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Workabout MX

Psion Workabout MX Service Manual

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Workabout MX
Service Manual
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Confidential - PSION INDUSTRIAL PLC
Workabout MX Service Manual
Version 1.0 iii
© Copyright Psion Industrial PLC 1998.
The information in this document is subject to change without notice. Psion and the Psion logo are registered trademarks, and Psion Workabout, MX, 3Link, SSD
and Solid State Disk are trademarks of Psion PLC. Some names referred to are registered trademarks. Psion Industrial reserves the right to change the designs and specifications of its products at
any time without prior notice.
Psion part no: A6124-0002-01 Version 1.0 - September 1998 English
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Confidential - PSION INDUSTRIAL PLC Workabout MX Service Manual
iv Version 1.0
Note
The Psion Workabout contains CMOS devices that may be damaged by electrostatic discharge (ESD). The following steps to minimise ESD must be taken before the unit is dismantled. To prevent any damage that could result if the unit or its parts are not handled properly, observe the following precautions during any handling procedures:
n Minimise all handling of static-sensitive components and assemblies. n Transport and store static-sensitive components and assemblies in their original
containers or in anti-static bags.
n Label accordingly any package that contains static-sensitive components or assemblies. n Discharge static electricity from the body by wearing a grounded anti-static wrist strap
while handling these components. Servicing static-sensitive components or assemblies should be done only at a static-free work station by qualified service technicians. Increasing the humidity in the work area minimises static electricity problems.
n Do not allow anything that can generate or hold a static charge on the work station
surface.
n Pick up components by their bodies, never by their leads. n Do not slide components over any surface. n Avoid handling components in areas with a floor or work-surface covering that can
generate static charge.
FCC Information for the USA
Radio and Television Interference:
This equipment radiates radio frequency energy and if not used properly - that is, in strict accordance with the instructions in this manual - may cause interference to Radio and Television reception. It has been tested and found to comply with the limits for a Class B computing device pursuant to part 15 of the FCC Rules. These are designed to provide reasonable protection against harmful interference in a residential installation. This equipment can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
n Reorient or relocate the receiving antenna. n Increase the separation distance between the equipment and the receiver. n If you are using the Workabout computer with a mains adapter, plug it into an outlet which is on a
different circuit from that to which the receiver is connected. Consult an authorised Psion dealer or an experienced radio/TV technician for help. This equipment was tested for FCC compliance under conditions that included the use of shielded
cables and connectors between it and the peripherals. It is important that you use shielded cable and connectors to reduce the possibility of causing Radio and Television interference. Shielded cables, suitable for the Workabout, can be obtained from an authorised Psion dealer. If the user modifies the Workabout or the Multiple Docking Station, and these modifications are not approved by Psion, the FCC may withdraw the user's right to operate the equipment. For customers in the USA, the following booklet prepared by the Federal Communications Commission may be of help: "How to Identify and Resolve Radio-TV Interference Problems". This booklet is available from the US Government Printing Office, Washington, DC 20402 - Stock No: 004-000-00345-4.
Y
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Confidential - PSION INDUSTRIAL PLC
Workabout MX Service Manual
Version 1.0 v
Table of Contents
Introduction.....................................................................................................1
Part Number Information................................................................................2
Serial Number Information.............................................................................2
Troubleshooting Guide..................................................................................4
Exploded View - General Assembly..............................................................6
Exploded View - Chassis Assembly..............................................................8
Exploded View - Drawer Assembly...............................................................9
Spares Kits....................................................................................................10
General Kits ...............................................................................................................10
Bottom Port Kits.........................................................................................................10
Drawer Kits.................................................................................................................11
Case Kits ....................................................................................................................11
LCD Kits.....................................................................................................................12
PCB Kits.....................................................................................................................12
Dismantling the Workabout.........................................................................13
Tools Required................................................................................................................13
Dismantling Procedure....................................................................................................13
Dismantling the Chassis Assembly..................................................................................14
Dismantling the Drawer Assembly...................................................................................16
Selecting the PCB Type ...............................................................................17
Re-assembly Instructions............................................................................18
Re-assembling the Drawer Assembly ..............................................................................18
Notes on Drawer Re-assembly ...................................................................................18
Re-assembling the Chassis Assembly .............................................................................19
Notes on Chassis Re-assembly ..................................................................................19
Final Re-assembly...........................................................................................................20
Notes on Final Re-assembly.......................................................................................20
Checking the Operation of the Options......................................................21
Checking the RS232 Interface.........................................................................................21
Testing the TTL Interface ................................................................................................22
Testing the Barcode Interface..........................................................................................22
Expansion Interface......................................................................................23
RS232 AT/TTL Serial Interfaces......................................................................................23
RS232 AT Serial/Barcode Interfaces...............................................................................24
Circuit Description........................................................................................25
LIF Converter..................................................................................................................25
Final Test .......................................................................................................26
Equipment.......................................................................................................................26
Test Setup.......................................................................................................................26
Test Sequence................................................................................................................27
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Confidential - PSION INDUSTRIAL PLC
Workabout MX Service Manual
Version 1.0 1
Introduction
The purpose of this service manual is to give an overview of the service procedures that may need to be performed on the Workabout by either a third party user, or a registered Psion service centre. It has been designed to be used by the service and repair technicians who have the responsibility of maintaining the products.
The Workabout uses both conventional and high-density surface mount component technology, which requires specialist servicing techniques. We therefore recommend that repairs are carried out at circuit board level, rather than at component level. We also encourage service centres to carry a small buffer stock of replaceable parts, to allow immediate exchange, should they need to be replaced.
Although a Final Test Unit is not essential to service a Workabout, it is recommended and is described in the Final Test section on page 26. The Final Test Unit (Psion part no. 1828­0100-01) is used within Psion during the manufacturing process to run a final check on the assembly. When a Workabout is connected to the Test Unit via the LIF Connector, test code (the test program) is downloaded into the machine, which then automatically performs an exhaustive and modifiable series of tests on the Workabout.
This test program can be run to monitor the liquid crystal display (LCD), keyboard, drawer switch, solid state disks (SSDs), serial channel, and piezo status. Operating, idle, and standby current consumption can also be measured. This can be very valuable when investigating or diagnosing a reported problem. Also, once a repair has been completed, a full test can be run to ensure that the repair has been done correctly and that no other fault has been introduced.
+ Note:- The information in this document is confidential and should therefore only be released under a non-disclosure agreement.
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Confidential - PSION INDUSTRIAL PLC Workabout MX Service Manual
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Part Number Information
The part numbers referred to throughout this manual typically do not show the revision suffix. Consequently, refer to your Psion distributor for information on the latest revision of a specific part.
The format of the part numbers issued by Psion Industrial is as follows:
NNNN-NNNN-NN
Part Category
Revision Suffix
Number
Serial Number Information
Each Workabout has a unique serial number that includes codes for the year and week it was manufactured. The serial number can therefore be used to determine whether a Workabout is still within its warranty period.
The serial number is located on a label on the Drawer Assembly. It has the following format:
1 number - year of manufacture. 1 = 1993 2 = 1994 … 9 = 2001
2 numbers -
week of manufacture
. 01 = first week in January 52 = last week in December
4 numbers -
unique identifier
. 0001 = first product of its type to be produced in a week 9999 = 9999th product of the same type to be produced in the same week
M L V T Y W W X X X X
1 letter - variant (see table below).
1 letter - used for manufacturing purposes.
The letter M -
generic code for the MX
.
1 letter -
product type
. A = alphanumeric keypad B = numeric keypad C = future variant
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Workabout MX Service Manual
Version 1.0 3
The table below lists the variant code for Workabout MX variants that are expected to be shipping within a few months of product launch. Further codes will be released along with new variants.
Code Option ports fitted
Top option ports Bottom option port A - ­B TTL & RS232 -
C BCR & RS232 ­D TTL & IrDA RS232 E Wand RS232 F Scanner RS232 G IrDA IrDA H TTL & RS232 IrDA
I-K reserved
L Scanner IrDA
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4 Version 1.0
Troubleshooting Guide
Fault Cause Cure
Machine fails to boot up.
1 Discharged/faulty
batteries.
2 Main PCB fault. 3 Fuse faulty. 4 Battery contact fault.
1 Replace alkalines/replace or recharge
Nicad pack.
2 Remove internals from machine and
check Main Power FFC ZIF Connector.
3 Remove fuse. Check and replace if
necessary.
4 Check for continuity of battery
contacts/Main FFC using multimeter. Replace if necessary.
Lines on LCD. 1 LCD damaged.
2 LCD ZIF open.
3 Main PCB problem.
1 Replace LCD. 2 Dismantle machine until Chassis
Assembly is exposed, close ZIF, reassemble.
3 Follow Dismantling the Workabout to
remove and replace Main PCB. Return
faulty PCB to Psion. Blue portions on LCD.
1 LCD damaged. 2 LCD ZIF open.
3 Main PCB problem.
1 Replace LCD. 2 Dismantle machine until Chassis
Assembly is exposed, close ZIF,
reassemble.
3 Follow Dismantling the Workabout to
remove and replace Main PCB. Return
faulty PCB to Psion. Cracks on LCD. LCD glass broken. Replace LCD. Workabout has problems with LIF communications.
Main PCB problem. Follow Dismantling the Workabout to
remove and replace Main PCB. Return
faulty PCB to Psion. Workabout has problems reading SSDs.
1 Warped Connector
Block Arm. 2 Main FFC faulty. 3 Door switch on Main
PCB damaged.
1 Dismantle machine, remove and
replace Connector Block. 2 Replace Drawer Assembly. 3 Follow Dismantling the Workabout to
remove and replace Main PCB. Return
faulty PCB to Psion.
No top port communications possible.
1 Damaged expansion
FFC.
2 Warped Connector
Block Arm.
3 Loose ZIF connector. 4 Door switch on Main
PCB damaged.
1 Replace Drawer Assembly. 2 Dismantle machine, remove and
replace Connector Block. 3 Remove outer case of machine,
relocate Expansion FFC and close ZIF. 4 Follow Dismantling the Workabout to
remove and replace Main PCB. Return
faulty PCB to Psion.
No infrared communications.
1 Top port damaged. 2 Bottom port damaged.
1 Replace Drawer Assembly. 2 Replace bottom infrared port flexi-
connector.
No TTL communications possible.
1 Damaged expansion
FFC.
2 Warped Connector
Block Arm.
3 Loose ZIF connector. 4 Door switch on Main
PCB damaged.
1 Replace Drawer Assembly. 2 Dismantle machine, remove and
replace Connector Block. 3 Remove outer case of machine,
relocate Expansion FFC and close ZIF. 4 Follow Dismantling the Workabout to
remove and replace Main PCB. Return
faulty PCB to Psion.
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Workabout MX Service Manual
Version 1.0 5
Fault Cause Cure
No Bar Code communications possible.
1 Damaged expansion
FFC.
2 Warped Connector
Block Arm.
3 Loose ZIF connector. 4 Door switch on Main
PCB damaged.
1 Replace Drawer Assembly. 2 Dismantle machine, remove and
replace Connector Block.
3 Remove outer case of machine,
relocate Expansion FFC and close ZIF.
4 Follow Dismantling the Workabout to
remove and replace Main PCB. Return
faulty PCB to Psion. Outer case/ keymat/window damaged.
User damage. Remove the outer case assembly and
replace. Make sure the labels on the new
case match the labels on the old case. Drawer cannot be closed.
1 Drawer derailed. 2 Mechanical
interference.
3 Drawer lock damaged.
1 Refit Drawer.
2 Remove case from machine. Check for
obstructions and interference caused by misplaced/ill-fitting batteries, battery contacts, SSDs, FFCs, PCBs, seals, etc.
3 Replace outer case. Drawer not opening when release button is pressed.
1 Drawer derailed. 2 Release button
damaged.
3 Mechanical
interference.
4 Drawer Spring
missing.
1 Refit Drawer.
2 Replace outer case or Drawer
Assembly.
3 Remove case from machine. Check for
obstructions and interference caused by misplaced/ill-fitting batteries, battery contacts, SSDs, FFCs, PCBs, seals, etc.
4 Replace Drawer Spring. Drawer will not
stay closed.
1 Mechanical
interference.
2 Drawer lock damaged.
1 Remove case from machine. Check for
obstructions and interference caused by misplaced/ill-fitting batteries, battery contacts, SSDs, FFCs, PCBs, seals, etc.
2 Replace outer case or Drawer
Assembly. Alphanumeric keys not working.
1 Damaged keymat. 2 Defective Main PCB.
1 Replace case.
2 Replace Main PCB. Nicad pack fails to charge.
1 Central contact not
connecting.
2 Battery contacts
damaged. 3 Nicad pack damaged. 4 Charger problems.
1 Replace Drawer Assembly. 2 Replace Drawer Assembly. 3 Replace Nicad pack.
4 Consult Docking Station Service Manual
Psion p/no: 6104-0004-01. Machine switches off when operated.
Main Power FFC damaged.
Replace Drawer Assembly.
Backlight does not work.
1 Backlight damaged. 2 Main PCB problem.
1 Replace backlight. 2 Replace Main PCB.
Backlight is dim. Backlight worn.
Approximate time to 50% brightness is 500 hours.
Replace backlight.
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Confidential - PSION INDUSTRIAL PLC Workabout MX Service Manual
6 Version 1.0
Exploded View - General Assembly
The following illustration shows the general assembly, dismantled into replaceable subassemblies and components.
Note that the numbered circles in the illustration correspond to the items in the REF. column of Table 1.
1
10
2
3
4
5
6
7
8
9
11
12
13
14
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Workabout MX Service Manual
Version 1.0 7
Table 1
REF. PART NO. DESCRIPTION QTY
1 A6204000601 LBL BOTTOM 1
A6204006301 LBL BTM RS232/LIF 1
A6224000201 LBL BTM IRDA/LIF 1 2 A83020003 SCREW M2.5x10MM POZ.CS 2 3 2821005001 MX ALPHA CASE + LATCH 1
TBS MX NUMERIC CASE + LATCH 1
2821004801 MX SCANNER CASE + LATCH 1
TBS MX SCANNER NUMERIC CASE + LATCH 1 4 A6224000301 LBL MX 2MB MEMORY 1 5 A8704001802 BOTTOM SEAL 1 6 A1804100801 MLDG D-TYPE BLANK 1
A8124000601 MX BTM FLEXI IRDA 1
2821004001 MX BTM FLEXI RS232 1 7 A8304003 SCREW M2x4MM PANHEAD BLACK 2 8 A8304000101 NUTSERTS 2 9 A83040003 SCREW M2x4MM PANHEAD BLACK 2
10 28210006001 EXPANSION PCB (Barcode/Wand) 1
A2802005002 DECODER PCB (Scanner) 1
A8104104801 DECODER PCB SUPPORT MOULDING (Scanner) 1
11 A8404000401 DRAWER SPRING 1 12 A8104100701 CONNECTOR BLOCK 1 13 A6224000401 LBL MX REAR CASE 1
A6224001301 LBL MX SCANNER REAR 1
14 A8704000701 LIF DUST COVER 1
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Confidential - PSION INDUSTRIAL PLC Workabout MX Service Manual
8 Version 1.0
Exploded View - Chassis Assembly
The following illustration shows the chassis assembly, dismantled into replaceable subassemblies and components.
Note that the numbered circles in the illustration correspond to the items in the REF. column of Table 2.
1
2
3
4
5
6
7
8
10
9
Table 2
REF. PART NO. DESCRIPTION QTY
1 A2802000301 LCD MODULE (240x100) 1 2 A8704000401 FOAM LCD SUPPORT 1 3 2821004601 MX PCB 2MB 1 4 A83040003 SCREW M2x4MM PANHEAD BLACK 1 5 A8104100702 CONNECTOR BLOCK 1 6 A8421000301 DRAWER SPRING 1 7 A8104100605 CPU FRAME 1 8 A2802000402 LCD BACKLIGHT 1 9 A8704000901 LCD SLEEVE 1
10 A8704003801 CHASSIS SEAL 1
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Confidential - PSION INDUSTRIAL PLC
Workabout MX Service Manual
Version 1.0 9
Exploded View - Drawer Assembly
The following illustration shows the Drawer Assembly, dismantled into subassemblies and components.
+ Note:- The Drawer Assembly is normally replaced as a complete kit (see Spares Kits on page 10). It is therefore not necessary to dismantle the Drawer Assembly. This illustration is included for information purposes only.
Note that the numbered circles in the illustration correspond to the items in the REF. column of Table 3.
1
6
2
3
4
5
7
Table 3
REF. PART NO. DESCRIPTION QTY
1 A83040028 SCREW M2x16MM TOP CAP 4 2 A8724000201 FOAM PIEZO SEAL 1 3 A83040003 SCREW M2x4MM PANHEAD BLACK 2 4 A8104100301 SSD BACK 1 5 A6204001101 BATTERY CONFIGURATION LABEL 1 6 A8104100501 LITHIUM BATTERY DOOR 1 7 A6204000401 TOP CAP LABEL - BLANK 2
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Confidential - PSION INDUSTRIAL PLC Workabout MX Service Manual
10 Version 1.0
Spares Kits
The following tables show the listed spares kits that are offered to service centres enabling thorough and complete service and repair work. These tables are correct at the time of printing this manual. Please refer to the latest Psion Industrial spares list for current information.
General Kits
PART NUMBER DESCRIPTION QTY
1828000101 MX GENERIC KIT
LBL BATTERY CONFIGURATION 10 BATTERY TAG 100 X 9 MM 30 MLDG SSD/BATT DRAWER NO CATCH 10 MLDG SSD BACK 5 MLDG LITHIUM DOOR 5 MLDG CPU FRAME 5 S3C MLDG CONN SUPPORT 5 MLDG D-TYPE BLANK 5 NUTSERTS 20 SCREW M2x4MM PANHEAD BLACK 40 THIN HEAD B TYPE DIA 2x4 LNG 20 DRAWER SPRING 20 FOAM LCD SUPPORT 10 LIF DUST COVER 10 LCD SLEEVE 10 PIEZO SEAL 10 CHASSIS SEAL 10 TOP CAP SEAL 10 SCREW M2x16MM TOP CAP 10 BOTTOM SEAL 20
1828000201 MX LABEL KIT
LBL MX 2MB MEMORY 25 LBL MX REAR CASE 25 LBL KBD 57AN - EURO 25 LBL TOP CAP BLANK 10 LBL TOP CAP FCC ID 10 LBL BTM RS232/LIF 5 LBL BTM IRDA/LIF 5
1828000301 MX LATCH KIT
MX CATCH ASSY 10
Bottom Port Kits
PART NUMBER DESCRIPTION QTY
1828001001 MX BTM PORT IRDA
MX BTM FLEXI IRDA 10 LBL BTM IRDA/LIF 10 BTM SEAL 10
1828001101 MX BTM PORT RS232
MX BTM FLEXI RS232 10 LBL BTM RS232 10 BTM SEAL 10
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Workabout MX Service Manual
Version 1.0 11
Drawer Kits
PART NUMBER DESCRIPTION QTY
1828002001 MX DRAWER KIT - RS232/TTL
MX RS232/TTL DRAWER 10 BTM SEAL 10
1828002101 MX DRAWER KIT - RS232/BCR
MX RS232/BCR DRAWER 10 BTM SEAL 10
1828002201 MX DRAWER KIT - INT WAND
MX WAND DRAWER 10 BTM SEAL 10
1828002301 MX DRAWER KIT - SCANNER
MX SCANNER DRAWER 10 BTM SEAL 10
1828002401 MX DRAWER KIT - IRDA
MX IRDA DRAWER 10 BTM SEAL 10
1828002501 MX DRAWER KIT - IRDA/TTL
MX TTL/IRDA DRAWER 10 BTM SEAL 10
1828002601 MX DRAWER KIT - BASE
MX BASE DRAWER 10 BTM SEAL 10
Case Kits
PART NUMBER DESCRIPTION QTY
1828003001 MX CASE KIT ALPHA GREY
MX ALPHA CASE + LATCH 10 LBL MX 2MB MEMORY 10 LBL MX REAR CASE 10 SCREW M2.5x10MM POZ.CS 20 LBL BOTTOM 10 BOTTOM SEAL 10 LBL BTM RS232/LIF 5 LBL BTM IRDA/LIF 5
1828003101 MX CASE KIT NUMERIC GREY
MX NUMERIC CASE + LATCH 10 LBL MX 2MB MEMORY 10 LBL MX REAR CASE 10 SCREW M2.5x10MM POZ.CS 20 LBL BOTTOM 10 BOTTOM SEAL 10 LBL BTM RS232/LIF 5 LBL BTM IRDA/LIF 5
1828003201 MX CASE KIT SCANNER
MX SCANNER CASE + LATCH 10 LBL MX 2MB MEMORY 10 LBL MX REAR CASE 10 SCREW M2.5x10MM POZ.CS 20 LBL BOTTOM 10 BOTTOM SEAL 10 LBL BTM RS232/LIF 5 LBL BTM IRDA/LIF 5
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Confidential - PSION INDUSTRIAL PLC Workabout MX Service Manual
12 Version 1.0
PART NUMBER DESCRIPTION QTY
1828003301 MX CASE KIT SCANNER NUMERIC
MX SCANNER NUMERIC CASE + LATCH 10 LBL MX 2MB MEMORY 10 LBL MX REAR CASE 10 SCREW M2.5x10MM POZ.CS 20 LBL BOTTOM 10 BOTTOM SEAL 10 LBL BTM RS232/LIF 5 LBL BTM IRDA/LIF 5
LCD Kits
PART NUMBER DESCRIPTION QTY
1808001401 W/A SPARES KIT BACKLIGHT KIT
ASSY EL/BACKLIGHT 3V
1808001520 W/A SPARES KIT-LCD
LCD MODULE (240X100)
PCB Kits
PART NUMBER DESCRIPTION QTY
1828004001 MX PCB 2MB
MX PCB 2MB 1
1828004101 MX SCANNER EXPANSION KIT
DECODER PCB 1 SUPPORT MOULDING 1 SCREW M2x4MM 2
1828004201 MX BARCODE/WAND EXPANSION KIT
EXPANSION PCB 1 SCREW M2x4MM 2
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Workabout MX Service Manual
Version 1.0 13
Dismantling the Workabout
The modular design of the Workabout is such that the internal workings of the product can be removed from the case by removing two screws. This means that if the outer case assembly becomes damaged, it can be replaced quickly and easily without the need to change any other component. If there is a fault in the Outer Case Moulding, LCD Window, Keyboard Frame, or Rubber Keymat, the entire case should be replaced.
+ Note:- In some cases the machine may be fitted with security screws that require a suitable screwdriver to remove them.
When you remove internal components from the case, take care not to damage the LCD Module. Do not bend the Module, as it is prone to fracturing. Do not touch the LCD Glass as it will show finger marks and smudges.
If the LCD glass is broken, be careful not to get any liquid in your mouth or eyes. In the event of any liquid crystal getting on skin or clothes, wash it off immediately with soap and plenty of
water and seek a doctor’s advice.
Tools Required
Tool Description Type
Crosshead Screwdriver Pozi Size - 0 Crosshead Screwdriver Phillips Size - 00 Screwdriver Flat Size - 2.5mm Nut Spinner n/a 4mm AF Knife/Scalpel n/a n/a Pliers Snipenose n/a
Dismantling Procedure
1 Press the drawer release button (or use a security key if necessary) and open the
Workabout.
2 Remove any batteries (including the Lithium Dry Cell) and SSDs that are inside the
Workabout.
3 Remove the fuse from its location beneath the main batteries. If the fuse is damaged,
replace it with a 1.25 AMP ‘Fast Blow’ glass fuse, 5mm ∅, 20mm long, Psion part number A4900-0041.
4 Remove the 2 screws from the base of the Workabout. 5 Pull the Chassis Assembly from the case (this may require a sharp tug). 6 If fitted, unclip the Expansion FFC from its ZIF Connector on the Main PCB and also from
the ZIF Connector(s) on the Expansion or Monitor PCB.
+ Note:- Take care not to crease or tear the FFC.
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14 Version 1.0
Drawer Assembly
Main Power FFC
Drawer Locating Clips -
Derail from the Chassis
Expansion
FFC ZIF
Main Power
FFC ZIF
Chassis Assembly
7 Unclip the Main Power FFC from its ZIF Connector. 8 Unclip the Drawer Assembly by derailing the Drawer from its tracks. 9 Slide the Drawer Assembly out of the Chassis Assembly.
+ Note:- Dismantling the Latch Assembly is not necessary as replacement cases are supplied complete with latches. The following step is for information only.
10 To remove the Latch Assembly, remove the 3 screws from the latch case. Be careful to
catch the internal springs and other components when you remove the case.
Dismantling the Chassis Assembly
1 Remove the Drawer Spring from the Connector Block.
+ Note:- The Drawer Spring should always be removed when you either remove or refit the Connector Block.
2 Remove the Bottom Connector Seal.
+ Note:- As a general rule, replace the Bottom Connector Seal whenever it is removed for servicing.
3 Remove the 2 screws from the LIF Connector.
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Version 1.0 15
6 If fitted, remove the Decoder or Expansion PCB:
a) On a Scanner Workabout, remove the FFCs from the ZIFs and then remove the 2
retaining screws on the Support Moulding.
b) On a Barcode/Wand Workabout, remove the FFC from the ZIF and then remove the 2
retaining screws.
Retaining screws
Expansion PCB
Monitor PCB
Barcode/Wand Scanner
7 Remove the Option Port FFC, if fitted, and remove the Option Port. 8 Remove the LCD Backlight Power Connector, if fitted.
LCD Backlight Power Connector
LCD Backlight
Power FFC
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9 Unclip the LCD ZIF from the Main PCB. There is a hole in the CPU frame moulding to
allow you to do this.
LCD ZIF Connector
LCD FFC
CPU Frame Moulding
10 Remove the Main PCB Screw. 11 Remove the Main PCB. 12 Remove the Chassis Seal. 13 Remove the LCD. The LCD Module is located on a pin on the CPU Frame moulding. This
pin is covered by the rubber LCD Sleeve. Handle the LCD Module by the glass so that you do not damage the circuit boards. Manoeuvre the module off the pin by wiggling the
module while holding the glass. 14 Remove the Backlight, if fitted. The Chassis Assembly is now dismantled.
Dismantling the Drawer Assembly
+ Note:- It is not necessary to dismantle the Drawer Assembly. This procedure is included for information purposes only.
1 Remove the Top Cap:
a) On base machines, the four screws that secure the Top Cap are covered by labels.
Remove the labels and then remove the screws.
b) On Option Machines, the screws are not covered.
Top Cap
4 screws
Labels on Base machines
2 Remove the foam Top Cap Seal and the Piezo Seal.
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Version 1.0 17
+ Note:- As a general rule, replace the Top Cap Seal and Piezo Seal whenever they are removed for servicing.
3 Remove the Expansion FFC if fitted. Ease the FFC out of the case by sliding it backwards
and forwards length-ways and pulling it gently up out of the insertion slot in the SSD Drawer moulding.
4 Remove the SSD Back. This is clipped onto the SSD Drawer at the top end. To remove it:
a) Remove the two securing screws. b) Remove the SSD Back by lifting its free end out by about 10mm and then prying the
top left-hand corner away from the SSD Drawer moulding until it becomes unclipped. Take care not to damage the Lithium Battery Contacts on the FFC.
5 Release the Piezo. The tail that connects the Piezo to the Main Power FFC is quite thin
and can be damaged if not handled correctly. Take care to release the strip of the FFC attached to the Piezo at the same time that the rest of the Main Power FFC assembly is
eased out of the SSD Drawer. 6 Remove the Fuse Contacts. The Drawer Assembly is now fully dismantled.
Selecting the PCB Type
The Workabout Main PCB can be programmed for use in the Scanner, Integral Wand, or Numeric versions by using a special Configuration SSD.
The Main PCB is supplied unprogrammed and the SSD allows you to select the PCB type using the product type/variant code as listed in the section Serial Number Information on page 2.
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18 Version 1.0
Re-assembly Instructions
The Workabout can be re-assembled by following the flow diagrams below. The flow diagrams show the correct sequence for re-assembling the subassemblies. Also
refer to the diagrams in the Dismantling Procedure steps on page 13, in reverse order, as you perform each re-assembly step.
Take care when you reinsert FFCs into ZIF Connectors. If you insert FFCs into the
connectors at an angle, it can cause open or short-circuits.
Make sure that the bends in the FFCs allow the drawer to open and close correctly.
Re-assembling the Drawer Assembly
1
2
Insert the Piezo and Main Power FFC assembly.
Insert the Fuse Contacts.
See Notes Step 2 below
3
Fit the SSD Back.
See Notes Step 3 below
4
Fit the 2 securing screws.
5
Insert the Expansion FFC (if fitted).
See Notes Step 5 below
6
Fit a
new
Top Cap Seal.
7
Fit a
new
Piezo Seal.
8
Screw the Top Cap to the Drawer Assembly.
The Drawer Assembly has now been re-assembled.
9
Apply End Cap labels.
No
Yes
Base machine?
Notes on Drawer Re-assembly
Step 2
Take care when sliding the Piezo tail into the SSD Drawer via the insertion slot.
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Step 3
Take care not to damage the Main Battery and Lithium Battery contacts.
Step 5
Ease the FFC into the case by sliding it backwards and forwards while pushing it gently down through the insertion slot in the SSD Drawer moulding.
Re-assembling the Chassis Assembly
1
2
Fit the LCD on top of the Backlight.
Place the Backlight, if fitted, in position.
3
Fit the Chassis Seal.
4
Fit the Main PCB.
5
Connect the Backlight Power Connector.
6
Fit the Option Port FFC or Blank.
7
Add the Expansion or Monitor PCB, if fitted.
8
Fit the Connector Block.
The Chassis Assembly has now been re-assembled.
11
Fit the Drawer Spring.
See Notes Step 1 below
See Notes Step 4 below
9
Fit the 2 LIF Connector Screws.
10
Fit a
new
Bottom Connector Seal.
Notes on Chassis Re-assembly
Step 1
Stick the LCD Backlight FFC to the side of the Chassis Assembly.
Step 4
Hold the Main PCB and Chassis Assembly parallel to each other and insert the LCD FFC into the LCD ZIF Connector. Lock the ZIF Connector. Now fit the Main PCB Screw.
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Final Re-assembly
1
2
Locate the Drawer rails in their tracks.
Slide the Drawer Assembly into the Chassis Assembly.
3
Connect the Main Power FFC to its ZIF Connector.
4
If fitted, connect the Expansion FFC to its ZIF Connectors.
5
Insert the Chassis Assembly into the case.
6
Fit 2 screws in the base of the case.
7
Insert the fuse.
8
Insert the Main and Lithium Batteries.
The Workabout has now been re-assembled.
9
Insert the SSDs.
10
Close the Workabout Drawer.
See Notes Step 5 below
See Notes Step 7 below
Expansion ZIF Connector
Main Power ZIF Connector
Notes on Final Re-assembly
Step 5
Take care to ensure that the Chassis Seal fits correctly.
Step 7
The fuse must be a 1.25 AMP ‘Fast Blow’ glass fuse, 5mm ∅, 20mm long, Psion part number A4900-0041.
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Checking the Operation of the Options
To accurately check the operation of fitted options, you need the following items:
n A bar code reader or a scanner that gives a TTL output. n An RS232 interface. n A bar code wand or scanner with a 9-way male connector with the following pin
arrangement:
Pin No. Signal
Name
Remarks
1 DCD Handshake - input 2 RX Bar Code Data Receive - input 3 GND 0V 4 GND 0V 5 DSR Handshake - input 6 DTR Handshake (Trigger or Enable) - output 7 GND 0V 8 GND 0V 9 VCCEXT 5V 200mA max
n An IBM-compatible PC able to run VT in MS-DOS or Terminal in Windows 3.1x. Any other
program that can be run to provide Glass Terminal Emulation can also be used.
Checking the RS232 Interface
You can use the Comms application on the Workabout to turn on the RS232 interface on the option board and check the RS232 interface. To check the RS232 interface:
1 Switch on the Workabout.
Switching the machine on after replacing a backup battery, or for the first time, causes the
Workabout to reboot. When you press the On button, the Workabout beeps and after a
pause of up to 5 seconds, the shell screen appears.
2 Press the Menu key. 3 Use the cursor keys to select the System screen option and press Enter.
4 On the System screen, use the cursor keys to position the highlight bar over the Comms
application and press Enter. 5 Plug a 9-way female to 9-way female null modem cable between the serial port on the PC
and the RS232 port on the Workabout. 6 On the PC, run VT in MS-DOS, or Terminal in Windows 3.1x. The default baud rate for
the RS232 port in the Workabout is 9600. Adjust the settings on the PC program to match.
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7 When a serial link has been established between the PC and the Workabout, any
characters you type on the Workabout appear on the PC screen and vice-versa. This indicates that the RS232 serial channel is working correctly.
8 To exist from the Comms program, press + on the Workabout.
Testing the TTL Interface
You can test the TTL interface by using a compatible barcode device. To do this, follow steps 1 to 4 of the RS232 Interface check procedure and then follow the steps below:
1 Plug a compatible barcode device into the TTL port. 2 If the barcode device is giving true data, set the expansion board port to D. If it is giving
inverted data, set the port to G: a) In the Comms application, press Menu and select Spec. (Use the ↑ and ↓ keys to
select an item and the ← and → keys to select a value.)
b) Set the baud rate to 9600 and the port to D or G as appropriate.
3 Scan some sample bar codes. The numerical equivalent of the barcode should appear in
the top left corner of the screen.
+ Note:- Always scan at least two different barcodes to ensure that a chance operation has not occurred.
4 To exist from the Comms program, press + on the Workabout.
Testing the Barcode Interface
The Barcode interface can be tested using a compatible barcode wand or scanner. To do this, follow steps 1 to 4 of the RS232 Interface check procedure and then follow the steps below:
1 Plug a compatible barcode device into the Barcode port. 2 Set the expansion board port to E and set the baud rate to 9600 (refer to the Testing the
TTL Interface instructions).
3 Scan some sample bar codes. The numerical equivalent of the barcode should appear in
the top left corner of the screen.
4 To exist from the Comms program, press + on the Workabout.
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Expansion Interface
The interfaces built into the Workabout are accessible by plugging in appropriate connectors or adapters at the top or bottom of the unit.
The top connectors provide RS232 AT and either a TTL-level serial interface or a bar code wand interface. The TTL-level serial interface can operate CCD barcode scanners or low power laser scanners.
The bottom connector provides access to the LIF connector for the docking interface, external power and SIBO serial interfaces.
The serial and barcode interfaces are provided by optional internal peripheral modules. These are fitted inside the Workabout and plug into an internal expansion connector.
RS232 AT/TTL Serial Interfaces
These are provided by the RS232 AT/TTL peripheral module which provides:
n an IBM-compatible RS232 AT serial interface at standard RS232 voltage levels n an RS232 TTL serial interface at 5V TTL levels n a 5V nominal (4.7V min.) software switched power supply (VCCEXT) which provides up to
200 mA, with a current limit at approximately 250mA The serial format and the polarity of the TTL-level interface can be programmed using
suitable software programs. The interfaces can be operated at a baud rate of 19,200.
+ Note:- Although both interfaces are present in the module, only one can be configured as operational at any one time.
The 9-way D-type male RS232 AT interface connector pin allocation is shown below:
Pin No. Signal
Name
Remarks
1 DCD Handshake - input 2 RX Serial Receive - input 3 TX Serial Transmit - output 4 DTR Handshake - output 5 GND 0V 6 DSR Handshake - input and EXON
(1)
7 RTS Handshake - output 8 CTS Handshake - input 9 GND 0V
(1) The EXON signal is the external wake-up control for the Workabout. If the RS232 AT/TTL
peripheral expansion module is configured correctly, the EXON signal switches on the Workabout
when an RS232 or TTL-level rising edge is applied to this signal. The RS232 AT interface is
enabled by opening port A (see Testing the TTL Interface on page 22 for instructions on how to do
this).
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The 9-way D-type female RS232 AT interface connector pin allocation is shown below:
Pin No. Signal
Name
Remarks
1 GND 0V 2 RX Serial Receive - input 3 TX Serial Transmit - output 4 VCCEXT 5V 200mA max
(1)
5 GND 0V 6 DSR Handshake - input 7 RTS Handshake - output 8 CTS Handshake - input 9 GND 0V
(1) The VCCEXT supply is switched on and off at the same time as the TTL serial port is opened and
closed. The RS232 TTL interface is enabled by opening port D for true data and port G for inverted data (see Testing the TTL Interface on page 22 for instructions on how to do this).
RS232 AT Serial/Barcode Interfaces
These are provided by the RS232 AT/Barcode peripheral module which provides:
n an IBM-compatible RS232 AT serial interface at standard RS232 voltage levels at up to
19,200 baud
n an RS232 TTL serial interface at 5V TTL levels n a 5V nominal (4.7V min.) software switched power supply (VCCEXT) which provides up to
200 mA, with a current limit at approximately 250mA
n a barcode wand interface with a 5V nominal (4.7V min.) software switched power supply
(VCCEXT) which provides up to 200 mA
The RS232 AT interface serial format can be programmed using suitable software programs and the barcode interface is provided by a Hewlett Packard HBCR-1612 barcode decoder device. This allows wands which generate digital signals to be connected directly to the barcode interface. The barcode interface format can be programmed using software, although this feature is not used if a Hewlett Packard barcode wand is being used, as the decoder requires a set format.
+ Note:- Although both interfaces are present in the module, only one can be configured as operational at any one time.
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The 9-way D-type male RS232 AT interface connector pin allocation is shown below:
Pin No. Signal
Name
Remarks
1 DCD Handshake - input 2 RX Serial Receive - input 3 TX Serial Transmit - output 4 DTR Handshake - output 5 GND 0V 6 DSR Handshake - input and EXON
(1)
7 RTS Handshake - output 8 CTS Handshake - input 9 GND 0V
(1) The EXON signal is the external wake-up control for the Workabout. If the RS232 AT/TTL
peripheral expansion module is configured correctly, the EXON signal switches on the Workabout
when an RS232 or TTL-level rising edge is applied to this signal. The RS232 AT interface is
enabled by opening port B (see Testing the TTL Interface on page 22 for instructions on how to do
this).
The 9-way D-type female RS232 AT interface connector pin allocation is shown below:
Pin No. Signal
Name
Remarks
1 DCD Handshake - input 2 RX Bar Code Data Receive - input 3 GND 0V 4 GND 0V 5 DSR Handshake - input 6 DTR Handshake (Trigger or Enable) - output 7 GND 0V 8 GND 0V 9 VCCEXT 5V 200mA max
(1)
(1) The VCCEXT supply is switched on and off at the same time as the barcode port is opened and
closed. The barcode interface is enabled by opening port E (see Testing the TTL Interface on page
22 for instructions on how to do this).
+ Note:- The Hewlett Packard barcode decoder uses 9600 baud, true data port settings.
Circuit Description
LIF Converter
The LIF Converter provides the interface between the mains adaptor, serial link and the Workabout. It also includes a charging circuit in the form of a linear regulator operating in constant current mode.
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Final Test
The section describes how to set up the Final Test and perform the test sequence on a Workabout.
+ Note:- These instructions do not describe how to perform tests on the Workabout Peripheral product range.
Equipment
You need the following equipment to perform the Final Test:
Qty Description Psion p/no.
1 Workabout Final Test Unit 1810-0001 1 Mains Lead 4801-0005 2 Test SSDs 2301-0115 1 Workabout Test Battery Cartridge 2800-0030 1 LIF Cable 2800-0005 1 Lithium Battery 4900-0018
+ Note:- The Final Test Unit is suitable for working with mains supplies in the range 90-130/180-260VAC @ 47-63Hz, without adjustment.
Test Setup
WARNING - There are hazardous voltages within the Final Test Unit. Please follow this
procedure carefully.
Follow the steps below to set up a Workabout for testing. 1 Insert the following items in the Workabout:
q 2 x test SSDs q 1 x lithium battery q 1 x Workabout Test Battery Cartridge
2 On the Final Test Unit:
a) Connect the LIF Cable and Ground Detect Probe to the Final Test Unit. b) Set the main battery switch to STANDBY. c) Set the DC Power switch to OFF.
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WORKABOUT
FINAL TEST UNIT
EXP SUPPLY OK
BAT. GROUND FAULT
THERMISTOR FAULT
STANDBYONOFF
ON
BATTERY CURRENT
GROUND DETECT PROBE
LIF CONNECTOR
A
Insert the LIF Connector
Insert the Ground Detect Probe
Main Battery switch to STANDBY
DC Power switch to OFF
3 Connect the LIF Connector to the Workabout. The LIF connector provides power to the
Workabout:
Final Test Unit
LIF Connector
Workabout unit contains:
■
Lithium battery
■
2 x test SSDs
■
Workabout Test Battery Cartridge
Ground detect probe
The Workabout is now ready for testing.
Test Sequence
1 Check the battery standby current reading on the Final Testing Unit ammeter.
Fail the 2M SR-DRAM unit if the reading is higher than 750µµA. 2 Check that the THERMISTOR FAULT lamp is not lit. 3 Move the Main Battery switch from STANDBY to ON.
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The Final Test Program is downloaded via the LIF cable, and the following menu is displayed on the Workabout:
MENU - FINAL - MX -
‘Version Number’
‘O/S’ RAM ‘size’ LANG ‘language’
All Cpu SSDs Expansion
Lcd Serial Sound
Keys Supply Drawer
Arrow keys move, ENTER selects
Check the following: a) The Final Test Program Version Number corresponds to the latest release. b) Check that the Operating System version number, RAM size and Language settings
are correct.
c) Check the ammeter reading on the Final Test Unit. Fail the unit if the reading is higher
than 25mA.
+ Note:- You can perform each check individually by selecting each option in turn from the test menu. This procedure uses the All option to run through all the checks in one go.
4 Select the All option from the test menu on the Workabout and press Enter.
A bold centre cross and a corner marker are displayed. The cross should be bold and even throughout and all corner should be complete, as shown in the example below:
5 Press any key to continue. 6 If the pattern is correct press Space. If the pattern is faulty press Esc. 7 Check that the LCD backlight is now ON. 8 Check the contrast range:
a) Press any key - the screen should be black. b) Press any key - the screen should be clear. c) Press any key a third time - the screen should return to normal. If the maximum and minimum contrast were correct, press Space. If they were not
correct, press Esc.
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9 Check all the Workabout keys:
a) Press any key to begin. A full keyboard map is displayed.
b) Press each key in turn and note that the selected key image changes from dark grey to
light grey.
10 When you are prompted to “Switch on the DC Supply”, move the DC Power switch on the
Final Test Unit to ON. 11 Check the battery ammeter reading. It should be zero. Check also that the DC Supply
indicator (the green LED on the Final Test Unit) is lit. 12 Check that the buzzer sounds. If the buzzers sounds press Space. If the buzzer does not
sound press Esc. + N.e:- Check on the Final Test Unit, that the EXP SUPPLY OK indicator is lit. 13 When you are prompted to “Open Drawer”, open the Workabout and check the Battery
Ground contact by touching the ground connection on the test battery cartridge with the
ground detect probe:
Ground
Workabout Test Battery Cartridge
The BATTERY GROUND FAULT indicator should go off when the probe touches the
metal.
14 Remove the solid state disks, battery pack and lithium battery. 15 Close the drawer and press any key.
If all the test have been passed, press Space to continue. 16 The EEPROM setting will be displayed and the serial number is required to be entered.
The serial number information is detailed on page 2 of this manual.
Each field should be correctly filled by using the arrow keys to select the field, and
entering the existing serial number displayed on the Workabout drawer. The variant
settings can be verified against the information given on page 3 of this manual.
Once compete, press Space to continue.
N.te the EEPROM setting screen will only be displayed if the Workabout passes all tests. 17 Remove the LIF Connector from the Workabout. The final test is now complete.
+ N.te:- If the test failed, remove the LIF Connector and set up the Workabout again, but when the test menu is displayed, select each test in turn from the test menu until you find the test that fails.
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