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AP-501/502 HardwareManual

Revision Date: 03 FEB 2010

AP-501/502 Hardware Manual

by Apollo Security Inc.

All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, ormechanical, including photocopying, recording, taping, or information storage and retrieval systems - without thewritten permission of Apollo Security, Inc.

While every precaution has been taken in the preparation of this document, Apollo Security assumes no responsibilityfor errors or omissions, or for damages resulting from the use of information contained in this document or from theuse of programs and source code that may accompany it. In no event shall the publisher and the author be liable forany loss of profit or any other commercial damage caused or alleged to have been caused directly or indirectly by thisdocument.


Magnetic Stripe Reader For Apollo Access Control Systems

W A R N I N GHIGH VOLTAGE, AC MAIN POWER SHOULD ONLY BE CONNECTED BY QUALIFIED,LICENSED ELECTRICIANS. ALL APPLICABLE LAWS AND CODES MUST BE FOLLOWED. IFTHIS PRECAUTION IS NOT OBSERVED, PERSONAL INJURY OR DEATH COULD OCCUR

Power should not be applied to the system until after the installation has been completed. If thisprecaution is not observed, personal injury or death could occur, and the equipment could bedamaged beyond repair.-Verify that the external circuit breaker which supplies power to the device power supply is turnedoff prior to installation.-Verify that the output voltage of the power supply is within specifications prior to connection to thedevice.

C A U T I O NSeveral important procedures should be followed to prevent electro-static discharge (ESD) damageto sensitive CMOS integrated circuits and modules.

-All transport of electronic components, including completed reader assemblies, should be in staticshield packaging and containers.-Handle all ESD sensitive components at an approved static controlled work station. These workstations consist of a desk mat, floor mat and a ESD wrist strap. Work stations are available fromvarious vendors including the 3M company.

FCC Compliance StatementThis device complies with Part 15 of FCC Rules. Operation is subject to the following twoconditions:

1.This device may not cause harmful interference, and 2.This device must accept any interference received, including interference that may cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class A digital device,pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protectionagainst harmful interference when the equipment is operated in a commercial environment. Thisequipment generates, uses, and can radiate radio frequency energy and, if not installed and usedin accordance with the instruction manual, may cause harmful interference to radiocommunications. Operation of this device in a residential area is likely to cause harmfulinterference in which case the user will be required to correct the interference at his/her ownexpense. The user is advised that any equipment changes or modifications not expressly approvedby the party responsible for compliance would void the compliance to FCC regulations andtherefore, the user's authority to operate the equipment.

IMPORTANT INFORMATION

AP-501/502 Hardware ManualI


Table of Contents

Part I Introduction 2

................................................................................................................................... 21 Overview

................................................................................................................................... 22 General Features

................................................................................................................................... 23 Modes Of Operation

Part II Hardware Layout 4

................................................................................................................................... 41 Terminal Connectors

................................................................................................................................... 42 DIP Switches

......................................................................................................................................................... 5DIP Switch Tables

......................................................................................................................................................... 5DIP Switch Function

................................................................................................................................... 63 Keypad

................................................................................................................................... 64 LEDs

................................................................................................................................... 65 Tamper Switch

................................................................................................................................... 76 Additional Installation Information

......................................................................................................................................................... 7Lightning Protection

......................................................................................................................................................... 7Site Preparation

......................................................................................................................................................... 7Junction Box Installation

......................................................................................................................................................... 7Back Box Installation

......................................................................................................................................................... 8Adapter Plate Installation

......................................................................................................................................................... 8Reader Chassis Ground

......................................................................................................................................................... 8Weather Shield

......................................................................................................................................................... 8Securing the Reader

Part III System Wiring 10

................................................................................................................................... 101 Power

................................................................................................................................... 102 Grounding

......................................................................................................................................................... 10DC Ground

......................................................................................................................................................... 10RS-485 Signal Ground (SG)

......................................................................................................................................................... 11Safety (Earth) Ground

......................................................................................................................................................... 11Grounding System

......................................................................................................................................................... 11Grounding Potential Difference Checks Before Connecting

................................................................................................................................... 123 Card Reader Wiring

Part IV Troubleshooting 14

................................................................................................................................... 141 Maintenance

Part V Specifications 16

Part VI Supplemental Figures 18

Part VII Table of Figures 31

IIContents


Part VIII Revision History 33

Index 34

Part

Introduction

I

2Introduction


1 Introduction

An access control system provides a means to replace traditional key and lock systems, which areeasy to defeat because of the ease of copying of keys and use by unauthorized personnel. Withelectronic access control, the exact areas a person is able to access as well as during what time isconfigurable through a central control system. In addition to the power of greater control, ahistorical record is maintained which is useful in the case of a system security breach or for otherpurposes including calculating work time and facility use costing.

1.1 Overview

The AP-501, OEM card reader, and AP-502, OEM card reader with keypad, read standard creditcards or high energy magnetic stripe access cards. The reader translates the card data read intouser selected output formats, as required by the OEM's controller. The AP-502, with its12-position keypad, provides integrated card/PIN access control. Either reader can also serve asa low cost, directly controlled, slave reader for the AP-500 or AP-550 card reader/controller toallow control of a second door.

1.2 General Features

• Wide input voltage range (+6 to +24 Vdc)• Low power/surface mount• 1 million pass read head, standard• Small, rugged, die cast aluminum (mullion mount)• Complete array of coordinated mounting hardware• Mounts with security screw/tamper switch• Attractive, weatherized finishes• 3 LEDs for access and reader status• 12 position keypad with audible feedback• Easy installation with single quick-connect cable• Audible indicator of access grant/deny• Card and PIN data share same output lines• Custom finishes/overlays available• Bi-directional swipe• Wide temperature range• DIP switch selected Wiegand data output formats• DIP switch selected output: Data 0/Data 1 or Clock/Data• Distance to access system controller up to 500 ft.(150M) with Wiegand output

1.3 Modes Of Operation

The AP-501/502 outputs card data in the user selected, DIP switch configured, format. Refer toSection 2 for the presently available formats. This feature enables the AP-501/502, mag stripereader, to be used in an existing Wiegand card based access system without making any changesto hardware or software.

The reader asserts local control when an access card mis-read is detected. It turns on the redLED and sounds the 'bad' tone (3 short beeps) on mis-reads. Invalid card data is not transmitted.

The AP-501/502 communicates with an AIM-4SL reader interface module, or with an OEM'saccess system controller using either Data 0/Data 1 or Clock/Data electrical output. Both outputlevels are TTL compatible (refer to Figure 14).

Part

Hardware Layout

II

4Hardware Layout


2 Hardware Layout

2.1 Terminal Connectors

The AP-501/502 has 1 terminal block for connecting power and reader communication andfeatures. The connection terminals are factory equipped with removable screw-down quickconnectors which are easily removed from the board by firmly grasping the connector and pullingaway from the board. If pliers are used to remove the connectors, they should be of therubber-tipped type. Take care in using any tools near the board not to damage on-board components. The proper location of the quick connectors is outlined in white on the board.

AP-501/502 Terminal Connections

Reader ConnectionsPosition Type Label

1 Ground (Reader Power) GND

2 Green LED Control GLED

3 Beeper (Buzzer) Control BZR

4 Weigand Data 1/Clock D1

5 Weigand Data 0/Data D0

6 VDC (Reader Power) VDC

7 Red LED Control RLED

8 Yellow LED Control YLED

Table 2.1: AP-501/502 Terminal Connections.

2.2 DIP Switches

The AP-501/502 has one block of DIP switches, with 4 switches. These switches are used to setoutput options for the reader. It is recommended to power the board down before making anychanges in the DIP switch settings as any changes will not take effect unless the power is cycled.

5 AP-501/502 Hardware Manual


2.2.1 DIP Switch Tables

Function 1 2 3 4 Description

Test Mode 0 0 0 0 Factory test only

Data OutputFormat

0 0 0 1 Standard format

0 0 1 0 Data 0/Data 1

0 0 1 1 Clock/Data

0 1 0 0 Wiegand Format 1

0 1 0 1 Wiegand Format 2

Table 2. 2: AP-501/502 DIP Switch Settings

2.2.2 DIP Switch Function

Test Mode—This DIP switch setting is used only during in-factory testing.

Standard Format—This format must be selected when the reader is to communicate with anAIM-4 reader interface.

Data 0/Data 1—Configures the reader to out put Data 0/Data 1 electrical output. Refer to Figure14 for specifications on the data format.

Clock/Data—Configures the reader to out put Clock/Data electrical output. Refer to Figure 14for specifications on the data format.

Weigand Format 1—Only the 7 digits prior to the first field separator (or End Sentinel)are used. These are translated into the following format and are then transmitted as Data0/Data1.

Bit 1: Even parity; calculated over the first 13 bits.Bit 2-25: Card numberBit 26: Odd parity; calculated over the last 13 bits.

Weigand Format 2—Only the 8 digits following the Start Sentinel are used. These aretranslated into the following format and are transmitted as Data 0/Data 1.

Bit 1: Even parity; calculated over the first 13 bits.Bit 2-9: Facility codeBit 10-25: Card numberBit 26: Odd parity; calculated over the last 13 bits.

Table 2.2.1 : DIP Switch Function

When used with the AIM-4, the facility code is checked to be in the range 0-255 and the card number in the range 0-65535.

Readings outside these ranges result in an indication of "access denied-bad card". The red LED is turned ON and the 'bad' tone (beep-beep-beep) is sounded.

6Hardware Layout


2.3 Keypad

The AP-502 is equipped with a 12-position membrane keypad. The following data is transmittedby the keypad to the reader interface:

• 1st bit (P) is even parity for the next 7 bits.• 2nd, 3rd, and 4th bits are 1,1,0 respectively.• The next 4 bits contain the message.

P 0-110-0000 Keypad Digit 01-110-0001 Keypad Digit 11-110-0010 Keypad Digit 20-110-0011 Keypad Digit 31-110-0100 Keypad Digit 40-110-0101 Keypad Digit 5 0-110-0110 Keypad Digit 6 1-110-0111 Keypad Digit 71-110-1000 Keypad Digit 80-110-1001 Keypad Digit 90-110-1010 Keypad Digit CLR1-110-1011 Keypad Digit ENT1-110-1101 Tamper Contact Open

2.4 LEDs

The AP-501/502 has three LEDs on the front of the unit to show the current status for access. When connected to an AIM-4 reader interface, the LEDs will function as follows.

LED's Status

Red ON Locked or access denied

Red flashing Waiting for card entry

Yellow flashing Waiting for PIN entry

Green ON Unlocked

Green flashing Access granted

The LEDs can also function in combination in the case of Red and Yellow flashing to indicate aCard OR PIN may be used for access.

NOTE: Depending on the reader interface that the AP-501/502 is connected to, the LEDs mayfunction differently.

2.5 Tamper Switch

The AP-501/502 is equipped with a reed-type anti-tamper switch. The magnet supplied from thereader should be fixed on the mounting plate opposite the reed switch so that when the reader ismounted to the bracket, the tamper switch will be secure. When the tamper switch is activated,the reader will transmit a tamper signal and may not function, depending on the system.



2.6 Additional Installation Information

2.6.1 Lightning Protection

Lightning can cause serious damage to electronic equipment. The following guidelines minimizethe risk of lightning damage to the equipment.

•DO NOT run wire across or near any lightning rod grounding wires. AVOID running wiresnear any cable or wires connected to an outside TV or radio antenna.

•Ground the case of the reader as shown in Figure 34.

•The following list of ground choices are in descending order of preference:

1. An 8-foot (2.5 meters) copper rod driven into the earth near the equipment.

2. A copper cold water pipe. The pipe must not be isolated by plastic coupling.DO NOT use radiator, plastic plumbing, or hot water pipes.

3. The AC electrical system ground wire.

•Use copper wire of 16 AWG minimum for grounding.

•Minimize ground wire length and choose a ground location as near the equipment aspossible.

•Follow installation procedures from the manufacturer when using MOVs or spark gapdevices for protection.

2.6.2 Site Preparation

Before installation of the reader and the door hardware, the installer must first prepare the site.The following steps are involved in the preparation:

1. Determine the exact location where the reader is to installed (See Figure 32).2. For in-wall mount, cut a hole on the wall to mount a 1-gang junction box.

2.6.3 Junction Box Installation

Cut a hole 2-1/8 inch by 4-1/2 inch (54 mm x 114 mm) on the wall. The installer must ensure thatthe hole cut is not larger than the back plate. One side of the junction box should be against a wallstud so that the junction box can be fastened to the stud.

2.6.4 Back Box Installation

The ABX-2 (P/N 400-650) surface mount enclosure is designed for mounting a reader onconcrete, stone or masonry surfaces. Knockouts for 3/4" conduit are provided on the top andbottom. See Figure 33. Fasten the enclosure to the surface with appropriate hardware.

8Hardware Layout


2.6.5 Adapter Plate Installation

The AMP-4 (P/N 400-630) is a brushed finish stainless steel plate which is used for mounting areader to a single-gang electrical box. The plate covers the J-box opening.

2.6.6 Reader Chassis Ground

The reader must be grounded to protect it from potential ESD (electro static discharge) damage. See Figure 34 for chassis ground detail.

2.6.7 Weather Shield

Use the AWS-30 metal weather shield (P/N 400-992), AWS-10, clear Plexiglas weather shield(400-990), or AWS-20 smoked Plexiglas shield (400-991), to protect the reader from rain, ice, andsnow. Refer to Figure 154.

For in-wall mount, the reader mounting bracket, adapter plate, and weather shield are mountedtogether onto the junction box.

When used for surface mount, the reader mounting bracket, back box, and weather shield aremounted together onto the wall, using appropriate anchors. Drill mounting holes in the weathershield as required.

Apply weather-stripping and or sealant between the weather shield and the mounting surface toseal out moisture from the mounting holes and the cable access hole.

2.6.8 Securing the Reader

Fasten the mounting bracket (slotted hole down) to the selected surface. Align the bracket thentighten down the mounting screws. The ground wire is installed on the top mounting bracketscrew.

Verify that the DIP switches are configured as required (see Section 2) and that all wiring is inplace and securely connected. Neatly fold back all excess cable into the wall or box.

Verify reader operation, then continue.

Hook the reader's mounting flange over the top tab of the mounting bracket, then push the readerflush against the mounting surface. Tighten down the security screw at the bottom of the reader tofasten the reader in place.

WARNING

Power should not be applied to the reader until after the installation has been completed. If thisprecaution is not observed, personal injury or death could occur, or the equipment could bedamaged beyond repair.

WARNING

Verify that the external circuit breaker which supplies power to the reader power supply is turnedoff prior to installation.

WARNING

Verify that the output voltage of the reader power supply is within specification prior to connectionto the reader.

Part

System Wiring

III

10System Wiring


3 System Wiring

SPECIAL NOTE: To guard personal safety and avoid damagingequipment it is important to have a full understanding ofelectrical wiring practices and safety. The following sectionsprovide general guidelines relating to the AP-501/502, but are nota substitute for complete training in dealing with electricalsystems!

3.1 Power

Power is supplied to the AP-501/502 by the voltage connection the terminal block (see Part 2.1 forexact locations of terminals). The power connection should be 12-24 VDC. Power consumption is100 mA.

Take care when selecting a power supply for use with the AP-501/502. Most power supplies in themarket today provide good input/output isolation, however those which do not provide isolation (orhave high leakage capacitance), coupled with accidental AC power lines interchange, presentserious ground fault problems for installers. With ground fault, the signal reference betweensubsystems may be 115 VAc (230 VAc) apart. If these subsystems are interconnected, the largepotential difference will cause equipment damage or personal injury. Apollo recommends the useof isolated continuous power supplies only. All Apollo supplied power supply assemblies aretransformer isolated for safety and to minimize ground loop problems.

3.2 Grounding

Special care should be taken when grounding the AP-501/502 controller and other devicesconnected to it via the direct communication lines. Each device must be grounded to provide ESDprotection, personnel safety, and signal reference for devices which communicate with each other.Grounding the reader provides a good shield against external transients. There are three types ofcircuit grounds in systems using Apollo products: DC ground, RS-485 signal ground, and Safety(Earth) ground.

NOTE: The AP-501/502 does not contain a serial interface but the system it is connected to likelywill. The references in this section refer to the general system and not necessarily the AP-501/502itself.

3.2.1 DC Ground

This is typically the minus (-) side of the DC output of the power supply. It is to be connected tothe DC ground input of all devices being powered by one supply. It must not be connected in anyway to any of the 5 RS-485 signals or the AC side of the line including Safety (Earth) ground (oneconnection to Safety (Earth) ground is acceptable, but this connection is usually internal in the hostcomputer and should not be introduced externally if direct connection is used (RS-232/485)).

3.2.2 RS-485 Signal Ground (SG)

This is the 5th wire used for the RS-485 communications. It is used to provide a commonreference between all devices on the line and should only be connected to each of the devices' SG input. The SG wire must not be allowed to touch any other potential, especially earth ground. The shield drain wire of the RS-485 communications cable is commonly used to connect the SGleads together. Usually this wire does not have an electrical insulator. It is important that the SG



wire is thoroughly insulated by the installer at all connection points. Improper insulation of thisconductor may allow accidental shorting to earth ground through conduit or other metalliccomponents, causing intermittent communications or equipment damage.

3.2.3 Safety (Earth) Ground

Safety ground is part of the AC power system. To avoid ground loop current, there must be onlyONE point at which the safety ground connects to the DC ground.

The RS-485 signal ground must be isolated from the safety ground. This means that the RS-485cable shield drain wire must be insulated at connection points so that it will NOT accidentally shortcircuit to the conduit in instances where the conduit is connected to the safety ground. (See Figure117)

Please check the applicable regulations and legislation in your country prior to installing theAP-501/502 controller and other Apollo products. In the US, the National Electrical Code, as wellas other safety regulations, require that all equipment chassis and/or enclosures be grounded inorder to prevent electrical shock hazards. Each device must have a green wire safety ground. Thefunction of the green wire safety ground is to provide a redundant path for fault currents and toinsure that the circuit breaker will open in the event of a fault. In addition, grounding the enclosureprovides a path for ESD dissipation, thus protecting sensitive electronic devices. (See Figures 115and 116)

3.2.4 Grounding System

A grounding system can be viewed as two subsystems: the DC system and the Ground System.The DC system consists of all interconnected power supply returns, DC distribution wiring, andload devices. The principal function of the DC system is to provide signal reference forcommunication. The Ground System consists of all chassis grounds for power supplies and otherdevices, safety grounds, and AC grounds. Ground connection should be made to avoid groundloop problems. (See Figure 115)

Ideally, there should be ONLY ONE ground return point in a power supply system. In a system witha PC (personal computer), it is likely that the PC already provides the DC Ground connection tothe Ground System (earth ground). Care must be taken NOT to create more ground connections.In systems with multiple PCs communicating to Apollo Hardware via direct connection, the groundpotential must be the same for inter-connection, or some form of isolation must be provided.

3.2.5 Grounding Potential Difference Checks Before Connecting

Before a device is connected to an RS-485 subsystem, it must be checked for ground fault.Uncorrected ground fault can damage all devices connected to the RS-485 communication line.

To check if there is ground fault for a new unit, follow the steps below (See Figures 105, 113, 115,116 and 120):

1. Apply power to all devices already successfully connected to the RS-485 line.

2. Power up the new unit, but DO NOT connect it to the RS-485 line.

3. Connect the signal ground (SG) of the RS-485 line through a 10k limiting resistor.

4. Measure the AC and DC voltage across the resistor. There should NOT be more than 1 volt across the resistor. Otherwise find and clear the fault.

12System Wiring


5. Connect the new unit to the RS-485 line only if no ground fault is found.

3.3 Card Reader Wiring

For minimal operation of the AP-501/502, in addition to the power connection, the datatransmissions lines (J4- 4 & 5) must be connected to the host reader interface. For mostinstallations, the LED connections and the buzzer will be used by the reader interface to controlthese user feedback devices. Refer to the documentation for your reader interface for the properconnection of these lines.

Run wires to the reader from the AIM-4 or access controller using 24 AWG shielded cable (Belden9504 or equivalent). Terminate the wires in the mating connector (J4), as shown in Figure 34 and35.

Part

Troubleshooting

IV

14Troubleshooting


4 Troubleshooting

The reader function can be verified after communications are functioning properly. Afterconfiguring the card format at the reader interface, swiping a card in the reader should generate anaccess message on the host computer. If the message is “Access Denied” the reason for themessage will indicate further steps to be performed. “Access Denied – Wrong Facility Code” willalso display the actual facility code on the card. This information should then be entered to the hostcomputer system. “Access Denied – Not in File” will display the actual card number of thepresented card. This card should then be added into the employee database of the host system.”Access Denied – Access Level Error” indicates that the cards is entered into the system but theAccess Level assigned to the card does not allow access to the particular door at this time. If nomessage is seen at the host and communication is correct, the card may contain invalid data at isbeing rejected locally at the reader.

On readers with integral keypads, the keypad may be verified by setting the reader into the Cardand PIN mode. After presenting a valid card, the reader should flash the yellow LED (if installedreader supports 3 color LEDs). This indicates the reader is waiting for a Pin entry. Enter a validPIN using the keypad and press the “ENTER” key. Access should be granted.

A faulty keypad can cause a reader to emit random beeps as the keypad grounds, thus starting aPIN sequence but not completing it. This behaviour can also be seen in condensing humidityconditions.

4.1 Maintenance

For proper operation of the AP-501/502 regular maintenance is required.

Cleaning the Magnetic Read Head and Card Slot

During use, dust particles, dirt, magnetic oxides and other contaminants will accumulate on themagnetic read head and in the card slot. These contaminants will affect the longevity of the readhead and cards, and will also cause mis-reads.

To maintain high reliability and prevent excessive wear, the read head and card slot must be regularly cleaned. The following cleaning schedule is recommended:

- Once per week for indoor, low usage readers.- Once per day for outdoor or high usage readers.

To clean, use a pre-saturated, disposable head cleaning card (ACC-10, P/N 400-900). Followthe cleaning instructions on the card package.

Cleaning the Exterior Surface

The exterior surfaces and the membrane keypad may be regularly cleaned with a soft cloth andmild detergent to remove finger prints and smudges.

Part

Specifications

V

16Specifications


5 Specifications

Power Requirements

+6 to +24Vdc @ 100mA

Operating Environment

Temperature: -40 to +85º CRelative Humidity: 0-80% non-condensing

Dimensions

Reader: 5.6"L X 1.98"W X 1.4"H (14.2 X 5 X 3.6 cm)Adapter plate: 6.0"L X 3.0"W X (15.2 X 7.6 cm)Back box: 5.8"L X 2.2"W X 1.2"H (14.7 X 5.6 X 3 cm)

Part

Supplemental

Figures

VI

18Supplemental Figures


6 Supplemental Figures























Part

Table of Figures

VII



7 Table of Figures

Number Description Page14 Electrical Outputs 1832 Junction Box Installation 1933 Surface Mount Installation 2034 In Wall Installation 2135 Reader/AIM-4 Wiring 22154 Weather Shield (Aluminum) 23105 Signal Ground 24113 Fault Caused by Incorrect AC Power Wiring 25115 Ground Connection 26116 Ground Fault Test Between Sub Systems 27117 Overview of Grounding / RS-485 Wiring 28120 Ground Fault Check 29

Part

Revision History

VIII



8 Revision History

REVISION HISTORY

Revision Date Description of changes EditorE 25 AUG 2006 Rewrite and accuracy review R. Burnside

E.1 03 FEB 2010 Add clock/data to terminal connectorlayout

R. Burnside

Index 34


Index

- A -AC power system 11

Access Control 2

- B -Baud Rate 5

- D -DC ground 10

Dimensions 16

- G -Ground connections 10

Faults 10, 11

Saftey (Earth) Ground 11

- I -Isolation (Power) 10

- K -Keypad 6

- L -LEDs 4, 12

- O -Operating Environment 16

- P -Power supply 10

- R -RS-485

Signal Ground 10

- S -Specifications 16

- T -Tamper 6

Terminal Connectors 4

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