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7932_HardwareServiceGuide

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William Frederick Prine

This document provides service and troubleshooting information for the NCR SelfServ Entertainment kiosk models 7932 and 2371-9990. It includes details on component locations, diagnostic utilities, calibration procedures, and steps for replacing parts like the touchscreen, motherboard, UPS, and more. Safety guidelines are provided for working on the kiosk and using ladders if required. The document is intended for hardware technicians servicing the kiosks.

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NCR SelfServ Entertainment – Multifunction / 7932 & 2371-9990 Release 1.0 Hardware Service Guide 27384 B005-0000-1886 Issue A
The product described in this book is a licensed product of NCR Corporation. NCR is a registered trademark of NCR Corporation. NCR SelfServ Entertainment Kiosk is either a registered trademark or a trademark of NCR Corporation in the United States and/or other countries. It is the policy of NCR Corporation (NCR) to improve products as new technology, components, software, and firmware become available. NCR, therefore, reserves the right to change specifications without prior notice. All features, functions, and operations described herein may not be marketed by NCR in all parts of the world. In some instances, photographs are of equipment prototypes. Therefore, before using this document, consult with your NCR representative or NCR office for information that is applicable and current. To maintain the quality of our publications, we need your comments on the accuracy, clarity, organization, and value of this book. Address correspondence to: Manager, Information Solutions Group NCR Corporation Discovery Centre 3 Fulton Road DD2 4SW Internet Address: http://www.info.ncr.com/eFeedback.cfm Copyright © 2009 By NCR Corporation Dayton, Ohio U.S.A. All Rights Reserved
i Preface This book provides information that is necessary to identify and repair problems. This includes troubleshooting information and step-by-step procedures for replacing hardware components. Audience This book is written for hardware installer/service personnel, system integrators, and field engineers. Notice: This document is NCR proprietary information and is not to be disclosed or reproduced without consent. Battery Information Battery Type Component/Location Device Part # Removal Instructions Lithium Motherboard / CPU 006-8612322 Page 154 Lithium JBM Router C120 006-8615023 Page 172 Lead Acid UPS – Eaton Powerware 5110 006-8614269 Page 163 Safety Requirements The NCR SelfServ Entertainment – Multifunction / 7932 & 2371-9990 conform to all applicable legal requirements. To view the compliance statements see the NCR SelfServ Entertainment Products Safety and Regulatory Guide (B005-0000-1904). Additional Safety Requirements Specific to NCR 7932 & 2371-9990 Kiosks The Soft Stop Rocker Switch (2371-9990) or Jumper (7932/TE1001) is a logic switch that only stops all PLC controlled motion. The AC line voltage primaries are live at all times — even after disconnecting the power cord. Therefore, perform a normal shut down of the Motherboard/CPU, power off the UPS, and then disconnect the AC power cord before servicing this terminal. Warning: Hazardous moving parts inside. Unexpected motion of mechanical parts may occur if the Limit Switch is pressed. Keep fingers and other body parts away from moving parts. The system may start unexpectedly if power is not disconnected. Warning: The NCR 7932 or 2371-9990 must be placed on a level surface with the casters locked. When relocating the kiosk, set the casters to their minimum height adjustment (fully screwed in) – using the Caster Wrench (part # 6039014898) – to prevent bent casters. Ladder Safety Worker safety must be considered if a ladder is required to service the NCR SelfServ Entertainment – Multifunction / 2372 kiosk. This can be a concern if the AC power outlet is located above the kiosk.
ii The NCR Ladder Safety Process (Infr.7.9.4.2.3_PRO_WCS-HR-EHS_GLOBAL) prohibits work on portable stepladders with employees’ feet above 3 Meters (10 Feet) without proper fall protection or the use of a mechanical/electric lift. It also identifies proper ladder selection and condition. Refer to the following website for the NCR Ladder Safety Process. http://cks1.ncr.com/local/gps.nsf/docsumm/5CDA704F3A1DDB9CC1256E4E005AC5E8?OpenDocument Additional Information Products • NCR SelfServ Entertainment – Multifunction / 7932 & 2371-9990 Parts Identification Manual (B005-0000-1934) • NCR SelfServ Entertainment Products Safety and Regulatory Guide (B005-0000-1904) • NCR Workstation and Peripherals AC Power Wiring Guide (BST0-2115-53) • NCR Ethernet Wiring Guide (BST0-2118-82) • NCR 6352XP Reader User Manual (Japanese) (B005-0000-1920)
iii Table of Contents Chapter 1: Product Overview 1 Introduction .................................................................................................................. 1 Removing the Kiosk Panels ......................................................................................... 2 Front Access Panel................................................................................................. 2 Side Panels............................................................................................................. 2 Rear Access Panel.................................................................................................. 2 Order of Operation ....................................................................................................... 3 Tools Required for Service........................................................................................... 5 Service Information...................................................................................................... 7 Component Location.................................................................................................... 8 Diagnostics................................................................................................................... 9 Administrative Login............................................................................................. 9 Service Utilities ..................................................................................................... 9 Service Utilities Main Functions..................................................................... 10 Setup & Config Functions............................................................................... 11 Diagnostic Tab Functions................................................................................ 12 XE 1.x Utilities Tab Functions........................................................................ 14 Accessing Service Utilities.............................................................................. 14 RFGate................................................................................................................. 15 MagTek USBMSR............................................................................................... 17 Physical Inventory ............................................................................................... 18 Physical Inventory Features ............................................................................ 18 Performing a Physical Inventory..................................................................... 19 GE PLC Audit, 2371-9990 .................................................................................. 20 Accessing GE PLC Audit, 2371-9990............................................................. 20 Using PLC Audit, 2371-9990.......................................................................... 20 Motion Exerciser (MoX) ..................................................................................... 23 Motion Exerciser 1.x (KAI) ............................................................................ 23 Motion Exerciser 2.x (AKPOS Motion Exerciser).......................................... 27 Motion Power ...................................................................................................... 32 Motion Log and PLC Commands........................................................................ 33 Response Strings ............................................................................................. 33 Handshaking.................................................................................................... 33 Command Strings............................................................................................ 34 Additional Command Strings.......................................................................... 34 Command Responses....................................................................................... 35 Busy Command Response............................................................................... 35 Example Communication Sequences .............................................................. 36
iv Kiosk Power ............................................................................................................... 38 UPS Assembly, 2371-9990 & 7932-8082 ........................................................... 38 Main Circuit Breaker ........................................................................................... 38 Customer Control Center (Pod) Assembly .......................................................... 39 PC Power Supply............................................................................................. 39 Touch Screen Monitor Power Supply ............................................................. 39 Control Panel Assembly ...................................................................................... 39 15 VDC Power ................................................................................................ 39 Vertical Motor Speed Controller Power.......................................................... 40 PLC Power ...................................................................................................... 40 24 VDC Power ................................................................................................ 40 Robotic Calibration .................................................................................................... 41 Calibration Check ................................................................................................ 41 Calibration Procedures......................................................................................... 41 Vertical Guide Alignment ............................................................................... 41 Leveling the Carriage Assembly ..................................................................... 42 Vertical Timing Belt Leveling Adjustment..................................................... 44 Vertical Sensor Adjustments ........................................................................... 46 Pick Height Adjustment .................................................................................. 49 Place Height Adjustment, 7932-8080/8082 & 8094 ....................................... 50 Carriage Recovery Procedure.......................................................................... 52 Gripper Horizontal Pick and Place Alignment................................................ 54 Vertical Position Transducer Adjustment, 7932-8082 & 8094 ....................... 56 Horizontal Position Transducer Adjustment, 7932-8082 & 8094................... 57 Interaction Slot Gate Proximity Sensor Calibration........................................ 59 Bin Structure Alignment.................................................................................. 61 Belt Tension Verification and Adjustment .......................................................... 64 Gate Strap Verification.................................................................................... 64 Gate Strap Adjustment .................................................................................... 65 Roller Belt Tension Verification ..................................................................... 66 Roller Belt Tension Adjustment...................................................................... 66 Insertion Axis Belt Tension Verification......................................................... 68 Insertion Axis Belt Tension Adjustment ......................................................... 68 Horizontal Belt Tension Verification .............................................................. 69 Horizontal Belt Tension Adjustment............................................................... 70 Vertical Belt Tension Verification .................................................................. 71 Vertical Belt Tension Adjustment................................................................... 74 Gripper Motor Belt Tension Adjustment and Verification.............................. 75 Chapter 2: Troubleshooting 77 System Assessment .................................................................................................... 77
v Visual Check........................................................................................................ 77 Functional Check................................................................................................. 78 Touch Screen Monitor................................................................................................ 81 Power Brick ......................................................................................................... 81 Cable Connections............................................................................................... 81 Power ON ............................................................................................................ 81 Monitor Settings .................................................................................................. 82 Calibrating a Touch Screen.................................................................................. 83 Touch Screen Connectivity.................................................................................. 85 Touch Screen Driver............................................................................................ 85 Tools Required ................................................................................................ 85 Procedure......................................................................................................... 85 Secondary Display, 2371-9990 .................................................................................. 86 Secondary Display Settings ................................................................................. 86 Power ON ............................................................................................................ 87 Magnetic Stripe Reader.............................................................................................. 89 RFID Components...................................................................................................... 91 Pod Speakers .............................................................................................................. 94 Adjusting the Volume.......................................................................................... 94 No Sound ............................................................................................................. 94 LAN / WAN Connectivity in the Kiosk..................................................................... 95 LAN ..................................................................................................................... 95 WAN.................................................................................................................... 95 JBM Electronics Gateway C120 Router.......................................................... 95 AirLink Raven-E Modem................................................................................ 99 Motherboard / CPU .................................................................................................. 101 Features.............................................................................................................. 101 CPU Power ........................................................................................................ 101 CPU Power Connections............................................................................... 101 New-Motherboard Power Reset .................................................................... 101 CPU Not Working ............................................................................................. 102 Spare USB Ports............................................................................................ 103 BIOS Settings................................................................................................ 103 Memory ......................................................................................................... 103 USB Port Headers.............................................................................................. 104 Communication Port Settings................................................................................... 105 COM1 ................................................................................................................ 105 COM2 ................................................................................................................ 105 Windows Device Manager................................................................................. 105 List COM Ports.................................................................................................. 107 Programmable Logic Controller (PLC), 7932-8080 & 2371-9990 .......................... 108
vi Features.............................................................................................................. 108 Power ................................................................................................................. 109 Resetting the PLC.............................................................................................. 109 PLC USB Connections ...................................................................................... 109 Soft Stop ............................................................................................................ 110 Inputs / Sensor & Switch Identification............................................................. 111 Outputs / Relay Identification............................................................................ 112 Programmable Logic Controller (PLC), 7932-8082 & -8094.................................. 113 Analog Outputs and Inputs ................................................................................ 113 Horizontal Position Transducer Output Voltages.......................................... 113 Vertical Position Transducer Output Voltages.............................................. 113 Analog Input Module .................................................................................... 113 Inputs / Sensor & Switch Identification............................................................. 114 Outputs / Relay Identification............................................................................ 115 Gripper Assembly Sensors....................................................................................... 116 Fiber Optic Sensors............................................................................................ 116 Fiber Optic Amplifiers .................................................................................. 116 Fiber Optic Amplifier Features ..................................................................... 116 Look Down Sensors........................................................................................... 117 Carriage Assembly Sensors...................................................................................... 118 Horizontal Sensor Bracket Assembly, 7932-8080 & 2371-9990 ...................... 118 Horizontal Position Transducer, 7932-8082 & -8094........................................ 118 Insertion Axis Proximity Sensors ...................................................................... 118 Left & Right Limit Switches ............................................................................. 119 Vertical Axis Sensors............................................................................................... 120 Vertical Sensor Assembly, 7932-8080 & 2371-9990........................................ 120 Vertical Position Transducer, 7932-8082 & -8094............................................ 120 Upper & Lower Slowdown Sensors .................................................................. 120 Upper & Lower Limit Switches......................................................................... 121 Interaction Slot & Gate Sensors ............................................................................... 122 Interaction Slot Sensor....................................................................................... 122 Gate Up Proximity Sensor................................................................................. 122 Gate Down Proximity Sensor ............................................................................ 122 Gate Through-Beam Sensor............................................................................... 122 Chapter 3: Component Replacement 123 Component Access................................................................................................... 123 Engaging Soft Stop............................................................................................ 123 Engaging the 2371-9990 Soft Stop Rocker Switch....................................... 123 Engaging the 7932 Soft Stop Jumper ............................................................ 123 Disengaging Soft Stop ....................................................................................... 123
vii Disengaging the 2371-9990 Soft Stop Rocker Switch .................................. 123 Disengaging the 7932 Soft Stop Jumper ....................................................... 124 Turning Kiosk Power Off .................................................................................. 124 Turning Kiosk Power On................................................................................... 125 Connecting an External USB Device................................................................. 125 7932 USB Connection................................................................................... 125 2371-9990 USB Connection.......................................................................... 125 Wire Ties ........................................................................................................... 126 Cable Connection............................................................................................... 126 Customer Control Center (Pod)................................................................................ 127 Removing the Pod.............................................................................................. 127 Tools Required .............................................................................................. 127 Procedure....................................................................................................... 127 Installing the Pod ............................................................................................... 128 Tools Required .............................................................................................. 128 Procedure....................................................................................................... 128 Memory Modules ..................................................................................................... 129 Removing Memory Modules............................................................................. 129 Installing Memory Modules............................................................................... 129 Motherboard Bracket Assembly............................................................................... 131 Removing the Motherboard Bracket Assembly................................................. 131 Tools Required .............................................................................................. 131 Procedure....................................................................................................... 131 Installing the Motherboard Bracket Assembly .................................................. 132 Tools Required .............................................................................................. 132 Procedure....................................................................................................... 132 Hard Drive................................................................................................................ 134 Removing the Hard Drive.................................................................................. 134 Tools Required .............................................................................................. 134 Procedure....................................................................................................... 134 Installing the Hard Drive ................................................................................... 135 Tools Required .............................................................................................. 135 Procedure....................................................................................................... 135 Restoring a Thumb Drive Image ....................................................................... 136 Tools Required .............................................................................................. 137 Procedure....................................................................................................... 137 Customize the Kiosk.......................................................................................... 138 Calibrate the touch screen ............................................................................. 138 Network Configuration.................................................................................. 139 The PC Power Supply .............................................................................................. 142 Removing the PC Power Supply ....................................................................... 142
viii Tools Required .............................................................................................. 142 Procedure....................................................................................................... 142 Installing the PC Power Supply......................................................................... 143 Tools Required .............................................................................................. 143 Procedure....................................................................................................... 143 The Touch Screen Monitor....................................................................................... 145 Removing the Touch Screen Monitor................................................................ 145 Tools Required .............................................................................................. 145 Procedure....................................................................................................... 145 Installing the Touch Screen Monitor ................................................................. 146 Tools Required .............................................................................................. 146 Procedure....................................................................................................... 146 Magnetic Stripe Reader............................................................................................ 148 Removing the Magnetic Stripe Reader.............................................................. 148 Tools Required .............................................................................................. 148 Procedure....................................................................................................... 148 Installing the Magnetic Stripe Reader................................................................ 149 Tools Required .............................................................................................. 149 Procedure....................................................................................................... 150 Pod Speakers ............................................................................................................ 151 Removing the Speakers ..................................................................................... 151 Tools Required .............................................................................................. 151 Procedure....................................................................................................... 151 Installing the Speakers....................................................................................... 152 Tools Required .............................................................................................. 152 Procedure....................................................................................................... 152 Motherboard / CPU .................................................................................................. 154 Removing the CPU............................................................................................ 154 Installing the CPU.............................................................................................. 154 RFID Reader ............................................................................................................ 156 Removing the RFID Reader Board.................................................................... 156 Tools Required .............................................................................................. 156 Procedure....................................................................................................... 156 Installing the RFID Reader Board ..................................................................... 156 Tools Required .............................................................................................. 156 Procedure....................................................................................................... 157 RFID Coaxial Cable................................................................................................. 158 Tools Required................................................................................................... 158 Replacing the RFID Coaxial Cable.................................................................... 158 RFID Antenna .......................................................................................................... 160 Removing the RFID Antenna ............................................................................ 160
ix Tools Required .............................................................................................. 160 Procedure....................................................................................................... 160 Installing the RFID Antenna.............................................................................. 161 Tools Required .............................................................................................. 161 Procedure....................................................................................................... 161 UPS........................................................................................................................... 163 Removing the UPS............................................................................................. 163 Tools Required .............................................................................................. 163 Procedure....................................................................................................... 163 Installing the UPS.............................................................................................. 163 Tools Required .............................................................................................. 163 Procedure....................................................................................................... 163 POP Wraps ............................................................................................................... 165 Removing the POP Wraps ................................................................................. 165 Tools Required .............................................................................................. 165 Procedure....................................................................................................... 165 Reinstalling the POP Wraps .............................................................................. 165 Tools Required .............................................................................................. 165 Procedure....................................................................................................... 165 Secondary Display Housing ..................................................................................... 167 Removing the Display Housing......................................................................... 167 Tools Required .............................................................................................. 167 Procedure....................................................................................................... 167 Reinstalling the Display Housing ...................................................................... 168 Tools Required .............................................................................................. 168 Procedure....................................................................................................... 168 Secondary Display / LCD Display ........................................................................... 170 Removing the Secondary LCD Display............................................................. 170 Tools Required .............................................................................................. 170 Procedure....................................................................................................... 170 Replacing the Secondary LCD Display ............................................................. 171 Tools Required .............................................................................................. 171 Procedure....................................................................................................... 171 Cellular Network...................................................................................................... 172 Removing the Aircard Modem .......................................................................... 172 Tools Required .............................................................................................. 172 Procedure....................................................................................................... 172 Removing the JBM Router ................................................................................ 172 Tools Required .............................................................................................. 172 Procedure....................................................................................................... 172 Replacing the JBM Router................................................................................. 173
x Tools Required .............................................................................................. 173 Procedure....................................................................................................... 173 Replacing the Aircard Modem........................................................................... 173 Tools Required .............................................................................................. 173 Procedure....................................................................................................... 174 PLC........................................................................................................................... 175 Removing the PLC............................................................................................. 175 Tools Required .............................................................................................. 175 Procedure....................................................................................................... 175 Installing the PLC.............................................................................................. 175 Tools Required .............................................................................................. 175 Procedure....................................................................................................... 176 Gripper Belts ............................................................................................................ 177 Tools Required................................................................................................... 177 Replacing the Gripper Belts............................................................................... 177 Gripper Motors......................................................................................................... 179 Tools Required................................................................................................... 179 Replacing the Gripper Motors ........................................................................... 179 Gripper Springs ........................................................................................................ 181 Tools Required................................................................................................... 181 Replacing the Gripper Springs........................................................................... 181 Insertion (Z-Axis) Belt............................................................................................. 184 Tools Required................................................................................................... 184 Replacing the Insertion (Z-Axis) Belt................................................................ 184 Insertion (Z-Axis) Motor.......................................................................................... 187 Tools Required................................................................................................... 187 Replacing the Insertion (Z-Axis) Motor ............................................................ 187 Horizontal Carriage Motor....................................................................................... 189 Tools Required................................................................................................... 189 Replacing the Horizontal Carriage Motor.......................................................... 189 Horizontal Belt ......................................................................................................... 191 Tools Required................................................................................................... 191 Replacing the Horizontal Belt............................................................................ 191 Gate Frame Assembly .............................................................................................. 193 Tools Required................................................................................................... 193 Removing the Gate Frame Assembly ................................................................ 193 Installing the Gate Frame Assembly.................................................................. 195 Gate Motor ............................................................................................................... 196 Tools Required................................................................................................... 196 Replacing the Gate Motor.................................................................................. 196 Roller Motor............................................................................................................. 198
xi Tools Required................................................................................................... 198 Replacing the Roller Motor ............................................................................... 198 Roller Spring ............................................................................................................ 200 Tools Required................................................................................................... 200 Replacing the Roller Spring............................................................................... 200 Vertical Proximity Sensor ........................................................................................ 202 Tools Required................................................................................................... 202 Replacing the Vertical Proximity Sensor........................................................... 202 Interaction Slot Sensor ............................................................................................. 203 Tools Required................................................................................................... 203 Replacing the Interaction Slot Sensor................................................................ 203 Vertical Motor.......................................................................................................... 204 Tools Required................................................................................................... 204 Replacing the Vertical Motor ............................................................................ 204 Chapter 4: Preventative Maintenance 207 Kiosk Preventive Maintenance................................................................................. 207 Cleaning the System Exterior ............................................................................ 207 Cleaning LCD Displays..................................................................................... 207 Cleaning the Magnetic Stripe Reader ................................................................ 208 Cleaning the Interaction Slot Roller .................................................................. 208 Interaction Slot Alignment................................................................................. 209 Cleaning the Gripper.......................................................................................... 210 Carriage Horizontal Shaft Corrosion Control.................................................... 211 Vertical Drive Shaft Flange Bearing Lubrication.............................................. 211 Appendix 212 CPU Connections ..................................................................................................... 212 Motherboard POST Errors ....................................................................................... 214 POST Beeps....................................................................................................... 214 Displayed POST Messages................................................................................ 214 Vertical Drive Motor Speed Controller Settings...................................................... 216 Motion Error Codes.................................................................................................. 217 XE 2.x Error Definitions .......................................................................................... 218 Fatal Error Definitions – Result Codes < 0........................................................ 218 Motion Error: -7 ........................................................................................... 218 Communication Halt Error: -6...................................................................... 218 Communication Breakdown Error: -5.......................................................... 218 Connection Lost Error: -4............................................................................. 218 No Connection Error: -3............................................................................... 219 Connecting Error: -2..................................................................................... 219
xii Loading Configuration Error: -1 .................................................................. 219 Success - Result Code = 0.................................................................................. 219 Success: 0 ..................................................................................................... 219 Non-Fatal - Result Codes > 0 ............................................................................ 220 Invalid Bin Number Fault: 1......................................................................... 220 Item On Picker Fault: 2 ................................................................................ 220 Empty Pick Fault: 3...................................................................................... 220 Pick Block Fault: 4....................................................................................... 221 Place Block Fault: 5...................................................................................... 221 Place Time Out – Interactive Slot Fault: 6 ................................................... 221 Motion Fault: 7............................................................................................. 222 Unsupported Run Mode Fault: 8 .................................................................. 222 Expel Reclaimed Fault: 9 ............................................................................. 222 Kiosk Power Distribution, 2371-9990...................................................................... 223 Pod Wiring and Cable Connections ......................................................................... 224 Bin Map.................................................................................................................... 225 Definition of Terms Used......................................................................................... 226 Initial System Inspection Checklist.......................................................................... 237 Visual Assessment............................................................................................. 237 Inspect System Components.............................................................................. 237 System Checkout ............................................................................................... 238 2371-9990 Wiring Schematics ................................................................................. 239
xiii Revision Record Issue Date Remarks A Oct 2009 First issue
1 Chapter 1: Product Overview Introduction The NCR SelfServ Entertainment – Multifunction / 7932 and 2371-9990 are self-service kiosks that permit a customer to select from over 400 movie titles. They can either rent or purchase the movies; giving the customer freedom of choice. The touch screen permits the customer to review the movie titles available. An optional Secondary display is available that plays an advertising piece for customer interest. Once the customer decides upon a movie and pays for it using the integrated credit card reader, the kiosk pulls the DVD from stock and presents it to the customer. The kiosk is a low cost way for a customer to buy or purchase a movie in a compact setting; cutting down on retail space needed for purchasing DVD products. The kiosk can be set up in any enclosed retail or business environment. Magnetic Stripe Reader (MSR)ouch Screen Pod LockFront Access Panel Lock Customer Interaction Slot Customer Interface T Customer Control Center (Pod)
2 Chapter 1: Product Overview Removing the Kiosk Panels Access to the kiosk is through the bottom front access panel and side panels. The front panel must be removed first to access Soft Stop. Soft Stop is a logic switch that stops all controlled motion. Once activated, the Soft Stop’s slow ticking sound indicates that it is safe to remove the side panels. Front Access Panel For 2371-9990 kiosks, the bottom front access panel provides access to the Main Circuit Breaker switch on the right, and to the Soft Stop Rocker Switch and USB port on the left side of the Front Electrical Panel. For 7932(-8080, -8082, -8094) kiosks, removal of the front access panel provides access to the Soft Stop Jumper, to the modem / router (if present), and to the USB cable that connects to the PLC’s USB-to-Serial converter. The front access panel lock may require a special merchandiser key. 1. Unlock the front access panel with the appropriate key in the lock on the lower left side. 2. Pull it back until the left side of the access panel is clear of the frame and then slide it off of the tapered pins on the right. For POP wrap, refer to POP Wraps on page 165. Side Panels The side panels are secured with locks. It’s necessary to remove the left and right side panels to access the kiosk’s internal mechanisms. 1. While the kiosk is powered, unexpected motion of mechanical parts may occur. There are hazardous moving parts inside. To prevent this, remove the front access panel (see Front Access Panel on page 2) and engage Soft Stop (refer to Engaging Soft Stop on page 123). 2. Unlock the top locks on the side panels before removing them. Rear Access Panel The rear access panel on the bottom provides access to the rear DIN rail of the Control Panel Assembly. 1. Unlock the rear access panel using the lock on its lower left side. 2. Pull it back until it’s clear of the frame and slide it off of the tapered pins that are on the right side.
Chapter 1: Product Overview 3 Order of Operation The order of operation is presented to demonstrate a sequence of events, sensor inputs and control outputs, when a DVD is returned to the Interaction Slot. Action Result 1. DVD inserted in the Interaction Slot Customer initiates the return process 2. Outside Product Sensor turns ON Indicates a product is in the Interaction Slot 3. Vertical Motor turns ON Carriage is moved to Interaction Slot level 4. Horizontal Motor turns ON Gripper is moved in front of the Interaction Slot 5. Vertical and Horizontal Motors stop Motors stop upon reaching destination 6. Z-Axis Motor turns ON Gripper moves forward to pick the Interaction Slot 7. Gripper Belts start turning The Gripper is prepared to accept the DVD 8. Rear Proximity Sensor turns ON Indicates Gripper is in the forward position 9. Gate Motor turns ON Interaction Slot Gate opens 10. Gate Up Proximity Sensor turns ON Gate is fully open, motor stops 11. Roller Motor turns ON Feeds case into Gripper 12. Through-Beam Sensor turns ON Case blocks Gate Through-Beam Sensor 13. Front Fiber Optic Amplifier turns ON Case blocks Fiber Optic Sensor 14. Front Look Down Sensor turns ON Case blocks Front Look Down Sensor Reflector as it travels onto the Gripper 15. Gate Through-Beam Sensor turns OFF Case is clear 16. Roller Motor stops 17. Gate Motor starts Interaction Slot Gate closes
4 Chapter 1: Product Overview Action Result 18. Gate Down Proximity Sensor turns ON Gate is closed, Gate motor stops 19. Fiber Optic Amplifier turns OFF Fiber Optic Sensor cleared 20. Rear Look Down Sensor turns ON Case blocks Rear Look Down Sensor Reflector as it travels on the Gripper 21. Gripper Belts stop turning Case is centered on Gripper 22. Insertion (Z) Axis Motor turns ON Gripper moves back to center on the Carriage Assembly 23. Front and Rear Proximity Sensor ON simultaneously Gripper is centered, Insertion (Z) Axis Motor stops 24. RFID Tag is read Inventory is returned to first available storage bin
Chapter 1: Product Overview 5 Tools Required for Service The following is a general list of tools useful in servicing NCR 7932 & 2371-9990 systems: • Kiosk Key Set (Site managers don’t have them) • Hex Wrenches o T-Handle-Standard; (9 in. Shaft, 3/32-1/4, part # 6039014929) o T-Handle-Standard; (6 in. Shaft, 3/32-1/4, part # 6039014928) o T-Handle-Balled End; (9 in. Shaft, 5/64-7/32, part # 6039014927) o 90 Degree / Balled End (Short Shaft) Combination set, 1/16 – 3/8 o Stub Hex Key Set (1/16-1/4, part # 6039014930) o 5/16” Stub Hex Key • Pliers / Wrenches o Channel Lock Pliers o Adjustable Pliers o Needle Nose Pliers: Standard and Precision - 2 ea. o Precision Diagonal Cutter - 2 ea. o Needle Nose Locking Pliers (Vise Grip) - 2 ea. o Snap Ring Pliers o Adjustable (Crescent) Wrenches o 13 mm Combination Wrench o 13 mm Deep Well Socket and Driver o 11/32 (9mm) Combination Wrench o 9/32 (7mm) Combination Wrench o 7/16 (11mm) Combination Wrench o 11/32 (9mm) Socket Wrench o 1/4 (7mm) Socket Wrench • Screw Drivers o Standard Set o 1/8” Blade, 4” Shaft o 1/8” Blade, 6” Shaft • Miscellaneous o Flashlight o Digital Multimeter o PC ATX Power Supply Tester – obtain locally at Office Depot: Coolmax PS-224 ATX Power Supply Tester Item #161085
6 Chapter 1: Product Overview o Caliper o Feeler Gauge Set o 12” Steel Ruler o Combination Square o Pocket Knife and/or Safety Razor Blades o 10’ Tape Measure o Permanent Marker o Post-it Notes o Assorted Cable Ties o Caster Wrench (part # 6039014898) o USB Keyboard (part # 8770195701) o USB Mouse (or other pointing device) o USB Header Cable o Stepladder o Shim Service Tool (part # 497-0464764) o Nominal Shim Plate (0.165” – part # 497-0464767) o Minimum Shim Plate (0.135” – part # 497-0464766) o Maximum Shim Plate (consists of the 0.165” shim plus the 0.048” shim – part # 497-0464765) o Motor Adapter Breakout Cable (NCR part # 497-0463735) o Loctite 222 (part # 006-8613969) o Loctite 242 (part # 006-8615141) o Loctite 425 (part # 006-8614243) o Lithium Soap based grease No. 2 / Shell Alvania
Chapter 1: Product Overview 7 Service Information If the use of an external USB device is required for maintenance, they can be connected to a USB port that is either located behind the kiosk’s Front Access Panel on the left side of the Front Electrical Panel (2371-9990 kiosks) or by disconnecting the USB cable that connects to the PLC’s USB-to-Serial converter (legacy 7932/TE1001 kiosks). For more information, refer to Connecting an External USB Device on page 125). Caution: Be careful when accessing components inside the kiosk while power is on. Depending upon the functions being performed, the electromechanical assemblies can start moving without warning. Avoid this by engaging the Soft Stop (refer to Engaging Soft Stop on page 123). A slow ticking sound from inside the kiosk confirms that Soft Stop is engaged. Remember that Soft Stop prevents motion, but the electrical hazards remain. The AC line voltage primaries are live at all times — even after disconnecting the power cord. To fully power down the kiosk, perform the Turning Kiosk Power Off procedure on page 124. 23412 Top View Battery Backup Surge Protection Surge Protection Only www.apc.com Back-UPS ES 550 Power on Replace Battery UPS UPS Power Switch 2371-9990 interior side view of floor panel featuring from left to right (front to back): UPS and Control Panel Assembly. Front Side Power Cord Entry Right Rear Right Front UPS Power Switch USB Soft Stop 2371-9990 front floor pan and Front Electrical Panel illustrated below. Note: UPS make, model and appearance may vary. Main Breaker Switch
8 Chapter 1: Product Overview Component Location The locations for the major components in the NCR SelfServ Entertainment – Multifunction / 7932 and 2371-9990 are shown in the following illustrations. Front Electrical Panel Assembly (2371-9990 only) Magnetic Stripe Reader (MSR) Customer Interface Touch Screen Pod Lock Customer Interaction Slot Front Shelf Assembly Vertical Drive Assembly Front Access Panel Lock Soft Stop Switch Main Circuit Breaker Rear Storage Area Carriage Assembly Control Panel Assembly Vertical Drive Assembly Right Carriage Rail Assembly Left Carriage Rail Assembly USB Port Upper Vertical Pulleys Customer Control Cente (Pod) r
Chapter 1: Product Overview 9 Diagnostics Nearly all of the kiosk’s diagnostics are accessed through Service Utilities. To access administrative diagnostic functions, it may be necessary to log off and log in with administrative access. Administrative Login To log into the kiosk with administrative access: 1. Call Help Desk/SST and request administrative access. 2. Remove the front access panel (refer to Front Access Panel on page 2). 3. Connect a USB keyboard above the Soft Stop Switch on the left side of the Electrical Sub Panel. 4. Press the keyboard’s Windows Logo key and touch Log Off (not restart) as the current user. 5. As Windows logs off the current user, hold the SHIFT key until the Login screen appears. 6. Log in with administrative access. Service Utilities Service Utilities is opened by double-tapping its desktop icon. The following is an example screen. Its actual appearance and the available options vary according to the kiosk’s current software release.
10 Chapter 1: Product Overview All diagnostic applications can be accessed from the Diagnostic tab in Service Utilities. From this window, touch the desired application’s button once to open that application. Note: A double touch on a Service Utilities menu button will open more than one instance of the associated application. This can result in false test results. Service Utilities Main Functions The main Service Utilities functions are a set of buttons that are always available, regardless of which tab is selected. They are as follows: On Screen Keyboard: Opens the on-screen keyboard for text and control entries without a physical keyboard. Lock Screen: Initiates a dialog box to set a password and lock the touch panel. In this manner, the system can be safely left unattended. Task Manager: Launches the Windows Task Manager. Reboot Computer: Performs a Windows Restart. Shutdown Computer: Performs an orderly shut down of the computer. Close: Closes the Service Utilities application.
Chapter 1: Product Overview 11 Setup & Config Functions Diagnostics: Accesses kiosk diagnostics, identical to selecting the Diagnostic tab. age 83). ode. e with the server. nt application. lays the contents of the TA_TX01 XML file. Calibrate Monitor: Opens the touch screen calibration application (see Calibrating a Touch Screen on p Start AKPOS Application Interface: Returns the kiosk to Rental M Change Site ID: Allows changes in the kiosk’s Site ID. Stop AKPOS Applications: Stops AKPOS applications. GP Update: Updates GP. Sync Date Time with Server: Synchronizes the kiosk’s date and tim Start Sync Client: Launches the Sync Clie View AKPOS Settings XML: Displays the contents of the AKPOS XML file. View TA_TX01 XML: Disp Status Box: Displays kiosk date, time, timezone and network information.
12 Chapter 1: Product Overview Diagnostic Tab Functions The Service Utilities Diagnostic tab provides rapid single-touch access to several Windows system tools in addition to diagnostic applications. The functions available from the Diagnostic tab are: View Product Handler Log: Displays the contents of the AKPOS Product Handler.log file. View Physical Inventory Log: Displays the contents of the Physical Inventory log. Displays the contents of the AKPOS_API.log file. contents of the Motion log (refer to Motion Error Codes on Start Product Handler: Launches the Product Handler application. Start Physical Inventory: Opens AKPOS Physical Inventory. For information about the Physical Inventory application, refer to Physical Inventory on page 18. Start User Interface: Starts the user interface. Start Motion Exerciser: Launches the Motion Exerciser. For information about the Motion Exerciser, refer to Motion Exerciser (MoX) on page 23. RFID UTC: Starts the RFID UTC utility. RFGate: Opens the RFGate application. For information about accessing and using RFGate, refer to RFGate on page 15. IDTech MSR Upgrade: Executes the IDTeck MSR upgrade application. View XE Kiosk Log: Displays the contents of the XE Kiosk Log. View AKPOS_API Log: View Motion Log: Displays the page 217).
Chapter 1: Product Overview 13 IDTech MSR HID Demo: Starts the IDTeck MSR HID Demo. Task List: Displays the contents of the Task List. asonic PLC. This 7). ity that tests the system’s 3GB memory. IPC Panasonic PLC Audit: Accesses PLC Audit for kiosks that use the Pan application is not used in 7932 and 2371-9990 kiosks. GE PLC Audit: Accesses PLC Audit for kiosks that use the GE PLC (2371-9990 only). For more information, refer to GE PLC Audit on page 20. MagTek USBMSR: Accesses the MagTek USBMSR utility (refer to MagTek USBMSR on page 1 Memory Tester: Starts a util Run AKPOS Application Interface: Returns the kiosk to Rental Mode. onfig /All: Lists the current settings for all active network connections. Login Required Area Certain Service Utility functions require administrative access. Before using these functions, call Help Desk/SST to request administrative access. For functions outside the scope of these n scre n on page 9). plorer RunAs user Below: Launches Windows Explorer. Display Settings: Opens the Display Properties window for viewing or changing the kiosk’s display settings. t k Settings: Opens the Network Settings windows for viewing or changing the kiosk’s network settings. buttons, it is necessary to log off (not restart), holding the SHIFT key to force it to the Logi en and log in with administrative access (refer to Administrative Logi CMD Prompt RunAs User Below: Opens the Command Prompt window for the execution of command line executables. Windows Ex Device Manager: Launches the Device Manager for viewing or changing device hardware properties. This is normally accessed through the Device Manager button under the Hardware tab within the System Properties window, which is accessed from the Windows taskbar’s Star menu to Settings, Control Panel, and System. Networ
14 Chapter 1: Product Overview XE 1.x Utilities Tab Functions 1 Motion Exerciser: Launches 1.x Motion Exerciser (see Motion Exerciser 1.x (KAI) onXE XE Auto Tester: Opens the Motion Auto Tester application. wer utility, which provides a quick and easy access to the RFID Reader Board functions for resetting the PLC and testing for the presence of media stuck in the Gripper Assembly (see Mo on Power on page 32). 217 Accessing Service Utilities 1. If there is no system power, turn the kiosk’s power on (refer to Turning Kiosk Power On, page 125). 2. If the kiosk is powered up, remove the bottom front panel (refer to Removing the Kiosk , Front Access Panel on page 2). 3. Connect a USB Keyboard to the rear of the eBox PC (PS/2 keyboard requires computer restart). 4. Access the Windows Task Manager by using the CTRL+SHIFT+ESC keyboard shortcut. 5. Close all applications listed in the Task Manager’s Applications tab. 6. Once all applications are closed, close the Task Manager window. 7. Double-touch the Service Utilities desktop icon. 8. Touch the Diagnostic tab. 9. To open a diagnostic application, single-touch the desired diagnostic’s button. 10. When finished with the current diagnostic, close its window by touching the red X in that window’s upper right corner. 11. When all diagnostic testing is complete, return the system to Rental Mode by pressing Service Utilities’ Reboot Computer button to restart the computer. Note: Double-touching a square diagnostic application button will open multiple instances of e same time can cause false results. page 23). 1 Motion XE1 Motion Power: Launches the Motion Po ti XE1 Motion Log: Displays the contents of the Motion Log (see Motion Error Codes on page ). the selected diagnostic. Opening multiple diagnostic applications at th
Chapter 1: Product Overview 15 RFGate Inv each individual RFI i ese numbers are programmed into the RFID Tag affixed to the DVD. The RFID Reader reads the tag on each DVD ate utili entory is identified by the Unique ID number (UID) pre-programmed into D tag. Mov e/game titles are also identified by a SKU number. Both of th and uses the UID and SKU to manage inventory. This can be tested using the RFG ty. To use RFGate: . ight corner of the RFGate window indicates Connected. If gs, n page 105. 1. Access Service Utilities through its desktop icon and select the Diagnostic tab (for further details, see Accessing Service Utilities on page 14) and single-touch the RFGate button 2. Verify the Status in the lower r not connected, confirm that no other RFID-related program (Motion Exerciser, Motion Power, etc.) is active, close and reopen RFGate, or refer to Communication Port Settin COM1 o 3. Switch the Soft Stop Rocker Switch to the OFF position to prevent the Carriage Assembly from moving. Listen for a slow ticking sound to verify that Soft Stop is engaged. For more information about the Soft Stop Rocker Switch, refer to Engaging Soft Stop on page 123. 4. Place a known-good RFID tag on top of the Case Hold Downs directly over the RFID antenna. 5. In the Read menu, touch ISO Inventory.
16 Chapter 1: Product Overview 6. The RFID tag is read and the 16 digit UID number is displayed in the Transponder Data window in a successful read. While other numbers are always displayed in the Transponder Data, Reader to Host Data and the Host to Reader Data windows, the UID is the most important as it identifies the DVD. It is not a successful read if no UID number is displayed. 8. To clear previously read RFID data, touch the Clear Data icon. 9. Test the RFID Reader Board by resetting the PLC through the Remote Reset Relay, initiating the homing motion sequence: Caution: Do not perform this while someone is working in the kiosk.
Chapter 1: Product Overview 17 a. From the Miscellaneous menu, touch Write Output. The Write Outputs dialog Output step. 10. then Exit. MagTek USBMSR MagTek USBMSR is a utility used to test the card reader. It is launched either from the Service Utilities Diagnostic tab (single touch) or from the MagTek USB MSR icon on the Windows desktop (double touch). Any magnetically encoded cards such as a credit card can be swiped after Swipe Card is displayed. formation encoded in the card is displayed. An error is displayed s, alth Dat slower swipes or faster card or missed read. also be indicated by a flashing red LED on the card reader immediately after displays. b. Set the Output 1 On checkbox. c. Touch the OK button. d. Reopen the Write Outputs dialog by repeating the Miscellaneous menu, touch Write e. Clear the Output 1 On checkbox. f. Press the OK button. The PLC restarts, initiating its homing motion sequence. To close RFGate, touch the Host Mode menu and After swiping the card, the in if a track is not correctly read. Credit cards generally display data for the first two track ough the card reader can read up to three tracks. a can be removed from the display by touching the Clear Dialog button. An error on any track may indicate a bad card reader. Try other cards, swipes to determine if it’s an actual error or if it was caused by a bad A bad read may the card swipe.
18 Chapter 1: Product Overview Physical Inventory Inventory is set up initially by using the Physical Inventory utility. This utility automatically updates the inventory database as the system picks the inventory and reads the data from the ication can be set to inventory the entire system or a range of bins. n Physical Inventory Features Inventory Occupied Unknown Bins: Inventories bins marked as OCCUPIED UNKNOWN. Inventory Only Empty Bins: Inventories bins marked as EMPTY. Inventory All Bins: Inventories all bins regardless of their status. This should only be done if starting a new physical inventory or if someone pressed the Reset Bin Map button. Direction: Toggles the order of the physical inventory. Pressing the button while it displays (REVERSE) shall reverse the order: last to first. Pressing the button while it displays (FORWARD) shall change the order to the usual first to last. Close: Closes the KAI Physical Inventory application. RFID tag. The appl KAI Physical Inventory is started by either touching the KAI Physical Inventory desktop ico or the Run KAI Physical Inventory button under the Service Utilities Diagnostic tab. Upon start up, the application connects to the database and initializes system motion. Once initialized, the Physical Inventory application is ready to accept commands. Start: Starts the inventory process. Stop: Halts the inventory process.
Chapter 1: Product Overview 19 Bin Range Buttons: These buttons are toggled to include (green) or exclude (red) bin ranges in the physical inventory. For example, touching green bin range buttons turns them red, indicating that those bins shall not be inventoried. Lock Screen: Initiates a dialog box to set a password and lock the touch panel. In this manner, the system can continue to process inventory safely while unattended. Clear All: Deselects all bin ranges for inventory. To inventory a select few, press the Clear All button and select the few to inventory. Select All: Selects all bin ranges for inventory. To inventory the majority, touch the Select All button and select the few that won’t be inventoried. Reset Bin Map: This will clear and reset the storage bin mapping. It should only be done if the bin configuration has been changed. A complete physical inventory is required if this action is performed. A confirmation box displays to remind the user of this button’s purpose. Press the Yes button if this is the desired action or No if this action is not desired. sical Inventory window first appears, its buttons remain ed initialization. Response Box: Commands are displayed in this box along with their results. Performing a Physical Inventory 1. Open the Physical Inventory application, using either the KAI Physical Inventory desktop icon or the Run KAI Physical Inventory button under the Service Utilities Diagnostic tab. When the Phy grayed out until Motion has complet 2. Select the bin ranges to be inventoried (refer to Bin Map in the Appendix on page 225). 3. Select the desired inventory option button. For all but the Direction button, a confirmatio box displays to remind the user of that button’s purpose. Press the Yes button if that is the desired action or No if that action is not desired. n
20 Chapter 1: Product Overview 4. Press the Start button. h the Close button. GE PLC Audit, l for the kiosk’s robotic mechanism. It provides quick status overviews and delivers logs for detailed failure analysis. nts several views of the GE PLC’s outputs to and inputs from the 1. Remove the front access panel (see Removing the Kiosk Panels, Front Access Panel on page 2). 2. Connect a USB keyboard, mouse or other pointing device (refer to Connecting an External USB Device on page 125). 3. From the taskbar, select Start, Programs, GE PLC Audit, GE PLC Audit. 5. Verify that the Physical Inventory procedure is running. RFID read information is displayed in the dialog box as well as any errors. Touching the Lock Screen button initiates a dialog box to set a password and lock the touch panel. In this manner, the system can continue to process inventory safely while unattended. 6. When finished with Physical Inventory, touc 2371-9990 The GE PLC Audit application is a debugging too Note: GE PLC Audit prese kiosk’s robotic mechanism, which may directly indicate the problem. They do not in themselves account for the environment, foreign objects and broken parts. The rest is for the operator to determine. Accessing GE PLC Audit, 2371-9990 Using PLC Audit, 2371-9990 Navigation between the PLC Audit application’s four reporting functions is accomplished by touching the tabs at the top.
Chapter 1: Product Overview 21 I/O The digital input indicates that the PLC is receiving a 0VDC signal on that input (the com the digital inputs is 24VDC). Some inputs are active low, and they are represented by bold Tab, 2371-9990 I/O tab shows all of the inputs to and outputs from the PLC. A green “On” symbol for a mon for text. A green “On” symbol for a relay output indicates that the relay is closed. System Status Tab, 2371-9990 Note: The System Status tab shows general system status including the current errors and the commanded and current location of each of the axes.
22 Chapter 1: Product Overview Current Non Fatal Errors show all errors that are recoverable, like an empty pick for example. reset by cycling power or issuing an Echo 6 (initialize) command from software. er cycle or Plac Not by t The Current Fatal Errors show all errors that are non-recoverable. Fatal errors will be accompanied by a fast clicking sound from relay Q24. For all fatal errors, the GE PLC must be Note: These error states are not preserved after resetting the plc via a pow software. e Height Adjustment Tab, 2371-9990 e: The Place Height Adjustment tab allows the user to modify the place height timer used he GE PLC. place height timer is used to determine how long to move upward after moving into ition on a place command. Inc The pos reasing the timer will result in a larger “bump” upward. If timer value and immediately send it to the GE PLC to be used. So, the place height adjustment process can be done while the robot is in motion (like when running random picks and places from Motion Exerciser). When satisfied with the place height, press the Save Permanently button. If the value is not saved permanently, the GE PLC will revert to its last permanently saved value on its next power cycle. Every time the Save Permanently button is pressed, the value is also written to a file on the Pod’s hard drive. So, if the plc is replaced, we can avoid having to repeat the place height adjustment process by loading this value back from this file. Pressing the Read Value From File on PC button will load the value and send it to the GE PLC. e permanently. this value is too large, the robot will begin hunting. If this value is too small, the DVD case may collide with the shelf of the bin it is being placed into. In either case the problem is fixed by changing the value. Remember to press the Save Permanently button when satisfied. Pressing the +/- buttons will adjust the The Save Permanently button will still have to be pressed to command the GE PLC to save the valu
Chapter 1: Product Overview 23 Motion Exercis ity used to test motion, validate communication by pressing a button under the Diagnostic tab in Service odes (refer to Motion Error layed in the Response Box all other SelfServ Entertainment applications, particularly the System Agent, Middleware and or Product Handler (2.x). Only one application should control the motion/mechanical interface at any time. r 1.x (KAI) The Motion Exerciser 1.x is used in most NCR SelfServ Entertainment – Multifunction / 7932 & 2371-9990 kiosk releases. If the link to MoX 1.x is missing, either use MoX 2.0 (see Motion Exerciser 2.x (AKPOS Motion Exerciser) on page 27) or open Windows Explorer and navigate to: C:V3plusKAI_motionexerciser.exe er (MoX) The Motion Exerciser is a multipurpose util and read RFID tags. It is started Utilities (see Accessing Service Utilities on page 14). Status, error c Codes on page 217), functions, and other system responses are disp at the bottom of the Motion Exerciser window. Note: Before running any version of MoX, be sure to terminate Otherwise, communications to the PLC lock up. Motion Exercise Motion Exerciser is a kiosk diagnostic tool that’s used in the field for troubleshooting the mechanical motion of a system. This application’s functions are divided into two areas: • Controls • Auto Run
24 Chapter 1: Product Overview Controls Area Initialize: Begins the initialization process. Motion Exerciser must initialize first in order to facilitate motion. The system initialization takes a few moments to complete. Clear Log: Clears the responses logged within the Response Box upon user confirmation. Pick: Picks inventory from the bin address in the Pick Bin Address field. The Gripper picks the case from the bin selected, centers itself on the Carriage, and stops. xecute in Address field. The Gripper places the case in the bin selected, centers itself on the Carriage, and stops. Place Bin Address: eric field to the right of the Place button. Enter the desired Place bin num cal keypad that appears when this field is touched. Pick/Place Swap: Switches the bin address between Pick and Place. Accept: as Pick except the pick command is not executed unless there is a case in the Inte t Accept/Expel Swap: Switches the bin address between Accept and Expel. r Off: Energizes the Remote Reset Relay, which removes power from the PLC. When followed by the Motion Power On button, the PLC resets. Motion Power On: Turns off the Remote Reset Relay, restoring power to the PLC. This is often used while servicing the system to reset the PLC (refer to Resetting the PLC on page 109). Caution: The Carriage Assembly moves toward the bottom when PLC power is restored and its homing motion sequence begins. Avoid getting in its way Pick Bin Address: Numeric field to the right of the Pick button. Enter the desired Pick bin number using the numerical keypad that appears when this field is touched. Note: If inventory is already on the Gripper when Pick is pressed, it is placed in the Dump Bin instead of executing the Pick command. Pick must be pressed again to e the pick. Place: Places inventory in the bin address in the Place B Num ber using the numeri Same rac ion Slot. Expel: Same as Place. If Expel is used to Place at the Interaction Slot the case must be removed from the slot before any other command can be executed. Motion Powe .
Chapter 1: Product Overview 25 Read RFID: Reads the RFID tagged inventory on the Gripper. On a successful read, the UID and SKU data are displayed in the RFID field. Print Test Receipt: This field is not applicable to current 7932 & 2371-9990 kiosk sy If a receipt printer were present, this button would test it by stems. printing a test receipt. Close: Closes the Motion Exerciser application. Auto Run Area The Auto Run section of Motion Exerciser permits the system to run automated test cycles. This is useful to observe and test system motion during the diagnostic process and after repairs. Pick Start: Beginning bin location of the first possible test starting range Pick End: The ending bin location of a first possible test ending range 3 in the to 298, etc. A Pick Step of -2 would go nge or second test range Note: To Pick from the Interaction Slot and place throughout the system, enter 35 Pick Start and Pick End fields. To test the Interaction Slot, enter 353 in all Pick and Place start and end fields. Pick Step: The number of incremental or decremental steps within the test range. Example: For a Pick Start-to-End range of 300 to 200, you could put a -1 in the Pick Steps to have the iteration move from 300 to 299 from 300 to 298 to 296, etc. Delay: The number of seconds between cycles or loops Place Start: Beginning of the possible place ra Place End: End of the possible place range or second test range
26 Chapter 1: Product Overview Note: Place Start and Place End should be the range of bins to Place to. To test the Interaction Slot, enter 353 in all Pick and Place start and end fields. tep of -2 would go of loops in the test. One loop consists of one pass through all cycles defined t of in, Place Step: The number of incremental or decremental steps within the defined Place bin range. Example: For a Place Start-to-End range of 300 to 200, you would put a -1 in the Place Steps to have the iteration move from 300 to 299 to 298, etc. A Place S from 300 to 298 to 296, etc. Loops: Number for the Auto Run by the Start, End and Step fields for Pick and Place. A cycle can consis two or four motions: a pick and then place back to same bin; or a pick, place to another b pick again, place back to original bin. Random Picks: Picks the inventory in random bins throughout the selected Auto Run test range. Random Places: Places the inventory in random bins throughout the selected range of Auto licable to current 7932 & 2371-9990 kiosk systems. ber of seconds between loops cle Stop: Ends Auto Run cycle AFTER completing the current loop. RFID Test: Tests RFID reads while picking and placing. Stop On Bad RFID: Stops Auto Run test on RFID read failure. Run test placement. Alt Bins Front Back: Used to alternate between the front bin ranges and the back bin ranges Alt Gates: This function is not app Single Case: One single case is used in the run. Delay: Num Start: Begins Auto Run cy Range Buttons: There are 20 range buttons. These permit selectable ranges to be turned on and off. Bins in the ranges bordered in green are used in the Auto Run and those bordered in red are skipped.
Chapter 1: Product Overview 27 Select All: Activates all ranges (Green). Clear All: Deactivates all ranges (Red). RFID: UID and SKU numbers read from an RFID tag are displayed anytime a is executed. In the event a tag is not read, -1 or -2 is displayed as an error code successful Pick (See RFID Components, page 91). Response Box: Commands are displayed in this box along with their results. Successful pick and place moves are indicated by Pick/Place response 0, error codes are displayed when unsuccessful (See Motion Error Codes on page 217). Motion Exerciser 2.x (AKPOS Motion Exerciser) The Motion Exerciser 2.x is used with the 2.0 version of the Xpress Entertainment kiosk automated cycle testing options. These features are slated for a later MoX releases. In the meantime, MoX 1.x may be available (see Motion Exerciser 1.x (KAI) on page 23). software suite. The key differences in functionality from the 1.x version are that the 2.x version lacks the
28 Chapter 1: Product Overview Motion Exerciser (MoX) is a kiosk diagnostic tool used for testing the mechanical motion and stem. You must make sure that the Gripper Assembly is not running l the motion control, as motion control can only be owned by one Note: Since the 7932 and 2371-9990 don’t currently feature a bar code reader, the BarCode dicator is red and reads ‘NA’. peripheral devices of a sy in order for MoX to initia application at any one time. It’s also helpful to be familiar with the bin structure when executing pick and place commands with MoX (refer to Bin Map on page 225). This application’s functions are divided into five areas: • General • Motion Control • BarCode • RFID • Magstripe area’s Connected in General Area Init o initialize all the devices in the kiosk (Motion Control, RFID andialize All: Attempts t Magstripe).
Chapter 1: Product Overview 29 List COM Ports: Lists all available COM ports and their configuration. This is a quick means of c COM ports are set correctly (refer to Communication Port Settings on page 105 for the correct settings). s ws Device Manager on page 105). Exe he configuration file for the MoX application, you can specify another el. In this manner, Clo Motion Control Area onfirming that all Device Manager: Brings up the Device Manager. Use for changing COM port configuration (refer to Windo cute Service: In t application that this button would execute. Lock Screen: Opens a dialog box to set a password and lock the touch pan the system can continue to process inventory safely while unattended. se: Closes the Motion Exerciser application. Connected: This field color indicates the COM port’ ted to the COM port for motion but has not y zed motion. ed indicates no connection a bin number in this field before selecting an action button (Pick, Place, Accept or Expel). Refer to Bin Map on page 225 for bin number mapping. plicable to current 7932 & 2371-9990 kiosk systems. followed by the on, the PLC resets. Initialize: nitialization process. Motion Exerciser must initialize first in order to fa ystem initialization takes a few moments to complete. Home: Initiates the homing motion sequence. Disconne while serv displa s cur ys the Motion Control COM port. The background rent status. Yellow indicates that MoX has connec et initialized. Green indicates that MoX has initiali nd no initialization.R Home Axis: This field is not applicable to current 7932 & 2371-9990 kiosk systems. Bin Number: Enter the Gate Num: This field is not ap Connect: Energizes the Remote Reset Relay, which removes power from the PLC. When Disconnect butt Begins the motion i cilitate motion. The s ct: Turns off the Remote Reset Relay, restoring power to the PLC. This is often used icing the system to reset the PLC (refer to Resetting the PLC on page 109).
30 Chapter 1: Product Overview Caution: The Carriage Assembly moves toward the bottom when PLC power is resto g motion sequence begins. Avoid gett red and its homin ing in its way. Pick: Picks inv bin address in the Pick Bin Address field. The Gripper picks the case f n the Carriage Frame, and stops. Place: Places i dress in the Pick Bin Address field. The Gripper picks the case from the bin selected, centers itself on the Carriage Frame, and stops. Accept: Interactio Expel: S If Expel is used to Place at the Interaction Slot the case must be removed entory from the rom the bin selected, centers itself o nventory in the bin ad Same as Pick except the pick command is not executed unless there is a case in the n Slot. ame as Place. from the slot before any other command can be executed. G s n Do is To app Gate Open: stems. G tion 990 kiosk systems. Do tion Do nct 371-9990 kiosk systems. M t a , BOTTOM, etc.) and this op ripp it sensor and test it ove: Moves the gripper to the specified location. mp bin. ate Size: This field i ot applicable to current 7932 & 2371-9990 kiosk systems. or Num: This field not applicable to current 7932 & 2371-9990 kiosk systems. p: This field is not licable to current 7932 & 2371-9990 kiosk systems. This function is not applicable to current 7932 & 2371-9990 kiosk sy ate Close: This func is not applicable to current 7932 & 2371-9 or Lock: This func is not applicable to current 7932 & 2371-9990 kiosk systems. or Unlock: This fu ion is not applicable to current 7932 & 2 ove To Limit: Selec n option in the box above this button (TOP tion will move the g er as far as it can to that axis in order to trip the lim . M Move To Scan: This bar code based inventory (VSI) function is not applicable to current 7932 & 2371-9990 kiosk systems. Dump: Takes any item on the gripper and dumps it in a du
Chapter 1: Product Overview 31 RFID Area Connected: This f OM port’s curren ield displays the RFID COM port. The background color indicates the t status. Green indicates an active connection. Red indicates no connection. Connect: ts t to the RFID ice, which typically happens by default after pressing the Init . Read: Atte to re n displays the results the window below the buttons. pts to reads only the unique serial ID number on the RFID tagged ventory on the Gripper. On a successful read, the results are displayed in the response area below. Re Bloc ttem le within the FID t em User Switch Off: U der to tri rem re the ser Switch ON: Utilizes the RFID reader to trip a switch for the PLC to ON. ation from the RFID reader device. Ba de A Th ar co sed n 2371-9990 kiosk syste d is eason, th r is red an ads ‘ Ma ripe A C Attemp o connect reader dev ialize All button mpts ad all information o the RFID tag on the gripper and in Read Inventory ID: Attem in ad k: A pts to read the programmab or encodable blocks of information R ag’s m ory space. tilizes the RFID rea p a switch for the PLC to off – used to otely start PLC. U Disconnect: Disconnects communic rCo rea is b de ba inventory (VSI) function is ot applicable to current 7932 & ms an not active. For that r e BarCode area’s Connected indicato d re NA’. gst rea
32 Chapter 1: Product Overview Connected: This field displays the Magstripe USB port. The background color indicates the ort’s current status. Green indicates an active connection. Red indicates no connection. Connect: s a o connect with t e device. Read: Att to r the M Di nnec con unication from applicable with OPOS interfaces). e onse B Com ed in this box along with their results. p Initiate n attempt t he Magstrip empts ead information from agstripe reader when a card is swiped. sco t: Dis nects comm the Magstripe reader devices (usually only R sp ox: mands are display Su ssful nd are indicated b displayed when unsuccessful (See Motion Error Codes Motion Power he KAI Motion Power utility is accessed from the KIA Motion Power desktop icon. It is oft use h a esktop Protocol (R otely reset the PLC and to test for the presence of med m Bo ’s in tpu ID Unlike the Motion Exerciser (MoX), it does not n se. This ma s it a nie et the PLC. Caution: Resetting the PLC (Motion Power Off sequence, causing the Carriage Assembly to move to the interaction slot (bin 353). Don’t get in its way. cce pick a place moves y Pick/Place response 0, error codes are on page 217). T en d throug Remote D DP) to rem ia stuck in the Gripper Asse ds RF bly. Motion Power tests the RFID Reader ower Relay.ard put/ou t functions, which rea tags and controls the Remote P eed to initialize motion prior to u ke conve nt way to res and On) initiates the homing motion Motion Power On: Deactivates RFID Write Output 1, which turns off the Remote Reset Relay and restores power to the PLC. Motion Power Off: Activates RFID Write Output 1, which energizes the Remote Reset Relay and removes power from the PLC.
Chapter 1: Product Overview 33 No alw te: If the Motion Power Off button hasn’t been used at least once, the Read RFID button ays fails. This is normal. displayed as an error code in the e KAI Motion Power application. Motion Log and The Motion Log is a diagnostic tool that can be used to review motion history in the system. It s between the PC (the Motherboard/CPU within the Pod) plifying isolation of motion issues. Access is through ative Login on page 9). The COM settings should be a the The PLC and PC make use of acknowledgment / non-acknowledgement handshaking. e PLC receives a valid command string, the PLC issues the following: Note: AK / NK or ACK / NAK do not receive further acknowledgement once received. • Upon receipt of a NK, the PC resends the command string to the PLC Read RFID: Reads the RFID tag after the Motion Power Off button has been used at least once. The results display in the RFID field and response box. RFID: UID and SKU numbers read from an RFID tag are displayed anytime a tag has been read successful. In the event a tag is not read, -1 or -2 is Response Box (refer to RFID Components on page 91 for detailed error code information). Response Box: Commands are displayed in this box along with their results. Close: Closes th PLC Commands consists of commands and response and the PLC with time stamps, sim Service Utilities’ View Motion Log button (refer to Service Utilities on page 9). Communication between the PC and PLC is bidirectional and accomplished through information transmitted via Hyperlink as part of specific ASCII strings to accomplish various tasks. Access to Hyperlink (Start, Programs, Accesseries, Communication, Hyperlink) requires administrative access (refer to Administr the same as outlined in Communication Port Settings, COM2 on page 105. These strings represent information needed by the PLC to locate target positions, define operational mode, and handshake status with the PC. Response Strings All Response strings from the PLC to the PC are 5 bytes long (4 characters + <CR> as terminator). Response stings are truncated or null characters (<00>) are appended to fill in 5 byte response. Handshaking When th AK<00><00><CR> When the PLC receives an invalid command string, the PLC issues the following: NK<00><00><CR> When the PC receives a valid command from the PLC, it sends the following: ACK<00><CR> When the PC receives an invalid command or no command response from the PLC, it sends the following: NAK<00><CR>
34 Chapter 1: Product Overview • Upon receipt of an NAK, the PLC If the PLC is currently trying to co resends the command response to the PC (not NK/AK). mplete a move command (VG…, ECHO 6, etc.), it mand string is as follows: x returns “MV<00><00><CR>”. Command Strings The general format of the main motion com VG=xD=yC=zR=www<CR> Where: = 0 move to location only x = 1 pick operation at location x = 2 place operation at location y = 0 Front Storage Area y = 1 Rear Storage Area z = 0 Column 0 z = 1 Column 1 z = 2 Column 2 z = 3 Column 3 row location, row 000 is the numbering location of Bin 1. See Bin Map, page 225. www 000 Represents - 119 uppermost row in the system. Note: Row numbering starts from 000 while Bin starts at 1. Thus, Row 000 column 0 is the Example: VG=0D=0C=0R=061 is a command string to move the Gripper in front of Bin 6 but not to pick or place. 2, Additional Command Strings Echo 6: mand string: s cannot take longer than 35 seconds ?P4104: the status of the Interaction Slot product sensor(s) the following 7 ter string is issued by the PC: 01<00><00><CR> A PLC Home/Reset is accomplished by issuing the following com ECHO 6<CR> Example Response: none After receipt of this command, the PLC references Gripper position through the Vertical and Horizontal Encoders and stops. No response is given when the proces is complete. The homing process To query charac ?P4104<CR> Example Response (2 characters):
Chapter 1: Product Overview 35 Bit 0 represents the Interaction Slot product sensor. This command is used in the UI PLCVER<CR> Example Response: 0304<CR> After a valid command string is received by the PLC from the PC, and the proper handshaking d the PC command has been carried out by the PLC, a command response is in the rent and return process to verify a rental has been removed from the Interaction Slot, to start a return, and to verify the Interaction Slot is empty prior to dispensing. 01 indicates product presence in the slot, 00 indicates product absence in the given slot. PLCVER: To query the PLC code revision the following 7 character string: This response is interpreted as PLC code revision number 0304 (3.04). Command Responses has occurred, an generated back to the PC as follows: Command Response Response Code 00<00><00><CR> Successful operation 15<00><00><CR> Place operation is blocked by an object or no product initially on platform to place 17<00><00><CR> Placement error – PLC has pulled product back on platform 30<00><00><CR> Empty pick – no product at location to be picked 34<00><00><CR> Failed pick – product at location, but could not be picked, product remains in bin 45<00><00><CR> Failed expel of product at Interaction Slot 54<00><00><CR> Failed accept of product at Interaction Slot 59<00><00><CR> Product has been automatically dumped at dump bin location by PLC 91<00><00><CR> Vertical axis timeout after 20 seconds 92<00><00><CR> Horizontal axis timeout after 12 seconds 93<00><00><CR> Insertion axis timeout after 6 seconds 94<00><00><CR> Safety sensors tripped – product impeding motion MV<00><00><CR> See Busy Command Response, page 35 These commands and responses are entered into the motion log in the sample form below. 080812 11:51:28 >> AK Received - for: VG=2D=0C=2R=091 080812 11:51:42 << ACK Sent - Command Response: 0 080812 11:51:42 Command Response: 0 Busy Command Response For all command strings that provide a command response (VG=…, ?P4104, PLCVER), if the PLC is currently trying to complete a move command, it returns a command response string of “MV<00><00><CR>”. In this case the command is NOT executed or queued by the PLC, and thus must be resent by the PC at a later time. Commands that do NOT return a command response string (for example Echo 6, Echo 7) are NOT executed.
36 Chapter 1: Product Overview Example Com Note that all occurrences of ‘PC’ munication Sequences within the example tables refer to the PC Motherboard/CPU Example 1: Echo 6 # Sender Command Description within the Pod. Seq 1 PC ECHO 6<CR> Command to PLC to home 2 PLC AK<00><00><CR> PLC acknowledging command Example 2: Move to first bin nder Command Description# Se 1 PC VG=0D=0C=0R=000<CR> Command to PLC to go to first bin 2 PLC AK<00><00><CR> 3 PLC 00<00> PLC acknowledging command <00><CR> Response (OK) from PLC regarding move PLC command 4 PC ACK<CR> PC acknowledges response from Exa lmp e 3: Failed command from PC # DescriptionSender Command 1 PC RG=0D=0C=0R=000<CR> Invalid command (RG) to PLC 2 PLC NK<00><00><CR> PLC responds with invalid command 3 PC VG=0D=0C=0R=000<CR> Command resent to PLC PLC AK<00><00><CR> PLC acknow4 ledging command move command 6 PC ACK<CR> PC acknowledges response from PLC 5 PLC 00<00><00><CR> Response (OK) from PLC regarding Example 4: Request status of input at Interaction Slot # Sender Command Description 1 PC ?P4104<CR> Command to PLC to report status of Interaction Slot input 2 PLC AK<00><00><CR> PLC acknowledging command 3 PLC 01<00><00><CR> Response (input ON ) from PLC regarding input state 4 PC ACK<CR> PC acknowledges response from PLC Command Description Example 5: Request version of PLC application # Sender 1 PC PLCVER<CR> Command to PLC to report application version 2 ><CR> PLC acknowledging command 3 PLC AK<00><00 PLC 0304<CR> Response (0304 ) from PLC regarding version info
Chapter 1: Product Overview 37 4 PC ACK<CR> acknowledges response from PLCPC Example 6: Failed response to version of PLC application # Sender Command Description 1 PC PLCVER<CR> Command to PLC to report application version 2 3 n 6 PC ACK<CR> PC acknowledges response from PLC PLC AK<00><00><CR> PLC acknowledging command PLC 0<CR> Incorrect response (0) from PLC regarding version info 4 PC NAK<CR> PC alerts PLC of invalid response received. 5 PLC 0304<CR> Response (0304 ) from PLC regarding versio info Example 7: Busy command response from PLC # DescriptionSender Command 1 Command to PLC to place at Interaction SlotPC VG=2D=0C=2R=091<CR> 2 PLC acknowledging command 3 PLC MV<00><00><CR> PLC responds with busy notice ACK<CR> PC acknowledges response, should delay before sending a new command PLC AK<00><00><CR> 4 PC
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7932_HardwareServiceGuide

  • 1. NCR SelfServ Entertainment – Multifunction / 7932 & 2371-9990 Release 1.0 Hardware Service Guide 27384 B005-0000-1886 Issue A
  • 2. The product described in this book is a licensed product of NCR Corporation. NCR is a registered trademark of NCR Corporation. NCR SelfServ Entertainment Kiosk is either a registered trademark or a trademark of NCR Corporation in the United States and/or other countries. It is the policy of NCR Corporation (NCR) to improve products as new technology, components, software, and firmware become available. NCR, therefore, reserves the right to change specifications without prior notice. All features, functions, and operations described herein may not be marketed by NCR in all parts of the world. In some instances, photographs are of equipment prototypes. Therefore, before using this document, consult with your NCR representative or NCR office for information that is applicable and current. To maintain the quality of our publications, we need your comments on the accuracy, clarity, organization, and value of this book. Address correspondence to: Manager, Information Solutions Group NCR Corporation Discovery Centre 3 Fulton Road DD2 4SW Internet Address: http://www.info.ncr.com/eFeedback.cfm Copyright © 2009 By NCR Corporation Dayton, Ohio U.S.A. All Rights Reserved
  • 3. i Preface This book provides information that is necessary to identify and repair problems. This includes troubleshooting information and step-by-step procedures for replacing hardware components. Audience This book is written for hardware installer/service personnel, system integrators, and field engineers. Notice: This document is NCR proprietary information and is not to be disclosed or reproduced without consent. Battery Information Battery Type Component/Location Device Part # Removal Instructions Lithium Motherboard / CPU 006-8612322 Page 154 Lithium JBM Router C120 006-8615023 Page 172 Lead Acid UPS – Eaton Powerware 5110 006-8614269 Page 163 Safety Requirements The NCR SelfServ Entertainment – Multifunction / 7932 & 2371-9990 conform to all applicable legal requirements. To view the compliance statements see the NCR SelfServ Entertainment Products Safety and Regulatory Guide (B005-0000-1904). Additional Safety Requirements Specific to NCR 7932 & 2371-9990 Kiosks The Soft Stop Rocker Switch (2371-9990) or Jumper (7932/TE1001) is a logic switch that only stops all PLC controlled motion. The AC line voltage primaries are live at all times — even after disconnecting the power cord. Therefore, perform a normal shut down of the Motherboard/CPU, power off the UPS, and then disconnect the AC power cord before servicing this terminal. Warning: Hazardous moving parts inside. Unexpected motion of mechanical parts may occur if the Limit Switch is pressed. Keep fingers and other body parts away from moving parts. The system may start unexpectedly if power is not disconnected. Warning: The NCR 7932 or 2371-9990 must be placed on a level surface with the casters locked. When relocating the kiosk, set the casters to their minimum height adjustment (fully screwed in) – using the Caster Wrench (part # 6039014898) – to prevent bent casters. Ladder Safety Worker safety must be considered if a ladder is required to service the NCR SelfServ Entertainment – Multifunction / 2372 kiosk. This can be a concern if the AC power outlet is located above the kiosk.
  • 4. ii The NCR Ladder Safety Process (Infr.7.9.4.2.3_PRO_WCS-HR-EHS_GLOBAL) prohibits work on portable stepladders with employees’ feet above 3 Meters (10 Feet) without proper fall protection or the use of a mechanical/electric lift. It also identifies proper ladder selection and condition. Refer to the following website for the NCR Ladder Safety Process. http://cks1.ncr.com/local/gps.nsf/docsumm/5CDA704F3A1DDB9CC1256E4E005AC5E8?OpenDocument Additional Information Products • NCR SelfServ Entertainment – Multifunction / 7932 & 2371-9990 Parts Identification Manual (B005-0000-1934) • NCR SelfServ Entertainment Products Safety and Regulatory Guide (B005-0000-1904) • NCR Workstation and Peripherals AC Power Wiring Guide (BST0-2115-53) • NCR Ethernet Wiring Guide (BST0-2118-82) • NCR 6352XP Reader User Manual (Japanese) (B005-0000-1920)
  • 5. iii Table of Contents Chapter 1: Product Overview 1 Introduction .................................................................................................................. 1 Removing the Kiosk Panels ......................................................................................... 2 Front Access Panel................................................................................................. 2 Side Panels............................................................................................................. 2 Rear Access Panel.................................................................................................. 2 Order of Operation ....................................................................................................... 3 Tools Required for Service........................................................................................... 5 Service Information...................................................................................................... 7 Component Location.................................................................................................... 8 Diagnostics................................................................................................................... 9 Administrative Login............................................................................................. 9 Service Utilities ..................................................................................................... 9 Service Utilities Main Functions..................................................................... 10 Setup & Config Functions............................................................................... 11 Diagnostic Tab Functions................................................................................ 12 XE 1.x Utilities Tab Functions........................................................................ 14 Accessing Service Utilities.............................................................................. 14 RFGate................................................................................................................. 15 MagTek USBMSR............................................................................................... 17 Physical Inventory ............................................................................................... 18 Physical Inventory Features ............................................................................ 18 Performing a Physical Inventory..................................................................... 19 GE PLC Audit, 2371-9990 .................................................................................. 20 Accessing GE PLC Audit, 2371-9990............................................................. 20 Using PLC Audit, 2371-9990.......................................................................... 20 Motion Exerciser (MoX) ..................................................................................... 23 Motion Exerciser 1.x (KAI) ............................................................................ 23 Motion Exerciser 2.x (AKPOS Motion Exerciser).......................................... 27 Motion Power ...................................................................................................... 32 Motion Log and PLC Commands........................................................................ 33 Response Strings ............................................................................................. 33 Handshaking.................................................................................................... 33 Command Strings............................................................................................ 34 Additional Command Strings.......................................................................... 34 Command Responses....................................................................................... 35 Busy Command Response............................................................................... 35 Example Communication Sequences .............................................................. 36
  • 6. iv Kiosk Power ............................................................................................................... 38 UPS Assembly, 2371-9990 & 7932-8082 ........................................................... 38 Main Circuit Breaker ........................................................................................... 38 Customer Control Center (Pod) Assembly .......................................................... 39 PC Power Supply............................................................................................. 39 Touch Screen Monitor Power Supply ............................................................. 39 Control Panel Assembly ...................................................................................... 39 15 VDC Power ................................................................................................ 39 Vertical Motor Speed Controller Power.......................................................... 40 PLC Power ...................................................................................................... 40 24 VDC Power ................................................................................................ 40 Robotic Calibration .................................................................................................... 41 Calibration Check ................................................................................................ 41 Calibration Procedures......................................................................................... 41 Vertical Guide Alignment ............................................................................... 41 Leveling the Carriage Assembly ..................................................................... 42 Vertical Timing Belt Leveling Adjustment..................................................... 44 Vertical Sensor Adjustments ........................................................................... 46 Pick Height Adjustment .................................................................................. 49 Place Height Adjustment, 7932-8080/8082 & 8094 ....................................... 50 Carriage Recovery Procedure.......................................................................... 52 Gripper Horizontal Pick and Place Alignment................................................ 54 Vertical Position Transducer Adjustment, 7932-8082 & 8094 ....................... 56 Horizontal Position Transducer Adjustment, 7932-8082 & 8094................... 57 Interaction Slot Gate Proximity Sensor Calibration........................................ 59 Bin Structure Alignment.................................................................................. 61 Belt Tension Verification and Adjustment .......................................................... 64 Gate Strap Verification.................................................................................... 64 Gate Strap Adjustment .................................................................................... 65 Roller Belt Tension Verification ..................................................................... 66 Roller Belt Tension Adjustment...................................................................... 66 Insertion Axis Belt Tension Verification......................................................... 68 Insertion Axis Belt Tension Adjustment ......................................................... 68 Horizontal Belt Tension Verification .............................................................. 69 Horizontal Belt Tension Adjustment............................................................... 70 Vertical Belt Tension Verification .................................................................. 71 Vertical Belt Tension Adjustment................................................................... 74 Gripper Motor Belt Tension Adjustment and Verification.............................. 75 Chapter 2: Troubleshooting 77 System Assessment .................................................................................................... 77
  • 7. v Visual Check........................................................................................................ 77 Functional Check................................................................................................. 78 Touch Screen Monitor................................................................................................ 81 Power Brick ......................................................................................................... 81 Cable Connections............................................................................................... 81 Power ON ............................................................................................................ 81 Monitor Settings .................................................................................................. 82 Calibrating a Touch Screen.................................................................................. 83 Touch Screen Connectivity.................................................................................. 85 Touch Screen Driver............................................................................................ 85 Tools Required ................................................................................................ 85 Procedure......................................................................................................... 85 Secondary Display, 2371-9990 .................................................................................. 86 Secondary Display Settings ................................................................................. 86 Power ON ............................................................................................................ 87 Magnetic Stripe Reader.............................................................................................. 89 RFID Components...................................................................................................... 91 Pod Speakers .............................................................................................................. 94 Adjusting the Volume.......................................................................................... 94 No Sound ............................................................................................................. 94 LAN / WAN Connectivity in the Kiosk..................................................................... 95 LAN ..................................................................................................................... 95 WAN.................................................................................................................... 95 JBM Electronics Gateway C120 Router.......................................................... 95 AirLink Raven-E Modem................................................................................ 99 Motherboard / CPU .................................................................................................. 101 Features.............................................................................................................. 101 CPU Power ........................................................................................................ 101 CPU Power Connections............................................................................... 101 New-Motherboard Power Reset .................................................................... 101 CPU Not Working ............................................................................................. 102 Spare USB Ports............................................................................................ 103 BIOS Settings................................................................................................ 103 Memory ......................................................................................................... 103 USB Port Headers.............................................................................................. 104 Communication Port Settings................................................................................... 105 COM1 ................................................................................................................ 105 COM2 ................................................................................................................ 105 Windows Device Manager................................................................................. 105 List COM Ports.................................................................................................. 107 Programmable Logic Controller (PLC), 7932-8080 & 2371-9990 .......................... 108
  • 8. vi Features.............................................................................................................. 108 Power ................................................................................................................. 109 Resetting the PLC.............................................................................................. 109 PLC USB Connections ...................................................................................... 109 Soft Stop ............................................................................................................ 110 Inputs / Sensor & Switch Identification............................................................. 111 Outputs / Relay Identification............................................................................ 112 Programmable Logic Controller (PLC), 7932-8082 & -8094.................................. 113 Analog Outputs and Inputs ................................................................................ 113 Horizontal Position Transducer Output Voltages.......................................... 113 Vertical Position Transducer Output Voltages.............................................. 113 Analog Input Module .................................................................................... 113 Inputs / Sensor & Switch Identification............................................................. 114 Outputs / Relay Identification............................................................................ 115 Gripper Assembly Sensors....................................................................................... 116 Fiber Optic Sensors............................................................................................ 116 Fiber Optic Amplifiers .................................................................................. 116 Fiber Optic Amplifier Features ..................................................................... 116 Look Down Sensors........................................................................................... 117 Carriage Assembly Sensors...................................................................................... 118 Horizontal Sensor Bracket Assembly, 7932-8080 & 2371-9990 ...................... 118 Horizontal Position Transducer, 7932-8082 & -8094........................................ 118 Insertion Axis Proximity Sensors ...................................................................... 118 Left & Right Limit Switches ............................................................................. 119 Vertical Axis Sensors............................................................................................... 120 Vertical Sensor Assembly, 7932-8080 & 2371-9990........................................ 120 Vertical Position Transducer, 7932-8082 & -8094............................................ 120 Upper & Lower Slowdown Sensors .................................................................. 120 Upper & Lower Limit Switches......................................................................... 121 Interaction Slot & Gate Sensors ............................................................................... 122 Interaction Slot Sensor....................................................................................... 122 Gate Up Proximity Sensor................................................................................. 122 Gate Down Proximity Sensor ............................................................................ 122 Gate Through-Beam Sensor............................................................................... 122 Chapter 3: Component Replacement 123 Component Access................................................................................................... 123 Engaging Soft Stop............................................................................................ 123 Engaging the 2371-9990 Soft Stop Rocker Switch....................................... 123 Engaging the 7932 Soft Stop Jumper ............................................................ 123 Disengaging Soft Stop ....................................................................................... 123
  • 9. vii Disengaging the 2371-9990 Soft Stop Rocker Switch .................................. 123 Disengaging the 7932 Soft Stop Jumper ....................................................... 124 Turning Kiosk Power Off .................................................................................. 124 Turning Kiosk Power On................................................................................... 125 Connecting an External USB Device................................................................. 125 7932 USB Connection................................................................................... 125 2371-9990 USB Connection.......................................................................... 125 Wire Ties ........................................................................................................... 126 Cable Connection............................................................................................... 126 Customer Control Center (Pod)................................................................................ 127 Removing the Pod.............................................................................................. 127 Tools Required .............................................................................................. 127 Procedure....................................................................................................... 127 Installing the Pod ............................................................................................... 128 Tools Required .............................................................................................. 128 Procedure....................................................................................................... 128 Memory Modules ..................................................................................................... 129 Removing Memory Modules............................................................................. 129 Installing Memory Modules............................................................................... 129 Motherboard Bracket Assembly............................................................................... 131 Removing the Motherboard Bracket Assembly................................................. 131 Tools Required .............................................................................................. 131 Procedure....................................................................................................... 131 Installing the Motherboard Bracket Assembly .................................................. 132 Tools Required .............................................................................................. 132 Procedure....................................................................................................... 132 Hard Drive................................................................................................................ 134 Removing the Hard Drive.................................................................................. 134 Tools Required .............................................................................................. 134 Procedure....................................................................................................... 134 Installing the Hard Drive ................................................................................... 135 Tools Required .............................................................................................. 135 Procedure....................................................................................................... 135 Restoring a Thumb Drive Image ....................................................................... 136 Tools Required .............................................................................................. 137 Procedure....................................................................................................... 137 Customize the Kiosk.......................................................................................... 138 Calibrate the touch screen ............................................................................. 138 Network Configuration.................................................................................. 139 The PC Power Supply .............................................................................................. 142 Removing the PC Power Supply ....................................................................... 142
  • 10. viii Tools Required .............................................................................................. 142 Procedure....................................................................................................... 142 Installing the PC Power Supply......................................................................... 143 Tools Required .............................................................................................. 143 Procedure....................................................................................................... 143 The Touch Screen Monitor....................................................................................... 145 Removing the Touch Screen Monitor................................................................ 145 Tools Required .............................................................................................. 145 Procedure....................................................................................................... 145 Installing the Touch Screen Monitor ................................................................. 146 Tools Required .............................................................................................. 146 Procedure....................................................................................................... 146 Magnetic Stripe Reader............................................................................................ 148 Removing the Magnetic Stripe Reader.............................................................. 148 Tools Required .............................................................................................. 148 Procedure....................................................................................................... 148 Installing the Magnetic Stripe Reader................................................................ 149 Tools Required .............................................................................................. 149 Procedure....................................................................................................... 150 Pod Speakers ............................................................................................................ 151 Removing the Speakers ..................................................................................... 151 Tools Required .............................................................................................. 151 Procedure....................................................................................................... 151 Installing the Speakers....................................................................................... 152 Tools Required .............................................................................................. 152 Procedure....................................................................................................... 152 Motherboard / CPU .................................................................................................. 154 Removing the CPU............................................................................................ 154 Installing the CPU.............................................................................................. 154 RFID Reader ............................................................................................................ 156 Removing the RFID Reader Board.................................................................... 156 Tools Required .............................................................................................. 156 Procedure....................................................................................................... 156 Installing the RFID Reader Board ..................................................................... 156 Tools Required .............................................................................................. 156 Procedure....................................................................................................... 157 RFID Coaxial Cable................................................................................................. 158 Tools Required................................................................................................... 158 Replacing the RFID Coaxial Cable.................................................................... 158 RFID Antenna .......................................................................................................... 160 Removing the RFID Antenna ............................................................................ 160
  • 11. ix Tools Required .............................................................................................. 160 Procedure....................................................................................................... 160 Installing the RFID Antenna.............................................................................. 161 Tools Required .............................................................................................. 161 Procedure....................................................................................................... 161 UPS........................................................................................................................... 163 Removing the UPS............................................................................................. 163 Tools Required .............................................................................................. 163 Procedure....................................................................................................... 163 Installing the UPS.............................................................................................. 163 Tools Required .............................................................................................. 163 Procedure....................................................................................................... 163 POP Wraps ............................................................................................................... 165 Removing the POP Wraps ................................................................................. 165 Tools Required .............................................................................................. 165 Procedure....................................................................................................... 165 Reinstalling the POP Wraps .............................................................................. 165 Tools Required .............................................................................................. 165 Procedure....................................................................................................... 165 Secondary Display Housing ..................................................................................... 167 Removing the Display Housing......................................................................... 167 Tools Required .............................................................................................. 167 Procedure....................................................................................................... 167 Reinstalling the Display Housing ...................................................................... 168 Tools Required .............................................................................................. 168 Procedure....................................................................................................... 168 Secondary Display / LCD Display ........................................................................... 170 Removing the Secondary LCD Display............................................................. 170 Tools Required .............................................................................................. 170 Procedure....................................................................................................... 170 Replacing the Secondary LCD Display ............................................................. 171 Tools Required .............................................................................................. 171 Procedure....................................................................................................... 171 Cellular Network...................................................................................................... 172 Removing the Aircard Modem .......................................................................... 172 Tools Required .............................................................................................. 172 Procedure....................................................................................................... 172 Removing the JBM Router ................................................................................ 172 Tools Required .............................................................................................. 172 Procedure....................................................................................................... 172 Replacing the JBM Router................................................................................. 173
  • 12. x Tools Required .............................................................................................. 173 Procedure....................................................................................................... 173 Replacing the Aircard Modem........................................................................... 173 Tools Required .............................................................................................. 173 Procedure....................................................................................................... 174 PLC........................................................................................................................... 175 Removing the PLC............................................................................................. 175 Tools Required .............................................................................................. 175 Procedure....................................................................................................... 175 Installing the PLC.............................................................................................. 175 Tools Required .............................................................................................. 175 Procedure....................................................................................................... 176 Gripper Belts ............................................................................................................ 177 Tools Required................................................................................................... 177 Replacing the Gripper Belts............................................................................... 177 Gripper Motors......................................................................................................... 179 Tools Required................................................................................................... 179 Replacing the Gripper Motors ........................................................................... 179 Gripper Springs ........................................................................................................ 181 Tools Required................................................................................................... 181 Replacing the Gripper Springs........................................................................... 181 Insertion (Z-Axis) Belt............................................................................................. 184 Tools Required................................................................................................... 184 Replacing the Insertion (Z-Axis) Belt................................................................ 184 Insertion (Z-Axis) Motor.......................................................................................... 187 Tools Required................................................................................................... 187 Replacing the Insertion (Z-Axis) Motor ............................................................ 187 Horizontal Carriage Motor....................................................................................... 189 Tools Required................................................................................................... 189 Replacing the Horizontal Carriage Motor.......................................................... 189 Horizontal Belt ......................................................................................................... 191 Tools Required................................................................................................... 191 Replacing the Horizontal Belt............................................................................ 191 Gate Frame Assembly .............................................................................................. 193 Tools Required................................................................................................... 193 Removing the Gate Frame Assembly ................................................................ 193 Installing the Gate Frame Assembly.................................................................. 195 Gate Motor ............................................................................................................... 196 Tools Required................................................................................................... 196 Replacing the Gate Motor.................................................................................. 196 Roller Motor............................................................................................................. 198
  • 13. xi Tools Required................................................................................................... 198 Replacing the Roller Motor ............................................................................... 198 Roller Spring ............................................................................................................ 200 Tools Required................................................................................................... 200 Replacing the Roller Spring............................................................................... 200 Vertical Proximity Sensor ........................................................................................ 202 Tools Required................................................................................................... 202 Replacing the Vertical Proximity Sensor........................................................... 202 Interaction Slot Sensor ............................................................................................. 203 Tools Required................................................................................................... 203 Replacing the Interaction Slot Sensor................................................................ 203 Vertical Motor.......................................................................................................... 204 Tools Required................................................................................................... 204 Replacing the Vertical Motor ............................................................................ 204 Chapter 4: Preventative Maintenance 207 Kiosk Preventive Maintenance................................................................................. 207 Cleaning the System Exterior ............................................................................ 207 Cleaning LCD Displays..................................................................................... 207 Cleaning the Magnetic Stripe Reader ................................................................ 208 Cleaning the Interaction Slot Roller .................................................................. 208 Interaction Slot Alignment................................................................................. 209 Cleaning the Gripper.......................................................................................... 210 Carriage Horizontal Shaft Corrosion Control.................................................... 211 Vertical Drive Shaft Flange Bearing Lubrication.............................................. 211 Appendix 212 CPU Connections ..................................................................................................... 212 Motherboard POST Errors ....................................................................................... 214 POST Beeps....................................................................................................... 214 Displayed POST Messages................................................................................ 214 Vertical Drive Motor Speed Controller Settings...................................................... 216 Motion Error Codes.................................................................................................. 217 XE 2.x Error Definitions .......................................................................................... 218 Fatal Error Definitions – Result Codes < 0........................................................ 218 Motion Error: -7 ........................................................................................... 218 Communication Halt Error: -6...................................................................... 218 Communication Breakdown Error: -5.......................................................... 218 Connection Lost Error: -4............................................................................. 218 No Connection Error: -3............................................................................... 219 Connecting Error: -2..................................................................................... 219
  • 14. xii Loading Configuration Error: -1 .................................................................. 219 Success - Result Code = 0.................................................................................. 219 Success: 0 ..................................................................................................... 219 Non-Fatal - Result Codes > 0 ............................................................................ 220 Invalid Bin Number Fault: 1......................................................................... 220 Item On Picker Fault: 2 ................................................................................ 220 Empty Pick Fault: 3...................................................................................... 220 Pick Block Fault: 4....................................................................................... 221 Place Block Fault: 5...................................................................................... 221 Place Time Out – Interactive Slot Fault: 6 ................................................... 221 Motion Fault: 7............................................................................................. 222 Unsupported Run Mode Fault: 8 .................................................................. 222 Expel Reclaimed Fault: 9 ............................................................................. 222 Kiosk Power Distribution, 2371-9990...................................................................... 223 Pod Wiring and Cable Connections ......................................................................... 224 Bin Map.................................................................................................................... 225 Definition of Terms Used......................................................................................... 226 Initial System Inspection Checklist.......................................................................... 237 Visual Assessment............................................................................................. 237 Inspect System Components.............................................................................. 237 System Checkout ............................................................................................... 238 2371-9990 Wiring Schematics ................................................................................. 239
  • 15. xiii Revision Record Issue Date Remarks A Oct 2009 First issue
  • 16.
  • 17. 1 Chapter 1: Product Overview Introduction The NCR SelfServ Entertainment – Multifunction / 7932 and 2371-9990 are self-service kiosks that permit a customer to select from over 400 movie titles. They can either rent or purchase the movies; giving the customer freedom of choice. The touch screen permits the customer to review the movie titles available. An optional Secondary display is available that plays an advertising piece for customer interest. Once the customer decides upon a movie and pays for it using the integrated credit card reader, the kiosk pulls the DVD from stock and presents it to the customer. The kiosk is a low cost way for a customer to buy or purchase a movie in a compact setting; cutting down on retail space needed for purchasing DVD products. The kiosk can be set up in any enclosed retail or business environment. Magnetic Stripe Reader (MSR)ouch Screen Pod LockFront Access Panel Lock Customer Interaction Slot Customer Interface T Customer Control Center (Pod)
  • 18. 2 Chapter 1: Product Overview Removing the Kiosk Panels Access to the kiosk is through the bottom front access panel and side panels. The front panel must be removed first to access Soft Stop. Soft Stop is a logic switch that stops all controlled motion. Once activated, the Soft Stop’s slow ticking sound indicates that it is safe to remove the side panels. Front Access Panel For 2371-9990 kiosks, the bottom front access panel provides access to the Main Circuit Breaker switch on the right, and to the Soft Stop Rocker Switch and USB port on the left side of the Front Electrical Panel. For 7932(-8080, -8082, -8094) kiosks, removal of the front access panel provides access to the Soft Stop Jumper, to the modem / router (if present), and to the USB cable that connects to the PLC’s USB-to-Serial converter. The front access panel lock may require a special merchandiser key. 1. Unlock the front access panel with the appropriate key in the lock on the lower left side. 2. Pull it back until the left side of the access panel is clear of the frame and then slide it off of the tapered pins on the right. For POP wrap, refer to POP Wraps on page 165. Side Panels The side panels are secured with locks. It’s necessary to remove the left and right side panels to access the kiosk’s internal mechanisms. 1. While the kiosk is powered, unexpected motion of mechanical parts may occur. There are hazardous moving parts inside. To prevent this, remove the front access panel (see Front Access Panel on page 2) and engage Soft Stop (refer to Engaging Soft Stop on page 123). 2. Unlock the top locks on the side panels before removing them. Rear Access Panel The rear access panel on the bottom provides access to the rear DIN rail of the Control Panel Assembly. 1. Unlock the rear access panel using the lock on its lower left side. 2. Pull it back until it’s clear of the frame and slide it off of the tapered pins that are on the right side.
  • 19. Chapter 1: Product Overview 3 Order of Operation The order of operation is presented to demonstrate a sequence of events, sensor inputs and control outputs, when a DVD is returned to the Interaction Slot. Action Result 1. DVD inserted in the Interaction Slot Customer initiates the return process 2. Outside Product Sensor turns ON Indicates a product is in the Interaction Slot 3. Vertical Motor turns ON Carriage is moved to Interaction Slot level 4. Horizontal Motor turns ON Gripper is moved in front of the Interaction Slot 5. Vertical and Horizontal Motors stop Motors stop upon reaching destination 6. Z-Axis Motor turns ON Gripper moves forward to pick the Interaction Slot 7. Gripper Belts start turning The Gripper is prepared to accept the DVD 8. Rear Proximity Sensor turns ON Indicates Gripper is in the forward position 9. Gate Motor turns ON Interaction Slot Gate opens 10. Gate Up Proximity Sensor turns ON Gate is fully open, motor stops 11. Roller Motor turns ON Feeds case into Gripper 12. Through-Beam Sensor turns ON Case blocks Gate Through-Beam Sensor 13. Front Fiber Optic Amplifier turns ON Case blocks Fiber Optic Sensor 14. Front Look Down Sensor turns ON Case blocks Front Look Down Sensor Reflector as it travels onto the Gripper 15. Gate Through-Beam Sensor turns OFF Case is clear 16. Roller Motor stops 17. Gate Motor starts Interaction Slot Gate closes
  • 20. 4 Chapter 1: Product Overview Action Result 18. Gate Down Proximity Sensor turns ON Gate is closed, Gate motor stops 19. Fiber Optic Amplifier turns OFF Fiber Optic Sensor cleared 20. Rear Look Down Sensor turns ON Case blocks Rear Look Down Sensor Reflector as it travels on the Gripper 21. Gripper Belts stop turning Case is centered on Gripper 22. Insertion (Z) Axis Motor turns ON Gripper moves back to center on the Carriage Assembly 23. Front and Rear Proximity Sensor ON simultaneously Gripper is centered, Insertion (Z) Axis Motor stops 24. RFID Tag is read Inventory is returned to first available storage bin
  • 21. Chapter 1: Product Overview 5 Tools Required for Service The following is a general list of tools useful in servicing NCR 7932 & 2371-9990 systems: • Kiosk Key Set (Site managers don’t have them) • Hex Wrenches o T-Handle-Standard; (9 in. Shaft, 3/32-1/4, part # 6039014929) o T-Handle-Standard; (6 in. Shaft, 3/32-1/4, part # 6039014928) o T-Handle-Balled End; (9 in. Shaft, 5/64-7/32, part # 6039014927) o 90 Degree / Balled End (Short Shaft) Combination set, 1/16 – 3/8 o Stub Hex Key Set (1/16-1/4, part # 6039014930) o 5/16” Stub Hex Key • Pliers / Wrenches o Channel Lock Pliers o Adjustable Pliers o Needle Nose Pliers: Standard and Precision - 2 ea. o Precision Diagonal Cutter - 2 ea. o Needle Nose Locking Pliers (Vise Grip) - 2 ea. o Snap Ring Pliers o Adjustable (Crescent) Wrenches o 13 mm Combination Wrench o 13 mm Deep Well Socket and Driver o 11/32 (9mm) Combination Wrench o 9/32 (7mm) Combination Wrench o 7/16 (11mm) Combination Wrench o 11/32 (9mm) Socket Wrench o 1/4 (7mm) Socket Wrench • Screw Drivers o Standard Set o 1/8” Blade, 4” Shaft o 1/8” Blade, 6” Shaft • Miscellaneous o Flashlight o Digital Multimeter o PC ATX Power Supply Tester – obtain locally at Office Depot: Coolmax PS-224 ATX Power Supply Tester Item #161085
  • 22. 6 Chapter 1: Product Overview o Caliper o Feeler Gauge Set o 12” Steel Ruler o Combination Square o Pocket Knife and/or Safety Razor Blades o 10’ Tape Measure o Permanent Marker o Post-it Notes o Assorted Cable Ties o Caster Wrench (part # 6039014898) o USB Keyboard (part # 8770195701) o USB Mouse (or other pointing device) o USB Header Cable o Stepladder o Shim Service Tool (part # 497-0464764) o Nominal Shim Plate (0.165” – part # 497-0464767) o Minimum Shim Plate (0.135” – part # 497-0464766) o Maximum Shim Plate (consists of the 0.165” shim plus the 0.048” shim – part # 497-0464765) o Motor Adapter Breakout Cable (NCR part # 497-0463735) o Loctite 222 (part # 006-8613969) o Loctite 242 (part # 006-8615141) o Loctite 425 (part # 006-8614243) o Lithium Soap based grease No. 2 / Shell Alvania
  • 23. Chapter 1: Product Overview 7 Service Information If the use of an external USB device is required for maintenance, they can be connected to a USB port that is either located behind the kiosk’s Front Access Panel on the left side of the Front Electrical Panel (2371-9990 kiosks) or by disconnecting the USB cable that connects to the PLC’s USB-to-Serial converter (legacy 7932/TE1001 kiosks). For more information, refer to Connecting an External USB Device on page 125). Caution: Be careful when accessing components inside the kiosk while power is on. Depending upon the functions being performed, the electromechanical assemblies can start moving without warning. Avoid this by engaging the Soft Stop (refer to Engaging Soft Stop on page 123). A slow ticking sound from inside the kiosk confirms that Soft Stop is engaged. Remember that Soft Stop prevents motion, but the electrical hazards remain. The AC line voltage primaries are live at all times — even after disconnecting the power cord. To fully power down the kiosk, perform the Turning Kiosk Power Off procedure on page 124. 23412 Top View Battery Backup Surge Protection Surge Protection Only www.apc.com Back-UPS ES 550 Power on Replace Battery UPS UPS Power Switch 2371-9990 interior side view of floor panel featuring from left to right (front to back): UPS and Control Panel Assembly. Front Side Power Cord Entry Right Rear Right Front UPS Power Switch USB Soft Stop 2371-9990 front floor pan and Front Electrical Panel illustrated below. Note: UPS make, model and appearance may vary. Main Breaker Switch
  • 24. 8 Chapter 1: Product Overview Component Location The locations for the major components in the NCR SelfServ Entertainment – Multifunction / 7932 and 2371-9990 are shown in the following illustrations. Front Electrical Panel Assembly (2371-9990 only) Magnetic Stripe Reader (MSR) Customer Interface Touch Screen Pod Lock Customer Interaction Slot Front Shelf Assembly Vertical Drive Assembly Front Access Panel Lock Soft Stop Switch Main Circuit Breaker Rear Storage Area Carriage Assembly Control Panel Assembly Vertical Drive Assembly Right Carriage Rail Assembly Left Carriage Rail Assembly USB Port Upper Vertical Pulleys Customer Control Cente (Pod) r
  • 25. Chapter 1: Product Overview 9 Diagnostics Nearly all of the kiosk’s diagnostics are accessed through Service Utilities. To access administrative diagnostic functions, it may be necessary to log off and log in with administrative access. Administrative Login To log into the kiosk with administrative access: 1. Call Help Desk/SST and request administrative access. 2. Remove the front access panel (refer to Front Access Panel on page 2). 3. Connect a USB keyboard above the Soft Stop Switch on the left side of the Electrical Sub Panel. 4. Press the keyboard’s Windows Logo key and touch Log Off (not restart) as the current user. 5. As Windows logs off the current user, hold the SHIFT key until the Login screen appears. 6. Log in with administrative access. Service Utilities Service Utilities is opened by double-tapping its desktop icon. The following is an example screen. Its actual appearance and the available options vary according to the kiosk’s current software release.
  • 26. 10 Chapter 1: Product Overview All diagnostic applications can be accessed from the Diagnostic tab in Service Utilities. From this window, touch the desired application’s button once to open that application. Note: A double touch on a Service Utilities menu button will open more than one instance of the associated application. This can result in false test results. Service Utilities Main Functions The main Service Utilities functions are a set of buttons that are always available, regardless of which tab is selected. They are as follows: On Screen Keyboard: Opens the on-screen keyboard for text and control entries without a physical keyboard. Lock Screen: Initiates a dialog box to set a password and lock the touch panel. In this manner, the system can be safely left unattended. Task Manager: Launches the Windows Task Manager. Reboot Computer: Performs a Windows Restart. Shutdown Computer: Performs an orderly shut down of the computer. Close: Closes the Service Utilities application.
  • 27. Chapter 1: Product Overview 11 Setup & Config Functions Diagnostics: Accesses kiosk diagnostics, identical to selecting the Diagnostic tab. age 83). ode. e with the server. nt application. lays the contents of the TA_TX01 XML file. Calibrate Monitor: Opens the touch screen calibration application (see Calibrating a Touch Screen on p Start AKPOS Application Interface: Returns the kiosk to Rental M Change Site ID: Allows changes in the kiosk’s Site ID. Stop AKPOS Applications: Stops AKPOS applications. GP Update: Updates GP. Sync Date Time with Server: Synchronizes the kiosk’s date and tim Start Sync Client: Launches the Sync Clie View AKPOS Settings XML: Displays the contents of the AKPOS XML file. View TA_TX01 XML: Disp Status Box: Displays kiosk date, time, timezone and network information.
  • 28. 12 Chapter 1: Product Overview Diagnostic Tab Functions The Service Utilities Diagnostic tab provides rapid single-touch access to several Windows system tools in addition to diagnostic applications. The functions available from the Diagnostic tab are: View Product Handler Log: Displays the contents of the AKPOS Product Handler.log file. View Physical Inventory Log: Displays the contents of the Physical Inventory log. Displays the contents of the AKPOS_API.log file. contents of the Motion log (refer to Motion Error Codes on Start Product Handler: Launches the Product Handler application. Start Physical Inventory: Opens AKPOS Physical Inventory. For information about the Physical Inventory application, refer to Physical Inventory on page 18. Start User Interface: Starts the user interface. Start Motion Exerciser: Launches the Motion Exerciser. For information about the Motion Exerciser, refer to Motion Exerciser (MoX) on page 23. RFID UTC: Starts the RFID UTC utility. RFGate: Opens the RFGate application. For information about accessing and using RFGate, refer to RFGate on page 15. IDTech MSR Upgrade: Executes the IDTeck MSR upgrade application. View XE Kiosk Log: Displays the contents of the XE Kiosk Log. View AKPOS_API Log: View Motion Log: Displays the page 217).
  • 29. Chapter 1: Product Overview 13 IDTech MSR HID Demo: Starts the IDTeck MSR HID Demo. Task List: Displays the contents of the Task List. asonic PLC. This 7). ity that tests the system’s 3GB memory. IPC Panasonic PLC Audit: Accesses PLC Audit for kiosks that use the Pan application is not used in 7932 and 2371-9990 kiosks. GE PLC Audit: Accesses PLC Audit for kiosks that use the GE PLC (2371-9990 only). For more information, refer to GE PLC Audit on page 20. MagTek USBMSR: Accesses the MagTek USBMSR utility (refer to MagTek USBMSR on page 1 Memory Tester: Starts a util Run AKPOS Application Interface: Returns the kiosk to Rental Mode. onfig /All: Lists the current settings for all active network connections. Login Required Area Certain Service Utility functions require administrative access. Before using these functions, call Help Desk/SST to request administrative access. For functions outside the scope of these n scre n on page 9). plorer RunAs user Below: Launches Windows Explorer. Display Settings: Opens the Display Properties window for viewing or changing the kiosk’s display settings. t k Settings: Opens the Network Settings windows for viewing or changing the kiosk’s network settings. buttons, it is necessary to log off (not restart), holding the SHIFT key to force it to the Logi en and log in with administrative access (refer to Administrative Logi CMD Prompt RunAs User Below: Opens the Command Prompt window for the execution of command line executables. Windows Ex Device Manager: Launches the Device Manager for viewing or changing device hardware properties. This is normally accessed through the Device Manager button under the Hardware tab within the System Properties window, which is accessed from the Windows taskbar’s Star menu to Settings, Control Panel, and System. Networ
  • 30. 14 Chapter 1: Product Overview XE 1.x Utilities Tab Functions 1 Motion Exerciser: Launches 1.x Motion Exerciser (see Motion Exerciser 1.x (KAI) onXE XE Auto Tester: Opens the Motion Auto Tester application. wer utility, which provides a quick and easy access to the RFID Reader Board functions for resetting the PLC and testing for the presence of media stuck in the Gripper Assembly (see Mo on Power on page 32). 217 Accessing Service Utilities 1. If there is no system power, turn the kiosk’s power on (refer to Turning Kiosk Power On, page 125). 2. If the kiosk is powered up, remove the bottom front panel (refer to Removing the Kiosk , Front Access Panel on page 2). 3. Connect a USB Keyboard to the rear of the eBox PC (PS/2 keyboard requires computer restart). 4. Access the Windows Task Manager by using the CTRL+SHIFT+ESC keyboard shortcut. 5. Close all applications listed in the Task Manager’s Applications tab. 6. Once all applications are closed, close the Task Manager window. 7. Double-touch the Service Utilities desktop icon. 8. Touch the Diagnostic tab. 9. To open a diagnostic application, single-touch the desired diagnostic’s button. 10. When finished with the current diagnostic, close its window by touching the red X in that window’s upper right corner. 11. When all diagnostic testing is complete, return the system to Rental Mode by pressing Service Utilities’ Reboot Computer button to restart the computer. Note: Double-touching a square diagnostic application button will open multiple instances of e same time can cause false results. page 23). 1 Motion XE1 Motion Power: Launches the Motion Po ti XE1 Motion Log: Displays the contents of the Motion Log (see Motion Error Codes on page ). the selected diagnostic. Opening multiple diagnostic applications at th
  • 31. Chapter 1: Product Overview 15 RFGate Inv each individual RFI i ese numbers are programmed into the RFID Tag affixed to the DVD. The RFID Reader reads the tag on each DVD ate utili entory is identified by the Unique ID number (UID) pre-programmed into D tag. Mov e/game titles are also identified by a SKU number. Both of th and uses the UID and SKU to manage inventory. This can be tested using the RFG ty. To use RFGate: . ight corner of the RFGate window indicates Connected. If gs, n page 105. 1. Access Service Utilities through its desktop icon and select the Diagnostic tab (for further details, see Accessing Service Utilities on page 14) and single-touch the RFGate button 2. Verify the Status in the lower r not connected, confirm that no other RFID-related program (Motion Exerciser, Motion Power, etc.) is active, close and reopen RFGate, or refer to Communication Port Settin COM1 o 3. Switch the Soft Stop Rocker Switch to the OFF position to prevent the Carriage Assembly from moving. Listen for a slow ticking sound to verify that Soft Stop is engaged. For more information about the Soft Stop Rocker Switch, refer to Engaging Soft Stop on page 123. 4. Place a known-good RFID tag on top of the Case Hold Downs directly over the RFID antenna. 5. In the Read menu, touch ISO Inventory.
  • 32. 16 Chapter 1: Product Overview 6. The RFID tag is read and the 16 digit UID number is displayed in the Transponder Data window in a successful read. While other numbers are always displayed in the Transponder Data, Reader to Host Data and the Host to Reader Data windows, the UID is the most important as it identifies the DVD. It is not a successful read if no UID number is displayed. 8. To clear previously read RFID data, touch the Clear Data icon. 9. Test the RFID Reader Board by resetting the PLC through the Remote Reset Relay, initiating the homing motion sequence: Caution: Do not perform this while someone is working in the kiosk.
  • 33. Chapter 1: Product Overview 17 a. From the Miscellaneous menu, touch Write Output. The Write Outputs dialog Output step. 10. then Exit. MagTek USBMSR MagTek USBMSR is a utility used to test the card reader. It is launched either from the Service Utilities Diagnostic tab (single touch) or from the MagTek USB MSR icon on the Windows desktop (double touch). Any magnetically encoded cards such as a credit card can be swiped after Swipe Card is displayed. formation encoded in the card is displayed. An error is displayed s, alth Dat slower swipes or faster card or missed read. also be indicated by a flashing red LED on the card reader immediately after displays. b. Set the Output 1 On checkbox. c. Touch the OK button. d. Reopen the Write Outputs dialog by repeating the Miscellaneous menu, touch Write e. Clear the Output 1 On checkbox. f. Press the OK button. The PLC restarts, initiating its homing motion sequence. To close RFGate, touch the Host Mode menu and After swiping the card, the in if a track is not correctly read. Credit cards generally display data for the first two track ough the card reader can read up to three tracks. a can be removed from the display by touching the Clear Dialog button. An error on any track may indicate a bad card reader. Try other cards, swipes to determine if it’s an actual error or if it was caused by a bad A bad read may the card swipe.
  • 34. 18 Chapter 1: Product Overview Physical Inventory Inventory is set up initially by using the Physical Inventory utility. This utility automatically updates the inventory database as the system picks the inventory and reads the data from the ication can be set to inventory the entire system or a range of bins. n Physical Inventory Features Inventory Occupied Unknown Bins: Inventories bins marked as OCCUPIED UNKNOWN. Inventory Only Empty Bins: Inventories bins marked as EMPTY. Inventory All Bins: Inventories all bins regardless of their status. This should only be done if starting a new physical inventory or if someone pressed the Reset Bin Map button. Direction: Toggles the order of the physical inventory. Pressing the button while it displays (REVERSE) shall reverse the order: last to first. Pressing the button while it displays (FORWARD) shall change the order to the usual first to last. Close: Closes the KAI Physical Inventory application. RFID tag. The appl KAI Physical Inventory is started by either touching the KAI Physical Inventory desktop ico or the Run KAI Physical Inventory button under the Service Utilities Diagnostic tab. Upon start up, the application connects to the database and initializes system motion. Once initialized, the Physical Inventory application is ready to accept commands. Start: Starts the inventory process. Stop: Halts the inventory process.
  • 35. Chapter 1: Product Overview 19 Bin Range Buttons: These buttons are toggled to include (green) or exclude (red) bin ranges in the physical inventory. For example, touching green bin range buttons turns them red, indicating that those bins shall not be inventoried. Lock Screen: Initiates a dialog box to set a password and lock the touch panel. In this manner, the system can continue to process inventory safely while unattended. Clear All: Deselects all bin ranges for inventory. To inventory a select few, press the Clear All button and select the few to inventory. Select All: Selects all bin ranges for inventory. To inventory the majority, touch the Select All button and select the few that won’t be inventoried. Reset Bin Map: This will clear and reset the storage bin mapping. It should only be done if the bin configuration has been changed. A complete physical inventory is required if this action is performed. A confirmation box displays to remind the user of this button’s purpose. Press the Yes button if this is the desired action or No if this action is not desired. sical Inventory window first appears, its buttons remain ed initialization. Response Box: Commands are displayed in this box along with their results. Performing a Physical Inventory 1. Open the Physical Inventory application, using either the KAI Physical Inventory desktop icon or the Run KAI Physical Inventory button under the Service Utilities Diagnostic tab. When the Phy grayed out until Motion has complet 2. Select the bin ranges to be inventoried (refer to Bin Map in the Appendix on page 225). 3. Select the desired inventory option button. For all but the Direction button, a confirmatio box displays to remind the user of that button’s purpose. Press the Yes button if that is the desired action or No if that action is not desired. n
  • 36. 20 Chapter 1: Product Overview 4. Press the Start button. h the Close button. GE PLC Audit, l for the kiosk’s robotic mechanism. It provides quick status overviews and delivers logs for detailed failure analysis. nts several views of the GE PLC’s outputs to and inputs from the 1. Remove the front access panel (see Removing the Kiosk Panels, Front Access Panel on page 2). 2. Connect a USB keyboard, mouse or other pointing device (refer to Connecting an External USB Device on page 125). 3. From the taskbar, select Start, Programs, GE PLC Audit, GE PLC Audit. 5. Verify that the Physical Inventory procedure is running. RFID read information is displayed in the dialog box as well as any errors. Touching the Lock Screen button initiates a dialog box to set a password and lock the touch panel. In this manner, the system can continue to process inventory safely while unattended. 6. When finished with Physical Inventory, touc 2371-9990 The GE PLC Audit application is a debugging too Note: GE PLC Audit prese kiosk’s robotic mechanism, which may directly indicate the problem. They do not in themselves account for the environment, foreign objects and broken parts. The rest is for the operator to determine. Accessing GE PLC Audit, 2371-9990 Using PLC Audit, 2371-9990 Navigation between the PLC Audit application’s four reporting functions is accomplished by touching the tabs at the top.
  • 37. Chapter 1: Product Overview 21 I/O The digital input indicates that the PLC is receiving a 0VDC signal on that input (the com the digital inputs is 24VDC). Some inputs are active low, and they are represented by bold Tab, 2371-9990 I/O tab shows all of the inputs to and outputs from the PLC. A green “On” symbol for a mon for text. A green “On” symbol for a relay output indicates that the relay is closed. System Status Tab, 2371-9990 Note: The System Status tab shows general system status including the current errors and the commanded and current location of each of the axes.
  • 38. 22 Chapter 1: Product Overview Current Non Fatal Errors show all errors that are recoverable, like an empty pick for example. reset by cycling power or issuing an Echo 6 (initialize) command from software. er cycle or Plac Not by t The Current Fatal Errors show all errors that are non-recoverable. Fatal errors will be accompanied by a fast clicking sound from relay Q24. For all fatal errors, the GE PLC must be Note: These error states are not preserved after resetting the plc via a pow software. e Height Adjustment Tab, 2371-9990 e: The Place Height Adjustment tab allows the user to modify the place height timer used he GE PLC. place height timer is used to determine how long to move upward after moving into ition on a place command. Inc The pos reasing the timer will result in a larger “bump” upward. If timer value and immediately send it to the GE PLC to be used. So, the place height adjustment process can be done while the robot is in motion (like when running random picks and places from Motion Exerciser). When satisfied with the place height, press the Save Permanently button. If the value is not saved permanently, the GE PLC will revert to its last permanently saved value on its next power cycle. Every time the Save Permanently button is pressed, the value is also written to a file on the Pod’s hard drive. So, if the plc is replaced, we can avoid having to repeat the place height adjustment process by loading this value back from this file. Pressing the Read Value From File on PC button will load the value and send it to the GE PLC. e permanently. this value is too large, the robot will begin hunting. If this value is too small, the DVD case may collide with the shelf of the bin it is being placed into. In either case the problem is fixed by changing the value. Remember to press the Save Permanently button when satisfied. Pressing the +/- buttons will adjust the The Save Permanently button will still have to be pressed to command the GE PLC to save the valu
  • 39. Chapter 1: Product Overview 23 Motion Exercis ity used to test motion, validate communication by pressing a button under the Diagnostic tab in Service odes (refer to Motion Error layed in the Response Box all other SelfServ Entertainment applications, particularly the System Agent, Middleware and or Product Handler (2.x). Only one application should control the motion/mechanical interface at any time. r 1.x (KAI) The Motion Exerciser 1.x is used in most NCR SelfServ Entertainment – Multifunction / 7932 & 2371-9990 kiosk releases. If the link to MoX 1.x is missing, either use MoX 2.0 (see Motion Exerciser 2.x (AKPOS Motion Exerciser) on page 27) or open Windows Explorer and navigate to: C:V3plusKAI_motionexerciser.exe er (MoX) The Motion Exerciser is a multipurpose util and read RFID tags. It is started Utilities (see Accessing Service Utilities on page 14). Status, error c Codes on page 217), functions, and other system responses are disp at the bottom of the Motion Exerciser window. Note: Before running any version of MoX, be sure to terminate Otherwise, communications to the PLC lock up. Motion Exercise Motion Exerciser is a kiosk diagnostic tool that’s used in the field for troubleshooting the mechanical motion of a system. This application’s functions are divided into two areas: • Controls • Auto Run
  • 40. 24 Chapter 1: Product Overview Controls Area Initialize: Begins the initialization process. Motion Exerciser must initialize first in order to facilitate motion. The system initialization takes a few moments to complete. Clear Log: Clears the responses logged within the Response Box upon user confirmation. Pick: Picks inventory from the bin address in the Pick Bin Address field. The Gripper picks the case from the bin selected, centers itself on the Carriage, and stops. xecute in Address field. The Gripper places the case in the bin selected, centers itself on the Carriage, and stops. Place Bin Address: eric field to the right of the Place button. Enter the desired Place bin num cal keypad that appears when this field is touched. Pick/Place Swap: Switches the bin address between Pick and Place. Accept: as Pick except the pick command is not executed unless there is a case in the Inte t Accept/Expel Swap: Switches the bin address between Accept and Expel. r Off: Energizes the Remote Reset Relay, which removes power from the PLC. When followed by the Motion Power On button, the PLC resets. Motion Power On: Turns off the Remote Reset Relay, restoring power to the PLC. This is often used while servicing the system to reset the PLC (refer to Resetting the PLC on page 109). Caution: The Carriage Assembly moves toward the bottom when PLC power is restored and its homing motion sequence begins. Avoid getting in its way Pick Bin Address: Numeric field to the right of the Pick button. Enter the desired Pick bin number using the numerical keypad that appears when this field is touched. Note: If inventory is already on the Gripper when Pick is pressed, it is placed in the Dump Bin instead of executing the Pick command. Pick must be pressed again to e the pick. Place: Places inventory in the bin address in the Place B Num ber using the numeri Same rac ion Slot. Expel: Same as Place. If Expel is used to Place at the Interaction Slot the case must be removed from the slot before any other command can be executed. Motion Powe .
  • 41. Chapter 1: Product Overview 25 Read RFID: Reads the RFID tagged inventory on the Gripper. On a successful read, the UID and SKU data are displayed in the RFID field. Print Test Receipt: This field is not applicable to current 7932 & 2371-9990 kiosk sy If a receipt printer were present, this button would test it by stems. printing a test receipt. Close: Closes the Motion Exerciser application. Auto Run Area The Auto Run section of Motion Exerciser permits the system to run automated test cycles. This is useful to observe and test system motion during the diagnostic process and after repairs. Pick Start: Beginning bin location of the first possible test starting range Pick End: The ending bin location of a first possible test ending range 3 in the to 298, etc. A Pick Step of -2 would go nge or second test range Note: To Pick from the Interaction Slot and place throughout the system, enter 35 Pick Start and Pick End fields. To test the Interaction Slot, enter 353 in all Pick and Place start and end fields. Pick Step: The number of incremental or decremental steps within the test range. Example: For a Pick Start-to-End range of 300 to 200, you could put a -1 in the Pick Steps to have the iteration move from 300 to 299 from 300 to 298 to 296, etc. Delay: The number of seconds between cycles or loops Place Start: Beginning of the possible place ra Place End: End of the possible place range or second test range
  • 42. 26 Chapter 1: Product Overview Note: Place Start and Place End should be the range of bins to Place to. To test the Interaction Slot, enter 353 in all Pick and Place start and end fields. tep of -2 would go of loops in the test. One loop consists of one pass through all cycles defined t of in, Place Step: The number of incremental or decremental steps within the defined Place bin range. Example: For a Place Start-to-End range of 300 to 200, you would put a -1 in the Place Steps to have the iteration move from 300 to 299 to 298, etc. A Place S from 300 to 298 to 296, etc. Loops: Number for the Auto Run by the Start, End and Step fields for Pick and Place. A cycle can consis two or four motions: a pick and then place back to same bin; or a pick, place to another b pick again, place back to original bin. Random Picks: Picks the inventory in random bins throughout the selected Auto Run test range. Random Places: Places the inventory in random bins throughout the selected range of Auto licable to current 7932 & 2371-9990 kiosk systems. ber of seconds between loops cle Stop: Ends Auto Run cycle AFTER completing the current loop. RFID Test: Tests RFID reads while picking and placing. Stop On Bad RFID: Stops Auto Run test on RFID read failure. Run test placement. Alt Bins Front Back: Used to alternate between the front bin ranges and the back bin ranges Alt Gates: This function is not app Single Case: One single case is used in the run. Delay: Num Start: Begins Auto Run cy Range Buttons: There are 20 range buttons. These permit selectable ranges to be turned on and off. Bins in the ranges bordered in green are used in the Auto Run and those bordered in red are skipped.
  • 43. Chapter 1: Product Overview 27 Select All: Activates all ranges (Green). Clear All: Deactivates all ranges (Red). RFID: UID and SKU numbers read from an RFID tag are displayed anytime a is executed. In the event a tag is not read, -1 or -2 is displayed as an error code successful Pick (See RFID Components, page 91). Response Box: Commands are displayed in this box along with their results. Successful pick and place moves are indicated by Pick/Place response 0, error codes are displayed when unsuccessful (See Motion Error Codes on page 217). Motion Exerciser 2.x (AKPOS Motion Exerciser) The Motion Exerciser 2.x is used with the 2.0 version of the Xpress Entertainment kiosk automated cycle testing options. These features are slated for a later MoX releases. In the meantime, MoX 1.x may be available (see Motion Exerciser 1.x (KAI) on page 23). software suite. The key differences in functionality from the 1.x version are that the 2.x version lacks the
  • 44. 28 Chapter 1: Product Overview Motion Exerciser (MoX) is a kiosk diagnostic tool used for testing the mechanical motion and stem. You must make sure that the Gripper Assembly is not running l the motion control, as motion control can only be owned by one Note: Since the 7932 and 2371-9990 don’t currently feature a bar code reader, the BarCode dicator is red and reads ‘NA’. peripheral devices of a sy in order for MoX to initia application at any one time. It’s also helpful to be familiar with the bin structure when executing pick and place commands with MoX (refer to Bin Map on page 225). This application’s functions are divided into five areas: • General • Motion Control • BarCode • RFID • Magstripe area’s Connected in General Area Init o initialize all the devices in the kiosk (Motion Control, RFID andialize All: Attempts t Magstripe).
  • 45. Chapter 1: Product Overview 29 List COM Ports: Lists all available COM ports and their configuration. This is a quick means of c COM ports are set correctly (refer to Communication Port Settings on page 105 for the correct settings). s ws Device Manager on page 105). Exe he configuration file for the MoX application, you can specify another el. In this manner, Clo Motion Control Area onfirming that all Device Manager: Brings up the Device Manager. Use for changing COM port configuration (refer to Windo cute Service: In t application that this button would execute. Lock Screen: Opens a dialog box to set a password and lock the touch pan the system can continue to process inventory safely while unattended. se: Closes the Motion Exerciser application. Connected: This field color indicates the COM port’ ted to the COM port for motion but has not y zed motion. ed indicates no connection a bin number in this field before selecting an action button (Pick, Place, Accept or Expel). Refer to Bin Map on page 225 for bin number mapping. plicable to current 7932 & 2371-9990 kiosk systems. followed by the on, the PLC resets. Initialize: nitialization process. Motion Exerciser must initialize first in order to fa ystem initialization takes a few moments to complete. Home: Initiates the homing motion sequence. Disconne while serv displa s cur ys the Motion Control COM port. The background rent status. Yellow indicates that MoX has connec et initialized. Green indicates that MoX has initiali nd no initialization.R Home Axis: This field is not applicable to current 7932 & 2371-9990 kiosk systems. Bin Number: Enter the Gate Num: This field is not ap Connect: Energizes the Remote Reset Relay, which removes power from the PLC. When Disconnect butt Begins the motion i cilitate motion. The s ct: Turns off the Remote Reset Relay, restoring power to the PLC. This is often used icing the system to reset the PLC (refer to Resetting the PLC on page 109).
  • 46. 30 Chapter 1: Product Overview Caution: The Carriage Assembly moves toward the bottom when PLC power is resto g motion sequence begins. Avoid gett red and its homin ing in its way. Pick: Picks inv bin address in the Pick Bin Address field. The Gripper picks the case f n the Carriage Frame, and stops. Place: Places i dress in the Pick Bin Address field. The Gripper picks the case from the bin selected, centers itself on the Carriage Frame, and stops. Accept: Interactio Expel: S If Expel is used to Place at the Interaction Slot the case must be removed entory from the rom the bin selected, centers itself o nventory in the bin ad Same as Pick except the pick command is not executed unless there is a case in the n Slot. ame as Place. from the slot before any other command can be executed. G s n Do is To app Gate Open: stems. G tion 990 kiosk systems. Do tion Do nct 371-9990 kiosk systems. M t a , BOTTOM, etc.) and this op ripp it sensor and test it ove: Moves the gripper to the specified location. mp bin. ate Size: This field i ot applicable to current 7932 & 2371-9990 kiosk systems. or Num: This field not applicable to current 7932 & 2371-9990 kiosk systems. p: This field is not licable to current 7932 & 2371-9990 kiosk systems. This function is not applicable to current 7932 & 2371-9990 kiosk sy ate Close: This func is not applicable to current 7932 & 2371-9 or Lock: This func is not applicable to current 7932 & 2371-9990 kiosk systems. or Unlock: This fu ion is not applicable to current 7932 & 2 ove To Limit: Selec n option in the box above this button (TOP tion will move the g er as far as it can to that axis in order to trip the lim . M Move To Scan: This bar code based inventory (VSI) function is not applicable to current 7932 & 2371-9990 kiosk systems. Dump: Takes any item on the gripper and dumps it in a du
  • 47. Chapter 1: Product Overview 31 RFID Area Connected: This f OM port’s curren ield displays the RFID COM port. The background color indicates the t status. Green indicates an active connection. Red indicates no connection. Connect: ts t to the RFID ice, which typically happens by default after pressing the Init . Read: Atte to re n displays the results the window below the buttons. pts to reads only the unique serial ID number on the RFID tagged ventory on the Gripper. On a successful read, the results are displayed in the response area below. Re Bloc ttem le within the FID t em User Switch Off: U der to tri rem re the ser Switch ON: Utilizes the RFID reader to trip a switch for the PLC to ON. ation from the RFID reader device. Ba de A Th ar co sed n 2371-9990 kiosk syste d is eason, th r is red an ads ‘ Ma ripe A C Attemp o connect reader dev ialize All button mpts ad all information o the RFID tag on the gripper and in Read Inventory ID: Attem in ad k: A pts to read the programmab or encodable blocks of information R ag’s m ory space. tilizes the RFID rea p a switch for the PLC to off – used to otely start PLC. U Disconnect: Disconnects communic rCo rea is b de ba inventory (VSI) function is ot applicable to current 7932 & ms an not active. For that r e BarCode area’s Connected indicato d re NA’. gst rea
  • 48. 32 Chapter 1: Product Overview Connected: This field displays the Magstripe USB port. The background color indicates the ort’s current status. Green indicates an active connection. Red indicates no connection. Connect: s a o connect with t e device. Read: Att to r the M Di nnec con unication from applicable with OPOS interfaces). e onse B Com ed in this box along with their results. p Initiate n attempt t he Magstrip empts ead information from agstripe reader when a card is swiped. sco t: Dis nects comm the Magstripe reader devices (usually only R sp ox: mands are display Su ssful nd are indicated b displayed when unsuccessful (See Motion Error Codes Motion Power he KAI Motion Power utility is accessed from the KIA Motion Power desktop icon. It is oft use h a esktop Protocol (R otely reset the PLC and to test for the presence of med m Bo ’s in tpu ID Unlike the Motion Exerciser (MoX), it does not n se. This ma s it a nie et the PLC. Caution: Resetting the PLC (Motion Power Off sequence, causing the Carriage Assembly to move to the interaction slot (bin 353). Don’t get in its way. cce pick a place moves y Pick/Place response 0, error codes are on page 217). T en d throug Remote D DP) to rem ia stuck in the Gripper Asse ds RF bly. Motion Power tests the RFID Reader ower Relay.ard put/ou t functions, which rea tags and controls the Remote P eed to initialize motion prior to u ke conve nt way to res and On) initiates the homing motion Motion Power On: Deactivates RFID Write Output 1, which turns off the Remote Reset Relay and restores power to the PLC. Motion Power Off: Activates RFID Write Output 1, which energizes the Remote Reset Relay and removes power from the PLC.
  • 49. Chapter 1: Product Overview 33 No alw te: If the Motion Power Off button hasn’t been used at least once, the Read RFID button ays fails. This is normal. displayed as an error code in the e KAI Motion Power application. Motion Log and The Motion Log is a diagnostic tool that can be used to review motion history in the system. It s between the PC (the Motherboard/CPU within the Pod) plifying isolation of motion issues. Access is through ative Login on page 9). The COM settings should be a the The PLC and PC make use of acknowledgment / non-acknowledgement handshaking. e PLC receives a valid command string, the PLC issues the following: Note: AK / NK or ACK / NAK do not receive further acknowledgement once received. • Upon receipt of a NK, the PC resends the command string to the PLC Read RFID: Reads the RFID tag after the Motion Power Off button has been used at least once. The results display in the RFID field and response box. RFID: UID and SKU numbers read from an RFID tag are displayed anytime a tag has been read successful. In the event a tag is not read, -1 or -2 is Response Box (refer to RFID Components on page 91 for detailed error code information). Response Box: Commands are displayed in this box along with their results. Close: Closes th PLC Commands consists of commands and response and the PLC with time stamps, sim Service Utilities’ View Motion Log button (refer to Service Utilities on page 9). Communication between the PC and PLC is bidirectional and accomplished through information transmitted via Hyperlink as part of specific ASCII strings to accomplish various tasks. Access to Hyperlink (Start, Programs, Accesseries, Communication, Hyperlink) requires administrative access (refer to Administr the same as outlined in Communication Port Settings, COM2 on page 105. These strings represent information needed by the PLC to locate target positions, define operational mode, and handshake status with the PC. Response Strings All Response strings from the PLC to the PC are 5 bytes long (4 characters + <CR> as terminator). Response stings are truncated or null characters (<00>) are appended to fill in 5 byte response. Handshaking When th AK<00><00><CR> When the PLC receives an invalid command string, the PLC issues the following: NK<00><00><CR> When the PC receives a valid command from the PLC, it sends the following: ACK<00><CR> When the PC receives an invalid command or no command response from the PLC, it sends the following: NAK<00><CR>
  • 50. 34 Chapter 1: Product Overview • Upon receipt of an NAK, the PLC If the PLC is currently trying to co resends the command response to the PC (not NK/AK). mplete a move command (VG…, ECHO 6, etc.), it mand string is as follows: x returns “MV<00><00><CR>”. Command Strings The general format of the main motion com VG=xD=yC=zR=www<CR> Where: = 0 move to location only x = 1 pick operation at location x = 2 place operation at location y = 0 Front Storage Area y = 1 Rear Storage Area z = 0 Column 0 z = 1 Column 1 z = 2 Column 2 z = 3 Column 3 row location, row 000 is the numbering location of Bin 1. See Bin Map, page 225. www 000 Represents - 119 uppermost row in the system. Note: Row numbering starts from 000 while Bin starts at 1. Thus, Row 000 column 0 is the Example: VG=0D=0C=0R=061 is a command string to move the Gripper in front of Bin 6 but not to pick or place. 2, Additional Command Strings Echo 6: mand string: s cannot take longer than 35 seconds ?P4104: the status of the Interaction Slot product sensor(s) the following 7 ter string is issued by the PC: 01<00><00><CR> A PLC Home/Reset is accomplished by issuing the following com ECHO 6<CR> Example Response: none After receipt of this command, the PLC references Gripper position through the Vertical and Horizontal Encoders and stops. No response is given when the proces is complete. The homing process To query charac ?P4104<CR> Example Response (2 characters):
  • 51. Chapter 1: Product Overview 35 Bit 0 represents the Interaction Slot product sensor. This command is used in the UI PLCVER<CR> Example Response: 0304<CR> After a valid command string is received by the PLC from the PC, and the proper handshaking d the PC command has been carried out by the PLC, a command response is in the rent and return process to verify a rental has been removed from the Interaction Slot, to start a return, and to verify the Interaction Slot is empty prior to dispensing. 01 indicates product presence in the slot, 00 indicates product absence in the given slot. PLCVER: To query the PLC code revision the following 7 character string: This response is interpreted as PLC code revision number 0304 (3.04). Command Responses has occurred, an generated back to the PC as follows: Command Response Response Code 00<00><00><CR> Successful operation 15<00><00><CR> Place operation is blocked by an object or no product initially on platform to place 17<00><00><CR> Placement error – PLC has pulled product back on platform 30<00><00><CR> Empty pick – no product at location to be picked 34<00><00><CR> Failed pick – product at location, but could not be picked, product remains in bin 45<00><00><CR> Failed expel of product at Interaction Slot 54<00><00><CR> Failed accept of product at Interaction Slot 59<00><00><CR> Product has been automatically dumped at dump bin location by PLC 91<00><00><CR> Vertical axis timeout after 20 seconds 92<00><00><CR> Horizontal axis timeout after 12 seconds 93<00><00><CR> Insertion axis timeout after 6 seconds 94<00><00><CR> Safety sensors tripped – product impeding motion MV<00><00><CR> See Busy Command Response, page 35 These commands and responses are entered into the motion log in the sample form below. 080812 11:51:28 >> AK Received - for: VG=2D=0C=2R=091 080812 11:51:42 << ACK Sent - Command Response: 0 080812 11:51:42 Command Response: 0 Busy Command Response For all command strings that provide a command response (VG=…, ?P4104, PLCVER), if the PLC is currently trying to complete a move command, it returns a command response string of “MV<00><00><CR>”. In this case the command is NOT executed or queued by the PLC, and thus must be resent by the PC at a later time. Commands that do NOT return a command response string (for example Echo 6, Echo 7) are NOT executed.
  • 52. 36 Chapter 1: Product Overview Example Com Note that all occurrences of ‘PC’ munication Sequences within the example tables refer to the PC Motherboard/CPU Example 1: Echo 6 # Sender Command Description within the Pod. Seq 1 PC ECHO 6<CR> Command to PLC to home 2 PLC AK<00><00><CR> PLC acknowledging command Example 2: Move to first bin nder Command Description# Se 1 PC VG=0D=0C=0R=000<CR> Command to PLC to go to first bin 2 PLC AK<00><00><CR> 3 PLC 00<00> PLC acknowledging command <00><CR> Response (OK) from PLC regarding move PLC command 4 PC ACK<CR> PC acknowledges response from Exa lmp e 3: Failed command from PC # DescriptionSender Command 1 PC RG=0D=0C=0R=000<CR> Invalid command (RG) to PLC 2 PLC NK<00><00><CR> PLC responds with invalid command 3 PC VG=0D=0C=0R=000<CR> Command resent to PLC PLC AK<00><00><CR> PLC acknow4 ledging command move command 6 PC ACK<CR> PC acknowledges response from PLC 5 PLC 00<00><00><CR> Response (OK) from PLC regarding Example 4: Request status of input at Interaction Slot # Sender Command Description 1 PC ?P4104<CR> Command to PLC to report status of Interaction Slot input 2 PLC AK<00><00><CR> PLC acknowledging command 3 PLC 01<00><00><CR> Response (input ON ) from PLC regarding input state 4 PC ACK<CR> PC acknowledges response from PLC Command Description Example 5: Request version of PLC application # Sender 1 PC PLCVER<CR> Command to PLC to report application version 2 ><CR> PLC acknowledging command 3 PLC AK<00><00 PLC 0304<CR> Response (0304 ) from PLC regarding version info
  • 53. Chapter 1: Product Overview 37 4 PC ACK<CR> acknowledges response from PLCPC Example 6: Failed response to version of PLC application # Sender Command Description 1 PC PLCVER<CR> Command to PLC to report application version 2 3 n 6 PC ACK<CR> PC acknowledges response from PLC PLC AK<00><00><CR> PLC acknowledging command PLC 0<CR> Incorrect response (0) from PLC regarding version info 4 PC NAK<CR> PC alerts PLC of invalid response received. 5 PLC 0304<CR> Response (0304 ) from PLC regarding versio info Example 7: Busy command response from PLC # DescriptionSender Command 1 Command to PLC to place at Interaction SlotPC VG=2D=0C=2R=091<CR> 2 PLC acknowledging command 3 PLC MV<00><00><CR> PLC responds with busy notice ACK<CR> PC acknowledges response, should delay before sending a new command PLC AK<00><00><CR> 4 PC