
The CPU board contains a lithium battery (button cell CR2032, 3 V, 210 mAh, 20
mm diameter) to keep the terminal's memory alive on power down.
Caution:
It is very important that the battery is of an approved brand (Duracell, Eveready,
Panasonic, Ray-O-Vac, Sanyo, Varta, Toshiba, Seiko or another major battery
manufacturer).
The battery must be replaced at least every 5 years. See Batteries for a
description how best to replace the battery.
Figure 1, Backup Battery case
65

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Safety
3.2.2 Short-circuit risk
Warning:
Although the battery voltage is relatively low, there is a risk of personal injury
(such as burns) if the battery poles are short-circuited. Make sure you do not
short-circuit the battery when using tools and other metal objects.
When working with equipment connected to the power supply:
· Remove rings, necklaces, watches, key rings with chains, etc.
· Always use insulated tools.
· Follow all applicable local worker safety regulations.
3.2.3 Caustic acid
Only batteries that are not maintenance-free need to be checked regularly.
Warning
The sulphuric acid used in lead batteries is caustic. Always wear eye protection
when checking the battery acid level and refilling with water. If you get acid in
your eyes, flush them immediately with water. There should possibilities for
flushing eyes available on facilities where the battery is charged. If you get acid
on your skin, wash immediately with soap and water.
Handle the battery with care during transportation and installation.
Follow all applicable local worker safety regulations.
3.2.4 Risk of explosion
Warning:
Battery charging develops hydrogen gas that is highly explosive and
inflammable. The charging area must therefore be well ventilated. Besides
hydrogen gas, an acid fog is also developed.
An explosion may also occur within a few seconds if the battery poles are short
circuited by a metal object such as a wrench and sulphuric acid will then be
spread around.
Fire extinguishers must be accessible and clearly marked. You must not smoke,
weld, cut, or use an open flame in the charging area. The charger must be OFF
both when you connect and when you disconnect the battery.
Follow all applicable local worker safety regulations.

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Safety
3.2.5 Disposal
Lead acid batteries should be disposed of according to the manufacturer's
instructions.
Old batteries must be discharged according your countries policies and laws.
3.3 LCD display
Warning:
The liquid inside the CWT LCD display is a hazardous substance.
If the display panel is damaged and the liquid crystal substance leaks out, be sure
not to get any in your mouth. If the substance comes into contact with your skin or
clothes thoroughly and promptly wash it off using soap and water.
See Display Module replacement for a description how to replace the display
unit.
3.4 Heavy lifting
Warning:
When lifting equipment that weighs more than 20 kg, always use a hoist, or let
two or more people lift it. There is a major risk of back injury or sprain.
The weight of the terminal depends on the configuration.
Follow all applicable local worker safety regulations.
3.5 Risk of tipping
Warning:
Before the terminal is fixed with screws to the floor or ground, there is a risk that
it may tip, especially if you open the doors.
The top cabinet can tip forward if it is not fixed to the pedestal.
78

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Safety
3.6 ESD protection
What is ESD?
ESD is an abbreviation for Electro Static Discharge.
Electrical charges are build up when materials are rubbed or
separated – e.g. when you walk across a carpet or get out of
your car. The charge, which may be several thousand volts, can
then be transferred to other objects if they get close enough.
Caution:
Handling ordinary plastic causes a charge to build up.
Most modern integrated circuits are extremely sensitive to ESD. The component
either ceases functioning altogether, causing the equipment to stop working, or
suffers damage that makes it extremely susceptible to further injury. This can
eventually result in intermittent faults that are extremely difficult to locate.
Caution:
Never expose ESD-sensitive components to shocks of static electricity.
Avoiding ESD damage
Rule number 1: Prevent charge build-up!
Plastic packaging and other large plastic objects can transfer charges to
conductive objects, which can then damage components. Except for special anti-
static plastic, all plastic must be kept away from unconnected printed circuit board
assemblies.
Rule number 2: If you need to work with electronic components or modules,
connect yourself through a wristband to a grounded part inside the terminal.
Avoid touching connector pins/poles and components on printed circuit board
assemblies.
Ensure that all components containing electronic parts are always stored in an
ESD protection bag when handled outside the terminal.
Remember that the bags’ insulating properties gradually wears out. Always use a
new bag.
The following ESD protection accessories can be ordered from Flowbird.

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Safety
0401-E0360
Wristband (for connection to the ticket
terminal cabinet)
0040-07012
ESD bag, small (fits print head and coin
verifier, etc.)
0040-07013
ESD bag, large (fits CPU board etc.)
4 Product description
Figure 2, CWTC
S4 Touch
The CWTC S4 Touch system is equipped with a touch enabled 800x480 pixels
colour display with adjustable luminescence. The CWTC S4 Touch features a
green wake-up button.
All buttons required for the user interaction are part of the user interface design
presented in the display. Even a full alpha-numeric keyboard can, for instance, be
presented in the display.
The information panel above the display is fully customizable. The surface can
also contain instructions or advertising elements.

Page 16CWT Compact S4 Touch Installation & Maintenance Manual for CWT 1.0-0Issue 3
Product description
4.1 Means of payment
The CWT Compact terminals support different means of payment and a number of
payment applications.
Payment applications
Currently the CWT Compact offers:
1. pre-payment, that is, the user pays in advance and receives a ticket
A special pre-payment application is Code Payment which requires that the
user enters a code or number, for instance a license plate number. The user
pays at the terminal using an available payment option.
2. Post-payment, that is, the user pays afterwards for the time used and receives
a ticket depending on the configuration.
The user checks in on the terminal on arrival with her credit or fleet card and
checks out and pays when she leaves. All steps of this process can be
followed in the WebOffice Post Payment menu. The feature is licensed.
Payment methods
The card and coin payment systems work independently of each other. Should
one payment unit be out of order for some reason, the other payment unit will
remain operable. A message in the display informs the customer about available
payment methods.
Cards
CWT Compact terminals offer the possibility to pay with credit/debit magnetic
stripe cards, smart cards (chip cards), contact less cards, and hybrid cards using
various card reader configurations.
The standard card reader in CWT Compact is a hybrid reader capable of reading
all track-2 ISO payment magstripe cards (common credit/debit cards) and ISO
smart cards (chip cards). The reader requires manual card insertion and retraction
of the card which enables the customer to remove the card if the terminal or
transaction fails. It is also possible to install card reader solutions to be used with
certain chip card applications, such as EMV2. The reader automatically detects if
an inserted card is a magnetic card or a chip only card and the card functions are
adapted accordingly.
To verify that a card is valid, the card number is evaluated according to prescribed
rules before being checked against a blacklist containing non-valid card numbers.

Page 17CWT Compact S4 Touch Installation & Maintenance Manual for CWT 1.0-0Issue 3
Product description
Coins
The CWT Compact supports coin payment. The terminal uses various techniques
for rejecting and disposing of foreign objects and not accepted coins. The coins
used for payment are collected in a coin box that needs to be emptied or replaced
on site.
Cash collection system
Flowbird provides a complete system for secure collection and transport of coins.
With this system, the coins will never be displayed at any stage of the collection
process. Contact Flowbird or your local Flowbird representative for more
information. An alternative source of information on this matter is
www.calegroup.se.
4.1.1 Coin system
The coin system consists of the coin unit in the cabinet and the vault with its coin
box in the pedestal.

Page 18CWT Compact S4 Touch Installation & Maintenance Manual for CWT 1.0-0Issue 3
Product description
Figure 3, Logical structure of the coin system
The coin unit is designed as a module that is fitted at the back of the cabinet door
by means of two key holes. The module is secured with two screws that only need
to be loosened slightly when the module is to be removed.
4.1.1.1 Anti-pin module
The function of the anti-pin module is to prevent external manipulation of the coin
system. The figures below illustrate the function principles of the anti-pin module.
The mechanism is seen from above.
The anti-pin module has a pair of metal-detector coils just inside the coin slot
opening. A bit further in there is a barrier plate that usually covers the coin slot.
The barrier plate is pulled into closed position by a tension spring.

Page 19CWT Compact S4 Touch Installation & Maintenance Manual for CWT 1.0-0Issue 3
Product description
Figure 4, Antipin inside view. CWTC S4 door
A slightly inclined trap door, operated by a solenoid plunger, is held in opened
(clock-wise) position by a permanent magnet inside the solenoid across which no
voltage is currently applied (the above figure shows the trap door in its closed
position).
The figure below illustrates the mechanism in idle mode before any metal object is
detected in the coin slot. The barrier plate is kept closed by a compression spring
and the trap door is in the open position.
CWT016 R3
Coin unit
Trap door
Coin slot
Metal-detector
coils
Barrier plate
Coin verifier
Scrap channel
Figure 5, Anti pin in idle mode. The barrier plate covers the coin slot opening and the
trap door rests in open position.
When a metal object is detected by the detector coils, a voltage is temporarily
applied across a separate coil in the solenoid which generates a magnetic field
that repulses the field of the permanent magnet. The trap door now rotates anti-
clockwise pulled by a tension spring mounted on the solenoid plunger. The trap
door also forces the barrier plate to the right to allow the metal object to be fully
inserted. See figure below.

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Product description
CWT017 R2
Coin unit
Trap door
Coin slot
Metal-detector
coils
Barrier plate
Coin verifier
Scrap channel
Metal object inserted
Figure 6, Barrier plate, and thus the antipin module, opens for metal objects.
The almost vertical trap door has a perpendicular shelf at its lower edge. This
shelf slopes downward and rearward toward the coin verifier. A round metal object
will roll along the shelf and fall into the coin verifier. A metal object that cannot roll
will fall into the scrap channel as the trap door is swung clock-wise by the solenoid
after a pre-set time delay.
CWT019 R2
Metal object that
cannot roll
Coin unit
Trap door
Barrier plate
Coin verifier
Scrap channel
Figure 7, Non-valid metal objects are scrapped.
The permanent magnet in the solenoid module will keep the trap door in open
position and thus no voltage needs to be applied to the solenoid continually which
reduces the power consumption.
As the trap door opens, the compression spring will close the coin slot by pushing
the barrier plate to the left.