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Instructions for upgrade of DL850/

EML224/GDS102 to CPU PCA-6742 from


CPU PCA 6135/6753.

Upgrade kit Part no Product:


SA-C124 GDS102
SA-C125 DL850N
SA-C126 DL850N27
SA-C135 EML224
SA-C132 GDS102S
SA-C133 DL850D
SA-C134 DL850D27

SKIPPER Electronics AS Telephone: +47 23 30 22 70


Enebakkveien 150 Telefax: +47 23 30 22 71
P. O. Box 151, Manglerud E-mail: support@skipper.no Document no: DI-C001
0612 Oslo, Norway Co. reg. no: NO-965378847-MVA Rev 1339A
www.skipper.no Date: 2014-08-06
SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Table of Contents
List of parts3
Additional parts in SA-C135 upgrade kit for EML224 graphic unit4
Part 1A: Removing the old CPU assembly CPU 6135 (EML224, DL850* pre 2007)5
Step 1A. Locate the different parts5
Step 2A. Loosen cables and unscrew I/O board6
Step 3A. Remove the old I/O board 7
Step 4A. Remove the old CPU board8
Step 5A. Remove the old motherboard 9
Step 6A. Remove the old computer plate and display cable10
Part 1B: Removing the old CPU assembly CPU 6753 (GDS102, DL850 after 2007)11
Step 1B. Locate the different parts, remove COM port card11
Step 2B. Disconnect flat cable from I/O board12
Step 3B. Remove the old I/O board13
Step 4B. Remove the old CPU board14
Step 5B. Loosen the old motherboard and computer plate15
Step 6B. Remove the old computer plate and display cable16
Part 2: Inserting the new CPU PCA 6742 Assembly17
Step 7. Mount the new display cable17
Step 8. Thread the display and power cable18
Step 9. Attach and secure the new computer plate19
Step 10. Place and secure the new CPU board20
Step 11. Connect the new com port split cable21
Step 12. Connect com cable to the new CPU board22
Step 13. Connect the printer cable to the new CPU board23
Step 14. Connect remaing cables to the new CPU board24
Step 15a. Connect power cable and adapter to Combo Terminal board25
Step 15b. Connect communication cable to Combo Terminal board 25
Step 16. Connect and secure the new I/O board26
Step 17. Insert Compact Flash in MESA board27
Step 18. Secure ribbon cables28
Step 19. Move jumper J400 to correct position29
Appendix 1. Units before upgrade30
Interconnections before upgrade, EML224 with PCA 6135 CPU board30
Interconnections, before upgrade, DL850 with PCA 6135 CPU board31
Interconnections before upgrade, GDS102 with PCA 6753 CPU board 32
Interconnections before upgrade DL850 with PCA 6753 CPU board33
Appendix 2. Units after upgrade34
Interconnections after upgrade, EML224 with PCA 6742 CPU board34
Interconnections after upgrade, DL850 with PCA 6742 CPU board35
Interconnections after upgrade, GDS102 with PCA 6742 CPU board36

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

List of parts
This document describes how to upgrade a faulty CPU unit PCA 6135 or PCA 6753 to the
newer generation PCA 6742. The document is split into 4 Parts.
1. The first part describes how do demount your existing unit. You will need to find your
current version of setup and follow this.
2. The second part then describes how to rebuild the unit with the new components.
3. Appendix 1. Unit interconnections before upgrade.
4. Appendix 2. Unit interconnections after upgrade.

This kit contains:


Part no Description Number of
Module SA-C131 CPU upgrd => 6742 w CPU plate, etc No setup CF 1
Containing:
PC-C053 PCB CPU 6742VEF Setup ready. No Flash card. 1
PI-C052 PCB Combo I/O with EPC1(for CPU 6742) 1
PM-C001 PCB Motherboard Combo 1*
ZZK-01063 Cable clip plastic TCFF-40-01 3*
ZZK-01064 Cable clip aluminium 51,0mm 40 way 2*
ZZK-01074 Power cable 5/12V 1
ZZK-01075 Power plug 5/12V retrofit (to be used with ZZK-01074) 1
ZZK-01076 Cable Screen PCA 6742 1
ZZK-01077 Cable Com 3/4 splitter for PCA 6742 1
ZZZ-030023 Flash card reader MESA 1*
ZZZ-030024 Flash card Sandisk X GB 1*
ZZZ-030025 Flat cable for flash card reader (IDE) 1*
ZAA-01032 Computer plate 1
DI-C001 Manual for CPU 6742 Combo platform upgrade kit 1

In addition you will have one of the following, depending on the existing setup.
Part no Description Number of
MB-G002 Bootable SW module for GDS102 1**
MB-G002S Bootable SW module for GDS102S 1**
MB-D004N Bootable SW module for DL850N 540 kHz Non docking 1**
MB-D004D Bootable SW module for DL850D 540 kHz Docking 1**
MB-D005N Bootable SW module for DL850N27 270 kHz Non 1**
docking
MB-D005D Bootable SW module for DL850D27 270 kHz Docking 1**
MB-E001 Bootable SW module for EML224 1**
* Pre-mounted on Computer plate. ** Pre-mounted on CPU.
The newer CPU’s software are much simpler to upgrade. This is performed using the
Compact flash disk on the new plate.

Tools needed for this upgrade are :


• Philips X screwdriver (PH1x80)
• 5,5 mm pipe spanner

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Additional parts in SA-C135 upgrade kit for EML224 graphic unit

Part no Revision Description Number of


ZZK-01031 Cable RS232 for DL850/EML224 CPU/Terminal PCB 1
ZZK-01032 Communication cable for DL850/EML224 RS422 1
Terminal/Terminal PCB
ZZZ-03001EML A14 PCB RS 422 Terminal for EML224 Cabinet 1

In the EML224 there are 2 additional changes that requires new parts.

The NMEA RS422 to RS232 conversion is performed on the terminal PCB before going to
CPU PCB.
The two NMEA cables ZZK-01031 and ZZK-01032 are supplied

A bug in the older version of ZZZ-030011EML prevented 2 way communication with the
sensor. Signal was received from sensor but no commands would be sent down from cabi-
net to sensor.
With the new version A14 of the PCB the 2 way communication is enabled.

Please note:
2 way communication requires 2 pairs (Rx and Tx) cables run from cabinet via electronic
unit to sensor.
In Software versions <1.27.23 No commands are sent to sensor.
In software version from 1.27.23 sensor format command is sent to the sensor (EML224
format).

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Part 1A: Removing the old CPU


assembly CPU 6135 (EML224, DL850*
pre 2007)
Step 1A. Locate the different parts
• Open the cabinet and take a overview of the electronics.
• In the door, the CPU board is positioned at the top, behind the I/O board. Both are
attached via an ISA bus to the motherboard on the left.
• The aluminium computer plate, CPU board, mother board and the I/O board need to be
replaced in this upgrade.

*Not all versions.

Motherboard. CPU board. I/O board. Computer plate.

Keyboard (not to be replaced).

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 2A. Loosen cables and unscrew I/O board

• Loosen all cables and screw (1) from the I/O board.
• Loosen COM cable from the old CPU board

Loosen old display cable. Loosen printer cable.

Remove
screw from
I/O board.

Loosen COM Loosen flat Loosen


cable. cable. VGA cable.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 3A. Remove the old I/O board


• Remove the old I/O board and loosen the rest of the cables on the CPU board.
• Remove the 3 screws/nuts from the CPU board.

CPU board. Remove screws/nuts.

Remove flat cable.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 4A. Remove the old CPU board


• Remove the old CPU board.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 5A. Remove the old motherboard

• Loosen the motherboard (4 screws) and disconnect the cables from it.
• Loosen the computer aluminium plate (2 screws and 2 nuts).

Remove screws and nuts.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 6A. Remove the old computer plate and display cable

• Remove the aluminium computer plate from the cabinet.


• Remove the old display cable.

Remove old display cable.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Part 1B: Removing the old CPU


assembly CPU 6753 (GDS102, DL850
after 2007)
Step 1B. Locate the different parts, remove COM port card

• Open the cabinet. In the door there is a stack of three cards. The CPU board is at the
bottom, behind the I/O board and in front is the COM port card. The motherboard is to
the left, holding the stack together.
• The aluminium computer plate, motherboard, CPU board and the I/O board need to be
replaced in this upgrade.
• Remove screw and COM cable from the COM port card on top.
• Remove COM port card (only on DL850).

Motherboard. CPU board. I/O board. Computer plate.

Note: MESA
board and flat
cable not on
GDS102. Disk
On Module
instead.

COM port card. COM Screw.


Note: Not on GDS102. cable.
Only on DL850.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 2B. Disconnect flat cable from I/O board

• Disconnect the flat cable from the I/O board.


• Unscrew the IO board (1 screw and 1 nut).

Disconnect flat cable. Remove screw and nut.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 3B. Remove the old I/O board

• Take out the I/O board and loosen the rest of the cables on the CPU board.
• Remove the stand-off and screw(s) from the CPU board.

Remove remaining cables Remove stand-off


on old CPU board. and screw(s).

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 4B. Remove the old CPU board

• Remove the CPU board.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 5B. Loosen the old motherboard and computer plate

• Loosen the motherboard with 4 screws and disconnect the cables from it.
• Loosen the computer aluminium plate (2 screws and 2 nuts).

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 6B. Remove the old computer plate and display cable

• Remove the aluminium computer plate from the cabinet, and remove the old display
cable.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Part 2: Inserting the new CPU PCA


6742 Assembly
Step 7. Mount the new display cable
• Demounting complete.
• Next re-assemble by first mounting the new display cable.
• Secure its connector with tape (own supply).

Insert the new cable and secure with tape.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 8. Thread the display and power cable

• Thread the display cable through the hole in the new aluminium computer plate as
shown. Ensure you also have thread power cable shown in the picture.

Thread the new power and display cable


through the new computer plate.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 9. Attach and secure the new computer plate

• Attach the aluminium computer plate to the cabinet door and secure it with 2 nuts and 2
screws. Lay the cables out as shown.

Secure the computer plate.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 10. Place and secure the new CPU board

• Mount the new CPU board and secure it with 3 screws.

Mount and secure the new CPU board.


(Note: Software in Compact flash on the rear side).

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 11. Connect the new com port split cable

• Connect the COM port split cable device first to the new CPU and mount the other ends
to the connectors on the Combo Terminal board of the cabinet (J400 and J401).
Note: This cable may look slightly different to the photo.

Connect the COM port split cable


between the CPU COM 34 and J400/
J401 on Combo Terminal board.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 12. Connect com cable to the new CPU board

• Connect the COM cable between J300 on Combo Terminal and the COM2 connector
on to the CPU board. (For details, see drawings in Appendix).

Connect the COM cable from Terminal board to the CPU board.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 13. Connect the printer cable to the new CPU board

• Connect the LPT (Printer) cable to the CPU board, bending it as shown.

Connect the printer cable to the CPU board

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 14. Connect remaing cables to the new CPU board

• Connect the new display cable, the external screen (VGA) cable and the IDE cable
from the CF- MESA cardreader and the power cable to the new CPU board.

Power cable. IDE cable.

VGA cable. Display cable.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 15a. Connect power cable and adapter to Combo Terminal


board

• Mount the power cable adaptor as shown, and line up the power cable like in this
picture. Clamp the cable inside the cable clamp to hold it. The adapter has numbers on
the connector 1, 2, 3, 4, matching the connector on the PCB. (Number 1 is the yellow
cable)

Step 15b. Connect communication cable to Combo Terminal board

• Connect the communication cable between D-SUB connector J100 on RS422 Terminal
board and D-SUB connector J301 on Combo Terminal board. (See Appendix for details)..

Power cable adaptor

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 16. Connect and secure the new I/O board


• Mount the new I/O board back in its slot, and secure it with 1 screw.
• Connect the flat ribbon cable as shown.

New I/O board.

Flat ribbon cable. Screw.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 17. Insert Compact Flash in MESA board


• Insert the Compact flash in the CF card reader, if not already inserted.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 18. Secure ribbon cables


• Secure the ribbon cables in its cable clips.

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Step 19. Move jumper J400 to correct position


• Move jumper (JP400) one step up from pin 2, 3 to pin 1, 2.
• You can now power up the unit.

Jumper JP400

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SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

Appendix 1. Units before upgrade


Interconnections before upgrade, EML224 with PCA 6135 CPU
board

PRINTER

VGA
EML 224 PCA 6135 Interconnection Diagram

PRINTER

VGA
ZZK 01030
ZZK 01035

NMEA
ZZK 01034

NMEA2

Frontpanel
POWER + GND

Fan

60 VA
Trafo
Sunday, January 18, 2009

NMEA
BUS
ZZK 01029
ZZK 01026
BUS

Revision 1339A Page 30 of 36


board
DL 850 PCA 6135 Interconnection Diagram
Sunday, January 18, 2009

Revision 1339A
ZZK 01034

PRINTER

ZZK 01026
BUS 2

RS-232 ZZK 01031


VGA
POWER + GND
ZZK 01030
NMEA2
ZZK 01029
BUS 1
PRINTER

ZZK 01032
RS-422
Fan
Frontpanel VGA
NMEA

Trafo
SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

60 VA
Interconnections, before upgrade, DL850 with PCA 6135 CPU

NMEA

Page 31 of 36
board
Interconnection Diagram GDS 102 with PCA 6753 CPU

Revision 1339A
Tuesday, June 29, 2010
ZZK-01034
LCD

ZZZ-030021
ZZA-01062
VGA

+5V
LCD
CPU Board I/O Board

ZZK-01029 ZZK-01026 Printer


BUS2
Frontpanel
ZZK-01043 ZZK-01056-59
GND + POWER

BUS1 VGA
VGA
Monitor

NMEA NMEA

ZZK-01030
NMEA1, COM1

Fan
ZZK-
01060
T1 T2

Trafo
80 VA
Buzzer
NMEA2
SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

ZZK01031 RS232, COM2


ZZK-
01018
Interconnections before upgrade, GDS102 with PCA 6753 CPU

Page 32 of 36
DL 850 Interconnection Diagram CPU PCA 6753
Tuesday, June 29, 2010

Revision 1339A
+5V

Serial IO

Combo IO
PRINTER

ZZK 01026 CPU PCA-6753


BUS

ZZK 01030
ZZK 01030
VGA
RS-232 ZZK 01031
POWER + GND

ZZK 01029
BUS

ZZK 01032
PRINTER
RS-422
Fan
Frontpanel VGA
NMEA

Trafo
SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

60 VA
NMEA
Interconnections before upgrade DL850 with PCA 6753 CPU board

Page 33 of 36
08.01.2009

Revision 1339A
ZZZ 030025

ZZK 01076

Logic:
IC 300. ZZA 01062
F10
+5V

Combo IO PRINTER

ZZK 01026 CPU PCA-6742VE


BUS

ZZK 01074
POWER + GND
ZZK 01031 VGA
RS-232

Logic:
ZZK 01029 IC 1300.
BUS B0

ZZK 01032
PRINTER
RS-422
Fan
Frontpanel VGA
NMEA

Trafo
60 VA
SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

NMEA ZZK 01077


Appendix 2. Units after upgrade

Page 34 of 36
Interconnections after upgrade, EML224 with PCA 6742 CPU board
DL 850 Display Unit (CPU PCA 6742VE) Interconnection Diagram
08.10.2010

Revision 1339A
ZZZ 030025

ZZK 01076

Logic:
IC 300.
F10
ZZK 01062 +5V

Serial IO
PRINTER
Combo IO

ZZK 01026 CPU PCA-6742VE


BUS
ZZK 01074
POWER + GND
ZZK 01031 VGA
RS-232

Logic:
ZZK 01029 IC 1300.
BUS B1

ZZK 01032
PRINTER
RS-422
Fan
VGA
Frontpanel
NMEA

Trafo
SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

60 VA
NMEA ZZK 01077
Interconnections after upgrade, DL850 with PCA 6742 CPU board

Page 35 of 36
Interconnection Diagram GDS 102 (PCA 6742VE)
10.01.2009
ZZZ-030025

Revision 1339A
ZZK-
01076
LCD

PCB Rev: D2 ZZA-01062 +5V


IC300: F10
LCD
CPU Board I/O Board
VGA

Printer

BUS2 ZZK-01026
ZZK-01029 Frontpanel
ZZK-01043
GND + POWER
ICDD2: C7A153 ZZK-01074
BUS1 VGA
Monitor

NMEA

IC1300: B1

Fan
ZZK-
01060
T1 T2

Trafo
80 VA
Buzzer
SKIPPER DI-C001 Instructions for upgrade of older generation CPUs to CPU PCA-6742

ZZK- ZZK-01077
01018

Page 36 of 36
Interconnections after upgrade, GDS102 with PCA 6742 CPU board