Simplex 4120 Installation Instructions Manual

4120 NPU CPU Replacement

Installation Instructions

 2000, Simplex Time Recorder Co., Westminster, MA 01441-0001 USA

All specifications and other information shown were current as of publication, and are subject to change without notice.

579-227

Rev. A

This publication describes the replacement procedure for the CPU card in the 4120 Network
Processing Unit (NPU).

Upon unpacking your Simplex product, inspect the contents of the carton for shipping damage. If
damage is apparent, immediately file a claim with the carrier and notify Simplex. Ship group
748-544 accompanies the product and contains the parts listed in the following table.

Part # Description Qty

636-995 New CPU Board 1

246-524 RAM Cards 2

734-038 New UL I/O Harness 1

734-037 New Hard Drive Harness 1

636-540 Hard Drive Kit 1

579-227 Installation Instructions 1

This publication discusses the following topics:

Topic Page #

Cautions and Warnings 2

Preparing System for Upgrade 3

Removing the Old CPU Board 5

Installing RAM in the New CPU Board 7

Connecting the New UL I/O Cable 8

Connecting the New CPU Board 9

Connecting the Hard Drive 11

Setting up the System for Reconfiguration 14

Configuring CMOS Setup 15

Upgrading from a 636-588 CPU Board 19

Introduction

Inspecting Contents
of Shipment

In this Publication

2

READ AND SAVE THESE INSTRUCTIONS. Follow the instructions in this installation

manual. These instructions must be followed to avoid damage to this product and associated
equipment. Product operation and reliability depends upon proper installation.

DO NOT INSTALL ANY SIMPLEX PRODUCT THAT APPEARS DAMAGED. Upon
unpacking your Simplex product, inspect the contents of the carton for shipping damage. If
damage is apparent, immediately file a claim with the carrier and notify Simplex.

ELECTRICAL HAZARD - Disconnect electrical field power when making any internal
adjustments or repairs. Servicing should be performed by qualified Simplex Representatives.

STATIC HAZARD - Static electricity can damage components. Therefore, handle as follows:

• Ground yourself before opening or installing components (use the 553-484 Static Control
Kit).

• Prior to installation, keep components wrapped in anti-static material at all times.

EYE SAFETY HAZARD - Under certain fiber optic application conditions, the optical output of
this device may exceed eye safety limits. Do not use magnification (such as a microscope or other
focusing equipment) when viewing the output of this device.

RADIO FREQUENCY ENERGY - This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in accordance with the instruction manual, may
cause interference to radio communications. It has been tested and found to comply with the
limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such interference when operated in a
commercial environment. Operation of this equipment in a residential area may cause interference
in which case the user at his own expense will be required to take whatever measures may be
required to correct the interference.

SYSTEM REACCEPTANCE TEST AFTER SOFTWARE CHANGES - To ensure proper
system operation, this product must be tested in accordance with NFPA72-1996, Chapter 7 after
any programming operation or change in site-specific software. Reacceptance testing is required
after any change, addition or deletion of system components, or after any modification, repair or
adjustment to system hardware or wiring.

All components, circuits, system operations, or software functions known to be affected by a
change must be 100% tested. In addition, to ensure that other operations are not inadvertently
affected, at least 10% of initiating devices that are not directly affected by the change, up to a
maximum of 50 devices, must also be tested and proper system operation verified.

Cautions and Warnings

3

The original CPU board in the 4120 NPU was part number 636-588 (386SX microprocessor).
Since then, there has been a replacement board, the 636-802 (486DX2 microprocessor). This
publication describes the procedure for a new upgrade. The new board is part number 636-995.
This manual focuses mostly on an upgrade from a 636-802 to a 636-995. There are also
instructions contained for upgrading from a 636-588 to a 636-995.

• If you are upgrading from a 636-802 to a 636-995, proceed with the instructions below and
disregard the section entitled “Upgrading from a 636-588 CPU Board” at the end of this
publication.

• If you will be upgrading from a 636-588 to a 636-995, see the section entitled “Upgrading
from a 636-588 CPU Board.”

1. Backup the network.

2. Insert a blank floppy diskette into the floppy drive.

3. From the DOS prompt, type “format a: /s” to make a system diskette.

4. Copy FDISK.EXE, FORMAT.COM, and SYS.COM from the DOS directory to your floppy
drive.

5. From the CMOS setup write down the hard drive’s settings, including the size, type, sectors,
etc.

6. Disconnect the panel’s batteries at the fuse.

7. Disconnect AC power at the breaker.

1. Remove the front cover on the chassis inside the main cabinet by removing the four T15 Torx
screws located at its corners.

2. Locate the CPU board within the chassis. It’s the vertically oriented board, second from the
left. Most of the ribbon cables in the case will be connected to it.

Figure 1. Contents of Chassis

Continued on next page

Preparing System for Upgrade

Introduction

Protect System
Settings

Label all Ribbon
Cables on the CPU
Card

Location of the CPU

Board within the

System Case

4

3. Label the ribbon cables attached to the CPU board.

Match up the position of each cable on the board with Figure 2 and use the labels suggested in
the callouts. You will use these labels later when you connect the cables to the new CPU
card.

Figure 2. Labels for Connections on the Old CPU Board

Preparing System for Upgrade, Continued

Label all Ribbon
Cables on the CPU
Card, (continued)

COM A

COM B

Panel

Parallel

Hard Drive

Floppy Drive

UL I/O

Front

Rear

Top

Bottom

5

1. Disconnect from the CPU board the cables you have labeled. Leave the other ends of the
cables attached at this time.

2. Remove the other end of the cable you labeled “hard drive.” This end is attached to the hard
drive, located in the drive assembly (see Figure 8) at the bottom right of the chassis. This
cable can be discarded, as you will be replacing it later.

1. Locate the UL I/O card. It is the card installed in the leftmost position of the chassis, to the
immediate left of the CPU board you are replacing.

2. Remove the ribbon cable from the position on the UL I/O card shown in Figure 3. The
opposite end of this cable should remain attached to the green box at the top of the chassis.

Figure 3. UL I/O Board

3. Remove the cable you labeled “UL I/O” from the UL I/O board (The position of this cable is
shown in Figure 3). This cable can be discarded, as you will be replacing it later.

Continued on next page

Removing the Old CPU Board

Disconnect Cables
from the CPU Board

Disconnect Cables
from the UL I/O
Board

Disconnect the

Cable Attached

Here

Disconnect the
UL I/O Labeled

Cable Here and

Discard

Front

Rear

Top

Bottom

6

1. Using a T15 size Torx screwdriver, remove the screw at the top edge of the CPU board. This
is the screw that fastens the board to the edge of the chassis.

2. Pull the board straight out of the case, following along the guides at the bottom of the case. It
may take some force to initially detach the edge of the board from the bus connection in the
rear of the case.

Removing the Old CPU Board, Continued

Remove the Old
CPU Board

7

You need to attach the two RAM cards (246-524) supplied in the ship group to the new CPU
board. There are four RAM locations on the new card and the RAM must be installed in
alternating slots. In other words, the cards go in either the first and third slots or the second and
fourth slots. Figure 4 shows the RAM slots on the new board.

Figure 4. Alternating RAM Slots

1. Insert each card by inserting the bottom of the card beneath the small gold pins extending
horizontally from the base of the RAM housing. To do this, hold the RAM at a 45° angle.
See Step one in Figure 5.

Note: The card will only fit in one way. There should be a key, or notch, in the bottom

of it that lets you know which side enters the base. This notch will also only fit
into the slot when the RAM card is facing the correct direction.

Figure 5. RAM Insertion

2. Once you have the card positioned correctly, rotate it up towards the center of the housing
until it clicks into the silver pins on either side. See Step two in Figure 5.

Installing RAM in the New CPU Board

Insert the RAM into
the New Board

Step 2

Step 1

Alternating
RAM
Locations

Key

8

Connect the 14-pin end of part 734-038, which is one of the ribbon cables shipped with the board,
to the connector on the UL I/O board shown in Figure 6. Be sure to count the number of holes on
each end of the cable, one has 16 pins and the other 14. The 14-pin end is what you must connect.
Attach the cable so that the colored stripe is on the bottom.

Figure 6. New UL I/O Cable Placement

Connecting the New UL I/O Cable

Attach 734-038

here

Front

Rear

Top

Bottom

9

1. Slide the new CPU board halfway into the same location in the case previously occupied by
the old board. Be sure to position the board into the plastic guides located at the bottom of the
case. The side of the board with all the connections on it should face to the right.

2. Connect the 16-pin end of the new UL I/O ribbon cable (734-038), the same cable that you
have previously attached to the UL I/O card, to the position on the new CPU card shown in
Figure 7 (on next page). This cable is not keyed. Make sure to attach the cable so that the
colored stripe is closest to the front of the case. Refer to Figure 7.

3. Slide the new CPU board the rest of the way into chassis, inserting it in the bus fixture in the
back.

Note: After the board has been inserted most of the way, you may feel some

resistance. You will need to apply some force to connect the board to the bus
fixture.

4. Reinsert the screw at the top of the case with the T15 Torx screwdriver. This completely
fastens the new board in place.

5. Refer to Figure 7 and match up the labels on the cables to the labeled positions on the new
CPU board. Attach each cable to the new board so that the colored stripe is on the bottom.

Continued on next page

Connecting the New CPU Board

Insert and Connect
the New CPU Board

10

Figure 7. Labeled Connections on New CPU Board

6. Connect one end of the new hard drive ribbon cable (734-037) to the CPU board in the
location labeled “Hard Drive” in Figure 7. Attach this cable so that the colored stripe is on
the bottom.

Connecting the New CPU Board, Continued

Insert and Connect
the New CPU Board,

(continued)

UL I/O

Front

Rear

COM B

COM A

Parallel

Panel

Hard Drive

Floppy Drive

Top

Bottom

from Step 2

colored

stripe

11

1. Locate the drive assembly containing both the hard drive and floppy drive at the bottom right
of the chassis. Note the placement of the white insulators at the bottom and rear of this
assembly.

2. Using a size T15 Torx screwdriver, remove the four screws and plastic insulators that fasten
the assembly to the bottom of the silver case. There are two screws on either side of the
assembly. The two screws toward the front of the case are shown in Figure 8.

3. Remove the screw and the corresponding plastic insulator that mount the assembly to the rear
of the chassis using a size T15 Torx screwdriver. The location of this screw is shown in
Figure 8 as well.

4. Remove the Drive Assembly. Put aside the white insulators that were resting below and
behind the assembly. You will need to re set these insulators later.

5. Locate the hard drive’s mounting bracket within the drive assembly.

6. While holding onto the mounting bracket, remove the two screws on either side of the
assembly that hold the mounting bracket in place. Use a T15 Torx screwdriver. Two of these
screws are shown in Figure 8.

7. Slide the mounting bracket, which contains the hard drive, out of the housing.

Continued on next page

Connecting the Hard Drive

Remove the Hard
Drive

Figure 8. Drive Assembly

(as seen in the case)

Figure 9. Hard Drive and

Mounting Bracket

(contained in Drive

Assembly)

Hard D

rive

Mounting

Bracket

Hard Drive

Mounting Bracket

Screws

Removed in

Step 6

Location of
Screw from

Step 3

Location of

Screws

Removed in

Step 2

12

Now that the mounting bracket has been removed from the drive assembly, you will be able to add
the adapter to the hard drive that will enable the new PC board to connect to the hard drive.

1. Attach the new PC board adapter (636-540) to the pins at the rear of the hard drive. Leave the
first set of four separate pins open. Attach the adapter to the remaining pins. One side of the
adapter is labeled “top-side.” This side should be facing up away from the hard drive, so you
can read it. See Figure 10.

Note: This connection is keyed. You will notice that one of the connector’s holes is

blocked. The blocked hole corresponds to the missing pin on the hard drive’s
connection port.

Figure 10. Attaching the PC Board Adapter to the Hard Drive

2. Locate the screw and rubber washer that came with the PC Board Adapter’s installation kit.

3. Place the rubber washer in between the holes in the adapter and the mounting bracket.

4. Fasten the screw through the hole in the top of the PC adapter board, the washer, and the
mounting bracket. Use a T9 size Torx screwdriver.

Note: The four screws that attach the hard drive to the mounting bracket may have to

be loosened in order to reposition the hard drive so that the hole in the mounting
bracket aligns with the hole on the board after it has been attached to the hard
drive. Be sure to retighten the screws afterwards if you need to do this.

Continued on next page

Connecting the Hard Drive, Continued

Add the PC Board
Adapter

Hard Drive

Mounting

Bracket

PC Board

Adapter

Leave these
Pins Open

13

1. Slide the mounting bracket, containing the hard drive, back into the drive assembly. The
topside of the PC board adapter should face toward the floppy drive.

2. Fasten the mounting bracket to the drive assembly by replacing the screws that were removed
on the sides of the assembly.

1. Reposition the drive assembly at the bottom of the case. Make sure the white insulator
washers are in place below and behind the assembly.

2. Replace the screws you have removed at the bottom and rear of the assembly, fastening both
the drive assembly and insulators in place.

1. Connect the other end of the new hard drive cable (734-037) into the hard drive’s PC board
adapter, which you just installed. This connection is keyed and will only fit one way.

2. Connect power to the white, four-pin port on the hard drive’s PC board adapter card. Use the
four-pin connector that extends from the same cable that powers the floppy drive.

Note: You may need to follow the power cable (marked by a white casing on the floppy

drive) from the floppy drive down until you find the unused four-pin connector. It
is a white plastic casing about three quarters of an inch wide. Plug this
connector into the white, four-pin port on the PC board adapter you’ve just
connected to the hard drive.

Fasten the cover back onto the chassis with the four screws you removed from each corner earlier.

Connecting the Hard Drive, Continued

Replace the Hard
Drive and Mounting
Bracket

Remount the Drive
Assembly

Connect Cables to
the Hard Drive

Close Chassis

14

The keyboard must be plugged in to edit the setup screens.

Connect the cord from the keyboard to the system unit. The keyboard plugs into the round
connection atop the system unit. There are two of these connections - the one for the keyboard is
the one furthest back. See Figure 11.

Figure 11. Top Edge of New CPU Board

Note: It is important that you connect the keyboard before applying power to

the system. Otherwise, you may cause electrical damage.

1. Turn on the power at the breaker.

2. Reconnect the battery cable at the fuse.

Setting up the System for Reconfiguration

Connect the
Keyboard

Power Up the
System

Front Rear

Keyboard

Connection

15

During system startup, you will see this prompt:

Press del key to enter Setup

Press [DELETE] while this message is on the screen to configure CMOS Setup.

Note: You will only have a short amount of time to do this. If you miss this message

and hit the delete key too late, press [CTRL + ALT + DELETE] to restart the
computer and try again.

Note: Make changes to the setup screens by using the arrow keys and the page up

and page down keys. The screens themselves provide instructions for altering
their content.

1. Highlight and select “Auto Detect Hard Disks” from the list on the main setup screen.

2. Make sure that the hard drive has been recognized and has the correct settings.

Note: If the Pri Master is listed as Type “Not Installed” then you may have improperly

connected the hard drive. Check the adapter and cable connections at the hard
drive and CPU board.

AMIBIOS SETUP – STANDARD CMOS SETUP

© 1996 American Megatrends, Inc. All Rights Reserved

Date (mm/dd/yyyy) : Sat, May 27. 1999 Base Memory: 640 KB
Time (hh/mm/ss) : 01:58:01 Extd Memory: 15 MB

Floppy Drive A : 1.44 MB 3½
Floppy Drive B : Not Installed
LBA Blk PIO 32Bit
Type Size Cyln Head Wpcom Sec Mode Mode Mode Mode
Pri Master : User 6194 13424 15 0 63 On On 4 Off
Pri Slave : Not Installed
Sec Master : Not Installed
Sec Slave : Not Installed

Boot Sector Virus Protection Disabled

Month: Jan -- Dec ESC:Exit : Sel
Day : 01 -- 31 PgUp/PgDn: Modify
Year : 1901 – 2099 F2/F3: Color

Figure 12. Auto Detect Hard Disks Screen

3. Press [ESC] to return to the main setup screen.

Continued on next page

Configuring CMOS Setup

Enter Main Setup
Screen

Check Settings on
the Auto Detect Hard
Drive Screen

16

1. Highlight and select “Advanced CMOS Setup” from the list on the main setup screen.

2. Make sure that “Floppy” is set as the 1st Boot Device.

3. Make sure that “ IDE-0” is set as the 2nd Boot Device.

AMIBIOS SETUP –ADVANCED CMOS SETUP

© 1996 American Megatrends, Inc. All Rights Reserved

Quick Boot Disabled Available Options:
1st Boot Device Floppy Disabled
2nd Boot Device IDE-0 Enabled
3rd Boot Device Disabled
Try Other Boot Devices No
Initial Display Mode BIOS
Display Mode at Add-On ROM Init Force BIOS
Floppy Access Control Read-Write
Hard Disk Access Control Read-Write
S.M.A.R.T. for Hard Disks Disabled
BootUp Num-Lock On
PS/2 Mouse Support Enabled
Primary Display VGA/EGA
Password Check Setup
Parity Check Disabled
Boot to OS/2 No
CPU MicroCode Updation Enabled
Internal Cache WriteBack ESC: Exit :Sel
External Cache Write Thru PgUp/PgDn: Modify
System BIOS Cacheable Enabled F2/F3: Color

Figure 13. Advanced CMOS Setup Screen

4. Press [ESC] to return to the main setup screen.

Note: To set the date, highlight and select “Standard CMOS Setup” from the main

setup screen and alter the contents as necessary.

Continued on next page

Configuring CMOS Setup, Continued

Check Setting in the
CMOS Screens

17

1. Highlight and select “Advanced Chipset Setup” from the list on the main setup screen.

2. Make sure that the USB Function is “disabled”.

3. Make sure that the IRQ12/M Mouse Function is “enabled”.

AMIBIOS SETUP –ADVANCED CHIPSET SETUP

© 1996 American Megatrends, Inc. All Rights Reserved

USB Function Disabled Available Options:
USB Keyboard/Mouse Legacy Support Disabled Disabled
USB Clock 48 Mhz Enabled
USB Passive Release Enable Enable
Global Triton2 Enable Enable
Memory Hole Disable
IRQ12/M Mouse Function Enabled
8Bit I/O Recovery Time (Sysclk) 1
16Bit I/O Recovery Time (Sysclk) 1
DRAM Timings 60ns
Refresh Rate 66Mhz
Turbo Read LeadOff Disabled
Read Burst Timing x333
Write Burst Timing x333
Fast RAS to CAS Delay (Clocks) 3
LeadOff Timing 7/6/3/4
Turbo Read Pipelining Disabled
Speculative LeadOff Disabled ESC: Exit :Sel
Turn-Around Insertion Disabled PgUp/PgDn: Modify
Memory Address Drive Strength 8ma/8ma F2/F3: Color

Figure 14. Advanced Chipset Setup Screen

4. Press [ESC] to return to the main setup screen.

Continued on next page

Configuring CMOS Setup, Continued

Check Settings on
the Advanced
Chipset Screen

18

1. Highlight and select “PCI/Plug and Play Setup” from the list on the main setup screen.

2. Make sure that the IRQs 5, 9, 10, 11, and 15 are set to “ISA/EISA” rather than PCI settings.

Note: The setting for IRQ 15 will not be visible on the screen that opens initially. Scroll

down the screen with the down arrow in order to see more of the list, including
IRQ 15.

AMIBIOS SETUP – PCI / PLUG AND PLAY SETUP

© 1996 American Megatrends, Inc. All Rights Reserved

Plug and Play Aware O/S No Available Options:
PCI Latency Timer (PCI Clocks) 64 No
PCI VGA Palette Snoop Disabled Yes
PCI IDE BusMaster Disabled
OffBoard PCI IDE Card Auto
OffBoard PCI IDE Primary IRQ Disabled
OffBoard PCI IDE Secondary IRQ Disabled
DMA Channel 0 PnP
DMA Channel 1 PnP
DMA Channel 3 PnP
DMA Channel 5 PnP
DMA Channel 6 PnP
DMA Channel 7 PnP
IRQ3 PCI/PnP
IRQ4 PCI/PnP
IRQ5 ISA/EISA
IRQ7 PCI/PnP
IRQ9 ISA/EISA ESC: Exit :Sel
IRQ10 ISA/EISA PgUp/PgDn: Modify
IRQ11 ISA/EISA F2/F3: Color

Figure 15. PCI/Plug and Play Setup Screen

3. Press [ESC] to return to the main setup screen.

Highlight and select “Save Settings and Exit” from the list on the main setup screen.

Whit

1. Enter “Run Time” to make sure that everything starts up correctly.

2. If OK, exit “Run Time.”

3. Disconnect Batteries.

4. Remove AC power at the breaker.

5. Remove the Keyboard.

6. Reapply AC power at the breaker and reconnect batteries.

7. Start up the system for regular operation.

Configuring CMOS Setup, Continued

Check Settings on
the PCI/Plug and
Play Screen

Save Settings

Verify Operation

19

1. Backup the network.

2. Insert a blank floppy diskette into the floppy drive.

3. From the DOS prompt, type “format a: /s” to make a system diskette.

4. Copy FDISK.EXE, FORMAT.COM, and SYS.COM from the DOS directory to your floppy
drive.

5. From CMOS setup write down the hard drive’s settings, including the size, type, sectors, etc.

6. Disconnect the panel’s batteries at the fuse.

7. Disconnect the AC power at the breaker.

1. Remove the front cover on the chassis inside the cabinet by removing the four T15 Torx
screws located at its corners.

2. Locate the CPU board within the chassis. It’s the vertically oriented board, second from the
left. Most of the ribbon cables in the case will be connected to it.

Figure 16. Contents of Chassis

3. Mark the colored edge (pin 1) orientation of the connections.

4. Carefully remove all harnesses from the CPU and UL I/O boards.

Continued on next page

Upgrading from a 636-588 CPU Board

Protect System
Settings

Prepare the Old CPU
Board for Removal

Location of the CPU

Board within the

System Case

579-227

Rev. A

1. Remove the CPU board from the motherboard and disconnect harnesses J1 and J5. Discard
the harness that connects to the hard drive.

2. Remove the harness on P7 of the UL I/O card and discard it.

3. Remove the harness that connects to the UL I/O card at P9.

4. Remove resistors R2, R3, R4, and R5 from the motherboard.

5. Remove the screw that fastens the CPU board to the edge of the chassis using a T15 size Torx
wrench. The screw is located at the top edge of the board.

6. Pull the board straight out of the chassis, following along the guides at the bottom of the case.
It may take some force to initially detach the edge of the board from the bus connection in the
rear of the case.

7. Proceed with the upgrade beginning at the section titled “Installing RAM in the New CPU
Board.”

White Text

Upgrading from a 636-588 CPU Board, Continued

Remove the Old
CPU Board