NCR RealPOS 7458
Release 1.0
Hardware Service
B005-0000-1442
Issue A
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i
Preface
Audience
This book is written for hardware installer/service personnel, system
integrators, and field engineers.
Notice: This document is NCR proprietary information and is not to
be disclosed or reproduced without consent.
Safety Warnings
Servicing
Caution: This product does not contain user serviceable parts.
Servicing should only be performed by a qualified service technician.
Fuse Replacement
Caution: For continued protection against risk of fire, replace only
with the same type and ratings of fuse.
Attention: Pour prévenir et vous protéger contre un risque de feu,
remplacer la fusible avec une autre fusible de même type, seulement.
Power Supply Cord Used as Disconnect Means
Caution: The power supply cord is used as the main disconnect
device. Ensure that the socket outlet is located/installed near the
equipment and is easily accessible.
Attention: Le cordon d'alimentation est utilisé comme interrupteur
général. La prise de courant doit être située ou installée å proximité du
matériel et être facile d'accés.
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ii
Lithium Battery Warning
Caution: Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type as recommended by the
manufacturer. The battery is battery is recyclable. At the end of its
useful life, under various state and local laws it may be illegal to
dispose of this battery into the municipal waste. Contact officials for
recycling options or proper disposal.
Attention: Il y a danger d'explosion s'il y a remplacement incorrect de
la batterie. Remplacer uniquement avec une batterie du même type ou
d'un type recommandé par le constructeur. Mettre au rébut les
batteries usagées conformément aux instructions du fabricant.
Battery Disposal (Switzerland)
Refer to Annex 4.10 of SR814.013 for battery disposal.
IT Power System
This product is suitable for connection to an IT power system with a
phase-to-phase voltage not exceeding 240 V.
Peripheral Usage
This terminal should only be used with peripheral devices that are
certified by the appropriate safety agency for the country of installation
(UL, CSA, TUV, VDE) or those which are recommended by NCR
Corporation.
Caution: DO NOT connect or disconnect a printer, keyboard, or any
other terminal-powered peripheral while the terminal is powered on.
Doing so may result in peripheral or system damage.
Environmental Consciousness
NCR is demonstrating its concern for the environment by designing an
intelligent power management system into this terminal that operates
efficiently whether the system is in a stand-alone or network
environment.
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iii
Grounding Instructions
In the event of a malfunction or breakdown, grounding provides a
path of least resistance for electric current to reduce the risk of electric
shock. This product is equipped with an electric cord having an
equipment-grounding conductor and a grounding plug. The plug must
be plugged into a matching outlet that is properly installed and
grounded in accordance with all local codes and ordinances. Do not
modify the plug provided – if it will not fit the outlet, have the proper
outlet installed by a qualified electrician. Improper connection of the
equipment-grounding conductor can result in a risk of electric shock.
The conductor with insulation having an outer surface that is green
with or without yellow stripes is the equipment-grounding conductor.
If repair or replacement of the electric cord or plug is necessary, do not
connect the equipment-grounding conductor to a live terminal. Check
with a qualified electrician or service personnel if the grounding
instructions are not completely understood, or if you are in doubt as to
whether the product is properly grounded.
Use only 3-wire extension cords that have 3-prong grounding plugs
and 3-pole receptacles that accept the product’s plug. Repair or replace
damaged or worn cords immediately.
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iv
References
•
•
•
•
•
•
•
•
•
•
•
NCR RealPOS 7458 Hardware User’s Guide (B005-0000-1440)
NCR RealPOS 7458 Site Preparation (B005-0000-1441)
NCR RealPOS 7458 Parts Identification Manual (B005-0000-1443)
NCR 5932 USB Keyboard User’s Guide (B005-0000-1395)
NCR 5932 Wedge Keyboard User’s Guide (BD20-1369-A)
NCR 5942 12.1-Inch LCD Monitor User’s Guide (B005-0000-1394)
NCR 5953 12.1-Inch DynaKey User’s Guide (B005-0000-1161)
NCR 5952 Wedge DynaKey User’s Guide (BD20-1370-A)
NCR 5964 12.1-Inch Touch LCD User’s Guide (B005-0000-1324)
NCR 5972 2 x 20 Customer Display User’s Guide (B005-0000-1372)
NCR 5973 International VFD Customer Display User’s Guide
(B005-0000-1162)
•
•
NCR 5982 5-Inch LCD Operator Display User’s Guide (BD20-1443-A)
NCR 7158 Thermal Receipt and Impact Printer Owner’s Guide
(B005-0000-1112)
•
•
•
•
•
•
NCR 7167 Two-Station POS Printer Owner’s Guide (B005-0000-1406)
NCR 7162 Printer Setup & User’s Guide (BD20-1453-A)
NCR 7194 Thermal Receipt Printer Owner’s Guide (B005-0000-1097)
NCR 7197 Receipt Printer Owner’s Guide (B005-0000-1409)
NCR 5945 Electronic Payment Terminal User’s Guide (B005-0000-1104)
NCR 5992 Signature Capture User’s Guide (B005-0000-1108)
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v
Table of Contents
Chapter 1: Product Overview
Introduction...........................................................................................1-1
Cabinet.............................................................................................1-2
Label Locations......................................................................................1-4
Chapter 2: POST Diagnostics
Power-On Self-Test (POST) Errors .....................................................2-1
Chapter 3: Hardware Service
Introduction...........................................................................................3-1
Safety Requirements ......................................................................3-1
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vii
Power Supply ......................................................................................3-48
AC Input ........................................................................................3-48
UPS .................................................................................................3-49
Key .............................................................................................3-56
Reset...........................................................................................3-57
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viii
Chapter 4: Cable Routing Guide
Primary IDE Cable................................................................................4-1
Flex Diskette Cable ...............................................................................4-4
Front Panel Cables ................................................................................4-5
UPS Battery Cables ...............................................................................4-6
Fan Cable................................................................................................4-7
UPS Power Cable ..................................................................................4-8
Appendix A: Feature Kits
Feature Kit List.....................................................................................A-2
Appendix B: Hardware Specifications
Performance Levels.............................................................................. B-1
Interrupts............................................................................................... B-1
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ix
Revision Record
Issue
Date
Remarks
A
Feb 2003 First issue
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x
Radio Frequency Interference Statements
Federal Communications Commission (FCC)
Information to User
This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in
a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause interference in which case the user
will be required to correct the interference at his own expense.
NCR is not responsible for any radio or television interference caused by unauthorized
modification of this equipment or the substitution or attachment of connecting cables
and equipment other than those specified by NCR. The correction of interference
caused by such unauthorized modification, substitution or attachment will be the
responsibility of the user. The user is cautioned that changes or modifications not
expressly approved by NCR may void the user’s authority to operate the equipment.
Canadian Department of Communications
This Class A digital apparatus complies with Canadian ICES-003.
This digital apparatus does not exceed the Class A limits for radio noise emissions
from digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications.
Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.
Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant les
limites applicables aux appareils numériques de la classe A prescrites dans le
règlement sur le brouillage radioélectriques édicté par le ministrère des
Communications du Canada.
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xi
Voluntary Control Council for Interference (VCCI)
International Radio Frequency Interference Statement
Warning: This is a Class A product. In a domestic environment this product may
cause radio interference in which case the user may be required to take adequate
measures.
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xii
Declaration of Conformity
NCR Corporation
Manufacturer's Name
NCR Corporation
Manufacturer's Address
Retail Solutions Division – Atlanta
2651 Satellite Boulevard
Duluth, GA 30096-5810
Information Technology Equipment
Class 7458
Type of Equipment
Model Number
100-120 V/200-240 V, 2.0 A/1.0 A, 50-60 Hz
Electrical Ratings (Input)
NCR Corporation, 1700 South Patterson Boulevard, Dayton, OH 45459,
USA, declares that the equipment specified above conforms to the
referenced EU Directives and Harmonized Standards.
EU Directive
Harmonized Standard(s)
89/336/EEC (EMC)
EN 55022
EN 55024
EN61003-2
EN61003-3
73/23/EEC (Low Voltage) EN 60 950
NCR Corporation
Retail Solutions Division — Atlanta
2651 Satellite Boulevard
Duluth, GA 30096-5810
European Contact:
International IP Counsel
206 Marylebone Road
London, NW1 6LY, England
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Chapter 1: Product Overview
Introduction
The NCR RealPOS 80 (also referred to as NCR 7458) is a powerful,
retail-hardened point-of-sale terminal targeted for general
merchandise, food and convenience store environments. It provides
exceptional scalability utilizing Intel Celeron and Pentium III
processors to address a range of price/performance levels and
operating system environments. The system offers superior
connectivity for retail, with support for legacy peripheral interfaces
(RS-232, PS/2, Parallel, and VGA), as well as emerging interface
standards such as Powered USB and a DVI video interface.
There are two color schemes available; Beige (G11) and Charcoal
Gray (CG1).
Beige (G11)
Charcoal Gray (CG1)
20311c
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1-2 Chapter 1: Product Overview
The 7458 is designed with serviceability in mind to reduce costly
downtime. It incorporates the latest in serviceability features including
tool free serviceability. Specifically, the 7458 incorporates:
•
•
•
Removable hard drive – The terminal utilizes a front-side
removable hard drive that slides easily out of the cabinetry without
the use of any tools, which simplifies replacement.
Slide out motherboard tray – All internal components are quickly
accessed and replaced without the aid of tools, which significantly
reduces repair times.
The removable tray results in faster upgrading of memory, hard
drive or other internal components.
Cabinet
The cabinet is optimized to accommodate either modular or integrated
configurations while providing expandability for future needs.
Outstanding flexibility has been designed into the optional integration
tray for use with unified configurations. This integration tray supports
a variety of NCR’s most popular peripheral options.
Internally, the following features are supported:
•
•
3 PCI slots
2 DIMM memory sockets supporting up to 512MB of PC133
SDRAM
•
•
•
•
•
Flex disk drive (standard)
Dual Hard Disks
CD ROM drive
Compact flash memory
Integrated battery back-up.
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Chapter 1: Product Overview 1-3
The following table highlights the standard features and options
available with the RealPOS 80 base Models:
Major Model
CPU
7458-1110
Intel 850MHz Celeron, 128MB Memory, Flex Disk, 4
RS-232, 4 Powered USB, Audio/Mic. and US Power
Cord. (G11)
7458-1111
7458-1200
7458-1201
7458-2200
Intel 850MHz Celeron, 128MB Memory, Flex Disk, 4
RS-232, 4 Powered USB, Audio/Mic. and US Power
Cord. (CG1)
Intel 850MHz Celeron, 128MB Memory, Flex Disk, Hard
Disk, 4 RS-232, 4 Powered USB, Audio/Mic. and US
Power Cords (G11)
Intel 850MHz Celeron, 128MB Memory, Flex Disk, Hard
Disk, 4 RS-232, 4 Powered USB, Audio/Mic. and US
Power Cords. (CG1)
Intel 1GHz Pentium III, 256MB Memory, Flex Disk, Hard
Disk, 4 RS-232 4 Powered USB, Audio/Mic. And US
Power Cords. (G11)
7458–2201
Intel 1GHz Pentium III, 256MB Memory, Flex Disk, Hard
Disk, 4 RS-232 4 Powered USB, Audio/Mic. And US
Power Cords. (CG1)
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1-4 Chapter 1: Product Overview
Label Locations
The serial number and model number are included on a label, which is
located on the bottom of the Electronics Box Tray, which can be seen
through a rectangular hole in the bottom of the cabinet. If the terminal
was shipped with an Operating System pre-installed then there is also
a Certificate of Authenticity label.
Note: The serial number is repeated on the inside of the Front Security
Door.
Class:7458-2201
S/N:36309845 Date:21 November 2002
Atlanta, GA 30096
NCR Corporation
Class 7458
Made in Singapore
100-240 Vac 6.0 A 50-60 Hz
This device complies with Part 15 of the FCC rules.
Operation is subject to the following two conditions:
(1) this device may not cause harmful interference, and
(2) this device must accept any ionterference received,
including interference that may cause indesired operation.
Model No: xxxx
Serial No: 54-xxxxxxxx
Date of Mfg. 04/10/03
This Class digital apparatus complies with
A
Canadian ICES-003
Get Appareli numeriqe de la classe est
A
conformo a la normo NMB-003 ju Canada
I. T. E.
E152553
ACN 000 003 592
NO.437
Windows 2000 Pro Embedded 1-2 CPU
Product Key:
H95X7-83WVV-CFCWW-M4MXX7-X6XGM
00019-068-654-234
20347
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Chapter 2: POST Diagnostics
Power-On Self-Test (POST) Errors
Whenever a recoverable error occurs during POST, the BIOS displays
an error message describing the problem.
If a system boot is incomplete (for example, the system is turned off
while it is going through the POST), then the next time the system is
powered on you may get a message stating that the previous boot was
incomplete. The BIOS will revert to safe values for the chip set, caches,
I/O components, etc. This provides the best possibility of returning to
the Setup routine and to normal functioning, but these values do not
always produce maximum system performance. To achieve maximum
performance after the BIOS has reverted to safe values, re-enter Setup
and select the maximum performance values.
If, for example, the terminal was simply turned off during POST, you
can return to the maximum performance values by simply entering
Setup and exiting or by rebooting.
During POST, you are asked to press <F1> and boot with the default
configuration. If you simply presses <F1> and then do not later return
to Setup, the system will boot; but the external cache will not be
enabled, even though the default configuration will enable the cache.
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2-2 Chapter 2: POST Diagnostics
Recoverable POST Errors
Whenever a recoverable error occurs during POST, the BIOS displays
an error message describing the problem. If the Beep Error Codes option
is set to ON in BIOS Setup, a series of 2 beeps is issued followed
four (4) groups of 1 to 4 tones. These tones correspond to a specific
Recoverable POST Error. The table below indicates this correlation.
These Beep Codes are to assist in understanding an error in the case
where the primary display is non-functional or a non-LCD/CRT.
Error and Beep Codes
The following is a list of the checkpoint codes written at the start of
each test and the beep codes issued for terminal errors. Not all Test
Points are issued by all of the systems. If no beeps are issued for that
code, the Beeps column remains blank. In such cases, rely on the on-
screen information.
Beeps
Error Message
Corrective Action
Disk Errors
1-1-1-1 0200: Failure Fixed Disk
Check cable/Replace
hard disk
Keyboard Errors
1-2-1-1 0210: Stuck Key
1-2-1-2 0211: Keyboard error
Replace Keyboard
Replace Keyboard
Replace Keyboard
1-2-1-3 0212: Keyboard Controller
Failed
1-2-1-4 0213: Keyboard locked –
Unlock key switch
Replace
Keyboard/Unlock
keyboard
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Chapter 2: POST Diagnostics 2-3
Beeps
Error Message
Corrective Action
Video Errors
1-3-1-1 0220: Monitor type does not
match CMOS - Run SETUP
Should not happen,
unless CMOS is
corrupted. Default
Parameters in Setup.
Memory Errors
1-4-1-1 0230: System RAM Failed at
offset:
Replace Memory
module
1-4-1-2 0231: Shadow Ram Failed at
offset:
Replace Memory
module
1-4-1-3 0232: Extended RAM Failed at
address line:
Replace Memory
module
1-4-1-4 Memory type mixing detected. Replace Memory
module
1-4-2-1 Single-bit ECC error occurred.
Replace Memory
module
1-4-2-2 Multiple-bit ECC error
occurred.
Replace Memory
module
CMOS Errors
2-2-1-1 0250: System battery is dead -
Replace and run SETUP
Replace CMOS battery
Run Setup
2-2-1-2 0251: System CMOS checksum
bad - Default configuration
used
Timer Errors
2-3-1-1 0260: System timer error
Real Time Clock Errors
Replace Motherboard
Replace Motherboard
2-4-1-1 0270: Real time clock error
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2-4 Chapter 2: POST Diagnostics
Beeps
Error Message
Corrective Action
2-4-1-2 0271: Check date and time
settings
Set Time and Date
Configuration Errors
3-1-1-1 0280: Previous boot incomplete
- Default configuration used
3-1-1-2 0281: Memory Size found by
POST differed from EISA
CMOS
Possible Hardware
problem with
Motherboard or
memory
Diskette Errors
3-4-1-1 02B0: Diskette drive A error
Replace drive or correct
setup to reflect no drive
3-4-1-2 02B1: Diskette drive B error
Replace drive or correct
setup to reflect no drive
3-4-1-3 02B2: Incorrect Drive A type -
run SETUP
Replace drive or correct
setup to reflect no drive
3-4-1-4 02B3: Incorrect Drive B type -
run SETUP
Replace drive or correct
setup to reflect no drive
Cache Errors
4-2-1-1 02D0: System cache error -
Cache disabled
Replace Cache
module/Motherboard
Other Errors
4-4-1-1 02F0: CPU ID:
Replace CPU
4-4-2-1 02F4: EISA CMOS not writeable Replace Motherboard
4-4-2-2 02F5: DMA Test Failed
Replace Motherboard
Replace Motherboard
Replace Motherboard
4-4-2-3 02F6: Software NMI Failed
4-4-2-4 02F7: Fail-safe Timer NMI
Failed
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Chapter 2: POST Diagnostics 2-5
Beeps
Error Message
Corrective Action
4-4-3-1 02F8: CPU over temperature
error
Check/replace Fan,
Check air vents, etc
4-4-3-2 02FA: Cannot read CPU
temperature
Check/replace Fan,
Check air vents, etc.
4-4-3-3 02FA: Cannot read CPU
temperature
Replace Motherboard
4-4-3-4 02FB: Cannot read System
temperature
Replace Motherboard
4-4-4-1 02FC: SMB Connect Failed
Replace Motherboard
Replace Motherboard
4-4-4-2 02FD: SMB clock chip
initialization failed
4-4-4-3 02FE: Battery not installed
Install Battery
The BIOS also can issue the following beep codes during POST:
•
One long tone followed by three short tones if the video
configuration fails.
•
One long tone followed by two short tones if an external ROM
module does not properly checksum to zero.
An external ROM module (LAN or Video board) can also issue audible
errors, usually consisting of one long tone followed by a series of short
tones.
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2-6 Chapter 2: POST Diagnostics
Terminal POST Errors
There are several POST routines that issue a POST Terminal Error and
shut down the system if they fail. Before shutting down the system, the
terminal-error handler issues a beep code signifying the test point
error, then writes the error to port 80h and attempts to initialize the
video. The handler writes the error in the upper left corner of the
screen (using both mono and color adapters). The routine derives the
beep code from the test point error as follows:
1. The 8-bit error code is broken down to four 2-bit groups.
2. Each group is made one-based (1 through 4) by adding 1.
3. Short beeps are generated for the number of times in each group.
Example: Test point 01Ah = 00 01 10 10 = 1-2-3-3 beeps
Test Points and Beep Codes
At the beginning of each POST routine, the BIOS outputs the test point
error code to I/O address 80h. Use this code during troubleshooting to
establish at what point the system failed and what routine was being
performed.
If the BIOS detects a terminal error condition, it halts POST after
issuing a terminal error beep code (see previous section) and
attempting to display the error code on upper left corner of the screen
and on the port 80h LED display.
If the system hangs before the BIOS can process the error, the value
displayed at the port 80h is the last test performed. In this case, the
screen does not display the error code.
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Chapter 3: Hardware Service
Introduction
This chapter discusses procedures for disassembling the 7458 hardware
for servicing. Topics include:
•
•
•
•
Safety requirements
Back Panel Cable connectors
Disassembly procedures
Board strapping information
Safety Requirements
Caution: This product does not contain user serviceable parts.
Servicing should only be performed by a qualified service technician.
Fuse Replacement
Caution: For continued protection against risk of fire, replace only
with the same type and ratings of fuse.
Attention: Pour prévenir et vous protéger contre un risque de feu,
remplacer la fusible avec une autre fusible de même type, seulement.
Lithium Battery Warning
Caution: Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type as recommended by the
manufacturer. Discard used batteries according to the manufacturer's
instructions.
Attention: Il y a danger d'explosion s'il y a remplacement incorrect de
la batterie. Remplacer uniquement avec une batterie du même type ou
d'un type recommandé par le constructeur. Mettre au rébut les
batteries usagées conformément aux instructions du fabricant.
Battery Disposal (Switzerland)
Refer to Annex 4.10 of SR814.013 for battery disposal.
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3-2 Chapter 3: Hardware Service
IT Power System
This product is suitable for connection to an IT power system with a
phase-to-phase voltage not exceeding 240 V.
Peripheral Usage
This terminal should only be used with peripheral devices that are
certified by the appropriate safety agency for the country of installation
(UL, CSA, TUV, VDE) or those which are recommended by NCR
Corporation.
Caution: DO NOT connect or disconnect a printer, keyboard, or any
other terminal-powered peripheral while the terminal is powered on.
Doing so may result in peripheral or system damage.
Grounding Instructions
In the event of a malfunction or breakdown, grounding provides a
path of least resistance for electric current to reduce the risk of electric
shock. This product is equipped with an electric cord having an
equipment-grounding conductor and a grounding plug. The plug must
be plugged into a matching outlet that is properly installed and
grounded in accordance with all local codes and ordinances. Do not
modify the plug provided – if it will not fit the outlet, have the proper
outlet installed by a qualified electrician. Improper connection of the
equipment-grounding conductor can result in a risk of electric shock.
The conductor with insulation having an outer surface that is green
with or without yellow stripes is the equipment-grounding conductor.
If repair or replacement of the electric cord or plug is necessary, do not
connect the equipment-grounding conductor to a live terminal. Check
with a qualified electrician or service personnel if the grounding
instructions are not completely understood, or if you are in doubt as to
whether the product is properly grounded.
Use only 3-wire extension cords that have 3-prong grounding plugs
and 3-pole receptacles that accept the product’s plug. Repair or replace
damaged or worn cords immediately.
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Chapter 3: Hardware Service 3-3
Back Panel Cable Connectors
The following illustrations identify the Back Panel connectors. The
optional USB Daughter Card has three 12V USB+ connectors, one 24V
USB+ connector, and Audio connectors.
AC Input Accessory AC Mic Audio Out 12V USB 24V USB
Mic
Audi
Out
* RS232/C
* RS232/A
(* Powered Serial Port)
* RS232/D
RS232/B VGA DVI-I
Parallel LAN
PS/2
20376
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3-4 Chapter 3: Hardware Service
Electronics Box Disassembly Procedures
This section explains how to disassemble the 7458 for service purposes.
Warning: Disconnect the AC power cord before disassembling the
Terminal.
Removing the Electronics Tray
1. Disconnect all cables from the back of the Electronics Box.
2. Turn the Security Door Key to the unlocked position.
Security Door
Key in Unlocked Position
20344
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Chapter 3: Hardware Service 3-5
3. Open the Security Door.
4. Pull the Release Latch forward to release the Electronics Tray.
Release Latch
20346
5. Slide the Electronics Tray out of the cabinet. About half way out
there is a Tray Stop on the side of the tray. Press in on the stop to
remove the Electronics Tray from the cabinet.
Tray Stop
20348
Replacing the Electronics Tray
Slide the Electronics Tray into the cabinet until it latches. Make sure the
Release Latch is completely closed in the lock position.
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Chapter 3: Hardware Service 3-7
2. Remove the USB Daughter Card.
a. Disconnect the USB Power Cable (P6) and the CD-ROM Audio
Cable (CN11, if present) from the USB Daughter Card.
b. Disconnect the USB Control Cable from the Motherboard.
USB Power Cable
(P6)
CD-ROM Audio Cable
(CN11)
USB Daughter
Card
USB Control Cable
20319
Note: When replacing the Daughter Card be sure to clamp the
USB Power Cable to the Power Supply as shown above.
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3-8 Chapter 3: Hardware Service
c. Remove the USB Daughter Card by lifting up on it and then
pivoting it out as shown below.
USB Daughter Card
USB Control Cable
Cable Clamp
20349
Replacing the USB Daughter Card
Note: The USB Daughter Card service assembly includes the
bracket.
a. Insert the two extensions on the bracket into the slots in the
Motherboard Chassis, pivot the assembly level, and push it
down to lock it in place.
b. Connect the USB Control Cable to the Motherboard.
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Chapter 3: Hardware Service 3-9
3. Use the illustration below for reference (Sheet Metal Tray not
shown). Disconnect the following cables from the Motherboard.
•
•
•
•
•
•
•
Front Panel Switch Cable (CN16)
Hard Disk Interface Cable (CN17)
Flexible Diskette Interface Cable (CN18)
UPS Control Cable (CN9)
Main Power Supply Connector (PS1)
CD-ROM/Flash Interface Cable (if applicable) (CN14)
Compact Flash Power Cable (if applicable) (CN15)
Hard Disk/CD-ROM
IDE-1 (CN17)
Flexible Diskette
(CN18)
2nd Hard Drive/Compact Flash
IDE-2 (CN14)
Front Panel
(CN16)
Compact Flash
Power
(CN15)
Power Supply
(PS1)
USB Card
(CN12)
UPS
(CN9)
19719a
4. Remove the Motherboard Tray assembly. Lift the back of the
assembly first and them work it out of the chassis.
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3-10 Chapter 3: Hardware Service
Replacing the Motherboard
Note: The Motherboard service assembly includes the sheet metal tray
and the PCI Tree Card.
1. Verify the board’s jumper settings. (See the Processor Board section)
2. Remove the CPU, Lithium Battery, and memory modules from the
old Motherboard assembly and install them on the new board. See
the Processor Board section later in this chapter for instructions how
to replace these items.
3. Follow the Removing the Motherboard instructions in reverse.
4. After powering up the terminal to verify that it is fully functional
you should re-flash the BIOS to ensure that it has the latest version.
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Chapter 3: Hardware Service 3-11
Removing a PCI Adapter Card
Adapter cards are connected to the PCI Riser Card inside the
Electronics Box.
1. Remove the Electronics Tray.
2. Release the Motherboard Tray Slide Latch and slide the
Motherboard Tray slightly toward the front of the terminal.
3. Disconnect any cables to the PCI Adapter Card.
4. Remove the PCI Card Latch. This is accomplished by lifting up on
the latch as shown below.
PCI Card Latch
AT Blank Brackets
20429
5. Disconnect the PCI Adapter Card from the PCI Riser Card.
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3-12 Chapter 3: Hardware Service
Removing the Power Supply
1. Disconnect all power cables.
•
•
•
•
•
Hard Disk Power
Hard Disk #2 Power
Flexible Diskette Power
CD-ROM Power
UPS Battery Power
Note: This is simplified by first removing the hard drive
assembly, if present. (See Removing the Second Hard Drive
section.).
•
•
USB Power
Motherboard Power
Note: The USB Daughter Card must be moved out of the way
in order to access the Motherboard Power Cable.
2. Remove the Power Cables from the Cable Clamp.
3. Release the Power Supply Latch and slide the Power Supply
toward the front of the terminal.
Cable Clamp
Power Supply
Power Supply Latch
20342
4. Remove the Power Supply.
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Chapter 3: Hardware Service 3-13
Replacing the Power Supply
The Power Supply has two hooks on the bottom that are used to hold it
in place.
1. Position the Power Supply in the terminal chassis so that the hooks
align with the slots in the chassis.
2. Slide the Power Supply toward the back of the terminal. The top of
the Power Supply slides under a turned over rail on the back of the
terminal.
3. Lock the Power Supply Latch.
4. Route the Power Cables through the Cable Clamp.
Removing the Flexible Disk Drive
1. Disconnect the cables from the Flexible Disk Drive.
2. Lift up on the green tab (under the ribbon cable) and slide the Flex
Drive Slide Latch away from the drive.
3. Remove the Flex Drive.
Flex Drive Slide Latch
Flex Drive Power Cable
Flex Drive Data Cable
20333
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3-14 Chapter 3: Hardware Service
Replacing the Flexible Disk Drive
1. Place the Flex Drive in the Flex Bracket, aligning the screw holes in
the Flex Drive with the two pins on the bracket.
Flex Drive
Flex Drive Bracket
CD-ROM Drive
Flex Drive Slide Latch
20340
2. Slide the Flex Slide Latch against the Flex Drive until it latches. The
bracket has two pins that align with the screw holes in Flex Drive.
3. Connect the cables.
Removing the CD-ROM Drive
1. Disconnect the Fan Cable and Ribbon Cablefrom the Front Control
Panel.
Ribbon Cable Connector
Fan Cable Connector
20505
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Chapter 3: Hardware Service 3-15
2. Press in on the latches on the sides of the disk drive assembly. At
the same time slide the drive assembly toward the back of the
terminal using your thumbs.
Note: Press on the top set of latches. The bottom latches are for the
Hard Drive Drawer.
Latches
20335
3. Lift the drive assembly out of the terminal and disconnect the
cables from the drive(s).
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3-16 Chapter 3: Hardware Service
4. Turn the assembly upside down and remove the CD-ROM Drive
from the bracket.
−
−
Disconnect the standoff by pulling up on the CD-ROM Drive
Remove the drive from the slots in the bracket
CD-ROM Drive
Standoff
Slots
Standoff
Flex Drive
Front Panel
Control Panel
20336
Replacing the Front Panel Control Board
The Front Panel Control Board is mounted on standoffs on the Flexible
Disk Drive/CD-ROM Bracket for easy removal/replacement.
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Chapter 3: Hardware Service 3-17
Replacing the CD-ROM Drive
1. Insert the two extensions of the CD-ROM Drive Bracket into the
slots in the bracket.
CD-ROM Drive Bracket
Standoff
Slots
20336a
2. Snap the standoff into the hole in the bracket.
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3-18 Chapter 3: Hardware Service
3. Install the Flexible Disk Drive/CD-ROM Assembly in the terminal.
There are two hooks on the bottom of the assembly that should
align with hooks on the Hard Disk Bracket. Slide the Flexible Disk
Drive/CD-ROM Assembly toward the front of the terminal until it
latches into position.
Ribbon Cable Connector
Fan Cable Connector
Flex Disk Power
Flex Disk
Hard Disk IDE
CD-ROM Power
(From Power
Y-Cable)
20337
Latch
4. Reconnect the cables to the disk assembly and Front Panel Control
Board.
Note: IDE interface cable connectors are color coded:
•
•
•
Blue connector – Motherboard
Black connector – Master Drive
Gray Connector – Slave Drive/Device (CD-ROM, Compact
Flash when the Secondary Hard Drive is present)
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Chapter 3: Hardware Service 3-19
Slave Drive
(Gray)
Motherboard
(Blue)
Master Drive
(Black)
20546
Removing the Hard Disk
Note: The Hard Disk can be removed without having to open the
cabinet.
1. Unlock and open the Security Door.
Hard Disk Security
Lock
Hard Disk Latch
Security Door
20345
2. Unlock the Hard Disk Security Lock.
3. Lift up on the Hard Disk Latch and remove the drive.
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3-20 Chapter 3: Hardware Service
Removing the Hard Disk Assembly
If necessary, the entire Hard Disk Assembly can be removed.
1. Disconnect the cables from the Hard Disk.
2. Press in on the latches on the sides of the Disk Drive Assembly. At
the same time slide the assembly toward the front of the terminal.
Flex Disk/CD-ROM Assembly Latch
Hard Disk Assembly Latch
20334
Replacing the Hard Disk Assembly
1. Insert the Hard Disk Assembly into the slot in the front of the
terminal. Slide it in until it latches.
Hard Disk
20339
2. Lock the Hard Drive Security Lock.
3. Connect the cables.
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Chapter 3: Hardware Service 3-21
Removing the Compact Flash
The terminal configuration determines where the Compact Flash is
mounted. It can be on the Secondary Hard Disk Bracket, the UPS
Battery Bracket, or on the chassis. All three locations contain the same
hole/slot pattern for the mounting the bracket.
1. Disconnect the Compact Flash Power Cable from the Motherboard.
2. Disconnect the Compact Flash Interface Cable (Ribbon Cable) from
the Compact Flash.
3. Remove the Compact Flash Assembly. The assembly has a hook on
the bottom end of the bracket and a snap connection standoff on
the top end. Unsnap the standoff and remove the assembly.
The card is mounted on four snap standoffs on the bracket for easy
removal.
Compact Flash
20332
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3-22 Chapter 3: Hardware Service
Replacing the Compact Flash
1. Hook the bottom of the Compact Flash Bracket onto the slot on the
Hard Disk Bracket (or UPS Bracket or the Chassis as applicable).
2. Snap the standoff into the hole on the bracket.
3. Connect the Compact Flash Power Cable and Compact Flash
Interface Cable.
Standoff
Slot
20331
Note: IDE interface cable connectors are color coded:
•
•
•
Blue connector – Motherboard
Black connector – Master Drive
Gray Connector – Slave Drive/Device (CD-ROM, Compact
Flash when the Secondary Hard Drive is present)
Slave Drive
(Gray)
Motherboard
(Blue)
Master Drive
(Black)
20546
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Chapter 3: Hardware Service 3-23
Removing the Secondary Hard Disk
1. Lift the Hard Disk Release Latch on the Hard Disk Bracket and
slide the drive assembly to the side as shown below to disengage it
from the chassis.
Hard Disk
Release Latch
20330
2. Disconnect the Hard Disk cables.
Replacing the Secondary Hard Disk
1. Verify the jumper settings on the Hard Disk is set to Master.
7 5 3 1
8 6 4 2
Master Setting (Pins 7-8)
20421
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3-24 Chapter 3: Hardware Service
2. Position the Hard Disk assembly over the hooks in the chassis base
and slide it into its latched position.
Hard Disk
20418
3. Connect the Power Cable (HDD3) to the Hard Disk.
4. Connect the Hard Disk Interface Cable to the Hard Disk and to
IDE-2 on the Motherboard.
5. Connect the Hard Disk cables.
Note: IDE interface cable connectors are color coded:
•
•
•
Blue connector – Motherboard
Black connector – Master Drive
Gray Connector – Slave Drive/Device (CD-ROM, Compact
Flash when the Secondary Hard Drive is present)
Slave Drive
(Gray)
Motherboard
(Blue)
Master Drive
(Black)
20546
6. Position the Hard Disk assembly over the hooks in the chassis base
and slide it into its latched position.
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Chapter 3: Hardware Service 3-25
Removing the UPS Battery Assembly
1. Remove the Secondary Hard Disk (if present).
2. Remove the Outside UPS Battery Bracket.
a. Release the latch on the by pressing the green tab toward the
back of the terminal as shown below.
b. Slide the bracket toward the side of the terminal to disengage
the hooks.
UPS Batteries
Release Latch
20329
3. Remove the batteries and disconnect the UPS Battery Cable.
4. Optional: If you need access to the Fan Cable remove the Inside
UPS Battery Bracket.
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3-26 Chapter 3: Hardware Service
Replacing the UPS Batteries
1. Connect the UPS Battery Cable to the Power Supply.
2. Insert the batteries in the bracket. This is a tight fit so be careful to
not cut the battery cables. Note the battery orientation. Also, make
sure the one battery is not sitting on top of the vertical sheet metal
extension in the base.
Vertical
Extention
Battery Orientation
20327
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Chapter 3: Hardware Service 3-27
3. Install the UPS Battery Cover.
a. Align the slots (3) in the bracket with the hooks in the chassis
b. Slide the bracket into its latched position.
Hooks
UPS Battery Cover
20328
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3-28 Chapter 3: Hardware Service
Removing the Fan
Note: The UPS Batteries (if present) must be removed before the Fan
can be removed (see the Removing the UPS Battery Assembly section.)
The Fan is mounted on two hooks and held in place by two Tension
Arms. The cable is connected to the Front Panel Control Board and is
held in place with two Cable Clamps.
Cable Clamp
Tension Arms
Hook
20384
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Chapter 3: Hardware Service 3-29
Circuit Boards
Processor Board
Flexible Diskette
(CN18)
IDE-2
(CN14)
DIMM2
IDE-1
DIMM1
(CN17) Front Panel
(CN16)
CPU
CPU Fan
Compact Flash
Power (CN15)
Reserved
(J1)
(CN10)
Power Supply
(PS1)
USB Card
(CN12)
RS232/C
(CN6)
RS232/A
(CN6)
PCI Riser Card
(PCI1)
RS232/D
(CN5)
RS232/B
(CN5)
UPS
VGA
(CN9)
(CN7)
DVI-I
(CN4)
Battery
Parallel
(CN3)
LAN
(CN2)
PS/2
(CN1)
19525
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3-30 Chapter 3: Hardware Service
Jumper Settings
COM1 Power
JP1
Pin 1 - 2
Pin 2 - 3
Default settings shown
COM1 Powered
Ring Indicator
Reserved
JP2
JP3
JP4
19547
Memory Configurations
Single
DIMM (MB)
Number of
DIMMs
Total Memory
(MB)
64
64
128
128
256
256
1
2
1
2
1
2
64
128
128
256
256
512
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Chapter 3: Hardware Service 3-31
Installing Memory Modules
The 7458 contains two DIMM sockets.
To install the DIMM, follow these steps:
1. Slide the Electronics Tray out of the terminal cabinet and locate the
DIMM socket.
2. Open the latches at the ends of one of the sockets.
19532
Note: The DIMM can be installed into either DIMM socket.
3. Align the DIMM in the socket and push it straight down (Note that
the DIMM connector is keyed).
17807
4. Ensure that the edges of the DIMM engage the latches and that the
latches are completely closed.
19533
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3-32 Chapter 3: Hardware Service
Replacing the CPU
CPU replacement kits include a CPU and a Heat Sink and Fan
Assembly. To replace these parts, use the following procedure.
1. Slide the Electronics Tray out of the terminal cabinet.
2. Locate the CPU (refer to Motherboard illustration earlier in this
section).
3. Remove any components that may obstruct removal of the CPU.
4. Unplug the Fan Harness.
5. Unhook the Heat Sink and Fan Assembly by pushing down on the
Retaining Clip and pivoting the clip away from the socket.
Retaining Clip
19544
6. Remove the Heat Sink and Fan Assembly.
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Chapter 3: Hardware Service 3-33
7. Unsnap the Lever on the CPU Socket and raise it to a vertical
position.
8. Carefully remove the CPU and place it in an anti-static packing.
18466a
9. Correctly position the new CPU over the CPU Socket and then
guide the pins gently into place. Once it is aligned in the socket,
push the CPU into the socket until it is fully seated.
Pin #1
18466
10. Lock the CPU in the socket by lowering the Lever and snapping it
into position.
11. Peel the thin plastic covering off the bottom of the new Heat Sink.
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3-34 Chapter 3: Hardware Service
12. Position the Heat Sink and Fan Assembly over the CPU (align the
Key) and lower it onto the CPU.
Caution: Make sure the Key is between the CPU and the
connector. Otherwise the CPU will overheat.
Key
17925
13. Hook the Clip on the left side of the CPU Socket. Then push down
on the Retaining Clip on the right side of the socket and hook it to
the socket.
Retaining Clip
19544a
14. Plug the Fan Harness into the Motherboard (CN10).
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Chapter 3: Hardware Service 3-35
Replacing the Lithium Battery
Caution: Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type as recommended by the
manufacturer. Discard used batteries according to the manufacturer's
instructions.
1. Slide the Electronics Tray out of the terminal cabinet.
2. Locate the Battery (see the board illustrations earlier in this section).
3. Pry the Battery out of the socket.
Positive Side of Battery
Pry Out Battery
19664
4. Insert the new battery.
5. Replace the Electronics Tray.
6. Run Setup and set defaults. Set the Date/Time and make any
desired special settings.
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3-36 Chapter 3: Hardware Service
USB Daughter Card
The USB Daughter Card provides powered USB connectors for
peripheral support.
Self-Healing Fuses: Each of the USB ports are fuse protected. The 24V
port uses a standard replaceable fuse. The 12V ports use Self-Healing
Fuses. If the current flow exceeds the fuse capacity, the fuse opens the
circuit. Once the cause of the excessive current draw (short, bad
peripheral etc) is removed, the fuse material cools down, and in few
seconds the fuse closes.
PC Beep USB Interface
CD-ROM Audio
F4, 3 A, 125 V
USB Power
24V USB
12V USB
Audio
Mic
20372
Controller Ports
•
Ports C & B are controlled by the USB controller at Bus 0, Device 7,
Function 2
•
Ports A & 24V are controlled by the USB controller at Bus 0, Device
7, Function 3
Note: The USB controller can be disabled in BIOS Setup under the
Advanced menu, in the OnChip Multi-function Device menu. It is
identified as OnChip USB 2 Device:.
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Chapter 3: Hardware Service 3-37
PIN ASSIGNMENTS
GROUND GROUND
Daughter Card Power Connector
1
3
5
7
9
2
+5V
4
6
8
GROUND
+5V
14
12
10
8
6
4
2
+5V
GND 24V 12V GND 5V GND GND
+3.3V
+12V
GROUND
13
11
9
7
5
3
1
GND 24V 12V 3.3V 5V
5V GND
10 +12V
11 +24V
12 +24V
13 +24V RTN
14 +24 RTN
View Looking Into Board
Audio Connectors
Amplified Stereo Out
Connector: Nike NK-025O
Microphone In
Connector: Nike NK-025P
PIN ASSIGNMENTS
PIN ASSIGNMENTS
1
2
3
GROUND
OUT 2
4
5
GROUND
GROUND
1
2
3
GROUND
MIC IN
4
5
GROUND
GROUND
OUT 1
GROUND
Color: ORANGE
Color: PINK
CD Audio In
Connector: Plastron LPHI-04S-020-3.0
PC Speaker Input
Connector: Nike 271S02-A01
PIN ASSIGNMENTS
PIN ASSIGNMENTS
1
2
3
4
CD_LEFT
GROUND
GROUND
CD_RIGHT
1
2
PC BEEP (SPEAKER)
GROUND
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3-38 Chapter 3: Hardware Service
Motherboard Interface Connector
25
26
23
24
21
22
19
20
17
18
15
16
13
14
11
12
9
7
8
5
6
3
4
1
2
10
View Looking Into Board
PIN ASSIGNMENTS
1
3
5
7
9
SYNC
2
4
6
8
SDOUT
SDIN
ACRST~
BITCLK
CD_OPEN_A
CD_ST_AB
CD_OPEN_B
REFRESH~
10 CPWOK
12 SD(1)
11 SD(0)
13 SD(2)
14 SD(3)
15 GROUND
17 USBDT0 -
19 USBDT1 +
21 GROUND
23 USBDT2 -
25 USBDT3 +
16 USBDT0 +
18 GROUND
20 USBDT1 -
22 USBDT2 +
24 GROUND
26 USBDT3 -
Connector: Molex C-GRID #70247-2601
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3-40 Chapter 3: Hardware Service
Ethernet Circuitry
The onboard Ethernet circuitry supports wiring in accordance with the
following specifications.
Standard
10/100Base-T
100 M bit/s
100 M
Data Rate
Segment Length
Max Segments between
Nodes
NA
Max Repeaters between
Nodes
4
Network Span
Nodes/Segment
Node Spacing
Cable
NA
NA
NA
CAT 5
The BIOS provides PXE Boot ROM capabilities for network loading.
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Chapter 3: Hardware Service 3-41
PCI LCD Board (5953-K152)
This PCI LCD Board provides a PCI bus interface for the 5953 12.1-Inch
DynaKey.
System Speaker
Connection
Power Harness Connector
VGA BIOS
Keyboard Header Connector
(for optional internal harness)
W1 Jumper Switch
and Shunt
LCD Connector
PS/2 Keyboard Connector
(Keyboard Adapter Cable)
16773
The jumper for W1 must either be placed in position 2-3 or not
installed at all.
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3-42 Chapter 3: Hardware Service
PCI LCD Board (5952-K052)
This PCI LCD Board provides a PCI bus interface for the 5952 10.4-Inch
DynaKey.
Panel Select Switch
(SW1)
Power Harness Connector
Keyboard Header Connector
(for optional internal harness)
VGA BIOS
LCD Connector
PS/2 Keyboard Connector
(Keyboard Adapter Cable)
15376
Setting the Panel Select Switch (SW1)
P1
P2
P3
Function
OFF
OFF
OFF
Panel 8 (Color DSTN) (Passive)
Panel 7 (Mono STN)
Panel 6 (Color TFT) (Active)
Panel 5 (Unused)
OFF
OFF
OFF
ON
ON
ON
ON
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
Panel 4 (5" Mono)
Panel 3 (Unused)
Panel 2 (Unused)
Panel 1 (Unused)
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Chapter 3: Hardware Service 3-43
PCI VGA Video Card (7456-K350)
This PCI card provides a PCI bus interface for CRTs used in dual
display configurations. Install the VGA PCI Card into a PCI slot in the
terminal. See the Hardware User’s Guide for information how to install
an adapter card. See the PCI VGA Video Card (7456-K350) for
installation information. For information about using the card in a Dual
Display configuration see the Customer Information Display User’s Guide
(BD20-1431-B).
20451
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3-44 Chapter 3: Hardware Service
4-Port PCI RS-232 Board (3030-K169)
The 4-Port RS-232 Board provides four additional RS-232 ports. The
board requires one unique IRQ and four eight-byte I/O addresses
which are automatically assigned by the PCI BIOS. It can operate in a
Windows 95/98/2000 or Windows NT environment. The board uses a
4-Port RS-232 cable to connect to peripheral devices. See the 4-Port PCI
RS-232 Board (3030-K169) for installation information.
18620
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Chapter 3: Hardware Service 3-45
4-Port PCI RS-232 Expansion Card (3212-K170)
The SIIG Full Profile PCI-4S RS-232 Board provides four additional
RS-232 ports. The board requires one unique IRQ and four eight-byte
I/O addresses which are automatically assigned by the PCI BIOS. It
can operate in a DOS/Windows 3.1x, Windows 95/98/98 SE/NT4.0/
2000 or Windows XP environment. The board uses a 4-Port RS-232
cable to connect to peripheral devices. See the 4-Port PCI RS-232
Expansion Card (3212-K170) for installation information.
20454
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3-46 Chapter 3: Hardware Service
2-Port PCI RS-232 Expansion Card (3212-K171)
The SIIG Full Profile PCI 2S RS-232 Board provides two additional
RS-232 ports. The board requires one unique IRQ and two eight-byte
I/O addresses which are automatically assigned by the PCI BIOS. It
can operate in a DOS/Windows 3.1x, Windows 95/98/98 SE/NT4.0/
2000 or Windows XP environment. The board has two RS-232 ports for
connecting peripheral devices. See the 2-Port PCI RS-232 Expansion
Card (3212-K171) for installation information.
20453
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Chapter 3: Hardware Service 3-47
Cash Drawer
Latch Assembly Wiring and Adjustments
Switch Assembly Detail
Route the Blue and Red
Yellow
wires under the cable tie.
Bend the wire leads to clear the
area of the mounting screw head.
Black
Blue
Red
Route wries under Latch Arm.
Green
Latches to the banded
end of the diode.
Solenoid Adjustment
Schematic
These surfaces
must be parallel
0.080 0.010
Drawer
Solenoid
6
5
4
3
2
1
Blue
Yellow
Green
Red
Black
Drawer
Open
Switch
Switch
20542
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3-48 Chapter 3: Hardware Service
Power Supply
The power supply provides power to the 7458 Terminal, as well as
various retail peripherals through the powered connectors. The power
supply is controlled by a logic on/off switch, which permits it to be
disabled through software. An AC outlet without a switch is provided
at the rear of the power supply for AC power to a CRT
Other features include:
•
Internal UPS including a battery charger and harness to 24 V lead
acid batteries
•
Un-switched AC convenience outlet (for CRT)
•
•
•
Auto sensing for 115 VAC/230 VAC operation
Cooling fan
TTL voltage compatible UPS signal harness (~UPS_OFF,
AC_GOOD, ~BATT_SENSE, and BATT_LO signals)
•
AUX peripheral power harness
Functionally, the terminal’s ON/OFF switch controls the power supply
control logic (~REM_EN) to activate the power supply. This switch
does not control actual AC mains voltage applied to the power supply.
AC Input
The power supply operates with the following voltage ranges.
Range
Nominal
Vrms
Minimum
Vrms
Maximum
Vrms
Input Current Max. Arms
Including CRT
Convenience Outlet
LOW (115) 100-127
HIGH (230) 200-240
90
136
265
5.3 A
2.6 A
8.3 A
180
4.6 A
DC Outputs
The power supply has the following DC outputs:
+3.3 V
+5 V
+12 V
-12 V
0.25 A
+5 VSB
2.0 A
+24 V
2.3 A
Voltage
10.0 A * 12.0 A * 11.5 A
Max. Current
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Chapter 3: Hardware Service 3-49
Maximum Rated Output Power
The maximum rated output power as defined as the sum of the
products of each nominal voltage and maximum load, which is 300 W
including battery charger output.
UPS
The UPS provides un-interruptible power to all DC outputs in the
event of an AC line interruption, until the support batteries reach a
specified level or until AC power is available again.
Note: The AC convenience outlet is not powered by the UPS during
AC line interruption.
The UPS is used for periods of time ranging from 1 minute to 30
minutes, depending on battery capacity and DC load of the system.
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3-50 Chapter 3: Hardware Service
Battery Performance
Transaction Ride-Through. The battery supports
full operation of the POS terminal and peripherals.
Application:
Maximum: 428 W (300 W DC output power and
70% efficiency)
Power Draw from
Battery
70% min, 75% typical
UPS Conversion
Efficiency:
1-30 minutes
Battery Support Time:
Battery Current Draw:
Battery Voltage:
16.5A max at 20V battery voltage
24 V nominal
4.0 Ah
Battery Capacity
Lead acid, starved electrolyte
Battery Chemistry:
18.0V min , 18.6V typical, 19.2V max (battery
disconnect)
Deep Discharge
Voltage:
21.0V min, 22.2V max
100uA max
Battery Low Voltage:
Battery Current Drain
(after deep discharge
cutoff):
3-5 years
Lifetime:
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Chapter 3: Hardware Service 3-51
Power Supply Cable Pin-Outs
HDD: P1
HDD: P2
12 V
GND
GND
5 V
YEL
BLK
BLK
RED
1
2
3
4
5
4
3
2
1
BRN: ~UPS_OFF
GRY: ~BATT_SENS
BPUR BATT_LO
WHT: AC_GOOD
BLK: GND
HDD: P3
FDD: P4
UPS: P8
6
GRY ~BATTS_RTN
GLK BATT_RTN
BLK BATT_RTN
RED 24V_BATT
RED BATT_CHG
RED BATT_CHG
5
4
3
2
1
BATT: P7
Power Supply
ATX: P10
3.3V : ORG
3.3V : ORG
GND : BLK
5V : RED
GND : BLK
5V : RED
GND : BLK
PWG :ORG/GRY Sripe
5VSB : PUR
12V : YEL
11 1
12 2
13 3
14 4
15 5
16 6
17 7
18 8
19 9
20 10
3.3V : ORG
-12V : BLU
GND : BLK
~REM_EN
GND : BLK
GND : BLK
GND : BLK
AUX: P6
5V : RED
5V : RED
GND : BLK
5V : RED
5V : RED
3.3V : ORG
12V : YEL
24V : BRN
GND : BLK
20423
2
4
6
8
1
3
5
7
GND : BLK
GND : BLK
5V : RED
GND : BLK
12V : YEL
24V : BRN
GND : BLK
10 9
12 11
14 13
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3-52 Chapter 3: Hardware Service
Clearing the Password
The password can be cleared as follows.
1. Turn the power off and disconnect power from the Terminal.
2. Slide the Electronics Tray out of the terminal cabinet.
3. Locate the Battery (see the board illustrations earlier in this section).
4. Use a small screwdriver and pry the Battery out of the socket.
Positive Side of Battery
Pry Out Battery
19664
5. Wait for about three minutes to clear the CMOS.
6. Replace the battery.
7. Replace the Cover.
8. Run Setup and set defaults. Set the Date/Time and make any
desired special settings.
9. Reassemble the Terminal and turn the power on.
10. Reset the CMOS memory and the password.
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Chapter 3: Hardware Service 3-53
Connector Pin-Out Identification
Primary Power (PS1)
Pin
Name
Function
1
+3.3 V
+3.3 volts VCC_3.3
2
3
4
5
6
7
8
9
+3.3 V
GND
+5 V
+3.3 volts VCC_3.3
Ground
+ 5 volts Vcc
Ground
GND
+5 V
+ 5 volts Vcc
Ground
GND
PWG
+5 VSB
Power Good
Standby +5 volts
+ 12 volts
10 +12 V
11 +3.3V
12 -12 V
13 GND
+3.3 volts VCC_3.3
- 12 volts
Ground
14 ~REM_EN Power on(Low Active)
15 GND
16 GND
17 GND
18 -5V
Ground
Ground
Ground
-5 volts –5V
+ 5 volts Vcc
+ 5 volts Vcc
19 +5v
20 +5v
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3-54 Chapter 3: Hardware Service
USB Daughter Card Power (CN12)
Pin
Name
Function
1
GND
Ground
2
3
4
5
6
7
8
9
GND
+5V
Ground
+ 5 volts
Ground
+ 5 volts
+ 5 volts
+3.3 volts
Ground
+ 12 volts
+ 12 volts
GND
+5V
+5V
+3.3V
GND
+12V
10 +12 V
11
+24V +24 volts
12 +24V
13 GND
14 GND
+24 volts
Ground
Ground
USB Daughter Card (CN12)
Pin
Name
Function
1
SYNC
2
3
4
5
CD_OPEN_A
SDOUT
CD_OPEN_B
ACRST~
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Chapter 3: Hardware Service 3-55
Pin
Name
Function
6
CD_ST_AB
7
8
9
PHONE
REFRESH~
SDIN
10 CPWOK
11 BITCLK
12 SD0
13 GND
14 SD1
15 GND
16 SD2
17 GND
18 SD3
19 GND
20 GND
21 USB_DT1~
22 USB_DT0~
23 USB_DT1
24 USB_DT0
25 USB_DT3~
26 USB_DT2~
27 USB_DT3
28 USB_DT2
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3-56 Chapter 3: Hardware Service
Front Panel (CN1)
Box Fan
Pin
Signal Name
1
+12V
2
Ground
Speaker
Pin
Signal Name
3
PC_OUT#
SPKR_POS
4
Key
Pin
Signal Name
5
Keyed
6
GND
Power LED
Pin
Signal Name
7
+5V through 330 ohm
GREENCTL#
8
Hard Drive LED
Pin
Signal Name
9
+5V
10 HDLED
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Chapter 3: Hardware Service 3-57
ON/OFF
Pin
Signal Name
11
PWRBTN#
Ground
12
Link Integrity LED
Pin
Signal Name
13
LINKLED
14
Ground
Reset
Pin
Signal Name
15
RST
16
Ground
Back Panel I/O
PS/2 Kybd/Mouse (CN1)
Pin
Signal Name
1
KBDData
2
3
4
5
6
MDATA
Ground
Vcc
KBClock
MCLOCK
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3-58 Chapter 3: Hardware Service
Serial COM1 (CN6)
Pin
Signal Name
1
DCD
2
3
4
5
6
7
8
9
Serial In - (SIN)
Serial Out - (SOUT)
DTR-
GND
DSR-
RTS-
CTS-
RI OR +12V for powered RS-232
Serial COM2 (CN5)
Pin
Signal Name
1
DCD
2
3
4
5
6
7
8
9
Serial In - (SIN)
Serial Out - (SOUT)
DTR-
GND
DSR-
RTS-
CTS-
RI
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Chapter 3: Hardware Service 3-59
Serial COM3 (CN6)
Pin
Signal Name
1
DCD
2
3
4
5
6
7
8
9
Serial In - (SIN)
Serial Out - (SOUT)
DTR-
GND
DSR-
RTS-
CTS-
+12V For powered RS232
Serial COM4 (CN5)
Pin
Signal Name
1
DCD
2
3
4
5
6
7
8
9
Serial In - (SIN)
Serial Out - (SOUT)
DTR-
GND
DSR-
RTS-
CTS-
+12V for powered RS232
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3-60 Chapter 3: Hardware Service
Serial COM5 UPS (CN9)
Pin
Name
Function
1
GND
GND
2
3
4
5
AC_Good
Batt_Lo
AC is present
Battery low warning
Batt_Sense# Battery connected
UPS_OFF# Enable UPS
Video Monitor (CN3)
Pin
Signal Name
1
Red
2
3
4
5
6
7
8
9
Green
Blue
No Connect
Ground
Analog Ground
Analog Ground
Analog Ground
+5V
10 Ground
11 No Connect
12 VID_SDA
13 Horizontal Sync.
14 Vertical Sync.
15 VID_SCL
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Chapter 3: Hardware Service 3-61
Ethernet (CN2)
Pin
Name
Function
1
TX+
Transmit Pos
2
3
4
5
6
7
8
9
TX-
Transmit Neg
Receive Pos
RX+
TERMPLANE
TERMPLANE
RX-
Receive Neg
TERMPLANE
TERMPLANE
FRAME GND
10 FRAME GND
CPU Fan (CN10)
Pin
Signal Name
1
GND
2
3
+12V
FAN_SENSE
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3-62 Chapter 3: Hardware Service
LCD Interface (CN4)
Pin
Signal Name
1
DATA2-
2
DATA2+
3
SHIELD2_4
DATA4-
4
5
DATA4+
6
DDCSCK
7
DDCSDA
8
ANALOG V-SYNC
DATA1-
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
DATA1+
SHIELD1_3
DATA3-
DATA3+
+5v
Return for +5V, V-SYNC H-SYNC(GND)
HOTDET
DATA0-
DATA0+
SHIELD0_5
DATA5-
DATA5+
SHIELDCLK
CLK+
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Chapter 3: Hardware Service 3-63
Pin
Signal Name
24
CLK-
C1 ANALOG RED
C2 ANALOG GREEN
C3 ANALOG BLUE
C4 ANALOG H_SYNC
C5 ANALOG GND (R,G&B return)
Parallel (CN3)
Signal Name
Pin
Pin
Signal Name
STROBE-
1
14 AUTO FEED#
15 ERROR#
16 INIT#
Data Bit 0
Data Bit 1
Data Bit 2
Data Bit 3
Data Bit 4
Data Bit 5
Data Bit 6
Data Bit 7
ACK#
2
3
4
5
6
7
8
9
17 SLCT IN#
18 Ground
19 Ground
20 Ground
21 Ground
22 Ground
10 23 Ground
11 24 Ground
BUSY
PE (Paper End) 12 25 Ground
SLCT 13
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3-64 Chapter 3: Hardware Service
IDE-1/IDE-2 (CN17, CN14)
Signal Name
Pin
Pin
Signal Name
Reset IDE
1
2
Ground
Host Data 7
Host Data 6
Host Data 5
Host Data 4
Host Data 3
Host Data 2
Host Data 1
Host Data 0
Ground
3
5
7
9
4
6
8
Host Data 8
Host Data 9
Host Data 10
10 Host Data 11
11 12 Host Data 12
13 14 Host Data 13
15 16 Host Data 14
17 18 Host Data 15
19 20 Key
DDRQ0 (DDRQ1)
21 22 Ground
I/O Write#
I/O Read#
IOCHRDY
23 24 Ground
25 26 Ground
27 28 Pull Down
DDACK0 (DDACK1)# 29 30 Ground
IRQ14 (IRQ15)
Addr 1
31 32 I/O CS16
33 34 N/C
Addr 0
35 36 Addr 2
Chip Select 1P (1S)#
Activity#
37 38 Chip Select 3P (3S)#
39 40 Ground
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Chapter 3: Hardware Service 3-65
Flexible Diskette (CN18)
Signal Name
Pin
Pin
Signal Name
Ground
1
2
DRVDEN0
Ground
Key
3
5
7
9
4
6
8
Reserved
DRVDEN1
Index#
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
10 Motor Enable 1#
11 12 Drive Select 0#
13 14 Drive Select 1#
15 16 Motor Enable 0#
17 18 DIR#
19 20 STEP#
21 22 Write Data#
23 24 Write Gate#
25 26 Track 0#
27 28 Write Protect#
29 30 Read Data#
31 32 HDSEL
33 34 DSKCHG Change#
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3-66 Chapter 3: Hardware Service
PCI Riser Card (PCI1)
Signal Name
Pin
Pin
Signal Name
-12V
61B1
1A1
NC
CLK2
62B2
2A2
+12V
GND
TD0
+5V
+5V
63B3
3A3
GNT1#
REQ1#
+5V
64B4
4A4
65 B5
66B6
5 A5
6A6
INTA#
INTC#
+5V
INTB#
INTD#
PRSNT#1
RESERVED
PRSNT#2
GND
67B7
7A7
68B8
8A8
69B9
9A9
RESRVED
+5V
70B10
71 B11
72B12
73B13
74B14
75B15
76B16
77B17
78B18
79B19
80B20
81B21
82B22
83B23
10A10
11 A11
12A12
13A13
14A14
15A15
16A16
17A17
18A18
19A19
20A20
21A21
22A22
23A23
RESRVED
GND
GND
GND
RESERVED
GND
RESRVED
RST#
CLK1
+5V
GND
GNT
REQ#
GND
+5V
PME
AD31
AD30
+3.3V
AD28
AD26
AD29
GND
AD27
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Chapter 3: Hardware Service 3-67
Signal Name
Pin
Pin
Signal Name
AD25
84B24
24A24
GND
AD24
IDSEL
+3.3V
AD22
AD20
GND
AD18
AD16
+3.3V
FRAME#
GND
TRDY
GND
STOP
+3.3V
SDONE
SBO
+3.3V
85 B25
86B26
87B27
88B28
89B29
90B30
91 B31
92B32
93B33
94B34
95B35
96B36
97B37
98B38
99B39
100B40
101B41
102B42
25 A25
26A26
27A27
28A28
29A29
30A30
31 A31
32A32
33A33
34A34
35A35
36A36
37A37
38A38
39A39
40A40
41A41
42A42
C_BE#3
AD23
GND
AD21
AD19
+3.3V
AD17
C_BE#2
GND
IRDY#
+3.3V
DEVSEL#
GND
LOCK#
PERR#
+3.3V
SERR#
+3.3V
GND
PAR
103 B43 43A43
C_BE#1 104 B44 44 A44
AD15
+3.3V
AD13
AD11
AD14
105 B45 45A45
106 B46 46 A46
107 B47 47 A47
GND
AD12
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3-68 Chapter 3: Hardware Service
Signal Name
Pin
Pin
Signal Name
AD10
GND
CON KEY
CON KEY
AD8
108 B48 48 A48
109 B49 49 A49
GND
AD9
B50
B51
A50
A51
CON KEY
CON KEY
C_BE#0
3.3V
110 B52 50A52
111 B53 51A53
112 B54 52A54
AD7
+3.3V
AD5
AD6
113B55
114B56
53 A55
54 A56
AD4
AD3
GND21
AD2
GND
AD1
115 B57 55 A57
116 B58 56 A58
117 B59 57 A59
AD0
+5V
+5V
ACK64#
+5V
118 B60
58 A60 REQ64#
119 B61 59A61
120 B62 60A62
+5V
+5V
+5V
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Chapter 3: Hardware Service 3-69
PCI Riser Card
Signal Name
Pin
Pin
Signal Name
GND
1B1
1A1
PGNT~(1)
GND
PCICLK1
GND
2B2
3B3
4B4
5 B5
6B6
7B7
8B8
9B9
10B10
2A2
3A3
4A4
5 A5
6A6
7A7
8A8
9A9
PGNT~(2)
GND
PCI_REQ1#
GND
PCICLK3
RISER_ID1
RESVD
PCI_CLK2
GND
PCI_REQ2#
GND
RISER_ID2
NOGO
PC/PCI_DREQ#
10A10 +12v
PC/PCI_DGNT# 11 B11 11A11 SER_IRQ
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3-70 Chapter 3: Hardware Service
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Chapter 4: Cable Routing Guide
Primary IDE Cable
Double Fold
P4 Specific Cables
Primary IDE Cable
IDE-1
Single Fold
UPS and Secondary Hard Disk Cables
are Routed Under IDE Cable
20517
Primary IDE Cable (Top view)
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4-2 Chapter 4: Cable Routing Guide
Hard Disk
Double Fold (even if no CD-ROM is present)
CD-ROM Drive
20516
Primary IDE Cable (Side view)
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Chapter 4: Cable Routing Guide 4-9
USB Daughter Card Cable
USB Daughter Board Cable
Double Fold
Single Fold
20510
The USB Cable is secured on the bottom of the card with an Adhesive
Cable Clamp.
Single Fold
Adhesive Cable Clamp (Bottom side of USB Card)
20511
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4-10 Chapter 4: Cable Routing Guide
Power Supply Harness Clamp
Clamp the following harnesses to the Cable Clamp next to the Power Supply:
- Motherboard Power Supply Harness
- UPS Harness
- USB Daughter Card Harness
- Audio Cable
- PC Beep Cable
20513
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Appendix A: Feature Kits
This section contains a comprehensive list of the available hardware
Feature Kits that can be installed in the customer environment. Kit
installation instructions (for those requiring instruction) are available
on the Information Products web sites.
•
•
Internet: http://www.info.ncr.com
NCR Intranet: http://inforetail.atlantaga.ncr.com
To locate the installation guides on these sites:
1. Select General Search.
2. Select the Kits icon.
3. In the Title field, enter the Kit Title.
Example: Memory
or
In the Product ID field, enter the Kit Number.
Example: 7458-K141
1. Select Search.
The file can be viewed online by left-mouse clicking on the pub
title, or if you prefer to download the entire file you can right-
mouse click on the title and then a Save target as.
If you aren’t sure of the title or number you can display all kits
associated with a terminal product class by:
1. In the Class drop-down list, enter the Class of the terminal.
Example: 7458
2. Select Search.
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A-2 Appendix A: Feature Kits
Feature Kit List
Part Number
Description
3212-K170
3212-K171
7456-K132
7456-K133
7456-K154
7456-K350
7458-K140
7458-K141
7458-K154
7458-K160
7458-K161
7458-K165
7458-K172
7458-K181
7458-K300
7458-K305
7458-K310
7458-K315
Standard Height 4-Port PCI Adapter Card
Standard Height 2-Port PCI Adapter Card
128MB DIMM memory upgrade (PC-133)
256MB DIMM memory upgrade (PC-133)
256MB Compact Flash Memory
PCI VGA Video Card
Internal CD ROM Drive (G11)
Internal CD ROM Drive (CG1)
256MB Compact Flash Memory
Removable Hard Disk Kit (G11)
Removable Hard Disk Kit (CG1)
Internal Second Hard Disk Kit (CG1)
PCI 4-Port Serial Expansion
UPS Battery
7458 Integration Tray (G11)
7458 Integration Tray (CG1)
7458 Integration Tray Accessories (G11)
7458 Integration Tray Accessories (CG1)
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Appendix B: Hardware Specifications
Performance Levels
850 MHz
Celeron
1 GHz P III
Processor
100 MHz
128 KB
133 MHz
256 KB
System Bus
Cache
Interrupts
IRQ
System Resource
NMI
I/O Channel Check
Reserved, System Timer
Reserved, Keyboard buffer full
Reserved, Cascade interrupt
Serial Port 2
0
1
2
3
4
Serial Port 1
5
Serial Ports 3 & 4
6
Reserved, Floppy
7
Parallel Port 1(Avail if disable)
Real Time Clock
8
9
10
11
12
13
14
15
Serial Port 3
Serial Port 4
Mouse (Avail if disabled)/UPS Serial Port
Reserved, Math coprocessor
On-board IDE (Avail if IDE disabled)
On-board IDE (Avail if IDE disabled)
*default settings
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Index
CD-ROM drive removal, 3-15
Compact Flash
Connectors
—2—
2-Port PCI RS-232 Expansion Card
CPU
—4—
4-Port PCI RS-232 Board (3030-K169),
4-Port PCI RS-232 Expansion Card
—D—
—A—
—E—
Adapter board
Ethernet circuitry, 3-40
—B—
—F—
Battery
Fan
Feature Kits, A-1
Flex Disk drive removal, 3-13
Fuses
—C—
Cable Routing, 4-1
Fan Cable. See
—H—
Flex Diskette Cable. See
Front Panel Cables. See
Primary IDE Cable. See
Secondary IDE Cable. See
UPS Battery Cables. See
Hard Disk drive removal, 3-20
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Index-2
Test points and beep codes, 2-6
POST errors, 2-1
—I—
IDE Cables
Power Supply Cable Pin-Outs, 3-51
Power-on self-test, 2-1
Processor board
—M—
Memory
Memory Configurations, 3-30
Model number, 1-4
—S—
—P—
—U—
Password
PCI LCD board
UPS Battery
USB Card
USB Daughter Card, 3-36
5952-K052, 3-42
PCI LCD Board (5953-K152), 3-41
PCI VGA Video Card (7456-K350), 3-43
POST
Recoverable errors, 2-2
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