Service Manual Trakker Antares® 241X Hand-Held Terminal
Intermec Technologies Corporation Corporate Headquarters 6001 36th Ave. W. Everett, WA 98203 U.S.A. www.intermec.com The information contained herein is proprietary and is provided solely for the purpose of allowing customers to operate and service Intermec-manufactured equipment and is not to be released, reproduced, or used for any other purpose without written permission of Intermec.
nuggetf d 39 Contents Contents Before You Begin v Safety Summary v Safety Icons vi Global Services and Support vi Warranty Information vi Web Support vii Who Should Read This Document? vii 1 2 Troubleshooting Troubleshooting the 241X 1-3 Replacing Parts Cautions 2-3 Replacing Parts 2-4 Opening the Terminal 2-4 Replacing the Radio (2415 Only) 2-5 Replacing the Memory Card (2410 Only) 2-8 Replacing the Main PCB 2-8 Replacing the Beeper 2-11 Replacing the LCD 2-13 Replacing the Display Lens 2-15 Replacing
Trakker Antares 241X Hand-Held Terminal Service Manual nuggetf 3 Exploded Views and Spare Parts Lists Exploded View 3-3 Spare Parts List 3-4 PDF 417 Scan Engine Exploded View 3-6 PDF 417 Scan Engine Spare Parts List 3-7 E1022 Linear Imager Exploded View 3-8 E1022 Linear Imager Spare Parts List 3-9 4 Theory of Operation Main PCB 4-3 Liquid Crystal Display (LCD) Interface 4-3 Keyboard Interface 4-3 Scanner Interface 4-4 Lithium-Ion Battery Charger 4-4 Lithium-Ion Main Battery 4-4 Backup Power Source 4-4 L
C d 39 nuggetf d 39 Before You Begin Before You Begin This section provides you with safety information, technical support information, and sources for additional product information. Safety Summary Your safety is extremely important. Read and follow all warnings and cautions in this document before handling and operating Intermec equipment. You can be seriously injured, and equipment and data can be damaged if you do not follow the safety warnings and cautions.
Trakker Antares 241X Hand-Held Terminal Service Manual nuggetf d 39 Safety Icons This section explains how to identify and understand warnings, cautions, and notes that are in this document. You may also see icons that tell you when to follow ESD procedures and when to take special precautions for handling optical parts.
C d 39 nuggetf d 39 Before You Begin Web Support Visit the Intermec web site at http://www.intermec.com to download many of our current manuals in PDF format. To order printed versions of the Intermec manuals, contact your local Intermec representative or distributor. Visit the Intermec technical knowledge base (Knowledge Central) at http://intermec.custhelp.com to review technical information or to request technical support for your Intermec product.
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1 Troubleshooting
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nugget Troubleshooting 1 This chapter describes how to troubleshoot problems with the terminal. Troubleshooting the 241X This table lists symptoms of common problems and their possible solutions. Symptom Possible Solution When you press q to turn on the terminal, the screen is blank and nothing happens. Try these possible solutions in order: OR When you press q to turn the terminal off, it does not enter Suspend mode and returns to the Boot menu. Keypad does not work.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget Troubleshooting the 241X (continued) Symptom Possible Solution Nothing is displayed on the screen. Try these possible solutions in order: Screen displays missing or “stuck” pixels and lines. Backlight does not work. Beeper does not work or the frequency or volume is not adequate. 1-4 • The contrast may be set too light or too dark. Press ( + to adjust the contrast. • The display/beeper flex cable may be disconnected.
nugget Troubleshooting 1 Troubleshooting the 241X (continued) Symptom Possible Solution Real time clock does not maintain correct time. Try these possible solutions in order: Scanner does not emit a beam, or scanner emits a beam but does not scan the bar code. Tethered scanner does not emit a beam. Terminal will not communicate in a serial network. • The main battery may not be able to hold a charge. Make sure that the backup capacitor is fully charged.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget Troubleshooting the 241X (continued) 1-6 Symptom Possible Solution Terminal will not communicate in an RF network. Try these possible solutions in order: • Make sure that the radio is configured properly for the network. If the radio is properly configured, there may be a problem with the access point. • The antenna may not be properly connected. Make sure that the antenna cables are or correctly connected to the radio.
2 Replacing Parts
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nugget Replacing Parts 2 This chapter explains how to open, replace parts in, and close the 241X hand-held terminal. It also provides preliminary cautions to follow when servicing the 241X. Cautions Note: Opening this product can result in voiding the warranty. The internal workings of this product can only be accessed by Intermec service personnel. Caution Integrated circuits on the printed circuit board (PCB) in the terminal are very sensitive to damage by electrostatic discharge (ESD).
Trakker Antares 241X Hand-Held Terminal Service Manual nugget Replacing Parts This section describes how to open, replace parts in, and close the 241X hand-held terminal. Each procedure also lists the tools and parts that you will need. Opening the Terminal To perform repairs on the 241X, you need to open the terminal. To open the terminal, you need the following tool: • #1 Phillips screwdriver To open the terminal 1. Press _ to turn off the terminal. 2.
nugget Replacing Parts 2 Replacing the Radio (2415 Only) To replace the radio, you need the following tools: • #1 Phillips screwdriver • Torque screwdriver You also need one of the following parts depending on the 2415’s configuration: • 802.11 2126 ETSI (P/N 070512S-002) • 802.11 2126 Japan (P/N 070514S-002) • 802.11 2126 Mexico (P/N 070517S-002) • 802.11 2126 U.S./Canada (P/N 070513S-002) • 802.11 PC24-11-FC/R ROTW (P/N 073348S-001) • 802.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 3. Remove the antenna cable or cables from the radio card. Mount strap Cut here a. If necessary, carefully cut the mount strap in half. b. Disconnect the antenna cable or cables from the radio card. 4. Install the new radio card. a. Compare the connector tabs on the new radio card to the connector on the main PCB to determine which side of the new radio card is the back (faces the main PCB). Main PCB 241XM014.eps b.
nugget Replacing Parts 2 6. Press the antenna cable or cables into the connectors on the radio. • If you are replacing an 802.11b radio, connect the antenna cables to ports | and || as shown. Antenna cable (2 places) Port I Port II 241XM018.eps • If you are replacing an OpenAir radio, connect the antenna cable to the connector on the radio. Antenna cable 241XM019.eps 7.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget Replacing the Memory Card (2410 Only) To replace the memory card, you need the following tools: • #1 Phillips screwdriver • Torque screwdriver You also need one of the following parts: • 2MB memory card (P/N 590092-001) • 4MB memory card (P/N 590092-002) To replace the memory card 1. Open the terminal. For help, see “Opening the Terminal” on page 2-4. 2. Remove the memory card from the main PCB. Memory card a.
nugget Replacing Parts 2 You also need one of the following parts: • 2MB main PCB (P/N 071589S-002) • 4MB main PCB (P/N 071588S-002) To replace the main PCB 1. Open the terminal. For help, see “Opening the Terminal” on page 2-4. Make sure you note the configuration on the serial number label on the bottom cover. 2. Remove the radio or memory card from the main PCB. a. Remove the screw holding the retaining block in place, and remove the retaining block. Radio or memory card Screw Retaining block b.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 5. Turn the main PCB over and remove the display/beeper flex cable from the main PCB. Main PCB Display/beeper flex cable Top cover 241XM035.eps 6. Connect the display/beeper flex cable to the new main PCB. 7. Install the new main PCB. 8. Connect the keypad flex cable to the main PCB. 9. Install the radio or memory card. a.
nugget Replacing Parts 2 Replacing the Beeper To replace the beeper, you need the following tools: • #1 Phillips screwdriver • Flathead screwdriver • Torque screwdriver You also need the following part: • Display/beeper flex cable assembly (P/N 069705-002) To replace the beeper 1. Open the terminal. For help, see “Opening the Terminal” on page 2-4. 2. Remove the main PCB. Follow Steps 2 through 5 for “Replacing the Main PCB” on page 2-9. 3. Remove the display/beeper flex cable from the LCD.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 5. Remove the adhesive backing from the new beeper, and attach it to the top cover. Make sure that the beeper is aligned with the alignment edge on the top cover. LCD Display/beeper flex cable Screw (four places) Beeper Alignment edge Top cover 241XM020.eps 6. Connect the display/beeper flex cable to the LCD. 7. Connect the display/beeper flex cable to the main PCB. 8. Install the main PCB. 9. Connect the keypad flex cable to the main PCB.
nugget Replacing Parts 2 Replacing the LCD To replace the LCD, you need the following tools: • #0 Phillips screwdriver or T5 Torx screwdriver • #1 Phillips screwdriver • Torque screwdriver You also need the following part: • LCD (P/N 071363S-001) To replace the LCD 1. Open the terminal. For help, see “Opening the Terminal” on page 2-4. 2. Remove the radio or memory card from the main PCB. a. Remove the screw holding the retaining block in place, and remove the retaining block.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 4. Gently lift the main PCB out of the top cover. Be careful not to rip the connection between the main PCB and the display/beeper flex cable. 5. Remove the display/beeper flex cable from the LCD. Display/beeper flex cable LCD Screw (four places) Top cover Beeper 241XM022.eps 6. Remove the four screws holding the LCD in place and remove the LCD. 7. Install the new LCD and tighten the screws to 0.226 Nm (2 in-lb). 8.
nugget Replacing Parts 2 Replacing the Display Lens To replace the display lens, you need the following tools: • #1 Phillips screwdriver • Torque screwdriver You also need the following parts: • One of these display lenses • 2410 (P/N 069423-003) • 2415 (P/N 069427-003) • Clear Orbit Label (if necessary) (P/N 071228-001) • Oracle Ready Label (if necessary) (P/N 072558-001) To replace the display lens 1. Open the terminal. For help, see “Opening the Terminal” on page 2-4. 2. Remove the LCD.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget You also need the following parts depending on the terminal’s configuration: • One of these display lenses • 2410 (P/N 069423-003) • 2415 (P/N 069427-003) • Clear Orbit Label (if necessary) (P/N 071228-001) • Oracle Ready Label (if necessary) (P/N 072558-001) • One of these keypad assemblies • • 37-key function numeric (P/N 069842S-004) • 37-key large numeric (P/N 069472S-004) • 55-key alphanumeric (P/N 069471S-004) One of thes
nugget Replacing Parts 2 4. Make sure the display lens is free from fingerprints and scratches. Remove the adhesive backing from the display lens and carefully apply it to the new keypad assembly. Firmly press the adhesive area of the new display lens onto the keypad assembly. 5. Use an ionized air gun to blow any dust out of the interior of the terminal. 6. Install the LCD in the new keypad assembly. Follow Steps 7 through 12 for “Replacing the LCD” on page 2-14. 7. Close the terminal.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 3. Remove the scan engine or E1022 linear imager assembly. • • For a standard scan engine or PDF 417 scan engine, remove the two screws holding the scan engine assembly in place. Screw (2 or 4 places) Scan engine or E1022 linear imager assembly Antenna For an E1022 linear imager, remove the four screws holding the E1022 linear imager assembly in place. 4. Remove the scan engine or linear imager assembly from the bottom cover. 5.
nugget • If you are installing a European OpenAir antenna, orient the antenna so that the antenna cable and the foam padding faces opposite of the bracket on the scan engine or linear imager assembly. Make sure that the antenna cable is positioned toward the top of the bracket. Replacing Parts Antenna 2 Antenna cable Foam padding 241XM024.eps Scan engine/ linear imager assembly 7. If you removed a standard scan engine or PDF 417 scan engine in Step 3, install the scan engine assembly. a.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget Replacing the Scan Engine Because finger oils can dissolve the reflective coating of the plastic mirrors, always wear finger cots or non-powdered latex gloves when handling optical parts.
nugget Replacing Parts 2 3. Remove the two screws holding the scan engine assembly in place. Screw (2 places) Scan engine assembly Antenna 241XM038.eps 4. Remove the scan engine assembly. 5. (2415 only) Turn the assembly over and remove the antenna. 6. Remove the three screws that hold the scan engine in place and remove the scan engine. 7. Install the new scan engine in the scan engine bracket and secure it with the three screws tightened to 0.226 Nm (2 in-lb). 8. (2415 only) Install the antenna.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 10. (2415 only) Install the radio card. a. Compare the connector tabs on the radio card to the connector on the main PCB to determine which way to insert the card. b. Slide the radio card into the connector. Firmly press the card into the connector until it stops. c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm (2 in-lb). 11. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
nugget Replacing Parts 2 3. Remove the two screws holding the scan engine assembly in place. Screw (2 places) Scan engine assembly Antenna 241XM038.eps 4. Remove the scan engine assembly. 5. (2415 only) Turn the assembly over and remove the antenna. 6. Remove the scan engine flex cable from the PDF 417 PCB assembly. PDF 417 scan engine Scan engine adapter Scan engine flex cable Screw (2 places) Scan engine bracket PDF 417 PCB assembly 241XM056 .eps Screw (3 places) 7.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 8. Remove the two screws that hold the scan engine in the scan engine adapter and remove the scan engine. 9. Install the new scan engine in the scan engine adapter and secure it with the two screws tightened to 0.226 Nm (2 in-lb). 10. Install the scan engine adapter in the scan engine bracket and secure it with the three screws tightened to 0.226 Nm (2 in-lb). 11. (2415 only) Install the antenna.
nugget • Replacing Parts 2 E1022 linear imager assembly (P/N 072612S-001) To replace the E1022 linear imager 1. Open the terminal. For help, see “Opening the Terminal” on page 2-4. 2. (2415 only) Remove the radio card from the main PCB. Radio card Screw a. Remove the screw holding the retaining block in place, and remove the retaining block. Retaining block b. Slide the radio card out of the connector on the main PCB. Note: The antenna cables are not shown for clarity. 241XM016.eps 3.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 5. (2415 only) Turn the assembly over and remove the antenna. 6. (2415 only) Install the antenna in the new E1022 linear imager assembly. For help, see Step 6 for “Replacing the Antenna” on page 2-18. 7. Place the E1022 linear imager assembly in the bottom cover and install the four screws that hold the assembly in place. Tighten the screws to 0.565 Nm (5 in-lb). 8. (2415 only) Install the radio card. a.
nugget Replacing Parts 2 3. Remove the scanner flex cable from the PDF 417 PCB assembly. Scanner flex cable PDF 417 PCB assembly Bottom cover 241XM055 .eps 4. Remove the PDF 417 PCB assembly. 5. Connect the scanner flex cable to the new PDF 417 PCB assembly. 6. (2415 only) Install the radio card. a. Compare the connector tabs on the radio card to the connector on the main PCB to determine which way to insert the card. b. Slide the radio card into the connector.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget You also need one of the following parts: • Scanner lens (P/N 069461-001) • E1022 scan window (P/N 072340-001) To replace the scanner lens or E1022 scan window 1. Open the terminal. For help, see “Opening the Terminal” on page 2-4. 2. (2415 only) Remove the radio card from the main PCB. Radio card Screw a. Remove the screw holding the retaining block in place, and remove the retaining block. Retaining block b.
nugget • Replacing Parts If you are replacing an E1022 scan window, push the scan window out of the bottom cover. 2 E1022 scan window Bottom cover 241XM039.eps 5. Make sure the new scanner lens or scan window is free from fingerprints and scratches. Install the new scanner lens or scan window. • If you are replacing a scanner lens, peel the backing off of the new scanner lens and place it on the scan engine bracket.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 8. (2415 only) Install the radio card. a. Compare the connector tabs on the radio card to the connector on the main PCB to determine which way to insert the card. b. Slide the radio card into the connector. Firmly press the card into the connector until it stops. c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm (2 in-lb). 9. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
nugget Replacing Parts 2 3. If you are repairing a 241X with a PDF 417 scan engine, remove the PDF 417 PCB assembly from the bottom cover. Scanner flex cable PDF 417 PCB assembly Bottom cover 241XM055 .eps 4. Remove the screw holding the radio/memory card support bar in place and remove the radio/memory card support bar. Screw (2 places) Radio/memory card support bar Radio/memory card support bracket Backup capacitor Bottom cover 241XM008.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 5. Remove the screw holding the radio/memory card support bracket in place and remove the radio/memory card support bracket. 6. Remove the backup capacitor. 7. Install the new backup capacitor. Make sure that the scanner reed switch is properly seated in the bottom cover. Scanner reed switch Wires 241XM033.eps 8. Install the radio/memory card support bracket and the radio/memory card support bar, and tighten the screws to 0.565 Nm (5 in-lb).
nugget Replacing Parts 2 Replacing the Bottom Cover To replace the bottom cover, you need the following tools: • #1 Phillips screwdriver • Torque screwdriver You also need the following parts: • • Bottom cover: • Standard bottom cover (scan engine or PDF 417 scan engine) (P/N 069456-001) • Multi-scanner bottom cover (scan engine, PDF 417 scan engine, or E1022 linear imager): • Multi-scanner bottom cover (P/N 072232-001) • E1022 scan window (P/N 072340-001) Scanner safety label: • Non-laser
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 3. Remove the scan engine or E1022 linear imager assembly. • • For a standard scan engine or PDF 417 scan engine, remove the two screws holding the scan engine assembly in place. Screw (2 or 4 places) Scan engine or E1022 linear imager assembly Antenna For an E1022 linear imager, remove the four screws holding the E1022 linear imager assembly in place. 241XM028.eps 4. Install the backup capacitor assembly in the new bottom cover.
nugget Replacing Parts 2 7. If you removed a standard scan engine or PDF 417 scan engine in Step 3, install the scan engine assembly. a. Place the assembly in the bottom cover. Make sure the assembly is firmly seated in the cover. Retainers b. Slide the assembly toward the top of the cover so that the front of the assembly slides under the retainers. c. Install the two screws that hold the scan engine assembly in place and tighten them to 0.565 Nm (5 in-lb). 241XM025.eps 8.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 11. Use standard print on demand practices to print a serial number label that contains the information you noted in Step 1, and attach the label to the terminal. 12. Close the terminal. For help, see the next procedure, “Closing the Terminal.” Closing the Terminal To close the terminal, you need the following tool: • #1 Phillips screwdriver • Torque screwdriver To close the terminal 1.
3 Exploded Views and Spare Parts Lists
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nugget 3 39 Exploded Views and Spare Parts Lists This chapter provides the exploded views and spare parts list for the 2410 and 2415 terminals. Exploded View To identify a part, find the part in the exploded view and locate its callout number in the following spare parts list. If you are repairing a 241X with a PDF 417 scan engine, see “PDF 417 Scan Engine Exploded View” on page 3-6. If you are repairing a 241X with an E1022 linear imager, see “E1022 Linear Imager Exploded View” on page 3-8.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 39 Spare Parts List To identify a part, find the callout number in this list and locate the part in the previous exploded view.
nugget 39 Exploded Views and Spare Parts Lists 3 Spare Parts List (continued) Callout Number Description Part Number 7 Radio (2415 only) (continued) OpenAir RM181 U.S./Canada OpenAir RM182 Euro OpenAir RM182 Israel/Spain OpenAir RM182 U.S.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 39 Spare Parts List (continued) Callout Number Description Part Number RF certification labels (continued) 2410 terminal, RM182 OpenAir, 2126 802.11b, and PC24-11-FC/R 802.11b Print On Demand Set White Ribbon 072691-001 591371-001 PDF 417 Scan Engine Exploded View This illustration shows the PDF 417 scan engine assembly in relation to the bottom cover.
nugget 39 Exploded Views and Spare Parts Lists 3 PDF 417 Scan Engine Spare Parts List To identify a part, find the callout number in this list and locate the part in the previous PDF 417 Scan Engine Exploded View.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget 39 E1022 Linear Imager Exploded View This illustration shows the E1022 linear imager assembly. To identify a part, find the part in the exploded view and locate its callout number in the following E1022 Linear Imager Spare Parts List. Screw (4 places) 1 2 3 4 241XM0004.
nugget 39 Exploded Views and Spare Parts Lists 3 E1022 Linear Imager Spare Parts List To identify a part, find the callout number in this list and locate the part in the previous E1022 Linear Imager Exploded View.
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4 Theory of Operation
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nugget Theory of Operation 4 This appendix contains the theory of operation for the 241X. Main PCB The main PCB contains the primary circuitry for the Trakker Antares® terminals. It also contains the Vadem VG-230, which is a PC/XT compatible processor.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget Scanner Interface The 241X has two scanner interface options: • Standard non-decoded scanner port. The ASIC (U501), in conjunction with PAL (U101), handles non-decoded scanner communication. Signals include SOS, Video, ScanEn, LasEn, and Gen-Cntl/AIM. • Serial communications port for decoded scanners. The Vadem VG-230 UART COM1 port interface controls serial communication to and from decoded scanners. Signals include TX, RX, CTS, and RTS.
nugget Theory of Operation 4 Memory Map Up to 1MB of directly addressable memory space is supported by the V30HL. The VG-230 provides access to additional memory space through 26 mapping registers. Each memory mapping register controls a 16K block of memory. The bottom 512K of the RAM array are always mapped to the base 512K of the 1MB memory space of the V30HL. The top 32K of the RAM array are always mapped to the CGA BUFFER area of the 1MB memory space of the V30HL.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget PC Card Interface The VG-230 supports a PC card interface compatible with the PCMCIA version 2.0 standard. Interfaces supported are: • I/O cards • Up to 64MB of memory • Flash memory • Execute in place (XIP) The PC card is powered by VCCRF, which is filtered VCC supply. Reset is an open collector signal generated from RESOUT* per the PCMCIA specification. The PC card programming voltage (VPPA) is switched from PS+12V with signal VPPEMA.
nugget Theory of Operation 4 Power Supplies Source Description VBATF Fused power that is generated from the main battery voltage (VBATMAIN) and goes out to the 16-pin interface connector. VCC230A A DC to DC Step-Up Converter that generates +5V, +5% from the main battery voltage. It draws its operating current from VBAT and supplies up to 1.5 A. It powers the Vadem VG-230, ASIC, PSRAM, PIC, switched VCCLCD, and 3finger reset function. The power supply switches between +5V when VPSYS is active and +3.
Trakker Antares 241X Hand-Held Terminal Service Manual nugget Display This is a custom display module. The display is a full graphics type, with a matrix of 160 pixels horizontally by 128 pixels vertically, allowing 16 lines of 20 characters per line to be displayed with an 8 x 8 pixel font. Several font sizes are supported. An ICON driver IC, DC/DC bias power supply, EL backlight, and EL DC/AC power supply are provided on the LCD module.
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