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CWT Call Box - KORE Telematics

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1. Pin 7 Ground Pin 8 Flash Write Protect Pin 9 and Pin 10 Pin 11 DSP Debug Q5 Pin 12 DSP Debug Q6 Revised April 2005 45 CWT Call Box Owners Manual Pin 13 DSP Debug Q7 Pin 14 DSP Debug Q8 J6 Function Board to Board Connection to TTY Board 6020 0310 J1 Pin 1 Ground Pin 2 Ground Pin 3 and Pin 4 Pin5 TTY Power 12 VDC Pin 6 TTY Power 12 VDC Pin 7 CPU Power 3 3 VDC Pin 8 CPU Power 3 3 VDC Pin 9 Peripheral On Pin 10 N C Pin 11 TTY On Pin 12 Display Current Spare Analog 1 Pin 13 and Pin 14 N C Pin 15 Reset Pin 16 through Pin 18 N C Pin 19 Read Write Pin 20 MCU Clock Pin 21 Data Strobe Pin 22 N C Pin 23 Address 0 Pin 24 Address 1 Pin 25 Address 2 Pin 26 Address 3 Pin 27 and Pin 28 N C Pin 29 TTY Select Pin 30 N C Pin 31 Data Line 0 Pin 32 Data Line 1 Pin 33 Data Line 2 Pin 34 Data Line 3 Pin 35 Data Line 4 Pin 36 Data Line 5 Pin 37 Data Line 6 Pin 38 Data Line 7 Pin 39 Data Line 8 Pin 40 Data Line 9 Pin 41 Data Line 10 Pin 42 Data Line 11 Pin 43 Data Line 12 Pin 44 Data Line 13 Pin 45 Data Line 14 Pin 46 Data Line 15 CWT Call Box Owners Manual Pin 47 and Pin 48 N C Pin 49 Ground Pin 50 Ground 7 3 Antenna Connection 50 ohm Impedance Coaxial Cable to Antenna Female TNC Connector Revised April 2005 47 CHAPTER 8 Miscellaneous 8 1 Call Box Customer Service Your call box system is designed to give you reliable trouble free service Howe
2. the call box will transition into the quiescent mode and will be ready to perform as designed Motorist Calls Motorist calls are placed when a person opens the call box door and pushes the call button When the call box controller senses that the front door is open it transitions the call box into the stand by mode With the call box in the stand by mode it is ready to place a telephone call interpret electronic access inputs or receive a telephone call If the outer door of the call box is then closed or if the door is left open for more than two minutes without further action the call box will automatically return to quiescent mode to avoid the waste of stored electrical energy When the user pushes the call button the call box controller instructs the cellular transceiver to place a telephone call out of flash memory location 1 which contains the telephone number for the PSAP center If the call box is in the middle of a report call when someone tries to use it for a motorist call the maintenance call will be aborted and the motorist call completed When a motorist initiates a call the call box automatically connects to the PSAP center When the dispatch operator answers the call they may request the call box ANI or receive call box information by using caller ID provided by the cellular carrier The dispatch operator may then converse with the call box user to determine their specific need Call Back Standby Occasionally there is
3. used to connect the Solar Panel to the Input Output board J10 6020 0307 The following page shows the cable connection used to connect an AC DC power supply to J10 of the Input Output board 6020 0307 POWER HARNESS 2 0 FT CN 271 Connector with CN 3 8 Polyolefin shrink tubing used over 3 4 shrink 3 4 Polyolefin shrink tubing used over P10 tubing 3 8 Polyolefin shrink tubing used over P1 TN TW P1 271 Connector CN with CN 061 pins SN X N SOS SESS SS AMX SSS SESS SS SSAA Viewed from wiring side Viewed from wiring side View B A View A Continuity Loop Continuity Loop Power Power Horn Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Horn Figure 6 DC Power Cable Wiring Revised April 2005 CWT Call Box Owners Manual 3 19 3 20 3 21 28 Tilt Alarm The tilt alarm will be reported if the call box tilts more than 45 from vertical for a period of 15 seconds or more In this case the technician should be prepared to replace the entire call box system Knockdown false alarms foundation failure or vandalism can cause tilts If the technician sees that the call box has been knocked over it will be necessary to determine the extent of the work needed to repair the call box If there is any mechanical breakage the call box should be replaced The proper personnel
4. CHAPTER 8 MISCELLANEOUS 49 8 1 Call Box Customer Seien are Hausa 49 8 2 Ordering Parts For Your Call Box 49 LIST OF FIGURES AND TABLES Figure 1 Functional Block Diagram etie eite ana 3 Figure 2 Call Box Installation Drawing u na 5 Figure 3 Call Box Front Panel iS Uo cedem Elda 6 Figure 4 Inside View of Call Box Electronics etri their eer te rn 6 Pol Cap oec E Er dit ung oV RP M I NUN ED PES e 26 Figure 6 DC Power Cable edi EEE 27 Figure 7 Call Box Interconnection Diagram ic uet id es pear Wine A sag eee 34 ADDENDUM CELLULAR CALL BOX INSTALLATION INSTRUCTIONS Revised April 2005 V CHAPTER 1 General Information and Specifications 1 1 Introduction Cellular call boxes provide vital communications services on highways parking areas bridges tunnels and other critical locations The call box system uses proven digital cellular telephone technology that is cost effective flexible readily installable even in remote or harsh environments and extremely reliable The call box system consists of five major elements Technologically Advanced Call Boxes The call box is an extremely rugged weatherproof unit constructed from a thick grade of Lexan polycarbonate The housing is designed for many years of durable service Within the housing is the call box controller whic
5. Check Tuning of Battery Charging Circuitry eene 17 PSAP Answer Center Call eter ee de 18 Troubleshooting Procedures cease eri ca cip ener rid Pa 18 The Call Box Does Not Complete Its Power On Sequence Properly 18 CWT Call Box Owners Manual 3 7 Transceiver Fails To Power Up and Recall Controller Memory Location 9 When an Alarm is 19 3 8 Maintenance Computer Phone Number Is Not Retrieved After Alarm Condition Is Encolintered i een 20 3 9 Maintenance Computer Does Not Answer Phone Call From the Call BOX teet uada tue deles rebos 20 3 10 Call Box Status Indication Not Normal eene 21 3 11 Call Box Does Not Get Programmed by the Maintenance Computer 24 3 12 Transceiver Does Not Power Down After Program Call 24 3 13 Us t Call Not Successnl sehen 25 3 14 Alarm Trois a e tert ade tr 25 3 15 Inner Door ATarm oiii etr ia 25 3 16 E A ht aU 26 3 17 No Solar Charging for 24 Hours 26 3 18 TULA n 28 3 19 Handset Alar cd eod iN UE ee SU Eo e ed totu 28 3 20 Ballery Alan 4 aqicde dec dotum Eden a wh See 28 3 21 Front Door Alan e doen ec io et P Calp 28 3 22 Mainten
6. a need for the PSAP center to remain in communication with the call box for an extended period of time In order to conserve cellular system airtime it may be desirable to disconnect the phone call and reestablish it at a later time To do this the dispatch operator will send a control code pause 7 by pressing two touch tone buttons on the telephone instrument causing the call box to enter the standby mode This essentially puts the call box on hold In this mode the call box requires 60 to 8596 less Revised April 2005 CWT Call Box Owners Manual cwt 2 5 battery power and conserves cellular airtime In the standby mode the call box controller will keep the cellular transceiver powered up and waiting for an inbound phone call The maintenance computer during a programming call programs the length of time the call box will remain in this standby mode Once this time has passed the call box will return to the quiescent state At any time while a motorist is on hold pushing the call button will bring the call box back to the active mode and reestablish the phone call with the PSAP center Once the PSAP center is ready to reconnect with the call box the operator recalls the cellular telephone number of the call box from the database and connects to the call box by normal means If the motorist is at the call box with the front door open the call box controller senses the cellular transceiver ringing and answers the phone call which r
7. given It is assumed that the tests are performed as outlined in Sections 3 1 through 3 4 If the tests are not performed as outlined the effectiveness of this Troubleshooting section is reduced The Call Box Does Not Complete Its Power On Sequence Properly This type of failure has many potential causes It could be anything from an improper cable connection to failure of the call box electronics The procedure outlined below is organized to provide the quickest and most logical way to determine the source of the problem l Check the main fuse F7 5 Amp first and then check the power connections on the battery If the connections are loose or not made simply correct the situation and re test the call box If the battery connections are reversed and power has been turned on a protection diode will shunt current to ground through the main fuse Correct the reversed power connection and replace the main fuse 2 Verify that the cable connection between the small radio interface board 6020 0678 mounted to the controller board and the cellular transceiver 1s secure and properly attached If connections are not properly made correct the problem and re test the call box 3 If the transceiver does not power up after turning on the call box power switch located on the I O board replace the controller and radio interface boards and re Revised April 2005 CWT Call Box Owners Manual cwt test If this does not fix the problem first r
8. probably involves an accident or theft On the other hand the outer door open sensor will commonly be masked as there is no need to act immediately when the outer door of the call box is left open When the call box controller receives an unmasked alarm it immediately brings the call box to the active state and places an alarm call to the maintenance center where the call is displayed on the computer screen If the alarm is masked the call box will report the alarm condition at its next scheduled report call time 2 7 Electronic Access Electronic access is a powerful feature that allows authorized individuals to use the call box for calls other than to the answer center The controller flash memory used in the call box has 30 memory slots for storing telephone numbers Flash memory locations 1 2 3 8 9 and 30 are reserved for normal call box system use while memory locations 4 through 7 and 10 through 29 are used for electronic access When authorized persons use a call box they first approach the unit and open the outer door This action causes the call box to transition into the standby mode The authorized person will then hold an automatic tone dialer up to the microphone of the handset The technician can then press a button on the tone dialer that will then issue a tone code to the microprocessor in the call box The automatic tone dialer is an off the shelf unit that stores many telephone numbers and plays them back in standard DTMF t
9. should be replaced User Call Not Successful When the call button is activated the call box controller board commands the cellular radio to place a call to the phone number stored in flash memory location 1 Several types of failures could cause a call to be unsuccessful but if the test procedure in Section 3 2 is followed prior to attempting the call all but a few failures should be eliminated These are detailed below 1 The most likely problem that would prevent a successful call is a problem with the cellular transceiver or the cellular network If a cellular reorder tone or intercept message is received when the call is attempted the problem could be either a fault with the cellular network such as poor coverage heavily loaded cellular network or cell site hardware failure or a problem with the cellular transceiver If the reorder tone is heard the call will be attempted up to five more times by the call box If the call is not completed verify that flash memory location 1 contains the proper phone number If an invalid number is entered it will result in a reorder tone Reprogram the memory location if necessary If the memory location is programmed properly contact the cellular carrier to see if cellular system problems have been reported in the area 2 If no audible activity takes place when the call button is activated the call button switch should be tested and or replaced Alarm Troubleshooting When a call box place
10. the box at the start of this line The night strobe is normally OFF if solar charging is not present If the night strobe is ON the picture of the strobe will show a lit light bulb Side Tone OFF or ON Side tone feedback from the handset microphone to the handset speaker is normally ON when the call box is powered up Side tone can be turned OFF by checking the box at the beginning of this line Audio Gain NORMAL or HIGH The handset speaker audio gain can be turned to high mode by checking the box at the start of this line Mic microphone NORMAL or MUTED The handset microphone can be changed to the muted mode by using this line Revised April 2005 CWT Call Box Owners Manual cwt p Charge Power OFF or ON The output of the solar panel cable or DC power cable can be noted for charge power on this line q Radio OFF or ON The radio power state is determined by this line r The picture of the call box located in the lower right side of the screen displays the current condition of the call box If the back door is open the picture will display a call box with the back door open If the front door is open the picture will display that as well If the front panel light is ON a lit light bulb will be displayed at the upper center part of the call box The call button can be tested by pushing the call button If a hand pointing to the button is displayed the call button is working properly Phone Numbers
11. the call box power is on this LED then indicates the battery charging condition ON Float OFF Charging Revised April 2005 17 CWT Call Box Owners Manual 3 4 3 5 2 If D6 is on measure the voltage between ground TP3 GND and TP2 BAT SET on the controller board TP2 is located near the middle left side of the controller board The voltage should be the voltage per cell of the battery when in the fully charged condition For most 12 volt batteries the voltage level should be set to 2 3 Volts per cell 3 If adjustment is necessary adjust the blue potentiometer until the proper value 2 3 VDC is displayed on the voltmeter PSAP Answer Center Call The call box should be tested for proper operation of a motorist call Open the call box front door and activate the Call button The call box will recall flash memory location 1 stored in the controller board and place the call Verify this operation with the answer center operator and determine that audio in both directions Tx and Rx audio are clear and undistorted If the call is not completed refer to the following Troubleshooting procedures Troubleshooting Procedures The Troubleshooting section is organized in conjunction with the call box test section The failures covered are in order of their potential occurrence during the call box test When a failure occurs during the call box test a reference to the appropriate paragraph of the troubleshooting section is
12. the call box power switch the ON position up Pause 2 seconds or until the controller board lower LED begins flashing D13 Click the EMTEST icon on the Windows desktop to start the EMTEST program 2 If the computer connects properly with the call box the number 1 box under polled modules will be checked If so click the Call Box tab located on the upper left part of the screen 3 The screen will now display the Call Box Programming and Diagnostics screen This screen is used to monitor the current state of the call box as well as testing all features Click the following two boxes a Manual Override of Outputs b Stop Maintenance Calls 4 The current state or condition of the following call box functions can be monitored and or tested a RSSI Received Signal Strength Indicator The RSSI is a measure of how well the call box is receiving the local cell site This measurement should be made with the antenna connected The reading is in negative dBm The proper range for reliable call box communications is from 55 dBm to 105 dBm The more negative the number the weaker the signal is being received from the nearest cell site For example a reading of 105 dBm is much weaker than a reading of 75 dBm Revised April 2005 13 CWT Call Box Owners Manual Handset Microphone PASS or FAIL Handset Ear Piece speaker PASS or FAIL Battery voltage PASS or FAIL The actual battery voltage can be read in green let
13. the inner door circuitry is deemed bad perform the following steps to determine the source of the problem a Make sure the magnet being used is strong enough to induce the alarm Attempt to induce the alarm by holding the call box main housing closed against the rear housing for a few seconds This uses the magnet from the back plate to initiate the inner door alarm If the alarm call is made the magnet used to induce the alarm is not strong enough b Check the connections on the proximity switch 6 If the proximity switch is properly located and securely connected and the problem still persists the proximity switch itself can be tested Disconnect the proximity switch from the harness and attach ohmmeter leads across the two pins of the switch wires Move a magnet onto the proximity switch and observe the ohmmeter When the magnet comes within 1 2 of the proximity switch the effective resistance should go to near 0 ohms If it does not the proximity switch should be replaced If the proximity switch appears to be in working order replace the following items in the order listed one at a time 1 Controller and radio interface boards 2 Sensor harness CWT Call Box Owners Manual 3 8 Maintenance Computer Phone Number Is Not Retrieved After Alarm Condition Is Encountered If the alarm circuitry is functioning and the transceiver has powered on but the call box does not place a call to the maintenance computer perfo
14. 0100 65 6040 4011 6040 4026 6040 4010 5204 0051 6020 0300 6020 0678 6020 0449 6020 0679 6020 0683 6040 4014 3070 0001 3070 0003 6040 4018 39 cwt CWT Call Box Owners Manual Lock Cover Assembly Lamp Bulb Solar Panel Assembly Solar Cable Battery 12VDC 17AH Battery Bracket Call Box Ringer Call Box Power Cable Main Ribbon Cable Controller to I O Board Phone Data Interface Cable How to Call Label Eng Spn Special Tools Call Box Programming Kit Aurora Call Box Install Kit Tamper Pruf Tool w bits Medeco Key 20 dB Inline RF Attenuator 30 dB Inline RF Attenuator 40 6040 4016 6232 0002 6040 4057 6060 0130 4240 0001 5004 0048 4230 0008 6060 0283 6060 0358 6060 0515 4410 0017 6000 0470 6040 4035 09 6040 4038 3076 0005 2035 0049 2035 0050 Revised April 2005 CWT Call Box Owners Manual 7 Wire List Cable List Database 7 1 Input Output Board 6020 0449 Connectors Cables J10 Function Solar Cable to Solar Panel Assembly or to DC Supply Module Pin 1 Solar Power or DC Power White Wire Pin 2 Solar Power or DC Power Red Wire Pin 3 Continuity Loop Green Wire Pin 4 Continuity Loop Black Wire Pin 5 Not Used or Optionally Ringer Orange Wire Pin 6 Not Used or Optionally Ringer Blue Wire J6 Function Handset Connector Block Terminal 1 Viewed from left to right Either White Wire Handset Speaker Terminal 2 Other White W
15. 3 inches above ground level Figure 1 Installation along roadsides Fill depression with dirt Mounting plate goes below ground level Fill the depression around mounting bolts Figure 2 Installations in parks and along walkways Page 1 of 6 3 Attaching Bands For Sign Mounting Figure 4 Tightening bands with the Band It Tool Band Gripper Nose of Tool Band the sign brackets to the pole using double wraps Buckle See Figures 3 and 4 Bridge pem Handle Place band in open slot of tool nose and in slide With thumb on band gripper lever apply tension by turning handle of tool clockwise After tension is created it is no longer necessary to hold band gripper lever as it locks itself under tension Place finger on Band It Band at buckle bridge while tensioning with tool handle When you feel Band It Band stop moving through buckle as you are turning handle maximum pressure is being exerted by the Band It Band around object being clamped Stop turning handle Figure 5 Pull Cutting Cutting Turn Tension Handle up to Handle Handle cut band counterclockwise for back off during Place the banding at increments that will insure the bottom of the signs Roll tool are 7 feet from over ground buckle Roll tool over buckle backing off with tension handle throughout entire rollin operation Failure to back off with tension handle throughout entire course of roll may result in breaking of b
16. Clear None Battery Alarm Encountered 3 20 Front Door Alarm Encountered 3 21 Battery Alarm with Front Door Alarm Encountered Program Call Being Made Program Call and Battery Alarm Encountered Program Call and Front Door Alarm Encountered Program Call Front Door Alarm and Battery Alarm Revised April 2005 CWT Call Box Owners Manual 3 Digit D status is concerned with handset alarms tilt alarms and solar panel alarms The following table refers to this digit Third Status Digit Table D DESCRIPTION OF STATUS SEE SECTION O All Clear None Solar Power Alarm is Encountered 3 17 2 Tilt Alarm is Encountered 3 18 3 Solar Alarm and Tilt Alarms Encountered 4 Handset Alarm Encountered 3 19 5 Handset and Solar Alarms Encountered 6 Handset and Tilt Alarms Encountered 7 Handset Tilt and Solar are Encountered 4 Digit E status is concerned with lamp alarms built in test alarms and inner door alarms The following table refers to this digit Fourth Status Digit Table E DESCRIPTION OF STATUS SEE SECTION O All Clear None Inner Door Alarm is Encountered 3 15 2 Built In Test Alarm is Encountered 3 Built In Test and Inner Door Alarms Encountered 4 Lamp Alarm Encountered 3 16 5 Lamp and Inner Door Alarms Encountered 6 Lamp and Built In Test Alarms Encountered 7 Lamp Built In Test and Inner Door Alarms Encountered Revised April 2005 23 CWT Call Box Owners Manual 3 11 24 The checksum di
17. Computer System The call box maintenance center employs a computer database with complete up to the minute near real time alarm information on the entire call box system thus it is able to keep the call box system virtually 10096 operational Computers running maintenance software designed for the call box are able to quickly recognize potential problems anywhere within the call box system Abnormal situations detected by the maintenance computer are promptly displayed and printed for action by maintenance personnel The Call Box Dispatch or PSAP Center The call box dispatch or PSAP center consists of an answering system that can detect ANI Automatic Number Identifier or ALI Automatic Location Identifier call box control codes are single or double touch tone commands Call duration call box volume control and ringer control can be accomplished by means of the touch tone pad on the dispatch telephone instrument For a complete system overview see the Functional Block Diagram Figure 1 2 Revised April 2005 CWT Call Box Owners Manual cwt MTSO Cell Site Answer Center Maintenance Computer Figure 1 Functional Block Diagram Revised April 2005 cwt CWT Call Box Owners Manual 1 2 Transceiver Specifications Kyocera Model M200 Series CDMA Transceiver ITEM Manufacturer Model Service Type Operating Bands CDMA AMPS Vocoders Temperature Range Tx RF Output Power Rx Sensitivit
18. Maintenance 5 1 Preventive Maintenance Preventive maintenance is recommended twice a year for each call box in the system environmental conditions as well as call box placement can greatly influence this figure Preventive maintenance consists of visual instrument and operational checks of the wiring and components to detect any possible deterioration of the call box operation The following items are checked and or performed as a normal part of the preventive maintenance routine Call Box Assembly Clean housing exterior and interior Clean call box handset Check front door for proper operation Check operation of interior panel light Check operation of blue strobe light if used Inspect and replace as necessary Weatherproof seals Electrical connections Antenna connections Call Box Operation Place call to PSAP center Verify ANI or ALI decoding Verify high quality bi directional audio Reprogram call box with maintenance computer Support Assembly Pole Pole assembly Anchor bolts if above ground Breakaway assembly if above ground Call box signs and brackets Antenna mounting and connections Antenna cable includes connection Horn mounting and connection Blue strobe where applicable Revised April 2005 35 CWT Call Box Owners Manual 36 Call Box Authorized Electronic Access Before preventive or corrective maintenance can be performed
19. South Tighten the solar assembly set screws P 4 of 6 Call Box Installation Instructions 7 Mounting the Call Box and making connections 7a Mount the Call Box to the back plate by slipping the call box onto the back plate mounting pins 7b Connect the antenna cable to the transceiver connector and connect the six pin solar cable to the Call Box Input Output board Note this connector is keyed and can be installed in only one direction 7c Using the diagram to the right turn the internal power switch to the on position 7d Push the excess cable back into the pole and carefully close the Call Box Call Box Installation Instructions Six Pin Solar Input Output Board Connector GPS Antenna Internal Hinged Door Power shown in open Switch position Transceiver Connector Controller CDMA Transceiver Board 9 O O O fo 7 o bes e S d Sealed Lead ensors an Acid Battery Harness Figure 6 Internal Electronics Page 5 of 6 8 Securing Call Box Ew _ Hole Plug P Cover Plate HW Lock Cover Plate 40 View shown without door and handset Lock the Call Box into the closed position using the large bolts and the spec
20. Specification No 07 205 CWT Call Box Owners Manual April 2005 LEXAN M200 CDMA CALL BOX P N 4421 0176 Appendix A CWT Call Box Owners Manual CHAPTER 1 1 1 1 2 1 3 1 4 CHAPTER 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 CHAPTER 3 3 1 3 2 3 3 3 4 3 5 3 6 Revised April 2005 TABLE OF CONTENTS GENERAL INFORMATION AND SPECIFICATIONS 1 A c p 1 Technologically Advanced Call 1 The Cellular Telephone Network irte rt eintreten 1 The Public Switched Telephone 2 The Call Box Maintenance Computer System eene 2 The Call Box Dispatch or PSAP nase 2 Transceiver Speclficatlons once ee ae 4 Kyocera Model M200 Series CDMA Transceiver 4 Call Box Speeifications using ln 4 Call Box aan ae ae 5 THEORY OF OPERATION 5 e onset uc tace curio nenn 7 Call Bor anne Ha Le abut eec 7 Program Call een amp Motorist 1 asien amp Call Back Standby eie 8 aa 9 Alan Cally O e eda 10 Electron e Access pni aae o algae 11 TROUBLESHOOTING ua 13 Test Proeedure a e AUR 13 Transceiver NAM Programming Kyocera Model M200 16
21. The battery leads are then disconnected and the battery exchanged Reassemble the mounting hardware Call box batteries contain lead and must be disposed of properly 33 CWT Call Box Owners Manual Front Panel Light Replacement Open the call box main housing and simply replace the light bulb located in a twist lock socket Strobe Light Replacement If Used Failure of the strobe light is cause for replacement of the entire blue strobe fixture Before replacing the light fixture test the strobe connector on the IO board for 12 VDC under the proper circumstances Flashing blue LED lights on at night when solar power is not present b To test the regulator output connector during the day disconnect the solar cable wait until the solar alarm has called into the maintenance computer and then test for 12 VDC at the strobe connector The drawing below shows the wiring harness interconnections and serves as the functional block diagram for the call box Inner Outer Call D Push D 4 Cellular S d Button s B NER icd Transceiver witc witc la Data Cable P N Subassy 6060 0515 eS P N 6060 0136 To Hands Free Module Call Box Controller Input Output Board f F Board Data Cable P N Subassy 6060 0358 Power Harness d P N Subassy 6060 0283 Figure 7 Call Box Interconnection Diagram Revised April 2005 CHAPTER 5 Preventive
22. aintenance computer phone number If it is correct there is a problem with the maintenance computer Contact the maintenance center to verify that the maintenance computer is on and running the appropriate software If the maintenance computer is in order attach a phone to the maintenance computer phone line and reinitiate the alarm If the phone in the maintenance center rings a hard failure exists within the maintenance computer If the phone does not ring the phone number programmed into memory location 9 may be wrong If necessary have a PC technician repair the maintenance computer but before calling the technician try to reset the computer by turning it off and then back on cold re boot 3 10 Call Box Status Indication Not Normal When a call box calls the maintenance computer the transceiver powers up and is assigned a channel This is the system setup procedure The transceiver will then dial the maintenance computer After two rings the maintenance computer will answer and ask the call box for status information and identification The call box responds with the status of the call box and its ANI Automatic Number Identification and checksum digit The format used is the following ABCDEXXXXc where A BCDE XXXX is the leading digit and never changes This digit is actually a DTMF star are four decimal numbers that contain the status information of the call box is the 4 digit ANI is the checksum numb
23. an immediate alarm is sent the maintenance computer captures the data A printout is then instantly generated showing all pertinent data The following information is normally sent out during the scheduled report call e Open front door e Controller board error e Excessive cellular errors e Call counts and air time usage 30 Revised April 2005 CHAPTER 4 Primary Repair Modular Level 4 1 4 2 Corrective Maintenance Corrective maintenance is performed on the call boxes on an as required basis Corrective maintenance is generally the result of a failed subassembly or destruction or damage to the call box The primary concern of corrective maintenance is to return defective call boxes to operational status as quickly as possible Corrective maintenance is initiated as a result of a report call an alarm call or a failure to report in as scheduled which generates an exception report at the maintenance center indicating a problem at the call box Maintenance center personnel will attempt to determine the extent of damage to a call box from the reports generated by the maintenance computer See Section 3 21 for a description of the maintenance reports Transceiver Considerations The cellular transceiver mounted within the call box main housing should be properly activated and tested prior to installation of the call box In addition to activation the controller board flash memory must have a minimum of three memory locations proper
24. ance Computer Reports ses terrestre kreisen 29 3 23 Preventive Maintenance Reports eerie dia ride 29 3 24 Corrective Maintenance Reports ie eu Oe He PAR ER Cn RO us 29 3 25 Exeeplion Reports emen i ad bol euo ea 29 3 26 Alarm Report in 30 CHAPTER 4 PRIMARY REPAIR MODULAR 31 4 1 Corrective Maintenanee utes 31 4 2 Transceiver Considerations eei e sene t SR err de 31 4 3 Cellular Transceiver Programming retire 32 4 4 Modular or Assembly 1 Pe ire 32 iv Revised April 2005 CWT Call Box Owners Manual 5 PREVENTIVE MAINTENANCE eee eren nennen nnn n nna 35 5 1 Preventive Maintenanee SS RE caa dude 35 5 2 Call Box Authorized Electronic 36 CHAPTER 6 CALL BOX PRIMARY PARTS 39 CHAPTER 7 WIRE LIST CABLE LIST 41 7 1 Input Output Board 6020 0449 41 7 2 Controller Board 6020 0300 Connectors Cables 44 7 3 Antenna Conectada IRA RA 47
25. and There is no loss of tension as band released is used up in the bend Pull up on cutting handle to cut the band Remove tool holding stub of band down with thumb LEAR Page 2 of 6 Clinch stub of band by hammering tabs down flat Call Box Installation Instructions 4 Attaching Signs Optional wind bracing to be installed at sign s left and right center edges See Figure 5 below Signs Install pipe between signs near center edges Nut Washers Bolt Figure 5 Optional Wind Bracing Page 3 of 6 Call Box Installation Instructions 5 Install sleeve Sleeve Gasket V Thread the black sleeve into the large center hole of the pole and place the large rubber gasket over the sleeve Antenna X 6 Install cables and solar assembly Solar Panel 6a Install the antenna cable and the solar cable in the pole and pass the ends out of the large center hole Please note the connectors for proper orientation and direction Set Screws 3 gt 8 Mount the call box back plate to the pole using the bolts and rubber washers with the square holes and tighten with the nuts Optional Horn Screw the antenna into the solar assembly and mount the solar assembly to the top of the pole after connecting the antenna cable and solar panel cable Carefully feed excess cable back into the pole Orient the solar panel so that it faces due
26. as burned out Typically this just requires replacement of the lamp which is done from inside the call box front housing assembly Occasionally a false lamp alarm may occur Before replacing the lamp open the front door of the call box If the lamp turns on the lamp alarm received was a false alarm The controller board should be replaced to correct this alarm condition only after verifying that the lamp wires are in good condition and the lamp is well seated in its socket No Solar Charging for 16 Hours Alarm The solar charging alarm will be reported if there is no power from the solar panel for an extended period of time 16 hours The technician should be prepared to replace the solar panel or solar cable and check the fuses for the call box when visiting a call box with a charging alarm The figure shown below shows the connections and pin out functions for the solar panel connector Cable to Pole Cap Manhatten Electric Cable P N M33406 Pin 1 Power Solar Pin2 Ground Pin3 Solar Panel Sense Pin4 Solar Panel Sense 5 Horn Pin6 Horn Figure 5 Pole Cap Wiring Revised April 2005 27 S SS S RSS SS S S US 3 24 SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS II II SS SS SS SS SS SS SS SS 061 pins E B CWT Call Box Owners Manual This page shows a detailed view of the solar supply cable 6060 0118
27. board provides power to the transceiver while in the call box The types of problems that may be seen if any of the controller board and or the radio interface board components fail are as follows e Call box fails to power up when front door is opened e Call box fails to make complete maintenance calls after power up e Call box sends false alarms to the maintenance computer e Call box fails to send report calls at scheduled check in date and time If transceiver testing has not solved the problem replace the controller and radio interface boards This is accomplished by removing the controller mounting plate screws and swinging open the mounting plate Remove the four controller board mounting screws Disconnect the following controller board cables Revised April 2005 CWT Call Box Owners Manual cwt Revised April 2005 e Ribbon Connector from Input Output Board at J1 e Radio Data Connector at J2 of the radio interface board Replace the controller and radio interface boards and reconnect all connectors Reinstall the transceiver and re test the call box for proper operation Check with the maintenance center computer for proper programming of this call box Call Box Handset If the call box handset is suspected as being defective the procedure for replacement is as follows a Open the call box housing assembly to the electronics section b Turn the call box power switch to the off position c Disconnect the four hands
28. date of initial installation When the call box is opened properly by maintenance personnel it will place a call to the maintenance computer and report an authorized entry The maintenance computer assumes that preventive maintenance is taking place and logs this information with time and date Management may then generate the preventive maintenance report that identifies all of the call boxes meeting these criteria Corrective Maintenance Reports The maintenance computer is notified by the call box of any failures as they occur The failures result in an alarm call from the call box to the maintenance computer Alarms that have been masked during initial call box programming will not make phone calls to the maintenance computer as they occur but they will identify themselves when the scheduled report call is made Alarm calls will notify the maintenance computer of failures with the battery solar power handset lamp opening of the inner door or any tilt in excess of 45 The maintenance computer software prints a report of the alarm call as soon as the call is received see Alarm Reports section Detailed reports of all alarm calls may also be generated Maintenance personnel typically should act on alarm calls as soon as they are received Exception Reports On a regular basis the maintenance computer software generates an exception report This report lists any call box that failed to call in during the previous reporting cycle This r
29. eestablishes contact between the PSAP center and the motorist If the call box patron does not respond to the operator s voice the operator can activate a ringer If no one answers the ringer the operator can terminate the call putting the call box into the quiescent mode Report Call Report calls are made by the call box at intervals that have been programmed by the maintenance computer At the report call time the call box controller transitions the call box into the active state and places a telephone call to the maintenance computer When the telephone link is established the maintenance computer will poll the call box for status The call box will respond with the status of the following items e Outer Door Open or Closed e Lamp Pass or Fail e Handset Good or Bad e Battery Voltage Acceptable or Unacceptable e Microprocessor Initialization Pass or Fail e Solar Panel or AC DC Module Disconnected e No Solar or DC Power Detected for 16 Hours e Inner Door Open or Closed e Call Box Standing or Tilted e Excessive Cellular Call Attempts Incomplete Maintenance Programming Radio Frequency Signal Strength Recent Account of Call Usage to the Answer Center Revised April 2005 9 CWT Call Box Owners Manual 2 6 After the status of these items is received the maintenance computer will terminate the telephone call and record the status information on the maintenance computer If the call box does not make its sc
30. eplace the transceiver data cable and then replace the transceiver itself If the transceiver does not make a programming call to the maintenance computer check to see that call box calling numbers and ANI have been programmed into the controller board This must be done using a computer and an Aurora Programming Kit 6000 0470 If the call box does not power the transceiver down after making a programming call replace the controller and or radio interface boards If the call box after successfully completing the power on sequence makes a call to the maintenance computer the call box is operating correctly 3 7 Transceiver Fails To Power Up and Recall Controller Memory Location 9 When an Alarm is Induced This situation will occur when an alarm is not acknowledged or the alarm circuitry does not function properly The procedure outlined below will assist in determining the source of the problem 1 Revised April 2005 A magnet passed over the inner door proximity switch should induce an alarm call Re attempt this alarm by holding the magnet on the proximity switch for two seconds If the call box does not respond induce a system power alarm by pulling the solar power cable out of the J10 connector If the call box then initiates a call to the maintenance computer there is a problem with the inner door circuitry If there is no response when the solar power alarm is induced replace the controller and radio interface boards If
31. eport includes the date and subsequent time span that the report covers the date and time of the report and the last status of any call boxes that did not report The software has a standard set of failure types and categorizes the call box into one or more of these types The report also contains the location of the call box that did not report in the last time it checked in and when it was scheduled to check in The exception report is generated automatically and requires no human intervention for it to function on a regular basis If necessary reports can be generated at will In addition to the report generation Revised April 2005 29 CWT Call Box Owners Manual the software offers the ability to archive raw data to floppy diskettes rectify any date or time change daylight savings time changes and leap year date changes and transfer report data via modem to other sites 3 26 Alarm Reports The call box continually is performing a built in self test in order to monitor its relative health The results of the built in test are sent from the call box to the maintenance computer This data is sent during a normally scheduled report call or in the event of detection of an abnormal condition Normally data is sent immediately upon any of the following events e Low battery e Failure of the solar panel e Tilt in excess of 45 e Failure of the handset microphone e Failure of the handset speaker e Inner door opened When
32. er This section of the maintenance manual identifies the various combinations of status digits and what the call box technician should do in each case l Revised April 2005 Digit B status is concerned with program errors cellular errors and report calls The following table refers to this digit Program errors refer to incomplete or faulty programming of the call box by the maintenance computer Cellular errors are recorded when the call box makes numerous 10 call attempts within a 24 hour period and the calls were not completed with a DTMF 0 This can occur if the programming report or alarm call are not terminated with a DTMF 0 at the end of the call These are dropped calls The report calls are the regularly scheduled check in calls made by the call box to the maintenance computer 21 CWT Call Box Owners Manual First Status Digit Table B DESCRIPTION OF STATUS SEE SECTION 0 AllClear None Report Call is Being Made 2 Cellular Error is Encountered 3 Cellular Error Encountered with a Report Call 4 Program Error Encountered 5 Program Error Encountered with a Report Call 6 Program Error and Cellular Error Encountered 7 Program and Cellular Error Encountered with a Report Call 2 Digit C status is concerned with program calls front door alarms and battery alarms The following table refers to this digit Oo EXE gt EM Second Status Digit Table DESCRIPTION OF STATUS SEE SECTION
33. et leads from the terminal block near top of the Input Output board d Remove the three board mounting screws e Move the IO board down and out of the way f Remove two screws of the handset strain relief bracket g Remove the old handset and install new handset h Install strain relief hardware 1 Reapply RTV or silicon sealer to the handset entrance hole j Connect either White lead to terminal block screw 1 Read left to right k Connect the other White lead to terminal block screw 2 1 Connect the Red lead to terminal block screw 3 m Connect the Black lead to terminal block screw 4 The call box should then be reprogrammed with the maintenance computer There should not be any handset alarm The call box can then be tested with the PSAP center and the audio checked in both directions for clarity and lack of distortion and proper volume level Call Box Low Battery Alarms If the maintenance computer reports low battery alarms day after day verify that AC main power is applied if used and or the solar panel tests properly for correct charging voltage and current the controller board is suspected The float charging circuitry may have failed Replace the controller board as outlined above After the controller board has been replaced the maintenance computer should no longer receive low battery alarms from that call box Battery Replacement Battery replacement requires removal of the battery bracket two screws
34. git is a modulo 10 checksum of the previous eight digits the four digit status bits and the four digits of the ANI of the call box The checksum is used to verify that a good communications path between the call box and the maintenance computer has resulted in proper data exchange The proper checksum number is obtained by adding the eight digits and subtracting the sum from the highest 10s digit in this case 20 For example call box number 0156 would send 040101563 at the beginning of a program call to the maintenance computer The checksum number is 3 and is calculated as follows 0 4 0 1 0 1 5 6 17 20 17 3 checksum The sum of the status bits plus the ANI digits is subtracted from the next highest 10s place to obtain the checksum number If the checksum is not correct the call will be re attempted If the inability to get the proper checksum remains it could be due to a failed call box controller board a problem with the cellular transceiver or poor cellular coverage at the location of the call box This can also occur if controller flash memory location 30 does not store a 4 digit ANI Call Box Does Not Get Programmed by the Maintenance Computer After the maintenance computer answers the call from the call box and requests status and ANI if the status indicates a program call is needed a series of DTMF tones will be exchanged between the maintenance computer and call box If there is a problem with the DTMF data exchange the mai
35. h provides the logic that monitors the call box sensors communicates with the maintenance system and ensures that call delivery is properly accomplished A high quality digital cellular transceiver is mounted in the call box enclosure The cellular transceiver provides the communication link between the call box and the cellular telephone network The call box handset is covered by a protective outer door mounted so that it helps shield environmental sound while the call box is in use Power for all call box functions is usually provided by a photovoltaic solar panel mounted at the top of the call box pole Alternately AC power can be used if available at the call box site location The Cellular Telephone Network The call box is able to communicate with the Public Safety Answering Point PSAP through radio links to cell sites Cellular telephone networks consist of a quantity of cell sites under the control of the Mobile Telephone Switching Office MTSO The MTSO establishes and controls the communication path between the cellular phone via the cell site and the normal land line telephone system This allows mobile customers to traverse an entire cellular system which may include being handed off from one cell site to another without noticeable interruption in the communication path Although call boxes are stationary devices the cellular network will still command handoffs to balance the call traffic resources The cellular system employs a d
36. heduled report call it will be identified on the next Exception Report run on the maintenance computer Normally call boxes are programmed to make report calls at times when conventional cellular usage and call box call usage is low This is typically between 10 00 p m and 6 00 a m Alarm Call The call box controller monitors multiple sensor inputs and performs self diagnostics If the call box controller senses an unacceptable condition from a sensor it either acts immediately on the input or it will note the condition for reporting on the next scheduled report call When the call box is programmed it receives information on which sensors to mask If a sensor is not masked the call box controller will act immediately on the unacceptable condition indicated from the sensor If the sensor is masked the call box will wait until its next report call to indicate the unacceptable situation to the maintenance computer The following sensors are part of every call box Outer Door Open Sensor This sensor detects when the outer door of the call box has been opened and causes the call box controller to place the call box in the standby mode If the sensor indicates the door has remained open for a defined programmable period of time it is recorded by the call box controller for either an immediate alarm call or the next scheduled report call depending on masking configuration Lamp Failure Sensor This sensor detects when a lamp filamen
37. hen the program loads click the NAM Programming Tab l The ESN Electronic Serial Number of the transceiver will be displayed in the upper left section of the screen This number can be displayed as a hexadecimal number having eight digits containing letters and numbers The ESN can also be displayed as a decimal number showing numbers only A Hex and Dec button allow the ESN to be displayed in either format Programming the cellular telephone number into the transceiver module can be done within the block shown at the middle of the screen 3 The top line shows the transceiver model number Kyocera M200 Directory Number Enter the new mobile number obtained from the carrier and matched up with the ESN of the transceiver This number will be 10 digits area code and phone number and should be entered without spaces or dashes MIN Enter the same 10 digit number as entered in the Directory Number line area code and phone number without dashes or spaces MCC This number is the Mobile Country Code and should always be 310 for the United States of America MNC This number is the Mobile Network Code and usually will be 00 especially if using the Verizon Network When all lines have been filled in correctly click the Save to Phone button This button will turn red and stay red during the transceiver programming process When this button turns green the transceiver has been successfully programmed Do not turn off call box p
38. ial tool and tips provided Lock the cover in place by using the key and turning the key continuously until the cover plate is firmly in place When lock cover is tight slowly turn key in opposite direction until a click is heard The key can now be removed Install the lock cover plate and tighten screws Install the upper hole plug over the upper mounting bolt The Call Box should now be tested to determine proper operation Call Box Installation Instructions Page 6 of 6
39. igital format known as CDMA Code Division Multiple Access CDMA has been likened to a party When everyone Revised April 2005 1 CWT Call Box Owners Manual talks at once no one can be understood however if everyone speaks a different language then they can be understood CDMA systems have no channels but instead encode each call as a coded sequence across the entire spectrum in what is called a pass band Each pass band is 1 23 MHz In the digital domain each voice conversation is modulated with a unique code called a pseudo noise code that makes it distinguishable from the other calls in the frequency spectrum Using a correlation calculation and the code the call was encoded with the digital audio signal can be extracted from the other signals being broadcast by other phones on the network This digital format has advantages over the older analog cellular systems A much larger number of individual calls can be made using a given amount of RF Radio Frequency spectrum Noise and interference can be suppressed as well The Public Switched Telephone Network The Public Switched Telephone Network PSTN employs a complex of telephone lines trunks and switching gear that routes telephone calls from the originating telephone to the destination phone number The telephone number specified by the call box will be passed to the PSTN by the MTSO which will then route the call to the PSAP center The Call Box Maintenance
40. in 45 Tilt Switch Pin 46 Power Down Pin 47 through Pin 50 N C BO Revised April 2005 CWT Call Box Owners Manual cwt Pin 51 Audio Ground Pin 52 Audio Ground Pin 53 Handset Microphone Pin 54 Handset Microphone Pin 55 Spare Analog 1 Pin 56 Spare Analog 2 Pin 57 and Pin 58 N C Pin 59 Ground Pin 60 Ground J1 Function Connection to Sensors and Call Button Pin 1 Ground Pin 2 Lamp Pin 3 Ground Pin 4 Call Button Pin5 Ground Pin Inner Door Switch Pin 7 Ground Pin 8 Front Door Switch Pin9 Ground Pin 10 Call Connect LED J2 Programming Port Normally Not Connected Pinl TXDI Pin2 TXD2 Pin3 TXD3 Pin 4 Power Down Pin5 and Pin 6 N C Pin7 CPU Power 3 3 VDC Pin8 Ground 9 Pin 10 RXD5 Pin 11 RXD4 Pin 12 RXD3 Pin 13 RXD2 Pin 14 RXDI J3 Function Second Call Button if used Pin 1 Second Call Button Pin2 Second Call Button Ground J4 Function Third Call Button if used Pin 1 Third Call Button Pin 2 Third Call Button Ground Revised April 2005 43 CWT Call Box Owners Manual J12 Function TTY Buttons if used Pin 1 Call Button Pin 2 Ground Pin 3 Call Button 2 if used Pin 4 Ground Pin 5 Call Button 3 if used Pin 6 Ground Pins 7 8 9 10 11 12 13 14 No Connection 7 2 Controller Board 6020 0300 Connectors Cables J4 Function Board to Board Connection to Radio Interface Board 6020 0678 Pin 1 Serial Data Pin2 Serial C
41. intenance facility number These secondary telephone numbers must already be programmed into the memory slots of the controller board The maintenance computer can remotely program these numbers After the call box has been put into the authorized entry mode with the 5 digit security number and Code 0 the service technician can locally program the call box through the Aurora Programming Kit and a laptop computer Revised April 2005 37 CHAPTER 6 Call Box Primary Parts List PART DESCRIPTION Antenna Sign Assembly Antenna 3 dB Cellular Dual Band Antenna GPS Assembly Antenna 3 dB Cellular Dual Band Stubby Antenna Cable Sign Mounting Kit Call Box Sign Fiberglass Eng Grade Generic Sign Wind Brace Kit Blue Strobe Assembly optional Strobe Assembly Blue Strobe Assembly Amber AC DC Power Supply optional AC DC Converter Module AC DC Converter Cable Call Box Complete Call Box Assembly Call Box Main Housing Assembly Call Box Back Plate Assembly Call Box Front Door Assembly Cellular Phone Kyocera M200 Verizon Controller Processor Board Aurora Radio Interface Board Input Output Board I O Cellular Phone Junction Board w M200 GPS Antenna Bias Board 29 Handset w Armored Cord Front Door Magnet Inner Door Magnet Pushbutton Assembly Revised April 2005 PART NUMBER 4210 0067 4210 0068 4210 0055 6060 0436 6040 4037 3090 0033 3090 0086 6000 0087 6000 0087 02 6040 0011 6060 0335 6000
42. ire Handset Speaker Analog Ground Terminal 3 Red Wire Handset Microphone Terminal 4 Black Wire Handset Microphone Analog Ground J7 Function Area Lighting Connector Pin 1 12VDC Pin 2 Ground J8 Function Strobe Connector Pin 1 12VDC Pin 2 Ground J9 Function Hands Free Output Connector Pin 1 12VDC Pin 2 Ground J11 Function Power Connector Pin 1 Ground Pin 2 Battery Revised April 2005 41 CWT Call Box Owners Manual J5 Function Cable to Controller Board Pin 1 Ground Pin2 Ground Pin3 and Pin 4 N C Pin5 Solar or DC Power Pin6 Solar or DC Power Pin7 Regulator Output Pin8 Regulator Output Pin9 Area Light Pin 10 Area Light Pin 11 Strobe Pin 12 Strobe Pin 13 Ringer Pin 14 Ringer Pin 15 Spare Output Pin 16 Spare Output Pin 17 Discrete Output Power 12VDC Pin 18 Discrete Output Power 12VDC Pin 19 TTY Power 12VDC 4 Pin 20 TTY Power 12VDC 4 Pin 21 Main Power 12VDC Pin 22 Main Power 12VDC Pin 23 and Pin 24 N C Pin 25 CPU Power 3 3VDC 4 Pin 26 CPU Power 3 3VDC 4 Pin 27 RXD4 Pin 28 RXD5 Pin 29 TXD3 Pin 30 RXD3 Pin 31 TXD2 Pin 32 RXD2 Pin 33 TXD1 Pin 34 RXDI Pin 35 and Pin 36 N C Pin 37 Lamp Pin 38 Missing Solar Panel Pin 39 Main Call Button Pin 40 2 Call Button if used Pin 41 3 Call Button if used Pin 42 Inner Door Pin 43 Outer Door Pin 44 Call Connect Light P
43. lock Pin3 TPUO Pin4 TPU 1 Pin5 TPU2 Pin6 TPU 3 Pin 7 Digital Output 8 Pin 8 Digital Output 4 Pin 9 Digital Input 7 Pin 10 Digital Input 6 Pin 11 Radio On Pin 12 Not Used Pin 13 Reset Pin 14 Digital Input 15 Pin 15 Digital Output 1 Pin 16 Digital Input 10 Pin 17 Digital Output 2 Pin 18 Peripheral On Pin 19 Main Power 12 VDC Pin 20 Main Power 12 VDC Pin 21 CPU Power 3 3 VDC Pin 22 Ground Pin 23 Ground Pin 24 Through Pin 28 N C Pin 29 Analog Ground Pin 30 N C Pin 31 Tone Gain Pin 32 Tone Gain Pin 33 and Pin 34 N C Pin 35 DSP Gain Pin 36 DSP Gain Pin 37 TX Audio BI Revised April 2005 CWT Call Box Owners Manual cwt Pin 38 TX Audio Pin 39 RX Audio Pin 40 RX Audio J1 Function Cable Connection to Input Output Board J11 See 6020 0449 J11 J3 Function MCU BDM Port Pin 1 Data Strobe Pin 2 Bus Error Pin 3 Ground Pin 4 Data Strobe Clock Pin 5 Ground Pin 6 Freeze Pin 7 Reset Pin 8 Data Strobe Input Pin 9 CPU Power 3 3 VDC Pin 10 Data Strobe Output J4 Function DSP JTAG Port Pin 1 Test Mode Select Pin 2 Test Reset Pin 3 Test Data In Pin 4 Ground Pin 5 CPU Power 3 3 VDC Pin 6 Ground Pin 7 Test Data Output Pin 8 Ground Pin9 Test Clock Pin 10 Ground Pin 11 Test Clock Pin 12 Ground Pin 13 Emulator Output Pin 14 Emulator Output J5 Function Flash Protect and Debug Pin 1 DSP Debug QI Pin 2 DSP Debug Q2 Pin 3 DSP Debug Q3 Pin 4 DSP Debug Q4 5 and Pin 6 N C
44. ly programmed with the appropriate numbers 1 Flash memory location 30 contains the 4 digit ANI Automatic Number Identifier 2 Flash memory location 9 contains the phone number of the maintenance computer 3 Flash memory location 1 contains the phone number of the PSAP answer center location 4 Optionally program flash memory location 8 for alarm computer number if used These three primary memory locations should be programmed prior to installation of the call box This is accomplished by using the Aurora Programming Kit 6000 0470 in conjunction with a laptop or other computer running Windows 98 or newer operating system The primary memory locations should be checked during any field maintenance visit where the call box indicates a failure to call the maintenance computer or the PSAP center Revised April 2005 31 CWT Call Box Owners Manual 4 3 4 4 32 Cellular Transceiver Programming When the call box is installed and or during a field maintenance visit it is important that the programming call to the maintenance computer be listened to carefully This allows the installer to monitor the status of the call box during the programming procedure The call box can then be tested while under control of the controller board The actions taken by the cellular transceiver can be audibly monitored using the call box handset Modular or Assembly Replacement The first step to modular or sub assembly repair or re
45. nic Access Call In addition to the active mode the call box may also enter the standby mode The standby mode is entered when an established telephone call is place on hold In the standby mode the call box electronics and the cellular transceiver are powered up The cellular transceiver however will not be transmitting The standby mode is also entered when the front door of the call box is opened Revised April 2005 7 CWT Call Box Owners Manual 2 3 2 4 Program Calls When a call box is installed it is capable of making motorist calls immediately but it still must be programmed with the information necessary to coordinate with the maintenance computer Therefore when all call boxes are first installed they make a program call to the maintenance computer This program call will be initiated by turning on the call box power switch or by using the electronic access feature The call box will give the maintenance computer its Automatic Number Identifier AND which allows the maintenance computer to recall information about this call box from a database The maintenance computer will recognize the fact that this call box requires programming and begin an exchange of data This data includes time of report call days between report calls what alarms are considered high priority current RF signal strength and any telephone numbers to be reprogrammed in the controller flash memory When the exchange of information is complete
46. ntenance computer will repeatedly ask the call box for information until the call box returns the correct information to the maintenance computer The technician at the call box can detect this exchange by paying close attention to the tones heard in the call box handset If the DTMF repeatedly is heard the call box is probably not listening properly to the maintenance computer This can also be the case if the DTMF is heard repeatedly without a response from the call box When this happens it is due to one of two failure mechanisms 1 This failure can occur when the quality of the cellular phone call is very poor This is identified by audible noise during the phone call and by an unusually long programming cycle If this occurs reprogramming the call box will usually clear itup In the case that call quality is always poor the antenna connection and the antenna itself should be tested On rare occasions the cellular transceiver could be the source of the noise that prevents the data exchange from occurring properly 2 If there is little or no noise during the call and is repeatedly heard the controller board and or the radio interface board of the call box should be replaced Revised April 2005 CWT Call Box Owners Manual cwt 3 12 3 13 3 14 3 15 Transceiver Does Not Power Down After Program Call If the transceiver does not power down after a program call the controller and radio interface boards
47. nto flash memory location 30 Clicking the Read Phone Numbers From Call Box button will read all current numbers programmed into the flash memory To make changes to any phone number or to change the ANI click the box of the line to edit The old number can be erased and a new number entered The phone numbers can begin with a 1 and area code or just be a local 7 digit phone number Dashes can be used as part of the phone number Edit all numbers that should be changed and then click the Save Phone Numbers to Call Box button To CWT Call Box Owners Manual 3 2 permanently save these numbers in the flash memory click Program Call Box Flash To indicate that all numbers were saved the Program Call Box Flash button will turn green 9 To load or save all phone numbers to a file click the Load or Save file buttons The file can then be named for future use and reference NAM Programming Tab The NAM Programming tab is used for this call box model The model number Kyocera M200 is displayed Internal programming of the cellular phone number and cellular network code is accomplished using the NAM Programming Tab See Section 3 2 below Transceiver NAM Programming Kyocera M200 Transceiver NAM programming cellular phone number must be done with the EMTEST computer connected to the call box Connect the EMTEST cable to the interconnect board J2 and turn the call box power switch on Click the EMTEST icon W
48. on the call box the service technician must first inform the maintenance computer at the maintenance control center that the entry to the call box is authorized and not the result of vandalism Unless the call box has been extensively damaged the following procedures must be performed To gain authorized access to the call box the service technician uses a DTMF dialer to send a 5 digit security number suffixed with one of the following access control codes The following code is used for electronic control features 82269X The final digit of the code is listed below and determines the type of control If the call box accepts the code the call box light will blink the same number of times as the suffix digit PREFIX 82269 Code 0 A service technician first opens the front door holds the dialer up to the handset microphone The technician then sends the 5 digit security number with this code suffix to indicate this is an authorized entry thus placing the call box in the authorized entry mode The call box lamp will blink 10 times to acknowledge the proper code This mode has a twenty minute time out If nothing is done within this time period the call box reverts to the quiescent mode Code 1 The service technician sends the 5 digit security number with this code suffix to place a program call The maintenance computer can then program the call box with the preset data The front panel light will flash one time and then make a com
49. ones when a memory recall action is taken If the proper access tones are given the call box controller will place a telephone call out of one of the available 24 memory slots of the controller flash memory The phone numbers in these 24 memory slots can be programmed during any call to the maintenance computer The electronic access feature has a great number of important applications One is to give maintenance personnel the capability to use that call box to telephone a repair center or other supervisory telephone numbers Maintenance personnel can also use electronic access to induce report calls or to obtain authorized entry into the call box Revised April 2005 11 CHAPTER 3 Troubleshooting 3 1 Test Procedure Digital call boxes are best tested using the Aurora Programming Kit 6000 0470 This kit contains a special call box connector cable software and instructions The software is loaded into any Windows 98 based computer or higher and the programming and test cable is connected to a serial or USB port To commence programming or call box testing connect the cable to J2 of the Input Output board Please note that the cable connector has one blocked pin connection Match this up with the missing pin at the J2 connector The call box should be powered off during this connection Once the cable is connected boot the computer to the Windows desktop The following test procedure should be followed Diagnostics tab 1 Turn
50. ould be replaced If the alarm returns after several days return to the call box and check the connections of the solar panel cable both upper and lower connector The float charging circuitry for the battery is located on the controller board With the call box turned on and when the upper green LED is lit the battery is fully charged and in float condition Front Door Alarm The front door alarm will occur when the front door is left open for long periods of time This can be caused by a broken spring mechanism on the door by a broken door or because the handset was not replaced in its cradle In the case of a false alarm the failure could be due to a bad proximity switch or a defect within the controller board Revised April 2005 CWT Call Box Owners Manual cwt 3 22 3 23 3 24 3 25 Maintenance Computer Reports The maintenance computer contains the programming software necessary to program the operational personality and system parameters for each of the call boxes and interacts with the call box hardware through a cellular and PSTN communication link The following is a brief description of the reports generated by the maintenance computer software Consult the maintenance computer software user s manual for detailed descriptions Preventive Maintenance Reports The computer database contains information pertaining to each of the call boxes that report to it This information includes such items as call box location and
51. ower during the programming process which can take up to 60 seconds to program When the Save to Phone button Revised April 2005 CWT Call Box Owners Manual cwt 3 3 has turned green the power to the call box must be turned off for the process to be completed Call box power can then be turned back on and EMTEST restarted and the NAM programming of the mobile number can then be verified 9 The transceiver module can also be programmed over the air Verizon Only This can be done when Verizon has the ESN numbers in their system and they have assigned mobile numbers to be matched with the ESNs To program the transceiver module over the air an antenna must be connected to the call box antenna port Connect the EMTEST computer to the interconnect board at J2 and turn the call box power on Click the EMTEST icon and then click the Callbox Tab When the program loads click the Diagnostics Tab Enter the number 2 2 8 9 9 in the dial box and then click the Send Tab This programming call can be monitored by listening to the call box handset Music will be heard and when three beeps are heard the transceiver module has been programmed This process can take up to 60 seconds Do not turn the call box off until this programming has completed as the transceiver can be damaged Exiting Call Box Programming and Diagnostics When finished with the Call Box Programming and Diagnostics program click the Return tab and then click the Exit but
52. placement is gaining access to the electronics compartment of the call box Remove the lock cover and unlock the face plate lock This requires a special Medico key Two tamperproof screws must be unscrewed on the right side of the main housing At this point the main housing can be opened on the hinges The following sections will describe the testing and or replacement of the major sub assemblies 1 Transceiver The transceiver is mounted to special circuit board attached to the controller board plate If transceiver problems are suspected the transceiver can be removed from the call box and replaced with the same model transceiver Place a push button call to the PSAP center If the call goes through the system test the audio in both directions to make sure there is no distortion If the call does not go through check for activation problems with the system carrier Substitute another active transceiver and re test the call box If it is determined that the transceiver has failed replace the transceiver This may necessitate doing an ESN change with the carrier and then programming the original cellular telephone number into the new transceiver See section 3 2 This must be done to protect the PSAP s ANI or ALI database 2 Controller Board The controller board controls the transceiver using a digital command set logic and timing The radio interface board passes commands to the transceiver from the controller board The radio interface
53. plete programming call Code 2 7 When any of these codes are entered the call box will place calls using the phone numbers stored in flash memory locations 2 through 7 Code 8 The service technician sends the 5 digit security number with this code suffix to place a call to the alarm computer Code 9 The service technician sends the 5 digit security number with this code suffix to place a status call to the maintenance computer The maintenance computer can also double as the alarm computer PREFIX 82267 _ Code 0 9 Entering any of these codes will cause the call box to make calls from the numbers stored in flash memory locations 10 through 19 For example by entering the number 822675 the call box will dial the telephone number stored in flash memory location 15 PREFIX 82268 _ Code 0 9 Entering any of these codes will cause the call box to make calls from the numbers stored in flash memory locations 20 through 29 For example by entering the number 822683 the call box will dial the telephone number stored in flash memory location 23 Revised April 2005 CWT Call Box Owners Manual cwt These codes are used to cause the call box to make calls out of memory slots 2 29 This gives the technician the ability to test the call box without accessing or disturbing the PSAP center Using these security codes the service technician can call cellular system test numbers the phone company or a local ma
54. rm the following troubleshooting procedure 1 Verify that the controller board flash memory location 9 is properly programmed with the maintenance computer phone number If it is not reprogram memory location 9 with the correct maintenance computer phone number and re test the call box 2 If flash memory location 9 is programmed properly and the phone call is not initiated either the controller board or radio interface board has failed or the cable between the radio interface board and the transceiver has failed Replace the controller boards first and if that does not fix the problem replace the cable 3 9 Maintenance Computer Does Not Answer Phone Call From the Call Box If the maintenance computer does not respond to an alarm or report call a problem could exist with the maintenance computer the call box or the cellular phone network Perform the following troubleshooting procedure to determine the source of the problem 1 Try to determine if the maintenance computer did not answer due to a phone system problem If necessary reinitiate the alarm and when the call box attempts to call the maintenance center listen for cellular reorder tones busy signals or a phone that rings with no answer a If a cellular reorder tone is encountered it could be due to poor cellular coverage in the area an improperly programmed cellular transceiver or an improperly activated cellular transceiver Refer to the transceiver programming instruc
55. s an alarm call to the maintenance computer it has sensed a failure or abnormal condition In addition this abnormal condition might be reported to the maintenance computer during a report call Whether an abnormal condition is reported during an alarm or report call is dependent on how the call box was programmed by the maintenance computer To correct the alarm condition received by the maintenance computer the following procedures should be followed by the call box technician Inner Door Alarm When the maintenance computer receives an inner door alarm it indicates that the call box has been opened If the alarm is of the authorized entry type it means that a call box technician or someone with the security code information has opened the call box An unauthorized inner door alarm should be acted on immediately A vandal breaking into the call box a false alarm or a mechanical failure of the call box housing could cause the unauthorized inner door alarm The technician should be prepared to replace the entire call box for this type of alarm False alarms could be caused by a failed proximity switch a missing door magnet or controller board failure See Section 3 7 for detailed troubleshooting methods for the inner door Revised April 2005 25 CWT Call Box Owners Manual 3 16 3 17 26 Molex P N 03 06 1062 with 6 ea 02 06 5135 Molex sockets Lamp Alarm The lamp alarm indicates that the call box front panel lamp h
56. t has failed Handset Failure Sensor If the handset ear piece or microphone assembly fails either by vandalism or function this sensor will alert the call box controller Battery Voltage Sensor This sensor checks the voltage level of the battery If the battery reaches a voltage level indicating low capacity 11 0 VDC the sensor will alert the call box controller The critical battery voltage level is factory set for the specific battery installed in the call box e Solar Panel Disconnected Should the solar panel or DC power cable be disconnected or cut a system power alarm will be sent to the maintenance computer 16 Hour Missing Power In the event that power is not detected for more than 16 hours the missing power sensor will alert the call box controller Inner Door Open Sensor This sensor indicates that the electronics compartment of the call box has been opened When used in conjunction with the electronic access feature the call box controller will distinguish between an authorized and unauthorized entry into the call box and send the alarm call out with this status Revised April 2005 CWT Call Box Owners Manual cwt e Tilt Sensor This sensor mercury switch detects whether the call box has been tilted beyond 45 from vertical position Typically sensors are masked unless there is reason to act upon the failure immediately The tilt sensor for instance should always be acted upon immediately since it
57. tab l Revised April 2005 Click the Phone Numbers tab to display all call box calling numbers and the ANI Automatic Number Identifier of the call box Flash memory locations 1 2 and 3 are reserved for the Answer Center phone numbers For one button call boxes the Answer Center phone number is programmed into memory 1 location Flash memory locations 4 through 7 and 10 through 29 are reserved for the owner of the call box system Any number programmed into these memory locations can be called with the use of a tone dialer and a specific code is used to select which number will be called This feature is not intended for the public See the section on Electronic Access Flash memory location 8 is used for an Alarm computer Some Answer Centers have a computer for the decoding of call box alarm calls such as tilt or handset failure These Answer Centers can take action immediately upon receipt of these alarms Flash memory location 9 is used for the telephone number of the call box maintenance computer When call box alarms occur this number will be dialed automatically by the call box to report the alarm condition Flash memory location 30 is used for the ANI Automatic Number Identifier of the call box The ANI is the number used by the call box maintenance computer to identify specific call boxes This number is also used by the Answer Center to ID call boxes Every call box in a system must have a unique 4 digit ANI programmed i
58. tch position Transceiver Connector CDMA Controller Transceiver o 9 BE ae ji 7 Figure 4 Inside View of Call Box Electronics Sealed Lead Sensors and Harness Acid Battery 6 Revised April 2005 CHAPTER 2 Theory of Operation 2 1 Call Box The call box will operate in one of three functional modes the quiescent mode the active mode or the standby mode The call box will be in the quiescent mode for the majority of each 24 hour day In the quiescent mode the call box controller powers down all but the essential electronics This reduces the overall power requirement of the call box significantly The call box will operate for approximately 11 days on a fully charged battery if operating in the quiescent mode with no solar charging provided In the quiescent mode the call box monitors internal and external sensors continuously If the status of any of these sensors requires action the call box controller will wake up the necessary electronic circuits and transition into the active mode call box electronics including the cellular transceiver are powered up when in the active mode In this mode the cellular transceiver is able to transmit and receive voice and data allowing the call box to make one of the following phone calls depending on the condition causing it to enter the active mode l Program Call 2 Motorist Call 3 Report Call 4 Alarm Call 5 Electro
59. tering just below the picture of the battery in the upper left corner of the screen Solar Sense PASS or FAIL Note the picture of the solar panel in the upper left section of the screen If the solar panel or DC power is connected a happy face will be shown if not a frowning face will be shown Tilt PASS or FAIL If the call box is tilted greater than 45 degrees from vertical Fail will be indicated This test uses the mercury tilt switch located on the Input Output board Front Panel Light PASS or FAIL If the lamp and wiring are good PASS will be indicated Front Panel Light OFF or ON The front panel light can be tested by checking and un checking the box at the beginning of this line This test will override the solar connection light disable feature of the call box Call Connected LED OFF or ON The call connected LED light can be tested by checking the box at the start of this line Horn OFF ON The horn or sounding device located up and under the solar panel can be tested by checking the box at the beginning of this line If the sounding device is ON the picture of this device will show a happy face that is opening and closing its mouth Area Light if used OFF or ON The area light if present can be tested with this line The picture of the area light will show a lit light bulb if this feature is ON Night Strobe if used OFF or ON The strobe light if present can be turned on by checking
60. tions Chapter 3 Section 3 2 to verify that it has been properly programmed If it has not correct the programming errors and re test the call box If improper cellular transceiver activation is suspected contact the cellular provider to verify the transceiver ESN and phone number If the problem is caused by poor cellular coverage in the area changing cellular providers or replacing the omni directional antenna with a high gain directional antenna or relocating the call box are the only alternatives unless the cellular network is simply having temporary difficulties If cellular coverage is good and the problem persists replace the cellular transceiver and re test the call box b If a busy signal is encountered it is either because the trunk is busy no phone line is available to carry the phone call or the maintenance computer phone line is off hook In both cases the call box will retry the call five times In general the maintenance computer should not be busy If it is it should be checked If the maintenance computer is locked in the off hook state it should be repaired by a qualified PC technician If the 20 Revised April 2005 CWT Call Box Owners Manual cwt busy signal is still encountered and the maintenance computer is functioning properly follow the procedure of Section 3 5 above If the maintenance computer does not answer the call verify that controller flash memory location 9 is properly programmed with the m
61. ton to terminate the program Turn the call box power switch to the off position down and remove the cable connection to J2 of the Input Output board The next time call box power is turned on the call box will call the maintenance computer for an operational programming call Check Tuning of Battery Charging Circuitry The battery charge controller circuitry is factory set to optimally charge the battery that was originally installed in the call box This circuitry is very stable and should not be adjusted unless problems with battery charging have been noted or the battery has been replaced The following procedure should be followed to tune the charging circuitry 1 Make sure the call box is fully connected and powered on The Input Output board power input connector J10 must be connected to a variable DC power supply and must have at least 17 Volts DC input to the board on the solar panel input pins Optionally the solar panel can be used as long as weather conditions are sunny and the time is near mid day In addition the green LED on the controller board 6020 0300 at D6 must be illuminated This is the battery float indicator When the LED is on the battery is in float mode and is not being charged by the power supply or solar panel This D6 LED can be used to test the solar panel power output or the AC DC supply output If the call box power switch is off and the DC power is connected the LED will be on lit if power is present When
62. ver should you experience any difficulty Call Box Customer Service is available for you If after reading these instructions and the Troubleshooting section you still are unable to isolate or resolve a problem contact Comarco Customer Service at the following number 1 800 487 9166 Our hours are 8 00 a m to 5 00 p m Pacific Time Monday Friday Our address is Comarco Wireless Technologies 2 Cromwell Irvine CA 92618 1816 Ordering Parts for Your Call Box System Repair parts can be ordered by calling the above 800 number See Chapter 6 for Comarco part names and part numbers Revised April 2005 49 ADDENDUM Cellular Call Box Installation Instructions 1 Installing Foundation 12 a 38 See Figure 1 1a Dig hole at least 41 See Figure 2 3 feet deep with a diameter of 12 inches Notched ends Vs in mounting plate must be oriented in the direction the call box will be facing Depending where the call box is to be installed use the diagrams at right to determine at what depth to cement the foundation 2 Mounting Pole To Foundation 2a When installing pole check direction of the 3 holes this is the side of the pole that the call box will be mounted 2b Mount pole to the foundation using the hardware supplied Call Box Installation Instructions Leave the mounting plate of foundation at least
63. with the correct equipment should repair foundation damage If it is a false alarm the technician should open up the call box and observe the tilt switch located at the lower right corner of the Input Output IO board If it appears to be straight replace the IO board and re test the call box Handset Alarm The handset alarm occurs when the microphone or the speaker of the handset fails The technician should visit the call box and make a push button a call and verify that the handset has failed before replacing it If the alarm is a false one the controller board should be replaced Battery Alarm The battery alarm is sent to the maintenance computer when the voltage level of the battery falls below a specified value 11 0 VDC A bad battery or failure to charge a good battery can cause this failure The battery alarm should be acted on quickly If a good battery is allowed to be totally discharged it can result in failure of the battery The first thing to check on the call box is the battery voltage with the battery disconnected from the call box If it is at an acceptable level the alarm is false In case of a false alarm replace the controller board If the alarm is valid the problem could be with the controller board or failure of the solar panel to charge the battery Check the output voltage of the solar cable assuming sunlight is present If the voltage at the solar supply cable is acceptable the battery is probably bad and sh
64. y CDMA AMPS Mode Preference CDMA Pass Band RF Output Impedance 1 3 Call Box Specifications ITEM Height Width Depth Weight Battery SPECIFICATION Kyocera M200 Module CDMA and AMPS 800 and 1900 MHz 800 MHz 13 Kbps Voice amp EVRC 30 C to 60 0 6 Watts 104 dBm 0 005 FER 116 dBm 12 dB SINAD Digital 1 23 MHz 50 ohm nominal SPECIFICATION 2 6 at center 13 12 extreme 8 0 47 4 lbs 17 Amp Hours 13 VDC Revised April 2005 CWT Call Box Owners Manual cwt 1 4 Box Drawings The following pages show a typical call box installation Figure 2 the front panel layout Figure 3 and the call box interior Figure 4 Pole Cap Assembly antenna and solar panel 14 foot pole 4 in diameter Reflective Sign m Call Box Figure 2 Call Box Installation Drawing Revised April 2005 CWT Call Box Owners Manual Handset Armored Figure 3 Call Box Front Panel Cable Panel Light Push Button Medeco International Lou Instructions Input Output Board Six Pin Solar Connector GPS Antenna Internal Power Hinged Door shown in open Swi

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