Nortel Millennium Card User manual

NTP: 506-6501-202
Millennium Card-based terminals:
Replacing parts
Document number: P0883899 Document issue: 00.01
Document status: Standard Date: June 1998
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Information in this document includes:
• Card terminals
• Inmate terminals
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Millennium terminals installation, operation, and
maintenance documentation modules
The table below shows all the customer-orderable books in the terminal
installation, operation and maintenance suite.These books can be ordered
separately as modules or in sets as documentation kits.
Title Order code
All terminals
Millennium terminals provisioning guide A0685011
Millennium terminals: using the craft interface P0883893
Millennium terminals: maintenance troubleshooting P0883894
Millennium terminals pocket troubleshooting guide P0883895
Multi-pay-based terminals
Millennium Multi-pay-based terminals: installing
terminal hardware P0883896
Millennium Multi-pay-based terminals: replacing parts P0883897
Card-based terminals
Millennium Card-based terminals: installing terminal
hardware P0883898
Millennium Card-based terminals: replacing parts P0883899
Desk terminals
Millennium Desk terminals: installing and replacing
hardware P0883900
Also available:
Accessory kit: binder, cover, and spine A0737727
Complete assembly kit (one each of all modules) A0737720
Multi-pay terminal documentation kit A0737722
Card terminal documentation kit A0737723
Desk terminal documentation kit A0737725
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Millennium Card-based terminals:
Replacing parts
Document number: P0883899
Issue: 00.01
Document status: Standard
Document date: June 1998
©1998 Northern Telecom (Nortel)
All rights reserved
Printed in Canada
NORTHERN TELECOM CONFIDENTIAL: The information contained in this document is the property
of Northern Telecom. Except as specifically authorized in writing by Northern Telecom, the holder of this
document shall keep the information contained herein confidential and shall protect same in whole or in
part from disclosure and dissemination to third parties and use same for evaluation, operation, and
maintenance purposes only.
Information subject to change without notice
Millennium is a trademark of Northern Telecom
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iv
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
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v
Millennium Card-based terminals: replacing parts
Publication history
June 1998
This is the standard release of the repair procedures for
Millennium Card and Inmate terminals, reflecting the
modularization of the Millennium terminals installation,
operation and maintenance information.This document
includes all information from the previous two standard
releases, listed below.
This issue also introduces the following new hardware revisions
• datajack card reader bezel
• universal telephony PCP, which has the datajack connector
• new keypad assembly which requires updates of both the
upper bezel assembly and lineswitch assembly to reflect
new connections of the keypad PCP and alerter functions
April 1997
Standard release for Millennium card terminals based on
firmware releaseMTR 1.9.Thisguidereflectsanupgradeof the
Millennium Manager platform to MSR 2.0.
The MSR 2.0 release is backwards compatible with MSR 1.6,
1.7, and 1.8 terminal vintages, therefore the previous versions
of this document and support documents still apply for those
terminals.
October 1996
Standard release of this document reflecting the release of the
IAS module, datajack module, and smart card alert feature for
MSR 1.7/1.8-based terminals.
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vi
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
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vii
Millennium Card-based terminals: replacing parts
Table of contents
1 Introduction 1-1
How this module is organized 1-2
Replaceable components 1-3
Terminal components 1-4
Identifying your terminal type 1-6
Telephony/control board identification 1-7
Tools and equipment required 1-7
Setup/restore flowchart 1-9
2 Maintenance overview 2-1
Before you enter the terminal 2-1
Saving call detail records (CDRs) 2-2
Preparing the terminal for maintenance 2-2
If you need to uninstall the terminal 2-5
Opening and closing the terminal 2-6
Opening the unlocked terminal 2-6
Restoring the terminal to operation 2-11
Replacing the front housing assembly 2-14
Flowchart 2-14
Removing the front housing 2-15
Replacing the housing lock 2-20
Flowchart 2-20
Replacing the lock 2-21
Replacing the handset, cord, and swivel 2-23
Flowchart 2-23
Replacing the swivel/handset assembly 2-25
Replacing the rear terminal PCP 2-28
Flowchart 2-28
Replacing the rear terminal board 2-29
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viii Table of contents
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
Describing inferred answer supervision 2-31
Flowchart 2-33
Positioning and connecting the IAS module 2-34
Upgrading tiebar pivots 2-39
Before you start 2-39
Flowchart 2-41
Removing the pivots 2-42
Installing new pivots 2-44
3 PCP assembly components 3-1
Removing the PCP assembly 3-2
Flowchart 3-3
Working with the PCP assembly 3-5
Removing the telephony or control PCP 3-11
Replacing firmware on the control PCP 3-15
Installing smart card alert (SCA) 3-18
Flowchart 3-18
Replacing the SCA daughter board 3-19
4 Upper bezel components 4-1
Replacing the display (VFD) 4-2
Flowchart 4-3
Replacing the two-line VFD 4-4
Replacing the upper bezel assembly 4-7
Flowchart 4-8
Replacing the upper bezel assembly 4-9
Replacing the display window 4-15
Flowchart 4-16
Replacing the window 4-17
Installing an internal instruction card 4-19
Installing the Inmate instruction plate 4-19
Replacing the external instruction card 4-20
Replacing the quick access keys bezel 4-21
Flowchart 4-22
Replacing quick access keys 4-23
Replacing the quick access keys label card 4-25
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Table of contents ix
Millennium Card-based terminals: replacing parts
5 Card and hookswitch parts 5-1
Replacing the card reader 5-2
Flowchart 5-3
Replacing card reader assembly parts 5-4
Explaining the datajack feature 5-11
Installing a card reader datajack bezel 5-12
Assembling an upgrade kit 5-12
Installing the datajack bezel 5-13
Making a datajack call 5-16
Replacing the alerter module 5-17
Flowchart 5-18
Steps for replacing the alerter module 5-19
Replacing the hookswitch module 5-22
Flowchart 5-23
Replacing the hookswitch 5-24
Replacing the hookswitch/alerter bezel 5-28
Flowchart 5-29
Replacing the bezel 5-30
Replacing the number card 5-32
6 Inmate terminal 6-1
Before you enter the terminal 6-1
Flowchart 6-2
Attaching a portable display 6-4
ESD precautions 6-6
Installing the portable display 6-7
Re-entering the craft interface 6-9
Removing the portable display 6-10
Index I-1
Figures
1 Introduction
Figure 1-1: Replaceable parts on the terminal, part 1 1-4
Figure 1-2: Replaceable parts on the terminal, part 2 1-5
Figure 1-3: Locating the product ID label 1-6
Figure 1-4: Flowchart — preparatory and completion process 1-9
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x Table of contents
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
2 Maintenance overview
Figure 2-1: Unlocking the upper housing 2-4
Figure 2-2: Proper sequence to open housing 2-7
Figure 2-3: How the housing assembly swings open 2-7
Figure 2-4: ESD connection and rear terminal PCP 2-8
Figure 2-5: Rear terminal PCP power connections 2-9
Figure 2-6: Connecting the IAS module and rear terminal PCP 2-10
Figure 2-7: Checking that the left tiebar is down (unlocked) 2-11
Figure 2-8: Flowchart — replacing the front housing 2-14
Figure 2-9: Hinge sockets and tiebar locations 2-17
Figure 2-10: Locking/unlocking the terminal with the tiebar 2-18
Figure 2-11: Flowchart — replacing the housing lock 2-20
Figure 2-12: Exploded view of lock assembly 2-21
Figure 2-13: Handset cord attaches through swivel 2-23
Figure 2-14: Flowchart — replacing handset and swivel assembly 2-24
Figure 2-15: Accessing the armored cord in the swivel 2-26
Figure 2-16: Accessing the armored cord in the swivel 2-27
Figure 2-17: Flowchart — replacing the rear terminal PCP 2-28
Figure 2-18: Replacing the rear terminal PCP 2-30
Figure 2-19: The IAS module in the front housing 2-31
Figure 2-20: Interconnection diagram showing IAS 2-32
Figure 2-21: Flowchart — installing an IAS module 2-33
Figure 2-22: Connections on the IAS module 2-35
Figure 2-23: Interconnect cable connector polarity 2-36
Figure 2-24: Wire positions on the terminal block 2-37
Figure 2-25: IAS module terminal block connections 2-38
Figure 2-26: Pivot locations on the rear housing 2-40
Figure 2-27: Flowchart — Replacing tiebar pivots 2-41
Figure 2-28: Locating the horizontal tie bar 2-43
3 PCP assembly components
Figure 3-1: PCP assembly components 3-2
Figure 3-2: Flowchart — working with the PCP assembly, page 1 3-3
Figure 3-3: Control PCP cable connections 3-7
Figure 3-4: PCP assembly in position 3-7
Figure 3-5: PCP assembly removed 3-9
Figure 3-6: Removing/replacing PCP assembly 3-10
Figure 3-7: Control/telephony PCP connection 3-12
Figure 3-8: Locating the PCP assembly frame tabs 3-13
Figure 3-9: Replacing firmware on the through-hole control PCP 3-17
Figure 3-10: Flowchart — replacing SCA daughter board, page 1 3-18
Figure 3-11: Positioning the SCA daughter board 3-21
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Table of contents xi
Millennium Card-based terminals: replacing parts
Figure 3-12: Keypad PCP smart card alert cable 3-23
Figure 3-13: Alerter/keypad SCA connections 3-23
Figure 3-14: External interface hookswitch connections 3-24
Figure 3-15: Smart card alert board connections (overhead view) 3-24
4 Upper bezel components
Figure 4-1: Upper bezel assembly outside view 4-1
Figure 4-2: Exterior view of VFD on Card-based terminals 4-2
Figure 4-3: Flowchart — Replacing the display 4-3
Figure 4-4: Locating the display screws 4-5
Figure 4-5: Exploded view of clamp plate/display 4-6
Figure 4-6: Upper bezel assembly outside view 4-7
Figure 4-7: Flowchart — Replacing upper bezel assembly 4-8
Figure 4-8: Bezel A alerter/hookswitch connectors 4-10
Figure 4-9: Hookswitch — Bezel B keypad/alerter connections 4-11
Figure 4-10: Locating the ID bezel and screws 4-12
Figure 4-11: Removing the clamp plate 4-12
Figure 4-12: Screws securing the upper bezel 4-13
Figure 4-13: Removing the assembly 4-14
Figure 4-14: Display window external view 4-15
Figure 4-15: Flowchart — Replacing the window assembly 4-16
Figure 4-16: ID bezel screws hold clamp plate 4-18
Figure 4-17: Removing the clamp plate 4-19
Figure 4-18: Replacing the external instruction card 4-20
Figure 4-19: Quick access keys bezels 4-21
Figure 4-20: Flowchart — Replacing the quick access keys bezel 4-22
Figure 4-21: Screws securing the bezel 4-24
Figure 4-22: Removing the quick access keys bezel 4-24
5 Card and hookswitch parts
Figure 5-1: Hookswitch and card reader bezels 5-1
Figure 5-2: Exterior view of the card reader assembly 5-2
Figure 5-3: Flowchart — replacing the card reader assembly 5-3
Figure 5-4: Rain shield sits on back of card reader 5-5
Figure 5-5: Accessing the card reader assembly 5-6
Figure 5-6: Lower view of card reader assembly 5-7
Figure 5-7: Attaching the card reader to the bezel 5-7
Figure 5-8: Bent-card guide on the multi-card reader 5-8
Figure 5-9: Upper view of multi-card reader and bezel 5-9
Figure 5-10: Setting the rain shield on the card reader 5-9
Figure 5-11: Rain shield in place 5-10
Figure 5-12: Locating the firmware on the through-hole control PCP 5-11
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xii Table of contents
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
Figure 5-13: Datajack plug fits into card reader bezel 5-13
Figure 5-14: Installing the teladapt support inside the bezel 5-14
Figure 5-15: Datajack connector with shorting loop 5-16
Figure 5-16: Locating the alerter in relation to external housing 5-17
Figure 5-17: Flowchart — replacing the alerter module 5-18
Figure 5-18: Accessing the alerter module 5-20
Figure 5-19: Locating the mattock fender 5-21
Figure 5-20: Position of the hookswitch on the external face 5-22
Figure 5-21: Flowchart — replacing the hookswitch module 5-23
Figure 5-22: Accessing the hookswitch module 5-25
Figure 5-23: Positioning the hookswitch rain shield 5-26
Figure 5-24: Underside of Module B 5-26
Figure 5-25: External view of the hookswitch/alerter bezel 5-28
Figure 5-26: Flowchart — replacing the hookswitch/alerter bezel 5-29
Figure 5-27: Locating the bezel screws 5-31
Figure 5-28: Locating the number plate window 5-32
Figure 5-29: Accessing the number card from inside 5-33
Figure 5-30: Locating the mattock fender 5-34
6 Inmate terminal components
Figure 6-1: Flowchart — Installing/removing portable display, page 1 6-2
Figure 6-2: Proper sequence to open housing 6-5
Figure 6-3: ESD and power connections inside the terminal 6-6
Figure 6-4: Connecting the VFD to the control PCP 6-8
Figure 6-5: Locking/unlocking the terminal with the tiebar 6-10
Figure 6-6: Reconnecting cables to the control PCP 6-11
Figure 6-7: Following the proper closing sequence 6-12
Tables
Table 1-1: Installation and maintenance tools 1-7
Table 3-1: Control PCP connections 3-6
Table 3-2: Telephony PCP and internal components connections 3-8
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1-1
Millennium Card-based terminals: replacing parts
1 Introduction
This guide is intended for the craftspeople who maintain
the Millennium Card-based terminals on-site.
It describes in detail how to correctly access the terminal
to do maintenance and how to replace each component.
Included is a chapter describing specific maintenance pro-
cedures for the Inmate terminal, which is a displayless,
Card-based terminal.The main difference in procedure in-
volves installing and removing an external portable display
used to view the craft interface menus.
The replaceable components can be ordered by the oper-
ating company, unless otherwise noted. Information about
ordering parts is available from Nortel sales offices.
Ensure that you read and understand the steps that must
be carried out before any parts are replaced.
Before you enter the terminal , always upload CDRs.
When you enter the terminal:
• Always connect your ESD wrist strap to an ESD point
inside the terminal.
• Always disconnect the power to the terminal
Specific instructions for these procedures are included in
this module.
This chapter also includes a flowchart giving the key points
to accessing the terminal for a maintenance session and
returning the terminal to operation.
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1-2 Introduction
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
How this module is organized
This module is organized into the following sections:
Chapter 1: Introduction describes the guide contents
and gives an overview of the terminal and
the replacement components.
Chapter 2: Accessing the terminal provides
instructions about accessing the terminal,
replacing the entire front housing, installing
a housing lock, and replacing the handset
and cord and swivel mount.It also includes
procedures for replacing the rear terminal
PCP and installing an inferred answer
supervision (IAS) module.
Chapter 3: PCP assembly components provides
instructions about removing the PCP
assembly so the internal components are
accessible, removing the telephony and
control PCPs from the assembly, replacing
firmware, and installing a smart card alert
daughter board.
Chapter 4: Upper bezel components provides
procedures for replacing the parts
associated with the upper bezel assembly.
This includes: the vacuum fluorescent
display (VFD), display window, the upper
bezel itself (two versions), quick access
keys bezel.
Chapter 5: Card and hookswitch parts provides
procedures for replacing: the card reader
assembly, with or without datajack
connector;two versions of the hookswitch
module; the alerter module; and the
hookswitch/alerter bezel.
Chapter 6: Inmate terminal provides instructions for
procedures relating specifically to the
Inmate terminal.
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Introduction 1-3
Millennium Card-based terminals: replacing parts
Index: provides cross-reference for information in
this module.
Replaceable components
Many of the components on the terminal are replaceable.
The list below lists these replaceable parts.
Some terminals may not have all the parts listed. For in-
stance, the Inmate terminal does not have quick access
keys. Instead, a blank bezel covers this area of the termi-
nal.
• * ID bezel, specific to operating company
• * front housing assembly
• upper housing lock, specific to operating company
• handset and armored cord assembly, swivel assembly
and cotter pin
• telephony printed-circuit pack (PCP)
• control PCP, control and voice firmware
• smart card alert daughter board (optional)
• rear terminal board
• IAS (inferred answer supervision) module (optional)
• * upper bezel assembly with integral keypad
• * display window assembly
• instruction card, provided by the operating company
• vacuum fluorescent display (VFD) with ESD shield
• * five-button and ten-button quick access keys bezel
• * card reader assembly
• alerter module
• hookswitch module with rain shield
• * hookswitch/alerter bezel assembly
• number card, provided by the operating company
• data jack connector (optional)
* These assemblies should have gaskets included.Do not
install these components without a gasket. Ensure the
gasket is undamaged if replacing it in the set.
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1-4 Introduction
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
Terminal components
Figure 1-1 and Figure 1-2 illustrate the various compo-
nents of the terminal.
Figure 1-1: Replaceable parts on the terminal, part 1
1
4
7
#
2
5
8
0
3
6
9
*
HOTEL
TAXI
ZA
506-001
ID bezel
Display
window
Upper bezel
assembly
Card reader
Customer-
specific
key lock
Swivel
Armored cord
and handset
assembly
Hookswitch/
alerter bezel
PCP assembly
telephony and
Front housing
(PCP assembly
in latched position)
VFD cutout
control PCPs
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Introduction 1-5
Millennium Card-based terminals: replacing parts
Figure 1-2: Replaceable parts on the terminal, part 2
205tiebars
+
-T
R
Rear housing
Outside service wires
Clamp plate
Hookswitch PCP
Rear terminal PCP
Locking
tiebars
Card reader
Alerter PCP
Front housing
(PCP assembly
removed)
Keypad PCP
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1-6 Introduction
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
Identifying your terminal type
Each terminal has a product ID label located in the top
righthand corner on the outside, and somewhere on the
inside, of the rear housing.
Refer to Figure 1-3.
• This label tells you the type of terminal and the release
number, which you may need to refer to when ordering
components.
• This label also has the warranty expiry date of the ter-
minal.
Figure 1-3: Locating the product ID label
See this:
Inmate terminal
The Inmate terminal does not have a
window assembly, a VFD assembly, or
quick access keys. A blank bezel covers
this area the quick access keys portion.
Thecardreaderisoptional.Ifacardreader
is not installed, the bezel is blank.
+
-T
R
T
NT5UXXXXXXXX R XXX
XXXXXXXXXX
WARRANTY EXP. 9612
QUALITY by DESIGN
CONCEPTION de QUALITÉ
PLL
SA®
P0XXXXXX-XX
Rear housing
Terminal
style no.
Warranty
expiry date
release
Terminal
number
Product ID label
Serial
number
service
wire
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Introduction 1-7
Millennium Card-based terminals: replacing parts
Telephony/control board identification
The following table lists the label color and the product en-
gineering code (PEC) that appears on control and telepho-
ny PCPs:
Tools and equipment required
Table 1-1 lists the tools and equipment required to install,
maintain, and test the Card terminal.
Board type PEC Color
Datajack telephony PCP NT5U4045 Yellow
MTR 1.7: Datajack control PCP Will vary Blue
MTR 1.7/1.9: control PCPs, standard
and datajack telephony PCPs Will vary White
Repaired boards Green
Note: Boards shipped with new terminals have a PEC which represents the
firmware shipped with the board. Replacement boards, shipped without firm-
ware, will have a different PEC.
Table 1-1: Installation and maintenance tools
Tool Use to
multimeter measure the voltage (Vdc) of the supplemen-
tary power supply
ESD wrist strap protect electronic components from electro-
static discharge (ESD) damage
T-tool or L-tool open the housing assembly
butt-end test set test the line to the terminal
dry type cleaning card clean the card reader.
test cards:magandchip cards test the ability of the terminal to process card
calls
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1-8 Introduction
NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998
upper housing key unlock the terminal
wire cutters trim line to attach to terminal connector.
electrical tape insulate live wires
7/16-inch wrench attach the lock cam to the lock.
7/8-inch wrench install the housing-assembly lock.
#1 type 1A cross-recess
screwdriver tighten and loosen M3 screws and to remove the number-card window.
#2 type 1A cross-recess
screwdriver tighten and loosen M3.5 screws and M5 screws.
chip puller replace firmware chips on the control PCP.
spare anti-static bags place PCP assembly or other ESD-sensitive
components into bags when they are
removed from the terminal, but not being
worked on.
Table 1-1: Installation and maintenance tools (continued)
Tool Use to
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