Kronos Timekeeper 400 Series Operating instructions

Document Part Number: 4701182-001
Document Revision: B
Maintenance and Troubleshooting Guide
Series 400 Terminal
This document provides information on maintaining the Series
400 terminal and resolving any user problems.

The information in this document is subject to change without notice and should not be construed as a commitment
by Kronos Incorporated. Kronos Incorporated assumes no responsibility for any errors that may appear in this
manual. This document or any part thereof may not be reproduced in any form without the written permission of
Kronos Incorporated. All rights reserved. Copyright 1995, 1999.
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Kronos Incorporated. CommLink, Comm.Mgr, DKC/Datalink, HyperFind, Labor Activity Manager, Labor Plus, Smart
Scheduler, Starter Series, Start.Labor, Start.Quality, Start.WIP, Tempo, the Tempo logo, and Timekeeper Web are
trademarks of Kronos Incorporated.
AS and AS400 are trademarks, and IBM is a registered trademark of International Business Machines Corporation.
INFORMIX-OnLine is a registered trademark of Informix Software, Inc. INTERSOLV is a registered trademark of
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Published by Kronos Incorporated
400 Fifth Avenue, Waltham, Massachusetts 02451-8746
Phone: [phone], Fax: [phone]
Kronos Incorporated Global Support: 1-800-394-HELP (1-800-394-4357)
For a complete list of the international subsidiaries, see the following Kronos Incorporated Web page:
http://www.kronos.com/info/locations.htm
Document Revision History
Document Revision Product Version Release Date
A400.3 November 1995
B400.6 May 1999

Contents
About This Guide
Guide Organization ....................................................................................viii
Conventions ..................................................................................................ix
Abbreviations and Terms ..............................................................................x
Related Documents ......................................................................................xii
Chapter 1: Introduction
The Series 400 Terminal and Its Parts ........................................................1-2
Mainboard ............................................................................................1-2
Available Options ................................................................................1-3
The Field Replaceable Unit and Options ...........................................1-11
Maintenance Basics ..................................................................................1-12
Tools Required for Maintenance .......................................................1-12
Safety Considerations ........................................................................1-12
Cleaning the Terminal ........................................................................1-13
Before You Call Global Support ..............................................................1-14
Chapter 2: Preventive Maintenance
The Lithium Battery ...................................................................................2-2
Determining the Lithium Battery’s Life ..............................................2-2
Replacing the Lithium Battery .............................................................2-3
The Lead-Acid Battery ...............................................................................2-6
Testing the Lead-Acid Battery .............................................................2-6
Replacing the Lead-Acid Battery .........................................................2-7
Verifying the Integrity of the Network .....................................................2-10

Contents
iv Kronos Incorporated
Chapter 3: Servicing the Series 400 Terminal
Handling Static-Sensitive Components ..................................................... 3-2
Saving and Restoring Data ......................................................................... 3-3
Terminal Service Utility ......................................................................3-3
SL400 for DOS .................................................................................... 3-9
Programming the Series 400 Terminal .............................................. 3-16
Removing and Replacing Parts of the Terminal ..................................... 3-19
Removing the Battery Backup Board ................................................ 3-22
Replacing the Battery Backup Board ................................................ 3-23
Removing the I/O Board ................................................................... 3-24
Replacing the I/O Board ....................................................................3-26
Removing the Mainboard .................................................................. 3-27
Replacing the Mainboard .................................................................. 3-28
Removing the Keypad ....................................................................... 3-30
Replacing the Keypad ........................................................................ 3-31
Removing the Keypad Membrane ..................................................... 3-32
Replacing the Keypad Membrane .................................................... 3-33
Removing the LCD ............................................................................ 3-33
Replacing the LCD ........................................................................... 3-34
Removing the Reader Cover ............................................................. 3-35
Replacing the Reader Cover .............................................................. 3-36
Upgrading Memory .................................................................................. 3-38
RAM Upgrade ................................................................................... 3-38
Boot-EPROM Upgrade ..................................................................... 3-41
Chapter 4: Troubleshooting
Terminal Hardware Failures ......................................................................4-2
Power-Up Failures ..................................................................................... 4-7
Badge-Reading Problems ........................................................................... 4-9
Keypad Problems ..................................................................................... 4-11
Lead-Acid Battery Backup Failures ......................................................... 4-12
Communications Problems ...................................................................... 4-14
Serial Troubleshooting ...................................................................... 4-14
Ethernet Troubleshooting .................................................................. 4-16

Contents
Series 400 Terminal Maintenance and Troubleshooting Guide v
Token Ring Troubleshooting .............................................................4-19
Chapter 5: Changing Terminal Firmware
Using the Correct Versions ........................................................................5-2
About the Flash Utility .........................................................................5-2
About the Boot-EPROM ......................................................................5-2
About the Flash Application Program .................................................5-3
Softloading an Application with SL400 .....................................................5-4
SL400 for Windows .............................................................................5-4
SL400 for DOS ....................................................................................5-7
Chapter 6: Using Maintenance Mode
Command Modes Overview .......................................................................6-2
Operating in Maintenance Mode ................................................................6-3
Maintenance Mode Password .....................................................................6-4
Commands List ...........................................................................................6-5
Executing Commands .................................................................................6-8
Appendix A: Error and Status Messages
Interpreting Error Messages ......................................................................A-2
Error Messages .........................................................................................A-3
Status Messages .......................................................................................A-18
Appendix B: Series 400 Terminal Part Numbers
Part Numbers .............................................................................................B-2
Index

Contents
vi Kronos Incorporated

About This Guide
This guide is specifically written for Kronos Customer Service Representatives
and all others who install, maintain, and service the Series 400 terminal.
The supported features for the Series 400 terminals vary among the applications.
You should check your application documentation or with your sales
representative to ensure that the application supports the features you need.
This preface contains the following sections:
wGuide Organization
wConventions
wAbbreviations and Terms
wRelated Documents

About This Guide
viii Kronos Incorporated
Guide Organization
This guide contains the following information:
wChapter 1, “Introduction,” provides information on the Series 400 terminal
and its parts and optional boards. Some basic maintenance information is
provided as well as a section for customers that explains what to do before
calling Kronos Global Support.
wChapter 2, “Preventive Maintenance,” provides information on performing
preventive maintenance on the Series 400 terminal such as replacing the
lithium and lead-acid batteries and verifying the integrity of the network.
wChapter 3, “Servicing the Series 400 Terminal,” describes the procedures
used to save and restore Series 400 terminal data and remove and replace
parts of the terminal. It also provides information on handling static-sensitive
components, and upgrading memory.
wChapter 4, “Troubleshooting,” includes information on troubleshooting Series
400 terminal hardware and power-up failures, resolving badge-reading,
keypad, and internal modem module problems, lead-acid battery failures, and
communication problems.
wChapter 5, “Changing Terminal Firmware,” describes how to use the SL400
utility to change Series 400 terminal firmware.
wChapter 6, “Using Maintenance Mode,” describes how to use maintenance
mode and provides a listing of the maintenance mode commands and
procedures.
wAppendix A, “Error and Status Messages,” contains a listing of error and
status messages, what they mean, and how to resolve the situations that cause
them to appear on the Series 400 terminal.
wAppendix B, “Series 400 Terminal Part Numbers,” lists part numbers relative
to the Series 400 terminal and its options.

Conventions
Series 400 Terminal Maintenance and Troubleshooting Guide ix
Conventions
This guide uses the following text conventions:
Convention Use
Note Emphasizes a key point.
Caution Notifies you of potential damage to your data.
Warning Notifies you of potential danger to you or damage to the
hardware you are using. Heed all warnings.
bold Indicates an important term or phrase.
File > Save Indicates a menu path. Select each item in sequence. In this
example, File > Save means “Select the File menu; then select
the Save option on that menu.”
italic Indicates a variable or placeholder for information that you
must specify. For example, filename.sql or password means
that you must supply a specific file name or password. Italic
also indicates a reference to another document.
user input Indicates information that you must type exactly as shown. For
example: Enter SuperUser for the user name.

About This Guide
xKronos Incorporated
Abbreviations and Terms
The guide uses the following abbreviations and terms:
Abbreviation Meaning
AC alternating current
AFT Arbiter File Transfer
APS Kronos Auxiliary Power Source
AWG American Wire Gauge
BABT British Approvals Board for Telecommunications
CCTV closed circuit television
CE Conformité Européene
CRC cyclical redundancy check
CRT cathode-ray tube
CSA Canadian Standards Association
DC direct current
DOS disk operating system (for example, IBM PC-DOS)
EEPROM electrically erasable programmable read-only memory
EPROM erasable programmable read-only memory
FCC Federal Communications Commission
FIFO first in, first out RAM Buffer
FRU field replaceable unit
I/O input/output
IKDE Imagekeeper®Data Exchange software
K kilobyte of memory
KOP Kronos Options Package
LCD liquid crystal display
LED light-emitting diode
MB megabyte of memory
OS operating system

Abbreviations and Terms
Series 400 Terminal Maintenance and Troubleshooting Guide xi
PC personal computer (for example, IBM PC/XT/AT or PS/2)
PIN personal identification number
PROM programmable read-only memory
RAM random access memory
TCP/IP Transmission Control Protocol/Internet Protocol
TKC Kronos Timekeeper Central®software
UDP User Datagram Protocol
UL Underwriter’s Laboratory
UPC Universal Product Code
VAC volts alternating current
VDC volts direct current
Abbreviation Meaning

About This Guide
xii Kronos Incorporated
Related Documents
Additional information relating to the Series 400 terminal can be found in these
other Kronos documents:
wTimekeeper Terminal Installation Guide (part number 4701180-001) provides
step-by-step instructions for installing the Series 400 terminal.
wSeries 400 Terminal Configuration Guide (part number 4701181-001)
provides information on configuring operating parameters on the Series 400
terminal. The guide also includes a list and explanation of the procedures and
steps that comprise these parameters, as well as configuration worksheets.
wSeries 400 Terminal Host Sofware Interface Guide (part number
4700692-001) provides information on configuring Series 400 terminals that
interact with Kronos data collection and access control host applications. The
guide also provides instructions configuring and communicating with Series
400 terminals that interact with host software other than Kronos applications.
wTimekeeper Terminal Supervisor’s Reference (part number 4701183-001)
explains the Series 400 terminal supervisor’s procedures and provides
information on supervisor and guard modes.
wTimekeeper Terminal Quick Reference Card (part number 4701184-001)
details operating mode functions, including how they appear on the Series 400
terminal, and the appropriate responses to terminal prompts. The card also
contains a list of error messages with their meanings and resolutions.
wSeries 400 Terminal Hardware Options (various part numbers) explains
available Series 400 terminal options in individual, stand-alone documents
that contain product information as well as troubleshooting procedures and
installation instructions.

Chapter 1
Introduction
The Series 400 terminal and the options associated with it are introduced in this
chapter. Also provided is some basic maintenance information you should
understand before you begin to service the terminal.
A section specifically for customers is included on the things to do before calling
Kronos Global Support and requesting a service call by a Customer Service
Representative (CSR).
This chapter contains the following sections:
wThe Series 400 Terminal and Its Parts
wMaintenance Basics
wBefore You Call Global Support

Chapter 1 Introduction
1-2 Kronos Incorporated
The Series 400 Terminal and Its Parts
Before you do any maintenance or troubleshooting of the Series 400 terminal, you
should become familiar with its parts. You also should be familiar with the option
boards that are available with the terminal.
Mainboard
Kronos provides two types of mainboards for the Series 400 terminal: the 186
board and the 177 board. Some of the connections on the 177 board differ from
the connections on the 186 board. The following figure shows in detail the 186
mainboard and its connector locations:

The Series 400 Terminal and Its Parts
Series 400 Terminal Maintenance and Troubleshooting Guide 1-3
Legend
1LCD cable connector (P2)
2Keypad cable connector (P1)
3Ethernet option connector (P3)
4LEDs (mounted on back side of board)
5Modem, Token Ring, or twinaxial option connector (J2)
6RS-485 termination/biasing switch (SW1)
7Not used and not on all mainboards (P4)
8Optics assembly (OP1) (mounted on back side of board beneath metal optics shield)
9RS-232/RS-485 configuration switch (SW2)
10 I/O board cable connector (P5)
11 Fuse (F1)
12 Internal Beeper (BPR1)
13 I/O port (TB1)
14 Communications port (TB2)
15 Battery backup cable connector (TB3)
16 Lithium battery (BATT1)
17 DC wall supply connector (J1 or J3)
The mainboard comes in different RAM sizes: 128K, 256K, 512K, and 1MB. For
the part numbers for the mainboards, see Appendix B, “Series 400 Terminal Part
Numbers.”
Available Options
You can add several options that plug into the mainboard, such as an I/O board, a
battery backup board, the Ethernet option board, the Token Ring interface board,
a modem option board, the auxiliary power source, and the twinaxial interface
option.
The following sections describe these options.

Chapter 1 Introduction
1-4 Kronos Incorporated
I/O Option Boards
You can add optional I/O boards (with connecting cable and mounting screw) to
the Series 400 terminal. These boards support the connection of optional devices.
The following figure shows the standard I/O board and the connector locations. A
proximity reader and magnetic reader I/O board and a dual reader I/O board are
also available.
Legend
1Mainboard cable connector (P1)
2RS-232 serial printer port (TB2)
3Remote indicator lights/Megabeep External beeper/Remote swipe bar code reader/
Wand bar code reader port (TB1)
4Kronos RS-485 remote swipe bar code reader RS-485/Termination jumper (SB1)
5Kronos RS-485 remote swipe bar code reader port (TB3)
6I/O port (TB4) for master synch and other less used hardware options

The Series 400 Terminal and Its Parts
Series 400 Terminal Maintenance and Troubleshooting Guide 1-5
Battery Backup Board
You can install an optional 12 VDC lead-acid battery and battery backup board in
the Series 400 terminal to provide it with up to 12 hours of full functionality.
There is another battery backup board that provides auxiliary power for the
proximity reader. The following figure shows the battery backup board and the
cable locations:
Legend
1Mainboard cable (INPUT)
2Fuse (F1)
3Battery cable (BATT)
Note
Battery backup board cables are soldered in.

Chapter 1 Introduction
1-6 Kronos Incorporated
Ethernet Option Board
You can install an optional Ethernet board in the Series 400 terminal. This option
board provides a way for Series 400 terminals and a host to connect to a standard
Ethernet network. TCP/IP UDP is the network protocol used for sending and
receiving messages. The following figure illustrates the Ethernet option board and
its connectors:
Legend
1Mainboard connector (J1)
2Flash
3Output jack (P1)
4ST-NIC chip

The Series 400 Terminal and Its Parts
Series 400 Terminal Maintenance and Troubleshooting Guide 1-7
Token Ring Board
You can install an optional Token Ring board in the Series 400 terminal. This
board provides direct connection from Series 400 terminals to the AS/400 Token
Ring network. The following figure illustrates the Token Ring board:
Legend
118-36 Volt supply cable (P6)
2DB9 output (P1)
3Twisted pair adapter output (P2)
4Mainboard connector (P3)
5Status LEDs

Chapter 1 Introduction
1-8 Kronos Incorporated
Modem Option Board
You can install an optional modem board in the Series 400 terminal. Two modem
boards are available: the 2400 option board and the high-speed (14.4Kbps) option
board. Each of these option boards makes it possible to establish communications
over telephone lines between the host and the Series 400 terminal.
The following figure illustrates the high-speed modem option board and its
connectors:
Legend
1RJ-11 jack for the telco cable
2Mainboard connector (P1)