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Intermec 073290-001

1. Mini PCI Host Bridge Scan I F 2 l Mini PCI Radio A Radio y Y Ethernet Ethernet S LW User LEDs Keypad Conn Low Batt Power Detect Supply Controller Low 3 3V vo MCLR POR Battery Supercap Battery Temperature Status Lep Monitoring 232 bu hed indicates optional feature CK30 Handheld Computer Service Manual Processor Core Processor System Clocks Chapter 4 Theory of Operation The CK30 platform is built around the Intel PXA255 Cotulla XScale processor U1 The low end configurations of the CK30 CK30AA and CK30BA use a 200MHz version of the PXA250 for cost reasons The high end configuration CK30CA uses a 400MHz version of the part Refer to Intel documentation for detailed information on the PXA255 XScale processor operation and features All clocks in the system are derived from two oscillators built into the PXA255 processor a 3 6864MHz oscillator driven by crystal Y3 and a 32 768kHz oscillator driven by crystal Y2 The 3 6864MHz clock is buffered and phase lock looped up in the PXA255 to drive the CPU memory FPGA and PXA255 internal peripheral clocks This oscillator is shut down during Suspend for power savings The 32 768KHz clock drives only the RTC It is turned on by software at boot time and then is left on continuously to keep the RTC running Oscillator Y
2. Host CPU I F FPGA_CS PCI HCR_CS ADDR DECODE RD WR CTL 10 MUX LOGIC PCI_IRQ SDCLK SDCSO SDCAS SDRAS BREQ BGNT CLK_OUT FPGA_CLK m CLK DLL trite i SDBUF_D7 0 DBP_HSYNC SOS VSYNC Scanner TETH DBP sos I F TETH PRESENT ILLUM LASEN RTS SPEED_RANGE_GDRD SCAN_FLASH_EN SCAN_TRIG IMAGER_PIXCLK SCAN LED_LOW USER_LED lt 2 1 gt GPIO DOCK_TRIG VOL lt 2 0 gt KEY_RET lt 7 0 gt HCR_WR2 HCR_WRS BATT FAULT IRQ REQ GNT ACT PME CLKRUN INTA INTB IDSEL AD31 0 C BE 3 0 PAR PERR SERR FRAME IRDY TRDY STOP DEVSEL RST PCLK Mini PCI Slot 2 CK30 FPGA Block Diagram FPGA Download PCI_CLK The FPGA is SRAM based and must be downloaded at boot time and on resume Its image is stored in system flash and downloaded from the PXA255 by a download driver using the FPGA parallel slave mode on data lines SA_MD7 0 This process clearly must precede loading of any drivers that expect to use the FPGA Software initiates the download by pulsing the FPGA_PGM signal low to clear the FPGA configuration space waiting for its INIT status to go high alternate function of signal SCAN_DREQ and starting the FPGA_CLK 48 CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation The loader then writes byte values to the FPGA with write st
3. The FPGA 3 3V IO ring supply is controlled separately through the Power Supply Controller U38 so that it can be sequenced off well after about 10ms the FPGA core voltage has been turned off and the PXA255 has suspended This ensures the FPGA IO remains stable while the core is being switched off e On PWR_EN high CPU waking or booting the PSC enables the FPGA IO ring power supply e On PWR_EN low CPU suspending the PSC waits 10ms and then disables the FPGA IO ring power supply This ensures that the FPGA core supply controlled by the CPU goes down first avoiding a failure mode in which FPGA IO pins pulse low when its IO ring and core supplies go down simultaneously e On cold boot the PSC holds the FPGA IO supply off for 100ms before releasing system reset and enabling the FPGA supply This ensures that the FPGA IO initializes correctly to a high impedance state on cold boot avoiding another failure mode that can occur if the FPGA latches in an erroneous state that can inhibit the PXA255 from booting CK30 Handheld Computer Service Manual 49 Chapter 4 Theory of Operation FPGA Bus Interface FPGA Clocks 50 Software is responsible for shutting off FPGA core power in a critical battery situation If FPGA power is still on when the system suspends it will be shut off in hardware by the Type 2 interlock mechanism described in Device Power Control on page 58 The FPGA occupies PXA255 memory areas 2 and
4. U23 s CD_WAKE output is always active even when U23 is shut down during Suspend This allows the RS 232 DCD signal to propagate through U23 and wake the system if it is docked with an active RS 232 device This feature is not supported in the current software A full set of scanner interface signals is available on 26 pin docking connector J13 This is intended for support of pick and run applications in which the CK30 may be docked in a vehicle dock that has a decoded or undecoded tethered scanner plugged in It may also be used for Specials applications needing to support an internal and a tethered scanner See Tethered Scanner Support Through Dock Connector on page 85 for details Regulated 5V power is provided through the dock connector for powering tethered scanners This power is switched through high side switch U13 controlled by the DOCK_EN signals from HCR register U11 This 5V power is normally powered off and the RS 232 chip disabled during Suspend and is automatically shut off in hardware if the main battery is critically low or removed A Class 2 Bluetooth link is supported through an optional module that plugs into Bluetooth connector J8 A duplicate set of connector pads J6 is provided for future support of larger Bluetooth modules The module includes its own chip antenna The Bluetooth module is powered through FET Q9 Software normally drives control signal BT_PWR_EN high off during Suspend for po
5. power 0 enable 1 disable Enable illumination PWM square wave Scan enable 0 disable 1 enable VSYNC 0 between frames 1 valid data HSYNC 0 between rows 1 valid row data DBP scanner usage Enable scanner power 0 enable 1 disable Laser enable 0 enable 1 disable Scan enable 0 enable 1 disable SOS Start of Scan toggles at start of each scan DBP Video 0 black 1 idle white Speed select 0 200 scans sec EV10 0 500 scans sec EL10 1 36 scans sec EV10 1 65 scans sec EL10 SE900 config bit 0 SE1200 aim beam Tethered undecoded scanner usage 10 pin only Enable scanner power 0 enable 1 disable Laser enable 0 enable 1 disable Scan enable 0 enable 1 disable SOS Start of Scan toggles at start of each scan DBP Video 0 black 1 idle white GoodRead Intermec active low Symbol active high CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation Using the Scanner Interface Signal Set Part 1 continued Signal Name IMAGER_PIXCLK TRIG_AIM SCAN_TRIG IMAGER_SD0 7 I2C_CLK I2C_DAT Source Destination FPGA IO HCR out FPGA_IO FPGA in PXA250 IO 2D Imager usage Pixel clock from scanner Data valid on rising edge DBP scanner usage Tethered undecoded scanner usage 10 pin only Beep Scanner present 0 no scanner installed 1 scanner in
6. 6 55V gt 6 94V allowed to resume These temperature ranges are approximate because the Vbat temperature compensation is not calibrated at manufacture Also because the battery level is averaged over 10 samples at 3 second intervals it may take up to 30 seconds for a threshold crossing to take effect These temperature ranges are approximate because the Vbat temperature compensation is done in hardware CK30 Handheld Computer Service Manual 61 Chapter 4 Theory of Operation Battery Status LED 62 Software Low Battery Thresholds The first low battery thresholds are defined in software as part of the power management driver running on the PXA255 Temperature compensated battery level sampled through PSC U38 see Battery Status Monitoring on page 60 is averaged over 10 samples When this value falls below the software threshold the power management code displays the appropriate battery status icon in the icon tray When the battery level drops below the 0 threshold the power management code also sends an I2C command to the PSC to turn on the red low battery LED indication Note that because the battery level is averaged over 10 samples at 3 second intervals it may take up to 30 seconds for a threshold crossing to take effect The red LED remains lit until the CK30 enters the Suspend state or the battery level averaged over 10 samples rises above the software threshold See the next section Battery Stat
7. A warm boot command followed by a battery supercap temperature status request Start 12 W A 61 A Start 12 W A 30 A a Ol A 50 A Start 12 R A 61 A 30 A 97 A 40 A EO A 5 N Stop Battery Status Monitoring 60 Main battery voltage under load is scaled through operational amplifiers U41 sampled through the PSC A D converter and made available to system power management software for accurate on display fuel gauging and device power management in the low battery operating region Reference D14 and operational amplifiers U41 provide the reference voltage for the PIC A D The PSC sends raw A D data over the 12C bus in response to I2C commands sent approximately every 3 seconds from the power management software running on the PXA255 See PSC 12C Syntax on page 59 CK30 internal temperature is sensed by thermistor RT3 read through a PSC A D and sent to the OS over the I2C bus in response to 12C command CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation Power management software on the PXA255 uses the battery voltage and temperature data for temperature compensated fuel gauging and low battery detection Three levels of battery status are indicated through an icon in the status bar Percentage of Charge Remaining Icon Displayed 67 to 100 charge remaining No icon displays 34 to 67 charge remaining qu 1 to 33 charge remaining Cy 0 charge remaining ch Low Bat
8. CK30 Handheld Computer Service Manual iii Contents 114000 Imager Assembly Exploded Views sis dese cidesessvisile luis diia dolorosos 35 IT4000 Imager Assembly Spare Parts Listados 35 Tethered Scan Flex Assembly Exploded Viera id 36 Tethered Scan Flex Assembly Spare Parts Distancia dal iba 36 Safety Labels Exploded Via aeae tay a aN o ikii 37 Satety Labels Spare Parts List li 37 4 Theory Of Operation oo ccccscssssessssssnecsssssssscsssecsssscsssseessuecssseessieeesseeseneesseeeen 39 SySteneAre ise Ute ass inr i tate arestelorear san leony lant vadey Sesshdett ceeded E N e 40 Processor Coresi di ld 41 A A anther ahs sas 41 Systemr Clocks a dead 41 Men aa 42 VO Simals ar e a p oto Galea a Eae 43 PO Buss io dll ts alii 47 FPGA AAA AAA EIN 47 EPGA Download 48 PPG As A coset Seeite ducts oun eea E aa ES 49 FPGA Bus Tercel nism stint eatin stating erent aria 50 FPGA COCR ss scores tees a aa 50 Power Syst m Sic eiheh HSS a ee a Le eit at ee Mia a 51 Architecture POWER Supplies us lndr cil io idad telde 51 Main Battery essre NA 52 NN a NS 53 External Power aien n e Altas e ad natalia 53 Power Management Arc aire cere ss is 54 Device Power tte alo SEAE E tM AS 56 Power Supply Controller PE ai 59 Battery Status Monitoring serosoa aeris dan ea dd 60 Lows Battery Handling doin raton ci ideas 61 Battery Status LED Sustainable rete aa hoar iiia 62 Reset Control A is Wie aaa Ea 63 TO Controleren nanki ea A 64 A O 65 A esse
9. JTAG_TRST PC DAT I2C_CLK SERIAL_PROG_CLK SERIAL_PROG_DATA GND PIC_VCC PIC_VPP CK30 Handheld Computer Service Manual Description Target 3 3V to power JTAG or 12C dongle PXA255 and FPGA TCK PXA255 TDI PXA255 TDO PXA255 and FPGA TMS FPGA TDI FPGA TDO PXA255 reset PXA255 JTAG reset I2C bus between PXA255 and PSC PIC I2C bus between PXA255 and PSC PIC PSC PIC programming serial bus PSC PIC programming serial bus 5V PIC Vcc 13V programming VPP for PSC PIC 93 Chapter 4 Theory of Operation Debug Board 94 FA aa w O _axasadgese o v 9000000000 lt 0 ieee O 0000000000 3 a 99999999902 PIC PROGRAMMER 900000000 CPU JTAG FPGA JTAG RE RESET o000000o ooooonu oon E 333382 38d8z 288 O RYORGS BLZORGS BRS nid TARGET q p SYSTEM e E Ei FLEX To P1 on target system 073048 JTAG Board and 073049 flex J33 J34 and J35 are 3 high density 40 pin SMT board to board connectors providing debug board access to the CK30 system bus and control signals These connectors are not installed on production boards and so are not intended as a field debug facility but could be soldered onto a production board to help diagnose a field problem as a last resort The signal set brought out through these connectors includes e SA_MD31 0
10. LCD Bias Generator gt LCD BIAS SUPPLY LCD_VDD_EN PWM BIAS ADJUST il Reset Core Voltage Regulator r Vcc 8 1 5V sus rest ji PWR_EN Aquila CX1 Power Supply Block Diagram 6 26 02 Architecture and Power Supplies CK30 Handheld Computer Service Manual H PLL_VCC 51 Chapter 4 Theory of Operation Power Supplies and Capacities Load VDC Capacity Regulator CPU core supply 1 30V 5A U45 Buck switcher from 3 3 VDC VCCN and VCCkp 3 3V 2A System 3 3V U39 from main battery or U44 from supercap PLL_VCC 1 3V 03A Filtered CPU core supply Core logic memory IO 3 3V 1A System 3 3V U39 from main battery or U44 from supercap and ATT_VCC Memory core 3 3V 4A System 3 3V U39 from main battery or U44 from supercap SD slot 3 3V ILOA Switched through FET Q10 from System 3 3V PCI slot 33V 1 04 Switched through U12 from System 3 3V Scanning subsystem 3 3V 2A Switched through U12 from System 3 3V 5V 25A Switched through U13 from System 5V Bluetooth 3 3V 15A Switched through Q9 from System 3 3V LCD display 3 3V 015A Bias supply U37 derived from 3 3V supply Backlight 3 3V 045A Color U48 derived from 3 3V supply Mono EL backlight drive built into LCD module Audio 3 3V BA Switched LDO from Vbatt_wall Beeper Audio amperes 5V 2A System 5V Main Battery The CK30 battery pack uses two Li Ion 18650 cells with a capacity of 2200mAh The cells are arranged in series for
11. full page Burst length 4 CAS lat 2 CAS lat 2 Sequential burst Sequential burst PCI Bus Mastering CK30 Handheld Computer Service Manual 71 Chapter 4 Theory of Operation 72 SDRAM Densities The SDRAM controller in the current version of the FPGA code supports 64Mbit 128Mbit and 256Mbit SDRAM densities The current CK30 configurations use 128Mbit and 256Mbit parts but the main board is designed to support up to 128MB using 512Mbit parts If system SDRAM is expanded to this size the FPGA SDRAM controller will require some modification to handle the 512Mbit density correctly Shared SDRAM Partition Also 128MB SDRAM straddles two of the PXA255 SDRAM partitions 0 and 1 But the PXA255 shares only Partition 0 with alternate bus masters like the FPGA So if CK30 SDRAM is expanded to 128MB the FPGA SDRAM controller is only able to transfer data to and from Partition 0 so the Ethernet and radio drivers have to ensure that the SDRAM buffer areas they use are always in Partition 0 Mini PCI Arbitration The bridge provides round robin arbitration among PCI slots This feature is not used in the CK30 since it has only one PCI slot but may play a role in future products that may have two slots A separate arbiter is provided to arbitrate between the PCI interface and the scanner interface also implemented in the FPGA This arbiter always gives priority to the scanner interface since missed frames of scanner data especially 2D ima
12. 25 machine screw P N 590870 001 Torx 4 20 x 625 self tapping screw P N 590872 001 Phillips flathead 4 40 x 875 screw P N 591882 001 To open the computer 1 Press Yo to turn off the CK30 amp 2 While holding the CK30 in one hand use your thumb to pull down on the Follow ESD Procedures 3 4 battery latch and pull the battery away from the computer Remove the six Torx screws four self tapping and two machine and the four Phillips screws from the bottom cover of the CK30 Screw 4 pesen Screw 3 2 places Screw 2 places B Screw ge 2 places Slowly open but do not entirely separate the top and bottom covers Be careful not to detach any connections from the main printed circuit board PCB CK30 Handheld Computer Service Manual 9 Chapter 2 Replacing Parts 5 Remove the scanner or imager flex cable from the main PCB 6 Disconnect the trigger reed switch cable from J4 on the main PCB The top and bottom covers are now separated y Scanner or imager flex cable Trigger reed switch cable 7 Lay both covers down so that the exterior sides face down Replacing the 802 11b g Radio and Antenna 10 de Follow ESD Procedures To replace the radio and antenna you need the following tools and parts T10 Torx screwdriver e Small Phillips screwdriver e Antenna cable remover P N 591802 001 e 2 4 GHz single feed antenna assembly P N 073360S 003 e Mini PCI r
13. FLASH_PROT SCAN_IRQ DONE CF_PWR_EN PCI_PWR_EN FPGA_PGM FPGA_PWR_EN TOUCH_IRQ Signal Description System resume interrupt from Bluetooth module This is a maskable resume source See Note 1 Enabled when you select system wakeup from Bluetooth wakeup event System resume interrupt from USB or dock serial interface Although this pin can be configured as a system wakeup interrupt it is duplicated on GPIO1 so that it will still function even after a low battery event like a battery change It is not necessary to use this bit as anything other than a run time host detect interrupt System resume interrupt from Mini PCI or CF radio This is a maskable resume source See Note 1 Enabled when you select system wakeup from a Mini PCI radio power management event SD slot card detect This is a maskable resume source See Note 1 It can be enabled to wake the system when an SD card is plugged in This is not a CK30 requirement and is not supported SD slot interrupt CF slot interrupt not used on CK30 CF slot card detect not used on CK30 Low batt or batt removed interrupt Software should start an orderly Suspend immediately This is not a resume source System flash write protect This should be left in the protected state and set high only when an intentional flash erase or write cycle must take place Scanner interface interrupt During FPGA download this doubles as the FPGA
14. 5 chip selects HCR PCI_CS and FPGA_CS Both chip selects are set up as Variable Latency IO areas The FPGA also combines these chip selects with the PWE strobe to create the write strobes for HCR registers U11 and U16 For this reason U11 and U16 cannot be written to until the FPGA is downloaded Clock Source As noted in System Clocks on page 41 the clock source for the FPGA is FPGA_CLK the 49 77MHz SDCLK2 output from the PXA255 Scanner I F Internal buffered versions of FPGA_CLK directly clock the count gathering logic scanner control state machine FIFOs and DMA buffer Another clock domain exists on the scanner interface side of this logic because of the 13 5MHz PIXCLK on the 2D imager PCI Bridge Because the bus interface side of the PCI bridge includes an SDRAM controller skew must be minimized between the internal 49 77MHz clock and SDCLK also 49 77MHz when the FPGA owns the bus This minimization is done by bringing out a copy of SDCLK CLK_OUT delaying it through a trace of length equal to the SDCLK run from FPGA to SDRAM and bringing it back as feedback into one of the FPGA internal DLLs Delay Locked Loop to de skew FPGA_CLK The 24 885MHz PCI bus clock output PCI_CLK is derived divide by 2 from this de skewed FPGA_CLK The LogiCore PCI interface used in the bridge is clocked from this external PCI_CLK rather than from an internal copy of it so that the bridge sees the same clock as the PCI card As w
15. Mini PCI device may assert PCI_PME interrupts B3 Off No power PCI_CLK is stopped in low state The Mini PCI device may assert PCI_PME interrupts The PCI bridge is shut down Mini PCI Slot Sideband Signals None of the Mini PCI sideband signals are supported AC97 interface 802 3 Ethernet data and LED signals modem Tip and Ring analog audio inputs and outputs On Pilot and early production boards one of the Mini PCI GND pins pin 114 is not grounded on the main PCB but is instead routed to a PXA255 GPIO input GPIO9 to serve as a card detect If the signal is low a card is installed This was never used and was removed in later PCB revisions CK30 Handheld Computer Service Manual 73 Chapter 4 Theory of Operation 802 11b g Radio 10 100Mb Ethernet Scanners 74 802 11b and 802 11g are supported through an Actiontec 802MIG2 Type 3A Mini PCI card based on the Intersil Prism GT chipset The 802MIG2 is a flashless card it has a small EEPROM for parameters like MAC address but there is no flash holding a firmware image Instead the firmware is downloaded to the card from CK30 system flash by the radio driver at boot time and on resume This radio is a bus mastering device It does not rely on interrupting the PXA255 to have it transfer data to and from the card Instead when it needs to transfer data to and from system SDRAM it initiates its own read and write transactions on the Mini PCI bus to the targe
16. OFF ON when so configured default is OFF OFF OFF OFF OFF OFF CK30 Handheld Computer Service Manual Computer suspended Main battery out ON OFF ON OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF Chapter 4 Theory of Operation Critical Shutdown Type Comments 2 e Additional power states may be supported depending on installed card 2 2 1 1 Only on models with 10 pin scan port option l Power may be left on in Suspend for tethered scanner support 1 Module supports additional power states 1 1 1 1 Codec supports standby state 57 Chapter 4 Theory of Operation 58 Device Power Control Peripheral devices both internal and external to the PXA255 are enabled and disabled under software control External devices also have hardware shutdown features to cut their power quickly in a critically low battery situation low battery hardware detect has tripped In normal suspends power to these devices is turned off under software control These devices fall in 2 categories depending on whether their functions can tolerate sudden removal of power without time for software to clean up See Critical Shutdown Type column in the Device Power States table on the previous page Both types include devices that may optionally be left on during Suspend Regardless of shutdown type those devices must be dumped immediately if the battery goes
17. S Aene praia a da 93 Debug Bota cuello aera e E e a Ea s 94 Firmware Upgraden id a e a Ed ave Ac 95 B gtloader usa e enaa A E a E ETE EEES TNS 95 OS Tima ges di a E ae EE aa e aa E Aee ANOTE R E e RE 95 In System Programmability of Programmable Devices n se 96 ACC ld 96 Conimectot Pl ie UI ii 96 ADT l Bay Communications Dot ans 99 AD2 4 Bay Communications Dock cnoroniioincnsinesgtaroentans peayenasscontonssncensecsasvens 100 CK30 Handheld Computer Service Manual v Contents ACI 4 Slot Battery Chargersin iaa 101 ACTA Bay Chato Docs lies Dista eli lll 102 vi CK30 Handheld Computer Service Manual Before You Begin Before You Begin Safety Summary This section provides you with safety information technical support information and sources for additional product information Your safety is extremely important Read and follow all warnings and cautions in this document before handling and operating Intermec equipment You can be seriously injured and equipment and data can be damaged if you do not follow the safety warnings and cautions Do not repair or adjust alone Do not repair or adjust energized equipment alone under any circumstances Someone capable of providing first aid must always be present for your safety First aid Always obtain first aid or medical attention immediately after an injury Never neglect an injury no matter how slight it seems Resuscitation Begin resuscitation immediately if someone is injur
18. TPERXN Description 5V USB bus power Used for USB wakeup USB Data USB Data Ground 97 Chapter 4 Theory of Operation 26 pin JAE Interface Connector Pin No 1 2 N ANH WN AQ 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 98 Signal Name GND VCC_EXT 5V TXD RTS DTR RXD CD CTS DSR VIDEO SOS TETH_SCAN GND GND TRIGGER LASEN BEEP GOODREAD VBUS UDC UDC TX TX RX RX GND 1 O to Terminal O fey O Description Ground External 5V 500 mA maximum output RS 232 TXD RS 232 RTS RS 232 DTR RS 232 RXD RS 232 DCD ActiveSync wakeup RS 232 CTS RS 232 DSR DBP from tethered undecoded scanner Start of scan from tethered undecoded scanner Active low input used to indicate an external scanner connection Ground Ground Trigger input from tethered undecoded scanner Laser enable output to tethered undecoded scanners Beep output to tethered undecoded scanner Good Read output to tethered undecoded scanners USB Wake up 5V power from USB host USB DATA Client USB DATA Client Ethernet TPETXP Ethernet TPETXN Ethernet TPERXP Ethernet TPERXN Ground CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation AD1 1 Bay Communications Dock The AD1 charges a single CK30 battery while on the unit It also provides a DB9 male connector for serial communications a
19. Wand emulation mode using only the DBP signal used by scanners with built in decode The CK30 platform uses the main processor to decode bar code information from undecoded 1D laser 1D CCD and CMOS based imagers and 2D imager input devices The interface also supports serial output decoded scanners CK30 Handheld Computer Service Manual 75 Chapter 4 Theory of Operation Scanner Interface Scanners are interfaced through two scanner ports on the CK30 main PCB e 22 pin vertical ZIF connector J2 supports the 12 and IT4000 2D imagers and may later be used on the EL10 Micro mirror laser The signal set is as defined by HHP for the IT4000 imager e 16 pin vertical ZIF connector J3 supports all the remaining scan engines and a 10 pin Stewart connector for tethered scanner support The signal set supports traditional laser interface signals plus SPI and new signals defined for the EV10 and EL10 scanners Because of the wide variety of scanners supported by the CK30 the interface signals are heavily reused The next table shows how the various scanners use the scanner interface signal set Blank fields mean the scanner does not use that signal Using the Scanner Interface Signal Set Part 1 Signal Name SCAN_PWR_EN ILLUM_LASEN_RTS SCAN_FLASH_EN SOS DBP Video SPEED RANGE GDRD 76 Source Destination U11 out FPGA_IO U11 out FPGA in FPGA in FPGA out 2D Imager usage Enable scanner
20. a nominal voltage of 7 23 VDC and charging voltage of 8 4V V to Unit Pin 3 Pin 6 Ground A AS I Charge Pin 4 Pin 5 Ground z Pin 2 AB1 Battery Pin Outs Main Battery Charging The CK30 itself contains no battery charging circuit Instead the charging circuitry resides in the charging accessory the AC1 4 bay charger or the AD1 AD2 or AC2 dock The battery may be charged either by itself in an AC1 or while installed in a CK30 in an AD1 AD2 or AC2 dock 52 CK30 Handheld Computer Service Manual Supercap External Power Chapter 4 Theory of Operation The charging current is applied through the contacts on the base of the battery the 26 pin dock connector is not used for charging See AD1 Charging on page 99 for details on the charging circuit in the dock A 10 farad 2 5V supercap C89 provides backup current to hold the machine state while the main battery is being replaced If the battery is removed without first suspending the CK30 a fully charged supercap can provide enough current to run the CK30 at full power for up to 1 second as it suspends and still maintain the machine state for up to 10 minutes at 25 C The supercap voltage is boosted to 3 2V by switching converter U44 and routed to the main 3 3V bus Switcher U44 is always on but draws very little current as long as the main 3 3V
21. addition when the system is suspended PWR_EN is low and scanner power is configured to be left on the SCAN_TRIG and DOCK_TRIG signals can generate a system wakeup interrupt through PXA255 GPIO1 See Resume Events on page 65 The SCAN_TRIG and DOCK_TRIG signals can also be driven by software as open drain outputs from the FPGA to an external tethered scanner but this is not implemented in the current software Scanning and Good Read Indication Dock Interface The green Good Read indicator above the LCD display is controlled by software through a register in the FPGA which drives LEDs D3 and D23 through NPN Q5 Software sets the LED intensity high by driving SCAN_LED_LOW low through the same FPGA register bypassing LED current limiting resistor R133 The Scanning Good read indicator on a tethered scanner is driven separately either by the scanner itself or through the SPEED_RANGE_GDRD signal from the FPGA The CK30 uses a 26 pin JAE docking connector in the base of the computer to provide RS 232 USB Ethernet batch option only and scanner interfaces CK30 Handheld Computer Service Manual 87 Chapter 4 Theory of Operation Dock Interface Signal Descriptions Pin Own Oo KR D 0 88 Signal Name TxD RxD RTS CTS DCD DTR DSR USB_ D USB_D USB_5V 5 VDC GND TETH_DBP VIDEO TETH_SOS TRIGGER LASEN DECODE BEEP Description Serial data output to dock PXA255 FF UAR
22. against corruption through three mechanisms e A software controlled block is locking within the parts themselves e PXA255 GPIO11 FLASH_PROT must be set high by software to allow writes e PXA255 output RESET_OUT holds the flash in a low power write protected state during Suspend CK30 Handheld Computer Service Manual 1 0 Signals Chapter 4 Theory of Operation Platform specific peripheral control input and output signals are implemented through PXA255 GPIO pins FPGA U8 I O pins and through HCR registers U11 and U16 In general signals are assigned among these devices according to these criteria PXA255 Used for signals that must hold their state through outputs Suspend and should not immediately be disabled on a critically low battery event PXA255 inputs Used for interrupts that may need to wake the system from Suspend HCR outputs Used for peripheral enable signals that must hold their state through Suspend but can and should be immediately dumped on a critically low battery event FPGA I O Used for I O that need not function during Suspend and can default to their inactive states during Suspend As much as possible the signals assignments are the same as in the 700C class products in order to maximize code re use See 609918 CX HW SW Interface SRS for more detailed information PXA255 GPIO Signal Descriptions PXA255 GPIO Can wake processor from Sleep state GPO GP1
23. backlight on and off through HCR register U16 signal BKLT_ON The monochrome display uses an EL backlight with drive circuitry built into the display module The color display uses a white LED backlight driven by backlight driver U48 Since U48 is stuffed on all PCB assemblies gate U27 senses when a monochrome display is installed and disables U48 for power savings Backlight High Low intensity control supported on the white LED backlight only is controlled through HCR register U11 signal BKLT_LOW using U48 RSET pin The CK30 computer supports replaceable keypads of up to 63 keys plus a handle trigger arranged in an 8 x 8 matrix scanned from the PXA255 processor Currently three keypad styles are defined 42 key 50 key and 52 key The keypad itself is a low profile elastomeric keypad with conductive carbon pucks similar to the M90 keypad It is adhesively attached to the top surface of the CK30 top cover and connects to the main PCB connector J11 through a hole in the top cover This facilitates keypad replacement in the field Keys are arranged in an 8 x 8 matrix Row Column position 0 0 is reserved for the handle trigger reed switch which connects to the main PCB through connector J4 The eight column lines KEY_DRV7 0 are driven from PXA255 GPIO pins GPIO73 GPIO66 configured as open drain outputs The 8 return row lines KEY_RET7 0 are pulled up through 10K resistors and monitored through the FPGA The FPGA incorporates a m
24. board described in Field Access Debug Port on page 93 PSC PIC The flash based firmware in the Power Supply Controller may be reprogrammed using proprietary programming tools from Microchip ProMate II programmer with an AC004004 adapter module and MPLAB development environment software The programming signals are accessible through debug port P1 using the 073048 JTAG board described in Field Access Debug Port on page 93 All of the docks chargers use the same Texas Instrument L ion charging chip BQ2954 In regards to charging the only difference between all of these accessories is the amount of charge current The power supply lump 073573 is also common to all docks and chargers The lump supplies up to 4 15A 12 VDC Male DB9 Serial Connector Pin No Signal Name 1 0 to Terminal Description 1 DCD I Data Carrier Detect 2 RXD I RS 232 RXD 3 TXD O RS 232 TXD 4 DIR O RS 232 DTR 5 GND Ground 6 DSR I RS 232 DSR 7 RTS O RS 232 RTS 8 CTS I RS 232 CTS 9 N C CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation 8 pin RJ45 Ethernet Connector Pin No ON DW KR WO NHN Type B USB Pin No 1 CK30 Handheld Computer Service Manual Signal Name TX TX RX N C N C RX N C N C Connector Signal Name VBUS UDC UDC GND 1 O to Terminal O O I 1 O to Terminal I I O 1 0 Description Ethernet TPETXP Ethernet TPETXN Ethernet TPERXP Ethernet
25. bracket 072864 001 5 Small engine scan window 073061 001 6 EV10 scan flex cable 072782 002 Phillips 4 20 x 250 thread form screw 525023 Steel Phillips M1 6 x 3mm screw 591883 001 34 CK30 Handheld Computer Service Manual Chapter 3 Spare Parts List and Exploded Views 1T4000 Imager Assembly Exploded View This illustration shows the IT4000 imager assembly in relation to the bottom cover To identify a part find the part in the exploded view and locate its callout in the following spare parts list Screw 3 places g IT4000 Imager Assembly Spare Parts List To identify a part find the callout in this list and locate the part in the previous exploded view Callout Description Part Number 1 IT4000 imager assembly 073416S 001 2 IT4000 scanner window assembly 073655 001 Phillips 4 20 x 250 thread form screw 525023 CK30 Handheld Computer Service Manual 35 Chapter 3 Spare Parts List and Exploded Views Tethered Scan Flex Assembly Exploded View This illustration shows the tethered scan flex assembly in relation to the bottom cover To identify a part find the part in the exploded view and locate its callout in the following spare parts list Screw 2 places 8 Screw gi 4 places Tethered Scan Flex Assembly Spare Parts List To identify a part find the callout in this list and locate the part in the previous exploded view Callout Description Part Number 1 Tethered scan flex assembly 07278
26. critical or is removed while the system is suspended Type 1 Type 1 devices are those whose power can be cut immediately on a critically low battery event These are generally non essential loads for example the display backlight that can be dumped right away to reduce the load on a critically low main battery or on the supercap if the main battery is being removed These loads are controlled through external hardware control registers HCRs U11 and U16 Ina critical battery situation signal BATT_FAULT_IRQ is driven low by comparator U36 Through U52 and U53 this asserts signal HCR_DISABLE which forces U11 and U16 outputs to High Z Pull ups and pull downs on these outputs then return the devices to their default off state Battery State System State HCR Outputs Device Power OK Not important Low Z Controlled by software Critical Not important High Z Off Type 2 Type 2 devices are those whose power cannot be cut immediately on critically low battery event These are loads that could cause data corruption if their power is removed before software can shut down cleanly for example the SD slot but that must be powered down right away on a critically low main event once the system is suspended These are kept powered as long as the PXA255 is awake so that their device drivers can complete any critical operations and then shut down cleanly These loads are controlled through PXA255 GPIO registers so that they will not automati
27. download done indication This is not a resume source Power enable for CF slot or Mini PCI slot Clear FPGA in preparation for download Power enable for scanner I F and Mini PCI FPGA Pen down interrupt from touch panel not used on CK30 Usage PXA255 input 4 interrupt PXA255 input interrupt PXA255 input 4 interrupt PXA255 input 0 no card 1 card installed PXA255 input 4 interrupt PXA255 input Y interrupt PXA255 input 0 card installed 1 no card PXA255 input 4 interrupt PXA255 output 0 disable writes 1 enable writes PXA255 input 4 interrupt T download done PXA255 output 0 slot power on 1 slot power off Pulse low to start program process 0 FPGA power on 1 FPGA power off Y interrupt Note 1 Maskable resume sources These resume events are automatically disabled by a low battery event like a battery change and must be re enabled by software when appropriate 44 CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation PXA255 GPIO Signal Descriptions continued PXA255 GPIO GP32 GP38 GP48 GP66 GP67 GP68 GP69 GP70 GP71 GP72 GP73 GP79 GP80 Function SDMMC_WP HCR_OE POE PCI_IRQ KEY_DRVO KEY_DRV1 KEY_DRV2 KEY_DRV3 KEY_DRV4 KEY_DRV5 KEY_DRV6 KEY_DRV7 PCI_SPARE SD_PWR_EN Signal Description SD slot write protect HCR registers output enable This signal floats
28. high going transition on GPIOS is interpreted as a card insertion and a low going transition as a card removal CK30 Handheld Computer Service Manual 91 Chapter 4 Theory of Operation Beeper 92 Connector J17 is modified with a retainer clip to hold the card in place during a drop and a debounce plate assembly that increases the contact force on the card to minimize contact bounce during drop Unfortunately the added contact force tends to defeat the slot s normal push push card latching mechanism making the card difficult to remove CK30 audio tones are simple square wave tones generated by one of the PXA255 s 2 Pulse Width Modulators Tone duration is software controlled based on OS timer ticks The 3 3V PWM output signal BEEP is first divided down through a crude volume control formed by resistors R126 through R129 The 3 base legs of the resistive divider are driven by open drain outputs of FPGA U8 so that the divide ratio can be set to 1 of 8 levels under software control The resistor values are chosen so that software could select at least 4 levels out of the 8 possible combinations that roughly approximate a logarithmic volume scale The scaled square wave is AC coupled to audio amplifier U19 which drives 2 side emitting 8 ohm electromagnetic transducers wired in parallel and mounted on a small PCB embedded in the display shock mount U19 is a push pull amplifier powered from the 5V rail to maxim
29. possible solutions in order The keypad interface may have a failed row column connection Or the keypad flex cable or keypad may be damaged For help see the Replacing the Keypad Assembly procedure on page 20 The main PCB assembly keypad interface may have failed For help see the Replacing the Main PCB procedure on page 15 Try these possible solutions in order The display assembly may be damaged For help see the Replacing the Display Assembly procedure on page 18 The main PCB assembly display interface may have failed For help see the Replacing the Main PCB procedure on page 15 CK30 Handheld Computer Service Manual Chapter 1 Troubleshooting Troubleshooting the CK30 continued Problem Solution Nothing is displayed on the Try these possible solutions in order screen The contrast may be set too light or too dark Press D and then repeatedly until you reach the desired contrast level If you have a CK30 with a color screen make sure the backlight is on by pressing 4 The display flex cable may be disconnected Make sure the display flex cable is connected to the display assembly and the main PCB The display assembly may be damaged For help see the Replacing the Display Assembly procedure on page 18 The main PCB assembly display interface may have failed For help see the Replacing the Main PCB procedure on page 15 Backlight does not wor
30. replaced Implementation Yes No Not supported in current software Yes Not supported in current software A tethered scanner left powered during Suspend can pull the SCAN_TRIG signal or DOCK_TRIGS if it is connected through the dock port low on a trigger pull The signal propagates through combinatorial logic U22 U28 U31 and U54 to flip flop U57 which ensures even narrow pulses trigger the PXA255 GPIO1 edge detect logic Yes Not supported in current software These all reside on Row 0 of the keypad matrix KEYRETO which is Yes routed to PXA255 GPIO1 as well as to the FPGA Each of these keys is enabled as a resume source by driving its keypad column line low on Yes Suspend A key closure then pulls GPIO1 low waking the system Yes Not supported in current software Serial port DCD and USB_WAKE divided down from the 5V supplied by a USB host are OR d together by U24 RC filtered and Yes differentiated by RC pair C180 R321 to present a high going pulse on signal DOCK_WAKE This goes through the same combinatorial logic as the tethered scanner signals described above waking the system through PXA255 GPIO1 No Not supported in current software PCI_PME from the Mini PCI card bypasses the FPGA PCI bridge which is powered down in Suspend and wakes the system through PXA255 GPIO4 No Not supported in current software The serial data signal from the Bluetooth module BT_RXD is routed to PXA255 GPIO2 which is set to
31. the CK30 is not in use Make sure that the AD1 or AD2 communications dock is working correctly If the communications dock is damaged replace it You may have a damaged main battery Replace the main battery Try these possible solutions in order The Ethernet communications parameters may not be set correctly Make sure the Ethernet communications settings are set correctly for the network Make sure that the AD1 or AD2 communications dock is working correctly If the communications dock is damaged replace it The Ethernet cable may be disconnected or damaged Make sure the cable is connected If damaged see the directions in Replacing the Ethernet Card on page 12 to replace the Ethernet cable The Ethernet card may be damaged For help see the Replacing the Ethernet Card procedure on page 12 The mini PCI interface or serial connector may have failed on the main PCB For help see the Replacing the Main PCB procedure on page 15 Try these possible solutions in order Make sure that the handle works by trying it on a known good CK30 Make sure the trigger reed switch cable is plugged into the main PCB assembly and is not damaged Replace the trigger reed switch assembly if necessary The trigger reed switch interface on the main PCB may have failed For help see the Replacing the Main PCB procedure on page 15 Chapter 1 Troubleshooting Troubleshooting the CK30 continued Prob
32. too out of focus to attempt a decode See 630063 Andromeda Imager Host Interconnect Architecture Spec for more detail on this scanner interface 1D MDS Scanner Interface Internal scanners using the MDS interface currently only the EV10 are handled through an SPI interface in the FPGA This is a future addition that is not yet covered in this document Serial RSTTL Scanner Interface Internal or tethered scanners with built in decode are typically supported using an asynchronous serial interface RSTTL or RS 232 at TTL signal level 82 CK30 Handheld Computer Service Manual Scanner Power Tethered Scanners Chapter 4 Theory of Operation Standard asynchronous serial signals TxD RxD RTS and CTS are multiplexed onto the 10 pin scanner connector as shown in the Tethered Scanner Signal Descriptions table on page 84 and routed through the FPGA SCAN_RTS and SCAN_CTS are accessed by software through memory mapped FPGA registers when the FPGA scanner interface is configured for serial scanners SCAN_TXD and SCAN_RXD are routed through the FPGA to the ST UART on the PXA255 The operating system maps this UART as COM3 3 3V and 5V scanner power is controlled through HCR register U11 output SCAN_PWR_EN The 22 pin scanner port supports only 3 3V scanner power The 16 pin scanner port supports both 3 3V and 5V power SCAN_PWR_EN switches both supplies on and off simultaneously through high side switches U12
33. 0 5250 42 key bezel assembly P N 073299 001 e CK30 ANSI 42 key bezel assembly P N 073300 001 e CK30 programmable 50 key bezel assembly P N 073293 001 e CK30 international 50 key bezel assembly P N 073294 001 e CK30 3270 5250 50 key bezel assembly P N 073295 001 e CK30 ANSI 50 key bezel assembly P N 073296 001 e CK30 programmable 52 key bezel assembly P N 073289 001 e CK30 international 52 key bezel assembly P N 073290 001 e CK30 3270 5250 52 key bezel assembly P N 073291 001 e CK30 ANSI 52 key bezel assembly P N 073292 001 To replace the bezel assembly 1 Separate one of the top corners of the CK30 overlay from the top cover 2 Pull up on the overlay until you have completely separated the overlay surrounding the display from the top cover 3 Using the top part of the overlay as a handle pull up until you start to pry up a corner of the keypad bezel CK30 Handheld Computer Service Manual 17 Chapter 2 Replacing Parts Once a corner of the bezel is loose gently pull up on the bezel to remove it Remove the adhesive residue left on the top cover from the bezel assembly Separate the adhesive strip from the back of your new bezel assembly Insert the keypad bezel end of the assembly snap it into place and then press down firmly on the overlay surrounding the display to attach the bezel assembly to the CK30 top cover Replacing the Display Assembly To replace the display assembly you need the fol
34. 072857 002 072859 002 072858 003 073297 001 073298 001 073299 001 073300 001 073293 001 073294 001 073295 001 073296 001 073289 001 073290 001 073291 001 073292 001 855 050 001 073497 002 072291S 006 072926S 007 073155 001 073382 001 073360S 003 072861 001 072863 001 073038 001 ABI The Bluetooth module is an option available on all models of the CK30 The Mini PCI radio assembly is only available on the CK30B and CK30C CK30 Handheld Computer Service Manual 31 Chapter 3 Spare Parts List and Exploded Views Ethernet Card Assembly Exploded View This illustration shows an exploded view of the Ethernet card assembly To identify a part find the part in the exploded view and locate its callout in the following spare parts list The Ethernet card is only available on the CK30A Screw 2 places Screw E y 2 places Ethernet Card Assembly Spare Parts List To identify a part find the callout in this list and locate the part in the previous exploded view Callout Description Part Number 1 Ethernet cable assembly 073096 001 2 Ethernet card assembly 073867 001 3 Mini PCI shield assembly 073382 001 Plastite flathead 2 28 x 250 screw 800 193 000 32 CK30 Handheld Computer Service Manual Chapter 3 Spare Parts List and Exploded Views SE1200 Scan Engine Assembly Exploded View This illustration shows the SE1200 scan engine assembly in relation to the bottom cover To identify a par
35. 1 Chapter 4 Theory of Operation Horizontal DBP_HSYNC and vertical SOS_VSYNC sync pulses from the scanner mark the start of lines and frames respectively The 8 bit pixel data is collected in a 32 deep FIFO which in turn feeds a 16 deep 32 bit wide DMA buffer When the DMA buffer is half full the FPGA asserts SCAN_DREQ to the PXA255 to request a DMA transfer and 8 32 bit words are direct memory accessed into a cached area of system SDRAM for decoding Although the imager resolution is 640x480 it actually sends 525 lines of 852 bytes per line Counters in the FPGA track when the first valid line and column bytes arrive so only valid data is sent to the FIFO The Blur Detect Exposure Sense block in the block diagram represents 2 special logic functions in the FPGA e Averaging logic This logic calculates the average pixel value over 2 rectangular regions of the image one 256x256 and one 256x64 The average pixel values are read by software through registers in the FPGA and used to adjust the scanner illumination If the optimum exposure can t be achieved through illumination software then adjusts the imager s integration time via 12C commands e Horizontal Focus Factor This logic performs a rolling sum of squares of deltas between adjacent pixels in a line to determine if the image is blurred from movement This result is read by software through a register in the FPGA to decide if the captured image is
36. 1 is included as an alternate stuffing option for a 3 6864MHz clock source Its 3 3V output is divided down through R11 and R198 to match the core voltage of the CPU approx 1 30V The oscillator is shut down during Suspend by the PWR_EN signal The major system clocks are all derived from the PXA255 3 6864MHz oscillator and its associated PLL CPU core 99 5MHz at boot time and resume Boot code then sets it to 199MHz CK30AA and CK30BA In the case of the CK30CA the boot code sets the CPU in Turbo mode doubling its speed to 398MHz CPU internal bus 99 5MHz SDCLK SDRAM clock 49 77MHz at boot time and resume Boot code then sets it to 99 5MHz An Automatic Power Down APD power saving feature in the PXA255 memory controller is used to turn this clock off when SDRAM is not being accessed FLASH_CLK 49 77MHz synchronous flash clock This clock defaults off at boot time and on resume and is enabled by boot code only if the installed flash parts are identified as K3C synchronous flash Boot code then initializes the memory controller to enable synchronous mode CK30 Handheld Computer Service Manual 41 Chapter 4 Theory of Operation Memory 42 FPGA_CLK 49 77MHz Enabled immediately before FPGA download FPGA_CLK serves both the scanner interface and Mini PCI bridge resident in the FPGA Audio Codec sampling in computers equipped with audio is based on the audio codec local 24 576MHz oscillator RAM U6 and U7 constitu
37. 2 screw P N 590371 001 Torx 4 40 x 25 machine screw P N 590870 001 Torx 4 20 x 625 self tapping screw P N 590872 001 Phillips flathead 4 40 x 875 screw P N 591882 001 To close the computer 1 Connect the trigger reed switch cable to J4 on the main PCB o d 2 Connect the scanner or imager flex cable to the main PCB Make sure you completely insert the scan flex cable up to the white alignment mark FollowESD 3 Carefully close the top and bottom covers Make sure that the cables are not Procedures pinched between the two covers CK30 Handheld Computer Service Manual 27 Chapter 2 Replacing Parts 4 Replace the six Torx screws four self tapping and two machine and tighten to 9 in lb 5 Replace the four Phillips screws and tighten to 2 to 3 in lb Screw 4 peses Screw 9 2 places Screw 2 places 8 Screw ge 2 places 6 While holding the CK30 in one hand insert the tabs on the bottom of the battery into the CK30 and snap the battery into place 28 CK30 Handheld Computer Service Manual Spare Parts List and Exploded Views This chapter provides the exploded views and spare parts list for the CK30A CK30B and CK30C handheld computers CK30 Handheld Computer Service Manual 29 Chapter 3 Spare Parts List and Exploded Views CK30 Exploded View This exploded view contains parts for the 802 11b g radio version of the CK30 To identify a part find the part in the exploded view a
38. 2MIG2 radio not connected to AP CK30CA only CPU at 400MHz Idling at splash screen color display backlight off not scanning Actiontec 802MIG2 radio not connected to AP Only CK30CA will be run in this mode While the computer is turned on the Idle Run and Turbo states are transparent to you The operating system handles switching among these states Note that current consumption varies greatly with processing load especially if a radio card is installed Values shown assume the CK30 has just completed a cold boot CK30 Handheld Computer Service Manual 55 Chapter 4 Theory of Operation Running Soft cold boot command 1 O key OR main battery lo I O key down 5 sec main battery critically low OR removed wan Resume main succeede batt out A Normal Suspending Y Y N Suspend A E failed Warm booting Cold booting N 2 pa 7 Resuming N A Reset switch pressed A Y Suspend successful 1 0 key down 5 seconds Y Ho Suspending HCRs off Pen failed Suspend successful 1 0 key doWn Main batt Oh AND Reset switch pressed AND VO key OR peripheral resume interrupt Main batt OK Main batt dead AND n supercap New Main ba dead installed Increasing power consumption of static states Static States Transiti
39. 5 is always the host the PSC is always a slave device at address 0x12 The following 12C bus protocol is used to send commands to the PSC and read data back All commands to the PSC are 1 byte long The PSC echoes back the command byte followed by a single data byte Host sends Start Slave ADDR write pa CMD1 CMD2 CMDn Start Slave ADDR read pag Where tacx ACK from PSC PSC responds CMD1 ack DATA1 ack CMD2 ack DATA2 ack CMDn ack DATAN nak CK30 Handheld Computer Service Manual 59 Chapter 4 Theory of Operation Where cx ACK from PXA255 inak NAK from PXA255 Hex Command Return Data 0x10 SetLowBatLED 0x10 0x11 ClearLowBatLED 0x11 0x12 PSCSoftwareVer 0x12 PSC firmware version byte 0x30 ReadMainBatVoltage 0x30 main battery voltage byte 0x40 ReadSuperCap Voltage 0x40 supercap voltage byte 0x50 ReadTemperature 0x50 temperature byte Ox5A PSCTest 0x5A 0x60 ColdBoot 0x60 0x61 WarmBoot 0x61 0x70 SuperCapChargeEnable 0x70 0x71 SuperCapChargeDisable 0x71 0x80 StartLowBatLEDFlash 0x80 0x81 StopLowBatLEDFlash 0x81 Several commands can be issued in a single burst before the host 2C driver attempts to read return values back from the PSC Examples W Write R Read A Ack N Nak A typical battery supercap temperature status request Start 12 W A 30 A 40 A 50 A Start 12 R A 30 A 95 A 40 A E1 A 50 A 56 N Stop
40. 6 004 2 Tethered scanner door 073366 001 3 Tethered scanner cover 073179 001 4 Tethered mount 073178 001 Steel Phillips 2 56 x 3 16 screw 591884 001 Phillips 2 28 x 250 thread form screw 525301 36 CK30 Handheld Computer Service Manual Chapter 3 Spare Parts List and Exploded Views Safety Labels Exploded View This illustration shows the location of the safety labels To identify a part find the part in the exploded view and locate its callout in the following spare parts list Safety Labels Spare Parts List To identify a part find the callout number in this list and locate the part in the previous exploded view Callout Description Part Number 1 Certification label set Bluetooth batch 073731 001 Batch 073732 001 803 with Bluetooth and radio 073320 002 804 with Bluetooth and radio 073702 002 805 with Bluetooth and radio 073706 001 808 with Bluetooth and radio 073708 001 P Warning laser label 073322 001 Blank warning laser label 073325 001 3 Aperture laser label 073321 001 Print on demand label set 073312 001 5 Microsoft license label 490 005 002 CK30 Handheld Computer Service Manual 37 Chapter 3 Spare Parts List and Exploded Views 38 CK30 Handheld Computer Service Manual 4 Theory of Operation This chapter provides the theory of operation for the CK30 handheld computers and its supporting accessories CK30 Handheld Computer Service Manual 39 Chapter 4 Theory of Operation System Architectur
41. Function PSC_IRQ KEY_RETO WAKEUP Signal Description Usage Interrupt from PSC PIC Toggles system between Run and PXA255 input Suspend 4 interrupt This is an Always enabled resume source Computer on PXA255 input Keypad matrix Row 0 This is also available through the FPGA b interrupt Duplicated here so that the eight keys in keypad Row 0 are functional at boot time and can be set to wake the computer In both those instances the FPGA is powered down Computer suspended System resume interrupt from enabled keypad keys handle trigger or tethered scanner trigger dock port DCD or USB host present In this usage this pin is a wakeup interrupt only Reading its state yields no information about what resume event caused the interrupt This is an Always enabled resume source y The resume events combined on this input are events that may be expected to still wake the computer after a battery change when all resume pins except GPIOO and GPIO1 will have been automatically disabled by the PXA255 CK30 Handheld Computer Service Manual 43 Chapter 4 Theory of Operation PXA255 GPIO Signal Descriptions continued PXA255 GPIO GP2 GP3 GP4 GP5 GP7 GP8 GP9 Can wake processor from Sleep state GP10 GP11 GP12 GP15 GP21 GP22 GP27 Function BT_WAKEUP HOST_DETECT PME CF_STSCHG SDMMC_CD SDMMC_IRQ SOCKETO_IRQ SOCKETO_CD BATT_FAULT_IRQ
42. I bridge IP from NMI Ltd CK30 Handheld Computer Service Manual 69 Chapter 4 Theory of Operation Bus I F SD31 Bo sa25 gt SCAN_DREQ SCAN_IR Host CPU I F DaM3 p Jui nog as nwB OF OO nPWE Uy RD ng RDIWR es FPGA_GS 08 HcRIPCL s Z y BUS por ale OS d ACTH PME REG CLKRUN PCI PCI_IR IRQ CT INTA IDSEL A AD31 0 C BE 3 0 PARo Mini PCl Slot SERR FRAME SDCL IRDY ssp UL Bee SDRA SDRA DEVSEL Controllg RST BREQ BGh CLK_OUT PCLK DLL Em FPGA_C E o ou DLL PCI_CLK 2 CK30 FPGA Block Diagram PCI Bridge The bridge maps PCI bus memory IO and configuration space into PXA255 processor space in Memory Area 2 In this mode the PXA255 functions as the initiator reading data from and writing data to the target PCI card as a memory mapped device The bridge also incorporates an SDRAM controller so that it can function as an alternate bus master In this mode the PCI card is the initiator and the SDRAM in Partition 0 is the target 70 CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation SDRAM Controller When the PCI card initiates a PCI transaction to read data from system SDRAM or write data to it the PCI bridge raises the SA_BREQ signal to request the system bus from PXA255 When the PXA255 has completed any pending operations it raises SA_BGNT to signal the FPGA to take over the bus as an alternate bus
43. PCB assembly light pipe assembly speaker PCB assembly to the new display assembly 19 CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts 8 Insert the new display assembly into the top cover 9 Attach the display flex cable and the keypad flex cable to the main PCB 10 Replace the main PCB and secure it with the two Phillips screws removed in Step 3 11 Connect the power indicator good read light pipe assembly cable and the speaker PCB cable to the main PCB 12 Close the CK30 For help see Closing the CK30 on page 27 Replacing the Keypad Assembly To replace the keypad assembly you need the following tools e T10 Torx screwdriver e Small Phillips screwdriver You also need one of the following parts depending on the CK30 configuration e CK30 42 key keypad assembly P N 072857 002 CK30 50 key keypad assembly P N 072858 003 CK30 52 key keypad assembly P N 072859 002 e Keypad flex cable P N 073094 001 KA22 x 6 WN 1412 Elco screw 591825 001 To replace the keypad assembly 1 Remove the bezel assembly For help see Replacing the Bezel Assembly on page 17 2 Pry up one corner of the keypad assembly and carefully lift it away from the top cover being careful not to detach or damage the keypad flex cable 3 Disconnect the keypad flex cable from the keypad assembly 20 CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts Keypad assembly
44. PCB and gently separate the main PCB from the top cover 5 Detach the display flex cable and the keypad flex cable from the main PCB and remove the main PCB CK30 Handheld Computer Service Manual 15 Chapter 2 Replacing Parts o 10 11 12 13 14 16 Screw Te places Display flex cable Keypad flex cable Remove the Bluetooth radio if necessary For help see Replacing the Bluetooth Radio on page 13 Attach the new LCD support bar to the new main PCB X LCD support f bar If necessary Replace the Bluetooth radio Attach the display flex cable and keypad flex cable to the main PCB Insert the main PCB into the top cover and replace the two Phillips screws at the top of the main PCB Replace the radio and antenna assembly or the Ethernet card Connect the power good read indicator light pipe assembly cable and the display cable to the main PCB Close the CK30 For help see Closing the CK30 on page 27 Download and configure the CK30 using factory tool T45556 You will also need an SD card containing the CK30 operating system files CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts Replacing the Bezel Assembly To replace the bezel assembly you need one of the following parts depending on the CK30 configuration e CK30 programmable 42 key bezel assembly P N 073297 001 e CK30 international 42 key bezel assembly P N 073298 001 e CK30 327
45. R_CS Qn CK30 FPGA Block Diagram 2D Imager Interface The scanner is enabled and controlled from the PXA255 through memory mapped registers in the FPGA and octal register U11 see Using the Scanner Interface Signal Set on page 76 e SCAN_PWR_EN is asserted low to switch 3 3V power through high side switch U12 to scanner connector J2 This is done at boot or resume time and the scanner is left powered while the CK30 is on e SCAN_FLASH_ENY is asserted high to enable the scanner e ILLUM_LASEN_RTS is pulsed by a PWM circuit in the FPGA to control the scanner illumination e SCAN_TRIG is set high to enable the scanner s aiming beam This is alternated with scanner illumination flashes because current imager devices cannot handle the current draw of both being on at the same time At boot time and resume time the scanner is enabled using SCAN_PWR_EN and SCAN_FLASH_EN and its configuration registers are initialized through the system I2C bus The imager engine resides on the I2C bus as slave address 0x40 Normally when the scanner is not enabled it is isolated from the I2C bus by analog switch U34 so that a non powered scanner cannot drag down the 12C bus Asserting SCAN_FLASH_EN also asserts SCAN_I2C_EN connecting the scanner to the I2C bus While scanning the scanner sends 8 bit parallel pixel data to the FPGA over lines IMAGER_SD0 7 synced to a 13 5MHz IMAGER_PIXCLK CK30 Handheld Computer Service Manual 8
46. Remove the adhesive residue left by the keypad assembly on the top cover Remove the adhesive backing from the new keypad assembly Keypad assembly Adhesive backing C gt e Connect the keypad flex cable to the keypad assembly and firmly attach the keypad assembly to the top cover Make sure the keypad flex cable properly z folds under the main PCB Insert a new bezel assembly For help see Replacing the Bezel Assembly on page 17 Replacing the SE1200 Scanner To replace the SE1200 scanner you need the following tools T10 Torx screwdriver Small Phillips screwdriver You also need one or more of the following parts depending on what you need to replace SE1200 standard range scan engine assembly P N 590014 004 SE1200 advanced long range scan engine assembly P N 591098 003 SE1200 CK30 scan flex cable P N 072781 003 SE1200 shield P N 073883 002 if necessary SE1200 visor P N 073703 003 Large scan mount bracket P N 072865 002 M2 x 0 4 by 4mm steel panhead screw P N 800 318 004 Phillips 2 28 x 250 thread form screw P N 525301 CK30 Handheld Computer Service Manual 21 Chapter 2 Replacing Parts To replace the SE1200 scanner a 1 Open the CK30 For help see Opening the CK30 on page 9 A 2 From the bottom cover remove the four Phillips screws that attach the scan engine assembly Follow ESD Procedures 3 Lift the scan engine assembly away from the bottom cover Screw 4 p
47. S vii Safety ICONS Troiei a A AA haat E NA viii Global Services and Sip port cd vated an aie in eaer i ix Who Should Read This Documentalista x 1 TrOUDISSNOO TINO ute 1 Troubleshooting the ED ii 2 2 Replacing Paris o sa 7 Caut nS hat it li a tino 8 Replaci Parts hrs lada cd labia oil ie less 9 Opening te GRO alain apio caia SEE T lla EN lila 9 Replacing the 802 11b g Radio and Antenna ccociccccnnnnnncnnnninonononnnannncncnnancnn canon 10 Replacing the Ethernet Cato dto ta pda dia tad 12 Replacing the Bluetooth Radio nadas 13 Replacing the Main DEB e aos 15 Replacing the Bezel Asset bly a 17 Replacing the Display Asseblricaa re 18 Replacing the Keypad Asscblv a 20 Replacing the SE1200 Scanner iii cio 21 Replacing the EV 1 Oi Scanner iiie in en 23 Replacing the IT4000 Tre ii 25 Replacing the Tethered Scanner is 25 Closing the UNO ainia aca t ta EEE ASE E E an Reia Niet 27 3 Spare Parts List and Exploded Views 29 CS0 Exploded Vit nl a a util 30 CEK530 Spare Parts Listes iia secvitusdoniss sdosouestetel S 31 Ethernet Card Assembly Exploded Vis iras 32 Ethernet Card Assembly Spare Parts List sist picsbotascnscdetanttuaetse dica bacoca blo aleteo bas call caera dos 32 SE1200 Scan Engine Assembly Exploded Meir 33 SE1200 Scan Engine Assembly Spare Parts Lista lso aiii adas 33 EV10 Scan Engine Assembly Exploded View sr sii tscaviiei iid paeticscdvactsotieatudstisenlevinstacascoes 34 EV10 Scan Engine Assembly Spare Parts Listo tias nds 34
48. SOS Scan_CTS 9 GoodRead Scan_TxD 84 Scanner Signal 5V in GND Trigger Enable Beep GND Video SOS Decode LED NC Description Switched scanner power Selectable flex option as either e 5 VDC 5 250mA maximum continuous default e Switched off when the CK30 suspends and on low battery Can be configured to stay on during Suspend but is shut off by hardware if the battery is critically low or removed Using a different tethered scan flex this voltage can be changed to e 3 3 VDC 45 150mA maximum continuous Active low bi directional trigger signal This is an open drain line driven and sensed by the FPGA under application software control and the scanner s trigger e 5V tolerant 3 3V CMOS input and open drain output 20K pull up to SCAN_VCC Active low laser enable output to tethered scanners For decoded scanners this signal becomes an active low TTL level serial RTS handshake 3 3V CMOS output Tri stated when SCAN_PWR_EN is off or SCAN_PORT 1 Can be driven in an open drain mode software selectable Beep output to tethered scanners 3 3V CMOS output Tri stated when BEEP_EN is off Bar code video input from non decoded scanners Active high or low only transitions are sensed e 5V tolerant 3 3V CMOS Schmitt trigger input 4 75k pull up to SCAN_VCC For decoded scanners this signal becomes a TTL level serial RxD input e 5V tolerant 3 3V CMOS input 4 75k pull up t
49. T Serial data input from dock PXA255 FF UART Serial handshake output to dock PXA255 FF UART Serial handshake input from dock PXA255 EF UART Serial handshake input from dock PXA255 FF UART Serial handshake output to dock PXA255 FF UART Serial handshake input from dock PXA255 FF UART Serial USB bi directional differential data Serial USB bi directional differential data 5V power from USB host 5V power from computer for tethered peripherals GND return DBP input from tethered undecoded scanner SOS input from tethered undecoded scanner When the TETH_PRESENT signal is high no undecoded tethered scanner present the TETH_SOS signal is used to indicate when a decoded serial tethered scanner is present 0 decoded scanner present 1 no decoded scanner present Trigger input from tethered undecoded scanner Laser enable output to tethered undecoded scanner GoodRead output to tethered undecoded scanner Beep output to tethered undecoded scanner Signal Characteristics RS 232 levels RS 232 levels 5K pull down RS 232 levels RS 232 levels 5K pull down RS 232 levels 5K pull down RS 232 levels RS 232 levels 5K pull down 3 3V differential CMOS bi directional 3 3V differential CMOS bi directional 5 VDC 5 350mA maximum Can be open collector with pull up to 5V or 5V CMOS output Can be open collector with pull up to 5V or 5V CMOS output Can be open collector with pull up to 5V
50. able to the mini PCI radio assembly Replace the mini PCI shield assembly Replace the antenna ground plane and antenna Close the CK30 For help see Closing the CK30 on page 27 CK30 Handheld Computer Service Manual 11 Chapter 2 Replacing Parts Replacing the Ethernet Card Follow ESD Procedures 12 To replace the Ethernet card you may need the following tools and parts e T10 Torx screwdriver e Small Phillips screwdriver Ethernet card assembly P N 073867 001 Ethernet cable assembly P N 073096 001 e 2 56 x 3 16 stainless steel screw P N 801 210 000 e 2 28 x 250 Plastite flathead screw P N 800 193 000 To replace the Ethernet card 1 Open the CK30 For help see Opening the CK30 on page 9 2 Disconnect the Ethernet cable from J12 on the main PCB 3 Remove the four Phillips screws two self tapping flathead and two machine from the mini PCI shield assembly and lift the shield off of the Ethernet card assembly 4 Open the retainer clips and pull the Ethernet card assembly away from the connector 5 Insert the new Ethernet card assembly into the connector until the two retainer clips lock in place Screw 2 places Screw g 2 places a read j Mini PCI shield assembly N ate Retainer clips CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts 6 Replace the mini PCI shield assembly by threading the Ethernet cable through the openin
51. ad LED 0 LED off 1 LED on Scan_LED_High Good Read LED intensity control 0 low intensity 1 high intensity User_LED1 User LED1 control 0 LED off 1 LED on User_LED2 User LED2 control 0 LED off 1 LED on 12C Bus FPGA The 12C bus is used for power management functions and for control of the 2D imager in CK30s so equipped The PXA255 I2C controller is the bus master the slave devices on the bus are Slave Device Address See this Section Power Supply Controller PSC U38 0x12 PSC 12C Syntax on page 59 2D imager engine 0x40 2D Imagers on page 80 The I2C bus CLK and DATA lines are pulled up through pull up resistors R10 and R12 Pads for an active pull up are provided U1 but as of the current release this device is not installed The PXA255 clocks the I2C bus at approximately 93kHz The CK30 architecture uses an SRAM based FPGA for the Mini PCI and scanner interfaces and for the keypad interface and a few GPIO functions For details of each functional block within the FPGA see the document section covering that function Mini PCI interface See Mini PCI Interface on page 69 Scanner interfaces See Scanners on page 74 Keypad interface See Key Matrix Scanning on page 67 Volume control See Beeper on page 92 CK30 Handheld Computer Service Manual 47 Chapter 4 Theory of Operation Bus I F SD31 0 A SA25 0 gt SCAN_DREQ Scanner I F SCAN_IRQ
52. adio assembly P N 073155 001 e 2 56 x 3 16 stainless steel screw P N 801 210 000 e 2 28 x 250 Plastite flathead screw P N 800 193 000 e 2 56 x 5 32 stainless steel screw P N 801 209 001 To replace the 802 11b g radio or antenna 1 Open the CK30 For help see the previous procedure 2 Remove the two Phillips screws from the top of the antenna assembly and remove the antenna ground plane 3 Remove the four Phillips screws two self tapping flathead and two machine from the mini PCI shield assembly and lift the shield off of the radio assembly CK30 Handheld Computer Service Manual 10 Chapter 2 Replacing Parts Screw y 2 places e 2 Antenna P Antenna ground gt plane Screw 2 places Screw Mini PCI shield a assembly Mini PCI 0 radio zi assembly Z Use the antenna cable remover tool to carefully lift the antenna off of the mini PCI radio assembly Insert the prongs under the antenna cable socket and lift gently Note Do not pull on the wire because the cable will break If you do not have an antenna cable remover insert your fingernails under the antenna cable socket and lift gently Open the radio card retainer clips and pull the mini PCI radio assembly away from the connector Insert the new mini PCI radio assembly into the connector until it cannot go in any further and then push it down until the radio retainer clips lock in place Attach your new antenna c
53. also has four 26 pin JAE connectors for interfacing with four CK30s Refer to Connector Pin Outs on page 96 for the connector pin outs The four 26 pin JAE connectors are right angle connectors mounted on separate PCBs each interfaces to the AD2 main PCB through two 10 pin headers J3 J5 J11 J13 J19 J21 J27 and J29 A CK30 that is inserted into the AD2 is powered directly from the 12V supply J6 J14 J22 and J30 are the contacts by which power is transferred to each of the four CK30s The AD2 has a five port 10 100 Ethernet switch to allow the end user to connect four CK30s to their network The switch chip is a Micrel Kendin part number KS8995X AD2 Charging The AD2 has four identical charging circuits one for each slot in the dock U2 TI BQ2954 controls all aspects of charging for the AD2 It uses a constant current constant voltage charging algorithm The AD2 is designed to charge the CK30 battery pack with a maximum charge current of 833 mA The sense resistor R80 is what sets the maximum charge current Imax 250 mV R80 The AD2 is also designed to only allow charging between 0 C and 45 C 7 C A battery that has been discharged through normal use on a CK30 recharges in less than five hours on the AD2 J7 J8 and J9 are the contacts by which the CK30 battery interfaces to the charging circuitry The voltage divider formed by R90 and R91 is used to notify the BQ2954 that a battery has been inserted It is als
54. an undecoded scanner is installed on the docking connector the TETHERED _PRESENT signal is asserted Software senses this and configures the FPGA to switch its count gathering logic from the internal scanner to the tethered scanner DBP video and SOS signals TETH_DBP and TETH_SOS through Schmitt trigger U9 This action also drives low the FPGA control line to analog switch U10 isolating the internal scanner from the ILLUM_LASEN_RTS and SPEED_RANGE_GDRD signals now being used to control the tethered scanner Actually U10 would normally already be open if internal scanner power is off e Decoded scanners are supported as serial true RS 232 devices using RS 232 buffer chip U23 and the FF UART signals on the PXA255 normally used for serial dock communications See RS 232 Port on page 89 Note that this is not the same as the ST UART used for tethered decoded scanners brought in through the 10 pin Stewart port e See Dock Interface on page 87 for docking connector pin out and tethered scanner power details Dock Scanner Auto Detect A TETH_PRESENT pin is provided on 26 pin docking connector J13 to indicate when an undecoded tethered scanner is plugged into the docking connector TETH_PRESENT Description 0 Scanner installed e FPGA count gathering logic takes its DBP and SOS inputs from TETH_DBP and TETH_SOS from docking connector e SPEED _RANGE_GDRD ILLUM_LASEN_ RTS and SCAN_TRIG signals are iso
55. and U13 the voltage appropriate to the installed scanner is selected through the scanner flex wiring A loopback pin on the connector feeds the selected voltage back to the interface s pull up resistors 5V power for tethered scanners attached through the docking connector TETH_SCAN_VCC is controlled by HCR register U11 output DOCK_EN through high side switch U13 Decoded output tethered scanners and undecoded DBP tethered scanners are supported through an optional 10 pin Stewart connector built onto a flex circuit that plugs into 16 pin scan port J3 e Undecoded tethered scanners use the FPGA count gathering interface See 1D DBP Scanner Interface on page 78 e Decoded scanners are supported as serial TT L level RS 232 devices See Serial RSTTL Scanner Interface on page 82 e Decoded scanners may also be supported as wand emulation or laser emulation devices see Wands and Wand Emulation on page 80 but serial is preferred to minimize power consumption and avoid speed and buffer size limitations Laser interface and TTL level serial signals are supported at the 10 pin Stewart connector using Intermec s standard pin out except that no battery power is provided on pin 10 CK30 Handheld Computer Service Manual 83 Chapter 4 Theory of Operation Tethered Scanner Signal Descriptions Pin Signal Name 1 Vext 2 GND 3 Trigger 4 Lasenable Scan_RTS 5 Beep 6 Shield 7 Video Scan_RxD 8
56. at is inserted into the AC2 is powered directly from the 12V supply J6 J14 J22 and J30 are the contacts by which power is transferred to each of the four CK30s AQ Charging The charging design is the same as the AD2 Refer to AD2 Charging for a detailed description of the charging algorithm AC2 Input Power Requirements The AC2 requires 12 VDC at 4A The 073573 power supply is qualified for use with the AC2 102 CK30 Handheld Computer Service Manual fatermec Corporate Headquarters 6001 36th Avenue West Everett Washington 98203 U S A telk 425 348 2600 fax 425 355 9551 www intermec com CK30 Handheld Computer Service Manual P N 073967 001
57. ave caused the audio driver to be turned off Charge the main battery The speaker assembly has failed or may be damaged For help see most of the Replacing the Display Assembly procedure on page 18 to replace the speaker assembly The speaker driver on the main PCB may be damaged For help see the Replacing the Main PCB procedure on page 15 CK30 Handheld Computer Service Manual Chapter 1 Troubleshooting Troubleshooting the CK30 continued Problem The CK30 will not communicate in a wireless network The CK30 battery will not hold a charge or discharges rapidly The CK30 will not communicate in an Ethernet network The AH1 handle does not activate a scanning beam CK30 Handheld Computer Service Manual Solution Try these possible solutions in order Make sure that the radio is configured properly for the network If the radio is properly configured there may be a problem with the access point Make sure that the antenna cables are correctly connected to the radio If the antenna cables are correctly connected the antenna or radio may be damaged For help see the Replacing the 802 11b g Radio and Antenna procedure on page 10 The mini PCI interface may have failed on the main PCB For help see the Replacing the Main PCB procedure on page 15 Try these possible solutions in order Make sure that you configure the CK30 to suspend power and turn off the backlight when
58. cally shut down the instant the battery goes critical In a critical battery situation signal BATT_FAULT_IRQ is driven low by comparator U36 replaced with signal RESET_OUT when the PXA255 suspends CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation The output BATT_FAULT then gates off the load enable lines through gates U17 U25 and U26 Flip flop U15 latches the state of BATT_FAULT so that these loads do not come back on again when power is restored Battery State System State Device Power OK Not important Controlled by software Critical or battery out Awake Controlled by software Critical or battery out Suspended Off Power Supply Controller PSC PIC processor U38 the PSC or Power Supply Controller is used to supervise the following low level power management functions These are discussed in further detail later in this section e Reset control e IO key suspend resume control e Battery voltage A D e Temperature A D e Suspend timeout enforcement e Supercap charging e Battery status LED control e FPGA IO power control The microcontroller is flash based and can be reprogrammed in system through the Debug port P1 behind the SD slot door see PSC PIC on page 96 While the CK30 is on the PSC functions as a peripheral of the power management code running on the PXA255 accepting commands and returning data over the 12C bus PSC 12C Syntax The I2C controller in the PXA25
59. ce when The IO key is pressed when the CK30 is suspended and the battery is too low to resume The battery level crosses below the hardware critical battery threshold The main battery is removed Red LED off Red LED flashes once when the warm boot completes Red LED flashes three times when the PSC comes out of reset and initiates the cold boot then once more when the boot completes Hard Reset Cold Boot Chapter 4 Theory of Operation Comments PSC turns off the LED when it sees system has suspended PWR_EN 0 All instances of the red LED flashing are driven directly by the PSC The power management driver commands the single flash This is a momentary false low battery indication that results from the time needed to average enough battery level samples to exceed the software low battery threshold The three flashes are driven directly by the PSC The power management driver commands the single flash This is a momentary false low battery indication that results from the time needed to average enough battery level samples to exceed the software low battery threshold Pushbutton switch SW1 inside the battery compartment is used for user commanded hard reset in the CK30 Hard reset asserts the PSC U38 reset input which in turn asserts the PXA255 reset input once a good main battery is installed This clears all PXA255 functions to a known state and asserts the PXA255 reset ou
60. cess Because it is an SRAM based device and is not even downloaded until well after the system reset is release system reset is not brought out to the FPGA After download functional blocks within the FPGA are reset through their own memory mapped control registers The audio codec Proto 0 only uses the AC97 interface reset AC_RST The Bluetooth module supplies its own power on reset PCI slot reset is provided through the PCI bus reset PCI RESET generated by the FPGA based PCI host bridge The Yo key is a simple contact closure to GND on the keypad PCB The IO_KEY signal is debounced in software by the PSC which then issues a PSC_IRQ interrupt to PXA255 GPIO 0 to suspend or resume the system PXA255 On a resume the PSC does not issue the interrupt if BATT_FAULT_IRQ is asserted main battery too low to resume CK30 Handheld Computer Service Manual Resume Events Source Yo key Suspend Resume RTC Alarm Tethered Scanner trigger Trigger Resume Keypad scanner Button Trigger Resume Handle trigger Trigger Resume 1 2 and 3 keys on the keypad ActiveSync connection DCD from docking serial port ActiveSync connection USB host present Mini PCI card PME power management event Bluetooth wakeup SD card insertion Chapter 4 Theory of Operation In addition to the Yo key the CK30 is designed to optionally wake from the following sources Wakes after battery
61. d spring P N 073495 001 e EV1O scan flex assembly P N 072782 002 e Small scan mount bracket P N 072864 001 e Phillips 4 20 x 250 thread form screw P N 525023 e Phillips M1 6 x 3mm steel screw P N 591883 001 To replace the EV10 scanner 1 Open the CK30 For help see Opening the CK30 on page 9 A 2 From the bottom cover remove the three Phillips screws that attach Follow ESD the EV10 scan engine assembly as shown in the next illustration Procedures 3 Lift the scan engine assembly away from the bottom cover CK30 Handheld Computer Service Manual 23 Chapter 2 Replacing Parts 24 4 Turn the scan engine assembly over and remove the two Phillips screws that attach the scan engine and ground spring to the small scan mount bracket 5 Disconnect the scan flex cable from the scan engine assembly Engine insulator S As EV10 scan engine assembly EV10 scan P flex cable a A Engine j ground Screw spring 3 places g Small scan mount bracket f Screw 6 Assemble the new scan engine for replacement a Remove the backing from the engine insulator and attach it to the top of the scan engine assembly b Connect the scan flex cable to the scan engine assembly Make sure you completely insert the scan flex cable up to the white alignment mark 7 Insert the EV10 scan engine assembly into the ground spring place it inside the scan mount bracket and attach it with the two screws removed i
62. data bus e SA_MA25 0 addr bus e Control signals RD WR WE OE PWE RESET_IN DQM3 0 RDY SCAN_DREQ PCI_IRQ SA_BREQ SA_BGNT e SDRAM control signals SDCAS SDRAS SDCS0 SDCKE e Clocks SDCLK FPGA_CLK e Chip selects FRGA_CS FLASH_CS PCI HCR_CS CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation A custom debug board supporting Ethernet logic analyzer connectors hexadecimal debug LEDs and test and reset switches connects to these connectors through a buffered pod board and flex and ribbon cable assembly 073274 PCB ASSY DEBUG CX1 073418 FLEX CIRCUIT J34 TEST FIXTURE 073419 FLEX CIRCUIT J33 TEST FIXTURE 073420 FLEX CIRCUIT J35 TEST FIXTURE 591813 CBL RIBBON 68 POS SHIELDED J33 is pinned out to be compatible with the commercially available Microsoft Debug Board See the Microsoft Debug Board Specification V2 4 for details Firmware Upgrade Bootloader 0S Image For the current release version 1 01 01 0229 of the CK30 the only upgrade route for the bootloader is to cold boot the CK30 with an SD card containing an image of the new bootloader The bootloader is divided into 2 parts Primary and Secondary Only the Secondary portion is intended to be field upgradeable the Primary bootloader is fixed This is partly for risk reduction the Primary bootloader is responsible for reading the upgrade image from the SD card and writing it to flash If the Primary bootloader
63. detect edges wakes the system on any serial message from the Bluetooth module No Not supported in current software Supported through signal SDMMC_CD on PXA255 GPIOS Devices routed to PXA255 interrupts other than GPIOO and GPIO 1 are not able to wake the system after a battery replacement or other critical battery event because in such an event the PXA255 automatically disables all wakeup interrupts except GPIOO and GPIO1 In all instances BATT_FAULT globally inhibits resume when the main battery is too low or removed and external power is not present CK30 Handheld Computer Service Manual 65 Chapter 4 Theory of Operation Suspend Events Display LCD Panel LCD Controller Bias Supply Source Conditions Yo key Suspend Resume None OS auto suspend timer None Application program initiated suspend None Suspend through Reader Command None Hardware critically low battery threshold Instantaneous battery level falls below includes battery removal U36 hardware critical battery threshold For help see the Low Battery Thresholds table on page 61 The CK30AA and CK30BA use a 160 x 160 transflective monochrome display with a gray scale depth of 4 bits per pixel The CK30CA uses a 160 x 160 transflective passive color display with a color depth of 16 bits per pixel The PXA255 internal LCD controller used to drive the display through an 8 bit LCD interface The PXA255 LCD controller has no dedicated
64. dio module and remove it from the main PCB 7 Replace the Bluetooth radio module 8 Replace the Phillips screw that attaches the Bluetooth radio retaining clip to the main PCB 9 Connect the display flex cable and the keypad flex cable to the main PCB 10 Replace the main PCB and secure it with the two Phillips screws removed in Step 3 Make sure the keypad flex cable properly z folds under the main PCB 11 Close the CK30 For help see Closing the CK30 on page 27 14 CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts Replacing the Main PCB To replace the main PCB you need the following tools e T10 Torx screwdriver e Small Phillips screwdriver You also need one of the following parts depending on the CK30 configuration CK30 64M 64M main PCB assembly P N 072291S 007 CK30 32M 32M main PCB assembly P N 072926S 008 e LCD support bar P N 073497 002 e KA22 x6 WN 1412 Elco screw 591825 001 To replace the main PCB 1 Open the CK30 For help see Opening the CK30 on page 9 2 Disconnect the power good read indicator light pipe assembly cable Follow ESD and the speaker PCB assembly cable from the main PCB Procedures Power good XA read indicator i S light pipe assembly cable 3 Remove the radio and antenna assembly or the Ethernet card For help see the appropriate procedure 4 Remove the two Phillips screws with captive washers from the top of the main
65. e The CK30 platform is a 32 bit 3 3V system with the processor and FPGA cores running at 1 3V and 2 5V respectively The design is contained on a single main PCB except for the following modules MIC FT Conn 4 e The keypad is a separate replaceable module that attaches to the exterior of the product connected to the main PCB through a flex cable The LCD and drivers are contained within a separate display module connected to the main PCB through a flex cable e The two speakers are mounted on a small PCB connected to the main PCB through a wired cable e Radio and Ethernet options are implemented with Mini PCI Type 3A cards i o gt wa i Touch _ Panel Conn l Enables Driver from HCR l i Touch JTAG 1 3V CPU Core Supply 2 5V FPGA Core Supply L system 3 3V 5V Suppl System 5V Das CK30 High Level Block Diagram 40 LCD 32kHz 3 68MHz VE Osc PXA255 Processor Power Management Pins Pins Reset US Resume E Logic Scanner VF Debug foo BAn A a come Debug Board E rl with a Other signals Ethernet controller E of interest gt m Debug LEDs 3 Logic Analyzer S E A K A connectors 2 ud Se a Pi bl E erica ES Regs 2 9 Optional 3 1 10 pin amp i Tethered ES FPGA Scanner Scan Port Conn _ Scan Engine
66. e 1 1 or marking state 77 Chapter 4 Theory of Operation Using the Scanner Interface Signal Set Part 2 continued Source Signal Name Destination SPEED RANGE FPGA out GDRD IMAGER_PIXCLK FPGA IO TRIG_AIM HCR out SCAN_TRIG FPGA_IO IMAGER_SD0 7 FPGA in 12C_CLK 12C_DAT PXA250 IO 1D DBP Scanner Interface 78 SPI Scanner Usage Speed select 0 200 scans sec EV10 0 500 scans sec EL10 1 36 scans sec EV10 1 65 scans sec EL10 SPI clock to scanner and scanner mode select 1D 2D select 0 2D 1 1D SPI data to scanner and scanner mode select EL10 Usage Speed select 0 500 scans sec 1 65 scans sec Scanner reset Active low 12C scanner control Tethered Decoded Scanner Usage 10 pin only TxD to scanner 0 0 or space state 1 1 or marking state Scanner present 0 no scanner installed 1 scanner installed Auto Detect Enable 0 enable 1 disable Trigger from scanner Active low Decoded Scanner E1025 Usage TxD to scanner 0 0 or space state 1 1 or marking state Trigger to scanner Active low Internal scanners and undecoded tethered scanners using the legacy DBP laser scanner interface are handled through count gathering logic in the FPGA See the next table for scanners using this interface scheme CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation Bus I F Scann
67. e Manual Chapter 4 Theory of Operation Mini PCI 3 3VAUX is supported though none of the currently supported cards makes use of it It is currently jumpered to PCI_3 3V which goes away if the slot is powered down but can be changed to system 3 3V always backed up through R165 The bridge also supports CLKRUN functionality although again none of the currently supported cards makes use of this This provides a means for the CK30 Mini PCI bridge to signal that the PCI clock is stopped and for Mini PCI cards to request the PCI clock stay on or be restarted See Mini PCI Specification Revision 1 0 for details The hardware includes provisions for PME functionality but this is not yet supported in software This provides a means for Mini PCI cards left powered during Suspend to wake the CK30 when a radio or Ethernet message directed to that CK30 is received Because the FPGA is powered off during Suspend the PME signal bypasses the FPGA host bridge controller and goes straight to PXA255 interrupt input GPIO4 which is capable of waking the system if a radio power management event occurs Supported Bus States BO Full on PCI_CLK is free running All PCI bus transactions are allowed The Mini PCI device may generate interrupts The Mini PCI device may assert PCI_PME interrupts Bl Light Sleep PCI_CLK is free running The Mini PCI device may assert PCI_PME interrupts B2 Deep Sleep PCI_CLK is stopped in low state The
68. ed and stops breathing Any delay could result in death To work on or near high voltage you should be familiar with approved industrial first aid methods Energized equipment Never work on energized equipment unless authorized by a responsible authority Energized electrical equipment is dangerous Electrical shock from energized equipment can cause death If you must perform authorized emergency work on energized equipment be sure that you comply strictly with approved safety regulations CK30 Handheld Computer Service Manual vii Before You Begin Safety Icons viii A Warning AN Caution Follow ESD Procedures Optics ES This section explains how to identify and understand dangers warnings cautions and notes that are in this document You may also see icons that tell you when to follow ESD procedures and when to take special precautions for handling optical parts A warning alerts you of an operating procedure practice condition or statement that must be strictly observed to avoid death or serious injury to the persons working on the equipment A caution alerts you to an operating procedure practice condition or statement that must be strictly observed to prevent equipment damage or destruction or corruption or loss of data This icon appears at the beginning of any procedure in this manual that could cause you to touch components such as printed circuit boards that are suscep
69. emory mapped register for software to read the state of KEY_RET7 0 It also includes interrupt logic that when enabled by software interrupts the processor on any edge of KEY_RET7 0 CK30 Handheld Computer Service Manual 67 Chapter 4 Theory of Operation While the keypad is idle software drives all eight column lines low and waits for an interrupt indicating a key press or release Software then checks KEY_RET7 0 to identify the row in which a key changed state and debounces the key change for approximately 8 ms If the key state is stable software polls the keys by driving column lines KEY_DRV7 0 low one at a time until the key column is identified The driver then drives all the column lines low again re enables the interrupt looks up the key scan codes and sends it to the operating system During Suspend the eight column drivelines are normally set to their Hi Z state See Wakeup Keys on the next page for exceptions No diodes are included in the keypad matrix for key chording support or multiple key rollover detection so keypad usage is limited to the sticky key model where modifier keys are pressed and released before pressing the modified key This method does not preclude sensing two keys down simultaneously but the driver software does currently not support this 2 6 Y E a AlE Gh gt frime div fms nl a aj C2 4 23424s Delta Time 98ms I Lock Delta Time ES Delta CT 4 24222
70. en inserted It is also used to determine whether to begin charging based on the battery voltage and an internal reference voltage in the BQ2954 CK30 Handheld Computer Service Manual 101 Chapter 4 Theory of Operation Temperature monitoring is done using a voltage divider formed by R1 R17 and a NTC thermistor RT1 If the battery voltage is at a value that the BQ2954 identifies as being below the reference voltage and the ambient temperature is within acceptable limits then a charge cycle will begin When a charge cycle begins pin 14 on the BQ2954 is modulated at 100kHz This pin controls a buck switcher formed by Q6 D1 and L2 This switcher is set to provide a constant 8 4 VDC from the 12 VDC supply Once the battery has reached 8 4V 100 mV 10 mV then the BQ2954 switches to the constant voltage phase of the charge cycle During this phase the BQ2954 slowly ramps down the charge current until the designed trip point Imax 15 is reached At this point charge current is terminated and the charge cycle is complete AC1 Input Power Requirements The ACI requires 12 VDC at 4A The 073573 power supply is qualified for use with the AC1 AC2 4 Bay Charging Dock The AC2 can charge four CK30 units at the same time The AC2 uses the same PCB as the AD2 The only difference is that all communications related circuitry has been removed The only function of the AC2 is to charge the battery of up to four CK30s simultaneously A CK30 th
71. er I F DBP_HSYNC SOS_VSYNC Scanner TETH DBP sos_ l F TETH PRESENT ILLUM LASEN RTS SPEED RANGE GDRD SCAN_FLASH_EN SCANTTRIG IMAGER_PIXCLK 10 MUX LOGIC SCAN_LED SCAN _LED_LOW GPIO ADDR DECODE RD WR CTL CK30 FPGA Block Diagram Count Gathering for 1D Scanners The scanner is enabled and controlled from the PXA255 through memory mapped registers in the FPGA and octal register U11 see the Using the Scanner Interface Signal Set table on page 76 e SCAN_PWR_EN is asserted low to switch 3 3V and 5V power through high side switches U12 and U13 to scanner connector J3 The scan flex is used to select the voltage appropriate to the installed scanner The selected voltage is also routed through a loop back on the flex to provide the appropriate pull up voltage SCAN_VCC for signals from open collector scanner outputs like SCAN_TRIG DBP_HSYNC and SOS_VSYNO Most scanners are powered up only when scanning is commanded but tethered scanners are powered continuously while the CK30 is on so that their triggers will work e SCAN_FLASH_EN is asserted low to enable the scanner and or start its dither mirror e ILLUM_LASEN RTS is asserted low to enable the laser or scanner illumination e SCAN_TRIG is set high or low depending on the scanner This is a general purpose control line used for spotter beam control scan speed selection scanner reset or tethered scanner auto detect enable depend
72. ered through FET Q10 Software normally turns on power through control signal SD_PWR_EN only when an SD card is detected in the slot while the CK30 is on Software is responsible for shutting off SD power in a critical battery situation If SD power is still on when the system suspends it is shut off in hardware by the Type 2 interlock mechanism described in Device Power Control on page 58 The SDMMC_IRQ signal is provided for future SDIO support but is currently not used SD card detect and write protect status are sensed through mechanical switches in the slot connector The SDMMC_CD and SDMMC_WP signals are monitored through PXA255 GPIOS and GPIO32 Resistor R189 is provided in the ground path for these switches so that the functional test fixture can override the actual switch settings to simulate insertion and removal of a card Note that the mechanical card detect switch has been found to be unreliable and can report the wrong card state especially in a drop In later revisions of the PCB the card detect switch is not used and alternate card detect scheme based on the SD card DAT3 data line currently unused in the CK30 s 1 bit interface is used instead In this scheme the SD card DAT3 is routed directly to PXA255 GPIOS and is held low by a weak pull down R182 SD slot power is enabled continuously while the computer is on An installed SD card pulls DAT3 high through a weak internal pull up overpowering R182 A
73. ervice personnel Integrated circuits on the printed circuit board PCB in the computer AN are very sensitive to damage by electrostatic discharge ESD Prevent Caution ESD by always wearing skin contact ground straps firmly attached to the equipment metal base assembly when working inside of the computer Never open the package without safeguarding the entire work area with ESD protection Failure to comply may result in damage to PCB components Because finger oils can dissolve the reflective coating of the plastic SS h Mirrors always wear finger cots or non powdered latex gloves when handling optical parts This icon appears at the beginning of any procedure in this manual that could cause you to touch components such as printed circuit boards A that are susceptible to damage from electrostatic discharge ESD When Follow ESD you see this icon you must follow standard ESD guidelines to avoid Procedures damaging the equipment you are servicing 8 CK30 Handheld Computer Service Manual Replacing Parts Chapter 2 Replacing Parts This section describes how to open replace parts in and close the CK30 handheld computer Each procedure also lists the tools and parts that you will need Opening the CK30 To replace the internal parts of the CK30 you need to open it To open the computer you need the following tools T10 Torx screwdriver Small Phillips screwdriver Phillips 2 56 x 312 screw P N 590371 001 Torx 4 40 x
74. fatermec Va Service Manual ho CK30 Handheld Computer Intermec Technologies Corporation Corporate Headquarters 6001 36th Ave W Everett WA 98203 U S A www intermec com The information contained herein is proprietary and is provided solely for the purpose of allowing customers to operate and service Intermec manufactured equipment and is not to be released reproduced or used for any other purpose without written permission of Intermec Information and specifications contained in this document are subject to change without prior notice and do not represent a commitment on the part of Intermec Technologies Corporation 2004 by Intermec Technologies Corporation All rights reserved The word Intermec the Intermec logo Norand ArciTech CrossBar Data Collection Browser dcBrowser Duratherm EasyCoder EasyLAN Enterprise Wireless LAN EZBuilder Fingerprint i gistics INCA under license InterDriver Intermec Printer Network Manager IRL JANUS LabelShop Mobile Framework MobileLAN Nor Ware Pen Key Precision Print PrintSet RoutePower TE 2000 Trakker Antares UAP Universal Access Point and Virtual Wedge are either trademarks or registered trademarks of Intermec Technologies Corporation Throughout this manual trademarked names may be used Rather than put a trademark or symbol in every occurrence of a trademarked name we state that we are using the names only in an editorial fashion and to the be
75. frame buffer but instead uses a Unified Memory Architecture the display refresh data is stored in system SDRAM and is direct memory accessed to the LCD controller The DMA controller is dedicated to the LCD controller and runs independently of the main PXA255 DMA controller Color 16 6 to 19 3 VDC Mono 18 5 to 23 7 VDC variable for contrast adjust Display Contrast Control 66 Display contrast is controlled through PXA255 PWM output PWMO signal CONTRAST Software adjusts the duty cycle of the pulses on this output The pulse stream is filtered through R213 C160 R214 and C159 to produce a DC value at the feedback pin of boost switcher U37 setting the output voltage Because the optimal contrast setting varies from display to display the default setting is dialed at Final Test and saved in system flash You can then adjust the contrast up or down from this midpoint with the revised setting saved in the system registry so that it is reapplied after warm or cold CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation boots The factory set default is restored if the registry is lost or Restore Defaults is selected from the Configuration Menu Temperature Compensation Backlight Keypad Key Matrix Scanning Temperature compensation is implemented in the software display driver using temperature information read through the PSC to vary the duty cycle of the PWM output Software turns the
76. g in the shield and replacing the four Phillips screws 7 Connect the Ethernet cable to J12 on the main PCB 8 Close the CK30 For help see Closing the CK30 on page 27 Replacing the Bluetooth Radio To replace the Bluetooth radio you need the following tools and parts e T10 Torx screwdriver Small Phillips screwdriver e Bluetooth radio P N 855 050 001 e Phillips 4 40 x 875 screw P N 590939 001 e Elco screw 591825 001 To replace the Bluetooth radio 1 Open the CK30 For help see Opening the CK30 on page 9 2 Disconnect the power good read indicator light pipe assembly cable Follow ESD and the speaker PCB assembly cable from the main PCB Procedures Power good ea read indicator S light pipe assembly cable 3 Remove the two Phillips screws with captive washers from the top of the main PCB and gently separate the main PCB from the top cover as shown in the next illustration 4 Detach the display flex cable and the keypad flex cable from the main PCB 5 From the backside of the main PCB remove the Phillips screw that attaches the Bluetooth radio retaining clip and pull it away from the main PCB CK30 Handheld Computer Service Manual 13 Chapter 2 Replacing Parts Screw Bluetooth radio 1 o retaining clip EX Bluetooth Py radio module Screw 2 places 7 CE Flip main PCB over to access Bluetooth radio Keypad flex cable 6 Lift up on the Bluetooth ra
77. ger data are more noticeable than delayed Ethernet or 802 11 transactions This arbitration is based on an internal FPGA signal that indicates when scanner based DMA activity is active or pending When that condition is true the arbiter prevents the PCI bridge from requesting the system bus If the PCI bridge already owns the bus when the scanner needs a DMA transfer the scanner task has to wait for the PCI transaction to complete But since PCI transactions are limited to a burst size of eight the PCI bridge is typically on the bus for less than a microsecond and the scanner task is not delayed for long Mini PCI Slot Power Management 3 3V power to the Mini PCI slot is controlled by software through PXA255 GPIO15 signal CF_PWR_EN driving high side switch U12 It is normally turned off during Suspend but in future OS releases it may be left powered during Suspend to support radio wakeup of the CK30 In order to give software a chance to shut cards down gracefully on Suspend power is not automatically shut down in hardware if the main battery becomes critically low or is removed while the system is running If slot power is still on when the system suspends it is shut off in hardware by the Type 2 interlock mechanism described in Device Power Control on page 58 This protects the system state if the main battery is low or removed while the Mini PCI device radio is left powered during Suspend CK30 Handheld Computer Servic
78. he battery voltage and an internal reference voltage in the BQ2954 Temperature monitoring is done using a voltage divider formed by R18 R19 and a NTC thermistor R23 If the battery voltage is at a value that the BQ2954 identifies as being below the reference voltage and the ambient temperature is within acceptable limits then a charge cycle begins When a charge cycle begins pin 14 on the BQ2954 is modulated at 100kHz This pin controls a buck switcher formed by Q4 D5 and L2 This switcher is set to provide a constant 8 4 VDC from the 12 VDC supply Once the battery has reached 8 4V 100mV 10mV then the BQ2954 switches to the constant voltage phase of the charge cycle During this phase the BQ2954 slowly ramps down the charge current until the designed trip point Imax 20 is reached At this point charge current is terminated and the charge cycle is complete The BQ2954 uses the current mirror UG to measure the charge current This measurement is used to compare against the designed trip point Imax 20 CK30 Handheld Computer Service Manual 99 Chapter 4 Theory of Operation AD1 Input Power Requirements The AD1 requires 12 VDC at 4A The 073573 power supply is qualified for use with the AD 1 AD2 4 Bay Communications Dock 100 The AD2 can charge four CK30 units at the same time It also provides four DB9 male connectors for serial communications and one 8 pin RJ45 connector for 10 100 Ethernet communications The AD2
79. her enable CK30 Handheld Computer Service Manual Usage 0 write protect 1 writes enabled 0 HCR regs low Z 1 HCR regs high Z W interrupt 0 scan column 1 idle 0 scan column 1 idle 0 scan column 1 idle 0 scan column 1 idle 0 scan column 1 idle 0 scan column 1 idle 0 scan column 1 idle 0 scan column 1 idle 0 SD power on 1 SD power off Usage 0 on 1 off 0 LED off 1 LED on 0 off l on 0 disable resume 1 enable resume 45 Chapter 4 Theory of Operation HCR Output Signal Descriptions continued HCR U16 U16 U11 U11 U11 U11 U11 U11 46 Bit 20 21 22 23 Function CF_RESET USB_EN LCD VEE_EN BKLT_ON BKLT_LOW DOCK_EN DISPLAY_EN TRIG_AIM SCAN_PWR_EN SCAN_12C_EN LASEN FPGA_RESET Signal Description Compact Flash slot 0 Reset unused in CK30 Enables pull up on USB bus to acknowledge host and start communications This can be used to hold off USB communications until the USB driver is ready or to disconnect a USB session in progress simulated cable disconnect LCD bias supply enable Backlight On Off control Backlight level Enables RS 232 communications through the 26 pin dock port Also used to switch tethered scanner power to dock connector This should be turned off on Suspend unless the computer has been configured to support trigger resume on a tethered sca
80. high on cold boot so that HCR register outputs float to their default off states through pull up and pull down resistors Once software has initialized the HCR registers software should enable the HCR outputs by setting this bit low Mini PCI IRQ CF slot OE if CF slot installed PCI bridge interrupts PCI card interrupts and keypad interrupts all share this line Keypad matrix column drive 0 Keypad matrix column drive 1 Keypad matrix column drive 2 Keypad matrix column drive 3 Keypad matrix column drive 4 Keypad matrix column drive 5 Keypad matrix column drive 6 Keypad matrix column drive 7 Spare I O from FPGA May be used as an interrupt GPIO or additional chip select to the FPGA Power enable for SD slot HCR Output Signal Descriptions HCR Bit U16 16 U16 17 U16 18 U16 116 Function BT_PWR_EN BLUE_LED AUDIO_EN RESUME_EN Signal Description Bluetooth module power enable Blue System Light control moved from 0x1400_0000 bit 15 Audio power supply enable Resume Enable for non I O key sources This enables and disables system resume from the following events Tethered scanner trigger on 10 pin port SCAN_TRIG Tethered scanner trigger on 26 pin port DOCK_TRIG Dock serial DCD USB host present Note that SCAN_PWR_EN must be asserted for SCAN_TRIG to wake the system through this mechanism Similarly DOCK_EN must be asserted for DOCK_TRIG to wake the system Dock DCD and USB need no ot
81. iew technical information or to request technical support for your Intermec product Telephone Support These services are available from Intermec Technologies Corporation Call 1 800 755 5505 Service Description and choose this option Factory Repair and Request a return 1 On site Repair authorization number for authorized service center repair or request an on site repair technician Technical Support Get technical support on 2 your Intermec product Service Contract Inquire about an existing 3 Status contract renew a contract or ask invoicing questions Schedule Site Surveys Schedule a site survey or 4 or Installations request a product or system installation Ordering Products Talk to sales 5 administration place an order or check the status of your order CK30 Handheld Computer Service Manual ix Before You Begin Who Should Read This Document This manual contains all of the information necessary to repair the CK30 handheld computer It provides an exploded view of the computer the spare parts lists procedures that describe how to replace parts and information about how to test the computer This manual is written for service technicians CK30 Handheld Computer Service Manual 7 Troubleshooting Use this chapter to troubleshoot problems you may encounter while using the CK30 CK30 Handheld Computer Service Manual Chapter 1 Troubleshooting Troubleshooting the CK30 Use this table
82. ing on the installed scanner See Using the Scanner Interface Signal Set on page 76 CK30 Handheld Computer Service Manual 79 Chapter 4 Theory of Operation e SPEED RANGE GOODREAD is set high or low depending on the scanner This is a general purpose control line used for spotter beam control scan speed selection GoodRead indication on tethered scanner or serial TxD to decoded output scanners depending on the installed scanner See Using the Scanner Interface Signal Set on page 76 Normally these signals are all driven at 3 3V levels But signals SCAN_FLASH_EN ILLUM_LASEN_ RTS and SPEED RANGE GOODREAD can be redefined in the FPGA as 5V tolerant open drain outputs This is required for the 5V SE1200 scan engines which otherwise would interpret a 3 3V level as low It is also used for some tethered scanners like the 1550C While scanning DBP and SOS signals from the scanner are buffered by Schmitt trigger U9 and routed to count gathering logic in the FPGA A 16 bit counter measures the time between DBP edges bars and spaces to create video counts that are collected in a 32 deep FIFO which in turn feeds a 16 deep 32 bit wide DMA buffer When the DMA buffer is half full the FPGA asserts SCAN_DREQ to the PXA255 to request a DMA transfer and eight 32 bit words are direct memory accessed into a cached area of system SDRAM for decoding SOS transitions generate interrupts to the PXA255 to signal start and end
83. ion on USB_WAKE propagates through U24 is debounced by R274 C147 and U33 and then is differentiated by C180 and R321 The resulting pulse goes through the resume logic on PXA255 GPIO1 see Resume Events on page 65 waking the system if this wakeup is enabled HCR U16 output RESUME_EN is high This feature is not supported in the current software Note that this wakeup method can be inhibited through U24 if the dock port serial DCD is asserted so CD_WAKE is high But in most cases this means the CK30 is already awake The CK30 supports RS 232 communications through the serial signals on dock interface connector J13 The signals are converted to true RS 232 levels by U23 and brought to the FF UART built into the PXA255 processor The operating system maps this port as COM2 CK30 Handheld Computer Service Manual 89 Chapter 4 Theory of Operation Scanner Interface Bluetooth 90 Full handshaking is supported except for RI Ring Indicate This was left out in anticipation of some DB9 cables supplying 5V instead of RI on DSub pin 9 U23 and its charge pumps are left on while the CK30 is on but it draws very little current with no RS 232 device attached It is shut off during Suspend by the DOCK_EN signal from HCR register U11 The MAX3244 AutoShutdown mode is not used because it doesn t wake up and restore RS 232 level conversion fast enough if the CK30 suddenly starts transmitting causing data corruption
84. ith CLK_OUT the PCLK etch length is kept approximately the same as the PCI_CLK trace to the card to minimize skew CK30 Handheld Computer Service Manual Power System Architecture Power Supplies Chapter 4 Theory of Operation 5 V to Status LEDs Vibatt wall from Svo Cur limited Switch Teth Scan Vcc Battery Pack PWR EN Regulator a fh DOCK_EN Cur limited Switch Scan 5 Volts SCAN_PWR_EN 3 3 Volt EE F Regulator Cur limited Switch gt Scan 3 3 Volts _ Cur limited Switch H 3 gt PCI_3 3 Volts LDO H AUDIO 5V EE CF_PWR_EN 3 3 volts Batt_Vcc Vecq e memory etc FET Switch H 3 gt SD_Vcc LDO SD_PWR_EN Voltage F Voltage Limit Supercap Charge FET Switch p gt BT_Veo detector Enable amp BT_PWR_EN Sensor 3 3 Volt Backup FPGA Regulator gt LDO 2 5 Volts Voltage E FPGA power enable Reference BATT_FAULT_IRQ lt PSC_IRQ e VDD_FAULT LED BACKLIGHT LED Backlight Supply 3 gt color display J Power Supply Controller 12C Bus RESET_IN 4 1 0 KEY gt Voltage Detect 3 3V Reset PROG EN l SERIAL_PROG_CLK 4 gt SERIAL_PROG_DATA Manual BKLT_ON BKLT_LOW E
85. ize the peak peak square wave across the speakers At max volume the P P output is about 7 3V limited by the amplifier s 3W drive limit Software enables U19 through HCR register U16 output AUDIO_EN driving FET Q14 and shuts it off during Suspend for power savings U19 draws about 7mA while idle On Suspend AUDIO_EN must be turned before the 5V supply decays to avoid any undesirable sound effects AUDIO_EN is automatically disabled in a critical battery situation by the Type 1 interlock mechanism described in Device Power Control on page 58 In this situation system software also immediately writes a O to the AUDIO_EN bit in HCR register U16 This prevents the system from oscillating if audio activity contributed to the low battery threshold being crossed with the audio load suddenly removed by AUDIO_EN going low the battery voltage can rapidly recover enough that HCR_DISABLE is de asserted If the AUDIO_EN bit on U16 were left high that would reapply the audio load causing the battery voltage to crash again C104 provides pop protection when U19 is enabled but also delays the audio amplifier bias stabilizing so there is a delay of about 150ms to 200ms before the amplifier is usable This delay is why the amplifier cannot be left disabled while idle and enabled only when needed The BEEP signal is also routed to the FPGA for 2 purposes e When a tethered undecoded scanner is being used the FPGA is configu
86. k Try these possible solutions in order Make sure you have a charged battery installed correctly For help see Charging and Installing the Battery in the CK30 Handheld Computer Users Manual The display assembly may be damaged For help see the Replacing the Display Assembly procedure on page 18 The backlight key on the keypad assembly may not be working properly For help see the Replacing the Keypad Assembly procedure on page 20 The backlight driver on the main PCB assembly may have failed For help see the Replacing the Main PCB procedure on page 15 Scanner does not emit a Try these possible solutions in order beam or scanner emits a beam but does not scan the bar code CK30 Handheld Computer Service Manual Make sure the scanner window is clean If the scanner window is badly scratched replace the scanner window Make sure the keypad flex cable is connected properly Make sure the scan engine flex cable is connected properly If the scan engine flex cable is damaged replace it The scan engine may be damaged For help see one of these procedures Replacing the SE1200 Scanner on page 21 Replacing the EV10 Scanner on page 23 or Replacing the IT4000 Imager on page 25 Chapter 1 Troubleshooting Troubleshooting the CK30 continued Problem The CK30 will not communicate in a serial network Real time clock does not maintain the correct time The
87. laces SE1200 scan engine assembly Large scan mount bracket 4 Turn the scan engine assembly over and remove the two Phillips screws that attach the scan engine to the large scan mount bracket 5 Disconnect the scan flex cable from the scan engine 6 Assemble the new scan engine for replacement a Remove the adhesive backing from the SE1200 visor and attach it to the front of the scan engine b Connect the scan flex cable to the scan engine Make sure you completely insert the scan flex cable up to the white alignment mark c Thread the scan flex cable through the opening in the shield and set the shield over the scan engine 22 CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts SE1200 scan flex engine Visor Shield Large scan mount bracket 2 places 7 Insert the scan engine in the scan mount bracket and attach it with the two Phillips screws removed in Step 4 8 Insert the scan engine assembly into the bottom cover and attach with the four Phillips screws removed in Step 2 9 Close the CK30 For help see Closing the CK30 on page 27 Replacing the EV10 Scanner To replace the EV10 scanner you need the following tools T10 Torx screwdriver e Small Phillips screwdriver You also need one or more of the following parts depending on what you need to replace e EV10 scan engine assembly P N 3 131010 01 02 e EV10 engine insulator P N 073657 001 e EV10 engine groun
88. lated from the internal scanner e Software turns off power to the internal scanner exception 1T 4000 1 Scanner removed FPGA count gathering logic takes its DBP and SOS inputs from the internal scanner e SPEED RANGE GDRD ILLUM_LASEN_RTS and SCAN_TRIG signals are connected through to the internal scanner e Software turns on power to the internal scanner when scanning is started 86 CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation The TETH_SOS pin on 26 pin docking connector J13 is used in conjunction with TETH_PRESENT to indicate when a decoded tethered scanner is plugged into the docking connector TETH_PRESENT TETH_SOS Description 0 x TETH_SOS functions as the tethered scanner SOS input into the FPGA 1 0 Tethered decoded scanner present 1 1 No scanner present Trigger and Scanner Control Since the keypad Scan button and the handle trigger are handled as keys in the scanned key matrix see Keypad on page 67 the trigger signal to internal scanners is a soft signal generated by the trigger driver in response to a named event from the keypad driver or under application control There is no direct connection between the trigger buttons and the scanner Tethered scanners though may have actual trigger signals These are sensed through FPGA inputs SCAN_TRIG for tethered scanners on the 10 pin port and DOCK_TRIG for scanners brought in through 26 pin dock port J13 In
89. lem Solution The CK30 cold boots or Try these possible solutions in order l i fter the mai y oses settings atter the main Make sure the main battery is fully charged battery is replaced e The bridge battery or the power circuitry on the main PCB may be faulty For help see the Replacing the Main PCB procedure on page 15 The CK30 cannot Try these possible solutions in order communicate with a BUS punter e Make sure your CK30 has the Bluetooth option installed From the CK30 System Main Menu select Diagnostics gt Hardware Diagnostics gt HW Config Table to view the configuration number for the CK30 You can use this number to determine if the Bluetooth option is installed e Make sure that a valid and available printer is within range of your CK30 e Make sure you have selected an available Bluetooth printer in the CK30 Configuration Utility screens e The Bluetooth radio may have failed For help see the Replacing the Bluetooth Radio procedure on page 13 6 CK30 Handheld Computer Service Manual 2 Replacing Parts Use this chapter to learn how to open replace parts in and close the CK30 handheld computer It also provides preliminary cautions to follow when servicing the CK30 CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts Cautions Z Note Opening this product can result in voiding the warranty The internal workings of this product can only be accessed by Intermec s
90. lines are also set to Hi Z on Suspend Note that a vulnerability may arise in future releases if the handle trigger is enabled as a wakeup key Since the handle trigger is a magnetic reed switch that is sensitive to mechanical shock abruptly snapping a main battery in place after a battery swap can unexpectedly wake the system by causing the reed switch to bounce The Yo key signal IO_KEY is a simple contact closure to GND It is not part of the scanned keypad matrix This signal is debounced in the PSC U38 for between 50 ms and 100 ms The long debounce period is necessary to prevent unwanted suspends in drop The keypad Scan Button where present and Handle Trigger are handled as scanned keys in the keypad matrix as opposed to using discrete IO They are placed in Row 0 of the keypad matrix for future trigger resume support See Wakeup Keys on page 68 Each returns a unique scan code so that they can be used for different scanning functions Multiple keypad formats and overlays are supported The installed keypad is identified through the hardware configuration table stored in non volatile memory flash The keypad itself has no provision to allow software to read a unique keypad ID Network Interface Mini PCI Interface A Mini PCI bridge is implemented in the FPGA as a high bandwidth interface to support Ethernet and 802 11g cards The bridge is based on LogiCore PCI interface IP from Xilinx and on PC
91. lowing tools T10 Torx screwdriver Small Phillips screwdriver Straight slot screwdriver You also need one or more of the following parts depending on the CK30 configuration Monochrome display assembly P N 073237S 001 Color display assembly P N 073238S 001 Power indicator good read light pipe assembly P N 073030 002 User indicator light pipe assembly P N 073362 001 Speaker PCB assembly P N 073146 002 KA22 x 6 WN 1412 Elco screw 591825 001 To replace the display assembly a dtd Follow ESD Procedures 3 18 Open the CK30 For help see Opening the CK30 on page 9 Disconnect the power good read indicator light pipe assembly cable and the speaker PCB assembly cable from the main PCB Remove the two Phillips screws with captive washers from the top of the main PCB and gently separate the main PCB from the top cover as shown in the next illustration Detach the display flex cable and the keypad flex cable from the main PCB and remove the main PCB CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts Keypad flex cable 5 Lift the display assembly away from the top cover 6 Remove the power indicator good read light pipe assembly and the speaker PCB assembly If necessary Remove and replace the user indicator light pipe assembly 7 Attach the power indicator good read light pipe assembly and the Power indicator good read light pipe assembly Speaker
92. master The SDRAM controller in the FPGA takes over for the PXA255 SDRAM controller according to the handoff procedure detailed in the Intel PXA255 Processor Developer s Manual The FPGA SDRAM controller is set up in advance by software for the appropriate SDRAM density It runs the SDRAM at 49 77MHz half the rate used by the PXA255 SDRAM controller The FPGA controller keeps the CAS latency set to 2 but resets the SDRAM burst length to full page mode so it can perform variable length bursts A single SDRAM burst of up to 8 words is then performed The burst length is limited to 8 as a simple way of ensuring that the FPGA does not hog the bus for too long and to avoid the complication of adding SDRAM refresh control to the FPGA When the burst is complete the FPGA SDRAM controller sets the SDRAM back to its previous burst length setting of four EM lua als lt gt reos fm A Al a C1 Os DOM 3 0 ADDRESS DOM 3 0 NPWE DATA WE DEW AD AWR FLASH_CS SDCKE SDCLK SbCSO SDRAS SDCAS FPGA_CLK FPGA_CS BGNT BREQ 4 C2 884ns 3 Delta Time Jezans F Lock Delta Time C2 F Delta F 0809C00 8 word burst 030000 DES 4CO j osason p 0308800 03 64C0D Select bank amp Bus Request Bus Grant a activate row Precharge Set SDRAM mode command Read command Set SDRAM mode command Addr 0x0809C00 so Addr 0x0808800 so command is 0x2027 command is 0x2022 Burst length
93. n 8 pin RJ45 connector for 10 100 Ethernet communications a Type B USB connector for USB communications and a 26 pin JAE connector for interfacing with the CK30 Refer to Connector Pin Outs on page 96 for the connector pin outs All of these communication methods are handled by the CK30 the connectors on the AD1 are simply used for passing the signals to and from the CK30 The 26 pin JAE connector is a right angle connector that is mounted on a separate PCB it interfaces to the AD 1 s main PCB through two 10 pin headers J4 and J5 A CK30 that is inserted into the AD1 is powered directly from the 12V supply J9 is the contact by which power is transferred to the CK30 AD1 Charging U1 TI BQ2954 controls all aspects of charging for the AD1 It uses a constant current constant voltage charging algorithm The AD1 is designed to charge the CK30 battery pack with a maximum charge current of 1 25A The sense resistor R15 is what sets the maximum charge current Imax 250 mV R15 The AD1 is also designed to only allow charging between 0 C and 45 C 7 C A battery that has been discharged through normal use on a CK30 recharges in less than three hours on the AD1 J10 J11 and J12 are the contacts by which the CK30 battery interfaces to the charging circuitry The voltage divider formed by R16 and R17 is used to notify the BQ2954 that a battery has been inserted It is also used to determine whether to begin charging based on t
94. n Step 4 8 Insert the scan engine assembly into the bottom cover and attach it with the three screws removed in Step 2 9 Close the CK30 For help see Closing the CK30 on page 27 CK30 Handheld Computer Service Manual Chapter 2 Replacing Parts Replacing the 1T4000 Imager To replace the T4000 imager you need the following tools and parts e T10 Torx screwdriver e Small Phillips screwdriver e IT4000 imager assembly P N 073416S 001 e Phillips 4 20 x 250 thread form screw P N 525023 To replace the IT4000 imager 1 Open the CK30 For help see Opening the CK30 on page 9 2 From the bottom cover remove the three Phillips screws that attach Follow ESD the IT4000 imager assembly Procedures 3 Lift the imager assembly away from the bottom cover Screw 3 places g 1T4000 imager assembly 4 Insert the new imager assembly and attach it with the three Phillips screws removed in Step 2 5 Close the CK30 For help see Closing the CK30 on page 27 Replacing the Tethered Scanner To replace the tethered scanner you need the following tools e T10 Torx screwdriver e Small Phillips screwdriver e Small straight slot screwdriver CK30 Handheld Computer Service Manual 25 Chapter 2 Replacing Parts You also need one or more of the following parts depending on what you need to replace e Tethered scan flex assembly P N 072786 004 e Tethered scanner door P N 073366 001 e Tethered sca
95. nd locate its callout in the following spare parts list See Ethernet Card Assembly Exploded View for Ethernet parts For exploded views of the EV10 SE1200 IT4000 and tethered scan engines see the sections later in this chapter Screw 4 places i Screw 2 places 30 CK30 Handheld Computer Service Manual CK30 Spare Parts List Chapter 3 Spare Parts List and Exploded Views To identify a part find the callout in this list and locate the part in the previous exploded view Callout 1 2 3 N 01 UL Hs 10 11 112 13 14 15 16 17 Description Speaker PCB assembly Power indicator good read light pipe assembly Display assembly Color Monochrome User indicator light pipe assembly Top cover assembly Keypad flex cable Keypad assembly 42 key keypad 50 key keypad 52 key keypad Bezel assembly 42 key programmable 42 key international 42 key 3270 5250 42 key VT ANSI 50 key programmable 50 key international 50 key 3270 5250 50 key VI ANSI 52 key programmable 52 key international 52 key 3270 5250 52 key VI ANSI Bluetooth module LCD support bar Main PCB assembly 64MB 64MB 32MB 32MB Mini PCI radio assembly Mini PCI shield assembly Antenna assembly Bottom cover assembly Large engine Small engine Trigger reed switch assembly Battery Part Number 073146 002 073030 002 073238S 002 073237S 001 073362 001 073094 001
96. ne eaa e eE nanei o eia Sates Eai nos tia E a eie EE aS 66 Dip A a a is a ii 66 ECD Panel a s 66 DI AA O A Or Mya Sara a mee em eae 66 Bl s Supply aaa 66 CK30 Handheld Computer Service Manual Contents Display Contrast Control idolo deacod 66 Temperature COMPeEnsaO A velocista Laredo pias 67 A A A A aee e aiae E 67 Keypad A A NN 67 EY Matriz CA 67 Wakeup A E ecstatic T he han Mose tnsadoacid Du e a eiS 68 YO Rey eee lati tiie cae rite ad eats oad bee Alleah Seea Saris 69 A A bent onvynr EET EE A A 69 Keypad TEN Se ce SS bu Mas E E E aE 69 Network It a a A E pier A aay 69 Mini POI Vinheta ce it ee a ea eaa e a ee E E E t eaei iaa 69 SODA bie Radio io n a a a aae eaer ia 74 A nenas e Aaeeea ae ae E TaS Ee aet 74 E TN 74 Scanner Nate racer rosada coins 76 TD DBP Scanner Interact RE AT S 78 Wands and Wand Emulation ar ii 80 DID MAGES a aaan O 80 ID MDS Scanner AAA A 82 Serial RSTTL Scanner Interface ccccceesccccsssscccssssseccessssecsessssscscssssecsesssesessaaees 82 Scanner Power sea Si iodo 83 A A A Oea test Enpi iE AaS 83 Tethered Scanner Support Through Dock Connector sseseseeseeeessesrsreresesesrsess 85 Trigger and Scanner Control slide ri arasa aS 87 Scanning and Good Read Indica ici csssecusiin dica addon stances 87 Dock Interact A AS 87 USB O 89 RS 232 Por id 89 AA O A E Wind EE n 90 A A O A A O aida ta a 90 Storage Carl a AS 91 NN 92 Debug Support asar a a e aa 93 Field Access Debug Porti cu aa n aerae aea a
97. nefit of the trademark owner with no intention of infringement There are U S and foreign patents pending Wi Fi is a registered certification mark of the Wi Fi Alliance Microsoft Windows and the Windows logo are registered trademarks of Microsoft Corporation in the United States and or other countries Bluetooth is a trademark of Bluetooth SIG Inc U S A This product includes software developed by the OpenSSL Project for use in the OpenSSL Toolkit http www opensssl org This product includes cryptographic software written by Eric Young EAY cryptsoft com This product uses Regex Index software during its operational phases The owner of Regex has granted use of the software to anyone provided such use is accompanied by the following copyright and permission notice Regex Index Version 3 31 16th Dec 2001 Copyright 1998 2001 Dr John Maddock Permission to use copy modify distribute and sell this software and its documentation for any purpose is hereby granted without fee provided that the above copyright notice appear in all copies and that both that copyright notice and this permission notice appear in supporting documentation Dr John Maddock makes no representations about the suitability of this software for any purpose It is provided as is without express or implied warranty ii CK30 Handheld Computer Service Manual Contents Contents Before You Declaracion vii o A aaa ek a are II ai sarei la
98. nner plugged into the dock port High enables LCD module logic 2D imager usage aiming LED control S9C decoder usage Trigger signal EV10 usage 1D 2D select SE900 usage spotter beam SE900HS usage 1D 2D Tethered scanner usage Auto detect enable disable E2010 usage Reset Scanner power control This should be turned off on Suspend unless the computer has been configured to support trigger resume on a tethered scanner plugged into the 10 pin port U34 gate control to isolate the 2D imager from the I2C bus when it is powered down Originally defined as a scanner control signal this HCR output is now unused Its function was moved to the FPGA Reset the FPGA logic and FIFOs Usage 0 idle 1 reset 0 USB disconnect 1 USB connect 0 off l on 0 off l on 0 high 1 low 0 disable dock serial and tethered power 1 enable dock serial and tethered power 0 LCD logic off 1 LCD logic on 1 Aim 0 Trigger 0 1D and 2D l 1D 0 Aim 0 2D l 1D 0 enable auto detect 0 reset 0 scanner power on 1 scanner power off 0 imager isolated from I2C bus 1 imager connected to I2C bus N A 0 reset 1 idle CK30 Handheld Computer Service Manual FPGA IO Signal Descriptions Chapter 4 Theory of Operation Function Signal Description Usage VOLO Beep volume control 000 lowest volume VOLI 111 highest volume VOL2 Scan_LED Scanner Good Re
99. nner cover P N 073179 001 Phillips 2 56 x 3 16 steel screw P N 591884 001 e Phillips 2 28 x 250 thread form screw P N 525301 To replace the tethered scanner 1 Open the CK30 For help see Opening the CK30 on page 9 2 From the bottom cover remove the four Phillips screws that attach Follow ESD the tethered scan flex assembly Procedures 3 Work the tethered scanner connector loose from the scan window and lift the tethered scan flex assembly away from the bottom cover Screw 4 places scan flex assembly 4 Remove the two Phillips screws that attach the tethered scan flex assembly to the mounting bracket 5 If you need to replace the tethered scanner door a Use a straight slot screwdriver to pry loose one of the lower tabs from the bottom door and push it out of the opening in the bottom cover 26 CK30 Handheld Computer Service Manual Closing the CK30 Chapter 2 Replacing Parts Tethered scanner door b Insert a new tethered scanner door and snap it in place Insert a new tethered scan flex assembly into the mounting bracket and attach it with the two screws removed in Step 4 Insert the tethered scan flex assembly into the bottom cover and attach it with the four screws removed in Step 2 Close the CK30 For help see the next procedure Closing the CK30 To close the CK30 you need the following tools T10 Torx screwdriver Small Phillips screwdriver Phillips 2 56 x 31
100. nual Supported Scanners Device EV10 1D imager E1022 E1025 EL10 Micro Mirror Laser SE900 SE900HS SE1200 SE1200ALR 12 and IT4000 2D imagers Tethered undecoded scanners 1550C01xx 128x wands Tethered decoded scanners 1400 1551E 1553 1800 ScanPlus Tethered decoded scanners 1400 1551E 1553 1555 1470B 1800 ScanPlus Interface Type DBP MDS DBP Decoded RSTTL DBP DBP DBP DBP DBP 8 bit parallel pixel data DBP Wand emulation Decoded RSTTL Chapter 4 Theory of Operation Support Status Supported in SE900 compatibility mode MDS mode to be added in a future release Supported in architecture but not implemented Supported in architecture but not implemented Supported but not released as a valid configuration This is implemented but not released as a valid configuration This is implemented but not released as a valid configuration Supported Supported Supported Supported Supported Supported but not released as a valid configuration Supported in a future release Supported Supported Supported in a future release Supported in a future release Supported in a future release DBP Legacy laser scanner interface using DBP SOS LAS_EN and SCAN_EN signals MDS High speed serial SPI interface developed by Toulouse for transferring raw A D data to the host processor RSTTL TTL level RS 232 from a scanner with built in decode Wand em
101. o SCAN_VCC e 0 0 or space state 1 1 or marking state SOS Start of Scan marker from laser scanner For decoded scanners this signal becomes an active low TTL level serial CTS handshake 5V tolerant 3 3V CMOS input 20K pull up to SCAN_VCC Active low bar code Good Read output to tethered scanners For decoded scanners this signal becomes a TTL level serial TxD output e 3 3V CMOS output Tri stated when SCAN_PWR_EN is off or SCAN_PORT 1 Can be driven in an open drain mode software selectable e 0 0 or space state 1 1 or marking state No connection CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation Pin 1 KEY 10 pin Stewart 937 SP 301010R K2 View looking into connector Tethered Scanner Connector Tethered Scanner Auto Detect The 072786 tethered scan flex assembly incorporates a MAX471 current sensor U1 to detect when a tethered scanner is plugged in This is intended as a piece of a scanner Plug and Play strategy but is not implemented in the current software Comparator U2 compares the current sensor output to a resistive divider reference and drives its open drain output connected to the IMAGER_PIXCLK FPGA input High Z float high no SCAN_5V current gt no scanner installed OV 25mASCAN_5V current gt scanner installed The TRIG_AIM signal in this case is used to enable and disable the auto detect feature such that when disabled the current sen
102. o the 8 pin RJ45 connector J1 Jl is the connector by which the end user connects to their Ethernet network AD2 Input Power Requirements The AD2 requires 12 VDC at 4A The 073573 power supply is qualified for use with the AD2 AC1 4 Slot Battery Charger The ACI can charge four CK30 batteries AB1 simultaneously AC1 Charging The design was done based on our input this makes the design of this charger very similar to all the in house designed CK30 chargers docks This charger also uses the TI BQ2954 to control charging The only difference is that the BQ2954 is configured for low side current sensing as opposed to all the in house designs which use high side current sensing The ACI has four identical charging circuits one for each slot in the charger U2 TI BQ2954 controls all aspects of charging for the AC1 It uses a constant current constant voltage charging algorithm The ACI is designed to charge the CK30 battery pack with a maximum charge current of 925 mA The sense resistor R27 is what sets the maximum charge current Imax 250 mV R27 The ACI is also designed to only allow charging between 0 C and 45 C 7 C A battery that has been discharged via normal use on a CK30 recharges in less than five hours on the AC1 J4 pins 1 2 and 3 are the contacts by which the AB1 battery interfaces to the charging circuitry The voltage divider formed by R22 and R21 is used to notify the BQ2954 that a battery has be
103. o used to determine whether to begin charging based on the battery voltage and an internal reference voltage in the BQ2954 Temperature monitoring is done using a voltage divider formed by R96 R98 and a NTC thermistor R130 If the battery voltage is at a value that the BQ2954 identifies as being below the reference voltage and the ambient temperature is within acceptable limits then a charge cycle begins When a charge cycle begins pin 14 on the BQ2954 is modulated at 100kHz This pin controls a buck switcher formed by Q10 D36 and L3 This switcher is set to provide a constant 8 4 VDC from the 12 VDC supply Once the battery has reached 8 4V 100 mV 10 mV then the BQ2954 switches to the constant voltage phase of the charge cycle CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation During this phase the BQ2954 slowly ramps down the charge current until the designed trip point Imax 20 is reached At this point charge current is terminated and the charge cycle is complete The BQ2954 uses the current mirror U3 to measure the charge current This measurement is used to compare against the designed trip point Imax 20 AD2 Ethernet Switch The KS8995X is a fully independent five port 10 100 Ethernet switch The switch is configured completely by resistor strapping per the KS8995X datasheet Each of the four 26 pin JAE connectors is connected to a port on the Ethernet switch The fifth port is connected t
104. of a frame of data At the end of a frame FPGA logic appends a OxFFFF end of data marker to the accumulated data and then pads the data with a DBP polarity value until the DMA buffer contains a complete DMA record The DBP polarity value is OxFFFA if DBP_HSYNC was high the last count recorded OxFFF5 if it was low See 605879 Existing Interface Specification for more detail on this scanner interface protocol Wands and Wand Emulation 2D Imagers 80 Wands and wand emulation devices also use the count gathering logic described in 1D DBP Scanner Interface on page 78 except that only the DBP_HSYNC signal is used Since there are no SOS or TRIGGER signals from the input device the FPGA is configured by software to automatically start its count gathering logic on the first DBP_HSYNC transition which is either the wand paper detect or the first bar of a label In the absence of SOS strobes counter overflow is used to sense the end of scanned data and append the end of data and polarity markers Internal 2D imagers are handled through custom interface logic in the FPGA CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation Bus I F Scanner I F SDBUF_D7 0 SD31 0 DBP_HSYNC SOS VSYNG D g SA25 0 9 SCAN_DREQ 9 ILLUM_LASEN_RTS x SCAN_FLASH_EN SCAN_IRQ gt SCAN_TRIG 7 2 IMAGER_PIXCLK Host CPU I F DQM3 0 ni n p WE 89 GPIO nPWE Q RDY n RD WR r GA_CS afa PCI HC
105. onal States XN System Power States and Transitions Device Power States 56 Power is switched to various parts of the design as indicated in the following table Some sections can be optionally left powered during Suspend to support user selected features like 802 11 WakeOnLAN Bluetooth wake on connect or tethered scanner trigger resume See individual specs for devices in this table that may support power states unique to that device see Supported Bus States on page 73 for Mini PCI slot supported power states Treatment of a device during a critical shutdown falls into two categories shown in the Critical Shutdown Type column See Device Power Control on the next page for more detail CK30 Handheld Computer Service Manual Device Power States Computer awake Device System On Power supply ON controller CPU core supply ON VCCN and VCCkp ON PLL_VCC ON Core logic ON memory and BATT_VCC GPIO expansion ON HCR registers Mini PCI slot ON SD slot ON Scanning interface ON Mini PCI FPGA Internal Scanner ON power External Scanner ON power Dock interface RS ON 232 USB Bluetooth ON LCD display ON LCD bias ON Backlight ON when needed Audio codec ON Audio amplifier ON Computer suspended Main battery in ON OFF ON OFF ON ON ON when so configured default is OFF OFF OFF OFF ON when so configured default is OFF ON when so configured default is
106. or 5V CMOS output Drives 5V CMOS input or NPN base with pull up to 5V Drives 5V CMOS input or NPN base with pull up to 5V Drives 5V CMOS input or NPN base with pull up to 5V CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation Dock Interface Signal Descriptions continued Signal Pin Name 12 TETH_PRE SENT 22 TX 23 TX 24 RX 25 RX USB Port RS 232 Port Description Signal Characteristics Scanner interlock to mux internal and external 3 3V CMOS undecoded scanners 0 undecoded scanner present 1 no undecoded scanner present Ethernet TX Ethernet TX Ethernet RX Ethernet RX The CK30 supports USB 1 1 12Mbps client functionality through the USB_D USB_D and USB_5V signals on dock interface connector J13 The USB client controller is built into the PXA255 processor U2 When the USB connection is used for serial port emulation the operating system maps it as COM1 USB_5V the 5V power supplied by the USB host is used only to detect the presence of a USB host it is not used to power any CK30 hardware It is divided down to 3 3V levels by R157 and R160 and routed as signal USB_WAKE to PXA255 interrupt input GPIO19 The USB software driver responds to the interrupt by trying to connect to a USB host through the PXA255 client controller If the CK30 is suspended USB_WAKE can be configured to wake the system through the DOCK_WAKE path a high going transit
107. red to route the BEEP signal through to the scanner on the IMAGER_PIXCLK line to scanner connector J3 CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation e Hardware tone duration control in the FPGA This was a contingency against concerns about WindowsCE interrupt latencies leading to noticeably sloppy software controlled tone durations In that event PXA255 PWM 1 would continue to generate the tones but a timer built into the FPGA would gate the signal to provide precise duration control R300 would be installed instead of R126 so that FPGA output FPGA_BEEP would drive the audio amplifier So far this feature has not been needed Audio amplifier Ul9 can also be driven from audio codec U18 This feature is included to enable future CK30 versions with VoIP support and is not currently installed Debug Support Field Access Debug Port All PXA255 and FPGA JTAG signals as well as the I2C bus and PIC U38 programming signals are available through 16 pin non ZIF flex connector P1 accessible through the SD slot door A special connector board 073048 001 and flex cable 073049 001 are used to attach JTAG emulators boundary scan tools or 12C monitoring tools and to reflash either system flash or U38 PSC firmware JTAG Interface Signal Descriptions Pin O ON DW KR O NHN na e e me a D MN KR WO N YF O Signal Name 3 3V JTAG_TCK JTAG_TDI JTAG_TDO JTAG_TMS FPGA_TDI FPGA_TDO RESET_IN
108. robe PWE serving as the CCLK download clock The FPGA IO is nominally Hi Z during download When the download is complete the FPGA enables its outputs When its internal DLLs have locked it raises its DONE output alternate function of signal SCAN_IRQ to signal the download was successful Software then initializes the FPGA internal register settings See Xilinx datasheets and app notes for details of the parallel slave download scheme After download signals SCAN_DREQ and SCAN_IRQ are no longer used by the FPGA as download status indications and take on their programmed functions of scanner DMA request and scanner interrupt line Because of the fairly high operating and standby currents of the FPGA it must be powered off during Suspend Since it will lose its configuration when power is removed its image must be re downloaded on every resume This also limits its use to functions that are needed only at run time FPGA Power Management The FPGA uses separate core and IO supplies 3 3V is switched through FET Q1 to the FPGA IO supply pins A separate switchable 2 5V supply U43 is provided for the FPGA core voltage The 2 5V supply is enabled and disabled under software control via the FPGA_PWR_EN signal inverted through U51 A section of operational amplifiers U41 functions as a slow turn on control for U43 This prevents a crippling inrush current surge that would otherwise result if the core supply were brought rapidly to 2 5V
109. s DSO 1 Sample ao DSU 1 Sample K LA 1 COLO LA 1 COL1 LA 1 COL2 LA 1 COL3 LA 1 COL4 LA 1 COLS LA 1 COLG LA 1 COL LA 1 GPIO 48 LA 1 INTA zizi J J LEMY J LA 1 ROWO LA 1 KEY_INT LA 1 KEY_INT_EN 5 U Typical Keypad Scanning Wakeup Keys Q Key pressed in Row 0 Debounce with resulting GP1048 columns interrupt Scanning the matrix Since the keypad matrix rows are read through the FPGA the keypad is not functional at boot or resume time until the FPGA is downloaded initialized and running However by routing one keypad row line KEY_RETO straight to PXA255 GPIO1 as well as to the FPGA the CK30 enables a small number of keys to serve as system wakeup keys CK30 Handheld Computer Service Manual 1 0 Key Scan Buttons Keypad ID Chapter 4 Theory of Operation Since KEY_RETO can toggle PXA255 GPIO1 which is always enabled as a system wakeup pin any key located in keypad Row 0 functions as a wakeup key if its column line is driven low during Suspend In the first three keypad styles the 1 2 3 Scan button where present and handle trigger keys are all placed in Row 0 as potential wakeup keys In future OS releases these may be user configured to wake the system from Suspend Current software though has no support for this feature All eight column
110. sor output is high Z so it does not interfere with the IMAGER_PIXCLK signal alternate scanner function BEEP TRIG_AIM 0 gt auto detect enabled TRIG_AIM 1 gt auto detect disabled Since some scanners draw little or no current until the trigger is pulled the auto detect feature may not function until the scanner trigger is pulled The auto detect signal should be ignored during transitions most often occurring on Suspend and Resume when the current sensor changes state as SCAN_5V is enabled and disabled possibly giving a false scanner detection Inverter U3 driven by the SCAN_EN signal is used to switch the DBP SOS and Trigger pull ups to pull downs to aid in the scanner auto ID process This is useful for distinguishing newer decoded output scanners from older legacy DBP mode undecoded scanners Tethered Scanner Support Through Dock Connector Decoded output tethered scanners and undecoded DBP tethered scanners are also supported through 26 pin docking connector J13 mostly so that a tethered scanner can be left attached to a vehicle dock and become active when the CK30 is docked CK30 Handheld Computer Service Manual 85 Chapter 4 Theory of Operation This is specifically not a CK30 requirement but is expected to be a requirement for future products which will all use the same docking connector e Undecoded scanners use the FPGA count gathering logic See 1D DBP Scanner Interface on page 78 When
111. stalled Using the Scanner Interface Signal Set Part 2 Signal Name SCAN_PWR_EN ILLUM_LASEN_RT S SCAN_FLASH_EN SOS DBP Video Source Destination U11 out FPGA_IO U11 out FPGA in FPGA in Enable aiming LED EV10 1D 2D select Auto Detect Enable 0 disable 0 2D 0 enable 1 enable 1 1D 1 disable SE900 aim beam Modulate SE900 config bit 2 Trigger from scanner illumination LEDs hea eas Not used on IT4000 8 bit Imager pixel data I2C imager control Tethered Decoded SPI Scanner Usage Enable scanner power 0 enable 1 disable Laser enable 0 enable 1 disable Scan enable 0 enable 1 disable SOS Start of Scan toggles at start of each scan SPI data from scanner CK30 Handheld Computer Service Manual EL10 Usage Enable scanner power 0 enable 1 disable Laser enable 0 enable 1 disable Scan enable 0 enable 1 disable SOS Start of Scan toggles at start of each scan DBP Video 0 black 1 idle white Decoded Scanner Usage 10 pin only Enable scanner power 0 enable 1 disable RTS to scanner Active low CTS from scanner Active low RxD from scanner 0 0 or space state 1 1 or marking state Scanner E1025 Usage Enable scanner power 0 enable 1 disable RTS to scanner Active low Scanner reflash enable Active high CTS from scanner Active low RxD from scanner 0 0 or space stat
112. supply U39 exceeds U44 3 2V output While the CK30 is still on signal PWR_EN holds U44 MODE pin low constant frequency mode increasing its efficiency under heavy load Once the system suspends PWR_EN goes high selecting U44 burst mode for higher efficiency under a light load Supercap Charging C89 is charged at a constant 2 5V through LDO U50 Power Supply Controller U38 enables supercap charging as long as main battery voltage is25 1V While the CK30 is docked in an AD1 AD2 or AC2 the dock provides 12V operating current through Pin 3 on the base of the battery The battery pack internal logic biases off the battery voltage sending the Pin 3 voltage from the dock to the CK30 while the battery charges DC voltage applied to the CK30 must not exceed 15 VDC CK30 Handheld Computer Service Manual 53 Chapter 4 Theory of Operation Power Management Architecture PXA250 based System Addr Data Bus Memory mapped Registers Data WinCE Addr Power Manager 5 Shutdn 52 c2z Intermec 9 z a if i Battery Manager Q oO jag n gE QO GPIO gt 2 8 89 INT Handler 120 driver Shuan Low Batt Detect Y Y 12C Power Supply IO Key Controller Core 1 3V 3 3V etc g Battery Supercap Temperature Rst SW Low 3 3V Monitoring T Detect Reset CK30 Power Managemen
113. t PCI bridge in the FPGA The PCI bridge in turn requests ownership of the PXA255 system bus to complete the transaction to or from system SDRAM At first release the radio is powered and active only when the computer is awake and is powered off during Suspend Primary power management is handled by the card itself and its driver The power management mode is user selectable through the configuration menus 10 100 Ethernet is supported through an Actiontec MP100R2 Type 3A Mini PCI Ethernet card based on the Realtek RTL8100BL controller This card is also a bus mastering device It does not rely on interrupting the PXA255 to have it transfer data to and from the card Instead when it needs to transfer data to and from system SDRAM it initiates its own read and write transactions on the Mini PCI bus to the target PCI bridge in the FPGA The PCI bridge in turn requests ownership of the PXA255 system bus to complete the transaction to or from system SDRAM The 802 3 sideband signals in the Mini PCI connector are not used Instead a short cable assembly is used to bring the 802 3 signals from a connector on the Mini PCI card to four position connector J12 on the CK30 main PCB From there the signals are routed to 26 pin dock connector J13 and passed on to an RJ45 network connector in the AD1 or AD2 dock The CK30 architecture supports the following internal scan engines and external tethered scanners CK30 Handheld Computer Service Ma
114. t find the part in the exploded view and locate its callout in the following spare parts list Screw 4 places i i Screw 2 places SE1200 Scan Engine Assembly Spare Parts List To identify a part find the callout in this list and locate the part in the previous exploded view Callout Description 1 SE1200 scan engine assembly Standard range Advanced long range SE1200 scan engine visor Large scan mount bracket Large engine scan window SE1200 scan engine shield SE1200 scan flex Phillips 2 28 x 250 thread form screw Steel M2 x 0 4 by 4mm panhead screw DN KR HY N CK30 Handheld Computer Service Manual Part Number 590014 004 591098 003 073703 003 072865 002 073044 002 073883 002 072781 003 525301 800 318 004 33 Chapter 3 Spare Parts List and Exploded Views EV10 Scan Engine Assembly Exploded View This illustration shows the EV10 scan engine assembly in relation to the bottom cover To identify a part find the part in the exploded view and locate its callout in the following spare parts list WS EN Screw 3 places 8 i A O 8 Screw 2 places EV10 Scan Engine Assembly Spare Parts List To identify a part find the callout in this list and locate the part in the previous exploded view Callout Description Part Number 1 EV10 engine insulator 073657 001 2 EV10 scan engine assembly 3 131010 01 02 3 EV10 engine ground spring 073495 001 4 Small scan mount
115. t Block Diagram 54 CK30 Handheld Computer Service Manual System Hardware Power States System Processor Power OS Power Power States States States Off N A N A Suspend Suspend Sleep Suspend Suspend Sleep Devices left on On Run Idle Run Turbo Power Consumption Typical at 8V N A 2mA N A N A 110mA 130mA 150mA 250mA 300mA Maximum at 8V N A lt 3mA N A N A 160mA 180mA 200mA 330mA 360mA Chapter 4 Theory of Operation Notes Conditions Main battery out supercap fully depleted Supercap fully charged If the supercap is depleted this current can be as high as 70mA As the supercap charges this current steadily declines Current consumption depends entirely on what devices are left powered during Suspend See the System Power States and Transitions table in the next section The operating system switches in and out of the Idle state too fast and unpredictably to make any typical current measurement repeatable CK30AA Batch CPU at 200MHz Idling at splash screen mono display backlight off not scanning CK30AA Ethernet but not connected CPU at 200MHz Idling at splash screen mono display backlight off not scanning CK30AA Ethernet connected CPU at 200MHz Idling at splash screen mono display backlight off not scanning CK30BA CPU at 200MHz Idling at splash screen mono display backlight off not scanning Actiontec 80
116. te the system RAM 32MBs for the CK30AA and CK30BA and 64MBs for the CK30CA The SDRAM is interfaced at 3 3V bus levels through the PXA255 memory controller at 99 5MHz with CAS latency of 2 The processor s Normal Mode addressing scheme is used SDRAM size is checked by the bootloader at boot time to configure the memory controller for different SDRAM BankxRowxColumn geometries The same CAS before RAS refresh period of 8us is used for both 128Mbit and 256Mbit SDRAM densities In the current CK30 32MB and 64MB configurations the SDRAM occupies partition 0 of the processor s SDRAM space Provision is made through not installed AND gate U3 to support 128MB SDRAM using 512MB chips In this case the SDRAM occupies partitions 0 and 1 FPGA U8 is an alternate bus master that can request the system bus and take over control of the SDRAM When U8 is in control it runs the SDRAM at 49 77MHz For more information see SDRAM Controller on page 71 Flash U4 and U5 constitute the system XIP flash 32MB for the CK30AA and CK30BA and 64MB for the CK30CA Intel K3C synchronous Strataflash is used for the 64MB configuration the 32MB configuration may be either J3A asynchronous or K3C synchronous Strataflash The system flash boots in asynchronous mode The boot code reads the flash ID and switches the flash to synchronous mode if K3C flash is detected Otherwise flash is handled as asynchronous page mode flash The flash is protected
117. tery Handling The first three battery status thresholds are defined in software the final critically low battery threshold is based on hardware comparator U36 Low Battery Thresholds Threshold to Threshold to Exit State Temp C Enter State State Action Software 2 3 lt 0 C lt 7 73V gt 7 83V Battery at approximately 67 capacity threshold 10 C lt 7 78V gt 7 88V capacity 2 3 battery status 20 C lt 7 83V gt 7 93V icon is displayed 30 C lt 7 87V gt 7 97V is lt 7 92V gt 8 02V 40 C lt 7 97V gt 8 07V 50 C Software 1 3 lt 0 C lt 7 07V EN Battery at approximately 33 capacity threshold 10 C lt 7 16V gt 7 26V capacity 1 3 battery status 20 C lt 7 25V gt 7 35V icon is displayed 30 C lt 7 35V gt 7 45V E lt 7 44V gt 7 54 V eve lt 7 53V gt 7 63V 50 C Software low lt 0 C lt 6 4V gt 6 5V Battery at 0 Empty battery threshold 10 C lt 6 54V gt 6 64V battery status icon is displayed 20 C lt 6 68V gt 6 78V and the red LED turns on 30 C lt 6 82V gt 6 92V o lt 6 96V gt 7 06V 40 C lt 7 10V gt 7 20V 50 C Critically low lt 0 C lt 5 82V gt 6 41V Critically low battery U36 battery 10 C lt 5 96V gt 6 55V asserts interrupt 20 C lt 6 15V gt 6 69V BATT_FAULT_IRQ to start 30 C lt 6 31V gt 6 80V a Suspend This state must be lt 6 45V gt 6 88V exited before the CK30 is w lt
118. tethered scanner does not work The beeper does not work or the frequency or volume is not adequate Solution Try these possible solutions in order The CK30 may not be properly configured for serial communications Make sure the serial communications parameters are properly configured The AAI serial adapter cable may have failed Replace the serial adapter cable The main PCB assembly serial interface may have failed For help see the Replacing the Main PCB procedure on page 15 Try these possible solutions in order The main battery may not be fully charged Make sure the main battery is fully charged The real time clock circuit on the main PCB assembly may be damaged or you experienced a backup power failure when changing the main battery For help see the Replacing the Main PCB procedure on page 15 Try these possible solutions in order There may be a problem with the tethered scanner or the scanner configuration Make sure the tethered scanner works and that the CK30 is properly configured for the scanner A low main battery may have caused the tethered scanner power to be turned off Charge the main battery The tethered scanner connector or flex cable assembly may be damaged For help see the Replacing the Tethered Scanner procedure on page 25 Try these possible solutions in order One or both of the sound portholes may be blocked Clean the porthole s A low main battery may h
119. tible to damage from electrostatic discharge ESD When you see this icon you must follow standard ESD guidelines to avoid damaging the equipment you are servicing Because finger oils can impede the performance of scanner parts and dissolve the reflective coating of the plastic mirrors always wear finger cots or non powdered latex gloves when handling optical parts Note Notes either provide extra information about a topic or contain special instructions for handling a particular condition or set of circumstances CK30 Handheld Computer Service Manual Before You Begin Global Services and Support Warranty Information To understand the warranty for your Intermec product visit the Intermec web site at http www intermec com click Support and then click Warranty Disclaimer of warranties The sample code included in this document is presented for reference only The code does not necessarily represent complete tested programs The code is provided as is with all faults All warranties are expressly disclaimed including the implied warranties of merchantability and fitness for a particular purpose Web Support Visit the Intermec web site at http www intermec com to download our current manuals in PDF format To order printed versions of the Intermec manuals contact your local Intermec representative or distributor Visit the Intermec technical knowledge base Knowledge Central at http intermec custhelp com to rev
120. to find common problems users may experience with their CK30 and possible solutions Problem You press Yo to turn on the CK30 and nothing happens The keypad does not work Some keys on the keypad work and others do not The display contains pixels or lines that are missing or always turned on Solution Try these possible solutions in order Make sure you have a charged battery installed correctly For help see Charging and Installing the Battery in the CK30 Handheld Computer Users Manual P N 073528 There may be a connection problem between battery contacts and the main PCB Clean the battery contacts The Yo key on the keypad may not be working properly Make sure that the keypad flex cable is connected properly to the keypad and the main PCB If everything is connected properly replace the keypad For help see the Replacing the Keypad Assembly procedure on page 20 There may be a power supply failure in the main PCB For help see the Replacing the Main PCB procedure on page 15 Try these possible solutions in order The keypad may be disconnected Make sure that the keypad flex cable is connected to the main PCB If everything is connected properly replace the keypad For help see the Replacing the Keypad Assembly procedure on page 20 The main PCB assembly keypad interface may have failed For help see the Replacing the Main PCB procedure on page 15 Try these
121. tput resetting the system flash CK30 Handheld Computer Service Manual 63 Chapter 4 Theory of Operation 1 0 Control 64 POR Reset Cold Boot Power On Reset circuit VR3 simultaneously asserts the PSC reset input and the PXA255 nRESET This ensures that the processor is always in reset as its power is ramped up Soft Reset Warm Boot Warm boot forces code execution to vector to boot code where the kernel is restarted without reinitializing the object store Warm boot is implemented as in the 700 and 241X products Pressing and holding the Yo key for several seconds e The PSC first wakes the system if it is suspended e The PSC starts a timer on Yo key down e Ifthe IO key is still down after approximately 5 seconds the PSC asserts signal VDD_FAULT to command a warm boot e If the Yo key is released before the timer expires the PSC treats it as a simple Suspend Resume command and asserts PSC_IRQ to suspend or resume the system The VDD_FAULT assertion causes the processor to suspend The PSC then awakes the system using PSC_IRQ Code execution starts as it would on a normal resume but checks the PXA255 power management registers to determine if the exception was triggered by VDD_FAULT If it was code execution vectors to the warm boot in the bootloader Peripheral Resets Other functional blocks in the computer have their own resets The FPGA generates its own internal reset as part of the download pro
122. us LED for more details on red LED states Hardware Critical Low Battery Threshold As the battery level declines further or the battery is removed the level crosses the hardware critical low battery threshold set by temperature compensated comparator U36 This interrupts the PXA255 through signal BATT_FAULT_IRQ to start a Suspend and interrupts the PSC so that it knows the PXA255 should be suspending When the system suspends the processor s RESET_OUT output is driven low causing U42 output BATT_FAULT to go low This inhibits the system from resuming until the battery is replaced or its level rises above U36 high going threshold BATT_FAULT_IRQ goes high PSC U38 drives red LED D16 through Q11 D16 to display the following battery and boot states The power management driver running on the PXA255 sends I2C commands to the PSC to use the red LED for low battery indication The PSC itself directly controls the red LED to indicate cold boot and other power management events CK30 Handheld Computer Service Manual Red LED States Power state No Battery Low Battery Good Battery Warm Boot Cold Boot Reset Control Indication Red LED off The red CK30 LED turns on continuously while CK30 is running once battery voltage falls below the software low battery threshold This continues until Suspend either by the Yo key or when the battery falls below the hardware critical battery threshold Red LED flashes twi
123. wer savings In future software releases the Bluetooth module may optionally be left powered during Suspend to support system wakeup from an incoming Bluetooth message Bluetooth power is automatically shut off in a critical battery situation by the Type 1 interlock mechanism described in Device Power Control on page 58 CK30 Handheld Computer Service Manual Chapter 4 Theory of Operation The module is interfaced through a 4 wire serial connection to the PXA255 s BT UART This UART and its counterpart in the Bluetooth module are capable of high speed operation up to 921 6kbps but in the current software are run at 115 2kbps The operating system maps this port as COM4 No Bluetooth reset is provided the Bluetooth module generates its own Power on reset However capacitor C153 can be installed to provide a reset when an Alps BC02 module is used The module s PCM interface is not used The Bluetooth module firmware interfaces to the CK30 at the Bluetooth HCI layer The higher stack levels are provided by Microsoft s Bluetooth driver and are included in the CK30 OS image Storage Card SD card Sandisk SD Secure Digital cards are supported in 1 bit mode through SD slot J17 and the SD MMC controller in the PXA255 processor For details of the SD interface and protocol refer to the SD spec and to 278693 001 Intel Y PXA255 Processor Developers Manual Revision 001 January 2003 The SD card is pow
124. were to become corrupted while upgrading itself the CK30 would become unusable and would have to be returned to a service depot for repair In the event the Primary bootloader becomes corrupted or needs service depot upgrade it can also be reflashed using Intel s JFLASH utility through the P1 JTAG port See Field Access Debug Port on page 93 using a parallel port JTAG cable such as the Insight Model IJC 2 For the current release version 1 01 01 0229 the only way to upgrade the OS image is to cold boot the CK30 with an SD card containing an image of the OS image The Primary bootloader boots the system and looks for a new image file on an installed SD card If the card and file are present the bootloader downloads the image into SDRAM erases the relevant portions of the system flash then writes the OS image to flash When the write is complete the system cold boots into the new image CK30 Handheld Computer Service Manual 95 Chapter 4 Theory of Operation In System Programmability of Programmable Devices Accessories Connector Pin Outs 96 FPGA The SRAM based FPGA supports two programming models In normal operation the FPGA is downloaded at boot time and on every resume by the FPGA download driver running on the PXA255 processor See FPGA Download on page 48 for details For debug purposes for instance if the OS is not running the FPGA can be also programmed via the JTAG port using the 073048 JTAG

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