Copyright: TRAKKER 242X Maintenance Manual


Contents
Repairing the Click on a topic for more information. Basic Features  Troubleshooting and Diagnostics  Repairing the Terminal and the Scan Module Terminal Spare Parts List and Exploded View  Scan Module Parts List and Exploded View  Specifications and Default Configurations Theory of Operation  PCB Parts Lists and Schematics  For help using this online document, press F1.


Basic Features

The TRAKKER Antares family of terminals includes:

T2420    A programmable data collection terminal that has 512K of RAM reserved for customer applications and a 750K flash drive to store applications and files. The T2420 uses an RS-232 serial port to transmit data to and from a host computer or PC.

T2425    A programmable, hand-held data collection terminal used to collect and transmit data by radio communications in a 2.4 GHz radio frequency (RF) network. The wireless terminal provides real-time communications through the Model 200 Controller to a host on an Ethernet, token ring, twinaxial, coaxial, or SDLC network. The terminal can run custom applications, screen mapping applications, or terminal emulation applications.

Click on an illustration callout for more information.


Using the Keypad

The terminal keypad contains several special keys that you can use to type characters or perform functions:

Key	Function
	The Backlight key turns on the backlight, changes the display contrast, and changes the beep volume.
	Use the Ctrl (Control) key to access characters or perform functions that do not have an actual key on the keypad.
	The cursor key moves the cursor around an application screen.
	Use the Enter key to enter information into the terminal.
, [image],	The [image] (Function Left), [image] (Function Right), and [image] (Shift) keys are held in a buffer until you press another key. When you press another key, the key combination is entered into the terminal. To flush the key from the buffer without performing any action, press the key again.
	Use the Space key when you want to enter a space.
I/O	When the terminal is off and you press the Suspend/Resume key, the terminal either resumes exactly where it was, or the terminal boots and restarts the application. When the terminal is on and you press this key, the terminal goes into Suspend mode.


Understanding the Audio Signals

Beep Sequence	Description
Low beep	A valid command was entered or the data entered was stored.
High beep	Valid data was entered, the terminal decoded a label, or the terminal decoded the last row of a two-dimensional symbology.
Three low beeps	An invalid command or invalid data was entered.
Four low beeps	The terminal was booted and POST executed successfully.
Low beep, high beep,  low beep, high beep	POST failed and did not execute successfully. For help, see Problems Operating the TRAKKER Terminal.
Click	You press a key or scan a bar code lable that uses a two-dimensional symbology .
Low beep every 15 seconds	The main battery pack is low. Replace or recharge the battery pack.
To make sure the beeper is working correctly, run a beeper test.


Operating the Terminal in a Network

The TRAKKER Antares terminal is a versatile hand-held terminal that you can easily add to your network or distributed data collection system. You can use the T2420 or T2425 as an end device in your wired network. The terminal has a serial port to transmit data to and from a host computer via RS-232 serial communications.	TRAKKER 2420 Terminal in a Wired Network
The T2425 communicates with a host computer in the Intermec 2.4 GHz network through the Model 200 Controller across the Ethernet network. The Access Point (0110, 0111, or 0115) acts as a bridge to allow communications between the Ethernet network and the wireless T2425 terminals.	TRAKKER 2425 Terminals in a 2.4 GHz Radio Frequency Data Collection Network


Scan Button

The scan button turns on the laser beam. When the beam is on,
both LEDs turn yellow.


2D Symbology

Two-dimensional (2D) symbologies use two dimensions to hold data,
allowing much more information to be stored in a smaller amount of space.
The terminal scan module can read Code 16K and Code 49 2D stacked
symbologies.

Note: The 2D symbology, PDF 417, is supported when you use the
module for cabled scanners with the Intermec 1470 Imager.
You configure PDF 417 on the 1470 Imager.


Backlight key

You can use the Backlight key to turn the display’s backlight on and off,
adjust the display contrast, or change the beep volume.


Cursor keys

The cursor keys are the oval-shaped keys that move the cursor up, down,
right, or left on the display.


Enter key

Enters data into the terminal.


Control key

Use this key to access characters or perform functions that do not have
an actual key on the keypad.


Shift key

Use this key to access characters or perform functions that do not have
an actual key on the keypad.


Function keys
Left and Right Function keys

Use these keys to access characters or perform functions that do not have
an actual key on the keypad.


Space key

Use this key when you want to enter a space.


Suspend/Resume

When you press this key the terminal goes into a Suspend mode. When you
press the key to resume, the terminal either resumes exactly where it was,
or the terminal boots and restarts the application.


Icons

Use the icons to monitor the status of special keys, battery power,
RF and network communications, and viewport movement.


POST

Power-on self test. This test runs when you boot the terminal. The test ensures that the terminal hardware and peripherals are operational.


Keypad

There are five keypad options: US alphanumeric, European alphanumeric, and
three different terminal emulation keypads (3270, 5250, and VTXXX ANSI).


CGA-compatible display

The terminal display is a backlit liquid crystal display (LCD) that is
16 lines by 20 characters. You can use the display to view data,
run terminal emulation applications, monitor the terminal status,
and other functions. Depending on the application, the viewport moves
around a full 25 line by 80 character display.

Note: If you are using the terminal in a cold environment, the screen
is slower displaying information.


Antenna for RF communications

The T2425 uses radio frequency (RF) to communicate with an access point
and the Model 200 Controller.

Note: The T2420 does not have an antenna and does not use RF communications.


Rechargeable batteries

The terminal uses a rechargeable lithium-ion battery pack and a rechargeable
NiCad backup battery to provide power.


Scan modules
Scan Module

You must attach a scan module to the terminal to scan bar code data.
There are two scan module options: a standard range scan module
and a module for cabled scanners.


Scanner LED indicators

The light emitting diodes (LEDs) let you know when the scanner beam
is on (yellow light) and when a bar code label is successfully scanned
(the LEDs turn green for 2 seconds and then turn off).


Contact Intermec at:
To order PCB parts list and schematics, contact Intermec at:

Phone: 1-425-348-2600, extension 6685.

Email: records@intermec.com

Email from the internal Intermec network: Records - 600K Docs

Document	Document Title	P/N
T2420 and T2425 Main PCB	PCB ASSY, POLLUX MAIN PORTABLE	062931
Scan Module PCB	PCB ASSY, PSC NGS-LC1 I/F PCB	063202


Troubleshooting and Diagnostics

Troubleshooting

Problems Operating the Terminal

Problems Scanning

Hardware Diagnostics

Battery Monitor

Battery Status

Beeper Status

Destructive RAM Test

Display Test

Hardware Configuration

Keypad Test

Radio Test

Serial Loopback

Scanner Test

Testing the Terminal

Radio

Access Point Communications

Model 200 Controller

An Application


Problems Operating the Terminal

Battery icon blinks and the terminal beeps once every 15 seconds.

Battery icon blinks and the terminal does NOT beep.

Battery icon remains on and the terminal beeps once every 15 seconds.

Scan a command and nothing happens.

Terminal appears to be locked up and you cannot enter data.

Terminal displays the Boot Menu.

Terminal is booting and you see a message that POST failed.

Terminal will not turn on.

Terminal will not turn on and the Battery icon appears on the display.

Terminal will not turn on or display the Battery icon after installing the lithium-ion battery.


Battery icon blinks and the terminal beeps every 15 seconds.

Immediately turn off the terminal. The lithium-ion battery is low.

Replace the lithium-ion battery. A fully charged lithium-ion battery will charge the NiCad battery in approximately 18 hours. (Replace the NiCad battery if the battery will not charge.)

NiCad battery specifications: 9.6V nominal voltage, 110 mAh nominal capacity, and 1.5A for two second surge power. The NiCad battery is charged to 12V at a maximum charge rate of 11 mA.

Note: The terminal should be in a warm environment when charging.


Battery icon blinks and the terminal does NOT beep.

Either the NiCad battery is not connected, or the charge is low. Check the NiCad battery wire connections both inside the battery compartment and inside the terminal case.

Turn off the terminal and the lithium-ion battery will charge the NiCad battery in approximately 18 hours. Replace the NiCad battery if it will not charge.

NiCad battery specifications: 9.6V nominal voltage, 110 mAh nominal capacity, and 1.5A for two second surge power. The NiCad battery is charged to 12V at a maximum charge rate of 11 mA.


Battery icon remains on and the terminal beeps every 15 seconds.

The lithium-ion battery charge is low (a few minutes of power are left). Replace the lithium-ion battery or charge the battery.


Scan a reader command, such as Backlight On, and nothing happens.

The reader commands are disabled. Scan the Enable Override command, found under “Command Processing” in your user’s manual, to temporarily enable all of the reader commands. When you are finished, remember to disable the override so that your data is not interpreted as a command.

You can also enable or disable reader commands through the TRAKKER Antares 2400 Menu System (Configuration Menu, Terminal Menu, Reader Command Menu).


Terminal appears to be locked up and you cannot enter data.

Wait at least 10 seconds and try again. If the terminal is trying to connecting to the controller, the terminal ignores any keyboard or scanner input. The Connect symbol must remain on before continuing.

Scan a bar code label to see if the terminal responds.

Press the I/O key to turn off the terminal. If the terminal turns off, press the I/O key to turn on the terminal.

If the terminal will not turn off, reset the terminal.

Remove the lithium-ion battery and the NiCad battery and wait for 1 minute. Install the NiCad battery and the lithium-ion battery and turn on the terminal.

If the terminal keeps returning to the Boot Menu, try reloading the firmware.


Terminal displays the Boot Menu.

Press B to boot the terminal and continue working. The Boot Menu appears when

you remove both batteries, replace the batteries, and then turn on the terminal.

you upgrade the firmware on the terminal and POST fails.


Terminal is booting and POST failed.

The screen displays the system that failed POST. To exit the error message, press Esc. The Boot Menu appears. Press B to boot the terminal and the application appears on the screen.


Terminal will not turn on.

Make sure a scan module is installed correctly. You must install either a scan module or a module for cabled scanners before you can turn on the terminal.

Check the keypad to make sure the I/O key is working correctly. Replace the top enclosure if there is a problem.

Check to make sure the lithium-ion battery is installed correctly.

The main battery pack may be discharged to the point where the terminal will not display the Battery icon. Replace the lithium-ion battery with a fully charged battery or charge the battery and try again. The terminal should be in a warm environment when charging.

Check the liquid crystal display (LCD) by running the Display Test. Check the connection to the main PCB. Replace the LCD if there is a problem.

If the terminal still will not turn on, replace the main PCB.


Terminal will not turn on and the Battery icon appears.

Check to make sure the main battery pack is installed correctly.

The lithium-ion battery pack may be discharged. Replace the lithium-ion battery with a fully charged battery pack or charge the battery pack and try again.


Terminal will not turn on or display the Battery icon after installing the lithium-ion battery.

If the lithium-ion battery pack is fully discharged, the terminal will not recognize the battery pack and will not display the Battery icon. Replace the lithium-ion battery or charge the battery pack.


Problems Scanning

Input device attached to the module for cabled scanners cannot read any bar code labels.

Input device connected to the module for cabled scanners does not work well or read bar codes quickly.

Scan module laser beam is not visible when you press the Scan button.

Scan module or input device will not read the bar code label.

Scanner LEDs do not light up when you press the Scan button.

Scanner LEDs do not turn off when you release the Scan button.

Standard range scan module does not read the bar code labels quickly, or the scanning beam seems to be faint or obscured.

Terminal decodes data that does not match the data encoded in the bar code label.


Input device attached to the module for cabled scanners cannot read any bar code labels.

Make sure one of these input devices is correctly and securely attached to the module for cabled scanners:

Intermec 126X and 127X wands

Intermec 146X CCD scanners

Intermec 151x, 1545, and 155x laser scanners

Intermec 1470 imager

Compatible Symbol scanners (reverse polarity enabled)

Make sure the terminal is configured for the input device.

Check the input device on another product to ensure it is working.


Input device attached to the module for cabled scanners does not work well and will not read bar codes quickly.

Try the following:

Setting the Scanner Selection command to the specific input device connected to the terminal.

Enable only the symbology you are scanning.

Check label quality.


Scan module laser beam is not visible when you press the Scan button.

Make sure the terminal is turned on. Press the I/O key to turn on the terminal.

You may be too far away from the bar code label. Move closer to the bar code label and scan the bar code again.

Try changing the scanning angle until the laser beam is the brightest. This is the best scanning angle.

Run a scanner diagnostics test to check the laser scanner and scan button.

	Warning Do not look directly into the window area or at a reflection of the laser beam while the laser is scanning. Long-term exposure to the laser beam can damage your vision.


Scan module or input device will not read the bar code labels.

Aim the scanner beam so it crosses the entire label in one pass.

Try scanning the bar code label again, but vary the scanning angle.

The bar code label print quality may be poor or unreadable. To check the quality of the bar code label, try scanning a bar code label that you know scans. Compare the two bar code labels to see if the bar code is damaged or of poor quality.

Enable only the bar code symbology you are scanning. From the Symbologies Menu, each enabled symbology has an asterisk (*) next to it.

Run a scanner diagnostics test to check the laser scanner and scan button.


Scanner LEDs do not light up when you press the Scan button.

If the scan module emits a red laser beam but the LEDs do not light, replace the main PCB in the unit.


Scanner LEDs do not turn off when you release the Scan button.

The scanner LEDs remain on if edge triggering is configured. If level triggering is configured instead of edge triggering and the LEDs remain on, replace the main PCB.


Standard range scan module does not read the bar code quickly, or the scanning beam is faint or obscured.

Clean the module window with a solution of ammonia and water and wipe dry. Protect the window from abrasive material and replace the window if it is scratched.


Terminal decodes data that does not match the data encoded in the bar code label.

Make sure to scan the entire label. The terminal may, on rare occasions, decode a bar code in a wrong symbology when multiple symbologies are enabled.

Enable only the symbology you are scanning.

Increase scanner redundancy.


Battery Monitor
Battery Monitor Diagnostic

Purpose    Use the Battery Monitor screen to get volts, temperature, and charging status of the lithium-ion battery. Note: The charging status indicates whether or not the terminal is charging through the external charge contacts at the bottom end of the terminal. Definition    The screen displays the current volts, temperature, and charging status (YES or NO). The number in parentheses is the hexadecimal value returned from the battery monitor processor. The SW Rev field is the firmware version running on the battery monitor processor.	Sample Screen


Battery Status
Battery Status Diagnostic

Purpose    Use the Battery Status screen to find out how much power remains in the lithium-ion battery and to get the current power status for the NiCad battery. Definition    Main Battery Capacity records the percentage of battery power remaining in the lithium-ion battery. You can continue using the battery until the Battery icon appears on the display to indicate a low battery. The backup battery test shows that the NiCad battery power is either GOOD or LOW. If the status is LOW, turn off the terminal and let the lithium-ion battery charge the NiCad battery (approximately 18 hours).	Sample Screen


Beeper Test
Beeper Test Diagnostic

Purpose    Test the scan module beeper to make sure the entire beep volume range and beep frequency range are available and working correctly. Definition    Press 1 to test the beep frequency range. The terminal will sound a series of beeps starting from a low frequency beep through the range to a high frequency beep, and then back to a low frequency beep. Press 2 to test the beep volume. The terminal sounds a series of beeps from a quiet beep to a very loud beep. Tests 3 and 4 also test the beep volume and frequency by playing a short tune.  Repair    If you do not hear any beeps during any of these tests, make sure a module (either the scan module or the module for cabled scanners) is installed correctly. Check the connections to the PCB in the scan module.	Sample Screen


Destructive RAM Test
Destructive RAM Test Diagnostic

Purpose    Use the Destructive RAM Test if you suspect the RAM may be bad.

Definition    Before you run this test, save the data. If you are running a TE application, end the current TE session. Press Y to start the test. All data in RAM will be lost. The terminal starts the RAM test and clears the display. You hear a beep after a successful test of each 64K block of data. After 15 beeps, a test pass is complete and the results appear.

The test will continue after a 5 second pause. To exit the test, press [image] after a test pass finishes. The terminal boots and starts the application.

If an error is found, the Destructive RAM Test stops and displays the error address, the data written to RAM, and the data read from RAM.

Sample Screen


Display Test
Display Test Diagnostic

Purpose    Use the Display Test screen if there are incomplete characters displayed on the liquid crystal display (LCD). This test uses four different test patterns to check every pixel on the LCD. Definition    Press [image] to display each of the four patterns. After 5 seconds, the screen displays the current test pattern. Press [image] display the next pattern. The first two patterns appear as a shaded pattern and turn off every other pixel. The third pattern turns on every pixel and appears as a black square. The fourth pattern turns off every pixel and appears as a clear square. Repair    If any of these patterns do not display correctly, the problem could be the LCD and/or the main PCB . Check and replace the damaged part.	Sample Screen


Hardware Configuration
Hardware Configuration Diagnostic

Purpose    The Hardware Configuration screen records the terminal’s hardware version. Use this screen to see the terminal’s radio frequency and country code configuration.

Definition    Press [image] to display the next screen of hardware information.

The country code information on the Hardware Configuration screen is only valid when the radio (Network Activate command) is enabled. If the radio is disabled, the country code information is not valid.

Sample Screen


Keypad Test
Keypad Test Diagnostic

Purpose    Use the Keypad Test to make sure the keypad is operating correctly and to find out the hexadecimal and decimal key code values. Definition    Press any key on the keypad to display the hexadecimal and decimal value of the key. When you press Esc to exit, the terminal pauses for a few seconds to display the hexadecimal and decimal values and then exits. Repair    If there are any problems, replace the top enclosure.	Sample Screen


Radio Test
Radio Test Diagnostic

Purpose    Use the Radio Test screen to verify a working radio. Definition    Before you start the test, make sure the radio (Network Activate command) is enabled. If the radio is disabled, the test results on the Radio Test screen are not valid. Press [image] to start the radio test. If SUCCESS or PASSED appears on the screen, the radio is working correctly. Repair    If FAILED appears on the screen, check the radio PCB connection on the radio frame.  Repeat the test and if it fails again, replace the radio PCB.	Sample Screen


Scanner Test
Scanner Test Diagnostic

Purpose    Use the Scanner Test to make sure the laser scanner, Scan button, or scanner trigger are operating correctly on the standard range scan module or a scanner attached to the module for cabled scanners. Definition    To start the test, press [image]. If the laser scanner turns on, the scanner is working correctly. If the laser scanner does not turn on when testing the module for cabled scanners, make sure you are using a laser scanner that is supported on the terminal. Also, check to make sure the laser scanner is securely attached to the module.  If the laser scanner still does not turn on, remove and replace the scan module and test the new module. If the laser beam still does not turn on, try scanning a bar code label. If the red laser beam turns on, the Scan button is working correctly. Repair    Check the scan engine. If the laser scanner does not turn on, replace the scan engine.	Sample Screen


RS-232 Loop Back
Serial Loopback Diagnostic

Purpose    Use the Serial Loopback test to verify that the RS-232 port hardware is functioning correctly. Definition    To run the test, you must connect the terminal to a host computer or other serial device via the communications dock or optical link adapter. The serial port test begins immediately. If the serial hardware is functioning correctly, the terminal displays WAITING and then RECEIVING. The test uses the serial communication settings that are listed on the bottom of the screen. On the host, you can use a serial communications package to send data to the terminal. If the terminal is communicating with the host, the data is echoed back. If there is a problem, an error message appears on the terminal screen. The status information on the screen is updated every 500 ms. Repair    If an error message appears, replace the main PCB.	Sample Screen


Running Diagnostics

1.	Press _f [image] T 2 M to access the Main Menu.

Note: You must press the [image] (Left Enter) key in this key sequence.

2.	Select the Diagnostics Menu and press [image].

3.	Select Hardware Diagnostics and press [image].

4.	Select a diagnostic test and then press [image].

A diagnostic screen appears.

Note: The Main Board Menu lets you select from the Battery Monitor, Beeper Test, or Destructive RAM Test.

To exit a diagnostic screen

1.	Press Esc to exit each diagnostic screen and to exit the diagnostics menus.

2.	Press Esc to exit the TRAKKER 2400 Menu System.

If you have made any changes, you are prompted to store the changes in flash memory.

When you exit the menu system, the terminal resumes running the application you started before entering the menu system.


Testing the Radio

1.	Press the I/O key to turn on the terminal.

2.	If the Radio icon does NOT appear on the display, the Network Activate command is successfully enabled and the radio is working.

Note: If the Radio icon remains on solid, the Network Activate command may be disabled, or there is a problem with the radio PCB.


Testing Communications with the Access Point

1.	Press the I/O key to turn on the terminal.

2.	If the Connect symbol blinks or remains on solid, the terminal is successfully communicating with the access point and is trying to establish communications with the controller.

If the Connect symbol is not blinking or is not on, check the network configuration.


Testing Communications with the Model 200 Controller

1.	Press the I/O key to turn on the terminal.

2.	If the Connect symbol on the display appears and remains on solid, the terminal is successfully communicating with the controller.

If the Connect symbol blinks or is not on, check the network configuration.

Note: The Connect symbol is not instantaneously updated, but it does tell you the communications status the last time data was sent from or received by the terminal.


Testing an Application

1.	Press the I/O key to turn on the terminal. The login or initial screen for your application appears on the terminal screen.

2.	Type data in a field or a scan bar code label to test the application.


Booting the Terminal

When you boot the terminal, the terminal runs POST to test each major subsystem. The terminal uses the configuration currently saved in flash memory. Once the terminal is finished booting, your application appears on the screen.

You can boot the terminal using these two methods:

Booting the Terminal on Resume    When you press the I/O key to turn off the terminal, it turns off and goes into Suspend mode. When you press the I/O key to turn on the terminal, it resumes or boots depending on the terminal configuration.

Use the Resume Execution configuration command to configure the I/O key.

Using the Boot Menu    The Boot menu appears after you:

remove both batteries, install them again, and turn on the terminal.

upgrade the firmware.

reset the terminal.


Resetting the Terminal

You only need to reset the terminal when the terminal or an application is locked up and will not respond to any key sequences. The terminal also boots and resets after a firmware upgrade or if you remove both batteries.

If the terminal or application is locked up and the terminal will not respond to any key sequences, reset the terminal. Before you reset the terminal, try the following in order:

Press the I/O key to turn off the terminal.

Scan the Reset Firmware label to restart the firmware and application.

If the terminal or application does not respond, reset the terminal.

To reset the terminal

1.	Place the terminal on a flat surface.

2.	Press the I/O key to turn off the terminal. If the terminal will not turn off, continue with the next step.

3.	Press and hold the _f and [image] keys and then press the I/O key. The green scanner LEDs light and the terminal turns off. Release the keys.

4.	Press the I/O key to turn on the terminal. The Boot Menu appears.

Note: If the terminal returns to the exact same screen, the reset sequence did not work. Repeat Step 1. Make sure you press and hold the _f and [image] keys, and then press the I/O key.

5.	Press B to boot the terminal. Once the terminal has finished booting, your application appears.

If the terminal still will not reset or boot, try loading the firmware.


To reset the terminal

1.	Press and hold the _f and [image] keys and then press the I/O key. The green scanner LEDs light and the terminal turns off. Release the keys.

2.	Press I/O to turn on the terminal. The Boot Menu appears.

Note: If the terminal returns to the exact same screen, the reset sequence did not work. Repeat Step 1. Make sure you press and hold the _f and [image] keys, and then press the I/O key.

3.	Press B to boot the terminal. Once the terminal has finished booting, your application appears.


Boot Menu

The Boot Menu contains these commands:

Boot System    If you remove the batteries, make sure you install a charged main battery pack or the terminal will not turn on. Press B to boot the terminal. Once the terminal is finished booting, your application appears on the screen.

Run Loader    Press L to load the terminal firmware.

Power Down    Press Q to turn off the terminal. When you turn on the terminal, the Boot Menu screen appears if POST passes.


TRAKKER Antares 2400 Menu System

The TRAKKER Antares 2400 Menu System is a menu-driven application that lets you configure the terminal, manage files, view system information, and run diagnostics. You can access the TRAKKER Antares 2400 Menu System while running any application.

Press _f [image] T 2 M to access the menu system.

Note: You must press the [image] (Left Enter) key in this key sequence.


Repairing the Terminal
Repairing the Terminal and Scan Module

Terminal	Scan Module
Antenna Antenna Cable Assembly  Battery Door  Bottom Enclosure  Display window  Keypad Overlay  Liquid Crystal Display (LCD)  Lithium-ion Battery Contact Assembly  Main PCB NiCad Battery  Optical Interface Window  Radio PCB  Top Enclosure	Enclosure  PCB and Base  Scan Engine  Scan Window


Replacing the Antenna
The antenna comes with a retaining ring.

1. Line up the antenna so that it is parallel to the bottom enclosure and the rotation limiting slot aligns with the retaining ring opening.  2. Insert the straight-slot screwdriver in the retaining ring opening and through the retaining ring inside.  3. Remove the retaining ring by prying it up and out of the opening.  4.  Pull the antenna out of the connection on the bottom enclosure.  5.  Place the new antenna into the connection and insert the retaining ring into the retaining ring opening. Note: You must completely insert the antenna into the connection or the retaining ring will not fit correctly. Turn on the terminal to test the repair and to verify communications.


Replacing the Antenna Cable Assembly
Order each part of the antenna cable assembly separately: cable and jack, sleeve, washer, and grommet.

1.	Remove the antenna.

2. Open the terminal.  3. Position the needlenose pliers on the cable jack (without pinching the cable) and insert the E-ring pliers or spanner wrench into the sleeve.  4. Unscrew the sleeve while holding the jack in position with the needlenose pliers. Separate the washer, cable, and sleeve. 5. Disassemble the sleeve and the grommet if you need to replace either and reassemble with a new sleeve and/or grommet. Replace the washer if necessary. 6.  Insert the sleeve into the antenna slot and place the washer and antenna cable into the antenna slot inside the bottom enclosure. Wedge the cable between the wall cases and bosses in the bottom enclosure. 7. Using the E-ring or spanner wrench, screw the sleeve while holding the cable jack stable with the needlenose pliers. Tighten to 9.5 in-lb. (1.07 N m).
8.	Close the terminal.

9.	Attach the antenna.

Turn on the terminal to test the repair and to verify communications.


Removing the antenna
To remove the antenna

1. Line up the antenna so it is parallel to the bottom enclosure and the rotation limiter slot aligns with the retaining ring opening.  2. Insert the straight-slot screwdriver in the retaining ring opening and through the retaining ring inside.  3. Pry the retaining ring up and out of the opening.  4. Pull the antenna out of the connection on the bottom enclosure.


To attach the antenna

Place the new antenna into the connection and insert
the retaining ring into the retaining ring opening.

Note: You must completely insert the antenna into the connection or the
retaining ring will not fit correctly.


Replacing the Battery Door

1. Open the battery door by sliding the latch down. 2. Remove the battery door by lifting up the top edge. 3. To insert the new battery door, hook the bottom edge of the door into the bottom case above the NiCad battery compartment. 4. Push the door down to close it over the battery compartment. 5. Slide the door latch toward the top end of the terminal to lock the door in place.
Note: If the battery door does not close, the lithium-ion battery may not be locked into place, or the NiCad wires may be pinched. Check both batteries and adjust until the door fits into place.


Removing the battery door
To remove the battery door

1. Open the battery door by sliding the latch down. 2. Remove the battery door by lifting up the top edge.


Replacing the Display Window
1.	Open the terminal.

2.	Remove the main PCB.

3.	Remove the LCD.

4.	Strip off the display window by using a small screwdriver to pry up a corner of the tape, or apply pressure on the front of the window until it pops out.

5.	Remove the protective liner from the inside of the window and the tape from the padding on the new window. Align the window (with the padding side facing up) in the top enclosure and firmly press the window into the top enclosure.

6.	Install the LCD.

7.	Install the main PCB.

8.	Close the terminal.


Replacing the Bottom Enclosure
The bottom enclosure includes the battery contact assembly, antenna cabling, and antenna.

1.	Open the terminal.

2.	Use the marking pen to write the serial number and configuration on the blank label in the new bottom enclosure.

3.	Close the terminal.


Replacing the Top Enclosure
The top enclosure comes with the display window. A keypad overlay, if needed, must be ordered separately.

1.	Turn off the terminal by pressing the I/O key.

2.	Remove the scan module.

3.	Remove the battery door.

4.	Remove the lithium-ion battery pack.

5.	Remove the NiCad battery.

6.	Unscrew the six Phillips screws holding the top and bottom enclosures together.

7. Slowly open, but do not entirely separate the top and bottom enclosures. Be careful not to rip any connections from the main PCB, but allow the NiCad battery cable to slip through the slot in the battery compartment.  8. Disconnect these cables: Antenna cable from connector J1 on the radio PCB (T2425 only). Battery pack cable from connector J3 on the main PCB. 9. Unlatch and disconnect these etchforms from the main PCB: Display from connector J2  Keyboard from connector J7
10.	Remove the LCD from the top enclosure.

11.	Install the new top enclosure.


To install a new top enclosure
Installing a New Top Enclosure
1.	Install the LCD in the top enclosure.

2.	Install the main PCB.

3.	Close the terminal.

4.	Align a new keypad overlay over the keys and press firmly between the keys to secure the overlay in place.


Replacing the Keypad Overlay
If you are replacing the keypad overlay with a different type of overlay, load a new terminal emulation or screen mapping application.

1.	Remove the current keypad overlay by prying up a corner and stripping it off the top enclosure.

2.	Align a new keypad overlay over the keys and press firmly into place. Press between the keys to secure the overlay in place.

3.	Reprogram the firmware if you are changing the terminal emulation or screen mapping application.


Replacing the Liquid Crystal Display (LCD)
Replacing the LCD
It is important for the replacement LCD to fit in the top enclosure window without being tilted or skewed.

1. Open the terminal. 2. Slowly lift the main PCB to expose two etchforms attached to the underside. Be careful not to rip any connections from the keypad or display.  3. Unlatch and disconnect these etchforms from the main PCB: Display from connector J2  Keyboard from connector J7 . 4. Unscrew the four Phillips screws securing the LCD to the top enclosure and remove it.  5. Align the main PCB so the screw slots line up with the posts in the top enclosure and the connections align. 6. Connect and latch these etchforms to the main PCB: Display to connector J2 Keyboard to connector J7 7. Make sure that the connections are fully latched and then place the main PCB into the top enclosure. 8. Close the terminal.


Installing the LCD
To install the LCD

1.  Position the new LCD so the glass is face down and the etchform aligns with the connection on the main PCB. Note: Ensure that the LCD is clean and free of dust and debris. 2. Screw in the four screws and tighten to 8 in-lb. (0.9 N m).


To remove the LCD

1. Slowly lift the main PCB to expose two etchforms attached to the underside. Be careful not to rip any connections from the keypad or display.  2. Unlatch and disconnect these etchforms from the main PCB: Display from connector J2 Keyboard from connector J7. 3. Unscrew the four Phillips screws securing the LCD to the top enclosure and remove it.


Replacing the Lithium-ion Battery Contact Assembly
The lithium-ion battery contacts are part of an assembly including the battery cable connection that plugs into the main PCB.

1.	Open the terminal.

2.	Remove the adhesive backed cover from the enclosure and the contact assembly.

3.	Using your hand, push the battery contact assembly through the bottom enclosure.

4.	Insert the new battery contact so the metal contacts are aligned to connect to the battery and the cables extend to the main PCB.

5.	Install the new adhesive backed cover.

6.	Close the terminal.


To install the lithium-ion battery pack

1. Hold the battery pack with the arrow pointing toward the top (screen) end of the terminal and the flat side facing down toward the inside of the battery compartment. 2. Place the battery pack into the middle of the battery compartment and hook the slots on the bottom of the battery pack into the slots on the bottom of the battery compartment. 3. Slide the battery pack toward the top end of the terminal until it fits and locks into the connectors inside the bottom case.


To remove the lithium-ion battery pack

1. Disconnect the battery pack from the connectors inside the bottom enclosure by sliding the battery pack toward the bottom end of the terminal. 2. Tilt the terminal to one side and let the battery pack drop out of the compartment into your hand.


Replacing the Lithium-ion Battery
Replacing the Lithium-ion Battery Pack

1. Remove the battery door.  2. Disconnect the battery pack from the connectors inside the bottom enclosure by sliding the battery pack toward the bottom end of the terminal. 3.  Tilt the terminal to one side and let the battery pack drop out of the compartment into your hand. 4. Hold a fully charged battery pack with the arrow pointing toward the top (screen) end of the terminal and the flat side facing down toward the inside of the battery compartment.
5. Place the battery pack into the middle of the battery compartment and hook the slots on the bottom of the battery pack into the slots on the bottom of the battery compartment. 6. Slide the battery pack toward the top end of the terminal until it fits and locks into the connectors inside the bottom case.


Replacing the Nicad Battey
Replacing the NiCad Battery

The NiCad battery is the backup battery for the terminal.

1.	Turn off the terminal by pressing the I/O key.

2.	Remove the battery door.

3. Remove the lithium-ion battery. 4. Disconnect the NiCad battery wire connectors. 5. Slide the NiCad battery out of the battery compartment and dispose of the battery. 6. Insert the new NiCad battery with the foam facing up. 7. Connect the battery wire connectors and make sure the connectors lock. This is a keyed connection that fits in one direction only. 8. Gently fold and push the battery wires into the battery compartment.
9. 	Install the lithium-ion battery pack.

10.	Replace the battery door.

11.	Press the I/O key to turn on the terminal and test the repair.


To install the NiCad battery

1. Insert the new NiCad battery with the foam facing up. 2. Connect the battery wire connectors and make sure the connectors lock. This is a keyed connection that fits in one direction only. 3. Gently fold and push the battery wires into the battery compartment.


To remove the NiCad battery

1. Disconnect the NiCad battery wire connectors. 2. Slide the NiCad battery out of the battery compartment. If you are replacing the battery, dispose of the battery properly.


Disposing of the NiCad Battery Pack

The Environmental Protection Agency has classified worn out or damaged
NiCad batteries or battery packs as hazardous waste. Dispose or recycle
the battery properly. Several states have passed legislation that prohibits
discarding these batteries into the municipal waste stream. If you have
questions on how to recycle or dispose of the NiCad battery, contact the
local, county, or state hazardous waste management office.


Replacing the Optical Interface Window

The optical interface window is located on the bottom enclosure at the bottom end.

1.	Pry the optical window off of the bottom enclosure, or open the terminal and push the window through from the inside of the enclosure.

2.	Remove the tape from the new window and align the window on the outside of the bottom enclosure.

3.	Press the window onto the bottom enclosure.

4.	If the terminal was opened, close the terminal.


Replacing the Main PCB
1.	Open the terminal.

2.	Remove the radio PCB from the frame on the main PCB.

3. Slowly lift the main PCB to expose two etchforms attached to the underside. Be careful not to rip any connections from the keypad or display.  4. Unlatch and disconnect these etchforms from the main PCB: Display from connector J2  Keyboard from connector J7  5.  Remove the main PCB and orient the new main PCB with the top enclosure so the screw slots line up with the posts and the keyboard and display connections align. 6. Connect and latch these etchforms to the main PCB: Display from connector J2  Keyboard from connector J7
7.	Make sure the connectors are fully latched and then place the main PCB into the top enclosure over the screw slots.

8.	Install the radio PCB in the radio frame on the main PCB.

9.	Close the terminal.


Connector J2

This connector is where the display etchform attaches
to the main PCB. Notice that the etchform is connected
in the opposite direction from connector J7 (the pins
point to the outside).


Connector J7

This connector is where the keyboard etchform attaches
to the main PCB. Notice that the etchform is connected
in the opposite direction from connector J2 (the pins
point to the inside).


Installing the main PCB
To install the main PCB

1. Align the main PCB so the screw slots line up with the posts in the top enclosure and the connections align. 2. Connect and latch these etchforms to the main PCB: Display to connector J2 Keyboard to connector J7 3. Make sure the connections are fully latched and then place the main PCB into the top enclosure.


To remove the main PCB

1. Remove the radio PCB from the frame on the main PCB. You may have to carefully rock the radio PCB back and forth to loosen the connection and then lift it off the frame. 2. Slowly lift the main PCB to expose two etchforms attached to the underside. Be careful not to rip any connections from the keypad or display.  3. Unlatch and disconnect these etchforms from the main PCB: Display from connector J2 Keyboard from connector J7 4. Remove the main PCB and orient the new main PCB with the top enclosure so the screw slots line up with the posts and the keyboard and display connections align.


Replacing the Radio PCB
The radio PCB is located on a frame on the main PCB.

1. Open the terminal 2. Remove the radio PCB from the frame on the main PCB by carefully rocking it back and forth and loosening it and then lifting it off the frame. 3. Place the new radio PCB on the radio frame so the four corner holes align with the frame posts and the protruding frame pins align with the holes on the radio PCB connector. 4.  Press the frame pins into the radio connector. You may need to use tweezers to fully engage the connection. Note: Be careful when using tweezers—it is possible to damage the connection. 5. Close the terminal


To remove the radio PCB

1. Carefully rock the radio PCB back and forth to loosen it from the radio frame.  2. Lift the radio PCB off of the frame.


To install a radio PCB
To install the radio PCB

1. Place the radio PCB on the radio frame so the four corner holes align with the frame posts and the protruding frame pins align with the holes on the radio PCB connector. 2. Press the frame pins into the radio connector. You may need to use tweezers to fully engage the connection. Note: Be careful when using tweezers—it is possible to damage the connection.


Opening the Terminal
1.	Turn off the terminal by pressing the I/O key.

2.	Remove the scan module from the terminal.

3.	Open and remove the battery door.

4.	Remove the lithium-ion battery (main battery).

5.	Remove the NiCad battery.

6.	Unscrew the six Phillips screws holding the top and bottom enclosures together.

7.	Slowly open but do not entirely separate the top and bottom enclosures. Be careful not to rip any connections from the main PCB, but allow the NiCad battery cable to slip through the slot in the battery compartment.

8.	If you are servicing a T2425, disconnect the antenna cable from connector J1 on the radio PCB by removing the tape and lifting it off.

9.	Disconnect the lithium-ion battery cable from connector J3 on the main PCB.

10.	Separate the top and bottom enclosures.


Closing the Terminal
1.	Carefully align the top and bottom enclosure and connect the lithium-ion battery cable to connector J3 on the main PCB.

Note: To protect the cable from being pinched when the terminal is closed, untangle and separate the black and red wires.

2.	If you are servicing a T2425, connect the antenna cable to connector J1 on the radio PCB. Use kapton tape to secure it in place.

Note: Check the bottom enclosure to make sure the antenna cable is wedged between the wall cases and bosses.

3.	Route the NiCad battery cable through the slot into the bottom enclosure and carefully close the top and bottom enclosure. Check to make sure the cables are not pinched between the two enclosures.

4.	Secure the top and bottom enclosures.

5.	Insert the NiCad battery.

6.	Insert the lithium-ion battery pack.

7.	Insert the battery door by hooking the bottom edge into the bottom case above the NiCad battery compartment. Push the door down to close it and slide the door latch forward to lock it in place.

Note: If the battery door does not close, the lithium-ion battery may not be locked into place, or the NiCad wires may be pinched. Check both batteries and adjust until the door fits into place.

8.	Install the scan module.

9.	Press the I/O key to turn on the terminal and test the repair.


To secure the top and bottom enclosures

1. Insert the six Phillips screws in the bottom enclosure. 2. Use the calibrated torque driver or calibrated Phillips screwdriver to screw and tighten the screws to 8 in-lb.  (0.9 N m).


Replacing the Scan Module Enclosure
The scan module enclosure includes two piezos.

1. Open the scan module. 2. Remove the scan assembly from the enclosure. Be careful not to press on the top or bottom of the scan engine inside the assembly. Also be careful not to rip any etchforms from the connections. 3. Rest the scan assembly on the PCB on the base. 4. Place the new enclosure over the scan assembly and base and press the two together until the scan module closes completely. Check the scan window to make sure it is aligned and clean of fingerprints or smudges. 5. Install the scan module on the terminal. 6. Press the I/O key to turn on the terminal and scan bar codes to test the repair.


Replacing the Scan Engine
The scan engine is located in the window frame. The scan engine and the window frame together make up the scan assembly.

Note: The scan engine is very fragile and must not be pressed or pushed on the top or bottom. Instead, hold the scan engine by the sides to prevent damage.

1.	Open the scan module.

2. Remove the scan engine from the scan assembly by sliding it out of the window frame. 3. Carefully holding the new scan engine by the sides only, insert it into the window frame. Do not press on the top or bottom of the scan engine, but make sure the sides and top are flush with the frame. 4. Connect and latch these etchforms to the PCB: Piezo to connection J2 Scan engine to connection J4 5. Rest the scan assembly on the PCB on the base. 6. Place the enclosure over the scan assembly and base and press the two together until the scan module closes completely.  7. Check the scan window to make sure it is aligned and clean of fingerprints or smudges.
8.	Install the scan module on the terminal.


Replacing the Scan Module PCB and Base
The PCB and base are attached in one piece.

1. Open the scan module. 2. Align the new base with the scan engine and connect and latch these etchforms to the new PCB: Piezo to connection J2 Scan engine to connection J4 3. Rest the scan assembly on the PCB on the base. 4. Place the enclosure over the scan assembly and base and press the two together until the scan module closes completely. Check the scan window to make sure it is aligned and clean of fingerprints or smudges. 5. Install the scan module. 6. Press the I/O key to turn on the terminal and scan bar codes to test the repair.


Replacing the Scan Window
The scan window is located on the window frame (the frame also houses the scan engine). The coating on the inside of the scan window is very fragile and should not be touched.

1. Open the scan module. 2. Carefully holding the scan engine by the sides only, remove it from the scan assembly by sliding it out of the window frame. 3. Remove the window by pressing on the inside until it pops off the window frame. 4. Carefully hold the new window and press it into the window frame. Do not touch the coating on the inside of the window. It is very fragile and is easily damaged. 5. Carefully holding the scan engine by the sides only, insert it into the window frame. Do not push on the top of the scan engine, but make sure the sides and top are flush with the assembly. 6. Connect and latch these etchforms to the PCB: Piezo to connection J2 Scan engine to connection J4
7.	Rest the scan assembly on the PCB on the base.

8.	Place the enclosure over the scan assembly and base and press the two together until the scan module closes completely. Check the scan window to make sure it is aligned and clean of fingerprints or smudges.

9.	Install the scan module.

10.	Press the I/O key to turn on the terminal and scan bar codes to test the repair. Check to make sure the beam is emitting correctly.


Opening the Scan Module

There are two methods for opening the scan module. Method 1 applies to scan modules built before May 1998.

1.	Remove the scan module from the terminal.

2.	Method 1    Slowly and firmly pull the PCB base and the scan module enclosure apart. You may need to start by using a small, straight-slot screwdriver to carefully pry open a corner of the module assembly. Do not entirely separate the enclosure from the base to prevent ripping the two etchforms from the connections.

Method 2    Remove the screws securing the PCB base to the scan module enclosure. Slowly pull apart the base and the enclosure, but do not entirely separate these parts to prevent ripping the two etchforms from the connections.

3.	Unlatch and disconnect these etchforms from the PCB:

Piezo from connection J2

Scan engine from connection J4


Removing the scan module
To remove the scan module

Unscrew the three screws that secure the scan module to the terminal and then lift the scan module from the terminal.


To install the scan module

1.	Align the scan module guides with the terminal guides and
gently press the module onto the terminal.

2.	Secure the module to the terminal with the three Phillips screws.
Tighten the screws to 8 in-lb. (0.9 N m).


Upgrading the Firmware to Reprogram the Keypad

You can upgrade the firmware on the terminal from a PC using serial communications. You connect the terminal serial port to the PC using the TD2400 communications dock or the optical link adapter.

To upgrade the firmware

1.	Connect the terminal to your PC.

2.	Start your PC and from Windows start the TRAKKER Antares Firmware Installation Utility.

3.	From the Firmware Installation Utility screen, select the COM port and the Firmware Type (application).

4.	On the terminal, press _f [image] T 2 M to access the Main Menu.

5.	Choose System Menu and press [image]. The System Menu appears.

6.	Choose Upgrade Firmware and press [image]. The Upgrade Firmware screen appears.

7.	Choose OK and press [image] to continue.

8.	Choose Yes to continue and upgrade the firmware. The terminal reboots and then displays the Loader Waiting screen.

To exit without upgrading the firmware, choose No.

Note: If you reach the Loader Waiting screen and cannot upgrade or continue, press Esc or I/O to exit without upgrading the firmware. The Boot Menu appears. Press B to boot the terminal and continue.

9.	On your PC, make sure you selected the COM port and Firmware Type, and then choose OK. The PC downloads the firmware and application. Once the download is complete, the terminal boots and runs the application. Repeat these instructions to upgrade the firmware on another terminal.


TRAKKER Antares Firmware Upgrade Kit

UDP Plus	067350S-001

TCP/IP	067351S-001


To Install a PC Card

1. Open the T2420. If there currently is a PC card connected to the main PCB, use a sharp knife to carefully cut through the middle of the adhesive foam strips holding the card to the board. 2. Remove the PC card from the board and then scrape any residual adhesive foam from the insulator on the board. Note: Be careful not to damage the insulator on the main PCB when cutting or scraping the adhesive foam strip. 3. To insert the new PC card, remove the top paper strips from the adhesive foam. Then angle (so it won’t stick) and slide the card into the connector on the main PCB. 4. When the PC card is securely connected, press and stick it to the board. 5. If there is not already a PC frame inside the bottom enclosure, insert the new PC frame into the bottom enclosure lining up the battery compartment slots so the battery cable can be inserted through the slot to the battery. 6. Close the T2420.


PC Card

066115S-001    PCMCIA 2MB

066116S-001    PCMCIA 4MB


Medium-sized Phillips screwdriver
Tools

Medium-sized Phillips screwdriver

Calibrated torque driver with a medium-sized Phillips bit
or medium-sized calibrated Phillips screwdriver

Tweezers


Small straight-slot screwdriver
Tools

Small straight-slot screwdriver


Needlenose pliers
Tools

Needlenose pliers

E-ring pliers or spanner wrench to match a 0.062 +/- 0.01 hole

Medium-sized Phillips screwdriver

Calibrated torque driver with a medium-sized Phillips bit
or medium-sized calibrated Phillips screwdriver


Medium-sized Phillips screwdriver2
Tools

Medium-sized Phillips screwdriver

Calibrated torque driver with a medium-sized Phillips bit
or medium-sized calibrated Phillips screwdriver


Medium-sized Phillips screwdriver only
Tools

Medium-sized Phillips screwdriver


Only Calibrated torque driver
Tools

Calibrated torque driver with a medium-sized Phillips bit
or medium-sized calibrated Phillips screwdriver


1 tip Phillips screwdriver
Tools

#1 tip Phillips screwdriver

Calibrated torque driver with a #1 Phillips bit or medium-sized
calibrated Phillips screwdriver


1 tip Phillips screwdriver only
Tools

#1 tip Phillips screwdriver


Calibrated torque driver only
Tools

Calibrated torque driver with a medium-sized Phillips bit
or medium-sized calibrated Phillips screwdriver


Kapton
Tools/Materials

Kapton

Medium-sized Phillips screwdriver

Calibrated torque driver with a medium-sized Phillips bit
or medium-sized calibrated Phillips screwdriver


Optional
Materials

Optional: TRAKKER Antares Firmware Kit:

UDP Plus	067350S-001

TCP/IP	067351S-001


Part No. 523550
Black Marking Pen

P/N 523550


Terminal Spare Parts List and Exploded View

Part No.	Description

1 Keypad Overlay 065064-002   Option 01 065091-001   Option 02, European 063537-003   Option 07, 5250 TE 063538-002   Option 06, 3270 TE 063539-002   Option 08, VTXXX ANSI   2 063686S-003 Top Enclosure   3 063425S-003 Display Window   4 063279S-002 Liquid Crystal Display (LCD)   5 062931S-007 Main PCB   6 Radio 063930S-001   Option 03, 2.4 GHz 2,6 063931S-001   Option 04, 2.4 GHz 0,1 063932S-001   Option 06, 2.4 GHz 1,1 063933S-001   Option 07, 2.4 GHz 2,0 063934S-001   Option 08, 2.4 GHz 1,51 065338S-001   Option 09, 2.4 GHz 1,25 067314S-001   Option 10, 2.4 GHz 1,48 067315S-001   Option 11, 2.4 GHz 1,14   7 064117S-004 Battery Contact Assembly   8 063816-001 Antenna Cable and Jack   9 589389-001 Washer 10 Bottom Enclosure 066215S-001   T2420 064366S-001   T2425 (incl. Antenna assy.) 11 063979-001 Grommet 12 064034-003 Sleeve 13 063825S-005 Antenna 14 064101-003 Retaining Ring 15 063189S-003 NiCad Battery 16 064316-002 Battery Door 17 063314-001 Optical Interface Window


Scan Module Spare Parts List
and Exploded View

Part No.	Description

1 063202S-005 PCB with base   2 590014S-002 Scan engine   3 063689-002 Scan Window   4 063309S-003 Enclosure


Display Window

063425S-003


Keypad Overlay

065064-002	Option 01

065091-001	Option 02, European

063537-003	Option 07, 5250 TE

063538-002	Option 06, 3270 TE

063539-002	Option 08, VTXXX ANSI


Top Enclosure

063686S-001


Liquid Crystal Display (LCD)

063279S-002


Main PCB

062931S-007


Radio

063930S-001  Option 03, 2.4 GHz 2,6

063931S-001  Option 04, 2.4 GHz 0,1

063932S-001  Option 06, 2.4 GHz 1,1

063933S-001  Option 07, 2.4 GHz 2,0

063934S-001  Option 08, 2.4 GHz 1,51

065338S-001  Option 09, 2.4 GHz 1,25

067314S-001  Option 10, 2.4 GHz 1,48

067315S-001  Option 11, 2.4 GHz 1,14


Battery Contact Assembly

064117S-004


Antenna Cable and Jack

063816-001


Washer

589389-001


Bottom Enclosure

066215S-001	T2420

064366S-001	T2425 (includes Antenna assembly)


Grommet

063979-001


Sleeve

064034-003


Antenna

063825S-005


Retaining Ring

064101-003


NiCad Battery

063189S-003


Battery Door

064316S-002


Optical Interface Window

063314-001


PCB with base

063202S-005


Scan engine

590014S-002


Window
Scan Window

063689-002


Enclosure

063309S-003


Intermec Corporation
To order parts. . .

Call Intermec Technologies Corporation at:

1-425-348-2600

Or send mail orders to:

Intermec Technologies Corporation
6001 36th Ave. West
P.O. Box 4280
Everett, Washington  98203-9280


Specifications and Default Configurations

Specifications	Default Configurations
Application Options	Bar Code Symbologies
Bar Code	Communications
Dimensions	Operations
Display
Electrical Specifications
Input Devices
Keypad Options
Memory

Network Support

Power

Radio Frequency

Relative Humidity

RF Network Support Options

Serial Communications

Standard Range Scan Module Optical Parameters

Temperature


Application Options

Programmable terminal

IBM 3270 terminal emulation

IBM 5250 terminal emulation

VT100/220/320 and ANSI terminal emulation

Screen mapping for 3270, 5250, or VT/ANSI terminals


Bar Code Symbologies

Codabar	Code 93
Code One	Code 128
Code 11	Interleaved 2 of 5
Code 16K	MSI
Code 2 of 5	PDF 417 (Note)
Code 39	Plessey
Code 49	UPC/EAN


Dimensions

Length	10.6 in (27 cm)
Height	2.8 in (7.0 cm) at scan module
Width	3.2 in (8.0 cm) at scan module 2.5 in (6.3 cm) at grip
Weight	T2420    22 oz (624g) T2425    27 oz (765g) Note: Includes the main battery and the backup battery.


Display

CGA-compatible

16 lines x 20 columns (128 x 160 dot matrix), backlit LCD

25 lines by 80 columns, virtual display with viewport feature


Electrical Specifications

T242X	7,2V  500mA


Input Devices for the Module for Cabled Scanners

You can attach these input devices to the module for cabled scanners:

Intermec 146x CCD scanners

Intermec 151x, 1545, and 155x laser scanners

Intermec 126X and 127X wands

Intermec 1470 Imager

Compatible Symbol scanners (with reverse polarity enabled)

Use an interface cable to connect the input device to the module.


Keypad Options

Full alphanumeric keypad with 56 keys, available as an English keypad or a multilingual European language keypad

Terminal emulation keypads for IBM 3270, IBM 5250, and VT/ANSI

Note: Terminal emulation keypads are available only in English. However, TE applications can display characters in the Western European languages.


Memory

2MB programmable flash memory, 750K available

1MB battery-backed RAM, 512K available

T2420 option for a 2MB or 4MB extended storage drive


Network Support

Host connectivity through an access point and Model 200 Controller

Ethernet network using UDP Plus protocol


Power

Operating	Rechargeable lithium-ion 1350 mAh battery pack
Memory Backup	Rechargeable NiCad 110 mAh battery


Radio Frequency Communications

2.4 GHz (to 2.4835 GHz) radio

Frequency hopping spread spectrum radio

100 mW maximum output power

1.6 Mbits per second data speed

Coverage ≥ 240 feet (80 meters)


RF Network Support Options

Connectivity to a host on an Ethernet, token ring, twinaxial, coaxial, or SDLC network through an access point and Model 200 Controller using UDP Plus protocol

Connectivity to a host on an Ethernet or token ring network through an access point using TCP/IP protocol


Relative Humidity

0% to 95% noncondensing humidity


Serial Communications

Optical serial communications port interface

RS-232C up to 38400 baud

XMODEM protocol for data transfer

Supports Configurable Serial Protocol and XON/XOFF


Standard Range Scan Module Optical Parameters

Bar Code Specification	Depth of Field / Scanning Range
5.0 mil code	5 to 7 inches 13 to 18 cm
7.5 mil code	5 to 11 inches  13 to 28 cm
10 mil code	4 to 15 inches 10 to 38 cm
15 mil code	4 to 21 inches 10 to 53 cm
20 mil code	4 to 24 inches 10 to 61 cm
40 mil code	5 to 28 inches 13 to 71 cm
55 mil code	6 to 30 inches  15 to 76 cm
55 mil code,  retroreflective	2 to 7 feet 61 to 2.1 m
100 mil code, retroreflective	3 to 13 feet 91 to 3.96 m


Temperature

You need to operate and store the terminal within the temperature ranges listed below.

Operation	Temperature Range
Charging the  lithium-ion battery	+32°F to +104°F 0°C to +40°C
Operating the terminal	-4°F to +122°F -20°C to +50°C
Storing the terminal (with or without batteries)	-4°F to +140°F -20°C to +60°C


Note

The PDF 417 symbology is supported when you use the module for cabled scanners with the Intermec 1470 imager.


Bar Code Symbologies
Default Configuration
Bar Code Symbologies

Parameter	Default
Codabar	Disabled
Code 11	Disabled
Code 16K	Disabled
Code 2 of 5	Disabled
Code 39	Enabled
Code 49	Disabled
Code 93	Disabled
Code 128	Standard
Interleaved 2 of 5	Disabled
MSI	Disabled
Plessey	Disabled
UPC/EAN	Enabled


Communications
Default Configuration
Communications

Parameter	Default
Controller IP Address	0.0.0.0
Default Router	0.0.0.0
Network Activate	Disabled
Network Loopback	Disabled
RF Domain	0
RF Security Identification	None
RF Wakeup On Broadcast	No (disabled)
Subnet Mask	255.255.255.0
Terminal IP Address	0.0.0.0
UDP Port	05555
Note: After you load the default configuration, you may need to set the primary network communications parameters to communicate with other devices in the 2.4 GHz network.


Operations
Default Configuration
Operations

Parameter	Default
Append Time	Disabled
Automatic Shutoff	0 minutes (disabled)
Beep Volume	Normal
Command Processing	All reader commands enabled
Decode Security	Moderate
Display Backlight Timeout	10 seconds
Display Contrast	3 (maximum contrast)
Keypad Caps Lock	Caps lock off
Keypad Clicker	Enabled
Postamble	No characters (disabled)
Preamble	No characters (disabled)
Resume Execution	Allowed
Scan Ahead	Disabled
Scanner Mode	One-Shot mode
Scanner Redundancy	Normal
Scanner Selection	All compatible scanners (Note)
Scanner Timeout	Disabled (no timeout)
Scanner Trigger	Level triggering
Time and Date	9601011200000
Time in Seconds	Disabled


Code 39

Full ASCII Code 39 is enabled with no check digit.


UPC/EAN

UPC-A/EAN-13 enabled, UPC-E and EAN-8 enabled, supplementals allowed, transmit check digit, transmit number system digit, and retain leading zero for UPC-A.


The Scanner Selection configuration
Note

The Scanner Selection configuration is only used when a module for cabled scanners is installed on the terminal.


Theory of Operation

Main PCB Microprocessor Memory Map Oscillators Flash Memory Pseudo Static RAM Scanner Interface Scanner LEDs Keyboard Interface Liquid Crystal Display (LCD) Interface PC Card Interface Piezo Driver ASIC Power Supplies Lithium-Ion Battery Charger NiCad Battery Charger Lithium-Ion Main Battery NiCad Backup Battery	Interface Modules Scan Module Module for Cabled Scanners Keyboard Display PC Card/Radio


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. The functions of the main PCB are:

Processing keyboard input

Processing output data to the liquid crystal display (LCD)

Decoding bar code data at the scanner interface

Providing radio communication interface (T2425 only)

COM4 interface at scanner port

COM1 interface at optical interface

The main PCB also provides interfaces to the main battery, backup battery, DC power supply interface to support external AC to DC converters to power the battery chargers and to power the main PCB externally.


Microprocessor

The Vadem VG-230 is based on the NEC V30HL 8086 CPU core, which provides PC/XT compatible core logic. The VG-230 uses a single bus architecture requiring only one address and one data bus.


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. Finally, the bottom 64K of the heavy access ROM array are always mapped to the top 64K of the 1MB memory space of the V30HL or ROM BIOS.


Oscillators

The Vadem VG-230 requires two crystal oscillators. The primary crystal frequency for the CPU oscillates at 32.215905 MHz and uses a third overtone configuration. The second crystal oscillates at 32.768 KHz and provides the real time clock frequency. The 32.768 KHz uses a fundamental design with a variable capacitor to achieve the accuracy setting required.


Flash Memory

The main PCB was designed to support 2MB of flash memory. To support the Asian character set, the main PCB was designed to accommodate an additional 2MB of flash memory. These memory configurations are supported on the main PCB:

2MB - one 16Mbit flash (28F016SA)

4MB - two 16Mbit flash (28F016SA)

4MB - one 32Mbit flash (DD28F032SA)

The flash memory selected for the main PCB provides very high read/write performance. The flash memory also features advanced write state machines.

The main PCB supports these additional features:

ASIC controlled boot address (BOOT-ADDR) signal for boot block swapping, allowing the boot block to be reprogrammed and the check sum validated before the new boot block is used.

ASIC controlled write protect (WP*) signal for controlling unwanted writes to the flash memory.

+12V programming voltage flash devices. However, with an alternate stuffing of components, +5V programming voltage flash devices could be supported.


Pseudo Static RAM

Two 512K Pseudo Static RAM devices are utilized in the main PCB to provide 1MB of RAM. The Pseudo Static RAM is powered by VCC230A. When the main PCB is in Suspend mode, the ASIC generates self refresh (SELF-REF*) to maintain memory. This feature was not supported in the original VG-230 architecture.


Scanner Interface

The scanner interface is located on the back side of the T2425 behind the LCD. This interface provides various interface options. They include:

The Vadem VG-230 UART COM1 port interface. Signals include TX, RX, CTS, and RTS.

The scanner/wand interface signals that include VIDEO, GOODREAD*, BEEP, TRIGGER*, SOS, LASENABLE).

Power supply interfaces: VBATF is created by fusing VBAT with a resetable fuse and VCCEXT is created by fusing VCC with a resetable fuse.

A high speed interface for downloading software at a fast data rate on the production line. Signals include DATA, CLOCK, and STATUS.

Future IrDA support which includes TXD and RXD from the ASIC UART and a control signal from the ASIC (IRDA-ON) that enables the IrDA interface or enables the optical interface.

Piezo driver signals for driving the piezo devices in the module assemblies. These signals are PIEZO+ and PIEZO-.

These discrete interfaces are supported:

Scanner interlock (SCAN-ILOCK)    This signal prevents the unit from turning on when the module is not installed, causes the unit to power down when a module is removed, and prevents "hot plugging" the module since the unit can not be powered when the module is removed.

Internal scanner (INT-SCAN)    This signal informs the software that the scanner supported in the module is either an internal or external scanner.


Scanner Light Emitting Diodes (LEDs)

The two scanner LEDs are located just below the display. The LEDs turn yellow when the scan button is pressed or an external scan trigger is pulled.

When a bar code label is decoded, the LEDs turn green. The LEDs stay green for a few seconds then turn off. The LEDs will avoid the delay and go directly to yellow on the next trigger pull. Laser Enable is represented by the yellow LEDs, while Good Read is represented by the green LEDs.


Keyboard Interface

The Vadem VG-230 provides a scanned keyboard interface, which is the method selected for the keyboard interface. The keyboard provides an ON/OFF button which is used by ASIC OR’d SCAN-ILOCK signal from the scanner interface to create EXT interrupt pulses to Vadem VG-230.

The keyboard provides a TRIGGER* interface for the scan button at the top of the keyboard. A reset interface is provided in the keyboard interface.

To generate the reset

Press and hold the _f and [image] keys, and then press the I/O key.


Liquid Crystal Display (LCD) Interface

The VG-230 supports signals FRAME, LOCLK, M, LCDU(0-3), and SHCLK for the LCD interface. The low battery is controlled independently from the ASIC while the remaining ICON interfaces are controlled from the ASIC using ICON-CLK, ICON-DATA, and ICON-CS. Discrete signal to the LCD include LCDEN, VPBIAS, LCD-CTRL, and LCD-ADJ. Backlight Signals are BACKLT-ON and BACKLT-HIGH. The LCD is powered from VCCBL, which is generated from VBAT, and VCCLCD, which is switched from VCC230A with the VPLCD signal.


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)

Radio versions of the T2425 use a flex cable assembly to interface the PC card to the radio assembly. 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. VPA is also wire OR’d with VCCRF per the PCMCIA specification.


Piezo Driver

Control signals BEEP0 and BEEP1 drive two 4 to 1 multiplexers to produce an AC waveform across the piezo speakers in the scan module. BEEP0 and BEEP1 are produced by the ASIC as a result of control registers in the ASIC. Volumes produced are off, low, medium, medium high, and high. Sound frequency is controlled by the frequency at which BEEP0 and BEEP1 are toggled.


ASIC

Terminal specific functionality is implemented in an ASIC. The general block diagram of the ASIC is shown below. The ASIC implements all digital logic necessary to implement terminal functionality. A second 8250-compatible UART is implemented to interface to intelligent input devices and to provide a factory test and debug interface for software development. The count gathering logic has been ported from the JANUS 20X0 product and has been enhanced to buffer counts-data, provide a terminal count interrupt, provide a DMA transfer on overflow, and initiate count gathering on a configurable white-to-black or black-to-white transition. The Beep control function has also been ported from the JANUS 20x0 and it allows beep duration to be set in hardware. An interrupt sharing multiplexer is provided that routes multiple interrupts to a single input of the 8259 interrupt controller.


Power System

The terminal power system is sourced by three main power sources: main battery, backup battery, and external charger. The main lithium-ion battery functions as the primary power source for the power system. The backup battery is a NiCad battery and provides energy to the system after the main battery is removed or the main battery loses power. The NiCad battery will not run any functions, but merely shuts down the system and stores data.

The external charger interface is powered from the optical module or communication dock accessories. All power sources are used to produce various VCC power sources for the system as well as +12V supply.


Power Supplies

Source	Description
VBAT	This is the main power source for the terminal. VBAT is the result of a diode OR function of the main battery (VBATMAIN), backup battery (VBACK), and the external DC (CHG+) power sources. Typically, VBAT is generated from the main battery voltage (VBATMAIN). The circuit that is between VBATMAIN and VBAT is essentially a diode that is designed to minimize the voltage drop between VBATMAIN and VBAT—adding extra life to the main battery. When VBATMAIN drops below +5.4 V+3%, VBAT will be sourced by the backup battery (VBACK) minus a diode drop. When a charger is applied to the external DC supply (CHG+), VBAT will be sourced by CHG+ minus a diode drop.
VBATF	This power source goes to the scan module interface connector. VBATF is connected to VBAT through a fuse. The VBATF fuse is resettable.
VCC230A	A +5V +4% switching power supply that drops to +3.5V +4% in Suspend mode. It draws its operating current from VBAT and supplies up to 1.1 A. It powers the Vadem VG-230, ASIC, PSRAM, PIC, and 3-finger reset function. The power supply is enabled when VCCEN* is active. The power supply switches between +5V when VPSYS is active and +3.5V when VPSYS is inactive.
VCC	A +5V +4% power supply that is switched OFF or ON by VCCC230A with VPSYS. It powers the scan module interface, optical interface, flash memory, and scanner LEDs. It also provides voltage for filtered VCCRF, switched VCCLCD, and fused VCCEXT.
VCCLCD	A +5V +4% power supply that is switched OFF or ON from VCC by VPLCD which is controlled by VG230. VCCLCD provides power to the LCD.
VCCEXT	This power source goes to the scan module interface connector. VCCEXT is connected to VCC through a fuse. The VCCEXT fuse is resetable.
VCCRF	VCCRF is a +5V +4% filtered VCC power source for the PC card/radio interface connector. VCCRF switches ON or OFF with VPSYS.
PS+12V	A +12V +4% switching power supply. It draws its operating current from VBAT and supplies up to 120 mA. The supply turns off with VPSYS* and ASIC-LLB. PS+12V is used to generate VPPA, APPF, backup battery charger voltage, and the piezo driver voltage.
VCC+12V	Switched from PS+12V with VPSYS and provides the +12V flash voltage (VPPF) as well as the drive voltage for the piezos.
VPPA	PC card programming voltage. Provides programming voltage to the PC card interface. When the PC card is not being programmed, VPPA is sourced from VCCRF. When the PC card is programmed, VPPA is switched to PS+12V with VPPENA.
VPPF	Flash memory programming voltage. The flash programming voltage is connected to VCC+12V R157.
VBAT-NEG	Negative voltage power supply for the piezo driver. VBAT-NEG is generated from VBAT with a negative voltage switching power supply.


Lithium-Ion Battery Charger

The lithium-ion or main battery charger is powered from the external DC charger interface (CHG+). The PIC microcontroller (U40) controls the CHARGE signal based on the level of the main battery (VBATMAIN), the ambient temperature (V-TEMP), and the state of the I-MIN comparator.

The PIC starts the charge cycle by enabling the charger with a logic HIGH on CHARGE. The charger applies a constant current charge of 135 mA to the main battery. The 135 mA charge current is controlled by a current feedback loop where the current-sense amplifier (U36) senses the current into the main battery and controls the adjust pin on regulator VR1. The battery charge controller (U37) senses 8.2 volts and starts increasing the voltage on the adjust pin of VR1 to lower the charge current into the main battery.

When U40 sees I-MIN change state, it terminates the charge cycle by pulling the CHARGE signal LOW. When the main battery reaches the recharge threshold, the charge cycle repeats.


NiCad Battery Charger

The NiCad or backup battery charger is powered from the +12V boost converter (PS+12V). The PIC microcontroller (U40) controls BB-CHG signal based on the level of the backup battery (VBACK), the ambient temperature (V-TEMP), and the result of load pulses.

The charge cycle starts with BB-CHG going high, which puts a momentary load on the backup battery. This load test is used to determine if the charge cycle should begin. If the decision is to charge the backup battery, U40 maintains a HIGH on BB-CHG which places a 10 mA constant current charge on the backup battery and continuously load tests the backup battery voltage by toggling the state of BB-CHG. U40 watches for a negative slope on the backup battery voltage (BVACK) then commands the charger off.

When the recharge threshold is reached on the backup battery, the charge cycle repeats. The load test is continuously performed during operation to determine the level on the backup battery and when to charge.


Lithium-Ion Main Battery

The terminal uses a lithium-ion battery pack. The maximum voltage on the battery pack is between 8.2 volts and 8.4 volts. The standard usage terminal model, with the backlight off at 21°C, will run for greater than 8 hours from the 1000 mAh Sony battery pack (589747) and greater than 10 hours from the 1350 mAh Sony battery pack (589557).


NiCad Backup Battery

The backup battery is a customer-replaced accessory. The backup battery is a rechargeable NiCad battery that is recharged from the main battery or external DC charger. The NiCad battery consists of four 2.4V NiCad-button-cells connected in series. Specifications on the NiCad battery are: 9.6V nominal voltage, 110 mAh nominal capacity, and 1.5A for 2 second surge power. The NiCad battery is charged to 12V with a maximum charge rate of 11 mA.


Interface Modules

Two interface modules are currently available for the terminal: the scan module and the module for cabled scanners.


Scan Module

The scan module houses a laser scan engine, an interface PCB, two piezos, a flex cable, and an etchform cable. The signals to and from the scan engine go to the ASIC on the main PCB after going through the interface PCB. An 8-position flex cable connects the engine to the interface PCB.

The signals from the main PCB to the piezos go through the interface PCB and an etchform cable. The etchform cable is pressed onto the piezos by foam and the plastic of the engine housing.


Module for Cabled Scanners

The module for cabled scanners includes a 10-position connector that enables the terminal to interface with tethered scanners. The module also houses the two piezos (beepers).

A small interface PCB connects the signals from the tethered scanner to the main PCB. Some signal conditioning is done in this interface PCB. The signals from a scanner go directly to the ASIC on the main PCB. The 10-position connector is mounted on a flex cable. The flex cable is inserted in a Ziff connector in the interface PCB.

Another flex circuit is used to route the beeper driver signals to the piezos. The flex circuit is pressed into the piezos by foam and the plastic housing of the 10-position connector.


Keyboard

The keyboard scanning electronics provide for an 8x12 matrix of up to 96 regular keys. The number of keys implemented depends on the keyboard layout and configuration The elastomeric keypad provides the operator indication of key travel and tactical feedback. Pushing a key activates the membrane keypad matrix. The membrane keypad switch resistance must be less than 300 ohms for a valid key press and greater that 10 k ohms for a valid open.


Display

This is a custom display module. Graphical icons (low battery, caps lock, memory card access, etc.) are tooled onto the display and function as system state indicators. 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. An ICON driver IC, DC/DC bias power supply, EL backlight, and EL DC/AC power supply are provided on the LCD module.


PC Card/Radio

The terminals use a PC card interface for additional user memory. User memory can consist of either Flash or SRAM type 1.0 or 2.0 PC cards.

The T2425 can also use the PC card as a radio interface. The radio is connected to the PC card by a radio flex cable connector. The radio is a Proxim RangeLAN2, 2.4 GHz frequency hopping, spread spectrum radio with a 1.6 Mbps data rate.