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Page 1 Tuesday, February 16, 1999 8:28 AM NTP: 506-6501-202 Millennium Card-based terminals: Replacing parts Document number: P0883899 Document issue: 00.01 Document status: Standard Date: June 1998 Information in this document includes: • Card terminals • Inmate terminals...
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rprbk202 Page iv Tuesday, February 16, 1999 8:28 AM NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998...
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PCP and alerter functions April 1997 Standard release for Millennium card terminals based on firmware release MTR 1.9. This guide reflects an upgrade of the Millennium Manager platform to MSR 2.0.
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rprbk202 Page vi Tuesday, February 16, 1999 8:28 AM NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998...
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 Millennium Card-based terminals: replacing parts...
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rprbk202 Page viii Tuesday, February 16, 1999 8:28 AM viii Table of contents 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...
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1 Introduction Figure 1-1: Replaceable parts on the terminal, part 1 Figure 1-2: Replaceable parts on the terminal, part 2 Figure 1-3: Locating the product ID label Figure 1-4: Flowchart — preparatory and completion process Millennium Card-based terminals: replacing parts...
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rprbk202 Page x Tuesday, February 16, 1999 8:28 AM x Table of contents 2 Maintenance overview Figure 2-1: Unlocking the upper housing Figure 2-2: Proper sequence to open housing Figure 2-3: How the housing assembly swings open Figure 2-4: ESD connection and rear terminal PCP Figure 2-5: Rear terminal PCP power connections Figure 2-6: Connecting the IAS module and rear terminal PCP 2-10...
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Figure 5-9: Upper view of multi-card reader and bezel Figure 5-10: Setting the rain shield on the card reader Figure 5-11: Rain shield in place 5-10 Figure 5-12: Locating the firmware on the through-hole control PCP 5-11 Millennium Card-based terminals: replacing parts...
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rprbk202 Page xii Tuesday, February 16, 1999 8:28 AM xii Table of contents 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...
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.
rprbk202 Page 2 Tuesday, February 16, 1999 8:28 AM 1-2 Introduction 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,...
• 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. Millennium Card-based terminals: replacing parts...
rprbk202 Page 4 Tuesday, February 16, 1999 8:28 AM 1-4 Introduction 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 Swivel ID bezel Display window VFD cutout Upper bezel assembly...
rprbk202 Page 6 Tuesday, February 16, 1999 8:28 AM 1-6 Introduction See this: 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. Inmate terminal The card reader is optional.
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rprbk202 Page 8 Tuesday, February 16, 1999 8:28 AM 1-8 Introduction Table 1-1: Installation and maintenance tools (continued) Tool Use to 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.
Disconnect power run craft interface tests? Install portable display Reconnect power Simulate locking the terminal (left tiebar up) Enter craft interface and run maintenance tests Upload CDRs, if required. Continued on next page Millennium Card-based terminals: replacing parts...
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rprbk202 Page 10 Tuesday, February 16, 1999 8:28 AM 1-10 Introduction Flowchart — Preparatory and completion, page 2 Continued from previous page Close and lock terminal Run craft interface procedures required you replacing to restore the terminal to control PCP or full operation firmware? –...
When your maintenance tasks are complete, you then re-INSTALL the terminal. In this instance, it is imperative that you upload CDRs before you start your maintenance procedures. Millennium Card-based terminals: replacing parts...
rprbk202 Page 2 Tuesday, February 16, 1999 8:28 AM 2-2 Maintenance overview • If you do not plan to change the control board or firm- ware, you do not need to re-INSTALL the terminal when you complete your tasks. However, we recommended that you still upload the CDRs as a precautionary measure.
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PIN. If you do not open the terminal within three minutes, the terminal times out. 5. If you have not already done so, insert the T- tool or L- tool into the hole above the key lock. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 4 Tuesday, February 16, 1999 8:28 AM 2-4 Maintenance overview This hole connects to the locking tiebars which secure the front housing to the rear housing. 6. Rotate the T- tool or L- tool counterclockwise until the tool stops turning to release the housing. Refer to Fig- ure 2-1.
Since the portable display cable prevents the terminal from closing, move the left side housing tiebar up (to lock) or down (to unlock) to simulate locking and unlocking. 2. With the handset on-hook, enter the access code. Millennium Card-based terminals: replacing parts...
rprbk202 Page 6 Tuesday, February 16, 1999 8:28 AM 2-6 Maintenance overview 3. When the PIN prompt appears, press # on the key- pad. The terminal is uninstalled. 4. Go to the section Opening and closing the terminal. Opening and closing the terminal Once you have completed the section Preparing the ter- minal for maintenance on page 2-2, you are ready to open the terminal housing to access the components.
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Overhead view – terminal open Front housing assembly Front of terminal Overhead view – terminal closed Pivot Hinge rod points 6. Attach your ESD wrist strap to an ESD connection point. Refer to Figure 2-4. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 8 Tuesday, February 16, 1999 8:28 AM 2-8 Maintenance overview Electrostatic • Electronic components are sensitive to electrostatic dis- discharge charge. Before working with (ESD) the PCP assembly, put on precautions your ESD wrist strap and connect it to the ESD points shown in Figure 2-4.
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ISWs will be connected to that module. Supplementary power connections Ribbon cable (J18) connects to control PCP Locating the rear terminal PCP inside the rear housing Rear housing Inside service wires (ISWs) Millennium Card-based terminals: replacing parts...
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rprbk202 Page 10 Tuesday, February 16, 1999 8:28 AM 2-10 Maintenance overview See this: IAS module If the terminal has an IAS module, which will be installed on the front housing: a. Disconnect the interconnect cable running between the IAS module and the rear terminal PCP from connector J1 on the IAS module.
2. Check that the cable connectors are all properly and firmly seated. See this: IAS module If the terminal has an IAS module, reconnect the interconnect cable from the rear terminal PCP to J1 on the IAS module. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 12 Tuesday, February 16, 1999 8:28 AM 2-12 Maintenance overview 3. Reconnect the power by reconnecting the ISWs to the terminal block on the rear terminal PCP or the IAS module, if there is one. If, after connecting power to the terminal, Telephony board not responding appears on the display.
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These procedures are described in Millennium termi- nals: using the craft interface . 7. When you are finished using the craft interface, close and lock the terminal. 8. Perform operation tests to confirm that the terminal is fully functional. Millennium Card-based terminals: replacing parts...
rprbk202 Page 14 Tuesday, February 16, 1999 8:28 AM 2-14 Maintenance overview Replacing the front housing assembly The following procedure describes how to remove and re- place the entire front housing assembly. This procedure would be necessary if the housing casing itself is vandalized, requiring that the housing assembly be turned in for repair.
ESD wrist strap discharge and connect it to the ESD con- (ESD) nection points inside the termi- precautions nal. • Place any components you re- move from the terminal into an anti-static bag. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 16 Tuesday, February 16, 1999 8:28 AM 2-16 Maintenance overview • confirmed that the terminal block is disconnected from the rear terminal PCP See this • Before disconnecting any ca- bles, disconnect the supplemen- tary power supply. • Do not reconnect power until you are ready to close the ter- minal.
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Rear housing Left Hinge brackets vertical for front housing tiebar Terminal block Rear terminal Tiebar hinge (in unlocked position) b) Check that the cable connectors on the PCP assembly are all properly and firmly seated. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 18 Tuesday, February 16, 1999 8:28 AM 2-18 Maintenance overview c) If the terminal needs an IAS module, ensure that it has been installed and properly connected. Refer to the section on installing an IAS module later in this chapter, if necessary.
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Page 6-10 for a detailed steps for removing the portable display. WARNING: Always disconnect the power before you disconnect the portable display. 11. Perform operations tests to confirm that the terminal is fully functional. Millennium Card-based terminals: replacing parts...
rprbk202 Page 20 Tuesday, February 16, 1999 8:28 AM 2-20 Maintenance overview Replacing the housing lock The housing key lock is a customer-specific item. The fol- lowing section describes how to replace this lock. Flowchart The following flow chart describes the key points to install- ing or replacing the lock assembly.
Tab at end of service cam Large, flat nut Lock assembly Small nut Double D hole in housing and lock washer 4. Thread the large, flat nut over the lock assembly and lock in place using a 7/8-inch wrench. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 22 Tuesday, February 16, 1999 8:28 AM 2-22 Maintenance overview 5. Slide the cam over the threaded end of the lock as- sembly, with the long end of the cam pointing up- wards. Refer to Figure 2-12. This projection should rest against the black tab at the end of the service cam above it.
Figure 2-13: Handset cord attaches through swivel Cord attaches to terminal through a swivel Handset and armored cord Flowchart The flowchart shown in Figure 2-14 describes the key points to replacing the handset and cord assembly and the swivel. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 24 Tuesday, February 16, 1999 8:28 AM 2-24 Maintenance overview Figure 2-14: Flowchart — replacing handset and swivel assembly At the terminal site Follow all the steps for Replacing preparing the terminal for handset maintenance, including: and cord? •...
3. Inside the housing, remove the cotter pin from the swivel as shown in Figure 2-15. The cotter pin fits into a groove in the swivel and lies flush against the inside of the housing. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 26 Tuesday, February 16, 1999 8:28 AM 2-26 Maintenance overview Figure 2-15: Accessing the armored cord in the swivel Swivel clamp Note: the cotter pin pulls out in this direction Top of front housing Clamp screw 4. Slide the swivel assembly out of the hole in the hous- ing, pulling the handset leads through as well.
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Secure the swivel with the cotter pin. 10. Route the handset cord through the cable clamp on the inside of the housing and reconnect it to the tele- phony PCP connector. 11. Reconnect the power. Millennium Card-based terminals: replacing parts...
rprbk202 Page 28 Tuesday, February 16, 1999 8:28 AM 2-28 Maintenance overview 12. Close and lock the terminal. Refer to Restoring the terminal to operation on page 2-11, if necessary. 13. Make a call to check the handset. Replacing the rear terminal PCP The rear terminal PCP controls power input into the termi- nal.
ESD- sensitive components. If you remove the wires from the rear terminal block, wrap the bare ends in tape to insulate them from the boards while you are working on the termi- nal. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 30 Tuesday, February 16, 1999 8:28 AM 2-30 Maintenance overview See this: IAS module In this configuration, the inside service wires are connected to the IAS module terminal block, which can be removed without discon- necting the wires. To disconnect the power from the rear terminal PCP: discon- nect the interconnect cable...
Figure 2-19. Figure 2-19: The IAS module in the front housing Card reader Alerter PCP Interconnect cable connects to rear terminal IAS module (in board mount) Terminal block to connect to outside wires Millennium Card-based terminals: replacing parts...
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rprbk202 Page 32 Tuesday, February 16, 1999 8:28 AM 2-32 Maintenance overview The module connects between the telephone line and the rear terminal board, as shown in the block diagram in Fig- ure 2-20. Figure 2-20: Interconnection diagram showing IAS Power, tip &...
Close and lock terminal Attach IAS module to Perform function tests bottom of front housing. Attach ISWs to terminal block on IAS module DO NOT PLUG IN YET Attach interconnect cable to J1 on the IAS module Millennium Card-based terminals: replacing parts...
rprbk202 Page 34 Tuesday, February 16, 1999 8:28 AM 2-34 Maintenance overview Positioning and connecting the IAS module The IAS module can be installed in the field. The following steps describe how to install or replace the module in the terminal.
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25 mm (1 inch) above the bottom of the front housing and centered horizontally. Mark an edge. c) Ensure that connectors J1 and J2 are facing to the left. d) Take the board mount out. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 36 Tuesday, February 16, 1999 8:28 AM 2-36 Maintenance overview Figure 2-23: Interconnect cable connector polarity Card reader Alerter PCP Interconnect cable connector (J1) Ring Connector to rear terminal Terminal IAS module block to (in board connect to mount) outside wires 4.
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PCP. Ensure that the ISWs do not touch the internal boards of the terminal. • Ensure the proper polarity when connecting the wires. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 38 Tuesday, February 16, 1999 8:28 AM 2-38 Maintenance overview 7. When the ISWs are attached correctly, plug the IAS terminal block into J2 on the IAS module. Route the two cables so they will not get caught when the housing is closed.
• #2 cross-recess or Phillips screwdriver • adjustable wrench See this: Inmate terminals It is not necessary to install the portable display to do this proce- dure. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 40 Tuesday, February 16, 1999 8:28 AM 2-40 Maintenance overview Figure 2-26: Pivot locations on the rear housing Hinge socket Rear housing Tiebars Outside line Tiebar pivots Rear terminal Horizontal tiebar (in unlocked position) Hinge socket NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998...
Remove front housing terminal PCP Remove rear terminal PCP Disconnect ESD strap Set aside from inside terminal Remove horizontal tiebar Close and lock terminal Remove each vertical tiebar and pivots. Perform function tests Millennium Card-based terminals: replacing parts...
rprbk202 Page 42 Tuesday, February 16, 1999 8:28 AM 2-42 Maintenance overview Removing the pivots The following procedure describes how to access the tie- bar pivots, remove them, and replace them with metal piv- ots. 1. This procedure assumes you have: •...
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Push tiebar as far counterclockwise as it will go. b) Twist the bar free of the pivots. 9. Remove the left-hand pivots. Remember the position of the pivots for when you have to replace them. Millennium Card-based terminals: replacing parts...
rprbk202 Page 44 Tuesday, February 16, 1999 8:28 AM 2-44 Maintenance overview Installing new pivots The following procedure describes how to install new piv- ots once the tiebars and old pivots have been removed. 1. Install three of the metal pivots on the left side in the same position as that of the plastic ones you removed.
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PCP on page 2-28, if necessary. 11. Remove ESD wrist band connection. 12. Close and lock the terminal. Refer to Restoring the terminal to operation on page 2-11, if necessary. 13. Test the function of the terminal. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 46 Tuesday, February 16, 1999 8:28 AM 2-46 Maintenance overview NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998...
PCP assembly • removing the telephony or control PCP from the PCP assembly • replacing firmware chips on the control PCP • installing the smart card alert (SCA) daughter board and connecting it Millennium Card-based terminals: replacing parts...
rprbk202 Page 2 Tuesday, February 16, 1999 8:28 AM 3-2 PCP assembly components Removing the PCP assembly The PCP assembly must be removed to replace a telepho- ny or control PCP and to uncover some components. The PCP assembly refers to the telephony and control PCPs and the plastic frame holding them.
Are you replacing the control or telephony Replace part or do PCP? maintenance inside the the terminal, as required. Remove the PCP from the PCP assembly frame and install new PCP Continued on the next page Millennium Card-based terminals: replacing parts...
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rprbk202 Page 4 Tuesday, February 16, 1999 8:28 AM 3-4 PCP assembly components Flowchart — working with the PCP assembly, page 2 Continued from the previous page Reinstall PCP assembly Restore terminal to operation, and reconnect all cables including running whatever Inmate terminal: Install craft interface procedures are external display at this point...
INSTALL routine when you are finished. • connected ESD strap inside the terminal • disconnected the power from the rear terminal PCP. 2. Disconnect the component cables from the control PCP. These connections are listed in Table 3-1. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 6 Tuesday, February 16, 1999 8:28 AM 3-6 PCP assembly components ESD warning • Before working with the PCP assembly, put on your ESD wrist strap and connect it to the ESD connection point in the terminal. • Before replacing any compo- nent, disconnect the power.
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PCP assembly to swing out. Figure 3-4: PCP assembly in position Inside of front housing assembly PCP assembly hinge (in latched position) brackets PCP assembly latch Press inward on latch at this point Millennium Card-based terminals: replacing parts...
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rprbk202 Page 8 Tuesday, February 16, 1999 8:28 AM 3-8 PCP assembly components 4. Grasp the plastic frame of the PCP assembly and swing it away from the front housing at about a 45-de- gree angle. 5. Disconnect the component cables from the telephony PCP.
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6. Hold the PCP assembly as shown in Figure 3-6, then lift the assembly straight up, and when it is free of the bracket hooks, move it away from the terminal. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 10 Tuesday, February 16, 1999 8:28 AM 3-10 PCP assembly components Figure 3-6: Removing/replacing PCP assembly assembly bracket hooks assembly Lift and hold by the plastic frame 7. Refer to Removing the telephony or control PCP on page 3-11, if you need to replace either PCP. If you are removing the PCP assembly in order to ac- cess other components, put the PCP assembly in a static-free bag until you need to re-install it.
INSTALL routine when you are finished. • confirmed that your ESD wrist strap is connected to an ESD point inside the terminal • confirmed that the power is disconnected from the rear terminal PCP Millennium Card-based terminals: replacing parts...
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rprbk202 Page 12 Tuesday, February 16, 1999 8:28 AM 3-12 PCP assembly components • removed the PCP assembly from the terminal. Re- fer to Removing the PCP assembly on page 3-2. Electrostatic • Before working with the PCP assembly, put on your ESD discharge wrist strap and connect it to (ESD)
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Table 3-1 on page 6 and Table 3-2 on page 8 list the cable connections between the components and the telephony and control PCPs. • Ensure that the cable connectors are seated se- curely in the appropriate board connectors. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 14 Tuesday, February 16, 1999 8:28 AM 3-14 PCP assembly components • Ensure that the cables are folded away from the edges of the terminal. See this Inmate terminal If you are working on an Inmate terminal, install the portable display now.
• You will need to run the IN- STALL routine when you finish. • connected your ESD strap inside the terminal • disconnected the power from the terminal block on the rear terminal PCP or the IAS module, if there is one. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 16 Tuesday, February 16, 1999 8:28 AM 3-16 PCP assembly components Electrostatic • Connect your ESD wrist strap to an ESD connection discharge (ESD) point in the terminal. • Disconnect the power at the rear terminal PCP. • DO NOT RECONNECT power until you are ready to close the terminal.
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9. Run the INSTALL routine. 10. Perform operation tests to ensure that the terminal works as expected. The tests performed will depend on the version of the firmware. Contact your Technical Assistance Manager (TAM) for the correct testing procedure. Millennium Card-based terminals: replacing parts...
rprbk202 Page 18 Tuesday, February 16, 1999 8:28 AM 3-18 PCP assembly components Installing smart card alert (SCA) This procedure describes how to install a smart card alert daughter board kit into an existing terminal or replace an installed daughter board. Note: This daughter board can only be used on smart card through-hole smart card control PCPs.
• Uninstall the terminal through the craft interface. • You will need to run the INSTALL terminal routine when you finish. • connected your ESD strap inside the terminal • disconnected the power from the rear terminal PCP Millennium Card-based terminals: replacing parts...
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rprbk202 Page 20 Tuesday, February 16, 1999 8:28 AM 3-20 PCP assembly components Electrostatic • Connect your ESD wrist strap to an ESD connection discharge (ESD) point in the terminal. • Disconnect the power at the rear terminal PCP. • DO NOT RECONNECT the power until you are ready to close the terminal.
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Line up the connector on the bottom of the daughter board with the U25 socket on the control PCP. Refer to Figure 3-11. Be very careful to keep the connectors straight when fitting them into the socket. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 22 Tuesday, February 16, 1999 8:28 AM 3-22 PCP assembly components b) Press straight down to seat the board in the socket. See this Installation note There are two small bead tantalum capacitors (C52 and C53) just above the U25 socket. Very gently press them sideways, to allow the board to be properly seated.
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J36 module (Refer to on the daughter board Figure 3-13) Figure 3-13: Alerter/keypad SCA connections Alerter PCP Connect to smart card alert Cable clamp Keypad PCP Hookswitch Top of front housing Millennium Card-based terminals: replacing parts...
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rprbk202 Page 24 Tuesday, February 16, 1999 8:28 AM 3-24 PCP assembly components Figure 3-14: External interface hookswitch connections (J52) smart card alert connector Keypad PCP Ribbon cable Mylar connects keypad to telephony cable Hookswitch 7. Connect the cable from the alerter module to connec- tor J37 on the smart card alert daughter board.
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12. Test the alarm: a) Take the handset off-hook. b) Insert a smart card into the card reader. c) Place the handset back on hook. d) Wait for the alarm to sound. e) Remove the smart card. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 26 Tuesday, February 16, 1999 8:28 AM 3-26 PCP assembly components NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998...
Figure 4-1: Upper bezel assembly outside view The upper bezel assembly includes the instruction window, the special keys, the keypad, and the support for the quick access keys or blank bezel HOT EL TAX I Millennium Card-based terminals: replacing parts...
rprbk202 Page 2 Tuesday, February 16, 1999 8:28 AM 4-2 Upper bezel components Replacing the display (VFD) The vacuum fluorescent display (VFD) is located behind the PCP assembly. It is attached to the clamp plate, which provides protection from the display being damaged through the display window.
PCP. from inside terminal Close and lock terminal Disconnect all cables connected to telephony and control PCPs Perform function tests Remove PCP assembly and put in anti-static bag Unscrew VFD from clamp plate and remove. Millennium Card-based terminals: replacing parts...
rprbk202 Page 4 Tuesday, February 16, 1999 8:28 AM 4-4 Upper bezel components Replacing the two-line VFD To replace the VFD in a Card terminal, follow these proce- dures: 1. This procedure assumes you have followed the direc- tions in Preparing the terminal for maintenance on page 2-2 and Opening and closing the terminal on page 2-6 •...
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Reconnect the power to the terminal by recon- necting the terminal block to the rear terminal PCP. b) Remove your ESD strap connection. c) Close and lock the terminal. 7. Perform operations tests to make sure the VFD and terminal are working. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 6 Tuesday, February 16, 1999 8:28 AM 4-6 Upper bezel components Figure 4-5: Exploded view of clamp plate/display Clamp plate Grommets between shield display under screws) Screws attach shield on the wraps around four corners display NTP: 506-6501-202 Issue: 01.01 Status: Preliminary Date: February 1998...
The two assemblies can be distinguished by how the alert- er cable connects. • Bezel A: the alerter cable connects to the keypad PCP. • Bezel B: the alerter cable connects to the external interface hookswitch PCP. Millennium Card-based terminals: replacing parts...
rprbk202 Page 8 Tuesday, February 16, 1999 8:28 AM 4-8 Upper bezel components Flowchart The following flow chart describes the key points to replac- ing the upper bezel assembly. Figure 4-7: Flowchart — Replacing upper bezel assembly At the terminal site Are you installing a Follow all the steps for...
Removing the PCP assembly on page 3-2. • Bezel A: the keypad connector is disconnected from the telephony PCP Bezel B: the keypad connector is disconnected from the Hookswitch PCP Millennium Card-based terminals: replacing parts...
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rprbk202 Page 10 Tuesday, February 16, 1999 8:28 AM 4-10 Upper bezel components 2. Bezel A: Disconnect the hookswitch cable (J13) from the connector on the keypad PCP (J51). Refer to Fig- ure 4-8. Figure 4-8: Bezel A alerter/hookswitch connectors Keypad PCP Hookswitch Cable clamp...
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With the other hand, remove the two screws from inside the terminal which hold the ID bezel and clamp plate in place. Refer to Figure 4-10. c) Remove the ID bezel from the front of the terminal. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 12 Tuesday, February 16, 1999 8:28 AM 4-12 Upper bezel components Figure 4-10: Locating the ID bezel and screws Inside the front housing Clamp plate ID bezel screws (J20/J7) Terminal exterior ID bezel 5. On the inside of the terminal, lift out the clamp plate with the VFD attached, as shown in Figure 4-11.
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Loosen three turns the bottom two screws on the keypad PCP. This releases the dialer bezel inter- lock. These screws are indicated in Figure 4-12. c) Grip the upper bezel assembly and pull it from the front of the terminal. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 14 Tuesday, February 16, 1999 8:28 AM 4-14 Upper bezel components Figure 4-13: Removing the assembly ID bezel Grip the edges of the assembly and pull it off the terminal housing HOT EL TAX I 9. Remove the quick access keys or blank bezel from the upper bezel assembly you removed and install it on the new assembly.
Refer to Figure 4-14. Note: The Inmate terminal does not use a display window assembly. Figure 4-14: Display window external view Display window VFD opening Millennium Card-based terminals: replacing parts...
rprbk202 Page 16 Tuesday, February 16, 1999 8:28 AM 4-16 Upper bezel components Flowchart The following flowchart describes the key points to replac- ing the display window. Figure 4-15: Flowchart — Replacing the window assembly At the terminal site Are you Follow all the steps for installing an preparing the terminal for...
2. On the outside of the terminal, hold your hand over the ID bezel, located at the top on the face of the terminal. 3. On the inside of the terminal, remove the two screws holding the ID bezel in place. Refer to Figure 4-16. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 18 Tuesday, February 16, 1999 8:28 AM 4-18 Upper bezel components Figure 4-16: ID bezel screws hold clamp plate Front housing (PCP assembly has been removed) Screws securing ID bezel and clamp plate Hook for the PCP assembly Clamp plate with VFD attached 4.
Seat the gasket around the window opening. b. Install the metal plate as you would the internal instruction card, ensuring that the plate is tightly sealed against the gasket. Millennium Card-based terminals: replacing parts...
rprbk202 Page 20 Tuesday, February 16, 1999 8:28 AM 4-20 Upper bezel components 9. Reassemble the components by reversing Steps 1 to to 5. Note: Ensure the gasket around the ID bezel is fitted properly when reinstalling the bezel. 10. Reinstall the PCP assembly as explained in Remov- ing the PCP assembly on page 3-2.
5. Position the new card so all its edges are covered. Replacing the quick access keys bezel Each Millennium Card terminal has a ten-button quick ac- cess key array, a five-button quick access key array, or a blank dialer bezel located under the main keypad.
rprbk202 Page 22 Tuesday, February 16, 1999 8:28 AM 4-22 Upper bezel components Flowchart The flowchart shown in Figure 4-20 describes the key points to replacing the quick access keys bezel. Figure 4-20: Flowchart — Replacing the quick access keys bezel At the terminal site Remove PCP assembly and put in anti-static bag...
2. Remove the two M5 tapping screws securing the dial- er bezel above the card reader on the inside of the up- per housing. Use a #2 type 1A cross-recess screwdriver. These screws are labelled in Figure 4-21. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 24 Tuesday, February 16, 1999 8:28 AM 4-24 Upper bezel components Figure 4-21: Screws securing the bezel Inside the front housing Hookswitch M5 screws (PCP module module holding removed) quick access key bezel Keypad PCP Alerter Rubber stud module behind dialer bezel...
Force a download to acquire the table which acti- vates the buttons. 11. Perform function tests. Note: For a detailed description of the craft interface down- load option, refer to Millennium terminals: using the craft interface . Millennium Card-based terminals: replacing parts...
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rprbk202 Page 26 Tuesday, February 16, 1999 8:28 AM 4-26 Upper bezel components NTP: 506-6501-202 Issue: 01.01 Status: Preliminary Date: February 1998...
These two external connectors allow the terminal to send data information from portable communications equipment. Figure 5-1: Hookswitch and card reader bezels Hookswitch/alerter bezel HO TE L TA XI Card reader bezel Millennium Card-based terminals: replacing parts...
rprbk202 Page 2 Tuesday, February 16, 1999 8:28 AM 5-2 Card and hookswitch parts Replacing the card reader The card reader is attached to the exterior card reader bezel. As a unit, this is inserted into the housing and then secured to the housing.
Disconnect the card rear terminal PCP reader cable from the control PCP Disconnect ESD strap from inside terminal Unscrew card reader assembly and remove from front housing Close and lock terminal Run craft interface and function tests. Millennium Card-based terminals: replacing parts...
rprbk202 Page 4 Tuesday, February 16, 1999 8:28 AM 5-4 Card and hookswitch parts Replacing card reader assembly parts The following section gives a detailed procedure for re- placing the card reader assembly and the various acces- sories which can be attached to it. 1.
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Tab on card reader fits into notch on rain shield 3. Remove the M5 tapping screw located under the card reader, in the middle. Use a #2 type 1A cross-recess screwdriver. Refer to Figure 5-5. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 6 Tuesday, February 16, 1999 8:28 AM 5-6 Card and hookswitch parts 4. Remove the two M3.5 tapping screws located on ei- ther side of the M5 screw. Use a #1 type 1A cross-recess screwdriver. These three screws attach the card reader bezel to the front housing assembly.
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7. Multi-card readers: If the new card reader does not have a card guide, check the old reader for this piece and snap it on to the new card reader. Refer to Figure 5-8 for positioning. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 8 Tuesday, February 16, 1999 8:28 AM 5-8 Card and hookswitch parts Figure 5-8: Bent-card guide on the multi-card reader Edge hooks over screws Multi-card reader, lower view on card reader Card slot (card reader bezel attaches at this end) Credit card inserted into Bottom edge of card...
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Figure 5-10: Setting the rain shield on the card reader Rain shield must Card reader attaches be rotated onto to card bezel at this end back of card reader Card reader (top view) Tab on card reader (underneath PCP extension) Notch Millennium Card-based terminals: replacing parts...
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rprbk202 Page 10 Tuesday, February 16, 1999 8:28 AM 5-10 Card and hookswitch parts c) Align the notch in the top edge of the rain shield with the tab extending from below the card reader circuit board at the back end of the card reader. d) Rotate the top of the rain shield upwards, towards the card reader, until the notch in the rain shield clicks onto the tab on the card reader, as shown in...
• Secondly, there are two types of datajack connectors. — The Nortel-supplied datajack is an external teladapt in the card reader bezel. Instructions for installing this bezel are in the section Installing a card reader datajack bezel on page 5-12 —...
rprbk202 Page 12 Tuesday, February 16, 1999 8:28 AM 5-12 Card and hookswitch parts Installing a card reader datajack bezel This bezel attaches in the same manner as a card reader bezel. See this: Datajack upgrade If you are installing the datajack bezel as an upgrade, you may need to replace the control PCP or Upload...
Refer to Preparing the terminal for maintenance on page 2-2 and Opening and closing the terminal on page 2-6, including: • connected your ESD wrist strap inside the terminal • disconnected the power at the rear terminal PCP Millennium Card-based terminals: replacing parts...
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rprbk202 Page 14 Tuesday, February 16, 1999 8:28 AM 5-14 Card and hookswitch parts Warning • Attach your ESD wrist strap inside the terminal. • Disconnect the power before disconnecting any other cables. • Do not reconnect power until you are ready to close the terminal.
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J34 on the lower right corner of the telephony PCP. Warning Ensure the power IS NOT CONNECTED at this point. Connecting cables to a live board can cause damage to the compo- nents or the boards. Millennium Card-based terminals: replacing parts...
rprbk202 Page 16 Tuesday, February 16, 1999 8:28 AM 5-16 Card and hookswitch parts The datajack connector cable is shown in Figure 5-15. Note that there must be a loop between the two out- side points. This shorting loop prevents the modem from drawing excess current off the line during data- jack operation.
Figure 5-16 shows the external location of the alerter fea- ture. Figure 5-16: Locating the alerter in relation to external housing HO TE L TA XI Alerter module sits behind hookswitch/ alerter bezel at this point Millennium Card-based terminals: replacing parts...
rprbk202 Page 18 Tuesday, February 16, 1999 8:28 AM 5-18 Card and hookswitch parts Flowchart The following flowchart describes the key points to replac- ing the alerter module. Figure 5-17: Flowchart — replacing the alerter module At the terminal site Replace PCP assembly if you removed it and Follow all the steps for...
PCP assembly to sit at a 90-degree angle in the front housing • Note: It is not necessary to remove the PCP as- sembly, this step gives access to the alerter cable connection. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 20 Tuesday, February 16, 1999 8:28 AM 5-20 Card and hookswitch parts 2. Disconnect the alerter cable (J14) from the connector on the keypad PCP (J52). See this Updated upper bezel/ hookswitch hardware If the keypad PCP is attached to the hookswitch module with a mylar (clear) ribbon cable, Vintage alert...
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2-11, if necessary. a) Reconnect the power to the terminal by recon- necting the terminal block or the wires to the rear terminal PCP. b) Remove your ESD strap connection. c) Close and lock the terminal. Millennium Card-based terminals: replacing parts...
rprbk202 Page 22 Tuesday, February 16, 1999 8:28 AM 5-22 Card and hookswitch parts Replacing the hookswitch module The hookswitch PCP is located on the handset side of the terminal, beside the keypad PCP, which it connects to. This module is also part of the hookswitch/alerter assem- bly.
PCP. Remove the PCP assembly. Close and lock terminal Disconnect the hookswitch module from wherever it is connected Perform function tests Unscrew the module and remove it from the terminal Millennium Card-based terminals: replacing parts...
rprbk202 Page 24 Tuesday, February 16, 1999 8:28 AM 5-24 Card and hookswitch parts Replacing the hookswitch To replace the hookswitch module, follow these steps: 1. This procedure assumes you have followed the direc- tions in Preparing the terminal for maintenance on page 2-2 and Opening and closing the terminal on page 2-6, including: Upload...
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5. Lift the hookswitch module away from the housing as- sembly. 6. Module B: Install the rain shield. a) Set the hookswitch rain shield in the recess in the terminal housing located under the assembly, as shown in Figure 5-23. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 26 Tuesday, February 16, 1999 8:28 AM 5-26 Card and hookswitch parts Figure 5-23: Positioning the hookswitch rain shield Rain shield fits around screw mount PCP assembly bracket hinge (sits over hookswitch) Hole for switch Hookswitch rain shield b) Fit the hookswitch into the rectangular hole in the rain shield.
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PCP. b) Remove your ESD strap connection. c) Close and lock the terminal. 11. Test the terminal function to ensure the new compo- nents work and the terminal does what is expected. Millennium Card-based terminals: replacing parts...
rprbk202 Page 28 Tuesday, February 16, 1999 8:28 AM 5-28 Card and hookswitch parts Replacing the hookswitch/alerter bezel The hookswitch/alerter bezel is attached to the left side of exterior of the terminal. It covers the alerter and hook- switch modules and contains the cradle that holds the handset.
Remove assembly from terminal. Close and lock terminal Disconnect cables from and to hookswitch module and remove the module Perform function tests Unscrew the hookswitch bezel and remove it from the terminal Millennium Card-based terminals: replacing parts...
rprbk202 Page 30 Tuesday, February 16, 1999 8:28 AM 5-30 Card and hookswitch parts Replacing the bezel To replace the hookswitch/alerter bezel, follow these steps: 1. This procedure assumes you have followed the direc- tions in Preparing the terminal for maintenance on page 2-2 and Opening and closing the terminal on page 2-6, including: Upload...
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2-11, if necessary. a) Reconnect the power to the terminal by recon- necting the terminal block or the wires to the rear terminal PCP. b) Remove your ESD strap connection. c) Close and lock the terminal. Millennium Card-based terminals: replacing parts...
rprbk202 Page 32 Tuesday, February 16, 1999 8:28 AM 5-32 Card and hookswitch parts 8. Test the terminal by making a local call. Also make an incoming call to test alerter. Replacing the number card The number card is supplied by the operating company and is the terminal ID number.
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If the terminal has a Mattock fender installed in front of the alerter module, you will have to access the number card from the front of the terminal. Refer to Figure 5-30. Use a penknife to pry the window off. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 34 Tuesday, February 16, 1999 8:28 AM 5-34 Card and hookswitch parts Figure 5-30: Locating the mattock fender Inside of front housing Mattock fender Alerter assembly NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998...
• In this case, you will need to run the INSTALL routine when you are finished to reinstall the terminal. • If you replace the telephony PCP, you will need to force a download of terminal tables when you are finished. Millennium Card-based terminals: replacing parts...
rprbk202 Page 2 Tuesday, February 16, 1999 8:28 AM 6-2 Inmate terminal Flowchart The following flow chart describes the process of installing and uninstalling the external portable display on an Inmate terminal. Figure 6-1: Flowchart — Installing/removing portable display, page 1 At the terminal site Close housing enough to see VFD display...
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Close and lock terminal Run whatever craft interface procedures are necessary to bring the terminal back to Perform function tests operation Slide the locking tiebar up to simulate locking the terminal. Millennium Card-based terminals: replacing parts...
rprbk202 Page 4 Tuesday, February 16, 1999 8:28 AM 6-4 Inmate terminal Attaching a portable display Since it is recommended that you upload the CDRs before doing maintenance on the terminal, you will need to attach the portable display immediately. The following procedure describes how to install the display.
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Check that the hinges are still connected inside the terminal. d) As you pull it forward, rotate the housing assembly on its pivot points so the front of the assembly faces your right. Millennium Card-based terminals: replacing parts...
rprbk202 Page 6 Tuesday, February 16, 1999 8:28 AM 6-6 Inmate terminal ESD precautions 1. Open the front housing wide enough so you can ac- cess the interior of the terminal. 2. Attach your ESD wrist strap to an ESD connection point on the rear housing.
3. Reconnect the power at the rear terminal PCP. 4. Partially close the housing so you have access to the keypad and can see the display clearly. Do not close it far enough to pinch the VFD ribbon cable. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 8 Tuesday, February 16, 1999 8:28 AM 6-8 Inmate terminal Figure 6-4: Connecting the VFD to the control PCP Connect portable VFD to this connector (J7) Front housing (PCP assembly in latched position) Control PCP Card reader 5. If you are still in the craft interface, this message ap- pears on the VFD: =MENU, #=INSTALL or dial item number...
Please use key now & open the terminal 6. Open the terminal housing again and slide the locking tiebar down to simulate opening the terminal. Refer to Figure 6-5. 7. Continue with your maintenance procedure. Millennium Card-based terminals: replacing parts...
rprbk202 Page 10 Tuesday, February 16, 1999 8:28 AM 6-10 Inmate terminal Figure 6-5: Locking/unlocking the terminal with the tiebar Rear housing Locking tiebar Locked Unlocked Rear terminal PCP Horizontal crossbar in locked position Horizontal crossbar in unlocked position Removing the portable display At the end of your maintenance session, perform the fol- lowing procedures to remove the portable display and re- turn the terminal to operation.
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6. Disconnect the portable VFD cable from J7 on the control PCP. Figure 6-6: Reconnecting cables to the control PCP Front housing (PCP assembly in latched position) Disconnect portable VFD from this connector (J7) Rear terminal connector (J5) Control PCP Millennium Card-based terminals: replacing parts...
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rprbk202 Page 12 Tuesday, February 16, 1999 8:28 AM 6-12 Inmate terminal 7. Reconnect the rear terminal PCP cable (J18) to the connector on the control PCP (J5) to reconnect the power. 8. Follow these steps to properly close the terminal housing: a) Ensure that: •...
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9. Lock the payphone by turning the T- or L-tool clock- wise to secure the housing. Then turn the key counter- clockwise until it stops. Millennium Card-based terminals: replacing parts...
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rprbk202 Page 14 Tuesday, February 16, 1999 8:28 AM 6-14 Inmate terminal NTP: 506-6501-202 Issue: 00.01 Status: Standard Date: June 1998...
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2-22 replacing rear terminal PCP 2-28 card reader replacing the card reader attaching the reader and bezel 5-7 assembly 5-2 cable connections 5-4 replacing the datajack card reader changing types 5-4 bezel 5-12 Millennium Card-based terminals: replacing parts...
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rprbk202 Page 2 Tuesday, February 16, 1999 8:28 AM I-2 Index card terminal (continued) connecting the IAS module 2-34 replacing the display window 4-15 control PCP replacing the external instruction labels 1-7 card 4-20 removing from the PCP assembly replacing the hookswitch module 5- 3-11 replacing firmware chips 3-15 replacing the hookswitch/alerter...
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5- IAS module replacing the hookswitch/alerter about the module 2-31 bezel 5-29 detailed steps for connecting 2-34 replacing the lock 2-20 installing 2-34 replacing the rear terminal PCP 2- interconnect diagram 2-32 Millennium Card-based terminals: replacing parts...
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rprbk202 Page 4 Tuesday, February 16, 1999 8:28 AM I-4 Index IAS module (continued) inmate terminal (continued) replacing 2-31 restoring to operation 2-11 terminal block for ISWs 2-10 unique parts 1-6 ID bezel, removing 4-11 upgrading tiebar pivots 2-39 identifying the terminal, product ID inside service wires (ISWs) label 1-6 insulating the wires 2-9...
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firmware on the control PCP 3-15 23, 5-5, 5-19, 5-30, 6-6 front housing assembly 2-14 precautions 2-8 handset, cord, and swivel 2-23 precautions when connecting 2-37 hookswitch module 5-22 warning 3-12 hookswitch/alerter bezel 5-28 prompt housing lock 2-20 Millennium Card-based terminals: replacing parts...
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rprbk202 Page 6 Tuesday, February 16, 1999 8:28 AM I-6 Index replacing (continued) terminal block inmate instruction plate 4-19 disconnecting the power 2-9 internal instruction card 4-19 when to reconnect the power 2-12 number card 5-32 terminal housing, opening the housing quick access keys bezel 4-21 rear terminal PCP 2-28 terminal release number 1-6...
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